Jeep Renegade 2015 2016 Repair Manual

Jeep Renegade
Service Manual: VEHICLE DATA

VEHICLE INFORMATION > INTERNATIONAL VEHICLE CONTROL AND DISPLAY
SYMBOLS > DESCRIPTION > DESCRIPTION
FCA US LLC uses international symbols to identify various systems on the vehicle.
The graphic symbols illustrated are used to identify various instrument controls, vehicle controls and
service information references. The symbols correspond to the controls and displays that are located on
the instrument panel and throughout the vehicle.
Fig 1: Information Symbols
Courtesy of CHRYSLER GROUP, LLC
INTERNATIONAL INFORMATION SYMBOL IDENTIFICATION
SYMBOL DESCRIPTION SYMBOL DESCRIPTION
1 115-Volt Power Inverter 11 Side Airbag
2 USB Connector 12 Seat Belt
3 Lighter 13 Airbag
4 Fuel Fill Side 14 Supplemental Restraint System

5 Spare Tire Winch 15 Power Steering Fluid
6 Fuse 16 See Owner's Manual
See Appropriate Service

7 Key Activate (Power Outlet) 17 Information
8 Warning 18 Emergency Release Handle
9 Child Seat Tether Anchor 19 Jack/Jack Tools Location
Lower Anchors and Tether for

10 Children (latch)
Fig 2: Indicator Symbols
INTERNATIONAL INDICATOR SYMBOL IDENTIFICATION
SYMBOL DESCRIPTION SYMBOL DESCRIPTION
1 Electronic Speed Control 30 Door Ajar

2 Hill Descent Control 31 Liftgate Open
Brake System Warning Parking

3 Traction Control 32 Brake
Electronic Stability
Program/Brake System
4 Assist System 33 All Wheel Drive
5 Security Indicator 34 Four Wheel Drive
6 Turn Signals 35 Four Wheel Drive Low
7 Water In Fuel 36 Tow/Haul
8 Low Fuel 37 Service Four Wheel Drive
9 Side Airbag 38 Service Four Wheel Drive
10 Seat Belt Reminder 39 Cruise Indicator
Brake System Warning Parking

11 Airbag Warning Light 40 Brake
12 Passenger Airbag Off 41 Tire Pressure Monitor
Failure Of Anti-Lock Braking

13 System 42 Sway Bar Disconnect Indicator
HEV Brake Regenerative

14 Light 43 Front Axle Lock
15 Electronic Throttle Control 44 Rear Axle Lock
16 HEV Service Light 45 Park Asist Indicator
17 Engine Oil 46 Park Brake Indicator
Electronic Stability Control/Traction

18 Battery Charging 47 Control Off
19 Glow Plug/Intake Air Heated 48 Trailer Brake System Off
20 Power Steering Fluid 49 Diesel Exhaust Fluid
21 Engine Coolant Temperature 50 Coolant Level
22 Malfunction Indicator Light 51 Fuel Cap
Transmission Oil
23 Temperature Light 52 EPS (Electric Power Steering)
24 Diesel Exhaust Brake 53 Icy Road Condition
25 High Beam 54 Electric Vehicle Plug In State
26 Front Fog Light 55 Vehicle Theft Alarm
27 Rear Fog Light 56 Stored Warnings
28 Cargo Lamp 57 Service ETC
29 Exterior Bulb Failure 58 Electric Vehicle System Service

Fig 3: Control Symbols
INTERNATIONAL CONTROL SYMBOL IDENTIFICATION
SYMBOL DESCRIPTION SYMBOL DESCRIPTION SYMBOL DESCRIPTION
Rear Window Convertible Top

1 Wiper 28 Cruise Indicator 55 Down
Rear Window
2 Intermittent Wiper 29 Hill Descent Control 56 Convertible Top Up
Rear Window
3 Washer 30 Park Assist Off 57 Door Lock
Program/Brake
Rear Window System Assist
4 Defrost 31 System 58 Window Lift
Convertible 4
5 Heated Mirror 32 Park Brake Release 59 Window Down
Adjustable
6 Turn Signals 33 Headlights 60 Window Lock
7 Adjustable Pedals 34 Low Beam 61 Power Rear Window
Voice Recognition
8 Horn 35 Front Fog Light 62 Button
Windshield Wiper
9 Intermittent 36 Rear Fog Light 63 Uconnect™ Button
10 Windshield Washer 37 Cargo Lamp 64 SwayBar Disconnect
Windshield Washer
11 Fluid Level 38 Hazard Lights 65 All Wheel Drive
Windshield 115-Volt Power

12 Electrically Heated 39 Inverter 66 Four Wheel Drive
Key Activate (Power

13 Windshield Defrost 40 Outlet) 67 Two Wheel Drive
Windshield Wiper Four Wheel Drive

14 And Washer 41 Exterior Bulb Failure 68 Low
Master Lighting Four Wheel Drive

15 Ventilating Fan 42 Switch 69 Lock
Four Wheel Drive

16 Air Conditioning 43 Dome Light 70 Auto
17 Upper Air Outlet 44 Park Lights 71 Front Axle Lock
Upper And Lower Instrument Panel

18 Air Outlet 45 Illumination 72 Rear Axle Lock
19 Lower Air Outlet 46 Program Off 73 EVIC Menu
Defrost And Lower Diesel Exhaust

20 Air Outlet 47 Brake 74 Navigation Button
21 Heated Seat Low 48 Overdrive Off 75 Step
22 Heated Seat High 49 Hood Release 76 Reset

23 Ventilated Seat 50 Trunk/Deck Release 77 Axle Lock Button
24 Recirculation 51 Door Ajar 78 Traction Control Off
Heated Steering Electronic Stability

25 Wheel 52 Liftgate Release 79 Control Off
Passenger Air Bag

26 Off 53 Sliding Door 80 Trailer Brakes
Electronic Speed
27 Control 54 Sliding Door
VEHICLE INFORMATION > INTERNATIONAL VEHICLE CONTROL AND DISPLAY

SYMBOLS > DESCRIPTION > DESCRIPTION > ENGINE COMPARTMENT
Fig 1: International Symbols
The graphic symbols illustrated are used to identify engine compartment lubricant and fluid inspection
and fill locations. The symbols correspond to the caps located within the engine compartment.
VEHICLE INFORMATION > LABEL, VEHICLE EMISSION CERTIFICATION

INFORMATION (VECI) > DESCRIPTION > DESCRIPTION
NOTE:
The Vehicle Emission Control Information (VECI) label(s) must be in place for the life of the
vehicle. When replacing the component in which the VECI label is adhered, a new VECI
label must also be adhered to the new component.
All models have a VECI Label. FCA US LLC permanently attaches the label in the engine compartment. It
cannot be removed without defacing information and destroying the label.
The label contains the vehicle's emission specifications and vacuum hose routings. All hoses must be
connected and routed according to the label.
VEHICLE INFORMATION > VEHICLE CERTIFICATION LABEL > DESCRIPTION >

DESCRIPTION
Fig 1: Space For VIN Code & Data Matrix - EEC
EEC
a. Space reserved for the labeling of the symbol of the corrected absorption coefficient of smoke
(diesel engines only)
b. Data Matrix with the information written on the plates

Fig 2: Space For VIN Code & Data Matrix - USA
USA
a. Space for the VIN code
Fig 3: Space For VIN Code & Data Matrix - Canada
CANADA

Fig 4: Space For VIN Code & Data Matrix - Mexico
MEXICO
VEHICLE INFORMATION > VEHICLE IDENTIFICATION NUMBER > DESCRIPTION >

DESCRIPTION
Fig 1: Vehicle Identification Number (VIN) Label

The Vehicle Identification Number (VIN) can be viewed through the windshield at the upper left corner of
the instrument panel, near the left windshield pillar. The VIN consists of 17 characters in a combination of
letters and numbers that provide specific information about the vehicle. Refer to the vehicle identification
number decoding charts below, for decoding information.
To protect the consumer from theft and possible fraud the manufacturer is required to include a Check
Digit at the ninth position of the vehicle identification number. The check digit is used by the
manufacturer and government agencies to verify the authenticity of the vehicle and official
documentation. The formula to use the check digit is not released to the general public.

DESCRIPTION > POSITIONS 1 - 3: WORLD MANUFACTURER IDENTIFIER
1 2 3 Manufacturer Vehicle Type
Z F B Fiat Group Automobiles S.p.A. MPV
Z A C Fiat Group Automobiles S.p.A. MPV

DESCRIPTION > POSITION 4: BRAKE SYSTEM & GVWR
Brake GVWR Range Active Active Belts, Active Active Active

System Belts, Air Bags, Belts, Air Belts, Belts,
Air Side Bags, No Air GVWR >
Bags Bags-Front Side Bags 10, 000
Pounds Kilograms
Row Bags-All lbs.
Rows
(2268 - 2721
Hydraulic 5001-6000 E
kg)
W = Incomplete Vehicle with Hydraulic Brakes
7 = Bus with Hydraulic Bra

DESCRIPTION > POSITIONS 5 - 7:
Define the following: brand, marketing name, drive wheels, cab/body type, drive position, and
price series.
JEEP RENEGADE (520) MPV
FWD AWD BODY TYPE DRIVE POSITION SERIES

J A A J B A Sport
Latitude (US-Mex.),
J A B J B B Sport Utility - 4
Left Hand Drive North (Can)
Door
- - - J B C Trailhawk
J A D J B D Limited

DESCRIPTION > POSITION 8: ENGINE
Code Displacement Cylinders Fuel Turbo Sales Codes
H 1.4 Liter 4 Gasoline Yes EAM
N 1.6 Liter 4 Diesel Yes EJK
C 1.6 Liter 4 Gasoline No EJH
Y 2.0 Liter 4 Diesel Yes EBT
T 2.4 Liter 4 Gasoline No ED6

DESCRIPTION > POSITION 9: CHECK DIGIT
0 through 9 or X

DESCRIPTION > POSITION 10: MODEL YEAR
F = 2015

DESCRIPTION > POSITION 11: ASSEMBLY PLANT
CODE PLANT
P MELFI (ITALY)

DESCRIPTION > POSITION 12 - 17: PLANT SEQUENCE NUMBER
A six digit number assigned by assembly plant.
Jeep Renegade
Service Manual: VEHICLE QUICK REFERENCE
CAPACITIES AND RECOMMENDED FLUIDS > SPECIFICATIONS > SPECIFICATIONS
ENGINE
Capacities
Description Type Part Number
U.S. Metric
Cooling System •
MOPAR®
Antifreeze/Coolant 10
Year/150, 000 Mile 1 Gallon -
Engine Coolant Formula OAT (Organic 68163848AA
5.5 Quarts 5.2 Liters
(1.4L Engine) Additive Technology) or (concentrate)
equivalent meeting the 68163849AA (50/50)
requirements of Material
Standard MS.90032.
Engine Coolant CUNA NC 956-16 ASTM

N/A 6.4 Quarts 6.1 Liters
(1.6L Engine) D3306 9.55523

(2.0L Engine) D3306 9.55523
MOPAR®
Standard MS.90032.
Engine Oil with Filter
SAE 5W-40 API Certified

Synthetic Engine Oil,
meeting the requirements
of Material Standard
Engine Oil - (1.4L
MS-12991 such as N/A 4.0 Quarts 3.8 Liters
Engine)
MOPAR®, Pennzoil®, and
Shell Helix®. Refer to
your engine oil filler cap
for correct SAE grade.
Engine Oil - (1.6L SAE 0W-30 ACEA C2

Engine) FIAT 9.55535-DS1

Engine Oil - (2.4L SAE 0W-20 API Certified

Engine Oil, meeting the N/A 5.5 Quarts 5.2 Liters
Engine)
Standard MS-6395 such
as MOPAR®, Pennzoil®,
and Shell Helix®. Refer to
Engine Oil Filter
MOPAR® Engine Oil Filter 68102241AA N/A N/A
(1.4L Engine)
Engine Oil Filter

MOPAR® Engine Oil Filter N/A N/A N/A
(1.6L Engine)
Engine Oil Filter

(2.0L Engine)
Engine Oil Filter

(2.4L Engine)
Fuel
Fuel Selection (1.4L 91 Octane, 0-10%

N/A 12.7 Gallons 48 Liters
Engine) Ethanol
Fuel Selection (1.6L

EN 590 Diesel N/A 12.7 Gallons 48 Liters
Engine)

Engine)

Engine) Ethanol

87 Octane, up to 85%
Engine) - Flex Fuel N/A 12.7 Gallons 48 Liters
Ethanol
(E85) Models Only
A/C Refrigerant System
Refrigerant R-1234yf - 1.0 Pounds 0.450 Kilograms
• Includes heater and coolant recovery bottle filled to MAX level.
CAUTION:
Nominal refill capacities are shown. A variation may be observed from vehicle to vehicle due
to manufacturing tolerance and refill procedure.
SPARK PLUGS
Gap
Description Part Number
U.S. Metric
Spark Plugs (1.4L Engine) 68070507AC 0.026 in 0.65 mm

Spark Plugs (2.4L Engine) SP148183AB 0.047 in 1.20 mm
TRANSAXLE
Capacity
U.S. Metric
Automatic
Use only MOPAR® ZF

8&9 Speed
ATF™Automatic
Transmission Fluid,
948TE Automatic 9.55550-AV5 or
68218925AA 6.35 Quarts 6.0 Liters
Transaxle equivalent. Failure to
use the correct fluid may
affect the function or
performance of your
transmission.
Manual
Use C Series Manual &

C635 Manual
Dual Dry Clutch 68092630AA 2.0 Quarts 1.88 Liters
Transaxle
Transmission Fluid
CHASSIS
Capacities
U.S. Metric
Axles
Use synthetic
Rear Differential
lubricant SAE N/A 0.63 Quarts 0.6 Liters
(RDM)
75W-90 API GL5
Transfer Case
Use synthetic
Power Transfer Unit
(PTU)
75W-90 API GL5
Chassis Systems
We recommend you
use MOPAR® DOT
4. If DOT 4 brake 12 oz. Bottle -
Brake Master Cylinder N/A N/A
fluid is not available, 04549625AD
then DOT 3 is
acceptable.
FUSE - RELAY LOCATIONS AND TYPES > SPECIFICATIONS > SPECIFICATIONS >
FUSES AND RELAYS
Fig 1: Engine Compartment Fuses/Distribution Unit
Engine Compartment Fuses/Distribution Unit
The fuses are grouped into four controllers located in the engine compartment, under the instrument panel
and on the inside of the left side cargo trim panel.
The engine compartment fuse panel is located on the left side of the engine compartment.
Cavity Maxi Fuse Cartridge Fuse Micro Fuse Description
F01 70 Amp Tan - - Module Body Computer
Module Body Computer,

F02 70 Amp Tan - -
Rear Distribution Units
Controller Power
F03 - 20 Amp Blue -
Supply Body Computer
Brake Control
F04 - 30 Amp Pink -
Electronics Module
Electric Power-Assisted
F05 70 Amp Tan - -
Steering
F06 20 Amp Yellow - - Engine Cooling fan

40 Amp Orange -
1.4 Without A/C
F07 50 Amp Red - 1.4 - - Engine Cooling fan
With A/C And All
2.4 Models
Automatic
F08 - 30 Amp Pink -
Transmission, GSM
F09 - - 5 Amp Tan Control Module Engine
F10 - - 15 Amp Blue Horn
10 Amp Red - 1.4

Engines Supply Secondary
F11 - -
25 Amp Clear - 2.4 Loads
Engines
F14 - - 7.5 Amp Brown Heater "Blow By"
Pump Power "After

F14 - - 5 Amp Tan
Run"
Brake Control Module

F15 40 Amp Orange - -
Pump
Engine Control Module

F16 - - 5 Amp Tan Power, Automatic
Transmission
10 Amp Red - 1.4

Engines
F17 - - Supply Primary Loads
15 Amp Blue - 2.4
Engines
12V Rear Cargo Outlet

F18 - - 20 Amp Yellow
Ignition Powered
Air Conditioner
F19 - - 7.5 Amp Brown
Compressor
Electronic Power
F20 - - 5 Amp Tan
Four-Wheel Drive
F21 - - 15 Amp Blue Fuel Pump
Power Control Module

Engine
Heated Windshield - If
F23 - - 30 Amp Green
Equipped
Electronic Unit Supply

F24 - - 15 Amp Blue
Automatic Transmission

20 Amp Yellow
F30 - - Constant Battery
(Customer Installed)
Powered
F83 - 40 Amp Green - Air Conditioning Fan

Power Supply All Wheel
Drive
Shift Lever Automatic

F87 - - 5 Amp Tan
Transmission
F88 - - 7.5 Amp Brown Heated Outside Mirrors
F89 - - 30 Amp Green Heated Rear Window
IBS Sensor (Battery

F90 - - 5 Amp Tan
State Of Charge)
Fig 2: Body Computer Fuse Center
Body Computer Fuse Center
The controller is located at the left side of the steering column at the bottom of the instrument panel.
Cavity Mini Fuse Description
Flashes/Electrical Movement Front

F31 7.5 Amp Brown
Seats/Fan Air Conditioning
F33 20 Amp Yellow Power Window Front (Driver Side)
F34 20 Amp Yellow Power Window Front (Passenger Side)
Supply Uconnect® System, Air

F36 15 Amp Blue Conditioning, Alarm, Power Folding
Outside Mirrors, USB Port
System Power Forward Collision
F37 10 Amp Red Warning Plus, All Wheel Drive (AWD),
IPC
F38 20 Amp Yellow Central Locking
F42 7.5 Amp Brown Power Under Lock and Key
F43 20 Amp Yellow Bi-directional Pump Washer
F47 20 Amp Yellow Power Rear Window (driver side)
F48 20 Amp Yellow Power Rear Window (passenger side)
Supply ParkSense, Spot Lights Front

Dome, Mirror, Electric Motor
F49 7.5 Amp Brown
Retractable Roof, Heated Front Seats,
Stabilizer Battery, ESC System, ESL
F50 7.5 Amp Brown Supply Air Bag
Alarm Power, Front Courtesy Light, Air

Conditioning Compressor, Brake Pedal
F51 7.5 Amp Brown Switch (NC), Plaque Automatic
Transmission, Compass, Rear Camera,
Leveling Headlights, Air Conditioning
Supply IPC/Starter Device/System

F53 7.5 Amp Brown
Keyless Enter-N-Go™
F94 15 Amp Blue Power Socket
Fig 3: Rear Cargo Fuse/Relay Distribution Unit
Rear Cargo Fuse/Relay Distribution Unit

To access the fuses, remove the access door from the left rear panel of the rear cargo area.
The fuses are contained in two units. Fuse holder no. 1 is located closest to the rear of the vehicle and fuse
holder no. 2 is located closest to the front of the vehicle.
On the controller there is also a 20 amp fuse for the sun visor of the retractable roof.
Fuse holders no. 1
F1 30 Amp Blue Power Inverter
F2 20 Amp Yellow HIFI Audio System
F3 20 Amp Yellow MY SKY
F4 7.5 Amp Brown Lumbar Adjustment Front Seat (Driver Side)
F5 30 Amp Green Power Seat (Driver Side)
F6 7.5 Amp Brown Power Seat (Driver Side And Passenger Side)
Lumbar Adjustment Front Seats (Driver Side And

F7 30 Amp Green
Passenger Side)
F8 20 Amp Yellow Heating Front Seats
Fuse holders no. 2
F1 10 Amp Red Controller Exterior Lighting On Trailer
F5 15 Amp Blue Controller Exterior Lighting Lights (Drivers Side)
F6 15 Amp Blue Controller Exterior Lighting Lights (Passenger Side)
HOISTING > STANDARD PROCEDURE > STANDARD PROCEDURE - HOISTING
In the event that it becomes necessary to raise the car, go to a Jeep Dealership, which is equipped with
surface lift or equivalent.
The points for lifting the vehicle using the lift are marked on the side skirts with the symbols shown in the
figure.
Fig 1: Marked Points For Lifting Vehicle
NOTE:
Be careful to select the lift pads sized to fit to the underbody of the car. Also, make sure to
correctly place the pads themselves at the openings indicated on the sill cladding. These
openings are not necessarily aligned with the triangle markings, which are specifically related
to the recommended location for the emergency jack, provided with the vehicle.
Fig 2: Hoisting Vehicle (1 Of 3)

JUMP STARTING > STANDARD PROCEDURE > STANDARD PROCEDURE - JUMP

STARTING
WARNING:
REVIEW ALL SAFETY PRECAUTIONS AND WARNINGS.
WARNING:
DO NOT JUMP START A FROZEN BATTERY, PERSONAL INJURY CAN RESULT.
WARNING:
DO NOT JUMP START WHEN MAINTENANCE FREE BATTERY INDICATOR DOT IS BRIGHT
COLOR.
WARNING:
DO NOT ALLOW JUMPER CABLE CLAMPS TO TOUCH EACH OTHER WHEN CONNECTED
TO A BOOSTER SOURCE.
WARNING:
DO NOT USE OPEN FLAME NEAR BATTERY
WARNING:
REMOVE METALLIC JEWELRY WORN ON HANDS OR WRISTS TO AVOID INJURY BY

ACCIDENTAL ARCING OF BATTERY CURRENT.
WARNING:
WHEN USING A HIGH OUTPUT BOOSTING DEVICE, DO NOT ALLOW BATTERY VOLTAGE
TO EXCEED 16 VOLTS.
WARNING:
REFER TO INSTRUCTIONS PROVIDED WITH DEVICE BEING USED.
CAUTION:
DO NOT ATTEMPT TO PUSH OR TOW THE VEHICLE TO START IT. THE VEHICLE CANNOT
BE STARTED THIS WAY. PUSHING WITH ANOTHER VEHICLE MAY DAMAGE THE
TRANSAXLE OR THE REAR OF THE VEHICLE.

STARTING > TO JUMP START A DISABLED VEHICLE:
Fig 1: Positive (+) & Negative (-) Battery Jumper Cables
1. On the disabled vehicle, remove the battery compartment lid from the passenger compartment
between the seats and inspect the battery.
1. Inspect the battery cable terminal clamps for damage. Replace any battery cable that has a
damaged or deformed terminal clamp.
2. Inspect the battery tray and battery hold down hardware for damage. Replace any damaged
parts.
3. Slide the thermal guard off of the battery case, if equipped. Inspect the battery case for
cracks or other damage that could result in electrolyte leaks. Also, check the battery terminal
posts for looseness. Batteries with damaged cases or loose terminal posts must be
replaced.
4. Inspect the battery thermal guard for tears, cracks, deformation or other damage. Replace
any battery thermal guard that has been damaged.
5. Inspect the battery built-in test indicator sight glass (if equipped) for an indication of the
battery condition. If the battery is discharged, charge as required. Refer to BATTERY,
STANDARD PROCEDURE .
2. Raise hood on disabled vehicle and visually inspect engine compartment for:
1. Generator drive belt condition and tension.
CAUTION:
If the cause of starting problem on disabled vehicle is severe, damage to booster

vehicle charging system can result.
3. When using another vehicle as a booster source, park the booster vehicle within cable reach.
Turn off all accessories, set the parking brake, place the automatic transmission in PARK or the
manual transmission in NEUTRAL and turn the ignition OFF.
4. On disabled vehicle, place gear selector in park or neutral and set park brake. Turn off all
accessories.
5. Connect jumper cables to booster battery. RED clamp to positive terminal (+). BLACK clamp to
negative terminal (-). DO NOT allow clamps at opposite end of cables to touch, electrical arc will
result. Review all warnings in this procedure.
CAUTION:
It is very important not to use the B+ connection at the TIPM when jump starting the
vehicle. The 150 amp fuse in the fuse block that feeds the TIPM will blow. Use only the
positive jump post (3) that is located in the wiper plenum on the right hand side of the
vehicle.
6. On the disabled vehicle, pull up and remove the protective cover (1) over the remote positive (+)
battery post.
7. Connect the RED jumper cable clamp (3) to positive (+) terminal. Connect BLACK jumper cable
clamp (2) to engine ground stud.
8. Start the engine in the vehicle which has the booster battery, let the engine idle a few minutes,
then start the engine in the vehicle with the discharged battery.
CAUTION:
Do not crank starter motor on disabled vehicle for more than 15 seconds, starter will
overheat and could fail.
9. Allow battery in disabled vehicle to charge to at least 12.4 volts (75% charge) before attempting
to start engine. If engine does not start within 15 seconds, stop cranking engine and allow starter
to cool (15 min.), before cranking again.

STARTING > DISCONNECT CABLE CLAMPS AS FOLLOWS:
Disconnect BLACK cable clamp from engine ground on disabled vehicle.
When using a Booster vehicle, disconnect BLACK cable clamp from battery negative terminal.
Disconnect RED cable clamp from battery positive terminal.
Disconnect RED cable clamp from battery positive terminal on disabled vehicle.
MAINTENANCE SCHEDULES > DESCRIPTION > SERVICE SCHEDULE (DIESEL - EMEA)
20, 40, 60, 80, 100, 120, 140, 160, 180, 200,
Kilometers:
000 000 000 000 000 000 000 000 000 000
Or Years: 1 2 3 4 5 6 7 8 9 10
Check tire conditions / wear and

adjust pressure, check expiration
• • • • • • • • • •
date on the Tire Service Kit
charge (if any).
Check lighting system operation

(headlights, turn signals,
rechargeable flashlight, passenger
• • • • • • • • • •
compartment, glove box,
instrument panel warning lights,
etc.).
Check and restore fluid levels

(engine coolant, brake / hydraulic
• • • • • • • • • •
clutch, windscreen washer,
battery, etc.).
Check emissions / exhaust gas; • • • • • • • • • •
Check, by means of diagnostic

socket, power system operation /
motor control, emissions and for • • • • • • • • • •
versions / markets, where
provided, engine oil degradation.
Visually inspect conditions and

integrity: exterior bodywork,
underbody protection, pipes and
• • • • •
hoses (exhaust, fuel system and
brakes), rubber parts (boots,
sleeves, bushings, etc.).
Check positioning / wear of

• • • • •
windscreen wiper front and rear.
Check windscreen wiper washer

• • • • •
and adjust nozzles.
Check cleanness of locks, hood

and trunk lever cleanness and • • • • •
lubrication.
Visually check condition and pad
wear of the front disc brakes and • • • • • • • • • •
operation.

wear of the rear disc brakes and • • • • • • • • • •
operation.
Inspect conditions drive belt / s

accessories (Versions without •
automatic tensioner).
Check accessory drive belt

tension (Versions without • •
Visually check conditions of the

•
timing belt.
Check oil level of transfer case. • •
Check oil level of rear differential. • •
Change engine oil and oil filter

(1)
(versions with DPF). (1)
Replace the accessory drive belt /

(2)
s. (2)
Replace the timing belt. (2) (2)
Replace the fuel filter. (3) • • •
Replace the air filter. (4) • • • • •
Change the brake fluid. • • • • •
Replace the cabin air filter. (4) (O)

O • O • O • O • O •
(•)
(1) The actual amount of oil change and oil filter depends on the condition of use of the car and is signaled
by light or message on the framework instruments. Must not exceed 2 years.
(1) If the car is used mainly on urban routes you need to replace the engine oil and filter every year.
(2) Areas not dusty: mileage recommended maximum 120, 000 km. Regardless of mileage, the belt must be
replaced every six years.
(2) Dusty areas, and / or heavy use (cold climates, urban use, long idling): Recommended maximum mileage
60, 000 km.
(3) In the case of filling the car with fuel of inferior quality to the planned European Specification is
recommended to replace this filter every 20, 000 km.
(4) On the use of the car in a dusty replace the filter every 20, 000 km.
(O) Interventions recommended.
(•) Interventions required.

NOTE:
Change the oil and filter change automatically every 240, 000 km.
MAINTENANCE SCHEDULES > DESCRIPTION > SERVICE SCHEDULE (GAS - EMEA)
The checks contained in the Service Schedule, once reached 120, 000 km / 8 years old, must be repeated
to start again from the first interval, thus respecting the same cadences previously performed.
15, 30, 45, 60, 75, 90, 105, 120, 135, 150,
Kilometers:
000 000 000 000 000 000 000 000 000 000
Or Years: 1 2 3 4 5 6 7 8 9 10

• • • • • • • • • •
date on the Tire Service Kit charge
(if any).

rechargeable flashlight, passenger • • • • • • • • • •
compartment, glove box, instrument
panel warning lights, etc.).

• • • • • • • • • •
clutch, windscreen washer, battery,
etc.).


• • • • •

• • • • •

• • • • •
and adjust nozzles.
lubrication.

operation.

operation.

Check accessory drive belt tension

(Versions without automatic • •
tensioner).

•
timing belt.
Change engine oil and oil filter. (1) • • • • •
Replace spark plugs. (2) • • • • •

(3)
s. (3)

O • O • O • O • O •
(•)
(1) If the vehicle is used with an annual mileage below 10, 000 Km, replace engine oil and filter every year.
(2) For versions 1.4 Turbo Multi Air, in order to ensure proper functionality and avoid serious damage to the
engine, it is essential only use spark plugs specifically certified for such engines, the same type and the
same brand (see SPARK PLUGS ).
strictly enforce the change interval of spark plugs provided in the Service Schedule. To replace the spark
plugs we recommend a Jeep Dealership.
60, 000 km.
(4) When using the car in dusty conditions replace the filter every 15, 000 km.
(O) Interventions recommended

(•) Interventions required
MAINTENANCE SCHEDULES > DESCRIPTION > NAFTA AND PUERTO RICO > OIL
CHANGE INDICATOR SYSTEM
The vehicle is equipped with an automatic oil change indicator system. The oil change indicator system will
remind you that it is time to take your vehicle in for scheduled maintenance.
The "Change Engine Oil" message will display in the Electronic Vehicle Information Center (EVIC) display.
The engine oil change indicator system is duty cycle based, which means the engine oil change interval
may fluctuate, dependent upon your personal driving style.
Based on engine operation conditions, the oil change indicator message will illuminate. This means that
service is required for your vehicle. Operating conditions such as frequent short-trips, trailer tow, extended
engine idle time, extremely hot or cold ambient temperatures will influence when the "Oil Change Required"
message is displayed. Severe Operating Conditions can cause the change oil message to illuminate as
early as 3, 500 miles (5, 600 km) since last reset. Have your vehicle serviced as soon as possible, within
the next 500 miles (805 km).
Unless reset, this message will continue to display each time you turn the ignition switch to the ON/RUN
position. To turn off the message temporarily, push and release the MODE button.
NOTE:
Under no circumstances should oil change intervals exceed 10, 000 miles (16, 000 km), 350
hours of engine run time or twelve months, whichever comes first.
Severe Duty All Models
Change Engine Oil at 4000 miles (6, 500 km) if the vehicle is operated in a dusty and off road environment.
This type of vehicle use is considered Severe Duty.
CHANGE INDICATOR - RESET
To reset the oil change indicator system (after performing the scheduled maintenance), refer to the following
procedure.
1. Turn the ignition switch to the ON position (do not start the engine).
2. Fully push the accelerator pedal slowly, three times, within 10 seconds.
3. Turn the ignition switch to the OFF/LOCK position.

NOTE:
If the indicator message illuminates when you start the vehicle, the oil change indicator system
did not reset. If necessary, repeat this procedure.
MAINTENANCE SCHEDULES > DESCRIPTION > NAFTA AND PUERTO RICO > ONCE A
MONTH OR BEFORE A LONG TRIP
Check engine oil level.
Check windshield washer fluid level.
Check tire pressure and look for unusual wear or damage. Rotate tires at the first sign of irregular
wear, even if it occurs before the oil indicator system turns on.
Check the fluid levels of coolant reservoir and brake master cylinder, fill as needed.
Check function of all interior and exterior lights.
CAUTION:
Failure to perform the required maintenance items may result in damage to the vehicle.
MAINTENANCE SCHEDULES > DESCRIPTION > NAFTA AND PUERTO RICO >
REQUIRED MAINTENANCE INTERVALS
At Every Oil Change Interval As Indicated By Oil Change Indicator System:
Change oil and filter.
Inspect battery and clean and tighten terminals as required.
Inspect brake pads, shoes, rotors, drums, hoses and park brake.
Inspect engine cooling system protection and hoses.
Check and adjust hand brake.
Inspect exhaust system.
Inspect engine air cleaner if using in dusty or off-road conditions.
Maintenance Chart
Mileage or time
passed 10, 20, 30, 40, 50, 60, 70, 80, 90, 100, 110, 120, 130, 140, 150,
(whichever 000 000 000 000 000 000 000 000 000 000 000 000 000 000 000
comes first)
Years 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15
16, 32, 48, 64, 80, 96, 112, 128, 144, 160, 176, 192, 208, 224, 240,
Or Kilometers
000 000 000 000 000 000 000 000 000 000 000 000 000 000 000
Check tire
condition/wear
and adjust
pressure, if
• • • • • • • • • • • • • • •
necessary,
check TIRE KIT
expiration date
(if provided).
Check operation
of lighting
system
(headlamps,
direction
indicators,
hazard warning
lights, luggage
• • • • • • • • • • • • • • •
compartment,
passenger
compartment,
glove
compartment,
instrument panel
warning lights,
etc.).
Check and, if
necessary, top
up fluid levels
(brakes/hydraulic
clutch, • • • • • • • • • • • • • • •
windshield
washer, battery,
engine coolant,
etc.).
Check engine
control system
• • • • • • • • • • • • • • •
operation (via
diagnostic tool).
Visually inspect
condition of:
exterior
bodywork,
• • • • • • •
underbody
protection, pipes
and hoses
(exhaust - fuel
system -
brakes), rubber
elements (boots,
sleeves,
bushings, etc.).
Check
windshield/rear
window wiper • • • • • • • •
blade
position/wear.
Check operation
of windshield
washer system • • • • • • • •
and adjust jets if
necessary.
Check
cleanliness of
hood and
tailgate locks • • • • • • • •
and cleanliness
and lubrication of
linkages.
Visually check
the condition and
• • • • • • • • • • • • • • •
wear of the front
and rear brakes.
Check the front

suspension, tie
rods, CV joints • • • • • • •
and replace if
necessary.
Visual inspect
the condition of
• • •
the accessory
drive belt.
Check the
tension of the
• • • • • • •
accessory drive
belt.
Replace the
accessory drive •
belt.
Inspect and
replace PCV
•
valve if
necessary.
Change engine
oil and replace
oil filter (*).
Inspect the PTU

• • •
fluid level.
Inspect the rear

differential fluid • • •
level.
Replace spark
plugs (1.4L
• • • • •
Turbo engine).
(**)
Replace spark
plugs (2.4L •
engine). (**)
Replace engine
• • • • •
air filter. (#)
Replace brake
fluid every two • • • • • • •
years.
Replace cabin
• • • • • • • • • • • • • • •
filter.
Change the
manual
transmission
fluid if using your
vehicle for any
of the following:
trailer towing,
heavy loading,
taxi, police,
delivery service
(commercial • •
service),
off-road, desert
operation or
more than 50%
of your driving is
at sustained
speeds during
hot weather,
above 90°F
(32°C).
Flush and
replace the
engine coolant • •
at 10 years or
150, 000 miles
(240, 000 km)
whichever
comes first.
Replace the
timing belt (1.4L •
Turbo Engine).
• Recommend replacement
• Mandatory service
(#) The engine air cleaner should be inspected at every oil change if used in dusty areas.
(*) The oil and oil filter replacement must be carried out when indicated by a warning light or message on the
instrument panel, or in any case should not exceed 1 year or 10, 000 miles (16, 000 km).
(**) The spark plug change is distance based only, yearly intervals do not apply. The following are essential
to ensure correct operation and prevent serious damage to the engine:
Only use spark plugs of the same make and type which are specially certified for such engines (refer
to SPARK PLUGS for further information).
Strictly comply with the spark plug replacement interval given in the "Maintenance Schedule" for spark
plug replacement.
Contact your authorized dealer if you have any questions.
WARNING:
You can be badly injured working on or around a motor vehicle. Do only service work for
which you have the knowledge and the right equipment. If you have any doubt about your
ability to perform a service job, take your vehicle to a competent mechanic.
Failure to properly inspect and maintain your vehicle could result in a component
malfunction and effect vehicle handling and performance. This could cause an accident
Failure to follow these instructions may result in possible serious or fatal injury.
MAINTENANCE SCHEDULES > INSPECTION > PERIODIC CHECKS
Every 1, 000 km or before long journeys, check and, if necessary, top up the following:
Engine coolant level;
Brake fluid level;
Windscreen washer fluid level;
Tire inflation pressure and condition;
Operation of lighting system (headlights, direction indicators, hazard warning lights, etc.)
Operation of screen wash/wipe system and positioning/wear of windscreen/rear window wiper blades;
Every 3000 km check and, if necessary, top up: engine oil level.
MAINTENANCE SCHEDULES > INSPECTION > DEMANDING USE OF THE CAR
If the car is used mainly in one of the following severe conditions:
Towing a trailer or caravan
Dusty roads
Short distances (less than 7-8 km) and repeated with external temperatures below zero
Engine frequently idling or driving long distances at low speeds or long inactivity you must do the
following checks more frequently than indicated in the Service Schedule:
Check pad conditions and wear of front disc brakes
Check cleanness of locks, hood and trunk lever cleanness and lubrication
Visually check conditions: engine, gearbox, transmission, pipes and hoses (exhaust - fuel - brakes),
rubber parts (boots - sleeves - bushings, etc.)
Monitor the state of battery charge and liquid level (electrolyte)
Visual check conditions accessory drive belts
Check and replace if necessary engine oil and oil filter
Inspection and possible replacement of cabin filter
Check and if necessary, replace air filter.
MAINTENANCE SCHEDULES > INSPECTION > 15, 000KM SERVICE (2.4L MULTIAIR2
1.4L TURBO MULTIAIR)
Check tire conditions / wear and adjust pressure, check expiration date on the Tire Service Kit charge
(if any).
Check lighting system operation (headlights, turn signals, rechargeable flashlight, passenger
compartment, glove box, instrument panel warning lights, etc.).
Check and restore fluid levels (engine coolant, brake / hydraulic clutch, windscreen washer, battery,
etc.).
Check emissions / exhaust gas. Refer to DIAGNOSIS AND TESTING .
Check, by means of diagnostic socket, power system operation / motor control, emissions and for
versions / markets, where provided, engine oil degradation.
Check positioning / wear of windscreen wiper front and rear.
Check windscreen wiper washer and adjust nozzles.
Visually check condition and pad wear of the front disc brakes and operation.
Visually check condition and pad wear of the rear disc brakes and operation.
If the car is used in dusty conditions replace the air filter cartridge operating as described below:
Remove the engine cover. Refer to COVER, ENGINE, REMOVAL AND INSTALLATION - 1.4L or
COVER, ENGINE, REMOVAL AND INSTALLATION - 2.4L.
Fig 1: Quick-Connect Hose & Screws
Remove the screws (1) fixing air filter cover.
Disconnect the quick connect (2) from the air filter cover.
Fig 2: Air Filter Cartridge & Cover
Lift the lid and replace the air filter cartridge (1).
Put into place the air filter cover, tighten the screws and the quick connect.
Install the engine cover. Refer to COVER, ENGINE, REMOVAL AND INSTALLATION - 1.4L or COVER,
ENGINE, REMOVAL AND INSTALLATION - 2.4L.
If the car is used in dusty replace the cabin air filter. Refer to FILTER, CABIN AIR, REMOVAL AND
INSTALLATION .
MAINTENANCE SCHEDULES > INSPECTION > 20, 000KM SERVICE (2.0L TURBO
DIESEL 1.6L TURBO DIESEL)
(if any).
etc.).
Visually inspect conditions and integrity: exterior bodywork, underbody protection, pipes and hoses
(exhaust, fuel system and brakes), rubber parts (boots, sleeves, bushings, etc.).
Replacing oil and oil filter is indicated by light or message on the instrument panel depending on the
use of the car. Must not exceed 2 years.
If the car is used mainly on urban routes you need to replace the engine oil and filter every year.
To replace oil and oil filter. Refer to FILTER, ENGINE OIL, REMOVAL AND INSTALLATION .
If refueling the car with fuel of inferior quality to the European specification provided it is
recommended to replace the fuel filter cartridge, operating as described below. (Refer to REMOVAL
AND INSTALLATION ). Refer to COVER, ENGINE, REMOVAL AND INSTALLATION .
Fig 1: Filter Element, Cover & Screws
Position the fuel filter in vise with protective jaws.

NOTE:
To avoid compromising the functionality of the new filter element, it is recommended to

protect hands with suitable gloves when opening the protective and all stages of
assembly.
Remove the screws (1a), remove the cover (1b) complete with filter element (1c) and place in a
suitable container.
Fig 2: Filter Element & Cover
Remove the filter element (1a) from the cover (1b).

Fig 3: Water Presence Sensor & Seal Ring
Check the correct position of the water presence sensor (1a) and seal ring (1b).
Fig 4: Tooth & Groove
Storing in its place the complete cover of filter element, taking care to engage the tooth with the
groove of the support.
Tighten the mounting screws on cover of fuel filter.
Remove the fuel filter from the vise (Refer to REMOVAL AND INSTALLATION ). Refer to COVER,
ENGINE, REMOVAL AND INSTALLATION .
If the car is used in dusty conditions replace the air filter cartridge operating as described below.
Fig 5: Air Filter Cover & Screws
Remove the screws fixing air filter cover (1).

Put into place the air filter cover and tighten the screws.
If the car is used in dusty conditions replace the cabin air filter. Refer to FILTER, CABIN AIR,
REMOVAL AND INSTALLATION .
MULTIAIR)
(if any).
etc.).
Check cleanness of locks, hood and trunk lever cleanness and lubrication.
Check belt tension on accessory drive (versions without automatic tensioner).
To replace oil and oil filter. Refer to FILTER, ENGINE OIL, REMOVAL AND INSTALLATION . If the car
is used with an annual mileage below 10, 000 km replace engine oil and filter every year.
NOTE:
In order to ensure proper functionality and avoid serious damage to the engine, it is
essential: only use spark plugs specifically certified for such engines, the same type and
the same brand; strictly enforce the change interval of spark plugs provided in SPARK
PLUGS .
Replace the spark plugs operating as described below.

Fig 1: Ignition Coil Wire Harness Connectors, Ignition Coils & Bolts
Disconnect the electrical connections of the ignition coils.
Remove the screws (2a) and remove the ignition coils (2b).
Fig 2: Spark Plug & Tool
With appropriate tool (1a), unscrew and remove the spark plug for the engine (1b).
Install the new engine spark plugs and tighten them to the specified torque.
Install the ignition coils and tighten the screws to the specified torque.
Connect the electrical connections of the ignition coils.
Replace the air filter cartridge operating as described below.

Remove the screws fixing air filter cover.
Disconnect the quick connect from the air filter cover.

Lift the lid and replace the air filter cartridge.
Install the engine cover. Refer to COVER, ENGINE, REMOVAL AND INSTALLATION .
Replace the brake fluid. Refer to STANDARD PROCEDURE .
Replace the cabin air filter. Refer to FILTER, CABIN AIR, REMOVAL AND INSTALLATION .
(if any).
etc.).

NOTE:

assembly.
suitable container.

Replace the air filter cartridge as described below.


MULTIAIR)
(if any).
etc.).

Remove the engine cover. Refer to COVER, ENGINE, REMOVAL AND INSTALLATION .

INSTALLATION .
MULTIAIR 2.0L TURBO DIESEL 1.6L TURBO DIESEL)
(if any).
etc.).

Visually check conditions timing belt.
Check oil level of transfer case. Refer to STANDARD PROCEDURE .
Check oil level of rear differential. Refer to FLUID, DIFFERENTIAL, STANDARD PROCEDURE .
To replace oil and oil filter. Refer to FILTER, ENGINE OIL, REMOVAL AND INSTALLATION - 1.6L/2.0L
or FILTER, ENGINE OIL, REMOVAL AND INSTALLATION - 2.4L . If the car is used with an annual
mileage below 10, 000 km replace engine oil and filter every year.
NOTE:
PLUGS .



Install the engine cover. Refer to COVER, ENGINE, REMOVAL AND INSTALLATION - 1.6L/2.0L or
COVER, ENGINE, REMOVAL AND INSTALLATION - 1.4L .
In the case of dusty areas and / or heavy use (cold climates, urban use, long idling) is recommended
to replace the drive belt / s accessories.
NOTE:
Regardless of mileage, the belt should be replaced every four years.
2.0L Turbo Diesel 1.6L Turbo Diesel
(if any).
etc.).
Check belt tension on the accessory drive (versions without automatic tensioner).
Visually check condition of timing belt.
4x4 versions only:
NOTE:
Replace the fuel filter cartridge, operating as described below. (Refer to REMOVAL AND
INSTALLATION ). Refer to COVER, ENGINE, REMOVAL AND INSTALLATION .

NOTE:

assembly.
suitable container.



(if any).
etc.).

INSTALLATION .
(if any).
etc.).
Visually check conditions / belt and accessory drive (versions without automatic tensioner).

NOTE:

assembly.
suitable container.


MULTIAIR)
(if any).
etc.).
NOTE:
PLUGS .




(if any).
etc.).

NOTE:

assembly.
suitable container.

Fig 3: Filter Element, Lid, Water Drain Line & Bleed Valve Hole
NOTE:

assembly.
Assemble by pressing the new filter element (1a) in the lid (1b) engaging the water drain line (1c) in
the hole (1d) of the bleed valve.
Place the filter element in the housing, taking care to engage the tooth with the groove of the support.

MULTIAIR)
(if any).
etc.).


INSTALLATION .
(if any).
etc.).

NOTE:
PLUGS .
Remove the engine cover. Refer to COVER, ENGINE, REMOVAL AND INSTALLATION - 1.6L/2.0L or


NOTE:
(if any).
etc.).
In case of non-dusty areas it is recommended to replace the drive belt / s accessories.
In case of non-dusty areas it is recommended to replace the timing belt.

NOTE:

assembly.
suitable container.

NOTE:

assembly.

MULTIAIR)
(if any).
etc.).

INSTALLATION .
(if any).
etc.).

4x4 versions only:
recommended to replace the fuel filter cartridge, operating as described below.

NOTE:

assembly.
suitable container.

NOTE:

assembly.

MULTIAIR)
(if any).
etc.).
NOTE:
PLUGS .




(if any).
etc.).

NOTE:

assembly.
suitable container.

NOTE:

assembly.

(if any).
etc.).

NOTE:

assembly.
suitable container.

NOTE:

assembly.

(if any).
etc.).

NOTE:

assembly.
suitable container.


NEW VEHICLE PREPARATION INSTRUCTIONS > STANDARD PROCEDURE > EMEA >
STANDARD PROCEDURE - PREPARATION FOR DELIVERY OF NEW VEHICLE
DEALERSHIP IDENTIFICATION DATA
Corporate name
Sincom code
VEHICLE IDENTIFICATION DATA
Model
Version
Chassis No.
CONFORMITY
• On-board documentation conformity
• Accessory check
• Check for and carry out the applicable Campaigns
VEHICLE INTERIOR
• Fitting fuses or deactivating Logistic Mode
• Anti-theft device/remote control operation check
Start up the engine and check the operation of:
• Electric handbrake
• Warning lights going out
• Horns, windscreen washer/wipers, hazard warning lights
• Reset the trip meter
Switch off the engine and check:
• Interior trim, exterior trim, seat belt mountings and sliding
• Adjust clock, date, language and unit of measurement
• Locks
ENGINE COMPARTMENT
Check and, if necessary, restore:
• Battery charge status
• Brake/clutch fluid level
• Engine oil level
• Power steering fluid level (for vehicles with hydraulic power steering)
• Screen washer fluid level
CAR EXTERIOR
Raise the vehicle and check:
• Condition of underbody
• No leaks from lubrication system
• No leaks from engine cooling system
• No leaks from the braking/clutch system

• No leaks from power steering system
• No leaks from fuel system
• No leaks from window washer system
• Condition of differential driveshaft boots
• Condition of brake hoses and pipes
Lower the vehicle and carry out:
• Check tire inflation pressure
• Fit wheel hub caps (where available)
FINAL CHECK
• Check front and rear seats
• Remove moving/transportation protections
• Remove labels from windscreen
• Wash vehicle and check for water penetration
• Dry vehicle
• Clean passenger compartment, windows and rear view mirrors
• Fit radio aerial
• Visually inspect vehicle exterior
• Secure the front and rear number plate mounting
• Apply "Inspected" label
NOTE:
The special cards containing instructions and warnings for the customer should not be
removed
Detected faults:
Date:
Operator's name:
Operator's signature:
NEW VEHICLE PREPARATION INSTRUCTIONS > STANDARD PROCEDURE > NAFTA >
STANDARD PROCEDURE - NEW VEHICLE PREPARATION
VEHICLE READINESS
NOTE:
This document is for reference purposes only. The instructions are not VIN-specific, and it is
not required to print or retain this document for each New Vehicle Prep performed.
Description Action
1. Ignition in the ON/RUN position
2. Headlights Off;
3. Turn on the right-hand turn indicator
4. Pull and hold the multifunction switch to

high-beam (or flash) mode
5. Hold the lever in this position for around 10

Place vehicle into Customer Mode (15
seconds.
Renegade)
NOTE:
IT IS NOT POSSIBLE TO ACTIVATE THE

LOGISTIC MODE MANUALLY.
Once out of Logistics Mode, the Battery indicator will

turn off.
Keep All Protective Transit Film and Wheel

Keep All Protective Transit Film and Wheel Covers &
Covers & Films on vehicle until sold, or up to
Films on vehicle until sold, or up to 180 Days.
180 Days
Inflate tire pressure to max side wall pressure Increase the tire pressure to maximum sidewall pressure
(except heavy duty trucks) if vehicle is going into lot storage.
Install all "Shipped Loose" items Install all "Shipped Loose" items.
Install Front License Plate Bracket (if required) Install Front License Plate Bracket.
Install Roof Rack Install Roof Rack.
Install Antenna Install Antenna.

Process.
1. Locate lower antenna module on vehicle roof.
2. Locate Pull Tab located on top of the roof

installed module.
3. Pull tab - removing protective film cover

Install Shark Fin Antenna
(protects lower module from elements during
shipping.
4. Locate upper shark fin (ships in vehicle trunk)

and place atop lower module.
5. Apply hand force to "snap" fit.
Install Wheel Center Caps Install Wheel Center Caps.
If vehicle is going into storage and tire pressure is being

Reset Tire Pressure Light Load Switch (if
set to max, switch the tire pressure light load setting to
equipped)
"max load" using the button on the instrument panel.
UNDERHOOD
Description Action
Verify the operation of the hood release system

including the inside hood release lever and the
outside hood secondary safety catch. Adjust if
necessary. The safety catch prevents the hood from
Hood Latch and Safety Catch - Adjust as Needed
going to the full open position until it is manually
released. To test the safety catch, unlatch the hood
with the interior hood release lever and attempt to
raise the hood without operating the safety catch.
Check the battery state of charge by connecting a

digital voltmeter at the jump-start locations. The
battery voltage should be at least 12.4 volts. If
Battery State-of-Charge - document voltage
charging is necessary, follow the service information
procedures and recharge the battery. Record
voltage on New Vehicle Prep (NVP) form.
Inspect the following for routing, loose attachments,

connections, and clearance. Reroute and tighten as
Loose Attachments, Routing and Clearance required: Brake Lines, Fuel Lines, Power Steering
Hoses, Vacuum Hoses, Clutch Lines, Refrigerant
Lines, Wiring, Belts.
Refer to the owner's manual or service information

All Fluid Levels
for proper fluid level inspection locations.
Visually inspect the underhood area to ensure

No Fluid Leaks present absence of fluid leaks. Check clamps for tightness
an full engagement.
ROAD TEST
Description Action
Perform Road Test, Mileage: Before ______ After

Record mileage before and after road test.
______
Engine Starts with All Keys Start vehicle with all sets of keys.
Verify all warning lights and gauges are operating

All Warning Lights and Gauges / No DTCs
properly, and no fault codes exist.
Ensure vehicle starts with push button, when key is

Keyless Go
inside vehicle.
Verify engine will only start while automatic

Engine Starts Only in Park & Neutral
transmission is in park or neutral.
Verify engine will only start when clutch is depressed

Engine Starts Only with Clutch Depressed
on manual transmission vehicles.
Apply the service brakes while the car is in motion. Be

sure the brake operation is smooth and positive.
Make sure the vehicle stops in a straight line and
Service and Parking Brakes without pulling to one side. Ensure there is no shudder
or vibration when braking. Ensure that the parking
brake is easy to operate. Make sure the parking brake
does not drag.
Ensure that the vehicle will only start when the brake
Brake Transmission Shift Interlock
is depressed on vehicles with automatic transmission.
Check for smooth shifting. Make sure shift lever

Clutch / Manual Transmission Shifting operates easily and smoothly. Check for proper
synchronization. The gears should not grind.
Make sure that the park lock mechanism holds the

vehicle. With the vehicle on a grade, put the
automatic transmission in park and slowly release the
Automatic Transmission Shifting service brake to check the operation of the park
mechanism. Make sure the shift lever operates easily
and smoothly. Check for smooth shifting. Check for
proper upshifting and downshifting.
Verify that Autostick feature allows proper shifting

Autostick
through the gears.
The engine should: start properly, idle smoothly and at

proper speed, be free from stumbling or hesitation,
produce sufficient power, be free of unusual noises,
Engine Performance - Cold
operate within the proper temperature range, and stop
when the ignition key is shut off or stop button is
depressed.

Engine Performance - Warm
depressed.
Check that the power assist works properly. Make
sure that the steering wheel does not vibrate
abnormally at idle or road speed. Ensure that the
Steering and Handling steering wheel is centered when traveling in a straight
line. Check that the vehicle does not drift to either
side on flat road surfaces. Make sure that the vehicle
does not vibrate or shake abnormally.
Check that the vehicle is free of noise, vibrations,

Noise, Vibration, Squeaks, or Rattles
squeaks, or rattles. Tighten any loose fasteners.
Check the heater operation after the vehicle has

reached operating temperature. Operate blower motor
Heater / Defrost- Front at all speeds. Operate the system in all modes. Check
for hot air at all appropriate outlets. Check for
temperature control operation.
Ensure that the A/C system cools properly. Operate

Air Conditioning blower motor at all speeds. Check for cool air at all
temperature outlets. Operate the system in all modes.
Rear Heater and Air Conditioning Check the rear heater and A/C for proper operation.
Ensure that the electric heated rear defroster

Defrost - Rear
operates correctly. Turn on and feel for warmth.
While on road test, verify that the visual warning

indicators located on the side view mirrors are
Blindspot Monitoring System (if equipped)
operating properly when an object is within the
detection zone.
Check the "on/off" switch. Check the "set" operation.

Check the "resume" function. Check the "accelerate"
Cruise Control (if equipped) and "decelerate" function. Check the "cancel" button.
Check the brake/clutch release function. If equipped,
verify operation of Adaptive Cruise Control function.
Refer to the service information on TechCONNECT for

Set Compass Variance / Calculation (if equipped)
information regarding compass setting procedures.
With vehicle in four wheel drive, press the sway bar

switch to activate the system. Verify that the "Sway
Electronic Sway Bar Disconnect (if equipped) Bar Indicator Light" is illuminated. *Warning- Do NOT
exceed 18 MPH / 29 KMPH while the front sway bar is
disconnected.
Shift the transfer case through all ranges to make sure

Transfer Case (if equipped)
all shifting is smooth and operates properly.
Use the terrain select switch to change the ride height

during normal driving conditions. Cycle through each
Load Leveling Air Suspension (if equipped)
selection and verify proper operation of the air
suspension system.
Verify that Tire Pressure Monitoring Indicator Light is

not illuminated when tires are above minimum inflation
Tire Pressure Monitoring System
recommendations. Ensure that indicator lamp is not
flashing/chiming.
Put vehicle in reverse and slowly back up toward an
Park Assist (if equipped) object. Verify that Park Assist warning icon, lights and
chimes operate properly as object is approached.
Put vehicle in reverse, verify that screen provides a

Back-Up Camera (if equipped)
clear and visible image from rear of vehicle.
INTERIOR
Description Action
From the interior of the vehicle, open and close all doors
to ensure ease of operation. Fully open and close the
Visually Inspect Interior Parts for Damage, Fit, glove box to ensure proper operation. Fully open and
etc. close the console door to ensure proper operation.
Check interior panels for proper fit and free from
damage.
Operate and visually inspect all interior lights and

switches, including: Dome/Map lamps, and if equipped
the following: vanity mirror lamps, glove box lamps, ash
All Interior Lamps and Horn
tray lamp, cigar lighter lamp, radio lamps, door mounted
lamps, illuminated entry system. Ensure that the horn
operates properly.
Check that the rearview mirror's day/night function Is

Rear View Mirror
operating properly.
Activate front windshield wipers, and if equipped, rear

window wipers and check for proper operation at all
speeds. Activate the front and if equipped, the rear
Front and Rear Wipers and Washers
washer. Check the spray pattern for proper operation
and aim. Check the intermittent wipe feature for proper
operation.
Check all interior door locks for proper operation,

All interior Door Locks including Child Locks including rear child safety door locks if equipped. Place
in the unlocked position.
Steering Wheel Mounted Controls Check all steering wheel controls for proper operation.
Verify the proper operation of the memory mirror and

Memory Mirror / Seat
seat system.
Cigar Lighter Check cigar lighter for proper operation.
Fully open and close all power windows to ensure proper

operation and sealing. Ensure that the windows operate
Power Windows and Window Lock Switch
properly at each door. Verify that window lock button is
operating properly.
Check the adjustable pedals for proper operation by

Power Adjustable Pedals (if equipped)
pressing the switch on the steering column.
Outside Power Mirrors Check power mirrors for proper operation.
Press Power Folding Mirror button on driver side door

Power Folding Outside Mirrors trim panel. The switch is located between the Left and
Right Power Mirror buttons.
Power Heated Mirrors (if equipped) Check power heated mirrors for proper operation.
Check for correct installation and operation of seat and

shoulder belts, and retractors. Check that the restraint
system safety labels regarding the use of seatbelts and
airbags are in place. Fully cycle the seats for proper
Seats and Seat Belts - All Adjustments
adjustments and verify that each seat is securely
mounted. Fold down and latch the rear seats. Pull
forward to check that the latches operate correctly.
Check for proper head restraint operation.
Cycle the Skyslider roof. Check and adjust alignment as

Skyslider (if equipped)
required.
Cycle sunroof. Ensure that the sunroof opens and

Power Sunroof (if equipped) closes easily. Verify proper operation of one touch
open/close feature if equipped.
Set all clocks to correct time. Refer to Owner's Manual

Set Clock(s)
for information regarding clock setting procedures.
Turn the radio on and check reception in both AM and

Audio System FM modes. Check that the CD player operates properly.
Check for good sound quality from all speakers.
On a vehicle equipped with the base RA1 radio this

option can be found in the EVIC under settings On a
Turn on the ECO light, The "Display fuel saver"
vehicle equipped with any other radio (RA2, 3, 4) this
option must be turned on
option can be found in the radio under
controls->settings->display
Satellite Radio (if equipped) Turn on satellite radio and verify reception.
Test the DVD player to ensure that a DVD will load

Video System(if equipped)
properly and display on the screen.
Satellite Streaming Video (if equipped) Satellite Streaming Video.
Wireless Headphones / Video Remote (if Check for proper operation of the Wireless Headphones
equipped) / Video Remote.
Heated Steering Wheel (if equipped) Verify that heated steering wheel is functioning properly.
Power Outlet(s) Check all power outlets for proper operation.
Check the child restraints and child seats for proper

Integrated Child Seat / Belt
operation.
Verify proper operation of power folding third row head

Power folding Headrests (if equipped) restraints by pressing the power folding switch located
on the instrument panel switch bank.
Check for proper operation of heated seats on all power

Heated Seats (if equipped)
levels, on all equipped seats.
Check for proper operation of ventilated seats on all

Power Cooled Seats (if equipped)
power levels, on all equipped seats.
Check for proper operation of the heated and cooled and
Heated / Cooled Cup Holders (if equipped)
cooled cup holders.
Check the rear cargo compartment cover is operating

Cargo Compartment Cover (if equipped)
properly.
Vinyl Floor Covering - (if equipped) Verify properly equipped.
EXTERIOR
Description Action
Inspect the body exterior for damage, loose or

missing items. During the inspection, ensure that no
Inspect Body and Paint for Damage and Fit/ Finish vehicle damage occurred from the time the vehicle
was received and the beginning of the New Vehicle
Preparation.
Operate and visually inspect the following:

Headlamps (High/Low Beams), turn signals, hazard
warning flashers, parking/tail/license plate lamps,
Exterior Lamps - Headlamps, Turn Signals, Hazards,
reverse/back up lamps, fog lamps, stop lamps
Park/Tail/License Plate, Trunk Lights, etc.
including center mounted stop lamp, daytime running
lamps (if equipped), clearance lamps, cargo bed
lamps, any other lamps.
Verify all doors lock and unlock with all mechanical

Lock and Unlock all doors with all mechanical keys
keys.
Open each door/liftgate/tailgate from the outside to

check outside door handle operation. Check the door
detent. Partially close all doors to check the
Doors, Liftgate and Tailgate- Adjust Strikers as
open-door detent. Close all doors/liftgates/tailgates
Needed
to check the operation of latches and strikers. Adjust
strikers as required. Verify liftgate/tailgate ease of
operation.
Verify all modes of operation of the power liftgate,

Power Liftgate - Inspect for fit and operation (if
including operating the liftgate using the inside
equipped)
switches and the Remote Keyless Entry transmitter.
Lock doors using the Remote Keyless Entry

Security Alarm Test (if equipped) Transmitter. Verify the operation of the Vehicle
Security System warning lamp.
Verify that the Keyless Enter-N-Go feature is

operating properly, by grabbing the door handle of the
Passive Entry (if equipped) locked vehicle, while the Remote Keyless Entry
transmitter key is within 5 feet of the vehicle. The
door should unlock automatically.
Remote Keyless Entry (if equipped) Verify that doors unlock properly using all key FOBS.
Verify that engine starts with all keys when using

Remote Start (if equipped)
Remote Keyless Entry Transmitter.
VEHICLE STORAGE
Description Action
Keep all protective transit film, wheel covers and Keep all protective transit film, wheel covers and
films on vehicle until sold films on vehicle until sold.
Inflate tire pressure to max side wall pressure

Inflate tire pressure to max side wall pressure (except heavy duty trucks.) Periodically move
vehicles to prevent Flat Spotting on tires
FINAL DETAIL & INSPECTION
Description Action
Perform all incomplete recalls and RRT's Perform all incomplete recalls and RRT's.
Remove exterior protective coatings/coverings from

Remove interior and exterior Transportation
vehicle, remove interior protective covers, grease
Protective Covers
markings on door jambs, unnecessary labels, etc.
Make sure that the body is free from paint chips or

scratches. Touch up any chips/scratches using thin
Inspect paint and body, touch up as needed
layers of paint. Ensure that the body is free from
dings and dents.

Test and record battery state of charge
procedures and recharge the battery. Record voltage
on New Vehicle Prep (NVP) form.
Connect the electrical connector to the navigation

port. Push the navigation port into the instrument
panel until it snaps into place securely. Install the
Install TomTom Navigation navigation mount holder and navigation screen.
Perform the 12-Volt Power Up procedure. Store
navigation screen for security reasons in accordance
to your dealership process.
Using wiTECH, take the Vehicle Tracking Module

Take Vehicle Tracking Module (VTM) out of
(VTM) out of Transport Mode. wiTECH Path: ECU >
Transport Mode using wiTECH
Miscellaneous > Change VTM Mode > Disable
Adjust tire pressures including spare to door

Adjust tire pressures including spare to door placard.
placard
Reset the Tire Pressure Light Load Switch back to

the "Light Load" setting using the switch on the
equipped)
instrument panel.
Wash the entire vehicle. Clean the tire sidewalls and

Wash and clean vehicle exterior wheel/wheel covers (use non - acidic wheel cleaner).
Clean exterior/interior glass surfaces.
Inspect the interior trim, seats, carpeting, and

Clean vehicle interior
moldings. Clean as necessary.
NEW VEHICLE PREPARATION INSTRUCTIONS > LICENSE PLATE INSTALLATION >
FRONT, BASE - EMEA
Fig 1: Front License Plate (Base) - EMEA
1.
2. Place the plate holder (1a) with the insert centering (1b) in the bumper, centering it with the
reference (1c) on the bumper.
3. Raise the number plate holder to align the side profiles.
Fig 2: Plate Holder & Mounting Screws
4. Support the plate holder (1a) and tighten the mounting screws (1b) provided.
5. Install the front license plate.

FRONT, TRAIL HAWK - EMEA
Fig 1: Front License Plate (Trail Hawk) - EMEA


REAR, EMEA
Fig 1: Rear License Plate - EMEA
1. Use a drill with a suitable bit to make holes in the marked points (1b) of the rear number plate
holder (1a).
2. Place the self-adhesive rubber pad in position.

Fig 2: Rear Number Plate Holder, Buffers & Fasteners
3. The rear number plate holder is equipped with buffers (1) with double-sided adhesive surface
protected by a film. Before fitting the number plate holder, carefully clean the area of the body
concerned, using denatured ethyl alcohol (or heptane).
4. Place the rear number plate holder (2a) in its housing, aligning the holes with the fastenings on the
tailgate (2b), then start the fixing screws (2c) without tightening.
5. Remove the adhesive buffer protective film tabs (3a) and tighten the fixing screws (2c).
6. Install the rear license plate.

FRONT, BASE - NAFTA
Fig 1: Front License Plate (Base) - NAFTA

FRONT, TRAIL HAWK - NAFTA
Fig 1: Front License Plate (Trail Hawk) - NAFTA


REAR, NAFTA
Fig 1: Mounting Point Plugs
1. Mount the back plate using the plugs (1) as mounting points for the screws.
TOWING > SPECIFICATIONS > DISTRIBUTION OF WEIGHT AND LOADS ON THE AXLES
1.4 MultiAir Turbo 1.6 16V Multijet 2.0 16V Multijet 2.0 16V Multijet
140CV 170CV
Maximum weight
1905 1905 2010/2080 (*) 2080
allowed (kg)
Maximum weight
allowed on the front 1050 1050 1150 1150
axles (kg)
Maximum weight
allowed on the rear 900 900 1000 1000
axles (kg)
NOTE:
Loads are not to exceed. It is the responsibility of the user to arrange the loads in the trunk
and/or cargo area in accordance with maximum weights allowed.
NOTE:
(*) Versions with automatic transmission.
TOWING > SPECIFICATIONS > LOAD
140CV 170CV
Payload including
585 kg 515 kg 580/550 kg (**) 545 kg
the driver (*)
NOTE:
(*) If special equipment is present (sunroof, towing hitch etc.) the empty weight increases and
consequently the payload will decrease, to still comply with the maximum permitted loads
NOTE:
(**) Versions with automatic transmission
TOWING > SPECIFICATIONS > TOWING
140CV 170CV
Trailer with brakes

1000 1000 1500/1000 (*) 1500
(kg)
Trailer without
400 400 400 400
brakes (kg)
Cargo on the ball

(trailer with brakes) 60 60 60 60
(kg)
The maximum load

weight on the roof 70 70 70 70
(kg) (**)
NOTE:
Versions with automatic transmission.
NOTE:
(**) Versions with roof rack.
TOWING > SPECIFICATIONS > VEHICLE TOWING POINTS
The tow ring supplied with the car, is located in the tool box inside the trunk.
TOWING > SPECIFICATIONS > VEHICLE TOWING POINTS > FRONT
Press and release the cap at the bottom, take the tow ring B from its seat in the tool support and tighten it
onto the threaded pin front.
TOWING > SPECIFICATIONS > VEHICLE WEIGHT
140CV 170CV
Empty weight (with all

fluids, fuel tank filled
to 90% and no 1320 1390 1430/1530 (*) 1535
optional equipment)
(kg)
NOTE:
(*) Versions with automatic transmission
TOWING > STANDARD PROCEDURE > STANDARD PROCEDURE - POINTS OF TOWING

VEHICLE
FRONT
Fig 1: Tow Ring & Cap (Front)
A press release the cap (A) at the bottom, take the tow ring (B) from its seat in the tool support and
tighten it onto the threaded pin front.
Fig 2: Tow Ring & Cap (Rear)
REAR
Remove the cap (A), take the tow ring (B) from its seat in the tool support and tighten it onto the
threaded pin back.
Fig 3: Rear Tow Hook (Fixed Type) - Trail Hawk Version
Trail Hawk Version
A tow hook, fixed type, is anchored to the body of the car.
General instructions
For versions with mechanical key, before starting to tow, turn the ignition key to RUN and then to STOP,
without extracting. Removing the key automatically engages the steering lock, making it impossible to steer
the wheels. Also check that the transmission is placed in neutral (for versions with automatic transmission
verify that the lever is in N). For versions with electronic key, move the ignition switch on RUN and then to
STOP, without opening the door. When towing, remember that without the help of the brake booster and the
electromechanical power steering to brake, it is necessary to exert more force on the pedal and steering is
required more energetic action on the steering wheel. Do not use flexible cables for towing and avoid jerks.
During towing operations make sure that fastening the joint to the car does not damage the components in
contact. When towing the car you must comply with the specific traffic regulations, relating to both the
towing device, both the behavior very to keep on the road. When towing the car does not start the engine.
Before screwing the ring, thoroughly clean the threaded seat. Before starting to tow also make sure first
screw down the ring into place. The front and rear tow hooks must only be used for rescue operations on
the roadway. Highway towing is permitted for short distances through the use of special device that
complies with the rules of the road (rigid bar), moving vehicle on the road in preparation for towing or
transport by tow truck. The hooks MUST NOT be used for vehicle recovery operations outside of the road
or in the presence of obstacles and / or for towing operations using cables or other non-rigid devices.
Respecting the above conditions, towing must take place with two vehicles (towing and towed) aligned as
much as possible on the same centerline.
TOWING > STANDARD PROCEDURE > STANDARD PROCEDURE - TOWING
CAUTION:
DO NOT use sling-type equipment when towing. When securing the vehicle to a flatbed truck,
do not attach to front or rear suspension components. Damage to your vehicle may result from
improper towing.
CAUTION:
Towing this vehicle in violation of the below requirements can cause severe transmission
damage. Damage from improper towing is not covered under the New Vehicle Limited
Warranty.
NOTE:
Vehicles with a discharged battery or total electrical failure when the Electric Park Brake (EPB)
is engaged, will need a wheel dolly or jack to raise the rear wheels off the ground when moving
the vehicle onto a flatbed.
NOTE:
This service information describes procedures for towing a disabled vehicle using a
commercial wrecker service.
FWD MODELS FOUR WHEEL DRIVE
Wheels
Towing AUTOMATIC MANUAL AUTOMATIC/MANUAL
OFF the
Condition TRANSMISSION TRANSMISSION TRANSMISSION 4X4
Ground
Flat Tow NONE NOT ALLOWED NOT ALLOWED NOT ALLOWED
Wheel Lift or Rear NOT ALLOWED NOT ALLOWED NOT ALLOWED

Dolly Tow Front OK OK NOT ALLOWED
Flatbed ALL BEST METHOD BEST METHOD OK
Towing A Disabled Vehicle
Proper towing or lifting equipment is required to prevent damage to your vehicle. Use only tow bars
and other equipment designed for this purpose, following equipment manufacturer's instructions. Use
of safety chains is mandatory. Attach a tow bar or other towing device to main structural members of
the vehicle, not to bumpers or associated brackets. State and local laws regarding vehicles under tow
must be observed.
If you must use the accessories (wipers, defroster, etc.) while being towed, the key must be in the
ON/RUN position.
Front Wheel Drive (FWD)
The manufacturer recommends towing your vehicle with all four wheels OFF the ground on a flatbed. If
flatbed equipment is not available, this vehicle must towed with the front wheels OFF the ground (using a
towing dolly, or wheel lift equipment with the front wheels raised).
Four-Wheel Drive (4WD)
The manufacturer requires towing with all four wheels OFF the ground. Acceptable methods are to tow the
vehicle on a flatbed, or with one end of the vehicle raised and the opposite end on a towing dolly.
Service Manual: AUDIO/VIDEO - NON-DTC BASED Jeep Renegade
DIAGNOSTICS
DIAGNOSIS AND TESTING > POOR OR NO SATELLITE AUDIO RECEPTION
For a complete wiring diagram, refer to SYSTEM WIRING DIAGRAMS article .
DIAGNOSIS AND TESTING > POOR OR NO SATELLITE AUDIO RECEPTION >

POSSIBLE CAUSES
Possible Causes
SATELLITE ANTENNA
SATELLITE ANTENNA CONNECTION
OPEN OR SHORTED SATELLITE ANTENNA CABLE
RADIO
DIAGNOSIS AND TESTING > POOR OR NO SATELLITE AUDIO RECEPTION >

DIAGNOSTIC TEST
1. CHECK THE ANTENNA CONNECTION
1. Turn the ignition off.
2. Disconnect the Satellite Antenna yellow connector at the Radio.
3. Inspect the Satellite Antenna connection.
Is the Antenna connection clean and secure?
Yes
1. Go To Step 2
No
1. Repair the Antenna connection as needed.
2. Perform the BODY VERIFICATION TEST. Refer to STANDARD PROCEDURE .
2. CHECK THE RADIO
1. Connect the (special tool #9977-6-SAT, Antenna) to the antenna connection on the
back of the Radio.
2. Turn the ignition on.
3. Turn the Radio on and set it to Satellite band.

4. Tune into several satellite stations.
Is the Satellite reception still poor or not available?
Yes
1. Replace the Radio in accordance to the service information. (Refer to RADIO ).
No
1. Go To Step 3
3. TEST THE ANTENNA CABLE AT THE GLOVE BOX OPENING
2. Disconnect the (special tool #9977-6-SAT, Antenna) from the Antenna cable at the
Radio.
3. Connect the antenna cable back up to the Radio.
4. Remove the Glove Box Assembly. (Refer to GLOVE BOX, INSTRUMENT PANEL ).
5. Disconnect the yellow SDAR antenna connector that is attached to the blower
housing.
6. Connect the (special tool #9977-6-SAT, Antenna) with the 9977-6-5 adapter, to the
SDAR antenna connector at the glove box opening.
9. Tune into several satellite stations.
Is the Satellite reception now poor or not available?
Yes
1. Replace the antenna cable between the Radio and the in-line connector at the
glove box opening.
No
1. Go To Step 4
4. TEST THE ANTENNA CABLE FROM THE GLOVE BOX OPENING TO THE ANTENNA
CONNECTOR
NOTE:
To continue this test, it will require the necessity of two technicians.

CAUTION:
Be extremely careful not to pull too hard on the headliner which could cause it to
buckle. Support it if it starts to drop.
2. Re-connect the yellow SDAR connector at the glove box opening.
3. Lower the headliner.
4. Once the headliner is loose, move the front seats forward and lower the front seat
backs and rest the headliner on top of the seats.
5. Disconnect the yellow SDAR antenna cable connector on the rear roof support at the
antenna base.
6. Connect the (special tool #9977-6-SAT, Antenna) to the yellow SDAR Antenna cable
connector near the antenna base.
9. Tune into several Satellite stations.
Is the Satellite reception now poor or not available?
Yes
1. Replace the Antenna cable from the glove box opening to the Satellite Antenna.
(Refer to ANTENNA, SATELLITE, AUDIO ).
No
1. Replace the Satellite Antenna base in accordance with the Service Information.
(Refer to ANTENNA, SATELLITE, AUDIO ).
DIAGNOSIS AND TESTING > POOR OR NO AM/FM AUDIO RECEPTION
DIAGNOSIS AND TESTING > POOR OR NO AM/FM AUDIO RECEPTION > POSSIBLE
CAUSES
Possible Causes
BAD ANTENNA GRID
BAD ANTENNA CONNECTION
ANTENNA MODULE
OPEN OR SHORTED ANTENNA CABLE
RADIO (RRM)
DIAGNOSIS AND TESTING > POOR OR NO AM/FM AUDIO RECEPTION >

DIAGNOSTIC TEST
1. CHECK THE ANTENNA CONNECTION
2. Disconnect the AM/FM Audio Antenna white connector at the rear of the Radio
(RRM).
3. Inspect the Audio Antenna connection.
Is the Antenna connection clean and secure?
Yes
1. Go To Step 2
No
1. Repair the Antenna connection as needed.
2. CHECK THE RADIO
1. Connect the (special tool #9977-6-FM, Antenna) to the antenna connection on the
back of the Radio.
2. Place the magnetic test antenna on the roof of the vehicle.
4. Turn the Radio on and set it to AM or FM band.
5. Tune in to several AM and FM stations.
Is the audio reception still poor or not available?
Yes
1. Replace the Radio in accordance to the service information. (Refer to RADIO ).

No
1. Go To Step 3
3. TEST THE ANTENNA MODULE AND GRID
2. Disconnect the test antenna and connect the harness connector to the Radio.
Fig 1: Antenna Cable, Mounting Fasteners & Antenna Module
3. Remove the right C-Pillar trim to gain access to the Antenna Module (3). (Refer to
INTERIOR ). Remove the mounting bolt holding the Antenna Module (1).
4. Disconnect the white AM/FM antenna cable connector (2) from the antenna module.
5. Connect the (special tool #9977-6-FM, Antenna) to the white AM/FM antenna cable
harness connector.
7. Turn the Radio on and set it to AM or FM band.
8. Tune in to several AM and FM stations.
Is the audio reception still poor or not available?

Yes
1. Go To Step 4
No
1. Check the antenna grid and repair if necessary. (Refer to DIAGNOSIS AND
TESTING ). If the grid checks good, replace the Antenna Module in accordance
with the Service Information.
4. TEST THE ANTENNA CABLE
2. Disconnect the (special tool #9977-6-FM, Antenna) from the Antenna cable.
Fig 2: Special Tool Jumper & Antenna Harness Connector
3. Connect the appropriate 50 Ohm test (special tool #9977-6-4, Jumper) (1) or (special
tool #9977-6-2, Jumper) (1) to the Antenna cable (2) at the Antenna Module harness
connector.
4. Disconnect the AM/FM Audio Antenna white connector at the rear of the Radio.
5. Connect the appropriate (special tool #9977-6-1, Adapter) (1) or (special tool
#9977-6-3, Adapter) (1) to the antenna cable (2) at the back of the Radio.
Fig 3: Special Tool, Antenna Harness Connector & DVOM
6. Measure the Resistance across the tool terminals.
Is the resistance above 52.5 or below 47.5 Ohms?
Yes
1. Go To Step 5
No
1. The source of the poor reception is not caused by the Radio or the Antenna
cable. Re-check the antenna grid and repair if necessary. (Refer to
DIAGNOSIS AND TESTING ). If the grid checks good, replace the Antenna
Module in accordance with the Service Information.
5. TEST THE ANTENNA CABLE FROM THE RADIO TO INLINE CONNECTOR
1. Disconnect the appropriate (special tool #9977-6-4, Jumper) or (special tool

#9977-6-2, Jumper) from the antenna cable at the Antenna Module connector.
2. Remove the Glove Box Assembly. (Refer to GLOVE BOX, INSTRUMENT PANEL ).
3. Disconnect the white AM/FM antenna connector mounted on the blower housing.
4. Connect the appropriate 50 Ohm test (special tool #9977-6-4, Jumper) (1) or (special
tool #9977-6-2, Jumper) (2) to the side of the Antenna cable (2) that leads to the
Radio.
5. Measure the Resistance across the tool terminals.
Yes
1. Replace the section of antenna cable from the Radio to inline connector.
No
1. Go To Step 6
6. TEST THE ANTENNA CABLE FROM THE INLINE CONNECTOR TO THE ANTENNA
MODULE
1. Disconnect the appropriate (special tool #9977-6-1, Adapter) or (special tool

#9977-6-3, Adapter) from the rear of the Radio.
2. Connect the appropriate (special tool #9977-6-1, Adapter) (1) or (special tool
#9977-6-3, Adapter) (1) to the Antenna cable (2) at the Antenna Module connector.
3. Measure the resistance across the tool terminals.
Yes
1. Replace the section of antenna cable from the inline connector to the Antenna
Module.
No
1. The source of the poor reception is not caused by the Radio or the Antenna
cable. Re-check the antenna grid and repair if necessary. (Refer to
DIAGNOSIS AND TESTING ). If the grid checks good, replace the antenna
module in accordance with the Service Information.
DIAGNOSIS AND TESTING > DIAGNOSIS AND TESTING - REAR CAMERA

INOPERATIVE
Fig 1: Rear Camera Module Circuit Diagram & Connector End View

INOPERATIVE > THEORY OF OPERATION
The Camera is activated when the ignition switch is in the RUN position. The (F923) circuit supplies
power to the camera. The camera sends a video signal (std. NTSC i.e. TV) to the Radio (RRM), using
circuits (X970) camera signal, (X971) signal return and (X972) camera shield, which displays on the
Radio screen. The screen toggles functions displaying only one kind of image at a time. And in reverse,
the rear camera has priority. The (Z917) circuit is ground for the system.

INOPERATIVE > WHEN MONITORED
Ignition on, vehicle in reverse.

INOPERATIVE > SET CONDITION
No rear picture is displayed on Radio display screen with the vehicle in reverse.

INOPERATIVE > POSSIBLE CAUSES
Possible Causes
(F923) FUSED RUN RELAY OUTPUT CIRCUIT
(Z913) GROUND CIRCUIT
(X970) CAMERA SIGNAL CIRCUIT
(X971) CAMERA RETURN CIRCUIT
(X972) CAMERA SHIELD
REAR CAMERA ASSEMBLY

INOPERATIVE > DIAGNOSTIC TEST
1. VERIFY OPERATION OF THE RADIO AND BACKUP LAMPS
1. Verify the operation of the Radio and Backup Lamps.
Does the Radio and Backup Lamps operate correctly?
Yes
1. Go To Step 2
No
1. Diagnose any problems with the Radio and Backup Lamps.
2. CHECK THE (F923) FUSED RUN RELAY OUTPUT CIRCUIT
2. Apply the parking brake.
3. Disconnect the License Plate Lamp/Rear Camera Assembly harness connector.
5. With a 12-volt test light connected to ground, check the (F923) circuit at the Rear
Camera connector.
NOTE:
The test light must illuminate brightly. Compare the brightness to that of a
direct connection to the battery. (
Does the test light illuminate brightly?
Yes
1. Go To Step 3
No
1. Repair the (F923) circuit for an open or high resistance.
3. CHECK THE (Z917) GROUND CIRCUIT
2. With a 12-volt test light connected to 12 volts, check the (Z917) Ground circuit at the
Rear Camera harness connector.
Yes
1. Go To Step 4
No
1. Repair the (Z917) Ground circuit for an open or high resistance.
4. CHECK THE (X970) CAMERA SIGNAL, THE (X971) RETURN, AND THE (X972) SHIELD
CIRCUITS FOR AN OPEN CIRCUIT
1. Disconnect the Radio harness connector.
2. Measure the resistance of the (X970) (X971) and (X972) circuits between the Rear
Camera harness connector and Radio harness connectors.
Is the resistance below 3.0 Ohms on the (X970) (X971) or (X972) circuits?
Yes
1. Go To Step 5
No
1. Repair the appropriate circuit for an open.
2. Perform the BODY VERIFICATION TEST. (Refer to STANDARD PROCEDURE

).
5. CHECK THE (X970) CAMERA SIGNAL, THE (X971) RETURN, AND THE (X972) SHIELD
CIRCUITS SHORTED TO GROUND
1. Check for continuity between ground between ground and the (X970) (X971) and
(X972) circuits at the Radio harness connector.
Is the resistance below 3.0 Ohms on the (X970) (X971) or (X972) circuits?
Yes
1. Repair the appropriate circuit for a short to ground.
No
1. Replace the License Plate Lamp/Rear Camera Assembly in accordance with

the Service Information. (Refer to CAMERA, REAR ).
DIAGNOSIS AND TESTING > MIT019 MULTI-MEDIA TESTER
A multimedia supplement to the instructions contained

in this article is available.
To view the multimedia example of the condition
described go to;
http://www.youtube.com/user/Mitchell1Tips
then type "A00603038.vid1" into the "Search
Channel" box.
DIAGNOSIS AND TESTING > MIT019 MULTI-MEDIA TESTER > MIT019 MULTI-MEDIA
TEST KIT
The MIT019 Multi-Media Test kit includes the tester, power outlet adaptor and a set of test tip cards. The
MIT019 can be updated by connecting to any computer using the USB connector on the tester. The
updates are supported through DealerConnect tech support. If the test cards are lost, a new set can be
downloaded from the tool by connecting to any supporting computer. The test card information in the tool
can be downloaded in one of 3 languages: English, Spanish or French.
TO DOWNLOAD THE TEST CARD INFORMATION:
1. Connect the MIT019 to a USB port on a computer (which will power the tool and display the
current software version).
2. Press the USB button on the MIT019.
3. Once the computer recognizes the MIT019, it will display 3 files available.
4. Select the file named "MANUAL".
5. Download the section required to create the test cards needed.
FOR UPDATES:
1. While holding down the zero button on the MIT019, connect the MIT019 to a USB port on a
computer (which will power the tool and display the current software version).
2. If you are a Chrysler Group LLC Dealership, visit: https://dealerconnect.chrysler.com.
3. If you are a Non-Chrysler Group LLC Dealership, visit: www.techauthority.com.
4. Locate the MIT019 software update page (verify that a newer software version is available).
5. Download the update file and run the. exe file.
6. Follow the on-screen instructions to install the update.
7. Disconnect the MIT019 USB connection from the computer and the tool is ready to use.
DIAGNOSIS AND TESTING > MIT019 MULTI-MEDIA TESTER > MIT019 MULTI-MEDIA
TESTER FUNCTIONALITY
The MIT019 Multi-Media Test kit was developed to help diagnose customer concerns with features of the
Multi-Media systems in their vehicles. The purpose of this tool is to simulate the following:
A known good cell phone
A known good media source (Ipod®, Ipad®, or MP3 players)
Using this tester will determine if the cause of concern is related to a vehicle system concern or the
customer`s device being used.
The MIT019 can be used to perform 7 different tests of specific operations:
1. Operation of the AUX port
2. Operation of the USB port for both power and Audio input concerns
3. Bluetooth phone pairing
4. Bluetooth hands free calling (send & receive) phone book push test
5. Bluetooth streaming audio
6. Bluetooth SMS messaging - send
7. Bluetooth SMS messaging - receive
NOTE:
When testing functions of the audio/media system, it is important to verify whether or not the
vehicle is equipped with an internal or external Hands Free Module. In some cases the
external Hands Free Module controls the operation of the external AUX and USB ports along
with the Uconnect functions.
It is important to determine what system features are supported by the audio system in the customer's
vehicle and device. For information on the operation and supported features of the vehicle's media
system, refer to the flowing websites:
Vehicle websites available to customers and dealership personnel:
http://www.dodge.com/en/uconnect
http://www.chrysler.com/en/uconnect
http://www.jeep.com/en/uconnect
http://www.ramtrucks.com/en/uconnect
http://www.fiatusa.com/en/BlueAndMe
http://www.driveuconnect.com
Vehicle information support websites for dealership personnel only:
DealerConnect
STAR cases
Technical Service Bulletins
wiTECH for radio updates
The MIT019 was designed to test the following Radio/Multi-Media systems:
2010 - present NTG4 Radio/Multi-Media systems
2011 - present PowerNet Radio/Multi-Media systems
2013 - present RRM Radio/Multi-Media systems

DIAGNOSIS AND TESTING > MIT019 MULTI-MEDIA TESTER > MIT019
FUNCTIONALITY TESTS
1. BELOW ARE THE 7 FUNCTIONALITY TESTS AVAILABLE USING THE MIT019

MULTI-MEDIA TESTER:
1. AUXILIARY INPUT JACK TEST
1. Go To Step 2
2. USB INPUT/OUTPUT TEST
1. Go To Step 3
3. BLUETOOTH PAIRING
1. Go To Step 4
4. BLUETOOTH HANDS FREE CALLING/PHONEBOOK PUSH TEST
1. Go To Step 5
5. BLUETOOTH STREAMING AUDIO TEST
1. Go To Step 6
6. BLUETOOTH SMS MESSAGING - SEND
1. Go To Step 7
7. BLUETOOTH SMS MESSAGING - RECEIVE
1. Go To Step 8
2. AUXILIARY INPUT JACK TEST
NOTE:
This test is designed to validate the ability of the Audio/Media system to play audio
from a customer's device that has been connected to the AUX port on the radio or
externally through a UCI (Universal Customer Interface / Multi-Media) port.
NOTE:
The AUX port cannot supply power to a connected device.
1. Connect the USB and Auxiliary Cable into the vehicle's audio ports.
2. Verify the MIT019 is in AUX Mode.
3. Using the vehicle controls, place the audio system into AUX (Line In) Mode. (Audio
system may automatically enter into AUX Mode.)
Does the Radio play audio from the MIT019?
Yes
1. Audio playback confirms that the Auxiliary Input is working correctly, no

system repairs are needed at this time.
2. Check the condition of the customer`s cords and device being used.
3. Check to make sure the customer`s device and cables are compatible with the
vehicle system.
4. Check the customer`s device for output and volume setting concerns.
5. Check for updates for the customer`s device relating to the customer`s
concern.
No
1. If Audio playback does not occur, refer to the appropriate Service

Information.
2. Check the Multi-Media ports for damaged connection points or debris in the
ports.
3. Check wiring circuits and connections to the AUX port for concerns.
4. Check for vehicle related system updates, STAR cases and TSBs related to the
customer`s concern.
5. If no updates are available for the concern, replace the Radio or Hands Free
3. USB INPUT/OUTPUT TEST
NOTE:
This test is designed to validate the ability of the Audio/Media system to play audio
from a customer's device that has been connected to the USB port on the radio or
the external USB port (Universal Customer Interface (UCI) / Multi- Media port). By
connecting the MIT019 to the USB ports it will also determine if the USB port can
provide power to a connected device.
1. Connect the USB Cable into the vehicle's USB port.
2. Place the MIT019 into USB Mode.
3. Using the vehicle controls, place the audio system into USB Mode. (Audio system
may automatically enter into USB Mode.)
Yes
1. Audio playback confirms that the USB Input is working correctly, no

system repairs are needed at this time.
2. Check the condition of the customer`s cords and device being used.
vehicle system.
4. Check the customer`s device for output and volume setting concerns.
5. Check for updates for the customer device relating to the customer`s concern.
No

Information.
2. Check the Multi-Media ports for damaged connection points or debris in the
ports.
3. Check wiring circuits and connections to the USB port for concerns.
4. Check for vehicle related system updates, Star on-line cases and TSBs related
to the customers concern.
NOTE:
The radio and external USB ports can only supply 5 volts at 500 mAs.
Check to see what the customer's device requires for operation or
charging. Some vehicles are equipped with a standalone USB charging
port that can supply 5 volts at 1.5 amps. For more information on system
operation and supported features see the vehicle supporting website "For
Owners Page" or the http://www.driveuconnect.com.
4. BLUETOOTH PAIRING
NOTE:
This test is designed to validate the pairing ability of the vehicles Audio/Media
system. Pairing the MIT019 to the vehicle system will simulate the use of a known
good compatible phone to test the system operation.
NOTE:
Before testing it is important to check the total number of devices paired to the
vehicles system. Each system has a limit to the number of items that can be paired
to the system. For more information on system operation and supported features
see the vehicle supporting website "For Owners Page" or the Driveuconnect website
at http://www.driveuconnect.com.
NOTE:
If the customer`s concern is the vehicle system was working with their device but
then stopped working correctly, verify and perform the following:
1. Check to see if the device was recently updated.
2. Clear the device pairing from the system.
3. Reboot the customer`s device.
4. Re-pair the device to the vehicle system.
5. Check the operation.
At times, cell providers will update the software or firmware in the customer`s device
(without the customer knowing) causing it to become out of sync with the vehicle`s
system.
NOTE:
During this test, use the power outlet adaptor supplied with the MIT019 Multi-Media
Test kit to supply the power and ground to the tester. This will confirm and
demonstrate the Bluetooth connection without anything connected to the
Audio/Media system ports.
NOTE:
In order for the tool to function correctly, first plug the MIT019 power supply adapter
into the 12 volt power outlet receptacle and confirm adapter power LED illuminates.
Then connect the MIT019 to the power supply adapter.
1. Connect the power outlet power adapter into the 12 volt receptacle.
2. Connect the USB Cable into the Power Outlet Power Adapter. (This assists in
showing the customer that the tool is utilizing a Bluetooth connection.)
3. Place the MIT019 into Bluetooth Mode.
4. Use the vehicle audio controls to place the audio system into ready to PAIR Mode.
(Audio system may automatically enter into Bluetooth Mode.)
5. Press the PAIR button on the MIT019 the unit will identify the Vehicle Audio System.
6. When prompted, enter the Pairing Pin number on the MIT019 then press enter. The
MIT019 will Pair and Connect to the vehicle audio system.
Does the MIT019 pair to the Audio/Media system?
Yes
1. If the MIT019 pairs to the system, the Hands Free connection is working
correctly, no part replacement is needed .
2. Check the total number of devices paired to the customer`s device.
vehicle system.
4. Check to see if the customer`s device supports the vehicle feature being
tested.
5. Check the customer`s device for concerns related to password locks, phone
book transfer settings and data transfer locks/settings.
6. For more information on system operation and supported features see the
vehicle supporting website "For Owners Page" or the Driveuconnect website at
http://www.driveuconnect.com.
No
1. If Pairing does not occur, refer to the appropriate Service Information.

Refer to DIAGNOSIS AND TESTING .
customers concern.
5. BLUETOOTH HANDS FREE CALLING / PHONE BOOK PUSH TEST
NOTE:
This test is designed to validate the ability of the Audio/Media system to place and
receive phone calls. The MIT019 will change the radio display to show
"MULTI-MEDIA TESTER" to confirm the phone-book-push was successful.
NOTE:
NOTE:
system.
NOTE:
During this test use the Power outlet adaptor supplied with the MIT019 Multi-Media
NOTE:
1. Be sure the MIT019 is properly paired.
2. From MIT019 in Bluetooth Mode, press the CALL button.
3. The vehicle should announce an incoming call.
4. The media system will display "MULTI-MEDIA TESTER", confirming successful push
of the phone book.
5. Using the vehicle controls, answer the call.
6. Audio playback will confirm the Hands Free connection is working correctly, no
system part replacement is needed.
7. Using the vehicle controls, end the call.
Does the Media system playback the incoming audio and display "MULTI-MEDIA
TESTER"?
Yes
1. If Audio playback occurs and the system displays "MULTI-MEDIA

TESTER", the system is working correctly; no part replacement is
needed.
vehicle system.
4. Check to see if the customer`s device supports the feature that the customer is
trying to use.
No
1. If Audio playback does not occur, reference appropriate Service

Information. Refer to DIAGNOSIS AND TESTING .
customers concern.
6. BLUETOOTH STREAMING AUDIO TEST
NOTE:
This test is designed to validate the ability of the Audio/Media system to play
streamed audio by a Bluetooth connected device.
NOTE:
NOTE:
system.
NOTE:
NOTE:
4. Leave the MIT019 in Bluetooth Audio Mode after pairing is complete.
5. Using the vehicle controls, place the audio system into Bluetooth Audio.
Yes
1. Audio playback will confirm that the Bluetooth Streaming Audio is

working correctly, no system part replacement is needed.

vehicle system.
tested.
No

Information. Refer to DIAGNOSIS AND TESTING .
customers concern.
7. BLUETOOTH SMS MESSAGING- RECEIVE
NOTE:
This test is designed to validate the ability of the Audio/Media system to receive a
SMS message.
NOTE:
NOTE:

system.
NOTE:
NOTE:
1. Connect the Power outlet Power Adapter into the 12 volt receptacle.
4. From Bluetooth Mode, press the SMS button.
5. MIT019 will send a new message to the vehicle audio system.
6. The vehicle audio system will confirm the receipt of a new message.
7. Using the vehicle controls, retrieve the message to verify proper functionality.
Does the Radio display the message "MULTI-MEDIA TESTER" from the MIT019?
Yes
1. If functioning correctly, no system part replacement is needed.
vehicle system.
tested.
No
1. If the Audio system does not display the new message, reference the
appropriate Service Information on system operation and supported
features. See the vehicle supporting website "For Owners Page" or the
Driveuconnect website at http://www.driveuconnect.com.
customers concern.
8. BLUETOOTH SMS MESSAGING-SEND
NOTE:
This test is designed to validate the ability of the Audio/Media system to send a
SMS message from the list of preset messages.
NOTE:
NOTE:
then stopped working correctly, verify the following:

system.
NOTE:
NOTE:
4. Using the vehicle controls, send a text message.
5. The MIT019 will display the chosen message.
Does the MIT019 Multi-Media Tester display on the tool the message sent by the
Multi-Media system?
Yes
1. If functioning correctly, no system part replacement is needed.
vehicle system.
tested.
No
1. If the MIT019 does not display the new message, reference the
appropriate Service Information on system operation and supported
features. See the vehicle supporting website "For Owners Page" or the
Driveuconnect website at http://www.driveuconnect.com.
customers concern.
Service Manual: AUDIO/VIDEO/ENTERTAINMENT Jeep Renegade
/CONNECTIVITY - SERVICE INFORMATION
DESCRIPTION AND OPERATION > DESCRIPTION AND OPERATION > DESCRIPTION
Several combinations of radio receivers and speaker systems are offered on this vehicle. The audio
system receives fused battery voltage from a fuse in the Body Control Module (BCM) at all times. The
RA4 radio receives additional fused battery voltage from the Voltage Stabilizer Unit.
There is an optional navigation system, the operator has the option of choosing a street address, point
of interest, trip itinerary and other features outlined in the operator's manual.
The audio system includes the following components:
Antenna (Cellular, Navigation, Satellite Audio). Refer to ANTENNA, SATELLITE, AUDIO,

DESCRIPTION AND OPERATION .
Antenna (AM/FM NAFTA and MW/LW/DAB EMEA Radio) (Refer to DESCRIPTION AND
OPERATION and ANTENNA, SATELLITE, AUDIO, DESCRIPTION AND OPERATION ).
Media Hub. Refer to MEDIA HUB, DESCRIPTION AND OPERATION .
Radio. Refer to RADIO, DESCRIPTION AND OPERATION .
Remote radio switches (if equipped). Refer to SWITCH, REMOTE RADIO, DESCRIPTION AND
OPERATION .
Speakers. Refer to SPEAKER, DESCRIPTION AND OPERATION .
DESCRIPTION AND OPERATION > DESCRIPTION AND OPERATION > OPERATION
The audio system components are designed to provide audio entertainment and information through the
reception, tuning and amplification of locally broadcast radio signals in both the Amplitude Modulating
(AM) and Frequency Modulating (FM) commercial frequency ranges. If the vehicle is so equipped, the
audio system can also receive, amplify or process certain cellular, satellite audio and satellite Global
Positioning System (GPS) radio signals. The audio system components operate on battery current
received through a fuse in the Body Control Module (BCM).
The optional navigation radio system receives GPS signals from up to eight satellites to display the
position and direction of the vehicle. Map information is supplied through a DVD-ROM. An electronic
gyro-sensor and the speed sensor in the vehicle enable the system to display the present vehicle
position even in locations where GPS signals may be blocked. When a destination is selected, the
navigation system uses information from the map to quickly calculate a route. As the vehicle is driven
along the chosen route, the operator is guided with pictorial displays and voice prompts.
On vehicles that are equipped with the optional remote radio switches, the BCM receives the input from
the switches on the steering wheel. The programming in the BCM allows it to process those inputs and
send the appropriate electronic command messages to the radio receiver over the Controller Area
Network (CAN) - B data bus to control the radio volume up or down, station seek up or down, preset
station advance, and mode advance functions.
DIAGNOSIS AND TESTING > DIAGNOSIS AND TESTING - AUDIO
Any diagnosis of the audio system should begin with the use of a diagnostic scan tool. Check for any
Diagnostic Trouble Code (DTC) data. If a DTC is found, refer to DIAGNOSTIC CODE INDEX and
perform the appropriate diagnostic procedure before proceeding in this article . Refer to the appropriate
Diagnostic & Testing article.
WARNING:
To avoid serious or fatal injury on vehicles equipped with airbags, disable the Supplemental
Restraint System (SRS) before attempting any steering wheel, steering column, airbags,
airbag curtains, knee blocker, seat belt tensioner, impact sensor or instrument panel
component diagnosis or service. Disconnect the IBS/negative battery cable assembly from
the negative battery post, then wait two minutes for the system capacitor to discharge before
performing further diagnosis or service. This is the only sure way to disable the SRS. Failure
to take the proper precautions could result in accidental airbag deployment.
AUDIO SYSTEM DIAGNOSTIC TABLE
CONDITION POSSIBLE CAUSES CORRECTION
1. Fuse inoperative. Check radio fuse.

RADIO INOPERATIVE Check "No Response from Radio". Refer to
2. Open wiring.
DIAGNOSIS AND TESTING .
NO AUDIO - BUT RADIO 1. Antenna problem. Perform the "Poor or No AM/FM Audio
LIGHTS UP Reception" test. Refer to DIAGNOSIS AND
TESTING .
2. Radio or Amplifier (if Check for loose or corroded radio/amplifier

equipped) connector connector. Repair, as required.
damaged.
3. Wiring damaged. Check for shorted or open wires. Repair

wiring as required.
4. Radio or Amplifier (if Check for continuity between radio chassis

equipped) ground damaged. and a known good ground. There should be
continuity. Repair ground as required.
5. Amplifier (if equipped) Refer to DIAGNOSIS AND TESTING .

inoperative.
6. Speakers inoperative. Refer to DIAGNOSIS AND TESTING .
NO RADIO DISPLAY 1. Fuse inoperative. Check radio fuse, Replace fuses as

required.
2. Radio connector Check for loose or corroded radio

damaged. connector. Repair as required.
3. Wiring damaged. Check for battery voltage at radio
connector. Repair wiring as required.
4. Radio ground circuit Check for continuity between radio chassis

damaged. and a known good ground. There should be
5. Radio inoperative. Check "No Response from Radio". Refer to

POOR AM/FM RADIO 1. Antenna inoperative. Perform the "Poor or No AM/FM Audio
RECEPTION Reception" test. Refer to DIAGNOSIS AND
TESTING .
2. Radio ground damaged. Check for continuity between radio chassis

and a known good ground. There should be
3. Radio inoperative. Refer to DIAGNOSIS AND TESTING or

Perform the "Poor or No Satellite Audio

POOR SDAR AUDIO 1. SDAR antenna
Reception" test. Refer to DIAGNOSIS AND
RECEPTION Inoperative.
TESTING .
SOUND DISTORTION 1. Door trim panel loose or Inspect door trim panel and correct as
(VIBRATION FROM missing fasteners. necessary. Replace any missing fasteners.
SPEAKER AREA, BUZZING -
HUMMING)
2. Water shield loose or Inspect water shield and adjust as

misaligned. required.
3. Items placed in door trim Remove items from door trim panel.
panel map pockets vibrating Ensure that vibration is no longer present.
or moving from side to side.
AMPLIFIER > DESCRIPTION AND OPERATION > DESCRIPTION AND OPERATION >
DESCRIPTION
Vehicles equipped with the 9-speaker Premium Sound System package have a separate 8-channel
amplifier unit. The amplifier is rated at 506 watts. The amplifier is mounted to the left rear quarter panel
behind the quarter trim panel.
AMPLIFIER > DESCRIPTION AND OPERATION > DESCRIPTION AND OPERATION >
OPERATION
The audio power amplifier receives fused battery current from a fuse in the rear Power Distribution
Center (PDC) and is grounded through a circuit of the body wire harness that is secured to the body
sheet metal at all times. The internal circuitry of the amplifier switches the amplifier on or off based upon
electronic messages that are received over the Controller Area Network (CAN) - Interior High Speed
(IHS) data bus from the Radio Receiver Module (RRM) whenever the RRM is turned on.
The amplifier receives analog sound signal inputs from the front and rear, left and right outputs of the
RRM, then provides the amplified speaker outputs for each of those channels to the appropriate
speakers through dedicated audio output circuits. The amplifier also receives electronic messages from
the Body Control Module (BCM) and the RRM over the CAN-IHS data bus that communicate the correct
channel settings for optimum speaker sound and output.
The hard wired circuits between components related to the amplifier may be diagnosed using
conventional diagnostic tools and procedures. Refer to the appropriate Diagnostic & Testing article. The
wiring information includes wiring diagrams, proper wire and connector repair procedures, details of wire
harness routing and retention, connector pin out information and location views for the various wire
harness connectors, splices and grounds.
However, conventional diagnostic methods will not prove conclusive in the diagnosis of the amplifier or
the electronic controls and communication between modules and other devices that provide some
features of the audio system. The most reliable, efficient and accurate means to diagnose the amplifier
or the electronic controls and communication related to audio system operation requires the use of a
diagnostic scan tool. Refer to the appropriate Diagnostic & Testing article.
AMPLIFIER > DIAGNOSIS AND TESTING > DIAGNOSIS AND TESTING - AUDIO
POWER AMPLIFIER
WARNING:
The audio power amplifier unit should be checked if there is no sound output noted from the speakers.
Refer to SPEAKER, DIAGNOSIS AND TESTING .
The hard wired circuits between components related to the audio power amplifier may be diagnosed
using conventional diagnostic tools and procedures. Refer to the appropriate Diagnostic & Testing
article. The wiring information includes wiring diagrams, proper wire and connector repair procedures,
details of wire harness routing and retention, connector pin out information and location views for the
various wire harness connectors, splices and grounds.
However, conventional diagnostic methods will not prove conclusive in the diagnosis of the amplifier or
the electronic controls and communication between modules and other devices that provide some
features of the audio system. The most reliable, efficient and accurate means to diagnose the amplifier
or the electronic controls and communication related to audio system operation requires the use of a
AMPLIFIER > REMOVAL AND INSTALLATION > REMOVAL AND INSTALLATION >
REMOVAL
Fig 1: Remove/Install Amplifier
1. Disconnect and isolate the negative battery cable. If equipped with an Intelligent Battery
Sensor (IBS), disconnect the IBS connector first before disconnecting the negative battery
cable.
2. Remove the left side quarter panel trim. Refer to PANEL, QUARTER TRIM, REMOVAL AND
INSTALLATION .
3. Remove the amplifier and mounting bracket retainers (2a and 2b).
4. Pull back the foam harness protectors and disconnect the amplifier wire harness connectors
(1).
Fig 2: Amplifier, Mounting Bracket & Fasteners
5. Remove the amplifier and mounting bracket from the vehicle.

6. Remove the four fasteners (1a) that secure the amplifier (1b) to the mounting bracket (1c) and
separate the amplifier from the mounting bracket.
AMPLIFIER > REMOVAL AND INSTALLATION > REMOVAL AND INSTALLATION >
INSTALLATION
Fig 1: Amplifier, Mounting Bracket & Fasteners

1. Position the amplifier (1b) to the mounting bracket (1c) and install the four fasteners (1a).
Tighten the fasteners securely.
Fig 2: Remove/Install Amplifier
2. Position the assembled amplifier and mounting bracket (2c) and install the three fasteners (2a
and 2b).
3. Connect the amplifier wire harness connectors (1). Position the foam harness protectors in
place.
4. Install the left side quarter panel trim. Refer to PANEL, QUARTER TRIM, REMOVAL AND
INSTALLATION .
5. Connect the negative battery cable. If equipped with an Intelligent Battery Sensor (IBS),
connect the IBS connector.
ANTENNA, SATELLITE, AUDIO > DESCRIPTION AND OPERATION > DESCRIPTION

AND OPERATION
Fig 1: Satellite Antenna
If the vehicle is equipped with satellite audio, a combined antenna for AM/FM and satellite and navigation
is used. For AM/FM only, the antenna looks similar and is mounted in the same location. For more
information, refer to ANTENNA, SATELLITE, AUDIO, REMOVAL AND INSTALLATION .
The audio system components are designed to provide audio entertainment and information through the
reception, tuning and amplification of locally broadcast radio signals in both the Amplitude Modulating
(AM) and Frequency Modulating (FM) commercial frequency ranges.
ANTENNA, SATELLITE, AUDIO > DIAGNOSIS AND TESTING > DIAGNOSIS AND
TESTING - SATELLITE ANTENNA
For information on diagnosing the SDARS antenna and cables, use the "Poor or No Satellite Audio
Reception" test. Refer to DIAGNOSIS AND TESTING . For information on diagnosing the GPS satellite
navigation system, refer to DIAGNOSIS AND TESTING . For information on diagnosing the satellite
antenna cables using the (special tool #9977-6, Kit, Radio Antenna Diagnostic), refer to DIAGNOSIS
AND TESTING and perform the Poor Or No Satellite Audio Reception test.
ANTENNA, SATELLITE, AUDIO > REMOVAL AND INSTALLATION > REMOVAL AND
INSTALLATION > REMOVAL
cable.
2. Remove the antenna mast.
3. Lower the headliner. Refer to HEADLINER, REMOVAL AND INSTALLATION .

Fig 1: Antenna, Connectors & Nut
4. Disconnect the antenna wiring harness connectors (2 and 3).
5. Remove the nut (4) securing the antenna.
6. Pull the antenna assembly (1) from the roof of the vehicle.
ANTENNA, SATELLITE, AUDIO > REMOVAL AND INSTALLATION > REMOVAL AND
INSTALLATION > INSTALLATION
Fig 1: Antenna, Connectors & Nut
1. Install the antenna (1) into the antenna mount opening on the roof.
2. Install the antenna mounting retaining nut (4) and securely tighten.
3. Connect the antenna wire harness connectors (2 and 3).
4. Install the headliner. Refer to HEADLINER, REMOVAL AND INSTALLATION .

5. Install the antenna mast.
connect the IBS connector to the negative battery cable.
7. Verify operation outside with a clear line of sight not obstructed by trees or buildings.
CAMERA, REAR > DESCRIPTION AND OPERATION > DESCRIPTION AND

OPERATION > DESCRIPTION
Fig 1: Rear View Camera (RVC) ParkView ® System
On vehicles equipped with Uconnect 5.0 or 6.5 UConnect ® touchscreen the image of the Rear View
Camera (RVC) of the ParkView ® system will appear on the radio display when reversing. The image is
displayed with lines representing the space occupied by the car that are automatically adapted to the
steering wheel rotation.
The RVC, which is located on the tailgate, produces a high resolution image with greater clarity and
sharpness to identify any obstacles.
Fig 2: Rear View Camera (RVC)

The RVC communicates with the Body Control Module (BCM) via the Local Interface Network (LIN2).
The RVC cannot be adjusted or repaired. If the RVC is damaged or ineffective, it must be replaced.
CAMERA, REAR > DESCRIPTION AND OPERATION > DESCRIPTION AND

OPERATION > OPERATION
The Rear View Camera (RVC) is powered by a ignition feed received through the backup lamp switch
output circuit from the Body Control Module (BCM) so that is only active when the transaxle is shifted
into the Reverse (R ) position. The RVC has a path to ground at all times through a take out and eyelet
terminal of the body wire harness secured to the body sheet metal. If the camera delay feature is
enabled, the RVC will remain active for 10 seconds, up to about 13 kilometers-per-hour (8 miles-
per-hour) or until the touch screen display is pressed after the gear selector is shifted from (R ) to
Neutral (N ) or Drive (D ).
The output of the camera is a video signal compatible to the National Television System Committee
(NTSC) standard composite video M format, or NTSC-M. The video signal is delivered to the radio video
display unit through the entire length of the vehicle by camera signal and the camera return circuits that
are arranged as a twisted pair, with an additional grounded foil jacket to protect the video signal from
corruption due to stray radiated signals within the vehicle environment. The ground shield is terminated
only at the video display (radio) end, not at the camera. Portions of these video signal wires are
contained within the body wire harness and a jumper harness located between the radio and the body
harness connector below the instrument panel at the right cowl side inner panel.
The hard wired circuits between components related to the RVC may be diagnosed using conventional
diagnostic tools and procedures. Refer to the appropriate Diagnostic & Testing article. The wiring
information includes wiring diagrams, proper wire and connector repair procedures, details of wire
However, conventional diagnostic methods will not prove conclusive in the diagnosis of the RVC or the
electronic controls and communication between modules and other devices that provide some features
of the RVC. The most reliable, efficient and accurate means to diagnose the RVC or the electronic
controls and communication related to RVC operation requires the use of a diagnostic scan tool. Refer
to the appropriate Diagnostic & Testing article.
CAMERA, REAR > DIAGNOSIS AND TESTING > DIAGNOSIS AND TESTING - REAR
CAMERA
The hard wired circuits of the Rear View Camera (RVC) and those between the RVC and the Radio may
be diagnosed using conventional diagnostic tools and procedures. Refer to the appropriate Diagnostic &
Testing article. The wiring information includes wiring diagrams, proper wire and connector repair
procedures, details of wire harness routing and retention, connector pin out information and location
views for the various wire harness connectors, splices and grounds.
However, conventional diagnostic methods will not prove conclusive in the diagnosis of the RVC or the
radio. The most reliable, efficient and accurate means to diagnose the electronic controls and
communication related to radio operation, as well as the retrieval or erasure of a DTC requires the use
of a diagnostic scan tool. Refer to the appropriate Diagnostic & Testing article.
WARNING:
NOTE:
Be certain to confirm the following prior to attempting any further diagnosis or testing of the
RVC. Use a diagnostic scan tool to confirm the rear view camera is setup in the vehicle
configuration.
REAR VIEW CAMERA DIAGNOSIS
1. Inspect lens for foreign

VIDEO IMAGE IS BLURRY OR 1. Dirt, smear, fingerprints on RVC material, and clean lens as
OBSTRUCTIVE lens. required, using the lens cleaning
procedure.
1. Check to be certain that the

radio has the latest software
1. Incorrect radio software.
update installed. Install the radio
software update if required.
2. Test and replace the radio

2. Ineffective radio fuse.
fuses if required.
3. Check for loose or damaged

wiring connections at the radio.
NO VIDEO DISPLAY IN RADIO - 3. Ineffective radio ground circuit.
Test and repair the open radio
DOES NOT DISPLAY CHECK
ground circuit if required.
ENTIRE SURROUNDINGS
MESSAGE BRIEFLY AFTER 4. Check for loose or damaged
SHIFTING INTO REVERSE wiring connections at the radio.
4. Ineffective radio feed circuit.
Test and repair the open radio
feed circuit if required.
5. Ineffective radio inputs or 5. Use a diagnostic scan tool to

outputs. test the radio inputs and outputs
including those received over the
CAN data bus. Refer to the
appropriate Diagnostic & Testing
article.
6. Use a diagnostic scan tool to
test the radio. Refer to the
6. Ineffective radio.
appropriate Diagnostic & Testing
article.
1. Test and repair the open

backup lamp switch output circuit
1. Backup lamps inoperative.
between the right and left tail
lamps if required.
2. Test and repair the open

NO CAMERA IMAGE IN RADIO backup lamp switch output circuit
VIDEO DISPLAY AND NO 2. Both backup lamps inoperative. between the Body Control Module
BACKUP LAMPS IN REVERSE (BCM) and the tail lamps if
required.
3. Use a diagnostic scan tool to

3. Ineffective BCM inputs or test the BCM inputs and outputs.
outputs. Refer to the appropriate
NO CAMERA IMAGE IN RADIO 1. Ineffective camera ground 1. Check for loose or damaged
VIDEO DISPLAY - DOES circuit. wiring connections at the camera,
DISPLAY CHECK ENTIRE the license plate applique and the
SURROUNDINGS MESSAGE left rear cargo door opening
BRIEFLY AFTER SHIFTING header. Test and repair the open
INTO REVERSE AND BACKUP camera ground circuit if required.
LAMPS DO OPERATE
2. Ineffective camera feed (backup 2. Check for loose or damaged
lamp switch output) circuit. wiring connections at the camera,
license plate applique and left
rear cargo door opening header.
Test and repair the open camera
feed (backup lamp switch output)
circuit if required.

wiring connections at the camera,
license plate applique, left rear
3. Ineffective camera shield cargo door opening header, right
circuit. cowl side inner panel and radio.
Test and repair the open or
shorted camera shield circuit if
required.

4. Ineffective camera return cargo door opening header, right
shorted camera feed circuit if
required.
5. Ineffective camera signal cargo door opening header, right
shorted camera signal circuit if
required.
6. Replace the ineffective camera

6. Ineffective camera.
if required.
CAMERA, REAR > CLEANING > CLEANING
NOTE:
The use of nylon gloves will prevent oil and debris on your hands from being transferred to
the camera body or lens surface. While wearing the gloves, care should be taken not to
contact exposed body parts such as the forehead, nose and arms. If contact is made
accidentally, gloves should be changed to mitigate the risk of contaminant transfer from the
surface of the gloves.
1. Using compressed air, blow diagonally across the camera lens.
2. Use a microfiber lens tissue to gently wipe the lens.
3. Examine the lens to verify the cleaning process. Proceed to Step #4 if the lens still shows
signs of oil or debris.
4. Apply a lens cleaning solution to a section of an unused lens tissue.
5. Slowly wipe in a circular motion around the edges of the lens to remove any dirt or
contamination from the periphery of the lens before cleaning the center.
6. Let the lens air dry.
7. Examine the lens to verify the cleaning process.
CAMERA, REAR > REMOVAL AND INSTALLATION > REMOVAL AND INSTALLATION
> REMOVAL
Fig 1: Remove/Install Rear View Camera (RVC)
1. Disconnect and isolate the negative cable from the battery. If equipped with an Intelligent
Battery Sensor (IBS), disconnect the IBS connector before disconnecting the negative cable
from the battery.
2. Using a suitable tool, release the four retaining tabs (3) of the Rear View Camera (RVC) bezel
(4) from the liftgate and pull the bezel out of the liftgate.
3. Disconnect the liftgate jumper wire harness connector (1) from the RVC (2) and remove the
RVC and bezel from the vehicle.
Fig 2: Rear View Camera (RVC) Bezel, Wire Connector & Screws
4. Remove the two screws (3) that secure the RVC (2) to the RVC bezel (1).
5. Remove the RVC from the RVC bezel.
CAMERA, REAR > REMOVAL AND INSTALLATION > REMOVAL AND INSTALLATION
> INSTALLATION
Fig 1: Rear View Camera (RVC) Bezel, Wire Connector & Screws
1. Position the Rear View Camera (RVC) (2) onto the RVC bezel (1).
2. Install and securely tighten the two screws (3) that secure the RVC (2) to the RVC bezel (1).
Fig 2: Remove/Install Rear View Camera (RVC)
3. Connect the liftgate jumper wire harness connector (1) to the RVC (2).
4. Position the RVC bezel (4) to the liftgate and press the RVC bezel into the liftgate until the four
retaining tabs (3) fully engage the liftgate.
MEDIA HUB > DESCRIPTION AND OPERATION > DESCRIPTION AND OPERATION >
DESCRIPTION
Fig 1: Media Hub
The possibility of connecting devices for audio playback on the car can be performed by means of:
a Universal Serial Bus (USB) port (1.5V) in the center console (standard)
a USB in the center console but available only with VP2 NAV and VP4
auxiliary power outlets (APO) placed in front and rear load areas
The media hub (1) is located in the forward surface of the center console (3). The media hub is a
centralized connection point in the vehicle that contains:
a 3.5 millimeter auxiliary audio input jack (4)
a powered USB port (2)
NOTE:
The powered USB port provides 5 volts at 1.5 amperes to charge the battery of a
connected media device.
Only the molded plastic media hub faceplate and the connection ports are visible within the center
console. The media hub housing, wiring and connections to the vehicle electrical system are concealed
on the underside of the console. Two latch tabs integral to the media hub housing secure the unit on the
back side of the mounting hole in the console.
Fig 2: USB Port In Center Console Storage Bin
There is also a USB port (1) in the center console storage bin (2). On the Sport model, this is a charge
only port as an option. All other models have the charge port as standard equipment with a fully
functioning USB port optional.
For USB sources the system can play files with the following extensions and formats:
MP3 (32 - 320 Kbps)
WAV
WMA (5 - 320 Kbps) mono and stereo
AAC (8 - 96 KHz) mono and stereo
M4A (8 - 96 kHz) mono and stereo
M4B (8 - 96 kHz) mono and stereo
MP4 (8 - 96 kHz) mono and stereo
For all USB sources, the system can also play the following Playlist formats:
M3U
WPL
NOTE:
The system supports only FAT32-formatted USB devices. The system does not support
devices with a capacity higher than 64 GB and does not support USB hubs connected to the
USB port.
The media hub and optional USB port cannot be adjusted or repaired. If either is ineffective or damaged
it must be replaced.
MEDIA HUB > DESCRIPTION AND OPERATION > DESCRIPTION AND OPERATION >
OPERATION
In vehicles so equipped, the media hub allows the audio content of various media devices to be
connected to Radio Receiver Module (RRM). Once connected, the audio content of the media device
may be accessed and played through the audio system components of the vehicle using the RRM
controls.
The hard wired circuits between the media hub and the RRM may be diagnosed using conventional
MEDIA HUB > REMOVAL AND INSTALLATION > REMOVAL AND INSTALLATION >
REMOVAL
Fig 1: Remove/Install Media Hub
cable.
NOTE:
Be certain to take the proper precautions to prevent the floor console and
instrument panel from receiving cosmetic damage during the following
procedures.
2. Remove the front floor console from the vehicle. Refer to CONSOLE, FLOOR, REMOVAL AND
INSTALLATION .
3. Roll the trim panel (2) of the lower instrument panel to gain access to the wire harness
connectors and disconnect the wire harness connectors (1a, 1b and 1c).
4. Working from the back side of the lower instrument panel trim panel (2), release the retaining
clips (3a) and remove the bezel with the USB/AUX sockets (3b) and 12V outlet (3c).
MEDIA HUB > REMOVAL AND INSTALLATION > REMOVAL AND INSTALLATION >
INSTALLATION
Fig 1: Remove/Install Media Hub
NOTE:
Be certain to take the proper precautions to prevent the floor console and instrument
panel from receiving cosmetic damage during the following procedures.
1. Position and insert the media hub bezel (1) into the lower instrument panel trim panel (2) until all
integral latches (3a) are fully engaged on the inside of the lower instrument panel trim panel (2).
2. Connect the wire harness connectors (1a, 1b and 1c) to the media hub and 12V outlet.
3. Install the front floor console into the vehicle. Refer to CONSOLE, FLOOR, REMOVAL AND
INSTALLATION .
RADIO > DESCRIPTION AND OPERATION > DESCRIPTION AND OPERATION >
DESCRIPTION
There are three Radio Receiver Modules (RRM) available in this vehicle, Uconnect® 3.0, Uconnect® 5.0
and Uconnect® 6.5. Each RRM has a distinct chassis design and is identified by a sales code. The
Uconnect® 3.0 RRM (Sales Code RA1) includes the following features:
AM/FM frequency reception
dot-matrix, single DIN, monochromatic display
six-channel presets
four speakers
iPod integration
Auxiliary/Universal Serial Bus (USB) Media Hub
USB port in the center console (optional)
vehicle personalization/settings
speed adjusted volume
The Uconnect® 5.0 RRM (Sales Code RA2) includes the following features:
12.7 centimeter (5.0 inch) full color touchscreen display
iPod integration
Auxiliary/USB Media Hub
integrated steering wheel controls
Radio Broadcast Data System (RBDS)

Bluetooth connectivity
Bluetooth streaming audio
hands-free phone
Voice Recognition (VR) commands
text message reader
six speakers (optional)
integrated Global Positioning System (GPS) navigation (optional)
ParkView® integrated rear view camera (optional)
Sirius XM satellite radio (optional)
iPod integration
hands-free phone
text message reader
nine speakers (optional)
Premium integrated 3D Global Positioning System (GPS) navigation (optional)
Sirius XM satellite radio (1-year subscription)
Hard wired circuitry connects the RRM to the electrical system of the vehicle. These hard wired circuits
are integral to several wire harnesses, which routes throughout the vehicle and retained by many
different methods. These circuits may be connected to each other and to the vehicle electrical system
through the use of a combination of soldered splices, splice block connectors, and many different types
of wire harness terminal connectors and insulators. Refer to the appropriate Diagnostic & Testing article.
The wiring information includes wiring diagrams, proper wire and connector repair procedures, further
details on wire harness routing and retention, as well as pin out and location views for the various wire
The RRM cannot be adjusted or repaired. If the RRM is damaged or ineffective, it must be replaced.
RADIO > DESCRIPTION AND OPERATION > DESCRIPTION AND OPERATION >
OPERATION
The Radio Receiver Module (RRM) becomes operational when it receives a wake up signal over the
Controller Area Network (CAN) - B data bus indicating the status of the ignition switch is On or
Accessory. For further information on the operation of the radio or media system in the vehicle, see the
heading for the appropriate audio system option in the User Guide or the Owner Manual. See the
Uconnect® web site (http://www.driveuconnect.com/ ) for more information, or refer to the For
Owners link on the vehicle brand web site for copies of those publications.
The RRM uses a roof mounted antenna for AM/FM signal reception and, depending upon vehicle optional
equipment, a roof mounted combination antenna that can receive Global Positioning System (GPS) and
satellite radio signals.
Depending upon the audio system options, the RRM can play audio from many different media sources.
The media can be played by connecting the source to the audio system via a 3.5 millimeter auxiliary
(AUX) port, a Universal Serial Bus (USB) port or through wireless Bluetooth audio streaming. Refer to
the Uconnect® web site (http://www.driveuconnect.com/ ) for compatibility information.
NOTE:
USB devices (e.g., camera memory USB adaptors, etc. excluding Apple products) must
comply with the MSD (Mass Storage Device) standard. This remote USB port can provide
power to the inserted device.
RADIO > REMOVAL AND INSTALLATION > REMOVAL AND INSTALLATION >
REMOVAL
NOTE:
For RA4 radios, if possible, the version of the map and Point Of Interest (POI) data should
be noted before the original radio is replaced with a new unit. If the version of the map and
POI data found on the new radio is not equal to or newer than the version that is found,
updated data will need to be downloaded and installed to the new radio at the expense of
the dealer. For the Navigation system restore and update procedures, refer to STANDARD
PROCEDURE .
Fig 1: Center Trim Bezel & Screws
cable.
2. Using trim stick C-4755 or equivalent, remove the center trim bezel (1b) from the instrument
panel.
Fig 2: Radio & Screws
3. Remove the four screws (1a) securing the radio (1b) to the instrument panel.
4. Pull the radio out far enough to access the back of the radio.
Fig 3: Radio Receiver Module Connectors
5. Disconnect the antenna cables (3), and radio wire harness connector (2).
6. If equipped, disconnect the USB connector (1).
7. Remove the radio from the instrument panel.
RADIO > REMOVAL AND INSTALLATION > REMOVAL AND INSTALLATION >
INSTALLATION
1. Position the radio near the instrument panel.
2. Connect the antenna cables (3) and radio wire harness connector (2).
3. If equipped, connect the USB connectors (1).

4. Position the radio into the instrument panel.
5. Install and securely tighten the four screws (1a) securing the radio (1b) to the instrument panel.
Fig 3: Center Trim Bezel & Screws
6. Install the instrument panel center bezel (1b). Be certain the four retaining tabs (1a) are fully
engaged to the instrument panel.
NOTE:
If this Electronic Control Unit (ECU) is being replaced with a new unit, a diagnostic
scan tool MUST be used to align the PROXI configuration data into the new ECU.
Follow the routine outlined in the diagnostic scan tool for PROXI Configuration
Alignment under Body Control Module (BCM) Miscellaneous Functions menu.
NOTE:
Uconnect® Access Applications and WiFi hotspot will be automatically updated in

the replacement radio through the radio's embedded cellular phone based on the
customers present subscription status. This update process may take up to an hour,
depending upon the number of apps and adequate cellular services accessibility.
The dealer is not expected to perform this process or to oversee it, but may need to
explain to the vehicle owner or operator that some features and applications may
not be fully restored and overall system response may be slowed until the process
has completed.
NOTE:
For RA4 radio only: Any factory replacement radio for the same vehicle will be
provided with the Navigation system already activated. Refer to the
Navigation/Telecommunication DESCRIPTION AND OPERATION for more
information.
SPEAKER > DESCRIPTION AND OPERATION > DESCRIPTION AND OPERATION >
DESCRIPTION
Fig 1: Base Equipment Four Speaker System
The base equipment four speaker 120-watt system includes speakers in four locations for the
Uconnect® 3.0 radio.
Two 15.2 X 23 centimeter (6 X 9 inch) speakers (1) located in the front door panels
Two 15.2 X 23 centimeter (6 X 9 inch) speakers (2) located in the rear door panels
Fig 2: Tweeter Speakers, Mid-Woofer Speakers & Rear Speakers

The six speaker 180-watt system includes speakers in six locations for the Uconnect® 5.0 and 6.5
radios.
Two 8.89 centimeter (3.5 inch) diameter midrange tweeters (1) located in the instrument panel
Two 15.2 X 23 centimeter (6 X 9 inch) speakers (2) located in the front door panels
Fig 3: Premium Nine Speaker System
As an option, the premium nine speaker Beats® by Dre 506-watt system includes speakers in nine
locations and an amplifier for the Uconnect® 6.5 radio.
Two 8.89 centimeter (3.5 inch) (1) diameter midrange tweeters located in the instrument panel
Two 15.2 X 23 centimeter (6 X 9 inch speakers (2) located in the front door panels
Two 2.54 centimeter (1 inch) (3) diameter tweeters located in the rear door panels by the door
handles
One 16.51 centimeter (6.5 inch) subwoofer (5) located behind the right side quarter trim panel
Eight channel 506-watt power amplifier (6) located behind the left side quarter trim panel
SPEAKER > DESCRIPTION AND OPERATION > DESCRIPTION AND OPERATION >
OPERATION
Two wires connected to each speaker, one feed circuit (+) and one return circuit (-), allow the audio
output signal electrical current from the amplifier section of the Radio Receiver Module (RRM) to flow
through each speaker voice coil.
The hard wired circuits between the RRM and the speakers may be diagnosed using conventional
SPEAKER > DIAGNOSIS AND TESTING > DIAGNOSIS AND TESTING - SPEAKER
WARNING:
CAUTION:
The speaker output of the radio is a "floating ground" system. Do not allow any speaker lead
to short to ground, as damage to the radio may result.
The hard wired circuits between components related to the audio system may be diagnosed using
However, conventional diagnostic methods will not prove conclusive in the diagnosis of the Radio
Receiver Module (RRM), the audio power amplifier or the electronic controls and communication
between modules and other devices that provide some features of the audio system. The most reliable,
efficient and accurate means to diagnose the RRM, the audio power amplifier or the electronic controls
and communication related to audio system operation requires the use of a diagnostic scan tool. Refer
1. If all speakers are inoperative, inspect all of the RRM related fuses. If OK, go to Step 2. If not
OK, repair the shorted circuit or component as required and replace the ineffective fuse.
2. If equipped with an audio power amplifier, check the fuse for the amplifier. If OK, go to Step 3.
If not OK, repair the shorted circuit or component as required and replace the ineffective fuse.
3. Transition the ignition switch to the On status. Turn the RRM On. Adjust the balance and fader
control controls to check the performance of each individual speaker. Note the speaker
locations that are not performing correctly. Go to Step 4.
4. Turn the RRM Off. Transition the ignition switch to the Off status. Disconnect and isolate the
negative battery cable. If equipped with an Intelligent Battery Sensor (IBS), disconnect the IBS
connector first before disconnecting the negative battery cable. If vehicle is not equipped with
an audio power amplifier, remove the RRM. If vehicle is equipped with an amplifier, disconnect
wire harness connector at the output side of the amplifier. Go to Step 5.
5. Check both the speaker feed (+) circuit and return (-) circuit cavities for the inoperative
speaker at the RRM wire harness connector for continuity to ground. There should be no
continuity. If OK, go to Step 6. If not OK, repair the shorted speaker feed (+) and/or return (-)
circuit(s) to the speaker as required.
6. Disconnect the wire harness connector at the inoperative speaker. Check for continuity
between the speaker feed (+) circuit cavities of the RRM wire harness connector or, if
equipped, the audio power amplifier wire harness connector and the speaker wire harness
connector. Repeat the check between the speaker return (-) circuit cavities of the RRM wire
harness connector and the speaker wire harness connector. In each case, there should be
continuity. If OK, replace the ineffective speaker. If not OK, repair the open speaker feed (+)
and/or return (-) circuit(s) as required.
SPEAKER > REMOVAL AND INSTALLATION > INSTRUMENT PANEL END SPEAKER >
REMOVAL
cable.
2. Remove the instrument panel speaker grill.

Fig 1: Removing/Installing Instrument Panel End Speaker
3. Remove the speaker (2) mounting fasteners (1).

Fig 2: Disconnecting/Connecting Speaker Electrical Connector
4. Disconnect the wire harness connector (2) and remove the speaker (1).
SPEAKER > REMOVAL AND INSTALLATION > INSTRUMENT PANEL END SPEAKER >
INSTALLATION
Fig 1: Disconnecting/Connecting Speaker Electrical Connector
1. Connect the wire harness connector (2) and install the speaker (1).
Fig 2: Removing/Installing Instrument Panel End Speaker
2. Install and securely tighten the speaker (2) mounting fasteners (1).
3. Install the instrument panel outer speaker grill.
SPEAKER > REMOVAL AND INSTALLATION > REAR DOOR TWEETER > REMOVAL
Fig 1: Rear Tweeter Grille, Wire Connector & Clips
cable.
2. Using trim stick C-4755 or equivalent, remove the rear tweeter grille (1b) from the rear door
trim panel.
3. Disconnect the tweeter wire harness connector (2) from the rear door tweeter.
Fig 2: Rear Door Tweeter, Grille & Clips
4. Release the tweeter (1b) from the three tweeter grille retaining clips (1a) and separate it from
the tweeter grille (1c).
SPEAKER > REMOVAL AND INSTALLATION > REAR DOOR TWEETER >
INSTALLATION
Fig 1: Rear Door Tweeter, Grille & Clips
1. Position the tweeter (1b) to the tweeter grille retaining clips (1a) and press the tweeter and the
tweeter grille (1c) together. Be certain the tweeter (1b) fully engages the retainers (1a) of the
tweeter grille (1c).
Fig 2: Rear Tweeter Grille, Wire Connector & Clips
2. Connect the tweeter wire harness connector (2) to the rear door tweeter.
3. Install the rear tweeter grille (1b) into the rear door panel. Be certain the tweeter grille retainers
(1a) fully engages the rear door panel.
SPEAKER > REMOVAL AND INSTALLATION > DOOR SPEAKER > REMOVAL
Fig 1: Speaker & Wire Connector
from the battery.
2. Remove the trim panel from the inside of the door to access the speaker. Refer to PANEL,
DOOR TRIM, REMOVAL AND INSTALLATION .
3. Remove the four fasteners that secure the speaker to the door inner panel.
4. Disconnect the wire harness (1a) connector from the speaker (1b).
5. Remove the speaker from the door panel.

SPEAKER > REMOVAL AND INSTALLATION > DOOR SPEAKER > INSTALLATION
1. Position the speaker (1b) to the door inner panel.
2. Connect the door wire harness connector (1a) to the speaker (1b).
3. Install and securely tighten the fasteners to secure the speaker (1b) to the door inner panel.
4. Install the door trim panel onto the inside of the door. Refer to PANEL, DOOR TRIM, REMOVAL
AND INSTALLATION .
SPEAKER > REMOVAL AND INSTALLATION > SUBWOOFER > REMOVAL

Fig 1: Remove/Install Subwoofer Assembly
cable.
2. Remove the right rear quarter trim panel. Refer to PANEL, QUARTER TRIM, REMOVAL AND
INSTALLATION .
3. Remove the five fasteners (2a) from right rear quarter trim panel support bracket (2b).
4. Disconnect the subwoofer assembly wire harness connector (1).
5. Remove the fasteners (3a) for the subwoofer (4).
6. Remove the subwoofer (4) from the cargo area.
SPEAKER > REMOVAL AND INSTALLATION > SUBWOOFER > INSTALLATION

Fig 1: Remove/Install Subwoofer Assembly
1. Position the subwoofer assembly (4) into the cargo area.
2. Install the fasteners (3a) for the subwoofer (4).
3. Connect the subwoofer assembly wire harness connector (1).
4. Position the right rear quarter trim panel support bracket (2b) and install the five fasteners (2a).
Securely tighten the fasteners.
5. Install the right rear quarter trim panel. Refer to PANEL, QUARTER TRIM, REMOVAL AND
INSTALLATION .
SWITCH, REMOTE RADIO > DESCRIPTION AND OPERATION > DESCRIPTION AND
Fig 1: Remote Radio Switches
The remote radio switches (1) are mounted to the back (instrument panel side) of the horizontal steering
wheel spokes (2). Each switch includes a momentary rocker with a momentary push button located in the
center, between the two ends of the rocker.
The right switch includes the following functions:
Volume Up
Mode
Volume Down
The left switch includes the following functions:
Seek Up
Preset
Seek Down
The remote radio switches (1) can not be adjusted or repaired and, if ineffective or damaged, the entire
switch unit must be replaced.
SWITCH, REMOTE RADIO > DESCRIPTION AND OPERATION > DESCRIPTION AND
The six switches in the two remote radio switch units are normally open, resistor multiplexed momentary
switches that are hard wired to the Body Control Module (BCM) through the steering wheel wire harness
and the clockspring on the steering column. The BCM reads the remote radio switch inputs then sends
the appropriate electronic messages to the Radio Receiver Module (RRM) over the Controller Area
Network (CAN) - B data bus to invoke the requested command.
The hard wired circuits between the remote radio switches and the BCM may be diagnosed using
However, conventional diagnostic methods will not prove conclusive in the diagnosis of the remote radio
switches or the electronic communication between modules that provide the features of the remote radio
switches. The most reliable, efficient and accurate means to diagnose the remote radio switches or the
electronic communication related to remote radio switch operation requires the use of a diagnostic scan
tool. Refer to the appropriate Diagnostic & Testing article.
SWITCH, REMOTE RADIO > DIAGNOSIS AND TESTING > DIAGNOSIS AND TESTING
- REMOTE RADIO SWITCHES
WARNING:
On vehicles equipped with airbags, refer to electrical, restraints before attempting any
steering wheel, steering column, or instrument panel component diagnosis or service.
Failure to take the proper precautions could result in accidental airbag deployment and
possible personal injury.
Any diagnosis of the audio system should begin with the use of the diagnostic scan tool. For information
on the use of the scan tool, refer to the appropriate Diagnostic & Testing article. For complete circuit
diagrams, refer to the appropriate SYSTEM WIRING DIAGRAMS article.
1. Remove the remote radio switch(es) from the steering wheel. Refer to SWITCH, REMOTE
RADIO, REMOVAL AND INSTALLATION .
2. Use an ohmmeter to check the switch resistances as shown in the Remote Radio Switch Test
chart.
REMOTE RADIO SWITCH TEST
Minimum Nominal Maximum

Switch Switch Position Resistance Resistance Resistance
(kilohms) (kilohms) (kilohms)
Right Volume Up 6.732 6.8 6.868
Right Volume Down 14.850 15 15.151
Right Mode Advance 0 0 0
Left Seek Up 1.188 1.2 1.212
Left Seek Down 3.267 3.3 3.333
Pre-Set Station
Left 0.465 0.47 0.474
Advance
3. If the switch resistance checks OK, go to Step 4. If not OK, replace the ineffective switch.
4. Check for continuity between the ground circuit cavity of the steering wheel wire harness
connectors for the switches and a good ground. There should be continuity. If OK, go to Step
5. If not OK, repair the open ground circuit as required.
5. Disconnect the appropriate wire harness connector from the Body Control Module (BCM).
Check for continuity between the radio control circuit cavity of the steering wire harness
connectors for the switches and a good ground. There should be no continuity. If OK, go to
Step 6. If not OK, repair the shorted radio control circuit as required.
6. Check for continuity between the radio control circuit cavities of the steering wheel wire
harness connectors for the switches and the BCM wire harness connector. There should be
continuity. If OK, use a diagnostic scan tool and the appropriate diagnostic procedures to test
the BCM, the Radio Receiver Module (RRM) and the Controller Area Network (CAN) data bus.
If not OK, repair the open radio control circuit as required.
SWITCH, REMOTE RADIO > REMOVAL AND INSTALLATION > REMOVAL AND
Fig 1: Remote Radio Switch & Cover
WARNING:
from the battery.
2. Working from the back of the steering wheel, unsnap and remove the remote radio switch
cover (1) from the remote radio switch.
Fig 2: Remote Radio Switch & Screw
3. Remove the screw (1) that secures the remote radio switch (2) to the steering wheel spoke
armature.
4. Carefully pull the remote radio switch (2) away from the steering wheel spoke armature.
Fig 3: Remote Radio Switch, Connector, Harness Retainers & Tabs
5. Carefully disconnect the remote radio switch connector (1) from the remote radio switch (3)
and release the wire harness from the harness retainers (4) on the remote radio switch.
6. Release the remote radio switch (3) from the four retaining tabs (2) on the remote radio switch
bezel and separate the remote radio switch (3) from the bezel.
SWITCH, REMOTE RADIO > REMOVAL AND INSTALLATION > REMOVAL AND
Fig 1: Remote Radio Switch, Connector, Harness Retainers & Tabs
WARNING:
1. Position the remote radio switch (3) to the remote radio switch bezel and combine them
together. Be certain to engage the retaining tabs (2) fully.
2. Working from the back of the steering wheel, connect the remote radio switch connector (1) to
the remote radio switch (3) and secure the wire harness in the harness retainers (4).
3. Position and carefully seat the remote radio switch (2) and wire harness to the steering wheel
spoke armature.
Fig 2: Remote Radio Switch & Screw
4. Install and securely tighten the screw (1) for the remote radio switch (2) to the steering wheel.
Fig 3: Remote Radio Switch & Cover
5. Install the remote radio switch cover (1). Be certain that the cover is snapped securely into
place.
Service Manual: CHIME/BUZZER/DRIVER ASSIST - Jeep Renegade
SERVICE INFORMATION
DESCRIPTION AND OPERATION > BLIND SPOT MONITOR SYSTEM > DESCRIPTION -
BLIND SPOT MONITOR SYSTEM
Fig 1: Blind Spot Monitoring (BSM) System
Blind Spot Monitoring (BSM)
The system continuously monitors the rear blind spots on both sides of the vehicle when any forward
gear is engaged and the speed of about 10 km/h (6 mph) is exceeded, through the use of two radar
modules mounted behind the rear bumper in the side area. If a vehicle detected in these areas does not
exceed the speed of approximately 50 km/h (31 mph), the system will warn the driver of its presence by
turning on the dedicated icon in the door mirror.
Fig 2: Blind Spot Monitoring (BSM) Warning Light
If another vehicle is overtaken slowly (with a speed lower than about 24 km/h / 15 mph) and this stays in
the blind spot for about 1.5 seconds, the warning light on the door mirror of the corresponding side lights
up. If the speed difference between the two vehicles is higher than about 24 km/h (15 mph), the warning
light does not light up.
Rear Cross Path Detection
The system monitors the vehicles and/or objects in the rear area of the vehicle (always through the two
radar sensors which also perform the BSM function) having a perpendicular movement to the vehicle and
speed lower than 35 km/h (22 mph), during reversing maneuvers providing feedback to the driver via
buzzer and/or visual icons.
Summary:
Monitors the vehicle's blind spots and warns the driver when another vehicle is present
It uses dual broadband radar sensors located behind the rear side panels
Lights up the icons in the door mirrors and, if necessary, uses the buzzer together with the
direction indicators (when this was previously selected into the dedicated menu)
Notifies the presence of vehicles in the blind spots when the lane is changed or other vehicles are
overtaking
Notifies the detection of vehicles moving in the rear area transversely to the vehicle, when this
vehicle is reversing
The driver can activate / deactivate the system and select the function mode via the radio menu.
Fig 3: Radar Sensors
Radar sensors
The radar sensors have an operation frequency that ranges from about 24 GHz to 200 MHz.
IMPORTANT:
The blind spot monitoring system can help the driver avoid accidents using visual and audible warnings.
However, the system is not a substitute for, and cannot mitigate unsafe driving practices. The driver
must remain alert and in control of the vehicle at all times.
DESCRIPTION AND OPERATION > BLIND SPOT MONITOR SYSTEM > OPERATION -
BLIND SPOT MONITOR SYSTEM
The primary components of the Blind Spot Monitor (BSM) system are the microcontroller based
Electronic Control Units (ECU) integral to each of the two RAdio Detection And Ranging (RADAR)
sensors, one behind each outboard side of the rear bumper fascia. Each ECU operates on battery
current received from a fuse in the Body Control Module (BCM) whenever the status of the ignition is On
and the ECU has a path to ground at all times through a take out and eyelet terminal of the body wire
harness that is secured to the body sheet metal. Each of these ECU communicate with each other as
well as with other electronic modules in the vehicle over the Controller Area Network (CAN) data bus
network.
The BSM system ECU continually monitor all of the BSM system circuits and components for readiness,
and will store a Diagnostic Trouble Code (DTC) for any fault that is detected. The ECU also
communicate with a diagnostic scan tool over the CAN data bus. When a BSM system ECU stores a
DTC, it sends an electronic request message to the Electronic Vehicle Information Center (EVIC) in the
Instrument Panel Cluster (IPC) and a SERVICE BLIND SPOT SYSTEM or BLIND SPOT SYSTEM
TEMPORARILY UNAVAILABLE textual message is displayed by the EVIC to alert the vehicle operator.
The BSM system ECU also monitor electronic messages received over the CAN data bus from the
Radio Receiver Module (RRM) indicating the Setup Menu settings selected by the customer for the BSM
system. The BSM system ECU receive and analyze data inputs directly from the radar sensors,
calculate and provide the proper hard wired outputs to illuminate the visual alert displays in their
respective right or left outside rear view mirrors, as well as calculate and communicate the proper
audible alert output requests to the IPC over the CAN data bus.
The BSM radar sensors allow the BSM system ECU to locate and identify nearby objects of interest
meeting the criteria established by algorithms within the system software. The BSM displays provide the
vehicle operator with a visual alert indicating that an object of interest has been detected within one of
the vehicle detection zones. The BSM audible alerts are then issued by the IPC based upon electronic
audible alert request messages received from the BSM system ECU. The BSM system ECU also send
electronic radio mute request messages over the CAN data bus to the Radio Receiver Module (RRM)
whenever an audible alert is requested. This message activates the radio mute function while the audible
alert is being sounded, then resumes normal radio function when the alert is completed.
The hard wired circuits between components related to the BSM system may be diagnosed using
conventional diagnostic tools and procedures. Refer to the appropriate SYSTEM WIRING DIAGRAMS
However, conventional diagnostic methods will not prove conclusive in the diagnosis of the BSM system
or the electronic controls and communication between ECU and other devices that provide some
features of this system. The most reliable, efficient and accurate means to diagnose the BSM system or
the ECU and communication related to BSM system operation requires the use of a diagnostic scan tool.
Refer to the appropriate Diagnostic & Testing article.
BLIND SPOT MONITOR SYSTEM > BLIND SPOT MONITOR MODE
Unless disabled in the setup routine settings received through the Radio Receiver Module (RRM), the
Blind Spot Monitor (BSM) mode is active only when the manual transmission gear selector is in a
position other than Reverse (R ) or the automatic transmission gear selector is in a position other than
Reverse (R ) or Park (P ). The BSM mode is intended to provide a visual alert to the driver when a
target vehicle (object of interest) is located in the lane adjacent to and just behind either outside rear
view mirror (the detection zone), in the blind spot area where vision of target vehicles may be inhibited
by the rear structure of the host vehicle. If a turn signal is activated in the host vehicle in the same
direction as that in which the target vehicle is located, an audible alert tone will also be generated. The
audible alerts of the BSM mode are not active unless the turn signal is activated.
The width of the BSM mode detection zone covers one traffic lane over on each side of the host vehicle,
approximately 4.0 m (13 ft). The length of the BSM mode detection zone starts at the outside rear view
mirror and extends approximately 4.5 m (15 ft) rearward from the rear edge of the rear fascia. The BSM
mode visual alerts are activated immediately if an object of interest is within the detection zone and
meets the warning criteria. However, the BSM system will not activate these alerts if:
The object of interest (target vehicle) comes from the rear of the detection zone and passes the
host vehicle at a speed greater that 50 km/h (31 mph).
The object of interest (target vehicle) enters the detection zone from the front and remains in the
zone for less than 1.5 seconds.
The object of interest (target vehicle) passes through the detection zone with a relative speed
greater than 20 km/h (12 mph).
The object of interest (target vehicle) passes the host vehicle from the opposite direction.
The BSM mode audible alert may be deactivated if the operator prefers using the Setup Menu within the
RRM. The BSM mode can be configured for visual and audible alerts, visual alerts only or for the entire
BSM system (including Rear Cross Path/RCP mode) to be turned Off.
BLIND SPOT MONITOR SYSTEM > REAR CROSS PATH MODE
Unless disabled in the Setup Menu settings received through the Radio Receiver Module (RRM), the
Blind Spot Monitor (BSM) system provides a feature called Rear Cross Path (RCP) mode. The RCP
mode is active only when the transmission gear selector (manual or automatic) is in the Reverse (R )
position. The RCP mode is intended to aid the driver when backing out of parking spaces where vision of
vehicles crossing laterally through the rear path of the host vehicle may be blocked. The host vehicle
must proceed slowly and cautiously out of the parking space until the rear end of the vehicle is exposed.
The BSM radar sensors will then have a clear view of the crossing traffic and, if an oncoming vehicle
(object of interest) is detected, will generate visual and audible alerts to the operator of the host vehicle.
The BSM system monitors the rear detection zones on both sides of the vehicle for objects that are
moving toward the side of the vehicle with speeds of from 1 to 3 km/h (1 to 2 mph) up to 35 km/h (22
mph), such as typically encountered in parking lot situations. In vehicles equipped with the BSM option,
the RCP mode is enabled from the factory as a default. The RCP mode can be manually disabled and
enabled by the vehicle operator using the setup routine of the IPC.
The RCP mode normally uses the same BSM system settings. However, the RCP mode will always
include the audible alert feature, even if it was disabled for the BSM mode using the RRM Setup Menu.
The audible alert can not be deactivated for the RCP mode. The RCP mode visual alert is illuminated
only in the display located on the same side of the vehicle where the object of interest is detected.
BLIND SPOT MONITOR SYSTEM > STANDBY MODE
The Blind Spot Monitor (BSM) system remains in standby mode as long as the park brake is applied in a
vehicle with a manual transmission, or while the automatic transmission gear selector lever is in the Park
(P ) position. In the standby mode the system receives vehicle information, responds to changes in the
Setup Menu settings received through the Radio Receiver Module (RRM) and can perform limited
self-diagnostics indicating hard system fault conditions.
DESCRIPTION AND OPERATION > CHIME WARNING SYSTEM > DESCRIPTION -

CHIME WARNING SYSTEM
A chime warning system is standard factory-installed equipment. The chime warning system uses an
electromechanical transducer that is soldered onto the electronic circuit board inside of the Instrument
Panel Cluster (IPC) to provide audible indications of various vehicle conditions that may require the
attention of the vehicle operator or occupants.
The electromechanical transducer can produce signals that vary in intensity and frequency, dependency
on the function being signalled. The microcontroller-based IPC utilizes electronic chime request
messages received from other modules in the vehicle over the Controller Area Network (CAN) data bus
along with hard wired inputs to monitor many sensors and switches throughout the vehicle. In response
to those inputs, the circuitry and programming of the IPC allow it to control the audible outputs that are
produced through its on-board transducer.
Hard wired circuitry connects the IPC and the various chime warning system switch and sensor inputs to
their modules and to each other through the electrical system of the vehicle. These hard wired circuits
are integral to several wire harnesses, which are routed throughout the vehicle and retained by many
different methods. These circuits may be connected to each other, to the vehicle electrical system and
to the IPC through the use of a combination of soldered splices, splice block connectors, and many
different types of wire harness terminal connectors and insulators. Refer to the appropriate SYSTEM
WIRING DIAGRAMS article. The wiring information includes wiring diagrams, proper wire and connector
repair procedures, further details on wire harness routing and retention, as well as pin out and location
The IPC chime warning system circuits and components cannot be adjusted or repaired. If the circuitry
or the on-board transducer are damaged or ineffective, the IPC unit must be replaced.
DESCRIPTION AND OPERATION > CHIME WARNING SYSTEM > OPERATION - CHIME
WARNING SYSTEM
The chime warning system operates on battery voltage received through a fuse in the Power Distribution
Center (PDC) on a non-switched fused B(+) circuit so that the system may operate regardless of the
ignition switch position. The chime warning system also monitors the ignition switch position so that
some chime features are functional only with the ignition switch in the On position, while others are
functional regardless of the ignition switch position.
The chime warning system provides an audible indication to the vehicle operator or occupants for the
following conditions:
Alarm, Warning or Danger Signals
Button Press Acknowledgment Beeps
The Instrument Panel Cluster (IPC) provides chime service for all available features in the chime warning
system. The IPC relies upon its internal programming, numerous hard wired inputs, and electronic
message inputs received from other modules over the Controller Area Network (CAN) data bus to
provide the chime warning system features. The internal programming of the IPC determines the priority
of each chime request input that is received, as well as the rate and duration of each chime that is to be
generated.
The hard wired circuits between components related to the chime warning system may be diagnosed
using conventional diagnostic tools and procedures. Refer to the appropriate SYSTEM WIRING
DIAGRAMS article. The wiring information includes wiring diagrams, proper wire and connector repair
However, conventional diagnostic methods will not prove conclusive in the diagnosis of the chime
warning system or the electronic controls and communication between modules and other devices that
provide some features of the chime warning system. The most reliable, efficient and accurate means to
diagnose the chime warning system or the electronic controls and communication related to chime
warning system operation requires the use of a diagnostic scan tool. Refer to the appropriate Diagnostic
& Testing article.
DESCRIPTION AND OPERATION > FORWARD COLLISION WARNING > FORWARD

COLLISION WARNING PLUS
Fig 1: Forward Collision Warning Plus (FCW+)

The Forward Collision Warning Plus (FCW+) operates from about 7 km/h (4 mph) to 200 km/h (124 mph).
By providing audible and visual alerts and through the use of the car's braking system, it creates a
jolt/jerk to draw the attention of the driver if a frontal collision is imminent.
Fig 2: Vehicle Braking System Activation Screen
If the driver does not react, the vehicle's braking system is activated to prevent or mitigate the potential
impact. Detail below:
It uses a radar sensor and a video sensor to detect if the vehicle is approaching another vehicle or
a big obstacle too fast and warns/helps the driver to avoid/mitigate any collision.
FCW+ meets the NHTSA and ENCAP regulations.
Using the dedicated menu, the driver can adjust the sensitivity (close, medium, far) and activate or
deactivate the warning.
The Prefill function prepares the braking system for an emergency braking.
FCW+ provides audible, visual and haptic alerts.
The jerk produced by the use of the braking system alerts the driver of the possible impact with a
haptic signal.
Advanced Brake Assist (ABA) : if the driver reacts, but does not brake enough, the ABA will
increase the braking force to prevent/reduce the collision.
Collision Mitigation System (CMS) : if the driver does not react, the system activates the
braking system to prevent/reduce the collision.
IMPORTANT: Both on versions equipped with manual gearbox and on those with automatic
transmission, after the vehicle is stopped the brake calipers may be stuck for about 2 seconds for safety
reasons. Make sure you press the brake pedal if the vehicle moves slightly forwards. The system has
been designed for road use only. If the vehicle is driven off-road, the system must be deactivated, to
avoid unnecessary warnings. By selecting the 4WD LOW mode, the system is automatically
deactivated.
DESCRIPTION AND OPERATION > FORWARD COLLISION WARNING > FORWARD

COLLISION WARNING PLUS
The Forward Collision Warning Plus (FCW+) system is only active when the status of the ignition switch
is ON and the PRNDL is in D (Drive). The system can be manually disabled and enabled by the vehicle
operator using menu options within the radio. The default status of FCW+ is "On". The system state is
kept in memory from one key cycle to the next. If the system is turned OFF, it will remain OFF when the
vehicle is restarted. The minimum speed for FCW+ activation is 7 km/h (4 mph).
Components that make up the FCW+ system are the Forward Facing Camera (FFC), Powertrain Control
Module (PCM), Switch Bank and the Adaptive Cruise Control Plus (ACC+) module. The ACC module is
the component that is responsible for the FCW+, Lane Departure Warning Plus (LDW+) and ACC+
decision making. The ACC module receives data from the FFC and performs a data fusion with its own
sensor data. At this point, the ACC module determines if a FCW+, LDW+ or ACC+ event needs to occur.
Since there are multiple modules involved in the operation of the FCW+ system, all faults or diagnostic
trouble codes should be checked during diagnosis. The system utilizes the radar sensor in front of the
vehicle, so any alignment or configuration issues may cause the system to be inoperative. If the ACC
radar detects incorrect or compromised information from the FFC, the ACC+ and the FCW+ will function
in an limited capacity. If the data consistency continue to occur from the FFC, a fault code will set.
NOTE:
The FCW+ does not stop the vehicles automatically, but alerts and assists the driver
to help avoid or mitigate a collision. If the driver does not respond to any of the
audible, visual, and haptic warnings, the impact may not be avoided
Fig 1: Forward Collision Warning Plus
The FCW+ system uses fusion of the sensor data from the ACC radar and the FFC to detect a probable
frontal or forward collision. The following actions will be performed when qualified:
Pre Fill - The pre-fill process prepares the brakes for emergency braking by engaging the pump
and applying a small amount of pressure to the brakes. This allows for immediate braking.
Sufficient pressure applied between the brake pads and the discs means that driver intervention
has a more immediate impact.
Audible and Visual Warnings - Audible sounds within the cabin of the vehicle and visual
warnings shown within the EVIC are activated when necessary to notify the driver.
Brake Jerk - A short deceleration is performed to alert the driver.
Collision Mitigation System (CMS) - CMS assists braking operation by automatically applying an
appropriate amount of braking force to help avoid or minimize the chances of hitting a vehicle. CMS
allows up to 1.5 seconds of braking to give the driver additional reaction time. When CMS
activates its automatic brake, it also turns the brake lights on.
Advanced Brake Assist (ABA) - Once the driver presses the brake pedal, advanced brake
assist (ABA) will engage If the driver is not applying enough force. ABA will increase the braking
force required to avoid or mitigate the accident. If the driver does not react to any of the previous
warnings, the collision cannot be avoided.
DESCRIPTION AND OPERATION > LANE DEPARTURE WARNING SYSTEM > LANE
DEPARTURE WARNING PLUS (LDW)
Fig 1: Lane Departure Warning Plus (LDW)
By means of a video sensor mounted behind the rear view mirror and in contact with the windshield, the
system is able to detect the lines on the road and keep the car on its own lane preventing involuntary
lane changes.
Fig 2: Driver Assist Screen
If the vehicle starts to drift into another lane and the driver, having the hands on the steering wheel, does
not use the direction indicator, the system alerts the driver that the car is going to depart from the lane
through two feedbacks: a visual indication on the instrument panel and a haptic signal by applying a
torque on the steering wheel.
Fig 3: Direction Indicator
Detail below:
The system uses a camera-based sensor to detect and measure the position of the vehicle within
the borders the lane.
During a drift towards another lane (direction indicator not active), the system will provide a visual
warning and a haptic warning by applying a torque to the Electric Power Steering (EPS) system.
The system checks if the driver's hands are on the steering wheel; if they are not present the
system provides a warning to induce the driver to position them. The system is deactivated if the
driver does not place the hands on the steering wheel within 5 seconds.
The system can be partially activated or deactivated via a button located in the center console.
The LED on the button will inform the driver on system status.
The driver can configure the amount of torque applied to the steering wheel as a feedback and the
distance from the area where the visual warning will start using the radio customization settings.
When activated, the system works at speeds higher than 60 km/h (37 mph) and lower than 180
km/h (110 mph).
The driver can bypass the system in different ways, including: use of direction indicators, torque
applied by the driver higher than that applied by the EPS system.
The system is deactivated automatically when a safety system such as ABS, TCS, ESC, FCW etc.
is activated.
DESCRIPTION AND OPERATION > LANE DEPARTURE WARNING SYSTEM > LANE
DEPARTURE WARNING (LDW+)
Fig 1: Lane Departure Warning (LDW+) - Circuit Diagram
Input/output:
ACC
FCW+ function status
Data on video objects

IPC
- Status, DTC, LDW function configuration and buzzer
BCM
LDW function ON/OFF switch
Status of LDW function LED
Brake pedal status
Direction indicator status
Vehicle speed
Status of acoustic warning for hands on the steering wheel
ORC
- Side acceleration value.
BSM/ESC
- ABS / ESC status
EPS
Steering angle
Torque applied to the steering wheel
CSS
- LDW activation/deactivation
LTM/ETM/HTM
- Audio signal for hands on the steering wheel LDW configuration status
RRM
- Buzzer
"Lane Assist" is a warning system which notifies the driver if they cross lanes, assisting the driver when
distracted. A video sensor, on the windshield near the interior rear view mirror, detects horizontal road
signs and the position of the vehicle in relation to them. If the vehicle is travelling in the middle of the
lane then the system does not intervene.
If, on the other hand, the vehicle gets close to the edge and the direction indicator is not operated, a
slight torque is applied to the steering wheel making the driver aware of what is happening. The drive
maintains full control of the vehicle and there is a great benefit in terms of safety.
The system is not on when the vehicle is started. The system can be partially activated or deactivated
via a button located on the left steering column stalk. When activated, the system starts recognizing
operating conditions, a condition signalled to the driver by the flashing icon on the instrument panel
display. The system can be switched off automatically in the following conditions:
the driver does not keep their hands on the steering wheel: the corresponding indication is shown
on the instrument panel and after a few seconds a buzzer sounds until the driver places their hands
back on the wheel. This is considered a dangerous condition and the system is automatically
deactivated;
intervention of vehicle safety systems (ABS, ASR and electric power steering). The automatic
switching off is signalled to the driver by three consecutive acoustic warnings and the message in
the instrument panel display.
The video sensor that manages the lane departure warning function has an ignition-controlled power
supply (INT) provided from a line protected by a fuse located in the Body Control Module (BCM).
The sensor is connected, via the CAN line to the BCM and to the instrument panel to manage the "lane
departure warning on" warning light and failure signals.
The lane departure warning function control button, located in steering column stalk, sends the activation
signal via LIN line to BCM.
Sensor is also connected to radar sensor of the ACC+ system, with a dedicated CAN line.
DESCRIPTION AND OPERATION > PARK ASSIST SYSTEM > DESCRIPTION - PARK
ASSIST SYSTEM
Fig 1: Park Assist System Screen
The system uses four sensors located in the rear bumper fascia. The sensors send ultrasonic waves
when the vehicle is driven in reverse at low speed. The sensors send and receive ultrasonic waves from
the echo coming back from any objects placed in the path of the vehicle. The control unit processes data
from the sensors and performs a data triangulation to determine the relative distance, depending on the
time elapsed between the output signal and the return signal. Acoustic warnings and signals are output
from the instrument panel to alert the driver of the proximity of an object at the rear of the vehicle.
Fig 2: Park Assist System Button (EMEA)

EMEA
Fig 3: Park Assist System Button (NAFTA)
NAFTA
The system can be deactivated using the button on the switch pod under the radio.
In case of system failure an audio signal is output and, when reverse is engaged, the display shows a
dedicated message for about 5 seconds.
Semi-automatic parking assist system (parallel and perpendicular)
When the car is equipped with the semi-automatic parking assist system (EMEA only), the PAM module
is able to park the vehicle in parallel or perpendicular spaces.
Fig 4: Semi-Automatic Parking Assist System (Parallel Parking)

Parallel Parking
Fig 5: Semi-Automatic Parking Assist System (Perpendicular Parking)
Perpendicular Parking
For the semi-automatic parking function the system uses 12 ultrasonic sensors. The ultrasonic sensors
are located on the front and rear bumpers. The two bumpers have 6 sensors each. Two of these
sensors are placed on the side of the bumper.
The driver activates the system by pressing the button of the switch pod on the center of the dashboard.
Fig 6: Semi-Automatic Parking Function Button (EMEA)

EMEA
Fig 7: Semi-Automatic Parking Function Button (NAFTA)
NAFTA
After activation, the EVIC displays the graphics that allows you to select the desired maneuver (parallel
or perpendicular parking).
Fig 8: EVIC Display (Parallel)
Parallel
Fig 9: EVIC Display (Perpendicular)
Perpendicular
When the system detects a suitable space, it will advise the driver to stop by visual and acoustic
signals.
It will communicate to the driver when to engage reverse and operate the brake. Through the combined
action with the electric power steering module, the system controls the movement of the steering wheel
and the steering angle. The driver controls the position of the gearbox, brake and accelerator.
The perpendicular and parallel parking are available on both sides of the vehicle.
Fig 10: Parallel Parking Mode Display
When the parallel parking mode is active, the driver is assisted also when driving out of the parking lot.
The RPA and PPPA system components cannot be adjusted or repaired. If any of these components is
damaged or ineffective, that component must be replaced.
ASSIST SYSTEM > REAR PARK ASSIST
A Rear Park Assist (RPA) system is an optional factory-installed electronic parking aid. During parking
and other similar vehicle maneuvers this system alerts the vehicle operator to the approximate relative
distance of obstacles located in the path immediately behind the vehicle which, due to the surrounding
rear vehicle structure, might be otherwise difficult to perceive. When an obstacle is detected, the system
uses graphics and chimes to provide the vehicle operator with visual and audible indications of the
presence and proximity of such objects.
The RPA system includes the following major components, which are described in further detail
elsewhere in this service information:
Body Control Module - The Body Control Module (BCM) serves as the gateway between the
Local Interface Network (LIN) data bus of the park assist Off switch and the Controller Area
Network (CAN) data bus network used to communicate between the Park Assist Module (PAM), the
Instrument Panel Cluster (IPC) and the Radio Receiver Module (RRM).
Instrument Panel Cluster - In vehicles equipped with the optional RPA system, the Electronic
Vehicle Information Center (EVIC) within the Instrument Panel Cluster (IPC) displays vehicle
graphics that illustrate the approximate location and relative distance of obstacles within the rear
path of the vehicle. The EVIC also displays textual warnings and error messages along with issuing
audible alerts related to the current operating status of the RPA system.
Park Assist Module - Vehicles equipped with the RPA system include a 4 channel Park Assist
Module (PAM), which is secured through integral mounting tabs to the left quarter inner panel above
the left rear wheel house, where it is concealed beneath the quarter inside trim within the cargo
area of the vehicle.
Park Assist Off Switch - The park assist system can be manually disabled or enabled using a
park assist Off switch. The park assist Off switch is integral to the instrument panel switch pod in
the instrument panel center stack below the Radio Receiver Module (RRM). This switch allows the
operator to turn the park assist system Off.
Park Assist Sensors - Vehicles equipped with the RPA system have four ultrasonic park assist
sensors that are concealed behind the rear bumper fascia. Only the sensor membrane is visible on
the outer surface of the rear bumper fascia. Each sensor is snapped into an individual molded
plastic mounting bracket located at horizontal intervals along the inside surface of the rear bumper
fascia.
Radio Receiver Module - In vehicles equipped with the RPA system, the PAM sends electronic
message requests to the RRM to mute audio system output during chime tone generation. In
addition, the RRM provides an interface that allows the vehicle operator to manually disable or
enable the RPA system using the Setup Menu function.
ASSIST SYSTEM > PARALLEL AND PERPENDICULAR PARK ASSIST
In Europe-Middle East-Africa (EMEA) markets only a Parallel and Perpendicular Park Assist (PPPA)
system is an optional factory-installed electronic parking aid. During parking and other similar vehicle
maneuvers this system alerts the vehicle operator to the approximate relative distance of obstacles
located in the paths immediately behind and ahead of the vehicle which, due to the surrounding vehicle
structures, might be otherwise difficult to perceive. When an obstacle is detected, the system uses
graphics and chimes to provide the vehicle operator with visual and audible indications of the presence
and proximity of such objects.
The PPPA is also capable of providing an autonomous brake warning feature. When enabled, this
feature will alert the vehicle operator when the automatic transmission gear selector is in the Reverse
(R ) position and an object is detected in the rear path of the vehicle by aggressively applying and
releasing the brakes. Following an autonomous brake warning application, an icon representing the rear
of the vehicle with three red arcs and the text BRAKE! will appear in the Electronic Vehicle Information
Center (EVIC) within the Instrument Panel Cluster (IPC). This brake warning feature is not available in
vehicles equipped with a manual transmission.
Finally, the PPPA provides a semiautomatic parallel and perpendicular park assist feature. When
enabled, this feature will identify a suitable parking spot and help to steer the vehicle into a selected
parallel or perpendicular parking spot accordingly.
The PPPA system includes the following major components, which are described in further detail
Antilock Brake Module - The Antilock Brake Module (ABM) controls the application of the vehicle
brakes to implement the autonomous brake warning feature when it receives the appropriate
electronic message input over the Controller Area Network (CAN) data bus from the Park Assist
Module (PAM).
Body Control Module - The Body Control Module (BCM) serves as the gateway between the
Controller Area Network (CAN) data bus networks used to communicate between the Park Assist
Module (PAM), the Antilock Brake Module (ABM), the Electronic Power Steering (EPS) module, the
Instrument Panel Cluster (IPC) and the Radio Receiver Module (RRM).
Electronic Power Steering Module - The Electronic Power Steering (EPS) module controls the
vehicle steering in order to maneuver the vehicle into a selected parallel or perpendicular parking
space based upon electronic message inputs received over the Controller Area Network (CAN)
data bus from the Park Assist Module (PAM).
Instrument Panel Cluster - In vehicles equipped with the optional PPPA system, the Electronic
Vehicle Information Center (EVIC) within the Instrument Panel Cluster (IPC) displays vehicle
graphics and amber or red arc sections that illustrate the approximate location of obstacles within
the front or rear paths of the vehicle. The EVIC displays graphics and text to support the parallel
and perpendicular parking features, textual warnings and error messages along with issuing audible
alerts related to the current operating status of the PPPA system.
Parallel And Perpendicular Park Assist On Switch - The Parallel and Perpendicular Park Assist
(PPPA) features of the optional PPPA system can be selected and toggled using a PPPA On
switch. The PPPA On switch is integral to the instrument panel switch pod, which is secured to the
instrument panel center stack just below the Radio Receiver Module (RRM). Refer to POD,
SWITCH, DESCRIPTION AND OPERATION . This switch allows the operator to turn the PPPA
features On and toggle between the parallel and the perpendicular park assist features.
Park Assist Module - Vehicles equipped with the PPPA system include a 12 channel Park Assist
Module (PAM), which is secured with plastic push-in fasteners through integral mounting tabs to the
inner surface of the lower deck opening closure panel just below the left tail lamp mounting panel,
where it is concealed beneath the left rear wheel house carpet extension within the trunk of the
vehicle.
Park Assist Off Switch - The optional PPPA system can be manually disabled or enabled using a
park assist Off switch. The park assist Off switch is integral to the instrument panel switch pod in
the instrument panel center stack below the heater and air conditioner controls. This switch allows
the operator to turn the PPPA system Off.
Park Assist Sensors - Vehicles equipped with the PPPA system have twelve ultrasonic park
assist sensors. Six are concealed behind the rear bumper fascia and six are concealed behind the
front bumper fascia. Only the sensor membrane is visible on the outer surface of the bumper
fascia. Each sensor is snapped into an individual molded plastic mounting bracket located at
horizontal intervals along the inside surfaces of the front and rear bumper fascias.
Radio Receiver Module - In vehicles equipped with the PPPA system, the PAM sends electronic
message requests to the RRM to generate audible signals indicating the approximate distance of
obstacles from the front and rear paths of the vehicle. The RRM is capable of generating repetitive
single chime tones at several varying frequencies or continuous tones through the front or rear
audio system speakers. If the audio system speakers are already in use, the RRM will mute that
output during chime tone generation. In addition, the RRM provides an interface that allows the
vehicle operator to manually disable or enable the PPPA system using the customer programmable
features option.
DESCRIPTION AND OPERATION > PARK ASSIST SYSTEM > OPERATION - PARK
ASSIST SYSTEM
Details for the two versions of the park assist system available for this vehicle (Rear Park Assist/RPA or
Parallel and Perpendicular Park Assist/PPPA) can be found under dedicated, separate headings within
this service information.
The hard wired circuits between components related to the park assist system may be diagnosed using
However, conventional diagnostic methods will not prove conclusive in the diagnosis of the park assist
system or the electronic controls and communication between modules and other devices that provide
some features of the park assist system. The most reliable, efficient and accurate means to diagnose
the park assist system or the electronic controls and communication related to park assist system
operation requires the use of a diagnostic scan tool. Refer to the appropriate Diagnostic & Testing
article.
ASSIST SYSTEM > REAR PARK ASSIST
The Rear Park Assist (RPA) system is active only when the status of the ignition is On, the transmission
gear selector lever is in the Reverse (R ) position and the vehicle speed is less than about 11 km/h (7
mph). The system can be manually disabled and enabled by the vehicle operator using the park assist
Off push button in the instrument panel switch pod. In vehicles equipped with this option, the system is
enabled from the factory as a default.
Reasons for disabling the system include trailer towing and off road use. With a trailer attached to the
vehicle the audible and visual RPA alerts would be incessant whenever the gear selector lever was in
the Reverse (R ) position due to the proximity of the trailer to the rear of the vehicle. Similarly, operating
the vehicle off road may cause the RPA alerts to become distracting due to the proximity of large trees
or boulders and the extreme rear approach angles that may be encountered while maneuvering on off
road trails or terrain.
When the system is disabled, a PARK ASSIST SYSTEM OFF graphic and textual message will appear
in the Electronic Vehicle Information Center (EVIC) display of the Instrument Panel Cluster (IPC) at the
beginning of each ignition On cycle, and whenever the gear selector lever is in the Reverse (R )
position. When the system is enabled, a PARK ASSIST SYSTEM ON graphic and textual message will
appear in the EVIC display of the IPC at the beginning of each ignition On cycle, and a PARK ASSIST
READY graphic and textual message will appear in the display whenever the gear selector lever is in
the Reverse (R ) position.
The microcontroller based, 4 channel Park Assist Module (PAM) is the central component of the RPA
system. It supplies voltage to the park assist sensors, receives and analyzes data from the sensors,
calculates and communicates the proper display information to the EVIC display, calculates and
communicates the proper audible outputs to the Radio Receiver Module (RRM), performs system
diagnostics and communicates with other electronic modules in the vehicle or with a diagnostic scan tool
over the Controller Area Network (CAN) data bus. The PAM operates on battery voltage received
through a fused ignition (run) fuse in the Power Distribution Center (PDC) and is grounded through a take
out of the body wire harness secured to the body sheet metal.
Four ultrasonic park assist sensors in the rear bumper fascia allow the RPA system to locate and
identify the proximity of nearby obstacles. These sensors each generate ultrasonic sound pulses when
triggered by the PAM, then signal the PAM when an echo of the reflected sound pulses is received. The
detection distance range from the rear of the vehicle is about 2 m (80 in), and the detection height range
from the ground is about 0.2 m (7.8 in) to about 0.8 m (31 in). The detection area extends somewhat
around both rear corners of the vehicle.
The EVIC display unit provides the vehicle operator with a graphical representation of the vehicle along
with numerous illuminated arc sections that indicate the relative location and range of detected objects.
The display is visible directly in front of the vehicle operator and operates based upon the electronic
message inputs received from the PAM over the CAN data bus. There are three regions at the rear of
the vehicle designated for arc alerts: Center, Left and Right. The Center region consists of six zones,
while the Right and Left regions consist of two zones. The zones range from furthest to nearest from the
rear of the vehicle. The arc sections are illuminated in an amber color until the nearest zone is reached,
at which point the arc sections become illuminated red in color.
Meanwhile, the RRM generates audible indications of a detected object by emitting a series of chime
tones that grow progressively higher in frequency as the vehicle gets closer to the object. As the vehicle
comes within about 30 centimeters (12 inches) of the object, the audible warning changes from a high
frequency series of chime tones to a single continuous tone. If the audio system is active when the RRM
receives a chime request message from the PAM, the audio output will be muted automatically while the
RPA audible warnings are being generated.
When the PAM monitors a problem in any of the RPA system circuits or components, it stores a fault
code or Diagnostic Trouble Code (DTC) in its memory circuit, sends an electronic message to the EVIC
and the EVIC displays a graphic with a SERVICE PARK ASSIST SYSTEM textual message. If the PAM
detects that the park assist sensors are inoperative due to an accumulation of road film, mud, ice or
snow on the rear fascia, the EVIC will display a WIPE OFF REAR PARK ASSIST SENSORS graphic
and textual message. When the system is disabled by the PAM due to a detected external error or
influence, a PARK ASSIST SYSTEM DISABLED graphic and textual message will appear in the EVIC
display of the IPC whenever a new ignition cycle begins and each time the gear selector lever is in the
Reverse (R ) position.
ASSIST SYSTEM > PARALLEL AND PERPENDICULAR PARK ASSIST
The Parallel and Perpendicular Park Assist (PPPA) system is active only when the status of the ignition
is On, the automatic transmission gear selector lever is in the Drive (D ) or Reverse (R ) position, the
manual transmission gear selector lever is in the Reverse R or is not in Reverse R and the vehicle
speed is less than about 11 km/h (7 mph). The front and rear park assist features of this system can be
manually disabled and enabled by the vehicle operator using the Park Assist Off push button in the
instrument panel switch pod. In vehicles equipped with this option, the system is enabled from the factory
as a default.
Reasons for disabling the system include trailer towing and off road use. With a trailer attached to the
vehicle the audible and visual park assist alerts would be incessant whenever the gear selector lever
was in the Reverse (R ) position due to the proximity of the trailer to the rear of the vehicle. Similarly,
operating the vehicle off road may cause the park assist alerts to become distracting due to the
proximity of large trees or boulders and the extreme front and rear approach angles that may be
encountered while maneuvering on off road trails or terrain.
When the system is disabled, a PARK ASSIST SYSTEM OFF graphic and textual message will appear
in the Electronic Vehicle Information Center (EVIC) display of the Instrument Panel Cluster (IPC) at the
beginning of each ignition On cycle, whenever the automatic transmission gear selector lever is in the
Drive (D ) or Reverse (R ) positions, or whenever the manual transmission gear selector lever is in the
Reverse (R ) or not in Reverse positions. When the system is enabled, a PARK ASSIST SYSTEM ON
graphic and textual message will appear in the EVIC display of the IC at the beginning of each ignition
On cycle, and a PARK ASSIST READY graphic and textual message will appear in the display
whenever the automatic transmission gear selector lever is in the Drive (D ) or Reverse (R ) positions
and the vehicle speed is less than about 11 kilometers-per-hour (7 miles-per-hour), or whenever the
manual transmission gear selector lever is in the Reverse (R ) or not in Reverse positions and the
vehicle speed is less than about 11 kilometers-per-hour (7 miles-per-hour).
The microcontroller based, 12 channel Park Assist Module (PAM) is the central component of the park
assist system. It supplies voltage to the park assist sensors, receives and analyzes data from the
sensors, calculates and communicates the proper display information to the EVIC display, calculates and
communicates the proper audible outputs to the Radio Receiver Module (RRM), performs system
diagnostics and communicates with other electronic modules in the vehicle or with a diagnostic scan tool
over the Controller Area Network (CAN) data bus. The PAM operates on battery voltage received
through a fused ignition (run) fuse in the Power Distribution Center (PDC) and is grounded through a take
out of the body wire harness secured to the body sheet metal.
Six ultrasonic park assist sensors in the front bumper fascia and six sensors in the rear bumper fascia
allow the park assist system to locate and identify the proximity of nearby obstacles. These sensors
each generate ultrasonic sound pulses when triggered by the PAM, then signal the PAM when an echo of
the reflected sound pulses is received. The detection distance range from the front of the vehicle is
about 1.2 m (47 in), or from the rear of the vehicle is about 2 m (80 in). The detection height range from
the ground is about 0.2 m (7.8 in) to about 0.8 m (31 in). The detection area extends somewhat around
both front and rear corners of the vehicle. In the PPPA system, the four sensors on the outboard right
and left ends of the front and rear fascias have increased range over the other eight sensors and are
not interchangeable.
In vehicles with an automatic transmission, the PPPA has an available autonomous brake warning
feature. When the transmission gear selector position is Reverse (R ), an object is detected at the rear
of the vehicle at a vehicle velocity based distance value and the ultrasonic sensors are capable of
detecting an object the PAM sends an electronic brake and release message to the Antilock Brake
Module (ABM) over the CAN data bus network. The autonomous brake warning is aggressively
performed by the ABM to reduce vehicle speed and pre-fill the brake hydraulic system in an effort to
warn and to give the vehicle operator more time to react to a detected object at the rear of the vehicle.
The autonomous brake warning feature is an alert function, not a comfort function; therefore, the brake
application will be sharp and sudden to disturb, rather than smooth and discrete. This feature is enabled
from the factory as a default, but can be manually disabled or enabled by the vehicle operator using the
customer programmable features settings menu of the Radio Receiver Module (RRM).
The EVIC display unit provides the vehicle operator with a graphical representation of the vehicle along
with numerous illuminated arc sections that indicate the relative location and range of detected objects.
The display is visible directly in front of the vehicle operator and operates based upon the electronic
message inputs received from the PAM over the CAN data bus. There are three regions at the front or
rear of the vehicle designated for arc alerts: Center, Left and Right. The Front Center region consists of
five zones, the Rear Center region consist of six zones, while the Right and Left regions at the front and
rear both consist of two zones. The zones range from furthest to nearest from the vehicle. The arc
sections are illuminated in an amber color until the nearest zone is reached, at which point the arc
sections become illuminated red in color.
Meanwhile, the RRM generates audible indications of a detected object by emitting a series of chime
tones that grow progressively higher in frequency as the vehicle gets closer to the object. As the vehicle
comes within about 30 cm (12 in) of the object, the audible warning changes from a high frequency
series of chime tones to a single continuous tone. If the audio system is active when the RRM receives
a chime request message from the PAM, the audio output will be muted automatically while the park
assist audible warnings are being generated.
The semiautomatic parallel and perpendicular parking feature is designed to assist the vehicle operator,
not to substitute for the vehicle operator. The vehicle operator must stay in full control of the
acceleration and braking of the vehicle. The driver initiates the parallel and perpendicular parking feature
by using the Parallel And Perpendicular Park Assist On push button in the instrument panel switch pod.
Once the parallel and perpendicular park feature is turned On, an Active Park Sense Search screen
pops up in the EVIC display unit. The initial search screen to pop up will be for the parallel parking
feature, but text at the bottom of the EVIC display advises, Press OK for Perpendicular Park . The
vehicle operator can then press the OK push button in the EVIC switch pod on the left horizontal spoke
of the steering wheel to toggle back and forth between the parallel parking space and perpendicular
parking space search screens. From this point through completion of the selected parking maneuver, the
system will automatically coach the vehicle operator through the location of an appropriate parking
space and the parking maneuver using both graphical representations and text that pops up within the
EVIC display unit.
During parallel and perpendicular parking maneuvers the PPPA system assists the vehicle operator by
measuring and identifying an appropriate parking space while driving slowly past the potential space.
Then the system calculates the appropriate trajectory and controls the steering wheel to steer the
vehicle into the selected space. Depending upon the parking maneuver selected, the PPPA system is
capable of steering a vehicle into a parallel or a perpendicular parking space on either the driver side or
the passenger side of the vehicle. The PAM controls the measuring and maneuvering of the vehicle by
monitoring the ultrasonic sensor inputs and sending the appropriate electronic messages to the
Electronic Power Steering (EPS) module over the CAN data bus.
When the PAM monitors a problem in any of the park assist system circuits or components, it stores a
fault code or Diagnostic Trouble Code (DTC) in its memory circuit, sends an electronic message to the
EVIC and the EVIC displays a graphic with a SERVICE PARK ASSIST SYSTEM textual message. If the
PAM detects that the park assist sensors are inoperative due to an accumulation of road film, mud, ice
or snow on the front or rear fascia, the EVIC will display a WIPE OFF FRONT PARK ASSIST
SENSORS or WIPE OFF REAR PARK ASSIST SENSORS graphic and textual message. When the
system is disabled by the PAM due to a detected external error or influence, a PARK ASSIST SYSTEM
DISABLED graphic and textual message will appear in the EVIC display of the IC whenever a new
ignition cycle begins and each time the automatic transmission gear selector lever is in the Drive (D ) or
Reverse (R ) position or the manual transmission gear selector lever is in the Reverse (R ) or not in
Reverse positions.
DIAGNOSIS AND TESTING > DIAGNOSIS AND TESTING - BLIND SPOT MONITOR
SYSTEM
WARNING:
The following textual messages related to the Blind Spot Monitor (BSM) system may appear within the
Electronic Vehicle Information Center (EVIC) display of the Instrument Panel Cluster (IPC):
BLIND SPOT SYSTEM OFF - This message to the vehicle operator when the ignition first
transitions to the On status indicates that the BSM system has been turned Off using the Setup
Menu of the Radio Receiver Module (RRM).
SERVICE BLIND SPOT SYSTEM - This message to the vehicle operator while the ignition status
is On indicates that the BSM system is unavailable due to a monitored system fault or faults.
BLIND SPOT SYSTEM TEMPORARILY UNAVAILABLE - This message to the vehicle operator
while the ignition status is On indicates that the BSM system is temporarily unavailable as a result
of one of the following:
1. Sensor Blockage - The amber BSM visual icon in both outside rear view mirrors will
be illuminated as long as blockage exists or until the ignition status transitions to Off,
whichever occurs first.
2. Monitored System Fault - The BSM system has detected a monitored system fault
condition and has stored a Diagnostic Trouble Code (DTC). The amber BSM visual
icon will be illuminated in both outside rear view mirrors for as long as the condition
exists or until the ignition status transitions to Off, whichever occurs first.
NOTE:
If the BLIND SPOT SYSTEM TEMPORARILY UNAVAILABLE message is received for a
minimum of 5 minutes, please verify that the outboard area at each end of the rear fascia
behind the rear wheel openings where the radar sensors are located is not blocked by snow,
ice or road debris. If the area is blocked, remove the blockage and verify that the message
is no longer present in the EVIC display.
NOTE:
If the vehicle has experienced any trauma in the outboard area at each end of the rear
fascia behind the rear wheel openings where the sensors are located, even if the fascia is
not damaged, the radar sensor may have become misaligned. A misaligned radar sensor
will result in the BSM system not operating properly.
The hard wired circuits between components related to the BSM system may be diagnosed using
However, conventional diagnostic methods will not prove conclusive in the diagnosis of the BSM system
or the electronic controls and communication between modules and other devices that provide some
features of the system. The most reliable, efficient and accurate means to diagnose the BSM system or
the electronic controls and communication related to BSM system operation requires the use of a
diagnostic scan tool. Refer to DIAGNOSIS AND TESTING or DIAGNOSIS AND TESTING .
DIAGNOSIS AND TESTING > DIAGNOSIS AND TESTING - CHIME WARNING SYSTEM
WARNING:
The hard wired circuits between components related to the chime warning system may be diagnosed
However, conventional diagnostic methods will not prove conclusive in the diagnosis of the chime
warning system or the electronic controls and communication between modules and other devices that
provide some features of the chime warning system. The most reliable, efficient and accurate means to
diagnose the chime warning system or the electronic controls and communication related to chime
warning system operation requires the use of a diagnostic scan tool. Refer to the appropriate Diagnostic
& Testing article.
DIAGNOSIS AND TESTING > DIAGNOSIS AND TESTING - FORWARD COLLISION

WARNING
The hard wired circuits between components related to the Forward Collision Warning (FCW+) system
may be diagnosed using conventional diagnostic tools and procedures. Refer to the appropriate
SYSTEM WIRING DIAGRAMS article. The wiring information includes wiring diagrams, proper wire and
connector repair procedures, details of wire harness routing and retention, connector pin out information
and location views for the various wire harness connectors, splices and grounds.
However, conventional diagnostic methods will not prove conclusive in the diagnosis of the FCW+
some features of the FCW+ system. The most reliable, efficient and accurate means to diagnose the
FCW+ system or the electronic controls and communication related to FCW+ system operation requires
the use of a diagnostic scan tool.
DIAGNOSIS AND TESTING > DIAGNOSIS AND TESTING - LANE DEPARTURE

WARNING SYSTEM
The hard wired circuits between components related to the Lane Departure Warning (LDW+) system
may be diagnosed using conventional diagnostic tools and procedures. Refer to the appropriate
However, conventional diagnostic methods will not prove conclusive in the diagnosis of the LDW+
some features of the LDW+ system. The most reliable, efficient and accurate means to diagnose the
LDW+ system or the electronic controls and communication related to LDW+ system operation requires
DIAGNOSIS AND TESTING > DIAGNOSIS AND TESTING - PARK ASSIST SYSTEM
WARNING:
A park assist system warning icon or textual message may appear within the Electronic Vehicle
Information Center (EVIC) reconfigurable display in the Instrument Panel Cluster (IPC). If a warning
appears in the EVIC display, and the condition is related to the park assist system; be certain to confirm
the following:
Be certain that the rear bumper fascia is free of dirt and debris to keep the system operating
properly. The park assist system is self correcting, please verify that the area of the rear bumper
fascia where the sensors are located (both the face and the back) is not blocked by ice, snow,
mud or other obstructions. If the area is blocked, remove the blockage, shift the transmission
selector lever into Reverse (R ) and verify the warning is no longer present in the EVIC display.
Be certain that the parking brake is not applied.
The presence of operating heavy construction equipment, large trucks and other vibrations in the
vicinity of the vehicle could impact the performance of the system.
The hard wired circuits between components related to the park assist system may be diagnosed using
the park assist system or the electronic controls and communication related to park assist system
article.
DISPLAY, BLIND SPOT > DESCRIPTION AND OPERATION > DESCRIPTION AND
Fig 1: Blind Spot Monitor (BSM) System Display
Vehicles equipped with the Blind Spot Monitor (BSM) system have a display that appears in both the
right and left outside rear view mirrors (1). The display consists of a translucent icon (2) in the mirror
glass that is illuminated by an amber Light Emitting Diode (LED) unit mounted behind the icon on the
mirror glass case. When illuminated, only the amber colored icon is visible on the outer surface of the
mirror glass. The LED unit for the display is connected to the vehicle electrical system along with the
other wiring for the power mirror through a dedicated take out and connector of the door wire harness.
The BSM displays are each integral to the outside rear view mirror glass and case unit. The displays
cannot be adjusted or repaired. If a BSM display is ineffective or damaged, the entire mirror glass and
case unit must be replaced. Refer to MIRROR, OUTSIDE REARVIEW, REMOVAL AND INSTALLATION .
DISPLAY, BLIND SPOT > DESCRIPTION AND OPERATION > DESCRIPTION AND
The Blind Spot Monitor (BSM) displays provide the vehicle operator with a visual alert that a target
vehicle (object of interest) has been detected by the BSM system within one of the BSM or Rear Cross
Path (RCP) detection zones. The BSM display is also illuminated momentarily as a bulb test each time
the ignition status transitions to On as a part of the BSM system self tests. If a BSM display remains
illuminated with the park brake applied or with the automatic transmission gear selector in the Park (P )
position, it indicates that the BSM system has registered a system fault and may require service.
Each BSM display is completely controlled by a hard wired output of the RAdio Detection And Ranging
(RADAR) smart sensor (also known as Left Blind Spot Sensor/LBSS or Right Blind Spot Sensor/RBSS)
for the same side of the vehicle as the display. The display units are grounded at all times through a
takeout and eyelet terminal of the body wire harness that is secured to the body sheet metal.
The hard wired circuits between the BSM displays and the LBSS or RBSS may be diagnosed using
article. However, conventional diagnostic methods will not prove conclusive in the diagnosis of the BSM
displays or the electronic controls and communication between other modules and devices that provide
some features of the BSM displays. The most reliable, efficient and accurate means to diagnose the
BSM displays or the electronic controls and communication related to BSM display operation requires
DISPLAY, BLIND SPOT > DIAGNOSIS AND TESTING > DIAGNOSIS AND TESTING -
BLIND SPOT DISPLAY
The hard wired circuits between the Blind Spot Monitor (BSM) displays and the Left Blind Spot Sensor
(LBSS) or Right Blind Spot Sensor (RBSS) may be diagnosed using conventional diagnostic tools and
procedures. Refer to the appropriate SYSTEM WIRING DIAGRAMS article. The wiring information
includes wiring diagrams, proper wire and connector repair procedures, details of wire harness routing
and retention, connector pin out information and location views for the various wire harness connectors,
splices and grounds.
However, conventional diagnostic methods will not prove conclusive in the diagnosis of the BSM
displays or the electronic controls and communication between other modules and devices that provide
some features of the BSM displays. The most reliable, efficient and accurate means to diagnose the
BSM displays or the electronic controls and communication related to BSM display operation requires
DISPLAY, BLIND SPOT > REMOVAL AND INSTALLATION > REMOVAL AND
The Blind Spot Monitor (BSM) display Light Emitting Diode (LED) indicator and icon are integral to the
outside rear view mirror glass and case unit. Refer to MIRROR, OUTSIDE REARVIEW, REMOVAL AND
INSTALLATION .
DISPLAY, BLIND SPOT > REMOVAL AND INSTALLATION > REMOVAL AND
The Blind Spot Monitor (BSM) display Light Emitting Diode (LED) indicator and icon are integral to the
outside rear view mirror glass and case unit. Refer to MIRROR, OUTSIDE REARVIEW, REMOVAL AND
INSTALLATION .
MODULE, BLIND SPOT > DESCRIPTION AND OPERATION > DESCRIPTION AND
The optional Blind Spot Monitor (BSM) system used in this vehicle has two control modules. One control
module is dedicated to each side of the vehicle. A Blind Spot Module (BSM) is integral to the Left Blind
Spot Sensor (LBSS) or Right Blind Spot Sensor (RBSS) for the same side of the vehicle. Refer to
SENSOR, BLIND SPOT, DESCRIPTION AND OPERATION .
MODULE, BLIND SPOT > DESCRIPTION AND OPERATION > DESCRIPTION AND
The optional Blind Spot Monitor (BSM) system used in this vehicle has two control modules. One control
module is dedicated to each side of the vehicle. The blind spot modules are each integral to the blind
spot sensor for the same side of the vehicle. Refer to SENSOR, BLIND SPOT, DESCRIPTION AND
OPERATION .
MODULE, BLIND SPOT > REMOVAL AND INSTALLATION > REMOVAL AND
Two blind spot modules are used in this vehicle, one for the left side and one for the right side. Each
blind spot module is integral to the blind spot sensor on the same side of the vehicle. Refer to SENSOR,
BLIND SPOT, REMOVAL AND INSTALLATION .
MODULE, BLIND SPOT > REMOVAL AND INSTALLATION > REMOVAL AND
Two blind spot modules are used in this vehicle, one for the left side and one for the right side. Each
blind spot module is integral to the blind spot sensor on the same side of the vehicle. Refer to SENSOR,
BLIND SPOT, REMOVAL AND INSTALLATION .
MODULE, PARK ASSIST > DESCRIPTION AND OPERATION > DESCRIPTION AND
Fig 1: Park Assist Module, Connector Receptacles & Mounting Tabs
The Parking Assist Module has the following characteristics:
It receives power supply for its operation.
It provides power supply to the 4 sensors.
It receives signals from the 4 ultrasonic sensors.
It manages the presence of a possible trailer: it is configured to deactivate the rear sensors when
a trailer is present.
It communicates and transmits data over the high-speed CAN-C2 network.
If a fixed tow hook is present, the signal "Trailer presence" informs the PAM control unit to deactivate the
rear sensors if a trailer is attached to the car. The signal "Trailer presence" is sent by the Trailer Tow
Module (TTM) via CAN-BH.
To ensure the proper operation of the system when the trailer is not attached to the vehicle, the PAM
control unit changes the sensor detection area range in order to take into account the space occupied
by the tow hook.
Fig 2: Semi-Automatic Parking Control Unit (PAM)
Semi-automatic parking control unit PAM
The semi-automatic parking control unit PAM has the following characteristics:
It manages the presence of a possible trailer: it is configured to deactivate the rear sensors when
a trailer is present.
It communicates and transmits data over the high speed CAN-C2 network.
The PAM cannot be adjusted or repaired and, if damaged or ineffective, it must be replaced with a new
unit. The PAM software is flash programmable.
The microcontroller in the Park Assist Module (PAM) contains the park assist system logic circuits. The
PAM uses On-Board Diagnostics (OBD) and can communicate with other electronic modules in the
vehicle as well as with the diagnostic scan tool using the Controller Area Network (CAN) data bus. This
method of communication is also used for park assist system diagnosis and testing through the 16-way
data link connector located on the driver side lower edge of the instrument panel.
The PAM provides voltage to the four park assist sensors located in the bumper fascia or fascias. The
PAM monitors return inputs from each of the sensors on dedicated hard wired data communication
circuits. These sensor inputs allow the PAM to determine when an obstacle is in the rear path of the
vehicle. When an obstacle is detected the sensor inputs allow the PAM logic to calculate the relative
location of the obstacle, and whether the distance to that obstacle is increasing or decreasing.
Pre-programmed decision algorithms and calibrations allow the PAM microcontroller to determine the
appropriate park assist system outputs based upon the inputs received from the park assist sensors and
electronic messages received from other modules in the vehicle over the CAN data bus. When the
programmed conditions are met the PAM sends electronic messages to the Instrument Panel Cluster
(IPC) over the CAN data bus to obtain the proper park assist system audible outputs and textual
messages in the IPC display. The PAM also broadcasts electronic messages over the CAN data bus to
enable the other electronic features of the park assist system.
The PAM microcontroller continuously monitors all of the park assist system electrical circuits and
components to determine the system readiness. If the PAM detects a monitored system fault, it sets a
Diagnostic Trouble Code (DTC) and sends the appropriate electronic messages to the IPC over the CAN
data bus to control operation of certain park assist system audible and textual warnings.
The PAM receives battery current on a fused ignition output (run-start) circuit through a fuse in the
Power Distribution Center (PDC). The PAM receives ground through a ground circuit and take out of the
body wire harness connected to the body sheet metal. These connections allow the PAM to be
operational whenever the status of the ignition is Start or On.
The hard wired circuits between components related to the PAM may be diagnosed using conventional
diagnostic tools and procedures. Refer to the appropriate SYSTEM WIRING DIAGRAMS article. The
However, conventional diagnostic methods will not prove conclusive in the diagnosis of the PAM or the
of the park assist system. The most reliable, efficient and accurate means to diagnose the PAM or the
electronic controls and communication related to park assist system operation requires the use of a
MODULE, PARK ASSIST > DIAGNOSIS AND TESTING > DIAGNOSIS AND TESTING -
PARK ASSIST MODULE
WARNING:
The hard wired circuits between components related to the Park Assist Module (PAM) may be diagnosed
of the park assist system. The most reliable, efficient and accurate means to diagnose the PAM or the
electronic controls and communication related to park assist system operation requires the use of a
MODULE, PARK ASSIST > REMOVAL AND INSTALLATION > REMOVAL AND
Fig 1: Remove/Install Park Assist Module (PAM)
from the battery.
2. Remove the trim from the left inner quarter panel (1) to access the Park Assist Module (PAM)
behind the left rear wheel house. Refer to PANEL, QUARTER TRIM, REMOVAL AND
INSTALLATION .
3. Remove the two nuts (2a) that secure the supplemental Junction Box (JB) (2b) and move the
JB aside.
Fig 2: Park Assist Module (PAM), Wire Connectors & Fasteners
4. Remove the two plastic push-pin retainers (1a) that secure the PAM (1b).
5. Disconnect the two or three wire harness connectors (2a and 2b) from the PAM connector
receptacles.
6. Remove the PAM (3) from the vehicle.
Fig 1: Park Assist Module (PAM), Wire Connectors & Fasteners

1. Position the Park Assist Module (PAM) (1b) into the left of the cargo are behind the left rear
wheel house.
2. Connect the two or three wire harness connectors (2a and 2b) to the PAM connector
receptacles.
3. Position the PAM to its mounting location.
4. Install the two plastic push-pin retainers (1a) that secure the PAM.
Fig 2: Remove/Install Park Assist Module (PAM)

5. Position the supplemental Junction Block (JB) (2b) onto the mounting studs.
6. Install and tighten the two nuts (2a) that secure the JB. Tighten the nuts securely.
7. Install the trim onto the left inner rear quarter panel. Refer to PANEL, QUARTER TRIM,
8. Connect the negative cable to the battery. If equipped with an Intelligent Battery Sensor (IBS),
reconnect the IBS connector.
NOTE:
SENSOR, BLIND SPOT > DESCRIPTION AND OPERATION > DESCRIPTION AND
Fig 1: (RADAR) Blind Spot Sensor & Connector Receptacle
Vehicles equipped with the optional Blind Spot Monitor (BSM) system have two primary components.
These components are the two RAdio Detection And Ranging (RADAR) blind spot sensors (1) (also
known as the Left or Right Blind Spot Sensors/LBSS or RBSS). In this vehicle, each sensor also
includes an internal microcontroller and control circuitry that monitors and controls both the sensor and
the blind spot display for the same side of the vehicle. This explains why the sensors are sometimes
referred to as smart sensors.
Each sensor with control circuitry is contained and protected within a molded plastic case that includes
an integral connector receptacle (2) at one end. The sensors are each connected to the vehicle
electrical system through a dedicated take out and connector of the rear bumper fascia wire harness.
The two sensors are concealed behind the outboard ends of the rear bumper fascia. Each sensor is
snapped into a dedicated molded plastic mounting bracket that is permanently affixed to the inside
surface of the fascia just behind the left and right rear wheel openings.
The blind spot sensors and control circuitry cannot be adjusted or repaired. If a sensor is damaged or
ineffective, it must be replaced with a new unit. The sensor module software is flash capable. The
mounting bracket for each sensor is serviced only as a unit with the rear bumper fascia.
SENSOR, BLIND SPOT > DESCRIPTION AND OPERATION > DESCRIPTION AND
The Blind Spot Monitor (BSM) RAdio Detection And Ranging (RADAR) smart sensors (also known as the
Left Blind Spot Sensor/LBSS and Right Blind Spot Sensor/RBSS) are each controlled by their on-board
microcontroller and control circuitry. When the microcontroller recognizes that the appropriate conditions
exist, it will energize the sensor to generate 25 Gigahertz radar pulses through the blind spot zone on
that side of the vehicle. The sensor receives and filters the radar signals being returned from any objects
detected within the zone, then transmits the appropriate data identifying the position and speed of
identified objects to the microcontroller.
The microcontroller analyzes the sensor data to determine whether any detected objects should be
reported. When it is determined that an object should be reported, the microcontroller sends electronic
request messages over the Controller Area Network (CAN) data bus to the Body Control Module (BCM)
and the Instrument Panel Cluster (IPC) to generate chime tones as an audible alert. The DDM or PDM
then controls its respective left or right BSM display directly through a hard wired output. The
microcontroller of the LBSS or RBSS also sends electronic messages to the Radio Receiver Module
(RRM) to mute any current output through the sound system speakers.
Each of the two BSM smart sensors is independent and communicates on the CAN data bus. The sensor
performs a bulb test by requesting illumination of the icon in its respective right or left blind spot display
for a few seconds each time the status of the ignition transitions to On. Each sensor microcontroller also
continually monitors the BSM system and the sensor circuits and will store a Diagnostic Trouble Code
(DTC) for any fault that is detected.
The hard wired circuits between of the smart sensors may be diagnosed using conventional diagnostic
tools and procedures. Refer to the appropriate SYSTEM WIRING DIAGRAMS article. However,
conventional diagnostic methods will not prove conclusive in the diagnosis of the smart sensors or the
electronic controls and communication between other modules and devices that provide some features
of the BSM system. The most reliable, efficient and accurate means to diagnose the smart sensors or
the electronic controls and communication related to LBSS or RBSS operation requires the use of a
diagnostic scan tool. Refer to DIAGNOSIS AND TESTING or DIAGNOSIS AND TESTING .
SENSOR, BLIND SPOT > DIAGNOSIS AND TESTING > DIAGNOSIS AND TESTING -
BLIND SPOT SENSOR
The hard wired circuits between the Blind Spot Monitor (BSM) smart sensors (also known as the Left
Blind Spot Sensor/LBSS and the Right Blind Spot Sensor/RBSS) may be diagnosed using conventional
However, conventional diagnostic methods will not prove conclusive in the diagnosis of the smart
sensors or the electronic controls and communication between modules and other devices that provide
some features of the BSM system. The most reliable, efficient and accurate means to diagnose the
smart sensors or the electronic controls and communication related to LBSS or RBSS operation
requires the use of a diagnostic scan tool.
SENSOR, BLIND SPOT > REMOVAL AND INSTALLATION > REMOVAL AND
Fig 1: Blind Spot Sensor Wire Connector
from the battery.
2. Raise and support the vehicle.
3. Reach up behind the outboard end of the rear bumper fascia to access and disconnect the
rear bumper fascia wire harness connector from the Left Blind Spot Sensor (LBSS) or Right
Blind Spot Sensor (RBSS) connector receptacle.
Fig 2: Remove/Install LBSS Or RBSS
4. Disengage the latch tabs of the sensor mounting bracket (1b) and pull the LBSS or RBSS (1a)
out of the bracket.
5. Remove the LBSS or RBSS (2) from the vehicle.

SENSOR, BLIND SPOT > REMOVAL AND INSTALLATION > REMOVAL AND
Fig 1: Remove/Install LBSS Or RBSS
1. Reach up behind the outboard end of the rear bumper fascia to position the Left Blind Spot
Sensor (LBSS) or Right Blind Spot Sensor (RBSS) (2) to the mounting bracket on the inside
surface of the fascia.
2. Using hand pressure, press the LBSS or RBSS (1a) firmly and evenly into the mounting
bracket (1b) until the latch tabs of the bracket are fully engaged.
Fig 2: Blind Spot Sensor Wire Connector
3. Connect the rear bumper fascia wire harness connector (1) to the LBSS or RBSS sensor
connector receptacle.
NOTE:
If this Electronic Control Unit (ECU) is being replaced with a new unit, a diagnostic scan tool
MUST be used to align the PROXI configuration data into the new ECU. Follow the routine
outlined in the diagnostic scan tool for PROXI Configuration Alignment under Body Control
Module (BCM) Miscellaneous Functions menu.
SENSOR, PARK ASSIST > DESCRIPTION AND OPERATION > DESCRIPTION AND
Fig 1: Park Assist Sensor
Vehicles equipped with the park assist system have up to twelve park assist sensors (3).
Fig 2: Rear Park Assist (RPA)
Vehicles with Rear Park Assist (RPA) have four sensors installed in the rear bumper fascia. Each of
these sensors is a Generation 5.0 sensor and is identical in construction and is interchangeable.
Fig 3: Parallel & Perpendicular Park Assist (PPPA)
Vehicles with Parallel and Perpendicular Park Assist (PPPA) have six sensors in the rear fascia and six
sensors in the front fascia. However, the sensors in each right and left outward-facing end of the front
fascia has a unique Generation 5.1 sensor, while the other ten sensors are still the Generation 5.0 type.
The Generation 5.1 sensors offer increased range required to support the parallel and perpendicular
parking features of the PPPA system. The only physical difference between the two sensor types
besides the part number is the offset location of the indexing feature (2) on the sensor body. This offset
indexing feature is designed to match up with an indexing notch in the sensor bracket to prevent
installation of a sensor in an incorrect location.
The numbering system for the park assist sensors allows for up to twelve sensors on the vehicle, six
front and six rear. The sensors are numbered in a clockwise manner starting at the left end of the front
fascia. Regardless of whether the vehicle is equipped with RPA or PPPA the left front sensor location is
always considered the number 1 sensor. The numbering continues in a clockwise direction around the
vehicle to the left rear sensor, which is always considered the number 12 sensor.
Only the membrane (4) of each sensor is visible through a hole in the outer vertical surface of the fascia.
The remainder of each sensor including the sensor mounting bracket, the sensor spacer (also known as
the O-ring or decoupling ring) and the sensor wiring connection is concealed behind the fascia. A sensor
wire harness behind the fascia connects the sensors to the vehicle electrical system.
The electronic circuitry and a communication chip for each sensor is enclosed and protected within the
molded black plastic sensor housing. The housing includes an integral connector receptacle (5) and two
integral latch tabs (1). The sensor membrane extends from the surface of the sensor housing, and is
finished to match the outer surface of the fascia.
A resilient O-ring spacer (also known as a decoupling ring) around the circumference of the sensor
membrane isolates the membrane from the openings in the fascia. Each sensor is snapped into its own
dedicated molded plastic mounting bracket. Each sensor mounting bracket is heat-staked to the back
side of the bumper fascia.
The park assist sensors cannot be adjusted or repaired. If a sensor is ineffective or damaged it must be
replaced with a new unit. The sensor spacers are available for individual service replacement. The
sensor mounting brackets are serviced only as a unit with the bumper fascia.
SENSOR, PARK ASSIST > DESCRIPTION AND OPERATION > DESCRIPTION AND
The park assist sensors are ultrasonic transceivers that are completely controlled by the Park Assist
Module (PAM). The sensors transmit and receive ultrasonic signals. The sensors each receive battery
current and ground in parallel from the PAM, but are each connected to individual dedicated serial bus
communication circuits to the module.
Each sensor membrane is oscillated, then quieted by the PAM in a pulsing fashion. While the sensor
membrane oscillates, it emits an ultrasonic signal. This signal will bounce or echo off of objects within the
field of vision for that sensor. While quieted, each membrane receives the echoes of the ultrasonic
signals it and the other sensors have transmitted. The sensors then communicate this echo pulse data
over the serial bus lines back to the PAM. The microcontroller within the PAM uses the intervals between
the ultrasonic transmission and reception data from the sensors to calculate the distance to any
obstacles identified by the ultrasonic echoes.
The hard wired circuits between components related to the park assist sensors may be diagnosed using
sensors or the electronic controls and communication between modules and other devices that provide
the park assist sensors or the electronic controls and communication related to park assist sensor
operation requires the use of a diagnostic scan tool.
SENSOR, PARK ASSIST > DIAGNOSIS AND TESTING > DIAGNOSIS AND TESTING -
PARK ASSIST SENSOR
The hard wired circuits between the park assist sensors and the Park Assist Module (PAM) may be
diagnosed using conventional diagnostic tools and procedures. Refer to the appropriate SYSTEM
repair procedures, details of wire harness routing and retention, connector pin out information and
location views for the various wire harness connectors, splices and grounds.
sensors or the electronic controls and communication between other modules and devices that provide
the park assist sensors or the electronic controls and communication related to park assist sensor
article.
SENSOR, PARK ASSIST > REMOVAL AND INSTALLATION > REMOVAL AND
INSTALLATION > REMOVAL - FRONT CENTER
Fig 1: Remove/Install Front Center Sensor
from the battery.
3. From the back of the front fascia, disconnect the wire harness connector (1a) from the
connector receptacle of the front center sensor (1b).
4. Carefully pry the park assist sensor bracket latch features (2a) away from the latch tabs of the
sensor far enough to disengage the sensor from the bracket.
5. Disengage the resilient O-ring spacer from around the circumference of the sensor membrane
protrusion.
INSTALLATION > REMOVAL - FRONT OUTBOARD
Fig 1: Remove/Install Front Outboard Sensor
from the battery.
3. Remove the front wheel and tire from the same side of the vehicle as the front outboard sensor
(1b) being serviced.
connector receptacle of the front outboard sensor (1b).
protrusion.
INSTALLATION > REMOVAL - FRONT OUTWARD FACING
Fig 1: Remove/Install Front Outward Facing Sensor
from the battery.
3. Remove the front wheel and tire from the same side of the vehicle as the outward facing
sensor (1b) being serviced.
connector receptacle of the outward facing sensor (1b).
protrusion.
INSTALLATION > REMOVAL - REAR
Fig 1: Remove/Install Rear Sensor
from the battery.
3. From the back of the rear fascia, disconnect the wire harness connector (1a) from the sensor
(1b) connector receptacle.
protrusion.
INSTALLATION > INSTALLATION - FRONT CENTER
Fig 1: Remove/Install Front Center Sensor

NOTE:
In vehicles equipped with the optional Parallel and Perpendicular Park Assist option, the
park assist sensors located in the outward facing ends of the front bumper fascia are unique
and must not be interchanged with any other forward or rearward facing park assist sensor.
1. Engage the O-ring spacer (also known as the decoupling ring) around the circumference of the
front center sensor (1b) membrane protrusion.
NOTE:
Production and all service replacement O-ring spacers are tapered. The wide side
(base) of the O-ring should be seated against the sensor housing and the narrow
side should be oriented toward the outer surface of the sensor membrane and the
front fascia.
2. From the back of the front fascia, align and insert the sensor (1b) into the sensor bracket
behind the front fascia until the bracket latch features (2a) are fully engaged over the latch tabs
of the sensor.
3. Connect the wire harness connector (1a) to the park assist sensor connector receptacle.
INSTALLATION > INSTALLATION - FRONT OUTBOARD
Fig 1: Remove/Install Front Outboard Sensor

NOTE:
front outboard sensor (1b) membrane protrusion.
NOTE:
front fascia.
of the sensor.
4. Install the removed left or right front wheel and tire assembly.
INSTALLATION > INSTALLATION - FRONT OUTWARD FACING
Fig 1: Remove/Install Front Outward Facing Sensor

NOTE:
front outward facing sensor (1b) membrane protrusion.
NOTE:
front fascia.
of the sensor.
4. Install the left or right front wheel and tire assembly.
INSTALLATION > INSTALLATION - REAR
Fig 1: Remove/Install Rear Sensor

NOTE:
sensor membrane protrusion.
NOTE:
rear fascia.
2. From the back of the rear fascia, align and insert the sensor (1b) into the sensor bracket
behind the rear fascia until the bracket latch features (2a) are fully engaged over the latch tabs
of the sensor.
SWITCH, PARK ASSIST > DESCRIPTION AND OPERATION > DESCRIPTION AND
Fig 1: Park Assist Switch
The park assist Off switch (2) and the Parallel and Perpendicular Park Assist (PPPA) On switch are
integral to the instrument panel switch pod (1), which is secured to the instrument panel center stack just
below the Radio Receiver Module (RRM).
The park assist Off switch push button is clearly identified with a white International Control and Display
Symbol graphic for Parking Aid and the text OFF . The PPPA On switch push button is clearly
identified with white International Control and Display Symbol graphics for Parking and Electric Power
Steering along with the text ON .
An amber Light Emitting Diode (LED) unit is illuminated behind a small clear plastic jewel-like lens in the
park assist Off push button to give a visual indication whenever the park assist system has been
manually disabled or if a system fault is monitored. Another amber LED unit is illuminated in the PPPA On
push button whenever that system has been enabled. Both switches are only functional while the status
of the ignition is On. The switch buttons also have panel lamps dimmer controlled illumination for night
visibility.
All of the circuitry and components of the park assist Off switch and the PPPA On switch are contained
within a molded black plastic instrument panel switch pod housing. A single connector receptacle is
integral to the back of the switch pod housing. The switch is connected to the vehicle electrical system
through a dedicated take out and connector of the instrument panel wire harness.
The park assist Off switch and the PPPA On switch cannot be adjusted or repaired and, if either switch
is ineffective or damaged, the entire instrument panel switch pod unit must be replaced with a new unit.
SWITCH, PARK ASSIST > DESCRIPTION AND OPERATION > DESCRIPTION AND
The status of the park assist Off switch and the Parallel and Perpendicular Park Assist (PPPA) On switch
is continually monitored by the circuitry within the instrument panel switch pod. The switch pod receives
battery voltage at all times on a fused battery feed circuit and has a path to ground at all times through
the instrument panel wire harness. The inputs to and outputs from the switch pod consist of electronic
message communication with the Body Control Module (BCM) over the single wire Local Interface
Network (LIN) data bus.
Each time the park assist Off switch or PPPA On switch push button is depressed the switch pod
circuitry sends an electronic switch status message input to the BCM over the LIN data bus. The BCM
then relays an electronic switch request message to the Park Assist Module (PAM) over the Controller
Area Network (CAN) data bus. The PAM responds to each switch request message by toggling the
status of the appropriate park assist system feature from enabled to disabled, or from disabled to
enabled, then sends an electronic system status message back to the BCM over the CAN data bus as
confirmation.
The BCM responds to the system status message by sending a message to the switch pod over the LIN
data bus to control the park assist Off switch or PPPA On switch Light Emitting Diode (LED) units so that
they are illuminated only when appropriate while the status of the ignition is On, and are extinguished
when the status of the ignition is anything except On. If the park assist system is disabled due to a
monitored fault or failure, a press of the park assist Off push button will result in the LED flashing on and
off for about 5 seconds, then lighting solid.
The hard wired circuits between components related to the park assist Off switch and the PPPA On
switch may be diagnosed using conventional diagnostic tools and procedures. Refer to the appropriate
SYSTEM WIRING DIAGRAMS article. However, conventional diagnostic methods will not prove
conclusive in the diagnosis of the electronic controls and communication between modules and other
devices that provide some features of the park assist system. The most reliable, efficient and accurate
means to diagnose the park assist Off switch, the PPPA On switch or the electronic controls and
communication related to park assist switch operation requires the use of a diagnostic scan tool. Refer
Service Manual: COMMUNICATION - NON-DTC BASED Jeep Renegade
DIAGNOSTICS
DIAGNOSIS AND TESTING > SCAN TOOL WILL NOT COMMUNICATE WITH CAN C1
DIAGNOSIS AND TESTING > SCAN TOOL WILL NOT COMMUNICATE WITH CAN C1 >
THEORY OF OPERATION
For an in-depth explanation of the CAN system operation, refer to the DESCRIPTION in
COMMUNICATION, DESCRIPTION AND OPERATION .
POSSIBLE CAUSES
Possible Causes
CAN C1 CIRCUIT SHORTED TO GROUND
CAN C1 CIRCUIT SHORTED TO VOLTAGE
ANY MODULE ON THE CAN C1 BUS
Always perform the COMMUNICATION PRE-DIAGNOSTIC TROUBLESHOOTING PROCEDURE

before proceeding. Refer to STANDARD PROCEDURE .
Fig 1: CAN Communication Circuit Schematic
NORMAL CAN CIRCUIT VOLTAGE TABLE
CIRCUIT NORMAL VOLTAGE VALUES
CAN C1 (-) 1.5 - 2.5 volts
CAN C1 (+) 2.5 - 3.5 volts
Difference Between CAN C1 (+) and CAN C1 (-) 0.5 volt
DIAGNOSTIC TEST
1. DIVIDE THE CONTROLLER AREA NETWORK (CAN) TO ISOLATE THE PROBLEM

NOTE:
This procedure assumes that the fault is active. The scan tool typically will not
communicate with this bus while the fault is active.
NOTE:
This procedure assumes that the scan tool is operating correctly. If necessary,
connect scan tool to another vehicle to be certain that the scan tool is operating
correctly.
1. Install the (special tool #CH7002, Break Out Box, J1962, 16-Way) on the Diagnostic
Link Connector (DLC).
NOTE:
Do not connect the scan tool to the (special tool #CH7002, Break Out Box,
J1962, 16-Way) during the following tests.
2. Disconnect the Drivetrain Control Module (DTCM) harness connector(s) that contain
the CAN C1 circuits.
4. Measure the voltage between ground and the CAN C1 (+) circuit at the DLC Breakout
Box. Compare results to NORMAL CAN CIRCUIT VOLTAGE TABLE.
5. Measure the voltage between ground and the CAN C1 (-) circuit at the DLC Breakout
Are the CAN C1 circuit voltages within the specified value for each circuit and within
0.5 volt of each other?
Yes
1. Go To Step 2
No
1. Go To Step 6
2. ISOLATE THE FAULTED CAN C1 CIRCUIT OR MODULE
1. Connect the DTCM harness connector.
NOTE:
The following CAN C1 modules must be disconnected in the order shown

as follows:
1. Powertrain Control Module (PCM)
2. Adaptive Cruise Control (ACC)
3. Transmission Control Module (TCM)
4. Antilock Brake System (ABS)
NOTE:
Once a harness connector is disconnected from a module, leave it

disconnected unless instructed otherwise.
2. Disconnect the harness connector of each module that is listed above, one at a time,
while monitoring the voltage of each CAN C1 circuit at the (special tool #CH7002,
Break Out Box, J1962, 16-Way) a significant change in voltage will indicate a faulty
module. Refer to the noted voltage readings from Step 1.
Was a significant change in voltage observed when disconnecting one of the listed
modules?
Yes
1. Replace the module that caused a significant change in voltage. Refer to the
appropriate Service Information.
No
1. Go To Step 3
3. DISCONNECT THE ELECTRONIC SHIFT MODULE (ESM)
1. Disconnect the ESM harness connector(s) while monitoring the voltage of each CAN
C1 circuit at the (special tool #CH7002, Break Out Box, J1962, 16-Way).
Was a significant change in voltage observed when disconnecting the ESM?
Yes
1. Go To Step 4
No
1. Go To Step 5
4. CHECK CAN C1 CIRCUITS BETWEEN ESM AND PCM
1. Check the CAN C1 (+) circuits and CAN C1 (-) circuits between the ESM and the
PCM for an open circuit, short to ground, and a short to another circuit.
Was a circuit problem found?
Yes
1. Repair the circuit(s) as necessary.
No
1. Replace the Electronic Shift Module (ESM) in accordance with the Service
Information. (Refer to ELECTRONIC CONTROL MODULES - SERVICE
INFORMATION ).
5. CHECK CAN C1 CIRCUITS BETWEEN DTCM AND ESM
1. Check the CAN C1 (+) circuits and CAN C1 (-) circuits between the DTCM and the
ESM for an open circuit, short to ground, and a short to another circuit.
Yes
No
1. Replace the Drivetrain Control Module (DTCM) in accordance with the Service
Information. Refer to MODULE, DRIVETRAIN CONTROL, REMOVAL AND
INSTALLATION .
6. ISOLATE THE REMAINING FAULTED CAN C1 CIRCUIT OR MODULE
1. Connect the DTCM harness connector.
NOTE:

as follows:
1. Radio Frequency (RF) Hub
2. Entertainment Telematics Module (ETM) (Radio)
3. Occupant Restraint Controller (ORC)
NOTE:
disconnected.
Break Out Box, J1962, 16-Way). A significant change in voltage will indicate a faulty
modules?
Yes
No
1. Go To Step 7
7. DISCONNECT THE INSTRUMENT PANEL CLUSTER (IPC)
1. Disconnect the IPC harness connector(s) while monitoring the voltage of each CAN
Was a significant change in voltage observed when disconnecting the IPC?
Yes
1. Go To Step 8
No
1. Go To Step 9
8. CHECK CAN C1 CIRCUITS BETWEEN IPC AND DTCM
1. Check the CAN C1 (+) circuits and CAN C1 (-) circuits between the IPC and the
DTCM for an open circuit, short to ground, and a short to another circuit.
Yes
No
1. Replace the Instrument Panel Cluster (IPC) in accordance with the Service
Information. Refer to MODULE, INSTRUMENT PANEL CLUSTER, REMOVAL
AND INSTALLATION .
9. DISCONNECT THE BODY CONTROL MODULE (BCM)
1. Connect the IPC harness connector.
2. Disconnect the BCM harness connector(s) while monitoring the voltage of each CAN
Was a significant change in voltage observed when disconnecting the BCM?
Yes
1. Replace the Body Control Module (BCM) in accordance with the Service
Information. Refer to MODULE, BODY CONTROL, REMOVAL AND
INSTALLATION .
No
1. Repair the CAN C1 circuit(s) between the BCM, IPC, and DLC for an open
circuit, short to ground, or a short to another circuit.
DIAGNOSIS AND TESTING > SCAN TOOL WILL NOT COMMUNICATE WITH CAN C2
THEORY OF OPERATION
POSSIBLE CAUSES
Possible Causes
CAN C2 CIRCUIT SHORTED TO GROUND
CAN C2 CIRCUIT SHORTED TO VOLTAGE
ANY MODULE ON THE CAN C2 BUS

CAN C2 (-) 1.5 - 2.5 volts
CAN C2 (+) 2.5 - 3.5 volts
Difference Between CAN C2 (+) and CAN C2 (-) 0.5 volt
DIAGNOSTIC TEST

NOTE:
NOTE:
correctly.
NOTE:
2. Disconnect the Electric Power Steering (EPS) Module harness connector(s) that
contain the CAN C2 circuits.
4. Measure the voltage between ground and the CAN C2 (+) circuit at the DLC Breakout
5. Measure the voltage between ground and the CAN C2 (-) circuit at the DLC Breakout
Are the CAN C2 circuit voltages within the specified value for each circuit and within
Yes
1. Go To Step 2
No
1. Go To Step 6
2. DISCONNECT THE ANTILOCK BRAKE SYSTEM (ABS) MODULE
1. Connect the EPS Module harness connector.
2. Disconnect the ABS Module harness connector(s) while monitoring the voltage of
each CAN C2 circuit at the (special tool #CH7002, Break Out Box, J1962, 16-Way).
Was a significant change in voltage observed when disconnecting the ABS Module ?
Yes
1. Using the schematics as a guide, check the ABS Module terminals and
connectors for corrosion, damage or pushed out terminals. Pay particular
attention to the power and ground circuits. If no problems are found, replace the
Antilock Brake System (ABS) Module in accordance with the Service
Information. Refer to MODULE, ANTI-LOCK BRAKE SYSTEM, REMOVAL AND
INSTALLATION .
No
1. Go To Step 3
3. DISCONNECT THE BODY CONTROL MODULE (BCM)
Was a significant change in voltage observed when disconnecting the BCM ?
Yes
1. Go To Step 4
No
1. Go To Step 5
4. CHECK CAN CIRCUITS BETWEEN ABS MODULE AND BCM
1. Check the CAN C2 (+) circuits and CAN C2 (-) circuits between the ABS Module and
the BCM for an open circuit, short to ground, and a short to another circuit.
Yes
No
1. Using the schematics as a guide, check the BCM terminals and connectors for
corrosion, damage or pushed out terminals. Pay particular attention to the
power and ground circuits. If no problems are found, replace the Body Control
Module (BCM) in accordance with the Service Information. Refer to MODULE,
BODY CONTROL, REMOVAL AND INSTALLATION .
5. CHECK CAN CIRCUITS BETWEEN BCM AND EPS MODULE
1. Check the CAN C2 (+) circuits and CAN C2 (-) circuits between the BCM and the
EPS Module for an open circuit, short to ground, and a short to another circuit.
Yes
No
1. Using the schematics as a guide, check the EPS Module terminals and
connectors for corrosion, damage or pushed out terminals. Pay particular
attention to the power and ground circuits. If no problems are found, replace the
Electronic Power Steering (EPS) Module in accordance with the Service
Information. Refer to COLUMN, REMOVAL AND INSTALLATION .
6. ISOLATE THE FAULTED CAN C2 CIRCUIT OR MODULE
1. Connect the EPS Module harness connector.
NOTE:

as follows:
1. Occupant Restraint Controller (ORC)
2. Forward Facing Camera Module (FFCM) (HALF)
3. Electronic Steering Lock (ESL) Module
4. Park Assist Module (PAM)
NOTE:

disconnected unless instructed otherwise.
Break Out Box, J1962, 16-Way) a significant change in voltage will indicate a faulty
modules?
Yes
No
1. Repair the CAN C2 circuit(s) between the ORC, DLC, and EPS Module for an
open circuit, short to ground, or a short to another circuit.
DIAGNOSIS AND TESTING > SCAN TOOL WILL NOT COMMUNICATE WITH CAN IHS
> THEORY OF OPERATION
> POSSIBLE CAUSES
Possible Causes
CAN IHS CIRCUIT SHORTED TO GROUND
CAN IHS CIRCUIT SHORTED TO VOLTAGE
ANY MODULE ON THE CAN IHS BUS

CAN IHS (-) 1.5 - 2.5 volts
CAN IHS (+) 2.5 - 3.5 volts
Difference Between CAN IHS (+) and CAN IHS (-) 0.5 volt
> DIAGNOSTIC TEST

NOTE:
NOTE:
correctly.
NOTE:
2. Disconnect the Entertainment Telematics Module (ETM) harness connector(s) that

contain the CAN IHS circuits.
4. Measure the voltage between ground and the CAN IHS (+) circuit at the DLC
Breakout Box. Compare results to NORMAL CAN CIRCUIT VOLTAGE TABLE.
5. Measure the voltage between ground and the CAN IHS (-) circuit at the DLC
Breakout Box. Compare results to NORMAL CAN CIRCUIT VOLTAGE TABLE.
Are the CAN IHS circuit voltages within the specified value for each circuit and within
Yes
1. Go To Step 2
No
1. Go To Step 7
2. DISCONNECT THE RADIO RECEIVER MODULE (RRM)
1. Connect the ETM harness connector.
2. Disconnect the RRM harness connector(s) while monitoring the voltage of each CAN
IHS circuit at the (special tool #CH7002, Break Out Box, J1962, 16-Way).
Was a significant change in voltage observed when disconnecting the Electronic

Shift Module (ESM)?
Yes
1. Go To Step 3
No
1. Go To Step 5
3. ISOLATE THE REMAINING FAULTED CAN IHS CIRCUIT OR MODULE
1. Connect the RRM harness connector.
NOTE:
The following CAN IHS modules must be disconnected in the order shown
as follows:
1. Right Blind Spot Sensor (RBSS)
2. Trailer Tow Module (TTM)
3. Amplifier (AMP)
4. Left Blind Spot Sensor (LBSS)
5. Comfort Steering Wheel Module (CSWM)
NOTE:

disconnected.
while monitoring the voltage of each CAN IHS circuit at the (special tool #CH7002,
Break Out Box, J1962, 16-Way). A significant change in voltage will indicate a faulty
modules?
Yes
No
1. Go To Step 4
4. CHECK CAN IHS CIRCUITS BETWEEN RRM AND ETM
1. Check the CAN IHS (+) circuits and CAN IHS (-) circuits between the RRM and the
ETM for an open circuit, short to ground, and a short to another circuit.
Yes
No
1. Replace the Radio Receiver Module (RRM) in accordance with the Service
Information. Refer to MODULE, RADIO RECEIVER, REMOVAL AND
INSTALLATION .
5. DISCONNECT THE INSTRUMENT PANEL CLUSTER (IPC)
1. Connect the RRM harness connector.
2. Disconnect the IPC harness connector(s) while monitoring the voltage of each CAN
Was a significant change in voltage observed when disconnecting the IPC harness
connector?
Yes
AND INSTALLATION .
No
1. Go To Step 6
6. CHECK CAN IHS CIRCUITS BETWEEN IPC AND RRM
1. Check the CAN IHS (+) circuits and CAN IHS (-) circuits between the IPC and the
RRM for an open circuit, short to ground, and a short to another circuit.
Yes
No
1. Replace the Radio Receiver Module (RRM) in accordance with the Service
Information. Refer to MODULE, RADIO RECEIVER, REMOVAL AND
INSTALLATION .
7. DISCONNECT THE BCM
1. Connect the ETM harness connector.
Was a significant change in voltage observed when disconnecting the BCM?
Yes
INSTALLATION .
No
1. Go To Step 8
8. DISCONNECT THE HVAC MODULE
1. Disconnect the HVAC Module harness connector(s) while monitoring the voltage of
each CAN IHS circuit at the (special tool #CH7002, Break Out Box, J1962, 16-Way).
Was a significant change in voltage observed when disconnecting the HVAC

Module?
Yes
1. Go To Step 10
No
1. Go To Step 9
9. CHECK CAN IHS CIRCUITS BETWEEN ETM AND HVAC MODULE
1. Check the CAN IHS (+) circuits and CAN IHS (-) circuits between the ETM and the
HVAC Module for an open circuit, short to ground, and a short to another circuit.
Yes
No
1. Replace the Entertainment Telematics Module (ETM) in accordance with the
Service Information. Refer to RADIO, REMOVAL AND INSTALLATION .
10. CHECK CAN IHS CIRCUITS BETWEEN BCM AND HVAC MODULE
1. Check the CAN C1 (+) circuits and CAN C1 (-) circuits between the BCM and the
HVAC Module for an open circuit, short to ground, and a short to another circuit.
Yes
No
1. Replace the HVAC Module in accordance with the Service Information. Refer to
MODULE, HVAC, REMOVAL AND INSTALLATION .
DIAGNOSIS AND TESTING > NO RESPONSE FROM ABS (ANTI-LOCK BRAKE

SYSTEM) MODULE

Fig 1: Anti-Lock Brake System Module Circuit Diagram

SYSTEM) MODULE > POSSIBLE CAUSES
Possible Causes
FUSED B(+) CIRCUITS OPEN OR SHORTED
FUSED IGNITION CIRCUIT OPEN OR SHORTED
GROUND CIRCUITS OPEN OR HIGH RESISTANCE
CONTROLLER AREA NETWORK (CAN) C1 BUS (+) CIRCUIT OPEN OR HIGH RESISTANCE
CAN C1 BUS (-) CIRCUIT OPEN OR HIGH RESISTANCE
CAN C2 BUS (+) CIRCUIT OPEN OR HIGH RESISTANCE
ANTI-LOCK BRAKE SYSTEM (ABS) MODULE

SYSTEM) MODULE > DIAGNOSTIC TEST
1. CHECK THE MODULE STATUS ON THE CAN C BUS
2. With the scan tool, read the CAN topology on the Vehicle View screen.
Does the Vehicle View screen indicate that the Module is active on the bus?
Yes
1. The condition or conditions that originally set this DTC are not present at this
time. Using the wiring diagrams as a guide, check all related splices and
connectors for signs of water intrusion, corrosion, pushed out or bent terminals,
and correct terminal tension and repair as necessary. If no problems are found,
test complete.
2. Perform the ABS VERIFICATION TEST. Refer to STANDARD PROCEDURE .
No
1. Go To Step 2
2. CHECK THE (A901) FUSED B(+) CIRCUITS FOR AN OPEN OR SHORT TO GROUND
NOTE:
The CAN bus will remain active with the scan tool connected and the ignition off.
NOTE:
Leave the scan tool connected and on the Vehicle View screen.
2. Disconnect the Anti-lock Brake System (ABS) Module harness connector.
3. With a 12-volt test light connected to ground, check the (A901) Fused B(+) circuits at
the ABS Module harness connector.
NOTE:
direct connection to the battery.
Yes
1. Go To Step 3
No
1. Repair the (A901) Fused B(+) circuits for an open or short to ground.
3. CHECK THE (F741) FUSED IGNITION RUN/START CIRCUIT FOR AN OPEN OR SHORT TO
GROUND
2. With a 12-volt test light connected to ground, check the (F741) Fused Ignition
RUN/START circuit at the ABS Module harness connector.
Yes
1. Go To Step 4
No
1. Repair the (F741) Fused Ignition RUN/START circuit for an open or short to
ground.
4. CHECK THE (Z914) GROUND CIRCUITS FOR AN OPEN OR HIGH RESISTANCE
1. With a 12-volt test light connected to 12 volts, check the (Z914) Ground circuits at
the ABS Module harness connector.
Yes
1. Go To Step 5
No
1. Repair the (Z914) Ground circuits for an open or high resistance.
5. CHECK THE CAN (D1) C1 BUS (+) CIRCUIT FOR AN OPEN OR HIGH RESISTANCE
1. Measure the voltage of the (D1) CAN C1 Bus (+) circuit at the ABS Module harness
connector.
Is the voltage below 2.5 volts?
Yes
1. Repair the (D1) CAN C1 Bus (+) circuit for an open or high resistance.
No
1. Go To Step 6
6. CHECK THE (D2) CAN C1 BUS (-) CIRCUIT FOR AN OPEN OR HIGH RESISTANCE
1. Measure the voltage of the (D2) CAN C1 Bus (-) circuit at the ABS Module harness
connector.
Yes
1. Repair the (D2) CAN C1 Bus (-) circuit for an open or high resistance.
No
1. Go To Step 7
7. CHECK THE (D52) CAN C2 BUS (+) CIRCUIT FOR AN OPEN OR HIGH RESISTANCE
1. Measure the voltage of the (D52) CAN C2 Bus (+) circuit at the ABS Module harness
connector.
Yes
No
1. Go To Step 8
1. Measure the voltage of the (D51) CAN C2 Bus (-) circuit at the ABS Module harness
connector.
Yes
No
1. Replace the Anti-lock Brake System (ABS) Module in accordance with the
Service Information. Refer to MODULE, ANTI-LOCK BRAKE SYSTEM,
DIAGNOSIS AND TESTING > NO RESPONSE FROM ACC (ADAPTIVE CRUISE

CONTROL) MODULE

Fig 1: Adaptive Cruise Control Module & Forward Facing Camera Module Circuit Diagram

CONTROL) MODULE > POSSIBLE CAUSES
Possible Causes
GROUND CIRCUIT OPEN OR HIGH RESISTANCE
ADAPTIVE CRUISE CONTROL (ACC) MODULE/ADAPTIVE SPEED CONTROL SENSOR

CONTROL) MODULE > DIAGNOSTIC TEST
Yes
test complete.
No
1. Go To Step 2
2. CHECK THE (F741) FUSED IGNITION CIRCUIT FOR AN OPEN OR SHORT TO GROUND
2. With a 12-volt test light connected to ground, check the (F741) Fused Ignition circuit
at the ACC module harness connector.
NOTE:
Yes
1. Go To Step 3
No
1. Repair the (F741) Fused Ignition circuit for an open or short to ground.
3. CHECK THE (Z912) GROUND CIRCUIT FOR AN OPEN OR HIGH RESISTANCE
ACC module harness connector.
Yes
1. Go To Step 4
No
1. Measure the voltage between ground and the (D1) CAN C1 Bus (+) circuit at the ACC
module harness connector.
Yes
No
1. Go To Step 5
1. Measure the voltage between ground and the (D2) CAN C1 Bus (-) circuit at the ACC
Yes
No
1. Using the schematics as a guide, check the ACC module pins, terminals, and
connectors for corrosion, damage, or terminal push out. Pay particular attention
to all power and ground circuits. If no problems are found, replace and program
the Adaptive Cruise Control (ACC) module in accordance with the Service
Information. Refer to MODULE, ADAPTIVE CRUISE CONTROL, REMOVAL
AND INSTALLATION .
DIAGNOSIS AND TESTING > NO RESPONSE FROM AMP (AMPLIFIER)
DIAGNOSIS AND TESTING > NO RESPONSE FROM AMP (AMPLIFIER) > POSSIBLE
CAUSES
Possible Causes
FUSED B(+) CIRCUIT OPEN OR SHORTED
CONTROLLER AREA NETWORK (CAN) IHS BUS (+) CIRCUIT OPEN OR HIGH RESISTANCE
CAN IHS BUS (-) CIRCUIT OPEN OR HIGH RESISTANCE
AMPLIFIER (AMP)
DIAGNOSIS AND TESTING > NO RESPONSE FROM AMP (AMPLIFIER) >

DIAGNOSTIC TEST
1. CHECK THE MODULE STATUS ON THE CAN IHS BUS
Yes
test complete.
No
1. Go To Step 2
2. CHECK THE FUSED B(+) CIRCUIT FOR AN OPEN OR SHORT TO GROUND

NOTE:
NOTE:
2. Disconnect the Amplifier (AMP) harness connector.
3. With a 12-volt test light connected to ground, check the Fused B(+) circuit at the
AMP harness connector.
NOTE:
Yes
1. Go To Step 3
No
1. Repair the Fused B(+) circuit for an open or short to ground.
3. CHECK THE GROUND CIRCUIT FOR AN OPEN OR HIGH RESISTANCE
1. With a 12-volt test light connected to 12 volts, check the Ground circuit at the AMP
harness connector.
Yes
1. Go To Step 4
No
1. Repair the Ground circuit for an open or high resistance.
4. CHECK THE CAN IHS BUS (+) CIRCUIT FOR AN OPEN OR HIGH RESISTANCE
1. Measure the voltage between ground and the CAN IHS Bus (+) circuit at the AMP
harness connector.
Yes
1. Repair the CAN IHS Bus (+) circuit for an open or high resistance.
No
1. Go To Step 5
5. CHECK THE CAN IHS BUS (-) CIRCUIT FOR AN OPEN OR HIGH RESISTANCE
1. Measure the voltage between ground and the CAN IHS Bus (-) circuit at the AMP
harness connector.
Yes
1. Repair the CAN IHS Bus (-) circuit for an open or high resistance.
No
1. Replace the Amplifier (AMP) in accordance with the Service Information. Refer
to AMPLIFIER, REMOVAL AND INSTALLATION .
DIAGNOSIS AND TESTING > NO RESPONSE FROM BCM (BODY CONTROL MODULE)

Fig 1: Body Control Module Circuit Diagram
> POSSIBLE CAUSES
Possible Causes
BODY CONTROL MODULE (BCM)
> DIAGNOSTIC TEST
Yes
1. Perform the TESTING FOR INTERMITTENT CONDITIONS procedure. Refer to

the appropriate TESTING & DIAGNOSTICS article in ENGINE PERFORMANCE
.
No
1. Go To Step 2
NOTE:
NOTE:
2. Disconnect the Body Control Module (BCM) C1 and C3 harness connectors.
the BCM C1 and C3 harness connectors.
NOTE:
Yes
1. Go To Step 3
No
2. Disconnect the Body Control Module (BCM) C7 harness connector.
the BCM C7 harness connector.
Does the test light illuminate brightly for both connections?
Yes
1. Go To Step 4
No
1. Repair the (Z908) Ground circuits for an open or high resistance.
1. Disconnect the Body Control Module (BCM) C8 harness connector.
2. Measure the voltage on the (D1) CAN C1 Bus (+) circuit at the BCM C8 harness
connector.
Yes
No
1. Go To Step 5
1. Measure the voltage on the (D2) CAN C1 Bus (-) circuit at the BCM C8 harness
connector.
Yes
No
1. Go To Step 6
6. CHECK THE (D52) CAN C2 BUS (+) CIRCUITS FOR AN OPEN OR HIGH RESISTANCE
1. Measure the voltage v the (D52) CAN C2 Bus (+) circuits at the BCM C8 harness
connector.
Yes
1. Repair the (D52) CAN C2 Bus (+) circuits for an open or high resistance.
No
1. Go To Step 7
7. CHECK THE (D51) CAN C2 BUS (-) CIRCUITS FOR AN OPEN OR HIGH RESISTANCE
1. Measure the voltage on the (D51) CAN C2 Bus (-) circuits at the BCM C8 harness
connector.
Yes
1. Repair the (D51) CAN C2 Bus (-) circuits for an open or high resistance.
No
INSTALLATION .

DIAGNOSIS AND TESTING > NO RESPONSE FROM CSWM (COMFORT SEAT AND
WHEEL MODULE)
Fig 1: Comfort Seat & Wheel Module Circuit Diagram

WHEEL MODULE) > POSSIBLE CAUSES
Possible Causes
CONTROLLER AREA NETWORK (CAN) BUS (+) CIRCUIT OPEN OR HIGH RESISTANCE
CAN BUS (-) CIRCUIT OPEN OR HIGH RESISTANCE
COMFORT SEAT AND WHEEL MODULE (CSWM)
WHEEL MODULE) > DIAGNOSTIC TEST
1. CHECK THE MODULE STATUS ON THE CAN BUS
Yes
test complete.
No
1. Go To Step 2
2. CHECK THE FUSED IGNITION CIRCUIT FOR AN OPEN OR SHORT TO GROUND
NOTE:
NOTE:
2. Disconnect the Comfort Seat Wheel Module (CSWM) harness connector.
3. With a 12-volt test light connected to ground, check the Fused Ignition circuit at the
CSWM harness connector.
NOTE:
Yes
1. Go To Step 3
No
1. Repair the Fused Ignition circuit for an open or short to ground.
Yes
1. Go To Step 4
No
4. CHECK THE (D157) CAN B BUS (+) CIRCUIT FOR AN OPEN OR HIGH RESISTANCE
1. Measure the voltage between ground and the (D157) CAN B Bus (+) circuit at the
Yes
1. Repair the (D157) CAN B Bus (+) circuit for an open or high resistance.
No
1. Go To Step 5
5. CHECK THE (D156) CAN B BUS (-) CIRCUIT FOR AN OPEN OR HIGH RESISTANCE
1. Measure the voltage between ground and the (D156) CAN B Bus (-) circuit at the
Yes
1. Repair the (D156) CAN B Bus (-) circuit for an open or high resistance.
No
1. Using the schematics as a guide, check the CSWM pins, terminals, and
to all power and ground circuits. If no problems are found, replace the Comfort
Seat Wheel Module (CSWM) in accordance with the Service Information. Refer
to MODULE, COMFORT SEAT AND WHEEL, REMOVAL AND INSTALLATION .
DIAGNOSIS AND TESTING > NO RESPONSE FROM DCSM (DUAL CLUTCH SHIFTER
MODULE)

Fig 1: Dual Clutch Shifter Module Circuit Diagram
MODULE) > POSSIBLE CAUSES
Possible Causes
FUSED (B+) CIRCUIT OPEN OR SHORTED
DUAL CLUTCH SHIFTER MODULE (DCSM)
MODULE) > DIAGNOSTIC TEST
1. CHECK THE MODULE STATUS ON THE CONTROLLER AREA NETWORK (CAN) C BUS
Yes
1. The condition or conditions that originally set this Diagnostic Trouble Code
(DTC) are not present at this time. Using the wiring diagrams as a guide, check
all related splices and connectors for signs of water intrusion, corrosion,
pushed out or bent terminals, and correct terminal tension and repair as
necessary. If no problems are found, test complete.
2. Perform the DCSM VERIFICATION TEST. Refer to STANDARD PROCEDURE .
No
1. Go To Step 2
2. CHECK THE (A901) FUSED B(+) CIRCUIT FOR AN OPEN OR SHORT TO GROUND
NOTE:
NOTE:
2. Disconnect the Electronic Shift Module (DCSM) harness connector.
3. With a 12-volt test light connected to ground, check the (A901) Fused B(+) circuit at
the DCSM harness connector.
NOTE:
Yes
1. Go To Step 3
No
1. Repair the (A901) Fused B(+) circuit for an open or short to ground.
DCSM harness connector.
Yes
1. Go To Step 4
No
4. CHECK THE (D1) CAN C BUS (+) CIRCUIT FOR AN OPEN OR HIGH RESISTANCE
1. Measure the voltage between ground and the (D1) CAN C Bus (+) circuit at the
Yes
1. Repair the (D1) CAN C Bus (+) circuit for an open or high resistance.
No
1. Go To Step 5
5. CHECK THE (D2) CAN C BUS (-) CIRCUIT FOR AN OPEN OR HIGH RESISTANCE
1. Measure the voltage between ground and the (D2) CAN C Bus (-) circuit at the
Yes
1. Repair the (D2) CAN C Bus (-) circuit for an open or high resistance.
No
1. Replace the DCSM in accordance with the Service Information.
DIAGNOSIS AND TESTING > NO RESPONSE FROM DTCM (DRIVE TRAIN CONTROL
MODULE)
Possible Causes
DRIVE TRAIN CONTROL MODULE (DTCM)
Yes
test complete.
2. Perform the DTCM VERIFICATION TEST. Refer to STANDARD PROCEDURE .
No
1. Go To Step 2
NOTE:
NOTE:
2. Disconnect the Drive Train Control Module (DTCM) harness connector.
DTCM harness connector.
NOTE:
Yes
1. Go To Step 3
No

DTCM harness connector.
Yes
1. Go To Step 4
No
1. With a 12-volt test light connected to 12 volts, check the Ground circuit at the DTCM
harness connector.
Yes
1. Go To Step 5
No
5. CHECK THE CAN C1 BUS (+) CIRCUIT FOR AN OPEN OR HIGH RESISTANCE
1. Measure the voltage between ground and the CAN C1 Bus (+) circuit at the DTCM
harness connector.
Yes
1. Repair the CAN C1 Bus (+) circuit for an open or high resistance.
No
1. Go To Step 6
6. CHECK THE CAN C1 BUS (-) CIRCUIT FOR AN OPEN OR HIGH RESISTANCE
1. Measure the voltage between ground and the CAN C1 Bus (-) circuit at the DTCM
harness connector.
Yes
1. Repair the CAN C1 Bus (-) circuit for an open or high resistance.
No
1. Replace the Drive Train Control Module (DTCM) in accordance with the Service
Information. Refer to MODULE, DRIVETRAIN CONTROL, REMOVAL AND
INSTALLATION .
DIAGNOSIS AND TESTING > NO RESPONSE FROM EPS (ELECTRIC POWER

STEERING MODULE)

Fig 1: Electric Power Steering Module Circuit Diagram

STEERING MODULE) > POSSIBLE CAUSES
Possible Causes
ELECTRIC POWER STEERING (EPS) MODULE

STEERING MODULE) > DIAGNOSTIC TEST
Yes
test complete.
2. Perform the EPS VERIFICATION TEST. Refer to STANDARD PROCEDURE .
No
1. Go To Step 2
NOTE:
NOTE:
2. Disconnect the Electric Power Steering (EPS) Module harness connector.

the EPS Module harness connector.
NOTE:
Yes
1. Go To Step 3
No
3. CHECK THE (F741) FUSED IGNITION SWITCH OUTPUT CIRCUIT FOR AN OPEN OR
SHORT TO GROUND
2. With a 12-volt test light connected to ground, check the (F741) Fused Ignition Switch
Output circuit at the EPS Module harness connector.
Yes
1. Go To Step 4
No
1. Repair the (F741) Fused Ignition Switch Output for an open or short to ground.
EPS Module harness connector.
Yes
1. Go To Step 5
No

5. CHECK THE (D51) CAN C2 BUS (+) CIRCUITS FOR AN OPEN OR HIGH RESISTANCE
1. Measure the voltage of the (D51) CAN C2 Bus (+) circuits at the EPS Module
harness connector.
Yes
1. Repair the (D51) CAN C2 Bus (+) circuits for an open or high resistance.
No
1. Go To Step 6
6. CHECK THE (D52) CAN C2 BUS (-) CIRCUITS FOR AN OPEN OR HIGH RESISTANCE
1. Measure the voltage of the (D52) CAN C2 Bus (-) circuits at the EPS Module
harness connector.
Yes
1. Repair the (D52) CAN C2 Bus (-) circuits for an open or high resistance.
No
1. Replace the Electric Power Steering (EPS) Module in accordance with the
Service Information. Refer to GEAR, REMOVAL AND INSTALLATION .
DIAGNOSIS AND TESTING > NO RESPONSE FROM ESL (ELECTRONIC STEERING

LOCK)

LOCK) > POSSIBLE CAUSES
Possible Causes
ESL MODULE (KL30) BATTERY FEED CIRCUIT OPEN OR SHORTED
ESL MODULE (KL15) IGNITION FEED CIRCUIT OPEN OR SHORTED
ESL MODULE GROUND CIRCUIT OPEN

CONTROLLER AREA NETWORK (CAN) C2 BUS (-) CIRCUIT OPEN OR HIGH RESISTANCE
ELECTRONIC STEERING LOCK (ESL) MODULE

LOCK) > DIAGNOSTIC TEST
Yes

the appropriate TESTING & DIAGNOSTICS article in ENGINE PERFORMANCE
.
No
1. Go To Step 2
2. CHECK THE (KL30) FUSED B(+) CIRCUIT FOR AN OPEN OR SHORT TO GROUND
NOTE:
NOTE:
2. Disconnect the Electronic Steering Lock (ESL) Module harness connector.
3. With a 12-volt test light connected to ground, check the (KL30) Fused B(+) circuit at
the ESL Module harness connector.
NOTE:
Yes
1. Go To Step 3
No
1. Repair the (KL30) Fused B(+) circuit for an open or short to ground.
2. Perform the ESL VERIFICATION TEST. Refer to STANDARD PROCEDURES .
3. CHECK THE (KL15) IGNITION FEED CIRCUIT FOR AN OPEN OR SHORT TO GROUND
2. With a 12-volt test light connected to ground, check the (KL15) Ignition Feed circuit
at the ESL Module harness connector.
Yes
1. Go To Step 4
No
1. Repair the (KL15) Ignition Feed circuit for an open or short to ground.
4. CHECK THE ESL MODULE GROUND CIRCUIT FOR AN OPEN OR HIGH RESISTANCE
1. With a 12-volt test light connected to 12 volts, check the ESL Module Ground circuit
at the ESL Module harness connector.
Yes
1. Go To Step 5
No
1. Repair the ESL Module Ground circuit for an open or high resistance.
1. Measure the voltage between ground and the CAN C2 Bus (+) circuit at the ESL
Module harness connector.
Yes
No
1. Go To Step 6
1. Measure the voltage between ground and the CAN C2 Bus (-) circuit at the ESL
Yes
No
1. Replace the ESL Module in accordance with the Service Information.
DIAGNOSIS AND TESTING > NO RESPONSE FROM ESM (ELECTRONIC SHIFT

MODULE)

Fig 1: Electronic Shift Module & Transmission Control Module Circuit Diagram

Possible Causes
ELECTRONIC SHIFT MODULE (ESM)

Yes
test complete.
No
1. Go To Step 2
NOTE:
NOTE:
2. Disconnect the Electronic Shift Module (ESM) harness connector.
ESM harness connector.
NOTE:
Yes
1. Go To Step 3
No
1. With a 12-volt test light connected to 12 volts, check the Ground circuit at the ESM
harness connector.
Yes
1. Go To Step 4
No
1. Measure the voltage between ground and the CAN C1 Bus (+) circuit at the ESM
harness connector.
Yes
No
1. Go To Step 5
1. Measure the voltage between ground and the CAN C1 Bus (-) circuit at the ESM
harness connector.
Yes
No
1. Replace the Electronic Shift Module (ESM) in accordance with the Service
Information.
DIAGNOSIS AND TESTING > NO RESPONSE FROM IPC (INSTRUMENT PANEL

CLUSTER)

Fig 1: Instrument Panel Cluster Circuit Diagram

CLUSTER) > POSSIBLE CAUSES
Possible Causes
INSTRUMENT PANEL CLUSTER (IPC)

CLUSTER) > DIAGNOSTIC TEST
Yes
test complete.
No
1. Go To Step 2
NOTE:
NOTE:
2. Disconnect the Instrument Panel Cluster (IPC) harness connector.

the IPC harness connector.
NOTE:
Yes
1. Go To Step 3
No
at the IPC harness connector.
Yes
1. Go To Step 4
No
IPC harness connector.
Yes
1. Go To Step 5
No

1. Measure the voltage between ground and the (D2) CAN C1 Bus (+) circuit at the IPC
harness connector.
Yes
No
1. Go To Step 6
1. Measure the voltage between ground and the (D1) CAN C1 Bus (-) circuit at the IPC
harness connector.
Yes
No
AND INSTALLATION .
DIAGNOSIS AND TESTING > NO RESPONSE FROM FFCM (FORWARD FACING

CAMERA MODULE)

Fig 1: Adaptive Cruise Control Module & Forward Facing Camera Module Circuit Diagram

CAMERA MODULE) > POSSIBLE CAUSES
Possible Causes
FORWARD FACING CAMERA MODULE (FFCM)

CAMERA MODULE) > DIAGNOSTIC TEST
Yes
test complete.
2. Perform the FORWARD FACING CAMERA VERIFICATION TEST. Refer to

No
1. Go To Step 2
NOTE:
NOTE:
2. Disconnect the Forward Facing Camera Module (FFCM) harness connector.

at the FFCM harness connector.
NOTE:
Yes
1. Go To Step 3
No

FFCM harness connector.
Yes
1. Go To Step 4
No

1. Measure the voltage between ground and the (D52) CAN C2 Bus (+) circuit at the
Yes

No
1. Go To Step 5
1. Measure the voltage between ground and the (D51) CAN C2 Bus (-) circuit at the
Yes

No
1. Using the schematics as a guide, check the FFCM pins, terminals, and
to all power and ground circuits and repair as necessary. If no problems are
found, replace the FFCM in accordance with the Service Information. Refer to
MODULE, FORWARD FACING CAMERA, REMOVAL AND INSTALLATION .

DIAGNOSIS AND TESTING > NO RESPONSE FROM HVAC
DIAGNOSIS AND TESTING > NO RESPONSE FROM HVAC > POSSIBLE CAUSES
Possible Causes
HVAC MODULE
DIAGNOSIS AND TESTING > NO RESPONSE FROM HVAC > DIAGNOSTIC TEST

Yes
test complete.
2. Perform the HVAC VERIFICATION TEST. Refer to STANDARD PROCEDURE .
No
1. Go To Step 2
NOTE:
NOTE:
2. Disconnect the HVAC Module harness connector.
HVAC Module harness connector.
NOTE:
Yes
1. Go To Step 3
No
HVAC Module harness connector.
Yes
1. Go To Step 4
No
1. With a 12-volt test light connected to 12 volts, check the Ground circuit at the HVAC
Yes
1. Go To Step 5
No
1. Measure the voltage between ground and the CAN IHS Bus (+) circuit at the HVAC
Yes
No
1. Go To Step 6
1. Measure the voltage between ground and the CAN IHS Bus (-) circuit at the HVAC
Yes
No
1. Replace the HVAC Module in accordance with the Service Information. Refer to
MODULE, HVAC, REMOVAL AND INSTALLATION .
DIAGNOSIS AND TESTING > NO RESPONSE FROM LBSS (LEFT BLIND SPOT
SENSOR)
SENSOR) > POSSIBLE CAUSES
Possible Causes
LEFT BLIND SPOT SENSOR (LBSS)
SENSOR) > DIAGNOSTIC TEST
Yes
test complete.
No
1. Go To Step 2
NOTE:
NOTE:
2. Disconnect the Left Blind Spot Sensor (LBSS) harness connector.
LBSS harness connector.
NOTE:
Yes
1. Go To Step 3
No
1. With a 12-volt test light connected to 12 volts, check the Ground circuit at the LBSS
harness connector.
Yes
1. Go To Step 4
No
1. Measure the voltage between ground and the CAN IHS Bus (+) circuit at the LBSS
harness connector.
Yes
No
1. Go To Step 5
1. Measure the voltage between ground and the CAN IHS Bus (-) circuit at the LBSS
harness connector.
Yes
No
1. Replace the Left Blind Spot Sensor (LBSS) in accordance with the Service
Information. Refer to SENSOR, BLIND SPOT, REMOVAL AND INSTALLATION .
DIAGNOSIS AND TESTING > NO RESPONSE FROM ORC (OCCUPANT RESTRAINT

CONTROLLER)

CONTROLLER) > POSSIBLE CAUSES
Possible Causes
OCCUPANT RESTRAINT CONTROLLER (ORC) MODULE

CONTROLLER) > DIAGNOSTIC TEST
NOTE:
Check the Body Control Module (BCM) for any ignition related DTCs before
proceeding. If set, refer to DTC INDEX .
Yes
test complete.
2. Perform the RESTRAINTS SYSTEM VERIFICATION TEST. Refer to

No
1. Go To Step 2
WARNING:
Turn the ignition off disconnect the 12-volt battery and wait two minutes before
proceeding. Failure to follow these instructions may result in possible serious or
fatal injury.
1. Disconnect the Occupant Restraint Controller (ORC) Module harness connector.
WARNING:
Turn the ignition on, then reconnect the 12-volt battery and wait two minutes
before proceeding. Failure to follow these instructions may result in
possible serious or fatal injury.
NOTE:
The CAN bus will remain active with the scan tool connected and the
ignition off.
NOTE:
ORC Module harness connector.
NOTE:
Yes
1. Go To Step 3
No

ORC Module harness connector.
Yes
1. Go To Step 4
No

1. With a 12-volt test light connected to 12 volts, check the Ground circuit at the ORC
Yes
1. Go To Step 5
No

1. Measure the voltage between ground and the CAN C1 Bus (+) circuit at the ORC
Yes

No
1. Go To Step 6
1. Measure the voltage between ground and the CAN C1 Bus (-) circuit at the ORC
Yes

No
1. Go To Step 7
1. Measure the voltage between ground and the CAN C2 Bus (+) circuit at the ORC
Yes

No
1. Go To Step 8
1. Measure the voltage between ground and the CAN C2 Bus (-) circuit at the ORC
Yes

No
1. Replace the Occupant Restraint Controller in accordance with the Service

Information. Refer to MODULE, OCCUPANT RESTRAINT CONTROLLER,
DIAGNOSIS AND TESTING > NO RESPONSE FROM PARK ASSIST MODULE (PAM)
DIAGNOSIS AND TESTING > NO RESPONSE FROM PARK ASSIST MODULE (PAM) >
POSSIBLE CAUSES
Possible Causes
CAN C BUS (-) CIRCUIT OPEN OR HIGH RESISTANCE
PARK ASSIST MODULE (PAM)
DIAGNOSIS AND TESTING > NO RESPONSE FROM PARK ASSIST MODULE (PAM) >
DIAGNOSTIC TEST
Yes
test complete.
No
1. Go To Step 2

NOTE:
NOTE:
2. Disconnect the Park Assist Module (PAM) harness connector.
PAM harness connector.
NOTE:
Yes
1. Go To Step 3
No
PAM harness connector.
Yes
1. Go To Step 4
No

1. With a 12-volt test light connected to 12 volts, check the Ground circuit at the PAM
harness connector.
Yes
1. Go To Step 5
No
1. Measure the voltage between ground and the CAN C1 Bus (+) circuit at the PAM
harness connector.
Yes
No
1. Go To Step 6
1. Measure the voltage between ground and the CAN C1 Bus (-) circuit at the PAM
harness connector.
Yes
No
1. Replace the Park Assist Module (PAM) in accordance with the Service
Information. Refer to MODULE, PARK ASSIST, REMOVAL AND INSTALLATION
.
DIAGNOSIS AND TESTING > NO RESPONSE FROM PCM (POWERTRAIN CONTROL

MODULE)
Fig 1: Powertrain Control Module Circuit Diagram

Possible Causes
GROUND CIRCUIT OPEN
FUSED IGNITION SWITCH OUTPUT (RUN-START) CIRCUIT OPEN OR SHORTED
FUSED ASD/MAIN RELAY OUTPUT CIRCUIT OPEN OR SHORTED
CAN C BUS (+) CIRCUIT OPEN
CAN C BUS (-) CIRCUIT OPEN
POWERTRAIN CONTROL MODULE (PCM)

1. TEST FOR AN INTERMITTENT CONDITION
NOTE:
Check for any Service Bulletin(s) related to the condition. If a Service Bulletin
applies, perform the procedure outlined in the Service Bulletin before continuing.
NOTE:
Make sure the battery voltage is between 10.0 and 16.0 volts.
2. With the scan tool, read the module status.
NOTE:
Check the BCM for any active CAN hardware DTCs and perform those
DTCs before proceeding. Refer to DTC INDEX .
Does the scan tool indicate that the module is active on the bus?
Yes
1. The no response condition is not present at this time. Using the wiring
diagram/schematic as a guide, inspect the wiring for chafed, pierced, pinched,
and partially broken wires and the wiring harness connectors for broken, bent,
pushed out, and corroded terminals.
No
1. Go To Step 2
2. CHECK THE (A209) FUSED B(+) CIRCUIT FOR AN OPEN OR SHORT
2. Disconnect the PCM C1 harness connector.
CAUTION:
Do not probe the PCM harness connectors. Probing the PCM harness
connectors will damage the PCM terminals resulting in poor terminal to pin
connection. Install the GPEC Diagnostic Adaptor to perform the diagnosis.
3. Connect the (special tool #10436, Adapter, GPEC Diagnostic).
4. Using a 12-volt test light connected to ground, probe the (A209) Fused B(+) circuit at
the GPEC Adaptor.
Yes
1. Go To Step 3
No
1. Repair the (A209) Fused B(+) circuit for an open or short.
2. Perform the POWERTRAIN VERIFICATION TEST. Refer to the appropriate

TESTING & DIAGNOSTICS article in ENGINE PERFORMANCE .
3. CHECK THE (Z909) GROUND CIRCUITS FOR AN OPEN/HIGH RESISTANCE
1. Using a 12-volt test light connected to 12 volts, probe the (Z909) Ground circuits at
the GPEC Adaptor.
Does the test light illuminate brightly at each ground circuit?
Yes
1. Go To Step 4
No

4. CHECK THE (F942) FUSED IGNITION SWITCH OUTPUT (RUN-START) CIRCUIT FOR AN
OPEN OR SHORT
2. Using a 12-volt test light connected to ground, probe the (F942) Fused Ignition
Switch Output (Run-Start) circuit at the GPEC Adaptor.
Yes
1. Go To Step 5
No
1. Repair the (F942) Fused Ignition Switch Output (Run-Start) circuit for an open
or short.

5. CHECK THE (F342) FUSED ASD RELAY OUTPUT CIRCUITS FOR AN OPEN OR SHORT
1. Turn the ignition off
CAUTION:
4. Remove the ASD Relay from the Power Distribution Center (PDC).
5. Connect a jumper between terminal 30 and terminal 87 at the ASD Relay connector
in the PDC.
6. Using a 12-volt test light connected to ground, probe the (F342) Fused ASD Relay
Output circuits at the GPEC Adaptor.
Does the test light illuminate brightly at each ASD Control Output circuit?
Yes
1. Go To Step 6
No
1. Repair the (F342) Fused ASD Relay Output circuit for an open or short.
6. CHECK THE (D27) CAN C BUS (+) CIRCUIT FOR AN OPEN/HIGH RESISTANCE
2. Disconnect the STAR CAN C Body Connector C6 harness connector.
3. Measure the resistance of the (D27) CAN C Bus (+) circuit between the STAR CAN C
Body Connector C6 harness connector and the GPEC Adaptor.
Is the resistance below 3.0 Ohms?
Yes
1. Go To Step 7
No
1. Repair the (D27) CAN C Bus (+) circuit for an open or high resistance.

7. CHECK THE (D28) CAN C BUS (-) CIRCUIT FOR AN OPEN/HIGH RESISTANCE
1. Measure the resistance of the (D28) CAN C Bus (-) circuit between the STAR CAN C
Body Connector C6 harness connector and the GPEC Adaptor.
Yes
1. Replace the Powertrain Control Module in accordance with the Service

Information. Refer to MODULE, POWERTRAIN CONTROL, REMOVAL AND
INSTALLATION .

No
1. Repair the (D28) CAN C Bus (-) circuit for an open or high resistance.

DIAGNOSIS AND TESTING > NO RESPONSE FROM RADIO-ETM
DIAGNOSIS AND TESTING > NO RESPONSE FROM RADIO-ETM > POSSIBLE

CAUSES
Possible Causes
RADIO (RRM)/ENTERTAINMENT TELEMATICS MODULE (ETM)
DIAGNOSIS AND TESTING > NO RESPONSE FROM RADIO-ETM > DIAGNOSTIC

TEST
Yes
test complete.
No
1. Go To Step 2
NOTE:
NOTE:
2. Disconnect the Radio (RRM) or Entertainment Telematics Module (ETM) harness

connector.
RRM/ETM harness connector.
NOTE:
Yes
1. Go To Step 3
No
1. With a 12-volt test light connected to 12 volts, check the Ground circuit at the
Yes
1. Go To Step 4
No
1. Measure the voltage between ground and the CAN C1 Bus (+) circuit at the
Yes
No
1. Go To Step 5
1. Measure the voltage between ground and the CAN C1 Bus (-) circuit at the
Yes
No
1. Replace the Radio (RRM) or Entertainment Telematics Module (ETM) in

accordance with the Service Information. Refer to MODULE, RADIO
RECEIVER, REMOVAL AND INSTALLATION .
DIAGNOSIS AND TESTING > NO RESPONSE FROM RBSS (RIGHT BLIND SPOT
SENSOR)
SENSOR) > POSSIBLE CAUSES
Possible Causes
RIGHT BLIND SPOT SENSOR (RBSS)
SENSOR) > DIAGNOSTIC TEST

Yes
test complete.
No
1. Go To Step 2
NOTE:
NOTE:
2. Disconnect the Right Blind Spot Sensor (RBSS) harness connector.
RBSS harness connector.
NOTE:
Yes
1. Go To Step 3
No

1. With a 12-volt test light connected to 12 volts, check the Ground circuit at the RBSS
harness connector.
Yes
1. Go To Step 4
No
1. Measure the voltage between ground and the CAN IHS Bus (+) circuit at the RBSS
harness connector.
Yes
No
1. Go To Step 5
1. Measure the voltage between ground and the CAN IHS Bus (-) circuit at the RBSS
harness connector.
Yes
No
1. Replace the Right Blind Spot Sensor (RBSS) in accordance with the Service
Information. Refer to SENSOR, BLIND SPOT, REMOVAL AND INSTALLATION .

DIAGNOSIS AND TESTING > NO RESPONSE FROM RFH (RADIO FREQUENCY HUB)
MODULE
Fig 1: Radio Frequency Hub Module Circuit Diagram

MODULE > POSSIBLE CAUSES
Possible Causes
RADIO FREQUENCY (RF) HUB MODULE
MODULE > DIAGNOSTIC TEST
Yes
test complete.
No
1. Go To Step 2
NOTE:
NOTE:
2. Disconnect the Radio Frequency (RF) Hub Module C1 harness connector.
the RF Hub Module C1 harness connector.
NOTE:
Yes
1. Go To Step 3
No
at the RF Hub Module C1 harness connector.
Yes
1. Go To Step 4
No
RF Hub Module C1 harness connector.

Yes
1. Go To Step 5
No
1. Measure the voltage between ground and the (D1) CAN C1 Bus (+) circuit at the RF
Hub Module C1 harness connector.
Yes
No
1. Go To Step 6
1. Measure the voltage between ground and the (D2) CAN C1 Bus (-) circuit at the RF
Hub Module C1 harness connector.
Yes
No
1. Replace the Radio Frequency (RF) Hub Module in accordance with the Service
Information. Refer to MODULE, RADIO FREQUENCY (RF HUB), REMOVAL
AND INSTALLATION .
DIAGNOSIS AND TESTING > NO RESPONSE FROM 9-SPEED TCM (TRANSMISSION

CONTROL MODULE)

Fig 1: Electronic Shift Module & Transmission Control Module Circuit Diagram

CONTROL MODULE) > POSSIBLE CAUSES
Possible Causes
TRANSMISSION CONTROL MODULE (TCM)

CONTROL MODULE) > DIAGNOSTIC TEST
Yes
test complete.
2. Perform the TRANSMISSION VERIFICATION TEST. Refer to the appropriate

TRANSMISSION ELECTRICAL DIAGNOSTICS article .
No
1. Go To Step 2
NOTE:
NOTE:

2. Disconnect the Transmission Control Module (TCM) harness connector.
TCM harness connector.
NOTE:
Yes
1. Go To Step 3
No

TCM harness connector.
Yes
1. Go To Step 4
No

1. With a 12-volt test light connected to 12 volts, check the Ground circuit at the TCM
harness connector.
Yes
1. Go To Step 5
No

1. Measure the voltage between ground and the CAN C1 Bus (+) circuit at the TCM
harness connector.
Yes

No
1. Go To Step 6
1. Measure the voltage between ground and the CAN C1 Bus (-) circuit at the TCM
harness connector.
Yes

No
1. Replace and program the Transmission Control Module (TCM) in accordance

with the Service Information. Refer to MODULE, TRANSMISSION CONTROL,

DIAGNOSIS AND TESTING > NO RESPONSE FROM DDCT TCM (TRANSMISSION

CONTROL MODULE)

Fig 1: Transmission Control Module Circuit Diagram

CONTROL MODULE) > POSSIBLE CAUSES
Possible Causes
IGNITION RUN/START OUTPUT
TRANSMISSION CONTROL MODULE (TCM)

CONTROL MODULE) > DIAGNOSTIC TEST
1. CHECK THE MODULE STATUS ON THE CONTROLLER AREA NETWORK (CAN) C BUS
Yes
1. The condition or conditions that originally set this Diagnostic Trouble Code
(DTC) are not present at this time. Using the wiring diagrams as a guide, check
all related splices and connectors for signs of water intrusion, corrosion,
pushed out or bent terminals, and correct terminal tension and repair as
necessary. If no problems are found, test complete.

No
1. Go To Step 2
NOTE:
NOTE:

2. Disconnect the Transmission Control Module (TCM) harness connector.
the TCM harness connector.
NOTE:
Yes
1. Go To Step 3
No
1. Repair the (A901) Fused B(+) circuit(s) for an open or short to ground.

3. CHECK THE (F741) IGNITION RUN/START OUTPUT CIRCUIT FOR AN OPEN OR SHORT
TO GROUND
2. With a 12-volt test light connected to ground, check the (F741) Ignition Run/Start
Output circuit at the TCM harness connector.
Yes
1. Go To Step 4
No
1. Repair the Ignition Run/Start Output circuit for an open or short to ground.

the TCM harness connector.
Yes
1. Go To Step 5
No
1. Repair the (Z908) Ground circuit(s) for an open or high resistance.

5. CHECK THE (D1) CAN C BUS (+) CIRCUITS FOR AN OPEN OR HIGH RESISTANCE
1. Measure the voltage between ground and the (D1) CAN C Bus (+) circuits at the TCM
harness connector.
Yes
1. Repair the (D1) CAN C Bus (+) circuit(s) for an open or high resistance.

No
1. Go To Step 6
6. CHECK THE (D2) CAN C BUS (-) CIRCUITS FOR AN OPEN OR HIGH RESISTANCE
1. Measure the voltage between ground and the (D2) CAN C Bus (-) circuits at the TCM
harness connector.
Yes
1. Repair the (D2) CAN C Bus (-) circuit(s) for an open or high resistance.

No
1. Replace the TCM in accordance with the Service Information. (Refer to

MODULE, TRANSMISSION CONTROL ).

DIAGNOSIS AND TESTING > NO RESPONSE FROM TPM (TIRE PRESSURE

MONITORING) MODULE

MONITORING) MODULE > POSSIBLE CAUSES
Possible Causes
TIRE PRESSURE MONITORING (TPM) MODULE

MONITORING) MODULE > DIAGNOSTIC TEST
Yes
test complete.
2. Perform the TPM VERIFICATION TEST. (Refer to the appropriate ELECTRICAL

DIAGNOSTICS article).
No
1. Go To Step 2
NOTE:
NOTE:
2. Disconnect the Tire Pressure Monitoring (TPM) module harness connector.
TPM module harness connector.
NOTE:
Yes
1. Go To Step 3
No

1. With a 12-volt test light connected to 12 volts, check the Ground circuit at the TPM
Yes
1. Go To Step 4
No

4. CHECK THE CAN BUS (+) CIRCUIT FOR AN OPEN OR HIGH RESISTANCE
1. Measure the voltage between ground and the CAN Bus (+) circuit at the TPM module
harness connector.
Yes
1. Repair the CAN Bus (+) circuit for an open or high resistance.

No
1. Go To Step 5
5. CHECK THE CAN BUS (-) CIRCUIT FOR AN OPEN OR HIGH RESISTANCE
1. Measure the voltage between ground and the CAN Bus (-) circuit at the TPM module
harness connector.
Yes
1. Repair the CAN Bus (-) circuit for an open or high resistance.

No
1. Replace the Tire Pressure Monitoring (TPM) module in accordance with the
Service Information. Refer to MODULE, TIRE PRESSURE MONITORING
(TPM), REMOVAL AND INSTALLATION .

DIAGNOSIS AND TESTING > NO RESPONSE FROM TTM (TRAILER TOW MODULE)

Fig 1: Trailer Tow Module Circuit Diagram
DIAGNOSIS AND TESTING > NO RESPONSE FROM TTM (TRAILER TOW MODULE) >
POSSIBLE CAUSES
Possible Causes
FUSED IGNITION RUN/START CIRCUIT OPEN OR SHORTED
TRAILER TOW MODULE (TTM)
DIAGNOSIS AND TESTING > NO RESPONSE FROM TTM (TRAILER TOW MODULE) >
DIAGNOSTIC TEST
Yes

the appropriate TESTING & DIAGNOSTICS article in ENGINE
PERFORMANCE.
No
1. Go To Step 2
NOTE:
NOTE:
2. Disconnect the Trailer Tow Module (TTM) C1 harness connector.
the TTM C1 harness connector.
NOTE:
Yes
1. Go To Step 3
No
3. CHECK THE (F741) FUSED IGNITION RUN/START CIRCUIT FOR AN OPEN OR SHORT TO
GROUND
2. With a 12-volt test light connected to ground, check the (F741) Fused Ignition
Run/Start circuit at the TTM C1 harness connector.
Yes
1. Go To Step 4
No
1. Repair the (F741) Fused Ignition Run/Start circuit for an open or short to
ground.
TTM C1 harness connector.
Yes
1. Go To Step 5
No
5. CHECK THE (C157) CAN IHS BUS (+) CIRCUIT FOR AN OPEN OR HIGH RESISTANCE
1. Measure the voltage on the (C157) CAN IHS Bus (+) circuit at the TTM C1 harness
connector.
Yes
1. Repair the (C157) CAN IHS Bus (+) circuit for an open or high resistance.
No
1. Go To Step 6
6. CHECK THE (C158) CAN IHS BUS (-) CIRCUIT FOR AN OPEN OR HIGH RESISTANCE
1. Measure the voltage on the (C158) CAN IHS Bus (-) circuit at the TTM C1 harness
connector.
Yes
1. Repair the (C158) CAN IHS Bus (-) circuit for an open or high resistance.
No
1. Replace the Trailer Tow Module (TTM) in accordance with the Service
Information.

Service Manual: ELECTRONIC CONTROL MODULES - SERVICE Jeep Renegade
INFORMATION
STANDARD PROCEDURE > MODULE REPLACEMENT GUIDE (RF-HUB, PCM, BCM, ESL)
NOTE:
NOTE: If using 14.01 tool software and replacing the RF-Hub, the 'PROXI Configuration
Alignment' procedure may need to be ran before running the 'Program Ignition FOBIKs'
procedure in addition to the 'PROXI Configuration Alignment' procedure already
documented in the below tables.
MODULE REPLACEMENT GUIDE (RF-HUB, PCM, BCM, ESL)

MODULE
Condition
Condition 1 Condition 2 Condition 4 Condition 5 Condition 6 Condition 7
3
RF-HUB (and
ELV/ESCL if New Existing Existing Existing Existing New New
equipped)
BCM Existing New Existing Existing Existing New Existing
FOBiKs Existing Existing New Existing Existing Existing New
PCM Existing Existing Existing New Existing Existing Existing
ESL Existing Existing Existing Existing New Existing Existing
PROGRAMMING
ASSOCIATED MODULE MISC. FUNCTION
ORDER
Program Flash update

Program
Restore Ignition PCM (if PCM Restore
RF-HUB Ignition RF-HUB
1 BCM PROXI FOBIKs arrives in a BCM PROXI
Replace FOBIKs Replace
Configuration (ignition generic Configuration
(ignition off)
off) state)
Program Program
BCM PCM PROXI
Ignition RF-HUB Ignition
2 Replaced (in Replaced (in Configuration
FOBIKs Replace FOBIKs
Vehicle Prep) Vehicle Prep) Alignment
(Ignition Off) (ignition off)
Program
'PROXI PROXI PROXI
RF-HUB Ignition
3 Configuration Configuration Configuration
Replace FOBIKs
Alignment Alignment Alignment
(Ignition Off)
Update Front Update Front Update Front

and Rear Check PCM and Rear and Rear
'PROXI
Axle Nominal VIN and Axle Nominal Axle Nominal
4 Configuration
Tire other PCM Tire Tire
Alignment
Pressure routines Pressure Pressure
Values Values Values
BCM
Program Tire Program Tire Program Tire
5 Replaced (in
Sensor IDs Sensor IDs Sensor IDs
Vehicle Prep)
Update Front
and Rear
Axle Nominal
6
Tire
Pressure
Values
Program Tire
7
Sensor IDs
KL MODULE REPLACEMENT GUIDE (RF-HUB, PCM, BCM, ESL)

MODULE
Condition Condition Condition Condition Condition
Condition 8 Condition 9
10 11 12 13 14
RF-HUB (and
ELV/ESCL if New Existing Existing Existing Existing New New
equipped)
BCM Existing New New Existing New Existing New
FOBiKs Existing New Existing New New New Existing
PCM New Existing New New New New New
ESL Existing Existing Existing Existing Existing Existing Existing
PROGRAMMING
ORDER
Program
Restore Restore Restore Restore
RF-HUB Ignition RF-HUB
1 BCM Proxi BCM Proxi BCM Proxi BCM Proxi
Replace FOBIKs Replace
Configuration Configuration Configuration Configuration
(Ignition Off)
Flash update Flash update

Program Program Program Program
PCM (if PCM PCM (if PCM
Ignition Ignition Ignition Ignition RF-HUB
2 arrives in a arrives in a
FOBIKs FOBIKs FOBIKs FOBIKs Replace
generic generic
(Ignition Off) (Ignition Off) (Ignition Off) (Ignition Off)
state) state)
Flash update Flash update Flash update

Program
PCM (if PCM BCM BCM PCM PCM (if PCM PCM (if PCM
Ignition
3 arrives in a Replaced (in Replaced (in Replaced (in arrives in a arrives in a
FOBIKs
generic Vehicle Prep) Vehicle Prep) Vehicle Prep) generic generic
(Ignition Off)
state) state) state)
Flash update
PCM PCM PROXI BCM PCM PCM (if PCM
4 Replaced (in Replaced (in Configuration Replaced (in Replaced (in arrives in a
Vehicle Prep) Vehicle Prep) Alignment Vehicle Prep) Vehicle Prep) generic
state)
PROXI PROXI Check PCM PCM PROXI BCM

5 Configuration Configuration VIN and Replaced (in Configuration Replaced (in
Alignment Alignment other PCM Vehicle Prep) Alignment Vehicle Prep)
routines
Update Front
Check PCM Check PCM and Rear
PROXI PCM
VIN and VIN and Axle Nominal
6 Configuration Replaced (in
other PCM other PCM Tire
Alignment Vehicle Prep)
routines routines Pressure
Values
Update Front
and Rear Check PCM
PROXI
Axle Nominal VIN and Program Tire
7 Configuration
Tire other PCM Sensor IDs
Alignment
Pressure routines
Values
Check PCM Check PCM

Program Tire VIN and VIN and
8
Sensor IDs other PCM other PCM
routines routines
Update Front
and Rear
Axle Nominal
9
Tire
Pressure
Values
Program Tire
10
Sensor IDs

MODULE
Condition Condition Condition 7 Condition Condition Condition Condition
15 16 18 19 20 21
RF-HUB (and
ELV/ESCL if New New New New New Existing Existing
equipped)
BCM New New New Existing Existing New New
FOBiKs New New Existing New Existing New Existing
PCM Existing New Existing Existing New Existing New
ESL Existing Existing New New New New New
PROGRAMMING
ORDER
Restore Restore Restore Restore Restore

RF-HUB RF-HUB
1 BCM Proxi BCM Proxi BCM Proxi BCM Proxi BCM Proxi
Replace Replace
Configuration Configuration Configuration Configuration Configuration
Flash update
Program Program Program
PCM (if PCM
RF-HUB RF-HUB RF-HUB Ignition Ignition Ignition
2 arrives in a
Replace Replace Replace FOBIKs FOBIKs FOBIKs
generic
(Ignition Off) (Ignition Off) (Ignition Off)
state)
Flash update
Program Program Program
ESL PCM (if PCM BCM BCM
Ignition Ignition Ignition
3 Replaced (in arrives in a Replaced (in Replaced (in
FOBIKs FOBIKs FOBIKs
Vehicle Prep) generic Vehicle Prep) Vehicle Prep)
(Ignition Off) (Ignition Off) (Ignition Off)
state)
Flash update
BCM PCM (if PCM BCM PROXI PCM ESL Replace PCM
4 Replaced (in arrives in a Replaced (in Configuration Replaced (in (in Vehicle Replaced (in
Vehicle Prep) generic Vehicle Prep) Alignment Vehicle Prep) Prep) Vehicle Prep)
state)
Update Front
and Rear
PROXI BCM ESL ESL Replace ESL Replace
Axle Nominal
5 Configuration Replaced (in Replaced (in (in Vehicle (in Vehicle
Tire
Alignment Vehicle Prep) Vehicle Prep) Prep) Prep)
Pressure
Values
Update Front
and Rear
PCM PROXI PROXI PROXI
Axle Nominal Program Tire
6 Replaced (in Configuration Configuration Configuration
Tire Sensor IDs
Vehicle Prep) Alignment Alignment Alignment
Pressure
Values
Update Front
and Rear Check PCM Check PCM
PROXI
Program Tire Axle Nominal VIN and VIN and
7 Configuration
Sensor IDs Tire other PCM other PCM
Alignment
Pressure routines routines
Values
Update Front
Check PCM and Rear
VIN and Program Tire Axle Nominal
8
other PCM Sensor IDs Tire
routines Pressure
Values
Update Front
and Rear
Axle Nominal Program Tire
9
Tire Sensor IDs
Pressure
Values
Program Tire
10
Sensor IDs

MODULE
Condition 22 Condition 23 Condition 24 Condition 25 Condition 26 Condition 27
RF-HUB (and
ELV/ESCL if Existing Existing New New New New
equipped)
BCM Existing New Existing New New New

FOBiKs New New New Existing New New
PCM New New New New Existing New
ESL New New New New New New
PROGRAMMING
ORDER
Program
Restore BCM Restore BCM Restore BCM Restore BCM
Ignition RF-HUB
1 Proxi Proxi Proxi Proxi
FOBIKs Replace
Configuration Configuration Configuration Configuration
(Ignition Off)
Flash update Program Program

PCM (if PCM Ignition Ignition RF-HUB RF-HUB RF-HUB
2
arrives in a FOBIKs FOBIKs Replace Replace Replace
generic state) (Ignition Off) (Ignition Off)
Flash update Flash update Program Program Program

PCM
PCM (if PCM PCM (if PCM Ignition Ignition Ignition
3 Replaced (in
arrives in a arrives in a FOBIKs FOBIKs FOBIKs
Vehicle Prep)
generic state) generic state) (Ignition Off) (Ignition Off) (Ignition Off)
Flash update Flash update

ESL Replace BCM PCM BCM
PCM (if PCM PCM (if PCM
4 (in Vehicle Replaced (in Replaced (in Replaced (in
arrives in a arrives in a
Prep) Vehicle Prep) Vehicle Prep) Vehicle Prep)
generic state) generic state)
PROXI PCM ESL Replace BCM ESL Replace BCM

5 Configuration Replaced (in (in Vehicle Replaced (in (in Vehicle Replaced (in
Alignment Vehicle Prep) Prep) Vehicle Prep) Prep) Vehicle Prep)
Check PCM ESL Replace PROXI PCM PROXI PCM

6 VIN and other (in Vehicle Configuration Replaced (in Configuration Replaced (in
PCM routines Prep) Alignment Vehicle Prep) Alignment Vehicle Prep)
Update Front Update Front

PROXI and Rear Axle ESL Replace and Rear Axle ESL Replace
7 Configuration Nominal Tire (in Vehicle Nominal Tire (in Vehicle
Alignment Pressure Prep) Pressure Prep)
Values Values
Check PCM PROXI PROXI

Program Tire Program Tire
8 VIN and other Configuration Configuration
Sensor IDs Sensor IDs
PCM routines Alignment Alignment
Check PCM Check PCM Check PCM

9 VIN and other VIN and other VIN and other
PCM routines PCM routines PCM routines
Update Front Update Front

and Rear Axle and Rear Axle
10 Nominal Tire Nominal Tire
Pressure Pressure
Values Values
Program Tire Program Tire

11
Sensor IDs Sensor IDs
STANDARD PROCEDURE > MODULE PROXI REQUIREMENTS
NOTE:
When replacing a module, a PROXI Alignment Procedure may need to be completed for that
module.
The PROXI Alignment Procedure is needed to learn the PROXI Configuration from the BCM. This
PROXI information configures the modules based on the content of the vehicle.
Refer to the table below for the list of which modules do and do not require the PROXI Alignment
Procedure.
MODULE REQUIRES PROXI
ABS YES
ACC YES
AMP YES
BCM MASTER OF THE PROXI CONFIGURATION DATA
CDM YES
CSWM YES
DTCM YES
ETM (high line RADIO) YES
EPS YES
ESL YES
ESM YES
FFC YES
HVAC YES
IPC YES
LBSS OR RBSS YES
ORC YES
PAM YES
PCM YES
RFHM YES
RRM (low line RADIO) YES
TCM YES
TPM YES
TTM YES
NOTE:
Some modules require several steps to replace the ECU. See the appropriate ECU replacement
procedure information for a full list of replacement steps.
COMMUNICATION > DESCRIPTION AND OPERATION > DESCRIPTION AND OPERATION >
DIGITAL NETWORKS
The vehicle features an electrical/electronic architecture called Next-Generation. Data transmission between
the various ECUs in the Next-Generation architecture occurs through the following digital networks:
CAN-C1 (high-speed 500 kb/s)
CAN-C2 (high-speed 500 kb/s)
CAN-BH (medium-speed 125 kb/s)
Fig 1: CAN-C1 Circuit Diagram
CAN-C1
The ECUs interconnected by the CAN-C1 are:
BCM (Body Control Module)
IPC (Instrument Panel Cluster)
ETM (Entertainment Telematic Module - Infotelematic Module VP2 with Nav or VP4)
ORC (Occupant Restraint Control - Airbag module)

RFH (Radio Frequency Module)
DTCM (Drive Train Control Module - Transmission Module)
ESM (Electronic Shifter Module - Automatic transmission selector lever module)
ABS (Anti-lock Braking System Module)
ACC (Adaptive Cruise Control Module)
TCM (Automatic Transmission Control Module)
ECM (Engine Control Module)
CAN-C1 reaches the DLC multiple diagnosis connector.
The 120-ohm terminal resistors of the CAN-C1 are located in the BCM and in the ECM.
Fig 2: CAN-C2 Circuit Diagram
CAN-C2
The CAN-C2 manages the data which is exchanged at high speed between the ECU modules of the vehicle
chassis.
The control units interconnected by the CAN-C2 are:
ABS (Anti-lock Braking System Module)
ESL (Electric Steering Wheel - Steering Lock Module)
PAM (Parking Aid Module)
EPS (Electric Power Steering Module.)
HALF (Haptic Lane Feedback - Lane maintenance assistance module)
ORC (Occupant Restraint Control)
The CAN-C2 is in the DLC multiple diagnosis connector.
The 120-ohm terminal resistors are in the ABS module and the ORC Airbag module.
Fig 3: CAN-BH Circuit Diagram
CAN-BH
The CAN-BH manages the data exchanged at medium speed between the electronic modules which manage
the passenger compartment comfort on the vehicle.
The control units interconnected by the CAN-BH are:
IPC (Instrument Panel Cluster)
RRM (Radio Receiver Module)
CSWM (Comfort Seat Wheel Module - Seat and Steering Wheel Heating Module)
LBSS (Left Blind Spot Sensor)
RBSS (Right Blind Spot Sensor)
AMP (Amplifier - Hi-Fi system amplifier)
TTM (Trailer Tow Module - Tow Hook Module)
HVAC (Heating Ventilation and Air Conditioning - Climate control module)
ETM (Entertainment Telematic Module - Infotelematic Module VP2, VP4)
The CAN-BH is in the DLC multiple diagnosis connector.
The 120-ohm terminal resistors are in the BCM and the IPC module.
Fig 4: LINs Circuit Diagram
LINs
Some Modules dialogue with certain vehicle components via LINs. The BCM uses 4 LINs to dialogue with the
following components:
LIN 1
IBS (Intelligent Battery Sensor - negative battery terminal IBS)
UAM (Ultrasonic Anti-tilt Module)
ASU (Alarm System Unit)
RLS (Rain Light Sensor - Rain sensor)
LIN 2
SWS (Steering Wheel Switch bank)
ASBM (Auxiliary Switch Bank Module - controls on dashboard)
TSBM (Terrain Selector Bank Module - Traction mode selector module on tunnel)
RVCM (Rear View Camera Module)
LIN 3
WSMP (Window Smart Motor Passenger)

WSMD (Window Smart Motor Driver)
LIN 4
CSWC (Cruise control Steering Wheel Commands)
The instrument panel (IPC) communicates via a LIN line with the following components:
ECSB (Emergency Call Switch Bank)
COM (Compass Module)
HUM (Humidity Sensor)
There is also a LIN line that connects the ECM to the voltage regulator of the intelligent alternator.
CONNECTOR, DATA LINK > DESCRIPTION AND OPERATION > DESCRIPTION AND
OPERATION > DATA LINK CONNECTOR
The vehicle is supplied with numerous electronic control units that perform a self diagnosis function. Connecting
to these control units via diagnostic equipment allows you to read the self-diagnosis information (parameters,
errors) or carry out available active diagnostics. All the diagnosis lines flow into the EOBD connector
(European On Board Diagnosis) which conforms with Directive 98/69/EC - ISO standard J1962 - located under
the dashboard near the Body Control Module (BCM). On the same connector it is possible to diagnose all
nodes (control units) connected both to the low transmission speed CAN-B for the management of standard
body functions and to the high-transmission speed CAN-C for dynamic vehicle controls (bus CAN-H and
CAN-L).
The 4x4 control unit also has an additional diagnosis connection, located next to the control unit itself.
Fig 1: DLC Connector Terminal Identification
DLC multiple diagnosis connector

The three networks are positioned in the multiple diagnosis connector in the following pins:
Pin 3 - CAN-BH High
Pin 11 - CAN-BH Low
Pin 12 - CAN-C2 High
Pin 13 - CAN-C2 Low
Pin 14 - CAN-C1 Low
Pin 6 - CAN-C1 High
Fig 2: DLC Location
DLC multiple diagnosis connector position
Digital network voltage levels
CAN-C1
Fig 3: Checking Voltage On CAN-C1 (High +)

Fig 4: Checking Voltage On CAN-C1 (Low -)
CAN-C2
Fig 5: Checking Voltage On CAN-C2 (High +)

Fig 6: Checking Voltage On CAN-C2 (Low -)
CAN-BH
Fig 7: Checking Voltage On CAN-BH (High +)

Fig 8: Checking Voltage On CAN-BH (Low -)

Fig 9: CAN System Waveform - Key Off
The CAN-C1, CAN-C2 and CAN-BH enter Sleep mode approximately 10-12 seconds after the key is turned to
OFF. The networks "wake up" with the key at OFF when one of the vehicle's doors passes from "Closed" status
to "Open" status.
The ACC module is connected to the Half module via a dedicated CAN-C line. The reason behind the dedicated
data transmission line between the two modules is the continuous exchange of information between them
during operation of the cruise control and of the FCW function.
Electrical continuity of the networks

Fig 10: Checking Resistance On CAN-C1 Circuit - (Pin 14 And Pin 6)

Fig 11: Checking Resistance On CAN-C2 Circuit - (Pin 12 And Pin 13)

Fig 12: Checking Resistance On CAN-BH Circuit - (Pin 11 And Pin 3)
The three digital networks CAN-C1, CAN-C2 and CAN-BH have 120-ohm terminal resistors. The electrical
continuity of the networks can be checked directly via the diagnosis connector by setting the multimeter to the
Ohm function. When the network is electrically continuous, the value that the operator needs to read on the
display is approximately 60 ohms for all three networks.
The central diagnostic socket receives a direct battery power supply from the line protected by a fuse located
in the BCM. The BCM receives a direct power supply from the battery through the line protected by maxi fuse in
the engine compartment junction unit. The BCM receives an ignition-operated power supply (INT). This signal is
used, amongst other things, to "wake up the network".
CONNECTOR, DATA LINK > DESCRIPTION AND OPERATION > MICROPOD II

Fig 1: VCI Pod & MICROPOD II
In order to diagnose the vehicle, the wiTECH must be supported by specific new equipment called Micropod II.
Fundamentally, the current VCI Pod is unable to dialogue with the vehicle systems through the three CANs. The
current VIC Pod can manage the dialogue via two CANs. For this reason, it is necessary to use the Micropod II
which will be distributed to the service network as specific equipment.
Fig 2: MICROPOD II Connection
The Micropod II is different to the VCI pod. It allows wi-fi connection, and no longer Bluetooth. The wi-fi
connection can be made using the current wiTECH access point (router) provided to the Jeep service network.
Alternatively, PC and Micropod II can be connected via USB cable.
In order to use the Micropod II, it must be configured for the desired wi-fi network. Below is the configuration
procedure.
MICROPOD II Wi-Fi mode configuration
In addition to USB methods, the MICROPOD can be used in Wi-Fi mode. Approximately 15 minutes are
required to set up the MICROPOD with Wi-Fi. Make sure that you have the time required and the USB cable
provided to hand.
Depending on the complexity of the network, the time taken to connect the MICROPOD to the Wi-Fi
network may vary from a few seconds to 5 minutes. In some cases, the support of your IT manager
may be required. It is also possible that some configurations of your internal network do not permit
correct use of Wi-Fi connection.
NOTE:
Not all networks and not all Wi-Fi configurations are ideal for using the MICROPOD in Wi-Fi mode.
In order not to encounter these problems, you can provide yourself with completely open Wi-Fi
access
Fig 3: MICROPOD II
If the name of the Wi-Fi network, the password and the relative ciphering are known, go straight to B1.
Otherwise, carry on with A 1.
For support, contact the WITECH PLUS HELP DESK

Fig 4: Check The Name Of Your Wi-Fi Network
A. Identifying network name and password
A 1. Check the name of your Wi-Fi network by clicking the dedicated icon near the clock
In the above example, the Wi-Fi network that the PC is connected to is called "wireless". To identify the
Password for the Wi-Fi network, right-click on the connected network and then click Properties
Fig 5: Security Tab
A 2. In the window that appears, click on the Security tab and Show characters
WARNING: the PC administrator password may be requested This window contains the Wi-Fi network
details.
In our example, they are:
SSID "wireless" = Wi-Fi name
Security "WPA2" = Security type
Enter Key "officina123" = Security key (password)

A 3. Close all windows and carry on with B 1
Fig 6: Enter Address
B. Setting up Wi-Fi on the MICROPOD II
B 1. Connect the USB cable between PC and MICROPOD
B 2. Wait for about 40 seconds and open the Internet Explorer browser
B 3. Enter the address 172.22.22.22 and press enter
B 4. The page below will be shown; click on Wireless Settings

Fig 7: Choosing A Name For The Network Profile
B 5. The page below will be shown;
B 6. click on New
B 7. Choose a name for the network profile that you're creating (e.g. "WORKSHOP") and click Add
B 8. Then select the "WORKSHOP" Profile

B 9. Select the option indicated by the red arrow
Fig 8: Completing Fields
B 10. Complete the fields indicated by the green box (the same as at A 2)
In our example, they are:
SSID "wireless" = Wi-Fi name
Security "WPA2" = Security type
Enter Key "officina123" = Security key
Confirm Key "officina123" = Confirm security key

Fig 9: Save Settings

B 11. Once completed, click on Save
Fig 10: Close Settings
B 12. Wait for the next screen and click on Close

Fig 11: Managing Networks
B 13. Then select Manage Networks
B 14. Select the option indicated by the red arrow: wireless

B 15. Click the Select & Start button next to the profile created previously (in our example
"WORKSHOP")
Fig 12: Overview
B 16. Wait for a minute and select Overview
If configuration is successful, the IP address for the Wi-Fi connection will appear, as in the red box above.
MODULE, ADAPTIVE CRUISE CONTROL > DESCRIPTION AND OPERATION >

DESCRIPTION AND OPERATION > DESCRIPTION
Fig 1: Adaptive Cruise Control Module
The ACC sensor contains the software required to operate normal Cruise Control, ACC+, and FCW+. The ACC
sensor determines the distance to a target vehicle and the speed at which the target vehicle is approached. If
the ACC sensor determines that intervention is required, the ACC sensor sends a message to other modules
over CAN-C to activate audible, visual and haptic warnings. The ACC sensor also sends torque requests to the
PCM and brake requests to the ABS module.
Fig 2: Adaptive Cruise Control Module Connector Terminal Identification
ACC pinout
1. Ground
2. CAN 1 H
3. CAN 1 L
4. N.C.
5. Private CAN
6. Private CAN
7. N.C.
8. 12V power supply
MODULE, ADAPTIVE CRUISE CONTROL > DESCRIPTION AND OPERATION >

DESCRIPTION AND OPERATION > OPERATION
Fig 1: Adaptive Cruise Control Module Circuit Diagram
ACC+ / HALF+ system wiring diagram
The hard wired inputs for the ACC module may be diagnosed using conventional diagnostic tools and
procedures. Refer to the appropriate wiring information. However, conventional diagnostic methods will not
prove conclusive in the diagnosis of the ACC module or the electronic controls or communication between
other modules and devices that provide features of the ACC and FCW system features. The most reliable,
efficient, and accurate means to diagnose the ACC module or the electronic controls and communication
related to ACC or FCW system operation requires the use of a diagnostic scan tool. Refer to the appropriate
diagnostic information.
MODULE, ADAPTIVE CRUISE CONTROL > REMOVAL AND INSTALLATION > ACC SENSOR
/ MODULE > REMOVAL - SENSOR
1. Disconnect and isolate the negative battery cable.
2. Remove the front fascia. Refer to FASCIA, FRONT, REMOVAL AND INSTALLATION .
Fig 1: Radar Wire Harness Connector & Wire Harness Retainer
3. Disconnect the electrical connection (1a) of the radar (1b).
NOTE:
Avoid pressing the central area of the sensor. Act only on the side edges.
4. Disengage the retainer (2a) of the wiring (2b).

Fig 2: Radar Sensor & Anchor Pins
5. Disconnect the sensor (1a) and then release the three pinned anchors (1b) securing the radar.
MODULE, ADAPTIVE CRUISE CONTROL > REMOVAL AND INSTALLATION > ACC SENSOR
/ MODULE > INSTALLATION - SENSOR
1. Check that the sensor / radar is not damaged.

Fig 1: Radar Sensor, Wiring, Retainer, Connector & Anchor Pins
2. Place the sensor (1a) and, acting on the side edges, insert seat the anchor pins (1b) making sure that
the fastening is correct.
NOTE:
During assembly avoid applying pressure on the pins toward the inside of the component,
since it may cause a partial detachment of the cover of the component.
3. Engage the retainer (2a) of the wiring (2b).
4. Connect the electrical connection (3a) of the radar (1a).
5. Install the front fascia. Refer to FASCIA, FRONT, REMOVAL AND INSTALLATION .
6. Perform the calibration of the radar. Refer to MODULE, ADAPTIVE CRUISE CONTROL, MODULE
PROGRAMMING .
MODULE, ADAPTIVE CRUISE CONTROL > REMOVAL AND INSTALLATION > ACC
BRACKET > REMOVAL - BRACKET

Fig 1: Bracket & Rivets
3. Using a drill, remove the rivets (1a) holding the bracket (1b) to cross (1c).
4. Remove the bracket (1b).
MODULE, ADAPTIVE CRUISE CONTROL > REMOVAL AND INSTALLATION > ACC
BRACKET > INSTALLATION - BRACKET
Fig 1: Bracket, Anchor & Bushings
1. Check that the bracket is not damaged.
2. Place the new bracket (1a) bushings anchor (1b) supplied with the spare.
3. Turn with a key bushings (1b) in their seats about half a turn, until it reaches the stop (approximately
14 daN / m).
4. Position the bracket and fasten with rivets.
6. Connect the negative battery cable.
MODULE, ADAPTIVE CRUISE CONTROL > MODULE PROGRAMMING > MODULE

ALIGNMENT - EMEA
SPECIAL TOOLS REQUIRED -
2021200000 - Reflective Mirror Support
2021201000 - Sealing Strip
This procedure must be performed in the following cases:
Removing / installing the radar sensor

Warning light indicated the failure of the radar sensor proximity
Rear axle adjustments
Replacing wheel rims or tires with a larger or smaller diameter component
Removing / installing the front end.
Fit the strap to the workshop floor:
It is advisable to place the strip parallel to a perimeter wall of the workshop and at a safe distance to
allow the operator to maneuver the equipment.
The floor can have an angle of maximum inclination of 3° downhill or an uphill maximum inclination of 1°.
Unevenness maxims:
surface adjustment control unit: 1 mm
vehicle control surface: 10 mm.

Fig 1: Level Indicator
1. Fit the tool support mirror on the strip, taking care to respect the vertical position by the level
indicated in the illustration.
Fig 2: Center Groove Position
2. Set the reflecting mirror to the center groove position as shown in illustration.
Determining the axis of travel - For the control and regulation of the sensor / proximity radar the mirror must
be adjusted in horizontal and vertical position relative to the axis of travel of the vehicle. Normally, the vehicle is
not located in a position exactly perpendicular to the control and also the measuring site may present surface
irregularities and / or a slope. This must be done for the left and right side of the vehicle.
On the basis of the determined values of both sides of the vehicle, the diagnosis system then calculates the
adjustments of the mirror for the alignment of the axis of travel.
Preparation Measure -
Before beginning the control and adjustment of the sensor / proximity radar must perform the following steps:
check the inflation pressure of the tires and, if necessary, correct it
place the vehicle on the measuring site so that it is possibly orthogonal to the strip on the floor. If the
deviation of the axis of travel of the vehicle with respect to the strip is greater than 5°, it is not possible to
base alignment
check that the distance between the sensor / radar proximity and the reflex mirror is 120 cm +/- 5 cm.
Fig 3: Cover
1. Disengage and remove the cover (1) for the sensor / proximity radar.
Fig 4: Tool On Right Rear Wheel
2. Fit the tool on the right rear wheel.

Fig 5: Adjusting Height Of Mask
3. Place the mask adjustable in the vicinity of the source of the laser beam as shown in illustration.
4. Turn on the laser beam and using the knob to adjust the height of the mask so that the laser beam
passes through the slit tighten the knob.
Fig 6: Laser Beam In Slot
5. Move the mask in the vicinity of the right front wheel as shown in the illustration and direct the laser
beam so that it passes through the slot.
Fig 7: Laser Beam In Bull's-Eye
6. Remove the mask, so that the laser beam on the mirror aligns with the strip.
7. The laser beam reflection of the mirror has to hit the bull's-eye mounted on the source of the laser
beam.
Fig 8: Horizontal Adjustment Knob & Graduated Plate
8. To achieve this goal you have to adjust the horizontal / vertical position of the reflecting mirror in the
following manner.
1. Horizontal adjustment: by moving the graduated plate (a) and locking knob (b).
Fig 9: Vertical Adjustment Thumbscrew
2. Vertical adjustment: through the thumbscrew

Fig 10: Graduated Scales (1 Of 2)
9. After adjustment of the mirror so that the laser beam is reflected on the target correctly, proceed to
the relief portion of the horizontal and vertical through the graduated scales shown below.
1. Relief horizontal dimension

Fig 11: Graduated Scales (2 Of 2)
2. Significant vertical dimension
10. Proceed similarly to the right side to make the relief of the horizontal and vertical portion of the left
side.
MIRROR ADJUSTMENT - Perform the arithmetic average of the horizontal and vertical dimensions on the
detected right and left side during alignment of the tool adjustment.
The mean value obtained from H horizontal dimensions and the value obtained by V vertical dimensions, should
be used to set the final position of the reflecting mirror.
Fig 12: Angle Adjustments Of Reflecting Mirror
ADJUSTING THE SENSOR / RADAR PROXIMITY - Connect the diagnostic tool to the control unit integrated
in the sensor / proximity radar and launch the procedure "active misalignment calibration radar".
The calibration procedure involves performing three measurements each time changing the angle of the
reflecting mirror. Acting on the tilting device of the reflecting mirror you get the required positions.
POSITION 1: mirror forward
POSITION 2: mirror in the middle (see illustration)
POSITION 3: mirror back

Fig 13: Vertical Adjustment
NOTE:
For vertical and horizontal radar, follow the directions given from the equipment of diagnosis.
SCREW POSITION 1: with a tool acting on the screw shown in the illustration for vertical adjustment.
Fig 14: Horizontal Adjustment
SCREW POSITION 2: with tool turn screw shown in the illustration for horizontal adjustment.
MODULE, ADAPTIVE CRUISE CONTROL > MODULE PROGRAMMING > MODULE

ALIGNMENT - NAFTA
A multimedia supplement to the instructions contained in this article

is available.
To view the multimedia example of the condition described go to;
http://www.youtube.com, search for "Mitchell1Videos"
then type, "A00735717.vid1" into the "Search Channel" box.
NOTE:
Special tool 2014000080 is available through a rental program. For additional details visit the
Mopar® Essential Tool website.
This procedure must be performed in the following cases:

Removing / installing the radar sensor
Warning light indicated the failure of the radar sensor proximity
Rear axle adjustments
Replacing wheel rims or tires with a larger or smaller diameter component
Removing / installing the front end.
Preparation Measure - The following steps must be performed before beginning the control and adjustment of
the sensor / proximity radar:
Check the inflation pressure of the tires and, if necessary, correct it.
Make sure the steering wheel is centered.
Check that there is at least 3 meters (10 feet) in front of the vehicle for space to setup the sensor.
The floor can have an angle of maximum inclination of 3° downhill or an uphill maximum inclination of 1°.
Fig 1: Unboxing Special Tool
1. Follow the instructions included in the special tool 2014000080 container for proper unboxing.
Fig 2: Plumb Bob, Tape Measure, Snap Line, Chalk Bottle & Laser
2. Verify the proper tools and components are in the shipping container. The following items are
included: plumb bob, tape measure, snap line, chalk bottle, and the laser for the mirror.
Fig 3: Assembling Special Tool
3. Assemble the alignment tool following the instructions included in the shipping container.
4. Once the tool is properly assembled, set it aside while performing the measurement procedure.
Fig 4: Marking Floor
5. Find the center of each wheel and with the plumb bob mark the floor for each wheel. The plumb bob
must be the same distance out from each wheel/tire.
Fig 5: Making Chalk Line
6. Use the chalk line to snap a line on both the left and right side of the vehicle along the marks made
with the plumb bob in the previous step. Extend the line that is snapped at least 3 meters (10 feet) in
front of the center of the front wheels. This will allow room to properly position the alignment tool.
Fig 6: Measuring Distance From Front Wheel
7. Once both side lines are extended, measure out about 3 meters (10 feet) from each front wheel mark
along the chalk line and mark the spot on the line.
Fig 7: Making Chalk Line Between Marks
8. Once both marks have been made, snap a chalk line between the two marks to create the front line
where the alignment tool will be placed.
Fig 8: Removing Trim Cover
9. Remove the trim cover for the alignment sensor.

Fig 9: Marking Floor
10. Find the horizontal center of the sensor and use the plumb bob to mark the location on the floor.
Fig 10: Measuring Distance From Mark
11. Measure a side chalk line to the sensor horizontal center mark. This will be the same length that the
center of the sensor tool will be placed on the front chalk line.
Fig 11: Positioning Tool
12. Position the sensor tool with the center lined up with the mark on the front line. Install the laser and
align the beam with the chalk line.
Fig 12: Leveling Tool
13. There are adjusters at the front and rear of the base of the sensor to level the tool.
Fig 13: Level
14. With the tilt cam in the 0 degree position, adjust the tool until the bubble is in the center of the level.
15. Measure from the horizontal mark on the floor to the vertical center of the sensor.
Fig 14: Setting Height Of Mirror
16. Set the height of the center of the mirror at the same height as the vertical center of the sensor.
Fig 15: Mirror In Position
17. Verify that the laser is still lined up with the front cha k line. Then make sure the bubble is still in the
middle of the level with the tilt cam in the 0 degree position.
18. Turn off the laser and remove it from the mirror.
19. Use the scan tool to perform the alignment procedure.
THE SENSOR / RADAR PROXIMITY - The calibration procedure involves performing three measurements,
each time changing the angle of the reflecting mirror. To adjust the angle, tilt the mirror forward and then turn the
tilt cam to the desired position.
POSITION 1: mirror forward (2 degrees forward)
POSITION 2: mirror in the middle (0 degrees)
POSITION 3: mirror back (2 degrees rearward)

Fig 16: Vertical Adjustment
NOTE:
For vertical and horizontal radar, follow the directions given from the equipment of diagnosis.
SCREW POSITION 1: with a tool acting on the screw shown in the illustration for vertical adjustment.
Fig 17: Horizontal Adjustment
SCREW POSITION 2: with tool turn screw shown in the illustration for horizontal adjustment.
MODULE, ANTI-LOCK BRAKE SYSTEM > REMOVAL AND INSTALLATION > REMOVAL AND
INSTALLATION
For the removal and installation of the ABS Module, refer to INTEGRATED CONTROL UNIT (ICU), REMOVAL
AND INSTALLATION .
MODULE, BODY CONTROL > DESCRIPTION AND OPERATION > DESCRIPTION AND
Fig 1: Body Control Module
The BCM, produced by Delphi, is an electronic control unit that manages and controls the following systems:
Exterior lighting
Internal lighting
Electric windows.
Door locking and unlocking
Tailgate locking/unlocking
Wipers and screen washer system
Fuel level gauge
Outside temperature
Immobilizer function
Brake fluid level
brake switch
Vehicle configuration
Diesel heater on Filter Relay Control.
Hazard warning lights control
Gateway functions between the high-speed (CAN-C1) and medium-speed (CAN-BH) CANs and LIN.
The BCM also constitutes an interconnection unit that ensures a protected supply for many electrical loads via
fuses
The BCM comprises two main boards:
the power board, which contains the fuses, internal relays and power connections;
the logic board which contains the microprocessor.
The Body Computer is positioned under the dashboard lining to the left of the steering wheel behind a plastic
cover which is removable for access to the fuses.
Fig 2: Body Control Module Fuse Identification
FUSE COMPONENT
F31 Flashing/Electric front seat movement/Climate control fan
F33 Front electric window (driver side)
Electric front window (passenger side)/Rear electric window control (driver side
F34
panel)/Wiper (1st and 2nd speed)
Alarm siren/Volumetric alarm sensor/Climate control/heating system/EMC

F36
Folding/RFHM/RRM/CSW/USB port/Voltage stabilizer/EOBD system/ESL
F37 Supply for Forward Collision Warning Plus system/All-wheel drive (AWD)/IPC
Safe Lock device (Driver side door unlocking for versions/markets, where
F38
provided)/Door unlocking/Central locking/Electric tailgate unlocking
F43 Windscreen/rear window washer pump
F47 Rear left electric window
F48 Rear right electric window
Supply for PAM/Front roof spot lights/Interior rear view mirror/Electric sun roof
F49
motor/Heated front seats/Stop/Start System/ESL/ Battery stabilizer/ESC system
F50 Airbags
Supply for LDW/CDU alarm/Rear roof light/Climate control compressor/Brake

F51 pedal switch (NC)/Automatic transmission panel/Compass/Rear
camera/Headlight alignment corrector/Climate control.
F53 IPC/Ignition device/Keyless Enter-N-Go system/ Brake switch (NO)
F54 Power socket
MODULE, BODY CONTROL > DESCRIPTION AND OPERATION > DESCRIPTION AND
The BCM manages the Logistic mode function. Some electrical loads are deactivated when the function is
active.
The Logistic mode can be deactivated using the diagnosis equipment (the command is in the "miscellaneous
functions" menu of the BCM). Alternatively, the function can be deactivated through a manual procedure. This
procedure is as follows:
Key to ON
Fig 1: Headlights Switch Off Position

The headlights must not be on: Headlights off.
Fig 2: Right Direction Indicator Position
Activate the right direction indicator.

Fig 3: Spot Light Position
Keep the lever in spot light position for approximately 10 seconds.
The configuration of the vehicle on those with Next-Generation architecture is called PROXY. PROXY consists
of a computer file with a maximum of 255 bytes. All modules requiring configuration will store a specific version
of the PROXY file. All other modules store only the part of the file pertaining to that module.
The BCM uses the PROXY file to perform a vehicle configuration check when the ignition key is turned to the
ON position. The BCM sends a PROXY configuration code to PROXY configured modules on all the networks.
PROXY configured modules will reply with their own configuration code. The BCM then compares the codes. If
a code mismatch is detected, the BCM will set a diagnostic trouble code (DTC). If the DTC is present for three
ignition cycles, the BCM sends a message to the IPC to flash the odometer.
The following diagnosis functions are in the "Miscellaneous Functions" menu of the BCM:
1. Restore Proxy configuration
2. Proxy alignment
Restoring the Proxy configuration allows you to rewrite, via wiTECH connected to the web, the proxy in the
BCM.
Proxy alignment allows the BCM to send the appropriate part of the Proxy to each individual module. For
example if the ORC (airbag) module is replaced during servicing, it needs to receive the airbag Proxy
information from the BCM in order to configure itself. The BCM extracts the part relating to the airbag module
from the Proxy and sends it to the latter in a file.
The Proxy alignment must always be carried out after running "restore vehicle configuration".
MODULE, BODY CONTROL > REMOVAL AND INSTALLATION > LEFT HAND DRIVE >
REMOVAL
2. Remove the steering column opening cover. Refer to COVER, STEERING COLUMN OPENING,
Fig 1: Body Control Module Brackets, Connector, Nut & Screws
3. Remove the connector (1a), remove the screws (1b), nut (1c) and remove the brackets (1d) from the
Body Control Module (BCM).
Fig 2: Body Control Module Connectors
4. Disconnect the electrical connectors (1).

Fig 3: Body Control Module, Bracket, Pin & Retainers
5. Using a suitable tool, release the retainer (1a) and then release the pin (1b) from the bracket (1).
6. Turn the BCM (2a), release the retainers (2b) and move the body computer.
Fig 4: Back Of Body Control Module Connectors
7. Disconnect the electrical connections (1) from the back of the BCM.
8. Remove the BCM from the vehicle.
MODULE, BODY CONTROL > REMOVAL AND INSTALLATION > LEFT HAND DRIVE >
INSTALLATION
1. Connect the wire harness connectors to the back of the Body Control Module (BCM).
2. Position and secure the BCM to the BCM mounting bracket.

3. Connect the electrical connectors to the front of the BCM.

Fig 3: Body Control Module Brackets, Connector, Nut & Screws
4. Position and secure the BCM brackets.
5. Install the steering column opening cover. Refer to COVER, STEERING COLUMN OPENING,
MODULE, BODY CONTROL > REMOVAL AND INSTALLATION > RIGHT HAND DRIVE >
REMOVAL

Fig 1: Side Trim, Retainers & Screws
2. Pry up the retainers (1a) with a suitable tool, remove the side trim (1b) and remove the screw (1c).
3. Remove the lower screws (2).

Fig 2: Glove Compartment & Screws
4. Open the glove compartment (1a) and remove the upper screws (1b).
Fig 3: Glove Box Assembly & Retainers
5. Remove the glove box assembly (1a) from the dashboard by releasing the retainers (1b).
Fig 4: BCM Electrical Connections
6. Disconnect the BCM electrical connections (1).
7. Remove the connector (1a), remove the screws (1b), nut (1c) and remove the brackets (1d) from the
8. Disconnect the electrical connectors (1).

Fig 6: Body Control Module, Bracket, Pin & Retainers
9. Using a suitable tool, release the retainer (1a) and then release the pin (1b) from the bracket (1c).
10. Turn the BCM (2a), release the retainers (2b) and move the BCM to access the rear connectors.
11. Disconnect the BCM electrical connections (1) from the back of the BCM (2).
12. Remove the BCM from the vehicle.
MODULE, BODY CONTROL > REMOVAL AND INSTALLATION > RIGHT HAND DRIVE >
INSTALLATION
1. Connect the electrical connections on the rear side of the assembly.
2. Place the Body Control Module (BCM) assembly in its housing and secure the retainers to the
bracket.
3. Connect the electrical connections on the front side of the assembly.
4. Fit the glovebox in its housing, engaging the retainers.

5. Tighten the glove box compartments internal and lower screws.
6. Tighten the side screw and reposition the trim in its housing, engaging the retainers.
7. Connect the negative battery terminal.
8. Perform BCM programming. Refer to MODULE, BODY CONTROL, MODULE PROGRAMMING .
MODULE, BODY CONTROL > MODULE PROGRAMMING > PROGRAMMING
NOTE:
During the Body Control Module (BCM) replacement procedure the original VIN and electronic
code (key code) will be needed.
NOTE:
In some cases the vehicle may exhibit a start and stall condition after the BCM is replaced. If this
occurs the key learn procedure may need to be ran and all keys relearned. Make sure that all
keys are present if key relearn is required; keys not present will be locked out.
NOTE:
Customer keys that are not present at the dealer after the BCM was replaced may not have RKE
functionality until the customer turns the key in the ignition.
When replacing any module not the replacement and programming order. For more information see the
MODULE REPLACEMENT AND PROGRAMMING ORDER GUIDE . Refer to STANDARD PROCEDURE .
1. Ensure that the ignition is in and remains in the RUN position while performing this procedure
2. Select the BCM module from the "Vehicle View" screen
3. Select the Misc. Functions tab with the "BCM View" menu options
4. Select the BCM Replaced routine and click the start button
5. Follow the prompts on the screen to complete the procedure.
MODULE, BODY CONTROL > MODULE PROGRAMMING > PROGRAMMING KEYS TO THE
BCM
NOTE:
All customer keys, including any previously programmed and replacement keys, must be
learned during this procedure.
The Body Control Module (BCM) may be programmed to recognize up to a total of eight key
fobs. When replacing or adding a key fob, the replacement/additional key fob must be
ordered through your parts department by VIN. The new key will arrive within 24 hours cut to
match the door lock cylinder in the vehicle for which it will be used. Once the new key fob
arrives, the BCM must be programmed to recognize it as a valid key fob.
If any previously programmed keys are not re-programmed during this procedure, they will
be permanently disabled.
The entire key procedure will require the key to be in the OFF position and with the hazard
lights turned on.
If the wrong key code is entered three times in a row it will lock out the BCM for a period of
24 hours.
Do NOT at any point during the procedure hit the CLOSE button, always hit CONTINUE until
procedure says it is completed successfully and it is now safe to turn off hazards. Hitting the
CLOSE button will cause the routine to end without learning the key.
1. Obtain security pin for the vehicle.
2. Insert a key (already programmed if possible) into the ignition to start the process.
3. Turn the ignition to the run position and connect to the vehicle using the scan tool.
4. Select "BCM" from the topology view and then the "MISC" tab.
5. The hazard lamps must be on during programming.
6. Select "Erase and Program Keys", then click "continue".
7. Turn key to off position as instructed in procedure. Follow routine, remove the key from the ignition as
instructed to program additional keys, wait 10 seconds between adding keys. Continue following tool
prompts to complete.
NOTE:
Do NOT at any point during the procedure hit the CLOSE button, always hit CONTINUE
until procedure says it is completed successfully and it is now safe to turn off hazards.
Hitting the CLOSE button will cause the routine to end without learning the key.
NOTE:
If at any point the customer needs a BCM replacement. The keys should be already programmed
to the BCM. If the vehicle exhibits a start and stall situation after the BCM is replaced the keys may
need to be reprogrammed using the program ignition keys procedure in the scan tool.
MODULE, COMFORT SEAT AND WHEEL > DESCRIPTION AND OPERATION >
Fig 1: Comfort Seat And Wheel Module
The Comfort Seat and Wheel Module (CSWM) (also known as the Heated Seat Module) is located under the
passenger front seat. It has a minimum of 2 electrical connectors and a maximum of 4 electrical connections.
and a push pin style retainer that secures it to the seat pan. The module can be accessed from under the
passenger seat with the seat in the full back and up position.
The CSWM is a CAN-IHS bus microcontroller providing outputs to the heated seat pads, heated steering wheel,
and ventilating up to two seats. The CSWM receives commands over the CAN IHS BUS from the BCM. The
seat thermistor is hard wired to the CSWM.
Heated Seats - The CSWM uses a Pulse Width Modulation (PWM) to provide power to the seat cushion and
back heating elements. The temperature sensor thermistor is located in the seat cushion. The thermistor
sensor feedbacks from each seat heating element to the CSWM to regulate the heater outputs to prevent any
seat temperature to rise above set points. Seat heating has two selectable heat settings which are HI and LO.
Depending on thermistor reading, the CSWM will start the heater output by adjusting the PWM heat level
according to the calibration table.
Heated Steering Wheel - The CSWM provides power to the steering wheel heating element. The heated
steering wheel is standard when the vehicle is equipped with front heated seats. During normal operation, the
CSWM will switch on the power for the heated wheel only if the engine is running. The heated steering wheel
temperature sensor is hardwired to the EVIC (switch) which sends that information over a LIN Bus through the
clockspring/SCCM to the BCM. The thermistor sensor feedbacks from the steering wheel heating element via
the CAN Internal High Speed (IHS) bus to the CSWM regulating the heater output to prevent the wheel
temperature to rise above the maximum threshold temperature set point.
MODULE, COMFORT SEAT AND WHEEL > DESCRIPTION AND OPERATION >
The Comfort Seat Wheel Module (CSWM) operates on fused battery current received from the ignition switch.
The module is grounded to the body at all times through the electrical connector. Inputs to the module include
CAN Internal High Speed (IHS) bus data bus messages and standard hardwired 12 volt power and ground. In
response to inputs, the CSWM will control the battery current to the appropriate heated seat elements.
When a heated seat switch IHS data bus signal is received by the CWSM, the module energizes the selected
heated seat element. The Low heat set point is about 38° C (100.4° F), and the High heat set point is about 42°
C (107.6° F).
The CSWM will automatically transition the output from high to low after a maximum period of 60 minutes has
elapsed. The CSWM will automatically transition the output from low to off after a maximum period of 45
minutes has elapsed.
In addition to operating the heated seat elements, the heated seat module sends LED illumination messages to
the instrument cluster (IC). The IC then sends the LED illumination message to the Integrated Center Stack
(ICS) so that the appropriate LEDs are illuminated for any given heating level. Pressing the switch once will
select high-level heating. Pressing the switch a second time will select low-level heating. Pressing the switch a
third time will shut the heating elements off.
If the CSWM detects a heated seat element OPEN or SHORT circuit, it will record and store the appropriate
Diagnostic Trouble Code (DTC).
Driver Seat Heat Systems
The element consists of a cushion element connected in parallel with a back element.
The seat cushion has a thermistor to provide feedback to the CSWM.
The seat cushion and seat back has a thermostat to automatically open the feed to the heated seat
system.
The heated seat cushion and seat back have a thermostat to automatically open the feed to turn the
heated seat system off if the temperature reaches or exceeds the operating parameters programmed to
the CSWM.
The CSWM is diagnosed using a scan tool. If the module detects a heated seat element OPEN or SHORT
circuit, the system will turn off and it will record and store the appropriate diagnostic trouble code (DTC). Refer
to DIAGNOSIS AND TESTING .
MODULE, COMFORT SEAT AND WHEEL > REMOVAL AND INSTALLATION > REMOVAL
AND INSTALLATION > REMOVAL

Fig 1: Comfort Seat And Wheel Module, Tie Strap, Tabs & Connectors
2. Disconnect the electrical connections (1).
3. Cut the tie (2a) and release the Comfort Seat and Wheel Module (CSWM) from retaining tabs (2b)
that secure it to the base of the seat (2c).
4. Remove the CSWM (3).
MODULE, COMFORT SEAT AND WHEEL > REMOVAL AND INSTALLATION > REMOVAL
AND INSTALLATION > INSTALLATION
1. Position the CSWM and secure it to the retainers and with a clamp at the base of the seat.
2. Connect the electrical connections.
MODULE, DRIVETRAIN CONTROL > REMOVAL AND INSTALLATION > REMOVAL AND
NOTE:
When replacing the DTCM, use the diagnostic scan tool to go to the menu "various functions" and
follow the steps for the "replacement unit" routine.
2. Using a trim stick or equivalent, remove the instrument panel side cover.
3. Lower the silencer panel.

Fig 1: Retainer

4. Remove the retainer (1) and position the reposition the side floor cover.
Fig 2: Protection Cover
5. Remove the protection cover (1).

Fig 3: Cover, Cable End & Nuts
6. Remove the nut remove the cable end (1).
7. Remove the nuts and remove the module with cover (2).
MODULE, DRIVETRAIN CONTROL > REMOVAL AND INSTALLATION > REMOVAL AND
1. Position the module with cover into place and tighten the nuts.
2. Connect the ground cable.
3. Install the protective cover.
4. Reposition and secure the side floor cover into the installed position.
5. Secure the silencer panel.
6. Install the instrument panel side cover.
8. Using the diagnostic scan tool, perform the "replacement unit" routine in the misc functions menu of
the DTCM.
MODULE, ELECTRIC POWER STEERING > DESCRIPTION AND OPERATION >
DESCRIPTION AND OPERATION
For the description and operation of the electric power steering module, refer to COLUMN, DESCRIPTION AND
OPERATION .
MODULE, ELECTRONIC STEERING LOCK (ESL) > REMOVAL AND INSTALLATION >
REMOVAL AND INSTALLATION > REMOVAL
1. Remove the steering column shroud. Refer to SHROUD, STEERING COLUMN, REMOVAL AND
INSTALLATION .
Fig 1: Electronic Steering Lock Module, Headless Screws & Connectors
2. Disconnect the steering column stalk electrical connection (1) and move the wiring aside.
3. Use a hammer and chisel to remove the headless screws (2a) and extract the electronic steering lock
module (2b) from its housing.
Fig 2: Electronic Steering Lock Module & Connector
4. Disconnect the electrical connection (1a) and keep the electronic steering lock module (1b).
MODULE, ELECTRONIC STEERING LOCK (ESL) > REMOVAL AND INSTALLATION >
REMOVAL AND INSTALLATION > INSTALLATION
1. Check that the electronic steering lock module is not damaged.
2. Connect the electrical connection.

3. Place the electronic steering lock module in its housing and tighten the new special screws until the
head shears off.
4. Connect the steering column stalk electrical connection and reposition the wiring.
5. Install the steering column shroud. Refer to SHROUD, STEERING COLUMN, REMOVAL AND
INSTALLATION .
7. Perform module programming as needed. For further information, refer to MODULE, ELECTRONIC
STEERING LOCK (ESL), MODULE PROGRAMMING .
MODULE, ELECTRONIC STEERING LOCK (ESL) > MODULE PROGRAMMING > ESL
PROGRAMMING
If the Electronic Steering Lock (ESL) module is replaced:
1. Connect the diagnostic scan tool to the vehicle.
2. Navigate to the Body Control Module (BCM) in the "Misc Functions" menu.
3. Start the "Secret key transfer to ECM/ESL" routine.
MODULE, FORWARD FACING CAMERA > DESCRIPTION AND OPERATION >

Fig 1: Forward Facing Camera
The Forward Facing Camera (FFC) module is a stand-alone monocular camera mounted to the inside interior of
the front windshield, within the Combined Rear View Mirror Module (CRVMM) housing, that captures and
processes video images. The camera will perform the following functions on this model:
Automatic High Beam Control (AHBC) - Based on ambient situations, the AHBC feature will control the
vehicle high-beam headlights automatically, relieving the driver of the manual operation of the high beam
headlights. The AHBC feature automatically turns off the high beams when there is oncoming traffic,
preceding traffic, presence of a village, high ambient lighting due to a town or twilight/dusk, when the
vehicle driving speed too low, delay and fog.
Object detection for supporting data fusion (ACC+) - The camera provides additional object, lane and
environmental conditions for data fusion. The FFC will also perform redundancy checks with the ACC
radar to verify accurate detection.
Lane Departure Warning (LDW+) - LDW+ utilizes camera-based machine vision sensor to detect and
measure vehicle position within lane boundaries (when enabled). The system can be turned on or off with
a single hard button on the Auxiliary Switch Bank Module (ASBM). The driver can configure the torque
feedback amount and warning zone start point through the personalization settings in the radio. Three
settings for each are provided.
Forward Collision Warning Plus (FCW+) - The FFC in conjunction with the radar sensor is used to
detect whether the vehicle is approaching another vehicle or large obstacle in its path too rapidly and will
warn/assist the driver in avoiding/mitigating the incident (when enabled). The driver has the ability to
adjust the sensitivity and turn brake support on or off in the radio.
The camera and bracket are not adjustable or repairable and must be replaced if inoperable or damaged.
MODULE, FORWARD FACING CAMERA > REMOVAL AND INSTALLATION > REMOVAL
1. Disconnect and isolate the negative battery cable. If equipped with an Intelligent Battery Sensor
(IBS), disconnect the IBS connector first before disconnecting the negative battery cable.
2. Separate the rear view mirror trim covers to gain access to the Forward Facing Camera (FFC). Refer
to MIRROR, REARVIEW, REMOVAL AND INSTALLATION .
Fig 1: Forward Facing Camera & Connector
3. Disconnect the electrical connector (1a) from the FFC (2a).
4. The FFC is attached to a bracket in a hook and rotate fashion. Rotate the FFC downwards while
disengaging the bracket's hooks to release from the bracket. It is easier to remove the FFC from the
passenger seat.
MODULE, FORWARD FACING CAMERA > REMOVAL AND INSTALLATION > REMOVAL
NOTE:
Ensure that both inside and outside of the windshield in the area of the Forward Facing Camera
(FFC) is clean of dirt, dust, or finger prints prior to installation.
1. Install the FFC to the bracket on the windshield. Position the FFC to the bracket attachment point
making sure that the alignment tabs are proper and set the FFC in place until the bracket locks
engage.
2. Connect the electrical connector to the back of the FFC.
3. Assemble the rear view mirror covers into place. Refer to MIRROR, REARVIEW, REMOVAL AND
INSTALLATION .
MODULE, FORWARD FACING CAMERA > MODULE PROGRAMMING > LDW+

CALIBRATION PROCEDURE
Fig 1: Forward Facing Camera Calibration Procedure
NOTE:
The following procedure explains how to calibrate the Forward Facing Camera (FFC) when
replacing the FFC (a replacement FFC is not factory calibrated). This procedure should also be
used when the windshield is replaced.
Perform the following checks and setup prior to performing the calibration procedure:
Confirm that the vehicle is unloaded (no luggage or extra weight being carried).
Check and correct the tire pressures as needed.
Check that the windshield is free of damage, is clean and that there are no impediments to the vision of
the FFC.
Place the vehicle on level ground and in good light.
Align the wheels to the longitudinal axis of the car.
Place the tool (1a) on a suitable support (1b), at a height from the ground (1c) of 90 cm and the distance
(1d) of 170 cm from the FFC.
NOTE:
The calibration procedure is performed by placing the equipment to two different distances from
the FFC. The diagnostic scan tool will warn when changing its position.
NOTE:
The equipment must be positioned perpendicular to the longitudinal axis of the car.
NOTE:
Small variations compared to the dimensions will prevent FFC calibration.
NOTE:
It is critical to not alter the position of he equipment between the two phases of the calibration
procedure. If possible, proceed with the handling of the vehicle itself and not the equipment. If this
is not possible, be very careful when moving the equipment to not alter the angle of the panel with
respect to the vehicle. Small variations compared to the dimensions will prevent FFC calibration.
CALIBRATION PROCEDURE
1. Connect the diagnostic scan tool and start the car. The system must not be activated.
2. Start the calibration function through the diagnostic scan tool.
3. At the end of the first phase of the calibration routine, the diagnostic tool will alert you to change the
location of the equipment.
4. Position the equipment at a distance of 270 cm from the FFC.
5. Proceed with the second phase of the calibration following the instructions on the diagnostic scan
tool.
6. The diagnosis scan tool will display a message indicating the end of the calibration procedure has
been reached. In case of calibration failure the diagnostic tool will also indicate the causes.
7. Disconnect the diagnostic scan tool and run a cycle key.
NOTE:
If during operation, the LDW+ system releases alerts inconsistent with the actual driving conditions
(eg: car properly between lanes but notice the crossing lane), the system must be calibrated
again.
MODULE, HVAC > REMOVAL AND INSTALLATION > REMOVAL AND INSTALLATION >
REMOVAL
WARNING:
Restraint System (SRS) before attempting any steering wheel, steering column, airbags, airbag
curtains, knee blocker, seat belt tensioner, impact sensor or instrument panel component
diagnosis or service. Refer to WARNING . Disconnect the IBS/negative battery cable assembly
from the negative battery post, then wait two minutes for the system capacitor to discharge before
performing further diagnosis or service. This is the only sure way to disable the SRS. Failure to
take the proper precautions could result in accidental airbag deployment.
NOTE:
Automatic A/C heater control shown in illustration, manual A/C heater control similar.
2. Remove the radio. Refer to RADIO, REMOVAL AND INSTALLATION .

Fig 1: A/C Heater Control, Retaining Clips & Connector
3. Reaching through the radio compartment to access the A/C heater control retaining clips (1a),
disengage the four retainers (1a) while pulling the A/C heater control (1b) away from the instrument
panel.
4. Disconnect the HVAC wire harness connector (2) from the A/C heater control (1b) and remove the
A/C heater control.
MODULE, HVAC > REMOVAL AND INSTALLATION > REMOVAL AND INSTALLATION >
INSTALLATION
NOTE:
Automatic A/C heater control shown in illustration, manual A/C heater control similar.
1. Position the A/C heater control (1b) to the instrument panel and connect the HVAC wire harness
connector (2).
2. Align the four retainers (1a) of the A/C heater control (1b) with the instrument panel and press into
place. Be certain all four retainers (1a) are fully engaged with the instrument panel.
3. Install the radio. Refer to RADIO, REMOVAL AND INSTALLATION .
4. Connect the negative battery cable. If equipped with an Intelligent Battery Sensor (IBS), connect the
IBS connector.
5. Initiate the Actuator Calibration function using a scan tool. Refer to STANDARD PROCEDURE .
NOTE:
MODULE, INSTRUMENT PANEL CLUSTER > DESCRIPTION AND OPERATION >

Fig 1: Instrument Panel Cluster (IPC)
The Instrument Panel Cluster (IPC) for this vehicle is located in the instrument panel above the steering column
opening. The IPC gauges and indicators are visible through an opening in the cluster bezel and are protected
by a clear plastic cluster lens that is secured to the cluster housing by integral latch formations.
The molded plastic cluster housing encloses and protects the perimeter of the IPC unit. The cluster housing
serves as the carrier for the instrument cluster circuitry, the gauge set, the indicators, an electronic display unit
as well as an audible tone transducer. Each of the cluster hard indicators as well as the general cluster
illumination is provided by dedicated Light Emitting Diode (LED) units soldered to the cluster electronic circuit
board. A molded plastic rear cover includes clearance holes for the connector receptacle and is secured to the
cluster housing by screws. The connector receptacle on the back of the IPC electronic circuit board connects
the unit to the electrical system of the vehicle through a dedicated take out and connector of the instrument
panel wire harness.
Just behind the cluster lens is the molded plastic cluster mask. The mask serves to separate and define the
layout of the various visible areas of the IPC and also trims the cluster overlay. The mask lays over the cluster
overlay, which is a laminated plastic unit. The dark, visible, outer surface of the overlay is marked with all of the
gauge dial faces and graduations, but this layer is also translucent. The darkness of this outer layer prevents
the cluster from appearing cluttered or busy by concealing the hard indicators that are not illuminated, while the
translucence of this layer allows those hard indicators that are illuminated to be readily visible. The underlying
layer of the overlay is opaque and allows light from the hard indicator LED units to be visible through the outer
layer of the overlay through predetermined stencil-like cutouts. The defined areas of the IPC are:
Tachometer (1)
- This is the analog tachometer scale.
Temperature Gauge (2)
- This is the analog temperature scale.
Electronic Display Unit (3)
- This is the electronic display unit. It includes an odometer display, several trip computer functions, a
message center, numerous predetermined soft indicators and several reconfigurable display options.
Fuel Level Gauge (4)
- This is the analog fuel level scale.
Speedometer (5)
- This is the analog speedometer scale.
Several versions of the IPC are offered on this vehicle. These versions accommodate all of the variations of
optional equipment and regulatory requirements for the various markets in which the vehicle is offered. The
microcontroller-based IPC utilizes integrated circuitry and information carried on the Controller Area Network
(CAN) data bus along with several hard wired inputs to monitor other sensors and switches in the vehicle. In
response to those inputs, the internal circuitry and programming of the IPC allow it to monitor many electronic
functions and features of the vehicle.
The IPC is mounted behind the steering wheel, is connected to the CAN and includes four gauges:
Tachometer (1)
- This is the electronic display unit. It includes an odometer display, several trip computer functions, a
message center, numerous predetermined soft indicators and several reconfigurable display options.
Speedometer (5)
At the center is a large display (available in two different versions and is reconfigurable), the Electronic Vehicle
Information Center (EVIC). In the various information positions are located numerous warning lights, described
in the service information of the functions to which they relate.
The IPC receives and manages the messages coming from the compass module and the humidity sensor (if
present) via the LIN line.
The BCM directly controls the door closing red flashing LED, located in the instrument panel.
For the versions in which the "SERVICE" menu is present, a dedicated menu for resetting the SERVICE will be
available in the IPC module diagnosis. The "SERVICE" resetting procedure must be carried out via diagnosis
equipment.
For versions in which the pre-delivery mileage RESET function is present, when the vehicle is new or with less
than 200 km (124 miles) the display shows the letter "H" before mileage. As long as mileage is below 200 km
(124 miles) and the "H" is displayed this can be reset, since it is considered as pre-delivery movement.
Resetting of pre-delivery mileage is carried out through diagnosis equipment in the IPC module diagnosis.
Within the IPC is placed a chime with the ability to manage reports of different intensity, in order to fulfill the
many functions (described in the diagrams of the functions to which they relate).
The IPC is a module of the CAN through which it exchanges information with the Body Control Module (BCM)
and other electronic control units, in detail:
- Speedometer: the function is to display on the dashboard of the car speed: this information comes from
the Antilock Brake System (ABS) control unit and Powertrain Control Module (PCM), using the BCM
- Engine RPM: the function is to display on the IPC the rotational speed of the engine by means of the
message sent via the CAN by the PCM
- Odometer: function provides for the display and storage of total and partial information that are
processed by the BCM through a counter that is transmitted via the CAN to the IPC
- Fuel level: the BCM receives the signal from the sensor built into the fuel pump inside the tank and
processes it to ensure an appropriate filtering / damping to the indicator of the IPC and also controls the
lighting of the "reserve" lamp
The IPC indicator circuit is able to detect any anomaly in the wiring or the sensor and provide an appropriate
indication to the IPC:
- Fuel level: in case of system malfunction, the index is placed at the beginning of scale and the light of
the "reserve" flashes.
- Engine coolant temperature: the function is to display on the IPC the coolant temperature and the
indicator light will light of excessive engine temperature by means of messages sent via the CAN by the
PCM. The temperature reading is always guaranteed, even in extreme conditions of operation.
- Low engine oil pressure: the function includes the lighting on the IPC of minimum engine oil pressure
warning light through a message sent via CAN by the PCM.
- Park Brake: the BCM acquires the status of the parking brake from the switch and communicates
specific activation to the IPC through the CAN, the function includes the lighting on the IPC of the "brake
fluid level too low" warning light; also, if this signal is associated to pass a certain threshold of speed, an
acoustic signal is activated.
- Insufficient brake fluid: the function includes the lighting on the IPC of the "brake fluid level too low"
warning light. The signal is sent via the CAN by the BCM.
The IPC gauges, indicators, LED units, control switches as well as the electronic display unit are all integral
components of the IPC and its electronic circuit board. If any part of the IPC is damaged or ineffective, the
entire IPC assembly must be replaced.
MODULE, INSTRUMENT PANEL CLUSTER > DESCRIPTION AND OPERATION >

The IPC has the hardware and software to simultaneously monitor multiple inputs. The microcontroller-based
IPC uses these inputs to control the gauges and indicators visible on the face of the cluster, and to display the
appropriate information in the electronic display unit to allow the vehicle operator to monitor the conditions of
many of the vehicle components and operating systems. The IPC display provides valuable information about
the various standard and optional powertrains, fuel and emissions systems, cooling systems, lighting systems,
safety systems and many other convenience items. The IPC is installed in the instrument panel so that all of
these monitors can be easily viewed by the vehicle operator when driving, while still allowing relative ease of
access for service.
Some of the IPC inputs are hard wired, but most are in the form of electronic messages that are transmitted by
other electronic modules over the Controller Area Network (CAN) data bus. The IPC microcontroller smooths
the input data using algorithms to provide gauge readings that are accurate, stable and responsive to operating
conditions. These algorithms are designed to provide gauge readings during normal operation that are
consistent with customer expectations. However, when abnormal conditions exist such as high coolant
temperature, the algorithm can provide an extreme output and the microcontroller can sound a chime through
the on-board audible tone transducer to provide distinct visual and audible indications of a problem to the
vehicle operator. The IPC may also produce audible warnings for other electronic modules in the vehicle based
upon electronic tone request messages received over the CAN data bus. Each audible warning is intended to
provide the vehicle operator with an audible alert to supplement a visual indication.
The Body Control Module (BCM) stores and compares vehicle configuration data with the IPC as well as with
other Electronic Control Units (ECU) in the vehicle. This process is referred to as PRogramming Of
Configuration of Systems Integrated (PROCSI) (also known as PROXI). If a configuration mismatch is
detected, the BCM sets a DTC. A configuration mismatch DTC will require the performance of a Restore BCM
PROXI Configuration routine, or a PROXI Configuration Alignment routine using a diagnostic scan tool.
The IPC circuitry operates on battery current received through a fused B(+) fuse on a non-switched fused B(+)
circuit. This arrangement allows the IPC to remain functional regardless of the status of the ignition switch. The
IPC circuitry is grounded through a ground circuit and take out of the instrument panel wire harness with an
eyelet terminal connector that is secured by a ground screw to a ground location on the instrument panel
structural support.
The hard wired circuits between components related to the IPC may be diagnosed using conventional
diagnostic tools and procedures. Refer to the appropriate wiring information. The wiring information includes
wiring diagrams, proper wire and connector repair procedures, details of wire harness routing and retention,
connector pin out information and location views for the various wire harness connectors, splices and grounds.
However, conventional diagnostic methods will not prove conclusive in the diagnosis of the IPC or the
electronic controls or communication between modules and other devices that provide some features of the
IPC. The most reliable, efficient and accurate means to diagnose the IPC or the electronic controls and
communication related to IPC operation requires the use of a diagnostic scan tool. Refer to the appropriate
MODULE, INSTRUMENT PANEL CLUSTER > REMOVAL AND INSTALLATION > REMOVAL
WARNING:
Fig 1: Steering Column Shroud Gap Hider & Fasteners
2. Lower the steering column to the downward most position.
3. Telescope the steering column to its extended most position.
4. Remove the instrument cluster bezel from the instrument panel. Refer to BEZEL, INSTRUMENT
CLUSTER, REMOVAL AND INSTALLATION .
5. Remove the two fasteners (1a) from the steering column shroud gap hider (1c) and remove the gap
hider from the vehicle.
Fig 2: Instrument Panel Cluster, Wiring Harness Connector & Fasteners
6. Remove the four fasteners (1a) that secure the instrument panel cluster (1b) to the instrument panel.
7. Disconnect the instrument panel wiring harness connector (2a) from the receptacle on the back of the
instrument panel cluster (2b).
8. Remove the instrument panel cluster (2b) from the instrument panel.
MODULE, INSTRUMENT PANEL CLUSTER > REMOVAL AND INSTALLATION > REMOVAL
WARNING:
NOTE:
Make sure that the steering column remains in the lowest position setting.
2. Position the instrument cluster close enough to the instrument panel to access and connect the
instrument panel wire harness connector (2a) to the receptacle on the back of the cluster housing.
3. Install and securely tighten the four screws (1a) that secure the instrument panel cluster to the
instrument panel.
4. Position the steering column shroud gap hider (1c) to the instrument panel and install the two
fasteners (1a). Be certain the retaining clips (1b) are fully engaged with the instrument panel.
5. Install the instrument cluster bezel onto the instrument panel. Refer to BEZEL, INSTRUMENT
IBS connector.
NOTE:
If this Electronic Control Unit (ECU) is being replaced with a new unit, a diagnostic scan
tool MUST be used to align the PROXI Configuration data into the new ECU. Follow the
routine outlined in the diagnostic scan tool for PROXI Configuration Alignment under
Miscellaneous Functions for the ECU menu item. Refer to MODULE, INSTRUMENT
PANEL CLUSTER, MODULE PROGRAMMING .
MODULE, INSTRUMENT PANEL CLUSTER > MODULE PROGRAMMING > PROGRAM THE
IPC (INSTRUMENT PANEL CLUSTER)
1. Connect the scan tool.
2. Check vehicle for DTC's.
3. Clear all stored DTC's.
4. Turn car OFF then ON and confirm DTC's are gone.
5. From the Vehicle View, Click on the IPC icon >> Misc. Functions >> Proxi Configuration
If required, continue to programming the next module.
MODULE, OCCUPANT RESTRAINT > DESCRIPTION AND OPERATION > DESCRIPTION

AND OPERATION > DESCRIPTION
Fig 1: Occupant Restraint Controller Module
The Occupant Restraint Controller (ORC) module, located on the floor tunnel under the instrument panel center
console, monitors the impact and occupant sensors and activates restraint system devices in the event of an
impact. The ORC also contains impact sensors that are used to determine the level of deployment and to verify
the information received from the remote sensors.
An arrow printed on the ORC label indicates the installation orientation. The arrow must point toward the front
of the vehicle. The ORC must be installed correctly for correct restraint system operation.
The ORC module will set a specific DTC which cannot be deleted, not even using the diagnostic tool. This will
happen when you reach:
3 activations of the pretensioners, EMEA only
2 activations of the pretensioners, NAFTA only
3 activations of the side airbags, EMEA only
2 activations of the side airbags, NAFTA only
1 activation of the pretensioners plus the front airbags; all versions
Any other combination of the above mentioned cases until one of the limits is reached
When one of the above mentioned limits is reached, the ORC module will have to be replaced.
In EMEA versions the front passenger airbag can be deactivated via the vehicle menu. A dedicated LED
indicates its deactivation.
Fig 2: Warning Indicators
The yaw or lateral acceleration sensor is installed inside the ORC module and is used for the correct operation
of the vehicle dynamic stability functions.
The impact sensor and safing sensor internal to the ORC are calibrated for the specific vehicle, and are only
serviced as a unit with the ORC. In addition, there are unique versions of the ORC for vehicles with or without
certain optional Supplemental Restraint System (SRS) components. The ORC cannot be repaired or adjusted
and, if damaged or ineffective, it must be replaced.
MODULE, OCCUPANT RESTRAINT > DESCRIPTION AND OPERATION > DESCRIPTION

AND OPERATION > OPERATION
The microcontroller within the ORC contains the SRS logic circuits and controls all of the SRS components.
The ORC uses On-Board Diagnostics (OBD) and can communicate with other electronic modules in the vehicle
as well as with the diagnostic scan tool using the Controller Area Network (CAN) data bus. This method of
communication is used for control of the airbag indicator in the Instrument Panel Cluster (IPC) and for SRS
diagnosis and testing through the 16-way data link connector located on the driver side lower edge of the
instrument panel.
The ORC microcontroller continuously monitors all of the SRS electrical circuits to determine the system
readiness. If the ORC detects a monitored system fault, it sets an active and stored Diagnostic Trouble Code
(DTC) and sends electronic messages to the IPC over the CAN data bus to turn On the airbag indicator. An
active fault only remains for the duration of the fault, or in some cases for the duration of the current ignition
cycle, while a stored fault causes a DTC to be stored in memory by the ORC. For some DTCs, if a fault does
not recur for a number of ignition cycles, the ORC will automatically erase the stored DTC. For other internal
faults, the stored DTC is latched forever.
The ORC receives battery current through two circuits; a fused ignition output (run) circuit through a fuse in the
Body Control Module (BCM) and a fused ignition output (run-start) circuit through a second fuse in the BCM.
The ORC receives ground through a ground circuit and take out of the instrument panel wire harness that is
secured by a nut to a weld stud on the floor panel transmission tunnel. These connections allow the ORC to be
operational whenever the status of the ignition is Start or On.
The ORC also contains an energy-storage capacitor. When the status of the ignition is Start or On this
capacitor is continually being charged with enough electrical energy to deploy the SRS components for up to
one second following a battery disconnect or failure. The purpose of the capacitor is to provide backup SRS
protection in case there is a loss of battery current supply to the ORC during an impact.
Various sensors within the ORC are continuously monitored by the ORC logic. These internal sensors, along
with several external impact sensor inputs allow the ORC to determine both the severity of an impact and to
verify the necessity for deployment of any SRS components. In vehicles manufactured for Europe-Middle
East-Africa (EMEA) markets, a remote front impact sensor (also known as an Early Crash Sensor/ECS) is
located on the back of the lower horizontal member of the radiator support near the center. In vehicles
manufactured for North America Free Trade Agreement (NAFTA) markets, remote front impact sensors are
located on the back of the right and left vertical members of the radiator support inboard of the headlamps. The
electronic impact sensors are accelerometers that sense the rate of vehicle deceleration, which provides
verification of the direction and severity of an impact.
The ORC also monitors inputs from the seat track position sensors (NAFTA market only), the front seat belt
switches, the rear seat belt switches (EMEA markets only), an internal rollover sensor and four additional
remote side impact sensors located on the left and right front door hardware module carriers and on the right
and left lower B-pillars to control deployment of the side curtain airbag units and, if equipped, the front seat
airbags (also known as pelvic and thoracic airbags). The ORC uses the seat belt switch inputs along with
inputs from the Occupant Detection Sensor (ODS) in the passenger front seat cushion to support the seat belt
alert feature, and will send electronic messages to the IPC to illuminate the seat belt indicator when
appropriate.
The impact sensors within the ORC are electronic accelerometer sensors that provide an additional logic input
to the ORC microcontroller. These sensors are used to verify the need for a SRS component deployment by
detecting impact energy of a lesser magnitude than that of the primary electronic impact sensors, and must
exceed a safing threshold in order for the SRS components to deploy. A separate impact sensor within the
ORC provides confirmation to the ORC microcontroller of side impact forces. This separate sensor is a
bi-directional unit that detects impact forces from either side of the vehicle.
Pre-programmed decision algorithms in the ORC microcontroller determine when the deceleration rate as
signaled by the impact sensors indicate an impact that is severe enough to require SRS protection. In NAFTA
market vehicles, based upon the severity of the monitored impact, the ORC also determines the level of front
airbag deployment force required for each front seating position. When the programmed conditions are met, the
ORC sends the proper electrical signals to deploy the front airbags, the front seat belt tensioners and either
side curtain and, if equipped, seat airbag unit.
The BCM stores and compares vehicle configuration data with the ORC as well as with other Electronic Control
Units (ECU) in the vehicle. This process is referred to as PRogramming Of Configuration of Systems Integrated
(PROCSI) (also known as PROXI). If a configuration mismatch is detected, the BCM sets a DTC. A
configuration mismatch DTC will require the performance of a Restore BCM PROXI Configuration routine, or a
PROXI Configuration Alignment routine using a diagnostic scan tool.
The hard wired inputs and outputs for the ORC may be diagnosed using conventional diagnostic tools and
procedures. Refer to the appropriate wiring information. However, conventional diagnostic methods will not
prove conclusive in the diagnosis of the ORC or the electronic controls and communication between other
modules and devices that provide some features of the SRS. The most reliable, efficient and accurate means
to diagnose the ORC or the electronic controls and communication related to SRS operation requires the use
of a diagnostic scan tool and may also require the use of the SRS Load Tool special tool along with the
appropriate Load Tool Jumpers and Adapters. Refer to the appropriate diagnostic information.
MODULE, OCCUPANT RESTRAINT > REMOVAL AND INSTALLATION > REMOVAL AND
WARNING:
To avoid serious or fatal injury on vehicles equipped with side curtain airbags, disable the
Supplemental Restraint System (SRS) before attempting any Occupant Restraint Controller (ORC)
diagnosis or service. The ORC may contain a rollover sensor, which enables the system to deploy
the side SRS components in the event of a vehicle rollover event. If an ORC containing a rollover
sensor is accidentally rolled during service while still connected to battery power, the side SRS
components will deploy. Disconnect and isolate the battery negative (ground) cable, then wait two
minutes for the system capacitor to discharge before performing further diagnosis or service. This
is the only sure way to disable the SRS. Failure to take the proper precautions could result in
accidental airbag deployment. Refer to WARNING .
WARNING:
WARNING:
To avoid serious or fatal injury, never strike or drop the Occupant Restraint Controller (ORC), as it
can damage the impact sensor or affect its calibration. The ORC contains the impact sensor,
which enables the system to deploy the SRS components. If an ORC is accidentally dropped
during service, the module must be scrapped and replaced with a new unit. Failure to observe this
warning could result in accidental, incomplete, or improper SRS component deployment.
Fig 1: Front Side Panel & Clips

1. Disconnect and isolate the negative cable from the battery. If equipped with an Intelligent Battery
Sensor (IBS), disconnect the IBS connector before disconnecting the negative cable from the battery.
Wait two minutes for the system capacitor to discharge before further service.
2. Remove the front side panel (1b) from the right side of the center floor console on the floor panel
center tunnel. Refer to CONSOLE, FLOOR, REMOVAL AND INSTALLATION .
Fig 2: Occupant Restraint Controller, Connector & Nuts
3. Disconnect the wire harness connectors (1) from the rearward-facing end of the Occupant Restraint
Controller (ORC) (2b). To disconnect the wire harness connector from the ORC, depress the release
tab and lift the lever arm on the connector.
4. Remove the three nuts (2a) that secure the ORC to the weld studs on the floor panel center tunnel.
5. Lift the ORC off of the weld studs and remove it from the vehicle.
MODULE, OCCUPANT RESTRAINT > REMOVAL AND INSTALLATION > REMOVAL AND
WARNING:
Supplemental Restraint System (SRS) before attempting any Occupant Restraint Controller (ORC)
diagnosis or service. The ORC may contain a rollover sensor, which enables the system to deploy
the side SRS components in the event of a vehicle rollover event. If an ORC containing a rollover
sensor is accidentally rolled during service while still connected to battery power, the side SRS
components will deploy. Disconnect and isolate the battery negative (ground) cable, then wait two
minutes for the system capacitor to discharge before performing further diagnosis or service. This
is the only sure way to disable the SRS. Failure to take the proper precautions could result in
accidental airbag deployment. Refer to WARNING .
WARNING:
WARNING:
To avoid serious or fatal injury, never strike or drop the Occupant Restraint Controller (ORC), as it
can damage the impact sensor or affect its calibration. The ORC contains the impact sensor,
which enables the system to deploy the SRS components. If an ORC is accidentally dropped
during service, the module must be scrapped and replaced with a new unit. Failure to observe this
warning could result in accidental, incomplete, or improper SRS component deployment.
Fig 1: Occupant Restraint Controller, Connector & Nuts
1. Carefully position the Occupant Restraint Controller (ORC) (2b) onto the weld studs on the top of the
floor panel center tunnel. When the ORC is correctly positioned, the bottom of the housing will fit flush
with the top of the floor panel center tunnel and the orientation arrow on the label on top of the
housing will be pointed forward in the vehicle.
2. Install and tighten the three nuts (2a) that secure the ORC to the weld studs on the top of the floor
panel center tunnel. Tighten the nuts securely.
3. Connect both wire harness connectors (1) to the rearward-facing end of the ORC. Be certain that the
latch on each connector is fully engaged.
Fig 2: Front Side Panel & Clips
4. Align the snap clips (1a) of the front side panel with the right side of the center floor console and snap
it into place. Refer to CONSOLE, FLOOR, REMOVAL AND INSTALLATION .
5. If this Electronic Control Unit (ECU) is being replaced with a new unit, a diagnostic scan tool MUST be
used to align the PROXI configuration data into the new ECU. Follow the routine outlined in the
diagnostic scan tool for PROXI Configuration Alignment under Body Control Module (BCM)
Miscellaneous Functions menu.
6. If this Electronic Control Unit (ECU) is being replaced with a new unit, the Initialize ORC
Miscellaneous Function must be run using a diagnostic scan tool.
7. Do not connect the negative cable to the battery at this time. The Supplemental Restraint System
(SRS) Verification Test procedure should be performed following service of any SRS component.
Refer to SUPPLEMENTAL RESTRAINT SYSTEM VERIFICATION TEST .
Fig 1: Park Assist Module, Connector Receptacles & Mounting Tabs
The Parking Assist Module has the following characteristics:
It manages the presence of a possible trailer: it is configured to deactivate the rear sensors when a
trailer is present.
It communicates and transmits data over the high-speed CAN-C2 network.

If a fixed tow hook is present, the signal "Trailer presence" informs the PAM control unit to deactivate the rear
sensors if a trailer is attached to the car. The signal "Trailer presence" is sent by the Trailer Tow Module (TTM)
via CAN-BH.
To ensure the proper operation of the system when the trailer is not attached to the vehicle, the PAM control
unit changes the sensor detection area range in order to take into account the space occupied by the tow
hook.
Fig 2: Semi-Automatic Parking Control Unit PAM
Semi-automatic parking control unit PAM
The semi-automatic parking control unit PAM has the following characteristics:
It manages the presence of a possible trailer: it is configured to deactivate the rear sensors when a
trailer is present.
It communicates and transmits data over the high speed CAN-C2 network.
The PAM cannot be adjusted or repaired and, if damaged or ineffective, it must be replaced with a new unit. The
PAM software is flash programmable.
The microcontroller in the Park Assist Module (PAM) contains the park assist system logic circuits. The PAM
uses On-Board Diagnostics (OBD) and can communicate with other electronic modules in the vehicle as well
as with the diagnostic scan tool using the Controller Area Network (CAN) data bus. This method of
communication is also used for park assist system diagnosis and testing through the 16-way data link
connector located on the driver side lower edge of the instrument panel.
The PAM provides voltage to the four park assist sensors located in the bumper fascia or fascias. The PAM
monitors return inputs from each of the sensors on dedicated hard wired data communication circuits. These
sensor inputs allow the PAM to determine when an obstacle is in the rear path of the vehicle. When an obstacle
is detected the sensor inputs allow the PAM logic to calculate the relative location of the obstacle, and whether
the distance to that obstacle is increasing or decreasing.
Pre-programmed decision algorithms and calibrations allow the PAM microcontroller to determine the
appropriate park assist system outputs based upon the inputs received from the park assist sensors and
electronic messages received from other modules in the vehicle over the CAN data bus. When the programmed
conditions are met the PAM sends electronic messages to the Instrument Panel Cluster (IPC) over the CAN
data bus to obtain the proper park assist system audible outputs and textual messages in the IPC display. The
PAM also broadcasts electronic messages over the CAN data bus to enable the other electronic features of the
park assist system.
The PAM microcontroller continuously monitors all of the park assist system electrical circuits and components
to determine the system readiness. If the PAM detects a monitored system fault, it sets a Diagnostic Trouble
Code (DTC) and sends the appropriate electronic messages to the IPC over the CAN data bus to control
operation of certain park assist system audible and textual warnings.
The PAM receives battery current on a fused ignition output (run-start) circuit through a fuse in the Power
Distribution Center (PDC). The PAM receives ground through a ground circuit and take out of the body wire
harness connected to the body sheet metal. These connections allow the PAM to be operational whenever the
status of the ignition is Start or On.
The hard wired circuits between components related to the PAM may be diagnosed using conventional
diagnostic tools and procedures. Refer to the appropriate wiring information. The wiring information includes
wiring diagrams, proper wire and connector repair procedures, details of wire harness routing and retention,
connector pin out information and location views for the various wire harness connectors, splices and grounds.
electronic controls and communication between modules and other devices that provide some features of the
park assist system. The most reliable, efficient and accurate means to diagnose the PAM or the electronic
controls and communication related to park assist system operation requires the use of a diagnostic scan tool.
Refer to the appropriate diagnostic information.
Fig 1: Left Inner Quarter Panel, Supplemental Junction Box & Nuts
1. Disconnect and isolate the negative cable from the battery. If equipped with an Intelligent Battery
Sensor (IBS), disconnect the IBS connector before disconnecting the negative cable from the battery.
2. Remove the trim from the left inner quarter panel (1) to access the Park Assist Module (PAM) behind
the left rear wheel house. Refer to PANEL, QUARTER TRIM, REMOVAL AND INSTALLATION .
3. Remove the two nuts (2a) that secure the supplemental Junction Box (JB) (2b) and move the JB
aside.
Fig 2: Park Assist Module, Push-Pin Retainers & Connectors
4. Remove the two plastic push-pin retainers (1a) that secure the PAM (1b).
5. Disconnect the two or three wire harness connectors (2a and 2b) from the PAM connector
receptacles.
6. Remove the PAM (3) from the vehicle.
Fig 1: Park Assist Module, Push-Pin Retainers & Connectors
1. Position the Park Assist Module (PAM) (1b) into the left of the cargo are behind the left rear wheel
house.
2. Connect the two or three wire harness connectors (2a and 2b) to the PAM connector receptacles.
3. Position the PAM to its mounting location.
4. Install the two plastic push-pin retainers (1a) that secure the PAM.
Fig 2: Left Inner Quarter Panel, Supplemental Junction Box & Nuts
5. Position the supplemental Junction Block (JB) (2b) onto the mounting studs.
6. Install and tighten the two nuts (2a) that secure the JB. Tighten the nuts securely.
7. Install the trim onto the left inner rear quarter panel. Refer to PANEL, QUARTER TRIM, REMOVAL
AND INSTALLATION .
NOTE:
tool MUST be used to align the PROXI configuration data into the new ECU. Follow the
routine outlined in the diagnostic scan tool for PROXI Configuration Alignment under Body
Control Module (BCM) Miscellaneous Functions menu.
MODULE, POWERTRAIN CONTROL > DESCRIPTION AND OPERATION > DESCRIPTION

AND OPERATION > PCM
The Powertrain Control Module (PCM) is located next to the engine compartment battery. The PCM is a digital
computer containing a microcontroller. The PCM receives input signals from various switches and sensors that
are referred to as PCM Inputs. Based on these inputs, the PCM adjusts various engine and vehicle operations
through devices that are referred to as PCM Outputs.
The PCM uses the CAN-C bus to perform engine diagnostics and flash operations.
MODULE, POWERTRAIN CONTROL > DESCRIPTION AND OPERATION > DESCRIPTION

The Powertrain Control Module (PCM) is a pre-programmed, microprocessor digital computer. The PCM
operates the fuel system, regulates ignition timing, air-fuel ratio, emission control devices, charging system,
certain transmission features, speed control, air conditioning compressor clutch engagement (if equipped) and
idle speed. The PCM can adapt its programming to meet changing operating conditions. It also receives input
signals from various switches and sensors. Based on these inputs, the PCM regulates various engine and
vehicle operations through different system components. These components are referred to as PCM Outputs.
The PCM adjusts ignition timing based upon inputs it receives from sensors that react to: engine RPM, manifold
absolute pressure, engine coolant temperature, throttle position, transmission gear selection (automatic
transmission), vehicle speed and the brake switch. It also adjusts idle speed based on inputs it receives from
sensors that react to: throttle position, vehicle speed, transmission gear selection, engine coolant temperature
and from inputs it receives from the air conditioning clutch switch and brake switch. As input signals change,
the PCM adjusts its response to the output devices. For example, the PCM must calculate different injector
pulse width, ignition timing and camshaft settings for idle as compared to wide open throttle (WOT). It also
adjusts the generator charge rate through control of the generator field and provides speed control operation
(depending on vehicle build).
The PCM will operate in two different modes, Open Loop and Closed Loop. During Open Loop operation, the
PCM still receives all input signals but responds only to a limited amount of inputs based on the algorithms for
output control. Inputs from the Oxygen (O2) Sensors and other sensors (depending on the PCM programming)
are not monitored during Open Loop operation. During Closed Loop operation, the PCM will monitor all inputs
and outputs. The inputs indicate to the PCM whether or not the calculated output settings result in an ideal
air-fuel ratio. This ratio is 14.7 parts air to 1 part fuel. By monitoring the exhaust oxygen content through the O2
Sensor and all other inputs, the PCM has the ability to fine tune the air handling, fuel control, ignition timing and
spark advance settings. This is done to achieve optimum fuel economy combined with low emission engine
performance.
NOTE:
Depending on vehicle build configuration, transmission and engine type, the PCM will be
programed with different software to meet the vehicle system needs. It is always important
to verify the Vehicle Identification Number (VIN) and software level in the PCM when
diagnosing concerns related to the PCM.
MODULE, POWERTRAIN CONTROL > REMOVAL AND INSTALLATION > 1.4L REMOVAL
AND INSTALLATION > 1.4L REMOVAL
2. Remove the engine beauty cover. Refer to COVER, ENGINE, REMOVAL AND INSTALLATION .
Fig 1: Powertrain Control Module Connectors - 1.4L
3. Disconnect the Powertrain Control Module (PCM) electrical connectors.

Fig 2: Powertrain Control Module, Ground Wire & Nuts - 1.4L
4. Remove the training nut and disconnect the ground wire.
5. Remove the PCM retaining nuts (2) and then remove the PCM from the vehicle.
AND INSTALLATION > 1.4L INSTALLATION
1. Position and install the PCM to the vehicle.
2. Connect the ground wire and wire retaining nut to the PCM.
3. Connect the wiring harness connectors to the PCM.
4. Install the engine beauty cover. Refer to COVER, ENGINE, REMOVAL AND INSTALLATION .
6. Connect the diagnostic scan tool to the vehicle and select "ECM" in "miscellaneous features".
Perform the "replacement unit" routine.
7. With key in the "OFF" position and with the emergency lights turned on, go to "control BCM" in
"miscellaneous features" and launch the "transfer secret key" procedure.
2. Remove the engine beauty cover. Refer to COVER, ENGINE, REMOVAL AND INSTALLATION .
Fig 1: Powertrain Control Module Connectors - 2.4L
3. Disconnect the Powertrain Control Module (PCM) electrical connectors.

Fig 2: Powertrain Control Module, Ground Wire & Nuts - 2.4L
4. Remove the training nut and disconnect the ground wire.
5. Remove the PCM retaining nuts (2) and then remove the PCM from the vehicle.
1. Position and install the PCM to the vehicle.
2. Connect the ground wire and wire retaining nut to the PCM.
3. Connect the wiring harness connectors to the PCM.
6. Connect the diagnostic scan tool to the vehicle and select "ECM" in "miscellaneous features".
Perform the "replacement unit" routine.
7. With key in the "OFF" position and with the emergency lights turned on, go to "control BCM" in
"miscellaneous features" and launch the "transfer secret key" procedure.
MODULE, POWERTRAIN CONTROL > MODULE PROGRAMMING > PROGRAMMING THE
CUSW PCM
This procedure is required when one or more of the following situations are true:
A Powertrain Control Module (PCM) has been replaced.
Diagnostic Trouble Code (DTC) P1602 - PCM Not Programmed is set.
An updated calibration or software release is available for either the PCM or Transmission Control
Module (TCM).
This procedure assumes that the scan tool is properly configured to the dealership network with either a wired
or wireless connection. For help on how to network the scan tool, use the "Help" tab at the top of the diagnostic
application.
Programming Procedure:
1. Connect a battery charger to the vehicle.
3. Ignition key should be in RUN position.
4. When a generic controller is installed, no VIN is in the PCM. There will be a screen from the scan tool
indicating that the scan tool cannot read the VIN.
5. Enter the correct VIN in order to flash the PCM.
NOTE:
No VIN is written into the PCM at this point. It is only used for the diagnostic information.
6. Next, a screen confirmation displays. Select continue.
7. The Vehicle Connection Wizard screen displays. Disregard and close this screen. The PCM must be
flashed before performing any diagnostics.
8. The Vehicle View Screen will indicate that a flash is available (lightning bolt) for the PCM. Reading all
DTC's at the bottom of the screen will indicate that "P1602 - PCM Not Programmed" is present and
active for the PCM
9. When the PCM is selected, the flash tab should be selected. Select the appropriate part number to
flash the controller.
10. Clear DTC's screen after the flash process completes.
11. Perform the "Proxy Configuration Alignment" found in the "Vehicle Preparations" menu. This
routine will copy the proxi into the PCM and write the PCM VIN.
12. Select PCM view and then select "
13. Select and run the "Learn ETC" routine. This routine is necessary to learn the throttle position
voltages and the accelerator pedal position.
14. Perform the "Cruise Control Learn" routine. Follow the prompts shown on the scan tool.
15. Module programming is complete.
MODULE, RADIO FREQUENCY (RF HUB) > DESCRIPTION AND OPERATION >
DESCRIPTION
The RFH module carries out a number of functions which depend on the type of key that comes with the
vehicle. It may have two different types of key:
Fobik key
Fig 1: Fobik Key

Mechanical groove key.
If the vehicle has the first type of key, it can't have the second type and vice versa.
Fig 2: Fobik Key Functions
Fobik key: RFH functions - When the car has a Fobik key, the RFH module carries out the following
functions:
Passive Entry
Key recognition (RFH is part of the Immobilizer system)
TPMS (tire pressure detection) function.

Fig 3: RFH Module & Run/Start Button Circuit Diagram
Since it has to recognize the keys, their codes are programmed in the RFH module. The ignition switch also
comprises a Start/Stop button named KIN module. The button is connected electrically to the RFH module
through a LIN line and a connection with an analogue signal called "Redundant Run". This signal permits the
RFH to determine whether the Start/Stop button has been pressed if there is a fault on the LIN line.
Fig 4: Antenna Locations
To carry out the Passive Entry function, the RFH module needs 5 low-frequency peripheral aerials that allow
the module to identify and locate the keys.
Aerial Name Aerial position.
1 Rear left door
2 Rear right door
3 Rear bumper
4 Dashboard
5 Luggage compartment
Fig 5: RFH Module & Antenna Circuit Diagram
The RFHM is located in the rear overhead compartment of the vehicle. The module be adjusted or repaired and,
if damaged or ineffective, it must be replaced.
Fig 6: RFH Module & Door Locks Circuit Diagram
The Passive Entry system also makes use of the two door locking buttons on the front handles, through which
car users can request door locking. Inside the handles are capacitive sensors (one per handle) which allow the
RFH module to determine whether the user's hand is near the inside of the handle.
The RFH module detects the vicinity of the key to the vehicle through aerials. The key recognition and
authentication stage begins when the vehicle user brings their hand towards the inside of the handle. At that
moment, the RFH reads the key ID and the secret code stored in it. If the RFH module identifies it as the key
encoded in its memory, it sends the request to unlock the doors or the driver door only (depending on the
setting in the "my car" menu) to the BCM.
Fig 7: Mechanical Groove Key
Mechanical groove key: RFH functions - If the vehicle comes with key with mechanical groove, the RFH
module carries out only the following function:
TPMS (tire pressure detection) function
In this case the RFH module is not a component of the immobilizer function, since the ID codes of the vehicle's
keys are stored in the BCM. Consequently, the ignition switch no longer comprises the KIN module (Start/Stop
button) but the classic mechanical switch.
MODULE, RADIO FREQUENCY (RF HUB) > REMOVAL AND INSTALLATION > REMOVAL
2. Lower the top portion of the liftgate weatherstrip.

Fig 1: Weatherstrip & Retainers
3. With the proper tool, remove the retainers (2).

Fig 2: RFH Module, Connectors & Nuts
4. Slightly lower the rear of the headlining and disconnect the electrical connections of the RFHM.
5. Remove the nuts (2a) and remove the RFHM (2b).
MODULE, RADIO FREQUENCY (RF HUB) > REMOVAL AND INSTALLATION > REMOVAL
1. Check that the RFHM is not damaged.
2. Place the RFHM to the vehicle and tighten the nuts.
3. Connect the electrical connectors to the RFHM.
5. Connect the diagnostic scan tool and perform the learning procedure.
6. Secure the headliner back in the installed position.
7. Secure the tailgate weatherstripping.
MODULE, RADIO FREQUENCY (RF HUB) > MODULE PROGRAMMING > PROGRAMMING
THE RF-HUB
If the Remote Frequency Hub Module (RFHM) is replaced on vehicles equipped with the Passive Entry key:
1. Position the ignition to OFF
2. Activate the hazard warning lights
3. Connect the scan tool
4. Navigate to RFH control unit located in "Misc Functions" menu
5. Select and perform the "RFH control unit replacement" routine and follow the prompted instructions
6. Once complete, perform the following routines located in the "Misc Functions" menu:
1. Write the rated front and rear tire pressure values
2. Program ID of rear right tire sensor
3. Program ID of rear left tire sensor
4. Program ID of front left tire sensor
5. Program ID of front right tire sensor
6. Carry out the "TPM sensor roller bench test" procedure.
7. Programming is complete.
MODULE, RADIO RECEIVER > DESCRIPTION AND OPERATION > DESCRIPTION AND
There are three Radio Receiver Modules (RRM) available in this vehicle, Uconnect® 3.0, Uconnect® 5.0 and
Uconnect® 6.5. Each RRM has a distinct chassis design and is identified by a sales code. The Uconnect® 3.0
RRM (Sales Code RA1) includes the following features:
dot-matrix, single DIN, monochromatic display
six-channel presets
four speakers
iPod integration
Auxiliary/Universal Serial Bus (USB) Media Hub

iPod integration
hands-free phone
text message reader
six speakers (optional)
integrated Global Positioning System (GPS) navigation (optional)
Sirius XM satellite radio (optional)
iPod integration
hands-free phone
text message reader

nine speakers (optional)
Premium integrated 3D Global Positioning System (GPS) navigation (optional)
Sirius XM satellite radio (1-year subscription)
Hard wired circuitry connects the RRM to the electrical system of the vehicle. These hard wired circuits are
integral to several wire harnesses, which routes throughout the vehicle and retained by many different
methods. These circuits may be connected to each other and to the vehicle electrical system through the use
of a combination of soldered splices, splice block connectors, and many different types of wire harness
terminal connectors and insulators. Refer to the appropriate wiring information. The wiring information includes
wiring diagrams, proper wire and connector repair procedures, further details on wire harness routing and
retention, as well as pin out and location views for the various wire harness connectors, splices and grounds.
The RRM cannot be adjusted or repaired. If the RRM is damaged or ineffective, it must be replaced.
MODULE, RADIO RECEIVER > DESCRIPTION AND OPERATION > DESCRIPTION AND
The Radio Receiver Module (RRM) becomes operational when it receives a wake up signal over the Controller
Area Network (CAN) - B data bus indicating the status of the ignition switch is On or Accessory. For further
information on the operation of the radio or media system in the vehicle, see the heading for the appropriate
audio system option in the User Guide or the Owner Manual. See the Uconnect® web site
(http://www.driveuconnect.com/ ) for more information, or refer to the For Owners link on the vehicle brand
web site for copies of those publications.
The RRM uses a roof mounted antenna for AM/FM signal reception and, depending upon vehicle optional
equipment, a roof mounted combination antenna that can receive Global Positioning System (GPS) and
satellite radio signals.
Depending upon the audio system options, the RRM can play audio from many different media sources. The
media can be played by connecting the source to the audio system via a 3.5 millimeter auxiliary (AUX) port, a
Universal Serial Bus (USB) port or through wireless Bluetooth audio streaming. Refer to the Uconnect® web
site (http://www.driveuconnect.com/ ) for compatibility information.
NOTE:
USB devices (e.g., camera memory USB adaptors, etc. excluding Apple products) must comply
with the MSD (Mass Storage Device) standard. This remote USB port can provide power to the
inserted device.
MODULE, RADIO RECEIVER > REMOVAL AND INSTALLATION > REMOVAL AND
NOTE:
For RA4 radios, if possible, the version of the map and Point Of Interest (POI) data should be
noted before the original radio is replaced with a new unit. If the version of the map and POI data
found on the new radio is not equal to or newer than the version that is found, updated data will
need to be downloaded and installed to the new radio at the expense of the dealer. For the
Navigation system restore and update procedures, refer to STANDARD PROCEDURE .
Fig 1: Center Trim Bezel & Tabs
2. Using trim stick C-4755 or equivalent, remove the center trim bezel (1b) from the instrument panel.
3. Remove the four screws (1a) securing the radio (1b) to the instrument panel.
4. Pull the radio out far enough to access the back of the radio.
5. Disconnect the antenna cables (3), and radio wire harness connector (2).
6. If equipped, disconnect the USB connector (1).
7. Remove the radio from the instrument panel.
MODULE, RADIO RECEIVER > REMOVAL AND INSTALLATION > REMOVAL AND
1. Position the radio near the instrument panel.
2. Connect the antenna cables (3) and radio wire harness connector (2).
3. If equipped, connect the USB connectors (1).

4. Position the radio into the instrument panel.
5. Install and securely tighten the four screws (1a) securing the radio (1b) to the instrument panel.
Fig 3: Center Trim Bezel & Tabs
6. Install the instrument panel center bezel (1b). Be certain the four retaining tabs (1a) are fully engaged
to the instrument panel.
IBS connector.
NOTE:
NOTE:
Uconnect® Access Applications and WiFi hotspot will be automatically updated in the
replacement radio through the radio's embedded cellular phone based on the customers
present subscription status. This update process may take up to an hour, depending upon
the number of apps and adequate cellular services accessibility. The dealer is not
expected to perform this process or to oversee it, but may need to explain to the vehicle
owner or operator that some features and applications may not be fully restored and
overall system response may be slowed until the process has completed.
NOTE:
For RA4 radio only: Any factory replacement radio for the same vehicle will be provided
with the Navigation system already activated. For more information, refer to the
NAVIGATION/TELECOMMUNICATION - SERVICE INFORMATION article.
MODULE, RADIO RECEIVER > MODULE PROGRAMMING > PROGRAM THE RADIO
2. Check vehicle for DTCs.
3. Clear all stored DTCs.
4. Turn car OFF then ON and confirm DTCs are gone.
5. Go to BCM >> Misc. Functions >> Proxi Alignment.
If required, continue to programming the next module.
MODULE, TIRE PRESSURE MONITORING (TPM) > DESCRIPTION AND OPERATION >
The Tire Pressure Monitoring (TPM) module is located inside the Radio Frequency Hub (RF hub). The Tire
Pressure Monitoring System (TPM) monitors the tire pressure of each tire and alerts the driver, through the
instrument panel cluster, when a low pressure tire condition exists or a TPM abnormal condition exists. The
TPM consists of the following components:
The tire pressure monitoring system comprises the following components:
Tire pressure sensor control unit.
Tire pressure monitoring sensors located in the valve of each wheel.
The Tire Pressure Monitor (TPM) module is able to receive individual tire pressure and temperature information
from the TPM sensors located inside the road wheels. The TPM module has a CAN network interface to
connect it to the vehicle network and carry out the following functions:
Receives and processes the radio frequency data signals from each TPM sensor located inside each
wheel.
Monitors the TPM sensor status.
Carries out self test.
Calculates information from TPM sensors to generate low pressure and malfunction warnings.
Transmits and receives information and status messages to other modules, the instrument panel cluster
(IPC) and body control module (BCM), on the CAN network.
Carries out diagnostic functions.
MODULE, TIRE PRESSURE MONITORING (TPM) > DIAGNOSIS AND TESTING >
DIAGNOSIS AND TESTING
Tire Pressure Monitoring (TPM) System Diagnosis
When diagnosing a tire pressure issue, first check the Tire Pressure Monitoring (TPM) warning light in the IPC
during starting. From the OFF position, switch ON and check the TPM warning light to observe one of the
following:
If after 10 seconds the warning light is on and constant (not flashing), then one or more of the tires has
low pressure or another fault exists.
If after 10 seconds the warning light flashes for 75 seconds, then remains on constantly, a fault has been
detected in the system.
Sensed tire pressure values are also displayed in the Electronic Vehicle Information Center (EVIC).
If the RF-Hub does not receive a signal from a sensor, dashes will be displayed in lieu of a pressure value.
If a low pressure warning is indicated, check the air pressure in all tires with an accurate pressure gauge. If the
pressure in the tire is low, diagnose and repair the cause of the low pressure. Reinstall the tire, or tires, on the
vehicle and allow approximately two minutes for the message or warning light to turn off. If the message or
warning light remains on, another fault is present.
If a system fault exists, check for the following conditions which may cause a system fault:
Signal interference due to electronic devices or driving next to facilities emitting the same radio
frequencies as the TPM sensors.
Accumulation of snow or ice around the wheels or wheel housings.
Using snow chains.
Using wheels not equipped with TPM sensors.
Incorrectly programmed Sensor ID numbers.
TPM system DTCs are stored in the RF-Hub. Check for DTCs using diagnosis equipment. For the procedure for
diagnosing TPM system DTCs, refer to the DTC INDEX article.
If a new sensor is installed, perform one of the following procedures in the TPM diagnosis check test to
program the RF-Hub with the new sensor ID.
Use the TPM-RKE 9936 analyzer, with the diagnosis equipment, to program the TPM module with the tire
pressure sensor ID.
Once the vehicle has remained stationary for more than 20 minutes, the RF-Hub should automatically
learn the sensor ID when the vehicle is driven for a minimum of 10 minutes while maintaining a continuous
speed above 24 km/h (15 mph).
PRESSURE LABEL PRESSURE THRESHOLD
psi mbar psi mbar
26 1793 22 1517
27 1862 22 1517
28 1931 23 1586
29 2000 24 1655
30 2069 25 1724
31 2138 25 1724
32 2207 26 1793
33 2276 27 1862
34 2345 28 1931
35 2414 28 1931
36 2483 29 2000
37 2552 30 2069
38 2621 31 2138
39 2690 31 2138
40 2759 32 2207
41 2828 33 2276
42 2897 34 2345
43 2966 35 2414
44 3034 35 2414
45 3103 36 2483
46 3172 37 2552
47 3241 38 2621
48 3310 38 2621
49 3379 39 2690
50 3448 40 2759
51 3517 41 2828
55 3793 44 3034
60 4138 48 3310
65 4483 52 3586
70 4828 56 3862
75 5172 60 4138
80 5517 64 4414
MODULE, TIRE PRESSURE MONITORING (TPM) > REMOVAL AND INSTALLATION >

Fig 1: Headliner, Tire Pressure Module, Connector & Nuts
2. Remove the top portion of the liftgate seal.
3. Slightly lower the rear of the headliner (1a) and disconnect the Tire Pressure Module (TPM) electrical
connector (1b).
4. Remove the TPM to body nuts (2a) and remove the TPM (2b).
MODULE, TIRE PRESSURE MONITORING (TPM) > REMOVAL AND INSTALLATION >
Fig 1: Headliner, Tire Pressure Module, Connector & Nuts
1. Position the Tire Pressure Module (TPM) (2b) to the body.
2. Install and tighten the TPM to body nuts (2a).
3. Connect the TPM wiring harness connector (1b).
4. Install the partially removed liftgate seal.

6. Connect the scan tool and perform the learn procedure.
MODULE, TIRE PRESSURE MONITORING (TPM) > MODULE PROGRAMMING >

PROGRAMMING
1. With the scan tool, go to "Tire Pressure Module (TPM)", select "Miscellaneous Functions" and
perform the Proxy Alignment procedure.
2. With the scan tool, go to "Tire Pressure Module (TPM)", select "Data Display", read "'Tire Placard
Pressure - Front" and "'Tire Placard Pressure - Rear" and confirm the values match the Tire Inflation
Pressure (Placard) label. Also, go into the Body Control Module (BCM), select Data Display and read
"'Tire Placard Pressure - Front" and "'Tire Placard Pressure - Rear" to confirm the values were
programmed correctly. If the Placard values are incorrect in the BCM or TPM Module, select the Body
Control Module (BCM) then under "Miscellaneous Functions", select "Update Pressure Threshold" and
enter the placard pressure value as seen on the Tire Inflation Pressure (Placard) label. Program the
Placard Pressure Values into the Tire Pressure Module (TPM).
3. With the scan tool, erase all stored DTCs.
4. Check for DTCs. If DTCs are present, refer to the DTC INDEX article.
MODULE, TRAILER TOW > DESCRIPTION AND OPERATION > DESCRIPTION AND
Fig 1: Trailer Tow Module
The vehicle can be equipped with a fixed tow hook. The external lighting of any trailer receives power supply
from the Trailer Tow Module (TTM). The TTM is located on the rear left side of the vehicle, above the wheel
arch.
Fig 2: Trailer Tow Module Connector
The TTM is electrically connected to the wiring of the trailer through a connector near the tow hook.
The TTM module shows all the rear light activation controls from the vehicle on the trailer.
MODULE, TRAILER TOW > DESCRIPTION AND OPERATION > DESCRIPTION AND
The Trailer Tow Module (TTM) is used to operate the trailer lamps and lighting system in conjunction with the
vehicles various module outputs. The TTM monitors CAN bus networks for lighting requests from the Body
Control Module and other inputs. The TTM itself is responsible for its own logic, actuation and sensing. The
TTM is also responsible for trailer light indicator activation sent from it over the bus to the Instrument Cluster
(IC).
Some of the CAN inputs received by the TTM include the following:
vehicle speed
reverse gear
stop lights OFF and ON requests
turn and hazard lights OFF and ON requests.
parking lights
rear for lighting
The TTM assures that these lighting functions are maintained synchronous with the vehicles lighting requests
as read on the CAN bus. The TTM then sends the appropriate output OFF or ON signal to the respective trailer
lights. The TTM also sends an output signal failure to the IC indicating if the light operation has failed. The IC
will then display the appropriate indiction.
Fig 1: Trailer Tow Module Circuit Diagram
1. Left side direction indicator (21 W)
2. Rear fog light (2x21 W)
3. Trailer light ground.
4. Right side direction indicator (21 W)
5. Left side light/number plate light (6x5 W)

6. Brake light (4x21 W)
7. Left side light/number plate light (6x5 W)
8. Reversing light (2x21)
9. + Battery power supply
10. Ignition-operated supply
11. Ground for tow hook socket
12. Ground for tow hook socket.
H1 - Right side direction indicator control (from Body Control Module/BCM)
H2 - Left side direction indicator control (from BCM)
H3 - Third brake light control (from BCM)
M1 - Side direction indicator on left side door mirror.
M2 - Side direction indicator on right side door mirror.
S1 - third brake light.

Fig 2: Trailer Tow Module Circuit Diagram (NAFTA Market)
1. Light ground on trailer
2. Side light/side marker/number plate light (12x5 W)
3. Left side brake light/direction indicator (2x21 W)
4. Right side brake light/direction indicator (2x21 W)
H1 - Right side direction indicator control (from BCM)
H2 - Left side direction indicator control (from BCM)

H3 - Third brake light control (from BCM)
M1 - Side direction indicator on left side door mirror.
M2 - Side direction indicator on right side door mirror.
S1 - Third brake light.
MODULE, TRANSMISSION CONTROL > DESCRIPTION AND OPERATION > DESCRIPTION

The Transmission Control Module (TCM) is mounted on the outside of the transmission case, over the
differential.
The electronic control system consists of various components providing inputs to the TCM. The TCM monitors
transmission sensors, shifter assembly, and bus messages to determine transmission shift strategy. After shift
strategies are determined, the TCM controls the actuation of transmission solenoids, which controls the routing
of hydraulic fluid within the transmission, by moving a sequence of four valves to make a shift occur.
The system performs its functions based on continuous real-time sensor feedback information. In addition the
TCM receives information from the rest of the vehicle over the CAN C bus. The CAN C bus is a high-speed
communication bus that allows real time control capability between various controllers. Most messages are
sent every 20 milliseconds. This means critical information can be shared between the transmission, engine,
and ABS controllers. The CAN C bus is a two wire bus with a CAN C Bus (+) circuit and a CAN C Bus (-) circuit.
These circuits are twisted pairs in the harness to reduce the potential of radio and noise interference.
The transmission control system automatically adapts to changes in engine performance, vehicle speed, and
transmission temperature variations to provide consistent shift quality. The control system ensures that clutch
operation during up-shifting and downshifting is more responsive without increased harshness. The TCM
activates the solenoid valves and moves valves in the valve body to achieve the necessary gear changes. The
required pressure level is calculated from the load condition, engine speed. Vehicle speed (from ABS module)
and transmission oil temperature, matched to the torque to be transmitted. Power for the transmission system
is supplied through the shifter mechanism (no transmission control relay).
MODULE, TRANSMISSION CONTROL > DESCRIPTION AND OPERATION > DESCRIPTION

The Transmission Control Module (TCM) regulates the amount of hydraulic pressure used to engage the
clutches and the Torque Converter Clutch (TCC), in addition to directing hydraulic pressure to engage or
release any given clutch for any given required gear.
The TCM will actuate the valves via solenoids based on the position of the shifter, transmission fluid
temperature, engine operating conditions, traction conditions and driver demands.
During a shift, the TCM will actuate the solenoids to match the gear ranges to the optimal torque range of the
engine based on the position of the accelerator pedal, shifter and vehicle speed as determined by the PCM
based on input from the Vehicle Speed Sensor (VSS) and Anti-lock Brake System (ABS) module.
Due to the complexity of the 948TE transmission control system, always refer to the appropriate transmission
electrical/electronic diagnostic information when attempting to diagnose transmission problems.
Some examples of direct inputs to the TCM are:
Battery (B+) voltage

Ignition Status
Transmission Range Sensor (TRS)
Cruise Control Switch
Throttle Position
Body Control Module (BCM)
Shifter Position
Pressure Switches
Transmission Temperature Sensor
Input Shaft Speed Sensor
Output Shaft Speed Sensor
Line Pressure Sensor
Some examples of indirect inputs to the TCM are:
Torque Reduction Confirmation
Engine Coolant Temperature
Scan Tool Communication
Based on the information received from these various inputs, the TCM determines the appropriate shift
schedule and shift points, depending on the present operating conditions and driver demand. This is possible
through the control of various direct and indirect outputs.
Some examples of TCM direct outputs are:
Solenoids
Torque Reduction Request
Some examples of TCM indirect outputs are:
Transmission Temperature
PRNDL Position
In addition to monitoring inputs and controlling outputs, the TCM has other important responsibilities and
functions:
Storing and Selecting Appropriate Shift Schedules
System Self-diagnostics
Diagnostic Capabilities (with scan tool)
MODULE, TRANSMISSION CONTROL > REMOVAL AND INSTALLATION > REMOVAL AND
1. Remove the engine cover. For 1.6/2.0L, refer to COVER, ENGINE, REMOVAL AND INSTALLATION .
For 1.4L, refer to COVER, ENGINE, REMOVAL AND INSTALLATION . For 2.4L, refer to COVER,
2. Remove the battery tray. Refer to TRAY, BATTERY, REMOVAL AND INSTALLATION .
3. Raise and support the vehicle. Refer to HOISTING, STANDARD PROCEDURE .
4. Remove the left front wheel and tire assembly. Refer to REMOVAL AND INSTALLATION .
Fig 1: Transmission Control Module Lower Mounting Bolts
5. Remove the two lower Transmission Control Module (TCM) mounting bolts (1).
6. Lower the vehicle.

Fig 2: Transmission Control Module Connector
7. Disconnect the TCM wire harness connector (1).

Fig 3: Transmission Control Module Upper Mounting Bolts
8. Remove the two upper TCM mounting bolts (1a).
9. Remove the TCM (1b) from the vehicle.
MODULE, TRANSMISSION CONTROL > REMOVAL AND INSTALLATION > REMOVAL AND
NOTE:
When replacing a Transmission Control Module (TCM), the TCM must be programmed.
Failure to properly program the TCM may result in the illumination of the Malfunction
Indicator Lamp (MIL) and setting DTC(s).
NOTE:
If this Electronic Control Unit (ECU) is being replaced with a new unit, a diagnostics scan
NOTE:
The Valve Body Solenoid Learn procedure must be performed when the TCM and/or valve
body is replaced. Failure to perform the Valve Body Solenoid Learn procedure will result in
reduced shift quality.
1. Place the TCM (2) in position on the transmission.
2. Install the two upper bolts to hold the TCM to the transmission.
3. Connect the wire harness connector into the TCM.
4. Raise the vehicle.
5. Install the two lower TCM mounting bolts and tighten securely.
6. Install the left front tire and wheel assembly. Refer to REMOVAL AND INSTALLATION .
8. Install the battery tray. Refer to TRAY, BATTERY, REMOVAL AND INSTALLATION .
9. Install the engine cover. For 1.6/2.0L, refer to COVER, ENGINE, REMOVAL AND INSTALLATION .
For 1.4L, refer to COVER, ENGINE, REMOVAL AND INSTALLATION . For 2.4L, refer to COVER,
IBS connector to the negative battery cable.
11. Perform TCM programming and verification. Refer to MODULE, TRANSMISSION CONTROL,
MODULE PROGRAMMING .
MODULE, TRANSMISSION CONTROL > MODULE PROGRAMMING > TCM

PROGRAMMING-948TE
PROGRAMMING THE TRANSMISSION CONTROL MODULE (TCM)
NOTE:
When replacing a Transmission Control Module (TCM), the TCM must be programmed.
NOTE:
Failure to properly program the TCM may result in the illumination of the Malfunction Indicator
Lamp (MIL) and setting DTC(s).
NOTE:
While performing the TCM programming procedure, the vehicle battery must be maintained
between 10 and 16 volts. Ambient temperature must be between 0° C (32° F) 60° C (140° F).
Vehicle must be in Park with brake pedal depressed.
1. Using the scan tool and Dealer Connect, download the appropriate TCM flash file to the scan tool.
2. Turn the Ignition ON, Engine not running.
3. Make sure the gear selector is in the PARK position.
4. Apply and hold the brake pedal for the duration of the programming procedure.
5. Following the menu on the scan tool, program the TCM.
NOTE:
If this Electronic Control Unit (ECU) is being replaced with a new unit or if a new
transmission has been installed, a diagnostic scan tool MUST be used to align the PROXI
configuration data into the new ECU.
Follow the routine outlined in the diagnostic scan tool for PROXI Configuration Alignment under Body
6. Using a scan tool, follow the on-screen instructions to perform the VIN Verification procedure. This
only needs to be done if a new ECU or a new transmission has been installed.
NOTE:
tool MUST be used to perform the Valve Body Solenoid Learn procedure. Failure to
perform the Valve Body Solenoid Learn procedure will result in reduced shift quality.
Using a scan tool, follow the on-screen instructions to perform the Valve Body Solenoid Learn
procedure.
NOTE:
tool MUST be used to perform the TCM Adaptation procedure. Failure to perform the TCM
Adaptation procedure will result in reduced shift quality.
Perform the TCM ADAPTATION procedure. Refer to TCM ADAPTATION - 948TE AND 9HP48 .
7. With the scan tool, erase DTCs.
8. With the scan tool, read TCM DTCs.
Does the scan tool display any DTCs?
Yes
1. Perform the appropriate diagnostic procedure(s).
No
1. Test Complete
2. Perform the TRANSMISSION VERIFICATION TEST. Refer to TRANSMISSION VERIFICATION

TEST - 948RE 9HP48 .
Jeep Renegade
Service Manual: HEATED GLASS - SERVICE INFORMATION
DIAGNOSIS AND TESTING > DIAGNOSIS AND TESTING - ELECTRIC BACK LIGHT
(EBL) SYSTEM
NOTE:
Illumination of the rear window defogger indicator lamp in the instrument cluster does not
necessarily mean that electrical current is reaching the rear window glass heating grid.
NOTE:
For complete circuit descriptions and diagrams, refer to appropriate SYSTEM WIRING
DIAGRAMS article .
Operation of the EBL system can be confirmed by the following:
1. Use a scan tool and check for Diagnostic Trouble Codes (DTCs) monitored by the Body
Control Module (BCM). If any applicable DTCs are found, repair as required. The rear defog
applicable DTCs are as follows; the rear defog function is not allowed to activate when any of
the following DTCs are active (rear defog operation is allowed when these DTCs are stored).
2. Turn the ignition to RUN and press the rear window defogger switch to on. Rear window
defogger operation can be checked by feeling the surfaces of the rear window glass. A distinct
difference in temperature between the grid lines (5) and the adjacent clear glass should be
detected within three to four minutes of operation.
3. If a temperature difference is not detected, use a 12 volt Direct Current (DC) voltmeter and
contact the rear glass heating grid terminal A (1) with the negative lead, and terminal B (2) with
the positive lead. The voltmeter should read battery voltage. If the voltmeter does not read
battery voltage, check the following:
1. Confirm the ignition is in RUN.
2. Confirm the rear window defogger switch is being read by the BCM (there is no DTC to
indicate a failed switch or open switch connection). Using the scan tool find the rear
defog monitor in the BCM module data. Press and release the rear defog switch while
monitoring; if the BCM input monitor does not toggle (ON/OFF) repair the open
connection between the switch and BCM or replace the failed switch.
3. Confirm the EBL feed wire is connected to the heating grid positive terminal and that
there is continuity between the heating grid and the EBL relay in the Power Distribution
Center (PDC).
4. Confirm the EBL ground wire is connected to the heating grid negative terminal and that
there is continuity to ground.
5. Confirm the EBL relay in the PDC is operational. See appropriate Wiring Information.
4. If broken defogger grid lines or bus bars are suspected, use a 12 volt DC voltmeter and
contact terminal A with the negative lead and each rear glass heating grid line at its mid-point C
with the positive lead. The voltmeter should read approximately 6 volts at each grid line
mid-point. If the voltmeter does not read approximately 6 volts, repair the open grid line(s) or
bus bar(s).
Service Manual: LAMPS/LIGHTING - EXTERIOR - SERVICE Jeep Renegade
INFORMATION
The exterior lighting system for this vehicle includes the following exterior lamp units:
Center High Mounted Stop Lamp - A standard equipment Center High Mounted Stop Lamp
(CHMSL) is located in the upper left rear cargo door.
Front Fog Lamps - Optional front fog lamp units are mounted near each outboard end of the front
fascia, below the front lamp units.
Rear Lamps - Optional front fog lamp units are mounted near each outboard end of the rear
fascia, below the tail lamp units.
Headlamps
- The vehicle is equipped with 70 mm double headlights to increase the light intensity and
consequently improve visibility in all conditions. When, on the other hand, it is equipped with
Bi-Xenon lighting technology (high/low lighting via single high-intensity discharge (HID) bulb), there
is twice as much light compared to the use of conventional bulbs, and the 70 mm headlight
increases the light intensity by approximately 15% and the lighting depth by approximately 20%.
Infrared halogen bulbs are used on the basic versions of the vehicle. The bulbs incorporate a
special coating that brings the inside of the capsule to higher temperatures than conventional
halogen bulbs, thus providing more light.
EMEA version headlights - Infrared halogen bulbs are used on the basic versions of the
vehicle. The bulbs incorporate a special coating that brings the inside of the capsule to higher
temperatures than conventional halogen bulbs, thus providing more light. Equipped with H4
60/55 W-type halogen bulb.
Fig 1: EMEA Version Headlights
NAFTA version headlights - Equipped with H13 60/55 W bulb. Infrared halogen bulbs are
used on the basic versions of the vehicle. The bulbs incorporate a special coating that brings
the inside of the capsule to higher temperatures than conventional halogen bulbs, thus
providing more light.
Fig 2: NAFTA Version Headlights
NAFTA/EMEA BI-XENON version headlights - The vehicle can be equipped with headlights
that use Bi-Xenon technology. The headlights are fitted with next-generation D5S 25W bulbs.
The use of these bulbs, despite a lower brightness compared to a 35 W Bi-Xenon bulb,
results in a considerable improvement in terms of lighting system complexity, because there
are no self-levelling headlight or headlight washer systems, and ballast is not used.
Fig 3: NAFTA/EMEA Bi-Xenon Version Headlights
License Plate Lamps - Two standard equipment rear license plate lamp units are integral to the
light bar and handle assembly, just above the license plate tub.
Fig 4: Rear Light Clusters
Rear Light Clusters
- The vehicle's rear light clusters are equipped with halogen bulbs that carry out the following
functions:
Side lights;
Brake lights
Direction indicators
LED Side marker (NAFTA)
Repeater Lamps - A repeater lamp is mounted to each front fender just behind the front wheel
opening.
Side Marker Lamps - A side marker lamp is integral to the front fascia forward of each front
wheel opening and to the rear fascia behind each rear wheel opening.
These exterior lighting lamp units and their controls are combined to provide the following exterior lighting
features:
Automatic Headlamps - The system automatically switches (if activated by the customer) from
main beam to dipped beam headlights if light sources outside of the vehicle are detected, such as
the light from the headlights of vehicles coming in the opposite direction, from the rear lights of
vehicles in front or from road lighting. If these conditions are not maintained, the system will
automatically switch back to main beam to increase night-time driving safety on poorly lit roads. If
these conditions are not maintained, the system will automatically switch back to main beam to
increase night-time driving safety on poorly lit roads.
The system uses a camera fitted near the interior rear view mirror and in contact with the
windscreen to process the images and detect the approaching lights or lights in front. When it
detects the headlights of an approaching vehicle, the lights of a vehicle in front or ambient light
(daylight, street lights and other sources), the HALF camera communicates with the BCM via CAN
and the BCM deactivates the main beam headlights before they inconvenience other drivers. The
function deactivates automatically (dipped beam headlights active) when the speed is below 20
km/h approx.
Backup Lamps - The backup (or reverse) lamps include a clear bulb, reflector and clear lens that
are integral to each rear lamp unit.
Brake Lamps - The brake (or stop) lamps include a clear bulb, reflector and red lens that are
integral to each rear lamp unit, and the red lens and multiple clear bulbs of the CHMSL.
Daytime Running Lamps - Daytime Running Lamps (DRL) are standard equipment. When DRL
is enabled, the lamps illuminate the clearance (front position or park) lamp bulb in the front
combination lamp unit to serve as the DRL. The DRL function can be turned on or off using the
Electronic Vehicle Information Center (EVIC) display menus.
Front Fog Lamps - The optional equipment front fog lamps include the clear bulb, reflector and
clear lens of each adjustable front fog lamp unit.
Rear Fog Lamps - The optional equipment rear fog lamps include the clear bulb, reflector and
clear lens of each adjustable rear fog lamp unit.
Hazard Warning Lamps - The hazard warning lamps include the bulbs, reflectors and lenses of
each lamp in the right and left, front and rear turn signal circuits. The hazard lights are activated via
a button located on the switch pod.
Headlamps - Most Renegade international models are equipped with dual 70-millimeter projector
beam headlamps for outstanding forward- and spread-light performance.
When equipped with a bi-functional (high/low beam capability in a single lamp) high-intensity
discharge (HID) xenon lighting system (optional) - a technology that produces more than two-times
the light output of tungsten-based systems - the 70-millimeter projector beams increases spread
light by 15-percent and delivers a 20-percent improvement in forward lighting (range).
The larger projector beam reduces the amount of perceived "pinpoint" glare associated with the
HID lamps; due to a wider spread light pattern, shoulder visibility is enhanced while a less
concentrated beam of light reduces perceived glare to oncoming vehicles. The new 25W module
based headlamp doesn't require a washer and leveling system. The new bulb is a stand-alone
system that delivers a significant improvement on lifetime (4000h) and CO2 emission reduction.
Halogen infrared bulbs are used on base offerings (similar to what's applied on all North American
models). The bulbs incorporate a special coating that makes them burn hotter within the bulb
chamber, and in turn, provides wider spread light and higher output than traditional halogen bulbs.
Park Lamps - The front park (also known as clearance or position) lamps include the clear bulbs,
reflectors and clear lenses integral to the front combination lamp unit. The rear park (tail) lamps
include the clear bulbs, reflectors and red lenses integral to each rear lamp unit.
Turn Signal Lamps - The front turn signal lamps include the amber bulbs, reflectors and clear
lenses that are integral to the combination lamp unit. The amber bulbs and clear lenses of the
repeater lamps on each front fender are also included in the front turn signal circuits. The rear turn
signal lamps include an amber bulb, a reflector and a clear lens that is integral to each rear lamp
unit.
Other components of the exterior lighting system for this vehicle include:
Backup Lamp Switch - On vehicles with a manual transmission, a plunger-type backup lamp
switch is actuated by the shifter mechanism within the transmission when REVERSE gear is
selected. On vehicles with an optional automatic transmission a stand-alone Transmission Range
Sensor (TRS) performs the backup lamp switch function.
Body Control Module - The Body Control Module (BCM) is located beneath the instrument panel
to the left of the steering column in the passenger compartment.
Brake Lamp Switch - A plunger-type brake lamp switch is located on the brake pedal support
bracket under the instrument panel and is actuated by the brake pedal arm when the brake pedal is
depressed.
Clockspring - The clockspring includes an integral turn signal cancel cam and both the left
(lighting) and right (wiper) multi-function switches. The clockspring is located near the top of the
steering column, directly beneath the steering wheel.
Fig 5: Exterior Light Switch
Exterior Light Switch
- The exterior light activation switch is located on the left side of the driver side dashboard. The
exterior light switch has A knob to manage the following functions:
Parking lights
DRL
Auto-light
Dipped beam headlights
Two switches built into the knob and used to activate the following functions:
Front fog lights
Rear fog lights

Two wheels used to control the following:
Instrument panel backlighting adjustment (EMEA/NAFTA)
Interior lighting adjustment (NAFTA)
Headlight level. (EMEA)
Fog Lamp Switch - Vehicles equipped with optional front or both front and rear fog lamps have a
momentary fog lamp switch integral to the lower instrument panel switch pod located in the lower
center of the instrument panel heater and air conditioner control head.
Hazard Switch - A momentary push button-actuated hazard switch is integral to the upper
instrument panel switch pod located in the center of the instrument panel just below the radio and
above the heater and air conditioner controls.
Instrument Panel Cluster - The Instrument Panel Cluster (IPC) is located in the instrument panel
above the steering column opening, directly in front of the driver.
Instrument Panel Switch Pod - A momentary push button-actuated hazard switch is integral to
the upper instrument panel switch pod located in the center of the instrument panel just below the
radio. Vehicles equipped with optional fog lamps have a momentary fog lamp switch integral to the
lower instrument panel switch pod located in the lower center of the instrument panel heater and air
conditioner control head.
Left Multi-Function Switch - The left (lighting) multi-function switch is integral to the clockspring
located on the steering column, just below the steering wheel. A control stalk that extends from the
left side of the switch is used to select the turn signal lamps (right or left) and to select the
headlamp beam (low, high or optical horn). A control knob on the control stalk is used to turn the
exterior lighting ON or OFF.
Park Brake Switch - A park brake switch is located on the park brake lever mechanism on the
floor panel transmission tunnel between the two front seats.
Trailer Tow Wiring - This device includes an electronic control unit (Trailer Tow Module/TTM) that
controls the operation of the external lights located on the trailer, as well as a connection located in
the luggage compartment left side. This connection outlet is located next to the towbar. The rear
park assist sensors are automatically disabled when the trailer tow electrical socket is in use.
Hard wired circuitry connects the exterior lighting system components to the electrical system of the
vehicle. These hard wired circuits are integral to several wire harnesses, which are routed throughout
the vehicle and retained by many different methods. These circuits may be connected to each other, to
the vehicle electrical system and to the exterior lighting components through the use of a combination of
soldered splices, splice block connectors, and many different types of wire harness terminal connectors
and insulators. Refer to the appropriate SYSTEM WIRING DIAGRAMS article. The wiring information
includes wiring diagrams, proper wire and connector repair procedures, further details on wire harness
routing and retention, as well as pin-out and location views for the various wire harness connectors,
Following are paragraphs that briefly describe the operation of each of the major exterior lighting
systems. The lamps and the hard wired circuits between components related to the exterior lighting
system may be diagnosed using conventional diagnostic tools and procedures. Refer to the appropriate
connector repair procedures, details of wire harness routing and retention, connector pin-out information
However, conventional diagnostic methods will not prove conclusive in the diagnosis of the exterior
lighting system or the electronic controls or communication between modules and other devices that
provide some features of the exterior lighting system. The most reliable, efficient, and accurate means to
diagnose the exterior lighting system or the electronic controls and communication related to exterior
lighting system operation requires the use of a diagnostic scan tool. Refer to the appropriate Diagnostic
& Testing article.
BACKUP LAMPS - The backup (or reverse) lamps have a path to ground at all times through a takeout
and eyelet terminal of the body wire harness that is secured by a ground screw to the body sheet metal.
On vehicles with a manual transmission, when REVERSE is selected, the backup lamp switch provides a
hard wired input to the Powertrain Control Module (PCM) through a reverse switch signal circuit. The
PCM then sends an electronic reverse transmission gear selector status message to the Body Control
Module (BCM) over the Controller Area Network (CAN) data bus. The BCM energizes a high side driver
which provides battery voltage to the backup lamps on the backup lamp feed circuit whenever the
ignition switch is in the ON position and the REVERSE position is selected with the transmission shift
linkage.
On vehicles with an automatic transmission, the Transmission Control Module (TCM) monitors a
multiplex input from the Transmission Range Sensor (TRS). When REVERSE is selected, the TCM
sends an electronic reverse transmission gear selector status message to other electronic modules
over the CAN data bus. Whenever the ignition switch is in the ON position and the BCM receives an
electronic message indicating the status of the transmission gear selector is REVERSE, the BCM
energizes a high side driver, which provides battery voltage to the backup lamps on the backup lamp
feed circuit.
BRAKE LAMPS - The brake (or stop) lamps and the Center High Mounted Stop Lamp (CHMSL) each
have a path to ground at all times through a takeout and eyelet terminal of the body wire harness that is
secured by a screw to the body sheet metal. The BCM receives a battery voltage input whenever the
brake lamp switch is closed by the brake pedal arm. The BCM then energizes a high side driver, which
provides battery voltage to the brake lamps and the CHMSL through a tail/stop lamp rear feed circuits.
DAYTIME RUNNING LAMPS - Vehicles with the Daytime Running Lamps (DRL) feature enabled
illuminate the clearance (position) lamp bulbs in the upper cavity of the two lower front combination lamp
units when the engine is running, the parking brake is released, the headlamps are turned OFF, and the
optional automatic transmission gear selector lever is in any position except PARK. The park lamps may
be ON or OFF for DRL to operate. For vehicles with a manual transmission, the DRL will operate in any
transmission gear selector lever position. The BCM must be programmed appropriately for this feature to
be enabled.
Once enabled, anytime the BCM receives an electronic message input over the CAN data bus from the
PCM indicating the engine is running, hard wired inputs indicating the left (lighting) multi-function switch is
in any position except headlamps ON and the parking brake lever is released, and from the TCM
indicating the automatic transmission gear selector lever is in any position except PARK, the BCM
energizes a high side driver, which provides battery voltage to the clearance lamp bulbs through the right
and left clearance lamp feed circuits.
FOG LAMPS - The front fog lamps have a path to ground at all times through their connection to the
headlamp and dash wire harness. The engine compartment wire harness has takeouts with eyelet
terminals that are secured by screws to the front end sheet metal within the engine compartment. The
BCM monitors a hard wired input from the fog lamp switch in the lower instrument panel switch pod to
determine whether the front fog lamps are selected. If the front fog lamps are selected and the left
(lighting) multi-function switch inputs indicate the headlamp low beams are ON, the BCM energizes a high
side driver, which provides battery voltage to the front fog lamps through the right and left front fog lamp
feed circuits.
The BCM also sends the appropriate electronic messages to the Instrument Panel Cluster (IPC) over the
CAN data bus to illuminate or extinguish the front fog lamp indicator. The BCM will automatically
de-energize the front fog lamps any time the headlamps are turned OFF or the headlamp high beams are
selected.
Each front fog lamp includes an integral adjustment screw to be used for static aiming of the fog lamp
beams.
HAZARD WARNING LAMPS - The BCM monitors a hard wired input from the hazard switch in the lower
instrument panel switch pod located in the center of the air conditioner and heater control head to
determine whether the hazard warning system has been selected. When the hazard warning system is
selected, the BCM controls hazard warning system operation and flash rate by energizing and
de-energizing high side drivers, which controls battery voltage outputs on the right and left turn signal
feed circuits. The BCM also sends electronic hazard switch status messages to the IPC over the CAN
data bus to control the illumination and flash rate of the left and right turn signal indicators, as well as to
control the click rate of an electromechanical relay soldered onto the IPC electronic circuit board that
emulates the sound emitted by a conventional hazard warning flasher.
HEADLAMPS - The headlamp system includes the BCM, the IPC and the left (lighting) multi-function
switch on the steering column. The headlamp bulbs have a path to ground at all times through their
connection to the headlamp and dash wire harness. The headlamp and dash wire harness has takeouts
with eyelet terminals that are secured by screws to the front end sheet metal within the engine
compartment. The BCM monitors hard wired inputs to determine the status of the left multi-function
switch and whether the headlamp high or low beams are selected. The BCM then controls headlamp
illumination through relays soldered onto the BCM internal circuit board.
When the BCM detects a change in headlamp beam selection, the BCM energizes or de-energizes a
high side driver, which controls an output to the solenoid that operates the shutter in each headlamp. The
BCM also sends the appropriate electronic messages to the IPC to control the illumination of the high
beam indicator. The BCM remembers which beams (LOW or HIGH) were selected when the headlamps
were last turned OFF, and energizes those beams again the next time the headlamps are turned ON.
Each headlamp includes an integral reflector adjustment screw to be used for static aiming of the
headlamps.
HEADLAMP DELAY - The headlamp delay feature (also known as the Follow Me Home feature)
includes the left (lighting) multi-function switch, the IPC and the BCM. The BCM controls this feature by
monitoring inputs from the ignition switch and the left (lighting) multi-function switch. If within two minutes
after the ignition switch is turned to the OFF position, the left multi-function switch control stalk is pulled
toward the steering wheel and released the BCM energizes the relay that controls the headlamp low
beams and the high side driver that controls the clearance (position) lamps for 30 seconds. Each
additional activation of the control stalk extends the delay by 30 seconds, up to a maximum of 210
seconds. The BCM automatically de-energizes the lamps after the selected time interval expires or,
immediately, if the control stalk is pulled toward the steering wheel and held for more than two seconds.
The BCM also sends the appropriate electronic messages to the IPC over the CAN data bus to control
the Follow Me Home indications in the IPC display.
PARK LAMPS - The park lamps system includes the left (lighting) multi-function switch, the IPC and the
BCM. The clearance (position) lamp bulbs in the upper cavity of each lower front combination lamp unit
have a path to ground at all times through their connection to the headlamp and dash wire harness. The
headlamp and dash wire harness has takeouts with eyelet terminals that are secured by screws to the
front end sheet metal within the engine compartment. The park (tail) lamp bulbs in each rear lamp unit
and the license plate lamps have a path to ground at all times through a takeout and eyelet terminal of
the body wire harness that is secured by a screw to the body sheet metal within the passenger
compartment.
The BCM monitors a hard wired input from the left (lighting) multi-function switch, then responds to this
input by energizing or de-energizing high side drivers, which control battery voltage outputs to the
appropriate lamps and bulbs through the proper park/tail/license/running lamp right and left circuits. The
BCM also provides the appropriate electronic messages to the IPC to control the illumination and lighting
level of the panel lamps.
TURN SIGNAL LAMPS - The turn signal lamps system includes the left (lighting) multi-function switch,
the IPC and the BCM. The front turn signal lamp bulbs in the lower cavity of each lower front combination
lamp unit. The rear turn signal lamp bulbs have a path to ground at all times through a takeout and eyelet
terminal of the body wire harness that is secured by a screw to the body sheet metal within the
passenger compartment.
The BCM monitors a hard wired input from the left (lighting) multi-function switch to determine the status
of the turn signal switch, then controls turn signal operation and flash rate by energizing and
de-energizing high side drivers, which control battery voltage outputs on the right or left turn signal feed
circuits. The BCM also sends electronic turn signal switch status messages to the IPC over the CAN
data bus to control the illumination and flash rate of the left or right turn signal indicators, as well as to
control the click rate of an electromechanical relay soldered onto the IPC electronic circuit board that
emulates the sound emitted by a conventional turn signal flasher.
DIAGNOSIS AND TESTING > DIAGNOSIS AND TESTING - EXTERIOR LIGHTING
WARNING:
Restraint System (SRS) before attempting any steering wheel, steering column, airbag, seat
belt tensioner, impact sensor or instrument panel component diagnosis or service.
Disconnect and isolate the battery negative (ground) cable, then wait two minutes for the
system capacitor to discharge before performing further diagnosis or service. This is the
only sure way to disable the SRS. Failure to take the proper precautions could result in
accidental airbag deployment.
NOTE:
When diagnosing the exterior lighting circuits, remember that high generator output can burn
out bulbs rapidly and repeatedly; and, that dim or flickering bulbs can be caused by low
generator output or poor battery condition. If one of these symptoms is a problem on the
vehicle, be certain to diagnose the battery and charging system, then repair as necessary.
NOTE:
A good ground is necessary for proper lighting operation. If a lighting problem is being
diagnosed that involves multiple symptoms, systems, or components, the problem can often
be traced to a loose, corroded, or open ground.
WARNING:
On vehicles equipped with the high voltage system, disconnecting the 12-volt battery
negative cable alone will not power down the 12-volt system. You must perform the 12-volt
Power Down procedure before proceeding. Failure to follow these instructions may result in
The lamps and the hard wired circuits between components related to the exterior lighting system may
be diagnosed using conventional diagnostic tools and procedures. Refer to the appropriate SYSTEM
repair procedures, details of wire harness routing and retention, connector pin-out information and
However, conventional diagnostic methods will not prove conclusive in the diagnosis of the electronic
controls or communication between modules and other devices that provide some features of the
exterior lighting system. The most reliable, efficient and accurate means to diagnose the exterior lighting
system or the electronic controls and communication related to exterior lighting system operation
requires the use of a diagnostic scan tool. Refer to the appropriate Diagnostic & Testing article.
ACRONYMS USED IN THE FOLLOWING SERVICE INFORMATION
Body Control Module BCM
Center High-Mounted Stop Lamp CHMSL
Daytime Running Lamps DRL
Instrument Panel Cluster IPC
Transmission Range Sensor TRS
DIAGNOSIS AND TESTING > DIAGNOSIS AND TESTING - EXTERIOR LIGHTING >
BACKUP LAMPS
BACKUP LAMP DOES NOT 1. Ineffective or missing bulb. 1. Test and replace backup lamp bulb if
ILLUMINATE required.
2. Ineffective ground circuit. 2. Test and repair open backup lamp

3. Ineffective feed circuit. 3. Test and repair open backup lamp
4. Ineffective switch. 4. Test and replace backup lamp switch

(manual transmission) or TRS
(automatic transmission) if required.
5. Ineffective BCM inputs or 5. Use a diagnostic scan tool to test the

outputs. BCM inputs and outputs. Refer to the
appropriate Diagnostic & Testing article.
BACKUP LAMP DOES NOT 1. Ineffective feed circuit. 1. Test and repair shorted backup lamp
EXTINGUISH feed circuit if required.
2. Ineffective switch. 2. Test and replace backup lamp switch

(manual transmission) or TRS
(automatic transmission) if required.

BRAKE LAMPS
BRAKE LAMP DOES NOT 1. Ineffective ground circuit. 1. Test and repair open brake lamp
ILLUMINATE ground circuit if required.
2. Ineffective fuse. 2. Test and replace the fuse in the BCM

if required.
3. Test and repair open brake lamp

3. Ineffective feed circuit. switch output circuit or stop lamp output
4. Test and replace brake lamp switch if

4. Ineffective switch.
required.

BRAKE LAMP DOES NOT 1. Ineffective feed circuit. 1. Test and repair shorted brake lamp
EXTINGUISH switch output circuit or stop lamp output
2. Adjust the brake lamp switch if

2. Improperly adjusted switch.
required.
3. Test and replace brake lamp switch if

3. Ineffective switch.
required.
DAYTIME RUNNING LAMPS
NOTE:
Before performing the following tests, determine whether the clearance (also known as
position or park) lamps operate. If the clearance lamps are also ineffective, diagnose and
repair that problem before attempting to repair the Daytime Running Lamps.
DAYTIME RUNNING LAMPS 1. Incorrect BCM 1. Use the IPC to check and configure
WILL NOT ILLUMINATE programming. BCM if required.
2. Automatic transmission in 2. Place the transmission gear selector

PARK position. lever in any position except PARK.
3. Parking brake applied. 3. Release the parking brake.
4. Engine not running. 4. Start the engine.

FOG LAMPS
FOG LAMP DOES NOT 1. Ineffective or missing bulb. 1. Test and replace front fog lamp bulb if
2. Ineffective ground circuit. 2. Test and repair open front fog lamp
3. Ineffective feed circuit. 3. Test and repair open front fog lamp
4. Test and replace front fog lamp switch

4. Ineffective front fog lamp
(lower instrument panel switch pod) if
switch.
required.
FOG LAMP DOES NOT 1. Ineffective feed circuit. 1. Test and repair shorted front fog lamp
EXTINGUISH feed circuit if required.
2. Test and replace front fog lamp switch

2. Ineffective front fog lamp
(lower instrument panel switch pod) if
switch.
required.

HAZARD WARNING LAMPS
HAZARD WARNING LAMPS 1. Ineffective hazard warning 1. Test and replace hazard warning
DO NOT FLASH switch. switch if required.
2. Use a diagnostic scan tool to test the

2. Ineffective BCM inputs or
BCM inputs and outputs. Refer to the
outputs.
HAZARD WARNING LAMPS 1. Ineffective hazard warning 1. Test and replace hazard warning
DO NOT STOP FLASHING switch. switch if required.

outputs.

1. Ineffective ABS inputs or
ABS inputs and outputs. Refer to the
HAZARD WARNING LAMPS outputs.
DO ACTIVATE ON PANIC
BRAKING 2. Use a diagnostic scan tool to test the
outputs.
HEADLAMPS
HEADLAMP DOES NOT 1. Ineffective or missing bulb. 1. Test and replace headlamp bulb if
2. Ineffective ground circuit. 2. Test and repair open headlamp
3. Ineffective feed circuit. 3. Test and repair open headlamp low

beam or high beam feed circuit if
required.
4. Ineffective headlamp 4. Test and replace the headlamp switch

switch. if required.

HEADLAMP DOES NOT 1. Ineffective feed circuit. 1. Test and repair shorted headlamp low
EXTINGUISH beam or high beam feed circuit if
required.


MARKER LAMP
MARKER LAMP DOES NOT 1. Ineffective or missing bulb. 1. Test and replace bulb if required.
ILLUMINATE
2. Ineffective ground circuit. 2. Test and repair open ground circuit if
required.
3. Ineffective feed circuit. 3. Test and repair open feed circuit if

required.

HEADLAMP DOES NOT 1. Ineffective feed circuit. 1. Test and repair shorted feed circuit if
EXTINGUISH required.


TURN SIGNAL LAMPS
ONE TURN SIGNAL LAMP 1. Ineffective or missing bulb. 1. Test and replace turn signal bulb if
DOES NOT ILLUMINATE required.
2. Ineffective ground circuit. 2. Test and repair open ground circuit if

required.
3. Test and repair open right or left turn

3. Ineffective feed circuit.
signal feed circuit if required.
4. Ineffective BCM inputs or 4. Use a diagnostic scan tool to test

outputs. the BCM inputs and outputs. Refer to
the appropriate Diagnostic & Testing
article.
ALL RIGHT SIDE OR ALL LEFT 1. Ineffective feed circuit. 1. Test and repair open right or left turn
SIDE TURN SIGNAL LAMPS signal feed circuit if required.
(OR BOTH SIDES) DO NOT
2. Test and replace left (lighting) multi-
FLASH 2. Ineffective left (lighting)
function switch (clockspring) if
multi-function switch.
required.
3. Ineffective BCM inputs or 3. Use a diagnostic scan tool to test

outputs. the BCM inputs and outputs. Refer to
the appropriate Diagnostic & Testing
article.
ALL RIGHT SIDE OR ALL LEFT 1. Ineffective or missing bulb. 1. Test and replace turn signal bulb if
SIDE TURN SIGNALS FLASH required.
TOO RAPIDLY (MORE THAN
100 FLASHES PER MINUTE) 2. Ineffective ground circuit. 2. Test and repair open bulb ground
3. Ineffective feed circuit. 3. Test and repair open right or left turn
signal feed circuit if required.
TURN SIGNALS DO NOT 1. Inspect and replace the turn signal

1. Ineffective cancel cam.
AUTOMATICALLY CANCEL cancel cam (clockspring) if required.
2. Inspect and replace the turn signal

2. Ineffective cancel
cancel actuator (clockspring) if
actuator.
required.
UNIT, FRONT LAMP > STANDARD PROCEDURE > LAMP LENS DEFOGGING
Some customers may report that on occasion, vehicle exterior lamp assemblies are fogged with a light
layer of condensation on the inside of the lenses. This may be reported after the lamps have been
turned on and brought up to operating temperature, turned off, and then rapidly cooled by cold water
(such as rain, or the water from a car wash). Lens fogging can also occur under certain atmospheric
conditions after a vehicle has been parked outside overnight (i.e., a warm humid day followed by clear
cool night). This will usually clear as atmospheric conditions change to allow the condensation to change
back into a vapor. Turning the lamps on will usually accelerate this process.
A lamp that exhibits condensation/fogging should be evaluated in a service bay environment by first
drying all water from the outside surface of the lens and operating the lamp for 20 minutes. If the
condensation/fogging has begun to clear from the lamp lens after 20 minutes with the lamps operating,
this indicates the lamp sealing has not been breached, and the lamp does not need to be replaced.
If the condensation/fogging has not begun to clear after 20 minutes with the lamps operating, or the lamp
has large amounts of water droplets visible on most internal surfaces, this indicates a problem with the
lamp sealing that has allowed water to enter the lamp. In this instance, the customer is also likely to
report that moisture in the lamp is always present and never disappears. A lamp that exhibits internal
moisture permanently should be replaced.
UNIT, FRONT LAMP > REMOVAL AND INSTALLATION > FRONT LAMP UNIT >
REMOVAL
1. Disconnect the negative battery cable.
Fig 1: Front Lamp Unit
3. Disconnect the electrical connector (1).
4. Detach the cable from the clip (2).
5. Remove the screws (3a).
6. Remove the front lamp unit (3b).

UNIT, FRONT LAMP > REMOVAL AND INSTALLATION > FRONT LAMP UNIT >
INSTALLATION
1. Place the front lamp unit to the vehicle for installation.
2. Secure the front lamp unit to the vehicle using the provided screws from the removal.
3. Connect the cable back into the clip.
4. Connect the wiring harness connector to the back of the front lamp unit.
UNIT, FRONT LAMP > REMOVAL AND INSTALLATION > FRONT LAMP UNIT
BRACKET > REMOVAL
1. Remove the appropriate side front lamp unit. Refer to UNIT, FRONT LAMP, REMOVAL AND
INSTALLATION .
Fig 1: Front Lamp Unit Brackets
2. Use a saw to remove the damaged bracket along the lines (1) shown in the figure.
UNIT, FRONT LAMP > REMOVAL AND INSTALLATION > FRONT LAMP UNIT
BRACKET > INSTALLATION
1. Grind the remaining parts of the bracket to allow the new bracket to fit to the front lamp unit
perfectly.
Fig 1: New Bracket, Reference Pin & Screws
2. Position the new bracket (1a), fitting the reference pin (1b) in the relevant housing of the front
lamp unit.
3. Install the screws (2a) and tighten them joining the bracket (1a) to the front lamp unit
4. Install the front lamp unit. Refer to UNIT, FRONT LAMP, REMOVAL AND INSTALLATION .
Fig 2: New Bracket Mounting Area
LAMP, BACKUP > REMOVAL AND INSTALLATION > REMOVAL AND INSTALLATION >
BACKUP LAMP REMOVAL
2. Remove the rear fascia. Refer to FASCIA, REAR, REMOVAL AND INSTALLATION .
Fig 1: Back Up Lamp & Screws
3. Remove the screws (1a) and remove the backup lamp (1b).
LAMP, BACKUP > REMOVAL AND INSTALLATION > REMOVAL AND INSTALLATION >
BACKUP LAMP INSTALLATION
1. Check that the lamp is not damaged.
2. Put the lamp in place and tighten the screws.
3. Install the rear fascia. Refer to FASCIA, REAR, REMOVAL AND INSTALLATION .
LAMP, CENTER HIGH MOUNTED STOP > REMOVAL AND INSTALLATION >

Fig 1: Tailgate Trim Panel & Fasteners
2. Remove the screw (1).
3. Using special tool, remove the retainers (2) securing the tailgate trim panel.
4. Remove the tailgate trim panel (3).

Fig 2: Upper Tailgate Trim Panel & Fasteners
6. Using special tool, remove the retainers (2) securing the upper tailgate trim panel.
7. Remove the upper tailgate trim panel (3).

Fig 3: Caps & Fasteners
8. Remove the caps (1a).
9. Remove the screws (1b) and the nuts (1c).

Fig 4: Rear Spoiler, Electrical Connector, Washer Hose, Washer Jet & Retainers
10. Using special tool, remove the retainers (1a) and flip the rear spoiler.
11. Disconnect the washer hose from the rear windshield washer jet (2).
12. Disconnect the electrical connection (3).
13. Remove the rear spoiler (1b).

Fig 5: Rear Spoiler, Third Brake Light & Fasteners
14. Working on the rear spoiler, remove the mounting nuts (1a), retainers (1b) and the third brake
light (1c) (CHMSL).
LAMP, CENTER HIGH MOUNTED STOP > REMOVAL AND INSTALLATION >
REMOVAL AND INSTALLATION > INSTALLATION - CHMSL
1. Ensure that the CHMSL is not damaged.
2. Place the CHMSL to the spoiler, engage the retainers and tighten the mounting nuts.
3. Connect the washer fluid hose to the rear spoiler.
4. Connect the electrical connections to the spoiler.
5. Position the rear spoiler for installation.
6. Install the upper tailgate trim panel.
7. install the lower tailgate trim panel.
LAMP, FOG > REMOVAL AND INSTALLATION > FRONT FOG LAMP > FRONT FOG
LAMP REMOVAL
2. Turn the steering wheel to the left.

Fig 1: Splash Shield & Screws
3. Remove the screws (1a) and pull back the splash shield to gain access to the front fog lamp
assembly.
Fig 2: Fog Lamp, Electrical Connector & Screws
5. Remove the screws (2a) securing the fog lamp.
6. Remove the fog lamp (2b).

LAMP, FOG > REMOVAL AND INSTALLATION > FRONT FOG LAMP > FRONT FOG
LAMP INSTALLATION
1. Properly position the fog lamp for installation.
2. Secure the fog lamp using the screws provided from the removal process.
3. Connect the wiring harness connector to the back of the fog lamp assembly.
4. Position the wheel splash shield and secure using the screws provided from the removal
process.
LAMP, FOG > REMOVAL AND INSTALLATION > REAR FOG LAMP > REAR FOG
LAMP REMOVAL
Fig 1: Fog Lamp & Screws
3. Disconnect the wiring harness connector from the back of the fog lamp (1b).
4. Remove the screws (1a) securing the fog lamp.
5. Remove the fog lamp.

LAMP, FOG > REMOVAL AND INSTALLATION > REAR FOG LAMP > REAR FOG
LAMP INSTALLATION
1. Properly position the fog lamp for installation.
2. Secure the fog lamp using the screws provided from the removal process.
3. Connect the wiring harness connector to the back of the fog lamp assembly.
LAMP, LICENSE PLATE > REMOVAL AND INSTALLATION > REMOVAL AND

Fig 1: License Plate Lamp & Retainers
2. Using a special tool, remove the license plate lamp (1a) by disengaging the retainers (1b).
3. Disconnect the wiring harness connector to the license plate lamp.
LAMP, LICENSE PLATE > REMOVAL AND INSTALLATION > REMOVAL AND
INSTALLATION > LICENSE PLATE LAMP - INSTALLATION
1. Connect the wiring harness connector the license plate lamp.
2. Snap the licence plate lamp into the proper installed position.

LAMP, PARK AND TURN SIGNAL > REMOVAL AND INSTALLATION > REMOVAL AND
2. Remove the appropriate front wheel.

Fig 1: Splash Shield & Screws

3. Remove the various screws (1a) securing the front part (1b) of the splash shield to the vehicle.
4. Pull back on the shield to gain access to the turn signal lamp assembly.
Fig 2: Turn Signal Lamp, Electrical Connectors & Screws
5. Working from within the front fascia, disconnect the electrical connectors (1a, 1b) from the turn
signal lamp (1c).
6. Remove the screws (2a) and remove the turn signal lamp (1c).
LAMP, PARK AND TURN SIGNAL > REMOVAL AND INSTALLATION > REMOVAL AND
INSTALLATION > TURN SIGNAL LAMP INSTALLATION
1. Check that the turn signal lamp is not damaged.
2. Position and install the turn signal lamp to the vehicle.
3. Connect the electrical connections to the back of the turn signal lamp assembly.
4. Install and tighten the appropriate front wheel splash shield.
5. Install the appropriate front wheel to the vehicle.
6. Connect the negative battery cable to the battery.
LAMP, MIRROR > REMOVAL AND INSTALLATION > REMOVAL AND INSTALLATION >
MIRROR SIGNAL LAMP REMOVAL

Fig 1: Exterior Mirror, Tabs & Retainers
2. Remove the exterior mirror (1a) with a special tool, disengaging the tabs (1b) by retainers (1c).
Fig 2: Side Repeater & Retaining Clips
3. Remove the side repeater (1a) releasing the retaining clips (1b).
4. Pry off the lamp holder.
5. Remove the side repeater bulb to be replaced as needed.

LAMP, MIRROR > REMOVAL AND INSTALLATION > REMOVAL AND INSTALLATION >
INSTALLATION
1. Check that the side repeater is not damaged.
2. Install the bulb socket to the lamp.
3. Install the lamp aligned to the retaining clips.
4. Install the exterior mirror cover.
LAMP, TAIL > REMOVAL AND INSTALLATION > REMOVAL AND INSTALLATION >
REMOVAL

Fig 1: Inner Cover & Tail Lamp Screw

2. Remove the inner cover (1).
3. Remove the inner tail lamp screw (2).

Fig 2: Tail Lamp & Wiring Connector
4. Pull the tail lamp (1) from the outboard side so access and disconnect the wiring harness
connector (2).
5. Remove the tail lamp from the vehicle.

LAMP, TAIL > REMOVAL AND INSTALLATION > REMOVAL AND INSTALLATION >
INSTALLATION
1. Position the tail lamp (1) to the body for installation.
2. Connect the electrical connector (2) to the back of the tail lamp and then seat the lamp to the
body.
Fig 1: Inner Cover & Tail Lamp Screw
3. Install and tighten the tail lamp assembly retaining screw (2).
4. Install the access panel cover (1).

Fig 2: Tail Lamp & Wiring Connector
SWITCH, HEADLAMP > REMOVAL AND INSTALLATION > REMOVAL AND

INSTALLATION > HEADLAMP SWITCH REMOVAL

Fig 1: Remove/Install Headlamp Switch Removal
2. Using the appropriate tool, remove the switch (1b) by depressing the retaining clips (1a).
3. Disconnect the wiring connector from the switch assembly.
SWITCH, HEADLAMP > REMOVAL AND INSTALLATION > REMOVAL AND

INSTALLATION > HEADLAMP SWITCH INSTALLATION
1. Check that the switch is not damaged.
2. Connect the wiring harness connector to the back of the headlamp switch.
3. Position the switch the dashboard opening and push inward until the retaining clips are
snapped in place.
SWITCH, MULTIFUNCTION > REMOVAL AND INSTALLATION > REMOVAL AND

INSTALLATION > REMOVAL AND INSTALLATION
NOTE:
The clockspring and stalk unit for this vehicle includes the right (wiper) multifunction switch,
the left (lighting) multifunction switch and the clockspring. The two multifunction switches and
the clockspring are inseparable from the clockspring and stalk unit and are serviced only as
a unit. If any function or feature of either multifunction switch or the clockspring is ineffective
or damaged, or if the Driver AirBag (DAB) has been deployed, the entire clockspring and
stalk unit must be replaced with a new unit.
SWITCH, STOP LAMP > REMOVAL AND INSTALLATION > REMOVAL AND
WARNING:
CAUTION:
Never remove or install the brake lamp switch while the brake pedal arm is disassembled
from the brake booster push rod.
CAUTION:
Do not depress, lift or move the brake pedal during brake lamp switch removal to avoid
switch damage. Do not depress, lift or move the brake pedal during brake lamp switch
installation to avoid improper switch adjustment.
Fig 1: Support Bracket & Brake Lamp Switch
1. Disconnect and isolate the battery negative cable.
2. Locate the brake lamp switch (1) on the brake pedal support bracket (3) on the dash panel
under the instrument panel.
3. Disconnect the body wire harness connector from the brake lamp switch.
4. Press the brake lamp switch against the bracket while rotating the switch housing clockwise
about 45 degrees to align the tabs on the switch locking collar with the keyed hole in the brake
pedal support bracket.
5. Pull the switch straight away from the keyed hole to remove it from the bracket.
6. Remove the switch from the vehicle.
Fig 2: Identifying Brake Switch Condition
NOTE:
If damage to the switch is present for any reason the switch is to be replaced. If a
switch is removed and the plunger length differs from a new switch, the switch
should always be replaced and not reinstalled. The nominal height for a new switch
(tip of the plunger to the body of the switch) is 16.90mm.
1. Defective brake switch due to the switch tab being sheared off.
2. Defective brake switch due to the switch tab being offset,
3. Normal operational brake lamp switch to be used for installation.
SWITCH, STOP LAMP > REMOVAL AND INSTALLATION > REMOVAL AND
WARNING:
CAUTION:
Never remove or install the brake lamp switch while the brake pedal arm is disassembled
from the brake booster push rod.
CAUTION:
Do not depress, lift or move the brake pedal during brake lamp switch removal to avoid
switch damage. Do not depress, lift or move the brake pedal during brake lamp switch
installation to avoid improper switch adjustment.
NOTE:
Be certain that the brake pedal bracket is not bent or damaged before installing or
reinstalling a brake lamp switch. Inspect the brake switch tab location making sure its
in the proper location indicating that the switch is not defective.
Fig 1: Identifying Brake Switch Condition
NOTE:
If damage to the switch is present for any reason the switch is to be replaced. If a
switch is removed and the plunger length differs from a new switch, the switch
should always be replaced and not reinstalled. The nominal height for a new switch
(tip of the plunger to the body of the switch) is 16.90mm.
1 - Defective brake switch due to the switch tab being sheared off.
2 - Defective brake switch due to the switch tab being offset.
3 - Normal operational brake lamp switch to be used for installation.

Fig 2: Support Bracket & Brake Lamp Switch
1. Position the brake lamp switch (1) near the brake pedal support bracket (3) on the dash panel
under the instrument panel.
2. Align the tabs on the brake lamp switch locking collar with the keyed hole in the brake pedal
support bracket.
3. Holding the brake lamp switch perpendicular to the support bracket, insert the tabs on the brake
lamp switch locking collar through the keyed hole in the support bracket until the switch housing
is firmly seated against the bracket.
4. Rotate the switch housing counterclockwise about 45 degrees to engage the tabs on the
locking collar with the support bracket.
5. Connect the body wire harness connector to the connector receptacle on the switch.
6. Connect the battery negative cable.

Service Manual: SPEED CONTROL - SERVICE Jeep Renegade
INFORMATION
DESCRIPTION AND OPERATION > ADAPTIVE > ADAPTIVE CRUISE CONTROL ACC
Fig 1: Adaptive Cruise Control Plus
The car can be equipped with Adaptive Cruise Control Plus (ACC +), which greatly increases the value
and comfort of the cruise control, especially in congested traffic.
The system uses a radar sensor mounted in the front area of the vehicle (in the lower portion behind the
front bumper) to detect objects on the trajectory of the car. If the lane ahead is clear, the system
maintains the speed set. When the system detects slow traffic or a vehicle ahead at a lower speed, it
will automatically adjust the speed of the car to keep a safe distance (which is set by the driver with the
dedicated button on the steering wheel) by using the engine load, the transmission and the brake system
of the vehicle.
The ACC works from about 30 km/h (20 mph) Detail below:
The radar is used to identify vehicles in the lane ahead and to keep the distance between the
vehicle and the vehicle ahead.
The ACC has the full functionality between approximately 30 km/h (20 mph) and 200 km/h (100
mph);
When the speed drops below 30 km/h (20 mph), the system is deactivated and warns the drivers
that they must use the brakes to stop the car, if necessary;
The driver can select one of four levels of distance depending on their preferences;
When the car is equipped with a manual transmission, the driver must shift up or down to keep the
engine at a correct rev value.
The system is always coupled with the speed limiter function (speed limitation function), which
informs the driver if the set speed is exceeded.
Fig 2: Adaptive Cruise Control Plus Switches
DRIVING ASSISTANCE SYSTEM CONTROLS DRIVER INPUTS

1. ACC ON/OFF Switch
2. ACC Closer Distance Switch
3. Speed Limiter switch
Fig 3: Driving Assistance System Distance Settings
The CC and ACC+ are activated by the mode switch on the front right side of the steering wheel. With
the function ACC+ the driver can choose one of four distance settings using the switch located on the
bottom right side of the steering wheel:
1. Very close 1.0 seconds
2. Close 1.3 seconds
3. Far 1.7 seconds
4. Very far 2.0 seconds
The steering wheel switch sends the driver input to the BCM over a LIN line. The BCM translates the
messages and sends them to the ACC sensor on CAN-C.
The ACC sensor interprets and processes all of the inputs received. If these inputs indicate a possible
collision, the ACC sensor sends messages to other modules on CAN-C. These modules perform actions
in an effort to assist the driver in the prevention of the collision and, if possible, in keeping the distance,
set by the driver, from the vehicle ahead.
The following output functions are performed based on decisions made by the ACC sensor processor:
IPC - Provides visual system status and warning messages
BCM - Translates ACC sensor audio warning requests and sends them to the audio system
controller
ABS module
Performs braking during ACC+ to maintain the set distance
Perform plausibility check on torque and brake requests
Translates ACC sensor torque requests and sends them to the PCM
Translates ACC sensor gear requests and sends them to the TCM
Slightly raises brake hydraulic pressure to decrease brake reaction time
Creates brake system hydraulic pressure pulses which cause the brake pedal to jerk warning
the driver of an impending collision
Performs braking during an FCW+ event
Performs braking with Advanced Brake Assist function
PCM - Performs torque requests received from ACC sensor via the ABS module
TCM - Performs transmission up and down shifts received from the ACC sensor via the ABS
module
Network Inputs - The ACC sensor receives inputs from other modules on the vehicle, such as:
ABS module
Vehicle speed
Vehicle Dynamics
Forward Facing Camera Module
Object Classification Data
Object Positioning Data
BCM - Steering Wheel Switch Inputs
PCM - Provides expected current torque values to the ACC sensor
TCM - Provides current transmission information to the ACC sensor
IMPORTANT: Driver assist systems are reactive type. While certain mitigation provided by these
systems may help prevent a collision, they cannot be assumed to insure accident avoidance in all
circumstance. The driver must remain alert and in control of the vehicle at all times and operate the
vehicle in a safe manner consistent with road and traffic conditions.
Fig 4: Speed Limiter Button
SPEED LIMITER - This device allows the speed of the vehicle to be limited to values which can be set
by the driver. The maximum speed can be set both with car stationary and in motion. The minimum speed
that can be set is 30 km/h.
When the device is active, the car speed depends on the pressure at the accelerator pedal, until the set
speed limit is reached. If necessary (in the event of overtaking for example), the programmed speed limit
can be exceeded by fully depressing the accelerator pedal.
By gradually reducing the pressure on the accelerator pedal, the function will be reactivated as soon as
the car speed drops below the set speed.
If the electronic Cruise Control has been activated previously, the S.L. button must be pressed twice.
The first press deactivates the Cruise Control function, the second press activates the Speed Limiter.
DESCRIPTION AND OPERATION > CONVENTIONAL > SPEED CONTROL
The function of speed control allows you to drive at a constant speed without pressing the accelerator
pedal. The function is managed by the Powertrain Control Module (PCM), which receives commands
from the speed control buttons on the steering wheel. The function is activated by pressing the speed
control switch which then stores a speed. Increase the speed with the (SET +) button or decrease the
speed with (SET -) button. The speed remains stored and can be restored at any moment by pressing
the RES (resume) button. The function is deactivated by pressing the DELETE key.
The function also automatically switches off:
Pressing the brake pedal
Pressing the clutch pedal
Switching off the engine
In these cases, the speed reached remains stored and will be set again to that speed by pressing the
RES. A activated system is indicated by a light on the instrument panel, connected via the CAN network
to the engine management.
SPEED LIMITER FUNCTION
Thee Speed Limiter function allows you to limit the speed of the vehicle to customer programmable
values. The speed limiter button is located on the steering wheel below the speed control buttons. The
maximum programmable speed is 30 km/h.
SWITCH, SPEED CONTROL > REMOVAL AND INSTALLATION > REMOVAL AND
1. Remove the air bag. Refer to AIR BAG, DRIVER, REMOVAL AND INSTALLATION .
Fig 1: Nut Cover
2. Release the cover (1) for the nut on the hub.

Fig 2: Airbag Module, Steering Wheel, Nut, Controls & Connector
3. Disconnect the electrical connection (1) for the steering column stalk.
4. Remove the steering wheel retaining nut (2).
5. Remove the steering wheel (3a) including the upper (3b) and lower (3c) steering wheel controls
and cruise control system controls (3d), releasing the wiring for the airbag module (3e).
Fig 3: Cover, Screw, Module, Wiring, Retainers & Connector
6. Use a suitable tool to pry up the cover (1a) and undo the screw underneath (1b).
7. Raise the module (2a) release the wiring (2b) from the retainers (2c) and disconnect the
electrical connection (2d).
Keep the module for the lower radio control.

Fig 4: Module, Screw, Wiring & Connector
8. Remove the screw (1a) and raise the module (1b).
9. Release the wiring (2a) from the retainers and the electrical connection (2b) from its housing.
Fig 5: Speed Control Switch & Connector
10. Disconnect the electrical connection (1).

NOTE:
Operate in the same way to remove the upper and lower radio control modules on the
opposite side of the steering wheel.
SWITCH, SPEED CONTROL > REMOVAL AND INSTALLATION > REMOVAL AND
1. Check that the steering wheel is not damaged.
2. If removed, refit the cruise control and radio control modules on the steering wheel, operating
as follows:
3. Position the wiring on the steering wheel and engage it with the retainers.
4. Connect the electrical connection then insert it in its housing.
5. Fit the cruise control module and upper radio control module on the steering wheel in position,
then tighten the screw.
6. Connect the electrical connection for the lower radio control module and secure the wiring to
the retainers.
7. Position the lower radio control module in its housing and tighten the screw.
8. Fit the cover in position.
9. Move the steering wheel closer and connect the electrical connection for the steering column
stalk unit.
10. Position the steering wheel in its housing, fitting the centering pin.
11. Tighten the steering wheel fixing nut to torque. 45-55 nM
12. Fit the cover for the nut on the hub.
13. Install the air bag. Refer to AIR BAG, DRIVER, REMOVAL AND INSTALLATION .
Service Manual: WIPER SYSTEM & WASHER SYSTEM - Jeep Renegade
SERVICE INFORMATION
The wiper system consists of the following components:
Fig 1: Front Electric Motor Connected To Front Wiper Mechanism
Front electric motor connected to the front wiper mechanism

Fig 2: Rear Electric Motor Connected To Rear Wiper Mechanism
Rear electric motor connected to the rear wiper mechanism

Fig 3: Activation Controls On Steering Column Stalk
Activation controls on the steering column stalk

Fig 4: Two-Way Electric Pump & Washer Fluid Reservoir
Two-way electric pump for the windshield and rear window washer circuit. The washer fluid circuit
is supplied by a two-way electric pump located in the lower part of the washer fluid reservoir.
Fig 5: Rain Sensor
RLS - Rain sensor (if Rain sensor = present in the BCM proxy)
The vehicle may be equipped with a rain detection sensor on the windshield. When rain/water is
detected on the windshield, the system will automatically operate the wipers. The system uses an
infrared sensor fitted behind the windshield in front of the interior rear view mirror. The sensor
continuously sends infrared rays against the windshield to detect the presence of water on the glass; if
detected, the sensor will send a signal on the Local Interface Network (LIN) data bus to the Body Control
Module (BCM), which will activate the wiper at the appropriate speed.
The rain sensor is built into an electronic Rain/Light Sensor Module (RLSM) which, in addition to
detecting moisture on the windshield, enables the dusk function by measuring ambient light levels.
According to this information and the sensitivity level set by the user, it controls both windshield cleaning
and running lights.
Operating conditions.
Ignition switch status Function that can be activated
OFF Servicing position
Front wiper
Rear wiper
ON
Windshield washer circuit
Rear window washer circuit.
Windshield wiper - cut-off
Rear window wiper - cut-off
Windshield washer circuit - cut-off
START
Rear window washer circuit - cut-off
Note: If the rain sensor is present, automatic mode
is selected by default during starting.
Fig 1: Activation Controls On Steering Column Stalk
Wiper activation controls on the steering column stalk.
The windshield (1st and 2nd speed) and rear window wipers can be activated via the controls on the
steering column stalk.
Fig 2: Steering Column Stalk Operation
The control on the steering column stalk is electrically connected to the Body Control Module (BCM).
This receives MUX signals (different levels of resistance according to the position of the lever) from the
steering column stalk.
The BCM controls the windshield and rear window wiper motors directly.
The BCM activates the electric pump of the washer pump circuit in accordance with the command from
the steering column stalk.
DESCRIPTION AND OPERATION > DESCRIPTION AND OPERATION > OPERATION >
OPERATING MODES - FRONT
Following are paragraphs that briefly describe the operation of each of the front wiper and washer
system operating modes.
Continuous Wipe Mode - When the Continuous Low position of the right (wiper) multifunction
switch control knob is selected, the switch provides a resistor multiplexed input to the BCM. The
BCM responds by energizing a relay that directs battery current to the low speed brush of the wiper
motor, causing the wipers to cycle at low speed.
When the Continuous High position of the right (wiper) multifunction switch control knob is
selected, the switch provides a resistor multiplexed input to the BCM. The BCM responds by
energizing a relay that directs battery current to the high speed brush of the wiper motor, causing
the wipers to cycle at high speed.
When the Off position of the right multifunction switch control knob is selected, the switch provides
a resistor multiplexed input to the BCM. The event that occurs depends upon the position of the
wiper blades on the windshield at the moment that the control knob Off position is selected.
If the wiper blades are in the down position on the windshield when the Off position is selected, the
park switch that is integral to the wiper motor is closed to ground, which provides a hard wired park
switch sense input to the BCM. The BCM then de-energizes the wiper motor and the wiper motor
ceases to operate.
If the wiper blades are not in the down position on the windshield at the moment the Off position is
selected, the park switch is an open circuit and the BCM continues running the wiper motor at low
speed until the wiper blades are in the down position on the windshield and the park switch input to
the BCM is again closed to ground.
Intermittent Wipe Mode - The following applies to vehicles not equipped with the optional
automatic wiper system (which is only available in vehicles manufactured for Europe-Middle
East-Africa/EMEA markets), or to vehicles equipped with the automatic wiper system that have
had that feature disabled using the setup menu in the Instrument Panel Cluster (IPC).
When the right (wiper) multifunction switch control knob is moved to one of the two Delay
(Intermittent) positions, the switch provides a resistor multiplexed input to the BCM. The BCM
electronic intermittent wipe logic circuit responds by calculating the correct length of time between
wiper sweeps based upon the interval selected using the control knob on the end of the control
stalk. The BCM logic also uses both time and electronic vehicle speed message inputs to
calculate the appropriate delay intervals. The BCM then provides control outputs to energize and
de-energize the relays to operate the wiper motor intermittently for one low speed cycle at a time.
Automatic Wipe Mode - If the vehicle is equipped with the optional automatic wiper system
(available only in vehicles manufactured for EMEA markets) and it is enabled, when the control
knob on the control stalk of the right (wiper) multifunction switch is moved to one of the two Delay
(Intermittent or Sensitivity) positions, the switch provides a resistor multiplexed input to the BCM.
The BCM, which is also a Local Interface Network (LIN) data bus master node, relays the wiper
switch sensitivity message to the Light Rain Sensor Module (LRSM) (also known as the Rain
Light Sensor Module/RLSM, the Light Sensor Module/LSM or the Rain Sensor Module/RSM),
which is a LIN slave node over the LIN data bus.
The LRSM monitors an area within the wipe pattern of the windshield glass for the accumulation of
moisture. Based upon internal programming and the selected sensitivity level, when sufficient
moisture has accumulated the LRSM sends the appropriate electronic wipe command messages
back to the BCM over the LIN data bus. Then the BCM operates the wiper system accordingly.
As the sensitivity level is set higher, the LRSM is more sensitive to moisture accumulation and will
send wipe commands more frequently. The BCM logic is also programmed to provide an
immediate wipe cycle each time the control knob on the control stalk of the multifunction switch is
moved from the Off position to one of the two sensitivity positions, and another immediate wipe
cycle each time the control knob is moved from a lower sensitivity position to a higher sensitivity
position.
Also, if a vehicle is equipped with automatic wipers but the feature has been disabled using the
setup menu in the IPC, when any sensitivity position is selected with the right multifunction switch
control knob the system will respond in the same manner as in the intermittent wipe mode. The
automatic wiper system has features designed to protect the mechanical components of the wiper
system, and will not allow automatic wiper operation under the following conditions:
Low Ambient Temperature - When the ambient temperature is below 0° C (32° F), the
automatic wipers will not operate during a new ignition cycle until the wiper switch has been
moved to a different position than that which was selected at the moment the current ignition
cycle began, or until a vehicle speed input is detected.
Transmission In Neutral - When the transmission gear selector is placed in the Neutral N
position while the ignition status is On, the automatic wipers will not operate during the
current ignition cycle until the wiper switch has been moved to a different position than that
which was selected at the moment that Neutral N was selected, until the vehicle speed is
greater than 8 km/h (5 mph) or until the transmission gear selector is moved out of the
Neutral N position, whichever occurs first.
Mist Wipe Mode - When the right (wiper) multifunction switch control stalk is moved upward to the
momentary Mist (Pulse) position, the switch provides a resistor multiplexed input to the BCM. The
BCM responds by energizing a relay that directs battery current to the low speed brush of the wiper
motor, causing the wipers to operate for one complete low speed cycle. The BCM can operate the
front wiper motor in this mode for only one low speed cycle at a time, or for an indefinite number of
sequential low speed cycles, depending upon how long the switch is held closed.
Headlamps On With Wipers Mode - The circuitry of the BCM provides an automatic Headlamps
On With Wipers mode for vehicles equipped with the optional automatic headlamps. This feature
can be enabled or disabled through the setup menu of the IPC. If this feature is enabled, when the
headlamp switch is in the Auto position, the headlamps will turn On automatically whenever the
windshield wipers are turned On; and, if the headlamps were turned On automatically when the
wipers were turned On, they will also turn Off automatically when the wipers are turned Off.
If this feature is enabled in vehicles equipped with the optional automatic wiper feature, when the
automatic wiper mode is selected the headlamps will turn On automatically only after the wipers
complete three automatic wipe cycles within about 30 seconds, and they will turn Off automatically
after 3 minutes elapse without any automatic wipe cycles unless ambient light conditions dictate
otherwise.
Wash Mode - When the control stalk of the right (wiper) multifunction switch is pulled rearward to
the momentary front Wash position, the switch provides a resistor multiplexed input to the BCM.
The BCM responds by providing battery current and ground to the washer pump/motor. This will
cause the washer pump/motor to be energized in the front wash direction for as long as the switch
is held closed and to be de-energized when the control stalk is released.
When the control stalk is pulled rearward to the momentary front Wash position while the front
wiper system is operating in the Delay mode (or sensitivity level with automatic wipers), the
washer pump/motor operation is the same. However, the BCM also overrides the Delay mode and
operates the front wiper motor in a continuous low speed mode for as long as the control stalk is
held in the Wash position, then reverts to the selected Delay mode or sensitivity level operation
several wipe cycles after the control stalk is released.
Wipe-After-Wash Mode - When the control stalk of the right (wiper) multifunction switch is pulled
rearward to the momentary front Wash position for more than about one-half second while the
wiper system is not operating, the BCM directs battery current and ground to the washer
pump/motor and energizes the wiper motor in a continuous low speed mode for as long as the
switch is held closed. When the control stalk is released, the BCM de-energizes the washer
pump/motor immediately, but allows the wiper motor to operate for about three additional wipe
cycles. An additional wipe cycle is performed about six seconds later before the BCM de-energizes
the wiper motor and parks the wiper blades near the base of the windshield.
The BCM monitors the changing state of the wiper motor park switch through a hard wired wiper
park switch sense circuit input. This input allows the BCM to monitor the number of wipe cycles
that occur after the control stalk is released, and to determine the proper interval at which to
de-energize the wiper motor to complete the Wipe-After-Wash mode cycle.
DIAGNOSIS AND TESTING > FRONT WIPER AND WASHER SYSTEM
WARNING:
If the wiper motor operates, but the wiper blades do not move on the windshield with the wiper arms
properly installed, replace the ineffective front wiper motor or wiper linkage module. If the washer
pump/motor operates, but no washer fluid is dispensed on the glass; or, if the wipers operate, but
chatter, lift, or do not clear the glass, clean and inspect the front wiper and washer system components
as required. Refer to CLEANING and INSPECTION .
The hard wired front wiper and washer system circuits and components may be diagnosed using
However, conventional diagnostic methods will not prove conclusive in the diagnosis of the front wiper
and washer system or the electronic controls and communication between other modules and devices
that provide some features of the front wiper and washer system. The most reliable, efficient and
accurate means to diagnose the front wiper and washer system or the electronic controls and
communication related to front wiper and washer system operation requires the use of a diagnostic scan
tool. Refer to the appropriate Diagnostic & Testing article.
FRONT WIPER AND WASHER SYSTEM DIAGNOSIS
WIPER MOTOR DOES NOT 1. Ineffective motor ground 1. Test and repair open wiper motor ground
OPERATE IN ANY SWITCH circuit. circuit if required.
POSITION
2. Test and repair low speed and high
2. Ineffective motor feed
speed feed circuits between Body Control
circuits.
Module (BCM) and wiper motor if required.
3. Ineffective right 3. Test and replace the clockspring and

multifunction switch. stalk unit if required.
4. Use a diagnostic scan tool for further

testing of the BCM. Refer to the
outputs.
5. Ineffective wiper motor. 5. Test and replace open or shorted wiper

motor as required.
WIPER MOTOR OPERATES 1. Ineffective wiper motor. 1. Check amperage draw with linkage
SLOWLY IN ALL SWITCH disconnected from wiper motor output shaft.
POSITIONS Correct draw should be about 6 amperes. If
incorrect, refer to the appropriate Possible
Cause that follows:
2. Test and repair shorted low and high

2. Amperage draw too low.
speed feed circuits if required.
3. Amperage draw too high. 3. With linkage disconnected from wiper

motor output shaft, check linkage and
pivots for binding. If binding is detected,
repair or replace wiper linkage module if
required. If no linkage binding detected,
replace the wiper motor if required.
WIPERS RUN AT HIGH 1. Ineffective motor feed 1. Test and repair low speed and high
SPEED WITH SWITCH LOW circuit wiring. speed feed circuits between BCM and the
SPEED SELECTED OR AT wiper motor if required.
LOW SPEED WITH SWITCH
HIGH SPEED SELECTED
1. Automatic wipers (Rain 1. Be certain that the automatic wipers

AUTOMATIC WIPERS ONLY
Sensing) feature has been (Rain Sensing) feature is enabled in the
ARE INOPERATIVE
disabled. Instrument Panel Cluster (IPC) setup menu.
WASHER PUMP DOES NOT 1. Ineffective washer pump 1. Test and repair open washer pump
OPERATE ground circuit. ground circuit if required.
2. Test and repair washer pump feed
2. Ineffective washer pump
circuits between BCM and washer pump if
feed circuit.
required.


outputs.
5. Test and replace open or shorted washer

5. Ineffective washer pump.
pump if required.
DIAGNOSIS AND TESTING > FRONT WIPER AND WASHER SYSTEM > DIAGNOSING
FALSE WIPES (AUTOMATIC WIPER ONLY)
False wipes are unnecessary wipes that occur when the control knob of the right multifunction switch is
in one of the two automatic wiper sensitivity positions and no rain or moisture is apparent within the wipe
pattern on the windshield glass. Because this system is designed to operate whenever it detects
moisture, if the switch is in one of the automatic wiper sensitivity positions any road spray, bug splatters
or mist from passing cars or trucks may occasionally cause the wipers to cycle. These are normal
characteristics of this system and are not false wipes.
False wipes generally are the result of foreign material or flaws that interfere with the system optics. The
optics for this system allow the Light Rain Sensor Module (LRSM) to precisely transmit several InfraRed
(IR) light beams and monitor the intensity of these beams reflected from the outer surface of the
windshield glass to determine the presence of moisture. The sensitivity of this system is such that
anything that distorts the focus or intensity of the IR light beams or impacts the ability of the photo
diodes within the LRSM to see and accurately measure these light beams can result in the LRSM logic
misinterpreting the resulting input data as moisture on the windshield. The optics for this system include
the lenses of the LRSM, the adhesive silicone gelatin (SilGel) layer that bonds the LRSM to the inside of
the windshield and the windshield glass.
The following procedure should only be used if false wipe occurrences are frequent and persistent.
Perform diagnosis of the wiper system, the right multifunction switch and microcontroller of the Body
Control Module (BCM) and the LRSM using a diagnostic scan tool and the appropriate diagnostic
procedures before performing the following:
NOTE:
The LRSM mounting bracket is serviced as a unit with the windshield glass. If either the
bracket or the glass is ineffective or damaged, the entire LRSM bracket and windshield
glass unit must be replaced. Also, if the LRSM is removed from the mounting bracket for any
reason, the integrity of the adhesive silicone gelatin (SilGel) layer of the LRSM will be
compromised and the silicone gelatin pad must be replaced with a new unit.
1. Carefully inspect the outer surface of the windshield glass for physical damage, including
scratches, cracks or chips in the vicinity of the LRSM mounting bracket. Scratches, cracks or
chips in the windshield glass outside the area of the LRSM mounting bracket lenses will
not cause false wipes. If OK, go to Step 2. If not OK, replace the damaged windshield.
2. From the outside of the windshield glass, carefully inspect the adhesive layer between the
windshield glass and the LRSM bracket for any large voids (air pockets). If an adhesive void
greater than about 1 millimeter (0.04 inch) is observed, replace the flawed silicone gelatin pad.
If OK, go to Step 3.
3. Lightly pull the LRSM away from the windshield bracket to confirm that both sides of the spring
steel LRSM mounting band are fully engaged with the mounting bracket on the inside of the
windshield glass. If OK, go to Step 4. If not OK, install the LRSM mounting band onto the
bracket as required.
4. Remove the LRSM from the mounting bracket. Carefully inspect the LRSM mounting bracket
for any physical damage and inspect the windshield glass area within the LRSM mounting
bracket for contamination. If OK, go to Step 5. If contaminated, clean any foreign material from
the windshield glass using rubbing alcohol and a lint-free cloth. If damaged, replace the
damaged LRSM bracket and windshield as a unit.
5. Carefully replace the LRSM with a new unit. Refer to MODULE, LIGHT RAIN SENSOR,
DIAGNOSIS AND TESTING > REAR WIPER AND WASHER SYSTEM
WARNING:
If the rear wiper motor operates, but the wiper motor output shaft does not move, replace the ineffective
rear wiper motor. If the washer pump/motor operates, but no washer fluid is dispensed on the glass; or, if
the wiper operates, but chatters, lifts, or does not clear the glass, clean and inspect the rear wiper and
washer system components as required. Refer to CLEANING and INSPECTION .
The hard wired rear wiper and washer system circuits and components may be diagnosed using
However, conventional diagnostic methods will not prove conclusive in the diagnosis of the electronic
controls and communication between other modules and devices that provide some features of the rear
wiper and washer system. The most reliable, efficient and accurate means to diagnose the rear wiper
and washer system or the electronic controls and communication related to rear wiper and washer
system operation requires the use of a diagnostic scan tool. Refer to the appropriate Diagnostic &
Testing article.
REAR WIPER AND WASHER SYSTEM DIAGNOSIS
WIPER MOTOR DOES NOT 1. Ineffective motor ground 1. Test and repair open wiper motor ground
OPERATE IN ANY SWITCH circuit. circuit if required.
POSITION
2. Test and repair motor feed circuit
2. Ineffective motor feed
between Body Control Module (BCM) and
circuits.
rear wiper motor if required.


4. Ineffective BCM inputs or testing of the BCM inputs and outputs.
outputs. Refer to the appropriate Diagnostic &
Testing article.
5. Ineffective wiper motor. 5. Test and replace open or shorted wiper

motor if required.
1. Test and repair wiper park switch input

1. Ineffective wiper motor
circuit between BCM and rear wiper motor if
park switch input circuit.
required.
WIPER DOES NOT PARK 2. Use a diagnostic scan tool for further
CORRECTLY testing of the BCM. Refer to the appropriate
outputs.
3. Ineffective wiper motor 3. Test and replace ineffective wiper motor

park switch. if required.
WIPER MOTOR OPERATES 1. Ineffective wiper motor. 1. Check amperage draw with wiper arm
SLOWLY disconnected from rear wiper motor output
shaft. Correct draw should be about 6
amperes. If incorrect, refer to the
appropriate Possible Cause that follows:
2. Test and repair shorted rear wiper motor

2. Amperage draw too low. signal and fused ignition switch output (run -
accessory) circuits if required.
3. Amperage draw too high. 3. With wiper arm disconnected from wiper
motor output shaft check for binding
between output shaft and motor output shaft
housing. If binding is detected, lubricate if
required. If no binding is detected, replace
the wiper motor if required.
1. Ineffective washer pump 1. Test and repair open washer pump

WASHER PUMP DOES NOT ground circuit. ground circuit if required.
OPERATE 2. Ineffective washer pump 2. Test and repair washer pump feed circuit
feed circuit. between BCM and washer pump if required.

testing of the BCM. Refer to the appropriate
outputs.
5. Test and replace open or shorted washer

5. Ineffective washer pump.
pump if required.
SPECIFICATIONS > TORQUE SPECIFICATIONS

TORQUE SPECIFICATIONS TABLE
DESCRIPTION N.m Ft. Lbs. In. Lbs. NEW FASTENER*
Front Wiper Arm Mounting Nut 30 22 -
Front Wiper Linkage Module

10 7 -
Mounting Screw
Rear Wiper Arm Mounting Nut 1.3 - 11
*NEW FASTENER: Do not reuse these fasteners. If removed, a new fastener must be installed and
tightened to specifications.
CLEANING > FRONT WASHER SYSTEM
CAUTION:
Never introduce petroleum-based cleaners, solvents, or contaminants into the washer

system. These products can rapidly deteriorate the rubber seals and hoses of the washer
system, as well as the rubber squeegees of the wiper blades.
CAUTION:
Never use compressed air to flush the washer system plumbing. Compressed air pressures
are too great for the washer system plumbing components and will result in further system
damage. Never use sharp instruments to clear a plugged washer nozzle or damage to the
nozzle orifice and improper nozzle spray patterns will result.
If the washer system is contaminated with foreign material, drain the washer reservoir by removing the
washer pump/motor unit from the reservoir. Clean foreign material from the inside of the washer pump
inlet filter screen and the washer reservoir using clean washer fluid, a mild detergent, or a non-abrasive
cleaner. Flush foreign material from the washer system plumbing by first disconnecting the washer hoses
from the washer nozzles, then running the washer pump/motor to run clean washer fluid or water through
the system. If a washer nozzle obstruction cannot be cleared, replace the washer nozzle.
CLEANING > FRONT WIPER SYSTEM
CAUTION:
Protect the rubber squeegees of the wiper blades from any petroleum-based cleaners,
solvents, or contaminants. These products can rapidly deteriorate the rubber squeegees.
The squeegees of wiper blades exposed to the elements for a long time tend to lose their wiping
effectiveness. Periodic cleaning of the squeegees and the windshield glass is suggested to remove any
deposits of salt, wax or road film. The wiper blades, arms and windshield glass should only be cleaned
using a sponge or soft cloth and windshield washer fluid, a mild detergent or a non-abrasive cleaner. If
the wiper blades continue to leave streaks, smears, hazing or beading on the glass after cleaning of the
squeegees and the glass, clean them again. Wiper blade assembly replacement will NOT resolve hazing
or beading.
CLEANING > REAR WASHER SYSTEM
CAUTION:
Never introduce petroleum-based cleaners, solvents or contaminants into the washer

system. These products can rapidly deteriorate the rubber seals and hoses of the washer
system, as well as the rubber squeegee of the wiper blade.
CAUTION:
Never use compressed air to flush the washer system plumbing. Compressed air pressures
are too great for the washer system plumbing components and will result in further system
damage. Never use sharp instruments to clear a plugged washer nozzle or damage to the
nozzle orifice and improper nozzle spray patterns will result.
If the washer system is contaminated with foreign material, drain the washer reservoir by removing the
washer pump/motor from the reservoir. Clean foreign material from the inside of the washer pump/motor
inlet filter screen and the washer reservoir using clean washer fluid, a mild detergent or a non-abrasive
cleaner. Flush foreign material from the washer system plumbing by first disconnecting the washer hose
from the rear washer nozzle, then running the washer pump/motor to run clean washer fluid or water
through the system. A plugged or restricted rear washer nozzle cannot be back-flushed due to the
integral check valve mechanism. If the rear washer nozzle obstruction cannot be cleared, replace the
rear washer nozzle.
CLEANING > REAR WIPER SYSTEM
CAUTION:
Protect the rubber squeegee of the wiper blade from any petroleum-based cleaners,
solvents or contaminants. These products can rapidly deteriorate the rubber squeegee.
The squeegee of a wiper blade exposed to the elements for a long time tends to lose its wiping
effectiveness. Periodic cleaning of the squeegee and the liftgate glass is suggested to remove any
deposits of salt, wax or road film. The wiper blade, arm and liftgate glass should only be cleaned using a
sponge or soft cloth and windshield washer fluid, a mild detergent or a non-abrasive cleaner. If the wiper
blade continues to leave streaks, smears, hazing or beading on the glass after cleaning of the squeegee
and the glass, clean them again. Wiper blade assembly replacement will NOT resolve hazing or beading.
INSPECTION > FRONT WASHER SYSTEM
The washer system components should be inspected periodically, not just when washer performance
problems are experienced. This inspection should include the following points:
1. Check for ice or other foreign material in the washer reservoir. If contaminated, clean and flush
the washer system. Refer to CLEANING .
2. Inspect the washer plumbing for pinched, leaking, deteriorated, or incorrectly routed hoses and
damaged or disconnected hose fittings. Replace damaged or deteriorated hoses and hose
fittings. Leaking washer hoses can sometimes be repaired by cutting the hose at the leak and
splicing it back together using an in-line connector fitting. Similarly, sections of deteriorated
hose can be cut out and replaced by splicing in new sections of hose using in-line connector
fittings. Whenever routing a washer hose or a wire harness containing a washer hose, it must
be routed away from hot, sharp or moving parts. Also, sharp bends that might pinch the washer
hose must be avoided.
INSPECTION > FRONT WIPER SYSTEM

Fig 1: Wiper Blades And Wiper Arms
The wiper blades and wiper arms should be inspected periodically, not just when wiper performance
1. Carefully inspect the wiper blades for any indications of worn or uneven edges (1), foreign
material deposits (2), hardening or cracking (3), deformation or fatigue (4) or splitting (5).
Inspect the wiper blade support components and the wiper arms for damage (6) or severe
corrosion. If the wiper arms and blades are contaminated with any foreign material, clean them
and the glass as required. Refer to CLEANING . If a wiper blade or arm is damaged, or if
severe corrosion is evident, replace the affected wiper arm or blade with a new unit. Do not
attempt to repair a wiper arm or blade that is damaged or severely corroded.
2. Carefully lift the wiper blade off of the glass. Note the action of the wiper arm hinge. The wiper
arm should pivot freely at the hinge, but with no lateral looseness evident. If there is any
binding evident in the wiper arm hinge, or if there is evident lateral play in the wiper arm hinge,
replace the wiper arm.
CAUTION:
Do not allow the wiper arm to spring back against the glass without the wiper blade
in place or the glass may be damaged.
3. Once proper hinge action of the wiper arm is confirmed, check the hinge for proper spring
tension. The spring tension of the wiper arm should be sufficient to cause the rubber squeegee
to conform to the curvature of the glass. Replace a wiper arm if it has insufficient spring
tension to maintain contact between the squeegee and the glass.
4. After cleaning and inspecting the wiper components and the glass, if the wiper blade still fails to
clear the glass without smearing, streaking or chattering, replace the wiper blade.
INSPECTION > REAR WASHER SYSTEM
The washer system components should be inspected periodically, not just when washer performance
1. Check for ice or other foreign material in the washer reservoir. If contaminated, clean and flush
the washer system. Refer to CLEANING .
2. Inspect the washer plumbing for pinched, leaking, deteriorated or incorrectly routed hoses and
damaged or disconnected hose fittings. Replace damaged or deteriorated hoses and hose
fittings. Leaking washer hoses can sometimes be repaired by cutting the hose at the leak and
splicing it back together using an in-line connector fitting. Similarly, sections of deteriorated
hose can be cut out and replaced by splicing in new sections of hose using in-line connector
fittings. Whenever routing a washer hose or a wire harness containing a washer hose, it must
be routed away from hot, sharp or moving parts. Also, sharp bends that might pinch the washer
hose must be avoided.
INSPECTION > REAR WIPER SYSTEM

Fig 1: Inspecting Wiper Blades
The rear wiper blade and wiper arm should be inspected periodically, not just when wiper performance
1. Carefully inspect the wiper blade for any indications of worn or uneven edges (1), foreign
material deposits (2), hardening or cracking (3), deformation or fatigue (4) or splitting (5).
Inspect the wiper blade support components and the wiper arm for damage (6). If the wiper arm
and blade are contaminated with any foreign material, clean them and the glass as required.
Refer to CLEANING . If the wiper blade or arm is damaged, replace it with a new unit. Do not
attempt to repair a wiper arm or blade that is damaged or corroded.
2. Carefully lift the wiper blade off of the glass. Note the action of the wiper arm hinge. The wiper
arm should pivot freely at the hinge, but with no lateral looseness evident. If there is any
binding evident in the wiper arm hinge, or there is evident lateral play in the wiper arm hinge,
replace the wiper arm.
CAUTION:
Do not allow the wiper arm to spring back against the glass without the wiper blade
in place or the glass may be damaged.
3. Once proper hinge action of the wiper arm is confirmed, check the hinge for proper spring
tension. The spring tension of the wiper arm should be sufficient to cause the rubber squeegee
to conform to the curvature of the glass. Replace a wiper arm if it has insufficient spring
tension to maintain contact between the squeegee and the glass.
4. After cleaning and inspecting the wiper components and the glass, if the wiper blade still fails to
clear the glass without smearing, streaking, chattering, hazing or beading, replace the wiper
blade.
ARM, WIPER > DESCRIPTION AND OPERATION > DESCRIPTION AND OPERATION -
FRONT WIPER ARM > DESCRIPTION - FRONT
Fig 1: Front Wiper Arm
The front wiper arms are the rigid members located between the wiper pivots that protrude from the cowl
plenum cover/grille panel near the base of the windshield and the wiper blades on the windshield glass.
These wiper arms feature an over-center hinge that allows easy access to the windshield glass for
cleaning. The wiper arm has a die cast metal pivot end (3) with a large tapered mounting hole at one
end. A molded black plastic cap fits over the wiper arm retaining nut to conceal the nut and the mounting
hole following wiper arm installation.
The wide end of a tapered, stamped steel channel (1) hinges on and is secured with a hinge pin (2) to
the blade end of the wiper arm pivot end. One end of a long, rigid, stamped steel strap (4) with a small
hole near its pivot end, is riveted and crimped within the narrow end of the stamped steel channel. The
tip of the wiper blade end of this strap has a stamped steel receptacle (5) crimped onto it to accept the
latching pivot block of the front wiper blade. Concealed within the stamped steel channel is a long
tension spring which is engaged with a wire hook on the underside of the die cast pivot end and is
hooked through a small hole in the steel strap. The entire wiper arm has a satin black finish applied to all
of its visible surfaces.
The driver and passenger side wiper arms are unique and are not interchangeable. A wiper arm cannot
be adjusted or repaired. If damaged or ineffective, the entire wiper arm unit must be replaced.
FRONT WIPER ARM > OPERATION - FRONT
The front wiper arms are designed to mechanically transmit the motion from the wiper pivots to the front
wiper blades. The front wiper arm must be properly indexed to the wiper pivot in order to maintain the
proper wiper blade travel on the glass. The tapered mounting hole in the wiper arm pivot end interlocks
with the serrations on the tapered outer circumference of the wiper pivot shaft, allowing positive
engagement and finite adjustment of this connection.
The mounting nut locks the front wiper arm to the threaded stud of the wiper pivot shaft. The spring-
loaded wiper arm hinge controls the down-force applied through the tip of the wiper arm to the front wiper
blade on the glass. The receptacle on the tip of the wiper arm provides a cradle for securing and latching
the wiper blade pivot block to the wiper arm.
REAR WIPER ARM > DESCRIPTION - REAR
Fig 1: Rear Wiper Arm
The rear wiper arm (3) is the rigid member located between the rear wiper motor output shaft (1) that
protrudes through the liftgate glass above the center of the liftgate glass opening and the wiper blade (4)
on the outside of the glass. The wiper arm is constructed of molded black plastic. A hinged pivot end is
also molded plastic.
A molded black plastic nut cover (2) with snap features on the back end and two pivot pins on the end
nearest the wiper blade fits over the wiper arm pivot end to conceal the wiper arm retaining nut and
mounting hole following wiper arm installation. The wiper arm hinge and tension spring are concealed on
the underside of the wide end of the arm, while an integral latch feature concealed on the underside of
the narrow end of the wiper arm accepts the pivot pin of the matching molded plastic wiper blade unit.
The rear wiper arm cannot be adjusted or repaired. If damaged or ineffective, the entire wiper arm unit
must be replaced.
REAR WIPER ARM > OPERATION - REAR
The rear wiper arm is designed to mechanically transmit the motion from the rear wiper motor output
shaft to the rear wiper blade. The wiper arm must be properly indexed to the motor output shaft in order
to maintain the proper wiper blade travel on the glass. The tapered hole in the wiper arm pivot end
interlocks with the serrations on the outer circumference of the tapered motor output shaft, allowing
positive engagement and finite adjustment of this connection.
A hex nut secures the wiper arm pivot end to the threads on the rear wiper motor output shaft and the
plastic cover snaps over this connection for a neat appearance. The spring-loaded wiper arm hinge
controls the down-force applied through the tip of the wiper arm to the wiper blade on the glass. The latch
formation on the tip of the wiper arm provides a cradle for securing and latching the wiper blade pivot pin
to the wiper arm.
ARM, WIPER > REMOVAL AND INSTALLATION > REMOVAL AND INSTALLATION -
FRONT WIPER ARM > REMOVAL - FRONT
Fig 1: Plastic Nut Cap
1. Open the hood.
2. Carefully pry the plastic nut cap (1) off of the nut on the pivot end of the wiper arm.
Fig 2: Wiper Arm & Nut
3. Remove the nut (1a) that secures the wiper arm (1b) to the wiper pivot shaft.
4. Lift the front wiper arm to its over-center position to hold the wiper blade off of the glass and
relieve the spring tension on the wiper arm to pivot shaft connection.
5. Use a slight rocking action to disengage the front wiper arm pivot end from the pivot shaft and
remove the wiper arm.
CAUTION:
The use of a battery terminal puller when removing the front wiper arm is NOT
recommended except as a last resort, as this may damage the front wiper arm.
Fig 3: Disengaging Wiper Arm From Pivot Shaft
6. If the rocking action failed to free the wiper arm from the pivot shaft, use a suitable battery
terminal puller (3) to disengage the wiper arm (1) from the pivot shaft (2).
7. Remove the wiper arm pivot end from the pivot shaft.
FRONT WIPER ARM > INSTALLATION - FRONT
Fig 1: Wiper Blade & Alignment Marks
NOTE:
Be certain that the wiper motor is in the park position before attempting to install the front
wiper arms. Transition the status of the ignition to On and move the right multifunction switch
control knob to its front wiper Off position. If the wiper pivots move, wait until they stop
moving, then transition the ignition status back to Off. The front wiper motor is now in its park
position.
1. The front wiper arms must be indexed to the pivot shafts with the front wiper motor in the park
position to be properly installed. Position the wiper arm pivot end onto the wiper pivot shaft so
that the lower edge of the wiper blade (2) is aligned with the wiper alignment marks (1), which
are etched marks near the lower margin of the windshield.
2. Once the wiper blade is aligned, lift the wiper arm (1b) away from the windshield slightly to
relieve the spring tension on the pivot end and push the pivot end of the wiper arm down firmly
and evenly over the pivot shaft.
3. Install and tighten the nut (1b) that secures the wiper arm to the pivot shaft. Tighten the nut to
the proper SPECIFICATIONS .
4. Wet the windshield glass, then operate the front wipers. Turn the wiper switch to the Off
position, then check for the correct wiper arm alignment position and readjust as required.
Fig 3: Plastic Nut Cap
5. Install the plastic nut cap (1) onto the wiper arm pivot nut.
REAR WIPER ARM > REMOVAL - REAR
Fig 1: Rear Wiper Arm, Plastic Nut Cover & Nut
1. Insert your fingertips under the lower edge at the back of the molded plastic nut cover (1), then
pull upward to unsnap and swing the cover off of the pivot end of the wiper arm (3).
2. Remove the nut (2) that secures the wiper arm to the rear wiper motor output shaft.
CAUTION:
The use of a battery terminal puller when removing the rear wiper arm is NOT
recommended as this may damage the rear wiper arm.
3. Use a slight rocking action to disengage the rear wiper arm pivot end from the motor output
shaft and remove the wiper arm.
REAR WIPER ARM > INSTALLATION - REAR
Fig 1: Rear Wiper Arm, Plastic Nut Cover & Nut
NOTE:
Be certain that the rear wiper motor is in the park position before attempting to install the rear
wiper arm. Transition the status of the ignition to On and move the rear wiper switch to its Off
position. If the wiper motor output shaft moves, wait until it stops moving, then transition the
ignition back to Off. The wiper motor is now in its park position.
1. The rear wiper arm (3) must be indexed to the rear wiper motor output shaft with the motor in
the park position to be properly installed. Position the wiper arm pivot end onto the motor
output shaft so that the tip of the wiper blade is aligned with the wiper alignment mark, which is
a horizontal T mark located within the upper margin of the blackout area at the bottom of the
liftgate glass.
2. With the rear wiper arm properly indexed, push the tapered mounting hole on the pivot end of
the wiper arm down over the output shaft.
3. Install and tighten the nut (2) that secures the rear wiper arm to the output shaft. Tighten the
nut to the proper SPECIFICATIONS .
4. Fold and snap the molded plastic nut cover (1) down over the nut on the pivot end of the rear
wiper arm.
5. Wet the liftgate glass and operate the rear wiper. Turn the rear wiper switch to the Off position,
then check for correct wiper arm position and readjust as required.
BLADE, WIPER > DESCRIPTION AND OPERATION > DESCRIPTION AND OPERATION
- FRONT WIPER BLADE > DESCRIPTION - FRONT
Fig 1: Wiper Blade, Wiper Arm & Integral Latching Pivot Block
This vehicle is equipped with frameless (also known as flat or beam) front wiper blades. Each front wiper
blade is secured by an integral latching pivot block (3) to the receptacle formation on the tip of each front
wiper arm, and rests on the glass near the base of the windshield when the wipers are not in operation.
The wiper blade consists of the following components:
Element (1) - The wiper element or squeegee is the resilient rubber member of the wiper blade
that contacts the glass.
Flexor (2) - The flexor is an integrated component in the frameless wiper blade running along the
entire length of the wiper element.
The front wiper blades for this vehicle are unequal length and are not interchangeable. The right blade is
50 centimeters (19.69 inches) long and the left blade is 55 centimeters (21.65 inches) long. They have
non-replaceable rubber elements (squeegees). The wiper blades cannot be adjusted or repaired. If
ineffective, worn or damaged the entire wiper blade unit must be replaced.
- FRONT WIPER BLADE > OPERATION - FRONT
The front wiper blades are moved back and forth across the glass by the front wiper arms when the
wipers are being operated. The wiper blade flexor is the flexible member secured the length of the wiper
blade element that evenly distributes the force of the spring-loaded wiper arm along the length of the
element. The combination of the wiper arm force and the flexibility of the flexor makes the element
conform to and maintain proper contact with the glass, even as the blade is moved over the varied
curvature that may be encountered across the glass surface.
The rubber element is designed to be stiff enough to maintain an even cleaning edge as it is drawn
across the glass, yet resilient enough to conform to the glass surface and flip from one cleaning edge to
the other each time the wiper blade changes directions.
- REAR WIPER BLADE > DESCRIPTION - REAR
Fig 1: Wiper Blade, Wirper Arm & Integral Pivot Pin
The rear wiper blade is secured by an integral pivot pin (2) to a receptacle near the tip of the rear wiper
arm, and rests near the base of the liftgate glass when the wiper is not in operation. The rear wiper
blade consists of the following components:
Superstructure (1) - The superstructure includes a molded black plastic bridge and plastic links
with claw formations that grip the wiper blade element. Also included in this unit is the pivot pin that
secures the superstructure to the wiper arm.
Element (3) - The wiper element or squeegee is the resilient rubber member of the wiper blade
that contacts the glass.
Flexor - The flexor is a rigid metal component running along the length of each side of the wiper
element where it is gripped by the claws of the superstructure.
The rear wiper blade is 26.00 centimeters (10.24 inches) long with a non-replaceable element
(squeegee). The wiper blade superstructure cannot be adjusted or repaired. If ineffective, worn or
damaged the entire wiper blade unit must be replaced.
- REAR WIPER BLADE > OPERATION - REAR
The rear wiper blade is moved back and forth across the liftgate glass by the wiper arm when the rear
wiper system is in operation. The wiper blade superstructure is the flexible frame that grips the wiper
blade element and evenly distributes the force of the spring-loaded wiper arm along the length of the
element. The combination of the wiper arm force and the flexibility of the superstructure makes the
element conform to and maintain proper contact with the glass, even as the blade is moved over the
varied curvature found across the glass surface.
The wiper element flexor provides the claws of the blade superstructure with a rigid, yet flexible
component on the element which can be gripped. The rubber element is designed to be stiff enough to
maintain an even cleaning edge as it is drawn across the glass, but resilient enough to conform to the
glass surface and flip from one cleaning edge to the other each time the wiper blade changes directions.
BLADE, WIPER > REMOVAL AND INSTALLATION > REMOVAL AND INSTALLATION -
FRONT WIPER BLADE > REMOVAL - FRONT
Fig 1: Tab, Wiper Arm & Element
CAUTION:
Do not allow the wiper arm to spring back against the glass without the wiper blade in place
or the glass may be damaged.
1. Lift the wiper arm (2) to raise the wiper blade and element (1) off of the glass, until the wiper
arm hinge is in its over-center position.
2. To remove the blade from the arm, depress the latch release tab (3) on the pivot block at the
tip of the arm downward (toward the wiper element and away from the wiper arm) and slide the
blade away from the tip of the arm far enough to disengage the pivot block from the receptacle
formation on the end of the arm.
3. Gently lower the tip of the wiper arm onto the glass.
FRONT WIPER BLADE > INSTALLATION - FRONT
Fig 1: Tab, Wiper Arm & Element
CAUTION:
Do not allow the wiper arm to spring back against the glass without the wiper blade in place
or the glass may be damaged.
1. Lift the wiper arm (2) off of the windshield glass, until the wiper arm hinge is in its over-center
position.
2. Position the wiper blade (1) near the receptacle formation on the tip of the wiper arm with the
latch side of the blade pivot block oriented towards the end of the wiper arm that is nearest to
the wiper pivot.
3. Push the wiper blade pivot block into the wiper arm receptacle until the latch tab (3) snaps into
place with an audible click.
4. Gently lower the wiper blade and element onto the glass.
REAR WIPER BLADE > REMOVAL - REAR
Fig 1: Blade Pivot Pin, Wiper Arm & Blade
1. Lift the rear wiper arm to raise the wiper blade and element off of the liftgate glass.
2. To remove the wiper blade (1) from the wiper arm (3), grasp the end of the blade nearest to the
motor output shaft, then rotate it out from under the arm far enough to access the blade pivot
pin (2) engaged within the latch features (4) from under the end of the arm.
3. Using a small screwdriver or another suitable tool, carefully pry the wiper blade pivot pin to
unsnap it from the latch features of the wiper arm.
4. Gently lower the tip of the wiper arm onto the glass.
REAR WIPER BLADE > INSTALLATION - REAR
Fig 1: Blade Pivot Pin, Wiper Arm & Blade

1. Lift the tip of the rear wiper arm (3) off of the liftgate glass.
2. Position the rear wiper blade (1) with the pivot pin (2) aligned with the opening of the latch
features (4) under the tip of the wiper arm.
3. Using hand pressure, press the wiper blade pivot pin firmly and evenly into the wiper arm
latches until it snaps into place.
4. Lower the wiper blade onto the glass.
CHECK VALVE, WASHER > DESCRIPTION AND OPERATION > DESCRIPTION AND
OPERATION > DESCRIPTION - FRONT
Diaphragm-type front washer system check valves are standard equipment in this vehicle. The check
valves for the front washer system are integral to their respective front washer nozzles. Refer to
NOZZLE, WASHER, DESCRIPTION AND OPERATION .
OPERATION > DESCRIPTION - REAR
Fig 1: Check Valve
The rear check valve (2) connects the liftgate spoiler washer hose to the supply washer hose and is
located near the upper liftgate header within the spoiler. The check valve consists of a molded plastic
valve body with a raised arrowhead (4) molded into its center section indicating the direction of the flow
through the valve. A barbed hose nipple (1 and 3) is formed on each side of the raised center section of
the valve body. Within the check valve body, a small diaphragm is held against the lip of an integral sump
well by a small plastic piston and a coiled spring.
The rear check valve cannot be adjusted or repaired and, if ineffective or damaged, it must be replaced.
OPERATION > OPERATION - FRONT
Diaphragm-type front washer system check valves are standard equipment in this vehicle. The check
valves for the front washer system are integral to their respective front washer nozzles. Refer to
NOZZLE, WASHER, DESCRIPTION AND OPERATION .
OPERATION > OPERATION - REAR
Fig 1: Identifying Check Valve

The rear check valve provides more than one function in this application. It prevents washer fluid from
draining out of the rear washer supply hoses back to the washer reservoir. This drain-back would result
in a lengthy delay from when the rear washer switch is actuated until washer fluid was dispensed through
the rear washer nozzle, because the washer pump would have to refill the rear washer plumbing from the
reservoir to the nozzle. Such a drain-back condition could also result in water, dirt, or other outside
contaminants being siphoned into the washer system through the washer nozzle orifice. This water could
subsequently freeze and plug the nozzle, while other contaminants could interfere with proper nozzle
operation and cause improper nozzle spray patterns. In addition, the rear check valve prevents washer
fluid from siphoning out through the rear washer nozzle after the rear washer system is turned Off.
When the washer pump pressurizes and pumps washer fluid from the reservoir through the rear washer
plumbing (5), the fluid pressure unseats a diaphragm (3) from over a sump well within the valve by
overriding the pressure applied to it by a piston (2) and coiled spring (1). With the diaphragm unseated,
washer fluid is allowed to flow toward the rear washer nozzle (4). When the washer pump stops
operating, the spring pressure on the piston seats the diaphragm over the sump well in the valve and
fluid flow in either direction within the rear washer plumbing is prevented.
CHECK VALVE, WASHER > REMOVAL AND INSTALLATION > REMOVAL AND
INSTALLATION > REMOVAL - REAR
Fig 1: Rear Check Valve, Barbed Nipple & Water Supply Hose
cable
2. Remove the spoiler from the outside of the upper liftgate header. Refer to SPOILER,
DECKLID, REMOVAL AND INSTALLATION .
3. Pull the spoiler away from the upper liftgate header far enough to access and disconnect the
washer supply hose from the barbed nipple (1) of the rear check valve (4).
4. Disconnect the liftgate washer supply hose (3) from the other barbed nipple of the rear check
valve and remove the check valve.
CHECK VALVE, WASHER > REMOVAL AND INSTALLATION > REMOVAL AND
INSTALLATION > INSTALLATION - REAR
Fig 1: Rear Check Valve, Barbed Nipple & Water Supply Hose
1. Connect the spoiler washer supply hose (3) to the barbed outlet nipple of the rear check valve
(4). Be certain that the raised arrow (2) that indicates the flow direction on the center section
of the valve is pointed toward the spoiler washer supply hose.
2. Position the liftgate spoiler close enough to the upper liftgate header to access and connect
the washer supply hose to the inlet barbed nipple (1) of the rear check valve.
3. Install the spoiler to the outside of the upper liftgate header. Refer to SPOILER, DECKLID,
HOSES AND TUBES, WASHER > DESCRIPTION AND OPERATION > DESCRIPTION
AND OPERATION - FRONT WASHER HOSES AND TUBES > DESCRIPTION - FRONT
The front washer plumbing consists of small diameter rubber hoses that are routed along with the rear
washer plumbing from the washer reservoir located at the left front corner of the engine compartment.
Both reservoir hoses are attached to their respective front or rear outlet nipple of the washer
pump/motor unit near the bottom of the reservoir. The front hose is then routed up into the engine
compartment. The engine compartment hose is routed along the left side of the inner fender to the hood
panel.
At the hood panel the front washer hose (1b) is routed through several retainers (1a) to a wye fitting on
the inner hood panel reinforcement. The two front nozzle supply hoses are attached to the wye fitting and
routed on the underside of the inner hood panel reinforcement to the two front washer nozzles (2).
Washer hose or tube is available for service only as roll stock, which must then be cut to length. The
molded plastic washer hose fittings cannot be repaired. If these fittings are ineffective or damaged, they
must be replaced.
AND OPERATION - FRONT WASHER HOSES AND TUBES > OPERATION - FRONT
Washer fluid in the washer reservoir is pressurized and fed by the washer pump/motor unit through the
front washer system plumbing and fittings to the two front washer nozzles. Whenever routing the washer
plumbing or a wire harness containing washer plumbing, it must be routed away from hot, sharp, or
moving parts; and, sharp bends that might pinch the plumbing must be avoided.
AND OPERATION - REAR WASHER HOSES AND TUBES > DESCRIPTION - REAR
The rear washer plumbing consists of small diameter rubber hoses that are routed along with the front
washer plumbing from the washer reservoir located at the left front corner of the engine compartment.
Both reservoir hoses are attached to their respective front or rear outlet nipple of the washer
pump/motor unit near the bottom of the reservoir. The rear hose is then connected to the body washer
hose that is sheathed within molded plastic convolute tubing for protection and routed within the body
wire harness along the left side of the inner fender to the dash panel.
The body wire harness containing the rear washer hose passes through a rubber grommet and a
clearance hole in the dash panel into the passenger compartment. Within the passenger compartment,
the body wire harness is routed along the left inner sill to the C-pillar, then up over the left rear wheel
house to the D-pillar. The body rear hose is contained within and routed from the left cowl side inner
panel to the liftgate with the body wire harness. The rear hose is then routed separately to the rear
washer nozzle in the spoiler trim above the center of the liftgate glass opening.
Washer hose or tube is available for service only as roll stock, which must then be cut to length. The
molded plastic washer hose fittings cannot be repaired. If these fittings are ineffective or damaged, they
must be replaced.
AND OPERATION - REAR WASHER HOSES AND TUBES > OPERATION - REAR
Washer fluid in the washer reservoir is pressurized and fed by the washer pump/motor unit through the
rear washer system plumbing and fittings to the rear washer nozzle. Whenever routing the washer
plumbing or a wire harness containing washer plumbing, it must be routed away from hot, sharp or
moving parts; and, any sharp bends that might pinch the plumbing must be avoided.
LINKAGE, WIPER ARM > DESCRIPTION AND OPERATION > DESCRIPTION AND
Fig 1: Wiper Arm Linkage
The front wiper linkage module is secured within the cowl plenum panel beneath the cowl plenum
cover/grille panel. The ends of the wiper pivot shafts protrude through dedicated openings in the cowl
plenum cover/grille panel to drive the wiper arms and blades and are the only visible components of the
front wiper linkage module.
The front wiper linkage module consists of the following components:
Bracket - The front wiper linkage module bracket (2) consists of the unit that supports the wiper
motor and transmission unit as well as the wiper pivot brackets at each end where the two wiper
pivots are secured. The front wiper linkage module bracket is secured within the cowl plenum by
three screws through rubber insulators (1).
Crank Arm - The front wiper motor crank arm is a stamped steel unit with a hole on the driven end
that is secured to the wiper motor output shaft with a nut and a double ball stud secured to the
drive end.
Linkage - Two stamped steel links (6) connect the wiper motor to the two wiper pivot lever arms.
The shorter drive link has a plastic socket-type bushing on one end and a plastic sleeve-type
bushing on the other end. The sleeve bushing on the shorter drive link is snapped over the double
ball stud on the crank arm and the socket bushing is snapped over the ball stud of the left pivot
lever arm. The plastic socket-type bushings on each end of the longer drive link are snapped over
the double ball stud of the crank arm and the ball stud of the right pivot lever arm.
Motor - The front wiper motor (4) is secured through stanchions integral to the transmission
housing to the linkage module bracket by three screws. The two-speed permanent magnet wiper
motor features an integral transmission, an internal park switch, and an internal automatic resetting
circuit breaker. An integral connector receptacle (5) connects the motor to the vehicle electrical
system.
Pivots - The two front wiper pivots (3) are secured to the ends of the wiper module bracket. The
lever arms that extend from each pivot shaft have ball studs that engage the bushings of the drive
links. The end of each pivot shaft where the wiper arms will be fastened each is tapered and
serrated with a threaded stud formation at the tip.
The front wiper linkage module cannot be adjusted or repaired. If any component of the module is
ineffective or damaged, the entire front wiper linkage module unit must be replaced.
LINKAGE, WIPER ARM > DESCRIPTION AND OPERATION > DESCRIPTION AND
The front wiper linkage module operation is controlled by the battery current inputs received by the wiper
motor through the Body Control Module (BCM). The wiper motor speed is controlled by current flow to
either the low speed or the high speed set of brushes. An automatic resetting circuit breaker protects the
motor from overloads.
The park switch is a single pole, single throw, momentary switch within the wiper motor that is
mechanically actuated by the wiper motor transmission components. The park switch alternately closes
the wiper park switch sense circuit to ground or to battery current, depending upon the position of the
wipers on the glass. This feature allows the motor to complete its current wipe cycle after the wiper
system has been turned Off, and to park the wiper blades in the lowest portion of the wipe pattern.
The wiper motor crank arm, the two wiper linkage members and the two wiper pivots mechanically
convert the rotary output of the wiper motor to the back and forth wiping motion of the wiper arms and
blades on the glass.
The hard wired inputs and outputs of the front wiper motor may be diagnosed using conventional
diagnostic tools and procedures. Refer to the appropriate SYSTEM WIRING DIAGRAMS article.
However, conventional diagnostic methods will not prove conclusive in the diagnosis of the front wiper
motor or the electronic controls and communication between other modules and devices that provide
some features of the front wiper and washer system. The most reliable, efficient and accurate means to
diagnose the front wiper motor or the electronic controls and communication related to front wiper motor
article.
LINKAGE, WIPER ARM > REMOVAL AND INSTALLATION > REMOVAL AND
Fig 1: Front Wiper Linkage Module, Wire Connector & Screws
NOTE:
The front wiper linkage module includes the front wiper motor.
from the battery.
2. Remove both front wiper arms from the wiper pivots. Refer to ARM, WIPER, REMOVAL AND
INSTALLATION .
3. Remove the cowl plenum cover/grille panel from over the front wiper linkage module. Refer to
COVER, COWL PANEL, REMOVAL AND INSTALLATION .
4. Disconnect the wire harness connector (1) from the connector receptacle for the front wiper
motor.
5. Remove the three screws (2a) that secure the module (2b) bracket to the cowl plenum.
6. Remove the front wiper linkage module from the cowl plenum as a unit.
LINKAGE, WIPER ARM > REMOVAL AND INSTALLATION > REMOVAL AND
Fig 1: Front Wiper Linkage Module, Wire Connector & Screws
NOTE:
The front wiper linkage module includes the front wiper motor.
1. Position the front wiper linkage module (2b) into the cowl plenum as a unit.
2. Install and tighten the three screws (2a) that secure the module bracket to the cowl plenum.
Tighten the screws to the proper SPECIFICATIONS .
3. Connect the wire harness connector (1) to the connector receptacle for the front wiper motor.
4. Install the cowl plenum cover/grille panel over the front wiper linkage module. Refer to COVER,
COWL PANEL, REMOVAL AND INSTALLATION .
NOTE:
Be certain to transition the ignition to the On status, then turn the front wiper switch
On and Off again to cycle the wiper motor and linkage to their natural park position
before installing the front wiper arms onto the wiper pivots.
5. Install both front wiper arms onto the wiper pivots. Refer to ARM, WIPER, REMOVAL AND
INSTALLATION .
MODULE, LIGHT RAIN SENSOR > DESCRIPTION AND OPERATION > DESCRIPTION
Fig 1: Light Rain Sensor Module Components
An automatic wiper system is an available option in vehicles manufactured for Europe-Middle East-Africa
(EMEA) markets. The Light Rain Sensor Module (LRSM) (1) is the primary component of the automatic
wiper system. The LRSM is also capable of performing an ambient light sensor function; therefore, it is
alternately referred to as the Rain Light Sensor Module (RLSM), the Light Sensor Module (LSM) or the
Rain Sensor Module (RSM). The LRSM is located on the inside of the windshield glass just below and to
the right of the inside rear view mirror mounting button. The LRSM is concealed from view within the
vehicle interior by a molded plastic inside rear view mirror bracket trim cover that fits over the top of the
LRSM housing and the LRSM mounting bracket, but the LRSM is visible through the windshield glass
from the exterior of the vehicle.
The molded black plastic LRSM housing has an integral connector receptacle (2) with three terminal
pins. These terminal pins connect the LRSM to the vehicle electrical system through a dedicated take
out and connector of the overhead wire harness that extends from above the headliner. The windshield
side of the housing is filled with a clear, silicone gelatin (also known as SilGel) adhesive membrane pad
(3), which serves as an optical coupler between the sensor and the inside of the windshield glass. A
spring steel retaining strap or clip extends forward on each side of the housing to latch the LRSM to a
molded black plastic mounting bracket, which is permanently bonded to the inside of the windshield glass.
Concealed and protected within the LRSM housing is the electronic circuitry of the module, which
includes an InfraRed (IR) diode and photocell based light and rain sensors, control electronics and Local
Interface Network (LIN) data bus communication management hardware. The LRSM is a LIN slave node
and communicates over a single LIN bus circuit with the Body Control Module (BCM). The BCM is a LIN
master node and a gateway to the Controller Area Network (CAN) data bus. The BCM controls the
exchange of electronic messages back and forth between the LRSM and other electronic modules in the
vehicle, as well as with a diagnostic scan tool connected to the Data Link Connector (DLC).
The LRSM cannot be adjusted or repaired. If ineffective or damaged, the entire module must be
replaced. The silicone gelatin adhesive membrane pad is available for separate service replacement.
The LRSM mounting bracket is serviced only as a unit with the windshield glass.
MODULE, LIGHT RAIN SENSOR > DESCRIPTION AND OPERATION > DESCRIPTION
The Light Rain Sensor Module (LRSM) (also known as the Rain Light Sensor Module/RLSM, the Light
Sensor Module/LSM or the Rain Sensor Module/RSM) senses moisture and ambient light levels on the
outside of the windshield glass and sends electronic messages to the Body Control Module (BCM) over
the Local Interface Network (LIN) data bus. The BCM relays messages back and forth between the
LRSM and other electronic modules in the vehicle.
For the rain sensor function, InfraRed (IR) diodes within the LRSM generate infrared light beams that are
aimed by the optics of the sensor through the windshield glass, while an IR photo diode monitors the
infrared light reflected back from the windshield glass. When sufficient moisture accumulates within the
wipe pattern on the windshield glass, less of the infrared light is reflected back and the sensor detects a
change in the monitored infrared light intensity. For the light sensor function, an IR photo diode within the
sensor monitors the intensity of the ambient infrared light received through the windshield glass and the
sensor optics.
The internal programming of the LRSM sends the appropriate electronic wipe command messages to
the BCM over the LIN data bus. The BCM then responds by activating or deactivating the wiper system.
Similarly, the LRSM provides electronic ambient light level messages to the BCM, and the BCM relays
these messages to other electronic modules in the vehicle.
The BCM microcontroller sends electronic wiper switch status and automatic wipe sensitivity level
messages over the LIN data bus to the LRSM based upon the driver-selected settings of the control
knob on the control stalk of the right (wiper) multifunction switch. The higher the selected wipe sensitivity
setting the more sensitive the LRSM is to the accumulated moisture on the windshield glass, and the
more frequently the LRSM will send wipe commands to the BCM to operate the wiper system.
The LRSM operates on battery current received through a fused ignition output (run/accessory) circuit.
The LRSM has a path to ground at all times through a take out of the body wire harness with an eyelet
terminal that is secured to the body sheet metal. Therefore, the LRSM is operational only when the
ignition status is On or Accessory.
If the BCM receives an electronic status message from the LRSM indicating a sensor failure condition, a
Rain Sensor Failure message should be displayed by the Instrument Panel Cluster (IPC). It is
important to note that the default operation of the automatic wiper system is continuous wipe On.
Therefore, if no command message is received by the BCM from the LRSM for more than about five
seconds when the Automatic wipe mode is selected, the wipers will default to Low Speed or High Speed
continuous wipe operation. The BCM must be properly configured for the automatic wipers in order for
this system to function.
The hard wired circuits of the LRSM may be diagnosed using conventional diagnostic tools and
procedures. Refer to the appropriate SYSTEM WIRING DIAGRAMS article. However, conventional
diagnostic methods will not prove conclusive in the diagnosis of the LRSM or the electronic controls and
communication between other modules and devices that provide some features of the automatic wiper
system. The most reliable, efficient and accurate means to diagnose the LRSM or the electronic controls
and communication related to LRSM operation requires the use of a diagnostic scan tool. Refer to the
MODULE, LIGHT RAIN SENSOR > STANDARD PROCEDURE > PROTECTIVE CAP
REMOVAL
Fig 1: Protective Cap, Adhesive Membrane, LRSM & Latches
CAUTION:
The Light Rain Sensor Module (LRSM) (3) is equipped with a clear, silicone gelatin (SilGel)
adhesive membrane (2) that serves as an optical coupler between the sensor and the
windshield glass. Extreme care must be exercised to protect this membrane from
contamination before it is installed in the vehicle. The LRSM should always be serviced only
in a dust-free environment. Do not touch the membrane with your fingers or tools. The
membrane should only come into contact with the clean and dry inside surface of the glass
within the mounting bracket bonded to the windshield. The service replacement LRSM is
shipped with a clear plastic protective cap (1) installed and secured to the outer
circumference of the LRSM by two latch features (4). This protective cap should not be
removed until immediately before the LRSM is to be installed using the following procedure.
Fig 2: Tabs, Protective Cap & LRSM
1. Firmly grasp the LRSM (3) by the outer circumference from the side opposite the SilGel
membrane pad.
2. Firmly grasp the protective shipping cap (2) of the LRSM by the two latch release tabs (1)
between your thumb and index finger from the SilGel membrane pad side of the module.
3. Firmly pinch the two latch release tabs together between your thumb and index finger far
enough to release the two latch features of the protective cap from the outer circumference of
the LRSM.
4. Pull the protective cap off of the LRSM.
5. Install the LRSM into the mounting bracket bonded onto the windshield as instructed in the
Installation procedure. Refer to MODULE, LIGHT RAIN SENSOR, REMOVAL AND
INSTALLATION .
MODULE, LIGHT RAIN SENSOR > STANDARD PROCEDURE > SILICONE GELATIN
PAD REPLACEMENT
Fig 1: LRSM & Adhesive Membrane
CAUTION:
The Light Rain Sensor Module (LRSM) is equipped with a clear, silicone gelatin (SilGel)
adhesive membrane that serves as an optical coupler between the sensor and the
within the mounting bracket bonded to the windshield. If contaminated, clean any foreign
material from the windshield glass using rubbing alcohol and a lint-free cloth. A
contaminated SilGel membrane will negatively impact LRSM performance.
CAUTION:
When installing the replacement silicone gelatin (SilGel) adhesive membrane pad onto the
Light Rain Sensor Module (LRSM), it is necessary to minimize air pockets trapped between
the SilGel membrane and the LRSM. Excessive air pockets will negatively impact LRSM
performance. It is important to adhere to the procedure steps in a deliberate manner to
achieve satisfactory results.
1. Carefully peel away the old silicone gelatin adhesive membrane pad (2) from the windshield
(optics) side of the Light Rain Sensor Module (LRSM) (1).
2. Thoroughly clean the windshield (optics) side of the LRSM using isopropyl alcohol and a clean,
lint-free cloth.
3. Using care not to contaminate, touch or damage the replacement pad, peel off the yellow
protective foil.
Fig 2: Protective Film & Replacement Pad
4. Looking through the transparent protective film (1), align and center the replacement pad (2)
over the windshield (optics) side of the LRSM. Then use a slow, smooth and deliberate motion
to roll the pad onto the windshield (optics) side of the LRSM.
5. With the transparent protective film still in place, use a thumb and a firm wiping motion to press
the entire surface pad against the windshield (optics) side of the LRSM.
6. To avoid contamination or damage of the replacement pad, do not remove the transparent
protective film until just before installing the LRSM onto the windshield. Refer to MODULE,
LIGHT RAIN SENSOR, REMOVAL AND INSTALLATION .
MODULE, LIGHT RAIN SENSOR > REMOVAL AND INSTALLATION > REMOVAL AND
Fig 1: LRSM, Harness Connector, Mount Bracket & Retaining Strap
cable
2. Remove the inside rear view mirror from the mounting button (3) on the inside of the windshield
glass (2). Refer to MIRROR, REARVIEW, REMOVAL AND INSTALLATION .
3. Disconnect the wire harness connector (1) from the connector receptacle for the Light Rain
Sensor Module (LRSM) (6).
4. Insert the tip of a small screwdriver into the rectangular cutout on one side of the spring steel
retaining strap (5) on the LRSM and carefully pry the end of the strap closest to the glass away
from the groove in the mounting bracket (4) on the windshield. Now rotate the loose side of the
strap away from the glass far enough to disengage the other side of the strap from the
mounting bracket groove.
5. Firmly grasp the connector receptacle of the LRSM to pull the module away from the windshield
glass and the mounting bracket.
6. If the LRSM will be reinstalled, the silicone gelatin (also known as SilGel) adhesive membrane
pad MUST be removed, discarded and replaced with a new unit as described in: STANDARD
PROCEDURE - Silicone Gelatin Pad Replacement.
MODULE, LIGHT RAIN SENSOR > REMOVAL AND INSTALLATION > REMOVAL AND
CAUTION:
The Light Rain Sensor Module (LRSM) is equipped with a clear, silicone gelatin (SilGel)
adhesive membrane that serves as an optical coupler between the sensor and the
within the mounting bracket bonded to the windshield. If contaminated, clean any foreign
material from the windshield glass using rubbing alcohol and a lint-free cloth. A
contaminated SilGel membrane will negatively impact LRSM performance.
CAUTION:
When installing the Light Rain Sensor Module (LRSM) it is necessary to minimize air
pockets trapped between the SilGel membrane and the windshield glass. Excessive air
pockets will negatively impact LRSM performance. It is important to adhere to the procedure
steps in a deliberate manner to achieve satisfactory results.
CAUTION:
To avoid excessive air pockets, do not try to install the spring steel retaining strap until
AFTER the Light Rain Sensor Module (LRSM) has been successfully positioned to the glass
within the mounting bracket bonded to the windshield.
Fig 1: LRSM & Mounting Bracket
1. If a new Light Rain Sensor Module (LRSM) is being installed, remove the protective shipping
cap from the LRSM as described in: STANDARD PROCEDURE - Protective Cap Removal. If
an existing LRSM is being reused, the silicone gelatin (also known as SilGel) adhesive
membrane pad MUST be removed, discarded and replaced with a new unit as described in:
STANDARD PROCEDURE - Silicone Gelatin Pad Replacement.
2. Grasp the LRSM (2) by the connector receptacle between your thumb and middle finger. Place
your index finger on the back of the LRSM at the point opposite the connector receptacle.
3. Align the LRSM with the mounting bracket (1) bonded onto the inside of the windshield glass
near the inside rear view mirror mounting button.
4. Slowly insert the LRSM into the mounting bracket at a slight angle so that the edge of the
module nearest the tip of your index finger makes the initial contact with the windshield glass.
5. Using a slow, deliberate motion and light pressure, draw your index finger across the back of
the LRSM toward the connector receptacle until the silicone gelatin adhesive membrane pad is
in full contact with the windshield glass.
Fig 2: LRSM, Harness Connector, Mount Bracket & Retaining Strap
6. Engage one side of the spring steel retaining strap (5) into the groove on one side of the
LRSM mounting bracket (4) on the inside of the windshield glass (2).
7. Depress the opposite side of the retaining strap over the LRSM firmly and evenly until it fully
engages the groove of the mounting bracket with an audible click.
8. Looking through the windshield from outside the vehicle, inspect the silicone gelatin adhesive
membrane pad for air pockets. If air pockets are observed, let the vehicle stand for about four
hours at room temperature to allow the air pockets to dissipate. If an adhesive void (air
pocket) greater than about 1 millimeter (0.04 inch) is observed, replace the flawed silicone
gelatin adhesive membrane pad with a new unit as described in: STANDARD PROCEDURE -
Silicone Gelatin Pad Replacement.
9. Connect the wire harness connector (1) to the LRSM connector receptacle (6).
10. Install the inside rear view mirror to the mounting button (3) on the inside of the windshield
glass. Refer to MIRROR, REARVIEW, REMOVAL AND INSTALLATION .
MOTOR, WIPER > DESCRIPTION AND OPERATION > DESCRIPTION AND
OPERATION - FRONT WIPER MOTOR > DESCRIPTION - FRONT
The front wiper motor is packaged with the wiper linkage module in this vehicle. Refer to LINKAGE,
WIPER ARM, DESCRIPTION AND OPERATION .

OPERATION - FRONT WIPER MOTOR > OPERATION - FRONT
The front wiper motor is packaged with the wiper linkage module in this vehicle. Refer to LINKAGE,
WIPER ARM, DESCRIPTION AND OPERATION .

OPERATION - REAR WIPER MOTOR > DESCRIPTION - REAR
Fig 1: Rear Wiper Motor, Output Shaft, Connector Receptacle & Rubber Insolators
The rear wiper motor (3) is located on the liftgate inner panel below the liftgate glass opening and
concealed behind the liftgate inner trim. The rear wiper motor is secured to the liftgate inner panel using
three blind rivets through three rubber insulators (2). The rear wiper motor output shaft (1) extends
through a clearance hole in the lower edge of the liftgate glass to drive the rear wiper arm and blade. A
rubber grommet is engaged within the output shaft clearance hole of the glass and seals the output shaft
when it passes through the glass.
An integral connector receptacle (4) connects the rear wiper motor to the vehicle electrical system
through a dedicated connector of the body wire harness. The single-speed, permanent magnet wiper
motor includes an integral transmission, the output shaft, an automatic resetting circuit breaker and the
rear wiper motor park switch.
The rear wiper motor cannot be adjusted or repaired. If any component of the motor is ineffective or
damaged, the entire rear wiper motor unit must be replaced. The motor output shaft rubber grommet is
available for individual service replacement.
OPERATION - REAR WIPER MOTOR > OPERATION - REAR
The rear wiper motor operation is controlled by the Body Control Module (BCM), which uses relays
soldered onto the BCM Printed Circuit Board (PCB) to control rear wiper system operation for energizing
or de-energizing the rear wiper motor. The BCM uses internal programming, hard wired inputs received
from the right (wiper) multifunction switch and the rear wiper motor park switch as well as electronic
messages received over the Controller Area Network (CAN) data bus to provide the rear wiper and
washer system operating modes.
The rear wiper motor park switch is a single pole, single throw, momentary switch within the wiper motor
that is mechanically actuated by the wiper motor transmission components. The park switch alternately
closes and opens a voltage signal for the rear wiper motor electronic control logic circuitry of the BCM.
The park switch is normally an open circuit when the rear wiper blade is in the parked position, and is
connected to fused ignition output when the rear wiper blade is anywhere except parked.
This park switch input allows the electronic logic circuits of the BCM to control all of the electronic
features of rear wiper motor operation and to keep the motor energized long enough to complete its
current wipe cycle and park the wiper blade at the base of the glass after the status of the rear wiper
system or the ignition transitions to Off. The internal BCM circuitry pulls the park switch sense input to
ground when the switch is open so that the microcontroller sees a ground when the wiper blade is
parked.
The rear wiper motor is grounded at all times through a take out with an eyelet terminal connector in the
body wire harness that is secured to a ground location in the passenger compartment. The automatic
resetting circuit breaker protects the motor from overloads. The rear wiper motor transmission converts
the rotary output of the wiper motor to the back and forth wiping motion of the rear wiper arm and blade
on the liftgate glass.
The hard wired inputs and outputs of the rear wiper motor may be diagnosed using conventional
However, conventional diagnostic methods will not prove conclusive in the diagnosis of the rear wiper
motor or the electronic controls and communication between other modules and devices that provide
some features of the rear wiper and washer system. The most reliable, efficient and accurate means to
diagnose the rear wiper motor or the electronic controls and communication related to rear wiper motor
article.
MOTOR, WIPER > REMOVAL AND INSTALLATION > REMOVAL AND INSTALLATION -
FRONT WIPER MOTOR > REMOVAL - FRONT
The front wiper motor is packaged and serviced only as a unit with the wiper linkage module in this
vehicle. Refer to LINKAGE, WIPER ARM, REMOVAL AND INSTALLATION .
FRONT WIPER MOTOR > INSTALLATION - FRONT
The front wiper motor is packaged and serviced only as a unit with the wiper linkage module in this
vehicle. Refer to LINKAGE, WIPER ARM, REMOVAL AND INSTALLATION .
REAR WIPER MOTOR > REMOVAL - REAR
Fig 1: Rear Wiper Motor, Wire Connector & Rivets
from the battery.
2. Remove the rear wiper arm from the rear wiper motor output shaft. Refer to ARM, WIPER,
3. Remove the trim from the inside of the liftgate inner panel. Refer to PANEL, TRIM, LIFTGATE,
4. Disconnect the body wire harness connector (1) from the rear wiper motor connector
receptacle.
5. Use a drill and the appropriate drill bit to carefully remove the three blind rivets (2) that secure
the rear wiper motor (3) to the liftgate inner panel.
6. Carefully pull the wiper motor away from the inside of the liftgate inner panel far enough to
disengage the output shaft from the rubber grommet in the clearance hole of the liftgate glass.
7. Remove the motor from the liftgate.
8. If necessary, working from the outside of the liftgate pry the rubber grommet from the output
shaft clearance hole in the glass and discard.
REAR WIPER MOTOR > INSTALLATION - REAR
Fig 1: Rear Wiper Motor, Wire Connector & Rivets
1. If removed, press a new rubber grommet into the rear wiper motor output shaft clearance hole
located in the liftgate glass.
2. Position the rear wiper motor (3) to the liftgate inner panel while guiding the output shaft
through the rubber grommet in the liftgate glass.
3. Install three new blind rivets (2) to secure the motor to the liftgate inner panel.
4. Connect the body wire harness connector (1) to the rear wiper motor connector receptacle.
5. Install the trim onto the inside of the liftgate inner panel. Refer to PANEL, TRIM, LIFTGATE,
6. Install the rear wiper arm onto the motor output shaft. Refer to ARM, WIPER, REMOVAL AND
INSTALLATION .
NOZZLE, WASHER > DESCRIPTION AND OPERATION > DESCRIPTION AND

OPERATION - FRONT WASHER NOZZLE > DESCRIPTION - FRONT
Fig 1: Fluidic Front Washer Nozzle, Latches, Orifices & Fittings
The fluidic front washer nozzles (2) are constructed of molded plastic and include an integral check
valve. Each nozzle has two integral latches (3) that secure them in dedicated holes in the hood panel
near the base of the windshield. The domed upper surface of the washer nozzle is visible on the outside
of the hood panel, and the two nozzle orifices (1) are oriented towards the windshield glass.
An integral diaphragm type check valve is contained within the body of each nozzle. The washer
plumbing fittings (4) for the washer nozzles extend below the hood panel and are accessible from the
engine compartment.
The front washer nozzles cannot be adjusted or repaired and, if ineffective or damaged, they must be
replaced.

OPERATION - FRONT WASHER NOZZLE > OPERATION - FRONT
The two front washer nozzles are designed to dispense washer fluid into the wiper pattern area on the
outside of the windshield glass. Pressurized washer fluid is fed to each nozzle from the washer reservoir
by the washer pump/motor unit through a single hose, which is attached to a barbed nipple on each
washer nozzle below the hood panel. A fluidic matrix within the washer nozzle causes the pressurized
washer fluid to be emitted from the nozzle orifice as an oscillating stream to more effectively cover a
larger area of the glass to be cleaned.
The integral check valve in each nozzle prevents washer fluid from draining out of the washer supply
hoses back to the washer reservoir. This drain-back would result in a lengthy delay after the washer
switch is actuated until washer fluid was dispensed through the nozzles, because the washer pump would
have to refill the washer plumbing from the reservoir to the nozzles. Such a drain-back condition could
also result in water, dirt, or other outside contaminants being siphoned into the washer system through
the washer nozzle orifice. This water could subsequently freeze and plug the nozzle, while other
contaminants could interfere with proper nozzle operation and cause improper nozzle spray patterns. In
addition, the check valve prevents washer fluid from siphoning through the washer nozzles after the
washer system is turned Off.
When the washer pump pressurizes and pumps washer fluid from the reservoir through the washer
plumbing, the fluid pressure unseats a diaphragm from over a sump well within the nozzle by overriding
the spring pressure applied to it by a piston. With the diaphragm unseated, washer fluid is allowed to flow
toward the nozzle orifice. When the washer pump stops operating, the spring pressure on the piston
seats the diaphragm over the sump well in the nozzle and fluid flow in either direction within the washer
plumbing is prevented.

OPERATION - REAR WASHER NOZZLE > DESCRIPTION - REAR
Fig 1: Fluidic Rear Washer Nozzle, Latches, Plumbing Fitting & Orifice
The fluidic rear washer nozzle (4) is constructed of molded plastic. The rear washer nozzle is secured by
two integral latch features (2) within a dedicated mounting hole located in the inner structure of the
spoiler panel above the liftgate glass opening. The spoiler must be removed from the liftgate to access
the rear washer nozzle for service.
The rear washer nozzle orifice (3) is oriented downward towards the liftgate glass through an elongated
oval opening in the outer surface on the underside of the spoiler and located just to the left of the Center
High Mounted Stop Lamp (CHMSL). The washer plumbing fitting (1) is concealed between the liftgate
outer panel and the spoiler.
The rear washer nozzle cannot be adjusted or repaired. If ineffective or damaged, the entire nozzle unit
must be replaced.

OPERATION - REAR WASHER NOZZLE > OPERATION - REAR
The rear washer nozzle is designed to dispense washer fluid into the wiper pattern area on the outside of
the liftgate glass. Pressurized washer fluid is fed to the nozzle from the washer reservoir by the washer
pump/motor unit through a single hose, which is attached to a barbed nipple on the back of the rear
washer nozzle. A fluidic matrix within the washer nozzle causes the pressurized washer fluid to be
emitted from the nozzle orifice as an oscillating stream to more effectively cover a larger area of the
glass to be cleaned.
NOZZLE, WASHER > REMOVAL AND INSTALLATION > REMOVAL AND

INSTALLATION - FRONT WASHER NOZZLE > REMOVAL - FRONT
Fig 1: Remove/Install Front Washer Nozzle
1. Remove the eight retainers (1) that secure the silencer pad (2b) to the inner hood panel
reinforcement.
2. Disengage the tabs (2a) of the silencer pad from the slots in the inner hood panel
reinforcement and remove the silencer pad.
Fig 2: Supply Hose, Washer Nozzles & Fasteners
3. From the underside of the inner hood panel reinforcement disconnect the supply hose (1b) from
the nipple of the front washer nozzle (2).
4. Release the two integral latch features of the front washer nozzle and push the nozzle out
through the mounting hole toward the outside of the hood panel.

INSTALLATION - FRONT WASHER NOZZLE > INSTALLATION - FRONT
Fig 1: Supply Hose, Washer Nozzles & Fasteners
1. Position the front washer nozzle (2) to the mounting hole from the outside of the hood panel.
2. Using hand pressure, push firmly and evenly on the top of the nozzle until the two integral
latches snap into place on the inside surface of the hood panel.
3. Connect the supply hose (1b) to the front washer nozzle nipple.
Fig 2: Remove/Install Front Washer Nozzle
4. Engage the four tabs (2a) of the hood silencer pad (2b) into the slots in the inner hood panel
reinforcement.
5. Install the eight retainers (1) that secure the silencer pad to the inner hood panel
reinforcement.

INSTALLATION - REAR WASHER NOZZLE > REMOVAL - REAR
Fig 1: Rear Washer Nozzle & Latches
1. Remove the spoiler from the outside of the liftgate. Refer to SPOILER, DECKLID, REMOVAL
AND INSTALLATION .
2. Working from the back of the spoiler, disconnect the washer hose and check valve from the
nipple of the rear washer nozzle (1a).
3. Using a trim stick or another suitable wide flat-bladed tool, compress the latch features (1b)
that secure the rear washer nozzle in the mounting hole of the spoiler panel far enough to
release the nozzle.
4. Remove the rear washer nozzle from the mounting hole of the spoiler panel.

INSTALLATION - REAR WASHER NOZZLE > INSTALLATION - REAR
Fig 1: Rear Washer Nozzle & Latches
1. Position the rear washer nozzle (1a) to the mounting hole of the liftgate spoiler panel. Be
certain that the nozzle orifice is oriented toward the liftgate glass.
2. Using hand pressure, press firmly and evenly on the rear washer nozzle until the latch features
(1b) snap into place behind the mounting hole of the liftgate spoiler panel.
3. Connect the check valve and rear washer supply hose unit to the nipple of the rear washer
nozzle.
4. Install the spoiler onto the outside of the liftgate. Refer to SPOILER, DECKLID, REMOVAL
AND INSTALLATION .
PUMP, WINDSHIELD WASHER > DESCRIPTION AND OPERATION > DESCRIPTION

Fig 1: Two-Way Electric Pump & Washer Fluid Reservoir
The washer pump circuit is supplied by a two-way electric pump located in the lower part of the washer
fluid reservoir, which is located between the left front fender and the fender inner shield ahead of the left
front wheel and the front wheel house splash shield. A small permanently lubricated and sealed electric
motor is coupled to the rotor-type washer pump. The electric motor is reversible and an integral valve
body allows the washer pump/motor unit to provide washer fluid to either the front or the rear washer
systems, depending upon the direction of the pump impeller rotation.
The washer pump is retained on the reservoir by the interference fit between the pump inlet nipple and
the grommet seal, which is a light press fit. This fit allows for mounting of the washer pump without the
use of fasteners. An integral connector receptacle on the top of the motor housing connects the unit to
the vehicle electrical system through a dedicated take out and connector of the engine compartment wire
harness.
The washer pump cannot be repaired. If ineffective or damaged, the entire washer pump must be
replaced. The rubber grommet seal/filter screen is available for separate service replacement.
PUMP, WINDSHIELD WASHER > DESCRIPTION AND OPERATION > DESCRIPTION

The washer pump features a reversible electric motor. The direction of the motor is controlled by hard
wired outputs from the Body Control Module (BCM). When battery current and ground are applied to the
two pump motor terminals, the motor rotates in one direction. When the polarity of these connections is
reversed, the motor rotates in the opposite direction. When the pump motor is energized, the rotor-type
pump pressurizes the washer fluid and forces it through the appropriate pump outlet nipple and into the
front or rear washer plumbing. The BCM controls the hard wired outputs to the pump motor based upon
hard wired resistor multiplexed inputs received from the front and rear washer switch circuitry contained
within the right (wiper) multifunction switch.
Washer fluid is drawn through the pump inlet nipple from the washer reservoir to the inlet port of the
washer pump housing. An integral valve body is located in a housing on the outlet port side of the pump
housing. A diaphragm in this valve body controls which washer system plumbing receives the washer
fluid being pressurized by the pump. When the pump impeller rotates in a counterclockwise direction, the
biased diaphragm is sealing off the rear washer system outlet and nipple so the pressurized washer fluid
is pushed out through the pump front outlet port and the front washer outlet nipple. When the pump
impeller rotates in a clockwise direction, pressurized washer fluid is pushed out through the pump rear
outlet port and moves the diaphragm to open the rear washer outlet nipple and seal off the front washer
outlet nipple, then the pressurized washer fluid is pushed out through the rear washer outlet nipple.
The washer pump and the hard wired motor control circuits from the BCM may be diagnosed using
article. However, conventional diagnostic methods will not prove conclusive in the diagnosis of the
washer pump or the electronic controls and communication between other modules and devices that
provide some features of the front and rear wiper and washer system. The most reliable, efficient and
accurate means to diagnose the washer pump or the electronic controls and communication related to
washer pump/motor unit operation requires the use of a diagnostic scan tool. Refer to the appropriate
PUMP, WINDSHIELD WASHER > REMOVAL AND INSTALLATION > REMOVAL AND
Fig 1: Front Wheel House Splash Shield & Fasteners
NOTE:
The washer pump/motor can be removed from the washer reservoir without removing the
reservoir from the vehicle.
1. Turn the steering wheel to move the front wheels to the full left position.
from the battery.
4. Remove the fasteners (1a) that secure the front of the left front wheel house splash shield to
the front of the front fender wheel opening and the front bumper fascia.
5. Pull the splash shield away from the front fascia far enough to access the washer pump/motor
unit.
Fig 2: Washer Pump, Front & Rear Washer Hose Fittings And Wire Connector
6. Disconnect the engine compartment wire harness connector (2) from the washer pump/motor
unit connector receptacle.
NOTE:
Note the installed position of the washer hoses prior to disconnecting them from the
washer pump.
7. Disconnect the front and rear washer hose fittings (1) from the barbed outlet nipples of the
washer pump and allow the washer fluid to drain into a clean container for reuse.
8. Using hand pressure, firmly grasp and pull the washer pump (3) upward far enough to
disengage the pump inlet nipple from the rubber grommet seal/filter screen in the reservoir.
Care must be taken not to damage the reservoir.
9. Remove the washer pump/motor unit from the washer reservoir.
10. Remove the rubber grommet seal from the washer pump mounting hole in the reservoir and
discard.
PUMP, WINDSHIELD WASHER > REMOVAL AND INSTALLATION > REMOVAL AND
Fig 1: Washer Pump, Front & Rear Washer Hose Fittings And Wire Connector
1. Lubricate a new rubber grommet seal/filter screen with clean washer fluid and install it into the
washer pump mounting hole in the washer reservoir. Always use a new rubber grommet
seal/filter screen on the reservoir.
2. Position the inlet nipple on the base of the pump housing of the washer pump/motor unit (3) to
the rubber grommet seal/filter screen in the reservoir.
3. Using hand pressure, press firmly and evenly downward on the top of the washer pump/motor
unit until the inlet nipple is fully seated in the rubber grommet seal/filter screen in the pump
mounting hole of the reservoir.
NOTE:
Be certain to connect the front and rear washer hoses to the proper outlet nipples of
the washer pump (rear washer hose goes to black nipple, front washer hose goes
to white nipple). Failure to properly connect the hoses will cause the front and rear
washer systems to operate incorrectly.
4. Connect the front and rear washer hose fittings (1) to the barbed outlet nipples of the washer
pump. Be certain that the rear washer hose is connected to the black nipple and the front
washer hose is connected to the white nipple.
5. Connect the engine compartment wire harness connector (2) for the washer pump/motor unit to
the connector receptacle on the top of the motor.
Fig 2: Front Wheel House Splash Shield & Fasteners
6. Install the fasteners (1a) to secure the left front wheel house splash shield to the front of the
front fender opening and the front bumper fascia.
7. Remove the support and lower the vehicle.
9. Fill the washer reservoir with the washer fluid drained from the reservoir during the removal
procedure.
RESERVOIR, WINDSHIELD WASHER > DESCRIPTION AND OPERATION >

Fig 1: Washer Fluid Reservoir, Pump/Motor Unit & Blind Rivets
A single washer fluid reservoir (1) is used for both the front and the rear washer systems. The molded
plastic washer fluid reservoir is mounted between the left front fender and inner fender shield and ahead
of the left front wheel, where it is concealed by the left front wheel house splash shield. The only visible
component of the washer reservoir is the filler neck and cap unit, which extends upward into the left front
corner of the engine compartment just behind the upper radiator cross member.
A yellow plastic filler cap with an International Control and Display Symbol icon for Windshield Washer
molded into it snaps over the open end of the filler neck. The cap hinges on an integral bail strap. Two
rubber O-rings seal the lower end of the filler neck to the fitting on the top of the reservoir and a unique
plastic retainer latches the filler neck to a stanchion on the front outboard corner of the battery tray.
There is a dedicated mounting hole in the sump area at the bottom of the reservoir provided for the
washer pump/motor unit (2). The outboard side of the washer reservoir has integral troughs which
secure the front and rear washer hoses as they are routed into the engine compartment. The sides of
the reservoir have integral mounting tabs that are used to secure the reservoir to the outboard side of
the left front end structure with blind rivets (3).
The washer reservoir cannot be repaired and, if ineffective or damaged, it must be replaced. The washer
reservoir, the rubber grommet seal/filter screen, the washer pump/motor unit, the filler neck and the filler
cap are each available for individual service replacement.
RESERVOIR, WINDSHIELD WASHER > DESCRIPTION AND OPERATION >

The washer fluid reservoir provides a secure, on-vehicle storage location for a large reserve of washer
fluid for operation of the front and the rear washer systems. The washer reservoir filler neck provides a
clearly marked and readily accessible point from which to add washer fluid to the reservoir.
The reversible front and rear washer pump is located in a sump area near the bottom on the outboard
side of the reservoir to be certain that washer fluid will be available to the pump as the fluid level in the
reservoir becomes depleted.
RESERVOIR, WINDSHIELD WASHER > REMOVAL AND INSTALLATION > REMOVAL

AND INSTALLATION > REMOVAL - FILLER NECK
Fig 1: Filler Neck, Base & Latch Tabs
1. Locate the filler neck of the washer reservoir in the left front corner of the engine compartment.
2. Observe the level of the washer fluid through the translucent filler neck and reservoir. If the
washer fluid level is above the base of the filler neck, siphon the washer fluid into a clean
container for reuse until it is below the base of the filler neck.
3. Disengage the latch tabs of the retainer (1a) on the filler neck (1b) from the stanchion on the
outboard front corner of the battery tray.
4. Use a back and forth twisting action to disengage the base (2a) of the filler neck from the filler
neck fitting on the top of the reservoir.
5. Remove the filler neck, retainer and filler cap from the engine compartment as a unit.

AND INSTALLATION > REMOVAL - RESERVOIR
Fig 1: Washer Reservoir, Pump & Blind Rivets
from the battery.
2. Remove the filler neck from the washer reservoir. Refer to RESERVOIR, WINDSHIELD
WASHER, REMOVAL AND INSTALLATION .
4. Remove the washer pump (1) from the washer reservoir without disconnecting the wiring and
hoses from the pump. Move the washer pump aside. Refer to PUMP, WINDSHIELD WASHER,
5. Remove the rubber grommet seal from the washer pump mounting hole in the reservoir and
discard.
6. Use a drill to remove the two blind rivets (2a) that secure the washer reservoir (2b) to the
outboard side of the left front support structure.
7. Remove the reservoir from the vehicle.

AND INSTALLATION > INSTALLATION - FILLER NECK
Fig 1: Filler Neck, Base & Latch Tabs
1. Be certain that the two O-ring seals on the base of the filler neck are properly positioned and in
good condition.
2. Position the filler neck (1b), retainer and filler cap into the left front corner of the engine
compartment as a unit.
3. Align the base of the filler neck (2a) with the filler neck fitting on the top of the reservoir.
4. Use a back and forth twisting action to engage the base of the filler neck into the filler neck
fitting on the top of the reservoir.
5. Align and snap the filler neck retainer (1a) onto the stanchion on the outboard front corner of
the battery tray. Be certain that the two latch features of the retainer are fully engaged with the
stanchion.
6. Refill the washer reservoir with any washer fluid drained from the filler neck during the removal
procedure.

AND INSTALLATION > INSTALLATION - RESERVOIR
Fig 1: Washer Reservoir, Pump & Blind Rivets
1. Position the washer reservoir (2b) to the left front support structure of the vehicle.
2. Align the reservoir mounting tabs with the mounting holes on the outboard side of the left front
support structure.
3. Install two new blind rivets (2a) to secure the reservoir to the outboard side of the left front
support structure.
4. Lubricate a new rubber grommet seal/filter screen with clean washer fluid and install it into the
washer pump mounting hole in the washer reservoir. Always use a new rubber grommet
seal/filter screen on the reservoir.
5. Install the washer pump/motor unit (1) into the reservoir. Refer to PUMP, WINDSHIELD
6. Install the fasteners to secure the left front wheel house splash shield to the front bumper
fascia.
8. Install the filler neck onto the washer reservoir. Refer to RESERVOIR, WINDSHIELD
10. Fill the washer reservoir with the washer fluid drained from the reservoir during the removal
procedure.
SWITCH, MULTIFUNCTION, RIGHT > DESCRIPTION AND OPERATION >

Fig 1: Right/Left Multifunction Switch & Clockspring
The wiper (right) multifunction switch (2) is located on the right side of the steering column, just behind
the steering wheel. This switch is the primary control for the front and rear wiper and washer systems.
The only visible components of the switch are the control stalk with a control knob and control sleeve
that extend through the steering column shrouds on the right side of the column. The remainder of the
switch including its mounting provisions and its electrical connection are concealed beneath the shrouds.
The switch housing and controls are constructed of molded black plastic. Each of the switch controls has
white International Control and Display Symbol graphics applied to it, which clearly identify its many
functions. The wiper (right) multifunction switch for this vehicle is integral to the clockspring and stalk unit
which also includes an integral lighting (left) multifunction switch (1) and the clockspring (3).
The wiper (right) multifunction switch provides the vehicle operator with a control interface for the
following wiper and washer system functions:
Continuous Front Wipers - The right multifunction switch control stalk provides detent switching
for two continuous front wipe modes, low speed or high speed.
Intermittent Front Wipers - The right multifunction switch control stalk provides detent switching
for two speed-sensitive intermittent front wipe modes.
Front Wiper Mist Mode - The right multifunction switch control stalk includes momentary
switching of the front wiper motor low speed circuit to provide a mist mode feature (sometimes
referred to as pulse wipe), which allows the vehicle operator to momentarily operate the front
wipers for one or more complete cycles.
Front Washer Mode - The right multifunction switch control stalk provides momentary switching
for control of front washer system operation.
Continuous Rear Wipe Mode - The right multifunction switch control knob provides detent
switching for a single continuous rear wiper mode.
Intermittent Rear Wipe Mode - The right multifunction switch control knob provides detent
switching for a single fixed interval intermittent rear wiper mode.
Rear Washer Mode - The right multifunction switch control stalk provides momentary switching for
control of rear washer system operation.
The wiper (right) multifunction switch cannot be adjusted or repaired. If any function or feature of the
switch is ineffective or if the switch is damaged, the entire clockspring and stalk unit must be replaced.
Refer to CLOCKSPRING, REMOVAL AND INSTALLATION .
SWITCH, MULTIFUNCTION, RIGHT > DESCRIPTION AND OPERATION >

Fig 1: Right Multifunction Switch Control Stalk, Knob & Sleeve
The wiper (right) multifunction switch uses resistor multiplexing to control the many functions and
features it provides using a minimal number of hard wired circuits. The switch receives clean grounds
from the Body Control Module (BCM), then provides resistor multiplexed return outputs to the BCM to
indicate the selected switch positions. The BCM then sends hard wired control outputs as well as
electronic switch status messages over the Controller Area Network (CAN) data bus to other electronic
modules in the vehicle.
Some of the hard wired inputs and outputs of the BCM and the wiper (right) multifunction switch unit may
WIRING DIAGRAMS article. However, the most reliable, efficient and accurate means to diagnose the
BCM and the wiper (right) multifunction switch requires the use of a diagnostic scan tool. Refer to the
Following are descriptions of how the wiper (right) multifunction switch is operated to control the
functions and features it provides:
Front Wiper Control - The right multifunction switch control knob (2) is rotated upward to one of
the two continuous wiper detents or to one of the two speed sensitive intermittent wipe detents. It
is rotated to the most downward detent position to select the front wiper Off position. The right
multifunction switch control stalk (1) is raised upward to the momentary front wiper Mist position.
The front wiper motor will continue to operate, one complete cycle at a time, for as long as the
control stalk is held in the Mist position. If the front wipers are active, the rear wipers are
automatically activated whenever the transmission gear selector is placed in the Reverse position.
The BCM reads the resistor multiplexed input from the wiper (right) multifunction switch, a hard
wired input from the manual transmission backup lamp switch (if equipped), an electronic reverse
gear selected message input from the automatic Transmission Control Module (TCM) (if
equipped) and electronic vehicle speed message inputs from the Antilock Brake Module (ABM)
and provides a hard wired output to control the relays that energize or de-energize the front and
rear wiper motors as appropriate.
Front Washer Control - The right multifunction switch control stalk is pulled rearward towards the
steering wheel to a momentary Front Wash position to activate the washer pump/motor in the front
washer mode. The washer pump/motor will continue to operate for as long as the control stalk is
held in this position. If the control stalk is held in the Front Wash position for more than about half a
second, the front wiper motor will begin to operate and will continue to operate for about three
complete strokes after the control stalk is released. There will also be one additional front wiper
stroke about six seconds after the control stalk is released. The BCM reads the resistor
multiplexed input from the wiper (right) multifunction switch and provides hard wired outputs to
control the washer pump/motor and the front wiper motor as appropriate.
Rear Wiper Control - The rear wiper mode is selected when the right multifunction switch control
sleeve (3) is rotated upward to the continuous wipe or the fixed interval intermittent rear wipe
detent positions. It is rotated to the most downward detent position to select the rear wiper Off
position. If the front wipers are active, the rear wipers will operate in a synchronous mode at half
the speed of the front wipers, or in a continuous mode whenever the transmission gear selector is
placed in the Reverse position. The BCM reads the resistor multiplexed input from the wiper (right)
multifunction switch and provides a hard wired output to control a relay that energizes or
de-energizes the rear wiper motor as appropriate.
Rear Washer Control - The right multifunction switch control stalk is pushed forward towards the
instrument panel to a momentary Rear Wash position to activate the washer pump/motor in the
rear washer mode. The washer pump/motor will continue to operate for as long as the control stalk
is held in this position. If the control stalk is held in the Rear Wash position for more than about half
a second, the rear wiper motor will begin to operate and will continue to operate for about three
complete strokes after the control stalk is released. There will also be one additional rear wiper
stroke about six seconds after the control stalk is released. The BCM reads the resistor
multiplexed input from the wiper (right) multifunction switch and provides hard wired outputs to
control the washer pump/motor and the rear wiper motor as appropriate.
SWITCH, MULTIFUNCTION, RIGHT > DIAGNOSIS AND TESTING > DIAGNOSIS AND
TESTING - RIGHT MULTIFUNCTION SWITCH
The internal circuitry of the wiper (right) multifunction switch and the hard wired circuits between the
switch and the Body Control Module (BCM) may be diagnosed using conventional diagnostic tools and
diagnostic methods will not prove conclusive in the diagnosis of the BCM or the electronic controls and
communication between modules and other devices that provide some features of the BCM-controlled
wiper and washer system. The most reliable, efficient and accurate means to diagnose the BCM or the
electronic controls and communication related to BCM-controlled wiper and washer system operation
SWITCH, MULTIFUNCTION, RIGHT > REMOVAL AND INSTALLATION > REMOVAL

NOTE:
The clockspring and stalk unit for this vehicle includes the wiper (right) multifunction switch,
the lighting (left) multifunction switch and the clockspring. The two multifunction switches and
stalk unit must be replaced. Refer to CLOCKSPRING, REMOVAL AND INSTALLATION .
SWITCH, MULTIFUNCTION, RIGHT > REMOVAL AND INSTALLATION > REMOVAL

NOTE:
The clockspring and stalk unit for this vehicle includes the wiper (right) multifunction switch,
the lighting (left) multifunction switch and the clockspring. The two multifunction switches and
stalk unit must be replaced. Refer to CLOCKSPRING, REMOVAL AND INSTALLATION .
Jeep Renegade
Service Manual: BODY - INTERIOR & EXTERIOR
WARNING > USE OF HEAT DURING REPAIR
WARNING:
FCA US LLC engineering's position on the use of heat during collision repair is as follows:
Any body panel or frame component damaged which is to be repaired and

reused, must be repaired using the "cold straightening" method. No heat may be
used during the straightening process.
During rough straightening prior to panel replacement, damaged panels or

frame components may be heated to assist in body/frame realignment. The
application of heat must be constrained to the parts which will be replaced and
not allowed to affect any other components.
This "no heat" recommendation is due to the extensive use of high strength and
advanced high strength steels in FCA US LLC products. High-strength materials can
be substantially and negatively affected from heat input which will not be obviously
known to the repairer or consumer.
Ignoring these recommendations may lead to serious compromises in the ability to

protect occupants in a future collision event, reduce the engineered qualities and
attributes, or decrease the durability and reliability of the vehicle.
This statement supersedes any previously released information by the FCA US LLC.
Failure to follow these instructions may result in serious or fatal injury.
WARNING > WARNINGS
WARNING:
Use an Occupational Safety and Health Administration (OSHA) approved breathing filter,
when spraying paint or solvents in a confined area. Failure to follow these instructions may
result in possible serious or fatal injury.
avoid prolonged skin contact with petroleum or alcohol based cleaning solvents.
do not stand under a hoisted vehicle that is not properly supported on safety stands.
CAUTION:
When holes are drilled or punched in an inner body panel, verify the depth of space to the
outer body panel, electrical wiring or other components. Damage to the vehicle can result.
do not weld exterior panels unless combustible material on the interior of vehicle is
removed from the repair area. Fire or hazardous conditions, can result.
always have a fire extinguisher ready for use when welding.
disconnect the negative (-) cable clamp from the battery when servicing electrical
components that are live when the ignition is off. Damage to electrical system can
result.
do not use abrasive chemicals or compounds on painted surfaces. Damage to finish

can result.
do not use harsh alkaline based cleaning solvents on painted or upholstered surfaces.
Damage to finish or color can result.
do not hammer or pound on plastic trim panel when servicing interior trim. Plastic
panels can break.
WARNING > WARNINGS > RESTRAINT WARNINGS
WARNING:
To avoid serious or fatal injury on vehicles equipped with the Supplemental Restraint
System (SRS), never attempt to repair the electrically conductive circuits or wiring
components related to the SRS for which there is no MOPAR wiring repair kit. It is important
to use ONLY the recommended splicing kit and procedure. For applicable and available
MOPAR wiring repair kits, please visit the MOPAR Connector Web Site at the following
address on the internet: (http://dto.vftis.com/mopar/disclaimer.asp). Inappropriate repairs can
compromise the conductivity and current carrying capacity of those critical electrical circuits,
which may cause SRS components not to deploy when required, or to deploy when not
required. Only minor cuts or abrasions of wire and terminal insulation where the conductive
material has not been damaged, or connector insulators where the integrity of the latching
and locking mechanisms have not been compromised may be repaired using appropriate
methods.
WARNING:
To avoid serious or fatal injury during and following any seat belt or child restraint anchor
service, carefully inspect all seat belts, buckles, mounting hardware, retractors, tether
straps, and anchors for proper installation, operation, or damage. Replace any belt that is
cut, frayed, or torn. Straighten any belt that is twisted. Tighten any loose fasteners. Replace
any belt that has a damaged or ineffective buckle or retractor. Replace any belt that has a
bent or damaged latch plate or anchor plate. Replace any child restraint anchor or the unit to
which the anchor is integral that has been bent or damaged. Never attempt to repair a seat
belt or child restraint component. Always replace damaged or ineffective seat belt and child
restraint components with the correct, new and unused replacement parts listed in the
Mopar® Parts Catalog. Failure to follow these instructions may result in possible serious or
fatal injury.
WARNING:
Restraint System (SRS) before attempting any steering wheel, steering column, airbag,
Occupant Classification System (OCS), seat belt tensioner, impact sensor or instrument
panel component diagnosis or service. Refer to WARNING . Disconnect and isolate the
battery negative (ground) cable, then wait two minutes for the system capacitor to discharge
before performing further diagnosis or service. This is the only sure way to disable the SRS.
Failure to follow these instructions may result in accidental airbag deployment.
WARNING:
To avoid potential physical injury or damage to sensitive electronic circuits and systems,
always disconnect and isolate the battery negative (ground) cable and the positive cable,
then ground the positive cable to discharge the Occupant Restraint Controller (ORC)
capacitor before performing any welding operations on the vehicle. Failure to take the
proper precautions could result in accidental airbag deployment, possible damage to the
Supplemental Restraint System (SRS) circuits and components, and possible damage to
other electronic circuits and components. Whenever a welding process is being performed
within 12 inches (30 centimeters) of an electronic module or wiring harness, then that
module or harness should be relocated out of the way, or disconnected. Always protect
against component or vehicle damage from weld spatter by using weld blankets and
screens.
WARNING:
To avoid serious or fatal injury, do not attempt to dismantle an airbag unit or tamper with its
inflator. Do not puncture, incinerate or bring into contact with electricity. Do not store at
temperatures exceeding 93° C (200° F). An airbag inflator unit may contain sodium azide
and potassium nitrate. These materials are poisonous and extremely flammable. Contact
with acid, water, or heavy metals may produce harmful and irritating gases (sodium
hydroxide is formed in the presence of moisture) or combustible compounds. An airbag
inflator unit may also contain a gas canister pressurized to over 17.24 kPa (2500 psi).
WARNING:
To avoid serious or fatal injury when handling a seat belt tensioner retractor. Exercise proper
care to keep fingers out from under the retractor cover and away from the seat belt webbing
where it exits from the retractor cover. Failure to follow these instructions may result in
WARNING:
To avoid serious or fatal injury, replace all Supplemental Restraint System (SRS)
components only with parts specified in the Mopar® Parts Catalog. Substitute parts may
appear interchangeable, but internal differences may result in inferior occupant protection.
WARNING:
To avoid serious or fatal injury, the fasteners, screws, and bolts originally used for the
Supplemental Restraint System (SRS) components must never be replaced with any
substitutes. These fasteners have special coatings and are specifically designed for the
SRS. Anytime a new fastener is needed, replace it with the correct fasteners provided in the
service package or specified in the Mopar® Parts Catalog.
WARNING:
To avoid serious or fatal injury when a steering column has an airbag unit attached, never
place the column on the floor or any other surface with the steering wheel or airbag unit face
down. Failure to follow these instructions may result in possible serious or fatal injury.
DIAGNOSIS AND TESTING > FRONT DOOR LOCK TESTING > FAILED RECOGNITION
OF THE PASSIVE ENTRY KEY
STEP WHAT TO DO OK (no problem PROBLEM FOUND CORRECTION

found)
EMERGENCY DOOR
UNLOCKING KEY
CONDITION CHECK The track is Replace the Passive
1 Go to step 2
Check the condition of damaged Entry key
the mechanical code
encrypted track
SECOND EMERGENCY
Also the second key
DOOR UNLOCKING Replace the second
2 End of diagnosis is not mechanically
KEY CONDITION passive entry key
recognized
CHECK
Check for the
mechanical recognition
of the second key
DIAGNOSIS AND TESTING > FRONT DOOR LOCK TESTING > FAILED RETENTION
OF THE EMERGENCY UNLOCKING MECHANICAL INSERT IN THE PASSIVE ENTRY
KEY

found)
PASSIVE ENTRY KEY

CONDITION CHECK
Check the condition of The key tooth is Replace the Passive

1 the key tooth of the End of diagnosis
damaged Entry key
emergency door
unlocking key built into
the Passive Entry key
DIAGNOSIS AND TESTING > FRONT DOOR LOCK TESTING > KEY DOES NOT
AUTOMATICALLY RETURN TO POSITION

found)
DOOR MECHANISM
OPERATION CHECK The device is
The device is not working; continue
equipped with a searching for the
realignment spring. cause of the Replace the door lock
1 End of diagnosis
Remove the device from problem by checking cylinder.
the vehicle and check the other
whether the idling components of the
activation torque is vehicle
higher the 0.3 N.m
DIAGNOSIS AND TESTING > FRONT DOOR LOCK TESTING > KEY WILL NOT OR IS
HARD TO TURN

found)
DOOR MECHANISM Torque higher than

1 End of diagnosis Go to step 2
OPERATION CHECK
Remove the device from

the vehicle and check 0.3 N.m
whether the idling
activation torque is
higher than 0.3 N.m
DOOR LOCK
CYLINDER CONDITION
CHECK
Apply rust remover and

then lubricate through Torque higher than Replace the front door
2 the key hole End of diagnosis
0.3 N.m lock cylinder.
Try again to activate the
mechanism; do not
exceed the torque of 2
N.m in order to not
damage the key
DIAGNOSIS AND TESTING > FRONT DOOR LOCK TESTING > KEY TURNS / POWER
AND MECHANICAL UNLOCKING AND LOCKING DOES NOT WORK

found)
DOOR MECHANISM
OPERATION CHECK Replace the front door
Remove the handle from exterior handle. Refer
The coupling shank
1 the vehicle and check End of diagnosis to HANDLE,
is damaged
the condition of the EXTERIOR, REMOVAL
coupling shank in the AND INSTALLATION .
handle component
DIAGNOSIS AND TESTING > FRONT DOOR LOCK TESTING > KEY TURNS / POWER
UNLOCKING AND LOCKING DOES NOT WORK BUT MECHANICAL UNLOCKING AND
LOCKING WORKS PROPERLY

found)
POWER UNLOCKING
OPERATION CHECK
Only the mechanical
1 Check that the door End of diagnosis Go to step 2
operation is working
power unlocking/locking
mechanism is working
correctly
CHECK USING
DIAGNOSTIC TOOL
Replace the body
Connect the diagnostic Door unlocking/locking control module. Refer
2 equipment to the body End of diagnosis system not working to MODULE, BODY
control module and check correctly CONTROL, REMOVAL
that the door AND INSTALLATION .
unlocking/locking system
is operating correctly
DIAGNOSIS AND TESTING > FRONT DOOR LOCK TESTING > LOCK CYLINDER
LOOSE

found)
DOOR LOCK
CYLINDER CHECK Replace the door lock
Presence of signs of a cylinder. Refer to
1 Check for the presence Continue to Step break-in on the side of CYLINDER, DOOR
of signs of a break-in on 2 the door lock cylinder LOCK, REMOVAL AND
the side of the door lock INSTALLATION .
cylinder
UNDER HEAD GASKET

CONDITION CHECK Continue to Step Under-head gasket Install a new gasket, if
2
Check for the presence 3 missing missing
of the under-head gasket
MOUNTING FORK Install a new fork and

CHECK Proceed to Step remove the old fork
3 Mounting fork missing
4 from the bottom of the
Check for the fixing fork door
MOUNTING FORK
CHECK INSTALLATION
CHECK Fork not
Replace and install the
4 End of diagnosis installed/secured
Check that the mounting fork
correctly
fork is positioned
correctly
DIAGNOSIS AND TESTING > GLOVE BOX LOCK TESTING > KEY CANNOT BE
INSERTED
STEP WHAT TO DO OK (no problem PROBLEM CORRECTION

found) FOUND
CHECK FUNCTIONALITY
OF THE LOCK
CYLINDER If any signs of
Continue to Step Replace the lock
1 forced entry on the
Check for signs of 2 cylinder
lock cylinder
tampering on the glove box
lock cylinder.
VERIFICATION OF LOCK
CYLINDER OPENING
Continue to Step Foreign objects Replace the lock
2 Check that the lock 3 found cylinder
cylinder opening is free of
foreign objects
CHECK FUNCTIONALITY
OF THE LOCK
CYLINDER
The key continues
Through the opening of the
to fail to be inserted
3 lock cylinder, spray a small End of diagnosis Proceed to Step 4
into the lock
amount of lubricant (avoid
cylinder
contact with the aesthetic
parts).
Try to re-insert the key.
CHECK FUNCTIONALITY
OF THE LOCK
CYLINDER The key continues
to fail to be inserted
Pull the lock cylinder from
into the lock Replace the lock
4 the door; verify the End of diagnosis
cylinder even once cylinder
integrity and functionality of
removed from the
the lock cylinder itself.
board
Try to re-insert the key in
the cylinder only.
DIAGNOSIS AND TESTING > GLOVE BOX LOCK TESTING > KEY CANNOT BE
TURNED IN LOW TEMPERATURES

found)
STATUS CHECK
GLOVE BOX LOCK
CYLINDER ASSEMBLY
The key continues
Through the opening of End of diagnosis Replace the lock
1 to fail to the lock
the lock cylinder, spray a cylinder
cylinder
small amount of lubricant
(avoid contact with the
aesthetic parts).
Try to operate the lock
mechanism; it is
recommended not to
exceed a torque of 2
N.m to avoid damaging
the key.
DIAGNOSIS AND TESTING > GLOVE BOX LOCK TESTING > KEY IS HARD TO TURN
STEP WHAT TO DO OK (no problem PROBLEM CORRECTION

found) FOUND
CHECK FUNCTIONALITY
OF THE LOCK CYLINDER
WITH SECOND KEY
Continue to Step The movement is Replace the lock
1 Verify the correct operation 2 still restricted cylinder
of the lock cylinder, using
the second key in the
cylinder
CHECK FUNCTIONALITY
OF THE LOCK
CYLINDER If any signs of
Continue to Step Replace the lock
2 forced entry on the
Check for signs of 3 cylinder
lock cylinder
tampering on the glove box
lock cylinder.
CHECK FUNCTIONALITY
OF THE LOCK
CYLINDER
Through the opening of the

lock cylinder, spray a small
amount of lubricant (avoid
Proceed to Step Turning torque more Replace the lock
3 contact with the aesthetic
4 than 0.3 N.m cylinder
parts).
Try to operate the lock

mechanism; it is
recommended not to
exceed a torque of 2 N.m
to avoid damaging the key.
CHECK ALIGNMENT slats

OF THE LOCK
CYLINDER
Slats are not Replace the lock
4 Pull the lock and, after Late diagnosis
aligned properly cylinder
inserting the key, verify the
complete alignment of the
slats
DIAGNOSIS AND TESTING > ROAD TESTING > ROAD TESTING WIND NOISE-FRONT
FLOOR
Fig 1: Tape On Front Door Seams
1. Apply tape to the various areas shown in the illustration.
2. Apply 50 mm (2 in.) masking tape in 150 mm (6 in.) lengths along weatherstrips, weld seams or
moldings. After each length is applied, drive the vehicle. If noise goes away after a piece of
tape is applied, remove tape, locate, and repair defect.
DIAGNOSIS AND TESTING > ROAD TESTING > ROAD TESTING WIND NOISE-HOOD
Fig 1: Tape On Hood Seams
DIAGNOSIS AND TESTING > ROAD TESTING > ROAD TESTING WIND NOISE-REAR
DOOR
Fig 1: Tape On Rear Door Seams
DIAGNOSIS AND TESTING > ROAD TESTING > ROAD TESTING WIND NOISE-
WINDSHIELD
Fig 1: Tape On Front Door
DIAGNOSIS AND TESTING > ROAD TESTING > ROAD TESTING

WIND-WINDSHIELD-REAR WINDOW
1. Apply a soapy water solution to the perimeter of the glass.
2. From inside the vehicle, blow with compressed air along the whole perimeter and visually
check for air bubbles.
3. If a leak is located on the vertical uprights, it is possible to repair by removing the pillar trim and
injecting sealant from the inside.
4. If a leak is located at the top, it is possible to repair by injecting sealant from the inside.
5. If a leak is located at the bottom, it is possible to repair by removing the necessary trim panels
and injecting sealant from the inside.
6. If a leak is widespread around the perimeter, it is recommended to remove the glass and install
with complete new sealant.
DIAGNOSIS AND TESTING > WATER LEAKS
Water leaks can be caused by poor sealing, improper body component alignment, body seam porosity,
missing plugs, or blocked drain holes. Centrifugal and gravitational force can cause water to drip from a
location away from the actual leak point, making leak detection difficult. All body sealing points should be
water tight in normal wet-driving conditions. Water flowing downward from the front of the vehicle should
not enter the passenger or luggage compartment. Moving sealing surfaces will not always seal water
tight under all conditions. At times, side glass or door seals will allow water to enter the passenger
compartment during high pressure washing or hard driving rain (severe) conditions. Overcompensating
on door or glass adjustments to stop a water leak that occurs under severe conditions can cause
premature seal wear and excessive closing or latching effort. After completing a repair, water test
vehicle to verify leak has stopped before returning vehicle to use.
DIAGNOSIS AND TESTING > WATER LEAKS > WATER LEAK TESTS
WARNING:
Do not use electric shop lights or tools in water test area. Personal injury can result.
When the conditions causing a water leak have been determined, simulate the conditions as closely as
possible.
If a leak occurs with the vehicle parked in a steady light rain, flood the leak area with an
open-ended garden hose.
If a leak occurs while driving at highway speeds in a steady rain, test the leak area with a
reasonable velocity stream or fan spray of water. Direct the spray in a direction comparable to
actual conditions.
If a leak occurs when the vehicle is parked on an incline, hoist the end or side of the vehicle to
simulate this condition. This method can be used when the leak occurs when the vehicle
accelerates, stops or turns. If the leak occurs on acceleration, hoist the front of the vehicle. If the
leak occurs when braking, hoist the back of the vehicle. If the leak occurs on left turns, hoist the
left side of the vehicle. If the leak occurs on right turns, hoist the right side of the vehicle. For
hoisting recommendations, refer to HOISTING, STANDARD PROCEDURE .
DIAGNOSIS AND TESTING > WATER LEAKS > WATER LEAK DETECTION
To detect a water leak point-of-entry, do a water test and watch for water tracks or droplets forming on
the inside of the vehicle. If necessary, remove interior trim covers or panels to gain visual access to the
leak area. If the hose cannot be positioned without being held, have someone help do the water test.
Some water leaks must be tested for a considerable length of time to become apparent. When a leak
appears, find the highest point of the water track or drop. The highest point usually will show the point of
entry. After leak point has been found, repair the leak and water test to verify that the leak has stopped.
Locating the entry point of water that is leaking into a cavity between panels can be difficult. The trapped
water may splash or run from the cavity, often at a distance from the entry point. Most water leaks of this
type become apparent after accelerating, stopping, turning, or when on an incline.
DIAGNOSIS AND TESTING > WATER LEAKS > WATER LEAK DETECTION > MIRROR
INSPECTION METHOD
When a leak point area is visually obstructed, use a suitable mirror to gain visual access. A mirror can
also be used to deflect light to a limited-access area to assist in locating a leak point.
DIAGNOSIS AND TESTING > WATER LEAKS > WATER LEAK DETECTION > BRIGHT
LIGHT LEAK TEST METHOD
Some water leaks in the luggage compartment can be detected without water testing. Position the
vehicle in a brightly lit area. From inside the darkened luggage compartment inspect around seals and
body seams. If necessary, have a helper direct a drop light over the suspected leak areas around the
luggage compartment. If light is visible through a normally sealed location, water could enter through the
opening.
DIAGNOSIS AND TESTING > WATER LEAKS > WATER LEAK DETECTION >
PRESSURIZED LEAK TEST METHOD
When a water leak into the passenger compartment cannot be detected by water testing, pressurize the
passenger compartment and soap test exterior of the vehicle. To pressurize the passenger compartment,
close all doors and windows, start engine, and set heater control to high blower in HEAT position. If
engine can not be started, connect a charger to the battery to make sure adequate voltage is supplied to
the blower. With interior pressurized, apply dish detergent solution to suspected leak area on the exterior
of the vehicle. Apply detergent solution with spray device or soft bristle brush. If soap bubbles occur at a
body seam, joint, seal or gasket, the leak entry point could be at that location.
DIAGNOSIS AND TESTING > WATER LEAKS > WATER LEAK-FRONT

COMPARTMENT
CHECK FOR FRONT

1 Result OK Result Not OK Action
WINDSHIELD LEAK
Check the front windshield

Continue to Step 2 Lack of sealant Repair the seal
seal.
2 CHECK WINDSHIELD Result OK Result Not OK Action
Visually inspect for:
Cracks in windshield
Replace the
Crack in windshield
Corrosion of Continue to Step 3 windshield or
or body corrosion
surrounding body restore body panel
panels
CHECK COWL
DRAINAGE
Clear the
Check for proper
Drain passage obstruction and
drainage. check for dirt, Continue to Step 4
obstructed verify proper
leaves, etc.
drainage
4 CHECK DASH PANEL Result OK Result Not OK Action
Check for missing or

loose plugs
Missing plug,
Check for damaged damaged grommet,
or loose grommets damaged Repair the damage
Diagnostic complete
component seal, found
Check body sealant missing body
sealant
Check seals of
fastened
components
DIAGNOSIS AND TESTING > WATER LEAKS > WATER LEAK-FRONT DOOR
1 CHECK DOOR SEAL Result OK Result Not OK Action
Check the door seal for:
Correct fit of the

door seal Door seal not fitted Repair or replace
Continue to Step 2
properly or damaged the door seal
Deterioration or
damage
CHECK DOOR
ALIGNMENT
Check the door for:

Alignment out of Align the door
Proper alignment Continue to Step 3 specification Repair or replace
Door seal damaged the door seal
Correct fit of the door
seal
3 CHECK GLASS SEALING Result OK Result Not OK Action
Check the glass sealing

for:
Check that glass Glass not closing Adjust glass

closes properly properly Adjust or replace
Continue to Step 4 Glass channel out of the glass channel
Check positioning of position or damaged Repair or replace
glass channel Glass seal damaged the glass seal
Check glass seals
CHECK DOOR
DRAINAGE
Clear the
Check the drains at the
Diagnostic obstruction and
bottom of the doors. Drains obstructed
complete verify proper
Check for dirt, leaves, etc.
drainage
DIAGNOSIS AND TESTING > WATER LEAKS > WATER LEAK-REAR COMPARTMENT
CHECK FOR REAR

WINDOW LEAK
Check the rear window

Continue to Step 2 Lack of sealant Repair the seal
seal.
2 CHECK REAR WINDOW Result OK Result Not OK Action
Cracks in window Replace the

Crack in window or
Diagnostic complete window or restore
Corrosion of body corrosion
body panel
surrounding body
panels
DIAGNOSIS AND TESTING > WATER LEAKS > WATER LEAK-REAR DOOR
1 CHECK DOOR SEAL Result OK Result Not OK Action
Check the door seal for:

Door seal not fitted Repair or replace
Correct fit of the Continue to Step 2
properly or damaged the door seal
door seal
Deterioration or
damage
CHECK DOOR
ALIGNMENT
Check the door for:
Proper alignment Alignment out of Align the door

Continue to Step 3 specification Repair or replace
Correct fit of the Door seal damaged the door seal
door seal
3 CHECK GLASS SEALING Result OK Result Not OK Action
Check the glass sealing

for:
Check that glass Glass not closing Adjust glass

closes properly properly Adjust or replace
Continue to Step 4 Glass channel out of the glass channel
Check positioning of position or damaged Repair or replace
glass channel Glass seal damaged the glass seal
Check glass seals
CHECK DOOR
DRAINAGE
Clear the
Check the drains at the
Diagnostic obstruction and
bottom of the doors. Drains obstructed
complete verify proper
Check for dirt, leaves, etc.
drainage
DIAGNOSIS AND TESTING > WIND NOISE
Wind noise is the result of most air leaks. Air leaks can be caused by poor sealing, improper body
component alignment, body seam porosity, or missing plugs in the engine compartment or door hinge
pillar areas. All body sealing points should be airtight in normal driving conditions. Moving sealing
surfaces will not always seal airtight under all conditions. At times, side glass or door seals will allow
wind noise to be noticed in the passenger compartment during high cross winds. Over compensating
door or glass adjustments to stop wind noise that occurs under severe conditions can cause premature
seal wear and excessive closing or latching effort. After a repair procedure has been performed, test
vehicle to verify noise has stopped before returning vehicle to use.
DIAGNOSIS AND TESTING > WIND NOISE > WIND NOISE-ENGINE COMPARTMENT
Fig 1: Tape On Hood Seams
1. Carry out a road test, letting the vehicle gradually reach the speeds where the noise starts: if
the wind noise persists, check that the plugs are present and that the bulkhead coupling rubber
seals in the dash panel are correctly fitted.
2. Remove the gummed paper from the area (A) and repeat the road test: if the wind noise
persists, check the buffers where the bonnet and the wings couple at the rear.
3. Remove the gummed paper from the area (B) and repeat the road test: if the wind noise
persists, check the condition of the front weatherstrip and make sure it is correctly fitted (it
should adhere perfectly to the crossmember when the bonnet is closed).
DIAGNOSIS AND TESTING > WIND NOISE > WIND NOISE-FRONT DOOR
Fig 1: Tape On Front Door Seams

1. Tape the various areas illustrated in the diagram using bodywork gummed paper.
2. Carry out a road test, letting the vehicle gradually reach the speeds where the noise starts. If
the wind noise persists, check for sealant between the wing and the pillar in the lower area.
3. Remove the gummed paper from the area (A) and repeat the road test. If the wind noise
persists, check the condition of the door housing seal in that area and make sure it adheres to
the body correctly. Also check the condition of the bonnet hinge buffer block.
4. Remove the gummed paper from the area (B) and repeat the road test. If the wind noise
persists, check the condition of the door housing seal in that area and make sure it adheres to
the body correctly.
5. Adjust the door hinges.
6. Remove the shims from the upper hinges or add some to the lower hinges so that the door and
the seal fit together better.
7. Remove the gummed paper from area (C) and repeat the road test, if the wind noise persists,
check the condition of the door housing seal in that area and make sure it adheres to the body
correctly.
8. Remove or add shims from/to the two hinges so that the door and the seal fit together better.
Remove the gummed paper from the area (D) and repeat the road test: if the wind noise
persists, check the condition of the glass scraper
9. Remove the gummed paper from the area (E) and repeat the road test: if the wind noise
persists, check the condition of the window seal.
DIAGNOSIS AND TESTING > WIND NOISE > WIND NOISE-REAR DOOR
Fig 1: Tape On Rear Door Seams
1. Tape the various areas illustrated in the diagram using bodywork gummed paper.
the wind noise persists, check for sealant between the wing and the pillar in the lower area.
3. Remove the gummed paper from area (A) and repeat the road test: if the wind noise persists,
adjust the door hinges.
5. Remove the gummed paper from area (B) and repeat the road test: if the wind noise persists,
adjust the door hinges.
7. Remove the gummed paper from area (C) and repeat the road test, if the wind noise persists,
check the condition of the door housing seal in that area and make sure it adheres to the body
shell correctly.
8. Remove the gummed paper from the area (D) and repeat the road test: if the wind noise
persists, check the condition of the glass scraper.
DIAGNOSIS AND TESTING > WIND NOISE > WIND NOISE-UNDERBODY
CHECK ENGINE BELLY

PAN
Check that belly pan is Belly pan not Fasten properly

Continue to Step 2
installed properly secured properly and securely
2 CHECK UNDERBODY Result OK Result Not OK Action
Check for missing

or loose plugs Missing plug,
damaged grommet,
Repair the damage
Check for damaged Diagnostic complete damaged component
found
or loose grommets seal, missing body
sealant
Check body
sealant
DIAGNOSIS AND TESTING > WIND NOISE > WIND NOISE-WINDSHIELD

Fig 1: Tape On Front Door
the wind noise persists, check that the windscreen has been correctly taped and also check
whether the wind noise might be coming from the sunroof area.
2. Remove the gummed paper from area (A) and repeat the road test: if the wind noise persists,
locate the noise in the front door area. Refer to WIND NOISE-FRONT DOOR .
STANDARD PROCEDURE > BUZZ, SQUEAKS AND RATTLES
Buzz, Squeaks and Rattles (BSRs) may be caused by any one or more of the following and may be
corrected as indicated:
Loose fasteners should be tightened to specifications.
Damaged or missing clips should be replaced.
Damaged trim panels should be replaced.
Incorrectly installed trim panels should be reinstalled properly.
Many BSR complaints such as loose trim, can be serviced using various tapes or lubricants. Tapes
including foam, flock and anti-squeak, can be used to eliminate noises caused by metal, plastic and vinyl
components. Long life lubricants and greases can also be used on a variety of components. Refer to
BUZZ, SQUEAKS AND RATTLES .
BUZZ, SQUEAKS AND RATTLES
ITEM FEATURES APPLICATIONS SERVICE TEMP
ITCH AND SQUEAK An abrasion resistant Between metal and metal, -40° to 107°C
TAPE material thin enough to metal and plastic, metal and (-40° to 225°F)
conform to most irregular vinyl, vinyl and plastic. Interior.
surfaces. Stops most Examples: Trim panels and
itches and squeaks. bezels.
BLACK NYLON Nylon Flock with an Between metal and metal, -40° to 82°C
FLOCK aggressive acrylic metal and plastic, vinyl and (-40° to 180°F)
adhesive. Provides for plastic.
cushioning and Examples: Pull cups, bezels,
compression fit, also clips, ducts, top cover to glass,
isolates components. cowl panel.
Water-resistant.
HIGH DENSITY Tear resistant, highly Between metal and metal, -40° to 82°C
URETHANE FOAM resilient and durable. metal and plastic. Water- (-40° to 180°F)
resistant.
Examples: I/P, heavy metal
rattles, isolating brackets.
OPEN CELL FOAM Soft foam conforms to Wire harness and connector -40° to 82°C
TAPE irregular surfaces. wrap. (-40° to 180°F)
Examples: Seals, gasket,
wiring, heat ducts.
CLOSED CELL Soft, conformable. Water- Wherever bulk is needed. -40° to 82°C
LOW DENSITY resistant. Prevents closing flutters and (-40° to 180°F)
FOAM TAPE rattles when applied to door
watershield.
Examples: Door, I/P.
NYE® GREASE 880 Long life. Suspensions. -40° to 200°C
Examples: Strut bushings, (-40° to 390°F)
sway bars.
KRYTOX® OIL Long life. Will not dry out or When access is not possible, -34° to 205°C
harm plastics or rubber. oil will migrate to condition. (-30° to 400°F)
Vinyl, rubber, plastic, metal.
Examples: Convertible top
bushings, pull cups trim panel
inserts.
KRYTOX® GREASE Long life. Will not dry out or Vinyl, rubber, plastic, metal, -34° to 205°C
harm plastics or rubber. glass. (-30° to 400°F)
Examples: Weather-strips,
backlite and windshield
moldings.
STANDARD PROCEDURE > HEAT STAKING
1. Remove the trim panel.
2. Bend or move the trim panel components at the heat staked joints. Observe the heat staked
locations and component seams for looseness.
3. Heat stake the components.
a. If the heat staked or component seam location is loose, hold the two components
tightly together and using a soldering gun with a flat tip, melt the material securing the
components together. Do not over heat the affected area, damage to the exterior of
the trim panel may occur.
b. If the heat staked material is broken or missing, use a hot glue gun to apply new
material to the area to be repaired. The panels that are being heat staked must be
held together while the applying the glue. Once the new material is in place, it may be
necessary to use a soldering gun to melt the newly applied material. Do not over heat
the affected area, damage to the exterior of the trim panel may occur.
4. Allow the repaired area to cool and verify the repair.
5. Install the trim panel.
STANDARD PROCEDURE > NET, FORM AND PIERCE REPAIR
CAUTION:
Failure to follow these recommendations could result in damage or failure to the part and the
related parts.
Net, form and pierce is a manufacturing process which takes place during the original build of the
vehicle. The original part will have a beveled platform that will decrease toward the fastener location
mounting hole. Replacement parts in these areas may not include bevel (form) or fastener hole (pierce)
and will need to be adapted for proper fit and finish.
The primary locations which may utilize net, form and pierce are:
fender reinforcement (at front end module mount)
fender tower mounts
hood hinge (lower half)
rear body header (liftgate hinge mounts)
strut tower (at upper control arm mount)
NOTE:
Shock tower is net, pierce only.
NOTE:
The thickness of shims is not to exceed the original thickness of the factory bevel. If more
shims are needed damage is still present and must be repaired properly.
If the replacement part did not come with a fastener hole, one of equal size and location will have to be
drilled. Body shims should be used in the fender reinforcement to front end module. The hood hinge area,
fender tower mounts, and rear body header will utilize washers as spacers where a specific spacer does
not exist. The shims and spacers should be sealed between each other and to the stationary surface.
Care should be taken when smoothing sealer around washers to give an undetectable repair. Refinish
the repair area per the paint manufacturer's recommendations for corrosion resistance and appearance
purposes.
STANDARD PROCEDURE > PLASTIC BODY PANEL REPAIR
There are many different types of plastics used in today's automotive environment. We group plastics in
three different categories: Rigid, Semi-Rigid, and Flexible. Any of these plastics may require the use of
an adhesion promoter for repair. These types of plastic are used extensively on FCA US LLC vehicles.
Always follow repair material manufacturer's plastic identification and repair procedures.
STANDARD PROCEDURE > PLASTIC BODY PANEL REPAIR > SAFETY PRECAUTION
AND WARNINGS
WARNING:
Eye protection should be used when servicing components. Personal injury can result.
Use an OSHA approved breathing mask when mixing epoxy, grinding, and spraying paint or
solvents in a confined area. Personal injury can result.
Avoid prolonged skin contact with resin, petroleum, or alcohol based solvents. Personal
injury can result.
Do not venture under a hoisted vehicle that is not properly supported on safety stands.
Personal injury can result.
CAUTION:
When holes must be drilled or cut in body panels, verify locations of internal body
components and electrical wiring. Damage to vehicle can result.
Do not use abrasive chemicals or compounds on undamaged painted surfaces around

repair areas. Damage to finish can result.
STANDARD PROCEDURE > PLASTIC BODY PANEL REPAIR > RIGID PLASTICS
Examples of rigid plastic use: fascias, hoods, doors, and other body panels, which include SMC, ABS,
and polycarbonates.
STANDARD PROCEDURE > PLASTIC BODY PANEL REPAIR > SEMI-RIGID PLASTICS
Examples of semi-rigid plastic use: interior panels, under hood panels, and other body trim panels.
STANDARD PROCEDURE > PLASTIC BODY PANEL REPAIR > FLEXIBLE PLASTICS
Examples of flexible plastic use: fascias, body moldings, and upper and lower fascia covers.
STANDARD PROCEDURE > PLASTIC BODY PANEL REPAIR > REPAIR PROCEDURE
The repair procedure for all three categories of plastics is basically the same. The one difference is the
material used for the repair. The materials must be specific for each substrate, rigid repair material for
rigid plastic repair, semi-rigid repair material for semi-rigid plastic repair and flexible repair material for
flexible plastic repair.
STANDARD PROCEDURE > PLASTIC BODY PANEL REPAIR > ADHESION
PROMOTER/SURFACE MODIFIER
Adhesion promoters/surface modifiers are required for certain plastics. All three categories may have
plastics that require the use of adhesion promoter/surface modifiers. Always follow repair material
manufacturer's plastic identification and repair procedures.
STANDARD PROCEDURE > PLASTIC BODY PANEL REPAIR > RIGID, SEMI-RIGID,
AND FLEXIBLE PLASTIC PARTS TYPES
CODE FAMILY NAME COMMON TRADE TYPICAL APPLICATION

NAME
ASA Acrylonitrile Styrene Acrylite Lurans Consoles, Grilles
ABS Acrylonitrile Butadiene Styrene Terluran A-pillars, Consoles, Grilles
ABS/PC ABS/PC Alloy Pulse, Proloy, Bayblend Doors, Instrument Panels
ABS/PVC ABS/PV Alloy Proloy, Pulse, Lustran, Door Panels, Grilles, Trim
Cyclovin
BMC Bulk Molding Compound BMC Fender Extensions
EMA Ehtylene Methyl Acrylate/Ionomer Surlyn, EMA, Ionomer Bumper Guards, Pads
METTON Metton Metton Grilles, Kick Panels,

Running Boards
MPPO Modified Polyphenylene Oxide MPPO Spoiler Assembly
PA Polyamid Zytel, Vydyne, PA, Fenders, Quarter Panels

Minlon
PET Thermoplastic Polyester Rynite Trim
PBT/PPO PBT/PPO Alloy Germax Claddings
PBTP Polybutylene Therepthalate PBT, PBTP, Pocan, Wheel Covers, Fenders,

Valox Grilles
PBTP/EEBC Polybutylene Bexloy, "M", Fascias, Rocker Panel,

Therepthalate/EEBC Alloy PBTP/EEBC Moldings
PC Polycarbonate Lexan, Merlon, Calibre, Tail Light Lenses, I/P Trim,

Makrolon PC Valance Panels
PC/ABS PC/ABS Alloy Germax, Bay Blends, Doors, Instrument Panels

Pulse
PPO Polyphenylene Oxide Azdel, Hostalen, Interior Trim, Door Panels,

Marlex, Prfax, Noryl, Splash Shields, Steering
GTX, PPO Column Shroud
PPO/PA Polyphenylene/Polyamid PPO/PA, GTX 910 Fenders, Quarter Panels

PR/FV Fiberglass Reinforced Plastic Fiberglass, FV, PR/FV Body Panels
PS Polystyrene Lustrex, Styron, PS Door Panels, Dash Panels
RTM Resin Transfer Molding RTM Body Panels

Compound
SMC Sheet Molded Compound SMC Body Panels
TMC Transfer Molding Compound TMC Grilles
UP Unsaturated Polyester SMC, BMC, TMC, Grille Opening Panel,

(Thermosetting) ZMC, IMC, XSMC, UP Liftgates, Flareside
Fenders, Fender
Extensions
EEBC Ether/Ester Blocked Co-Polymer EEBC Bumpers
EEBC/PBTP EEBC/Polybutylene Terepthalate EEBC, PBTP, BEXLOY Bumper, Rocker Panels
EMPP Ethylene Modified Polypropylene EMPP Bumper Covers
EPDM Ethylene/Propropylene Diene EPDM, Nordel, Vistalon Bumpers

Monomer
EPM Ethylene/Propropylene EPM Fenders

Co-Polymer
MPU Foam Polyurethane MPU Spoilers
PE Polyethylene Alathon, Dylan, -

Lupolen, Marlex
PP Polypropylene (Blends) Noryl, Azdel, Marlox, Inner Fender, Spoilers,

Dylon, Pravex Kick Panels, A-Pillars,
Door Panels, B-Pillars,
Quarter Panels, Sport Bar
Trim, Liftgate Trim, Decklid
Trim Scuff Plates, Kick
Panels, Consoles
PP/EPDM PP/EPDM Alloy PP/EPDM Spoilers, Grilles
PUR Polyurethane Colonels, PUR, PU Fascias, Bumpers
PUR/PC PUR/PC Alloy Texin Bumpers
PVC Polyvinyl Chloride Apex, Geon, Vinylite Body Moldings, Wire

Insulation, Steering
Wheels
RIM Reaction Injected Molded RIM, Bayflex Front Fascias, Modular

Polyurethane Windows
RRIM Reinforced Reaction Injected PUR, RRIM Fascias, Body Panels,

Molded Body Trims
TPE Thermo Polyethylene TPE, Hytrel, Bexloy-V Fascias, Bumpers,

Claddings
TPO Thermopolyolefin Polytrope, Renflex, Bumpers, End Caps,
Santoprene, Visaflex, Telcar, Rubber, Strips,
ETA, Apex, TPO, Sight, Interior B-Pillar
Shields, Claddings
TPP Thermo-Polypropylene TPP Bumpers
TPU Thermopolyurethane, Polyester TPU, Hytrel, Texin, Bumpers, Body Side,

Estane Moldings, Fenders,
Fascias
STANDARD PROCEDURE > PLASTIC BODY PANEL REPAIR > PANEL SECTIONING
If it is required to section a large panel for a plastic repair, it will be necessary to reinforce the panel. To
bond two plastic panels together, a reinforcement must overlap both panels. The panels must be beveled
at a 20 degree angle. The area to be reinforced should be washed, then sanded. Be sure to wipe off any
excess soap and water when finished. Lightly sand or abrade the plastic with an abrasive pad or
sandpaper. Blow off any dust with compressed air or wipe with a clean dry rag.
When bonding plastic panels, follow repair material manufacturers recommendations. Be sure that
enough adhesive has been applied to allow squeeze out and to fill the full bond line. Once the pieces
have been brought together, do not move them until the adhesive is cured. The assembly can be held
together with clamps, rivets, etc. A faster cure can be obtained by heating with a heat lamp or heat gun.
After the parts have been bonded and have had time to cure, rough sand the seam and apply the final
adhesive filler to the area being repaired. Smooth the filler with a spreader, wooden tongue depressor, or
squeegee. For fine texturing, a small amount of water can be applied to the filler surface while
smoothing. The cured filler can be sanded as necessary and, as a final step, cleanup can be done with
soapy water. Wipe the surface clean with a dry cloth allowing time for the panel to dry before moving on
with the repair.
STANDARD PROCEDURE > PLASTIC BODY PANEL REPAIR > PANEL

REINFORCEMENT
Structural repair procedures for rigid panels with large cracks and holes will require a reinforcement
backing. Reinforcements can be made with several applications of glass cloth saturated with structural
adhesive. Semi-rigid or flexible repair materials should be used for semi-rigid or flexible backing
reinforcement. Open meshed fiberglass drywall tape can be used to form a reinforcement. The drywall
tape allows the resin to penetrate through and make a good bond between the panel and the adhesive.
Structurally, the more drywall tape used, the stronger the repair.
Another kind of repair that can be done to repair large cracks and holes is to use a scrap piece of similar
plastic and bond with structural adhesive. The reinforcement should cover the entire break and should
have a generous amount of overlap on either side of the cracked or broken area.
When repairing plastic, the damaged area is first "V'd" out, or beveled. Large bonding areas are
desirable when repairing plastic because small repairs are less likely to hold permanently. Beveling the
area around a crack at a 20 degree angle will increase the bonding surface for a repair. It is
recommended that sharp edges be avoided because the joint may show through after the panel is
refinished.
Panel repair for both flexible and rigid panels are basically the same. The primary difference
between flexible panel repair and rigid panel repair is in the adhesive materials used.
The technician should first decide what needs to be done when working on any type of body panel.
One should determine if it is possible to return the damaged part to its original strength and
appearance without exceeding the value of the replacement part.
When plastic repairs are required, it is recommended that the part be left on the vehicle whenever
possible. That will save time, and the panel will remain stationary during the repair. Misalignment
can cause stress in the repair areas and can result in future failure.
STANDARD PROCEDURE > PLASTIC BODY PANEL REPAIR > VISUAL INSPECTION
Composite materials can mask the severity of an accident. Adhesive bond lines, interior structure of the
doors, and steel structures need to be inspected carefully to get a true damage assessment. Close
inspection may require partial removal of interior trim or inner panels.
Identify the type of repair: Puncture or Crack - Damage that has penetrated completely through the
panel. Damage is confined to one general area; a panel section is not required. However, a backer
panel, open fiberglass tape, or matted material must be bonded from behind.
STANDARD PROCEDURE > PLASTIC BODY PANEL REPAIR > PANEL SURFACE
PREPARATION
If a body panel has been punctured, cracked, or crushed, the damaged area must be removed from the
panel to achieve a successful repair. All spider web cracks leading away from a damaged area must be
stopped or removed. To stop a running crack in a panel, drill a 6 mm (0.250 in.) hole at the end of the
crack farthest away from the damage. If spider web cracks can not be stopped, the panel will require
replacement. The surfaces around the damaged area should be stripped of paint and freed from wax and
oil. Scuff surfaces around repair area with 360 grit wet/dry sandpaper, or equivalent, to insure adhesion
of repair materials.
STANDARD PROCEDURE > PLASTIC BODY PANEL REPAIR > PATCHING PANELS
An panel that has extensive puncture type damage can be repaired by cutting out the damaged material.
Use a suitable reciprocating saw or cut off wheel to remove the section of the panel that is damaged.
The piece cut out can be used as a template to shape the new patch. It is not necessary to have access
to the back of the panel to install a patch. Bevel edges of cutout at 20 degrees to expose a larger
bonding area on the outer side. This will allow for an increased reinforcement area.
STANDARD PROCEDURE > PLASTIC BODY PANEL REPAIR > PANEL PATCH
FABRICATIONS
A patch can be fabricated from any rigid fiberglass panel that has comparable contour with the repair
area. Liftgates and fenders can be used to supply patch material. If existing material is not available or
compatible, a patch can be constructed with adhesive and reinforcement mesh (drywall tape). Perform
the following operation if required:
1. Cover waxed paper or plastic with adhesive backed nylon mesh (drywall tape) larger than the
patch required.
2. Tape waxed paper or plastic sheet with mesh to a surface that has a compatible contour to the
repair area.
3. Apply a liberal coat of adhesive over the reinforcement mesh. If necessary apply a second or
third coat of adhesive and mesh after first coat has cured. The thickness of the patch should
be the same as the repair area.
4. After patch has cured, peel waxed paper or plastic from the back of the patch.
5. If desired, a thin film coat of adhesive can be applied to the back of the patch to cover mesh
for added strength.
STANDARD PROCEDURE > PLASTIC BODY PANEL REPAIR > PANEL PATCH
INSTALLATION
1. Make a paper or cardboard pattern the size and shape of the cutout hole in the panel.
2. Trim 3 mm (0.125 in.) from edges of pattern so patch will have a gap between connecting
surfaces.
3. Using the pattern as a guide, cut the patch to size.
4. Cut scrap pieces of patch material into 50 mm (2 in.) squares to use as patch supports to
sustain the patch in the cutout.
5. Drill 4 mm (0.160 in.) holes 13 mm (0.5 in.) in from edge of cutout hole.
6. Drill 4 mm (0.160 in.) holes 13 mm (0.5 in.) away from edge of patch across from holes drilled
around cutout.
7. Drill 3 mm (0.125 in.) holes in the support squares 13 mm (0.5 in.) from the edge in the center
of one side.
8. Scuff the backside of the body panel around the cutout hole with a scuff pad or sandpaper.
9. Mix enough adhesive to cover one side of all support squares.
10. Apply adhesive to cover one side of all support squares.
11. Using number 8 sheet metal screws, secure support squares to back side of body panel with
adhesive sandwiched between the panel and squares.
12. Position patch in cutout against support squares and adjust patch until the gap is equal along
all sides.
13. Drill 3 mm (0.125 in.) holes in the support squares through the pre-drilled holes in the patch.
14. Apply a coat of adhesive to the exposed ends of the support squares.
15. Install screws to hold the patch to support squares. Tighten screws until patch surface is flush
with panel surface.
16. Allow adhesive to cure, and remove all screws.
17. Using a 125 mm (5 in.) 24 grit disc grinder, grind a 50 mm (2 in.) to 75 mm (3 in.) wide and 2
mm (0.080 in.) deep path across the gaps around the patch. With compressed air, blow dust
from around patch.
18. Apply adhesive backed nylon mesh (drywall tape) over gaps around patch.
19. Mix enough adhesive to cover the entire patch area.
20. Apply adhesive over the mesh around patch, and smooth epoxy with a wide spreader to reduce
finish grinding. Use two to three layers of mesh and adhesive to create a stronger repair.
STANDARD PROCEDURE > PLASTIC BODY PANEL REPAIR > PATCHED PANEL
SURFACING
After patched panel is installed, the patch area can be finished using the same methods as finishing
other types of body panels. If mesh material is exposed in the patched area, grind surface down, and
apply a coat of high quality rigid plastic body filler. Prime, block sand, and paint as required.
SPECIFICATIONS > BODY LUBRICATION > LUBRICATION REQUIREMENTS
Body mechanisms and linkages should be inspected, cleaned, and lubricated, as required, to maintain
ease of operation and to provide protection against rust and wear. When performing other under hood
services, the hood latch release mechanism and safety catch should be inspected, cleaned, and
lubricated. During the winter season, external door lock cylinders should be lubricated to help with proper
operation when exposed to water and ice.
Prior to the application of any lubricant, the parts concerned should be wiped clean to remove dust and
grit. If necessary, a suitable solvent can be used to clean the item to be lubricated. After lubricating a
component, any excess oil or grease should be removed.
SPECIFICATIONS > BODY LUBRICATION > LUBRICANT APPLICATION > DOOR LOCK
CYLINDERS
1. Apply a small amount of lubricant directly into the lock cylinder.
2. Apply a small amount of lubricant to the key.
3. Insert key into lock cylinder and cycle the mechanism from the locked to the unlocked position.
NOTE:
Do not add more lubricant.
4. Cycle the lock cylinder mechanism several times to allow the lubricant to flow throughout the
cylinder.
5. Wipe all lubricant from exterior of lock cylinder and key.
SPECIFICATIONS > BODY LUBRICATION > LUBRICANT APPLICATION > ALL OTHER
BODY MECHANISMS
1. Clean component as described above.
2. Apply specified lubricant to all pivoting and sliding contact areas of component.
SPECIFICATIONS > BODY LUBRICATION > LUBRICANT USAGE
ENGINE OIL
door hinges - hinge pin and pivot contact areas
hood hinges - pivot points
liftgate hinges
MOPAR® SPRAY WHITE LUBE OR EQUIVALENT
door check straps
liftgate latches
liftgate prop pivots
ash receiver
fuel filler door remote control latch mechanism
parking brake mechanism
sliding seat tracks
liftgate latch
MOPAR® MULTIPURPOSE GREASE OR EQUIVALENT
all other hood mechanisms
MOPAR® LOCK CYLINDER LUBRICANT OR EQUIVALENT

door lock cylinders
liftgate lock cylinder
SPECIFICATIONS > LOADS AND REINFORCEMENTS
The table contains the names and symbols for the fillers and reinforcements in the recyclable materials
used on the vehicle.
NAME ISO SYMBOL
GLASS BALLS GB
GLASS FIBRE GF
GLASS MATTING GM
MINERAL DUST FILLERS MD
TALC DUST TD
WOOD CHIPPINGS (SAWDUST) WD
TEXTILE FIBRES (SYNTHETIC OR NATURAL) SF
CALCIUM CARBONATE KD
The table contains the names and symbols for the thermoplastic elastomers with heat ratings used on
the vehicle.
NAME ISO SYMBOL
POLYOLEFIN PP + EPDM
POLYOLEFIN PP + NBR
POLYOLEFIN PP + NR
OLEFIN TECEA
POLYESTER - POLYETHER TEEE
BLOCK STYRENE COPOLYMERS S/B/S
BLOCK STYRENE COPOLYMERS S/E/S
BLOCK STYRENE COPOLYMERS S / EB / S
SPECIFICATIONS > THERMOPLASTIC RECYCLABLE MATERIALS
The table contains the names and symbols for the main thermoplastic materials used on the vehicle.
NAME ISO SYMBOL

ACRYLONITRILE BUTADIENE STYRENE, ABS ABS
CELLULOSE CA
AROMATIC POLYAMIDES PA
- with 6 C atoms in a monomer structure PA 6
- with 2 monomer structures each with 6 C atoms PA66
- with 11 C atoms in a monomer structure PA11
- with 12 C atoms in a monomer structure PA 12
AROMATIC POLYAMIDES + ABS PA + ABS
POLYCARBONATES PC
POLYCARBONATE ALLOYS / ABS PC + ABS
POLYETHYLENES PE
METACRYLICS PMMA
ACETALS POM
POLYPROPYLENES PP
MODIFIED POLYPHENYL OXIDES PPE
THERMOPLASTIC ALLOYS
PPE + PA
(POLYPHENYLOXIDES/POLYAMIDES)
FLEXIBLE VINYLS PVC - P
RIGID VINYLS PVC
SPECIFICATIONS > THERMOSETTING ELASTOMERS
The table contains the names and symbols for the thermosetting elastomer materials with heat ratings
used on the vehicle.
NAME ISO SYMBOL
CHLOROETHYL VINYL ETHER ACRYLATE ACM
CHLORINATED POLYETHYLENE CM
CHLOROSULPHANATED POLYETHYLENE CSM
ETHYLENE PROPYLENE DIENE MONOMER EPDM
ETHYLENE PROPYLENE COPOLYMER EPM
FLUORO ELASTOMER FPM
POLYISOBUTENE IM
ETHYLENE ACRYLATE AEM

EPICHLOROHYDRIN HOMOPOLYMER CO
EPICHLOROHYDRIN COPOLYMER ECO
PROPYLENE OXIDE GPO
BUTADIENE BR
CHLOROPRENE CR
ISOBUTENE- ISOPRENE (BUTYL) IIR
BROMOBUTYL BIIR
CHLORO BUTYL CIIR
SYNTHETIC ISOPRENE IR
NITRILE BUTADIENE NBR
HYDROGENATED NITRILE HNBR
CARBOXYLASED NITRILE XNBR
ISOPRENE NR
STYRENE BUTADIENE SBR
FLUORO SILICON MFQ
METHYL PHENYL SILICON MPQ
METHYL PHENYL VINYL SILICON MPVQ
METHYL SILICON MQ
METHYL VINYL SILICON MVQ
POLYURETHANE AU
POLYURETHANE POLYETHER EU
MICROCELLULAR POLYURETHANE PUM
The table contains the names and symbols of the special fibres with heat ratings used on the vehicle.
NAME ISO SYMBOL
LIGNOTOCK - CEKAZELL >PF - WD 85<
FIBRIT MASONITE >PF - WD 99<
EVERSTIFF > PP + S/B - SF50 <
WOODSTOCK >PP - WD 50<
Resined textile fibres for roof linings > PF - SF60 <
Resined textile fibres for sound insulation > PF - SF70 <
Glass fibre matting + resined textile fibres for roof

> GM, PF - SF60 <
lining
GLASUTEC >GM, PUR, GM
GLASUTHERM > GM, PUR, GM <
GLASS - FOAM > PUR - GF30 <
SPECIFICATIONS > THERMOSETTING RECYCLABLE MATERIALS
The table contains the names and symbols of the main thermosetting materials used on the vehicle.
NAME ISO SYMBOL
PHENOLIC PF
POLYURETHANE PUR
UNSATURATED THERMOSETTING POLYESTERS
- For compression stamping (SMC) UP
- For injection stamping (BMC) UP

TORQUE SPECIFICATIONS
Front door check to body bolts 27 20 -
Front door exterior handle nuts 9 7 80
Front door hinge pivot bolts 25 18 -
Front door hinge to body bolts 45 33 -
Front door hinge to door bolts 45 33 -
Front door latch bolts 26 19 -
Front door rear glass guide nuts 9 7 80
Front door regulator nuts 10 - 89
Front door striker bolts 27 20 -
Front fender bolts 9 - 80
Front seat back bolts 35 26 -
Front seat bolts 35 26 -
Hood hinge to body bolts 25 18 -
Hood hinge to hood bolts 25 18 -

Hood latch bolts 24 18 -
Instrument panel carrier bolts 20 15 -
Liftgate hinge to body bolts 30 22 -
Liftgate hinge to liftgate bolts 30 22 -
Liftgate latch bolts Securely - -
Liftgate striker bolts 25 18 -
Rear door exterior handle nuts 8 - 71
Rear door hinge pivot bolts 25 18 -
Rear door hinge to body bolts 45 33 -
Rear door hinge to door bolts 45 33 -
Rear door interior handle bolt 9 - 80
Rear door latch bolts 26 19 -
Rear door striker bolts 19 14 -
Rear seat nuts 25 18 -
Rear seat pivot bracket bolt 25 18 -
Seat track bolts Securely - -
SPECIFICATIONS > VEHICLE DIMENSIONS
The dimensions are given in millimeters and refer to the vehicle equipped with standard tires.
The height refers to the vehicle unloaded.

Fig 1: Vehicle Dimensions
A B C D E F G H I
4255 892 2570 793 1667/1697* 1551 2023 1552 1805
NOTE:
(*) With luggage rack
According to the size of the wheel a slight variations are possible compared to the supplied information.
SPECIFICATIONS > VEHICLE DIMENSIONS > TRAILHAWK VERSION
The dimensions are given in millimeters and refer to the vehicle equipped with standard tires.
The height refers to the vehicle unloaded.

Fig 1: Vehicle Dimensions - Trailhawk
A B C D E F G H I
4259 892 2570 797 1697/1727* 1541 2023 1541 1805
NOTE:
(*) With luggage rack
According to the size of the wheel a slight variations are possible compared to the supplied information.
SPECIFICATIONS > VEHICLE DIMENSIONS > LUGGAGE COMPARTMENT
CAPACITY (V.D.A NORMS)
Rear seats folded down (capacity measured at the parcel shelf)
Vehicle download and reconfigurable cargo floor in "position 0" (all lower floor): 351 liters
Vehicle download and reconfigurable cargo floor in "position 1" (all upper floor): 341 liters
Vehicle download and reconfigurable cargo floor in "position 1" (all upper floor) and spare tire (215/65
/R17): 256 liters
/R16): 297 liters
Rear seats folded down (capacity measured at the roof)
Vehicle download and reconfigurable cargo floor in "position 0" (all lower floor): 530 liters
Vehicle download and reconfigurable cargo floor in "position 1" (all upper floor): 513 liters
/R17): 428liters
/R16): 469 liters
SPECIFICATIONS > VEHICLE DIMENSIONS > MINIMAL HEIGHT FROM THE

GROUND/ANGLE CHARACTERISTICS
Fig 1: Minimal Height Vehicle Dimensions
"MINIMUM HEIGHT FLOOR" (Reference A)
The value of the height is measured in near the bottom of the differential. It also determines those
relating to "angle of attack", "Departure angle" and to "Ramp Angle".
Dimensions are in mm and refer to the vehicle fitted with standard tires.
Versions with front wheel drive (FWD): 171 mm
Versions with all-wheel drive (4WD): 201 mm
Trailhawk versions with all-wheel drive (4WD LOW): 225 mm

"ANGLE OF ATTACK" (reference B)
The angle of attack is determined by the horizontal line of the road surface and the tangent line passing
between the front wheel and the lower point of greatest projection of the car.
The greater the angle, the smaller the possibility of bumping, with the bodywork or the chassis, during a
steep slope or in a passage of the obstacle.
Versions with front wheel drive (FWD): 17.9°
Versions with all-wheel drive (4WD): 21°
Trailhawk versions with all-wheel drive (4WD LOW): 30.5°
"OUTPUT ANGLE" (reference C)
The output angle is determined by the same lines of the "angle of attack" and refers to the rear of the
vehicle.
Versions with all-wheel drive (4WD): 32.1°
"BACK ANGLE" (reference D)
The value of "Ramp Angle" is related to the height from the floor of the vehicle and the vehicle's ability to
overcome a hump, more or less accentuated without the vehicle, touching off the same with its lower
parts more prominent (normally the underbody), remains resting on the ground with the frame or with the
body, which would cause the loss of wheel grip.
These, not having a proper grip on the ground, they will not have enough grip to advance the vehicle and
will end up going around in circles.
The greater the height, the greater the angle off. Keep in mind that the greater the height, the lower its
stability due to rising center of gravity, thus reducing the angle of lateral tipping.
Versions with all-wheel drive (4WD): 24°
SPECIFICATIONS > VEHICLE WEIGHT
140CV 170CV
Empty weight (with

all fluids, fuel tank
filled to 90% and no 1320 1390 1430/1530 (*) 1535
optional equipment)
(kg)
NOTE:
SPECIAL TOOLS > SPECIAL TOOLS
Tool (EMEA) Tool (NAFTA) Name Function
1823015000 C-4829A Trim Stick Trim Removal
1878077000 C-4755 Trim Stick Trim Separation
1878017001 * Staple Pliers Install Seat Cover
1878086000 * Tool Remove outer belt seal
*Tool not available for NAFTA. Use a commercially available tool or contact Mopar Essential Tools to
order the custom EMEA tool.
BODY STRUCTURE > DESCRIPTION > GENERAL PANELS AND FRAMEWORK >
The vehicle is equipped with the following identification plates:
V.I.N. plate.
Body paintwork color identification plate.
Body marking.
Engine marking.
For further details, refer to VEHICLE INFORMATION .
NOTE:
After a repair operation, it may be necessary to replace the panel components that have the
vehicle identification number on them or the number may be damaged.
NOTE:
In that case, you must follow the laws in force in the country in which the vehicle is
registered to carry out the restoration of that marking.
NOTE:
A similar procedure should be carried out if the plate containing the vehicle identification
number is damaged or removed.
VEHICLE TOWING POINTS
WARNING:
When towing the vehicle you must comply with the specific traffic regulations, relating to the
tow hook and the actions to take towing on the road. Thoroughly clean the threaded holes
before screwing the hook. Before starting to tow, be sure to screw down the tow hook tightly.
Make sure the ignition key is inserted into the relative ignition switch and that the steering
lock is not engaged. With the engine off you do not have the help of the brake booster and
power steering, so you need to exert more effort on both the brake pedal and on the steering
wheel.
Fig 1: Towing Eye Location - Front
The vehicle is equipped with a threaded seat at the front and rear (A) for the installation of towing eye
(B). The tow ring is located in the tool kit provided with the vehicle, located in the tool kit inside the trunk.
Fig 2: Towing Eye Location - Rear
TRAILHAWK VERSION
In these versions the towing hook is a fixed type and is anchored to the body of the car.
VEHICLE LIFTING POINTS
Fig 1: Vehicle Lifting Points
To raise the vehicle using lifting arms or with a workshop lift, place the ends of the arms or the lift only in
the areas indicated in the illustration.
WARNING:
Before raising the vehicle with the portable lifts, engage the hand brake and block the
wheels by placing wedges in front of the front wheels and behind the rear wheels. After
lifting the vehicle, support it with suitable safety stands.
GENERAL SAFETY INSTRUCTIONS
The activities related to the repair of the body involve the use of specialty equipment and work tools as
well as the handling of substances and chemicals to be treated in accordance with the suppliers
recommendations.
Special attention should be paid to:
The proper use of materials, tools and equipment: Before performing any operation, carefully read
the instruction manuals and carefully follow the instructions and the safety regulations prescribed.
Regarding the areas equipped for work, which must be equipped with a ventilation system that
guarantees legally admissible levels relative to fresh air exchange, filtration of harmful substances
(solvents) and dust suppression.
Handling of hazardous substances are to be used according to the instructions and

recommendations of the supplier.
The collection and disposal of waste is to be carried out in accordance with current regulations.
When working with and handling dangerous and hazardous substances it is imperative that appropriate
accident prevention measures must be taken (wearing protective clothing, masks, gloves, goggles etc.).
VEHICLE REPAIR PROCEDURES STAGES
The vehicle repair procedures stages usually consist of the following stages:
Checking vehicle measurements
Cutting/removing damaged elements and preparing the body for welding
Welding replacement parts
Preparing for painting
Painting
Restoring anti corrosion conditions
Sound insulation, sealants
Check and restore specified vehicle measurements-
This is the first stage of the repair operation during which the distortion suffered by the body is measured
and evaluated and the elements involved are identified.
The first actual repair operation is also carried out during this stage: pulling the body to restore the
correct dimensions before cutting and removing the damaged elements.
Pulling the body-
Pulling the body to restore its dimensions is carried out on the alignment bench (frame rack), where it is
possible to secure the body using clamps and connections to be fitted in accordance with the specific
instructions for each vehicle, which come with the bench (rack).
Templates, positioned in the recommended places, are used to check the body measurements either
using the measurements given by the manufacturer of the template for each model or, alternatively,
those for the vehicle given in SPECIFICATIONS .
Fig 1: Frame Rack
Example of a possible alignment bench (frame rack).
GENERAL REPAIR INSTRUCTIONS
CAUTION:
Before performing any work on the car disconnect the battery terminals.
For safety reasons and for a better quality repair, IT IS FORBIDDEN TO:
Replace the structural parts of the body without using a repair bench. The use of the bench makes
it possible to guarantee the restructuring of the vehicle with the original manufacturing
measurements, ensuring the correct positioning of the components that make up the front and the
rear part of the vehicle.
Heat the structural parts of the body to straighten them.
Cut and weld any bodywork component and reinforcement, edge to edge, on the same line.
Remove the damaged components by cutting them along the joints, following the cutting lines given in the
Service Information. Correctly carried out, this operation involves a difference of several centimeters
between the two cutting lines in order to distribute the fusion spots created by the welding.
Fig 1: Frame Implementation
The diagram illustrates a possible implementation.
WARNING:
Removing the damaged components is the repair stage during which the most potentially
dangerous equipment is used. Before carrying out any operation, carefully read the
instruction manual and the safety instructions and warnings given by the manufacturer
together with the equipment, and strictly follow all safety precautions.
The use of the following is required for removing damaged panels:
Power jig saws

Circular saws
Power chisels (only if necessary)
Plasma cutting systems
Electric drills
Milling machines for spot weld removal
Grinders
Hammers and dolly blocks
Disc grinders
Air extractor fans

Fig 2: Using Power Jig Saw
Power jig saw- This type of saw makes it possible to make fast, precision cuts with the possibility of
regulating the speed of the blade so that it can be adapted to suit different situations.
Fig 3: Vibrating Circular Saw
Vibrating circular saw- A vibrating saw is used in situations which require high precision cutting; for
example, the panel in a box section is to be replaced, overlapping on the panel that should not be
damaged. By adjusting the speed and the number of oscillations it is possible to achieve the precision
required, according to the usage conditions. The high safety level for this instrument means that it is
advisable to use it as an alternative to other types of saws.
Fig 4: Using Pneumatic Chisel
Pneumatic chisel-
The pneumatic chisel is used to remove pieces of sheet metal, its use is indicated when:
It is not possible to use the power saw, the milling machine or the drill (for example, when behind
the sheet metal to be cut there is another that must not be damaged)
It is possible to separate the welded panel directly by inserting the chisel tip between the two
panels along the join, in order to leave no edges to be removed at a later stage.
The different tips which can be fitted increase its versatility of use.
Plasma cutting system- This cutting system, produced through the combined effect of an electrical arc
and gas or a gas mixture, is used if very large panels have to be removed. Depending on the thickness
of the panel and the depth of the cut, the value of the current and flow of gas can be adjusted in
accordance with the instruction manual supplied by the manufacturer.
WARNING:
The use of plasma cutting systems requires the use of an extraction system to remove
harmful gases and fumes.
Fig 5: Using Electric Drill
Electric drill- Electric drills are normally used in cases where a milling machine cannot be used. The
correct use of the drill for removing spot welds, where panels are overlapping is illustrated below. The tip
to be used for these operations is identical to the one fitted on the milling machine. The weld spot must
be marked using a drift punch, in order to provide support for the centering point, thereby preventing the
cutter from slipping and damaging the surrounding area; the cutter should then be pushed until it reaches
slightly deeper than the thickness of the panel to be removed (see illustration below).
Fig 6: Using Milling Tip
1- Panel to be detached.
2- Box section panel preventing the use of the milling wheel.
Example of the correct use of a milling tip.

Fig 7: Using Milling Machine
Milling machine (for spot weld removal)-
A milling machine for removing spot welds is used after the panel to be replaced has been cut to allow
the removal of the metal off-cuts remaining on the edges of the body.
The milling machine works on the panel, cutting it as far as the panel underneath and insulating the spot
weld.
After removing all the spot welds, the piece cut off can be removed using pliers.
A cutting speed of around 1000 RPM should be used to perform the operation.
Adjust the milling depth using the special screw.
CAUTION:
Do not drill matching components. If holes have been made accidentally, close them using
(MIG) welding. The presence of holes decreases the resistance of the component involved
and can also increase penetration by water and corrosive agents.
Lever and dolly block- These tools are used when panels need to be hammered straight in order to
provide a reaction point supporting the panel. The dolly blocks are designed so that they can be adapted
to suit the different shapes of the panel and, when the work area permits, they can replace the hammer.
The levers have the same usage instructions as the dolly blocks, however they are designed so that
they can be introduced through openings and restricted spaces into areas that are difficult to reach.
Dolly blocks and levers are also used to remove distortions from the edge of panels that are not
removed, thereby allowing them to be matched with replaced panels, preventing the structure from being
weakened.
WELDING REPLACEMENT PARTS
CAUTION:
If you need to carry out any welding or machining that could trigger flames near the fuel
system components, fuel or other flammable parts of the vehicle, remove the component
from the vehicle and plug the open lines connections. Disconnect the electrical connections
of the control units (IE, ABS, Air Bag, Air Conditioner, Body Computer, etc.) that could be
damaged during processing.
The welding of the body elements can be carried out, depending on the requirements, with different
methods:
Spot welding
Wire welding (MIG)
Brazing
Equipment-
The equipment used for these operations are:
Welding machines with clamps (spot welding)
Continuous wire welding (MIG)
Oxy-acetylene torches (brazing)
General information on electric spot welding-
During spot welding the heat required to melt the metal is provided by the resistance to the flow of
current which the metal opposes.
Spot welding is carried out on panels where the join edges are overlapping and takes place through
localized fusion of the metal that makes up the panel so no weld metal is required for this type of welding.
In areas where three or more panels are overlapping, the spot welding must be repeated a second time.
The type of join that is produced is discontinuous; the weld spots must be correctly spaced in order to
confer good mechanical resistance, in accordance with the precise instructions (see the tables below).
Spot welding-
In the case of spot welding, check:
That the arms are correctly aligned
That the diameter of the ends of the electrodes are correct
The flatness and correct matching of the edges of the weld
The correct welding sequence.
CAUTION:
Before welding, apply electro-weldable galvanized coating/weld through primer to the edges
of the join in order to protect the box sections from corrosion.
Fig 1: Spot Welding Sequence
A. Electro-weldable galvanized coating

B. Correct welding sequence
C. Incorrect welding sequence
D. Size of the electrode

Fig 2: Reference Values For Spot Welding
Spot welder, geometric specifications of the electrode depending on the thickness of the panel and the
welding sequence.
A. Table for determining the distance of the spot welds from the edges of the panels according to
their thickness.
B. Table of reference values for the correct spacing of spot welds depending on the thickness of
the panel.
Fig 3: Spot Welding At Corners
NOTE:
Do not weld corner shaped surfaces. If welds are made on this type of surface it produces a
concentration of tension that causes it to break.
A. Area where welding should not be carried out
Seam welding (MIG)-
NOTE:
MIG welding should be used for parts where spot welding cannot be used.
When seam (MIG) welding, check:
The speed of the wire
The correct execution of the seam welding beads (alternation of welding sections)
In this welding system the electrode (an automatic advance continuous wire) is protected by an
atmosphere of inert gases (this is where the initials MIG come from - Metal Inert Gas). - The continuous
advance of the wire (which constitutes both the electrode and the weld metal), allows long welds to be
made with no interruptions. The flow of inert gases sent to the welding area eliminates the air
surrounding the fusion bath, preventing the oxidation of the metal. It also carries out the function of a
protective coating for coated electrode welding. For these reasons, MIG welding differs from welding
carried out with a coated electrode due to the absence of slag on the weld bead. Neither is it affected by
the porosity that may be seen with normal arc welding.
WARNING:
The use of MIG welding systems requires use of an extraction system to remove the harmful
gases and fumes.
Operating methods-
In order to butt weld two panels correctly using a MIG welder: grind or dress the panel thoroughly,
position the equipment so that when carrying out the welding the torch outer casing does not become
twisted or folded in such a way that could obstruct the advance of the wire, wear protective clothing and
a suitable mask with an anti-glare visor (standard no. 8 glass for currents of 40-60A and no. 9 for
currents of 80-200A). Be certain to have good electrical contact. Regulate the flow of gas in accordance
with the instructions from the equipment's manufacturer. Make two tack welds at the ends of the join line
and one in the middle, then make tack welds in between the two sections defined in this way. The spot
welds should be 25 - 30 mm apart.
Fig 4: Correct Welding
The illustration shows the correct application of the welding (1).

NOTE:
The correct gap is about 1 mm.
Carrying out welding (2) using an inert gas electrode (MIG) to join adjacent panels.
It is not advisable to seam weld initially because, in addition to being difficult in practical terms, it may
cause the panel to become distorted as a result of the build up of heat involved.
The difficulty in carrying out a single seam weld is that the torch must be moved fairly slowly to produce
good penetration of the weld but sufficiently quickly so as not to run the risk of "burning" the panel.
Moving the torch too quickly also leads to a poor seal of the weld seam because, after grinding the
seam, an insufficient layer of filler material remains to guarantee the strength of the joint.
After initially welding the panel, use a rigid disc grinder to grind the weld spots level with the panel.
At this point the alignment of the panels must be checked and, if necessary, corrected using a hammer
and steel punch.
Then proceed with filling the gaps between the various spot welds through alternating welding sections,
keeping the torch at an angle of about 60° (see previous illustration).
1. Tack welding the joint. The tack welds at the back of the panel are illustrated. Grinding the joint
tack welds.
2. Welding.
3. The illustration shows two alternatives for the correct welding sequence in order to prevent the
distortion of the panel.
The advantage of the welding operation is confirmed by the appearance of the rear of the weld seam
which must show a series of spherical caps side by side for the entire length of the joint.
The MIG welder can also be used for joining overlapping panels where only one side is accessible.
To carry out spot welding, the panels must adhere perfectly and the torch must be perpendicular to the
surface.
In this way the action of the electrode initially melts the first panel, then the second, where a crater is
produced which is filled by the advance of the electrode.
In order to carry out this operation correctly, the welding machine must be regulated to current values
that are suitable for the thickness of the panels being worked on with the torch resting on its supports
and pressure on the surface to facilitate the panels being brought close together.
If the panels are thicker than 1.5 - 2.5 mm, make an initial 0.6 mm hole at the sites of the plug welds.
Fig 5: Overlap Welding
1. Panel join area
2. Electrode
3. Plug weld
4. Torch
5. Hole (only for thick panels)
General rules for visible welding-

Fig 6: Welding Examples
The following are important rules to be reckoned with:
Incomplete penetration (p) should be 15-30% of the thickness of the panel (see illustration - point A
incorrect welding, point B correct welding).
The height of the seam (a) should be 60% of the thinnest thickness (s), the clearance (g) between
the panels before welding should be 20% of the thinnest thickness for at least two thirds of the
length (l) of the seam (see illustration, point C and detail X). the diagram illustrates the value of the
convexity (c) of the seam depending on the length (l) of the weld section.
The convexity (e) of the shape of the weld seam section should depend on the length of the actual
seam (see illustration, point D).
Brazing-
Welding using brazing applies only if it is necessary to replace sheet metal that was previously welded
with this type of welding and should only be carried out at the points recommended by the manufacturer.
This type of welding does not guarantee mechanical properties that are comparable with the other
systems described previously and therefore does not apply to the joining structural components.
WARNING:
When using oxy-acetylene torches for brazing observe the safety rules on their use and be
certain that they operate safely. The use of this welding system requires the use of an air
extraction system for the elimination of smoke and noxious gases.
Air filtration and purification systems-
Fig 7: Mobile Air Filtration And Purification System
When carrying out work that produces fumes, gases and dusts which are dangerous to the mechanic, air
filtration and purification systems must be used.
These systems are designed for the various requirements to handle different volumes of air that require
purification. The operation of these systems is usually based on the combined action of mechanical and
electro-static filtration and purification using activated charcoal.
Filtration takes place in two stages: mechanical elimination, using mesh filters, of the largest particles of
dust, then ionization of the air flow, which statically charges the particles of dust. These are then
eliminated from the flow through an electrostatic process.
The flow of air is then purified by passing through activated charcoal filters. In these systems, in addition
to the specific efficiency, the ease of handling and noise levels have been improved and are never
exceeds a level of discomfort.
PAINTING
General information-
Painting the body has two basic objectives: protecting the surfaces of the panels from the elements and
an aesthetic function of providing color and shine.
The large number of chemical products used in painting operations require that special care must be
taken over their handling and usage.
These painting operations involve the emission of paint fumes and solvent vapors which, if inhaled by
the technician, could seriously affect the health and should only be performed in specialty spray booths.
The technician should always wear a mask and protective clothing.
For operations that do not take very long, filtration masks can be used. For longer operations,
pressurized masks must be used for total protection.
Equipment-
The following equipment is used during painting operations:
Filtration masks and protective clothing
Masking and taping machines
Spray booths and baking ovens
Spray guns
Infrared lamps
Polishing machines
Protective clothing-
When carrying out painting operations, suitable protective clothing must be worn to protect the
technician from contact with harmful substances.
It is also advisable to use a barrier cream on any exposed areas (face, hands, arms), which must be
removed at the end of the painting operations.
Fig 1: Filtration Mask
Filtration mask-
This type of mask only protects the technician's respiratory system and protective goggles and headgear
should also be worn at the same time. Its use is recommended for small retouching operations.
Fig 2: Pressurized Mask
Pressurized mask-
This type of mask guarantees protection of the face and hair and is supplied with fresh air from the
compressed air system used for the spray gun.
The air is purified further with a degree of separation close to 100%, by an activated charcoal filter fitted
to the operator's belt.
The slight excess pressure created inside the helmet prevents the penetration of paint vapors.
The use of this mask is advisable for long painting operations.
Spray booth-
Spray booths are used for painting operations and for baking prepared parts. If the extent of the damage
repaired is medium or large, it would be helpful to have a special spray booth and a hot air circulation
oven for drying the paint.
The area should be equipped with an air conditioning system and filtered by purifiers, mainly comprising
activated charcoal filters.
The optimum painting conditions that should be maintained in the booth during the painting stage are as
follows:
Constant temperature between 22 - 25 °C (71 - 77 °F)
Constant relative humidity of 75 - 80%
The area in question could be:
A combined painting and drying booth
A separate painting booth and drying oven
Fig 3: Using Spray Gun
Use of the spray gun
A - Method of normal usage
B - Use from the bottom to the top
C - Use from the top to the bottom
Spray guns-
Developments in the study of ergonomics and spray painting techniques have led to a new type of High
air Volume and Low atomization Pressure (HVLP) spray gun that allows a considerable reduction in paint
overspray. This type of spray gun has been designed to be lighter with a grip that reduces fatigue and
eliminates cramp and with controls that require far less effort than conventional spray guns. The handling
of the spray gun is also made easier by the even weight distribution and by the improved less bulky
design that allows greater control over the part being worked on. The most interesting aspect of this
spray gun is the supply system that allows painting in any direction, even with the cup facing downwards,
also improving the cleaning procedures with considerable savings in terms of time and materials. The
possibility of painting from the top or the bottom, in addition to preventing the formation of areas that are
too wet or too dry, also allows access to areas of the bodywork that are difficult to reach. Special care
has been taken over the ease of adjustment. This requires minimal, simple movements. This spray gun is
extremely efficient, combining a very fine atomization capacity for any product, even water soluble, used
by technicians at a pressure of 0.7 g (10 PSI) or below. Thanks to these capabilities for using paint
materials, it has been possible to achieve a considerable economic saving and improved working
conditions.
Portable infrared (IR) lamps-
If the operation is restricted to small retouches, then the use of an oven is not practical. In these cases
the paint can be dried using special infrared lamps fitted on parabolic mirrors. The use of one or more
lamps positioned so that the surface that has been retouched is subject to an even temperature allows
the paint film to bake and the result is comparable to that achieved in an oven.
This type of lamp greatly reduces drying times, thereby also reducing energy consumption. The lamp
should only be used when the paint has already dried to the extent that dust is kept to the outside of the
applied finish (flashed off).
Fig 4: Using Polisher
Polishing machines-
The paint should only be polished after the paint has been baked and after it has cooled down to ambient
temperature.
Polishing is also necessary if there are defects in the paint work such as dust, overspray, sagging,
orange peel or small scratches.
To remedy these defects, there are numerous products to be applied either manually or mechanically
using a polishing machine.
The tool should be parallel to the surface to be polished and should not be at an angle, in order to
prevent the paint from overheating and producing circular concentric grooves.
Painting cycles-
It should be pointed out that all painting operations must be carried out using appropriate equipment.
It is recommended to use the specific environmentally-friendly solvents for cleaning the equipment.
There is a silver paintwork identification plate on the vehicle, normally inside the hood or the luggage
compartment lid/tailgate, which contains the original color identification code for respraying or touching
up.
The products used must comply to the laws in force in terms of safety, hygiene and the environment. In
the absence of these, must meet European Community standards. It is the responsibility of the final user
to check beforehand that the conditions of usage are compatible with the recommendations in the
supplier safety documents.
As far as the practical aspects are concerned, suppliers must certify that the aesthetic/functional
features (e.g. mechanical properties, resistance to ageing and protection against corrosion) meet the
corporate technical specifications when applied in accordance with the methods indicated in detail in the
"product technical chart". Conformity with corporate specifications guarantees that the manufactured
article will be in line with the original painting process quality standards.
This certification implies absolute adherence to the instructions laid down for the individual products on
Safety Data Sheet that the supplier is obliged to deliver to the user in compliance with the legislation in
force in the territory (for Italy pursuant to Legislative Decrees 52/97 and 285/98 and subsequent
amendments and additions).
BODYWORK REPAIRS (PANEL SUPPORT)
If a body panel is being replaced, check that dimensions, materials and surface treatment (galvanizing,
cataphoresis, e-coating) of the replacement part conform to the manufacturer's specifications.
NOTE:
Visually inspect the condition and suitability for use of the replacement sheet metal parts. If
there are small dimples, it is permissible to restore the appearance and level the defect with
a small amount of putty after straightening (insofar as possible) using levers, files, etc. It can
be applied after cleaning (painting through cataphoresis or e-coating) the surface near the
defect; after it has completely hardened, dry sand using P180-P220 grade sandpaper.
Painting a panel secured to the bodywork by a mechanical fastening-
Clean the replacement panel with a low Volatility Organic Compound (VOC) to remove any dust or
grease that may be present.
Gently dry sand the entire surface to be painted, using P320 grade sandpaper and a rotary/orbital
power sander equipped with an vacuum cleaner.
NOTE:
Take care not to nick/remove the cataphoretic painting (e-coating).

Remove any residues of dust using compressed air and clean the entire surface using a low VOC
detergent or an anti-static product.
If during the above described operations (point 2) the sheet metal is accidentally stripped by the
removal of the cataphoresis (e-coat) and zinc coating, anti-corrosion protection must be restored
by spraying a thick epoxy primer on the affected areas.
If appropriate, seal the joints by applying (single or two component) sealant that hardens at
ambient temperature.
Apply a filler, prepared previously following the instructions on the product technical chart, by
spraying 2 crossover coats, at intervals of a few minutes, until the thickness recommended on the
product technical chart is reached (2 - 4 crossover coats). Wait for 10 to 15 minutes at ambient
temperature before starting the drying process.
Dry the base coat in an oven at a temperature of 40° - 60° C (104° - 140° F) about 30 - 40
minutes.
When it is dry (and the panel is cold), dry sand the surface using P400 grade sandpaper to remove
any defects.
Remove any residues of dust using compressed air and clean the entire surface firstly using a low
VOC detergent and then finish off with an anti-static cloth.
Prepare the paint (single stage or two stage) and/or the clear coat for spraying following the
instructions on the technical chart for the product and use it within the recommended time.
Apply the paint in 2 crossover coats with a few seconds in between until the desired thickness and
color matching is achieved.
Leave the paint to dry at ambient temperature, following the instructions on the supplier's technical
chart for the time and conditions.
For aesthetic finishes with single stage paint, dry in the oven at a temperature of 60° C (140° F)
for 40 minutes. Alternatively, dry using an IR ray lamp, following the instructions described by the
manufacturer (distance of radiant panel from the surface to be dried; exposure time).
For two stage paint aesthetic finishes, proceed with the application of the clear coat (opaque base
coat) prepared previously in accordance with the instructions on the technical chart with 2 or 3
crossover coats with intervals of a few seconds in between.
Dry in the oven at a temperature of 60° C (140° F) for 40 minutes. Alternatively, dry using an IR ray
lamp, following the instructions described by the manufacturer (distance of radiant panel from the
surface to be dried; exposure time).
Polish the surface at least 24 hours after the last coat has baked (and the panel is cold).
Painting a replacement panel secured to the bodywork by welding -
NOTE:
Before spot welding the panels, apply electro-weldable galvanizing protection to the ground
edges of the join area (as described in the Service Manual).
Clean the replacement panel with a low VOC detergent to remove any dust or grease that may be
present.
Fasten the replacement body panel to the bodywork by welding, preserving the integrity of the
surrounding surfaces/elements by masking them and - wherever possible - by disassembling them.
Wait until the work surfaces have cooled down, then proceed with removing the spatter and oxides
that have formed in the proximately of the welding seam.
Brushing and dry sanding with P80 - P120 grade sandpaper.
If the welding is visible and it is therefore necessary to restore the aesthetic aspect and continuity
of the profiles, fill the joint and once it has totally hardened level it out using dry P100 - P120 grit
sandpaper on a pneumatic random orbital sander.
If during these operations the sheet metal is accidentally stripped by the removal of the
cataphoresis (e-coat) and zinc coating, anti-corrosion protection must be restored by spraying a
high build epoxy primer on the affected areas.
Apply a filler primer, prepared previously following the instructions on the product technical chart,
by spraying 2 crossover coats, at intervals of a few minutes, until the thickness recommended on
the product technical chart is reached (2 - 4 crossover coats). Wait for 10 to 15 minutes at
ambient temperature before starting the drying process.
Dry the primer coat in an oven at a temperature of 40° - 60° C (104° - 140° F) for about 30 - 40
minutes.
Inspect the surface that has been worked on and remove any defects by dry-sanding the surface
using P400 grade sandpaper.
For aesthetic finishings with a two stage paint, proceed to apply the clear coat prepared earlier
following the instructions provided in the technical sheet with 2 or 3 cross-coats and with a flash
time of a few seconds between coats.
Partial repainting (one or more parts) of the bodywork-
Protect the areas not involved in the painting operation by masking.
Restore the aesthetic appearance (profile and surface appearance) of the damaged panel. Lastly,
level the area worked on using filler which can be applied after cleaning the surface using special
detergent if the damage caused has not exposed the panel or if the panel has been exposed, the
corrosion protection should be restored through the local application of an epoxy primer.
After the filler is completely set, dry sand using P180 - P220 grade sandpaper.
Then smooth the area to be re-painted with P150 or P220 grit sandpaper, widening the perimeter
of the area to be worked on with a slight surface unevenness tapering off towards the exterior,
taking care to eliminate all traces of oxidation from the stripped sheet metal.
Apply a primer filler, prepared previously following the instructions on the product technical chart,
the product technical chart is reached (2 - 4 crossover coats). Wait for 10 to 15 minutes at
ambient temperature before starting the drying process
Dry in an oven at a temperature of 40° - 60° C (104° - 140° F) for about 30 - 40 minutes.
Check the surface that has been worked on and remove any defects by dry-sanding the surface
using P 400 grade sand paper.
For aesthetic finishes with single coat paint, dry in the oven at a temperature of 60° C (140° F) for
40 minutes. Alternatively, dry using an IR ray lamp, following the instructions described by the
For aesthetic finishes with a two stage paint, proceed to apply the clear coat prepared earlier
surface to be dried; exposure time)
PAINTING PLASTIC COMPONENTS PROCEDURE
(Thermoplastic type Poleofinica (PP) example: fascias)
Painting a replacement bumper (fascia)-
In the case of replacement, check that the replacement part complies with the corporate technical
specifications in terms of dimensions, materials and surface treatment (black base with solvent or water
adhesion promoter 3 ± 0.5 gloss with adhesion promoter and aesthetic finish function).
NOTE:
In the presence of small surface defects, the aesthetic appearance of the part may be
restored by levelling out the defect by filling it with filler. This may be done after cleaning of
the surface around the defect; after total hardening, smooth with P320 - P400 grit dry
sandpaper.
Degrease the bumper (fascia) as a precaution to remove any dust or grease using
detergent (example: isopropyl alcohol).
Gently sand the surface using fine grade sandpaper (example: P600), taking care not
to remove too much of the adhesion promoter film.
NOTE:
If anti-static liquids are used, first check their compatibility with the black coating because
some of them may be particularly aggressive and even cause its removal with the result that
the aesthetic finish does not adhere.
Blow through with compressed air (filtered and purified) and clean using anti-static cloths/special
detergents.
Mask the areas not being painted in the body tint (example: rubbing strips, lower section, etc.).
instructions on the technical chart for the product and use it within the recommended time
Wait until the treated surface has cooled down, then remove the masking.
NOTE:
When removing the masking at the joints between parts that are not painted and those which
are, in order to prevent peeling, it is advisable to remove the masking after drying.
Take care over the non painted (black) parts to prevent the unpainted parts on show turning white.
Polish the surface using fine abrasive paste and/or polish.
Partial repainting of a bumper-
Blow compressed air through the affected area involved in the repair to allow the complete removal
of the aesthetic finish that has been affected.
Mask the areas not being painted in the body color.
Apply the primer and filler adhesion promoter, prepared previously following the instructions on the
product technical chart, by spraying 2 crossover coats, at intervals of a few minutes, until the
thickness recommended on the product technical chart is reached (2 - 4 crossover coats). Wait
10-15 minutes at ambient temperature before proceeding with drying.
If needed, restore the aesthetic appearance (profile and surface aspect) of the affected
component. Lastly, use filler to level the area being worked on.
After the filler has completely set, dry-sand using P320 - P400 grade sandpaper.
Then smooth the area to be re-painted with P150 or P220 grit sandpaper, widening the perimeter
of the area to be worked on with a slight surface unevenness tapering off towards the exterior.
Dry in the oven at a temperature of 40° - 60° C (104° - 140° F) for about 30 - 40 minutes.
Inspect the surface previously worked on and remove any defects by dry sanding the surface
using P 400 grade sandpaper.
Prepare the paint (single stage or two sage) and/or the clear coat for spraying following the
Allow the paint to dry at ambient temperature, following the instructions on the supplier's technical
For aesthetic finishes with single coat paint, dry in the oven at a temperature of 60° C (140° F) for
40 minutes. Alternatively, dry using an IR ray lamp, following the instructions described by the
Proceed with drying in the oven at a temperature of 60° C (140° F) for 40 minutes. Alternatively,
dry using an IR ray lamp, following the instructions described by the manufacturer (distance of
radiant panel from the surface to be dried; exposure time).
PAINTING A THERMOSETTING PLASTIC COMPONENT (KMC-BMC-SMC)-
If a thermosetting element is being replaced, check that dimensions, materials and surface treatment
(insulating primer) of the replacement part conform to the company's technical specifications.
Replacement-
Visually check the integrity and suitability for use of the replacement part.
NOTE:
In the presence of small surface defects, the aesthetic appearance of the part may be
restored by levelling out the defect by filling it with filler. This may be done after cleaning of
the surface around the defect; after total hardening, smooth with P320 - P400 grit dry
sandpaper.
Repair-
Restore the appearance (profile and surface appearance) of the affected area.
Blow compressed air on the affected repair area.
Level the surface using filler; it can be applied after cleaning the surface using appropriate
detergent.
After the filler is completely set, dry sand using P320 - P400 grade sandpaper.
Painting-
Mask the areas not being painted, as appropriate; then overhaul the surface involved using P150
or P220 grade abrasive paper extending the perimeter of the area being worked on, in the case of
a repair operation, through surface shading towards the outside.
Apply the primer coat, prepared previously following the instructions on the product technical chart,
the product technical chart is reached (2 - 4 crossover coats). Wait 10-15 minutes at ambient
temperature before proceeding with drying.
Dry in the oven at a temperature of 40° - 60° C (104° - 140° F) for about 30 - 40 minutes.
Inspect the surface that has been worked on and remove any defects by dry-sanding the surface
using P400 grade sandpaper.
Remove any residues of dust using compressed air and clean the entire surface first using a low
Allow the paint to dry at ambient temperature, following the instructions on the supplier's technical
For aesthetic finishes with single stage paint, dry in the oven at a temperature of 60° C for 40
minutes. Alternatively, dry using an IR ray lamp, following the instructions described by the
PAINTING A THERMOPLASTIC COMPONENT-
For the repair/painting, identify the specific product line for the materials constituting the surfaces on
which the operation is to be carried out. Then proceed by following the instructions given on the
technical charts, and the operating methods described in the previous paragraphs.
RESTORING CORROSION PROTECTION/SOUND INSULATION/SEALANT
TREATMENTS
WARNING:
When using chemical products, strictly follow the safety instructions on the safety data sheet
that the supplier must supply to the user.
The treatments carried out on the body in order to produce the necessary corrosion resistance, sound
insulation and sealant properties may be damaged or destroyed during the repair operations.
They must be restored during the appropriate repair operations in order to restore the vehicle to its
original condition.
Tooling-
The following equipment is used:
Pneumatic guns for sealant product extrusion
Foam injection systems
Wax based oil injection systems
In box sections that are replaced or repaired by welding or overheating, the internal anti corrosion
protection must be renewed by:
Applying rust converter to hot spots or welded areas which must dry for at least 24 hours at
ambient temperature 20° C (68° F)
Applying wax protection in the replaced or repaired box section (type PPG 853.764 or an
equivalent product)
Renewing the rigid expanded polyurethane foam in the box sections (example: BOSTON PUR
foam, TORGGLER - Merano Schiuma P.U.R. - or an equivalent product)
Renewing the sealer for the joints, where necessary
Sealing the flanges for the moving parts (example doors and hood) supplied as replacement parts
according to the following instructions; clean the area of the spare part which has undergone
cataphoretic treatment, using heptane or anti-silicone/anti-static solvents
Fig 1: Sealant Application
Example of sealant application
A - Sealant
Applying a bead of SIKAFLEX 221 SIKA (*) polyurethane sealant of the shape and in the position
illustrated in the diagram
Leave the sealant to dry for 24 hours at ambient temperature 20° C (68° F) or 40 minutes at 60° C
(140° F)
Carrying out the normal painting cycle for the component. Apply sound deadening product or stone
chipping paint to the outer parts replaced or repaired, as necessary
(*) Alternatively, use a similar 3M product or other equivalent products, following the supplier's
instructions.
BODY STRUCTURE > DESCRIPTION > SYMBOLS REMOVAL AND INSTALLATION
NOTE:
The following is the graphic index chart and description of the symbols that appear in the
repair procedures
Fig 1: Tool Symbols

BODY STRUCTURE > DESCRIPTION > SYMBOLS REMOVAL AND INSTALLATION >
SYMBOLS
1- Cutting with alternating saw 15- Removing spot welds with hammer and chisel
2- Cutting with circular blade saw 16- Removing treatment with power knife
3- Cleaning with rotary brush 17- Spot welding
4- Removing spot welds with spot weld removal

18- MIG welding
tool
5- Removing spot welds with drill. Drilling for MIG

19- Welding with oxy-acetylene torch
welding
6- Removing body panel with chisel. Drilling for

20- Grinding
MIG welding
7- Applying electro-weldable/weld through

21- Applying rust-proofing protection
protections
8- Applying high thickness electro-weldable/weld

22- Application of sealants
through protections
9- Centering components 23- Application of underbody protection
10- Measurement 24- Application of paint
11- Fastening components 25- Application of protective waxes
12- Fastening threaded rivets 26- Application of foam products
13- Checking alignment gaps 27- Heating with hot air
14- Straightening edges with hammer and dolly

28- Removing metal off-cuts
block
BODY STRUCTURE > DESCRIPTION > SYMBOLS REMOVAL AND INSTALLATION >
MACHINING SYMBOLS
Shown below are the symbols of the processes that are described in the repair procedures with an
example of their application. In the illustrations for the procedures, next to the number of the procedure
steps for welding operations, sometimes there are numbers between parentheses that indicate the
number of spot welds to be made or to filled by MIG welding.
Fig 1: Cutting With A Power Tool Or Pneumatic Chisel

Fig 2: Spot Welding

Fig 3: Spot Welding (Three Panels)

Fig 4: MIG Welding Seam

Fig 5: Brazing

Fig 6: MIG Fill/Plug Welding

Fig 7: Sealing
BODY STRUCTURE > GAP AND FLUSH > SPECIFICATIONS > SPECIFICATIONS
BODY GAP AND FLUSH SPECIFICATIONS FOR THE ADJUSTMENT OF MOVING PARTS
To facilitate and verify moving parts disassembly operations, the existing gaps are shown (in millimeters)
to allow appropriate adjustment.
The adjustment procedure is explained in the service information describing moving part removal and
installation procedures.
Fig 1: Front View Of Vehicle With Measurement Positions
Fig 2: Front Measurements

Fig 3: Side View Of Vehicle With Measurement Positions

Fig 4: Side Measurements (1 Of 3)



Fig 7: Rear View Of Vehicle With Measurement Positions

Fig 8: Rear Measurements (1 Of 2)

Fig 9: Rear Measurements (2 Of 2)

Fig 10: Top View Of Vehicle With Measurement Positions - Removable Roof

Fig 11: Top Measurements - Removable Roof

Fig 12: Top View Of Vehicle With Measurement Positions - Sunroof

Fig 13: Top Measurements - Sunroof
BODY STRUCTURE > BEAM, LOAD PATH > REMOVAL AND INSTALLATION >
Fig 1: Load Path Beam Removal (1 Of 3)
1. Remove the front fender. Refer to FENDER, FRONT, REMOVAL AND INSTALLATION .
2. Remove the front fender bracket. Refer to BRACKET, FENDER MOUNTING, REMOVAL AND
INSTALLATION .
3. Be certain that the components connected are not distorted by checking the body alignment
measurements with suitable equipment (reference rigs, templates or gauges).
4. Straighten the body as necessary.
5. With the use of a rotary brush, remove the paint and gain access to the spot welds.
6. With the use of a spot weld cutting tool, release the spot welds (1) shown in the illustration.
7. With the use of a drill, remove the spot welds (2) shown in the illustration.
8. With the use of a disc grinder, remove the spot welds (3) shown in the illustration.
9. With the use of a chisel and hammer, remove the welds previously released.
10. Remove the cutouts from the vehicle.

12. With the use of a drill, release the spot welds (2) shown in the illustration.
13. With the use of a jig saw, cut along the cut line (3).

16. With the use of a hammer and dolly block, straighten the edges (1) of the mating components.
17. With the use of a grinding disc, remove any residue of the spot welds.
18. With the use of a rotary brush, clean the previously treated areas (1).
19. Apply electro-weldable paint/weld through primer to the areas (1) to be welded.
BODY STRUCTURE > BEAM, LOAD PATH > REMOVAL AND INSTALLATION >
Fig 1: Load Path Beam Installation (1 Of 5)
1. With the use of a rotary brush, remove the anti-corrosion treatment around the entire perimeter
(1) of the inner and outer parts.
2. Use the hacksaw to cut the inner part, following the line shown in the illustration to adjust to the
required size.
3. With the use of a drill, drill holes (2) in the parts.
4. Apply electro-weldable paint/weld through primer to the boarders (3) to be welded.

6. With the use of a drill, drill holes (1) in the parts.

8. Position the inner part correctly on the vehicle internal pillar and secure it with the self-locking
clamps.
9. Check alignment and surrounding gaps.
10. With the use of a spot welder, apply spot welds to the areas (1) shown in the illustration.
11. With the use of a MIG welder, apply plug welds filling in the areas (2) shown in the illustration.
12. With the use of a MIG welder, apply continuous weld to the area (3) shown in the illustration.
13. Position the outer part correctly on the vehicle internal pillar and secure it with the self-locking
clamps.
15. With the use of a spot welder, apply spot welds to the areas (1) shown in the illustration.
17. With the use of a MIG welder, apply seam weld to the area (3) shown in the illustration.
18. Correct any distortions of the sheet metal using a hammer and dolly block.
19. With the use of a grinding disc, smooth the welds.
20. With the use of a rotary brush, clean the previously welded areas (1).
21. Apply corrosion protection to the areas involved in the welding.

22. Seal the seams between the parts and the vehicle in the areas (1) shown in the illustration.
23. Install the front fender bracket. Refer to BRACKET, FENDER MOUNTING, REMOVAL AND
INSTALLATION .
24. Install the front fender. Refer to FENDER, FRONT, REMOVAL AND INSTALLATION .
BODY STRUCTURE > BOW, ROOF > REMOVAL AND INSTALLATION > REMOVAL
Fig 1: Roof Bow Removal (1 Of 2)
1. Remove the roof panel. Refer to PANEL, ROOF, REMOVAL AND INSTALLATION .
6. With the use of a drill equipped with a spot weld cutting bit, release the spot welds (2) shown in
the illustration.
7. Use a chisel and hammer to remove the areas previously released.
8. Remove the supporting roof bow (3).

Fig 2: Roof Bow Removal (2 Of 2)

9. With the use of a disc grinder, remove any residue of the spot welds.
10. With the use of a hammer and dolly block, straighten the contour and defamations of the sheet
metal as necessary.
11. Apply electro-weldable paint/weld through primer to the areas (1) affected.
BODY STRUCTURE > BOW, ROOF > REMOVAL AND INSTALLATION > REMOVAL
Fig 1: Roof Bow Installation (1 Of 2)
1. Remove the anti-corrosion coating from the service part in the areas (1) indicated.
2. Apply electro-weldable paint/weld through primer to the areas (1) that contact the body.
Fig 2: Roof Bow Installation (2 Of 2)
3. Position the service part (1) correctly on the vehicle and secure it with the self-locking clamps.
4. Check the alignment of the part.
5. With the use of a spot welder, weld the points (2) indicated in the illustration.
6. With the use of a disc grinder, smooth the spot welds.
7. With the use of a rotary brush, clean the previously worked areas.
8. Install the roof panel. Refer to PANEL, ROOF, REMOVAL AND INSTALLATION .
BODY STRUCTURE > PAN, FLOOR > REMOVAL AND INSTALLATION > CENTER
FLOOR PAN REMOVAL AND INSTALLATION > REMOVAL
Fig 1: Center Floor Pan Removal (1 Of 5)
BODY STRUCTURE > PAN, FLOOR > REMOVAL AND INSTALLATION > CENTER
FLOOR PAN REMOVAL AND INSTALLATION > INSTALLATION
Fig 1: Center Floor Pan Installation (1 Of 6)
2. With the use of a drill, drill holes (2) in the areas shown in the illustration.
3. Apply electro-weldable paint/weld through primer to the boarders (1).

4. Position the service part (1) correctly on the vehicle internal pillar and secure it with the
self-locking clamps.

14. Seal the seams between the parts and the vehicle in the areas (1) shown in the illustration.
BODY STRUCTURE > PAN, FLOOR > REMOVAL AND INSTALLATION > REAR FLOOR
PAN REMOVAL AND INSTALLATION > REMOVAL
1. Remove the rear closure panel. Refer to PANEL, REAR CLOSURE, REMOVAL AND
INSTALLATION .

Fig 1: Rear Floor Pan Removal (1 Of 2)
5. Release the spot welds (1) shown in the illustration.
6. Use a drill to remove the spot welds (1) not accessible with a spot weld cutting tool.
8. Leave the front and side panels in place and remove the rear pan floor (2).
Fig 2: Rear Floor Pan Removal (2 Of 2)
PAN REMOVAL AND INSTALLATION > INSTALLATION
Fig 1: Rear Floor Pan Installation (1 Of 4)
2. Drill the service part in accordance to where the welds will be placed (1).
3. Apply electro-weldable paint/weld through primer on the areas drilled.

4. Position the rear floor into position.
6. Insert the edges of the rear floor (1) beneath the related front and side panels.
8. With the use of a spot welder, weld the areas (3) shown in the illustration.
11. Apply corrosion protection to the areas affected.
12. Apply sealer to the seams.
13. Install the rear closure panel. Refer to PANEL, REAR CLOSURE, REMOVAL AND
INSTALLATION .
PAN EXTENSION REMOVAL AND INSTALLATION > REMOVAL
INSTALLATION .
2. Remove the rear floor pan. Refer to REAR FLOOR PAN REMOVAL AND INSTALLATION .

Fig 1: Rear Floor Pan Extension Removal (1 Of 2)
5. With the use of a drill, release the spot welds (1) indicated in the illustration.
6. With the use of a chisel and hammer, remove the spot welds previously released.
7. Remove the rear floor pan extension (2) from the vehicle.
Fig 2: Rear Floor Pan Extension Removal (2 Of 2)
8. With the use of a rotary brush, clean the previously treated areas.
9. With the use of a hammer and dolly block, straighten the edges of the mating components.
11. Apply electro-weldable paint/weld through primer to the areas highlighted.
PAN EXTENSION REMOVAL AND INSTALLATION > INSTALLATION
Fig 1: Rear Floor Pan Extension Installation (1 Of 4)
1. Remove the anti-corrosion treatment from the entire perimeter of the inner and outer part using
a rotary brush.
2. With the use of a drill and the service part placed on a bench, drill holes at the points (1)
indicated.
3. Apply elctro-weldable paint/weld through primer to the locations drilled.

4. Position the service part (1) correctly on the rear frame rail and floor pan.
6. With the use of a MIG welder, apply plug welds filling in the holes (2) made previously.
8. With the use a of rotary brush, clean the areas previously welded.
10. Install the rear floor pan. Refer to REAR FLOOR PAN REMOVAL AND INSTALLATION .
11. Seal the seams.
INSTALLATION .
BODY STRUCTURE > PANEL, BODY SIDE APERTURE > REMOVAL AND
INSTALLATION > SILL-BODY SIDE APERTURE REMOVAL AND INSTALLATION >
REMOVAL
Fig 1: Sill-Body Side Aperture Removal (1 Of 3)
2. Remove the front door lower hinge. Refer to HINGE, DOOR, REMOVAL AND INSTALLATION .

5. With the use of a rotary brush, remove the sealer (where applied) and paint to gain access to
the spot welds.
6. With the use of a jigsaw, cut along the cut lines (1) shown in the illustration on the body side
aperture sill.
7. With the use of a spot weld cutting tool, release the spot welds shown in the illustration.

9. With the use of a grinding wheel, remove the weld (2) shown in the illustration.
10. With the use of a chisel and hammer, remove the welds previously released and areas where
there is adhesive joining the sheet metal.


15. Apply electro-weldable paint/weld through primer to the areas (1) highlighted.
16. Apply sealant to the joining sheet metal areas (2).
INSTALLATION > SILL-BODY SIDE APERTURE REMOVAL AND INSTALLATION >
INSTALLATION
Fig 1: Sill-Body Side Aperture Installation (1 Of 4)
1. Cut at the cut lines (1) as indicated in the illustration, leaving enough length to for overlapping.
2. Remove the anti-corrosion treatment from the entire perimeter (2) of the inner and outer part
using a rotary brush.
3. With the use of a drill, drill holes (3) in the area shown in the illustration.
4. Apply elctro-weldable paint/weld through primer to the boarders of the areas to be welded.
5. Position the body side aperture sill service part correctly on the vehicle and secure it with the
7. With the use of a spot welder, apply spot welds to the areas (1) indicated in the illustration.
8. With the use of a MIG welder, apply seam welds to the area (2) indicated in the illustration.
11. Correct any distortions to the sheet metal using a hammer and dolly block.
12. Use a grinding disc to smooth the welds.
13. Use a rotary brush to clean the previously welded areas.

15. Seal the seams between the parts and the vehicle in the areas (1) indicated.
16. Install the front door lower hinge. Refer to HINGE, DOOR, REMOVAL AND INSTALLATION .
INSTALLATION > SILL SECTION-BODY SIDE APERTURE REMOVAL AND

Fig 1: Sill Section-Body Side Aperture Removal (1 Of 2)
3. With the use of a rotary brush, remove the paint to gain access to the spot welds.
4. With the use of a jigsaw, cut along the cut lines (1), in the affected area, of the body side
aperture sill.
Fig 2: Sill Section-Body Side Aperture Removal (2 Of 2)
12. Apply sealant to the joint plate (2).
INSTALLATION > SILL SECTION-BODY SIDE APERTURE REMOVAL AND
Fig 1: Sill Section-Body Side Aperture Installation (1 Of 3)
NOTE:
Be certain to leave the service panel long enough to allow for overlapping.
1. Cut the service part at the points (1) shown in the illustration. Be certain that the section of the
panel remains for overlapping.
4. Apply sealant to the junction plate in the area (3) shown in the illustration.
5. Position the body side aperture sill service part correctly on the vehicle and secure it with the
INSTALLATION > UPPER-BODY SIDE APERTURE REMOVAL AND INSTALLATION >
REMOVAL

Fig 1: Upper-Body Side Aperture Removal (1 Of 4)
5. With the use of a jigsaw, cut along the cut lines (1) shown in the illustration.
6. With the use of a spot weld cutting tool, release the spot welds (2).
9. With the use of a jigsaw, cut along the cut line (2) shown in the illustration.

INSTALLATION > UPPER-BODY SIDE APERTURE REMOVAL AND INSTALLATION >
INSTALLATION
Fig 1: Upper-Body Side Aperture Installation (1 Of 7)
NOTE:
5. Position the service part correctly on the vehicle and secure it with the self-locking clamps.

BODY STRUCTURE > PANEL, QUARTER > REMOVAL AND INSTALLATION >
QUARTER PANEL REMOVAL AND INSTALLATION > REMOVAL

Fig 1: Quarter Panel Removal (1 Of 7)
3. With the use of a rotary brush, remove the paint to gain access to the spot welds.
9. With the use of a chisel and hammer, release the beads of sealant in the areas shown in the
illustration (1).
10. With the use of a chisel and hammer, remove the welds previously released and areas where
there is adhesive joining the sheet metal.
11. Remove the quarter panel (rear fender) and clippings from the vehicle
13. With the use of a disc grinder, remove any residue of the sealant and spot welds.
17. With the use of a disc grinder, remove any residue of the sealant and spot welds.
QUARTER PANEL REMOVAL AND INSTALLATION > INSTALLATION
Fig 1: Quarter Panel Installation (1 Of 7)
a rotary brush.
NOTE:
4. Apply elctro-weldable paint/weld through primer to the boarders of the areas (3) to be welded.
5. Apply sealant to the joining sheet metal areas (1).

QUARTER PANEL EXTENSION REMOVAL AND INSTALLATION > REMOVAL
1. Remove the quarter panel. Refer to PANEL, QUARTER, REMOVAL AND INSTALLATION .

Fig 1: Quarter Panel Extension Removal (1 Of 2)
8. Remove the quarter panel extension from the vehicle.
Fig 2: Quarter Panel Extension Removal (2 Of 2)
QUARTER PANEL EXTENSION REMOVAL AND INSTALLATION > INSTALLATION
Fig 1: Quarter Panel Extension Installation (1 Of 3)
a rotary brush.
2. With the use of a drill, drill holes at the points (1) indicated.
3. Apply elctro-weldable paint/weld through primer to the boarders (2) involved in welding.
4. Position the service part correctly on the vehicle interior pillar and secure it with the
7. With the use of a MIG welder, apply plug welds filling in the holes (2) indicated in the
illustration.

12. Seal the seams between the service part and the vehicle in the area (1) highlighted.
13. Install the quarter panel. Refer to PANEL, QUARTER, REMOVAL AND INSTALLATION .
QUARTER PANEL INNER REMOVAL AND INSTALLATION > REMOVAL
2. Remove the upper body side aperture. Refer to PANEL, BODY SIDE APERTURE, REMOVAL
AND INSTALLATION .
4. Remove the quarter panel extension. Refer to QUARTER PANEL EXTENSION REMOVAL AND
INSTALLATION .
5. Remove the taillamp mounting panel. Refer to PANEL, TAILLAMP MOUNTING, REMOVAL AND
INSTALLATION .
6. Remove the liftgate opening trough. Refer to TROUGH, LIFTGATE OPENING, REMOVAL AND
INSTALLATION .
7. Remove the outer rear wheelhouse. Refer to OUTER REAR WHEELHOUSE REMOVAL AND
INSTALLATION .

Fig 1: Quarter Panel Inner Removal (1 Of 5)
19. Remove the inner quarter panel from the vehicle.

23. Apply electro-weldable paint/weld through primer to the areas (1) indicated.
27. Apply electro-weldable paint/weld through primer to the areas (1) indicated.
QUARTER PANEL INNER REMOVAL AND INSTALLATION > INSTALLATION
Fig 1: Quarter Panel Inner Installation (1 Of 5)
1. Remove the anti-corrosion treatment from the entire perimeter of the inner and outer service
part (1) using a rotary brush.
NOTE:
Drill holes in the corresponding holes previously on the body, in order to be certain
subsequent correct coupling and welding of the sheet metal.
4. Remove the anti-corrosion treatment from the entire perimeter of the inner and outer service
part (1) using a rotary brush.
NOTE:
Drill holes in the corresponding holes previously on the body, in order to be certain
subsequent correct coupling and welding of the sheet metal.
6. Apply elctro-weldable paint/weld through primer to the boarders involved in welding.

illustration.
illustration.
illustration.
21. Install the outer rear wheelhouse. Refer to OUTER REAR WHEELHOUSE REMOVAL AND
INSTALLATION .
22. Install the liftgate opening trough. Refer to TROUGH, LIFTGATE OPENING, REMOVAL AND
INSTALLATION .
23. Install the taillamp mounting panel. Refer to PANEL, TAILLAMP MOUNTING, REMOVAL AND
INSTALLATION .
24. Install the quarter panel extension. Refer to QUARTER PANEL EXTENSION REMOVAL AND
INSTALLATION .
25. Install the body side aperture quarter panel. Refer to PANEL, QUARTER, REMOVAL AND
INSTALLATION .
26. Upper the upper body side aperture. Refer to PANEL, BODY SIDE APERTURE, REMOVAL
AND INSTALLATION .
BODY STRUCTURE > PANEL, REAR CLOSURE > REMOVAL AND INSTALLATION >
Fig 1: Rear Closure Panel Removal (1 Of 3)
4. With the use of a drill, remove the spot welds (1) highlighted in the illustration.
6. Remove the outer portion of the closure panel.

8. With the use of a drill, remove the spot welds (1) highlighted in the illustration.

10. Remove the inner portion of the closure panel.
BODY STRUCTURE > PANEL, REAR CLOSURE > REMOVAL AND INSTALLATION >
Fig 1: Rear Closure Panel Installation (1 Of 9)
3. Apply electro-weldable paint/weld through primer to the boarders involved.

4. Position the inner service part (1) correctly on the vehicle internal pillar and secure it with the
6. With the use of a spot welder, apply spot welds (2) in the areas shown in the illustration.
11. Apply corrosion protection to the areas (1) involved in the welding.
12. Seal the seams between the parts and the vehicle.
14. Apply electro-weldable paint/weld through primer to the boarders (1) involved.
15. Position the exterior service part correctly on the vehicle internal pillar and secure it with the
17. With the use of a spot welder, apply spot welds (1) in the areas shown in the illustration.
19. With the use of a grinding disc, smooth the welds in the highlighted area (1).
20. With the use of a rotary brush, clean the previously welded areas.
BODY STRUCTURE > PANEL, ROOF > REMOVAL AND INSTALLATION > REMOVAL

Fig 1: Roof Panel Removal (1 Of 3)
3. With the use of a vibrating knife equipped with an appropriate blade, cut the sealant (1)
between the roof bows and the roof.
5. With the use of a jig saw, cut the roof along the cut line (2).
7. With the use of a drill, release the spot welds not accessible with the spot weld cutting tool.
9. Remove the cutouts of sheet metal.

10. With the use of a jig saw, cut the roof along the cut line (1).
12. With the use of a drill, release the spot welds not accessible with the spot weld cutting tool.
14. Remove the cutouts of sheet metal.

17. Remove the sealant from the roof bows.
BODY STRUCTURE > PANEL, ROOF > REMOVAL AND INSTALLATION > REMOVAL
Fig 1: Roof Panel Installation (1 Of 4)
2. Use a drill to drill the parts at the points (2) indicated.

4. Apply a bead of sealant along the roof bows (1).

7. With the use of a spot welder, weld the points (2) indicated in the illustration.
8. With the use of a MIG welder apply plug welds to fill in the holes (3) made previously.
9. Correct any contour and deformations of the sheet metal using a hammer and dolly block.
10. With the use of a grinding wheel, smooth the welds.
11. With the use of a rotary brush, clean the previously welded areas.

BODY STRUCTURE > PANEL, TAILLAMP MOUNTING > REMOVAL AND

INSTALLATION > REMOVAL AND INSTALLATION > REMOVAL
INSTALLATION .

Fig 1: Taillamp Mounting Panel Removal (1 Of 2)
5. With the use of a rotary brush, remove the paint and access to the spot welds.
7. With the use of a drill, release the spot welds (2).
8. Use a chisel and hammer to remove the welds previously released.

9. Remove the taillamp mounting panel and cutouts from the vehicle.
Fig 2: Taillamp Mounting Panel Removal (2 Of 2)
13. Apply electro-weldable paint/weld through primer to the highlighted areas (1).
BODY STRUCTURE > PANEL, TAILLAMP MOUNTING > REMOVAL AND
INSTALLATION > REMOVAL AND INSTALLATION > INSTALLATION
Fig 1: Taillamp Mounting Panel Installation (1 Of 2)
2. With the use of a drill, drill holes at the indicated points (1).
3. Apply elctro-weldable paint/weld through primer to the highlighted border areas (2) involved in
welding.
Fig 2: Taillamp Mounting Panel Installation (2 Of 2)
4. Position the part (1) correctly on the vehicle and secure it with the self-locking clamps.

6. With the use of a spot welder, apply spot welds at the indicated points (1).
7. With the use of a MIG welder, apply plug welds filling in the holes (2) previously made.
INSTALLATION .
BODY STRUCTURE > PLATE, FRONT SIDERAIL > REMOVAL AND INSTALLATION >
Fig 1: Front Siderail Plate Removal (1 Of 2)
2. Use a rotary brush to remove the paint and gain access to the plate welds.
3. Use the jigsaw along the cut lines (1) shown in the illustration.
4. Use a chisel and hammer to remove the plate.

5. Remove the plate from the vehicle.
Fig 2: Front Siderail Plate Removal (2 Of 2)
6. Straighten the edges of the front frame rail with the use of a hammer and dolly block.
7. With the use of a grinding wheel, remove any welding residue.
8. Use a rotary brush and clean the previously treated areas.
9. Apply electro-weldable paint/weld through primer to the area (1) to be welded.
BODY STRUCTURE > PLATE, FRONT SIDERAIL > REMOVAL AND INSTALLATION >
Fig 1: Front Siderail Plate Installation (1 Of 3)
1. Remove the anti-corrosion treatment from the areas to be welded using a rotary brush.
2. Apply electro-weldable paint/weld through primer to the area (1) to be welded.

3. Correctly position the part on the vehicle and check the alignment and squaring.
4. Use a MIG welder to seam-weld the areas (1) indicated in the illustration.
6. Use a grinding wheel to smooth the welds (1).
8. Apply corrosion protection to the areas affected.
BODY STRUCTURE > RAIL, FRONT FRAME > REMOVAL AND INSTALLATION >
1. Remove upper load path beam. Refer to BEAM, LOAD PATH, REMOVAL AND INSTALLATION .
2. Remove the front wheelhouse. Refer to WHEELHOUSE, FRONT, REMOVAL AND

INSTALLATION .

Fig 1: Front Frame Rail Removal (1 Of 6)
5. Use a rotary brush to remove the paint and gain access to the spot welds.
7. Grind the spot welds not accessible with a drill.
9. Remove the part (2) from the vehicle.

14. Remove the inner part (2) from the vehicle.

19. Remove the part (2) from the vehicle.

21. With the use of a grinding wheel, remove any residue of the spot welds.
23. Apply electro-weldable paint/weld through primer to the areas shown in the illustration (1).
Fig 1: Front Frame Rail Installation (1 Of 8)
1. Remove the anti-corrosion treatment from the entire perimeter of the internal support (1) using
a rotary brush.
2. Drill out the part at the indicated points (2).
3. Apply elctro-weldable paint/weld through primer to the areas involved.


7. Remove the anti-corrosion treatment from the entire perimeter of the internal support (1) using
a rotary brush.

10. Position the service parts (1) correctly on the vehicle and secure it with the self-locking
clamps.
12. With the use of a MIG welder, apply plug welds to fill in the holes (2) made previously.
clamps.
19. Use a spot welder to weld the points (3) indicated in the illustration.
20. Correct any distortions to the panel using a hammer and dolly block.
21. Use a grinding wheel to smooth the welds along the perimeter (1).

27. Seal the seams between the service part and the vehicle.
28. Install the front wheelhouse. Refer to WHEELHOUSE, FRONT, REMOVAL AND
INSTALLATION .
29. Install upper load path beam. Refer to BEAM, LOAD PATH, REMOVAL AND INSTALLATION .
SECTIONING REMOVAL AND INSTALLATION > REMOVAL
1. Remove the front side rail plate. Refer to PLATE, FRONT SIDERAIL, REMOVAL AND
INSTALLATION .
Fig 1: Front Frame Rail Sectioning Removal (1 Of 3)
4. Use the jigsaw along the cut line (1) shown in the illustration.

10. Remove the cut parts from the vehicle.

SECTIONING REMOVAL AND INSTALLATION > INSTALLATION
Fig 1: Front Frame Rail Sectioning Installation (1 Of 7)
1. Use the jigsaw and cut the parts along the cut lines (1) shown in the illustration and adjust them
as necessary.
2. Use a drill to drill holes in the parts at locations shown in the illustration (2).

5. Position the parts (1) correctly on the vehicle and secure it with the self-locking clamps.
7. Use a MIG welder to seam-weld along the joint areas (2).

8. Use a spot welder to perform the spot welds (1) where indicated.
10. Use a MIG welder to seam-weld along the joint area (3).


18. Apply elctro-weldable paint/weld through primer to the ends of the parts (1).
19. Instal the front siderail plate. Refer to PLATE, FRONT SIDERAIL, REMOVAL AND
INSTALLATION .
BODY STRUCTURE > RAIL, REAR FRAME > REMOVAL AND INSTALLATION >
INSTALLATION .
2. Remove the taillamp mounting panel. Refer to PANEL, TAILLAMP MOUNTING, REMOVAL AND
INSTALLATION .
3. Remove the rear floor pan. Refer to PAN, FLOOR, REMOVAL AND INSTALLATION .
4. Remove the rear floor pan extension. Refer to REAR FLOOR PAN EXTENSION REMOVAL
AND INSTALLATION .
5. Remove the rear inner wheelhouse. Refer to WHEELHOUSE, REAR, REMOVAL AND
INSTALLATION .
INSTALLATION .

Fig 1: Rear Frame Rail Removal (1 Of 2)
11. With the use of a drill, release the spot welds.
13. Remove the rear frame rail and trimmings from the vehicle.
Fig 2: Rear Frame Rail Removal (2 Of 2)
Fig 1: Rear Frame Rail Installation (1 Of 3)
NOTE:
1. Cut the service rear frame rail along the cut line (1), being certain to leave enough length on
the part to allow for overlapping.

4. Position the part (1) correctly on the vehicle and secure it with the self-locking clamps.
6. Use a MIG welder to seam-weld along the area (2) indicated in the illustration.

12. Install the rear floor pan extension. Refer to REAR FLOOR PAN EXTENSION REMOVAL AND
INSTALLATION .
13. Install the rear floor pan. Refer to PAN, FLOOR, REMOVAL AND INSTALLATION .
INSTALLATION .
15. Install the rear inner wheelhouse. Refer to WHEELHOUSE, REAR, REMOVAL AND
INSTALLATION .
16. Install the taillamp mounting panel. Refer to PANEL, TAILLAMP MOUNTING, REMOVAL AND
INSTALLATION .
INSTALLATION .
SECTIONING REMOVAL AND INSTALLATION > REMOVAL
INSTALLATION .
2. Remove the rear floor pan. Refer to PAN, FLOOR, REMOVAL AND INSTALLATION .
3. Remove the rear floor pan extension. Refer to REAR FLOOR PAN EXTENSION REMOVAL
AND INSTALLATION .
4. Remove the rear wheelhouse reinforcement. Refer to REINFORCEMENT REAR

WHEELHOUSE REMOVAL AND INSTALLATION .

Fig 1: Rear Frame Rail Sectioning Removal (1 Of 2)
11. Remove the part from the vehicle.
Fig 2: Rear Frame Rail Sectioning Removal (2 Of 2)
SECTIONING REMOVAL AND INSTALLATION > INSTALLATION
Fig 1: Rear Frame Rail Sectioning Installation (1 Of 3)
1. Cut the service rear frame rail along the cut line (1), respecting the need to maintain a section
of sheet metal for layering.

4. Position the part correctly on the vehicle and secure it with the self-locking clamps.
6. With the use of a MIG welder, apply plug welds filling on the areas (1) in the illustration.
7. Using a MIG welder, seam-weld along the area (2) indicated in the illustration.
12. Seal the seams between the parts and the vehicle, in the areas (1) shown in the illustration.
13. Install the rear floor pan extension. Refer to REAR FLOOR PAN EXTENSION REMOVAL AND
INSTALLATION .
14. Install the rear floor pan. Refer to PAN, FLOOR, REMOVAL AND INSTALLATION .
15. Install the rear wheelhouse reinforcement. Refer to REINFORCEMENT REAR WHEELHOUSE
INSTALLATION .
BODY STRUCTURE > REINFORCEMENT, B-PILLAR > REMOVAL AND INSTALLATION

> REMOVAL AND INSTALLATION > REMOVAL
2. Remove the roof bow. Refer to REMOVAL AND INSTALLATION .

Fig 1: B-Pillar Reinforcement Removal (1 Of 5)
8. With the use of a drill, release the spot welds that can not be accessed with the spot weld
cutting tool.
16. With the use of a grinding wheel remove the welds (4) shown in the illustration.
BODY STRUCTURE > REINFORCEMENT, B-PILLAR > REMOVAL AND INSTALLATION

> REMOVAL AND INSTALLATION > INSTALLATION
Fig 1: B-Pillar Reinforcement Installation (1 Of 7)
3. Apply elctro-weldable paint/weld through primer to the boarders involved with welding.
8. Position the service part correctly on the interior pillar and secure it with the self-locking
clamps.
11. With the use of a MIG welder, apply weld to the areas (2) indicated in the illustration.
12. Position the service part correctly on the interior pillar and secure it with the self-locking
clamps.
15. Position the service part correctly on the vehicle's B-pillar and secure it with the self-locking
clamps.
18. With the use of a MIG welder, apply plug welds to the areas (2) indicated in the illustration.
19. With the use of a MIG welder, apply seam welds to the areas (3) indicated in the illustration.

NOTE:
Be certain that to leave the service panel long enough to allow for overlapping.
24. Cut the outer B-pillar service part at the cut lines (1) leaving enough length for overlap.
32. With the use of a MIG welder, apply plug welds to the areas (3) indicated in the illustration.

39. Install the roof bow. Refer to REMOVAL AND INSTALLATION .
BODY STRUCTURE > REINFORCEMENT, COWL SIDE > REMOVAL AND

2. Remove the load path beam. Refer to BEAM, LOAD PATH, REMOVAL AND INSTALLATION .

Fig 1: Cowl Side Reinforcement Removal (1 Of 4)
NOTE:
Use care to only cut the outer piece of sheet metal.
NOTE:
Use care to only cut the outer piece of sheet metal.
13. With the use of a drill, release the spot welds (3), not accessible with the spot weld cutting
tool.
15. Remove the outer part from the vehicle.

17. With the use of a drill, release the spot welds (1) at the indicated points.
19. Remove the cowl side reinforcement from the vehicle.

BODY STRUCTURE > REINFORCEMENT, COWL SIDE > REMOVAL AND

Fig 1: Cowl Side Reinforcement Installation (1 Of 12)
3. Apply elctro-weldable paint/weld through primer to the boarders involved.

NOTE:
Be certain that to leave the service panel long enough to allow for overlapping.
4. With the external service part placed on a workbench cut at the cut lines (1) as indicated in the
illustration.

8. Position the cowl side reinforcement correctly on the vehicle and secure it with the self-locking
clamps.

13. Use a grinding disc to smooth the welds in the highlighted area.

17. Apply elctro-weldable paint/weld through primer to the areas (2) indicated.
18. Position the external part (1) correctly on the vehicle and secure it with the self-locking clamps.
20. With the use of a circular saw, cut the edges of the panel sheet to obtain a perfect joint line.
21. Remove the external service part and the excess pieces of cutoff sheet metal used for the
adjustment.
30. With the use of a MIG welder, butt weld in the seam areas (1).
32. Use a grinding disc to smooth the welds in the area highlighted (1).

35. Use a grinding disc to smooth the welds in the area highlighted (1).

38. Seal the seams between the internal parts and the vehicle in the area highlighted (1).
39. Install the load path beam. Refer to BEAM, LOAD PATH, REMOVAL AND INSTALLATION .
BODY STRUCTURE > REINFORCEMENT, FUEL FILLER DOOR > REMOVAL AND
2. Be certain the components connected are not distorted by checking the body alignment

Fig 1: Fuel Filler Door Reinforcement Removal (1 Of 2)
7. Remove the fuel door reinforcement from the vehicle.

Fig 2: Fuel Filler Door Reinforcement Removal (2 Of 2)
BODY STRUCTURE > REINFORCEMENT, FUEL FILLER DOOR > REMOVAL AND
Fig 1: Fuel Filler Door Reinforcement Installation (1 Of 4)
a rotary brush.
3. Apply elctro-weldable paint/weld through primer to the highlighted border areas (2) involved in
welding.
4. Apply sealant to the area (1) shown in the illustration.

12. Apply corrosion protection to the area (1) involved in the welding.
BODY STRUCTURE > TROUGH, LIFTGATE OPENING > REMOVAL AND

Fig 1: Liftgate Opening Trough Removal (1 Of 2)

9. Remove the liftgate opening trough and cut-outs from the vehicle.
Fig 2: Liftgate Opening Trough Removal (2 Of 2)

BODY STRUCTURE > TROUGH, LIFTGATE OPENING > REMOVAL AND

Fig 1: Liftgate Opening Trough Installation (1 Of 2)
a rotary brush.
Fig 2: Liftgate Opening Trough Installation (2 Of 2)
illustration.
BODY STRUCTURE > WHEELHOUSE, FRONT > REMOVAL AND INSTALLATION >
1. Remove upper load path beam. Refer to BEAM, LOAD PATH, REMOVAL AND INSTALLATION .

Fig 1: Front Wheelhouse Removal (1 Of 5)

4. Use a rotary brush to remove the paint and gain access to the spot welds (1).
7. Remove the strut tower reinforcement from the vehicle.

14. Remove the part from the vehicle.

15. With the use of a hammer and dolly, straighten the edges of the mating components.
BODY STRUCTURE > WHEELHOUSE, FRONT > REMOVAL AND INSTALLATION >
Fig 1: Front Wheelhouse Installation (1 Of 9)
1. Remove the anti-corrosion treatment from the entire perimeter of the inside and outside of the
service part using a rotary brush.



clamps.
11. Position the service parts correctly on the vehicle and secure it with the self-locking clamps.
14. Position the service parts correctly on the vehicle and secure it with the self-locking clamps.
16. Use a spot welder to weld the points indicated in the illustration (1).

25. Seal the seams between the service part and the vehicle.
26. Install the upper load path beam. Refer to BEAM, LOAD PATH, REMOVAL AND
INSTALLATION .
BODY STRUCTURE > WHEELHOUSE, REAR > REMOVAL AND INSTALLATION >
INNER REAR WHEELHOUSE REMOVAL AND INSTALLATION > REMOVAL
2. If servicing the right side, remove the fuel door reinforcement. Refer to REINFORCEMENT,
FUEL FILLER DOOR, REMOVAL AND INSTALLATION .
INSTALLATION .
4. Remove the outer rear wheelhouse. Refer to OUTER REAR WHEELHOUSE REMOVAL AND
INSTALLATION .

Fig 1: Rear Wheelhouse Removal (1 Of 2)
10. Remove the cutout sheet metal.

Fig 2: Rear Wheelhouse Removal (2 Of 2)
INNER REAR WHEELHOUSE REMOVAL AND INSTALLATION > INSTALLATION
Fig 1: Rear Wheelhouse Installation (1 Of 4)
a rotary brush.
3. Apply elctro-weldable paint/weld through primer to the edges involved in welding.

9. Use a grinding disc to smooth the welds in the highlighted area (1).

13. Install the outer rear wheelhouse. Refer to OUTER REAR WHEELHOUSE REMOVAL AND
INSTALLATION .
INSTALLATION .
15. If servicing the right side, install the fuel door reinforcement. Refer to REINFORCEMENT,
OUTER REAR WHEELHOUSE REMOVAL AND INSTALLATION > REMOVAL
2. If servicing the right side, remove the fuel door reinforcement. Refer to REINFORCEMENT,
INSTALLATION .

Fig 1: Outer Rear Wheelhouse Removal (1 Of 2)
9. Remove the cutout sheet metal.

Fig 2: Outer Rear Wheelhouse Removal (2 Of 2)
OUTER REAR WHEELHOUSE REMOVAL AND INSTALLATION > INSTALLATION
Fig 1: Outer Rear Wheelhouse Installation (1 Of 5)
3. Apply elctro-weldable paint/weld through primer to the areas involved in welding.


INSTALLATION .
14. If servicing the right side, install the fuel door reinforcement. Refer to REINFORCEMENT,
REINFORCEMENT REAR WHEELHOUSE REMOVAL AND INSTALLATION > REMOVAL
Fig 1: Reinforcement Rear Wheelhouse Removal (1 Of 2)
INSTALLATION .
6. Remove the rear wheelhouse reinforcement (2) from the luggage compartment on the affected
side of the vehicle.
Fig 2: Reinforcement Rear Wheelhouse Removal (2 Of 2)

REINFORCEMENT REAR WHEELHOUSE REMOVAL AND INSTALLATION >
INSTALLATION
Fig 1: Reinforcement Rear Wheelhouse Installation (1 Of 3)
2. With the service part placed on a workbench, use a drill to drill holes (1) in the area shown in
the illustration.
3. Apply elctro-weldable paint/weld through primer to the boarders involved.

4. Position the service part (1) correctly on the rear floor pan extension.
6. With the use of a MIG welder, apply plug welds filling the holes (2) previously made.
8. Use a grinding disc to smooth the welds in the highlighted area.
INSTALLATION .
DECKLID/HATCH/LIFTGATE/TAILGATE > HINGE, LIFTGATE > REMOVAL AND

NOTE:
It is not necessary to remove the liftgate to replace one or both hinges. The hinges can be
replaced one at a time.
Fig 1: Liftgate Hinge & Bolts
1. Remove the upper quarter trim panels. Refer to PANEL, QUARTER TRIM, REMOVAL AND
INSTALLATION .
2. By hand, carefully lower the rear of the headliner to access the liftgate hinge to body bolts.
3. Using a grease pencil or equivalent, mark the position of the liftgate hinge (1b) on the body and
liftgate to aid in installation.
4. With the help of an assistant, support the liftgate and remove the liftgate hinge bolts (1a).
Fig 2: Liftgate Hinge & Body Bolt
5. Carefully lower the rear of the headliner and remove the liftgate hinge to body bolt (1a), and
remove the liftgate hinge (1b).
DECKLID/HATCH/LIFTGATE/TAILGATE > HINGE, LIFTGATE > REMOVAL AND

NOTE:
With assistance, support the lift gate while the hinges are being installed.
NOTE:
Use a suitable body sealer on the hinge to body mating surfaces prior to installation.
Fig 1: Liftgate Hinge & Body Bolt
1. Place the liftgate hinge (1b) onto the vehicle and loosely install the bolt (1a) from under the
headliner.
2. Align the liftgate hinge with the reference mark made previously and tighten the liftgate hinge to
body bolt to the proper specification. Refer to SPECIFICATIONS .
3. Place the liftgate into the hinge and loosely install the bolts (1a).
4. Align the liftgate with the reference mark made previously and tighten the liftgate hinge to
liftgate bolts to the proper specification. Refer to SPECIFICATIONS .
5. Check the liftgate for proper alignment and operation, adjust if necessary.
6. Install the upper quarter trim panels. Refer to PANEL, QUARTER TRIM, REMOVAL AND
INSTALLATION .
DECKLID/HATCH/LIFTGATE/TAILGATE > LATCH, LIFTGATE > REMOVAL AND

Fig 1: Liftgate Latch, Switch, Retainers & Screws
1. Remove the liftgate trim panel. Refer to PANEL, TRIM, LIFTGATE, REMOVAL AND
INSTALLATION .
2. Remove the bolts (1a) and the liftgate latch.
3. Disconnect the wire harness connector from the liftgate latch (1b).
DECKLID/HATCH/LIFTGATE/TAILGATE > LATCH, LIFTGATE > REMOVAL AND
1. Connect the wire harness connector to the liftgate latch (1b).
2. Install the liftgate latch and tighten the bolts (1a).

3. Install the liftgate trim panel. Refer to PANEL, TRIM, LIFTGATE, REMOVAL AND
INSTALLATION .
DECKLID/HATCH/LIFTGATE/TAILGATE > LIFTGATE > DISASSEMBLY AND

ASSEMBLY > DISASSEMBLY AND ASSEMBLY > DISASSEMBLY
NOTE:
The operation should be carried out with the liftgate removed.

1. Remove the wiper motor. Refer to MOTOR, WIPER, REMOVAL AND INSTALLATION .
2. Remove the liftgate glass. Refer to GLASS, LIFTGATE, REMOVAL AND INSTALLATION .
3. Remove the liftgate latch screws (1a).
4. Disconnect the wiring connector and remove the liftgate latch (1b).
5. Release the liftgate release switch retainers (2a).
6. Disconnect the wiring connector and remove the liftgate release switch (2b).
7. Using trim stick (special tool #C-4755, Trim Stick) or equivalent, release the license plate light
retainers (1b).
8. Disconnect the license plate lamp wiring connector and remove the lamp (1a).
Fig 3: Rubber Bumper, Taillamp Pad & Rivets
9. Unscrew the rubber bumper (1) and remove.
10. With the use of a drill equipped with an appropriate tip, remove the rivets (2a).
11. Remove the taillamp pad (2b).
DECKLID/HATCH/LIFTGATE/TAILGATE > LIFTGATE > DISASSEMBLY AND

ASSEMBLY > DISASSEMBLY AND ASSEMBLY > ASSEMBLY
Fig 1: Rubber Bumper, Taillamp Pad & Rivets
1. Inspect the liftgate to be certain that it is not damaged.
2. Position the taillamp pad (2b) and install two rivets (2a).
3. Install the rubber bumper (1).

4. Connect the license lamp (1a) wiring connector.
5. Position the license lamp (1a) and insert the retainers (1b) fully.
6. Connect the liftgate release switch (2b) wiring connector.
7. Position and insert the liftgate release switch (2b) engaging the retainers (2a) fully.
8. Position the liftgate latch (1b) and insert the wiring connector fully.
9. Install the liftgate latch screws and tighten securely.

10. Install the liftgate glass. Refer to GLASS, LIFTGATE, REMOVAL AND INSTALLATION .
11. Install the wiper motor. Refer to MOTOR, WIPER, REMOVAL AND INSTALLATION .
DECKLID/HATCH/LIFTGATE/TAILGATE > LIFTGATE > REMOVAL AND INSTALLATION

Fig 1: Rubber Boots, Wire Harness & Connectors

1. Remove the spoiler. Refer to SPOILER, DECKLID, REMOVAL AND INSTALLATION .
2. Open and support the liftgate.
3. Disconnect all the wire harness connectors (1a, 1c, 1d, 1e) and unclip the wire harness (1f)
from the liftgate.
4. Remove the gas props. Refer to PROP, GAS, LIFTGATE, REMOVAL AND INSTALLATION .
5. Using a flat bladed tool detach the rubber boots (2) from the liftgate.
6. Remove the wiring harness from the liftgate.

7. Using a grease pencil or equivalent, mark the hinge location to aid during installation.
8. With the aid of an assistant, remove the bolts (1a) and remove the liftgate.
DECKLID/HATCH/LIFTGATE/TAILGATE > LIFTGATE > REMOVAL AND INSTALLATION
NOTE:
A suitable body sealant should be used when removing or moving the hinges.
1. With aid of an assistant holding the liftgate, position the liftgate and loosely install the bolts
(1a).
2. Align the liftgate with the reference mark made previously and tighten the liftgate hinge to
liftgate bolts to the proper specification. Refer to SPECIFICATIONS .
3. Install the gas props. Refer to PROP, GAS, LIFTGATE, REMOVAL AND INSTALLATION .
Fig 2: Rubber Boots, Wire Harness & Connectors
4. Route the wiring harness in the liftgate and attach the rubber boots (2) into the liftgate.
5. Router the wiring harness and connect the wire harness connectors (1a, 1c, 1d, 1e).
6. Check and adjust the liftgate if necessary.
7. Install the spoiler. Refer to SPOILER, DECKLID, REMOVAL AND INSTALLATION .
DECKLID/HATCH/LIFTGATE/TAILGATE > PANEL, TRIM, LIFTGATE > REMOVAL AND

Fig 1: Lower Decklid Trim Panel, Clips & Screw

cable.
2. Remove the screw (1) from the lower decklid trim panel (3).
3. Using a trim stick or equivalent, release the retaining clips (2) and remove the lower liftgate
trim panel.
Fig 2: Upper Decklid Trim Panel, Clips & Screws

4. Remove the two screws (1a).
5. Using a trim stick or equivalent, release the retaining clips (2) and remove the upper liftgate
trim panel (3).
DECKLID/HATCH/LIFTGATE/TAILGATE > PANEL, TRIM, LIFTGATE > REMOVAL AND

Fig 1: Upper Decklid Trim Panel, Clips & Screws
1. Position the upper liftgate trim panel (3) onto the liftgate. Using hand pressure, press firmly to
engage the retaining clips (2).
2. Install the two screws (1a) and tighten securely.

Fig 2: Lower Decklid Trim Panel, Clips & Screw
3. Position the lower liftgate trim panel (3) onto the liftgate. Using hand pressure, press firmly to
4. Install the screws (1) and tighten securely.

DECKLID/HATCH/LIFTGATE/TAILGATE > PROP, GAS, LIFTGATE > REMOVAL AND
CAUTION:
Do not use any type of pliers on the machined surface of the gas prop to assist in
supporting the hood or decklid. Use a proper device for support, or the help of an assistant.
Fig 1: Incorrect Way To Prop Hood
1. Open and support the liftgate with a suitable prop or block.

Fig 2: Releasing Retaining Clip
2. Using a small flat bladed tool (3), or equivalent, release the retaining clip (2) while pulling the
ball socket (1) away from the ball stud (4).
Fig 3: Gas Prop & Ends
3. Release the gas prop ends (1a) and remove the gas prop (1b).
DECKLID/HATCH/LIFTGATE/TAILGATE > PROP, GAS, LIFTGATE > REMOVAL AND

Fig 1: Gas Prop & Ends
1. Install the gas prop (1b) over the ball studs and hand tap so that the retaining clips (1a) snap
into place.
2. Make sure the retaining clips are seated into the ball socket fully.
DECKLID/HATCH/LIFTGATE/TAILGATE > SPOILER, DECKLID > REMOVAL AND
Fig 1: Covers, Bolts & Nuts
1. Remove liftgate trim panels. Refer to PANEL, TRIM, LIFTGATE, REMOVAL AND
INSTALLATION .
2. Remove the bolts covers (1a) and the bolts (1b).
3. Remove the nuts (1c).

Fig 2: Spoiler, Clips, Washer Hose & Connector
4. Using a trim stick or equivalent, release the retaining clips (1a) lift the spoiler (1b) from the
body.
5. Disconnect the washer hose (2) from the washer nozzle.
6. Disconnect the wire harness connector (3) and remove the spoiler.
DECKLID/HATCH/LIFTGATE/TAILGATE > SPOILER, DECKLID > REMOVAL AND
NOTE:
When the spoiler is removed for repair or replacement, the gaskets at the spoiler
attachment locations should be replaced.
Fig 1: Spoiler, Clips, Washer Hose & Connector
1. Position spoiler (1b) and connect the washer hose (2) to the washer nozzle. Connect the wire
harness connector (3).
2. Align the retaining clips (1a) to the body and hand tap the spoiler to engage.
Fig 2: Covers, Bolts & Nuts
3. Install the bolts (1b) loosely.
4. Install the nuts (1c) and tighten securely. Start in the center and work your way out to the ends
when tightening the nuts and bolts.
5. Install the bolt covers (1a).
6. Install the liftgate trim panels. Refer to PANEL, TRIM, LIFTGATE, REMOVAL AND
INSTALLATION .
DECKLID/HATCH/LIFTGATE/TAILGATE > STRIKER, LIFTGATE LATCH > REMOVAL

AND INSTALLATION > REMOVAL AND INSTALLATION > REMOVAL
1. Remove the liftgate sill plate. Refer to PLATE, SCUFF, LIFTGATE SILL, REMOVAL AND
INSTALLATION .
2. Mark the latch striker location on the inside of the liftgate opening with a grease pencil to aid
during installation.
3. Remove the two fasteners that secure the latch striker.
4. Remove the latch striker from the vehicle.
DECKLID/HATCH/LIFTGATE/TAILGATE > STRIKER, LIFTGATE LATCH > REMOVAL

AND INSTALLATION > REMOVAL AND INSTALLATION > INSTALLATION
1. Position the liftgate latch striker to the body and align using the marks made during removal.
2. Install two bolts and tighten the liftgate latch bolts to the proper specification. Refer to
SPECIFICATIONS .
3. Adjust the latch striker position as necessary to achieve proper liftgate latch operation.
4. Install the liftgate sill plate. Refer to PLATE, SCUFF, LIFTGATE SILL, REMOVAL AND
INSTALLATION .
DOOR - FRONT > CHECK, DOOR > REMOVAL AND INSTALLATION > REMOVAL AND
Fig 1: Door Check Arm, Screw & Connector
2. Remove the screw (2a) of the door check arm (2b) to the A-pillar and close the door to retract
the check itself.
3. Remove the door trim panel. Refer to PANEL, DOOR TRIM, REMOVAL AND INSTALLATION .
4. Disconnect the wiring connector (1a) from the front speaker (1b).
5. Remove the front speaker.

Fig 3: Door Check Arm, Seal & Nuts
6. Remove the nuts (1) securing the door check (2) to the door.
7. Remove the door check (2) through the speaker opening.
8. Retrieve the seal (3).
DOOR - FRONT > CHECK, DOOR > REMOVAL AND INSTALLATION > REMOVAL AND
1. Install the door check nuts and tighten the nuts on the door securely.
2. Position the front speaker (1b) and connect the speaker wiring connector (1a).
3. Install front speaker.

4. Position the check arm (2b) back and install the screw (2a).
DOOR - FRONT > CYLINDER, DOOR LOCK > REMOVAL AND INSTALLATION >
Fig 1: Lock Block, Cover & Screw
1. Remove the protective cover (1a).
2. Loosen the screw (1b) by turning clockwise.
3. Remove the lock block (2) from the door.

DOOR - FRONT > CYLINDER, DOOR LOCK > REMOVAL AND INSTALLATION >
1. Insert the lock block fully and tighten the screw securely.
2. Instal the protective cap.

DOOR - FRONT > DOOR > ADJUSTMENTS > ADJUSTMENTS
NOTE:
It is recommended that you adjust the rear door before adjusting the front door. Refer to
DOOR, REAR .
Door adjustment measurements should be taken from stationary or welded body

panels like the roof, rocker or quarter panels.
Fig 1: Link, Strap Bolt & Bolts
1. When adjustment is carried out after having removed the door, tighten the hinge bolts to the
proper specification. Refer to SPECIFICATIONS .
2. Remove the striker. Refer to STRIKER, DOOR LATCH, REMOVAL AND INSTALLATION .
3. If necessary, provisionally tighten the bolts (1) securing the hinges to the door and body.
4. Remove the check strap bolt (2a) and close the door temporarily to return the link (2b).
NOTE:
Initially adjust the door within the door housing. To do this, the bolts securing the
hinges to the body must be loosened.
5. For the upper hinges remove the instrument panel assembly, refer to CARRIER, INSTRUMENT
PANEL, REMOVAL AND INSTALLATION .
6. For the lower hinges remove the cowl trim panel, refer to PANEL, COWL TRIM, REMOVAL
AND INSTALLATION .
Fig 2: Hinges, Bolts & Adjustment Directions

7. Loosen the bolts (1a) securing the hinges (1b) to the body.
8. Adjust the door position by means of the slotted bolt holes until it is correctly aligned in the door
housing.
NOTE:
It is advisable to work on one hinge at a time. The arrows (2) indicate the possible
movements for the adjustment.
9. After adjustment, tighten the bolts (3) to the proper specification. Refer to SPECIFICATIONS .
Fig 3: Rubber Plug
10. If removed, fit the rubber plug (1) for the lower hinge.
Fig 4: Upper Hinge Protection
11. If removed, fit the protection (1) for the upper hinge.
Fig 5: Hinges & Bolts
12. For the upper hinges install the instrument panel assembly, refer to CARRIER, INSTRUMENT
13. For the lower hinges remove the cowl trim panel, refer to PANEL, COWL TRIM, REMOVAL
AND INSTALLATION .
NOTE:
If necessary, adjust the alignment of the door with the fender and the rear door,
working as follows.
14. Open the door.

15. Loosen the bolts (1a) securing the hinges (1b) to the door.
16. Adjust the door position by means of the slotted screw holes until it is correctly aligned with the
fender and rear door.
NOTE:
It is advisable to work on one hinge at a time. The arrows indicate the possible
movements for the adjustment.
17. After adjustment, tighten the bolts to the proper specification. Refer to SPECIFICATIONS .
18. Install the striker. Refer to STRIKER, DOOR LATCH, REMOVAL AND INSTALLATION .
19. If necessary, touch up the paint in the half hinge area.
20. Check that the striker and the door lock are correctly matched and that the alignment is correct
with the door closed.
DOOR - FRONT > DOOR > DISASSEMBLY AND ASSEMBLY > DISASSEMBLY AND
ASSEMBLY > DISASSEMBLY
Fig 1: Handle & Screws
2. Remove the outside rearview mirror. Refer to MIRROR, OUTSIDE REARVIEW, REMOVAL
AND INSTALLATION .
3. Remove the front door glass. Refer to GLASS, DOOR, REMOVAL AND INSTALLATION .
4. Remove the front door. Refer to DOOR, REMOVAL AND INSTALLATION .

5. Remove the front door hinge. Refer to HINGE, DOOR, REMOVAL AND INSTALLATION .
6. Working from inside of the door trim panel, remove the mounting screws (1a) and remove the
handle (1b).
Fig 2: Speaker Trim Bezel & Retainers
7. Using trim stick (special tool #C-4755, Trim Stick) or equivalent, release the retainers (1a)
securing the speaker trim bezel (1b) to the door trim panel.
8. Remove the speaker trim bezel (1b) from the door trim panel.
9. Disconnect the wiring connector (1a) from the front speaker (1b).
10. Remove the front speaker.

Fig 4: Front Door Lower Molding & Retainers
11. With the use of a trim stick or equivalent, pry out on the front door lower molding (1b) releasing
the retainers (1a).
12. Remove the front door lower molding (1b) from the door.
13. Remove the nuts (1) securing the door check (2) to the door.
14. Remove the door check (2) through the speaker opening.
15. Retrieve the seal (3).

Fig 6: Front Door Applique & Screws
16. Remove the screws (1a) and remove the front door applique (1b), releasing it from the door
glass channel.

Fig 8: Handle, Support & Hooks
20. Push the handle (1a) in the direction of the arrow, releasing the hooks (1b) from the handle
support (1c).
21. Rotate and remove the handle (1a).

Fig 9: Door Gasket & Screw
22. Remove the door gasket (1).
23. Loosen the screw (2).

Fig 10: Side Curtain Air Bags Sensor, Screws, Retainers, Grommets & Connectors
24. Remove the door latch mounting screws (1a).
25. Release the rotating retainers (1b) securing the carrier plate.
26. Position the carrier plate slightly away from the front door.
27. Release the wiring harness grommets (2a).

28. Disconnect the latch wiring connector (2b), the window motor wiring connector (2c) and the
side curtain air bags sensor (2d).
29. Release the wiring harness from the routing retainers.
30. Remove the entire carrier plate including the latch and external handle support.
Fig 11: Rubber Stop Block
31. Pry off the rubber stop block (1).

Fig 12: Front Door Weatherstrip & Retainers
32. With the use of a trim stick or equivalent, pry out the retainers (1a) and remove the front door
weatherstrip (1b).
NOTE:
It is recommended to use masking tape to avoid damaging the weatherstrip.
Fig 13: Front Door Wiring Harness, Connector & Retainers
33. Disconnect the wiring connector (1a).
34. Release the wiring retainers (1b).
35. Remove the front door wiring harness (2).

Fig 14: Power Window Motor & Screws
36. Remove the window motor mounting screws (1a).
37. Remove the window motor (1b) from the carrier plate.
38. Remove the side curtain air bag sensor mounting screws (2a).
39. Remove the side curtain air bag sensor (2b) from the carrier plate.
40. Remove the front door trim grab handle bracket mounting screws (3a).
41. Remove the front door trim grab handle bracket (3b) from the carrier plate.
Fig 15: Lock Support & Clips
42. Disengage the retaining clips (1a) and fold the lock support (1b).
Fig 16: Rear Glass Guide, Bracket, Lock Cover & Clip
43. Separate the linkage by disengaging the clip (1b).
44. Remove the rear glass guide (2a) from the guide on the lock cover (2b) by pulling in the
direction of the arrow, disengaging the bracket (2c).
Fig 17: Outside Door Handle Front Support, Guide, Bracket, Retainer, Latch Cable & Outer
End
45. Release the retainer (1a) of the latch cable (1b) and disconnect the outer end (1c).
46. Remove the outside door handle front support (2a) from the guide (2b) by pulling in the
direction of the arrow, disengaging the bracket (2c).
Fig 18: Latch & Grommets
47. Release the cables grommets (2a).
48. Remove the latch (1b) complete with control cables from the carrier plate.
DOOR - FRONT > DOOR > DISASSEMBLY AND ASSEMBLY > DISASSEMBLY AND
ASSEMBLY > ASSEMBLY
1. Position the latch complete with the control cables and insert the cable grommets onto the
carrier plate.
2. Engage the clips and attach insert the latch support.
3. Insert the outside door handle bracket onto the front guide.
4. Connect the end of the latch cable and secure the clip.
5. Position the power window motor, insert the screws and tighten securely.
6. Position side curtain air bag sensor, insert the screws and tighten securely.
7. Position the door trim panel grab handle bracket, insert the screws and tighten securely.
8. Position the front door wiring harness, engage the routing retainers and connect the wiring
connector.
9. Position the door latch, insert the screws and tighten securely.
10. Insert the rubber stop block.
11. Position the front door weatherstrip and insert the retainers fully.
12. Connect the door latch wiring connector.
13. Connect the window motor wiring connector.
14. Connect the side air bag sensor wiring connector.
15. Position and insert the wiring harness grommets.

Fig 1: Outer Handle Support Bracket, Handle Hole, Gasket & Screw
16. Position the outer handle support bracket (1a) inside the door.
17. Push in the direction of the arrow, connecting it to the handle hole (1b) on the door.
18. Install the gasket (1c).
19. Tighten the screw (1d) securely.
20. Position the carrier plate and secure by tightening the rotating retainers.
21. Install the exterior handle, engaging the hooks to the handle support.
22. Insert the lock block fully and tighten the screw securely.
23. Instal the protective cap.
24. Position the front door applique within the door glass channel. Insert the screws and tighten
securely.
25. Position the door check, including the seal, inserting it through the speaker opening.
26. Install the door check nuts and tighten the nuts on the door securely.
27. Position the lower molding on the door and insert the retainers fully.
28. Position the front speaker and connect the speaker wiring connector.
29. Working from inside the front door trim panel, install the speaker trim bezel by aligning and
inserting the retainers fully.
30. Working from inside of the door trim panel, position the interior handle and install the screws
securely.
31. Install the front door upper and lower half hinges. Refer to HINGE, DOOR, REMOVAL AND
INSTALLATION .
32. Install the front door. Refer to DOOR, REMOVAL AND INSTALLATION .
33. Install the front door glass. Refer to GLASS, DOOR, REMOVAL AND INSTALLATION .
34. Install the outside rearview mirror. Refer to MIRROR, OUTSIDE REARVIEW, REMOVAL AND
INSTALLATION .
DOOR - FRONT > DOOR > REMOVAL AND INSTALLATION > REMOVAL AND

NOTE:
To protect the vehicle finish, apply several layers of masking tape on the front edges of the
door and the front fender prior to loosening the hinges.
2. Disconnect the electrical connector (1a).
3. Remove the screw (2a) of the door check arm (2b) to the A-pillar and close the door to retract
the check itself.
Fig 2: Lower Hinge Pivot Bolt
4. Remove the lower hinge pivot bolt (1).

Fig 3: Upper Hinge Bolt
5. Remove the upper hinge bolt (1).

Fig 4: Front Door
6. Lift and remove the door (1).
DOOR - FRONT > DOOR > REMOVAL AND INSTALLATION > REMOVAL AND
Fig 1: Front Door
NOTE:
1. Position the door (1) on the hinges.

Fig 2: Upper Hinge Pivot Bolt
2. Install the upper hinge pivot bolt (1) and hand tighten only.
Fig 3: Lower Hinge Pivot Bolt
3. Install the lower hinge pivot bolt (1) and hand tighten only.
4. Connect the electrical connector (1a).
5. Position the check arm (2b) back and install the screw (2a).
7. Check door electrical systems to make sure they are functioning properly.
8. Adjust the door striker as necessary. Refer to STRIKER, DOOR LATCH, ADJUSTMENTS .
9. Tighten the upper and lower hinge pivot bolts to the proper specification. Refer to
SPECIFICATIONS .
DOOR - FRONT > GLASS, DOOR > REMOVAL AND INSTALLATION > REMOVAL AND
Fig 1: Inside Handle, Trim Cover & Screw
1. Pull the inside handle (1a) of the front side door and using trim stick (special tool #C-4755,
Trim Stick) or equivalent, remove the trim cover (1b).
2. Pull the inside handle and remove the screw (2).

Fig 2: Pad & Screw
3. Using a trim stick or equivalent, remove the pull cup trim (1a) and remove the screw (1b).
4. Remove the pull cup (2).

Fig 3: Switch Assembly, Clips & Connectors
5. Using a trim stick or equivalent, release the retaining clips (1b) and remove the switch pod
(1a).
6. Disconnect the electrical connectors (2a, 2b).

Fig 4: Door Trim Panel Screw
7. Remove the screw (1) on the inside of the front armrest on the door trim panel.
Fig 5: Trim Panel Screws & Covers
8. Pry off the covers (1a), remove the screws attaching the trim panel (1b) and the screw at the
bottom of the panel (1c).
Fig 6: Inner Door Panel, Cables & Retainers
9. Using a trim stick or equivalent, release the push pin retainers (1a) and separate the door trim
panel.
10. Release the retainers (2a) of the cables (2b) and release the ends (2c) and remove the inner
door panel (1b).
Fig 7: Glass Run & Groove
11. Pry the glass run (1) from the back rail of the glass run channel.
12. Release the run from the upper corner of the rear groove (2).
Fig 8: Applique & Screws
13. Remove the screws (2a) and remove applique (2b).

Fig 9: Glass Run, Gasket, Outer Belt Molding & Retainers
14. Disengage from the seat the front part (1a) and then the upper part (1b) of the channel.
15. Remove the full glass run (2a) and release the gasket (2b) from the front rail of the glass run
channel.
NOTE:
Work carefully trying to avoid bending and to prevent damage to the glass run
channel.
16. Lift the outer belt molding (3a) starting from the rear end, disengaging from the seat using the
special tool #1878086000 (3b).
17. Remove the outer belt molding (3a) disengaging from the retainers (4a) on the body.
NOTE:
Masking tape is recommend to prevent damage to the body.
NOTE:
If outer belt molding must be reused, be careful not to deform.

Fig 10: Front Door, Glass, Caps, Holes & Screws
WARNING:
Use care when removing the door glass to prevent breakage. Do not force the glass
out of the door. Failure to follow this warning may result in serious injury.
18. Pry the caps (1a) on the carrier plate inside the front side door (1b).
19. Temporarily connect the switches on the door and connect the negative terminal of the battery.
20. Position the glass down until the attachment screws (3a) are accessible through the holes (2)
under the plugs.
21. Remove the screws (3a) and remove the glass (3b).
Fig 11: Fixed Front Door Glass & Screws
22. Remove the inner (1a) and outer (1b) screws of the fixed front door glass (1c)
Fig 12: Fixed Glass/Glass Run Channel Assembly, Bracket, Speaker & Screws
23. Remove the screws (1a) and remove the front speaker (1b).
24. Working from inside the speaker opening release the run channel (2a) from the bracket (2b).
25. Remove the fixed glass/glass run channel assembly (3) from the door.
DOOR - FRONT > GLASS, DOOR > REMOVAL AND INSTALLATION > REMOVAL AND
NOTE:
If the door glass did not move in the door using with power window switch, replace the
regulator and/or the regulator motor or repair the electrical concern prior to installing the
door glass.
1. Check that the fixed front door glass is not damaged.
2. Position the fixed glass/glass run channel assembly back into the door glass opening.
3. Working from inside the speaker opening secure the run channel to the bracket.
4. Install the speaker and install the screws.
5. Install the inner and outer screws of the fixed front door glass.
WARNING:
Use care when removing the door glass to prevent breakage. Do not force the glass
out of the door. Failure to follow this warning may result in serious injury.
6. Install the glass (3b) into the glass opening.
7. Position the glass down until the attachment screws are accessible through the holes under
the plugs.
8. Tighten the screws.
9. Seat the access caps fully.
10. Position the glass run seal back into the glass opening.
11. Install the applique and install the screws.
12. Starting from the lower part, seat the glass run seal into the channel and seat fully.
13. Seat the remaining top and then front of the seal fully.
14. Install the outer belt molding taking care not to damage.
15. Verify that all carrier plate fasteners are in tact and replace if necessary.
16. Position the trim panel into place and connect the cables.
17. Install the trim panel and seat the push pin fasteners fully.
18. Install the trim panel screws and install the trim covers.
19. Install the screw into the armrest opening.

20. Connect the switch pod electrical connections.
21. Install the switch pod and seat the clips fully.
22. Install the pull cup and install the screw. Install the pull cup trim.
23. Install the release handle screw and install the trim.
25. Operate the glass and check for interference between the guides and outer belt molding.
DOOR - FRONT > HANDLE, EXTERIOR > REMOVAL AND INSTALLATION > REMOVAL

4. Push the handle (1a) in the direction of the arrow, releasing the hooks (1b) from the handle
support (1c).
5. Rotate and remove the handle (1a).

DOOR - FRONT > HANDLE, EXTERIOR > REMOVAL AND INSTALLATION > REMOVAL
Fig 1: Interior Handle & Screws
1. Working from inside of the door trim panel, position the interior handle (1b) and install the
screws (1a) securely.
2. Install the trim panel. Refer to PANEL, DOOR TRIM, REMOVAL AND INSTALLATION .
DOOR - FRONT > HANDLE, INTERIOR > REMOVAL AND INSTALLATION > REMOVAL

cable.
2. Remove the trim panel. Refer to PANEL, DOOR TRIM, REMOVAL AND INSTALLATION .
3. Working from inside of the door trim panel, remove the mounting screws (1a) and remove the
handle (1b).
DOOR - FRONT > HANDLE, INTERIOR > REMOVAL AND INSTALLATION > REMOVAL
1. Working from inside of the door trim panel, position the interior handle (1b) and install the
screws (1a) securely.
2. Install the trim panel. Refer to PANEL, DOOR TRIM, REMOVAL AND INSTALLATION .
DOOR - FRONT > HINGE, DOOR > REMOVAL AND INSTALLATION > REMOVAL AND
Fig 1: Body Side Hinge Half & Bolts
NOTE:
2. Remove the front door. Refer to DOOR, REMOVAL AND INSTALLATION .
3. Remove the bolts (1a, 1b) and remove the body side hinge half (2).
Fig 2: Door Hinge Half & Bolt

4. Remove the bolt (1) and remove the door hinge half (2).
DOOR - FRONT > HINGE, DOOR > REMOVAL AND INSTALLATION > REMOVAL AND
Fig 1: Door Hinge Half & Bolt

NOTE:
1. Install the door hinge half (2).
2. Install the bolt (1) and hand tighten only.

Fig 2: Body Side Hinge Half & Bolts
3. Install the body side hinge half (2).
4. Install the bolts (1a, 1b) and hand tighten only.
5. Install the door. Refer to DOOR, REMOVAL AND INSTALLATION .

DOOR - FRONT > LATCH, DOOR > REMOVAL AND INSTALLATION > REMOVAL AND
1. Remove the carrier plate. Refer to PLATE, CARRIER, REMOVAL AND INSTALLATION .
2. Release the cables grommets (2a).

3. Remove the latch (1b) complete with control cables from the carrier plate.
DOOR - FRONT > LATCH, DOOR > REMOVAL AND INSTALLATION > REMOVAL AND

1. Position the latch (1b) complete with the control cables and insert the cable grommets (2a)
onto the carrier plate.
2. Install the carrier plate. Refer to PLATE, CARRIER, REMOVAL AND INSTALLATION .
DOOR - FRONT > PANEL, DOOR TRIM > REMOVAL AND INSTALLATION > REMOVAL
Fig 1: Inside Handle, Trim Cover & Screw
1. Pull the inside handle (1a) of the front side door and using trim stick (special tool #C-4755,
Trim Stick) or equivalent, remove the trim cover (1b).
2. Pull the inside handle and remove the screw (2).
Fig 2: Pad & Screw
3. Using a trim stick or equivalent, remove the pull cup trim (1a) and remove the screw (1b).
4. Remove the pull cup (2).

5. Using a trim stick or equivalent, release the retaining clips (1b) and remove the switch pod
(1a).
6. Disconnect the electrical connectors (2a, 2b).

7. Remove the screw (1) on the inside of the front armrest on the door trim panel.
Fig 5: Trim Panel Screws & Covers
8. Pry off the covers (1a), remove the screws attaching the trim panel (1b) and the screw at the
bottom of the panel (1c).
Fig 6: Inner Door Panel, Cables & Retainers
9. Using a trim stick or equivalent, release the push pin retainers (1a) and separate the door trim
panel.
10. Release the retainers (2a) of the cables (2b) and release the ends (2c) and remove the inner
door panel (1b).
DOOR - FRONT > PANEL, DOOR TRIM > REMOVAL AND INSTALLATION > REMOVAL
NOTE:
Prior to reinstalling the door trim panel, replace any trim panel retaining clips that may have
been damaged during the removal process.
1. Verify that all carrier plate fasteners are in tact and replace if necessary.
2. Position the trim panel into place and connect the cables.
3. Install the trim panel and seat the push pin fasteners fully.
4. Install the trim panel screws and install the trim covers.
5. Install the screw into the armrest opening.
6. Connect the switch pod electrical connections.
7. Install the switch pod and seat the clips fully.
8. Install the pull cup and install the screw. Install the pull cup trim.
9. Install the release handle screw and install the trim.
11. Operate the glass and check for interference between the guides and outer belt molding.
DOOR - FRONT > PLATE, CARRIER > REMOVAL AND INSTALLATION > REMOVAL
Fig 1: Door Gasket & Screw
2. Remove the front door glass. Refer to GLASS, DOOR, REMOVAL AND INSTALLATION .
3. Remove the exterior handle. Refer to HANDLE, EXTERIOR, REMOVAL AND INSTALLATION .
4. Remove the door gasket (1).
5. Loosen the screw (2).

6. Remove the door latch mounting screws (1a).
7. Release the rotating retainers (1b) securing the carrier plate.
8. Position the carrier plate slightly away from the front door.
9. Release the wiring harness grommets (2a).

10. Disconnect the latch wiring connector (2b), the window motor wiring connector (2c) and the
side curtain air bags sensor (2d).
11. Release the wiring harness from the routing retainers.
12. Remove the entire carrier plate including the latch and external handle support.
DOOR - FRONT > PLATE, CARRIER > REMOVAL AND INSTALLATION > REMOVAL

5. Position the carrier plate and secure by tightening the rotating retainers.
Fig 2: Outer Handle Support Bracket, Handle Hole, Gasket & Screw
10. Install the exterior handle. Refer to HANDLE, EXTERIOR, REMOVAL AND INSTALLATION .
11. Install the front door glass. Refer to GLASS, DOOR, REMOVAL AND INSTALLATION .
DOOR - FRONT > STRIKER, DOOR LATCH > ADJUSTMENTS

Fig 1: Striker & Screws
1. Loosen the screws (1a) of the striker (1b).

Fig 2: Striker Adjustment
2. Move the striker (1) into the correct position.
3. The arrows (2) indicated the allowable movements.
4. Tighten the screws (3) to the proper specification. Refer to SPECIFICATIONS .
5. Check the operation of the door and repeat adjustments as necessary.
DOOR - FRONT > STRIKER, DOOR LATCH > REMOVAL AND INSTALLATION >
Fig 1: Striker & Bolts
1. Using a grease pencil or equivalent, mark the installed position of the door latch striker (1b) in
relationship to the B-pillar to aid installation.
2. Remove the bolts (1a) and remove the striker (1b).
DOOR - FRONT > STRIKER, DOOR LATCH > REMOVAL AND INSTALLATION >
Fig 1: Striker Adjustment
1. Place the striker (1a) in position and partially tighten the bolts (1b).
2. Move the striker into the correct position, using the slotted openings in the bolts. The arrows
(2) indicate the possible movements for the adjustment.
3. Tighten the bolts (1b) to the proper specification. Refer to SPECIFICATIONS .
4. Check that the striker and the door lock are correctly coupled and that the alignment is correct
with the door closed.
DOORS - REAR > CHECK, DOOR > REMOVAL AND INSTALLATION > REMOVAL AND
Fig 1: Door Check & Screw
1. Remove the screw (1a) securing the door check (1b) to the B-pillar.
2. Close the door to retract the door check (1b).

Fig 2: Door Check, Seal & Nuts
3. Remove the door trim panel.
4. Remove the seal (1) from the door.
5. Remove the mounting nuts (2) securing the door check (3) to the door.
6. Remove the door check (3) from the door.
DOORS - REAR > CHECK, DOOR > REMOVAL AND INSTALLATION > REMOVAL AND
1. Position the door check (3), tighten the mounting nuts (2) securely and insert the seal (1).
2. Install the door trim panel.

3. Position the check arm (1b) back into place and install the bolt (1a).
DOORS - REAR > DOOR, REAR > DISASSEMBLY AND ASSEMBLY > DISASSEMBLY
AND ASSEMBLY > DISASSEMBLY
Fig 1: Inner Door Trim & Retainers
2. Using trim stick (special tool #C-4755, Trim Stick) or equivalent, release the retainers (1a).
3. Remove the inner door trim (1b) from the rear door.
Fig 2: Inside Handle, Cover & Screw
4. Pull the inside handle and with the use of an appropriate tool, remove the cover (1b).
5. Remove the screw (1a).

Fig 3: Power Window Switch Bezel, Grab Handle Pad, Fastener, Retainers & Connector
6. Remove the grab handle pad (1a).
7. Remove the fastener (1b).
8. With the use of a trim stick or equivalent, release the retainers (2b) securing the power window
switch bezel (2a) to the door trim pad.
9. Disconnect the power window switch electrical connector (3).

10. Remove the power window switch bezel (2a).
Fig 4: Rear Door Armrest Screws
11. Remove the screws (1) from inside the rear door armrest.
12. Remove the screw (1) from the bottom of the door trim panel.
Fig 6: Door Trim Panel, Retainers, Clips & Cables
13. With the use of a trim stick or equivalent, release the door trim panel retainers (1a).
14. Position the door trim panel (1b) slightly away from the door.
15. Release the clips (2a) securing the cables (2b) and remove the cable ends (2c).
16. Remove the door trim panel (1b).

Fig 7: Speaker Trim Bezel & Retainers
17. With the use of a trim stick or equivalent, release the retainers (1a) securing the speaker trim
bezel (1b) to the door trim panel.
18. Remove the speaker trim bezel (1b) from the door trim panel.
Fig 8: Inner Door Handle & Screws
19. Working from the inside of the door trim panel, remove the three screws (1a) and remove the
inner door handle.
Fig 9: Outer Door Belt Molding, Glass Channel, Rear Appliques & Screws
20. With the use of a trim stick or equivalent, pry up on the outer door belt molding (1a).
21. Remove the door glass channel (1b).
22. Remove the screws (2a) and remove the rear door front and rear appliques (2b), releasing
them from the door glass guides.
Fig 10: Rear Door Carrier Plate, Covers & Fasteners
23. Open the access covers (1a) located on the rear door carrier plate (1b).
24. Temporarily connect the window switch and the negative battery cable.
25. Position the glass so that the mounting fasteners (3) are aligned within the access holes.
26. Remove the mounting screws (3).

Fig 11: Rear Door Glass
27. Remove the rear door glass (1).

Fig 12: Rubber Stop Block
28. Pry off the rubber stop block.

Fig 13: Rear Door Weatherstrip & Retainers
29. With the use of a trim stick or equivalent, pry out the retainers (1a) and remove the rear door
weatherstrip (1b).
NOTE:
It is recommended to use masking tape to avoid damaging the weatherstrip.
Fig 14: Protective Cover
30. Remove the protective cover (1).

Fig 15: Tool, Hole & Side Plate
31. Insert an appropriate tool (1a) through the hole (1b) and turn in the direction of the arrow
hooking the slide plate (1c).
32. Pull the tool in the direction of the arrow moving the slide plate (1c) rearward.
Fig 16: Exterior Door Handle & Cap-Block
33. Pull and hold the exterior door handle (1a) outward and then remove the cap-block (1b).
34. Push the handle (1a) in the direction of the arrow and release the hooks (1b) from the handle
support (1c).
35. Rotate and remove the handle.

Fig 18: Door Handle Gasket & Screw
36. Remove the door handle gasket (1).

Fig 19: Door Latch Screws
38. Remove the screws (1) securing the door latch.

Fig 20: Speaker & Screws
39. Remove the speaker mounting screws (1a).
40. Remove the speaker (1b) from the carrier plate.

Fig 21: Speaker & Connector
41. Disconnect the wiring connector (1a).
42. Remove the speaker from the carrier plate.

Fig 22: Carrier Plate & Clamps
43. Turn the clamps (1a) and remove the entire carrier plate (1b) including the latch and external
handle support.
Fig 23: Connector, Retainer & Grommet
44. Disconnect the latch wiring connector (1a).
45. Release the wiring from the retainer (1b).
46. Pry off the wiring harness grommet (2).

Fig 24: Grommet, Connector & Wiring Harness
47. Disconnect the window motor wiring connector (1a).
48. Release the wiring harness (1b) from the retainers.
49. Release the speaker wiring harness (2) from the retainers.
50. Pry off the grommet (3).

Fig 25: Window Motor & Screws
51. Remove the window motor mounting screws (1a).
52. Remove the window motor (1b) from the carrier plate.
53. Remove the screws from the grab handle bracket and remove the bracket.
Fig 26: Door Glass Rear Guide & Retainer
54. Press the spring retainer (1a) and remove the door glass rear guide (1b).
Fig 27: Lock Support & Clips
55. Disengage the retaining clips (1a) and fold the lock support (1b).
Fig 28: Exterior Door Handle Support, Cable & Retainer
56. Release the external handle support from the lock by disengaging the retaining part (1b).
57. Remove the latch cable (2b) by releasing the latch cable retainer (2a) and disconnecting the
end (2c).
58. Remove the exterior door handle support (3).

Fig 29: Rear Door Latch & Grommets
59. Release the cable grommets (1a).
60. Remove the rear door latch (1b), complete with control cables.
Fig 30: Front Glass Guide & Nuts
61. Remove the nuts (1a) and remove the front glass guide (1b).
62. Remove the seal (1) from the door.
63. Remove the mounting nuts (2) securing the door check (3) to the door.
64. Remove the door check (3) from the door.

Fig 32: Harness, Clips & Connector
65. Press the retaining clips (1a) and release the electrical connection (1b) from the door.
66. Remove the wiring port and harness (2b).

Fig 33: Rear Door Outer Molding, Tape & Clips
67. Release the retaining clips (2a) and double sided tape (1b).
68. Remove the rear door outer molding (1c) from the door.
Fig 34: Bottom Seal
69. Release and remove the bottom seal (1) on the rear door.
DOORS - REAR > DOOR, REAR > DISASSEMBLY AND ASSEMBLY > DISASSEMBLY
AND ASSEMBLY > ASSEMBLY
1. Align and insert the bottom seal on the rear door.
2. Position the rear door outer molding and engage the retainers fully.
3. Place the wiring harness into the door, fasten the retainers and engage the harness connector
fully.
4. Position the door check, tighten the mounting nuts securely and insert the seal.
5. Position the front glass guide, install the nuts and tighten securely.
6. Position the latch, complete with control cables, to the carrier plate and insert the cable
grommets.
7. Engage the retainer for the exterior handle support.
8. Install the rear glass guide by engaging the spring retainer.

9. Engage the latch rod to the external handle support.
10. Position the power window motor to the carrier plate, install the screws and tighten securely.
11. Position the grab handle bracket to the carrier plate, install the screws and tighten securely.
12. Route the speaker wiring and engage the harness retainers.
13. Route the window motor wiring, insert the wiring connector and engage the harness retainers.
14. Engage the latch wiring connector and secure the harness to the wiring retainers.
Fig 1: Exterior Handle Support Bracket, Hole, Gasket & Screw
15. Position the carrier plate near the door and position the exterior handle support bracket (1a) to
the handle hole (1b).
16. Slide the bracket in the direction of the arrow.
17. Install the door handle gasket (1c).
18. Install the screw (1d) and tighten securely.
19. Position the latch to the door and install the screws securely.
20. Position the carrier plate and turn the clamps securing it to the inner door fully.
21. Install the exterior door handle, engaging the hook portion of the handle to the handle support.
22. Insert the cap-block and through the side hole insert an appropriate tool to push the slide plate
inward engaging the slide plate fully.
23. Install the protective cover to the inner door.
24. Connect the speaker wiring connector to the speaker.
25. Position the speaker and install the screws securely.
26. Install the rubber stop block.
27. Install the rear door weatherstrip, engaging the retaining clips fully.
28. Insert and position the door glass through the opening on the top of the rear door.
29. Install the door glass screws and tighten securely.
30. Close the access covers on the carrier plate.
31. Install the rear door front and rear appliques and tighten the screws.
32. Install the door glass channel.
33. Install the belt molding.
34. Temporarily connect the control switches on the door and connect the battery negative cable.
35. Move the door glass up and down to check that there is no interference in the guides.
36. Before installing the door trim panel, inspect the inner door and carrier plate to be certain that
parts are undamaged and operating properly. Replace as necessary.
37. Position the door trim panel near the door but do not attach it to the door at this stage.
38. Connect the inner door handle lock and latch cables by inserting the ends and engaging the
retainers.
39. Align the door trim panel to the door and with use of sufficient pressure install the clips on the
door trim panel into the corresponding retainers on the door.
40. Install and tighten the mounting screw, on the bottom of the trim panel, securely.
41. Install and tighten the mounting screws inside the armrest pocket, securely.
42. Connect the power window switch wiring connector.
43. Position the window switch bezel into the door trim panel engaging the retainers fully.
44. Install the screw into the grab handle pocket and tighten securely.
45. Install the pad into the pocket.
46. Pull the inside door handle, install the screw and tighten securely.
47. Install the cover into the door handle pocket.
48. Position the inner door trim and engage the retainers fully.
49. Connect the battery negative battery cable.

DOORS - REAR > DOOR, REAR > REMOVAL AND INSTALLATION > REMOVAL AND
Fig 1: Rear Door Wiring Connector
2. Disconnect the rear door wiring connector (1).

3. Remove the screw (1a) securing the door check (1b) to the B-pillar.
4. Close the door to retract the door check (1b).

Fig 3: Bottom Hinge Bolt
5. Remove the bolt (1) securing the bottom hinge.

Fig 4: Top Hinge Bolt
6. Remove the bolt (1) securing the top hinge.

Fig 5: Rear Door
7. Lift and remove the rear door (1).
DOORS - REAR > DOOR, REAR > REMOVAL AND INSTALLATION > REMOVAL AND
1. Position the rear door onto the vehicle.
2. Loosely install the upper hinge bolt.
3. Loosely install the lower hinge bolt.
4. Connect the rear door wiring connector.
5. Pull the door check to the open position.
6. Loosely install the door check screw.
8. Check the various systems on the door to verify proper functioning.
9. Tighten the upper and lower hinge bolt to the proper torque specifications. Refer to
SPECIFICATIONS .
10. Tighten the door check securely.
DOORS - REAR > HINGE, DOOR > REMOVAL AND INSTALLATION > REMOVAL >
UPPER HINGE
Fig 1: Body Hinge & Bolts
NOTE:
cable.
2. Remove the door. Refer to REMOVAL AND INSTALLATION .
3. Remove the screws (1) securing the hinge (2) to the body.
4. Remove the fixed hinge (2).

Fig 2: Door Hinge & Bolt
5. Remove the screw (1) securing the hinge (2) to the door.
6. Remove the movable hinge (2).
DOORS - REAR > HINGE, DOOR > REMOVAL AND INSTALLATION > REMOVAL >
LOWER HINGE
Fig 1: Fixed Body Hinge & Bolt
cable.
2. Remove the door. Refer to REMOVAL AND INSTALLATION .
3. Remove the screws (1) securing the hinge (2) to the body.
4. Remove the fixed hinge (2).

Fig 2: Movable Door Hinge & Bolts
5. Remove the screw (1) securing the hinge (2) to the door.
6. Remove the movable hinge (2).
DOORS - REAR > HINGE, DOOR > REMOVAL AND INSTALLATION > INSTALLATION >
UPPER HINGE
Fig 1: Door Hinge & Bolt
NOTE:

Fig 2: Body Hinge & Bolts
4. Install the bolts (1) and hand tighten only.
5. Install the door. Refer to REMOVAL AND INSTALLATION .
DOORS - REAR > HINGE, DOOR > REMOVAL AND INSTALLATION > INSTALLATION >
LOWER HINGE
Fig 1: Movable Door Hinge & Bolts

Fig 2: Fixed Body Hinge & Bolt
4. Install the bolts (1) and hand tighten only.
5. Install the door. Refer to REMOVAL AND INSTALLATION .
DOORS - REAR > STRIKER, DOOR LATCH > ADJUSTMENTS > REMOVAL
Fig 1: Striker & Screws
1. Loosen the screws (1a) of the striker (1b).

Fig 2: Striker Adjustments
2. Move the striker (1) into the correct position.
3. The arrows (2) indicated the allowable movements.
4. Tighten the screws (3) to the proper specification. Refer to SPECIFICATIONS .
5. Check the operation of the door and repeat adjustments as necessary.
DOORS - REAR > STRIKER, DOOR LATCH > REMOVAL AND INSTALLATION >
Fig 1: Striker & Bolts
1. Using a grease pencil or equivalent, mark the location of the striker (2) on the door to aid in
installation.
2. Remove the bolts (1) and remove the striker (2).
DOORS - REAR > STRIKER, DOOR LATCH > REMOVAL AND INSTALLATION >
Fig 1: Striker, Bolts & Adjustments
1. Place the striker (1) into position using the marks made during removal.
2. Install the bolts (3) without tightening them.
3. Adjust the position of the striker; the arrows (2) show the possible movements.
4. Tighten the bolts (3) to the proper specification. Refer to SPECIFICATIONS .
EXTERIOR > BRACKET, FENDER MOUNTING > REMOVAL AND INSTALLATION >
Fig 1: Bracket & Bolts
3. Remove the bolts (1a).
4. Remove the bracket (1b).
EXTERIOR > BRACKET, FENDER MOUNTING > REMOVAL AND INSTALLATION >
1. Check that the front fender mounting surface is not damaged.
2. Position the fender bracket (1b).
3. Install the bolts (1a) and tighten securely.
EXTERIOR > COVER, COWL PANEL > REMOVAL AND INSTALLATION > REMOVAL
Fig 1: Cowl Panel & Retainers
1. Remove the wiper arms. Refer to ARM, WIPER, REMOVAL AND INSTALLATION .
2. Using trim stick (special tool #C-4755, Trim Stick) or equivalent, release the retainers (1a) and
the central side of the cowl panel (1b).
Fig 2: Cowl Panel
3. Release the upper portion of the cowl panel (1) from the conduit on the windshield and remove
the cowl panel.
EXTERIOR > COVER, COWL PANEL > REMOVAL AND INSTALLATION > REMOVAL
Fig 1: Cowl Panel
1. Install the cowl panel and secure the upper portion of the cowl panel (1) to the conduit on the
windshield.
Fig 2: Cowl Panel & Retainers
2. Install the retainers (1a) and seat fully.
3. Install the wiper arms. Refer to ARM, WIPER, REMOVAL AND INSTALLATION .
EXTERIOR > CROSSMEMBER, HEADLAMP MOUNTING > DISASSEMBLY AND

ASSEMBLY > DISASSEMBLY > 1.4L TURBO MULTIAIR, 1.6L TURBO DIESEL, 2.0L
TURBO DIESEL 120CV / 140C
Fig 1: Prop Rod & End
1. Remove the headlamp mounting crossmember. Refer to CROSSMEMBER, HEADLAMP

MOUNTING, REMOVAL AND INSTALLATION .
2. Raise the rod (1a) supporting the engine compartment lid open, turn the end (1b) and remove it
from its seat releasing it on the front end.
Fig 2: Rod Support
3. Rotate and remove the latch rod support (1).

Fig 3: Covers
4. Release the upper radiator retainer covers and remove the covers (1).
Fig 4: Radiator, Retainers & Pins
5. Rotate the radiator (1a) down and remove the upper retainers (1b).
6. Lift the radiator assembly up and off of the lower pins (2a) and remove.
Fig 5: Bracket & Screw
7. Remove the screw (1a) and remove the bracket (1b) of the valve support charging of the air
conditioning.
Fig 6: Airbag Sensor, Clip & Nut
8. Remove the nuts (1a) and remove the front Air Bag sensors (1b).
9. On the right side, release the clip (2) retaining the wiring.
Fig 7: Retainer & Bolt
10. Remove the screws (1a), release the retainers (1b) and remove the radiator mounting
brackets.
Fig 8: Retainers
11. Release and remove retainers (1).

ASSEMBLY > DISASSEMBLY > 2.0L TURBO DIESEL 170 CV
Fig 1: Prop Rod

2. Remove the nut (1a) and remove Air Bag deceleration sensor (1b).
3. Release the front-end retainers (2a) of the wiring (2b) of the sensor, with the appropriate tool.
4. Remove the sensor (1b) with wiring (2b).

Fig 2: Sensor, Bracket, Screw, Wiring & Retainers
5. Remove the screw (1a) and remove the bracket (1b) of the support pipe of the air conditioning.
6. Detach the front-end retainers (2a) of the wiring (2b) of the sensor, with the appropriate tool.
7. Remove the sensor (1b) with wiring (2b).

Fig 3: Bracket & Bolt
8. Remove the screw (1a) and remove the bracket (1b) for the air conditioning pipe support.
Fig 4: Relay & Nut
9. Remove the nut (1a) and remove the relay (1b).

Fig 5: Cover & Retainers
10. Remove covers (1a) for the upper radiator retaining, after having disengaged the central
retaining (1b) and upper and lower (1d) retainers (1c).
Fig 6: Radiator Assembly, Supports, Pins & Seats
11. Move the upper part (1a) of the radiator assembly (1b) by disengaging the elastic supports (1c)
from the seats.
12. Lift and remove the radiator (1b) disengaging its lower pins (2a) from the seats (2b) of the
crossmember.
Fig 7: Crossmember, Bracket & Screws
13. Remove the screws (1a) and remove the reinforcement bracket (1c) from the crossmember
(1b).
Fig 8: Crossmember, Bracket, Clamp & Screws
14. Remove the screws (1a) and remove the bracket (1c) from the crossmember (1b).
15. Move the hose clamp (2a).
16. Remove the front-end (1b).

ASSEMBLY > DISASSEMBLY > 2.4L MULTIAIR2
Fig 1: Flange

2. Remove the flange (1), left and right side, retaining elastic block the radiator.
Fig 2: Flexible Blocks
3. Release the flexible blocks (1), left and right sides and remove the radiator from the
crossmember.
Fig 3: Radiator Support Brackets Screws
4. Remove the screws (1) and remove the radiator support brackets complete with dowel.
Fig 4: Front Air Bags Sensor Wiring & Support Bracket
5. Remove the screw and remove the support bracket (1).
6. Disconnect the wiring (2), remove the nut and remove the front air bags sensor, right side.
Fig 5: Front Air Bags Sensor Nut
7. Remove the nut (1) and remove the front air bags sensor, left side.
Fig 6: Hood Support Rod
8. Release and remove the hood support rod (1).

ASSEMBLY > ASSEMBLY > 1.4L TURBO MULTIAIR, 1.6L TURBO DIESEL, 2.0L
TURBO DIESEL 120CV / 140C
1. Check the crossmember for damage and repair as necessary.
2. Secure the A/C lines to the crossmember.
3. Install the radiator support brackets and install the screws.
4. Install the air bag sensors and install the nuts.
5. Install the wiring retaining clip on the right side.
6. Install the A/C refill valve support bracket and install the screw.
7. Install the radiator assembly onto the lower support brackets and seat the upper supports fully.
8. Install the upper support covers.
9. Install the hood support rod support bracket.
10. Install the hood support rod.
11. Install the headlamp mounting crossmember. Refer to CROSSMEMBER, HEADLAMP


ASSEMBLY > ASSEMBLY > 2.0L TURBO DIESEL 170 CV
Fig 1: Bracket, Screws & Clips
2. Position the bracket (1b) onto the crossmember and install the screws (1c).
3. Install the retaining clips (2a).

Fig 2: Bracket & Screws
4. Install the reinforcement bracket (1a) onto the crossmember and install the screws (1b).
Fig 3: Radiator Assembly, Pins & Bushings
5. Install the radiator assembly (1a) and seat the lower pins (1b) into the lower bushings (1c) and
seat fully.
6. Position the upper radiator (2a) back onto the crossmember and seat the upper support
bushings (2b) fully.
Fig 4: Retaining Covers & Clips
7. Install the retaining covers (1a) and seat the center retaining clip (1b), the upper clip (1c) and
the lower clips (1d) fully.
Fig 5: Air Bag Deceleration Sensor, Nut, Wiring & Support Brackets
8. Install the relay and install the nut.
9. Install the A/C line mounting bracket and install the screw.
10. Install the Air Bag deceleration sensor (1a) and install the nut (1b).
11. Position the wiring (2b) back into the support brackets (2a) and seat fully.
Fig 6: Prop Rod & Support Bracket
12. Position the rod (1b) back onto the crossmember.
13. Secure the rod end (2a) in the support hole.
14. Secure the rod (1b) into the support bracket (1a).
Fig 7: Prop Rod & End
15. Raise the rod (1a) supporting the hood open, turn the end (1b) and remove it from its seat
releasing it on the front end.

ASSEMBLY > ASSEMBLY > 2.4L MULTIAIR2
1. Install the hood support rod.
2. Install the front air bag sensors and install the nuts.
3. Install the A/C line support bracket and install the screw.
4. Install the lower radiator support brackets and install the screws.
5. Install the radiator assembly and seat the lower pins into the lower bushings and seat fully.
6. Position the upper radiator back onto the crossmember and seat the upper support bushings
fully.
7. Install the retaining covers, left and right side, retaining the upper support bushings.

EXTERIOR > CROSSMEMBER, HEADLAMP MOUNTING > REMOVAL AND

INSTALLATION > REMOVAL > 1.4L TURBO MULTIAIR, 1.6L TURBO DIESEL
Fig 1: Intake Air Tube Nut & Clips
3. Remove the engine cover. For 1.6/2.0L, refer to COVER, ENGINE, REMOVAL AND
INSTALLATION . For 1.4L, refer to COVER, ENGINE, REMOVAL AND INSTALLATION .
4. Drain the engine coolant. Refer to STANDARD PROCEDURE .
5. Recover the refrigerant from the refrigerant system. Refer to PLUMBING, STANDARD
PROCEDURE .
7. Remove the headlight assemblies. Refer to UNIT, FRONT LAMP, REMOVAL AND
INSTALLATION .
8. Remove the intake air tube nut (1).
9. Open the retaining clips (2).

Fig 2: Bumper, Screws & Nuts
10. Remove the screws (1a), nuts (1b) and remove the bumper (1c).
Fig 3: Brackets & Bolts
11. Remove the screws (1a) and remove the brackets (1b).
Fig 4: Coolant Tank & Retaining Clips
12. Release the retaining clips (1a) and position the coolant tank (1b) aside freeing the lower pin.
Fig 5: Coolant Line & Clips
13. Release the engine coolant line (1b) from the retaining clips (1a).
Fig 6: Washer Bottle Retaining Rivet
14. Remove the washer bottle retaining rivet (1).

Fig 7: A/C Refill Valve & Clip
15. Open the retaining clip (1a) and position the A/C refill valve (1b) aside.
Fig 8: Front Air Bag Sensor Electrical Connectors
16. Disconnect the front air bag sensor electrical connectors (1).
Fig 9: Wiring & Connectors
17. Disconnect the electrical connections (1a) and (1b).
18. Release the spring retainer and position aside the wiring (2).
Fig 10: Left Side Wiring & Retaining Clips
19. Release the retaining clips (1a) and position aside the wiring (1b) on the left side.
Fig 11: Right Side Wiring & Retaining Clips
20. Release the retaining clip (1a) and position aside the wiring (1b) on the right side.
Fig 12: Coolant Inlet Pipe And Intercooler Outlet Pipe Couplings
21. Disconnect the quick coupling (1) of the coolant inlet pipe.
22. Disconnect the quick coupling (2) of the intercooler outlet pipe.
Fig 13: Coolant Outlet Pipe, Intercooler Inlet Hose & Clamp
23. Disconnect the quick coupling of the coolant outlet pipe (1).
24. Remove the clamp (2a) and disconnect the intercooler inlet hose (2b).
Fig 14: A/C Pipes & Bolts
25. Remove the screws (1d) and disconnect the pipes (1b) of the air conditioning.
Fig 15: Supporting Device Under Crossmember
26. Place a suitable supporting device (1a) under the crossmember (1b).
27. Lower the vehicle so that the crossmember is resting on the lifting device.
Fig 16: Shock Absorbers, Screws & Nuts
28. Working on both sides, remove the screws (1a) and nuts (1b) securing and removing shock
absorbers (1c).
Fig 17: Headlamp Supporting Crossmember
29. Remove the headlamp supporting crossmember (1).
30. Disassemble the crossmember as necessary. Refer to CROSSMEMBER, HEADLAMP

MOUNTING, DISASSEMBLY AND ASSEMBLY .

INSTALLATION > REMOVAL > 2.0L TURBO DIESEL
Fig 1: Cool Air Inlet, Retainers & Nut
3. Remove the belly pan. Refer to BELLY PAN, REMOVAL AND INSTALLATION .

PROCEDURE .
INSTALLATION .
8. Working on the right side of the crossmember, remove the nut (1a) of the cool air inlet (1b).
9. Remove the cool air inlet (1b) releasing the retainers (2a) from the air filter housing.
Fig 2: Energy Absorber, Nuts & Bolts
10. Remove the screws (1a) securing the energy absorber (1b).
11. Remove the three nuts (2a) and remove the energy absorber (1b).
Fig 3: Air Duct, Seats, Retainers & Screws
12. Remove the screws (1a) of the lower air duct (1b).
13. Release the retainers (2a) of air duct (1b), from the seats (2b) of the crossmember.
14. Retrieve the air duct (1b).

Fig 4: Automatic Transmission Oil Cooler Lines, Clamps & Clips
15. Open the retaining clamps (1a) and free up the automatic transmission oil cooler lines (1b).
16. Carefully release the retaining clips (2a) and disconnect the lines (1b) from the fittings (2b) of
the automatic transmission oil cooler (2c).
NOTE:
Using suitable tools, plug the fittings disconnected to prevent the system
contamination.
Fig 5: A/C Lines, Fittings & Screws
17. Remove the screws (1a) and disconnect the A/C condenser fittings (1b) and (1c) of the lines
(1d) (first).
NOTE:
Using suitable tools, plug the fittings disconnected to prevent the system
contamination.
Fig 6: A/C Lines, Bracket & Clamps
18. Working on the right side of the crossmember, open the clamps (1a) and free up the A/C lines
(1b).
19. Release the crossmember electrical wiring bracket (2a) with special tool #1823015000.
Fig 7: Engine Coolant Pipe, Intercooler Radiator Inlet Pipe, Coupling, Retainer & Clamp
20. Working on the lower right side of the radiators, release the spring retainer (1a) and
disconnect the quick coupling (1b) of the engine coolant pipe (1c) from the radiator output.
21. Open the clamp (2a) and disconnect the intercooler radiator inlet pipe (2b).
Fig 8: Intercooler Radiator Pipe, Coupling & Retainer
22. Working on the lower left side of the radiators, release the spring retainer (1a) and disconnect
the quick coupling (1b) of the intercooler radiator pipe (1c).
Fig 9: Engine Coolant Bottle & Retainer
23. Lift and disengage the retainers (1a) and slide the engine coolant bottle (1c) in the direction of
the arrow (1b) by releasing the retainers (1d).
24. Position aside the reservoir (1c) after having released the lower restraint.
Fig 10: Coolant Line & Clamps
25. Release the engine coolant line (1b) from the clamps (1a).
Fig 11: Engine Coolant Inlet Pipe, Coupling & Retainer
26. Working on the upper left side of the radiators, release the spring retainer (1a) and disconnect
the quick coupling (1b) of the engine coolant inlet pipe (1c) of the radiator.
Fig 12: Washer Fluid Reservoir, Crossmember, Rivet, Retainers, Wiring & Connectors
27. Remove the rivet (1a) securing the front of the washer fluid reservoir (1b).
28. Release the electrical wiring (2c) retainers (2b) of the crossmember (2a).
29. Disconnect the electrical connections (3a, 3b).

Fig 13: Windshield Wiper Fluid Reservoir, Ground Terminal & Nut
30. Working behind the windshield wiper fluid reservoir (1a), remove the nut (1b) and disconnect
the ground terminal (1c).
Fig 14: A/C Line & Clip
31. Working behind the right front headlamp compartment, open the retaining clip (1a) and release
the A/C line (1b).
Fig 15: Crossmember, Support Rod & Screws
32. Release the hood support rod (1a) and support the hood with a suitable device or lower it so
that it rests on the body without engaging the latch. Insert spacers to prevent latch
engagement.
33. Place a suitable supporting device (2a) under the crossmember (2b).
34. Remove the screws (3a) securing the crossmember (2b) to the car and remove the
crossmember.


INSTALLATION > REMOVAL > 2.4L MULTIAIR2
Fig 1: Cold Air Tube Mounting Nut
4. Remove the engine cover. Refer to COVER, ENGINE, REMOVAL AND INSTALLATION .
PROCEDURE .
INSTALLATION .
9. Support the hood with a suitable supporting device.
10. Remove the cold air tube mounting nut.

Fig 2: Front Bumper, Nuts & Bolts
11. Remove the screws (1a), nuts (1b) and remove the front bumper (1c).
Fig 3: A/C Lines
12. Remove the screws and disconnect the supply and return lines (1) from the A/C condenser.
Fig 4: Transmission Line Clips
13. With suitable tool to release the clips (1) and disconnect the discharge and return to automatic
transmission oil cooler.
Fig 5: Quick Coupling Sleeve & Clip
14. Open the clip (1) and release the discharge and return to automatic transmission oil cooler.
15. Disconnect the quick coupling sleeve (2) radiator water outlet.
Fig 6: Fan Wiring & Connector
16. Detach the wiring (1) from the retaining clips and disconnect the electrical connections of the
resistor and electric fan.
Fig 7: Pipe & Clip
17. Open the clip and disengage the pipe discharge / charge coolant conditioner plant.
Fig 8: Front Air-Bag Sensor Connector
18. Disconnect the electrical connection (1) of the front airbag sensor, right side.
Fig 9: Radiator Water Supply Quick Coupling Sleeve
19. Disconnect the radiator water supply quick coupling sleeve (1).
Fig 10: Washer Bottle Retaining Rivet
20. Remove the washer bottle retaining rivet (1).

Fig 11: Crossmember Bracket & Bolt
21. Disengage the crossmember wiring retaining clips.
22. Remove the screws and remove the crossmember bracket (1) from the left and right side.
23. Place a suitable supporting device under the crossmember.
24. Lower the vehicle so that the crossmember is resting on the lifting device.
25. Remove the screws (1) attaching the crossmember to the left and right side.
26. Remove the nuts (2a) and remove energy absorbers left and right side (2b).
27. Remove the crossmember after having disengaged from the provisional attachment to the
engine.


INSTALLATION > INSTALLATION > 1.4L TURBO MULTIAIR, 1.6L TURBO DIESEL
2. If necessary, reassemble the crossmember. Refer to CROSSMEMBER, HEADLAMP

3. Install the headlamp supporting crossmember.
4. Working on both sides, install the shock absorbers and tighten the screws and nuts to the
5. Remove the supporting device from under the crossmember.
6. Connect the A/C lines and tighten the screws.
NOTE:
Always replace the o-rings and lubricate them with coolant prior to assembly.
7. Connect the intercooler inlet pipe and secure it with a new clamp.
8. Connect the radiator outlet pipe quick coupling.
9. Connect the intercooler quick coupling of the outlet pipe.
10. Connect the radiator inlet pipe quick coupling.
11. Position the wiring on the right side and secure the spring retainer.
12. Position the wiring on the left side and secure the retaining clips.
13. Position the wiring of the cooling electric motor and secure the spring retainer.
14. Connect the electrical connections for the electrical motor and resistance adjustment.
15. Connect the electrical connections of the front air bag sensors.
16. Position the A/C refill valve back into place and secure the retaining clip fully.
17. Install the washer fluid retaining rivet.
18. Secure the coolant pipes from the tank to the engine retaining clips.
19. Position the coolant recovery bottle in place and seat the lower pin fully.
20. Put in place the brackets from third load in front-end and tighten the screws to the specified
torque
21. Install the lower crossmember brackets and install the screws.
22. Tighten the bracket screws to the proper specification. Refer to SPECIFICATIONS .
23. Install the bumper and install the screws.
24. Tighten the bumper screws to the proper specification. Refer to SPECIFICATIONS .
25. Secure the A/C lines to the retaining clips and seat fully.
26. Install the cold air intake nut.
27. Install the headlight assemblies. Refer to UNIT, FRONT LAMP, REMOVAL AND INSTALLATION
.

30. Fill the engine coolant. Refer to STANDARD PROCEDURE .
31. Recharge the refrigerant system. Refer to PLUMBING, STANDARD PROCEDURE .
32. Install the engine cover. For 1.6/2.0L, refer to COVER, ENGINE, REMOVAL AND

INSTALLATION > INSTALLATION > 2.0L TURBO DIESEL
Fig 1: Crossmember, Support Rod & Fasteners

5. Install the crossmember (1a) with the aid of the platform (1b) and by a second operator.
6. Tighten the screws (2a) securing the crossmember (1a) of the car, without tightening; their final
tighten will be carried out in the following steps for the bumper installation.
7. Lift the engine hood and support with the hood support rod (3a).
Fig 2: Washer Fluid Reservoir, Crossmember, Rivet, Retainers, Wiring & Connectors
8. Working behind the right front headlamp compartment, install the A/C line and secure with the
retaining clip.
9. Working behind the windshield wiper fluid reservoir, disconnect the cable end of the mass of
the electric wiring, then tighten the nut.
10. Connect the electrical connections (1a, 1b).
11. Secure the retainers (2b) of the electrical wiring (2c) to the crossmember (2a).
12. Install the rivet (3a) securing the front of the washer fluid reservoir (3b).
Fig 3: Coolant Tubing & Clamps
13. Working on the upper left side of the radiator, connect the radiator inlet pipe quick coupling
then engage the retaining clip.
14. Secure engine coolant tubing (1b) to the clamps (1a).

Fig 4: Coolant Reservoir & Retainers
15. Place the engine coolant reservoir (1a) onto the lower retainer.
16. Slide in the direction of the arrow brackets (2a) of the reservoir (1a), by engaging the retainers
(2b), then engage the retainers (2c).
Fig 5: Intercooler Pipe, Quick Coupling & Clip
17. Working on the lower left side of the radiator, connect the quick coupling (1b) of the intercooler
pipe (1c), then securing the retaining clip (1a).
Fig 6: Engine Coolant Pipe, Intercooler Radiator Inlet Pipe, Coupling, Retainer & Clamp
18. Working on the lower right side of the radiator, connect the quick coupling (1b) of the engine
coolant pipe (1c) then secure the retaining clip (1a).
19. Connect the intercooler radiator inlet pipe (2b) secure the clamp (2a).
Fig 7: A/C Lines & Clamps
20. Working on the right side of the front-end, secure the clamps (1a) to the A/C lines (1b).
21. Secure the electrical wiring bracket (2a).

Fig 8: A/C Lines, Fittings & Screws
NOTE:
Replace the ring O-ring seals. Use only rings seal washer with part HNBR
elastomeric material resistant to refrigerant R1234yf. The use of rings seal washer
with other elastomeric material is liable to have serious losses of refrigerant from
the air conditioner.
22. Connect the fittings (1a) and (1b) of the condenser lines (1c). Then tighten the screws (first)
and tighten them to the to the proper specification. Refer to SPECIFICATIONS .
Fig 9: Automatic Transmission Oil Cooler Lines, Clamps & Clips
23. Connect the automatic transmission oil lines (1a) to fittings (1b) of the radiator (1c) then
engage the retaining clips (1d).
24. Close the retainer clips (2a) on the automatic transmission oil lines (1a).
Fig 10: Air Duct, Seats, Retainers & Screws
25. Place the air cooler (1a) and secure the retainers (1b) in the seats (1c).
26. Tighten the screws (2a) of the lower air duct (1a).
27. Place the bumper (1a) and tighten the three nuts (1b).
28. Install the screws (2a) securing the bumper (1a), without tightening.
29. Check the correct position of the crossmember (3a), then tighten the screws (2a) and screws
(3b) to the proper specification. Refer to SPECIFICATIONS .
30. Install the cool air inlet to the air filter box, then tighten the nut.
.
36. Check the oil level of the automatic transmission.

INSTALLATION > INSTALLATION > 2.4L MULTIAIR2
Fig 1: Energy Absorbers, Nuts & Bolts

5. Position the energy absorbers into place, the left and right (1a) and tighten the nuts (1b) to the
6. Tighten the screws (2) attaching the crossmember to the left and right side.
Fig 2: Support Bracket & Bolt
7. Put into place the support brackets (1) and tighten the screws to the proper specification.
Refer to SPECIFICATIONS .
Fig 3: Bumper, Nuts & Bolts
8. Secure the wiring retaining clips to the crossmember.
9. Install the rivet attaching the washer fluid reservoir.
10. Connect the water supply quick coupling sleeve to the radiator.
11. Connect the front airbag sensors electrical connections of the left and right side.
12. Secure the coolant conditioner discharge / charge pipe in the spring retainer.
13. Connect the electrical connections of the resistor and the electric fan and engage the wiring in
the retaining clips.
14. Connect the water outlet quick coupling sleeve from the radiator.
15. Connect the discharge and return to automatic transmission oil cooler and engage the retaining
clips
16. Connect the supply and return lines from the air conditioner condenser and tighten the screws.
17. Put into place the bumper (1a) and tighten the screws (1b) to the proper specification, then
tighten the nuts (1c). Refer to SPECIFICATIONS .
18. Tighten the cold air mounting nut socket to the crossmember.
.
24. Install the engine cover. Refer to COVER, ENGINE, REMOVAL AND INSTALLATION .
25. Install the belly pan. Refer to BELLY PAN, REMOVAL AND INSTALLATION .
EXTERIOR > DOOR, FUEL FILL > REMOVAL AND INSTALLATION > REMOVAL AND
Fig 1: Fuel Filler Door, Guides, Tab & Support
1. Open the fuel filler door (1).
2. Insert a screwdriver into the slot (2a) and press the inner end of the tab (2b) disengaging it
from holder (2c) of the door (2d).
3. Then remove the door (2d) from the support (3a) by pulling in the direction of the arrow,
disengaging the guides (3b).
EXTERIOR > DOOR, FUEL FILL > REMOVAL AND INSTALLATION > REMOVAL AND
1. Check that the door is not damaged.
2. Position the door onto the guides.
3. Slide the door onto the guides and seat the retainers fully.
4. Close the door.
EXTERIOR > FENDER, FRONT > REMOVAL AND INSTALLATION > REMOVAL AND
Fig 1: Front Fender Upper Bolts

3. Apply adhesive tape to the surrounding body panels to protect against damage.
4. Remove the three upper bolts (1) securing the fender.

Fig 2: Door Opening Bolt
5. Open the front side door.
6. Remove the bolt (1) from the door opening.

Fig 3: Wheel Housing Bolt
7. With the use of a rotating brush, remove the sealant protection.
8. Remove the bolt (1) from the wheel housing.

Fig 4: Lower Fender Bolts
9. Remove the two bolts (1) from the lower fender.

Fig 5: Fender & Support Bracket Lower Bolts
10. Remove the two lower bolts (1) securing the fender (2) to the support bracket.
11. Remove the fender from the vehicle.
EXTERIOR > FENDER, FRONT > REMOVAL AND INSTALLATION > REMOVAL AND
Fig 1: Front Fender
1. Inspect the fender to be certain there is no damage.
2. Remove any sealant from the body and fender.
3. Restore any sealant from the body and fender.
4. Position the fender on the vehicle and loosely install the bolts.
5. Check the alignment of the fender to the door and the hood.
6. Tighten the fender bolts securely.
EXTERIOR > GRILLE > REMOVAL AND INSTALLATION > REMOVAL AND
Fig 1: Grille, Retainers & Screws
3. Remove the screws (1a), release the retainers (1b) and remove the grille (1c).
EXTERIOR > GRILLE > REMOVAL AND INSTALLATION > REMOVAL AND
1. Make sure the grille is not damaged.

2. Position the grille back into place and seat the retainers fully.
3. Install the screws.
EXTERIOR > HOUSING, FUEL FILL > REMOVAL AND INSTALLATION > REMOVAL
Fig 1: Fuel Filler Housing, Tube & Retainers
2. Remove the rear wheelhouse splash shield. Refer to SHIELD, SPLASH, REAR
WHEELHOUSE, REMOVAL AND INSTALLATION .
3. Remove the fuel filler door. Refer to DOOR, FUEL FILL, REMOVAL AND INSTALLATION .
4. Working from the inside of the wheel arch release the fuel filler tube (1a) by releasing the
retainers (1b).
5. Release the retainers (2a) and then remove the fuel filler housing (2b) complete with drainage
tube.
EXTERIOR > HOUSING, FUEL FILL > REMOVAL AND INSTALLATION > REMOVAL
1. Fit the housing on the fuel filler tube engaging the retaining clips.
2. Position the housing into the sheet metal and seat the retainers fully.
3. Tighten the fuel filler tube screw.
4. Install the fuel filler door. Refer to DOOR, FUEL FILL, REMOVAL AND INSTALLATION .
5. Install the rear wheelhouse splash shield. Refer to SHIELD, SPLASH, REAR WHEELHOUSE,
EXTERIOR > MIRROR, OUTSIDE REARVIEW > REMOVAL AND INSTALLATION >
Fig 1: Switch Unit, Clips & Connectors
1. disconnect battery
2. Use the suitable tool to pry up the switch unit (1a) from its housing, releasing the retaining clips
(1b).
3. Disconnect the electrical connections (2a, 2b).
4. Remove the switch unit.

Fig 2: Wiring Retainer & Connector
5. Working from inside the switch unit compartment, release the wiring retainer (1a) and
disconnect the electrical connection of the door window (1b).
Fig 3: Door Mirror & Retainers
6. Use a suitable tool #1878077000 to pry up the molding of the base securing the door mirror
(1a), releasing the retainers (1b).
Fig 4: Door Mirror & Screws
7. Undo the screws (1a) and move the door mirror (1b) aside.
Fig 5: Door Mirror, Wiring & Bulkhead
8. Pry up the bulkhead (1a) and extract the wiring section (1b).
9. Release the sensor from the wiring and keep the door mirror.
EXTERIOR > MIRROR, OUTSIDE REARVIEW > REMOVAL AND INSTALLATION >
1. Check that the rear view mirror is not damaged.
2. If removed position the rearview mirror cover back and seat the tabs on the retainers fully.
3. Fit the bulkhead.
4. Fit the wiring with the sensor.
5. Place the door mirror in its housing.
6. Tighten the screws securing the door mirror.
8. Working from inside the switch unit compartment, secure the wiring retainer.
9. Connect the switch unit electrical connections.
10. Place the switch unit in position and attach the retainers.
EXTERIOR > RACK, LUGGAGE > REMOVAL AND INSTALLATION > REMOVAL AND
Fig 1: Caps & Screws
1. Remove the caps (1).
2. Remove the screws (2).

Fig 2: Rack Rail, Caps & Screws
3. Remove the caps (1).
4. Remove the screws (2) and remove the rack rail (2b).
EXTERIOR > RACK, LUGGAGE > REMOVAL AND INSTALLATION > REMOVAL AND
1. Check that the roof rack rails are not damaged, replace the parts as necessary.
2. Install the roof rack rail.
3. Apply suitable thread locker to the screws and install the screws.
4. Install the screw caps.
EXTERIOR > SHIELD, SPLASH, FRONT WHEELHOUSE > REMOVAL AND

Fig 1: Front Wheelhouse Splash Shield & Fasteners
2. Remove the front wheel. Refer to REMOVAL AND INSTALLATION .
3. Undo the screws (1a) and nuts (1b).
4. Use the special tool #1878077000 to pry up the button (2a) and remove the additional wheel
liner (2b) prying it up from its housing.
EXTERIOR > SHIELD, SPLASH, FRONT WHEELHOUSE > REMOVAL AND
1. Position the splash shield back onto the vehicle and install the screws and nuts.
EXTERIOR > SHIELD, SPLASH, REAR WHEELHOUSE > REMOVAL AND

Fig 1: Rear Wheelhouse Splash Shield & Fasteners
2. Remove the wheel. Refer to REMOVAL AND INSTALLATION .
3. Remove the screws (1a) and nuts (1b).
4. Using trim stick (special tool #C-4755, Trim Stick) or equivalent, remove the push pin fasteners
(1c).
5. Remove the shield (2).

EXTERIOR > SHIELD, SPLASH, REAR WHEELHOUSE > REMOVAL AND
1. Install the splash shield and install the push pin fasteners.
2. Install the screws and nuts.
3. Install the wheel. Refer to REMOVAL AND INSTALLATION .
HOOD > CABLE, HOOD RELEASE > REMOVAL AND INSTALLATION > REMOVAL AND
NOTE:
Take note of the cable routing for correct installation.

Fig 1: Hood Latch Release Assembly & Screw
1. Remove the hood latch release cable from the hood latch.
2. Loosen the cowl top panel as needed to unclip the hood latch release cable. Refer to COVER,
COWL PANEL, REMOVAL AND INSTALLATION .
3. Unclip the hood latch release cable from the body.
4. Remove the driver side cowl trim panel. Refer to PANEL, COWL TRIM, REMOVAL AND
INSTALLATION .
6. Remove the hood latch release cable grommet from the dash panel and remove the hood latch
release assembly (1).
HOOD > CABLE, HOOD RELEASE > REMOVAL AND INSTALLATION > REMOVAL AND
Fig 1: Hood Latch Release Assembly & Screw
1. Install the hood latch release cable through the hole in the dash panel and seat the hood latch
release cable grommet.
2. Position the hood latch release assembly (1) and install the screw (2). Tighten the screw
securely.
3. Install the driver side cowl trim panel. Refer to PANEL, COWL TRIM, REMOVAL AND
INSTALLATION .
4. Route the hood latch release cable and clip into place.
5. Install the cowl top panel. Refer to COVER, COWL PANEL, REMOVAL AND INSTALLATION .
6. Install the cable end into the hood latch.

HOOD > HINGE, HOOD > REMOVAL AND INSTALLATION > REMOVAL AND
Fig 1: Hood, Hinge & Nuts
1. Open and support the hood (1c) with a suitable prop or block.
2. Remove the cowl top panel. Refer to COVER, COWL PANEL, REMOVAL AND
INSTALLATION .
3. Using a grease pencil or equivalent, mark the position of the hood hinge (1b) to aid in
installation.
4. With the help of an assistant holding the hood, remove the hinge nuts (1a) from the hood.
5. Remove the nuts from the body and remove the hood hinge.
HOOD > HINGE, HOOD > REMOVAL AND INSTALLATION > REMOVAL AND
1. With the help of an assistant, position the hood hinge (1b) onto the body and loosely install the
nuts.
2. Align the hood hinge with the reference mark made previously and tighten the hood hinge to
body nuts to the proper specification. Refer to SPECIFICATIONS .
3. Position the hood to the hood hinge and loosely install the nuts (1a).
4. Align the hood hinge with the reference mark made previously and tighten the hood hinge to
hood nuts to the proper specification. Refer to SPECIFICATIONS .
5. Verify proper hood latch operation and fit of hood. Adjust if necessary.
HOOD > HOOD > REMOVAL AND INSTALLATION > REMOVAL AND INSTALLATION >
REMOVAL
Fig 1: Silencer, Tabs & Push Fasteners
1. Open the hood and remove the push fasteners (1).
2. Release the tabs (2a) and remove the silencer (2b).

Fig 2: Windshield Washer Hose & Connectors
3. Disconnect the windshield washer hose from the connectors (2).
4. Unclip the windshield washer hose (1a) from the hood and position aside.
5. Using a grease pencil or equivalent, mark the position of the hood hinge (1b) to aid in
installation.
6. With the help of an assistant holding the hood (1c), remove the hinge nuts (1a) from the hood
and remove the hood.
HOOD > HOOD > REMOVAL AND INSTALLATION > REMOVAL AND INSTALLATION >
INSTALLATION
NOTE:
The Vehicle Emission Control Information (VECI) label(s) must be in place for the life of the
vehicle. When replacing the component to which the VECI label is adhered, a new VECI
label must also be adhered to the new component.
1. With assistance from a helper, position the hood (1c) onto the hood hinges (1b) and loosely
install the nuts (1a).
2. Align the hood with the reference mark made previously and tighten the hood hinge to hood
nuts to the proper specification. Refer to SPECIFICATIONS .
Fig 2: Windshield Washer Hose & Connectors
3. Route and clip the windshield washer hose (1a) to the hood.
4. Connect the windshield washer hose to the connectors (2).
Fig 3: Silencer, Tabs & Push Fasteners
6. Position the silencer (2b) and then install the push fasteners (1).
HOOD > LATCH, HOOD > REMOVAL AND INSTALLATION > REMOVAL AND
1. Using a grease pencil or equivalent, mark the position of the hood latch to aid in installation.
2. Remove the fasteners from the hood latch.
3. Turn the hood latch over and remove the hood latch release cable from the hood latch.
HOOD > LATCH, HOOD > REMOVAL AND INSTALLATION > REMOVAL AND
1. Install the hood latch release cable into the hood latch.
2. Position the hood latch and loosely install the bolts.
3. Align the hood latch with the reference mark made previously and tighten the hood latch bolts
to the proper specification. Refer to SPECIFICATIONS .
INSTRUMENT PANEL > BEZEL, INSTRUMENT CLUSTER > REMOVAL AND

Fig 1: Instrument Cluster Bezel Covers & Screws

1. Lower the steering column to the lowest position and telescope the steering wheel full
rearward.
2. Remove the screw covers (1a) and the screws (1b).

Fig 2: Instrument Cluster Bezel
3. Using a trim stick or equivalent, release the instrument cluster bezel (1a) and remove.
INSTRUMENT PANEL > BEZEL, INSTRUMENT CLUSTER > REMOVAL AND

Fig 1: Instrument Cluster Bezel
1. Position the instrument cluster bezel (1a) and hand tap to engage the retaining tabs (1b).
Fig 2: Instrument Cluster Bezel Covers & Screws
2. Install the screws (1b) and tighten securely. Install the screw covers (1a).
INSTRUMENT PANEL > CARRIER, INSTRUMENT PANEL > REMOVAL AND

Fig 1: Bolt In Engine Compartment
1. Remove the front doors. Refer to DOOR, REMOVAL AND INSTALLATION .
2. Remove the instrument panel cover. Refer to COVER, INSTRUMENT PANEL, REMOVAL AND
INSTALLATION .
3. Remove the cowl side trim panels. Refer to PANEL, COWL TRIM, REMOVAL AND
INSTALLATION .
4. In the engine compartment, remove the bolt (1).

Fig 2: Ground Straps & Connectors
5. On the left side of vehicle, remove the nut and the ground strap (1a).
6. On the right side of vehicle, remove the nut and the ground strap (1b).
7. Disconnect the wire harness connectors (2c and 2d).
8. Disconnect the wire harness connector (2a) from the airbag control module.
Fig 3: BCM Wire Harness Connectors
9. Disconnect the wire harness connectors (1) from the BCM.

Fig 4: Area To Cut Carpet & Wire Harness
10. Cut the carpet along the line (1).
11. Unclip the wire harness (2) from the body.

Fig 5: Instrument Panel Brackets Bolts
12. Remove the bolts (1) from the instrument panel brackets.
Fig 6: Instrument Panel Carrier & Bolts
13. Remove the bolts (1a) that secure the HVAC housing to the instrument panel carrier (1b).
Fig 7: Positioning Instrument Panel Carrier To Body
14. Using a paint marker, mark (2) the position of the sides of the instrument panel carrier (3) to
the body (1) to aid during installation.
15. Using a pocket ruler (4) or feeler gauge (5), measure and record the distance (6) from the
instrument panel carrier to the body (1) on both sides of the vehicle, to aid during installation.
Fig 8: Bolts & Covers
16. Remove the bolt hole covers (1a) on both side of the vehicle.
17. With the help of an assistant, one person on each side of the vehicle, loosen the bolts (1b)
from both ends of the instrument panel carrier.
18. Carefully roll the instrument panel carrier slightly rearward to make sure there is nothing
attached, then remove.
INSTRUMENT PANEL > CARRIER, INSTRUMENT PANEL > REMOVAL AND

NOTE:
Installation of the instrument panel carrier will require three people. One on each end and
one in the middle.
Fig 1: Centering Bushings
1. Verify that the four centering bushings (1) are fully screwed in and rotate freely.
NOTE:
The resetting of the centering bushings allows the instrument panel carrier to be
installed properly using the measurements taken during removal.
NOTE:
Inspect the centering bushings and replace if necessary.
2. Position the instrument panel carrier into the vehicle.
NOTE:
Make sure that all wiring harnesses are routed properly and are not pinched when
installing the instrument panel carrier.
Fig 2: Bolts & Covers
3. Start the bolts (1b) on both sides of the vehicle. Do not tighten the bolt until the instrument
panel carrier is positioned properly.
Fig 3: Positioning Instrument Panel Carrier To Body
4. Using a pocket ruler (4) or feeler gauge (5), position the instrument panel carrier (3) to the
body (1) as noted during removal.
5. Align the marks (2) made during removal.
6. Tighten the carrier bolts gradually. This will allow the centering bushings to recover the
clearances between the instrument panel carrier and the body correctly.
7. Once all four bolts are secured, tighten the instrument panel carrier bolts to the proper
specification. Refer to SPECIFICATIONS .
Fig 4: Instrument Panel Carrier & Bolts
8. Install the bolts (1a) that secure the instrument panel carrier (1b) to the HVAC housing and
tighten securely.
Fig 5: Instrument Panel Brackets Bolts
9. Install the bolts (1) at the center of the instrument panel and tighten securely.
Fig 6: Area To Cut Carpet & Wire Harness
10. Route and clip the wire harness (2) to the body.
Fig 7: BCM Wire Harness Connectors
11. Connect the wire harness connectors (1) to the Body Control Module.
Fig 8: Ground Straps & Connectors
12. Connect the wiring harness connector (2a) to the airbag control module.
13. On the right side of vehicle, install the ground strap (1b) and nut. Tighten securely.
14. Connect the wire harness connectors (2c and 2d).
15. On the left side of vehicle, install the ground strap (1a) and nut. Tighten securely.
Fig 9: Bolt In Engine Compartment
16. In the engine compartment, install the bolt (1) and tighten securely.
17. Install the cowl side trim panels. Refer to PANEL, COWL TRIM, REMOVAL AND
INSTALLATION .
18. Install the instrument panel cover. Refer to COVER, INSTRUMENT PANEL, REMOVAL AND
INSTALLATION .
19. Install the front doors. Refer to DOOR, REMOVAL AND INSTALLATION .
INSTRUMENT PANEL > COVER, INSTRUMENT PANEL > REMOVAL AND

WARNING:
WARNING:
To avoid serious or fatal injury when removing a deployed airbag, rubber gloves, eye
protection, and a long-sleeved shirt should be worn. There may be deposits on the airbag
unit and other interior surfaces. In large doses, these deposits may cause irritation to the
skin and eyes.
WARNING:
To avoid serious or fatal injury, use extreme care to prevent any foreign material from
entering the passenger airbag, or becoming entrapped between the passenger airbag
cushion and the instrument panel top pad. Failure to observe this warning could result in
occupant injuries upon airbag deployment.
Fig 1: Wire Harness & Screws

1. Remove the instrument cluster. Refer to REMOVAL AND INSTALLATION .
2. Remove the clockspring. Refer to CLOCKSPRING, REMOVAL AND INSTALLATION .
3. Remove the floor console. Refer to CONSOLE, FLOOR, REMOVAL AND INSTALLATION .
4. Remove the switch pod. Refer to POD, SWITCH, REMOVAL AND INSTALLATION .
6. Remove the A/C and Heater controls. Refer to CONTROL, A/C AND HEATER, REMOVAL AND
INSTALLATION .
7. Remove the center air outlet and right side air outlet. Refer to OUTLET, AIR, REMOVAL AND
INSTALLATION .
8. Remove the screws (2a) and unclip the wire harness (1a and 1b).
Fig 2: Wire Harness Clips & Screws
9. Remove the screws (1a and 2a).
10. Unclip the wire harness (2c and 3a).

Fig 3: Passenger Airbag Bolts, Connector & Screws
11. Remove the screws (1a and 1b).
12. Remove the two passenger airbag bolts (3a).
13. Disconnect the passenger airbag wire harness connector (2).

Fig 4: Instrument Panel Cover & Clips
14. Release the retaining clips (1b) and carefully remove the instrument panel cover (1a) from the
instrument panel carrier.
INSTRUMENT PANEL > COVER, INSTRUMENT PANEL > REMOVAL AND

WARNING:
WARNING:
skin and eyes.
WARNING:
entering the passenger airbag, or becoming entrapped between the passenger airbag
cushion and the instrument panel top pad. Failure to observe this warning could result in
occupant injuries upon airbag deployment.
Fig 1: Instrument Panel Cover & Clips
1. Carefully position the instrument panel cover (1a) onto the instrument panel carrier and engage
the retaining clips (1b).
2. Route the wire harness for the Radio, A/C controls, switch pod and instrument cluster through
the instrument panel cover.
Fig 2: Passenger Airbag Bolts, Connector & Screws
3. Install the screws (1a and 1b) and tighten securely.
4. Install the two passenger airbag bolts (3a) and tighten to the proper specification. Refer to
SPECIFICATIONS .
5. Connect the passenger airbag wire harness connectors (2).

Fig 3: Wire Harness Clips & Screws
6. Install the screws (1a and 2a) and tighten securely.
7. Clip the wire harness (2c and 3a) to the instrument panel cover.
Fig 4: Wire Harness & Screws
8. Install the screws (2a) and tighten securely.
9. Clip the wire harness (1a and 1b) to the instrument panel cover.
10. Install the center air outlet and right side air outlet. Refer to OUTLET, AIR, REMOVAL AND
INSTALLATION .
11. Install the A/C and Heater controls. Refer to CONTROL, A/C AND HEATER, REMOVAL AND
INSTALLATION .
13. Install the switch pod. Refer to POD, SWITCH, REMOVAL AND INSTALLATION .
14. Install the floor console. Refer to CONSOLE, FLOOR, REMOVAL AND INSTALLATION .
15. Install the clockspring. Refer to CLOCKSPRING, REMOVAL AND INSTALLATION .
16. Install the instrument cluster. Refer to REMOVAL AND INSTALLATION .
17. Do not reconnect the negative cable to the battery at this time. The Supplemental Restraint
System (SRS) Verification Test procedure should be performed following service of any SRS
component. Refer to SUPPLEMENTAL RESTRAINT SYSTEM VERIFICATION TEST .
INSTRUMENT PANEL > COVER, STEERING COLUMN OPENING > REMOVAL AND
Fig 1: Instrument Panel Side Cover, Clips & Screw
1. Using a trim stick or equivalent, remove the instrument panel side cover (1b).
2. Remove the screw (1c).

Fig 2: Steering Column Opening Cover, Clips & Screws
4. Using a trim stick or equivalent, remove the steering column opening cover (2a).
INSTRUMENT PANEL > COVER, STEERING COLUMN OPENING > REMOVAL AND
Fig 1: Steering Column Opening Cover, Clips & Screws
1. Install the steering column opening cover (2a) onto the instrument panel and hand tap to
engage the retaining clips (2b).

Fig 2: Instrument Panel Side Cover, Clips & Screw
3. Install the screws (1c) and tighten securely.
4. Position the instrument panel side cover (1b) and hand tap to engage the retaining clips (1a).
INSTRUMENT PANEL > GLOVE BOX, INSTRUMENT PANEL > REMOVAL AND
Fig 1: Instrument Panel Side Cover, Silencer Panel & Screws
1. Using a trim stick or equivalent, remove the instrument panel side cover (1b).
2. Remove the screw (1c).
3. Lower the silencer panel (2a) and remove the screws (2b) at the bottom of the glove box.
Fig 2: Glove Box Door & Screws
4. Open the glove box door (1a) and remove the screws (1b).
Fig 3: Glove Box Assembly, Clips & Connector
5. Using a trim stick or equivalent, remove the glove box assembly (1a) and disconnect the wire
INSTRUMENT PANEL > GLOVE BOX, INSTRUMENT PANEL > REMOVAL AND
Fig 1: Glove Box Assembly, Clips & Connector
1. Position the glove box assembly (1a) near the instrument panel and connect the wire harness
connector (2).
2. Position the glove box assembly into the instrument panel and hand tap to engage the retaining
clips (1b).
Fig 2: Glove Box Door & Screws
3. Open the glove box door (1a) and install the screws (1b). Tighten the screws securely.
Fig 3: Instrument Panel Side Cover, Silencer Panel & Screws
4. Install the screws (2b) and tighten securely.
5. Secure the silencer panel (2a) into place.
6. Install the screw (1c) and tighten securely.
7. Position the instrument panel side cover (1b) and hand tap to engage.
INTERIOR > CONSOLE, FLOOR > REMOVAL AND INSTALLATION > REMOVAL AND
Fig 1: Floor Console Side Panel
1. Remove the front floor console side panels (1b).

Fig 2: Clips, Boot & Retainers
2. Using a trim stick or equivalent, lift the shifter bezel (1b).
3. Disconnect the wire harness connector from the shifter bezel.
4. Release the clips (2a and 2b) and release the shifter boot (2c) from the shifter bezel.
NOTE:
It is not necessary to remove the shifter boot or shifter handle from vehicle.
Fig 3: Floor Console Screws
5. Remove the screws (1) on each side at the front of the floor console.
Fig 4: Cup Holder Liner & Screw
6. Remove the cup holder liner (1a) and remove the screw (1b).
Fig 5: Cover & Bolt
7. Move the front seats to the full forward position.
8. Remove the screw covers (1) and the bolts (2) on both side of the rear floor console.
Fig 6: Floor Console Rear Cover, Retainers & Connector
9. Using a trim stick or equivalent, remove the rear floor console cover (1b) and disconnect the
wire harness connector (2).
Fig 7: Rear Floor Console & Connectors
10. Disconnect the wire harness connectors (1a and 1b).
11. Pull the rear floor console slightly rearward and remove.
Fig 8: Front Floor Console Bolts
12. Remove the bolts (1) on both sides of the front floor console.
Fig 9: Front Floor Console & Connectors
13. Pull the front floor console (2) slightly rearward and disconnect the wire harness connectors
(1a, 1b, 1c).
14. Remove the front floor console.

INTERIOR > CONSOLE, FLOOR > REMOVAL AND INSTALLATION > REMOVAL AND
Fig 1: Front Floor Console & Connectors
1. Position the front floor console (2) and connect the wire harness connectors.
Fig 2: Front Floor Console Bolts
2. Install the bolts (1) and tighten securely.

Fig 3: Rear Floor Console & Connectors
3. Position the rear floor console (2) into the vehicle and connect the wire harness connectors
(1a and 1b).
4. Connect the wire harness connector (2) and install the rear floor console cover (1b).
Fig 5: Cover & Bolt
5. Install the screws (2) and tighten securely. Install the screw covers (1).
Fig 6: Cup Holder Liner & Screw
6. Install the screw (1b) and tighten securely. Install the cup holder liner (1a).
Fig 7: Floor Console Screws
7. Install the screws (1) on each side at the front of the floor console and tighten securely.
Fig 8: Floor Console Side Panel
8. Position the front floor console side panels (1b) and hand tap into place.
Fig 9: Clips, Boot & Retainers
9. Align the clips (2a and 2b) to the shifter bezel and snap into place.
10. Connect the wire harness connector to the shifter bezel.
11. Position the shifter bezel (1b) onto the floor console and hand tap into place.
INTERIOR > CONSOLE, OVERHEAD, FRONT > REMOVAL AND INSTALLATION >
Fig 1: Overhead Console, Handsfree Microphone, Protective Wrap & Retainers
2. Using a trim stick or equivalent, release the retaining clips (1b) and lower the overhead
console (1a).
3. Disconnect the wire harness connectors (2b and 2c) and remove.
INTERIOR > CONSOLE, OVERHEAD, FRONT > REMOVAL AND INSTALLATION >
Fig 1: Overhead Console, Handsfree Microphone, Protective Wrap & Retainers

1. Connect the wire harness connectors (2b and 2c).
2. Align the retaining clips (1b and 1c) and push firmly and evenly on the sides of the overhead
console (1a) to engage the retaining clips.
INTERIOR > HEADLINER > REMOVAL AND INSTALLATION > REMOVAL AND
NOTE:
In the event the headliner is damaged or creased during removal, it will need to be replaced
with a new headliner.
Use clean gloves or make sure your hands are clean before removing the headliner.
Fig 1: Grab Handles & Screw Covers
2. Remove the A-pillar trim panels. Refer to PANEL, A-PILLAR TRIM, REMOVAL AND
INSTALLATION .
3. Remove the overhead console. Refer to CONSOLE, OVERHEAD, FRONT, REMOVAL AND
INSTALLATION .
4. Open the screw covers (2a). Remove the screws and the grab handles.
Fig 2: Visor, Support, Screws & Covers
5. Using a small flat bladed tool, open the screw cover (2) and remove the screw (3). Remove
both visors (1a).
6. Using a small flat bladed tool, open the screw cover (1b) and remove the screw (4a). Remove
both visor supports (4b).
7. Remove the rearview mirror. Refer to MIRROR, REARVIEW, REMOVAL AND INSTALLATION .
8. Remove the upper B-pillar trim panels. Refer to PANEL, B-PILLAR TRIM, UPPER, REMOVAL
AND INSTALLATION .
9. Remove the upper quarter trim panels. Refer to PANEL, QUARTER TRIM, REMOVAL AND
INSTALLATION .
10. Loosen the weatherstrip at the top of the door openings.

Fig 3: Headliner & Push Fasteners

11. Release the push fasteners (1a) at the front of the headliner.
12. Release the push fasteners (1b) at the rear of the headliner and remove the headliner through
the liftgate opening.
INTERIOR > HEADLINER > REMOVAL AND INSTALLATION > REMOVAL AND
NOTE:
In the event the headliner is damaged or creased during installation, it will need to be
replaced with a new headliner.
Use clean gloves or make sure your hands are clean before removing the headliner.
Fig 1: Headliner & Push Fasteners
1. Position the headliner into the vehicle and engage the push fasteners (1a and 1b).
2. Install the A-pillar trim panels. Refer to PANEL, A-PILLAR TRIM, REMOVAL AND
INSTALLATION .
3. Install the rearview mirror. Refer to MIRROR, REARVIEW, REMOVAL AND INSTALLATION .
4. Install the upper B-pillar trim panels. Refer to PANEL, B-PILLAR TRIM, UPPER, REMOVAL
AND INSTALLATION .
5. Install the upper quarter trim panels. Refer to PANEL, QUARTER TRIM, REMOVAL AND
INSTALLATION .
6. Install the overhead console. Refer to CONSOLE, OVERHEAD, FRONT, REMOVAL AND
INSTALLATION .
Fig 2: Visor, Support, Screws & Covers

7. Install the visor supports (4b) and tighten the screws securely.
8. Install the visors (1a) and tighten the screws securely.
9. Install the weatherstrip at the top of the door openings.

Fig 3: Grab Handles & Screw Covers
10. Position the grab handles (1) and install the screws. Tighten the screws securely then install
the screw covers (2a).
INTERIOR > MIRROR, REARVIEW > REMOVAL AND INSTALLATION > REMOVAL AND
Fig 1: Mirror Trim, Tabs & Clips

2. Using a small flat bladed tool, release the clips on each side of the upper mirror trim (1a) and
remove.
3. Using a trim stick or equivalent, release the clips (2b) and remove the lower mirror trim (2a).
Fig 2: Mirror, Base, Button & Connector
4. Disconnect the wire harness connector (1) from the rear view mirror.
5. Grasp the rear view mirror by the base (2a) and rotate it clockwise approximately 90 degrees
and remove.
INTERIOR > MIRROR, REARVIEW > REMOVAL AND INSTALLATION > REMOVAL AND
Fig 1: Mirror, Base, Button & Connector

1. Place the rear view mirror (2a) onto the mirror button (2c).
2. Grasp the mirror by the base and rotate it approximately 90 degrees counter-clockwise until
the mirror locks into place.
NOTE:
The mirror must be fully seated onto the button before rotating.
3. Connect the wire harness connector (1).

Fig 2: Mirror Trim, Tabs & Clips
4. Install the lower mirror trim (2a) from the bottom. Make sure the tabs (2b) engage fully.
5. Insert the bottom of the upper mirror trim (1a) and engage the tabs (1b).
INTERIOR > PANEL, A-PILLAR TRIM > REMOVAL AND INSTALLATION > REMOVAL
Fig 1: Instrument Panel Side Cover & Cowl Side Upper Cover
1. Using a trim stick or equivalent, remove the instrument panel side cover (1a).
2. Loosen the door opening weatherstrip from the body.
3. Using a trim stick or equivalent, remove the cowl side upper cover (1b).
Fig 2: A-Pillar Trim Panel, Tether & Lock
4. By hand, pull inward at the top of the A-pillar trim panel (1b) and release it from the body.
5. Using a flat bladed tool, remove the tether lock (2a).
6. Using a flat bladed tool, press the tab to disengage the tether (2b) and slide it out of A-pillar
trim panel.
7. Rotate the top of the A-pillar towards the center of the vehicle, then lift upward to remove it
from the instrument panel.
INTERIOR > PANEL, A-PILLAR TRIM > REMOVAL AND INSTALLATION > REMOVAL
Fig 1: A-Pillar Trim Panel, Tether & Lock

1. Position the bottom of the A-pillar trim panel (1b) into the top of the instrument panel.
2. Insert the tether (2b) into the A-pillar trim panel. Make sure the tab is fully engaged, and the
tether is secured properly.
3. Install the tether lock (2a).
4. Align the retaining clips and hand tap to engage.


5. Install the cowl side upper cover (1b).
6. Install the weatherstrip seal to the body.
7. Install the instrument panel side cover (1a).
INTERIOR > PANEL, B-PILLAR TRIM, LOWER > REMOVAL AND INSTALLATION >
Fig 1: Center B-Pillar Trim Panel & Clips
1. Remove the cowl side trim panel. Refer to PANEL, COWL TRIM, REMOVAL AND
INSTALLATION .
2. Remove the rear seat cushion. Refer to SEAT CUSHION, REMOVAL AND INSTALLATION .
3. Using a trim tool or equivalent, remove the center B-pillar trim panel (1b).
Fig 2: Lower B-Pillar Trim Panel & Push Fasteners
4. Using a trim tool or equivalent, remove the push fasteners (1a) and the lower B-pillar trim panel
(1b).
INTERIOR > PANEL, B-PILLAR TRIM, LOWER > REMOVAL AND INSTALLATION >
Fig 1: Lower B-Pillar Trim Panel & Push Fasteners
1. Position the lower B-pillar trim panel (1b) and hand tap into place.
2. Position the lower B-pillar trim panel (1b) and hand tap into place.
3. Install the cowl side trim panel. Refer to PANEL, COWL TRIM, REMOVAL AND
INSTALLATION .
4. Install the rear seat cushion. Refer to SEAT CUSHION, REMOVAL AND INSTALLATION .
INTERIOR > PANEL, B-PILLAR TRIM, UPPER > REMOVAL AND INSTALLATION >
1. Using a trim tool or equivalent, remove the center B-pillar trim panel (1b).
Fig 2: Upper B-Pillar Trim Panel, Upper Seat Belt Turning Loop, Cover & Screws
2. Remove the screw cover (1a) and the screw (1b).
4. Move the seat belt height adjuster to the lowest position.
5. Remove the front seat upper seat belt turning loop (2b). Refer to RETRACTOR, SEAT BELT,
6. Starting at the bottom of the B-pillar trim panel, pull by hand to release the retaining clips and
remove.
INTERIOR > PANEL, B-PILLAR TRIM, UPPER > REMOVAL AND INSTALLATION >
Fig 1: Upper B-Pillar Trim Panel, Upper Seat Belt Turning Loop, Cover & Screws

1. Align the seat belt height adjuster and position the upper B-pillar trim panel (3b) onto the body.
Hand tap to engage the retaining clips.
2. Install the screw (1b) and screw cover (1a). Tighten the screw securely.
4. Install the front seat upper seat belt turning loop (2b). Refer to RETRACTOR, SEAT BELT,

5. Position the center B-pillar trim panel (1b) onto the body. Hand tap to engage the retaining clips
(1a).
INTERIOR > PANEL, COWL TRIM > REMOVAL AND INSTALLATION > REMOVAL AND

1. Using a trim stick or equivalent, remove the instrument panel side cover (1a).
2. Loosen the door opening weatherstrip from the body.
3. Using a trim stick or equivalent, remove the cowl side upper cover (1b).
Fig 2: Hood Release Handle
4. Using a trim stick or equivalent, remove the hood release handle (1).
Fig 3: Cowl Side Trim & Clips
5. Lift the cowl side trim (1b) at the rear, then pull rearward and remove.
INTERIOR > PANEL, COWL TRIM > REMOVAL AND INSTALLATION > REMOVAL AND
Fig 1: Cowl Side Trim & Clips
1. Install the cowl side trim (1a) at the front, then hand tap the rear to install the retaining clips.
Fig 2: Hood Release Handle
2. Install the hood release handle (1).

3. Install the cowl side upper cover (1b).
4. Install the weatherstrip seal to the body.
5. Install the instrument panel side cover (1a).

INTERIOR > PANEL, QUARTER TRIM > REMOVAL AND INSTALLATION > REMOVAL
Fig 1: Seat Belt & Lower Anchor Bolt
1. Remove the seat belt lower anchor bolt (1a).

Fig 2: Upper Quarter Trim Panel, Seat Belt Bezel, Retainers, Screws & Covers
2. Remove the screw covers (1a) then remove the screws (1b).
3. Using a trim stick or equivalent, remove the seat belt bezel (3a).
4. Loosen the liftgate weatherstrip.
5. Using a trim stick or equivalent, release the retainers (2b) and remove the upper quarter trim
panel (2a).
6. If removing the upper quarter trim panel completely, first remove the seat belt lower anchor
bolt.
8. Remove the liftgate sill plate. Refer to PLATE, SCUFF, LIFTGATE SILL, REMOVAL AND
INSTALLATION .
Fig 3: Lower Quarter Trim Panel, Cargo Hook, Screw, Bolt & Clips

9. Remove the screw (2a) securing the lower quarter trim panel (2c).
10. Remove the bolt (1b) and the cargo hook (1a).
11. Loosen the liftgate weatherstrip
12. Using a trim stick or equivalent, release the retaining clips (2b) and loosen the lower quarter
trim panel.
13. Disconnect the wire harness connectors and remove the lower quarter trim panel.
INTERIOR > PANEL, QUARTER TRIM > REMOVAL AND INSTALLATION > REMOVAL
Fig 1: Lower Quarter Trim Panel, Cargo Hook, Screw, Bolt & Clips
1. Position the lower quarter trim panel (2c) in the vehicle and connect the wire harness
connectors.
2. Hand tap the lower quarter trim panel to engage the retaining clips (2b).
3. Install the cargo hook (1a) and tighten the bolt (1b) securely.

Fig 2: Upper Quarter Trim Panel, Seat Belt Bezel, Retainers, Screws & Covers
5. Route the seat belt (3b) through the upper quarter trim panel.
6. Position the upper quarter trim panel (2a) and hand tap to engage the retaining clips (2b).
7. Install the screws (1b) and tighten securely. Install the screw covers (1a).
Fig 3: Seat Belt & Lower Anchor Bolt
8. Install the seat belt lower anchor bolt (1a). Refer to RETRACTOR, SEAT BELT, REMOVAL AND
INSTALLATION .
9. Install the liftgate sill plate. Refer to PLATE, SCUFF, LIFTGATE SILL, REMOVAL AND
INSTALLATION .
10. Install the liftgate weatherstrip.
INTERIOR > PLATE, SCUFF, LIFTGATE SILL > REMOVAL AND INSTALLATION >
Fig 1: Rear Cargo Covers
1. Remove the rear cargo covers (1a and 1b).

Fig 2: Liftgate Sill Plate, Screws & Covers
2. Remove the weatherstrip along the top of the liftgate sill plate.
3. Open the screw covers (1a) and remove the screws (1b).
4. Remove the screws (2a) and lift the liftgate sill plate (2b) and remove.
INTERIOR > PLATE, SCUFF, LIFTGATE SILL > REMOVAL AND INSTALLATION >
Fig 1: Liftgate Sill Plate, Screws & Covers
1. Position the liftgate sill plate (2b) and install the screws (2a). Tighten the screws securely.
2. Install the screws (1b) and tighten securely. Close the bolt covers (1a).
3. Install the weatherstrip along the top of the liftgate sill plate.
Fig 2: Rear Cargo Covers
4. Install the rear cargo covers (1a and 1b).
PAINT > SPECIFICATIONS > SPECIFICATIONS
Because of late model changes to the available paint colors for each vehicle the current color codes can
be found on the Vehicle Certification Label. Refer to DESCRIPTION .
EXTERIOR COLORS
EXTERIOR COLOR PAINT CODE
Black Clear Coat DX8
Solar/Detonator Yellow Clear Coat EYB (VR 178)
Sierra /Cosmos Blue JB4 (VR 364/B)
Mojave Sand/Mocha Latte KTA (VR 231/B)
Anvil Clear Coat LDS (VR385/A)
Commando Clear Coat LGH (VR 145/B)
Dune Clear Coat LTT
Omaha/Spritz Orange NKP (VR 562/A)
Colorado/Passion Red NRX (VR 176)
Glacier/Silver Grey Metallic NSN (VR 348)
Alpine White PWV (VR 296)
Carbon Black Metallic NXB (VR876/B)
INTERIOR COLORS
INTERIOR COLOR Order Code COLOR CODE
Bark Brown / Ski Grey TS GT5 / PS4
Black / Sandstorm XU LXH / LTU
Black X9 LXH
SEATS, FIRST ROW > WARNING > WARNING
WARNING:
During and following any seat belt or child restraint anchor service, carefully inspect all
seat belts, buckles, mounting hardware, retractors, tether straps, and anchors for
proper installation, operation, or damage. Replace any belt that is cut, frayed, or torn.
Straighten any belt that is twisted. Tighten any loose fasteners. Replace any belt that
has a damaged or inoperative buckle or retractor. Replace any belt that has a bent or
damaged latch plate or anchor plate. Replace any child restraint anchor or the unit to
which the anchor is integral that has been bent or damaged. Never attempt to repair a
seat belt or child restraint component. Always replace damaged or faulty seat belt and
child restraint components with the correct, new and unused replacement parts listed in
the FCA US LLC Mopar® parts catalog. Failure to follow these instructions may result
in personal injury or death.
On vehicles equipped with airbags, disable the supplemental restraint system before
attempting any steering wheel, steering column, airbag, occupant classification
system, seat belt tensioner, impact sensor, or instrument panel component diagnosis
or service. Refer to WARNING . Disconnect and isolate the battery negative (ground)
cable, then wait two minutes for the system capacitor to discharge before performing
further diagnosis or service. This is the only sure way to disable the supplemental
restraint system. Failure to take the proper precautions could result in accidental
airbag deployment. Failure to follow these instructions may result in personal injury or
death.
On vehicles equipped with airbags, before performing any welding operations

disconnect and isolate the battery negative (ground) cable and disconnect all wire
harness connectors from the Occupant Restraint Controller (ORC). Failure to take the
proper precautions could result in accidental airbag deployment and other possible
damage to the supplemental restraint system circuits and components. Failure to follow
these instructions may result in personal injury or death.
Replace all restraint system components only with parts specified in the FCA US LLC
Mopar® parts catalog. Substitute parts may appear interchangeable, but internal
differences may result in inferior occupant protection. Failure to follow these
instructions may result in personal injury or death.
The fasteners, screws, and bolts originally used for the restraint system components
must never be replaced with any substitutes. These fasteners have special coatings
and are specifically designed for the restraint system. Any time a new fastener is
needed, replace it with the correct fasteners provided in the service package or
specified in the FCA US LLC Mopar® parts catalog. Failure to follow these instructions
may result in personal injury or death.
On vehicles equipped with the Occupant Classification System (OCS), do not hang any
after market devices from the front passengers seat back. Do not install a front drivers
seat back cover with map pocket onto the passenger seat. Failure to follow these
instructions may result in personal injury or death.
The Seat Weight Sensor is a sensitive, calibrated unit and must be handled carefully.
Do not drop or handle roughly. If dropped or damaged, replace with another sensor.
Failure to follow these instructions may result in personal injury or death.
The front passenger seat must be handled carefully as well. When removing the seat,
be careful when setting on floor not to drop. If dropped, the sensor may be inoperative.
Failure to follow these instructions may result in personal injury or death.
When the seat is on the floor, no one should sit in the front passenger seat. This
uneven force may damage the sensing ability of the seat weight sensors. If sat on and
damaged, the sensor may be inoperative. Failure to follow these instructions may
result in personal injury or death.
SEATS, FIRST ROW > COVER, SEAT BACK, FRONT > REMOVAL AND INSTALLATION
WARNING:
Disable the airbag system before attempting any front seat diagnosis or service. Disconnect
and isolate the negative battery (ground) cable and wait two minutes for the airbag system
capacitor to discharge before performing further diagnosis or service. This is the only sure
way to disable the airbag system. Failure to follow these instructions may result in accidental
airbag deployment and possible serious or fatal injury. Refer to WARNING .
Fig 1: Headrest & Releases
1. Before proceeding with the following repair procedure, review all warnings and cautions. Refer
to SEATS, FIRST ROW, WARNING .
2. Remove the front seat back. Refer to SEAT BACK, FRONT, REMOVAL AND INSTALLATION .
3. Push the release (2a and 2b) and remove the headrest (1).
Fig 2: Headrest Sleeve & Tab
4. Using a small flat bladed tool, push the tab (1b) of the headrest sleeve (1a) and pull out to
remove.
Fig 3: Seat Back Zippers
5. Unzip the seat back zippers (1a and 1b).

Fig 4: J-Clip Retainer & Connector
6. Release the J-clip retainer (1) at the bottom of the seat.
7. Disconnect the harness connector (2).

Fig 5: Seat Back Cover
8. Remove the seat air bag from the seat back. Refer to AIR BAG, SEAT, REMOVAL AND
INSTALLATION .
9. Remove the seat back foam and seat back cover (1) as an assembly, from the seat back
frame.
10. Pull the seat back cover away from the foam and remove the hog rings.
SEATS, FIRST ROW > COVER, SEAT BACK, FRONT > REMOVAL AND INSTALLATION
WARNING:
Fig 1: Seat Back Cover
2. Position the seat back cover (1) onto the seat back foam and install new hog rings.
3. Position the seat back foam assembly onto the seat back frame.
4. Install the seat air bag into the seat back. Refer to AIR BAG, SEAT, REMOVAL AND
INSTALLATION .
Fig 2: J-Clip Retainer & Connector
5. Pull the seat back cover tight and fasten the J-clip retainers (1).
6. Connect the harness connector (2).

Fig 3: Seat Back Zippers
7. Close the seat back zippers (1a and 1b).

Fig 4: Headrest Sleeve & Tab
8. Install the headrest sleeves (1a) and hand tap to engage the tab (1b).
9. Install the headrest.
10. Install the front seat back. Refer to SEAT BACK, FRONT, REMOVAL AND INSTALLATION .
SEATS, FIRST ROW > COVER, SEAT CUSHION, FRONT > REMOVAL AND
WARNING:
Fig 1: J-Hooks & Connector
2. Remove the front seat back. Refer to SEAT BACK, FRONT, REMOVAL AND INSTALLATION .
3. Release the J-hooks (1) from the rear of the cushion.
4. Disconnect the wire harness connector (2).

Fig 2: J-Hook
5. Release the J-hook (1) from the front of the cushion.

Fig 3: J-Hooks
6. Release the J-hooks (1) from the sides of the cushion.

Fig 4: Seat Cover
7. Loosen the seat cover (1) from the foam.

Fig 5: Seat Cover, Foam & Hog Ring
8. Pull the seat cover (2a) away from the foam and remove the hog rings (1).
SEATS, FIRST ROW > COVER, SEAT CUSHION, FRONT > REMOVAL AND
WARNING:
Fig 1: Seat Cover, Foam & Hog Ring
1. Position the seat cover (2a) onto the foam (2b) and install new hog rings (1).
Fig 2: Seat Cover
2. Pull the seat cover (1) tight over the foam.

Fig 3: J-Hooks
3. Route the wire harness, if equipped
4. Attach the J-hooks (1) to the sides of the cushion.

Fig 4: J-Hook
5. Attach the J-hook (1) to the front of the cushion.

Fig 5: J-Hooks & Connector
6. Attach the J-hooks (1) to the rear of the cushion.
7. Connect the wire harness connector (2).
8. Install the front seat back. Refer to SEAT BACK, FRONT, REMOVAL AND INSTALLATION .
SEATS, FIRST ROW > SEAT BACK, FRONT > REMOVAL AND INSTALLATION >
Fig 1: Bottom J-Clip
2. Remove the side shields. Refer to SIDE SHIELDS, SEAT CUSHION, FRONT, REMOVAL AND
INSTALLATION .
3. Open the J-clip (1) at the bottom on the seat back.

Fig 2: Wire Harness & Connectors
4. Disconnect the wire harness connectors (2a and 2b).
5. Unclip the harness (1a, 1b and 1c) from the seat frame.
Fig 3: Recliner Rod, Harness & Bolts
6. Remove the recliner rod (1).
7. Unclip the wire harness (3).
8. Remove the two bolts (4) on each side of the seat back and remove.
SEATS, FIRST ROW > SEAT BACK, FRONT > REMOVAL AND INSTALLATION >
Fig 1: Recliner Rod, Harness & Bolts
2. Install the seat back onto the adjuster and install the bolts (4). Tighten the front seat back bolts
Fig 2: Wire Harness & Connectors
3. From under the seat, route the seat back wiring harness (1a, 1b and 1c) and connect the wire
harness connectors (2a and 2b).
Fig 3: Bottom J-Clip
4. Close the J-clip (1) at the bottom on the seat back.
5. Install the side shields. Refer to SIDE SHIELDS, SEAT CUSHION, FRONT, REMOVAL AND
INSTALLATION .
SEATS, FIRST ROW > SEAT, FRONT > REMOVAL AND INSTALLATION > REMOVAL
WARNING:
Disable the airbag system before attempting any component diagnosis or service of the front
seats, when equipped with front seat air bags. Disconnect and isolate the negative battery
(ground) cable, then wait two minutes for the airbag system capacitor to discharge before
performing further diagnosis or service. This is the only sure way to disable the airbag
system. Failure to take the proper precautions may result in accidental airbag deployment
and possible serious or fatal injury. Refer to WARNING .
Fig 1: Rear Track Cover & Bolts
3. Move the front seat to the full forward position.
4. Using a trim stick, remove the rear track cover (1b).

5. Remove the two seat bolts (2).
Fig 2: Wire Harness Connector & Bolts
6. Move the front seat to the full rearward position.
7. Disconnect the wire harness connector (1).
8. Remove the two seat bolts (2).
9. Remove the front seat from the vehicle.
CAUTION:
Do not use the adjuster release bar as a handle when removing or installing the
front seat.
SEATS, FIRST ROW > SEAT, FRONT > REMOVAL AND INSTALLATION > REMOVAL
2. Position the front seat into the vehicle.
CAUTION:
Do not use the adjuster release bar as a handle when removing or installing the
front seat.
3. Loosely install the front seat bolts (2) and connect the wire harness connectors (1).
Fig 2: Rear Track Cover & Bolts
4. Move the front seat (1) to the full forward position.

5. Loosely install the rear seat bolts (2) and tighten to OUTBOARD bolt to the proper
6. Slide the seat rearward and forward to make sure the track is aligned properly, then tighten the
INBOARD bolt to the proper specification. Refer to SPECIFICATIONS .
7. Install the rear seat track cover (1b).

8. Slide the seat rearward and tighten the bolts (2) to the proper specification. Refer to
SPECIFICATIONS .
SEATS, FIRST ROW > SIDE SHIELDS, SEAT CUSHION, FRONT > REMOVAL AND
Fig 1: Cover & Tabs
1. Using a small flat bladed tool, remove the cover (1a) from the height adjusting handle.
Fig 2: Height Adjusting Handle & Screws
2. Remove the screws (1) and the height adjusting handle (2).
Fig 3: Recline Handle & Clip
3. Using a hook tool remove the clip (1a) and remove the recline handle (1b).
Fig 4: Side Shield, Retaining Tab & Screw
4. Remove the screw (1a) at the rear of the side shield (1b).
5. Using a trim stick or equivalent, release the retaining clips (2a) and the side shield (1b).
Fig 5: Side Shield, Seat Belt Buckle, Bolt, Screws & Clips
6. Remove the seat belt buckle bolt (1a) and the seat belt buckle (1b).
7. Remove the screws (5) from the side shield (6b).
8. Using a trim stick or equivalent, release the retaining clips (6a) and remove the side shield.
SEATS, FIRST ROW > SIDE SHIELDS, SEAT CUSHION, FRONT > REMOVAL AND
Fig 1: Side Shield, Seat Belt Buckle, Bolt, Screws & Clips
1. Position the side shield (6b) onto the seat frame and engage the retaining tab (6a).

3. Tighten the seat belt buckle bolt (1a) and tighten to the proper specification. Refer to
SPECIFICATIONS .
Fig 2: Side Shield, Retaining Tab & Screw
4. Position the side shield (1b) onto the seat frame and engage the retaining tab (2a).
5. Install the screw (1a) and tighten securely.

Fig 3: Recline Handle & Clip
6. Install the clip (1a) onto the recline handle (1b), then install onto the seat.
Fig 4: Height Adjusting Handle & Screws
7. Position the height adjusting handle (2) and install the screws (1). Tighten the screws securely.
Fig 5: Cover & Tabs
8. Install the cover (1a) and engage the tabs (1b).
SEATS, FIRST ROW > TRACK, MANUAL FRONT > REMOVAL AND INSTALLATION >
Fig 1: Seat Track & Bolts
1. Remove the seat from the vehicle. Refer to SEAT, FRONT, REMOVAL AND INSTALLATION .
2. Move the seat track (1a) rearward and remove the bolts (1b).
3. Move the seat track (2a) forward and remove the bolt (2b).
Fig 2: Seat Track, Handle & Bolts
4. Move the seat track (1a) rearward and remove the bolts (1b).
5. Remove the seat adjust handle (2b) and seat track.
SEATS, FIRST ROW > TRACK, MANUAL FRONT > REMOVAL AND INSTALLATION >
Fig 1: Seat Track, Handle & Bolts
1. Install the seat adjuster handle (2b) onto the seat track (1a).
2. Position the seat track and install the bolts (1b). Tighten the seat track bolts to the proper
Fig 2: Seat Track & Bolts
3. Move the seat track (1a) as necessary and install the bolts (1b and 2b).
4. Tighten the seat track bolts to the proper specification. Refer to SPECIFICATIONS .
5. Install the seat into the vehicle. Refer to SEAT, FRONT, REMOVAL AND INSTALLATION .
SEATS, REAR > ARMREST, SECOND ROW > REMOVAL AND INSTALLATION >
Fig 1: Right Side Rear Seat, Armrest & Bolt
1. fold the right side rear seat (1a) to the full forward position.
2. With the armrest (1b) in the folded down position, remove the bolt (2).
Fig 2: Armrest & Bolt
3. With the armrest in the folded down position, remove the bolt (1) and remove the armrest (2).
SEATS, REAR > ARMREST, SECOND ROW > REMOVAL AND INSTALLATION >
Fig 1: Armrest & Bolt
1. Position the armrest and install the bolt (1).

Fig 2: Right Side Rear Seat, Armrest & Bolt
2. Install the inboard bolt (2) and tighten the rear seat armrest bolts to the proper specification.
SEATS, REAR > SEAT BACK, REAR > REMOVAL AND INSTALLATION > REMOVAL
Fig 1: Seat Backs, Center Seat Belt & Release Handles
1. Release the center seat belt (1b) at the bottom.
2. Pull the release handles (2a) and fold both seat backs (2b and 2c) down.
Fig 2: Seat Back Pivot, Bracket, Bushing & Bolt
3. Remove the pivot bracket bolt (1a) and open the pivot bracket (1b).
4. Lift the seat back pivot (2c) out of the center pivot bracket.
5. Using a pry tool (2a), release the locking bushing (2b) and lift the seat back and remove.
SEATS, REAR > SEAT BACK, REAR > REMOVAL AND INSTALLATION > REMOVAL
NOTE:
The 60% split rear seat back must be installed before the 40% split rear seat back.
Fig 1: Seat Back Pivot, Bracket, Bushing & Bolt
1. Engage the locking bushing (2b) into the out pivot bracket.
2. Place the seat pivot (2c) into the pivot bracket.
3. Close the pivot bracket (1b) and install the pivot bracket bolt (1a).
4. Tighten the rear seat pivot bracket bolt to the proper specification. Refer to
SPECIFICATIONS .
Fig 2: Seat Backs, Center Seat Belt & Release Handles
5. Raise the seat back and install the center seat belt (1b).
SEATS, REAR > SEAT CUSHION > REMOVAL AND INSTALLATION > REMOVAL AND
Fig 1: Cargo Cover & Support
1. Lift and remove the cargo cover (1a) and support (1b).
Fig 2: Seat Cushion & Nuts
2. Fold the seat backs forward and remove the nuts (1a) at the rear of the seat.
3. Raise the seat backs and remove the seat cushion (1b).
SEATS, REAR > SEAT CUSHION > REMOVAL AND INSTALLATION > REMOVAL AND
Fig 1: Seat Cushion & Nuts
1. Position the rear seat cushion (1b) and install the nuts (1a). Tighten the rear seat nuts to the
Fig 2: Cargo Cover & Support
2. Install support (1b) and the cargo cover (1a).
STATIONARY GLASS > WARNING > WARNING

WARNING:
Do not operate the vehicle within 24 hours of windshield installation. It takes at least 24
hours for urethane adhesive to cure. If it is not cured, the windshield may not perform
properly in an accident.
Urethane adhesives are applied as a system. Use glass cleaner, glass prep solvent,
glass primer, PVC (vinyl) primer and pinch weld (fence) primer provided by the
adhesive manufacturer. If not, structural integrity could be compromised.
FCA US LLC does not recommend glass adhesive by brand. Technicians should
review product labels and technical data sheets, and use only adhesives that their
manufactures warrant will restore a vehicle to the requirements of FMVSS 212.
Technicians should also insure that primers and cleaners are compatible with the
particular adhesive used.
Be sure to refer to the urethane manufacturer's directions for curing time specifications,
and do not use adhesive after its expiration date.
Vapors that are emitted from the urethane adhesive or primer could cause personal
injury. Use them in a well-ventilated area.
Skin contact with urethane adhesive should be avoided. Personal injury may result.
Always wear eye and hand protection when working with glass.
CAUTION:
Protect all painted and trimmed surfaces from coming in contact with urethane or primers.
Be careful not to damage painted surfaces when removing moldings or cutting urethane
around windshield.
STATIONARY GLASS > SPECIFICATIONS > BODYWORK GLASS AND WINDOWS
Component Type Name Classification Q.ty Validity
Glass/Window Activator for

- - - -
compartment PUR
Glass Glass Sealant N.71711976 - - -
STATIONARY GLASS > GLASS, LIFTGATE > REMOVAL AND INSTALLATION >
REMOVAL
Fig 1: Lower Trim Panel, Push Pin Fasteners & Screw
2. Remove the rear wiper arm. Refer to ARM, WIPER, REMOVAL AND INSTALLATION .
3. Remove the screw (1) from the pull cup.
4. Using trim stick (special tool #C-4755, Trim Stick) or equivalent, release the push pin fasteners
(2) and remove the lower trim panel (3).
Fig 2: Upper Trim, Push Pin Fasteners & Screws
6. Using trim stick or equivalent, release the push pin fasteners (2) and remove the upper trim (3).
Fig 3: Caps, Bolts & Nuts
7. Pry off the caps (1a), remove the screws (1b) and nuts (1c).
Fig 4: Rear Spoiler, Push Pin Fasteners, Washer Hose & Connector
8. Using trim stick or equivalent, release the push pin fasteners (1a) and fold the spoiler down
(1b).
9. Disconnect the rear washer hose (2).
11. Remove the rear spoiler (1b).

Fig 5: Rear Window Defogger Electrical Connectors
12. Disconnect the rear window defogger electrical connectors (1) and position aside to avoid
damage while cutting the urethane adhesive.
Fig 6: Suction Cups On Glass
13. Remove the wiper motor gasket (1).
14. Apply a double layer of adhesive tape to the body to prevent damage.
15. Apply suction cups (3) onto the glass to prevent accidental damage from falling while cutting
the glass adhesive.
Fig 7: Removing Liftgate Glass
NOTE:
Protect interior car parts with suitable covers.

NOTE:
The strip of rear window sealant can be cut using piano wire. To cut with a vibrating
cutter, an adequate cutter usage capacity is required, as well as an appropriate
choice of blades in accordance with the cutting areas and the obstructions present.
NOTE:
To make the cut by piano wire, proceed as follows.
NOTE:
The following procedure is done using standard equipment.
16. Cut a length of piano wire of about 80 cm then, using pliers, introduce one end (1a) of the
piano wire through the strip of sealant (1b) fixing the windscreen (1c).
17. Fasten one end (1a) of the wire to the special retaining tool (2a) located inside the vehicle.
Fasten one end (2b) of the wire to the traction handle (2c) located outside the vehicle.
18. The operator inside the car must keep the end of tool (2a) on the sealant bead (1b) about 30
cm from the point where the wire passes through. The other operator, outside the car, has to
pull the handle (2c), following the profile of the rear window and then cut the strip of sealant
(1b). When necessary, position an adequately-sized spatula (2d) by the tool (2a), to protect
the inner parts of the car. Repeat the operation in sections of about 30 cm until the bead of
sealant (1b) is completely cut.
NOTE:
During the cutting stage, bear in mind that the piano wire must also cut the two
needle retainers (3a).
19. After cutting the entire sealant strip, use suction pads, with the help of a second operator, to
remove the rear window (1c) and rest it on a support stand.
GLASS REMOVAL TOOLS
Fig 1: Common Glass Tools Needed To Remove Stationary Glass
Common glass tools needed to remove Stationary Glass
1- Extractor® Express™ or equivalent, equipped with flat blade
2- Two handled wire type cut out tool
3- Cold knife equipped wit a 25 mm (1 in.) blade
4 - Cold knife equipped with an 38 mm (1.5 in.) blade
5 - Long knife
INSTALLATION
Fig 1: Liftgate Fence Line, Support Pins & Adhesive Tape
1. Using suitable equipment, cut and level the strip of adhesive in the rear window housing,
leaving a thickness of between 0.25 and 1 mm, taking care not to scratch the paintwork. The
thickness of the adhesive remaining in the housing will act as a support for the new bonding.
2. Remove the adhesive tape (2).
3. Thoroughly clean the liftgate fence line (3) and degrease fully using ammonia based glass
cleaner.
4. Check the support pins (4) for damage and replace if necessary.
NOTE:
When bonding more than 60 minutes after the bead of adhesive has been cut and
levelled, the surface of the adhesive must be treated using glass prep adhesion
promoter and it is necessary to wait for 15 minutes before installing the glass.
INSTALLATION > PREPARATION OF THE REMOVED GLASS
Fig 1: Glass, Perimeter Area & Spacers
1. Repair any paint damage if necessary.
NOTE:
The glass (1) that is removed can only be reused if it has not been damaged during
the removal.
2. With suitable tool to cut and smooth the bead of adhesive on the glass so as to leave a
thickness between 0.25 and 1 mm to avoid scratching the paint. The thickness of adhesive
remaining will be the support for the new bonding.
3. Clean the perimeter area (3) of the glass thoroughly and degrease fully ammonia based glass
cleaner. Check that the glass is not damaged.
4. If not present, install new spacers (4).
5. Install the wiper motor gasket.

6. When bonding more than 60 minutes after the bead of adhesive has been cut and levelled, the
surface of the adhesive must be treated using glass prep adhesion promoter and it is
necessary to wait for 15 minutes before installing the glass.
INSTALLATION > NEW GLASS PREPARATION
Fig 1: Perimeter & Spacers
1. Degrease the perimeter (1) of the new glass to be bonded using an ammonia based glass
cleaner.
2. Check the spacers (2) for damage and replace if necessary.
3. Install the wiper motor gasket.
4. Apply glass adhesion promoter (primer) to the entire perimeter (3) cleaned previously.
NOTE:
Wait for about 15 minutes before continuing with the next operation to allow the
adhesion promoter (primer) to evaporate completely
INSTALLATION > LIFTGATE GLASS INSTALLATION
Fig 1: Glass & Masking Tape
1. Test fit the glass (1a) centering in the glass over the wiper motor shaft and then in the liftgate
opening and mark the position using masking tape (2) as a reference.
2. Cut the strips of tape and remove the glass.

Fig 2: Bead Of Adhesive
3. Apply a bead of adhesive (1) along the perimeter of the glass as evenly as possible.
NOTE:
Start the operation from the lower center edge and continue without breaks along
the entire perimeter of the glass.
Fig 3: Glass
4. Position the glass (1) in its seat immediately after applying the adhesive and settle it into
position using the tape applied previously as a guide.
Fig 4: Glass & Strap
5. Position a strap (1a), as shown in the illustration, and tension it so that even pressure is
exerted on the entire glass (1b) to ensure that the bonding between the glass (1b), adhesive
(1c) and fence line (1d) is correct.
NOTE:
Do not move the vehicle for the time recommended by the adhesive manufacturer.
NOTE:
Before installing the components removed from the vehicle, check that there are no
infiltration points by carrying out a water leakage test.
6. Connect the rear window defogger electrical connectors.
7. Position the spoiler back and connect the washer hose.
8. Connect the stop light electrical connector.
9. Install the spoiler.
10. Install the nuts and screws and install the caps.
11. Install the upper trim panel and seat the push pins fully.
12. Install the lower trim panel and seat the push pins fully.
13. Install the rear wiper arm. Refer to ARM, WIPER, REMOVAL AND INSTALLATION .
STATIONARY GLASS > GLASS, QUARTER > REMOVAL AND INSTALLATION >
REMOVAL
Fig 1: Upper Trim Panel, Covers, Clips & Screws
1. Using trim stick (special tool #C-4755, Trim Stick) or equivalent, remove the trim covers (1a).
2. Remove the screws (1b).
3. Using a trim stick or equivalent, release the retaining clips (2b) and separate the upper trim
panel (2a).
Fig 2: Removing Quarter Glass
4. Apply a double layer of adhesive tape (1) on the body, along the edges of the glass.
5. Cut a segment of a piano wire (2) with a length of about 70 cm.
6. Attach the wire tool handles (3) to the ends of the wire (2).
7. With the aid of a second operator, cut the cord of the sealant (4a) and the centering pins (4b)
and remove the glass.
GLASS REMOVAL TOOLS
5 - Long knife
INSTALLATION
Fig 1: Fence Line, Tape & Adhesive
1. Using suitable equipment, cut and level the strip of adhesive (1) in the quarter glass housing,
leaving a thickness of between 0.25 and 1 mm, taking care not to scratch the paintwork. The
thickness of the adhesive remaining in the housing will act as a support for the new bonding.
2. Remove the adhesive tape (2).
3. Thoroughly clean the quarter glass fence line (3) and degrease fully using ammonia based
glass cleaner.
NOTE:
promoter and it is necessary to wait for 15 minutes before installing the glass.
INSTALLATION > NEW GLASS PREPARATION
Fig 1: Glass Seal & Alignment Pins
cleaner.
NOTE:
3. Verify the glass seal (2a) and the alignment pins (2b) are free of damage.
INSTALLATION > QUARTER GLASS INSTALLATION
Fig 1: Adhesive Area
NOTE:
Start the operation from the front center edge and continue without breaks along the
entire perimeter of the glass.
Fig 2: Installing Quarter Glass

2. Position the glass (1) in its seat using the pins provided, immediately after applying the
adhesive.
3. Place the strap (2a) as indicated in the illustration and tighten so as to exert an even pressure
on the whole glass, in order to make sure the correct bonding between the glass (1), adhesive
(2b) and the fenceline (2c).
NOTE:
NOTE:
4. Install the upper quarter trim panel and seat the retaining clips fully.
5. Install the screws and install the screw covers.
STATIONARY GLASS > WINDSHIELD > REMOVAL AND INSTALLATION > REMOVAL
Fig 1: Grab Handle, Tabs & Retainers
2. Remove the A-pillar trim. Refer to PANEL, A-PILLAR TRIM, REMOVAL AND INSTALLATION .
3. Remove the dome lamp assembly. Refer to LAMP, DOME, REMOVAL AND INSTALLATION .
4. Pull down the grab handle (1).

5. Remove the tabs (2a) and release the grab handle retainers (2b).
6. Remove both grab handle assemblies.

Fig 2: Visor, Support, Flange, Grip & Screws
7. Disconnect the sun visor (1a) from the support (1b).
8. Unhook the flange (2).

10. Remove the sun visor (1a) releasing the retainer located inside the support (4a).
11. Remove the grip (1b) after opening its flange (5a) and remove the screw (5b).
Fig 3: Mirror, Nut & Retainers
12. Turn the rear view mirror (1a) and release the retainers (1b) on the retaining nut (1c) on the
windshield.
13. Remove the mirror.

Fig 4: Bolt Cover
14. Pry off the bolt cover of the wiper arm.

15. Remove the nut (1a) and remove the wiper arms (1b).
Fig 6: Cowl Trim Panel & Retaining Buttons
16. Using trim stick (special tool #C-4755, Trim Stick) or equivalent, release the retaining buttons
(1a) and the center and side of the cowl trim panel (1b).
Fig 7: Upper Cowl Trim
17. Release the upper cowl trim (1) and remove the cowl trim panel.
Fig 8: Molding & Retainers
18. Using a trim stick or equivalent, release the retainers (1b) and remove the molding (1a).
Fig 9: Retainers
19. Using a trim stick or equivalent, remove the retainers (1).
20. Slightly lower the front of the head liner and insert shims to keep it slightly lowered.
Fig 10: Suction Cups On Windshield
21. Protect the fascia and fenders as necessary.
22. Apply a double layer of adhesive tape (1) on the body, along the edges of the windshield.
23. Apply the glass two suction cups (2) for later removal.
Fig 11: Heated Windshield Connector
24. Disconnect the heated windshield electrical connector (1).
25. Fold connector (2) over the windshield and secure with tape to prevent damage.
Fig 12: Removing Windshield

NOTE:
The strip of windscreen sealant can be cut using piano wire. To cut with a vibrating
cutter, an adequate cutter usage capacity is required, as well as an appropriate
choice of blades in accordance with the cutting areas and the obstructions present.
To cut using a piano wire, proceed as described below.
1. Cut a length of piano wire of about 50 cm then, using pliers, introduce one end (1a) of the
piano wire through the bead of sealant (1b) securing the windscreen (1c).
2. Fasten one end (1a) of the wire to the special retaining tool (2a) located inside the vehicle.
Fasten one end (2b) of the wire to the traction handle (2c) located outside the vehicle.
3. Before proceeding to the cutting step, lower the pins (3) so that they can be reused.
4. The operator inside the car must keep the end of tool (2a) on the sealant bead (1b) about 30
cm from the point where the wire passes through. The other technician, outside the vehicle,
should pull the handle (2c) following the surround of the windshield and they should cut the
bead of sealant (1b). When necessary, position an adequately-sized spatula (2d) by the tool
(2a) to protect the inner parts of the car. Repeat the operation in sections of about 30 cm until
the bead of sealant (1b) is completely cut.
NOTE:
Be careful to avoid damaging the heated glass wiring during the cutting process.
5. After cutting around the bead of sealant remove the glass using the suction cups positioned
above. Place the glass on a suitable support stand.
STATIONARY GLASS > WINDSHIELD > REMOVAL AND INSTALLATION > GLASS
REMOVAL TOOLS
5 - Long knife
STATIONARY GLASS > WINDSHIELD > REMOVAL AND INSTALLATION >

INSTALLATION > FENCE CLEANING
Fig 1: Sealant, Tape, Fence Line & Support Pins
WARNING:
Do not operate the vehicle within 24 hours of windshield installation. It takes at least 24
hours for urethane adhesive to cure. If it is not cured, the windshield may not perform
properly if the vehicle is in an accident.
WARNING:
CAUTION:
To help prevent water leaks, partially roll down the left and right door glass before installing
the windshield. This avoids pressurizing the passenger compartment if a door is slammed
before the urethane is cured.
CAUTION:
Protect all painted and trimmed surfaces from coming in contact with urethane or primers.
1. Using suitable equipment, cut and level the bead of sealant (1) in the windscreen housing
leaving a thickness of between 0.25 and 1 mm, taking care not to scratch the paint. The
thickness of the sealant remaining in the housing will act as a support for the new bonding.
2. Remove the tape (2).
3. Thoroughly clean the windshield fence line (3) and degrease fully using ammonia based glass
cleaner.
4. Check the support pins (4) for damage and replace if necessary.
NOTE:
promoter and it is necessary to wait for 15 minutes before installing the windshield.

INSTALLATION > PREPARATION OF THE REMOVED GLASS
Fig 1: Glass, Adhesive & Seals
1. Repair any paint damage if necessary.
NOTE:
The glass (1) that is removed can only be reused if it has not been damaged during
the removal.
2. Using a suitable tool, cut and level the bead of adhesive (2a) on the glass so that it is as thin
as possible. The remaining adhesive does not have to be completely removed; take care not
to damage the black screen-printing on the glass perimeter, the perimeter seals (2b) and the
circuit of the heated windscreen.
NOTE:
The perimeter seals (2b) also act as spacers to prevent the glass from sinking in
relation to the body, during the bonding stage.
3. Clean the perimeter area (3) of the glass thoroughly and degrease fully ammonia based glass
cleaner. Check that the glass is not damaged.
NOTE:
promoter and it is necessary to wait for 15 minutes before installing the windshield.

INSTALLATION > NEW WINDSHIELD PREPARATION
Fig 1: Perimeter & Locating Pins
cleaner.
2. Check for the presence of locating pins (2).

NOTE:

INSTALLATION > WINDSHIELD INSTALLATION
Fig 1: Glass, Tape & Adjustment Pins
1. Test fit the glass (1) centering in the windshield opening and mark the position using masking
tape (2) as a reference.
2. Lift the adjustment pins (3).
3. Cut the strips of tape and remove the glass.

Fig 2: Bead Of Adhesive On Glass
NOTE:
Start the operation from the lower left edge and continue without breaks along the
entire perimeter of the glass.
Fig 3: Glass In Position
2. Position the glass (1) in its seat immediately after applying the adhesive and settle it into
position using the tape applied previously as a guide.
Fig 4: Strapping Glass In Position
3. Position a strap (1a), as shown in the illustration, and tension it so that even pressure is
exerted on the entire window (1b) to ensure that the bonding between the glass (1b), adhesive
(1c) and fence line (1d) is correct.
NOTE:
NOTE:
4. Remove the tape securing the heated glass electrical connector.
5. Secure the upper cowl trim panel and install the panel.
6. Install the push pin fasteners and seat fully.
7. Install the wiper arms and install the nuts without tightening.
Fig 5: Wiper Alignment Marks
8. Position the wiper arm pivot end onto the wiper pivot shaft so that the lower edge of the wiper
blade is aligned with the wiper alignment marks (1), which are etched marks near the lower
margin of the windshield.
9. Tighten the nut that secures the wiper arm to the pivot shaft. Tighten the nut to specification.
10. Install the wiper arm bolt covers.

11. Install the cowl trim panel side retainers.
12. Remove the shims placed in the headliner during removal.
13. Install the rearview mirror onto the retaining nut on the windshield.
14. Install the visors and the visor supports. Install the screws securing the visor and the support.
15. Install the front door seals.
16. Install the dome lamp assembly. Refer to LAMP, DOME, REMOVAL AND INSTALLATION .
17. Install the A-pillar trim. Refer to PANEL, A-PILLAR TRIM, REMOVAL AND INSTALLATION .
WEATHERSTRIP/SEALS > CAUTION > CAUTION
Some body mounted weatherstrips are sealed to the body using a white mastic compound.
CAUTION:
Door and Liftgate weatherstrip seals that use a white mastic sealant must be replaced with a
new weatherstrip and any mastic must be cleaned from attachment flanges whenever the
weatherstrip is removed.
CAUTION:
Failure to follow these recommendations could result in damage or failure to the part and the
related parts.
WEATHERSTRIP/SEALS > SEAL, DOOR OPENING, FRONT > REMOVAL AND

Fig 1: Front Door Seal
1. Separate and remove the seal (1).
WEATHERSTRIP/SEALS > SEAL, DOOR OPENING, FRONT > REMOVAL AND

Fig 1: Front Door Seal & Junction Mark
1. Check that the seal is not damaged.
2. Position the seal (1a), by placing the junction mark (1b) in the area of the door check, as
shown in the illustration.
3. Check for correct door operation.

WEATHERSTRIP/SEALS > SEAL, DOOR OPENING, REAR > REMOVAL AND
Fig 1: Rear Door Seal
1. Separate and remove the seal (1).
WEATHERSTRIP/SEALS > SEAL, DOOR OPENING, REAR > REMOVAL AND

Fig 1: Rear Door Seal & Junction Mark
1. Check that the seal is not damaged.
2. Position the seal (1), by placing the junction mark (2) in the area of the door check, as shown
in the illustration.
3. Check for correct door operation.

Jeep Renegade
Service Manual: FRAME AND BUMPERS
1871000700 C-4150A Extractor Tie Rod End Separator
1878077000 C-4755 Trim Stick Trim Separation
Disassembly/Replacement
2000043000 * Universal Tool
Crossmember Front/Rear
Pin Round/Conical Disassembly/Replacement

2000043300 *
Centering Body Crossmember Front/Rear
Crossmember Disassembly/Replacement
2000043500 *
Centering Pin/Bracket Crossmember Front/Rear
Crossmember Disassembly/Replacement
2000043600 *
Centering Pin Crossmember Front/Rear
*Tool not available for NAFTA. Use a commercially available tool or contact Mopar® Essential Tools to

NEW
Description N.m Ft Lbs In Lbs
FASTENER*
Front bumper bolts 45 33 -
Front belly pan bolts 20 15 -
Front crossmember lower reaction rod front bolt 90 + 45° 66 + 45° -
Front crossmember lower reaction rod rear bolt 90 + 45° 66 + 45° -
Front suspension crossmember bolts 120 + 45° 89 + 45° -
Load beam bolts 100 74 -
Lower load beam extension bolts 45 33 -
Load beam support bracket bolts 50 37 -
Rear bumper bolts 25 18 -
Rear lower control arm to rear crossmember bolts 125 92 -
Rear lower control arm to rear knuckle bolts + 90° 100 + 90° 74 + 90° -
Rear strut to rear knuckle + 90° 100 + 90° 74 + 90°

Rear suspension crossmember bolts 120 89 -
Side belly pan bolts 20 15 -
Sway bar link to stabilizer bar nut 80 59 - X
Wheel speed sensor screw 7 - 61
BUMPERS > FASCIA, FRONT > DISASSEMBLY AND ASSEMBLY > DISASSEMBLY
AND ASSEMBLY > DISASSEMBLY
Fig 1: Headlight Assembly & Mounting Screws
2. Working from both sides, loosen the mounting screws (1a) and remove the headlight assembly
(1b).
Fig 2: Reinforcement & Screws
3. Remove the screws at the top (1a) and remove reinforcement (1b).
Fig 3: Fascias, Screws & Retainers
4. Remove the screws (1a), release the retainers (1b) and separate the upper fascia (1c) and
lower (1d).
Fig 4: Fascias & Screws
5. Remove the screws (1a) and separate the smaller gauge (1b) and upper (1c) of the lower
fascia.
Fig 5: Grille, Grille Insert & Retainers
6. If necessary, disassemble the grille (1a), the retainers (1b), separate grille (1c) and the grille
insert (1d).
NOTE:
If the retainers are damaged, the grille insert must be replaced.
Fig 6: Fog Light Caps, Cap Tow Bar & Retainers
7. Working from both sides remove the fog light caps (1a) and the cap tow bar (1b) releasing
retainers (1c).
Fig 7: Grille Elements & Retainers
8. Remove the grille elements (1a) by releasing the retainers (1b).
BUMPERS > FASCIA, FRONT > DISASSEMBLY AND ASSEMBLY > DISASSEMBLY
AND ASSEMBLY > ASSEMBLY
1. Install the grille elements by securing the retainers.
2. Working from both sides install the fog light caps and the cap tow bar securing retainers.
3. If necessary, assemble the grille and the grille insert and seat the retainers fully.
NOTE:
If the retainers are damaged, the grille insert must be replaced.
4. Reassemble the lower and upper lower fascia and tighten the screws.
5. Reassemble the upper and lower fascia, securing retainers and tighten the screws.
6. Install the reinforcement and tighten the screws at the top.
7. Working from both sides, install the headlight assembly tighten the mounting screws.
BUMPERS > FASCIA, FRONT > REMOVAL AND INSTALLATION > REMOVAL AND
Fig 1: Retaining Clips, Front Wheel Moldings & Screws
2. Using trim stick or equivalent, release the retaining clips (1a) and remove the front wheel
moldings (1b).
3. Remove the screws (2) on both side of the vehicle.

Fig 2: Front Wheel Splash Shield-To-Fascia Screws
4. Remove the screws (1) securing the front wheel splash shields to the fascia.
Fig 3: Screws

Fig 4: Release Handle, Wire Harness Connectors, Front Fascia & Screws
8. Remove the screws (1a) and position the release handle (1b) aside.
9. Remove the screws (2) at the top of the front fascia.
10. Disconnect the wire harness connectors (3) from the head lamps.
11. If equipped, disconnect the wire harness connectors from the fog lamps.
12. Remove the front fascia (4).
BUMPERS > FASCIA, FRONT > REMOVAL AND INSTALLATION > REMOVAL AND
Fig 1: Release Handle, Wire Harness Connectors, Front Fascia & Screws

1. Position the front fascia (4) and install the screws (2). Tighten the screws securely.
2. Position the release lever (1b) and install the screws (1a). Tighten the screws securely.
3. Connect the wire harness connectors (3) to the head lamps.
4. If equipped, connect the wire harness connectors to the fog lamps.

Fig 2: Screws
5. From under the vehicle, install the screws (1) and tighten securely.
Fig 3: Front Wheel Splash Shield-To-Fascia Screws
6. Install the screws (1) securing the front wheel splash shields to the front fascia, and tighten
securely.
Fig 4: Retaining Clips, Front Wheel Moldings & Screws
7. Install the screws (2) on both side of the vehicle, and tighten securely.
8. Position the front wheel moldings (1b) and hand tap to engage the retaining clips.

BUMPERS > FASCIA, REAR > DISASSEMBLY AND ASSEMBLY > DISASSEMBLY AND
ASSEMBLY > DISASSEMBLY
Fig 1: Refector, Fascia Side, Screws & Retainers
2. Remove the rear fog lights. Refer to LAMP, FOG, REMOVAL AND INSTALLATION .
3. Remove the screws (1a) and remove the reflector (1b).
5. Separate the retainers (3a) and remove the fascia side (3b).
BUMPERS > FASCIA, REAR > DISASSEMBLY AND ASSEMBLY > DISASSEMBLY AND
ASSEMBLY > ASSEMBLY
1. Install the fascia sides and seat the retainers fully.
3. Install the reflector and tighten the screws.
4. Install the rear fog lights. Refer to LAMP, FOG, REMOVAL AND INSTALLATION .
BUMPERS > FASCIA, REAR > REMOVAL AND INSTALLATION > REMOVAL AND
Fig 1: Screws
2. Remove the tail lamps. Refer to LAMP, TAIL, REMOVAL AND INSTALLATION .
3. Remove the screws (1) at the bottom of the rear fascia.

Fig 2: Rear Wheel Molding, Clips & Screws
4. Using a trim stick or equivalent, release the clips (1a) and remove the rear wheel moldings
(1b).
5. Remove the screws (2a and 2b) from both sides of the front fascia.
Fig 3: Rear Fascia & Screws
6. Remove the screws (1a and 1b).
7. Remove the rear fascia.

8. Remove the screws (1a) and the reflectors (1b).
10. Using a small flat bladed tool, release the tabs (3a) and remove the rear fascia extension (3b).
BUMPERS > FASCIA, REAR > REMOVAL AND INSTALLATION > REMOVAL AND
1. Position the rear fascia extension (3b) and engage the tabs (3a).
2. Install the reflectors (1b) and tighten the screws (1a) securely.
Fig 2: Rear Fascia & Screws
4. Position the rear fascia (2) and install the screws (1a and 1b). Tighten the screws securely.
Fig 3: Rear Wheel Molding, Clips & Screws
5. Install the screws (2a and 2b) on both sides of the front fascia. Tighten the screws securely.
6. Position the rear wheel molding (1b) and hand tap to engage the retaining clips (1a).
Fig 4: Screws
7. Install the screws (1) at the bottom of the rear fascia and tighten securely.
8. Install the tail lamps. Refer to LAMP, TAIL, REMOVAL AND INSTALLATION .
BUMPERS > REINFORCEMENT, BUMPER, FRONT > REMOVAL AND INSTALLATION

Fig 1: Wiring Retaining Clips & Bracket Screws
2. Release the wiring retaining clips (1).
3. Remove the bracket screws (2).

Fig 2: Power Steering System Cooling Lines, Bumper, Clip And Bolts
4. Open the clip (1a) and move the power steering system cooling lines (1b) as necessary to
access the crossmember bolts.
5. Remove the bolts (2a) and remove the bumper (2b).

BUMPERS > REINFORCEMENT, BUMPER, FRONT > REMOVAL AND INSTALLATION
Fig 1: Power Steering System Cooling Lines, Bumper, Clip And Bolts
1. Install the bumper (1a) and install the bolts (1b).
2. Tighten the bolts (1b) and tighten the bolts to the proper specification. Refer to
SPECIFICATIONS .
3. Position the power steering cooling lines (2a) back into place and secure the clips (2b).
Fig 2: Wiring Retaining Clips & Bracket Screws
4. Install the bracket screws (1) and secure the wiring retaining clips (2).
FRAME > WARNING > USE OF HEAT DURING REPAIR
WARNING:
FCA US LLC engineering's position on the use of heat during collision repair is as follows:
Any body panel or frame component damaged which is to be repaired and

reused, must be repaired using the "cold straightening" method. No heat may be
used during the straightening process.
During rough straightening prior to panel replacement, damaged panels or

frame components may be heated to assist in body/frame realignment. The
application of heat must be constrained to the parts which will be replaced and
not allowed to affect any other components.
This "no heat" recommendation is due to the extensive use of high strength and
advanced high strength steels in FCA US LLC products. High-strength materials can
be substantially and negatively affected from heat input which will not be obviously
known to the repairer or consumer.
Ignoring these recommendations may lead to serious compromises in the ability to

protect occupants in a future collision event, reduce the engineered qualities and
attributes, or decrease the durability and reliability of the vehicle.
This statement supersedes any previously released information by the FCA US LLC.
Failure to follow these instructions may result in serious or fatal injury.
FRAME > WARNING > WARNINGS
WARNING:
Use an Occupational Safety and Health Administration (OSHA) approved breathing filter,
when spraying paint or solvents in a confined area. Failure to follow these instructions may
avoid prolonged skin contact with petroleum or alcohol based cleaning solvents.
do not stand under a hoisted vehicle that is not properly supported on safety stands.
CAUTION:
When holes are drilled or punched in an inner body panel, verify the depth of space to the
outer body panel, electrical wiring or other components. Damage to the vehicle can result.
do not weld exterior panels unless combustible material on the interior of vehicle is
removed from the repair area. Fire or hazardous conditions, can result.
always have a fire extinguisher ready for use when welding.
disconnect the negative (-) cable clamp from the battery when servicing electrical
components that are live when the ignition is off. Damage to electrical system can
result.
do not use abrasive chemicals or compounds on painted surfaces. Damage to finish

can result.
do not use harsh alkaline based cleaning solvents on painted or upholstered surfaces.
Damage to finish or color can result.
do not hammer or pound on plastic trim panel when servicing interior trim. Plastic
panels can break.
FRAME > WARNING > WARNINGS > RESTRAINT WARNINGS
WARNING:
components related to the SRS for which there is no Mopar® wiring repair kit. It is important
Mopar® wiring repair kits, please visit the Mopar® Connector Web Site at the following
address on the Internet: (http://dto.vftis.com/mopar/disclaimer.asp). Inappropriate repairs can
compromise the conductivity and current carrying capacity of those critical electrical circuits,
which may cause SRS components not to deploy when required, or to deploy when not
required. Only minor cuts or abrasions of wire and terminal insulation where the conductive
material has not been damaged, or connector insulators where the integrity of the latching
and locking mechanisms have not been compromised may be repaired using appropriate
methods.
WARNING:
Mopar® Parts Catalog. Failure to follow these instructions may result in possible serious or
fatal injury.
WARNING:
panel component diagnosis or service. Disconnect and isolate the battery negative (ground)
cable, then wait two minutes for the system capacitor to discharge before performing further
diagnosis or service. This is the only sure way to disable the SRS. Failure to follow these
instructions may result in accidental airbag deployment.
WARNING:
screens.
WARNING:
WARNING:
To avoid serious or fatal injury when handling a seat belt tensioner retractor. Exercise proper
care to keep fingers out from under the retractor cover and away from the seat belt webbing
where it exits from the retractor cover. Failure to follow these instructions may result in
WARNING:
components only with parts specified in the Mopar® Parts Catalog. Substitute parts may
appear interchangeable, but internal differences may result in inferior occupant protection.
WARNING:
service package or specified in the Mopar® Parts Catalog.
WARNING:
FRAME > CROSSMEMBER, FRONT SUSPENSION > REMOVAL AND INSTALLATION >
2.0L TURBO DIESEL 120HP/140HP > REMOVAL
Fig 1: Steering Column-To-Pinion Steering Box Screw
2. Remove the front wheels. Refer to REMOVAL AND INSTALLATION .
4. Remove the front wheelhouse splash shields. Refer to SHIELD, SPLASH, FRONT
6. Remove the screw (1) securing the steering column to the pinion steering box.
Fig 2: Bolt
7. Remove the bolts (1) and the load beam extensions.

Fig 3: Reinforcement Bracket Bolt
8. Remove the bolts and remove the reinforcement bracket (1).

Fig 4: Lower Load Beam & Bolts
9. Remove the bolts (1a) and remove the lower load beams (1b).
Fig 5: Stabilizer Bar Link Nut
10. Remove the stabilizer bar link nuts (1) at the front struts. Separate the stabilizer bar links from
the front struts.
Fig 6: Stabilizer Bar Link & Nut
11. Remove the stabilizer bar link nuts (1a) at the stabilizer bar. Separate the stabilizer bar links
(1b) from the stabilizer bar.
Fig 7: Tie Rod-To-Knuckles Nut
12. Remove the nuts (1) securing the tie rods to the knuckles.
Fig 8: Special Tool & Tie Rod
13. Fit the special tool #1871000700 (1a) and release the tie rods (1b) from the knuckles.
Fig 9: Wheel Swing Arm Bolt
14. Remove the bolts (1) at the wheel swing arms and separate the lower swing arms from the
knuckles.
Fig 10: Exhaust Pipe Support Bracket-To-Suspension Crossmember Bolts
15. Loosen the bolts (1) attaching the exhaust pipe support brackets to the suspension
crossmember.
Fig 11: Drainage Pipe, Nut & Screw
16. Remove the discharge pipe support bracket screw (1).
17. Remove the nuts (2a) and unhook the drainage pipe (2b) from the catalytic converter and
secure it to the side. Remove the gasket.
Fig 12: Lower Reaction Rod Bolts
18. Remove the bolt (1) securing the lower reaction rod to the engine.
19. Loosen the bolt (2) securing the lower reaction rod to the suspension crossmember.
Fig 13: Swing Arm Bolt
20. Loosen the bolt securing the swing arm, left and right, to suspension crossmember.
Fig 14: Bolts
21. Loosen the swing arm bolts (1).
22. Loosen the stabilizer bar bolts (2).
23. Loosen the steering gear bolts (3).

Fig 15: Supporting Front Suspension Crossmember
NOTE:
The following step requires the use of universal tool #2000043000, body centering
conical/round pin #2000043300, crossmember centering pin/bracket #2000043500
and crossmember centering pin #2000043600.
24. Using a suitable hydraulic lift, support the front suspension crossmember with the gear (1a),
(1b), (1c) and (1d) as shown in illustration.
Fig 16: Front Suspension Crossmember Bolt
25. Remove the bolts (1) attaching the front suspension crossmember to the left and right side
panels.
Fig 17: Front Suspension Crossmember & Bolts
26. Remove the bolts (1a) and remove the front suspension crossmember (1b).
27. Remove the front exhaust pipe.
28. Remove the bolt and remove the lower reaction rod to the suspension crossmember.
29. Remove the screws and bolts previously loosened and remove control arms, left and right.
30. Remove the screws previously loosened and remove the stabilizer bar.
31. Unscrew the bolts previously loose and remove the steering box.
2.0L TURBO DIESEL 120HP/140HP > INSTALLATION
1. With the tools used during removal, install the crossmember (1a) and tighten the screws (1b) to
the proper specification. Refer to SPECIFICATIONS .
2. Tighten the bolts attaching the crossmember to the left and right side panels to the proper
Fig 3: Supporting Lower Control Arm
3. Remove the crossmember lifting devise.
4. Place a suitable hydraulic jack under the lower control arm as shown in illustration.
5. Tighten the lower control arm to the suspension bolts to the proper specification. Refer to
FRONT, SPECIFICATIONS .
6. Tighten the stabilizer bar to the suspension bolts to the proper specification. Refer to FRONT,
SPECIFICATIONS .
7. Tighten the steering gear to the suspension bolts to the proper specification. Refer to
SPECIFICATIONS .
8. Tighten the reaction rod bolt (1) to the crossmember to the proper specification. Refer to
SPECIFICATIONS .
9. Tighten the reaction rod bolt (2) to the transmission bracket to the proper specification. Refer
to SPECIFICATIONS .
Fig 5: Drainage Pipe, Nut & Screw
10. Connect the exhaust pipe (1a) complete with new gasket to the catalytic converter and tighten
the new nuts (1b) to the proper specification. Refer to SPECIFICATIONS .
11. Install the bolt (2) and tighten to the proper specification. Refer to SPECIFICATIONS .
12. Install the bolts (1) attaching the exhaust pipe support brackets to the suspension
crossmember and tighten to the proper specification. Refer to SPECIFICATIONS .
Fig 7: Lower Ball Joint Boot
13. Check the integrity of the lower ball joint boot (1).
14. Attach the lower control arms to the steering knuckles and tighten the bolts (1) to the proper
specification. Refer to FRONT, SPECIFICATIONS .
Fig 9: Outer Tie Rod End-To-Steering Knuckle Nut
15. Connect the outer tie rod ends to the steering knuckles and install new nuts (1).
16. Tighten the nuts to the proper specification. Refer to FRONT, SPECIFICATIONS .
17. Install the stabilizer links (1a) and install the nuts (1b).
19. Install the upper stabilizer nuts (1) and tighten to the proper specification. Refer to FRONT,
SPECIFICATIONS .
20. Install the lower load beams (1a) and install the bolts (1b).
21. Tighten the bolts to the proper specification. Refer to SPECIFICATIONS .

Fig 13: Bolt
22. Install the lower load beam extensions and install the bolts (1).

24. Install the steering shaft onto the steering gear and tighten the bolt (1) to the proper
26. Install the front wheelhouse splash shields. Refer to SHIELD, SPLASH, FRONT
28. Install the front wheels. Refer to REMOVAL AND INSTALLATION .
29. Check and adjust alignment. Refer to WHEEL ALIGNMENT, STANDARD PROCEDURE .
2.4L MULTIAIR2, 1.4L TURBO MULTIAIR > REMOVAL
Fig 2: Bolt


the front struts.
knuckles.
Fig 10: O2 Sensor Electrical Connection
15. Disconnect the O2 sensor electrical connection to the catalytic converter.

Fig 11: Exhaust Pipe Support Bracket Bolt
16. Remove the bolts (1) of the front bracket supporting the exhaust pipe.
Fig 12: Support Bracket Bolts
17. Remove the bolts (1) securing the rear support bracket to the discharge pipe.
18. Remove the support bracket bolt (2).

Fig 13: Discharge Pipe & Nut
19. Remove the nuts and release the discharge pipe (1) from the catalytic converter and support it
to the side.
Fig 16: Bolts

NOTE:
(1b), (1c) and (1d) as shown in the illustration.
panels.
2.4L MULTIAIR2, 1.4L TURBO MULTIAIR > INSTALLATION
4. Place a suitable hydraulic jack under the lower control arm as shown in FIG.
SPECIFICATIONS .
SPECIFICATIONS .
8. Tighten the reaction rod bolt to the crossmember to the proper specification. Refer to
SPECIFICATIONS .
9. Tighten the reaction rod bolt to the transmission bracket to the proper specification. Refer to
SPECIFICATIONS .
Fig 5: Discharge Pipe & Nut
10. Connect the exhaust pipe complete with new gasket to the catalytic converter and tighten the
new nuts (1) to the proper specification. Refer to SPECIFICATIONS .
Fig 6: Support Bracket Bolts
11. Install the exhaust support bracket and install the bolts (1).
12. Tighten the bolts (1) to the proper specification. Refer to SPECIFICATIONS .
13. Install the support bolt (2) and tighten to the proper specification. Refer to SPECIFICATIONS .
Fig 7: Exhaust Pipe Support Bracket Bolt
14. Install the exhaust support bracket bolts (1) and tighten to the proper specification. Refer to
SPECIFICATIONS .
SPECIFICATIONS .

Fig 14: Bolt

2.0L TURBO DIESEL 170HP > REMOVAL
Fig 2: Load Beam & Bolts
8. Remove the bolts (2) and remove the lower load beams.
the front struts.
knuckles.
Fig 8: Brackets & Collar Bolts
14. Remove the front bracket bolts (1).
15. Remove the rear bracket bolts (2).
16. Loosen the collar bolt (3).

Fig 9: Discharge Pipe & Collar Bolts
17. Remove the discharge pipe support collar bolt (1).
18. Remove the nuts and separate the discharge pipe (2) from the catalytic converter and secure
it to the side.
Fig 12: Bolts

NOTE:
panels.
2.0L TURBO DIESEL 170HP > INSTALLATION
Fig 4: Reaction Rod Bolts
5. Tighten the reaction rod bolt to the crossmember to the proper specification. Refer to
SPECIFICATIONS .
6. Tighten the reaction rod bolt to the transmission bracket to the proper specification. Refer to
SPECIFICATIONS .
Fig 5: Exhaust Pipe & Bolt
7. Connect the exhaust pipe (1) complete with new gasket to the catalytic converter and tighten
the new nuts to the proper specification. Refer to SPECIFICATIONS .
Fig 6: Collar & Support Bracket Bolts
9. Install the exhaust support brackets and install the bolts (2, 3).
10. Tighten the bolts (2, 3) to the proper specification. Refer to SPECIFICATIONS .
11. Install the collar bolt (1).

SPECIFICATIONS .
Fig 12: Load Beam & Bolts

1.6L TURBO DIESEL > REMOVAL
Fig 2: Bolt


the front struts.
knuckles.
Fig 10: O2 Sensor Electrical Connection
15. Disconnect the O2 sensor electrical connection to the catalytic converter.

16. Remove the bolts (1) of the front bracket supporting the exhaust pipe.
Fig 12: Connection, Bolt & Nuts
17. Remove the bolt (1) securing the exhaust pipe support bracket collar.
18. Unscrew the connection (2) and disconnect the exhaust gas downstream particulate filter
(DPF) outlet pipe.
19. Unscrew the nuts (3) and disconnect the discharge pipe from the particulate filter (DPF).
Fig 15: Bolts

NOTE:
panels.
1.6L TURBO DIESEL > INSTALLATION
SPECIFICATIONS .
SPECIFICATIONS .
8. Tighten the reaction rod bolt (1) to the crossmember to the proper specification. Refer to
SPECIFICATIONS .
9. Tighten the reaction rod bolt (2) to the transmission bracket to the proper specification. Refer
to SPECIFICATIONS .
Fig 5: Connection, Bolt & Nuts
10. Connect the exhaust pipe complete with new gasket to the catalytic converter and tighten the
new nuts (1) to the proper specification. Refer to SPECIFICATIONS .
11. Install and tighten the exhaust gas pressure pipe downstream of the particulate filter (DPF) (2).
13. Install the bolts (1) attaching the exhaust pipe support brackets to the suspension
crossmember and tighten to the proper specification. Refer to SPECIFICATIONS .
SPECIFICATIONS .

Fig 14: Bolt

FRAME > CROSSMEMBER, REAR SUSPENSION > REMOVAL AND INSTALLATION >
2.4L MULTIAIR2, 1.4L TURBO MULTIAIR > REMOVAL - 4X2
Fig 1: Sway Bar Link & Nut
2. Remove the hub and bearing. Refer to HUB AND BEARING, REMOVAL AND INSTALLATION .
3. Remove the rear muffler. Refer to MUFFLER, EXHAUST, REMOVAL AND INSTALLATION .
4. Remove the nut (1) and disconnect the sway bar link from the stabilizer bar.
5. Proceed in the same way to disconnect the right side sway bar link from the stabilizer bar.
Fig 2: Left Rear Lower Control Arm Bolts
6. Remove the bolt (1) securing the left rear lower control arm to the rear knuckle.
7. Remove the bolt (2) securing the left rear lower control arm to the crossmember.
8. Remove the left rear lower control arm.
9. Proceed in the same way to disconnect the right side rear lower control arm from the
crossmember.
Fig 3: Left Front Lower Control Arm Bolts
10. Remove the bolt (1) securing the left front lower control arm to the rear knuckle.
11. Remove the bolt (2) securing the left front lower control arm to the crossmember.
12. Remove the left front lower control arm.
13. Proceed in the same way to remove the right side lower control arm.
Fig 4: Cap
14. Remove the cap (1), left and right side to use the hole in the body for the location tool.
Fig 5: Tools, Bolt & Rear Suspension Crossmember
NOTE:
15. Position the tool (1a) as indicated in the illustration, remove the bolts (1b) and remove the rear
suspension crossmember (1c).
2.4L MULTIAIR2, 1.4L TURBO MULTIAIR > INSTALLATION 4X2
Fig 1: Tools, Bolt & Rear Suspension Crossmember
1. With the tools used for removal, position the rear suspension crossmember (1a) and tighten
the bolts (1b) to the proper specification. Refer to SPECIFICATIONS .
2. Remove the tools and install the caps in the holes on the body, on the right and left side.
3. Position the lower control arms, left side, and loosely install the bolts to the crossmember and
rear knuckle.
Fig 2: Wheel Speed Sensor & Screw
NOTE:
Be certain the wheel speed sensor does not approach any magnetic fields.
4. On the left side, remove the screw and wheel speed sensor (1) from the knuckle.
Fig 3: Electrical Connection
5. Disconnect the electrical connection (1) for the electric parking brake electromechanical
actuator on the break caliper.
Fig 4: Hydraulic Lift & Bolts
6. Place a suitable hydraulic lift (1) under the rear knuckle.
7. Remove the bolts (2) securing the rear strut to the rear knuckle.
Fig 5: Rear Knuckle & Strut Holes
8. Lower the hydraulic lift, in order to secure the rear strut to the suspension crossmember as
appropriate so as to move the lower part of the rear strut away from the rear knuckle (1).
9. Use the hydraulic lift to make sure that the mounting holes for the rear knuckle correspond to
the holes of the rear strut.
Fig 6: Hydraulic Lift & Bolts
10. Use the hydraulic lift (1) to raise the rear knuckle by about 95 mm (2.5 in).
11. Tighten the bolt (2) attaching the rear lower control arm to the rear knuckle to the proper
12. The bolt securing the rear lower control arm to the crossmember will be tightened to torque
specification during the toe-in alignment.
Fig 7: Front Rear Lower Control Arm Bolts
13. Tighten the bolt (1) securing the front rear lower control arm to the front of the rear suspension
crossmember to the proper specification. Refer to SPECIFICATIONS .
14. Tighten the bolt (2) securing the front rear lower control arm to the rear knuckle to the proper
Fig 8: Rear Strut-To-Rear Knuckle Bolts
15. Turn the hydraulic lift to lower the rear knuckle to align it to the mounting holes on the rear strut
and insert the bolts.
16. Remove the hydraulic lift.
17. Tighten the rear strut to rear knuckle bolts to proper specification. Refer to SPECIFICATIONS .
Fig 9: Wheel Speed Sensor & Screw
18. Connect the electrical connection for the electric parking brake electromechanical actuator on
the break caliper.
19. Position the wheel speed sensor on the left side and insert the screw. Tighten the wheel speed
sensor screw to the proper specification. Refer to SPECIFICATIONS .
20. Proceed in the same way to install the lower control arms on the right side.
Fig 10: Sway Bar Link & Nut
21. Connect the sway bar link to the stabilizer bar and install a new nut to the proper specification.
22. Proceed in the same way to install the sway bar link to the stabilizer bar.
23. Install the rear muffler. Refer to MUFFLER, EXHAUST, REMOVAL AND INSTALLATION .
24. Install the hub and bearing. Refer to HUB AND BEARING, REMOVAL AND INSTALLATION .
25. Perform wheel alignment. Refer to WHEEL ALIGNMENT, STANDARD PROCEDURE .
4X4 > REMOVAL - 4X4
2. Remove the rear muffler. Refer to MUFFLER, EXHAUST, REMOVAL AND INSTALLATION .
3. Remove both rear tires and wheels. Refer to REMOVAL AND INSTALLATION .
4. Remove the rear brake hose. Refer to TUBES AND HOSES, BRAKE, REMOVAL AND
INSTALLATION .
5. Remove rear disc brakes. Refer to CALIPER, DISC BRAKE, REAR, REMOVAL AND
INSTALLATION .
6. Remove the rear suspension knuckle with hub and bearings. Refer to KNUCKLE, REAR,
7. Remove the rear halfshafts Refer to REMOVAL AND INSTALLATION .
8. Remove the rear stabilizer bar. Refer to STABILIZER BAR, REAR SUSPENSION, REMOVAL
AND INSTALLATION .
9. Remove the rear drive line module. Refer to REMOVAL AND INSTALLATION .
Fig 1: Rear Suspension Control Arms & Bolts
10. Remove the bolts (1) and remove the rear suspension control arms.
Fig 2: Supporting Rear Suspension Crossmember
NOTE:
The following step requires the use of universal tool 2000043000, body centering
conical/round pin 2000043300, crossmember centering pin/bracket 2000043500
and crossmember centering pin 2000043600
11. Using a suitable hydraulic lift, support the rear suspension crossmember with the tools (1a, 1b,
1c and 1d), as shown in the illustration.
Fig 3: Rear Suspension Crossmember & Bolt
12. Remove the bolts (1a) and remove the rear suspension crossmember (1b).
4X4 > INSTALLATION 4X4
Fig 1: Rear Suspension Crossmember & Bolt
1. With the tools used for removal, position the rear suspension crossmember (1a) and tighten
2. Remove the hydraulic lift complete with tools.
3. Install the rear suspension control arms but do not tighten the fasteners at this time.
4. Install the rear drive line module. Refer to REMOVAL AND INSTALLATION .
5. Install the rear stabilizer bar. Refer to STABILIZER BAR, REAR SUSPENSION, REMOVAL
AND INSTALLATION .
6. Install the rear halfshafts Refer to REMOVAL AND INSTALLATION .
7. Install the rear suspension knuckle with hub and bearings. Refer to KNUCKLE, REAR,
8. Install rear disc brakes. Refer to CALIPER, DISC BRAKE, REAR, REMOVAL AND
INSTALLATION .
9. Install the rear brake hose. Refer to TUBES AND HOSES, BRAKE, REMOVAL AND
INSTALLATION .
10. Install both rear tires and wheels. Refer to REMOVAL AND INSTALLATION .
11. Install the rear muffler. Refer to MUFFLER, EXHAUST, REMOVAL AND INSTALLATION .
UNDER BODY PROTECTION > BELLY PAN > REMOVAL AND INSTALLATION >
REMOVAL AND INSTALLATION > 1.4L MULTIAIR TURBO, 1.6L TURBO DIESEL
Fig 1: Belly Pan, Retainers & Screws
REMOVAL
2. Remove the screws (1a) securing the belly pan (1b).
3. Remove the belly pan (1b) release the retainers (2a).
REMOVAL AND INSTALLATION > 2.0L TURBO DIESEL 4X4
Fig 1: Belly Pan & Screws
REMOVAL
2. Remove the screws (1a) securing lower fascia.
3. Support the belly pan (2a) with a suitable lifting device.
4. Remove the screws (3a) securing the belly pan.
5. Remove the belly pan (2a).
REMOVAL AND INSTALLATION > 1.4L MULTIAIR TURBO, 1.6L TURBO DIESEL
INSTALLATION
1. Check that the belly pan is not damaged.

2. Position the belly pan back onto the vehicle and seat the retainers fully.
REMOVAL AND INSTALLATION > 2.0L TURBO DIESEL 4X4
Fig 1: Belly Pan & Screws
INSTALLATION
2. Using a suitable lifting device, position the belly pan back onto the vehicle.
3. Tighten the screws (2a) securing to the proper specification. Refer to SPECIFICATIONS .
4. Install the screws (3a) securing the lower fascia.
UNDER BODY PROTECTION > BELLY PAN, SIDE > REMOVAL AND INSTALLATION >
Fig 1: Underbody Lift Points
2.4L MultiAir2
2. If you use bridge lift arms, put the pads of the lift arms only at the points indicated underbody,
using, if necessary suitable spacers pads rubber or wood.
Fig 2: Belly Pan, Nuts & Retainers
3. Remove the nuts (1).
4. Remove the retainers (2) and remove the belly pan (3).
Fig 3: Belly Pans & Screws
2.0L Turbo Diesel 4X4
2. Support the belly pan (1a, 1b) with a suitable lifting device.
3. Remove the screws (2a) and remove the belly pan (3).
UNDER BODY PROTECTION > BELLY PAN, SIDE > REMOVAL AND INSTALLATION >
2.4L MultiAir2
2. Position the belly pan back onto the vehicle and seat the retainers fully.
2.0L Turbo Diesel 4X4

2. Using a suitable lifting device, position the belly pan back onto the vehicle.
3. Tighten the screws to the proper specification. Refer to SPECIFICATIONS .

Jeep Renegade
Service Manual: HEATED SEATS - SERVICE INFORMATION
Fig 1: Switch Unit
The car can be equipped with heated front seats and heated steering wheel. Both can be activated or
deactivated through dedicated keys of the switch unit on the Centre console.
The driver and front passenger seats have two heating setting levels while the steering wheel has only
one level.
On models equipped with Remote Start, the heated steering wheel and the heated seats will activate
automatically during the remote start at temperatures below 40°F (4.4°C).
When the occupants of the front seats request the activation of the heated seats (two heating levels) or
the steering wheel through the central control panel, the command is sent via LIN line to the BCM. The
BCM translates the command received and sends it via BH CAN to the seats/steering wheel heating
control unit (CSWM). The CSWM will supply the heater pads placed on the front seat backrests and
cushions and will receive the signal directly from the two temperature sensors (one per seat) in the
cushions, to learn the temperature of the seats and implement the correct strategies for supplying the
heater pads. The heater pads in the steering wheel cover are supplied directly by the CSWM, while the
temperature signal is received by the SWS (steering wheel switch unit) and sent via LIN to the BCM
which will put it on the CAN network.
The CSWM monitors the operation of the system and will generate the appropriate DTCs in the event of
failure.
When operating the heated seat switch, one of three switch positions can be selected: OFF, LOW, or
HIGH. The CSWM can provide three levels of power to the heating elements for the HIGH setting. These
power levels are changed by modulating the pulse width of the positive side of the circuit. The strategy
used by the CSWM is to operate the heating element at the highest pulse-width until the target time or
temperature for the pulse width is met. The CSWM then reduces the pulse width and repeats this
process until the system times out. When the LOW setting is selected, the pulse width remains at 25%
until the target temperature or time is reached (205 minutes for leather and 115 minutes for fabric). The
following table provides an overview of the adjustment strategy used to control the amount of current
provided to the seat heating elements:
Parameter name Definition Unit Leather Fabric

Temp_OFF Maximum temperature for heating program °C 67 55
DH_S3 PWM for heating - high level 3 s 100% 100%
TempSH3 Maximum temperature for seat heating level 3 °C 50 34
T1S First timing program for seat heating min. 25 20
DH_S2 PWM for heating level 2 s 40% 70%
T2S Second timing program for seat heating min. 85 35
T3S Third timing program for seat heating min. 145 95
DL_S1 PWM for heating level Low s 25% 25%
TempSL1 Maximum temperature for heating program Low °C 65 48
T4S Fourth timing program for seat heating min. 205 115
Fig 1: Heated Systems Circuit Diagram
1. CSWM
2. Cushion heater
3. Backrest heater
4. BCM
5. SWS (steering wheel switch unit)
6. Steering wheel heater
7. CSS (central control panel)
8. Cushion heater
9. Backrest heater
10. Clock spring junction
Power supply of the seat heating control unit reaches from relay switch located in the luggage
compartment fuse box, through a line protected by a fuse.
Relay switch receives an ignition-operated power supply (INT) from the line protected by a fuse.
The control unit then connects via CAN to the other network nodes.
The BCM receives a direct power supply from the battery through the line protected by a maxi fuse
located in the engine compartment junction unit.
The BCM receives an ignition-operated power supply (INT). This signal is used, amongst other things, to
"wake up the network".
The coil activation signal reaches the BCM via the LIN line.
Controls for the steering wheel coil are sent through coil spring, whose control thermostat is located in
the steering wheel controls.
DIAGNOSIS AND TESTING > DIAGNOSIS AND TESTING - HEATED SEAT SYSTEM
NOTE:
Vehicles equipped with the heated seat option utilize a low voltage cut-off feature. This
feature turns off power to the heated seat system anytime vehicle voltage is below 11.7 volts
or above 15.5 volts. Be certain to check the vehicle electrical system for proper voltage
anytime the heated seat system appears inoperative.
NOTE:
If a Diagnostic Trouble Code (DTC) can not be verified, it is a good indication that an
intermittent fault condition may be present. To help find an intermittent problem, sit in the seat
in question and move around the heating elements within the seat while testing continuity.
Wiggle the heated seat wire harness and electrical connectors while testing continuity.
NOTE:
For complete circuit diagrams, refer to appropriate SYSTEM WIRING DIAGRAMS article .
Wiring Information includes wiring diagrams, connector pin-out and location views, details of
wire harness routing and retention, splice and ground locations and proper wire and
connector repair procedures.
Before testing any individual components in the heated seat system, check the following:
Check the vehicles battery open-circuit voltage and charging system performance. If the vehicle's
electrical system is defective or weak it may not be suppling sufficient energy to operate the
heated seat system.
Using a scan tool, check for any Diagnostic Trouble Codes (DTCs) related to the Body Control
Module (BCM) and the heated seat switches. If any DTCs are found, repair as necessary. Refer to
If there are no DTCs and a front heated seat does not operate properly, verify heated seat relay
operation, and repair as necessary.
If there are no DTCs and the front seat heating elements are receiving battery power and have a
good ground, test the seat heating elements for proper operation, and repair as necessary.
If there are no DTCs and the front heated seat system functions properly, but the Light Emitting
Diode (LED) indicator in a heated seat switch does not illuminate, replace the seat switch
assembly located in the seat frame housing.
PAD, HEATER > REMOVAL AND INSTALLATION > REMOVAL AND INSTALLATION >
HEATED SEAT PAD - REMOVAL
2. Remove the seat cushion and cover. Refer to SEAT CUSHION, REMOVAL AND
INSTALLATION .
Fig 1: Heating Pad, Adhesive Surfaces & Wiring
3. Remove the heating pad (1a) by detaching the adhesive surfaces (1b) and (1c) and
disengaging the wiring (1d).
4. If the adhesive starts peeling off the adhesive surfaces (1b) of the heating pad, replace the
heating pad.
NOTE:
Be careful not to damage the passenger occupant sensor in the padding of the
passenger seat cushion.
PAD, HEATER > REMOVAL AND INSTALLATION > REMOVAL AND INSTALLATION >
HEATED SEAT PAD - INSTALLATION
1. Check that the heating pad is not damaged.
2. If the heating pad is being reused, apply adhesive spray for plastics to the adhesive surfaces.
3. If using a new heating pad, remove the protective film of adhesive surfaces.
4. Put the heating pad in place, centering on padding slots and feed the wiring harness connector
through the connector hole on the padding.
5. Install the heating pad to the adhesive surfaces.
6. Wait the necessary time for the adhesive glue to dry before installing the cover.
7. If reusing the heating pad, refer to the time indicated by the supplier of spray glue used.
8. For new heating pad installations, refer to the time specified by the supplier of the parts.
9. Install the seat cover and cushion. Refer to SEAT CUSHION, REMOVAL AND INSTALLATION .

Jeep Renegade
Service Manual: POWER LOCKS - SERVICE INFORMATION
A power operated door lock system is standard factory-installed equipment on this vehicle. The power
lock system allows all doors to be locked or unlocked electrically. Locking or unlocking the vehicle using
the power lock system can be accomplished by two different methods:
Power Lock System - Operating the door lock switch located in the instrument panel center stack
operates lock and unlock for all doors on this vehicle.
Remote Keyless Entry System - Depressing the Lock or Unlock button of the standard
equipment Remote Keyless Entry (RKE) system transmitter can also be used to lock or the front
and side doors. A third button is added for rear cargo doors on cargo and glazed door vans.
Additional details of each of these subsystems and their components can be found in the subheadings
and paragraphs that follow.

> POWER LOCK SYSTEM
Door locking function - The electric door locks are controlled by the BCM. This locks and unlocks the
doors on the basis of two control types: external and internal.
External controls - The external door locking/unlocking commands can arrive from the following
components:
Closing/opening buttons on RF remote controls of keys
Key cylinder on driver door handle
Passive Entry System.
The BCM receives the RF signals from the locking/unlocking buttons on the remote controls via an
aerial. The movement of the key cylinder on the driver door handle is detected by a switch connected
electrically to the BCM.
Fig 1: Door Lock And Unlock Switch
The internal door locking/unlocking commands can arrive from the following components:
Buttons on driver door panel
Buttons on passenger door panel.
Car speed above 20 km/h (speed information for BCM via CAN)
Door unlock request from FPS (Fire Prevention System).
In every ignition switch position (OFF, RUN, START) the BCM, before sending the door locking/unlocking
command, checks the status of the doors (open or closed) through the switches in the locks.
Status of door status switches
Driver side door switch: if the door is closed the switch is open; if the door is open the switch is
closed.
Passenger side door switch: if the door is closed the switch is open; if the door is open the switch
is closed.
Rear door switches: if the doors are closed the switches (left and right) are open; if the doors are
open, the switches are closed.
Tailgate switch: if the tailgate is closed, the switch is closed; if the tailgate is open, the switch is
open.
Bonnet switch: if the bonnet is open the switch is open; if the bonnet is closed the switch is closed.
(There is only a bonnet switch if there is an alarm.)
System without Passive Entry - The BCMs on NAFTA-version vehicles can manage door locking even
if one or more doors are open. Door locking will not be carried out only if the key is in the ignition switch.
The BCMs on EMEA-version vehicles cannot manage door locking if one or more doors are open.
System with Passive Entry - Where there is the passive entry system, the doors can be locked
centrally even if one or more doors are open. When the last door is closed, the BCM will request that the
RH module locates the keys: if these are outside of the car, the doors will maintain "locked" status. If, on
the other hand, they are inside the vehicle, the BCM will centrally unlock the doors. EMEA-version
vehicles may have electric locks with deadlocking. It is not available for NAFTA-version vehicles.
Fig 2: Electric Locks Assembly
Electric locks - Inside the electric locks is a PTC element in series with their electric motors. The PTC
elements permits thermal protection in the event that the BCM continues to supply current to the motors
due to a fault. The resistance of the PTC element increases as its temperature increases, consequently
interrupting the electrical circuit.

> REMOTE KEYLESS ENTRY SYSTEM
The Remote Keyless Entry (RKE) system is standard factory-installed equipment on this vehicle. The
RKE system includes the following major components, which are described in further detail elsewhere in
this service information:
Body Control Module - The Body Control Module (BCM) is the RKE system control module.
SKREEM controller and the RF receiver. The BCM is located under the driver side end of the
instrument panel in the passenger compartment.
Remote Keyless Entry System Transmitter - The Remote Keyless Entry (RKE) system
transmitter is the battery powered, wireless and portable Radio Frequency (RF) user controller for
all of the features of the RKE system.
These components and their controls are combined to provide the following RKE system features:
Remote Locking - Depressing the Lock button of the FOBIK while within transmitter range will
lock all of the vehicle doors and the liftgate.
Remote Unlocking - Depressing the Unlock button of the RKE transmitter while within
transmitter range will unlock the vehicle and activate the Illuminated Entry System.
Hard wired circuitry connects many of the RKE system components to the electrical system of the
the vehicle electrical system and to the RKE system components through the use of a combination of
soldered splices, splice block connectors, and many different types of wire harness terminal connectors
and insulators. Refer to the appropriate wiring information. The wiring information includes wiring
diagrams, proper wire and connector repair procedures, further details on wire harness routing and
retention, as well as pin-out and location views for the various wire harness connectors, splices and
grounds.
POWER DOORLOCK
The power lock system uses non-switched battery current received through a fused B(+) fuse so that the
system remains operational regardless of the ignition switch position. The Body Control Module (BCM) is
the primary power lock system controller. The power lock switch (also known as the door inhibit switch)
is hard wired to the BCM.
When the BCM receives an input from the power lock switch, it provides the appropriate hard wired
control outputs to energize or de-energize the power lock relays soldered onto its printed circuit board.
The relays control the flow of battery current and ground to each of the power lock motors to lock or
unlock each of the doors.
The BCM also stores the power lock system Customer Programmable feature settings received from the
Electronic Vehicle Information Center (EVIC) circuitry of the Instrument Panel Cluster (IPC). The BCM
uses these settings and internal programming along with hard wired and electronic message inputs to
determine the proper outputs needed to produce each of the appropriate power lock system features.
The power lock system circuits are continually monitored and controlled by the microcontroller and
software contained within the BCM. When the BCM monitors a problem in any of the power lock system
circuits or components, it stores a fault code or Diagnostic Trouble Code (DTC) in its memory circuit.
The hard wired circuits between components related to the power lock system may be diagnosed using
conventional diagnostic tools and procedures. Refer to the appropriate wiring information. The wiring
harness routing and retention, connector pin-out information and location views for the various wire
However, conventional diagnostic methods will not prove conclusive in the diagnosis of the power lock
system or the electronic controls or communication between other modules and devices that provide
some features of the power lock system. The most reliable, efficient, and accurate means to diagnose
the power lock system or the electronic controls and communication related to power lock system
operation, as well as the retrieval or erasure of a DTC requires the use of a diagnostic scan tool. Refer
to the appropriate diagnostic information.
REMOTE KEYLESS ENTRY SYSTEM
The Remote Keyless Entry (RKE) system uses non-switched battery current received through a fused
B(+) fuse so that the system remains operational regardless of the ignition switch position. The Body
Control Module (BCM) is the primary RKE system controller as well as the Radio Frequency (RF) RKE
receiver. The BCM validates the vehicle access code of each RKE transmitter from which it receives RF
signal inputs. It ignores requests from any transmitter for which it has no stored vehicle access code.
When the BCM receives an input from a valid transmitter source, it uses internal programming to provide
the appropriate hard wired outputs to invoke the proper RKE system features and responses.
The RKE system circuits and transmitter inputs are continually monitored by the microcontroller and
software contained within the BCM. When the BCM monitors a problem in any of the RKE system
circuits or transmitters, it stores a DTC in its memory circuit. The hard wired circuits between
components related to the RKE system may be diagnosed using conventional diagnostic tools and
procedures. Refer to the appropriate wiring information. The wiring information includes wiring diagrams,
proper wire and connector repair procedures, details of wire harness routing and retention, connector
pin-out information and location views for the various wire harness connectors, splices and grounds.
However, conventional diagnostic methods will not prove conclusive in the diagnosis of the RKE system
or the electronic controls and devices that provide features of the RKE system. The most reliable,
efficient, and accurate means to diagnose the RKE system or the electronic controls related to RKE
system operation, as well as the retrieval or erasure of a DTC requires the use of a diagnostic scan
tool. Refer to the appropriate diagnostic information.
DIAGNOSIS AND TESTING > DIAGNOSIS AND TESTING - POWER LOCKS AND
REMOTE KEYLESS ENTRY SYSTEM > POWER LOCK SYSTEM
Following are tests that may help to diagnose the hard wired components and circuits of the power lock
system. However, these tests may not prove conclusive in the diagnosis of this system. The most
reliable, efficient, and accurate means to diagnose the power lock system requires the use of a
diagnostic scan tool and the appropriate diagnostic information. The diagnostic scan tool can provide
confirmation that the power lock motors are receiving the proper hard wired outputs from the Body
Control Module (BCM) for them to perform their power lock system functions.
Refer to the appropriate wiring information. The wiring information includes wiring diagrams, proper wire
and connector repair procedures, details of wire harness routing and retention, connector pin-out
information and location views for the various wire harness connectors, splices and grounds.
REMOTE KEYLESS ENTRY SYSTEM > POWER LOCK SYSTEM > PRELIMINARY
DIAGNOSIS
As a preliminary diagnosis for the power lock system, note the system operation while you actuate both
the Lock and Unlock functions with the power lock switch and with the Remote Keyless Entry (RKE)
transmitter. Then, proceed as follows:
1. If the entire power lock system fails to function with either the power lock switch or the RKE
transmitter, check the fused B(+) fuse for the power lock system in the Power Distribution
Center (PDC).
2. If the power lock system functions with the power lock switch, but not with the RKE transmitter,
proceed to diagnosis of the RKE system.
3. If the power lock system functions with the RKE transmitter, but not with the power lock switch,
proceed to diagnosis of the door lock switch.
4. If only one power lock motor fails to operate with the power lock switch and the RKE
transmitter, proceed to diagnosis of the power lock motor.
REMOTE KEYLESS ENTRY SYSTEM > REMOTE KEYLESS ENTRY SYSTEM
Following are tests that may help to diagnose the Remote Keyless Entry (RKE) system. However, these
tests may not prove conclusive in the diagnosis of this system. The most reliable, efficient, and accurate
means to diagnose the RKE system requires the use of a diagnostic scan tool and the appropriate
diagnostic information. The diagnostic scan tool can provide confirmation that the Body Control Module
(BCM) is being sent the proper Radio Frequency (RF) signals by the RKE transmitters to perform its
RKE system functions.
and connector repair procedures, details of wire harness routing and retention, connector pin-out
REMOTE KEYLESS ENTRY SYSTEM > REMOTE KEYLESS ENTRY SYSTEM >
PRELIMINARY DIAGNOSIS
As a preliminary diagnosis for the RKE system, first confirm that the power lock system operates
satisfactorily. If the power lock system fails to operate correctly, repair that problem before attempting to
diagnose the RKE system. Next, note the RKE system operation while you perform both the Lock and
Unlock functions with the RKE transmitter. Then, proceed as follows:
1. If the power lock system functions with the power lock switch, but not with the RKE transmitter,
proceed to diagnosis of the RKE transmitter.
2. If the RKE transmitter checks okay, proceed to diagnosis of the BCM. The use of a diagnostic
scan tool and the appropriate diagnostic information are required.
ANTENNA, PASSIVE ENTRY > REMOVAL AND INSTALLATION > FLOOR CONSOLE >
REMOVAL
Fig 1: Passive Entry Antenna, Connector & Screws
3. Disconnect the wiring connector (1) from the passive entry antenna (2b).
4. Remove the mounting screws (2a) and remove the passive entry antenna.
ANTENNA, PASSIVE ENTRY > REMOVAL AND INSTALLATION > FLOOR CONSOLE >
INSTALLATION
1. Make sure that the passive entry antenna is not damaged.
2. Place the antenna and tighten the screws.
3. Connect the electrical connector to the antenna.
ANTENNA, PASSIVE ENTRY > REMOVAL AND INSTALLATION > LIFTGATE >
LIFTGATE - REMOVAL
Fig 1: Tailgate Trim Panel, Retainers & Screw
2. Remove the retaining screw (1).
3. Using special tool, remove retainers (2) from the tailgate trim panel.
4. Remove the tailgate trim panel (3).

Fig 2: Antenna, Support, Rivets & Connector
5. Disconnect the antenna electrical connection (1).
6. Remove the rivets (2a) and remove the antenna from the tailgate (2b) with the support (2c).
ANTENNA, PASSIVE ENTRY > REMOVAL AND INSTALLATION > LIFTGATE >
INSTALLATION
1. Make sure the passive entry antenna is not damaged.
2. Place the antenna and secure using rivets.
3. Connect the electrical connector to the antenna.
ANTENNA, PASSIVE ENTRY > REMOVAL AND INSTALLATION > REAR DOOR >
REMOVAL

Fig 1: Rear Door Flange & Retainers
2. Remove the retainers (1a) and remove the flange from the rear door (1b).
Fig 2: Inside Handle, Flange & Screw
3. Pull the inside handle (1a) of the rear side door and use a suitable tool to remove the flange
(1b).
4. Pull the inside handle and remove the screw.

Fig 3: Switch, Pad, Clips & Screw
5. Remove the pad (1a) and remove the screw below (1b).
6. Use the appropriate tool to prop the power window control switch (2a), releasing the retaining
clips (2b).
7. Disconnect the electrical connections.

Fig 4: Screws Inside Of Rear Armrest
8. Loosen the screws on the inside of the rear armrest on the door.
Fig 5: Door Panel Screw
9. Remove the screw at the bottom of the panel.

Fig 6: Inner Door Panel, Latches, Rods, Ends & Retainers
10. Using a special tool, remove the retainers (1a) and fold the inner door panel (1b).
11. Untie the latches (2a) of the tie rods (2b) and unplug the ends (2c) and remove the inner door
panel (1b).
Fig 7: Passive Entry Antenna, Connector & Screws
12. disconnect the connector (1) from the passive entry antenna (2b).
13. Remove the mounting screws (2a) and remove the antenna passive entry from rear door (2b).
ANTENNA, PASSIVE ENTRY > REMOVAL AND INSTALLATION > REAR DOOR >
INSTALLATION
2. Place the antenna and tighten the screws.
3. Before installing the door panel, check that all the fixings of the panel and the inner frame door
are intact. If necessary replace them.
4. Place the inner panel near the door, without reattach at this stage.
5. Connect the tie rods to the inside handle, securing fasteners and engaging the ends.
6. By exerting a consistent pressure, fit the hardware of the door panel in their seats on the door
frame.
7. Tighten the bottom mounting screws.

8. Tighten the inside front armrest screw.
9. Connect window switch electrical connections.
10. Install the window switch.
11. Screw the retaining screw and insert the mat.
12. Pull the inside door handle front side, tighten the screw and mount the flange.
13. Insert the flange in the inside rear of the rear door and engage the retainers.
ANTENNA, PASSIVE ENTRY > REMOVAL AND INSTALLATION > REAR FASCIA >
REMOVAL
Fig 1: Passive Entry Antenna, Connector & Rivets
3. Disconnect the passive entry antenna (2b) wiring harness connection (1).
4. Using a drill fitted with a suitable tip, remove the rivets (2a) and remove the antenna.
ANTENNA, PASSIVE ENTRY > REMOVAL AND INSTALLATION > REAR FASCIA >
INSTALLATION
2. Place the passive entry antenna and secure it with suitable rivets.
3. Connect the electrical connection to the antenna.
SWITCH, LOCK > REMOVAL AND INSTALLATION > REMOVAL AND INSTALLATION >
DRIVER DOOR GANG SWITCH - REMOVAL

Fig 1: Pad & Screw
2. Remove the pad (1a) and unscrew the screw below (1b).
3. Using the suitable tool, lift the gang switch assembly (1a) by releasing the retaining clips (1b).
4. Disconnect the electrical connections (2a, 2b)
SWITCH, LOCK > REMOVAL AND INSTALLATION > REMOVAL AND INSTALLATION >
DRIVER DOOR GANG SWITCH - INSTALLATION
1. Connect the driver door gang switch electrical connector.
2. Seat the driver door gang switch into the door panel.
3. Insert and tighten the screw securing the switch to the door.
4. Insert the cover.

Service Manual: POWER MIRRORS - SERVICE Jeep Renegade
INFORMATION
SWITCH, MIRROR > DIAGNOSIS AND TESTING > DIAGNOSIS AND TESTING
1. Remove the power mirror switch.
2. Disconnect the wiring harness connector from the switch.
3. Using a ohmmeter, test for continuity between the terminals of the switch.
4. If results shown in the table are not obtained, replace the switch.
POWER MIRROR SWITCH TEST
SWITCH POSITION CONTINUITY BETWEEN
MIRROR SELECT SWITCH IN "LEFT"

POSITION
UP 6-16
15-13
DOWN 8-16
15-13
LEFT 6-16
15-13
RIGHT 8-13
15-16
MIRROR SELECT SWITCH IN "RIGHT"

POSITION
UP
14-16
17-13
DOWN 14-13
17-16
LEFT 7-16
14-13
RIGHT 7-13
14-16
DRIVER POWER FOLDING MIRROR

CLOSING 11-13
12-16
PASSENGER POWER FOLDING MIRROR
CLOSING 1-13
10-16
Jeep Renegade
Service Manual: POWER SEATS - SERVICE INFORMATION
MOTOR, LUMBAR > REMOVAL AND INSTALLATION > REMOVAL AND
INSTALLATION > SEAT BACK LUMBAR MOTOR - REMOVAL
2. Remove the front seat back and cover. Refer to COVER, SEAT BACK, FRONT, REMOVAL
AND INSTALLATION .
Fig 1: Lumbar Pad, Lining, Retainers & Connector
3. Disconnect the lumbar actuator connector (1).
4. Untie the lining of the actuator (2a) from the seat suspension, lumbar retainers (2b) and
remove the lumbar pad (2c).
MOTOR, LUMBAR > REMOVAL AND INSTALLATION > REMOVAL AND
INSTALLATION > SEAT BACK LUMBAR MOTOR - INSTALLATION
1. Place the lumbar motor and pad to the seat and snap the button retainers.
2. Connect the actuator lining to the seat suspension.
3. Connect the lumbar motor electrical connector.
4. Install the front seat back and cover. Refer to COVER, SEAT BACK, FRONT, REMOVAL AND
INSTALLATION .
MOTOR, SEAT > REMOVAL AND INSTALLATION > SEAT CUSHION LIFT MOTOR >
POWER SEAT CUSHION LIFT MOTOR - REMOVAL
2. Remove the front seat. Refer to SEAT, FRONT, REMOVAL AND INSTALLATION .
Fig 1: Seat Cushion Lift Motor Connector
3. Working from the bottom side of the seat, disconnect the electrical connection (1).
Fig 2: Seat Cushion Lift Motor, Lifting Mechanism & Screws
4. Remove the mounting screws (1a) and remove the motor (1b) freeing the end (1c) by the lifting
mechanism (1d).
MOTOR, SEAT > REMOVAL AND INSTALLATION > SEAT CUSHION LIFT MOTOR >
POWER SEAT CUSHION LIFT MOTOR - INSTALLATION
1. Check that the motor for lifting the front seat cushion front is not damaged.
2. Working on the lower side of the seat position when the motor by tying the ends to the lifting
mechanism.
5. Install the seat. Refer to SEAT, FRONT, REMOVAL AND INSTALLATION .
MOTOR, SEAT > REMOVAL AND INSTALLATION > SEAT FORE - AFT MOTOR >
POWER SEAT FORE-AFT MOTOR - REMOVAL
Fig 1: Power Seat Fore-Aft Motor Connector
3. Working from the bottom side of the seat, disconnect the electrical connection.
Fig 2: Power Seat Fore-Aft Motor, Clips, Tabs & Retainers
4. Working on both sides push the motor (1a) in the direction of the arrow, releasing the retaining
clips (1b) and centering tabs (1c), then disengage flexible control (1d) by retainers (1e).
Fig 3: Power Seat Fore-Aft Motor & Ends Of Flexible Controls
5. Working from both sides, pull the ends of the flexible controls (1a) and retrieve the motor (1b).
6. If necessary, dismantle the flexible controls by disconnecting the seat rail ends.
MOTOR, SEAT > REMOVAL AND INSTALLATION > SEAT FORE - AFT MOTOR >
POWER SEAT FORE-AFT MOTOR - INSTALLATION
1. Check that the power seat motor and flexible controls are not damaged.
2. If removed, install the flexible controls and insert the ends into the seat rails.
3. Working on the underside of the seat, insert in the seat rails, then place in the seat motor by
inserting the centering tabs and placing the retaining clips.
4. Install the flexible controls to the appropriate retaining clips.
MOTOR, SEAT > REMOVAL AND INSTALLATION > SEAT HEIGHT ADJUST MOTOR >
POWER SEAT HEIGHT ADJUST MOTOR - REMOVAL
Fig 1: Seat Height Adjust Motor, Gear, Bracket, Nuts & Screw
3. Working from the underside of the seat, push aside the cushion padding, remove the mounting
nuts (1a) and release the bracket (1b).
4. Working from the outside of the seat, disconnect the electrical connection.
5. Remove the screw (3a) and retrieve the motor (3b) disengaging the gear (3c) by the lifting
mechanism (3d).
MOTOR, SEAT > REMOVAL AND INSTALLATION > SEAT HEIGHT ADJUST MOTOR >
POWER SEAT HEIGHT ADJUST MOTOR - INSTALLATION
1. Check that the set height motor is not damaged.
2. Working on the lower side, install the gear mechanism to the motor.
3. Working on the underside of the seat, push aside the cushion padding and install the bracket
and tighten the mounting nuts.
4. Working on the outside of the seat, connect the electrical connection and tighten the screw.
5. Install the seat. Refer to SEAT, FRONT, REMOVAL AND INSTALLATION .
SWITCH, LUMBAR CONTROL > REMOVAL AND INSTALLATION > SEAT BACK >
LUMBAR CONTROL SEAT BACK SWITCH - REMOVAL
2. Remove the seat side shield. Refer to SIDE SHIELDS, SEAT CUSHION, FRONT, REMOVAL
AND INSTALLATION .
Fig 1: Lumbar Switch & Retainers
3. Remove the lumbar switch (1a) by disengaging the retainers (1b).
SWITCH, LUMBAR CONTROL > REMOVAL AND INSTALLATION > SEAT BACK >
LUMBAR CONTROL SEAT BACK SWITCH - INSTALLATION
1. Check that the lumbar control switch is not damaged.
2. Install the lumbar control switch to the seat side shield.
3. Connect the electrical harness connector to the switch.
4. Install the seat side shield. Refer to SIDE SHIELDS, SEAT CUSHION, FRONT, REMOVAL AND
INSTALLATION .
SWITCH, LUMBAR CONTROL > REMOVAL AND INSTALLATION > FOUR WAY >
LUMBAR CONTROL FOUR WAY SEAT SWITCH - REMOVAL
INSTALLATION .
Fig 1: Four Way Seat Switch, Bracket & Retainers
3. Remove the retainers (1a) and remove the mounting bracket (1b).
4. Remove lumbar control switch (2a) by disengaging the retainers (2b).
SWITCH, LUMBAR CONTROL > REMOVAL AND INSTALLATION > FOUR WAY >
LUMBAR CONTROL FOUR WAY SEAT SWITCH - INSTALLATION
1. Check that the lumbar control switch is not damaged.
2. Install the lumbar control switch to the seat side shield.
3. Connect the electrical harness connector to the switch.
INSTALLATION .
SWITCH, SEAT, POWER > REMOVAL AND INSTALLATION > REMOVAL AND
INSTALLATION > POWER SEAT SWITCH - REMOVAL

Fig 1: Power Seat Switch, Side Shield, Screw, Retainers & Connectors
2. Remove the screw (1a) securing the seat side shield (1b).
3. Release the retainers (2a) and remove the seat side shield (1b).
4. Disconnect the electrical connections (3a) and (3b).

Fig 2: Power Seat Switch & Retainers
5. Remove the power seat switch (1a) by disengaging the retainers (1b).
SWITCH, SEAT, POWER > REMOVAL AND INSTALLATION > REMOVAL AND
INSTALLATION > POWER SEAT SWITCH - INSTALLATION
1. Check that the power seat switch is not damaged.
2. Install the switch to the side seat shield.
3. Connect the electrical connections to all switches on the side seat shield.
4. Install the side seat shield.
5. Tighten the screw securing the rear of the side seat shield.

Service Manual: POWER TOP/SUNROOF - SERVICE Jeep Renegade
INFORMATION
Fig 1: Power Top/Sunroof
The electric sun roof comprises two glass panels (the front one is mobile and the rear one fixed) and is
fitted with an electrically operated sun blind.
Fig 2: Power Top/Sunroof Open
The positions that can be assumed by the front panel are:
Totally open
Swivel position.
The movement can be carried out using three buttons installed in a dedicated switch panel located on
the roof light cluster.
Fig 3: Power Top/Sunroof Switch
KEY
1. Blind opening/closing
2. Roof opening/closing
3. Swivel position opening/closing (Vent)
When the opening button is pressed, the roof will automatically move to the opening position, without the
need to hold the button down.
If during the movement the button is pressed again, the roof will stop in the current position. The same
applies to the blind.
To bring the roof into swivel position, press and release the specific button. This type of swivel opening
can be activated irrespective of the position of the sun roof. If the button is pressed again during the
movement to reach the swivel opening position, the roof will stop.
The sun roof and the electric blind are equipped with an anti-pinch safety system capable of detecting
the presence of an obstacle whilst the roof is closing: if this happens, the system intervenes and the
movement of the glass is immediately reversed.

> DESCRIPTION - MYSKY
Fig 1: MySky Sunroof
The MySky™ sun roof is a new and exclusive sun roof concept, specially developed for this vehicle. The
roof has two panels, a front and a rear one, that can be individually or simultaneously removed,
depending on the occupants' choice.
The panels are made of a special material that can guarantee total soundproofing of the passenger
compartment, is lightweight, and has optimal resistance and high rigidity.
Fig 2: MySky Sunroof Design
KEY
1. Granular film application
2. Fiberglass
3. Honeycomb cardboard
4. Fiberglass
The panels are made of a lightweight material which is perfectly resistant to atmospheric agents, such
as rain, hail, wind, etc.
Front and rear panels are distinguished by a dedicated symbol on the bottom of the panels themselves.
On some versions, the front panel might be electrically operated.
Regardless of the type of panel movement, both can be removed independently.

Fig 1: Power Top/Sunroof Motors
Key
1. Blind movement motor
2. Sun roof glass movement motor
In the rear part of the roof there are two electric motors, with simple electronics, to manage the sun roof
functions such as automatic opening and anti-pinch.
The BCM controls the intensity of the lighting for the switch panel on the front roof light. Depending on
the position of the switch, an earth signal is sent to the electronic circuit of the blind or roof movement
motor, to identify the type of command requested: opening, closing or swivel position (VENT).
The switch position signals for opening and closing, along with the vehicle speed signals, panel-operated
supply +15 and direct battery supply +30 reach the electronic circuit of the two roof movement motors.
The electronic circuit installed on the roof movement motors manages, in addition to movement, the
anti-pinch function. To do this they need to recognize the sun roof and blind limit switches.
Electric sun roof limit switch initialization procedure - Following an automatic motion malfunction
while opening/closing or an emergency maneuver, the automatic operation of the sun roof must be
initialized again.
Proceed as follows:
move the roof to fully closed position;
move the ignition device to STOP and keep it there for 10 seconds;
bring the ignition device to MAR;

press the roof movement button in "closing" position;
press the button for at least 10 seconds, then you should hear the mechanical stop of the roof
motor;
press the roof movement button in the "closing" position again within 5 seconds;
hold the roof movement button down: in this position, the roof will perform an automatic opening
and closing cycle. Otherwise, repeat the operations starting from the beginning;
hold the roof movement button down until the roof is completely closed: the initialization procedure
has ended.
Fig 2: Power Top/Sunroof Circuit Diagram
KEY
1. BCM
2. Switch panel on front roof light
3. Blind movement motor
4. Roof movement motor
Switch panel pinout
Pin 4 blind opening signal

Pin 5 blind closing signal
Pin 10 lighting regulation power supply
Pin 11 Earth
Pin 12 roof opening signal
Pin 13 roof closing signal
Pin 14 swivel position signal
Blind movement motor panel pinout
Pin 1 earth
Pin 3 +15
Pin 5 blind opening signal
Pin 6 +30
Pin 8 vehicle speed
Pin 10 blind closing signal
Roof movement motor panel pinout
Pin 1 earth
Pin 3 +15
Pin 4 swivel position signal
Pin 5 roof opening signal
Pin 6 +30
Pin 8 vehicle speed
Pin 10 roof closing signal

Fig 3: Protective Caps
Emergency closing
- If the control buttons fail to operate, the sun blind and the sun roof can be moved manually, proceeding
as described below:
Sun blind movement: remove protective cap A on the internal trim;
Sun roof movement: remove protective cap B on the internal trim;
Insert the Allen key into housing A (to move the blind) or B (to move the sun roof) and insert it in
the movement wheel fitted on the engine assembly. Rotate the Allen key clockwise to open the roof
(or the blind) or counterclockwise to close the roof (or the blind).
OPERATION
Fig 1: Motor, Panels & Handles
PANEL REMOVAL
1. Insert for unlocking the rear panel release handle
2. Front panel electric movement motor
3. Handle for releasing the rear panel
4. Insert for unlocking the front panel handle
5. Handle for releasing the front panel
Proceed as follows to remove the panels: Working from inside the passenger compartment, insert
the special key to unlock the lever inside the dedicated housing and rotate it next to the unlocked
symbol, in order to unlock the lock and simultaneously pull the handle, which is under the panel, to end of
travel;
Refitting the panels:
Front panel -
working from outside, place the panel correctly on its guides, slightly rearward;
slide the panel forward slightly to end of travel;
working from inside the passenger compartment, use the handle under the panel to lock it;
make sure that the panel has been properly refitted (there should be no clearance between the
panel and the guides). Working from inside the passenger compartment, push the panel from the
bottom upwards, to make sure that it is properly secured to the dedicated locks.
Rear panel -
working from outside, place the panel correctly on its guides, slightly rearward;
slide the panel forward slightly to end of travel;
make sure that the panel has been properly refitted (there should be no clearance between the
panel and the guides). Working from inside the passenger compartment, push the panel from the
bottom upwards, to make sure that it is properly secured to the dedicated locks.
Fig 2: Handle Release Key
Handle release key - The key to unlock/lock the roof panel release handle is provided on vehicles
equipped with MySky.
Fig 3: Roof Opening Buttons
Electric panel movement
1. Roof opening button
2. Roof opening button in swivel position
The occupants of the vehicle can completely open the front panel in automatic mode by pressing the roof
opening button only once. From the position of complete opening pull the button to completely close the
front panel in automatic mode.
Front panel swivel opening function (Vent) - To bring the roof into swivel position, press and release
the specific button. This type of swivel opening can be activated irrespective of the position of the sun
roof.
Anti-pinching device - The front panel of the roof features an anti-pinch safety system capable of
detecting the presence of an obstacle whilst the panel is being opened and closed. When this happens,
the system stops and the movement of the panel is immediately reversed.
Fig 4: Roof Opening Buttons Circuit Diagram
KEY
1. BCM
2. Switch panel on front roof light
3. Front panel movement motor

Service Manual: POWER WINDOWS - SERVICE Jeep Renegade
INFORMATION
Fig 1: Power Window Switch Module
Electric windows - The front and rear windows are managed by the Body Computer (BCM). Vehicle
users can move the windows using the switches on the door panels. All windows on the vehicle (front
and rear) can be moved using the switch module on the driver side door panel. The BCM moves the front
windows in manual and automatic mode. The motion of the front windows is assisted by the anti-pinch
function.
Fig 2: Window Movement Mechanism & Carrier
The window movement mechanism is connected to a carrier with screws. The carrier is located behind
the door panel and is in turn screwed to the frame of the door itself. To remove the window movement
mechanism, remove the carrier and disassemble at bench.
Fig 3: Power Window Electric Motor
Both the electric motors of the front electric window mechanisms incorporate an electronic unit that
exchanges data with the BCM via LIN. The integrated electronic unit, in addition to providing a supply to
the electric motors in "raising" and "lowering" modes, manages the anti-pinch function.
Fig 4: Front Power Window Circuit Diagram
The switch in the driver side switch unit that operates the passenger side window is connected to the
BCM. When the switch is operated, the BCM receives the signal and then instructs the electronic unit of
the passenger side motor to move the window via LIN. The electronic unit, in its turn, provides a supply
to the electric motor for the raising or lowering motion.
Fig 5: Rear Power Window Circuit Diagram
The electric motors of the rear window movement mechanisms do not have an electronic unit that
manages the electrical command to the motor itself. It is controlled directly by the BCM in "raising" and
"lowering" modes.
Fig 6: Power Window Motor Connector End View
NOTE: Pin 1 down and Pin 2 up
In the following ignition "switch" conditions:
OFF
ACC.
ON.
ON with Engine running.
During starting.
FRONT WINDOWS
The electronic unit built into the driver side electric motor can raise and lower the window in accordance
with the command that arrives from the switch located on the driver side panel switch unit. The electronic
unit can activate the electric motor only if the LIN line through which it communicates with the BCM is in
normal operating conditions. If the LIN line is no longer in normal operating conditions, but in sleep mode,
the electronic unit cannot move the window.
The LIN line enters sleep mode after three minutes with the ignition switch or KIN in OFF position. During
the three minutes from key-off, the LIN line is active and the window can be moved (comfort enable
function). If the driver or passenger door is opened in the course of the three minutes, the comfort
enable function is deactivated.
The electric windows for the doors are operated through the switches on the driver's side door (both
windows) and the passenger side door (passenger side only).
The electronic circuit inside the controls operates the front electric window motors - both driver's and
passenger side - which are operated in automatic mode, according to the following logic:
if the button is pressed for between 60 and 300 milliseconds, operation is manual: the glass goes
up/down only with the button pressed;
if the button is pressed for longer than 300 milliseconds, operation is automatic: even if the button
is released, the glass continues to go up/down until the end of travel or the implementation of the
anti-crush safety system if fitted;
pressing the button again whilst the window is moving stops it in the position that it is in;
if the button is pressed for less than 60 milliseconds, this is ignored (it is treated as an accidental
knock).
The electronic circuit inside the motors manages the anti-crush safety function: i.e. it acquires
information about the possible presence of an obstacle during window closure (rising); the anti-crush
function is performed by a Hall effect sensor that senses overloads on the window motor; the
intervention threshold is set when the force of the obstacle encountered along the window travel (e.g. a
finger, a hand) exceeds 7/8 kg (2.0 lbs).
The electronic unit automatically reverses the actuator which retracts the window by around 20 mm as
required by regulations in force.
The power supply logic of the electric window controls is called "comfort enable":
the electric window function operates only with the ignition on, with the following exception: after a
key-off, the windows can be operated for 3 minutes; when this time period elapses, the system no
longer acquires new commands.
if one of the doors is opened during the timed period, new commands are no longer acquired, but
any commands received before the opening of the door are brought to a conclusion.
if one of the doors is already open at key off, any commands received before the opening of the
door are brought to a conclusion.
The power window system allows each of the door windows to be raised and lowered electrically by
actuating a switch on each door panel. A master switch on the drivers door allows the driver to raise or
lower each door window. The power window system operates only when the ignition switch is in the RUN
or ACCESSORY position.
Front door window lift motors use permanent type magnets. The B+ and ground applied at the motor
terminal pins will cause the motor to rotate in one direction. Reversing current through the motor
terminals will cause the motor to rotate in the opposite direction.
The power window switches control the battery and ground feeds to the power window motors. The
passenger door power window switches receive their battery and ground feeds through the circuitry of
the drivers window switch.
DIAGNOSIS AND TESTING > DIAGNOSIS AND TESTING - POWER WINDOWS
For complete circuit diagrams, refer to appropriate SYSTEM WIRING DIAGRAMS article.
DIAGNOSIS AND TESTING > DIAGNOSIS AND TESTING - POWER WINDOWS >
POWER WINDOW DIAGNOSIS
Suggested process to diagnose inoperative power windows:
1. Connect the diagnostic scan tool to check for diagnostic trouble codes and to validate
operation of the power window system.
2. Check for damaged fuses and replace as needed.
3. Confirm power to the motor and the motor ground integrity.
4. Using the diagnostic scan tool, confirm window switch actuation is recognized.
5. If the power window motor is receiving proper current and ground and does not operate,
proceed with motor test.
1. Remove front door trim panel as necessary to gain access to power window motor
wire connector.
2. Disconnect power window motor wire connector from door harness.
3. Using two jumper wires, connect one to a battery (+) source and the other to a good
ground (-).
4. Connect the Negative (-) jumper probe to one of the motor connector terminals.
5. Momentarily touch the Positive (+) jumper probe to the other motor connector
terminal.
When positive probe is connected the motor should rotate in one direction to either
move window up or down. If window is all the way up or down the motor will grunt and
the inner door panel will flex when actuated in that one direction.
6. Reverse jumper probes at the motor connector terminals and window should now
move in opposite direction. If window does not move or grunt, replace the motor. If
window moved completely up or down, reverse the jumper probes and cycle window
to the opposite position to verify full operation. If motor grunts and does not move,
verify that regulator is not binding.
MOTOR, WINDOW REGULATOR > REMOVAL AND INSTALLATION > REMOVAL AND
INSTALLATION > POWER WINDOW MOTOR - REMOVAL
1. Remove the interior door panel. Refer to PANEL, DOOR TRIM, REMOVAL AND
INSTALLATION .
Fig 1: Power Window Motor & Screws
2. Disconnect the electrical connector to the power window motor.
3. Remove the retaining screws (1a) and remove the power window motor (1b).
MOTOR, WINDOW REGULATOR > REMOVAL AND INSTALLATION > REMOVAL AND
INSTALLATION > POWER WINDOW MOTOR - INSTALLATION
1. Position the motor to the door shield and secure using retaining screws.
2. Connect the electrical connector to the motor.
3. Install the door trim panel. Refer to PANEL, DOOR TRIM, REMOVAL AND INSTALLATION .
SWITCH, POWER WINDOW > DIAGNOSIS AND TESTING > DIAGNOSIS AND
TESTING - POWER WINDOW SWITCHES
The master window switch has an Auto-Down feature. Actuation of the master switch to the second
down position will move the drivers side window completely down. The electronic switch will
automatically disconnect the motor approximately one second after the window bottoms out. Failure of
the electronic switch to detect stall current, will cause the switch to disconnect after approximately 13
seconds. The auto down function can be canceled by any movement of that switch.
MASTER WINDOW SWITCH TEST
SWITCH CONTINUITY BETWEEN (OHMS)

POSITION
OFF 5/13 AND 2
5/13 AND 3
5/13 AND 6
5/13 AND 7
LEFT FRONT 3 AND 13 (67 +/- 25)

UP-NON
EXPRESS
LEFT FRONT 3 AND 13 (2519 +/- 25)

DOWN-NON
EXPRESS
RIGHT 5 AND 13 (649 +/- 25)

FRONT
UP-NON
EXPRESS
RIGHT 5 AND 13 (2519 +/- 25)

FRONT
DOWN-NON
EXPRESS
LEFT REAR 3 AND 2 (2519 +/- 25)

UP
LEFT REAR 2 AND 13 (2519 +/- 25)
DOWN
RIGHT REAR 4 AND 13 (649 +/- 25)

UP
RIGHT REAR 4 AND 13 (2519 +/- 25)

DOWN
LOCK
9 AND 13 (0)
SWITCH
LOCKOUT 16 AND 13
SWITCH
(SWITCH
NOT
DEPRESSED)
PASSENGER WINDOW SWITCH TEST
SWITCH CONTINUITY RESISTANCE

POSITION BETWEEN VALUE
UP 3 AND 2 649 Ω ± 10%
SWITCH, POWER WINDOW > REMOVAL AND INSTALLATION > REMOVAL AND
INSTALLATION > DRIVER DOOR GANG SWITCH - REMOVAL

Fig 1: Pad & Screw
2. Remove the pad (1a) and unscrew the screw below (1b).
3. Using the suitable tool, lift the gang switch assembly (1a) by releasing the retaining clips (1b).
4. Disconnect the electrical connections (2a, 2b)
SWITCH, POWER WINDOW > REMOVAL AND INSTALLATION > REMOVAL AND
INSTALLATION > DRIVER DOOR GANG SWITCH - INSTALLATION
1. Connect the driver door gang switch electrical connector.
2. Seat the driver door gang switch into the door panel.
3. Insert and tighten the screw securing the switch to the door.
4. Insert the cover.

Service Manual: VEHICLE THEFT SECURITY - SERVICE Jeep Renegade
INFORMATION
DESCRIPTION AND OPERATION > VEHICLE THEFT SECURITY SYSTEM >
DESCRIPTION - VEHICLE THEFT SECURITY SYSTEM
The Vehicle Theft Security System (VTSS) includes various features that provide protection against
unauthorized vehicle access and operation. VTSS is comprised of two primary subsystems: Sentry Key
Immobilizer System (SKIS) and the Vehicle Theft Alarm (VTA). Additional details of each of these
subsystems and their components can be found elsewhere within this service information.
Except for the Sentry Key transponders which rely upon Radio Frequency (RF) communication, hard
wired circuitry connects the VTA and SKIS components to the electrical system of the vehicle. These
hard wired circuits are integral to several wire harnesses, which are routed throughout the vehicle and
retained by many different methods. These circuits may be connected to each other, to the vehicle
electrical system and to the SKIS or VTA components through the use of a combination of soldered
splices, splice block connectors, and many different types of wire harness terminal connectors and
insulators. Refer to the appropriate SYSTEM WIRING DIAGRAMS article. The wiring information
routing and retention, as well as pin out and location views for the various wire harness connectors,
DESCRIPTION AND OPERATION > VEHICLE THEFT SECURITY SYSTEM >

OPERATION - VEHICLE THEFT SECURITY SYSTEM
The VTSS is comprised of two primary subsystems: SKIS and VTA. Additional operational details on
each of these two subsystems of the VTSS can be found elsewhere within this service information.
DESCRIPTION AND OPERATION > SENTRY KEY IMMOBILIZER SYSTEM >

DESCRIPTION - SENTRY KEY IMMOBILIZER SYSTEM
The Sentry Key Immobilizer System (SKIS) is factory-installed standard equipment on this vehicle. The
SKIS provides passive vehicle protection, immobilizing the vehicle by preventing the engine from
operating unless a valid electronically encoded key or FOB with Integrated Key (FOBIK) is detected. In
vehicles not equipped with the optional Passive Entry - Keyless Go (PEKG) system the valid key must
be present in the ignition lock cylinder. In vehicles equipped with the PEKG system, the valid FOBIK
must only be present somewhere within the passenger compartment of the vehicle for the engine to
continue to operate. Vehicles with this equipment can be readily identified by the illumination of the
security indicator in the Instrument Panel Cluster (IPC) for about three seconds after the status of the
ignition transitions to On as a SKIS bulb test.
The SKIS includes the following major components, which are described in further detail elsewhere in
this service information:
Body Control Module - The Body Control Module (BCM) is concealed within the instrument panel
outboard of the steering column. Refer to MODULE, BODY CONTROL, DESCRIPTION AND
OPERATION .
Ignition Switch - The ignition switch is located on the right side of the steering column in vehicles
without the optional PEKG system.
Keyless Ignition Node - The Keyless Ignition Node/KIN (also known as the start and stop switch
or the push button switch) is located on the right side of the steering column in vehicles with the
optional PEKG system. (Refer to DESCRIPTION AND OPERATION ).
Low Frequency Antenna - Vehicles equipped with the PEKG system have several low frequency
antenna units strategically placed within the vehicle. (Refer to DESCRIPTION AND OPERATION ).
Powertrain Control Module - The Powertrain Control Module (PCM) is located in the engine
compartment and provides the SKIS engine control logic. Refer to MODULE, POWERTRAIN
CONTROL, DESCRIPTION AND OPERATION .
Radio Frequency Hub Module - The Radio Frequency Hub Module (RFHM) is located on the
upper liftgate opening header where it is concealed above the rear headliner trim. Refer to
MODULE, RADIO FREQUENCY (RF HUB), DESCRIPTION AND OPERATION .
Security Indicator - A security indicator is integral to the IPC. Refer to DESCRIPTION AND
OPERATION .
Sentry Key Immobilizer Module - In vehicles not equipped with the optional PEKG system the
Sentry Key Immobilizer Module (SKIM) is integral to the BCM. Refer to MODULE, BODY
CONTROL, DESCRIPTION AND OPERATION . In vehicles equipped with the optional PEKG
system the SKIM is integral to the RFHM. Refer to MODULE, RADIO FREQUENCY (RF HUB),
Sentry Key Immobilizer Antenna - A antenna ring is located around the circumference of the
ignition switch lock cylinder and concealed beneath the steering column shrouds in vehicles without
the optional PEKG system. Refer to ANTENNA, SENTRY KEY, DESCRIPTION AND OPERATION .
Sentry Key Transponder - The Sentry Key transponder microchip is located on the circuit board
within the Remote Keyless Entry (RKE) transmitter of each ignition key or within each FOBIK.
Refer to KEY, TRANSPONDER, DESCRIPTION AND OPERATION .
The BCM, the PCM and the RFHM each contain a microcontroller and programming that allow them to
communicate with each other and other electronic modules in the vehicle using the Controller Area
Network (CAN) data bus. In addition, in vehicles so equipped the KIN and the RFHM communicate with
each other using a Local Interface Network (LIN) data bus. Refer to COMMUNICATION, DESCRIPTION
AND OPERATION .
Except for the Sentry Key transponders, which rely upon Radio Frequency (RF) communication, hard
wired circuitry connects the various SKIS components to the electrical system of the vehicle. These
hard wired circuits are integral to several wire harnesses, which are routed throughout the vehicle and
retained by many different methods. These circuits may be connected to each other, to the vehicle
electrical system and to the SKIS components through the use of a combination of soldered splices,
splice block connectors, and many different types of wire harness terminal connectors and insulators.
Refer to the appropriate SYSTEM WIRING DIAGRAMS article. The wiring information includes wiring
diagrams, proper wire and connector repair procedures, further details on wire harness routing and
retention, as well as pin out and location views for the various wire harness connectors, splices and
grounds.
DESCRIPTION AND OPERATION > SENTRY KEY IMMOBILIZER SYSTEM >

OPERATION - SENTRY KEY IMMOBILIZER SYSTEM
The SKIS is designed to provide passive protection against unauthorized vehicle use by disabling the
engine after about two seconds of running, whenever any method other than a valid Sentry Key or
FOBIK is used to attempt starting the vehicle. The SKIS is considered a passive protection system
because it is always active when the ignition system is energized and does not require any customer
intervention.
In vehicles without the optional PEKG system the SKIS uses Radio Frequency (RF) communication to
obtain confirmation that the key in the ignition switch lock cylinder is a valid key for operating the vehicle.
In vehicles with the optional PEKG system the SKIS uses Low Frequency (LF) Radio Frequency (RF)
communication to obtain confirmation that the FOBIK within the passenger compartment is valid for
operating the vehicle.
In vehicles without the optional PEKG system the microcontroller-based BCM contains the SKIS
software. The BCM monitors a hard wired input from the Sentry Key antenna. In vehicles with the
optional PEKG system the microcontroller-based RFHM uses electronic messages over a dedicated LIN
data bus to communicate with the KIN. In both systems the BCM or the RFHM also use electronic
messages to communicate with other electronic modules in the vehicle over the CAN data bus. Refer to
The BCM or the RFHM performs a self-test of the SKIS each time the status of the ignition transitions
out of Off, and will store fault information in the form of a Diagnostic Trouble Code (DTC) if a system
malfunction is detected. The BCM or the RFHM will also send an electronic message to the IPC if a fault
is detected, and the IPC responds by illuminating the security indicator or displaying a textual message
in the Electronic Vehicle Information Center (EVIC) display.
The hard wired circuits between components related to the SKIS may be diagnosed using conventional
However, conventional diagnostic methods will not prove conclusive in the diagnosis of the SKIS or the
of the SKIS. The most reliable, efficient and accurate means to diagnose the SKIS or the electronic
controls and communication related to SKIS operation requires the use of a diagnostic scan tool. Refer
DESCRIPTION AND OPERATION > VEHICLE THEFT ALARM > DESCRIPTION -

VEHICLE THEFT ALARM
The Vehicle Theft Alarm (VTA) is factory-installed equipment on this vehicle. VTA is available in two
different configurations; base and premium. The base system provides perimeter vehicle protection by
monitoring the vehicle doors, the ignition status and the liftgate. In vehicles built for certain markets
where it is required equipment, the perimeter protection also includes monitoring of the hood.
The premium system adds vehicle interior intrusion and anti-tilt protection to the features found in the
base system. If unauthorized vehicle access, intrusion or tampering is detected with either of these
systems, either the vehicle horn or an alarm siren (if equipped) is pulsed as an audible deterrent and
certain exterior lamps are flashed as a visual deterrent.
The VTA includes the following major components, which are described in further detail elsewhere in this
service information:
Ajar Switches - An ajar switch is integral to the latch mechanism of each front door, rear door and
the liftgate. In vehicles manufactured for certain markets where it is required or equipped with the
optional remote start system, a hood ajar switch is integral to the left hood latch mechanism.
Alarm Siren Module - An alarm siren module is located on the engine compartment side of the
dash panel. The alarm siren is used only in vehicles built for sale in certain markets where it is
required equipment. Refer to SIREN, DESCRIPTION AND OPERATION .
Body Control Module - The Body Control Module (BCM) is concealed within the instrument panel
outboard of the steering column. Refer to MODULE, BODY CONTROL, DESCRIPTION AND
OPERATION .
Ignition Switch - The ignition switch is located on the right side of the steering column in vehicles
without the optional Passive Entry - Keyless Go (PEKG) system. (Refer to DESCRIPTION AND
OPERATION ).
Keyless Ignition Node - The Keyless Ignition Node (KIN) (also known as the start and stop
switch or the push button switch) is located on the right side of the steering column in vehicles with
the optional PEKG system. (Refer to DESCRIPTION AND OPERATION ).
Radio Frequency Hub Module - The Radio Frequency Hub Module (RFHM) is located on the
upper liftgate opening header where it is concealed above the rear headliner trim. The RFHM is
only part of the vehicle theft alarm in vehicles equipped with the optional PEKG system. Refer to
MODULE, RADIO FREQUENCY (RF HUB), DESCRIPTION AND OPERATION .
Security Indicator - The security indicator is integral to the Instrument Panel Cluster (IPC)
located in the instrument panel above the steering column and directly in front of the driver. Refer
to DESCRIPTION AND OPERATION .
Ultrasonic And Anti-tilt Module - In vehicles equipped with the premium VTA, an Ultrasonic and
Anti-tilt Module (UAM) is integral to the roof lamp unit in the headliner near the center of the upper
windshield opening header panel.
The BCM, the IPC and the RFHM each contain a microcontroller and programming that allow them to
communicate with each other and other electronic modules in the vehicle using the Controller Area
Network (CAN) data bus. In addition, in vehicles so equipped the KIN, the RFHM, the UAM, the alarm
siren module and the BCM communicate with each other using a Local Interface Network data bus.
Refer to COMMUNICATION, DESCRIPTION AND OPERATION .
DESCRIPTION AND OPERATION > VEHICLE THEFT ALARM > OPERATION - VEHICLE
THEFT ALARM
The base version of the VTA is designed to provide either active or passive perimeter protection of the
vehicle by monitoring the vehicle doors, the ignition status, the liftgate and the power lock switches. In
vehicles built for certain markets where it is required equipment, or those equipped with the optional
remote start system (North America Free Trade Agreement/NAFTA market only), the BCM also monitors
an input from the hood ajar switch integral to the left hood latch. If the VTA system detects any attempt to
compromise a monitored vehicle system or feature, the vehicle horn is pulsed as an audible deterrent
and certain exterior lamps are flashed as a visual deterrent.
The BCM includes the logic and control circuits for the base versions of the VTA. Each of the ajar
switches provides hard wired inputs to the BCM, while the BCM provides control outputs to the vehicle
horns and lighting systems. In vehicles not equipped with the optional PEKG system, the BCM also
monitors the status of the ignition switch through a hard wired input. In vehicles equipped with the PEKG
system, the RFHM monitors the status of the KIN through a private serial bus and relays this information
to the BCM as electronic messages transmitted over the CAN data bus.
The premium version of the VTA includes an UAM. The UAM provides interior intrusion protection as well
as vehicle tow-away and tire theft protection. The UAM includes the logic and control circuits for these
features of the VTA and is also a slave node communicating over the Local Interface Network (LIN) data
bus. The UAM is armed and disarmed by electronic messages received over the LIN data bus from the
BCM, which is a LIN master node. While armed, the UAM uses external ultrasonic transmit and receive
transducers to monitor the vehicle interior for movement as well as internal accelerometers to monitor
vehicle pitch and roll. When an exception is detected, the UAM relays this information to the BCM over
the LIN data bus, and the BCM invokes the VTA audible and visual alerts. In vehicles with a UAM, the
horn output function of the BCM is replaced by an output of the alarm siren module that is controlled by
the BCM over the LIN data bus.
The hard wired circuits between components related to the VTA system may be diagnosed using
However, conventional diagnostic methods will not prove conclusive in the diagnosis of the VTA system
or the electronic controls and communication between modules and devices that provide some features
of the VTA system. The most reliable, efficient and accurate means to diagnose the VTA system or the
electronic controls and communication related to VTA system operation requires the use of a diagnostic
scan tool. Refer to the appropriate Diagnostic & Testing article.
DESCRIPTION AND OPERATION > VEHICLE THEFT ALARM > OPERATION - VEHICLE
THEFT ALARM > OPERATING MODES - VEHICLE THEFT ALARM
Following are paragraphs that briefly describe the operation of each of the Vehicle Theft Alarm (VTA)
operating modes.
Enabling - The Body Control Module (BCM) and the Radio Frequency Hub Module (RFHM) must
have the VTA function electronically enabled in order for the VTA to perform as designed. The BCM
stores and compares vehicle configuration data with other Electronic Control Units (ECU) in the
vehicle, including the RFHM. This process is referred to as PRogramming Of Configuration of
Systems Integrated (PROCSI) (also known as PROXI). If a configuration mismatch is detected, the
BCM sets a Diagnostic Trouble Code (DTC). A configuration mismatch will require the performance
of a Restore BCM PROXI Configuration routine, or a PROXI Configuration Alignment routine using
a diagnostic scan tool.
Alarm - The VTA alarm output provides both visual and audible outputs; however, the time
intervals of these outputs vary by the requirements of the market for which the vehicle is
manufactured. In all cases, the visual output will be a flashing On and Off of the exterior turn signal
lamps, while the audible output will be either a pulsing of the horn or, if the vehicle is so equipped,
the siren. For vehicles with the base version of the VTA, the inputs that will trigger the alarm include
a change in the status of the ignition, the door ajar switches, the liftgate ajar switch and, in
vehicles built for certain markets where they are required, the hood ajar switch. In vehicles with the
premium version of the VTA, the inputs that will trigger the alarm also include any movement
detected within the vehicle passenger compartment, or a change in the vehicle pitch or roll of
greater than about 0.5 degrees.
Arming - Arming of the VTA occurs when the vehicle is exited and the key is removed from the
ignition switch (without Passive Entry - Keyless Go/PEKG) and the switch status is Off or the
status of the KIN (with PEKG) is Off, the exterior lighting is turned Off, then the Lock button on the
Remote Keyless Entry (RKE) transmitter is depressed or the Lock button on the Passive Entry
(PE) is pressed to lock the vehicle. For active arming to occur, the doors and the liftgate must be
closed and the status of the ignition switch or the KIN must be Off when the RKE transmitter or PE
handle Lock button is depressed. Arming will not occur if a key is in the ignition switch lock cylinder
or a FOB with Integrated Key (FOBIK) is within the vehicle interior.
Pre-arming of the VTA is initiated when a door or the deck lid is open when the vehicle is locked
using a power door lock switch or when the RKE Lock button is pressed. Pre-arming will not occur
if a FOBIK is within the vehicle interior. When the VTA is pre-armed, the arming sequence is
delayed until all of the doors and the liftgate have been closed. The VTA will remain in pre-armed
mode for up to 16 seconds after all doors and the liftgate have been closed.
Once the VTA begins the arming sequence, the security indicator in the Instrument Panel Cluster
(IPC) will flash rapidly for about 16 seconds. This indicates that VTA arming is in progress. If the
status of the ignition switch or KIN changes, if a door or the liftgate is unlocked or opened by any
means, the security indicator will stop flashing and the arming process will abort. Once the arming
sequence is successfully completed, the security indicator will flash at a slower rate, indicating that
the VTA is armed.
The VTA arming sequence will occur regardless of whether a door or the liftgate is open or closed,
but the security indicator will illuminate solid and the open door or the liftgate will not be protected
unless the door or the liftgate is closed when the VTA arming sequence first begins.
On vehicles equipped with the hood ajar switch, the VTA arming sequence will occur regardless of
whether the hood is open or closed, but the security indicator will illuminate solid and the engine
compartment will not be protected unless the hood is closed when the VTA arming sequence first
begins. Also, if the status of the hood ajar switch changes from open to closed during the 16
second arming process, the security indicator will switch from solid to flashing. Once the arming
process is successfully completed, the security indicator will flash at a slower rate, indicating that
the VTA is armed.
Disarming - Passive disarming of the VTA occurs when the vehicle is unlocked by depressing the
Unlock button of the RKE transmitter. Once the alarm has been activated, this disarming method
will also deactivate the alarm. Unlocking a door with a key will not disarm the VTA or deactivate
the alarm. On vehicles equipped with PE, if one of the valid FOBIK units is located outside the
vehicle and within 1.5 meters (5 feet) of the driver or passenger front door handles, grab the
Passive Entry (PE) handle and enter the vehicle, then press the Start/Stop/Button (SSB) to
transition the ignition status to On. This requires at least one valid FOBIK be located within the
passenger compartment of the vehicle.
Power-Up Mode - When the armed VTA senses that the battery has been disconnected and
reconnected, it enters its power-up mode. In the power-up mode the armed alarm system remains
armed following a battery failure or disconnect. If the VTA was armed prior to a battery disconnect
or failure, the technician or vehicle operator will have to disarm the alarm system after the battery
is reconnected. The power-up mode will also apply if the battery goes dead while the system is
armed, and battery jump-starting is attempted. The VTA will be armed until the technician or vehicle
operator has disarmed the alarm system. If the VTA is in the disarmed mode prior to a battery
disconnect or failure, it will remain disarmed after the battery is reconnected or replaced, or if
jump-starting is attempted.
Tamper Alert - The VTA tamper alert feature will illuminate an icon in the IPC when the ignition
first transitions to On if the alarm was triggered and has since timed out, or if the battery has been
disconnected and reconnected. This feature alerts the vehicle operator that the VTA alarm was
activated while the vehicle was unattended.
Antitilt And Intrusion Alarm Disabling - The antitilt and intrusion alarm is an exclusive feature of
the premium version of the VTA. When this version of the VTA is armed, the Ultrasonic and Antitilt
Module (UAM) uses ultrasonic transmit and receive transducers to monitor the interior of the
vehicle for movement and low gravity accelerometers to monitor vehicle pitch and roll. If interior
motion or change in vehicle attitude are detected, the UAM sends an electronic message to the
BCM over the Local Interface Network (LIN) data bus to invoke the audible and visual alarm
features.
The antitilt and intrusion alarm features of the premium VTA can be disabled by depressing a button
on the roof lamp unit during VTA pre-arming, while the security indicator is still flashing rapidly. A
Light Emitting Diode (LED) unit next to the button is illuminated as a visual confirmation that the
antitilt and intrusion alarm features disable request has been received. The default for the UAM
features is enabled; therefore, the disable procedure must be repeated each time the VTA is
disarmed, then armed again to prevent the system from monitoring interior movement and vehicle
pitch and roll.
DIAGNOSIS AND TESTING > VEHICLE THEFT SECURITY SYSTEM
The Vehicle Theft Security System (VTSS) is divided into two basic subsystems: Sentry Key Immobilizer
System (SKIS) and Vehicle Theft Alarm (VTA). The recommended procedures for diagnosis and testing of
each of these two VTSS subsystems can be found elsewhere within this service information.
DIAGNOSIS AND TESTING > SENTRY KEY IMMOBILIZER SYSTEM
WARNING:
The hard wired circuits between modules and components related to the Sentry Key Immobilizer System
(SKIS) may be diagnosed using conventional diagnostic tools and procedures. Refer to the appropriate
However, conventional diagnostic methods will not prove conclusive in the diagnosis of the SKIS or the
electronic controls and communication between other modules and devices that provide features of the
SKIS. The most reliable, efficient and accurate means to diagnose the SKIS or the electronic controls
and communication related to SKIS operation requires the use of a diagnostic scan tool. Refer to the
SENTRY KEY IMMOBILIZER SYSTEM DIAGNOSIS
1. Ineffective Light-Emitting 1. Use a diagnostic scan tool to perform

Diode (LED). the Instrument Panel Cluster (IPC)
actuator test. Refer to the appropriate
2. Ineffective fuse. 2. Check the Radio Frequency Hub

Module (RFHM) fused B(+) fuse and the
fused ignition output (run-start) fuse in the
Power Distribution Center (PDC). Replace
SECURITY INDICATOR
the fuses, if required.
FAILS TO LIGHT DURING
BULB TEST 3. Ineffective ground circuit. 3. Test and repair the open ground circuit
at the connector for the RFHM, if required.
4. Ineffective battery feed 4. Test and repair the open battery feed
circuit. circuit at the connector for the IPC, if
required.
5. Ineffective ignition feed 5. Test and repair the open ignition feed
circuit. circuit at the connector for the IPC, if
required.
1. Invalid key in the ignition

switch lock cylinder or an 1. Remove the invalid key or FOBIK and
SECURITY INDICATOR invalid FOB with Integrated try again with a known valid key or FOBIK.
FLASHES FOLLOWING Key (FOBIK).
BULB TEST 2. Use a diagnostic scan tool and the
2. Key-related fault. appropriate diagnostic information for
further diagnosis.
1. Use a diagnostic scan tool and the

1. SKIS system
appropriate diagnostic information for
SECURITY INDICATOR malfunction/fault detected.
further diagnosis.
LIGHTS SOLID
FOLLOWING BULB TEST 2. Use a diagnostic scan tool and the
2. SKIS system ineffective. appropriate diagnostic information for
further diagnosis.
DIAGNOSIS AND TESTING > VEHICLE THEFT ALARM
WARNING:
The hard wired circuits between modules and components related to the Vehicle Theft Alarm (VTA)
system may be diagnosed using conventional diagnostic tools and procedures. Refer to the appropriate
However, conventional diagnostic methods will not prove conclusive in the diagnosis of the VTA or the
VTA. The most reliable, efficient and accurate means to diagnose the VTA or the electronic controls and
communication related to VTA operation requires the use of a diagnostic scan tool. Refer to the
ANTENNA, SENTRY KEY > DESCRIPTION AND OPERATION > DESCRIPTION AND
Fig 1: Ignition Switch, Sentry Key Antenna & Ignition Lock Cylinder
The Sentry Key antenna (2) is used only on vehicles that are not equipped with the optional Passive
Entry - Keyless Go (PEKG) system. The antenna is located on the right side of the steering column
adjacent to the ignition switch (1) and is concealed beneath the steering column shrouds. The housing
for the antenna is a molded plastic halo-like ring. When the antenna ring is properly installed, it is
secured around the circumference of the ignition lock cylinder (3) housing by three retainers integral to
the antenna housing. A single connector receptacle is also integral to the antenna housing and is
connected to the vehicle electrical system through a dedicated take out and connector of the steering
column wire harness.
The Sentry Key antenna cannot be adjusted or repaired. If ineffective or damaged, the entire antenna
unit must be replaced.
ANTENNA, SENTRY KEY > DESCRIPTION AND OPERATION > DESCRIPTION AND
In vehicles not equipped with the optional PEKG system, the Sentry Key Immobilizer Module (SKIM)
control circuitry integral to the Body Control Module (BCM) includes a Radio Frequency (RF) transceiver.
In vehicles equipped with the optional PEKG system, a Sentry Key antenna is not used and the Radio
Frequency Hub Module (RFHM) includes the SKIM control circuitry.
In vehicles without PEKG, the SKIM circuitry transmits RF signals to, and receives RF signals from the
Sentry Key transponder through the tuned Sentry Key antenna enclosed within the molded plastic
antenna housing. If this antenna is not mounted properly around the ignition lock cylinder housing,
communication problems between the SKIM control circuitry and the transponder may arise. These
communication problems will result in Sentry Key transponder-related faults.
When the status of the ignition switch is On, the SKIM control circuitry transmits an RF signal to the
transponder in the ignition key. The SKIM then waits for an RF signal response from the transponder. If
the response received identifies the key as valid, the SKIM control circuitry sends a valid key message
to the Powertrain Control Module (PCM) over the Controller Area Network (CAN) data bus. If the
response received identifies the key as invalid, or if no response is received from the key transponder,
the SKIM sends an electronic invalid key message to the PCM.
The PCM will enable or disable engine operation based upon the status of the SKIM messages. It is
important to note that the default condition in the PCM is an invalid key; therefore, if no message is
received from the SKIM by the PCM, the engine will be disabled and the vehicle immobilized after two
seconds of running.
The SKIM performs a self-test each time the status of the ignition transitions to On, and will store fault
information in the form of a Diagnostic Trouble Code (DTC) in BCM memory if a system malfunction is
detected. The Sentry Key antenna can be diagnosed, and any stored DTC can be retrieved using a
ANTENNA, SENTRY KEY > REMOVAL AND INSTALLATION > REMOVAL AND
WARNING:
Fig 1: Retainers, Sentry Key Antenna & Steering Column Wire Harness Connector
cable
2. Remove both the upper and lower shrouds from the steering column, but do not remove the
steering column from the vehicle. Refer to SHROUD, STEERING COLUMN, REMOVAL AND
INSTALLATION .
3. Disengage the three retainers (1) that secure the perimeter of the Sentry Key antenna (2) to
the ignition lock cylinder housing.
4. Disconnect the steering column wire harness connector (3) from the antenna connector
receptacle.
5. Remove the Sentry Key antenna from the ignition lock cylinder housing.
ANTENNA, SENTRY KEY > REMOVAL AND INSTALLATION > REMOVAL AND
WARNING:
Fig 1: Retainers, Sentry Key Antenna & Steering Column Wire Harness Connector
1. Position the Sentry Key antenna (2) close enough to the ignition lock cylinder housing to
access and connect the steering column wire harness connector (3) to the antenna connector
receptacle.
2. Position the antenna over the end of the ignition lock cylinder and engage the three retainers
(1) that secure the antenna to the lock cylinder housing.
3. Install the upper and lower shrouds onto the steering column. Refer to SHROUD, STEERING
COLUMN, REMOVAL AND INSTALLATION .
KEY, TRANSPONDER > DESCRIPTION AND OPERATION > DESCRIPTION AND

Fig 1: Remote Keyless Entry (RKE) & Passive Entry Keyless Go (PEKG) System Transponder Key
Two unique variations of a transponder key are available for this vehicle. They are:
Remote Keyless Entry System Transponder Key - The Remote Keyless Entry (RKE) system
transponder key (1) is used in combination with a rotary-type ignition switch. This transponder key
is used for vehicles that are equipped with the RKE system, but not with the optional Passive Entry
- Keyless Go (PEKG) system.
Passive Entry - Keyless Go System Transponder Key - The PEKG system transponder key (2)
is also known as a FOB with Integrated Key (FOBIK). However, unlike the RKE transponder key,
the PEKG transponder key is used in combination with a Keyless Ignition Node (KIN) featuring a
push button-type ignition switch. This transponder key is used only for vehicles that are equipped
with the PEKG system.
Each transponder key used in the Sentry Key Immobilizer System (SKIS) has a transponder chip
included on the circuit board beneath the cover of the integral RKE transmitter. In addition to having a
blank key that must be cut to match the mechanical coding of the ignition and door lock cylinder (without
PEKG) or only the door lock cylinder (with PEKG) and programmed for operation of the RKE system,
each new Sentry Key has a unique transponder identification code that is permanently programmed into
it by the manufacturer, and which must be programmed into the Sentry Key Immobilizer Module (SKIM)
integral to the Body Control Module (BCM) (without PEKG) or the Radio Frequency Hub Module (RFHM)
(with PEKG) to be recognized by the SKIS as a valid key.
The Sentry Key transponder cannot be adjusted or repaired. If ineffective or damaged, the entire key
and RKE transmitter or FOBIK unit must be replaced.
KEY, TRANSPONDER > DESCRIPTION AND OPERATION > DESCRIPTION AND

In vehicles not equipped with the optional Passive Entry - Keyless Go (PEKG) system, when the status
of the ignition transitions to On, the Sentry Key Immobilizer Module (SKIM) integral to the Body Control
Module (BCM) communicates through its antenna with the Sentry Key transponder using a Radio
Frequency (RF) signal. The SKIM then listens for a RF response from the transponder through the same
antenna. The Sentry Key transponder chip is within the range of the SKIM transceiver antenna ring when
it is inserted into the ignition lock cylinder. The SKIM determines whether a valid key is present in the
ignition lock cylinder based upon the response from the transponder.
In vehicles equipped with the optional PEKG system, when the status of the ignition (also known as the
Keyless Ignition Node/KIN or the push button switch) transitions to On it provides a hard wired input to
the BCM and an electronic message input to the Radio Frequency Hub Module (RFHM) over a dedicated
Local Interface Network (LIN) data bus. The RFHM relies upon several Low Frequency (LF) antenna
units to challenge the Sentry Key transponders using a LF signal, then monitors responses from the
Sentry Key transponders received as Very High Frequency (VHF) signals. The RFHM determines
whether a valid key is present based upon the response from the transponder.
If a valid key is detected, an electronic valid key message is broadcast by the BCM or the RFHM to the
Powertrain Control Module (PCM) over the Controller Area Network (CAN) data bus, and the PCM allows
the engine to continue running. If the PCM receives an electronic invalid key message from the BCM or
the RFHM, or receives no message from the SKIM or the RFHM over the CAN data bus, the engine will
be disabled after about two seconds of operation. The Instrument Panel Cluster (IPC) will also respond
to the electronic invalid key message on the CAN data bus by flashing the security indicator On and
Off.
MODULE, SENTRY KEY IMMOBILIZER (SKIM) > DESCRIPTION AND OPERATION >
The Body Control Module (BCM) is the central component of the immobilizer function. The Secret Key
Code is sorted in the following components: BCM, engine management module Powertrain Control
Module (PCM), Electric Steering-column Lock (ESL) module, ignition keys and Radio Frequency Hub
Module (RFHM).
The BCM or the RFHM cannot be adjusted or repaired. If ineffective or damaged the BCM or RFHM must
be replaced. Refer to MODULE, BODY CONTROL, DESCRIPTION AND OPERATION or MODULE,
RADIO FREQUENCY (RF HUB), DESCRIPTION AND OPERATION .
MODULE, SENTRY KEY IMMOBILIZER (SKIM) > DESCRIPTION AND OPERATION >
If the car has keys with a mechanical groove, the key identifiers are stored in the Body Control Module
(BCM). When the vehicle user turns the ignition switch to "ON", the relay that distributes the ignition-
operated supplies is activated and the instrument panel switches on. At this point the secret code
request (IMMO CODE REQUEST) leaves the Powertrain Control Module (PCM) for the BCM. This
energizes the key transponder through the antenna in the ignition switch and reads the key ID
information and the secret code. If the key is recognized as "valid", the BCM responds to the PCM's
request (IMMO CODE RESPONSE), thus initiating the encrypted (mini-crypt) dialogue with the PCM. At
the end of the dialogue between BCM and PCM, if the outcome is positive, the PCM will allow the engine
to be started. If the outcome is negative, the PCM will not enable engine starting. In this case, the BCM
will send a request to the Instrument Panel Cluster (IPC) to switch on the Code Immobilizer warning light.
If the vehicle has FOB with Integrated Key (FOBIK) keys, the key identifiers are stored in the Radio
Frequency Hub Module (RFHM). When the vehicle user presses the Keyless Ignition Node (KIN) and
Start/Stop module, this sends the RFHM (via the Local Interface Network (LIN) data bus and the
analogue "redundant run" signal) the information that the button has been pressed. At this point, the
RFHM advises the BCM that the button has been pressed. The BCM, in turn, will send a request to the
RFHM to read and identify the FOBIK identifier. If the RFHM recognizes the FOBIK (inside the car) as a
"valid FOBIK", it sends this information to the BCM, which in turn sends a request to the Electric
Steering-column Lock (ESL) module to release the steering column. After release, the ESL will send
confirmation to the BCM, which will activate the relay that distributes the +15 supplies (the panel
switches on). With the +15, the encrypted (mini-crypt) dialogue between BCM and PCM is triggered: the
PCM sends a secret code request (IMMO CODE REQUEST) to the +15 for the BCM, which will respond
to the request (IMMO CODE RESPONSE). If the outcome of the dialogue is positive, the PCM will permit
the engine to be started. If the outcome is negative, the PCM will not enable engine starting. In this
case, the BCM will send a request to the IPC to switch on the Code Immobilizer warning light.
MODULE, SHAFT LOCK > DESCRIPTION AND OPERATION > DESCRIPTION AND
Fig 1: Electric Steering Lock (ESL)
Vehicles manufactured for Europe-Middle East-Africa (EMEA) markets only have an electromechanical
device called an Electric Steering Lock (ESL) that locks (key OFF) and unlocks (key ON) the steering
upon request by the Body Control Module (BCM). The steering lock module is located on the steering
column in the same position where the ignition switch would be found. The electric steering lock is only
present on cars with Fobik-type key and the KIN module (Start/Stop button). Cars with a key with groove
have the classic mechanical steering lock.
The ESL module transmits data and communicates with the other modules involved in the immobilizer
system via CAN-C2.
In normal operating conditions the ESL module unlocks the steering column if, and only if, the key in the
vehicle is identified by the immobilizer system as a "valid key".
MODULE, SHAFT LOCK > DESCRIPTION AND OPERATION > DESCRIPTION AND
NOTE:
The Radio Frequency Hub Module (RFHM) and the Electric Steering Lock (ESL) module are
no longer linked electronically. During servicing, one can be replaced independently of the
other.
Steering column locking
Before sending the steering locking request to the ESL module, the Body Control Module (BCM) checks
the following parameters:
Ignition status: the transition from "ON" or "ON" with engine running statuses to the "OFF" status
must be detected.
Driver side door status: the transition from "driver side door closed" status to "driver side door
open" status must be detected.
For versions with automatic transmission only. Automatic transmission status: the transmission
must be in Park ("P") status.
If one of the three conditions is not satisfied, the BCM will not send the steering column locking request
to the ESL module.
Obviously, if the vehicle has a manual gearbox, the BCM will only check the first two parameters (ignition
status and driver side door status). If they are satisfied, the ESL module will lock the steering column
when the vehicle speed is below a minimum threshold.
The electric steering lock detects the vehicle speed through a VSO signal from the Antilock Brake
System (ABS) module. The acquisition of the VSO signal continues even after the ignition switch is
turned to "OFF".
Steering column unlocking
When the BCM receives the information that the "Stop & Start" button has been pressed from the RFHM,
it requests that the RFH carries out key recognition. If the key is identified as a "valid key", the BCM will
send a steering column unlocking request to the ESL module. If instead the key is identified as an
"invalid key" or "missing key", the BCM will not send any steering column unlocking request.
MODULE, SHAFT LOCK > REMOVAL AND INSTALLATION > REMOVAL AND
WARNING:
Fig 1: Electric Steering Lock (ESL) Module, Tamper-Resistant Screws & Wire Connector
cable.
2. Remove the instrument cluster bezel. Refer to BEZEL, INSTRUMENT CLUSTER, REMOVAL
AND INSTALLATION .
3. Remove the steering column upper and lower shrouds. Refer to SHROUD, STEERING
4. Disconnect the steering column multifunction switch wire harness connector (1) and move the
wiring aside.
5. Use a hammer and chisel to remove the tamper-resistant screws (2a) and extract the
Electronic Steering Lock (ESL) module (2b) from its housing.
Fig 2: Electronic Steering Lock (ESL) Module & Wire Connector

6. Disconnect the steering column wire harness connector (1a) and remove the ESL module (1b)
from the vehicle.
MODULE, SHAFT LOCK > REMOVAL AND INSTALLATION > REMOVAL AND
WARNING:
Fig 1: Electronic Steering Lock (ESL) Module & Wire Connector
1. Connect the steering column wire harness connector (1a) to the Electronic Steering Lock
(ESL) module (1b).
Fig 2: Electric Steering Lock (ESL) Module, Tamper-Resistant Screws & Wire Connector
2. Position the ESL module to the steering column and install new tamper-resistant screws (2a).
Tighten the screws until the heads break off.
3. Connect the steering column multifunction switch wire harness connector (1) to the
multifunction switch.
4. Install the steering column upper and lower shrouds. Refer to SHROUD, STEERING COLUMN,
5. Install the instrument cluster bezel. Refer to BEZEL, INSTRUMENT CLUSTER, REMOVAL AND
INSTALLATION .
NOTE:
If the electronic steering lock module is replaced, connect the diagnosis scan tool to
the vehicle DLC, go to "BCM" in the "Miscellaneous functions" menu and start the
"Secret key transfer to the ECM/ESL" procedure.
MODULE, ULTRASONIC AND ANTI-TILT > DESCRIPTION AND OPERATION >

Fig 1: Ultrasonic Anti-Tilt Module (UAM) (1 of 2)

Fig 2: Ultrasonic Anti-Tilt Module (UAM) (2 of 2)
An ultrasonic and anti-tilt security system uses ultrasonic waves to detect motion in the cab when the
vehicle is locked by remote control.
Should the vehicle be tilted to remove a wheel or towed, the vehicle's alarm will sound.
The alarm activates in the following cases:
When an attempt is made to force open a door, the hood or the liftgate (perimeter protection)
When the ignition system is activated outside of the security system on the vehicle
Cutting of battery cables
The module for the system is supplied power by the battery. The module and sensors are located inside
the roof light cover.
The UAM and the two ultrasonic transducers cannot be adjusted or repaired. If ineffective or damaged,
the entire roof lamp unit must be replaced.
MODULE, ULTRASONIC AND ANTI-TILT > DESCRIPTION AND OPERATION >

The Ultrasonic Anti-tilt Module (UAM) communicates with the Body Control Module (BCM) via the Local
Interface Network (LIN) serial data bus.
The BCM controls the activation of the anti-lift system and ultrasonic sensors and provides the
configuration and calibration parameters that are used by the sensors for correct operation. In the other
direction, the UAM sends the BCM information on its status.
Fig 1: Anti-Lift Button
Disabling anti-lift and volumetric sensors
With the vehicle stationary and key off, the user can press the dedicated button to manually disable the
volumetric and anti-lift function.
When the UAM detects a press of the dedicated button, it informs the BCM via the LIN data bus and
provides the user with a visual indication through the LED on the button.
MODULE, ULTRASONIC AND ANTI-TILT > DIAGNOSIS AND TESTING > DIAGNOSIS
AND TESTING - ULTRASONIC AND ANTI-TILT MODULE
The hard wired circuits between the Ultrasonic and Anti-tilt Module (UAM) (also known as the Ultrasonic
Alarm Module/UAM or the Intrusion Transceiver Module/ITM) and the Body Control Module (BCM) may
repair procedures, details of wire harness routing and retention, connector pin out information and
However, conventional diagnostic methods will not prove conclusive in the diagnosis of the UAM or the
of the Vehicle Theft Alarm (VTA) system. The most reliable, efficient and accurate means to diagnose the
UAM or the electronic controls and communication related to VTA system operation requires the use of a
MODULE, ULTRASONIC AND ANTI-TILT > REMOVAL AND INSTALLATION >

Fig 1: Ultrasonic Anti-Tilt Module (UAM), Wire Connector, Roof Lamp Unit & Screws
from the battery.
2. Remove the roof lamp unit (4) from the headliner. Refer to CONSOLE, OVERHEAD, FRONT,
3. Disconnect the roof lamp unit wire harness connector (2) from the Ultrasonic and Anti-tilt
Module (UAM) (1) (also known as the Ultrasonic Alarm Module/UAM or the Intrusion
Transceiver Module/ITM).
4. Remove the two screws (3) that secure the mounting tabs of the UAM to the roof lamp unit
housing.
5. Disengage and remove the UAM from the roof lamp unit housing.
MODULE, ULTRASONIC AND ANTI-TILT > REMOVAL AND INSTALLATION >
Fig 1: Ultrasonic Anti-Tilt Module (UAM), Wire Connector, Roof Lamp Unit & Screws
1. Position the Ultrasonic and Anti-tilt Module (UAM) (1) (also known as the Ultrasonic Alarm
Module/UAM or the Intrusion Transceiver Module/ITM) to the roof lamp unit housing (4).
2. Install and tighten the two screws (3) that secure the mounting tabs of the UAM to the roof lamp
unit housing.
3. Connect the roof lamp unit wire harness connector (2) to the UAM.
4. Install the roof lamp unit to the headliner. Refer to CONSOLE, OVERHEAD, FRONT, REMOVAL
AND INSTALLATION .
SIREN > DESCRIPTION AND OPERATION > DESCRIPTION AND OPERATION >
DESCRIPTION
Fig 1: Alarm Siren Unit (ASU) (1 of 2)

Fig 2: Alarm Siren Unit (ASU) (2 of 2)
The Alarm Siren Unit (ASU) module communicates with the Body Control Module BCM via the Local
INterface Network (LIN) serial data bus.
The BCM controls the activation of the siren and supplies the configuration of the parameters that are
used by the ASU to operate correctly (e.g. sound levels, number of alarm cycles per execution, etc.).
In the other direction, the ASU sends the BCM the information on its status.
The LIN data bus is also used to send and receive the messages regarding the "Heart Beat" function,
which monitors the integrity of the connections between the BCM and the siren module.
The alarm siren module cannot be repaired or adjusted and, if ineffective or damaged, it must be
replaced.
SIREN > DESCRIPTION AND OPERATION > DESCRIPTION AND OPERATION >
OPERATION
The microcontroller within the alarm siren module provides the siren unit features and functions based
upon internal programming and electronic arm and disarm messages received from the Body Control
Module (BCM) over a Local Interface Network (LIN) data bus connection. The BCM monitors inputs from
the Ultrasonic and Anti-tilt Module (UAM) (also known as the Ultrasonic Alarm Module/UAM or the
Intrusion Transceiver Module/ITM) to control the output to the alarm siren module. The siren module
receives battery voltage on a fused B(+) circuit through a fuse in the BCM and receives a path to ground
through a ground circuit in the headlamp and dash wire harness. These connections allow the siren to
remain operational, regardless of the status of the ignition.
When the premium version of the Vehicle Theft Alarm (VTA) is armed, the siren module continuously
monitors electronic message inputs from the BCM to sound its internal siren. While armed, the siren also
enters its auto-detect mode. While in the auto-detect mode, if the siren module detects that its power
supply or communication circuits are being tampered with or have been sabotaged, it will sound an
audible alarm and continue to operate through an on-board backup battery. If the siren module is in its
disarmed mode when its power supply or communication circuits are interrupted, the siren will not sound.
The alarm siren module will also notify the BCM when the backup battery requires charging, and the BCM
will send electronic messages that will allow the backup battery to be recharged through the battery
voltage and ground circuits to the alarm siren module only while the status of the ignition is On and the
engine is running. This prevents the potential discharge of the main battery while the vehicle is not being
operated.
The alarm siren module will self-detect problems with its internal and external power supply and
communication circuits, then send electronic messages indicating the problem to the BCM upon
receiving an arm or disarm request message. The BCM will store a Diagnostic Trouble Code (DTC) for
any detected alarm siren module fault. The DTC can then be retrieved with a diagnostic scan tool
through the 16-way Data Link Connector (DLC) located under the driver side lower edge of the
instrument panel over the Controller Area Network (CAN) data bus.
The hard wired inputs and outputs for the alarm siren module may be diagnosed using conventional
However, conventional diagnostic methods will not prove conclusive in the diagnosis of the alarm siren
module or the electronic controls and communication between other modules and devices that provide
some features of the VTA system. The most reliable, efficient and accurate means to diagnose the alarm
siren module or the electronic controls and communication related to alarm siren module operation
SIREN > REMOVAL AND INSTALLATION > REMOVAL AND INSTALLATION >
REMOVAL
Fig 1: Alarm Siren Module, Connector Receptacle & Mounting Bracket
from the battery.
2. Locate the alarm siren module (1) on the engine compartment side of the dash panel, below
the driver side windshield.
3. Disconnect the headlamp and dash wire harness connector from the connector receptacle (2)
for the siren.
4. Remove the fastener that secures the siren mounting bracket (3) to the dash panel.
5. Remove the siren and mounting bracket from the engine compartment as a unit.
SIREN > REMOVAL AND INSTALLATION > REMOVAL AND INSTALLATION >
INSTALLATION
Fig 1: Alarm Siren Module, Connector Receptacle & Mounting Bracket
NOTE:
If the alarm siren module has been replaced with a new unit, a diagnostic scan tool MUST
be used to initialize and configure the new unit in the Body Control Module (BCM) before the
Vehicle Theft Security System (VTSS) can operate as designed. Follow the programming
steps outlined in the diagnostic scan tool for INITIALIZE SIREN under MISCELLANEOUS
FUNCTIONS for the BODY CONTROL MODULE/BCM menu item as appropriate.
1. Position the alarm siren module (1) and mounting bracket (3) as a unit to the engine
compartment side of the dash panel, below the driver side windshield.
2. Install and tighten the fastener that secures the mounting bracket to the dash panel. Tighten the
fastener securely.
3. Connect the headlamp and dash wire harness connector to the connector receptacle (2) of the
siren.
SWITCH, HOOD AJAR > DESCRIPTION AND OPERATION > DESCRIPTION AND
Fig 1: Left Hood Latch Mechanism & Wire Connector
The hood ajar switch is a normally closed, single pole, spring-loaded plunger, leaf actuated switch that is
integral to the left hood latch mechanism (1) located on the left front fender load beam near the fender
ledge in the engine compartment. In vehicles manufactured for Europe-Middle East-Africa (EMEA)
markets the hood ajar switch is a feature of the Vehicle Theft Alarm (VTA) system. The hood ajar switch
in vehicles manufactured for North America Free Trade Agreement (NAFTA) markets is a feature of the
optional Remote Start System and not of the Vehicle Theft Alarm (VTA) system.
The molded plastic switch body has an integral pigtail wire harness and connector (2) on one end
containing two terminal pins. The switch is connected to the vehicle electrical system through a
dedicated take out and connector of the headlamp and dash wire harness.
The hood ajar switch can not be adjusted or repaired. If damaged or ineffective, the entire left hood latch
and hood ajar switch unit must be replaced.
SWITCH, HOOD AJAR > DESCRIPTION AND OPERATION > DESCRIPTION AND
The hood ajar switch is actuated by the hood latch mechanism and the hood latch striker. When the hood
is closed and properly latched, the hood ajar switch is an open circuit. When the hood is open or only
partially latched, the hood ajar switch is a closed circuit. The hood ajar switch is hard wired in series
between ground and a signal circuit of the Body Control Module (BCM).
The BCM reads the hard wired hood ajar switch input through an internal pull-up resistor, then uses this
input to control other electronic functions and features of the vehicle. The BCM may also send electronic
hood ajar switch status messages to other electronic modules in the vehicle over the Controller Area
Network (CAN) data bus.
The hood ajar switch as well as the hard wired inputs and outputs of the switch may be diagnosed using
article.
SWITCH, HOOD AJAR > DIAGNOSIS AND TESTING > DIAGNOSIS AND TESTING -
HOOD AJAR SWITCH
cable
2. Disconnect the pigtail wire harness connector for the hood ajar switch at the left hood latch.
3. Check for continuity between the two terminals of the hood ajar switch pigtail connector. There
should be continuity with the hood latch open, and no continuity with the hood latch closed. If
not OK, replace the left hood latch with the ineffective hood ajar switch. If OK, go to Step 4.
4. Test the ground circuit between ground and the hood ajar switch for continuity. If not OK, repair
the open ground circuit as required. If OK, go to Step 5.
5. Test the circuit between the hood ajar switch and the Body Control Module (BCM) for continuity
to ground. There should be no continuity. If not OK, repair the shorted circuit as required. If OK,
go to Step 6.
6. Test the circuit between the hood ajar switch and the BCM for continuity. There should be
continuity. If not OK, repair the open circuit as required. If OK, go to Step 7.
7. Use a diagnostic scan tool and the appropriate diagnostic procedure to complete testing of the
BCM.
SWITCH, HOOD AJAR > REMOVAL AND INSTALLATION > REMOVAL AND
The hood ajar switch used in this vehicle is integral to the left hood latch mechanism. Refer to LATCH,
HOOD, REMOVAL AND INSTALLATION .
SWITCH, HOOD AJAR > REMOVAL AND INSTALLATION > REMOVAL AND
The hood ajar switch used in this vehicle is integral to the left hood latch mechanism. Refer to LATCH,
HOOD, REMOVAL AND INSTALLATION .
Service Manual: ANTILOCK BRAKE SYSTEM (ABS) - Jeep Renegade
SERVICE INFORMATION
WARNING > WARNING
WARNING:
All the operations should be carried out taking great care to avoid personal injury. The
engine compartment contains many moving parts, components at high temperatures and live
wires. Follow the warnings given below very carefully when working in the engine
compartment: Turn off the engine and wait for it to cool down, do not smoke, do not use
naked flames and ensure a fire extinguisher is available nearby. The use of special
equipment is required for certain procedures. The use of these tools is vital for working
safely. Follow the current workshop safety regulations. Where necessary, this service
information contains specific procedures to be followed to prevent dangerous situations from
arising. When using chemical products, carefully follow the safety instructions on the safety
card. The safety card must be provided to the consumer by the supplier. The electronic
ignition system produces voltages of 20, 000 V and above which could be very hazardous
to people especially if they are suffering from a heart condition. Therefore take great care
when working on these systems or in the vicinity of their components.
CAUTION > CAUTION
CAUTION:
All the operations should be carried out taking great care to avoid damaging components.
To release parts that are sticking, tap gently using an aluminum or lead hammer if iron
materials are involved; use a wooden or resin hammer for light alloy parts. When
dismantling, check that components that should be marked have the appropriate references.
When refitting, lubricate the parts, where necessary, to prevent seizing or binding during the
initial operating period. When refitting it is vital to respect the adjustment nut tightening
torques. Each time they are refitted, replace gaskets, oil seals, flexible washers, safety
washers, self-locking nuts, pretreated screws, shear bolts and all parts that have
deteriorated. Use adhesive paper or a clean cloth to suitably protect those parts of the
engine which, if they remain uncovered after dismantling, will allow dust or foreign bodies to
enter. Only genuine spare parts should be used to replace units or components that have
been removed: this is the only way of ensuring the interchangeability and perfect operation
of the various components.
DESCRIPTION AND OPERATION > DESCRIPTION AND OPERATION
DESCRIPTION
Fig 1: ABS Module
BRAKING SYSTEM MODULE (ABS MODULE)
The electronic stability control system (ESC) on the vehicle is a sophisticated four-channel (independent
control of all four wheels on the vehicle) active management system. The dynamic control system helps
the driver to maintain control in difficult or adverse conditions such as wet, snow-covered or icy roads,
tight corners and evasive maneuvers.
The ESC system determines the driver's intentions and maintains dynamic control of the vehicle in
general to keep the dynamic forces within the safety limits in all driving conditions, doing this nearly
transparently, so that the control seems almost intuitive.
The ESC system primarily complements the ABS and traction control, to control all four wheels of the
vehicle independently in accordance with the signals from the yaw sensor and steering angle sensor.
The algorithm of the system determines when to intervene on the basis of the data received from the
following sensors: wheel speed, yaw, lateral acceleration, master cylinder pressure, steering angle and
vehicle speed.
If the driver pushes the vehicle so that it exceeds the grip limits of the road surface and that the vehicle
overseers or understeers, the system instantaneously analyses the data input from the sensors and
corrects the loss of control by applying one, several or all of the brakes to adjust the yaw rate,
maintaining the vehicle in the direction set by the driver.
OPERATION
The ESC system includes the following functions:
Panic Brake Assist (PBA) detects emergency braking by measuring the brake operation speed
and increases the braking power if necessary. In certain conditions, the braking assistance may
activate the ABS more rapidly compared to vehicles that don't have this function. The more rapid
intervention of the ABS has the potential to reduce the stopping distance, compensating for the
delayed intervention of the driver on the brakes.
Electronic Traction Control (BLD - Electronic Brake Differential) applies braking force to the
wheel of a single axle which is slipping in order to permit both wheels on the axle to receive a
sufficient drive torque value, thus improving the traction in all road and weather conditions.
Hill Start Assist (HSA) allows the driver to move their foot from the brake pedal to the accelerator
and keep the vehicle braked in the process. The system maintains the braking pressure for about
two seconds after the release of the brake pedal. The system reduces the braking pressure on the
wheel's calipers in accordance with the pressure on the accelerator pedal.
Rollover mitigation (ERM - Electronic Roll Mitigation) uses the information from the ESC
system sensors to determine in advance whether the vehicle is at risk of entering a potential
rollover situation, then activates the brakes individually and requests that the Powertrain Control
Module reduce the torque provided if necessary.
Trailer Sway Control (TSC) reduces the sway of the vehicle caused by the trailer that may occur
in adverse conditions (side wind and traffic). The system monitors the motion of the vehicle with
respect to the trajectory envisaged by the driver and applies alternate pressure to the brakes to
slow down the vehicle then increases the pressure on a front wheel to counteract the effect of the
trailer.
Hydraulic Boost Failure Compensation (HBFC) detects failure in the brake servo (vacuum loss)
through a sensor. If failure is detected, the brake module activates the ABS pump to assist braking.
Electronic Brake Prefill (EBP) detects whether the driver raises their foot from the accelerator
pedal and, if detected, the brake module applies light braking pressure (not enough to decelerate
the vehicle) to ensure that the brake pads are aligned correctly in anticipation of emergency
braking.
Activation of brake lights above a deceleration threshold permits the indication of vehicle
deceleration to other vehicles by simulating braking.
This function permits the activation of the brake lights for at least 1 second in two situations: during
the operation of the Adaptive Cruise Control (ACC), Hill Descent Control (HDC) or Hill Start Assist
(HSA), the brake lights are activated when the brake fluid pressure exceeds a minimum threshold
value; during Electronic Stability Control (ESC) or Trailer Sway Control (TSC), when the
deceleration exceeds the set threshold.
•Dynamic steering control (DST - Dynamic Steering Torque) uses the integration of the ESC
system with the electric power steering to increase the level of safety on the whole vehicle. In
critical situations (understeer, oversteer, braking on surfaces with different grip conditions), through
the DST function, the ESC system controls the steering, providing additional torque on the steering
wheel, to suggest the most appropriate maneuver to the driver. The coordinated action of the
brakes and steering increases the sensation of safety and control of the vehicle.
DIAGNOSIS AND TESTING > DIAGNOSIS AND TESTING - INSPECTION AND ROAD
TEST > DIAGNOSIS AND TESTING - INSPECTION AND ROAD TEST
1. Visually inspect the ABS for damaged or disconnected components and connectors.
2. Verify the brake lamps are operational. If they are not, repair them prior to continuing.
3. Connect a scan tool to the Data Link Connector located under the instrument panel to the left
of the steering column. If the scan tool does not power-up, check the power and ground
supplies to the connector.
4. Turn the ignition key to the ON position.
5. Using the scan tool, read and record any Diagnostic Trouble Codes (DTCs). If any DTCs are
present, refer to the appropriate diagnostic information.
If no problems are observed, it will be necessary to road test the vehicle.
Many ABS conditions judged to be a problem by the driver may be normal operating conditions.
To become familiarized with the normal operating characteristics of this anti-lock brake system.
Refer to DESCRIPTION AND OPERATION .
WARNING:
Conditions that result in turning on the red brake warning indicator lamp may
indicate reduced braking ability.
Before road testing a brake complaint vehicle, note whether the red BRAKE warning indicator
lamp, amber ABS warning indicator lamp, or both are turned on. If it is the red BRAKE warning
indicator, there is a brake hydraulic problem that must be corrected before driving the vehicle
The following conditions will cause the red BRAKE lamp to illuminate:
1. Low fluid in the brake reservoir
2. Park Brake engaged
3. Brake hydraulic problem
4. ABS issue that will not allow the Brake Proportioning function
If the amber ABS warning indicator is on, road test the vehicle as described below. While only
the amber ABS warning indicator is on, the ABS is not functional. The ability to stop the car
using the base brake system should not be affected.
6. Turn the key to the OFF position and then back to the ON position. Note whether the amber
ABS warning indicator lamp continues to stay on.
7. If the amber ABS warning indicator lamp stays on, shift into gear and drive the car to a speed
of approximately 25 km/h (15 mph) to complete the ABS Start-Up and Drive-Off Cycles. If at
this time the amber ABS warning indicator lamp stays on, refer to the appropriate diagnostic
information.
8. If the amber ABS warning indicator lamp goes out at any time, drive the vehicle a short
distance. Accelerate the vehicle to a speed of at least 50 km/h (31 mph). Bring the vehicle to a
complete stop, braking hard enough to cause the ABS to cycle. Repeat this action several
times. Using the scan tool, read and record any (DTCs). If any DTCs are present, refer to the
appropriate diagnostic information.
VEHICLE STABILITY CONTROL SYSTEM ESP / ESC
Perform a road test looking for a square or a round free.
Making sure not to cause any obstruction or danger to traffic, run a curved path in order to
activate the ESP system: we must cause the ESP warning light for 2-3 seconds.
For brake torque specifications, refer to SPECIFICATIONS .
ELECTRICAL > SENSOR, DYNAMICS > REMOVAL AND INSTALLATION > REMOVAL
The dynamic sensor is built into the Occupant Restraint Control Module (ORC) for removal. Refer to
MODULE, OCCUPANT RESTRAINT CONTROLLER, REMOVAL AND INSTALLATION .
ELECTRICAL > SENSOR, DYNAMICS > REMOVAL AND INSTALLATION > REMOVAL
The dynamic sensor is built into the Occupant Restraint Control Module (ORC) for installation. Refer to
MODULE, OCCUPANT RESTRAINT CONTROLLER, REMOVAL AND INSTALLATION .
ELECTRICAL > SENSOR, WHEEL SPEED, FRONT > REMOVAL AND INSTALLATION >
3. Remove the tire and wheel assembly. Refer to REMOVAL AND INSTALLATION .
Fig 1: Wheel Speed Sensor Electrical Connector
4. Disconnect the wheel speed sensor electrical connector (1). Detach the wiring from the routing
retainers.
Fig 2: Wheel Speed Sensor Bolt
5. Remove wheel speed sensor bolt (1) and remove the wheel speed sensor from the knuckle.
ELECTRICAL > SENSOR, WHEEL SPEED, FRONT > REMOVAL AND INSTALLATION >
1. Install the wheel speed sensor (1) and the wheel speed sensor bolt (1). Tighten the wheel
speed sensor bolt to the proper torque specification. Refer to SPECIFICATIONS .
2. Connect the wheel speed sensor wiring to the routing retainers.
3. Connect wheel speed sensor electrical connector.
4. Install the tire and wheel assembly. Refer to REMOVAL AND INSTALLATION .
ELECTRICAL > SENSOR, WHEEL SPEED, REAR > REMOVAL AND INSTALLATION >

Fig 1: Rear Wheel Speed Sensor Connector
4. Disconnect the rear wheel speed sensor connector (1). Detach the wiring from the body
retainers.
Fig 2: Rear Wheel Speed Sensor Bolt
5. Remove the rear wheel speed sensor bolt (1) and the wheel speed sensor (1) from the
knuckle.
ELECTRICAL > SENSOR, WHEEL SPEED, REAR > REMOVAL AND INSTALLATION >
Fig 1: Rear Wheel Speed Sensor And Bolt
1. Install the rear wheel speed sensor and bolt (1). Tighten the rear wheel speed sensor bolt to
the proper torque specification. Refer to SPECIFICATIONS .
2. Connect wheel speed sensor wiring to the body.
3. Connect the wheel speed sensor electrical connector.
ELECTRICAL > SWITCH, ELECTRONIC STABILITY PROGRAM (ESP) > DESCRIPTION

> DESCRIPTION AND OPERATION
NOTE:
The Electronic Stability Control (ESC) may also be referred to as Electronic Stability
Program (ESP) depending on the vehicle model year and configuration. Certain components
may also reference ESP, ESC, or use the traction control symbol.
The Electronic Stability Control off Switch is an integral part of the instrument panel switch pod located in
center of the instrument panel. The ESC Off switch turns the Electronic Stability Control off whenever the
switch is depressed. Depressing the switch a second time turns the ESC back on. The switch resets
itself each time the ignition is cycled.
When the ESC Off switch is depressed and released, turning ESC off, it does not completely turn the
system off. The ESC system reduces torque management to a lesser amount, but ESC function can still
occur if the system perceives the need.
The ESC function lamp is illuminated in the cluster whenever the ESC system is turned off.
ELECTRICAL > SWITCH, ELECTRONIC STABILITY PROGRAM (ESP) > REMOVAL

NOTE:
The ESC Off Switch is an integral part of the instrument panel switch pod located in center of the
instrument panel. Refer to POD, SWITCH, REMOVAL AND INSTALLATION .
ELECTRICAL > SWITCH, ELECTRONIC STABILITY PROGRAM (ESP) > REMOVAL

NOTE:
The ESC Off Switch is an integral part of the instrument panel switch pod located in center of the
instrument panel. Refer to POD, SWITCH, REMOVAL AND INSTALLATION .
HYDRAULIC/MECHANICAL > INTEGRATED CONTROL UNIT (ICU) > REMOVAL AND

NOTE:
When replacing the control unit, connect the diagnostic tool to the OBD port and go to
"control BSM" and go to the menu "actuators" and start the process of "activating the
automatic functions."
1. Drain the brake fluid. Refer to STANDARD PROCEDURE .
Fig 1: Primary And Secondary Brake Tubes
3. Remove the primary and secondary brake tubes (1) from the Hydraulic Control Unit (HCU).
4. Remove the primary and secondary brake tubes (1) from the master cylinder.
Fig 3: Integrated Control Unit (ICU) Electrical Connector & Brake Tubes
5. Disconnect the Integrated Control Unit (ICU) electrical connector (2).
6. Remove the four brake tubes (1) from the HCU.

Fig 4: ICU Bracket, Bolt & Nut
7. Remove the nut (1a) and bolt (1b) fastening the ICU bracket to the body. Remove the
assembly from the vehicle.
8. To remove the ICU bracket, remove bolts (1a) and (1b), and separate the ICU from the bracket
(1c).
9. If necessary to remove Anti-lock Brake Module (ABM). Refer to MODULE, ANTI-LOCK BRAKE
SYSTEM, REMOVAL AND INSTALLATION .
HYDRAULIC/MECHANICAL > INTEGRATED CONTROL UNIT (ICU) > REMOVAL AND

1. If the Anti-lock Brake Module (ABM) was removed from the Hydraulic Control Unit (HCU) for
installation. Refer to MODULE, ANTI-LOCK BRAKE SYSTEM, REMOVAL AND INSTALLATION
.
2. Position the Integrated Control Unit (ICU) to the ICU bracket (1c) and tighten the ICU to ICU
bracket bolts (1a) (1b) to the proper torque specification. Refer to TORQUE SPECIFICATIONS
.
Fig 2: ICU To Body Bolt & Nut
3. Position the ICU into the vehicle, and tighten the ICU to body bolt (1b) and nut (1c) to the
proper torque specification. Refer to TORQUE SPECIFICATIONS .
Fig 3: ICU Electrical Connector & Brake Tubes
4. Install the four brake tubes (3) to the HCU and tighten to the proper torque specification. Refer
to TORQUE SPECIFICATIONS .
5. Connect the ICU electrical connector (2).

6. Install the primary and secondary brake tubes (1) to the master cylinder, and tighten to the
7. Install the primary and secondary brake tubes (1) to the HCU, and tighten to the proper torque
specification. Refer to TORQUE SPECIFICATIONS .
9. Fill and bleed out braking system. Refer to STANDARD PROCEDURE .
10. If a new ABS control unit is being installed, connect a scan tool and calibrate the yaw sensor
and the steering angle sensor.
Jeep Renegade
Service Manual: BASE BRAKES - SERVICE INFORMATION
WARNING > WARNING
WARNING:
FCA US LLC does not manufacture any vehicles or replacement p arts that contain asbestos.
Aftermarket products may or may not contain asbestos. Refer to aftermarket product
packaging for product information. Whether the product contains asbestos or not, dust and
dirt can accumulate on brake parts during normal use. Follow practices prescribed by
appropriate regulations for the handling, processing and disposing of dust and debris.
WARNING:
When bleeding the brake system wear safety glasses. A clear bleed tube (1) must be
attached to the bleeder screws and submerged in a clear container filled part way with clean
brake fluid (2). Direct the flow of brake fluid away from yourself and the painted surfaces of
the vehicle. Brake fluid at high pressure may come out of the bleeder screws when opened.
WARNING:
DUST AND DIRT ACCUMULATING ON BRAKE PARTS DURING NORMAL USE MAY
CONTAIN ASBESTOS FIBERS FROM PRODUCTION OR AFTERMARKET LININGS.
BREATHING EXCESSIVE CONCENTRATIONS OF ASBESTOS FIBERS CAN CAUSE
SERIOUS BODILY HARM. EXERCISE CARE WHEN SERVICING BRAKE PARTS. DO NOT
CLEAN BRAKE PARTS WITH COMPRESSED AIR OR BY DRY BRUSHING. USE A
VACUUM CLEANER SPECIFICALLY DESIGNED FOR THE REMOVAL OF ASBESTOS
FIBERS FROM BRAKE COMPONENTS. IF A SUITABLE VACUUM CLEANER IS NOT
AVAILABLE, CLEANING SHOULD BE DONE WITH A WATER DAMPENED CLOTH. DO
NOT SAND, OR GRIND BRAKE LINING UNLESS EQUIPMENT USED IS DESIGNED TO
CONTAIN THE DUST RESIDUE. DISPOSE OF ALL RESIDUE CONTAINING ASBESTOS
FIBERS IN SEALED BAGS OR CONTAINERS TO MINIMIZE EXPOSURE TO YOURSELF
AND OTHERS. FOLLOW PRACTICES PRESCRIBED BY THE OCCUPATIONAL SAFETY
AND HEALTH ADMINISTRATION AND THE ENVIRONMENTAL PROTECTION AGENCY
FOR THE HANDLING, PROCESSING, AND DISPOSITION OF DUST OR DEBRIS THAT
MAY CONTAIN ASBESTOS FIBERS.
CAUTION > CAUTION
CAUTION:
All the operations should be carried out taking great care to avoid damaging components.
To release parts that are sticking, tap gently using an aluminum or lead hammer if iron
materials are involved; use a wooden or resin hammer for light alloy parts. When
dismantling, check that components that should be marked have the appropriate references.
When refitting, lubricate the parts, where necessary, to prevent seizing or binding during the
initial operating period. When refitting it is vital to respect the adjustment nut tightening
torques. Each time they are refitted, replace gaskets, oil seals, flexible washers, safety
washers, self-locking nuts, pretreated screws, shear bolts and all parts that have
deteriorated. Use adhesive paper or a clean cloth to suitably protect those parts of the
engine which, if they remain uncovered after dismantling, will allow dust or foreign bodies to
enter. Only genuine spare parts should be used to replace units or components that have
been removed: this is the only way of ensuring the interchangeability and perfect operation
of the various components.
DESCRIPTION > DESCRIPTION
The vehicle's braking system features ABS and TCS traction control as standard and is made by TRW
Automotive.
Fig 1: Brake System Components
The system consists of the following components:

DESCRIPTION > DESCRIPTION > FRONT ROTORS
Fig 1: Front Rotor Dimensions
They are all by Brembo and ventilated type.
Two types of front disc are available (two different part numbers) :
X=305 mm; Y=28 mm fitted on models with 1.4 Turbo MultiAir (160 HP 170 HP), 2.0 MultiJet (170
HP and 140 HP) and 2.4 Tiger Shark engine versions.
X=281 mm; Y= 26 mm fitted on models with 1.4 Turbo MultiAir 140 HP and 1.6 MultiJet 120 HP
engine versions.
DESCRIPTION > DESCRIPTION > REAR ROTORS

Fig 1: Rear Rotor Dimensions
The rear discs are all by Brembo and non-ventilated type.
Rear discs with the same geometrical characteristics are fitted on all models: X=278 mm; Y=12 mm.
DESCRIPTION > DESCRIPTION > FRONT BRAKE CALIPERS

Fig 1: Front Caliper Dimensions
The front brake calipers are floating type with single 60 mm piston. The front brake calipers are made by
Mando Corporation.
DESCRIPTION > DESCRIPTION > REAR BRAKE CALIPERS

Fig 1: Rear Caliper (1 Of 3)
The rear calipers are floating type with single 38 mm piston. The rear calipers are produced by TRW.
The rear caliper features an electric actuator through which the parking brake is engaged/released.
From the mechanical point of view, the actuator is fitted with an electric motor (4) which moves, through
an epicyclic gear set (1), an output shaft which is in its turn fitted in a spindle (3). The spindle is screwed
into a female screw (2). When the motor turns the spindle, the spindle drives the female screw (2) away
(engages the brake) or brings it back (releases the brake) depending on the motor's direction of rotation.
DIAGNOSIS AND TESTING > DIAGNOSIS AND TESTING - BASE BRAKE SYSTEM
DIAGNOSIS CHARTS > BRAKE NOISE
CONDITION POSSIBLE CORRECTION

CAUSES
DISC BRAKE CHIRP 1. Excessive 1. Diagnose and correct as necessary.

brake rotor runout.
DISC BRAKE MOAN 1. Rear disc brake 1. Remove lower guide pin bolt and inspect for special
OR HOWL WHILE caliper guide pin sleeve on tip. If sleeve is present, remove upper and lower
BRAKING IN bolts installed in guide pin bolts and install special sleeved bolt in upper
REVERSE incorrect location and standard guide pin bolt in lower location. Refer
to CALIPER, DISC BRAKE, REMOVAL AND
INSTALLATION and CALIPER, DISC BRAKE, REAR,
locations.
REMOVAL AND INSTALLATION . Perform on both sides of
vehicle as necessary.
DISC BRAKE RATTLE 1. Broken or 1. Replace brake pads.

OR CLUNK missing spring
clips.
2. Caliper guide 2. Tighten guide pin bolts.

pin bolts loose.
3. Missing 3. Replace missing abutment shims.

abutment shims.
DISC BRAKE 1. Brake pad 1. Replace brake pads.

SQUEAK AT LOW linings.
SPEED (WHILE
APPLYING LIGHT
BRAKE PEDAL
EFFORT)
SCRAPING (METAL- 1. Foreign object 1. Inspect brakes and remove foreign object.
TO-METAL). interference with
brakes.
2. Brake pads 2. Replace brake pads. Inspect rotors. Reface or replace as

worn out. necessary.
SCRAPING OR 1. ABS wheel 1. Inspect, correct or replace faulty component(s).

WHIRRING speed sensor
hitting tone wheel.
DIAGNOSIS CHARTS > OTHER BRAKE CONDITIONS
BRAKES CHATTER 1. Disc brake rotor has excessive 1. Isolate condition as rear or
thickness variation. front. Reface or replace brake
rotors as necessary.
BRAKES DRAG (FRONT OR 1. Contaminated brake fluid. 1. Check for swollen seals.
ALL) Replace all system components
containing rubber.
2. Binding caliper pins or bushings. 2. Replace pins and bushings
3. Mis-adjusted brake lamp switch. 3. Replace stop lamp switch.

Refer to SWITCH, STOP LAMP,
4. Master cylinder not fully 4. Inspect master cylinder and

returning. replace as necessary.
5. Binding brake pedal. 5. Replace brake
pedal/bushings.
BRAKES DRAG (REAR ONLY) 1. Electric Parking Brake (EPB) 1. EPB module will set codes
caliper actuators (one or both) are
not released. Or the EPB module or
EPB actuators are not responding.
BRAKES GRAB 1. Contaminated brake pad. 1. Inspect and clean, or replace

pads. Repair source of
contamination.
2. Improper power brake booster 2. Refer to BOOSTER, POWER

assist. BRAKE .
EXCESSIVE PEDAL EFFORT 1. Obstruction of brake pedal. 1. Inspect, remove or move

obstruction.
2. Low power brake booster assist. 2. Refer to BOOSTER, POWER

BRAKE .
3. Glazed brake linings. 3. Reface or replace brake

4. Brake pad lining transfer to 4. Reface or replace brake

brake rotor. rotors as necessary. Replace
brake pads.
EXCESSIVE PEDAL EFFORT 1. Power brake booster (vacuum 1. Check booster vacuum hose
(HARD PEDAL - CAN'T SKID assist). and engine tune for adequate
WHEELS) vacuum supply. Refer to
BOOSTER, POWER BRAKE .
EXCESSIVE PEDAL TRAVEL 1. Air in brake lines. 1. Bleed brakes.

(VEHICLE STOPS OK)
2. Fill reservoir. Check entire

2. Brake fluid low in reservoir system for leaks; repair or
replace as required.
EXCESSIVE PEDAL TRAVEL 1. One of the two hydraulic circuits 1. Inspect system for leaks.
(ONE FRONT WHEEL LOCKS is malfunctioning. Check master cylinder for
UP DURING HARD BRAKING) internal malfunction.
PEDAL PULSATES/SURGES 1. Disc brake rotor has excessive 1. Isolate condition as rear or
DURING BRAKING thickness variation. front. Reface or replace brake
PEDAL IS SPONGY 1. Air in brake lines. 1. Bleed brakes.
2. ABS EVBP not functioning. 2. Refer to DIAGNOSIS AND

TESTING and appropriate
STOP LAMPS STAY ON 1. Brake lamp switch out of 1. Replace stop lamp switch.
adjustment. Refer to SWITCH, STOP LAMP,
2. Brake pedal binding. 2. Inspect and replace as
necessary.
3. Power brake booster not 3. Replace power brake booster.

allowing pedal to return completely.
VEHICLE PULLS TO RIGHT OR 1. Frozen brake caliper piston. 1. Replace frozen piston or
LEFT ON BRAKING caliper. Bleed brakes.
2. Contaminated brake pad lining 2. Inspect and clean, or replace

(most likely front lining). pads. Repair source of
contamination.
3. Pinched brake lines. 3. Replace pinched line.
4. Leaking piston seal. 4. Replace piston seal or brake

caliper.
5. Suspension problem. 5. Refer to FRONT

SUSPENSION & WHEEL
ALIGNMENT or REAR
SUSPENSION .
DIAGNOSIS CHARTS > RED BRAKE WARNING INDICATOR
RED BRAKE WARNING 1. Electric Park brake not 1. Check EPB switch position.
INDICATOR ON released.
2. Electric Park Brake 2. Check EPB switch position.

switch.
3. Brake fluid level low in 3. Fill reservoir. Check entire system for
reservoir. leaks. Repair or replace as required.
4. Brake fluid level switch. 4. Disconnect switch wiring connector. If lamp

goes out, replace switch.
5. Mechanical instrument 5. Refer to appropriate diagnostic information.

cluster (MIC) problem.
6. ABS EVBP malfunction. 6. Refer to DIAGNOSIS AND TESTING and

STANDARD PROCEDURE > STANDARD PROCEDURE - BRAKE FLUID LEVEL
Always clean the master cylinder reservoir and cap before checking fluid level.
The fluid fill level is indicated on the side of the master cylinder reservoir.
The correct fluid level is to the MAX indicator on the side of the reservoir. If necessary, add fluid to the
proper level.
STANDARD PROCEDURE > STANDARD PROCEDURE - BRAKE FLUID LEVEL >

MANUAL BLEEDING PROCEDURE
Fig 1: Bleeding Brakes
NOTE:
To bleed the brakes manually, the aid of a helper will be required.
1. Attach a clear plastic hose (1) to the bleeder screw and feed the hose into a clear jar (2)
containing enough fresh brake fluid to submerge the end of the hose.
2. Have a helper pump the brake pedal three or four times and hold it in the down position.
3. With the pedal in the down position, open the bleeder screw at least one full turn.
4. Once the brake pedal has dropped, close the bleeder screw. After the bleeder screw is closed,
release the brake pedal.
5. Repeat the above steps until all trapped air is removed from that wheel circuit (usually four or
five times).
6. Bleed the remaining wheel circuits in the same manner until all air is removed from the brake
system. Monitor the fluid level in the master cylinder reservoir to make sure it does not go dry.
7. Check and adjust brake fluid level to the FULL mark.
8. Check brake pedal travel and feel. If pedal travel is excessive or if the pedal feels excessively
spongy, some air may still be trapped in the system. Re-bleed the brakes as necessary
including the IPB Caliper Brake Bleeding Procedure on the rear calipers as listed below.
9. Test drive the vehicle to verify the brakes are operating properly and pedal feel is correct.
STANDARD PROCEDURE > STANDARD PROCEDURE - BRAKE FLUID LEVEL >

PRESSURE BLEEDING PROCEDURE
Follow the pressure bleeder manufacturer's instructions for use of the pressure bleeding equipment.
Fig 1: Bleeding Brakes

1. Install (special tool #6921, Cap, Master Cylinder) on the master cylinder fluid reservoir. Attach
the fluid hose from the pressure bleeder to the fitting on (special tool #6921, Cap, Master
Cylinder).
2. Attach a clear plastic hose (1) to the bleeder screw and feed the hose into a clear jar (2)
containing enough fresh brake fluid to submerge the end of the hose.
3. Open the bleeder screw at least one full turn or more to obtain a steady stream of brake fluid.
4. After approximately 120-240 ml (4-8 ounces) of fluid have been bled through the brake circuit
and an air-free flow is maintained in the clear plastic hose and jar, close the bleeder screw.
5. Repeat this procedure at all the remaining bleeder screws.
6. Check and adjust brake fluid level to the FULL mark on the reservoir.
7. Check brake pedal travel and feel. If pedal travel is excessive or if the pedal feels excessively
spongy, some air may still be trapped in the system. Re-bleed the brakes as necessary
including the IPB Caliper Brake Bleeding Procedure on the rear calipers as listed below.
8. Test drive the vehicle to verify the brakes are operating properly and pedal feel is correct.
Brake/clutch system
2000001400 * Cap
depression
* Tool not available for NAFTA. Use a commercially available tool or contact Mopar Essential Tools to
SPECIFICATIONS > TECHNICAL SPECIFICATIONS
BRAKING SYSTEM
1.4 MultiAir Turbo 2.4 MultiAir 1.6 16V Multijet 2.0 16V Multijet
Type Hydraulic power steering. Front and rear disc
Master cylinder
15/16"
diameter
Servo cylinder
10"
diameter
FRONT BRAKES
Disc type Self-venting

Disc diameter (mm) 281 ± 0.2 305 ± 0.2 281 ± 0.2 305 ± 0.2
Minimal Thickness
26 ± 0.1 28 ± 0.1 26 ± 0.1 28 ± 0.1
(mm)
Minimal Thickness
26
allowed (mm)
Caliper piston
57 60 57 60
diameter (mm)
REAR BRAKES
Disc type Full
Disc diameter (mm) 278 ± 0.2
Minimal Thickness
12 ± 0.1
(mm)
Minimal Thickness
10
allowed (mm)
Caliper piston
38
diameter (mm)

BRAKE SYSTEM TORQUE SPECIFICATIONS
NEW
DESCRIPTION N.m Ft. Lbs. In. Lbs.
FASTENER *
ABM mounting screws to the HCU 2 - 17
Brake Caliper Adapter to Knuckle Bolts -

165 122 -
Front
Brake Caliper Adapter to Knuckle Bolts -

57 42 -
Rear
Brake Caliper to Caliper Adaptor Bolts -

35 26 -
Front
Brake Caliper to Caliper Adaptor Bolts -

35 26 -
Rear
Brake Hose to Brake Caliper - Front 17 13 -
Brake Hose to Brake Caliper - Rear 17 13 -
Brake Pedal/Booster Nuts 22 17 - X

Brake Rotor to Hub Bolt - Front 7 - 61
Brake Rotor to Hub Bolt - Rear 7 - 61
Brake Tube to Brake Hose Nuts 17 13 -
Brake Tube to ICU Nuts 17 13 -
Brake Tube to Master Cylinder Nuts 17 13 -
Dust Shield to Knuckle Bolts 7 - 61
Electric Park Brake (EPB) Actuator to

12 9 -
Caliper Bolts
Electric Vacuum Pump to Cylinder Head

23 17 - X
Bolts
ICU to Bracket Nuts 8 - 71
ICU Bracket to Body Bolt 25 18 -
ICU Bracket to Body Nut 25 18 - X
Master Cylinder to Brake Booster Nuts 17 13 - X
Wheel Speed Sensor Head to Knuckle Bolt -

7 - 61
Front
Wheel Speed Sensor Head to Knuckle Bolt -

7 - 61
Rear
* New Fastener: Do not reuse these fasteners. If removed, a new fastener must be installed and
ELECTRICAL > PUMP, ELECTRIC VACUUM > DIAGNOSIS AND TESTING >
DIAGNOSIS AND TESTING - BRAKE VACUUM SYSTEM
OPERATION CHECK VACUUM PUMP AND VACUUM CIRCUIT FOR SERVO
Relieve the pressure in the brake servo motor has stopped by repeated forceful drives and releases the
brake pedal.
With the brake pedal pressed to start the engine without accelerating.
Make sure that after a few seconds the brake pedal remains as a function of pressure due to the action
of the brake booster.
Release the brake pedal and without further drives off the engine.
After about 10 minutes, with the engine off, pump the brake pedal and check on the first drive, lowering
the corresponding contribution to the brake booster and subsequent drives the progressive hardening.
ELECTRICAL > PUMP, ELECTRIC VACUUM > REMOVAL AND INSTALLATION >
2. Remove engine cover. For 1.6L/2.0L Diesel, refer to COVER, ENGINE, REMOVAL AND
INSTALLATION . For 1.4L, refer to COVER, ENGINE, REMOVAL AND INSTALLATION . For
2.4L, refer to COVER, ENGINE, REMOVAL AND INSTALLATION .
Fig 1: ECM Connectors & Quick Connect Fitting
3. Disconnect the engine control module electrical connectors (1).
4. Disconnect the quick connect fitting (2) at the vacuum pump.

Fig 2: Vacuum Pump Engine Bolts
5. Remove the three vacuum pump to engine bolts (1), and remove the vacuum pump from the
vehicle.
ELECTRICAL > PUMP, ELECTRIC VACUUM > REMOVAL AND INSTALLATION >
Fig 1: Vacuum Pump O-Rings
1. If removed or replaced, install both of the vacuum pump o-rings (1).

Fig 2: Vacuum Pump Engine Bolts
2. Install the three vacuum pump to engine bolts (1), and tighten to the proper specification. Refer
Fig 3: ECM Connectors & Quick Connect Fitting
3. Connect the quick connect fitting (2) at the vacuum pump.
4. Connect the engine control module electrical connectors (1).
5. Install engine cover. For 1.6L/2.0L Diesel, refer to COVER, ENGINE, REMOVAL AND
ELECTRICAL > SWITCH, BRAKE FLUID LEVEL > REMOVAL AND INSTALLATION >
For the removal of the brake fluid level switch. Refer to RESERVOIR, BRAKE MASTER CYLINDER,
ELECTRICAL > SWITCH, BRAKE FLUID LEVEL > REMOVAL AND INSTALLATION >
For the installation of the brake fluid level switch. Refer to RESERVOIR, BRAKE MASTER CYLINDER,
HYDRAULIC/MECHANICAL > BOOSTER, POWER BRAKE > DIAGNOSIS AND

TESTING > DIAGNOSIS AND TESTING - MASTER CYLINDER/POWER BOOSTER
1. Start the engine and check the booster vacuum hose connections. A hissing noise indicates a
vacuum leak. Correct any vacuum leaks before proceeding.
2. Stop the engine and pump the brake pedal until all vacuum reserve in the booster is depleted.
3. Press and hold the brake pedal under light foot pressure. The pedal should hold firm. If the
pedal falls away, there may be an external leak or the master cylinder is faulty (internal
leakage).
4. Start the engine and note pedal action. It should fall away slightly under light foot pressure,
then hold firm. If no pedal action is discernible, the power booster, vacuum supply or vacuum
check valve is faulty, proceed to the POWER BOOSTER VACUUM TEST.
5. If the POWER BOOSTER VACUUM TEST passes, rebuild the booster vacuum reserve as
follows: Release the brake pedal. Increase engine speed to 1500 RPM, close the throttle and
immediately turn off the ignition to stop the engine.
6. Wait a minimum of 90 seconds and try brake action again. The booster should provide two or
more vacuum assisted pedal applications. If the vacuum assist is not provided, the booster is
faulty.
HYDRAULIC/MECHANICAL > BOOSTER, POWER BRAKE > REMOVAL AND

INSTALLATION > LHD > REMOVAL
1. Remove the engine cover. For 1.6L/2.0L Diesel, refer to COVER, ENGINE, REMOVAL AND
2. Remove the Integrated Control Unit (ICU). Refer to INTEGRATED CONTROL UNIT (ICU),
Fig 1: Master Cylinder To Clutch Pedal Hose
3. If equipped, disconnect the hose (1) from the master cylinder to clutch pedal.
Fig 2: Brake Booster Push Rod Retaining Clip
4. Release the brake booster push rod retaining clip (1).

Fig 3: Brake Booster To Brake Pedal Nuts
5. Remove brake booster to brake pedal nuts (1).

Fig 4: Brake Booster Adhesive Gasket
6. Remove the brake booster from the adhesive gasket (1), and remove it from the vehicle.
NOTE:
Be sure to retrieve the cup off the end of the brake booster push rod.
Fig 5: Brake Booster Nuts
7. Remove the master cylinder to brake booster nuts (1a).
NOTE:
Remove any sealant from the body. In case of replacement of the brake booster, be
sure to remove and residue from the adhesive seal.

INSTALLATION > LHD > INSTALLATION
1. Position the master cylinder on the brake booster, install and tighten the master cylinder to
brake booster nuts (1b) to the proper specification. Refer to TORQUE SPECIFICATIONS .
2. Place the cup on to the end of the brake booster push rod, then install the brake booster with a
NEW gasket into the vehicle.
Fig 2: Brake Booster To Brake Pedal Nuts
3. Install and tighten the brake booster to brake pedal nuts (1) to the proper specification. Refer
4. Install a NEW push rod retaining clip on the brake servo push rod, then install the push rod on
the brake pedal.
5. If equipped, connect the hose from the master cylinder to clutch pedal.
6. Install the Integrated Control Unit (ICU). Refer to INTEGRATED CONTROL UNIT (ICU),
7. Install the engine cover. For 1.6L/2.0L Diesel, refer to COVER, ENGINE, REMOVAL AND

INSTALLATION > RHD > REMOVAL
cable.
3. Remove the pedal assembly. Refer to PEDAL(S), BRAKE AND/OR ACCELERATOR,

Fig 1: Master Cylinder & Nuts
4. Working from the engine compartment, remove the nuts (1a) securing the master cylinder (1b).
Fig 2: Brake Booster Spacer
5. Remove the brake booster spacer (1).

Fig 3: Brake Booster, Master Cylinder, Studs, Vacuum Tube & Seal
6. Remove the brake booster (1a) releasing the master cylinder (1b) and its stud bolts (1c).
7. Disconnect the vacuum tube (2).
8. Remove the brake booster (1a) and the seal (3b).

INSTALLATION > RHD > INSTALLATION
1. Position the seal on the brake booster.
2. Connect the vacuum tube to the brake booster.
NOTE:
Take care not to damage the vacuum tube.
3. With the help of another person, position the brake booster and its seal to the master cylinder,
install and tighten the master cylinder to brake booster nuts to the proper specification. Refer
4. Install the brake booster spacer onto the booster.
5. Install the pedal assembly. Refer to PEDAL(S), BRAKE AND/OR ACCELERATOR, REMOVAL
AND INSTALLATION .
HYDRAULIC/MECHANICAL > CALIPER, DISC BRAKE > REMOVAL AND

INSTALLATION > 1.4L - 1.6L > REMOVAL - 1.4L - 1.6L
Fig 1: Master Cylinder Cap
1. Remove the master cylinder cap (1), and install the vacuum tool 2000001400.
4. Remove the appropriate brake hose from the caliper. Refer to TUBES AND HOSES, BRAKE,
Fig 2: Caliper Bolts
5. Remove the caliper to caliper adaptor bolts (1a), and remove the caliper.
6. If necessary, transfer the brake pads.

INSTALLATION > 1.4L - 1.6L > INSTALLATION - 1.4L - 1.6L
1. If removed, install the brake pads onto the caliper.

2. Install the caliper onto the caliper adaptor, and tighten both caliper to caliper adaptor bolts (1a)
to the proper specification. Refer to TORQUE SPECIFICATIONS .
3. Install the removed brake hose to the caliper. Refer to TUBES AND HOSES, BRAKE,
6. Fill and bleed the braking system. Refer to STANDARD PROCEDURE .

INSTALLATION > 1.4L 4X4 - 2.0L - 2.4L > REMOVAL - 1.4L 4X4 - 2.0L - 2.4L
4. Remove the appropriate brake hose from the caliper. Refer to TUBES AND HOSES, BRAKE,
Fig 2: Removing Caliper Bolts
5. While holding the inside nut, remove the caliper to caliper adaptor bolts (1).
Fig 3: Caliper
6. Remove the caliper (1) from the caliper adaptor.

INSTALLATION > 1.4L 4X4 - 2.0L - 2.4L > INSTALLATION - 1.4L 4X4 - 2.0L - 2.4L
Fig 1: Caliper
1. Install the caliper (1) onto the caliper adaptor, and tighten both caliper to caliper adaptor bolts
HYDRAULIC/MECHANICAL > CALIPER, DISC BRAKE, REAR > REMOVAL AND

3. Remove the correct brake hose from the caliper. Refer to TUBES AND HOSES, BRAKE,
Fig 1: Electric Park Brake Connector
4. Disconnect the Electric Park Brake (EPB) actuator electrical connector (1).
Fig 2: Caliper & Adaptor Bolts
5. Remove both the caliper to caliper adaptor bolts (1a), and remove the caliper (1b).
6. If necessary, remove the EPB actuator from the caliper. Refer to ACTUATOR, ELECTRIC
PARK BRAKE, REMOVAL AND INSTALLATION .
HYDRAULIC/MECHANICAL > CALIPER, DISC BRAKE, REAR > REMOVAL AND

1. If removed, install the Electric Park Brake (EPB) actuator onto the caliper. Refer to
ACTUATOR, ELECTRIC PARK BRAKE, REMOVAL AND INSTALLATION .
2. Install the caliper (1b) onto the caliper adaptor, and tighten both caliper to caliper adaptor bolts
(1a) to the proper specification. Refer to TORQUE SPECIFICATIONS .
3. Connect the EPB actuator electrical connector (1).
HYDRAULIC/MECHANICAL > FLUID > DIAGNOSIS AND TESTING > DIAGNOSIS AND
TESTING - BRAKE FLUID CONTAMINATION
Indications of fluid contamination are swollen or deteriorated rubber parts. Swelling indicates the
presence of petroleum in the brake fluid.
To test for contamination, put a small amount of drained brake fluid in clear glass jar. If the fluid
separates into layers, there is mineral oil or other fluid contamination of the brake fluid.
If the brake fluid is contaminated, drain and thoroughly flush the brake system. Replace all the rubber
parts or components containing rubber coming into contact with the brake fluid including: the master
cylinder and reservoir; caliper seals; ABS hydraulic control unit; and all hydraulic fluid hoses.
HYDRAULIC/MECHANICAL > FLUID > SPECIFICATIONS > SPECIFICATIONS
The brake fluid used in this vehicle must conform to DOT 4 specifications and SAE J1703 standards. No
other type of brake fluid is recommended or approved for usage in the vehicle brake system. Use only
Mopar® Brake Fluid DOT 4 Motor Vehicle or equivalent from a tightly sealed container.
CAUTION:
Never use reclaimed brake fluid or fluid from a container which has been left open. An open
container will absorb moisture from the air and contaminate the fluid.
CAUTION:
Never use any type of a petroleum-based fluid in the brake hydraulic system. Use of such
type fluids will result in seal damage of the vehicle brake hydraulic system causing a failure
of the vehicle brake system. Petroleum based fluids would be items such as engine oil,
transmission fluid, power steering fluid, etc.
HYDRAULIC/MECHANICAL > MASTER CYLINDER, BRAKE > REMOVAL AND

INSTALLATION > LHD > REMOVAL
1. Remove the brake fluid reservoir. Refer to RESERVOIR, BRAKE MASTER CYLINDER,
Fig 1: Primary And Secondary Brake Tubes & Brake Booster Nuts
2. Remove the primary and secondary brake tubes from the master cylinder (1).
3. Loosen the master cylinder to brake booster nuts (2), and remove the master cylinder.
Fig 2: Master Cylinder O-Ring
4. Remove the master cylinder o-ring, and discard.

INSTALLATION > LHD > INSTALLATION
Fig 1: Primary And Secondary Brake Tubes & Brake Booster Nuts
1. Install the master cylinder with a NEW o-ring, and tighten the master cylinder to brake booster
nuts (1) to the proper specification. Refer to TORQUE SPECIFICATIONS .
2. Install and tighten the primary and secondary brake tubes (2) to the proper specification. Refer
3. Install the brake fluid reservoir. Refer to RESERVOIR, BRAKE MASTER CYLINDER,
4. Fill and bleed the brake fluid reservoir. Refer to STANDARD PROCEDURE .
5. Start engine and let idle for approximately 30 seconds, then turn off and wait about 1 minute.
Fully stroke brake pedal to assure there are several strokes with assist prior to depletion of
vacuum. If not, check for missing seal between master cylinder and booster.

INSTALLATION > RHD > REMOVAL
cable.
Fig 1: Brake-Clutch Fluid Reservoir Cap
3. Remove the brake-clutch fluid reservoir cap (1) and install the special tool 2000001400.
NOTE:
To prevent impurities from entering the brake-clutch fluid reservoir, before undoing
the cap clean it and the entire upper surface of the reservoir next to the filler
thoroughly.
4. Remove the fuel filter and mounting bracket. Refer to FILTER, FUEL, REMOVAL AND
INSTALLATION .
Fig 2: Fuel Tubes, Quick Couplings, Retaining Clips, Bracket & Screw
5. Disconnect the quick coupling (1a), open the retaining clip (1b) and remove the fuel supply tube
(1c).
6. Disconnect the quick coupling (2a), open the retaining clip (2b) and move the fuel return tube
(2c) to the side.
7. Remove the fixing screw (3a) and remove the fuel pipe mounting bracket (3b).
Fig 3: Master Cylinder, Quick Couplings, Brake Tubes & Nuts
8. Remove both the primary and secondary brake tubes (1) from master cylinder to hydraulic
control unit.
9. Disconnect the quick couplings for the hoses (2) from the reservoir.
NOTE:
Seal the pipes to prevent the brake-clutch fluid from escaping, even in part.
10. Remove the fixing nuts (3a) and remove the master cylinder (3b).
Fig 4: O-Ring
11. Remove and discard the o-ring (1).

INSTALLATION > RHD > INSTALLATION
1. Install the master cylinder with a NEW o-ring, and tighten the master cylinder to brake booster
nuts to the proper specification. Refer to TORQUE SPECIFICATIONS .
2. Connect the quick couplings for the hoses from the reservoir.
3. Install and tighten the primary and secondary brake tubes (2) to the proper specification. Refer
4. Position the fuel pipe mounting bracket in its housing and tighten the fixing screw.
5. Position the fuel return pipe, connect the quick coupling and engage the retaining clip.
6. Position the fuel supply pipe, connect the quick coupling and engage the retaining clip.
7. Install the fuel filter and bracket. Refer to FILTER, FUEL, REMOVAL AND INSTALLATION .
8. Remove the special tool fitted previously and tighten the cap for the brake-clutch fluid
reservoir.
11. Fill and bleed the brake fluid reservoir. Refer to STANDARD PROCEDURE .
12. Start engine and let idle for approximately 30 seconds, then turn off and wait about 1 minute.
Fully stroke brake pedal to assure there are several strokes with assist prior to depletion of
vacuum. If not, check for missing seal between master cylinder and booster.
HYDRAULIC/MECHANICAL > PADS, BRAKE, FRONT > REMOVAL AND

INSTALLATION > 1.4L - 1.6L > REMOVAL 1.4L - 1.6L
2. Remove tire and wheel assembly. Refer to REMOVAL AND INSTALLATION .

Fig 1: Brake Caliper Retainer Spring
3. Remove the brake caliper retainer spring (1).

4. Remove the dust caps from the caliper mounting bolts.
5. Remove the caliper to caliper adaptor bolts (1a).

Fig 3: Brake Pads
6. Remove the inner brake pad (1) from the caliper.
7. Remove the outer brake pad (2) from the caliper adaptor.

INSTALLATION > 1.4L - 1.6L > INSTALLATION 1.4L - 1.6L
1. Using a suitable tool, push the brake caliper piston into the caliper housing.
2. On the brake pad contacting surfaces, grease the brake caliper and adaptor
Fig 1: Brake Pads & Mounting Hardware
3. Position the outer brake pad (1a) onto caliper adaptor as shown in illustration.
4. Position the inner brake pad (2a) into the caliper as shown in illustration.
5. Position the brake caliper onto the caliper adaptor. Tighten the caliper to caliper adaptor bolts
6. Install the dust caps for the caliper mounting bolts.

9. Pump brake pedal several times to set pads to caliper and brake rotor.
CAUTION:
When NEW brake pads have been installed, keep in mind that braking
effectiveness might be somewhat reduced during the first brake applications
following installation.
10. Check and adjust brake fluid level in reservoir.
11. Road test vehicle making several stops to wear off any foreign material on brakes and to seat
brake shoes.

INSTALLATION > 1.4L 4X4 - 2.0L - 2.4L > REMOVAL - 1.4L 4X4 - 2.0L - 2.4L
Fig 1: Caliper Adaptor Bolt & Nut
3. While holding the nut (1a), remove the caliper to caliper adaptor bolt (1b).
Fig 2: Brake Pads
4. Rotate the caliper upwards and remove the brake pads (1).
NOTE:
Remove all traces of glue on the brake caliper. Avoid the use of degreasers not
compatible with the rubber parts of the brake caliper.
Fig 3: Abutment Shims
5. Remove the abutment shims (1) from the caliper adaptor.
6. Using the appropriate cleaner, clean the seats of the shims on the caliper bracket.

INSTALLATION > 1.4L 4X4 - 2.0L - 2.4L > INSTALLATION - 1.4L 4X4 - 2.0L - 2.4L
Fig 1: Brake Pads & Wear Sensor
1. Install the new abutment shims on the brake caliper adaptor
2. Install the new brake pads (1) onto the caliper adaptor.
NOTE:
The inner brake pad has the wear sensor (a) mounted to the pad.
3. Position the brake caliper back onto the caliper adaptor, install and tighten the caliper to caliper
adaptor bolt to the proper specification. Refer to TORQUE SPECIFICATIONS .
CAUTION:
brake shoes.
HYDRAULIC/MECHANICAL > PADS, BRAKE, REAR > REMOVAL AND INSTALLATION

Fig 1: Electric Park Brake Harness & Clip
3. Remove the brake hose retainer clip (1) and remove the brake hose from the strut.
4. Remove the Electric Park Brake (EPB) harness (2) from the strut.
Fig 2: Caliper Adaptor Bolt
5. While holding the nut (1a), remove the lower caliper to caliper adaptor bolt (1b)
Fig 3: Brake Pads
6. Rotate the brake caliper upwards and remove the brake pads (1).
NOTE:
Remove all traces of glue on the brake caliper. Avoid the use of degreasers not
compatible with the rubber parts of the brake caliper.
Fig 4: Abutment Shims
7. Remove the abutment shims (1).
8. Using the appropriate cleaner, clean the seats of the shims on the caliper bracket.
HYDRAULIC/MECHANICAL > PADS, BRAKE, REAR > REMOVAL AND INSTALLATION

Fig 1: Brake Pads
1. Install the new abutment shims on the caliper bracket.
2. Install the new brake pads (1) onto the caliper bracket
Fig 2: Brake Pad Identification
NOTE:
The inner pad is marked by the letter "B" stamped on the ends for attachment to
slide pegs.
NOTE:
The outer pad is marked by the letters "A" stamped on the ends for attachment to
slide pegs.
Fig 3: Pneumatic Tool & Piston
NOTE:
Connect The diagnostic tool to the diagnostic socket of the car and go to the "unit
BSM / EPB." Go to the menu "actuators" and launch the procedure "maintenance
mode".
NOTE:
Run the procedure "setback piston brake calipers."
NOTE:
At The end of the brake caliper assembly, launch the procedure "check assembly
electric parking brake."
3. Using the pneumatic tool (1a) retract the piston (1b) of the rear brake caliper.
4. Position the brake caliper back onto the caliper adaptor, install and tighten the caliper to caliper
adaptor bolt to the proper specification. Refer to TORQUE SPECIFICATIONS .
5. Install the Electric Park Brake (EPB) harness to the strut.
6. Install the brake hose to the strut, and install the retainer clip.
CAUTION:
brake shoes.
HYDRAULIC/MECHANICAL > PEDAL(S), BRAKE AND/OR ACCELERATOR >

REMOVAL AND INSTALLATION > LHD > REMOVAL
1. If equipped with a manual transmission, remove the Integrated Control Unit (ICU). Refer to
INTEGRATED CONTROL UNIT (ICU), REMOVAL AND INSTALLATION .
2. Remove the drivers knee airbag. Refer to AIR BAG, KNEE BLOCKER, REMOVAL AND
INSTALLATION .
3. Remove the drivers lower air duct.

Fig 1: Brake Fluid Reservoir To Clutch Pedal Hose & Damper From The Clutch Pedal
4. If equipped, disconnect the brake fluid reservoir to clutch pedal hose (1).
5. Lift the clip and disconnect the damper from the clutch pedal (2).
Fig 2: Accelerator Pedal Connector
6. Disconnect the accelerator pedal electrical connector (1).

Fig 3: Intermediate Shaft Pinch Bolt
7. Remove the intermediate shaft pinch bolt (1), and remove the intermediate shaft from the
steering gear.
Fig 4: Reinforcement Plate & Nuts
8. Remove the reinforcement plate nuts (1a), and remove the reinforcement plate (1b).
Fig 5: Retaining Tabs
9. Push back on the retaining tabs (1) of the brake booster push rod to disengage from the brake
pedal.
NOTE:
Do not reuse the brake booster push rod retainer. Also, be sure to save the brake
booster push rod cup upon removal.
Fig 6: Clutch Pedal Position Switch Connector
10. If equipped, disconnect the clutch pedal position switch electrical connector (1).
11. Remove the brake pedal switch by rotating the it 45°.

12. Remove the pedal assembly to brake booster nuts (1) on the accelerator pedal side.
Fig 8: Pedal Assembly & Brake Booster Nuts
13. Remove the pedal assembly to brake booster nuts (1) on the clutch pedal side.
14. Remove the pedal assembly (2) from the vehicle.

REMOVAL AND INSTALLATION > LHD > INSTALLATION
1. Install and tighten the pedal assembly to brake booster nuts to the proper specification. Refer
2. Install the brake pedal switch by rotating it in 45°.
NOTE:
The brake pedal switch must be installed with the brake pedal in the rest position.
3. If equipped, connect the clutch pedal position switch electrical connector.
4. Install the brake booster push rod cup, and install the NEW brake booster push rod to brake
pedal retainer.
NOTE:
It will be necessary to press down on the brake pedal to connect the retainer.
5. Install the reinforcement plate, and tighten the reinforcement plate nuts to the proper
Fig 1: Intermediate Shaft Pinch Bolt
6. Position the intermediate shaft to the steering gear. Install the intermediate shaft pinch bolt (1),
and tighten bolt to the proper specification. Refer to TORQUE SPECIFICATIONS .
7. Connect the accelerator pedal electrical connector.
8. If equipped, install the brake fluid reservoir to clutch pedal hose.
9. Install the drivers lower air duct.
10. Install the drivers knee airbag. Refer to AIR BAG, KNEE BLOCKER, REMOVAL AND
INSTALLATION .
11. If equipped with a manual transmission, install the Integrated Control Unit (ICU). Refer to
INTEGRATED CONTROL UNIT (ICU), REMOVAL AND INSTALLATION .

REMOVAL AND INSTALLATION > RHD > REMOVAL
WARNING:
component diagnosis or service. Refer to WARNING . Disconnect the IBS/negative battery
cable assembly from the negative battery post, then wait two minutes for the system
way to disable the SRS. Failure to take the proper precautions could result in accidental
airbag deployment.
NOTE:
Straighten the front wheels, engage the first steering lock towards the right and remove the
ignition key.
NOTE:
Keep the steering column adjustment lever closed during all the removal and installation
stages.
2. Remove the electric steering column from the vehicle. Refer to COLUMN, REMOVAL AND
INSTALLATION .
Fig 1: Reinforcement Plate & Screws
3. Remove the fixing screws (1a) and remove the reinforcement plate (1b).
Fig 2: Clutch Pedal & Accelerator Pedal Bolts
4. Disconnect the electrical connection of the clutch pedal (1a) and of the accelerator pedal (1b).
Fig 3: Brake Servo Push Rod Fork, Clip & Pin
5. Pry up the clip (1a), remove the pin (1b) and disconnect the brake servo push rod fork (1c)
from the brake pedal.
Fig 4: Pedal Unit Mounting Nuts
6. Remove the nuts securing the brake servo to the pedal unit support.
7. Remove the nuts fixing the pedal unit mounting to the body.
Fig 5: Removing Brake Pedal Switch
8. Release the brake pedal switch (1a) from the pedal unit support, rotating it through 45° towards
the clutch pedal and release the relevant wiring section from the pedal unit support.
9. Loosen the instrument panel carrier assembly following the procedure, and move the assembly
back until there is enough room to remove the pedal assembly. Refer to CARRIER,
INSTRUMENT PANEL, REMOVAL AND INSTALLATION .
Fig 6: Pedal Unit Support & Stud Bolts
10. Release the pedal unit support (1a) from the stud bolts on the body (1b), from the brake servo
and their stud bolts (1c) and remove it from its housing.
Fig 7: Brake Servo Spacer
11. If necessary, remove the brake servo spacer (1).

REMOVAL AND INSTALLATION > RHD > INSTALLATION
1. If removed, place the brake servo spacer in its housing.
2. Install and tighten the NEW pedal assembly to brake booster nuts to the proper specification.
Refer to TORQUE SPECIFICATIONS .
3. Tighten the NEW nuts securing the brake booster to the pedal unit support to the proper
4. Connect the fork of the brake booster push rod to the brake pedal, fit the pin and the clip.
5. Position the brake pedal switch in its housing and secure it to the pedal unit support, rotating it
through 45° towards the accelerator pedal; secure the relevant wiring section to the pedal unit
support.
NOTE:
The brake pedal switch must be fitted with the brake pedal in rest position.
6. Position the instrument panel carrier assembly back into place, and follow the procedure to
install related components. Refer to CARRIER, INSTRUMENT PANEL, REMOVAL AND
INSTALLATION .
7. Connect the electrical connection of the clutch pedal and of the accelerator pedal.
8. Install the reinforcement plate, and tighten the reinforcement plate nuts to the proper
9. Install the electric steering column. Refer to COLUMN, REMOVAL AND INSTALLATION .
HYDRAULIC/MECHANICAL > RESERVOIR, BRAKE MASTER CYLINDER > REMOVAL

AND INSTALLATION > LHD > REMOVAL
1. Remove the battery. Refer to BATTERY, REMOVAL AND INSTALLATION .
3. Siphon the brake fluid from the reservoir. Refer to STANDARD PROCEDURE .
Fig 1: Brake Reservoir To Clutch Pedal Hose & Brake Fluid Level Switch Connector
4. If equipped, remove the brake reservoir to clutch pedal hose (1).
5. Disconnect the brake fluid level switch electrical connector (2).

Fig 2: Brake Reservoir To Master Cylinder Screw
6. Remove the brake reservoir to master cylinder screw (1).

Fig 3: Brake Fluid Reservoir Seals & Brake Fluid Level Switch Clip
7. Remove and discard the brake fluid reservoir seals (1).
8. Compress the brake fluid level switch clip (2) and remove the switch.

AND INSTALLATION > LHD > INSTALLATION
1. Install the brake fluid level switch into the brake fluid reservoir.
2. Install the brake fluid reservoir with NEW seals, and tighten the brake fluid reservoir to master
cylinder screw.
3. Connect the brake fluid level switch electrical connector.
4. If equipped, connect the brake reservoir to clutch pedal hose.
6. Install the battery. Refer to BATTERY, REMOVAL AND INSTALLATION .

AND INSTALLATION > RHD > REMOVAL
3. Siphon the brake fluid from the reservoir. Refer to STANDARD PROCEDURE .
4. Remove the fuel filter and mounting bracket. Refer to FILTER, FUEL, REMOVAL AND
INSTALLATION .
Fig 1: Fuel Supply Pipe, Quick Coupling & Clip
5. Disconnect the quick coupling (1a), open the retaining clip (1b) and remove the fuel supply pipe
(1c).
Fig 2: Brake Fluid Level Switch Connector
6. Disconnect the brake fluid level switch electrical connector (1).

Fig 3: Brake-Clutch Fluid Reservoir, Hoses, Quick Couplings, Nut & Screw
7. Disconnect the quick couplings of the hoses (1) from the brake master cylinder.
8. Disconnect the hose (2) of the clutch master cylinder.
9. Remove the fixing nut (3a) and screw (3b) and remove the brake-clutch fluid reservoir (3c).
AND INSTALLATION > RHD > INSTALLATION
1. Place the brake-clutch fluid reservoir in its housing and tighten the fixing nut and screw.
2. Connect the hose of the clutch master cylinder.
3. Connect the quick couplings of the hoses to the brake master cylinder.
4. Connect the brake fluid level switch electrical connector.
5. Position the fuel supply pipe, connect the quick coupling and lock the retaining clip.
6. Install the fuel filter and mounting bracket. Refer to FILTER, FUEL, REMOVAL AND
INSTALLATION .
HYDRAULIC/MECHANICAL > ROTOR, BRAKE > REMOVAL AND INSTALLATION >

FRONT > FRONT ROTOR REMOVAL
3. Remove the front brake pads. Refer to PADS, BRAKE, FRONT, REMOVAL AND
INSTALLATION .
Fig 1: Caliper Adaptor & Bolts
4. Remove the caliper adaptor to front knuckle bolts (1a), and remove the caliper adaptor (1b)
Fig 2: Brake Rotor & Retaining Bolt
5. Remove the brake rotor retaining bolt (1a), and remove the rotor (1b).

FRONT > FRONT ROTOR INSTALLATION
1. Install the brake rotor (1a).
2. Install and tighten the brake rotor retaining pin (1b) to the proper specification. Refer to
TORQUE SPECIFICATIONS .
3. Install the brake caliper adaptor (1a) and tighten the caliper adaptor to rear knuckle bolts (1b)
4. Install the front brake pads. Refer to PADS, BRAKE, FRONT, REMOVAL AND INSTALLATION .

REAR > REAR ROTOR REMOVAL
3. Disconnect the Electric Park Brake (EPB) electrical connector (1).

4. Remove the caliper to caliper adaptor bolts (1a), and remove the caliper (1b) from the adaptor.
NOTE:
Make sure that the brake caliper is suitably supported.
5. Remove the rear brake pads. Refer to PADS, BRAKE, REAR, REMOVAL AND
INSTALLATION .
6. Remove the caliper adaptor to rear knuckle bolts (1a), and remove the caliper adaptor (1b)
7. Remove the brake rotor retaining bolt (1a), and remove the rotor (1b).

REAR > REAR ROTOR INSTALLATION
1. Install the brake rotor (1a).
2. Install and tighten the brake rotor retaining pin (1b) to the proper specification. Refer to
3. Install the brake caliper adaptor (1a) and tighten the caliper adaptor to rear knuckle bolts (1b)
4. Install the rear brake pads. Refer to PADS, BRAKE, REAR, REMOVAL AND INSTALLATION .
5. Connect the Electric Park Brake (EPB) electrical connector.
HYDRAULIC/MECHANICAL > TUBES AND HOSES, BRAKE > REMOVAL AND

INSTALLATION > FRONT BRAKE FLEXIBLE HOSE > REMOVAL - FRONT BRAKE
FLEXIBLE HOSE
Fig 2: Brake Line Nut & Retainer Clip
4. Remove the front brake hose to body retainer clip (1).
5. Loosen the brake line nut (2), then remove the brake line from the hose.
Fig 3: Brake Hose, Nut & Strut Retainer Spring
6. Remove the brake hose to strut retainer spring (1), then remove hose from strut.
7. Loosen and remove the brake hose (2b) from the caliper.

INSTALLATION > FRONT BRAKE FLEXIBLE HOSE > INSTALLATION - FRONT BRAKE
FLEXIBLE HOSE
Fig 1: Brake Hose, Nut & Strut Retainer Spring
1. Position the brake hose (1a) to the caliper, and tighten the brake hose nut (1b) to the proper
2. Install the brake hose onto the strut retainer and install retainer clip (2).
3. Position the brake line to the hose, and tighten the brake line nut (1) to the proper
4. Install the brake hose to body retainer clip (1).
7. Bleed the out the braking system. Refer to STANDARD PROCEDURE .

INSTALLATION > REAR BRAKE FLEXIBLE HOSE > REMOVAL - REAR BRAKE
FLEXIBLE HOSE
4. Remove the rear brake hose to body retainer clip (1a).
5. Loosen the brake line nut (1b), then remove the brake line from the hose.
Fig 3: Brake Hose To Strut Retainer Spring
6. Remove the brake hose to strut retainer spring (1), then remove the hose from strut.
Fig 4: Brake Hose & Nut
7. Loosen and remove the brake hose (1b) from the caliper.

INSTALLATION > REAR BRAKE FLEXIBLE HOSE > INSTALLATION - REAR BRAKE
FLEXIBLE HOSE
Fig 1: Brake Hose & Nut
1. Position the brake hose (1a) to the caliper, and tighten the brake hose nut (1b) to the proper
Fig 2: Brake Hose To Strut Retainer Spring
2. Install the brake onto the strut retainer and install the retainer clip (1).
3. Position the brake line to the hose, and tighten the brake line nut (1a) to the proper
4. Install the brake hose to body retainer clip (1b).
7. Bleed out the braking system. Refer to STANDARD PROCEDURE .

INSTALLATION > MASTER CYLINDER TO ICU BRAKE LINE > REMOVAL - MASTER
CYLINDER TO ICU BRAKE LINE
Fig 2: Integrated Control Unit Nut & Retainer Clip
3. Remove the brake line retainer clip (1).
4. Loosen and remove the brake line to Integrated Control Unit (ICU) nut (2).
Fig 3: Brake Line & Nut
5. Loosen and remove the brake line to master cylinder nut (1a).
6. Remove the brake line (1b) from the vehicle.

INSTALLATION > MASTER CYLINDER TO ICU BRAKE LINE > INSTALLATION -
MASTER CYLINDER TO ICU BRAKE LINE
Fig 1: Brake Line & Nut
1. Position the brake line (1a) into the vehicle.
2. Install and tighten the brake line to master cylinder nut (1b) to the proper specification. Refer to
Fig 2: Integrated Control Unit Nut & Retainer Clip
3. Install and tighten the brake line to Integrated Control Unit (ICU) nut (1) to the proper
4. Install the brake line retainer clip (2).

INSTALLATION > LEFT FRONT BRAKE TUBE > REMOVAL - LEFT FRONT BRAKE
TUBE
Fig 1: Brake Line & Retainer Clip
2. Remove the brake line from the retainer clips (1).
5. Remove the engine belly pan. Refer to BELLY PAN, REMOVAL AND INSTALLATION .
Fig 2: Wheel Speed Sensor Wiring, Brake Line To Brake Hose Nut & Retainer Clip
6. Remove the wheel speed sensor wiring (1) from the routing retainer.
7. Loosen and remove the brake line to brake hose nut (2).
8. Remove the brake line from the body retainer clip (3).
Fig 3: Left Front Brake Tube
9. From inside the left front wheel well, remove the left front brake tube (1) from the vehicle.

INSTALLATION > LEFT FRONT BRAKE TUBE > INSTALLATION - LEFT FRONT
BRAKE TUBE
1. Position the left front brake tube into the vehicle.

2. Install the brake line into the body retainer clip (1).
3. Install and tighten the brake line to brake hose nut (2) to the proper specification. Refer to
4. Install the wheel speed sensor wiring (3) into the routing retainer (3).
5. Install the engine belly pan Refer to BELLY PAN, REMOVAL AND INSTALLATION .
8. Install the brake line into the remaining retainer clips.

INSTALLATION > RIGHT FRONT BRAKE TUBE - 1.4L > REMOVAL
3. Evacuate the A/C system. Refer to STANDARD PROCEDURE .

Fig 2: Brake Line & Two Inside Body Retainer Clips
10. Remove the brake line from the two inside body retainer clips (1).

Fig 3: Brake Line & Body Retainer Clips
12. Remove the remaining brake line to body retainer clips (1).
Fig 4: Return Pipe, Quick Coupling & Screw
13. Disconnect the quick coupling (1a), loosen the screw (1b) and remove the return pipe of the
cooling fluid from evaporator (1c).
Fig 5: Vacuum Sensor Connector
14. Disconnect the vacuum sensor electrical connector (1).

Fig 6: Vacuum Sensor & Retaining Clip
15. Open the retaining clip (1a) and remove the vacuum sensor (1b) from the brake booster.
Fig 7: PCM Wiring & Connectors
16. Disconnect the Powertrain Control Module (PCM) electrical connector (1).
17. Disconnect the engine wiring harness connector (2).
18. Open the retaining clips and remove the wiring (3).
Fig 8: Heater Core Couplings
19. Disconnect the quick connect couplings at the heater core (1).
Fig 9: Refrigerant Return Nut
20. Loosen the nut (1) and remove the refrigerant return from the evaporator.
Fig 10: Refrigerant Delivery Pipe Nut
21. Loosen the nut (1) and gently move aside the refrigerant delivery pipe.
Fig 11: Right Front Brake Line
22. From inside the engine bay, remove the right front brake line (1) from the vehicle.

INSTALLATION > RIGHT FRONT BRAKE TUBE - 1.4L > INSTALLATION
1. Position the right front brake line into the vehicle.
2. Install the refrigerant delivery tube to the evaporator and tighten the nut to the proper
3. Install the refrigerant return tube to the evaporator with NEW O-ring and tighten the nut to the
4. Connect the quick couplings to the heater core.
5. Connect the engine wiring harness electrical connector.
6. Connect the Powertrain Control Module (PCM) electrical connector, and install wiring harness
retaining clips.
7. Install the vacuum sensor and engage the retaining clip.
8. Connect the vacuum sensor electrical connector.
9. Install the refrigerant return line to the evaporator with NEW O-ring and tighten the screw.
10. Engage all the brake line retaining clips.

17. Fill and bleed the engine coolant. Refer to STANDARD PROCEDURE .
18. Recharge the A/C system. Refer to STANDARD PROCEDURE .

INSTALLATION > RIGHT FRONT BRAKE TUBE - 1.6L - 2.0L > REMOVAL
3. Remove the air cleaner assembly.
4. Remove the fuel filter assembly and bracket. Refer to FILTER, FUEL, REMOVAL AND
INSTALLATION .
Fig 1: Wheel Speed Sensor Wiring, Brake Hose Nut & Retainer Clip
Fig 2: Brake Line Body Retainer Clips
13. Remove the brake line from the two inside body retainer clips (1).

Fig 3: Remaining Brake Line Body Retainer Clip
15. Remove the remaining brake line to body retainer clips (1).
Fig 4: Brake Tube & Retainer
16. Remove the brake tube from the retainer (1) (2).
Fig 5: Brake Tube Retainer
17. Remove the brake tube from the retainer (1).

Fig 6: Suction And Liquid Line Nuts
18. Remove the suction and liquid line nuts (1) from the expansion valve.
Fig 7: A/C Line Retainers
19. Open and remove the A/C lines from the retainers (1).
Fig 8: A/C Line, Coupling & Clip
20. Open the retaining clip (1a), disconnect the quick coupling (1b) and remove the A/C line (1c).
Fig 9: A/C Line Retainer Bracket
21. Remove the A/C line retainer bracket (1).

Fig 10: Vacuum Sensor Connector

Fig 11: Vacuum Sensor & Retaining Clip
23. Open the retaining clip (1a) and remove the vacuum sensor (1b) from the brake booster.
Fig 12: Differential Pressure Sensor Connector & Mounting Nuts
24. Disconnect the differential pressure sensor electrical connector (1).
25. Remove the differential pressure sensor mounting nuts (2) and position aside.
26. Remove the Powertrain Control Module (PCM). Refer to MODULE, POWERTRAIN CONTROL,
Fig 13: PTO Electrical Connector
27. Disconnect the PTO electrical connector (1).

Fig 14: Heater Core Hoses
28. Disconnect the heater core supply and return hoses from the heater core.

INSTALLATION > RIGHT FRONT BRAKE TUBE - 1.6L - 2.0L > INSTALLATION
2. Install the heater core supply and return hoses.
3. Connect the PTO electrical connector.
4. Install the Powertrain Control Module (PCM). Refer to MODULE, POWERTRAIN CONTROL,
5. Position the differential pressure sensor and install the mounting nuts.
6. Connect the differential connector electrical connector.
7. Install the vacuum sensor and engage the retaining clip.
9. Install the A/C line retainer bracket.
10. Install the A/C line and secure the line in the retainers.
11. Install the suction and liquid line to the expansion valve and tighten to the proper specification.
12. Install the brake line into the remaining retainers.


20. Install the fuel filter assembly and bracket. Refer to FILTER, FUEL, REMOVAL AND
INSTALLATION .
21. Install the air cleaner assembly.

INSTALLATION > RIGHT FRONT BRAKE TUBE - 2.4L > REMOVAL
1. Depressurize the fuel system. Refer to FUEL DELIVERY, STANDARD PROCEDURE .
6. Remove the air cleaner intake tube.
Fig 2: Vacuum Sensor & Transmission Connectors
14. Disconnect the transmission electrical connector (2).

Fig 3: Heater Core Hoses
15. Disconnect the heater core supply and return hoses.

Fig 4: Vacuum Servo Hose
16. Disconnect and remove the vacuum servo hose (1).

Fig 5: Fuel Line Retainers & Couplings
17. Disconnect the fuel lines from the retainers (1), and disconnect the quick couplings (2).
Fig 6: A/C & Fuel Lines Retaining Clips
18. Open the retaining clips and remove the A/C lines (1) and fuel lines (2).
Fig 7: Brake Line Retainer
19. Remove the brake line from the retainer (1).

Fig 8: Fuel & Brake Lines Retaining Clips
20. Disconnect the fuel lines from the retainer clips (1).
21. Remove the brake line (2) from the retainer clip.

INSTALLATION > RIGHT FRONT BRAKE TUBE - 2.4L > INSTALLATION
2. Install all the fuel lines in the retaining clips.
3. Install all the A/C lines in the retaining clips.
4. Connect all the fuel line couplings.
5. Install the vacuum servo hose.
6. Connect the heater core supply and return hoses.
7. Connect the transmission electrical connector.
9. Engage all the brake line retaining clips.

17. Install the air cleaner intake tube.
INSTALLATION > ICU TO REAR CONNECTOR > REMOVAL - ICU TO REAR
CONNECTOR
1. Remove the Integrated Control Unit. Refer to INTEGRATED CONTROL UNIT (ICU), REMOVAL
AND INSTALLATION .
4. Remove the left front tire and wheel assembly. Refer to REMOVAL AND INSTALLATION .
Fig 1: Brake Line Rear Fitting & Retainer Clip
5. Remove the brake line from the retainer clip (1) and loosen the rear fitting (2).
Fig 2: Brake Line Retainer Clips
6. Remove the retainer clips (1) securing the rear brake lines.

Fig 3: Retainer Clips
8. Remove the retainer clips (1) securing the brake line, and remove the brake line from the
vehicle.

INSTALLATION > ICU TO REAR CONNECTOR > INSTALLATION - ICU TO REAR
CONNECTOR
1. Position the brake line into the vehicle.
2. Install all brake line retainer clips.

Fig 1: Brake Line Rear Fitting & Retainer Clip
3. Tighten the rear brake line fitting (1) to the proper specification, and install brake line into
retainer clip (2). Refer to TORQUE SPECIFICATIONS .
4. Install the left front tire and wheel assembly. Refer to REMOVAL AND INSTALLATION .

INSTALLATION > BOTH REAR BRAKE TUBES > REMOVAL - BOTH REAR BRAKE
TUBES
Fig 2: Left Side Protection Shield & Nuts
4. If equipped, loosen the nuts (1a), release the buttons and remove the left side protection shield
(1b).
Fig 3: Right Side Cover & Nuts
5. If equipped, loosen the nuts (1a), release the buttons and remove the right side cover (1b).
Fig 4: Guard & Screws
6. Loosen the screws and remove the guards (1).

Fig 5: Brake Line Fittings & Clip
7. Open the clip (1a) and loosen the rear brake line fittings (1b).
Fig 6: Brake Lines & Retainer Clip Screws
8. Loosen the retainer clip screws (1a), and disengage the brake lines (1b).
Fig 7: Brake Line Clips On Fuel Tank
9. Disengage the brake lines from the retainer clips (1) on the fuel tank.
Fig 8: Brake Line To Brake Hose Nut & Spring
10. Disengage the spring (1a), loosen and remove the brake line to brake hose nut (1b).
Fig 9: Brake Line Retaining Clips
11. Disengage the brake lines from the retaining clips (1).
Fig 10: Brake Line To Brake Hose Nut & Clip
12. Open the clip (1a), loosen and remove the brake line to brake hose nut (1b).

INSTALLATION > BOTH REAR BRAKE TUBES > INSTALLATION - BOTH REAR
BRAKE TUBES
Fig 1: Brake Line To Brake Hose Nut & Clip
1. Position the right rear brake line in the vehicle, tighten the brake line to brake hose nut (1a) to
the proper specification and engage the retainer clip (1b). Refer to TORQUE
SPECIFICATIONS .
2. Engage all the right rear brake line retainer clips.

Fig 2: Brake Line To Brake Hose Nut & Spring
3. Position the left rear brake line in the vehicle, tighten the brake line to brake hose nut (1a) to
the proper specification and engage the retainer clip (1b). Refer to TORQUE
SPECIFICATIONS .
4. Engage all the left rear brake line retainer clips.

Fig 3: Brake Line Fittings & Clip
5. Install and tighten both brake line fittings (1a) to the proper specification and engage the
retainer clips (1b). Refer to TORQUE SPECIFICATIONS .
6. If equipped, install all protection shields.
PARKING BRAKE > DESCRIPTION AND OPERATION > DESCRIPTION AND

OPERATION
Fig 1: Electric Parking Brake Switch

The car is equipped with an electric parking brake (EPB), which ensures the best use and performance
compared to a manually operated.
The electric parking brake is equipped with a:
Switch, on the floor console
Actuator, on each rear caliper
Electric control module

The system uses the switch on the central tunnel and two electromechanical actuators, each
installed on a rear brake caliper.
If the vehicle is in motion, pull up and hold the button to engage the parking brake for any
eventuality. The system will operate by increasing the hydraulic pressure.
If the vehicle is stationary, it is only necessary to pull the button upwards once to engage the
parking brake. To release the parking brake, press the brake pedal and press the parking brake
button downwards.
The Drive Away Release function automatically releases the electric parking brake if the seat belt
is fastened, a gear is engaged and the accelerator is pressed in order to move the vehicle.
The Safe Hold function, when the vehicle speed is lower than 5 km/h, but not in Parking, and the
driver detection algorithm determines that the user is about to exit the vehicle, causes the EPB to
apply the parking brake to stop the vehicle safely.
The Auto Apply function, when the vehicle speed is lower than approximately 3 km/h and the
automatic transmission is set to parking, causes the EPM to apply the parking brake automatically.
With manual gearbox, the parking brake will engage automatically when the ignition switch is set to
OFF.
The status of the EPB functions can be configured in the dedicated Uconnect system menu.
PARKING BRAKE > DIAGNOSIS AND TESTING > HANDBRAKE INEFFECTIVE
NOTE:
Using the handbrake, do not block the rear wheels.
STEP WHAT TO DO THE RESULTS OF THE CHECKS
1 CHECK WITH EVERYTHING OK PROBLEMS INTERVENTION

DIAGNOSTIC TOOL ENCOUNTERED
Connect the
diagnosis tool and
check on the 1. Failure to 1. Restore the correct
BSM/EPB unit communicate with the feeding of the
running errors: BSM/EPB BSM/EPB
the absence of
anomalies; Continue to step 2
in parameters: 2. The presence of 2. Continue as

errors in BSM/EPB directed by the
plausibility of all unit diagnosis tool
parameters

DIAGNOSTIC ENCOUNTERED
TOOL
With diagnostic tool

connected, run under
actuators diagnosis Continue to step 4 Actuators do not turn on Continue to step 3
of rear brake
calipers

1. Faulty electrical 1. Restore electrical

Check the connections connections
continuity/isolation of 2. Replace rear brake
electrical connections
Continue to step 4 2. Electrical calipers actuators.
between BSM/EPB unit connections are Refer to ACTUATOR,
and actuators rear correct: actuator ELECTRIC PARK
calipers anomaly BRAKE, REMOVAL
AND INSTALLATION .

TOOL
Replace ABS
Verify the correct controller. Refer to
operation of the INTEGRATED
End of diagnosis Problem persists
static and dynamic CONTROL UNIT (ICU),
brake REMOVAL AND
INSTALLATION .
PARKING BRAKE > DIAGNOSIS AND TESTING > HANDBRAKE INEFFECTIVE >
HANDBRAKE BLOCK
NOTE:
In the case of manual operation of the system, if required, via button, a change of status
(off/insert) the system indicates any anomaly (inability to change of State) with acoustic
signalling (buzzer).
The handbrake is stuck on;
The anomaly is normally signalled by indicator light malfunction parking brake;
STEP WHAT TO DO THE RESULTS OF THE CHECKS

TOOL
Connect the
diagnosis tool and
check on CAN
network information: 1. Continue as
1. Error Control indicated by the
absence of diagnostic tool
inactive
control;
Continue to step 2
absence of
control in
error;
2. Continue as
absence of 2. Dial Controllers CAN
indicated by the
control unit fail
diagnostic tool
CAN dial in
error

Connect the
diagnosis tool and 1. Continue as
1. The presence of
check on the indicated by the
errors
BSM/EPB unit in diagnostic tool
errors: End of diagnosis
the absence of 2. Handbrake switch

anomalies 2. Continue to step 3
error
3 CHECK ELECTRICAL EVERYTHING OK PROBLEMS INTERVENTION

SYSTEM ENCOUNTERED
1. Replace switch.
Verify the functionality of Refer to SWITCH,
the handbrake and 1. Switch malfunction ELECTRIC PARK
switch the wiring BRAKE, REMOVAL
End of diagnosis
insulation/continuity AND INSTALLATION .
between circuit-breaker
and BSM/EPB unit 2. Broken links/non- 2. Restore electrical
insulated connections
PARKING BRAKE > ACTUATOR, ELECTRIC PARK BRAKE > REMOVAL AND

Fig 1: Electric Park Brake Actuator, Connector & Screws
3. Disconnect the Electric Park Brake (EPB) actuator electrical connector (1).
4. Remove the EPB actuator screws (2), and remove the EPB actuator from the caliper.
PARKING BRAKE > ACTUATOR, ELECTRIC PARK BRAKE > REMOVAL AND
1. Position the Electric Park Brake (EPB) actuator to the caliper and tighten the screws.
2. Connect the EPB actuator electrical connector.
PARKING BRAKE > SWITCH, ELECTRIC PARK BRAKE > REMOVAL AND
Fig 1: Electric Park Brake Switch, Connector & Screws
3. Remove the screws (1a) and disconnect the Electric Park Brake (EPB) switch electrical
connector (1b).
4. Remove the EPB switch from the floor console.

PARKING BRAKE > SWITCH, ELECTRIC PARK BRAKE > REMOVAL AND
1. Position the Electric Park Brake (EPB) switch to the floor console, and tighten the EPB to floor
console screws.
2. Connect the EPB switch electrical connector.

Jeep Renegade
Service Manual: FRONT HALF SHAFT
This vehicle is equipped with halfshafts that consist of a fixed Constant Velocity (CV) joint at the
outboard end connected by a solid shaft to a plunging CV joint on the inboard end. The inner CV joint has
a splined connection into the transmission. The outer joint has a spline connection to the wheel hub and
is retained with a steel lock nut.
All the halfshaft assemblies use the same type of inner and outer joints. The inner joint is a tripod joint
that allows for the changes in halfshaft length through the jounce and rebound travel of the front
suspension. The outer joint is a Rzeppa joint that allows articulation during front suspension travel and
steering. Both tripod joints and Rzeppa joints are true constant velocity CV joint assemblies.
The inner tripod joints are designed with a retention feature that prevents the tripod rollers from coming
out of the inner joint housing up to a specific load. If this feature is overcome and any of the rollers are
pulled past the retention feature the joint will lock up and no longer function properly. The entire halfshaft
assembly must be replaced if it locks up.
1.4 Turbo MultiAir 1.6 16V Multijet 1.6 16V Multijet
DRIVE Front Front AWD/4WD
DIAGNOSIS AND TESTING > DIAGNOSIS AND TESTING - HALF SHAFT > VEHICLE
INSPECTION
Fig 1: C/V Joint, Tripod Joint, Halfshaft & Inner/Outer Boots
The general appearance of the halfshafts should be clean and oil free around the Constant Velocity (CV)
joint (3) and tripod (1) boots (2). Grease on or around the boots is a sign of leakage and the boots or
halfshaft should be replaced.
DIAGNOSIS AND TESTING > DIAGNOSIS AND TESTING - HALF SHAFT > NOISE OR
VIBRATION IN TURNS
Vibration associated with the Constant Velocity (CV) joints in the halfshafts occur in the 3rd and 6th
order. Use a vibration analyzer to determine the frequency of the vibration.
SYMPTOM POSSIBLE CAUSE REPAIR
Clicking noise while turning. Lack of lube in CV joint boots. Replace the halfshaft.
Chuckling or snap noise while Tighten wheel or hub nut. Replace

Loose wheel or hub nut.
turning. damaged components.
Remove halfshaft and rotate side

Loud knocking noise centering on Damaged Differential side/pinion
gears by hand. Replaced
inner CV tripod joints. gears.
damaged transaxle components.
Noise may also be caused by another component of the vehicle coming in contact with the halfshaft,
brake or wheel assemblies.
DIAGNOSIS AND TESTING > DIAGNOSIS AND TESTING - HALF SHAFT > CLUNKING
NOISE DURING ACCELERATION
Replace hub nut and

Clunk/snap noise during launch or Loose hub nut. properly tighten.
shifting into drive or reverse.
Damaged hub splines. Replace hub bearing and
halfshaft.
Severely worn or damaged tripod

Clunking noise at low speed. Replace halfshaft.
or CV joint.
Rattle/clunk over bumps. Grease

Loss of lube in CV joint boots. Replace halfshaft.
slung around undercarriage.
DIAGNOSIS AND TESTING > DIAGNOSIS AND TESTING - HALF SHAFT > SHUDDER
OR VIBRATION DURING ACCELERATION
Engine rotating beyond Replaced damaged or worn

limits. engine/transaxle mounts.
Shudder or vibration on
acceleration. Worn or damaged halfshaft Replace halfshaft.
inner tripod joint.
Replace worn or damaged
Severely worn or damaged suspension or steering
suspension or steering component.
component.
Align front end. Refer to
Front end severely out of WHEEL ALIGNMENT,
alignment. STANDARD PROCEDURE .
DIAGNOSIS AND TESTING > DIAGNOSIS AND TESTING - HALF SHAFT > VIBRATION
AT HIGHWAY SPEEDS
Vibration associated with the CV joints in the halfshafts occur in the 3rd and 6th order (3 or 6 events for
each rotation). The inner tripod joint with three pivot axis has three events in each rotation of the
halfshaft. This will produce a 3rd order vibration of the wheel rotation speed. The outer CV joint with 6
pivot axis balls has six events in each rotation of the halfshaft. This will produce a 6th order vibration of
the wheel rotation speed. A 6th order vibration will create a high pitch sound, like gear noise. Use a
vibration analyzer to determine the frequency of the vibration before replacing components.
Low frequency vibration, Foreign material (plastic bags,

Clean debris from around
matching wheel speed. Wheel organic sinew and road debris)
halfshaft.
balance and runout is OK. fouling the half shaft.
Faulty inner tripod joint. Replace halfshaft.

High frequency vibration
matching 3rd order wheel speed. Vehicle ride height is Return vehicle to proper ride
modified. height.
High pitch whine sound with Faulty outer CV joint. Replace halfshaft.
possible high frequency vibration
in the floor matching 6th order Vehicle ride height is Return vehicle to proper ride
wheel speed. modified. height.

FRONT HALF SHAFT TORQUE SPECIFICATIONS
For Halfshaft Installation procedure, refer to

Hub Nut, All Engines X
Intermediate Shaft Bearing to

26 19 - -
Bracket Bolts, 1.4 Turbo MultiAir
Intermediate Shaft Bearing to
20 15 - -
Bracket Bolts, 1.6 Turbo Diesel
Intermediate Bracket to Engine

Block and Oil Pan Bolts, 1.6 Turbo 50 37 - -
Diesel
99341011 * Jaws Half Shaft Removal
1840005004 * Puller Bridge Half Shaft Removal
1847017001 * Slide Hammer Half Shaft Removal
Hub Nut Removal and

1870815000 * Spanner Wrench
Installation
Tie Rod End Removal

1871000700 C-4150A Tie Rod Separator
From Knuckle
Seal Mounting on
2000036600 * Seal Installer
Differential
Dust Seal on Differential

2000040443 8902A Seal Installer
Assembly
Removing Half Shaft

2000001600 * Puller
from Hub
2000040488 * Puller Half Shaft Removal
REMOVAL AND INSTALLATION > 1.4L TURBO MULTIAIR, WITHOUT INTERMEDIATE

SHAFT > REMOVAL
NOTE:
Never handle the halfshaft assembly by the inner or outer boots. This can cause damage to
the boot, which will allow contaminants to enter the Constant Velocity (CV) joint.

Fig 1: Hub Nut Staked Area
4. Using a suitable punch, lift the two staked areas (1) in the hub nut to avoid damaging the
halfshaft.
Fig 2: Special Tool & Hub Nut
5. Fit the tool 1870815000 (1) to the brake disc.
NOTE:
The used hub nut is not reusable.
6. Remove the hub nut (2) from the halfshaft and DISCARD .
Fig 3: Tie Rod Nut
7. Unscrew and DISCARD the nut (1) securing the tie rod end to the steering knuckle.
Fig 4: Disconnecting Tie Rod
8. Fit the tool 1871000700 (EMEA) or (special tool #C-4150A, Press, Ball Joint) (NAFTA) (1a)
and disconnect the tie rod (1b) from the steering knuckle.
Fig 5: Ball Joint Pinch Bolt
9. Remove the ball joint pinch bolt (1).
10. Disengage the ball joint from the steering knuckle.
11. Disengage the halfshaft from the wheel hub.

Fig 6: Removing Halfshaft
12. With the tools 1847017001 (1a), 1840005004 (1b) and 99341011 (1c), remove the halfshaft
(1d).
REMOVAL AND INSTALLATION > 1.4L TURBO MULTIAIR, WITHOUT INTERMEDIATE

SHAFT > INSTALLATION
NOTE:
Fig 1: Boot Tension Ring
1. Inspect the ball joint boot and the boot tension ring (1) for damage.
2. Position the halfshaft into the differential and wheel hub.

3. Position the ball joint stud into the steering knuckle tighten the pinch bolt (1) to the proper
Fig 3: Tie Rod End Nut
4. Connect the tie rod end to the steering knuckle and tighten the NEW nut (1) to the proper
NOTE:
Always install a NEW hub nut. The original hub nut is one time use only and must
be discarded when removed.
5. Fit the tool 1870815000 and install a NEW hub nut, tighten the nut using the following
procedure:
1. tighten the nut to 70 N.m (52 Ft Lbs)
2. tighten the nut an additional 60°

Fig 4: Correct Hub Nut Staking
NOTE:
Do not use air tools while staking hub nut.
NOTE:
The hub nut must be staked so that it looks similar to Fig 4. Both edges must be
split and bent into the shape shown (3) in illustration. The staking must be in the
opposite direction from the forward rotation of the wheel.
6. Stake the hub nut as shown in illustration.
9. Check and correct the transmission fluid level. Refer to the appropriate Service Information .
REMOVAL AND INSTALLATION > 1.6L AND 2.0L TURBO DIESEL (120 / 140 HP)
WITHOUT INTERMEDIATE SHAFT > REMOVAL
NOTE:
Fig 1: Lifting Staked Area
halfshaft.
NOTE:

Fig 3: Tie Rod End & Nut
7. Remove and DISCARD the nut (1) securing the tie rod end to the steering knuckle.

Fig 6: Brake Rotor Retaining Pin
11. Remove the disc brake rotor retaining pin (1).

Fig 7: Disengaging Halfshaft From Wheel Hub
12. Disengage the halfshaft from the wheel hub using tool 2000001600 (1), position the knuckle
and rotor assembly aside.
13. Remove the tool, install the disc brake rotor retaining pin and tighten to the proper
Fig 8: Halfshaft
14. Pry the halfshaft (1) from the differential and remove the halfshaft assembly.
REMOVAL AND INSTALLATION > 1.6L AND 2.0L TURBO DIESEL (120 / 140 HP)
WITHOUT INTERMEDIATE SHAFT > INSTALLATION
NOTE:
1. Position the halfshaft into the differential and wheel hub.

NOTE:
procedure:

NOTE:
Do not use air tools on staking tool while staking hub nut.
NOTE:
REMOVAL AND INSTALLATION > 2.0L TURBO DIESEL (170 HP), 2.4L MULTIAIR
WITHOUT INTERMEDIATE SHAFT > REMOVAL
NOTE:
halfshaft.
6. Remove the hub nut (2) from the halfshaft and discard. The used hub nut is not reusable.
Fig 3: Tie Rod Nut
7. Unscrew the nut (1) securing the tie rod end to the steering knuckle.
and disconnect the tie rod (1b) from the wheel upright.

Fig 6: Removing Halfshaft With Special Tool
12. With the tool 2000040488 (1a) remove the halfshaft (1b).
REMOVAL AND INSTALLATION > 2.0L TURBO DIESEL (170 HP), 2.4L MULTIAIR
WITHOUT INTERMEDIATE SHAFT > INSTALLATION
NOTE:
2. Position the half shaft into the differential and wheel hub.
3. Position the ball joint stud into the steering knuckle tighten the NEW pinch bolt (1) to the
proper specification. Refer to FRONT, SPECIFICATIONS .
NOTE:
procedure:

NOTE:
NOTE:
REMOVAL AND INSTALLATION > AWD / 4WD RIGHT SIDE, WITHOUT INTERMEDIATE
SHAFT > REMOVAL
NOTE:
halfshaft.
6. Remove the hub nut (2) from the halfshaft and DISCARD . The used hub nut is not
reusable.
Fig 4: Disconnecting Tie Rod End
and disconnect the tie rod (1b) from the wheel upright.
11. If equipped with a 1.4L Turbo, disengage the halfshaft from the wheel hub.
Fig 6: Disengaging Halfshaft
12. If equipped with a 2.0 Turbo Diesel or 2.4L MultiAir, use tool 2000001600 (1) to disengage the
halfshaft from the wheel hub.
13. If equipped with a 1.4L MultiAir, use tools 1847017001 (1a), 1840005004 (1b) and 99341011
(1c) to remove the halfshaft (1d).
Fig 8: Disengaging Halfshaft From PTU
14. If equipped with a 2.0 Turbo Diesel or 2.4L MultiAir, use tool 2000040488 (1a) to disengage
the halfshaft (1b) from the Power Transfer Unit (PTU).
REMOVAL AND INSTALLATION > AWD / 4WD RIGHT SIDE, WITHOUT INTERMEDIATE
NOTE:
Fig 1: Snap Ring & O-Ring
1. Install a NEW snap ring (1) on the halfshaft.
2. Install a NEW O-ring (2) on the halfshaft.

4. Position the halfshaft into the Power Transfer Unit (PTU) and wheel hub.
NOTE:
procedure:

NOTE:
NOTE:
11. Check and correct the PTU fluid level. Refer to STANDARD PROCEDURE .
REMOVAL AND INSTALLATION > 1.4L TURBO MULTIAIR WITH INTERMEDIATE

SHAFT > REMOVAL
NOTE:
4. Using a suitable punch, lift the two staked areas in the hub nut (1) to avoid damaging the
halfshaft.
NOTE:
NOTE:
Use care when separating the ball joint stud from the knuckle so the ball joint boot
does not get cut.

Fig 6: Intermediate Shaft Bearing Bolts
12. Remove bolts (1) mounting the intermediate shaft bearing to the bearing support.
Fig 7: Halfshaft With Intermediate Shaft
13. Remove the halfshaft (1) with the intermediate shaft from the vehicle.
REMOVAL AND INSTALLATION > 1.4L TURBO MULTIAIR WITH INTERMEDIATE

NOTE:
1. Position the halfshaft and intermediate shaft assembly into the differential and wheel hub.
2. Install the intermediate shaft bearing to bearing support bolts and tighten to the proper
Fig 1: Tension Ring
NOTE:
procedure:

NOTE:
NOTE:
REMOVAL AND INSTALLATION > 1.6L TURBO DIESEL WITH INTERMEDIATE SHAFT
> REMOVAL
NOTE:
halfshaft.
NOTE:
NOTE:
does not get cut.

Fig 6: Brake Rotor Retaining Pin
11. Remove the disc brake rotor retaining pin (1).

Fig 7: Disengaging Halfshaft
12. Disengage the halfshaft from the wheel hub using tool 2000001600 (1), position the knuckle
and rotor assembly aside.
13. Remove the tool, install the disc brake rotor retaining pin and tighten to the proper
15. Remove the halfshaft with the intermediate shaft (1) from the vehicle.
REMOVAL AND INSTALLATION > 1.6L TURBO DIESEL WITH INTERMEDIATE SHAFT
> INSTALLATION
NOTE:
2. Install the intermediate shaft bearing to bearing support bolts (1) and tighten to the proper
Fig 2: Tension Ring
4. Position the ball joint stud into the steering knuckle tighten the NEW pinch bolt (1) to the
NOTE:
6. Fit the tool 1870815000 (1a) and install a NEW hub nut (1b), tighten the nut using the following
procedure:

NOTE:
NOTE:
REMOVAL AND INSTALLATION > 2.4L MULTIAIR WITH INTERMEDIATE SHAFT >
REMOVAL
NOTE:
halfshaft.
NOTE:
8. Fit the tool 1871000700 (EMEA) or (special tool #C-4150A, Press, Ball Joint) (NAFTA) (1) and
disconnect the tie rod (2) from the steering knuckle.
NOTE:
does not get cut.

13. Remove the halfshaft with the intermediate shaft from the vehicle.
REMOVAL AND INSTALLATION > 2.4L MULTIAIR WITH INTERMEDIATE SHAFT >
INSTALLATION
NOTE:
2. Install the intermediate shaft bearing to bearing support bolts and tighten to the proper
Fig 1: Tension Ring
NOTE:
procedure:

NOTE:
NOTE:
Jeep Renegade
Service Manual: PROPELLER SHAFT
PROPELLER SHAFT TORQUE SPECIFICATIONS
Center Bearing Support Bolts 50 37 - X
Tool (EMEA) Tool (NAFTA) Name Function Usage
2000043000 * Axle Support Fixture Support Axle
2000043400 * Adjustable Bracket Support Axle
Removing Rear Drive

2019500030 * Elastic Ring Spreader
Shaft
REMOVAL AND INSTALLATION > 1.4 TURBO MULTIAIR > REMOVAL
CAUTION:
Propeller shaft removal is a two-person operation. Never allow propeller shaft to hang from
the center bearing, or while only connected to power transfer unit (PTU) or rear driveline
module flanges. A helper is required. If a propshaft section is hung unsupported, damage
may occur to the joint, boot, and/or center bearing from over-angulation. This may result in
driveline vibrations.
2. Remove the belly pan. Refer to BELLY PAN, REMOVAL AND INSTALLATION and BELLY PAN,
SIDE, REMOVAL AND INSTALLATION .
Fig 1: Downstream Oxygen Sensor Wire Harness Connector & Routing Clip
3. Disconnect the downstream oxygen sensor wire harness connector (2) and disengage the
wiring from the routing clip (1).
Fig 2: Rear Exhaust Hanger Bracket Bolts & Exhaust Clamp Nut
4. Remove the bolts (1) securing the rear exhaust hanger bracket supporting the crossunder pipe
at the front crossmember.
5. Loosen the exhaust clamp nut (2) securing the muffler to the crossunder pipe.
Fig 3: Front Exhaust Pipe Support Bracket Bolts & Exhaust Pipe Support Bracket Bolt
6. Remove the crossunder pipe front hanger support bracket bolts (1).
7. Remove the crossunder pipe bracket bolt (2) from the engine oil pan.
Fig 4: Exhaust Pipe At Catalytic Converter & Nuts
8. Remove the crossunder pipe to catalytic converter flange nuts (1).
9. Remove and discard the exhaust flange gasket.

Fig 5: Support Tools Under Propeller Shaft
NOTE:
Protect the propeller shaft coating with a suitable duct tape to prevent any scratches
caused by the propeller shaft support tools.
10. Position support tools 2000043000 (1b) and 2000043400 (1a) under the propeller shaft.
Fig 6: Protective Sleeve
11. Install the protective sleeve (1) at the center propeller shaft joint to protect the boot as shown
in illustration.
NOTE:
The protective sleeve is provided in the parts package with the dust cover and snap
rings for the propeller shaft.
Fig 7: Propeller Shaft Center Support Bolts
12. Loosen the propeller shaft center support bolts (1).

Fig 8: Jack Under Transmission
13. Place a suitable jack (1) under the transmission.

Fig 9: Rear Engine Mount Through Bolt
14. Remove the rear engine mount through bolt (1).
15. Adjust the jack to carefully shift the powertrain forward.

Fig 10: Dust Cover
NOTE:
The dust cover must be replaced every time the propeller shaft is removed.
16. Slide the dust cover (1) at the front of the propeller shaft away from the Power Transfer Unit
(PTU) to access the snap ring.
Fig 11: Propeller Shaft Snap Ring Tool
NOTE:
The snap ring must be replaced every time the propeller shaft is removed.
17. Use tool 2019500030 (1) to open propeller shaft snap ring at the PTU.
Fig 12: Propeller Shaft At PTU
18. Disconnect the propeller shaft (1) from the PTU.
19. Remove the tool 2019500030.

20. Install the rear engine mount through bolt and torque to the proper specification. Refer to
21. Remove the jack from under the transmission.
22. Remove the previously loosened propeller shaft center support bolts.
Fig 14: Dust Cover
NOTE:
23. Slide the dust cover (1) at the rear of the propeller shaft towards the differential to access the
snap ring.
Fig 15: Opening Propeller Shaft Snap Ring
NOTE:
24. Use tool 2019500030 (1) to open propeller shaft snap ring at the Rear Driveline Unit (RDU).
Fig 16: Propeller Shaft & Pinion
25. Disconnect the propeller shaft from the pinion of the RDU (1).

Fig 17: Propeller Shaft At RDU
27. Lower the propeller shaft until the rear joint of the shaft is under the RDU as shown in
illustration.
NOTE:
Pay close attention to avoid excessive articulation between the two halves of the
propeller shaft during removal.
28. Turn the jack to remove the drive shaft, guiding it away from the front suspension
crossmember.
REMOVAL AND INSTALLATION > 1.4 TURBO MULTIAIR > INSTALLATION
CAUTION:
NOTE:
Lightly apply grease to the splines prior to installation.
Fig 1: Pinion Shaft Dust Seal
1. Install a NEW dust seal (1) on the pinion shaft of the Rear Driveline Unit (RDU).
Fig 2: Front Of Propeller Shaft Dust Seal
2. Install a NEW dust seal (1) on the front shaft of the propeller shaft.
Fig 3: Drive Shaft Snap Ring
3. Install a NEW snap ring (1) in the drive shaft.

Fig 4: PTU Snap Ring
4. Install a NEW snap ring (1) in the Power Transfer Unit (PTU).
NOTE:
5. Position the propeller shaft on the support tools 2000043000 and 2000043400.
Fig 5: Protective Sleeve At Center Propeller Shaft Joint
in illustration.
7. Raise the propeller shaft into the vehicle positioning the front of the shaft above the front cross
member and the steering gear.
Fig 6: Propeller Shaft Snap Ring Seated
8. Connect the propeller shaft (1) to the pinion of the RDU, verify the snap ring is seated in the
groove of the pinion shaft.
Fig 7: Rear Propeller Shaft Dust Cover
9. Position the new dust cover (1) over the joint at the rear of the propeller shaft.
Fig 8: Center Support Bracket Bolts
10. Loosely install the NEW bolts (1) for the center support bracket.
Fig 9: Propeller Shaft Snap Ring & Dust Cover
11. Connect the propeller shaft (1) to PTU, verify the snap ring is (1) seated in the groove of the
propeller shaft.
12. Position the new dust cover (2) over the joint at the front of the propeller shaft.
13. Tighten the center support bracket bolts (1) to the proper specification. Refer to
SPECIFICATIONS .
14. Remove the propeller shaft support tools.
15. Remove the tape and the protective sleeve from the propeller shaft.
Fig 11: Flange Nuts
16. Connect the crossunder pipe to the catalytic converter using a NEW flange gasket and tighten
the NEW nuts (1) to the proper specification. Refer to SPECIFICATIONS .
Fig 12: Front Exhaust Pipe Support Bracket Bolts & Exhaust Pipe Support Bracket Bolt
17. Install the crossunder pipe front hanger support bracket bolts (1) and tighten to the proper
18. Install the crossunder pipe bracket bolt (2) to the engine oil pan and tighten to the proper
Fig 13: Rear Exhaust Hanger Bracket Bolts & Exhaust Clamp Nut
19. Install the bolts (1) securing the exhaust hanger bracket supporting the crossunder pipe at the
front crossmember and tighten to the proper specification. Refer to SPECIFICATIONS .
20. Tighten the exhaust clamp nut (2) securing the muffler to the crossunder pipe to the proper
21. Connect the downstream oxygen sensor wire harness connector and disengage the wiring
from the routing clip.
22. Install the belly pan. Refer to BELLY PAN, REMOVAL AND INSTALLATION and BELLY PAN,
REMOVAL AND INSTALLATION > 2.0 TURBO DIESEL -120 / 140 HP > REMOVAL
CAUTION:
Fig 1: Crossunder Pipe Front And Rear Hanger Bolts
3. Remove the crossunder pipe front and rear hanger bolts (1) at the front crossmember.
Fig 2: Crossunder Pipe To DPF Flange Nuts & Bracket Bolt
4. Remove the crossunder pipe to Diesel Particulate Filter (DPF) flange nuts (1).
5. Remove the crossunder pipe bracket bolt (2).

NOTE:
in illustration.
NOTE:



Fig 8: Dust Cover
NOTE:
NOTE:

Fig 12: Dust Cover
NOTE:
snap ring.
NOTE:

illustration.
NOTE:
crossmember.
REMOVAL AND INSTALLATION > 2.0 TURBO DIESEL -120 / 140 HP > INSTALLATION
CAUTION:
NOTE:

NOTE:
in illustration.
8. Connect the propeller shaft to the pinion of the RDU, verify the snap ring (1) is seated in the
propeller shaft.
SPECIFICATIONS .
Fig 11: DPF Flange Nuts & Crossunder Pipe Bracket Bolt
16. Connect the crossunder pipe to the Diesel Particulate Filter (DPF) using a NEW flange gasket
and tighten the NEW nuts (2) to the proper specification. Refer to SPECIFICATIONS .
18. Install the crossunder pipe bracket bolt (1) and tighten to the proper specification. Refer to
SPECIFICATIONS .
Fig 12: Front And Rear Crossunder Pipe Hanger Bolts
19. Install the front and rear crossunder pipe hanger bolts (1) at the front crossmember and tighten
REMOVAL AND INSTALLATION > 2.0 TURBO DIESEL -170 HP > REMOVAL
CAUTION:
Fig 1: Propeller Shaft Skid Plate & Fasteners
3. Remove the nuts and remove the propeller shaft skid plate.
Fig 2: Crossunder Pipe Front And Rear Hanger Bolts
4. Remove the crossunder pipe front and rear hanger bolts (1) at the front crossmember.
Fig 3: Crossunder Pipe To DPF Flange Nuts & Bracket Bolt
5. Remove the crossunder pipe to Diesel Particulate Filter (DPF) flange nuts (1).

NOTE:
in illustration.
NOTE:



Fig 9: Dust Cover
NOTE:
NOTE:

Fig 13: Dust Cover
NOTE:
snap ring.
NOTE:

illustration.
NOTE:
crossmember.
REMOVAL AND INSTALLATION > 2.0 TURBO DIESEL -170 HP > INSTALLATION
CAUTION:
NOTE:

NOTE:
in illustration.
8. Connect the propeller shaft to the pinion of the RDU, verify the snap ring (1) is seated in the
propeller shaft.
SPECIFICATIONS .
Fig 11: DPF Flange Nuts & Crossunder Pipe Bracket Bolt
16. Connect the crossunder pipe to the Diesel Particulate Filter (DPF) using a NEW flange gasket
and tighten the NEW nuts (2) to the proper specification. Refer to SPECIFICATIONS .
18. Install the crossunder pipe bracket bolt (1) and tighten to the proper specification. Refer to
SPECIFICATIONS .
Fig 12: Front And Rear Crossunder Pipe Hanger Bolts
19. Install the propeller shaft skid plate and tighten the nuts.
20. Install the front and rear crossunder pipe hanger bolts (1) at the front crossmember and tighten
REMOVAL AND INSTALLATION > 2.4 MULTIAIR > REMOVAL
CAUTION:

Fig 1: Rear Exhaust Hanger Bracket Bolts
3. Remove the bolts (1) securing the rear exhaust hanger bracket supporting the crossunder pipe
at the front crossmember.
Fig 2: Support Brackets Bolts & Flange Nuts
4. Remove the crossunder pipe front hanger support bracket bolts (1).
6. Remove the crossunder pipe to catalytic converter flange nuts (3).

NOTE:
in illustration.
NOTE:



Fig 8: Dust Cover
NOTE:
NOTE:

Fig 12: Dust Cover
NOTE:
snap ring.
NOTE:

25. Lower the propeller shaft (1) until the rear joint of the shaft is under the RDU as shown in
illustration.
NOTE:
crossmember.
REMOVAL AND INSTALLATION > 2.4 MULTIAIR > INSTALLATION
CAUTION:
NOTE:

NOTE:
in illustration.
8. Connect the propeller shaft (1) to the pinion of the RDU, verify the snap ring is seated in the
propeller shaft.
SPECIFICATIONS .
Fig 11: Support Brackets Bolts & Flange Nuts
16. Connect the crossunder pipe to the catalytic converter using a NEW flange gasket and tighten
the NEW nuts (1) to the proper specification. Refer to SPECIFICATIONS .
17. Install the crossunder pipe bracket bolt (2) to the engine and tighten to the proper specification.
Fig 12: Rear Exhaust Hanger Bracket Bolts
19. Install the bolts (1) securing the rear exhaust hanger bracket supporting the crossunder pipe at
the front crossmember and tighten to the proper specification. Refer to SPECIFICATIONS .
Jeep Renegade
Service Manual: REAR DRIVELINE MODULE
The primary benefits of All Wheel Drive (AWD) with a Rear Drive Unit (RDU) are:
Superior straight line acceleration, and cornering on all surfaces.
Better traction and handling under adverse conditions, resulting in improved hill climbing ability and
safer driving.
The AWD system intelligently anticipates/selects front, or AWD in varying torque splits based on
conditions, driving style and on a host of "triggers" such as:
Input to vehicle switches/interfaces such as gear selection; ESC button actuation; wiper settings;
and temperature settings
Environmental influences such as surface grade; vehicle speed; launch characteristics; and
relating ESC events
Dynamic factors including wheel slip; detection of understeer/oversteer; steering angle rate; and
acceleration/deceleration rates
Based on all these inputs and more, the system is capable of anticipating, and then delivering infinitely
variable amounts of torque combinations between the front and rear driven wheels at launch, all in
milliseconds and without driver intervention or feedback.
DIAGNOSIS AND TESTING > REAR DRIVE UNIT (RDU) OPERATION
Driveline module operation requires a relatively straight-forward diagnosis. Refer to the following chart:
1. Check Drivetrain Control Module 1. Review DTCM diagnosis and

No All Wheel Drive (AWD) in (DTCM) for DTC's. testing article.
forward or reverse directions,
propeller shaft turning. 2. Diagnose and repair or replace
2. Rear Driveline Unit (RDU) failure.
as necessary.
1. Review DTCM diagnostic and

No AWD in forward or reverse 1. Check DTCM for DTC's. testing article.
directions, propeller shaft not
turning. 2. Power Transfer Unit (PTU) 2. Diagnose and repair or replace
component failure. as necessary.
1. Replace worn or incorrect

Vibration at all speeds, 1. Mis-matched tires, worn tires on
(mis-matched) tires with same
continuous torque transfer. front axle.
make and size.
DIAGNOSIS AND TESTING > REAR DRIVE UNIT (RDU) NOISE

Different sources can be the cause of noise that the RDU assembly is suspected of making. Refer to the
following causes for noise diagnosis.
DIAGNOSIS AND TESTING > REAR DRIVE UNIT (RDU) NOISE > REAR DRIVELINE
UNIT (RDU) ASSEMBLY NOISE
The most important part of RDU service is properly identifying the cause of failures and noise
complaints. The cause of most RDU failures is relatively easy to identify. The cause of RDU noise is
more difficult to identify.
If vehicle noise becomes intolerable, every effort should be made to isolate the noise. Many noises that
are reported as coming from the RDU may actually originate at other sources. For example:
Tires
Road surfaces
Wheel bearings
Engine
Transmission
Exhaust
Propeller shaft (vibration)
Vehicle body (drumming)
RDU noises are normally divided into two categories: gear noise or bearing noise. A thorough and
careful inspection should be completed to determine the actual source of the noise before replacing the
RDU. Other sources of noise from the rear RDU are the actuator and low fluid level.
The rubber mounting bushings help to dampen-out RDU noise when properly installed. Inspect to confirm
that no metal contact exists between the RDU case and the body or suspension cradle. The complete
isolation of noise to one area requires expertise and experience. Identifying certain types of vehicle
noise baffles even the most capable technicians. Often such practices as:
Increase tire inflation pressure to eliminate tire noise.
Listen for noise at varying speeds with different driveline load conditions.
Swerving the vehicle from left to right to detect wheel bearing noise.
All RDU assemblies produce noise to a certain extent. Slight carrier noise that is noticeable only at
certain speeds or isolated situations should be considered normal. Carrier noise tends to peak at a
variety of vehicle speeds. The actuator may be audible in certain situations that may be normal. Noise is
NOT ALWAYS an indication of a problem within the carrier or RDU components.
DIAGNOSIS AND TESTING > REAR DRIVE UNIT (RDU) NOISE > TIRE NOISE
Tire noise is often mistaken for driveline module noise. Tires that are unbalanced, worn unevenly or are
worn in a saw-tooth manner are usually noisy. They often produce a noise that appears to originate in
the driveline module.
Tire noise changes with different road surfaces, but driveline module noise does not. Inflate all four tires
with approximately 20 psi (138 kPa) more than the recommended inflation pressure (for test purposes
only). This will alter noise caused by tires, but will not affect noise caused by the differential. Rear axle
noise usually ceases when coasting at speeds less than 30 mph (48 km/h); however, tire noise
continues, but at a lower frequency, as the speed is reduced.
After test has been completed lower tire pressure back to recommended pressure.
DIAGNOSIS AND TESTING > REAR DRIVE UNIT (RDU) NOISE > GEAR NOISE (DRIVE
PINION AND RING GEAR)
Abnormal gear noise is rare and is usually caused by scoring on the ring gear and drive pinion. Scoring
is the result of insufficient or incorrect lubricant in the carrier housing.
Abnormal gear noise can be easily recognized. It produces a cycling tone that will be very pronounced
within a given speed range. The noise can occur during one or more of the following drive conditions:
Drive
Road load
Float
Coast
Abnormal gear noise usually tends to peak within a narrow vehicle speed range or ranges. It is usually
more pronounced between 30 to 40 mph (48 to 64 km/h) and 50 to 60 mph (80 to 96 km/h). When
objectionable gear noise occurs, note the driving conditions and the speed range.
DIAGNOSIS AND TESTING > REAR DRIVE UNIT (RDU) NOISE > BEARING NOISE
(DRIVE PINION AND DIFFERENTIAL)
Defective bearings produce a rough growl that is constant in pitch and varies with the speed of vehicle.
Being aware of this will enable a technician to separate bearing noise from gear noise.
Drive pinion bearing noise that results from defective or damaged bearings can usually be identified by
its constant, rough sound. Drive pinion front bearing is usually more pronounced during a coast
condition. Drive pinion rear bearing noise is more pronounced during a drive condition. The drive pinion
bearings are rotating at a higher rate of speed than either the differential side bearings or the axle shaft
bearing.
Differential side bearing noise will usually produce a constant, rough sound. The sound is much lower in
frequency than the noise caused by drive pinion bearings.
Bearing noise can best be detected by road testing the vehicle on a smooth road (black top). However, it
is easy to mistake tire noise for bearing noise. If a doubt exists, the tire treads should be examined for
irregularities that often causes a noise that resembles bearing noise.
DIAGNOSIS AND TESTING > REAR DRIVE UNIT (RDU) NOISE > ENGINE AND
TRANSMISSION NOISE
Sometimes noise that appears to be in the driveline module assembly is actually caused by the engine
or the transmission. To identify the true source of the noise, note the approximate vehicle speed and/or
RPM when the noise is most noticeable. Stop the vehicle next to a flat brick or cement wall (this will help
reflect the sound). Place the transmission in NEUTRAL . Accelerate the engine slowly up through the
engine speed that matches the vehicle speed noted when the noise occurred. If the same noise is
produced, it usually indicates that the noise is being caused by the engine or transmission.

RDM TORQUE SPECIFICATIONS
Rear Drive Unit (RDU) Mounting

90 + 45° 66 + 45° - -
Bolts
Center Bearing Support Bolts 50 37 - X
RDM SPECIFICATIONS
DESCRIPTION SPECIFICATION
DIFFERENTIAL FLUID FILL CAPACITY 0.6 Liters
2000043000 * Axle Support Fixture Support Axle
2000043400 * Adjustable Bracket Support Axle
Removing Rear Drive

2019500030 * Elastic Ring Spreader
Shaft
REMOVAL AND INSTALLATION > REMOVAL AND INSTALLATION > REMOVAL

CAUTION:
Propeller shaft installation is a two-person operation. Never allow propeller shaft to hang
from the center bearing, or while only connected to the transmission or rear axle flanges. A
helper is required. If a propeller shaft section is hung unsupported, damage may occur to
the shaft, coupler, and/or center bearing from over-angulation. This may result in driveline
vibrations and/or component failure.
2. Remove the muffler. Refer to MUFFLER, EXHAUST, REMOVAL AND INSTALLATION .
3. Remove both rear tires and wheels. Refer to REMOVAL AND INSTALLATION .
4. Remove the rear suspension knuckles with hub and bearings. Refer to KNUCKLE, REAR,
5. Remove both rear halfshafts. Refer to REMOVAL AND INSTALLATION .
6. Remove the rear stabilizer bar. Refer to STABILIZER BAR, REAR SUSPENSION, REMOVAL
AND INSTALLATION .
Fig 1: Differential Actuator Connector
7. Disconnect the electrical connector (1) of the differential actuator.

Fig 2: Positioning Support Tools Under Propeller Shaft
NOTE:
CAUTION:
Do not allow the propeller shaft to hang from the vehicle unsupported. Damage may
occur to the joint, boot, and center bearing from over-angulation.
in illustration.
NOTE:
10. Remove the propeller shaft center support bolts (1).

Fig 5: Dust Cover
NOTE:
snap ring.
NOTE:

Fig 8: Front RDU Mounting Bolt
15. Position a suitable hydraulic lift to support the RDU and remove the front RDU mounting bolt
(1).
Fig 9: RDU & Isolator Through Bolts
16. Remove the rear RDU isolator through bolts (1a) and remove the RDU (1b).
Fig 10: Actuator & Screws
17. If necessary, remove the screws and the actuator (1) from the RDU.
REMOVAL AND INSTALLATION > REMOVAL AND INSTALLATION > INSTALLATION
CAUTION:
Propeller shaft installation is a two-person operation. Never allow propeller shaft to hang
from the center bearing, or while only connected to the transmission or rear axle flanges. A
helper is required. If a propeller shaft section is hung unsupported, damage may occur to
the shaft, coupler, and/or center bearing from over-angulation. This may result in driveline
vibrations and/or component failure.
1. If removed, install the Rear Driveline Unit (RDM) actuator and tighten the screws.
Fig 1: RDU & Isolator Through Bolts
2. Raise the RDU (1a) into position and tighten the through bolts (1b) to the proper specification.
Fig 2: Front RDU Mounting Bolt
3. Install the front RDU mounting bolt (1) and tighten to the proper specification. Refer to
SPECIFICATIONS .

Fig 3: Dust Seal
5. Install a new dust seal (1) on the pinion shaft of the RDU.
Fig 4: Snap Ring
6. Install a new snap ring (1) in the drive shaft.

7. Connect the propeller shaft to the pinion of the RDU, verify the snap ring is seated in the
groove on the pinion shaft.
Fig 6: Dust Cover
8. Position the new dust cover over the joint at the rear of the propeller shaft.
9. Install the propeller shaft center support bolts and tighten to the proper specification. Refer to
SPECIFICATIONS .
12. Connect the differential actuator wire harness connector.

Fig 8: RDU Code Location
NOTE:
If replacing the RDU, it is necessary to record the last two characters of the code in
the area indicated (a) of the new RDU for performing the self learning procedure.
13. When replacing the RDU connect the diagnostic scan tool, enter Miscellaneous Functions of
the DriveTrain Control Module (DTCM) and run the self-learning procedure for the RDU.
14. Check and correct the fluid level in the RDU. Refer to FLUID, DIFFERENTIAL, STANDARD
PROCEDURE .
15. Install the rear stabilizer bar. Refer to STABILIZER BAR, REAR SUSPENSION, REMOVAL
AND INSTALLATION .
16. Install the rear halfshafts. Refer to REMOVAL AND INSTALLATION .
17. Install the rear knuckles. Refer to KNUCKLE, REAR, REMOVAL AND INSTALLATION .
18. Install the rear tires and wheels. Refer to REMOVAL AND INSTALLATION .
19. Install the muffler. Refer to MUFFLER, EXHAUST, REMOVAL AND INSTALLATION .
FLUID, DIFFERENTIAL > STANDARD PROCEDURE > DIFFERENTIAL FLUID FILL
The rear differential oil change is not a scheduled maintenance service.
The correct fill level is just below the bottom edge of the fill plug hole. Be sure the vehicle is on a level
surface, or is hoisted in a level manner, in order to obtain the correct fill level.

Fig 1: Rear Differential Oil Filler Cap
2. Remove the rear differential oil filler cap (1) and check the oil level is just below the bottom
edge of the fill hole.
3. If necessary, add the specified fluid. Refer to CAPACITIES AND RECOMMENDED FLUIDS,
SPECIFICATIONS .
4. Clean and install the differential fill plug (1) and tighten.
ACTUATOR, AXLE SHAFT > REMOVAL AND INSTALLATION > REMOVAL AND

Fig 1: Rear Differential Actuator Wire Harness Connector
2. Disconnect the wire harness connector (1) at the rear differential actuator.
Fig 2: Rear Differential Actuator & Screws
3. Remove the screws (1a) and remove the rear differential actuator (1b).
ACTUATOR, AXLE SHAFT > REMOVAL AND INSTALLATION > REMOVAL AND
1. Install the rear differential actuator and tighten the screws.
2. Connect the wire harness connector at the rear differential actuator.

Jeep Renegade
Service Manual: REAR HALF SHAFT
CAUTION:
Never grasp half shaft assembly by the boots. This may cause the boot to pucker or crease
and reduce the service life of the boot.
Avoid over angulating or stroking the C/V joints when handling the half shaft.
Half shafts exposed to battery acid, transmission fluid, brake fluid, differential fluid or
gasoline may cause the boots to deteriorate. Failure to follow these instructions will result in
damage.
2. Remove the rear wheel hub and bearing assembly. Refer to HUB AND BEARING, REMOVAL
AND INSTALLATION .
3. Using the tools 1847017001 (1a), 1840005004 (1b) and 99341011 (1c), remove the halfshaft
from the Rear Drive Unit (RDU).
Fig 2: Dust Cover
4. If necessary, remove the dust cover (1).

Fig 3: Oil Seal
5. Remove the oil seal (1).
CAUTION:
Never grasp half shaft assembly by the boots. This may cause the boot to pucker or crease
and reduce the service life of the boot.
Avoid over angulating or stroking the C/V joints when handling the half shaft.
Half shafts exposed to battery acid, transmission fluid, brake fluid, differential fluid or
gasoline may cause the boots to deteriorate. Failure to follow these instructions will result in
damage.
NOTE:
Use care when installing half shaft to axle assembly. The half shaft installation angle
should be minimized to avoid damage to the seal upon installation.
Fig 1: Installing Oil Seal
1. If removed, use the tool 2000036600 (1) install a new oil seal.
Fig 2: Snap Ring
2. Install a NEW snap ring on the stub shaft.
3. Install the halfshaft until the circlip engages in the RDU.
4. Install the rear hub and bearing assembly. Refer to HUB AND BEARING, REMOVAL AND
INSTALLATION .
5. Check wheel alignment. Refer to WHEEL ALIGNMENT, STANDARD PROCEDURE .

Service Manual: BATTERY SYSTEM - SERVICE Jeep Renegade
INFORMATION
Batteries - The batteries fitted on the vehicle differ according to model and market. Some examples are
given below:
Vehicle model Battery type
1.4-MAIR/2-170 HP ATX 72AH L3 HD S/S
1.4-MAIR/2-170 HP MTX 63AH 450 A L2 HD S/S
1.4-MAIR-160 HP MTX H5 500 CCA (NAFTA)
1.6- MJ 120 HP-2.0 MJ-140 HP MTX 72AH L3 S/S
1.6- EVO 110 HP MTX 72AH L3 S/S
2.4 TIGER SHARK ATX 70AH 600A SAE (NAFTA)
2.4 TIGER SHARK ATX 70AH 640 L3 EN2

Fig 1: Junction Unit On Battery
Junction unit on battery - The junction units from CBA battery are indicated below:
Fig 2: Fuses Fitted In The CBA
The following fuses are fitted in the CBA:
F1 70 A for the protection of the additional PTCs
F2 40 A for the protection of the additional PTCs
F3 40 A for the protection of the trailer setup
CAL Not connected
CBA for vehicle:
1. 1.4 MultiAir / 2.0 MJet / 1.6 MJet1
2. 1.6 Etorque / 2.4 Tiger shark
3. 1.4 MultiAir / 2.0 MJet / 1.6 MJet1
4. 2.4 Tiger shark
5. 1.6 Etorque
The battery system is designed to provide a safe, efficient, reliable and mobile means of delivering and
storing electrical energy. This electrical energy is required to operate the engine starting system, as well
as to operate many of the other vehicle accessory systems for limited durations while the engine and/or
the charging system are not operating. The battery system is also designed to provide a reserve of
electrical energy to supplement the charging system for short durations while the engine is running and
the electrical current demands of the vehicle exceed the output of the charging system. In addition to
delivering, and storing electrical energy for the vehicle, the battery system serves as a capacitor and
voltage stabilizer for the vehicle electrical system. It absorbs most abnormal or transient voltages
caused by the switching of any of the electrical components or circuits in the vehicle.
SPECIFICATIONS > BATTERY
1.4 Turbo MultiAir 1.6 16V MultiAir 2.0 16V Multijet
Voltage (V) 12 12 12
63
Capacity (Ah) 72 72
72 (*)
450
Intensity (A) 570 570
570 (*)
(*) Cold Countries

Generator M12 70 52
Generator M8 25 18.5
Battery Nut M8 14 10.5
Battery Box Screw M8 20 15
Ground Cable 14 10.5
Ground Cable Side Post 16 12
BATTERY > DESCRIPTION AND OPERATION > DESCRIPTION AND OPERATION >
DESCRIPTION
Low-maintenance conventional batteries are used on this vehicle. These batteries have non-removable
battery cell caps. Under normal service, the composition of this battery reduces gassing and water loss
at normal charge rates.
Conventional batteries are made up of six individual cells that are connected in series. Each cell
contains positive charged cell groups made of lead oxide, and negatively charged cell groups made of
sponge lead. The cells are submerged in a sulfuric acid and water solution called electrolyte.
The battery performs the function of a chemical storage device for electrical energy generated by the
alternator. It must be capable of supplying high current for starting and powering other electrical loads.
The battery function is also to serve as a stabilizing component in the charging system by providing
energy when the system demands exceed the output of the generator.
BATTERY > DESCRIPTION AND OPERATION > DESCRIPTION AND OPERATION >
OPERATION
The battery is designed to store electrical energy in a chemical form. When an electrical load is applied
to the terminals of the battery, an electrochemical reaction occurs. This reaction causes the battery to
discharge electrical current from its terminals. As the battery discharges, a gradual chemical change
takes place within each cell. The sulfuric acid in the electrolyte combines with the plate materials,
causing both plates to slowly change to lead sulfate. At the same time, oxygen from the positive plate
material combines with hydrogen from the sulfuric acid, causing the electrolyte to become mainly water.
The chemical changes within the battery are caused by the movement of excess or free electrons
between the positive and negative plate groups. This movement of electrons produces a flow of
electrical current through the load device attached to the battery terminals.
As the plate materials become more similar chemically, and the electrolyte becomes less acid, the
voltage potential of each cell is reduced. However, by charging the battery with a voltage higher than
that of the battery itself, the battery discharging process is reversed. Charging the battery gradually
changes the sulfated lead plates back into sponge lead and lead dioxide, and the water back into sulfuric
acid. This action restores the difference in the electron charges deposited on the plates, and the voltage
potential of the battery cells. For a battery to remain useful, it must be able to produce high-amperage
current over an extended period. A battery must also be able to accept a charge, so that its voltage
potential may be restored.
The battery is vented to release excess hydrogen gas that is created when the battery is being charged
or discharged. However, even with these vents, hydrogen gas can collect in or around the battery. If
hydrogen gas is exposed to flame or sparks, it may ignite. If the electrolyte level is low, the battery may
arc internally and explode. If the battery is equipped with removable cell caps, add distilled water
whenever the electrolyte level is below the top of the plates. If the battery cell caps cannot be removed,
the battery must be replaced if the electrolyte level becomes low.
BATTERY > DIAGNOSIS AND TESTING > DIAGNOSIS AND TESTING - BATTERY
WARNING:
IF THE BATTERY SHOWS SIGNS OF FREEZING, LEAKING OR LOOSE POSTS, DO NOT

TEST, ASSIST-BOOST, OR CHARGE. THE BATTERY MAY ARC INTERNALLY AND
EXPLODE. PERSONAL INJURY AND/OR VEHICLE DAMAGE MAY RESULT.
WARNING:
EXPLOSIVE HYDROGEN GAS FORMS IN AND AROUND THE BATTERY. DO NOT SMOKE,
USE FLAME, OR CREATE SPARKS NEAR THE BATTERY. PERSONAL INJURY AND/OR
VEHICLE DAMAGE MAY RESULT.
WARNING:
THE BATTERY CONTAINS SULFURIC ACID, WHICH IS POISONOUS AND CAUSTIC.

AVOID CONTACT WITH THE SKIN, EYES, OR CLOTHING. IN THE EVENT OF CONTACT,
FLUSH WITH WATER AND CALL A PHYSICIAN IMMEDIATELY. KEEP OUT OF THE
REACH OF CHILDREN.
A battery that will not accept a charge is inoperative, and must be replaced. Further testing is not
required. A fully-charged battery must be load tested to determine its cranking capacity. A battery that is
fully-charged, but does not pass the load test, is inoperative and must be replaced.
NOTE:
Completely discharged batteries may take several hours to accept a charge. Refer to
STANDARD PROCEDURE for the proper battery charging procedures.
BATTERY > DIAGNOSIS AND TESTING > DIAGNOSIS AND TESTING - BATTERY >
MIDTRONICS GR8 BATTERY TESTER
The Midtronics GR8 battery tester is designed to help diagnose the cause of an inoperative battery. for
instructions on the use of the Midtronics GR8 battery tester. Refer to BATTERY, STANDARD
PROCEDURE .
BATTERY > STANDARD PROCEDURE > BATTERY CHARGING
Battery charging is the means by which the battery can be restored to its full voltage potential. A battery
is fully-charged when:
Midtronics (special tool #GR8-1220KIT-CHRY, AGM Battery Tester/Charger Station) tester
indicates battery is OK.
All of the battery cells are gassing freely during battery charging.
Open-circuit voltage of the battery is 12.65 volts or above.
WARNING:
Never exceed twenty amperes when charging a cold (-1° C [30° F] or lower) battery. The
battery may arc internally and explode. Personal injury and/or vehicle damage may result.
WARNING:
If the battery shows signs of freezing, leaking, loose posts, do not test, assist-boost, or
charge. The battery may arc internally and explode. Personal injury and/or vehicle damage
may result.
WARNING:
EXPLOSIVE HYDROGEN GAS FORMS IN AND AROUND THE BATTERY. DO NOT SMOKE,
USE FLAME, OR CREATE SPARKS NEAR THE BATTERY. PERSONAL INJURY AND/OR
VEHICLE DAMAGE MAY RESULT.
WARNING:
THE BATTERY CONTAINS SULFURIC ACID, WHICH IS POISONOUS AND CAUSTIC.

AVOID CONTACT WITH THE SKIN, EYES, OR CLOTHING. IN THE EVENT OF CONTACT,
FLUSH WITH WATER AND CALL A PHYSICIAN IMMEDIATELY. KEEP OUT OF THE
REACH OF CHILDREN.
WARNING:
If the battery is equipped with removable cell caps, be certain that each of the cell caps is in
place and tight before the battery is returned to service. Personal injury and possible vehicle
damage may result from loose or missing cell caps.
CAUTION:
Always disconnect and isolate the battery negative cable before charging a battery. Do not
exceed sixteen volts while charging a battery. Damage to the vehicle electrical system
components may result.
CAUTION:
Battery electrolyte will bubble inside the battery case during normal battery charging.
Electrolyte boiling or being discharged from the battery vents indicates a battery
overcharging condition. Immediately reduce the charging rate or turn off the charger to
evaluate the battery condition. Damage to the battery may result from overcharging.
CAUTION:
The battery should not be hot to the touch. If the battery feels hot to the touch, turn off the
charger and let the battery cool before continuing the charging operation. Damage to the
battery may result.
After the battery has been charged to 12.65 volts or greater, perform a load test to determine the battery
cranking capacity. For the proper battery load test procedures, refer to BATTERY, STANDARD
PROCEDURE . If the battery will endure a load test, return the battery to service. If the battery will not
endure a load test, it is inoperative and must be replaced.
Clean and inspect the battery hold-down, tray, terminals, posts, and top before completing battery
service.
BATTERY > STANDARD PROCEDURE > BATTERY CHARGING > CHARGING A

COMPLETELY DISCHARGED BATTERY
The following procedure should be used to recharge a completely discharged battery. Unless this
procedure is properly followed, a good battery may be needlessly replaced.
1. Measure the voltage at the battery posts with a voltmeter, accurate to 1/10 (0.10) volt. If the
reading is below ten volts, the battery charging current will be low. It could take some time
before the battery accepts a current greater than a few milliamperes. Such low current may not
be detectable on the ammeters built into many battery chargers.
2. Disconnect and isolate the battery negative cable. Connect the Midtronics (special tool
#GR8-1220KIT-CHRY, AGM Battery Tester/Charger Station).
NOTE:
Some battery chargers are equipped with polarity-sensing circuitry. This circuitry
protects the battery charger and the battery from being damaged if they are
improperly connected. If the battery state-of-charge is too low for the polarity-
sensing circuitry to detect, the battery charger will not operate. This makes it appear
that the battery will not accept charging current. See the instructions provided by the
manufacturer of the battery charger for details on how to bypass the polarity-
sensing circuitry.
3. Battery chargers vary in the amount of voltage and current they provide. The amount of time
required for a battery to accept measurable charging current at various voltages is shown in
the CHARGE RATE TABLE. If the charging current is still not measurable at the end of the
charging time, the battery is inoperative and must be replaced. If the charging current is
measurable during the charging time, the battery may be good and the charging should be
completed in the normal manner.
CHARGE RATE TABLE
Voltage Hours
16.0 volts maximum up to 4 hours
14.0 to 15.9 volts up to 8 hours
13.9 volts or less up to 16 hours
BATTERY > STANDARD PROCEDURE > BATTERY CHARGING > CHARGING TIME
REQUIRED
The time required to charge a battery will vary, depending upon the following factors:
Battery Capacity - A completely discharged heavy-duty battery requires twice the charging time
of a small capacity 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 battery charger is connected to a cold battery, the current accepted by the battery
will be very low at first. As the battery warms, it will accept a higher charging current rate
(amperage).
Charger Capacity - A battery charger that supplies only five amperes will require a longer
charging time. A battery charger that supplies twenty amperes or more will require a shorter
charging time.
State-Of-Charge - A completely discharged battery requires more charging time than a partially
discharged battery. Electrolyte is nearly pure water in a completely discharged battery. At first, the
charging current (amperage) will be low. As the battery charges, the specific gravity of the
electrolyte will gradually rise.
The Battery Charging Time Table gives an indication of the time required to charge a typical battery at
room temperature based upon the battery state-of-charge and the charger capacity.
BATTERY CHARGING TIME TABLE
Charging Amperage 5 Amps 10 Amps 20 Amps
Open Circuit Voltage Hours Charging @ 21° C (70° F)
12.25 to 12.49 6 hours 3 hours 1.5 hours

Below 10.00 18 hours 9 hours 4.5 hours
BATTERY > STANDARD PROCEDURE > GR8 BATTERY TESTER / CHARGER
Always use the Midtronics GR8 Instruction Manual that was supplied with the tester as a reference. If
the Instruction Manual is not available the following procedure can be used:
WARNING:
Always wear appropriate eye protection and use extreme caution when working with
batteries.
BATTERY > STANDARD PROCEDURE > GR8 BATTERY TESTER / CHARGER >
BATTERY TESTING
1. If testing the battery OUT-OF-VEHICLE, clean the battery terminals with a wire brush before
testing. . If the battery is equipped with side post terminals, install and tighten the supplied lead
terminal stud adapters. Do not use steel bolts. Failure to properly install the stud adapters, or
using stud adapters that are dirty or worn-out may result in false test readings.
2. If testing the battery IN-THE-VEHICLE, make certain all of the vehicle accessory loads are
OFF, including the ignition. Connect the Midtronics GR8 directly to the battery posts.
NOTE:
Multiple batteries connected in parallel must have the ground cable disconnected to
perform a battery test. Failure to disconnect may result in false battery test readings.
3. Using the ARROW key select in or out of vehicle testing and press ENTER to make a
selection.
4. If not selected, choose the Cold Cranking Amp (CCA) battery rating. Or select the appropriate
battery rating for your area (see menu). The tester will then run its self programmed test of the
battery and display the results. Refer to TEST RESULTS-CHARGING SYSTEM .
5. While viewing the battery test result, press the CODE button and the tester will prompt you for
the last 4 digits of the VIN. Use the UP/DOWN arrow buttons to scroll to the correct character;
then press ENTER to select and move to the next digit. Then press the ENTER button to view
the SERVICE CODE. Pressing the CODE button a second time will return you to the test
results.
NOTE:
The SERVICE CODE is required on every warranty claim submitted for battery replacement.
BATTERY > STANDARD PROCEDURE > GR8 BATTERY TESTER / CHARGER > QUICK
REFERENCE GUIDE
Inspect the battery for damages and check the electrolyte level. Always use the necessary safety
precautions when working with batteries to prevent severe injury or death. Follow all manufacturers'
instructions and BCI (Battery Council International) safety recommendations, which include the following
precautions:
REFERENCE GUIDE > MAIN MENU
The Main Menu is the starting point for all tools and utilities, which are depicted as icons. Some icons
lead directly to the function they represent, while others are menu icons that lead to two or more options.
Fig 1: Identifying Battery Tester Main Menu Icon 1
Automatically tests, charges, and provides battery decision using the information you select in a series
of screens. Start here to generate warranty codes.
Tests the starting and charging systems.

Maintains battery voltage at 13.5 volts to provide uninterrupted reprogramming of ECUs and retain
vehicle system settings.
Includes a utility to view and print a test counter, a data transfer utility, the software version and date,
the Midtronics GR8 serial number for the control module, and current wireless channel.
The Setup Menu lets you customize options in the Midtronics GR8 to suit your needs.
Provides a list of topics and definitions. Also includes Midtronics Customer Service phone numbers.
REFERENCE GUIDE > CHARGE/TEST MENU
Fig 1: Identifying Charge/Test Menu Icon 1
Automatically tests and charges battery, starting, and charging system. Generates a warranty code for
Replace and Bad Cell decisions.
Pre Delivery Inspection (PDI): For testing delivered vehicles and lot maintenance. Uses the same inputs
as a diagnostic charge.
Dual Battery Charge mode allows the charger to be used with dual battery systems.
Makes high output current available to boost charge an in-vehicle battery and assist in starting the
engine.
Provides a timed charge that ranges from 5 to 120 minutes or a continuous charge that ends when you
press the STOP key.
In this mode the charger can provide a trickle charge for long term, low amp battery charging.
Generates 15-digit warranty codes for physically defective batteries or customer good will.
REFERENCE GUIDE > GR8 BATTERY TESTER
Fig 1: Identifying GR8 Battery Tester Components
1. Control module: Backlit graphical display and keypad for data entry.
2. ON/OFF switch: ON/OFF switch Turns power on and off to the GR8.
3. STATUS light: Lights in conjunction with beeping alarm to indicate transitions and warnings.
4. Data card slot: For future upgrades via a data card. The slot contains a plastic filler card for
protection.
REPLACE BATTERY DECISIONS > BATTERY DECISIONS
Fig 1: Battery Test Screen - Example
1. Battery Decisions
2. Select Rating
3. Measured capacity
4. Measured voltage
5. Good Range
NOTE:
The warranty code screen will only be displayed for REPLACE BATTERY and BAD
CELL-REPLACE decisions.
6. Enter this number into scan tool

7. Replace range
8. Replaced AMP Hours
9. Charging Time
REPLACE BATTERY DECISIONS > TEST RESULTS-CHARGING SYSTEM
A REPLACE BATTERY or BAD CELL-REPLACE decision gives you the option of generating a warranty
code. Enter that warranty code into your scan tool in the Midtronics warranty code validation routine.
Fig 1: Battery Tester Test Results Screen - Example
1. Loads-off current at rev if amp clamp is used
2. Loads-off DC voltage at rev
3. Decision
4. Loads-on DC voltage at rev
5. Loads-on current at rev if amp clamp is used
6. Bar graph of DC voltage within normal range (loads on and off)
7. Graph of diode waveform
8. Peak-to-peak AC voltage
9. Normal DC voltage range
REPLACE BATTERY DECISIONS > TEST RESULTS-STARTER SYSTEM
Fig 1: Test Results-Starter System Example
1. Average cranking voltage

2. Average cranking current if amp clamp is used
3. Cranking time in seconds
4. Y axis = System performance: cranking voltage
BATTERY > STANDARD PROCEDURE > IGNITION-OFF DRAW TEST
A multimedia supplement to the instructions contained in this

article is available.
To view the multimedia example of the condition described go
to;
then type, "A00735755.vid1" into the "Search Channel"
box.
The term Ignition-Off Draw (IOD) identifies a normal condition where power is being drained from the
battery with the ignition switch in the Off position. A normal vehicle electrical system will draw from five
to thirty-five milliamperes (0.005 to 0.035 ampere) with the ignition switch in the Off position, and all
non-ignition controlled circuits in proper working order. Up to thirty-five milliamperes are needed to
enable the memory functions for the Powertrain Control Module (PCM), digital clock, electronically tuned
radio, and other modules which may vary with the vehicle equipment.
Excessive IOD can be caused by:
Electrical items left on.
Inoperative or improperly adjusted switches.
Inoperative or shorted electronic modules and components.
An internally shorted generator.
Intermittent shorts in the wiring.
If the IOD is over thirty-five milliamperes, the problem must be found and corrected before replacing a
battery. In most cases, the battery can be charged and returned to service after the excessive IOD
condition has been corrected.
1. Verify that all electrical accessories are off. Turn off all lamps, remove the ignition key, and
close all doors. If the vehicle is equipped with an illuminated entry system or an electronically
tuned radio, allow the electronic timer function of these systems to automatically shut off (time
out). This may take up to ten minutes. See the ELECTRONIC MODULE IGNITION-OFF DRAW
TABLE below for more information.
ELECTRONIC MODULE IGNITION-OFF DRAW (IOD) TABLE
Time Out?
IOD After
Module (If Yes, Interval And Wake-Up IOD
Time Out
Input)
Radio No 1 to 3 milliamperes N/A

Audio Power
No up to 1 milliampere N/A
Amplifier
Powertrain Control
No 0.95 milliampere N/A
Module (PCM)
Instrument Cluster No 0.44 milliampere N/A
2. Determine that the underhood lamp is operating properly, then disconnect the lamp wire
harness connector or remove the lamp bulb.
3. Turn off all electrical accessories.
4. Disconnect the battery negative cable.
CAUTION:
Do not open any doors, or turn on any electrical accessories with the lowest
milliampere scale selected, or the multimeter may be damaged.
5. Connect a 10 gauge jumper wire between the negative battery cable and the negative battery
post.
6. Turn the ignition key ON and then OFF and wait 10 minutes for all systems to enter sleep
mode.
NOTE:
Do not break the connection between the jumper wire and the battery. If the
connection between the battery negative terminal post and the negative cable
terminal clamp is lost during any part of the IOD test, the electronic timer function
will be activated and all of the tests will have to be repeated.
7. Set an electronic digital multimeter to its highest amperage scale. Connect the multimeter to
the battery negative cable terminal clamp and the battery negative terminal post, but not on the
jumper connection.
8. Remove the jumper wire without breaking the digital multimeter connection.
9. The multimeter leads must be securely clamped to the battery negative cable terminal clamp
and the battery negative terminal post, but not the jumper wire.
10. The high-amperage IOD reading on the multimeter should be very low or nonexistent,
depending upon the electrical equipment in the vehicle. If the amperage reading remains high,
remove and replace each fuse or circuit breaker in the BCM and PDC, one at a time until the
amperage reading becomes very low, or nonexistent. Refer to the appropriate wiring
information for complete BCM and PDC, circuit breaker, and circuit identification. This will
isolate each circuit and identify the circuit that is the source of the high-amperage IOD. If the
amperage reading remains high after removing and replacing each fuse, disconnect the wire
harness from the generator. If the amperage reading now becomes very low or nonexistent,
diagnose and repair the Charging System as necessary. After the high-amperage IOD has
been corrected, switch the multimeter to progressively lower amperage scales and, if
necessary, repeat the fuse and circuit breaker remove-and-replace process to identify and
correct all sources of excessive IOD. It is now safe to select the lowest milliampere scale of
the multimeter to check the low-amperage IOD.
11. Observe the multimeter reading. The low-amperage IOD should not exceed thirty-five
milliamperes (0.035 ampere). If the current draw exceeds thirty-five milliamperes, isolate each
circuit using the fuse and circuit breaker remove-and-replace process. The multimeter reading
will drop to within the acceptable limit when the source of the excessive current draw is
disconnected. Repair this circuit as required; whether a wiring short, incorrect switch
adjustment, or an inoperative component is the cause.
BATTERY > STANDARD PROCEDURE > OPEN-CIRCUIT VOLTAGE TEST
A battery open-circuit voltage (no load) test will show the approximate state-of-charge of a battery.
Before proceeding with this test, completely charge the battery, refer to the appropriate battery charging
procedure.
1. Before measuring the open-circuit voltage, the surface charge must be removed from the
battery. Turn on the headlamps for fifteen seconds, then allow up to five minutes for the battery
voltage to stabilize.
2. Disconnect and isolate both battery cables, negative cable first.
3. Using a voltmeter connected to the battery posts (see the instructions provided by the
manufacturer of the voltmeter), measure the open-circuit voltage.
See the OPEN-CIRCUIT VOLTAGE TABLE. This voltage reading will indicate the battery state-of-charge,
but will not reveal its cranking capacity. If a battery has an open-circuit voltage reading of 12.4 volts or
greater, it may be load tested to reveal its cranking capacity.
OPEN CIRCUIT VOLTAGE TABLE
Open Circuit Voltage Charge Percentage
11.7 volts or less 0%
12.0 volts 25%
12.2 volts 50%
12.4 volts 75%
12.6 volts or more 100%
BATTERY > REMOVAL AND INSTALLATION > 1.4L REMOVAL AND INSTALLATION >
REMOVAL 1.4L
Fig 1: Retainers, Clamp, Lever & Hexagon Socket
1. Disconnect the clamp (1a) of the negative pole of the battery, after having loosened by turning
the lever (1b). Loosen the lever (1b) by wrench applied to the hexagon socket (1c).
2. Press retainers (1a) and disconnect the positive battery terminal.

Fig 2: Power Supply Box, Plate, Screws, Nuts, Battery Positive Terminal & Power Box
3. Remove the nuts (1a) and disconnect the electrical connections from the power supply box
(1b).
4. Remove the screws (2a) and remove the plate (2b).
5. Loosen the positive terminal (3b) nut (3a).
6. Disconnect the battery positive terminal (3b) from the power box (1b).
Fig 3: Battery, Nut & Retaining Belt
7. Remove the nut (1a) and move the bracket with retaining belt (1b).
8. Remove the battery.
9. Check that the battery is not damaged.
BATTERY > REMOVAL AND INSTALLATION > 1.4L REMOVAL AND INSTALLATION >
INSTALLATION 1.4L
Fig 1: Battery, Nut & Retaining Belt
1. Position the battery for installation.
2. Place the retaining strap bracket (2a) on the battery and tighten the nut (2b) to the proper
torque specification. Refer to SPECIFICATIONS .
Fig 2: Battery Positive Terminal, Power Box, Nut, Plate, Screws & Power Supply Box
3. Connect the battery positive terminal (1a) to the power box (1b), then tighten the nut (1c) of the
positive terminal.
4. Place the plate (2b) and tighten the screws (2c).
5. Connect the electrical connections to the power supply box (1b) and tighten the nuts (3a).
6. Place the lid of the box power on the positive battery terminal, then engage the retainers.
Fig 3: Control Lever, Terminal, Clamp, Cable & Lever
7. Ensure that the control lever (1a) is in the open position.
8. Insert the terminal (2a) to the negative battery pole and press it fully.
9. Turn the lever (1a) and tighten the clamp (2a) on the negative pole. If necessary, rotate the
lever (1a) by means of a key applied to the hexagonal socket (3a). Check that the cable (3b)
follows the correct path without tension and forcing.
10. Apply manipulate the cable (3b) to check that the terminal (2a) is correctly hooked.
BATTERY > REMOVAL AND INSTALLATION > 1.6L - 2.0L REMOVAL AND
INSTALLATION > BATTERY REMOVAL 1.6L - 2.0L
Fig 1: Release, Cable, Negative Battery Pole, Terminal, Nut & Battery
1. Press the release (1a) and disconnect the cable (1b) from the negative battery pole (1c).
2. Loosen the terminal nut (2a) and disconnect the terminal (2b) complete with the intelligent
battery sensor, from the battery (2c). Isolate the terminal (2b).
Fig 2: Retainers & Cover
3. Press retainers (1a) and disengage the cover (1b) from the power supply box from the seat
cover (1a).
Fig 3: Terminal, Nut & Positive Battery Post
4. Loosen the nut (1a) and disconnect the terminal (1b) with the power supply box from the
positive terminal (1c) of the battery. Isolate the terminal (1b).
Fig 4: Battery, Retaining Belt & Nut
5. Remove the nut (1a) and move the battery retaining belt (1b) bracket.
6. Remove the battery.
7. check that the battery is not damaged.
BATTERY > REMOVAL AND INSTALLATION > 1.6L - 2.0L REMOVAL AND
INSTALLATION > BATTERY INSTALLATION 1.6L - 2.0L
1. Place the battery in place for installation.
2. Place the retaining strap bracket (2a) and tighten the nut (2b) to the specified torque.
Fig 1: Terminal, Nut & Positive Battery Post
3. Connect the positive battery terminal (1a) then tighten the positive terminal nut (1b).
Fig 2: Retainers & Cover
4. Install the positive battery terminal cover.

Fig 3: Release, Cable, Negative Battery Pole, Terminal, Nut & Battery
5. Connect the terminal (1a) to the negative pole of the battery and tighten the nut (1b).
6. Install and secure the negative battery cable to the battery.

Fig 4: Battery, Retaining Belt & Nut
CABLES, BATTERY > DESCRIPTION AND OPERATION > DESCRIPTION AND

The standard battery cables are large gauge, stranded copper wires sheathed within a heavy plastic or
synthetic rubber insulating jacket. The wire used in the battery cables combines excellent flexibility and
reliability with high electrical current carrying capacity. The battery cables feature a clamping type female
battery terminal made of stamped sheet metal that is die cast onto one end of the battery cable wire. A
pinch-bolt and nut are installed at the open end of the female battery terminal clamp. Large eyelet type
terminals are crimped onto the opposite end of the battery cable wire and then soldered. The battery
positive cable wires feature a larger female battery terminal clamp to allow connection to the larger
battery positive terminal post. The battery negative cable wires have a smaller female battery terminal
clamp.
The battery harness includes both the battery positive and negative cables to the remote battery
connection and may include portions of the wiring circuits for other components on some vehicles. The
starter harness includes both the battery positive and negative cables from the remote battery
connection to the starter and engine ground location. The battery cables are part of the engine wiring
harness. If the cables need to be serviced. The engine harness will need to be replaced as an assembly.
CABLES, BATTERY > DESCRIPTION AND OPERATION > DESCRIPTION AND
The battery cables connect the battery terminal posts to the vehicle electrical system. These cables also
provide a path back to the battery for electrical current generated by the charging system for restoring
the voltage potential of the battery. The female battery terminal clamps on the ends of the battery cable
wires provide a strong and reliable connection of the battery cable to the battery terminal posts. The
terminal pinch bolts allow the female terminal clamps to be tightened around the male terminal posts on
the top of the battery. The eyelet terminals secured to the opposite ends of the battery cable wires from
the female battery terminal clamps provide secure and reliable connection of the battery cables to the
vehicle electrical system.
One wire has an eyelet terminal that connects the battery positive cable to the B(+) terminal stud of the
Body Control Module (BCM), and the other wire has an eyelet terminal that connects the battery positive
cable to the B(+) terminal stud of the engine starter motor solenoid. The battery negative cable terminal
clamp has one wire as an eyelet terminal that connects the battery negative cable to the vehicle
powertrain through a ground connection, typically on the engine cylinder block.
CABLES, BATTERY > REMOVAL AND INSTALLATION > 1.4L REMOVAL AND
1. Open the hood to access the battery.

Fig 1: Battery Pole Clamp, Lever, Hexagon Socket, Clamp, Ground Cable, Nut & Chassis
Terminal
2. Disconnect the negative battery pole clamp (1a), after having loosened by turning the lever
(1b). If you need to turn the lever (1b), use a wrench applied to the hexagon socket (1c).
3. Open the clamp (2a) and disconnect the battery ground cable (2b).
4. Remove the nut (3a) and disconnect the battery ground cable from the chassis terminal (3b).
Fig 2: Battery Cable, Ground Terminal, Gearbox, Screw & Ground Wire
6. Remove the under guard body protection.
7. Remove the screw (1a) and disconnect the battery cable (1c) ground terminal (1b) from the
gearbox (1d).
8. Retrieve the battery ground wire (1c).

9. Check that the ground wire from the battery is not damaged and that the individual wires are
securely attached to the connections. If needed, perform the appropriate checks of continuity.
1. Position the negative battery cable for installation.

Fig 1: Battery Negative Cable, Gearbox Terminal & Screw
2. Connect the battery negative cable (1b) to the gearbox terminal (1a) then tighten the screw
(1c) to the specified torque.
3. Install the under guard protection cover.

Fig 2: Battery Negative Cable, Chassis, Nut, Clamp, Control Lever, Terminal & Hexagonal
Socket
5. Connect the battery negative cable (1b) to the chassis (1a). Tighten the nut (1c) to the
specified torque.
6. Apply the clamp (2a) to the negative battery cable.

7. Ensure that the control lever (3a) is in the open position.
8. Insert the terminal (4a) on the negative pole of the battery. press fully to seat.
9. Turn the lever (3a) by tightening the clamp (4a) on the negative pole. If necessary, rotate the
lever (3a) by turning the hexagonal socket (5a). Check that the cable (1b) follows the correct
path without tension or forcing.
10. Apply gentle pressure to the cable (1b) and check that the clamp (4a) stays correctly hooked.
INSTALLATION > NEGATIVE BATTERY CABLE REMOVAL - 1.6L
NOTE:
Battery terminals must be disconnected only with the ignition key on STOP or removed for at
least one minute and never with key on or when the engine is running.
Fig 1: Negative Battery Pole, Terminal & Release

1. Press the release (1a) and disconnect the terminal (1b) from the negative battery pole (1c).
Fig 2: Ground Lead & Retaining Clip
2. Open the retaining clip (1a) and disengage the ground wire (1b).
Fig 3: Ground Wire, Gearbox & Terminal
4. Remove the under guard protection cover.
5. Remove the screw (1a) and disconnect the ground wire (1b) from the gearbox (1c).
NOTE:
The positioning of the terminal (1b) on the gearbox can change depending on the
type of gearbox installed.
6. Remove the nut (2a) and disconnect the ground wire (1b) from the frame.
7. Recover the ground wire (1b).
8. Check that the ground wire is not damaged and that the individual wires are securely attached
to the connections. If needed, perform continuity checks.
INSTALLATION > NEGATIVE BATTERY CABLE INSTALLATION - 1.6L
Fig 1: Chassis Ground, Nuts & Ground Wire
1. Place the ground cable for installation.
2. Connect the cable terminal to the chassis ground (1a) then screw the nut (1b) and tighten to
the proper torque specification.
3. Connect the terminal to the gearbox of the ground wire (1a) and tighten the nut (2a) to the
proper torque specification.
4. Install the under guard protection covers.
5. Engage the ground lead to the retaining clip.

6. Connect the terminal to the negative post pole and engage the retainer.
CABLES, BATTERY > REMOVAL AND INSTALLATION > 2.0L 4WD REMOVAL AND
INSTALLATION > NEGATIVE BATTERY CABLE REMOVAL - 2.0L
NOTE:
Battery terminals must be disconnected only with the ignition key on STOP or removed for at
least one minute and never with key on or when the engine is running.
1. Press the release (1a) and disconnect the terminal (1b) from the negative battery pole (1c).
2. Open the retaining clip (1a) and disengage the ground wire (1b).
Fig 3: Ground Wire, Gearbox, Screw & Terminal
3. Remove the left front wheel splash shield. Refer to SHIELD, SPLASH, FRONT
4. Remove the screw (1a) and disconnect the ground wire (1c) from the gearbox (1d).
NOTE:
The positioning of the terminal (1b) on the gearbox can change depending on the
type of gearbox installed.
5. Remove the nut (2a) and disconnect the ground wire (1c) from the frame.
6. Recover the ground wire (1c).

7. Check that the ground wire is not damaged and that the individual wires are securely attached
to the connections. If needed, perform continuity checks.
CABLES, BATTERY > REMOVAL AND INSTALLATION > 2.0L 4WD REMOVAL AND
INSTALLATION > NEGATIVE BATTERY CABLE INSTALLATION - 2.0L
1. Position the negative battery cable for installation.

Fig 1: Chassis Ground, Nuts & Ground Wire
2. Connect the cable terminal to the chassis ground (1a), then screw the nut (1b) and tighten it to
the specified torque.
3. Connect the terminal to the gearbox of the ground wire (1a), then tighten the screw (2a) and
tighten to the specified torque.
4. Install the left front wheel splash shield. Refer to SHIELD, SPLASH, FRONT WHEELHOUSE,
5. Engage the ground lead to the retaining clip.
6. Connect the terminal to the negative battery pole and to engage the retainer.
MODULE, VOLTAGE STABILITY (VSM) > DESCRIPTION AND OPERATION >

Fig 1: Voltage Stabilizer Module
The voltage stabilizer module can be included to support the audio system. The purpose of this module is
to stabilize the voltage level sent to the audio system during the start-up stages, when fluctuations in the
voltage value may occur.
The voltage stabilizer is located behind the glove compartment in front of the passenger's legs.
MODULE, VOLTAGE STABILITY (VSM) > DESCRIPTION AND OPERATION >
Fig 1: Voltage Stabilizer, ETM, BCM & Joint For Steering Wheel Controls
KEY
1. Voltage stabilizer
2. ETM
3. BCM
4. Joint for steering wheel controls
Voltage Stabilizer pinout
Pin Function
3 +30
4 +50 from T20 relay
6 Earth
7 +15
8 +30 OUT
TRAY, BATTERY > REMOVAL AND INSTALLATION > 1.6L - 2.0L REMOVAL AND
INSTALLATION > 1.6L - 2.0L BATTERY TRAY REMOVAL

Fig 1: Battery Tray Cover & Drain Pipe

2. Remove the battery tray cover (1a) with the drain pipe (1b).
Fig 2: Washer Fluid Tank Retainer, Retaining Clip, Clamps, Screws & Battery Tray
3. Disconnect the washer fluid tank retainer (1a) from the tray.
4. Disconnect the wiring retaining clip (2a) from the tray.
5. Open the wiring retaining clamps (3).
6. Remove the screws (4a) and remove the battery tray (4b).
Fig 3: Guard & Screw
7. If necessary, loosen the screw (1a) and remove the guard (1b).
TRAY, BATTERY > REMOVAL AND INSTALLATION > 1.6L - 2.0L REMOVAL AND
INSTALLATION > 1.6L - 2.0L BATTERY TRAY INSTALLATION
1. Check that the battery box with fastening strap battery is not damaged.
2. Check that the battery tray is not damaged.

Fig 1: Guard & Screw
3. If removed, place the guard (1b) and tighten the screw (1a).
Fig 2: Battery Tray, Screws, Retaining Clamps, Clip & Washer Fluid Reservoir Retainer
4. Place the battery tray (1a) with the battery fastening strap, then tighten the screws (1b) to the
specified torque.
5. Apply the wiring retaining clamps (2).
6. Connect the wiring retaining clip retainer (3a).
7. Connect the washer fluid reservoir retainer (4a).

Fig 3: Battery Tray Cover & Drain Pipe
8. Install the battery tray cover (1a) and drain pipe (1b).
9. Install the battery to the battery tray. Refer to BATTERY, REMOVAL AND INSTALLATION .
TRAY, BATTERY > REMOVAL AND INSTALLATION > 2.4L REMOVAL AND
INSTALLATION > 2.4L BATTERY TRAY REMOVAL
Fig 1: Connectors, Nut & Power Plant Unit Mass Injection-Ignition Cable
2. Unscrew the nut (2a) and unplug the power plant unit mass injection-ignition (2b).
Fig 2: Washer Fluid Assembly, Retaining Clips & Bottom Cover
3. Remove the bottom cover (1).
4. Untie the washer fluid assembly (2).
5. Open the wiring retaining clips (3).

Fig 3: Battery Tray & Screws
6. Remove the screws (1a) and remove the battery tray (1b) with the PCM attached.
Fig 4: PCM Battery Tray & Nuts
7. If necessary, remove the nuts (1a) and remove the PCM (1b) battery tray.
8. Check that the battery box is not damaged.
TRAY, BATTERY > REMOVAL AND INSTALLATION > 2.4L REMOVAL AND
INSTALLATION > 2.4L BATTERY TRAY INSTALLATION
1. Check that the battery tray is not damaged.
2. If removed, install the PCM to the battery tray. Tighten the screws to the proper torque
specification.
3. Attach the washer fluid assembly to the battery tray.
4. Install the battery tray to the vehicle.
5. Secure the PCM to the battery tray.
6. Connect the electrical connections to the PCM.
7. Install the battery to the battery tray. Refer to BATTERY, REMOVAL AND INSTALLATION .
Jeep Renegade
Service Manual: CHARGING - SERVICE INFORMATION
The vehicle may be equipped with two types of generators: intelligent or conventional. The petrol
engines of NAFTA version vehicles are equipped with generators with conventional voltage adjustment.
The petrol and diesel engines of EMEA version vehicles are equipped with intelligent generators.
Fig 1: Denso Intelligent Alternator
DENSO intelligent alternator - This alternator is available on the 120 A and 150 A versions in
accordance with the type of engine it is fitted on. This graphic is the alternator fitted on the 1.4 MultiAir
140 HP.
Adjustment voltage 10.6 V-16 V
Rated voltage 13.8 V
Rated current (1800-6000 rpm) 105 A-120 A
Max. speed 18, 000 rpm
Voltage regulator Electronic type (connected with PCM via LIN)

Fig 2: Denso Intelligent Alternator Recharging Wiring Diagram
Fig 3: Denso Conventional Alternator
Denso conventional alternator - This alternator is fitted on the 1.4 MultiAir 160 HP engine of NAFTA
version vehicles.
Adjustment voltage 10.6 V-16 V
Rated voltage 14 V
Rated current (1800-6000 rpm) 85 A-150 A
Maximum continuous speed 18, 000 rpm
Voltage regulator Conventional electronic type

Fig 4: Denso Conventional Alternator Recharging wiring diagram.
1.4L / 2.4L
The starting and charging system comprises the battery, starter motor and the generator.
The starter consists of a DC motor powered by the battery and an electromagnet exciter.
With the ignition key in the ON position, the generator indicator light (LED) on the instrument panel turns
on and power is transmitted to the voltage regulator in the generator.
In these conditions, the exciter circuit (rotor) is enabled to ground provided by the Powertrain Control
Module (PCM).
With the generator in rotation, a magnetic field is generated on the electric circuit (stator) that allows a
three phase AC voltage to be delivered by the diode bridge to the B+ terminal.
The battery is then charged and the PCM receives voltage from the generator hen it reaches the
calibrated specification (13.7 - 14.2 V).
The efficiency of the charging system is controlled by the Body Control Module (BCM):
The PCM sends the voltage signal to the BCM which controls the efficiency of the generator
charging by detecting two parameters: the voltage signal coming from the generator itself, and the
starter motor signal which is also received on the CAN network by the PCM.
The BCM signals the cluster to turn on the insufficient charging warning when the ignition is
switched ON until the voltage is above 5.5 volts. If the voltage drops below 4.5 volts with the
engine above 700 RPMs, the indicator will turn on accompanied by a display message in the
information center of the cluster.
The startup logic is also implemented by PCM located in the engine compartment.
1.6L / 2.0L With STOP / START

Module (PCM).
This engine uses an electronically controlled generator, equipped with a controller that receives
commands from the PCM: in this way you get the best performance in terms of:
Reduction in fuel consumption and emissions
Improvement of powertrain performance and vehicle dynamics
The Start & Stop system automatically shuts down the engine whenever the vehicle is stationary and
restarts it when the driver intends to resume driving.
The system is essentially based on a starter system (battery and starter) being able to perform, quickly
and relatively quiet, the restarting of the engine and to support a number of starts much higher than that
required for a traditional system.
Strategies for implementation and monitoring of the shutdown and restart of the system is managed by
the PCM and the Body Control Module (BCM) directly or via the CAN network.
The starter is upgraded to a heavy duty cycle starter, and the generator is also upgraded increasing the
capabilities of current delivery.
Besides the changes on the battery, in order to incorporate Start & Stop strategies, an Intelligent Battery
Sensor (IBS) is used. The IBS has the function to monitor the status of the battery and communicate it to
the network nodes or to enable an optimal management of the battery in the framework of the Start &
Stop strategies.
The IBS is located on the negative battery terminal.
A Neutral Position Sensor is mounted on the gearbox providing output from the sensor to a controller
concerning gear range position.
Automatic shutdown and restart of the motor are marked by a specific indicator on the instrument cluster.
If the indicator is flashing, this indicates a possible fault with the Start & Stop system.
The device is activated / deactivated manually via the switch between the controls next to the gear
lever.
DIAGNOSIS AND TESTING > DIAGNOSIS AND TESTING - CHARGING SYSTEM

The following procedures may be used to diagnose the charging system if:
the check gauges lamp (if equipped) is illuminated with the engine running
the voltmeter (if equipped) does not register properly
an undercharged or overcharged battery condition occurs.
Remember that an undercharged battery is often caused by:
accessories being left on with the engine not running
a faulty or improperly adjusted switch that allows a lamp to stay on. Refer to the IGNITION-OFF
DRAW TEST for more information.
DIAGNOSIS AND TESTING > DIAGNOSIS AND TESTING - CHARGING SYSTEM >
DIAGNOSIS AND TESTING - ON-BOARD DIAGNOSTIC SYSTEM
The Body Control Module (BCM) monitors critical input and output circuits of the charging system,
making sure they are operational. A Diagnostic Trouble Code (DTC) is assigned to each input and output
circuit monitored by the OBD system. Some circuits are checked continuously and some are checked
only under certain conditions.
If the OBD system senses that a monitored circuit is bad, it will put a DTC into electronic memory. The
DTC will stay in electronic memory as long as the circuit continues to be bad. The BCM is programmed
to clear the memory after 40 good trip if the problem does not occur again.
The following procedures may be used to diagnose the charging system if:
the check gauges lamp or battery lamp is illuminated with the engine running
the voltmeter (if equipped) does not register properly
an undercharged or overcharged battery condition occurs.
Remember that an undercharged battery is often caused by:
accessories being left on with the engine not running
a faulty or improperly adjusted switch that allows a lamp to stay on. Refer to Ignition-Off Draw Test,
see BATTERY, STANDARD PROCEDURE .
loose generator belt.
INSPECTION
The Body Control Module (BCM) monitors critical input and output circuits of the charging system,
making sure they are operational. A Diagnostic Trouble Code (DTC) is assigned to each input and output
circuit monitored by the On-Board Diagnostic (OBD) system. Some charging system circuits are
checked continuously, and some are checked only under certain conditions.
Refer to the DTC INDEX article for more DTC information. This will include a complete list of DTC's
including DTC's for the charging system.
To perform a complete test of the charging system, refer to the appropriate Diagnostic Service
Procedures and the scan tool. Perform the following inspections before attaching the scan tool.
1. Inspect the battery condition. Refer to BATTERY for procedures.
2. Inspect condition of battery cable terminals, battery posts, connections at engine block, starter
solenoid and relay. They should be clean and tight. Repair as required.
3. Inspect all fuses in both the Body Control Module (BCM) and Power Distribution Center (PDC)
for tightness in receptacles. They should be properly installed and tight. Repair or replace as
required.
4. Inspect generator mounting bolts for tightness. Replace or tighten bolts if required, refer to
SPECIFICATIONS .
5. Inspect generator drive belt condition and tension.
6. Inspect automatic belt tensioner (if equipped). Refer to the ENGINE COOLING SYSTEM for
more information.
7. Inspect generator electrical connections at generator field, battery output, and ground terminal
(if equipped). Also check generator ground wire connection at engine (if equipped). They
should all be clean and tight. Repair as required.
DIAGNOSTIC TROUBLE CODES
A DTC description can be read using the scan tool. Refer to the appropriate Diagnostic Service
Information .
A DTC does not identify which component in a circuit is bad. Thus, a DTC should be treated as a
symptom, not as the cause for the problem. In some cases, because of the design of the diagnostic test
procedure, a DTC can be the reason for another DTC to be set. Therefore, it is important that the test
procedures be followed in sequence, to understand what caused a DTC to be set.
ERASING DIAGNOSTIC TROUBLE CODES
The Scan Tool must be used to erase a DTC.
SPECIFICATIONS > GENERATOR
1.4 Turbo MultiAir 2.4 MultiAir 1.6 16V Multijet 2.0 16V Multijet
Rated voltage (V) 13.8 - 13.8 (**) 13.8

120 (**)
Rated current (A) 120 - LIN HS100 (**)
150 (****)
Voltage regulator
LIN HS100 - LIN HS100 (**) LIN HS100
(type)
Regulation voltage at
- - - -
20 ° C (V)
(*) 170hp and 140HP Start & Stop to light tropic market
(**) Start & Stop versions
(***) Four-wheel drive versions with Start Stop market & tropic light
(****) Versions for Cold Countries
SPECIFICATIONS > TORQUE SPECIFICATION

TORQUE SPECIFICATION
Generator M12 70 52
Generator M8 25 18.5
Battery Nut M8 14 10.5
Battery Box Screw M8 20 15
Ground Cable 14 10.5
Ground Cable Side Post 16 12
GENERATOR > REMOVAL AND INSTALLATION > 1.4L REMOVAL AND

2. Remove the air conditioner compressor. Refer to COMPRESSOR, A/C, REMOVAL AND
INSTALLATION .
Fig 1: Electrical Connections & Generator
3. Disconnect the electrical connections (1a) and (1b) from the generator (1c) after removing the
nuts.
Fig 2: PTU Motor, Screws & Electrical Connection
4. Drain the oil from the gearbox to rear wheel drive.
5. Remove the four screws (1a) of PTU motor (1b).
6. Remove the motor from the PTU.
7. Disconnect the electrical connection (3a) from the PTU motor.
8. Remove the PTU.
NOTE:
Replace the PTU motor o-ring whenever the motor is removed / replaced.
NOTE:
Ensure dust and dirt from getting into the box of the transfer case.
Fig 3: Upper & Lower Generator Bolts
9. Remove the upper (1b) and Lower (1a) generator (1c) bolts.
Fig 4: Electrical Connections & Alternator
10. Disconnect the electrical connections then remove the alternator (1c).
11. Check that the alternator is not damaged.

Fig 1: Alternator & Electrical Connection
1. Enter in the alternator (1b), and connect the electrical connection (1a).
Fig 2: Top & Lower Alternator Mounting Screws
2. Tighten the screw at the top (1b) and the lower mounting screw (1a) of the alternator (1c), and
tighten them to the specified torque.
Fig 3: PTU Motor, Electrical Connection & Screws
3. Replace the o-ring motor PTU (1a) before reinstalling it in place.
4. Connect the electrical connection (2a) of the motor PTU.
5. Plug in the motor PTU (1a) by engaging its connecting shaft.
6. Tighten the four screws (4a) of motor fixing PTU (1a).
7. Add oil to the gearbox rear-wheel drive.

Fig 4: Alternator & Electrical Connections
8. Connect the electrical connections (1a) and (1b) of the alternator (1c) and tighten the relevant
nuts.
9. Charge the AC system. Refer to COMPRESSOR, A/C, REMOVAL AND INSTALLATION .

INSTALLATION > INSTALLATION > EMEA 1.4L PROGRAMMING
Using the diagnostic scan tool, perform the following procedure once a new generator has been
installed:
1. Select ECM View
2. Select MISC FUNCTIONS
3. Select the Intelligent Alternator (IAM) replacement routine and follow the prompts on the
scan tool.

1. Hoist the vehicle.
2. Disconnect the negative battery terminal.
3. Drain the engine coolant

Fig 1: Generator & Bolt
4. Remove the lower generator bolt (1a).

5. Lower the vehicle on the hoist.
Fig 2: Plug Control Unit & Nut
6. Working behind the engine, remove the nut (1a) and move the plug control unit (1b) out of the
way.
Fig 3: Injection ECU, Wiring Clamp & Electrical Connections
7. Disconnect the injection ECU (1c) electrical connections (1a, 1b).
8. Open the wiring clamp (2a).

Fig 4: Pressure Sensor, Nuts, Ground Wire Terminal, Clips, Screws & Injection Control Unit
9. Remove the nuts (3a) and move the particulate filter pressure sensor (3b) out of the way,
complete with bracket.
10. Remove the nut and disconnect the ground wire terminal (1a).
11. Open the various retainer clips (2a) and free the wiring (2b) from the support (2c) of the
injection control unit.
12. Remove the nuts (3a) and screws (3b), then remove the injection control unit media (2c).
Fig 5: Spring Retainer, Quick Coupling & Coolant Pipe
13. Operating in the compartment of the injection control unit, disengage the spring retainer (1a)
and disconnect the quick coupling (1b) of the return engine coolant pipe (1c) from the heater.
14. Move the pipe (1c) out of way.

Fig 6: Heat Exchanger, Quick Coupling, Pipe & Electrical Connector
15. Working from the top of the engine, the heat exchanger motor oil (1a), disengage the spring
retainer and disconnect the quick coupling (1b) of the pipe (1c).
16. Disconnect the electrical connection (2a) of the pressure sensor on the engine oil heat
exchanger.
Fig 7: Generator, Electrical Connections, Screws & Spacer
17. Working behind the right rear of the engine, disconnect the electrical connections (1a, 1b) of
the generator (1c).
18. Working on the left side of the generator (1c) unscrew its top screw (2a) and loosen the screw
(2b) of the spacer (2c).
19. Remove the generator (1c) out of the compartment of the injection control unit.
20. Check that the generator is not damaged.

1. Place the generator for installation.

Fig 1: Generator & Screws

2. Tighten the screws (2a) to the specified torque.
Fig 2: Electrical Connections & Generator
3. Connect the electrical connections (1a, 1b) to the generator (1c).

Fig 3: Electrical Connection, Quick Coupling, Pipe & Heat Exchanger
4. Connect the electrical connection (1a) of the pressure sensor on the engine oil heat
exchanger.
5. Connect the quick coupling (2a) of the pipe (2b) to the heat exchanger motor oil (2c) and then
bind the spring retainer.
Fig 4: Coolant Pipe, Quick Coupling & Spring Retainer
6. Position the return engine coolant pipe (1a) from the heater and connect the quick coupling
(1b) and then bind the spring retainer (1c).
Fig 5: Support, Nuts, Screws, Wiring & Retaining Straps
7. Place the injection control unit support (1a) and tighten the nuts (1b) and screws (1c).
8. Connect the wiring (2a) to the injection ECU support (1a) and apply various retaining straps
(2b).
9. Connect the ground wire and screw the nut (3a).

Fig 6: Pressure Sensor, Nuts & Retaining Clip
10. Place the particulate filter pressure sensor (1a), complete with bracket, then screw the nuts
(1b).
11. Place the harness and apply the retaining clip (2a).
12. Place the unit plugs and screw the nut.
13. Refill the engine cooling circuit.

14. Connect the battery.
15. Remove the car from the bridge lifting.

1. Hoist the vehicle.
2. Disconnect the negative battery terminal.
3. Drain the engine coolant

Fig 1: Generator & Bolt
4. Remove the lower generator bolt (1a).
5. Lower the vehicle on the hoist.

6. Working behind the engine, remove the nut (1a) and move the plug control unit (1b) out of the
way.
Fig 3: Injection ECU, Electrical Connections, Nuts, Clamp & Pressure Sensor
7. Disconnect the injection ECU (1c) electrical connections (1a, 1b)
8. Open the wiring clamp (2a).
9. Remove the nuts (3a) and move the particulate filter pressure sensor (3b) out of the way,
complete with bracket.
Fig 4: Ground Wire Terminal, Electrical Connector, Clips, Wiring, Support, Screws, Nuts &
Injection Control Unit
10. Remove the nut and disconnect the ground wire terminal (1a).
11. Disconnect the PTU electrical connector (2a).
12. Open the various retainer clips (3a) and free the wiring (3b) from the support (3c) of the
injection control unit.
13. Remove the nuts (4a) and screws (4b), then remove the injection control unit media (3c).
Fig 5: Spring Retainer, Quick Coupling & Coolant Pipe
14. Operating in the compartment of the injection control unit, disengage the spring retainer (1a)
and disconnect the quick coupling (1b) of the return engine coolant pipe (1c) from the heater.
15. Move the pipe (1c) out of way.

Fig 6: Electrical Connections, Generator, Screws & Spacers
16. Working behind the right rear of the engine, disconnect the electrical connections (1a, 1b) of
the generator (1c).
17. Working on the left side of the generator (1c) unscrew its top screw (2a) and loosen the screw
(2b) of the spacer (2c).
18. Remove the generator (1c) out of the compartment of the injection control unit.
19. Check that the generator is not damaged.

1. Place the generator for installation.

Fig 1: Generator & Screws

2. Tighten the screws (2a) to the specified torque.
Fig 2: Generator & Electrical Connections
3. Connect the electrical connections (1a, 1b) to the generator (1c).

Fig 3: Injection Control Unit Support, Nuts, Screws, Wiring, Retaining Straps, Electrical
Connector & Ground Wiring
4. Connect the quick return line from the heater and air conditioning to engage the retainer.
6. Connect the wiring (2a) to the injection control unit support (1a) and apply various retaining
straps (2b).
7. Connect the PTU power cord electrical connector (3a), and then engage it to its support.
8. Connect the ground wire (4a) and screw the nut.

Fig 4: Pressure Sensor, Nuts & Retaining Clip
(1b).
11. Place the unit plugs and screw the nut.
12. Refill the engine cooling circuit.
13. Connect the battery.
14. Remove the car from the hoist.

2. Remove the engine beauty cover. Refer to REMOVAL AND INSTALLATION .
3. Remove the right front wheel. Refer to REMOVAL AND INSTALLATION .
4. Remove the accessory drive serpentine belt. Refer to REMOVAL AND INSTALLATION .
Fig 1: Upstream Oxygen Sensor Electrical Connection
5. Disconnect the upstream oxygen sensor electrical connection (1).

Fig 2: Exhaust Manifold Upper Heat Shield Bolts & Bracket
6. Disengage and oxygen sensor wiring and remove the bracket (1).
7. Remove the exhaust manifold upper heat shield bolts (2) and then remove the shield.
Fig 3: Generator Nut & Wiring
8. Remove the nut to disconnect the wiring (1) to the generator.

Fig 4: Upper And Lower Generator Mounting Bolts
9. Remove the upper and lower generator mounting bolts (1).
10. Remove the generator from the engine compartment.

1. Position the generator to the engine compartment for installation.

Fig 1: Upper And Lower Generator Mounting Bolts
2. Install the upper and lowers generator mounting bolts (1).

Fig 2: Generator Nut & Wiring
3. Connect the wiring harness to the generator stud and secure to the generator using a bolt (1).
Fig 3: Exhaust Manifold Upper Heat Shield Bolts & Bracket
4. Install the exhaust manifold heat shield cover (2).
5. Install the oxygen sensor wiring bracket (1).
6. Connect the oxygen sensor wiring (1).

7. Connect the upstream oxygen sensor wiring harness connector to the sensor (1).
8. Install the accessory drive serpentine belt. Refer to REMOVAL AND INSTALLATION .
9. Install the right front wheel. Refer to REMOVAL AND INSTALLATION .
10. Install the engine beauty cover. Refer to REMOVAL AND INSTALLATION .
REGULATOR, VOLTAGE > REMOVAL AND INSTALLATION > 1.6L - 2.0L DIESEL
Fig 1: Retaining Clips & Cover
3. Remove the retaining clips (1a) and remove the cover (1b).
Fig 2: Spacer, Washer, Screws & Voltage Regulator
4. Remove the nut, washer and the spacer (1).
5. Remove the retaining nut and remove the washer (2).
7. Remove the voltage regulator (4).

8. Check that the voltage regulator is not damaged.
REGULATOR, VOLTAGE > REMOVAL AND INSTALLATION > 1.6L - 2.0L DIESEL
Fig 1: Spacer, Washer, Screws & Voltage Regulator

1. Press the brushes (brushes) (1a) and position the voltage regulator (1b) in place.
3. Place the washer and tighten the nut.
4. Place the spacer and washer and tighten the nut.

Fig 2: Retaining Clips & Cover
5. Position the cover and engage the retaining clips.
REGULATOR, VOLTAGE > REMOVAL AND INSTALLATION > 1.6L GAS REMOVAL
1. Remove the generator. Refer to REMOVAL AND INSTALLATION .
Fig 1: Alternator Cover, Internal Retainers & Screws
2. At bench, remove the alternator cover (1a), releasing its three internal retainers (1b) next to
the three screws (1c). In order to disengage the cover retainers, use a blade tool under the
areas (1d) and push outwards, then lift them.
Fig 2: Voltage Regulator, Armature, Blades & Screws
3. Remove the screws (1a) and remove the voltage regulator (1b) from its housing, releasing its
blades (1c) from the armature (1d).
REGULATOR, VOLTAGE > REMOVAL AND INSTALLATION > 1.6L GAS REMOVAL
1. Check that the voltage regulator is not damaged.
Fig 1: Generator Armature
2. Clean the generator armature (1).

Fig 2: Voltage Regulator, Brushes, Armature & Screws
3. Place the voltage regulator (1a) in its housing and engage the brushes (1b) with the armature
(1c).
4. Tighten the screws (2) securing the voltage regulator.
5. Position the cover on the generator and engage the three inner retainers.
6. Install the generator. Refer to REMOVAL AND INSTALLATION .

PULLEY OR FAN, GENERATOR > REMOVAL AND INSTALLATION > 1.6L - 2.0L
DIESEL REMOVAL AND INSTALLATION > GENERATOR PULLEY OR FAN REMOVAL
3. Remove the generator. Refer to GENERATOR, REMOVAL AND INSTALLATION .

Fig 1: Cover & Pulley
4. With the proper tool, pry off the cover (1a) from the pulley (1b) on the generator.
Fig 2: Ribbed Socket, Pulley & Hexagonal Socket
5. Insert the special tool into the ribbed socket (1a) of the pulley (1b).
6. Insert a wrench on the hexagonal socket (2a).
7. Lock the rotation of the alternator using the key in the socket (2a), then using a key on the
tool, unscrew the pulley (1b) from the generator.
8. Check that the pulley is not damaged.
PULLEY OR FAN, GENERATOR > REMOVAL AND INSTALLATION > 1.6L - 2.0L
DIESEL REMOVAL AND INSTALLATION > GENERATOR PULLEY OR FAN
INSTALLATION
Fig 1: Ribbed Socket, Pulley & Hexagonal Socket
1. Position the pulley (1a) on the shaft of the generator, use the tool provided on the ribbed grip
(1b) and a wrench on the hexagonal socket (1c), and tighten.
Fig 2: Cover & Pulley
2. Install the pulley cover.
3. Install the generator. Refer to GENERATOR, REMOVAL AND INSTALLATION .
PULLEY OR FAN, GENERATOR > REMOVAL AND INSTALLATION > 1.6L GAS
1. Remove the generator. Refer to REMOVAL AND INSTALLATION .

Fig 1: Generator Pulley, Socket & Nut
2. At bench, lock the rotation of the generator shaft placing a spanner in the socket (1a), then
remove the nut (1b).
3. Extract the generator pulley.
PULLEY OR FAN, GENERATOR > REMOVAL AND INSTALLATION > 1.6L GAS
1. Check that the generator pulley is not damaged.
2. Place the generator pulley in its housing.

Fig 1: Generator Pulley, Socket & Nut
3. Lock the rotation of the generator shaft placing a spanner in the socket (2a), then tighten the
nut (1b).
4. Place the generator guard, then tighten the two fixing nuts.
5. Install the generator. Refer to REMOVAL AND INSTALLATION .

Service Manual: CIRCUIT TESTING PROCEDURES - Jeep Renegade
NON-DTC-BASED DIAGNOSTICS
WARNING > GENERAL WARNINGS
WARNINGS provide information to prevent personal injury and vehicle damage. Below is a list of
general warnings that should be followed any time a vehicle is being serviced.
WARNING:
Always wear safety glasses for eye protection.
WARNING:
Use safety stands anytime a procedure requires being under a vehicle.
WARNING:
Be sure that the ignition switch is always in the off position, unless the procedure requires it
to be on.
WARNING:
Set the parking brake when working on any vehicle. An automatic transmission should be in
park. A manual transmission should be in neutral.
WARNING:
Operate the engine only in a well-ventilated area.
WARNING:
Keep away from moving parts when the engine is running, especially the fan and belts.
WARNING:
To prevent serious burns, avoid contact with hot parts such as the radiator, exhaust
manifold(s), tail pipe, catalytic converter and muffler.
WARNING:
Do not allow flame or sparks near the battery. Gases are always present in and around the
battery.
WARNING:
Always remove rings, watches, loose hanging jewelry and avoid loose clothing.
DESCRIPTION > CIRCUIT FUNCTIONS
All circuits in the wiring diagrams use an alpha/numeric code to identify the wire and its function. To
identify which circuit code applies to a system, refer to the CIRCUIT IDENTIFICATION CODE CHART.
NOTE:
This chart shows the main circuits only and does not show the secondary codes that may
apply to some models.
CIRCUIT IDENTIFICATION CODE CHART
CIRCUIT CODE 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 MULTIPLE
I NOT USED
J OPEN
K POWERTRAIN CONTROL MODULE
L EXTERIOR LIGHTING
M INTERIOR LIGHTING
N MULTIPLE
O NOT USED
P POWER OPTION (BATTERY FEED)
Q POWER OPTIONS (IGNITION FEED)
R PASSIVE RESTRAINT
S SUSPENSION/STEERING
T TRANSMISSION/TRANSAXLE/TRANSFER CASE
U OPEN
V SPEED CONTROL, WIPER/WASHER
W WIPERS
X AUDIO SYSTEMS
Y TEMPORARY
Z GROUNDS
DESCRIPTION > CIRCUIT INFORMATION
Each wire shown in the wiring diagrams contains a code which identifies the main circuit, a specific
portion of the main circuit, gauge of wire, and color.
As an example, circuit A 2 18 LB/YL is decoded in the following manner:
Circuit Type: A (Battery Feed Circuit)
Circuit Level: 2 (Level Two)
Wire Size: 18 (Eighteen Gauge Wire)
Wire Color: LB/YL (Light Blue with Yellow Tracer)
WIRE COLOR CODE CHART
COLOR CODE COLOR
BL BLUE
BK BLACK
BR BROWN
DB DARK BLUE
DG DARK GREEN
GY GRAY
LB LIGHT BLUE
LG LIGHT GREEN
OR ORANGE
PK PINK
RD RED
TN TAN
VT VIOLET
WT WHITE
YL YELLOW
* WITH TRACER
DIAGNOSIS AND TESTING > WIRING HARNESS TESTING > TROUBLESHOOTING

TOOLS
When diagnosing a problem in an electrical circuit there are several common tools necessary. These
tools are listed and explained below:
Voltmeter
The voltmeter is used to measure the electrical pressure or the voltage difference between two points. A
voltmeter reads available voltages such as battery voltage, generator output voltage, and voltage drop
across a component or conductor. A high voltage drop may indicate a high resistance in the circuit. The
voltmeter can be used to locate an open circuit and circuits with an unintentional ground. Observing
polarity, always connect a voltmeter in parallel to the existing circuit. If the leads are reversed on a
digital multimeter, a minus sign appears in the display.
CAUTION:
Most of the electrical components used in today's vehicles are Solid State. When checking
voltages in these circuits, use a meter with a 10 - megohm or greater impedance rating.
Ohmmeter
The ohmmeter is used to measure the resistance of a component or the resistance between two points
in a circuit in ohms, and to check a portion of the circuit for continuity. Some meters have a built-in tone
to indicate that the circuit has continuity. No resistance indicates a short circuit or unintentional ground
whereas resistance that is higher than specification indicates a high resistance in the circuit such as a
loose, dirty or corroded connection, or a defective component. An "OL" reading means that the circuit or
component had infinite resistance; an open circuit or defective component is indicated. Ohmmeters have
an internal battery and must never be connected to a power circuit. Connecting an ohmmeter to a
powered circuit causes the meter fuse to blow and can damage its dry cell battery. Ohmmeters can be
connected into a circuit without regard to polarity, unless the circuit contains a diode. When using an
ohmmeter, the component or portion of the circuit must be isolated from other components or branches
to avoid false readings.
CAUTION:
Most of the electrical components used in today's vehicles are Solid State. When checking
resistance in these circuits use a meter with a 10 - megohm or greater impedance rating. In
addition, make sure the power is disconnected from the circuit. Circuits that are powered up
by the vehicle's electrical system can cause damage to the equipment and provide false
readings.
Ammeter
Amperage or current is the measure of the rate of electron "flow" in a circuit. It is measured in the unit of
the Ampere, simply called an Amp (A). In order to measure current in a circuit, the circuit must be broken
or opened, and an ammeter must be inserted in series (in-line) with the circuit so that all the current that
flows through the circuit will have to go through the meter. When measuring current in this manner, it
requires the meter be made part of the circuit, this type of measurement is more difficult than measuring
either voltage or resistance.
When an ammeter is placed in series with a circuit, it ideally drops no voltage as current goes through it.
In other words, it acts very much like a piece of wire, with very little resistance from one test probe to
the other. Consequently, an ammeter will act as a short circuit if placed in parallel (across the terminals
of) a substantial source of voltage. If this is done, a surge in current will result, potentially damaging the
meter. Ammeters are generally protected from excessive current by means of a small fuse located inside
the meter housing. If the ammeter is accidently connected across a substantial voltage source, the
resultant surge in current will "blow" the fuse and render the meter incapable of measuring current until
the fuse is replaced.
Consult the owner's manual of the particular model of meter you own for details on measuring current.
CAUTION:
Do not crank the engine or turn on any accessories that may draw more than 10 Amps. You
may open the protective fuse in the multimeter.
12-Volt Test Light
The 12-Volt test light when properly used, is one of the best and quickest pieces of test equipment
available for troubleshooting 12-volt power systems. It's especially good for times when there are only
two voltages, battery voltage and no voltage. For example, if you're checking to see if you have 12 volts
on the Battery(+), the test light will immediately tell you if voltage is present or not.
With any test equipment, you should confirm that it's in good working order before you begin testing. For
a test light, you have to have a voltage source. Connect the test light's ground clip to a good ground and
touch it to a point where you believe that there is 12-volt supply. If the light doesn't light up, check the
light by connecting it directly across the battery. Initially, make sure that you have the ground clip on the
negative battery terminal. If you touch the probe to the positive terminal, the test light should light up. If it
doesn't and the battery is not completely dead, the test light isn't working properly. The test light must be
in proper working order before any circuit testing can occur.
Jumper Wire
The sole purpose of the jumper wire is to complete a circuit. It is nothing more than a suitable length of
insulated wire with terminals or connectors on each end. Jumper wires may be bought or made with
various sizes of wire and styles of terminals including alligator clips, spade lugs and pin plugs, and should
include a fuse device of some type for circuit and component protection. A jumper wire is used to verify
a faulty conductor by substituting a known good one. It is jumped across a suspicious conductor in the
circuit. If the circuit works with the jumper, but not without, there is an open somewhere in the area being
jumped. A jumper wire is ONLY used to bypass a faulty conductor (including switches and connectors).
NEVER bypass a load device with a jumper wire. The circuit needs the resistance from the load device
and shorting across it causes high current flow, which could damage other components.
WARNING:
Never use a jumper wire across a load, such as a motor, connected between a battery feed
and ground.
Fig 1: Probing Tool
1 - SPECIAL TOOL 6801
2 - PROBING END
Probing Tools
These tools are used for probing terminals in connectors. Select the proper size tool from Special Tool
Package (special tool #6807, Terminal Tools) and insert the probing end (2) into the terminal being
tested. Use the other end of the tool (1) to insert the meter probe.
DIAGNOSIS AND TESTING > WIRING HARNESS TESTING > INTERMITTENT AND
POOR CONNECTIONS
Most intermittent electrical problems are caused by faulty electrical connections or wiring. It is also
possible for a sticking component or relay to cause a problem.
Before condemning a component or wiring assembly, check the following items:
Connectors are fully seated
Spread terminals, or terminal push out
Terminals in the wiring assembly are fully seated into the connector/component and locked into
position
Dirt or corrosion on the terminals. Any amount of corrosion or dirt could cause an intermittent
problem
Damaged connector/component casing exposing the item to dirt or moisture
Wire insulation that has rubbed through causing a short to ground
Some or all of the wiring strands broken inside of the insulation
DIAGNOSIS AND TESTING > WIRING HARNESS TESTING > TROUBLESHOOTING

WIRING PROBLEMS
When troubleshooting wiring problems there are six steps which can aid in the procedure. The steps are
listed and explained below. Always check for non-factory items added to the vehicle before doing any
diagnosis. If the vehicle is equipped with these items, disconnect them to verify these add-on items are
not the cause of the problem.
Perform the following Six Step Diagnosis Process:
1. Verify the problem.
2. Verify any related symptoms. Do this by performing operational checks on components that are
in the same circuit (Refer to the SYSTEM WIRING DIAGRAMS article).
3. Analyze the symptoms. Use the wiring diagrams to determine what the circuit is doing, where
the problem most likely is occurring and where the diagnosis will continue.
4. Isolate the problem area.
5. Repair the problem area.
6. Verify the proper operation. For this step, check for proper operation of all items on the
repaired circuit (Refer to the SYSTEM WIRING DIAGRAMS article).
NOTE:
The Six Step Diagnosis Process used by Chrysler is a time proven process. The basic
concepts of this process have been used by others for problem solving for many years. The
successful application of this process requires a solid understanding of the conditions that
affect each step, and when its time to advance to the next step. These conditions based on
experience formulate what is known as "Best Practices".
STANDARD PROCEDURE > CHECK A 12-VOLT FUSED BATTERY B(+) CIRCUIT FOR
VOLTAGE > THEORY OF OPERATION
Fig 1: Checking 12-Volt Fused Battery B(+) Circuit For Voltage
The purpose of the following procedure(s) is to demonstrate how to check the voltage of a 12-volt fused
battery B(+) circuit with a test light or voltmeter.
NOTE:
The circuit shown in illustration is an example, and is intended for demonstrational purpose
only.
The following are circuit tests covered in this procedure:
Testing 12-Volt Fused Battery B(+) Circuit Voltage With A Test Light
Testing 12-Volt Fused Battery B(+) Circuit Voltage With A Voltmeter
NOTE:
Perform the following test using a known good test light or functioning multimeter:
Below is a list of possible causes that could be related to a No Voltage condition.
Possible Causes
OPEN CIRCUIT (CHAFED, PIERCED, PINCHED OR BROKEN WIRES)
OPEN FUSE
OPEN IN-LINE CONNECTOR (BENT, PUSHED OUT OR CORRODED TERMINALS)
STANDARD PROCEDURE > CHECK A 12-VOLT FUSED BATTERY B(+) CIRCUIT FOR
VOLTAGE > DIAGNOSTIC TEST
1. TESTING 12-VOLT FUSED BATTERY B(+) CIRCUIT VOLTAGE WITH A TEST LIGHT
Fig 1: Testing 12-Volt Fused Battery B(+) Circuit Voltage With Test Light
NOTE:
Before testing any circuits, first verify the 12-volt test light is operating properly.
Connect the 12-volt test light to battery ground or to any other known good ground.
Touch the lead of the test light to Battery(+). If the test light is operational, it should
illuminate brightly.
2. Disconnect the wire harness connector from the component that is being tested.
NOTE:
Check connectors - Clean/repair as necessary.
3. At this time, leave all in-line connectors connected.

4. Connect the 12-volt test light to a known good ground.
5. Use the test light lead to carefully probe the Battery or Ignition voltage circuit in the
harness connector.
6. First check with the ignition off, next check with the ignition on, and lastly check while
cranking the engine.
Yes
1. The circuit is not open at this time or the condition that originally caused the
open may not be present at this time. Continue to monitor the test light and
wiggle the wire harness and connectors to check for an intermittent open or
excessive resistance condition.
2. Use the wiring diagram as a guide to trace the circuits and look for any in-line
connectors where the open could occur intermittently.
3. Look for any chafed, pierced, pinched, or partially broken wires.
4. Look for broken, bent, pushed out or corroded terminals. Verify that there is
good pin to terminal contact in the related wire harness connectors.
5. Perform any Technical Service Bulletins (TSBs) that may apply.
No
1. Repair the open in the circuit. Use the wiring diagram as a guide to trace the
circuit and look for any in-line connectors where the open could occur.
2. One method to help isolate the open is to disconnect any in-line connectors
and measure the resistance from one side of the in-line connector to the
matching component harness connector. If the open goes away, the open is on
the other side of the in-line connector.
3. If this is a fused circuit, make sure to inspect the fuse. If the fuse is open,
check the circuit for a short to ground before installing a new fuse. The circuit
may have a short to ground causing the fuse to open. This short to ground
could be in the wire harness or in one of the components the circuit is supplying
voltage to.
2. TESTING 12-VOLT FUSED BATTERY B(+) CIRCUIT VOLTAGE WITH A VOLTMETER

Fig 2: Testing 12-Volt Fused Battery B(+) Circuit Voltage With Voltmeter
NOTE:
The connector displayed in the graphics are only an example.
NOTE:
3. At this time leave all in-line connectors connected.
4. Use a multimeter set to measure DC voltage.

5. Connect the ground lead of the meter to a known good ground.
6. Use the positive lead of the multimeter and probe the circuit that is being checked for
voltage.
7. Ignition on, engine not running.
Is the voltage within specifications for this circuit?
Yes
1. The circuit is functioning properly or the condition that originally caused the
open or short may not be present at this time. Continue to measure the voltage
and wiggle the wire harness and connectors while checking for an intermittent
open or short.
connectors where the short could occur intermittently.
No
1. Repair the open or short to ground in the circuit. Use the wiring diagram as a
guide to trace the circuits and look for any in-line connectors where the short
could occur.
2. One method to help isolate the open or short is to disconnect any in-line
connectors that the circuit being checked runs through and check for the
voltage again. If the voltage is present, the open or short is on the other side of
the in-line connector.
STANDARD PROCEDURE > CHECK A 12-VOLT SWITCHED BATTERY B(+) CIRCUIT

FOR VOLTAGE > THEORY OF OPERATION
Fig 1: Checking 12-Volt Switched Battery B(+) Circuit For Voltage
The purpose of the following procedure is to demonstrate how to check the voltage of a 12-Volt switched
battery B(+) circuit with a test light or voltmeter.
NOTE:
only.
Testing 12-Volt Switched Battery B(+) Circuit Voltage With A Test Light
Testing 12-Volt Switched Battery B(+) Circuit Voltage With A Voltmeter
NOTE:
Possible Causes
OPEN FUSE
FAULTY SWITCH
STANDARD PROCEDURE > CHECK A 12-VOLT SWITCHED BATTERY B(+) CIRCUIT

FOR VOLTAGE > DIAGNOSTIC TEST
1. TESTING 12-VOLT SWITCHED BATTERY B(+) CIRCUIT VOLTAGE WITH A TEST LIGHT
Fig 1: Testing 12-Volt Switched Battery B(+) Circuit Voltage With Test Light

NOTE:
NOTE:
3. At this time, leave all in-line connectors connected.
5. Use the test light lead to carefully probe the Battery or Ignition voltage circuit in the
harness connector.
6. First check with the ignition off, next check with the ignition on, and lastly check while
cranking the engine.
Yes
1. The circuit is not open at this time or the condition that originally caused the
open may not be present at this time. Continue to monitor the test light and
wiggle the wire harness and connectors to check for an intermittent open or
excessive resistance condition.
No
1. Repair the open in the circuit. Use the wiring diagram as a guide to trace the
2. One method to help isolate the open is to disconnect any in-line connectors
and measure the resistance from one side of the in-line connector to the
matching component harness connector. If the open goes away, the open is on
the other side of the in-line connector.
3. If this is a fused circuit, make sure to inspect the fuse. If the fuse is open,
check the circuit for a short to ground before installing a new fuse. The circuit
may have a short to ground causing the fuse to open. This short to ground
could be in the wire harness or in one of the components the circuit is supplying
voltage to.
2. TESTING 12-VOLT SWITCHED BATTERY B(+) CIRCUIT VOLTAGE WITH A VOLTMETER

Fig 2: Testing 12-Volt Switched Battery B(+) Circuit Voltage With Voltmeter
NOTE:
The connector displayed in the graphics are only an example.
NOTE:
4. Use a multimeter set to measure DC voltage.
voltage.
Is the voltage within specifications for this circuit?
Yes
1. The circuit is functioning properly or the condition that originally caused the
open or short may not be present at this time. Continue to measure the voltage
and wiggle the wire harness and connectors while checking for an intermittent
open or short.
No
1. Repair the open or short to ground in the circuit. Use the wiring diagram as a
guide to trace the circuits and look for any in-line connectors where the short
could occur.
2. One method to help isolate the open or short is to disconnect any in-line
connectors that the circuit being checked runs through and check for the
voltage again. If the voltage is present, the open or short is on the other side of
the in-line connector.
STANDARD PROCEDURE > CHECK A 5-VOLT SUPPLY CIRCUIT FOR VOLTAGE >
THEORY OF OPERATION
Fig 1: Checking 5-Volt Supply Circuit For Voltage
The purpose of the following procedure is to demonstrate how to check the voltage of a 5-Volt supply
circuit with a voltmeter.
NOTE:
only.
Testing A 5-Volt Supply Circuit For Voltage
Testing A 5-Volt Supply Circuit And Sensor Ground Circuit
NOTE:
Perform the following test using a known good multimeter:
Possible Causes
ELECTRONIC CONTROL MODULE (5-VOLT SUPPLY OUTPUT)
STANDARD PROCEDURE > CHECK A 5-VOLT SUPPLY CIRCUIT FOR VOLTAGE >
DIAGNOSTIC TEST
1. TESTING A 5-VOLT SUPPLY CIRCUIT FOR VOLTAGE

Fig 1: Testing 5-Volt Supply Circuit For Voltage With Voltmeter

2. Disconnect the sensor harness connector.
NOTE:
4. Set the multimeter to measure DC voltage.
5. Connect the negative lead of the multimeter to a known good ground.
6. With the positive lead of the multimeter, carefully probe the 5-volt supply circuit.
Is the voltage between 4.7 and 5.2 volts?
Yes
1. Go To Step 2
No
1. Check the 5-volt supply circuit for an open or short to ground. For further
assistance, perform the appropriate Sensor Reference Voltage DTC diagnostic
procedure.
2. TESTING A 5-VOLT SUPPLY CIRCUIT AND SENSOR GROUND CIRCUIT

Fig 2: Testing 5-Volt Supply Circuit And Sensor Ground Circuit
1. With the multimeter set to measure DC voltage.
2. Move the negative lead of the multimeter to carefully probe the sensor ground or
sensor return circuit in the harness connector.
3. With the positive lead of the multimeter, carefully probe the 5-volt supply circuit.
Is the voltage between 4.7 and 5.2 volts?
Yes
1. At this time the 5-Volt Supply and sensor ground circuit are working properly.
Continue to measure the voltage between the wires, wiggle the wire harness
and connectors while checking for an intermittent condition.
No
1. Repair the open or excessive resistance in the Sensor Ground (Sensor Return)
circuit.
STANDARD PROCEDURE > CHECK A CIRCUIT FOR A SHORT TO GROUND >

THEORY OF OPERATION
Fig 1: Checking Circuit For A Short To Ground
The purpose of the following procedure is to demonstrate how to check a circuit for a Short to Ground.
NOTE:
only.
Testing For A Short To Ground Using An Ohmmeter
NOTE:
Below is a list of possible causes that could be related to a Short to Ground condition.
Possible Causes
SHORTED CIRCUIT (CHAFED, PIERCED OR PINCHED WIRES)
SHORTED IN-LINE CONNECTOR (BENT, PUSHED OUT OR CORRODED TERMINALS)
STANDARD PROCEDURE > CHECK A CIRCUIT FOR A SHORT TO GROUND >

DIAGNOSTIC TEST
TESTING FOR A SHORT TO GROUND USING AN OHMMETER

Fig 1: Testing For A Short To Ground Using An Ohmmeter
NOTE:
Before measuring the resistance of any circuit, first measure the resistance between the two
leads of the multimeter. Take this value and subtract it from the value recorded when
measuring the resistance of the circuit being checked (The meter leads can add 0.5 ohm or
more of total resistance).
2. Disconnect the wire harness connectors from the module and component for the suspected
circuit being shorted to ground.
NOTE:
3. With the component wire harness connectors disconnected, use a meter set to measure Ohms
(Ω), and measure the resistance between the circuit and a known good ground.
4. Use the negative lead of the meter and touch a known good ground.
5. Use the positive lead of the meter and carefully probe the circuit suspected of having the short.
Is the resistance to ground below 10k ohms ?
Yes
1. Repair the short to ground. Use the wiring diagram as a guide to follow the path of the
circuit.
2. One method to help isolate the short is to disconnect any in-line connectors that the
circuit being tested runs through and measure for the short again. If the short goes away,
the short is on the other side of the in-line connector.
No
1. The circuit is not shorted to ground or the condition that originally caused the short may
not be present at this time. Continue to measure the resistance, wiggle the wire harness
and connectors while checking for an intermittent short.
2. Use the wiring diagram as a guide to trace the circuits and look for any in-line connectors
where the short could occur intermittently.
4. Look for broken, bent, pushed out or corroded terminals. Verify that there is good pin to
terminal contact in the related wire harness connectors.
STANDARD PROCEDURE > CHECK A CIRCUIT FOR A SHORT TO VOLTAGE >

THEORY OF OPERATION
Fig 1: Battery Circuit Diagram
The purpose of the following procedure is to demonstrate different methods of checking for a short to
voltage in a circuit. When diagnosing a DTC it might be necessary to verify that proper voltage is on a
circuit or that a circuit is not shorted high.
NOTE:
only.
Testing For A Short To Battery Voltage Using A Voltmeter
Testing For A Short To Switched Battery Voltage Using A Voltmeter
Testing For A Short To Battery Voltage Using A 12-Volt Test Light

Testing For A Short To Switched Battery Voltage Using A 12-Volt Test Light
NOTE:
Below is a list of possible causes that could be related to a Short To Voltage condition.
Possible Causes
STANDARD PROCEDURE > CHECK A CIRCUIT FOR A SHORT TO VOLTAGE >

DIAGNOSTIC TEST
1. TESTING FOR A SHORT TO BATTERY VOLTAGE USING A TEST LIGHT

Fig 1: Testing For A Short To Battery Voltage Using A Test Light
NOTE:
2. Disconnect the wire harness connectors of all components that contain the circuits
that are suspected of having the short.
NOTE:

5. Use the lead of the test light and carefully probe the circuit suspected of having the
short.
WARNING:
When the engine is operating, do not stand in direct line with the fan. Do
not put your hands near the pulleys, belts or fan. Do not wear loose
clothing. Failure to follow these instructions may result in possible serious
or fatal injury.
6. First, check with the ignition off, next with the ignition on, and lastly while cranking the
engine.
Yes
1. Repair the short to voltage. Use the wiring diagram as a guide to trace the
circuits and look for any in-line connectors where the short could occur.
2. One method to help isolate the short is to disconnect any in-line connectors
that the circuit being checked runs through and check for the short again. If the
short goes away, the short is on the other side of the in-line connector.
No
1. The circuit is not shorted to voltage or the condition that originally caused the
short may not be present at this time. Continue to measure the resistance and
wiggle the wire harness to check for an intermittent short.
NOTE:
By disconnecting the wire harness connectors you may have

eliminated the source of the voltage causing the short. Use the wiring
diagram as a guide, check to see if there are any battery circuits in
the same wire harness as the circuit you are testing. It is necessary to
check for a short to those circuits using an ohmmeter. Perform the
Check for a Short Between Multiple Circuits diagnostic procedure.
Refer to STANDARD PROCEDURE .
good pin to terminal contact in the related component and wire harness
connectors.
2. TESTING FOR A SHORT TO SWITCHED IGNITION VOLTAGE USING A TEST LIGHT

Fig 2: Testing For A Short To Switched Ignition Voltage Using A Test Light
NOTE:
that are suspected of having the short.
NOTE:
5. Use the lead of the test light and carefully probe the circuit suspected of having the
short.
WARNING:
or fatal injury.
6. First, check with the ignition off, next with the ignition on, and lastly while cranking the
engine.
Yes
1. Repair the short to voltage. Use the wiring diagram as a guide to trace the
No
short may not be present at this time. Continue to measure the resistance and
NOTE:

good pin to terminal contact in the related component and wire harness
connectors.
3. TESTING FOR A SHORT TO BATTERY VOLTAGE USING A VOLTMETER

Fig 3: Testing For A Short To Battery Voltage Using A Voltmeter
2. Disconnect the wire harness connectors of the components that contain the circuit
that is suspected as having a short.
NOTE:
4. With all the component wire harness connectors disconnected, use a multimeter set
to measure DC voltage.
a short.
Is there any voltage present?
Yes
1. Repair the short to battery voltage. Use the wiring diagram as a guide to trace
the circuits and look for any in-line connectors where the short could occur.
that the circuit being checked runs through and measure for the short again. If
the short goes away, the short is on the other side of the in-line connector.
No
short may not be present at this time. Continue to measure the voltage and
NOTE:


4. TESTING FOR A SHORT TO SWITCHED IGNITION VOLTAGE USING A VOLTMETER
Fig 4: Testing For A Short To Switched Ignition Voltage Using A Voltmeter
that are suspected as being shorted.
NOTE:
4. With all the component wire harness connectors disconnected, use a multimeter set
to measure DC voltage.
6. Use the positive lead of the multimeter and probe the circuit suspected of having the
short.
Is any voltage present?
Yes
1. Repair the short to ignition voltage. Use the wiring diagram as a guide to trace
the circuits and look for any in-line connectors where the short could occur.
No
short may not be present at this time. Continue to measure the voltage and
NOTE:

STANDARD PROCEDURE > CHECK FOR AN OPEN GROUND CIRCUIT > THEORY OF
OPERATION
Fig 1: Checking 12-Volt Switched Battery B(+) Circuit For Voltage
The purpose of the following procedure is to demonstrate how to check the operation of a generic
ground circuit with a test light.
NOTE:
only.
Testing Ground Circuit With Test Light

NOTE:
Perform the following test using a known good test light:
Possible Causes
OPEN GROUND CIRCUIT (CHAFED, PIERCED, PINCHED OR BROKEN WIRE)
STANDARD PROCEDURE > CHECK FOR AN OPEN GROUND CIRCUIT > DIAGNOSTIC
TEST
TESTING GROUND CIRCUIT WITH TEST LIGHT
Fig 1: Testing Ground Circuit With Test Light

NOTE:
Before testing any circuits, first verify the 12-volt test light is operating properly. Connect the
12-volt test light to battery ground or to any other known good ground. Touch the lead of the
test light to Battery(+). If the test light is operational, it should illuminate brightly.
2. Disconnect the wire harness connectors of the components that contain the ground circuit
suspected of containing excessive resistance.
NOTE:
4. With all the component wire harness connectors disconnected, connect the 12-volt test light to
Battery(+).
5. Use the test light lead to lightly probe the ground circuit in the harness connector.
Yes
1. The suspected ground circuit is not open or the condition that originally caused the open
or excessive resistance is not present at this time. Another way to check for an open
would be to use an ohmmeter and measure the resistance of the ground circuit. While
continuing to measure the resistance of the circuit, wiggle the wire harness and
connectors to check for an intermittent open or poor connection.
where the open could occur intermittently.
No
1. Repair the open in the ground circuit. Use the wiring diagram as a guide to trace the
2. One method to help isolate the open is to disconnect any in-line connectors and measure
the resistance from one side of the in-line connector to the matching component harness
connector. If the open goes away, the open is on the other side of the in-line connector.
STANDARD PROCEDURE > CHECK FOR A SHORT BETWEEN MULTIPLE CIRCUITS >
THEORY OF OPERATION
The purpose of the following procedure is to demonstrate how to check for a short circuit between
multiple circuits.
NOTE:
only.
Testing For A Short Between Multiple Circuits

NOTE:
Below is a list of possible causes that could be related to a Multiple Short condition.
Possible Causes
STANDARD PROCEDURE > CHECK FOR A SHORT BETWEEN MULTIPLE CIRCUITS >
DIAGNOSTIC TEST
TESTING FOR A SHORT BETWEEN MULTIPLE CIRCUITS

Fig 1: Testing For A Short Between Multiple Circuits
NOTE:
2. Disconnect the wire harness connectors of the components that contain the circuits that are
suspected of being shorted together.
NOTE:
4. With all the component wire harness connectors disconnected, use a multimeter set to Ohms
(Ω), and measure the resistance between the applicable circuits in one of the harness
connectors.
5. Use one lead of the multimeter and carefully probe the circuit suspected of being shorted.
6. Use the other lead of the meter and one at a time, carefully probe the other circuits in the
harness connector.
Is the resistance below 10k ohms when probing any two circuits?
Yes
1. Repair the short between the circuits. Use the wiring diagram as a guide to trace the
2. One method to help isolate the short is to disconnect any in-line connectors that the
circuit being tested runs through and measure for the short again. If the short goes away,
the short is on the other side of the in-line connector.
No
1. The circuit is not shorted or the condition that originally caused the short may not be
present at this time. Continue to measure the resistance and wiggle the wire harness and
connectors while checking for an intermittent short.
NOTE:
By disconnecting the wire harness connectors you may have eliminated the
source that was causing the short.
where the short could occur intermittently.
STANDARD PROCEDURE > CHECK THE RESISTANCE OF A CIRCUIT USING AN

OHMMETER > THEORY OF OPERATION
The purpose of the following procedure is to demonstrate how to check the resistance of a circuit with
an ohmmeter.
NOTE:
only.
Testing For An Open Circuit Using An Ohmmeter

NOTE:
Below is a list of possible causes that could be related to an Open Circuit condition.
Possible Causes
STANDARD PROCEDURE > CHECK THE RESISTANCE OF A CIRCUIT USING AN

OHMMETER > DIAGNOSTIC TEST
TESTING FOR AN OPEN CIRCUIT USING AN OHMMETER

Fig 1: Testing For An Open Circuit Using An Ohmmeter
NOTE:
2. Disconnect the wire harness connectors of the components that contain the circuit suspected
of being open.
NOTE:
4. With the component wire harness connectors disconnected, use a multimeter set to Ohms (Ω),
and measure the resistance of the circuit.
5. Use one lead of the meter and probe the circuit in one harness connector.
6. Use the other lead of the meter and probe the same circuit in the other harness connector.
Is the resistance in the circuit below 10k ohms?
Yes
1. The circuit does not contain any excessive resistance or the condition that originally
caused the excessive resistance may not be present at this time. Continue to measure
the resistance of the circuit, wiggle the wire harness and connectors to check for an
intermittent open or poor connection.
where the open could occur intermittently.
No
1. Repair the excessive resistance in the circuit between the two wire harness connectors.
Using the wiring diagram as a guide, trace the circuit and check for any in-line
connectors where the open or excessive resistance could occur.
2. One method to help isolate the open is to disconnect any in-line connectors and measure
the resistance from one side of the in-line connector to the matching component harness
connector. If the open or excessive resistance is not present, the open or excessive
resistance is on the other side of the in-line connector.
STANDARD PROCEDURE > CHECK FOR EXCESSIVE CURRENT DRAW > THEORY OF
OPERATION
What is current draw?
Current draw, or parasitic draw is an electrical load that draws current from the battery when the ignition
is turned off. Some are considered normal, some above normal. Normal draw comes from various
electronic devices connected to battery positive at all times. Many vehicle modules draw a few mA
(milliamps) as a means to "Keep Alive Memory". Whether it's the clock in the radio or the last known
position of the memory mirrors, these tiny amounts of current typically will only add up to 20 or 30 mA.
The vehicle can sit parked for days, even a few weeks without any problems of excessive battery drain
that might prevent starting. As long as the vehicle is driven periodically in order for the alternator to
recharge the battery there is no problem. A problem may occur, in situations such as new vehicles in
dealer stock or long term airport parking situations.
Below are some examples of modules and components that require keep alive memory:
Powertrain Control Module (PCM)
Body Control Module (BCM)
Memory Seat Module (MSM)
Radio
What is excessive current draw?
Excessive current draw can be determined by an ammeter reading in excess of 50 mA. The typical
"normal" current draw will not exceed 20 or 30 mA.
How to locate the problem?
Locating the problem involves a process of elimination. If the problem is not obvious, like the trunk light
staying on, you will have to start troubleshooting:
Start by removing one fuse at a time until you see the reading on the meter drop off (be careful to
reinstall the fuses in their proper location).
Once you've determined the high-draw circuit, there still may be a half-dozen loads, each
individually drawing current from the battery.
To zero in on that circuit or circuits, use the schematic diagram and disconnect each device on the
circuit one-at-a-time and check the meter.
When the milliamp reading drops off significantly, you've found the problem.
Perform the following test to determine where the cause of the draw is located:
Possible Causes
INSTALLED AFTERMARKET ACCESSORIES (AUDIO SYSTEMS, VEHICLE ALARMS, ETC.)
COURTESY LIGHTS REMAINING ON (INTERIOR, TRUNK, HOOD, ETC.)
BATTERY CHARGERS PLUGGED INTO THE CIGARETTE LIGHTER/POWER OUTLETS
STANDARD PROCEDURE > CHECK FOR EXCESSIVE CURRENT DRAW >

DIAGNOSTIC TEST
TESTING FOR PARASITIC DRAW

NOTE:
For a more accurate current draw reading, wait 20 minutes to make sure all modules have
powered down before continuing. Some modules may stay powered up longer than others.
Fig 1: Testing For Parasitic Draw Using Multimeter
Turn the ignition off.
1. Disconnect the Negative battery cable (ground).
2. Using a multimeter, set the multimeter leads up to properly measure Amperage.
3. Connect the ground lead that is plugged into the COM port of the multimeter to the Negative
battery post/terminal.
4. Connect the other lead of the multimeter that is plugged into the Amp port of the multimeter to
the Negative battery cable.
CAUTION:
Do not crank the engine or turn on any accessories that may draw more than 10
Amps. You may open the protective fuse in the multimeter.
5. While monitoring the amperage reading on the multimeter, begin to remove fuses (one at a
time) from each fuse location on the vehicle and see if the amperage drops.
NOTE:
1. Only remove one fuse at a time until the cause of the voltage draw is
determined.
2. Many vehicles have multiple fuse locations on the vehicle.
6. If the amperage does not drop, install the fuse you just removed and remove the next fuse.
Does the amperage drop to between 0.02 to 0.04 of an Amp when removing any fuses?
Yes
1. Use the wiring diagram as a guide to help indicate what components or modules are
powered by the fuse.
2. At this point you can install the fuse and begin disconnecting the components powered by
the fuse.
1. When the amperage drops after disconnecting a component this will indicate which
component is at fault.
2. It is important to know how long some modules are designed to remain awake.
3. You don't want to replace a component that is operating normally.
4. The condition that originally caused the draw may not be present at this time.
No
1. The condition that originally caused the draw may not be present at this time.
3. Look for broken, bent, pushed out or corroded ground terminals.
STANDARD PROCEDURE > CIRCUIT LOAD TESTING PROCEDURE

A multimedia supplement to the instructions contained in this
article is available.
To view the multimedia example of the condition described go
to;
then type, "A00705195.vid.1" into the "Search Channel"
box.
STANDARD PROCEDURE > CIRCUIT LOAD TESTING PROCEDURE > THEORY OF

OPERATION
A circuit load test can be performed to test the ability of a circuit to carry the current required to operate
a connected device. A circuit load test should be performed after a circuit has passed a resistance test
using a DVOM and the circuit is still suspected of a failure.
A single copper wire strand will carry enough current to light a test light bulb, while showing very
low resistance using a DVOM.
Some test lights are insufficient for load testing because of the very low resistance bulb being
used.
The Load Test tool listed below will require higher current flow to power the bulb; and this will test
the ability of the circuit to carry a load.
This test will indicate if the circuit being tested can carry the current required to operate a
connected device.
WARNING:
To avoid possible serious or fatal injury, DO NOT load test any air bag/restraint system
components or circuits using the procedures listed here. Refer to the RESTRAINTS -
SERVICE INFORMATION article for proper air bag/restraint system testing procedures.
CAUTION:
Do not load test any circuits with components still connected to the circuit.
NOTE:
Depending upon the location of the circuit in question, this test may require jumper wires.
NOTE:
Use the wiring diagrams as a guide to trace the circuits and look for any in-line connectors
where the circuit failure could occur intermittently. Look for any chafed, pierced, pinched, or
partially broken wires. Look for broken, bent, pushed out or corroded terminals - clean/repair
as necessary. Verify that there is good pin to terminal contact in the related wire harness
connectors.
Fig 1: Load Test Tool
Here is an example of a simple tool you can build to test a circuit`s ability to carry a load.
Fig 2: Load Test Tool Components
The following is a list of components required to build a load test tool:
1. 3156 Bulb
2. 3156 Bulb socket
3. Negative alligator clip with covers
4. Positive alligator clip with covers
5. 2 Amp mini fuse
6. Mini fuse holder
7. 2' to 4' of Black 16ga wire
8. 2' to 4' of Red 16ga wire
9. Approved back probe tool
10. Shrink tubing
11. Solder
STANDARD PROCEDURE > CIRCUIT LOAD TESTING PROCEDURE > LOAD TESTING
A GROUND CIRCUIT
DIAGNOSTIC LOAD TEST (GROUND CIRCUIT)

Fig 1: Performing Diagnostic Load Test (Ground Circuit)
1. Disconnect the connector from the device(s) to gain access and isolate the terminal for the
circuit being tested.
2. Connect the positive lead of the load test tool to the positive side of the battery.
3. Using an approved connector back probe tool, connect the negative lead of the load test tool
to the circuit being tested at point (A).
CAUTION:
Use only approved connector back probe tools when back probing a connector so
as not to cause damage to the terminals or insulation of the connector. Damage to
the terminals can cause poor terminal contact or retention. Damage to the insulation
can introduce corrosion due to water infiltration.
Does the bulb light bright, when compared to a direct battery connection?
Yes
1. The circuit being tested can carry a load, check other circuits, connectors and terminals
for concerns.
No
1. Repair the circuit, connector or terminal that has an open or excessive resistance.
2. Perform any related Recalls or Technical Service Bulletins (TSBs) that may apply.
A BATTERY OR IGNITION FEED CIRCUIT
DIAGNOSTIC LOAD TEST (BATTERY/IGNITION FEED CIRCUIT)
Fig 1: Performing Diagnostic Load Test (Battery/Ignition Feed Circuit)
2. Using an approved connector back probe tool, connect the positive lead of the load test tool to
the circuit being tested at point (A).
3. Connect the negative lead of the load test tool to the negative side of the battery or ground.
CAUTION:
Yes
for concerns.
No
A BATTERY OR IGNITION FEED CIRCUIT AND GROUND CIRCUIT
DIAGNOSTIC LOAD TEST (BATTERY FEED & GROUND CIRCUIT)
Fig 1: Performing Diagnostic Load Test (Battery Feed & Ground Circuit)
2. Using an approved connector back probe tool, connect the positive lead of the load test tool to
the circuit being tested at point (A).
to the circuit being tested at point (B).
CAUTION:
Yes
for concerns.
No
1. Test the circuits individually to determine which circuit is the cause of the test failure.
A CIRCUIT FOR AN OPEN OR HIGH RESISTANCE
DIAGNOSTIC LOAD TEST (OPEN/HIGH RESISTANCE CIRCUIT)
Fig 1: Performing Diagnostic Load Test (Open/High Resistance Circuit)
1. Disconnect all components from the circuit being tested.
2. Connect the positive lead of the load test tool to the positive side of the battery (A).
to the circuit being tested at point (B).
4. Using an approved connector back probe tool, connect a jumper wire to the circuit being tested
at point (C).
5. Then connect the other end of the jumper wire to the negative side of the battery or ground (D).
CAUTION:
Yes
for concerns.
No
STANDARD PROCEDURE > VOLTAGE DROP TEST PROCEDURE > THEORY OF

OPERATION
Voltage drop is the reduction in voltage in an electrical circuit between the voltage source and load
components. The wires and connectors of a circuit should contain almost no resistance and all the
voltage should be consumed through the load. The "load" is the component using the power, such as a
light, starter, or blower motor. If a circuit has excessive resistance, it prevents the wire from carrying
sufficient current under high load conditions. A voltage drop test is an effective way to locate excessive
resistance in connections and circuits.
To perform a voltage drop test, a Digital Volt Ohm Meter (DVOM) is used to measure the voltage drop
across a live circuit or connection while it is under the load. If the circuit or connection being tested has
excessive resistance, the DVOM will measure the voltage that the resistance is using. Little or no
voltage drop should be read, ideally less than 0.2 of a volt , anything greater indicates excessive
resistance and the circuit or connection should be inspected for cleaning or repair.
Possible Causes
EXCESSIVE CIRCUIT RESISTANCE (CHAFED, PIERCED OR CORRODED WIRES)
HIGH RESISTANCE WITH IN-LINE CONNECTOR (BENT, PUSHED OUT OR CORRODED

TERMINALS)
STANDARD PROCEDURE > VOLTAGE DROP TEST PROCEDURE > DIAGNOSTIC
TEST
TESTING FOR VOLTAGE DROP
Fig 1: Testing For Voltage Drop
2. Use the wiring diagram as a guide, trace the circuit being tested and locate the components
related to the circuit.
3. Set the multimeter to measure DC voltage.
4. Carefully back probe the two component harness connectors of the circuit being tested.
WARNING:
When the engine is operating, do not stand in direct line with the fan. Do not put
your hands near the pulleys, belts or fan. Do not wear loose clothing. Failure to
follow these instructions may result in possible serious or fatal injury.
NOTE:
If you are testing the starting circuit, disable the engine so the engine does not start.
5. Crank the engine for five seconds if you are testing the starting circuit and monitor the
multimeter voltage reading.
6. For circuits that don't require the engine running, turn the ignition on.
7. For circuits that require the engine running, start the engine.
NOTE:
If the circuit you are checking needs to be operating, such as the Blower Motor or a
Lamp, do so now.
8. Monitor the voltage reading.
9. The voltmeter will show the difference in voltage between the two points.
Is the voltage less than 0.2 of a Volt?
Yes
1. At this time the circuit is functioning properly. Continue to measure the voltage between
the components and wiggle the wire harness and connectors while checking for an
intermittent condition.
where the excessive resistance could occur intermittently.
No
1. Repair the excessive resistance in the circuit.
2. Use the wiring diagram as a guide to trace the circuit and look for any in-line connectors
where the excessive resistance may occur.

STANDARD PROCEDURE > ELECTROSTATIC DISCHARGE (ESD) SENSITIVE

DEVICES
Fig 1: Electrostatic Discharge Symbol
All ESD sensitive components are solid state and a symbol is used to indicate this. When handling any
component with this symbol, comply with the following procedures to reduce the possibility of
electrostatic charge build up on the body and inadvertent discharge into the component. If it is not known
whether the component is ESD sensitive, assume that it is.
Perform the following procedure when handling ESD sensitive components:
1. Always touch a known good ground before handling the component. This should be repeated
while handling the component and more frequently after sliding across a seat, sitting down from
a standing position, or walking a distance.
2. Avoid touching electrical terminals of the component, unless instructed to do so by a written

procedure.
3. When using a voltmeter, be sure to connect the ground lead first.
4. Do not remove the component from its protective packing until it is time to install the
component.
5. Before removing the component from its package, ground the package to a known good ground
on the vehicle.
STANDARD PROCEDURE > WIRE SPLICING

described go to;
Channel" box.
CAUTION:
If additional wire is needed when making a splice repair to any wire, it is important that the
same or next larger size wire gauge be used. Refer to the appropriate wiring diagram for the
original wire gauge size.
Fig 1: Splice Band
1. Remove 13 millimeters (0.50 inch) of insulation from each wire that needs to be spliced.
2. Place a piece of adhesive sealant-lined heat shrink tubing (Part Number 04778570 or
equivalent) over the wire on one side of the splice. Be certain the length of tubing will be
sufficient to cover and seal the entire repair area.
3. Place the strands of the wires being spliced so that they are overlapping each other within the
splice band (1).
Fig 2: Crimping Tool
4. Using a crimping tool (1) (Mopar® Part Number 05019912AA, Miller Special Tool Number
(special tool #10042, Crimper, Wire/Terminal) or equivalent) crimp the splice band and wires
together securely.
Fig 3: Solder Splice
CAUTION:
Never use acid core solder for electrical wiring repairs.
5. Using Rosin Core type solder (1) only and a suitable soldering iron (3), solder the wire and
splice band connection (2) together.
Fig 4: Heat Shrink Tube
6. Center the heat shrink tubing (2) over the splice joint repair and heat using a suitable heat gun.
Heat the joint until the tubing is tightly sealed and sealant (1) begins to ooze out of both ends of
the tubing.
REMOVAL > CONNECTOR TERMINAL REMOVAL

Fig 1: Removal Of Dress Cover
1 - DRESS COVER
2 - CONNECTOR LOCK
3 - CONNECTOR
1. Disconnect battery.
2. Release Connector Lock (2).
3. Disconnect the connector (3) being repaired from its mating half/component.
4. Remove the dress cover (if applicable) (1).

Fig 2: Connector Secondary Terminal Lock
1 - Secondary Terminal Lock
5. Release the Secondary Terminal Lock, if required (1).

Fig 3: Terminal Removal
1 - TYPICAL CONNECTOR
2 - PICK FROM TERMINAL REMOVER KIT 10300
3 - APEX CONNECTOR
5 - AUGAT CONNECTOR
6 - ELECTRICAL TERMINAL REMOVAL TOOL
7 - MOLEX CONNECTOR
9 - THOMAS AND BETTS CONNECTOR
10 - TERMINAL REMOVER
11 - CONNECTOR
12 - ELECTRICAL TERMINAL REMOVER
6. Position the connector locking finger away from the terminal using the proper special tool. Pull
on the wire to remove the terminal from the connector.
INSTALLATION > CONNECTOR TERMINAL INSTALLATION
1. Select a wire from the terminal repair kit that best matches the color and gauge of the wire
being repaired.
2. Cut the repair wire to the proper length and remove one-half (1/2) inch of insulation.
3. Splice the repair wire to the wire harness (see Wire Splicing procedure). Refer to STANDARD
PROCEDURE .
4. Insert the repaired wire into the connector.
5. Install the connector locking wedge, if required, and reconnect the connector to its mating
half/component.
6. Re-tape the wire harness starting at 1-1/2 inches behind the connector and 2 inches past the
repair.
7. Connect battery and test all affected systems.

Jeep Renegade
Service Manual: HORN SYSTEM - SERVICE INFORMATION
An electrically-operated dual-note horn system is standard factory-installed equipment in this vehicle.

The horn system features one low-note horn unit and one high-note horn unit. The Power Distribution
Center (PDC) contains the horn fuse and the horn relay. Depressing either side of the upper surface of
the Driver AirBag (DAB) trim cover in the center of the steering wheel actuates the horn switch contacts,
which provides the vehicle operator with a convenient, audible signaling device that can be used to alert
pedestrians or the operators of other vehicles in near proximity.
The horn system includes the following major components, which are described in further detail
Horn Relay - The horn relay is an International Standards Organization (ISO) micro relay located
within the Power Distribution Center (PDC). The PDC is located on the left side of the engine
compartment outboard of the battery.
Horns - The low note and high note electromagnetic diaphragm-type trumpet horns are each
secured by a mounting bracket to the right and left fender front lower brackets ahead of each front
wheel house splash shield, below each front combination lamp and behind each outboard end of
the front bumper fascia.
Horn Switch Plate - The floating horn switch plate is secured to the back of the DAB housing
within the steering wheel hub cavity and also serves as the mounting bracket between the DAB
and the steering wheel. The horn switch rotates with the steering wheel and is connected to the
vehicle electrical system through the steering wheel wire harness and a pass-through circuit of the
clockspring at the top of the steering column.
Power Distribution Center - The Power Distribution Center (PDC) is located on the left side of
the engine compartment outboard of the battery. Refer to DESCRIPTION AND OPERATION .
Hard wired circuitry connects the various horn system components to each other through the electrical
system of the vehicle. These hard wired circuits are integral to several wire harnesses, which are routed
throughout the vehicle and retained by many different methods. These circuits may be connected to
each other and to the vehicle electrical system through the use of a combination of soldered splices,
splice block connectors and many different types of wire harness terminal connectors and insulators.
and connector repair procedures, further details on wire harness routing and retention as well as pin out
The horn operates on battery current received from a horn relay located in the Power Distribution Center
(PDC) through a fuse also located in the PDC. The vehicle operator can control typical horn system
signaling through the horn switch within the hub of the steering wheel. When the upper surface of the
Driver AirBag (DAB) trim cover is depressed, it provides a hard wired ground path to the Body Control
Module (BCM). In response to that input the BCM uses a Low Side Driver (LSD) to provide a ground
path to the control coil of the horn relay. The horn system circuit is designed so that the system will
remain operational, regardless of the status of the ignition switch.
The horns can also be activated by the BCM to support each of the following features:
Remote Keyless Entry System - Remote Keyless Entry (RKE) system Lock request audible
verification.
Remote Keyless Entry System - Remote Keyless Entry (RKE) system Panic mode audible alert
for North America Free Trade Agreement (NAFTA) markets only.
Remote Start System - Remote Start System Start request audible verification for North
America Free Trade Agreement (NAFTA) markets only.
Vehicle Theft Alarm - Vehicle Theft Alarm (VTA) audible alarm except in vehicles manufactured for
markets where an alarm siren is required.
The hard wired circuits between components related to the horn system may be diagnosed using
However, conventional diagnostic methods will not prove conclusive in the diagnosis of the horn system
features of the horn system. The most reliable, efficient and accurate means to diagnose the horn
system or the electronic controls and communication related to horn system operation requires the use
of a diagnostic scan tool.
DIAGNOSIS AND TESTING > DIAGNOSIS AND TESTING - HORN SYSTEM
WARNING:
airbag deployment.
NOTE:
A continuously sounding horn is immediately resolved by removing the horn relay from the
Power Distribution Center (PDC).
HORN SYSTEM DIAGNOSIS

HORN SOUNDS 1. Damaged or ineffective 1. Test and repair shorted horn feed
CONTINUOUSLY horn feed circuit. circuit if required.
2. Damaged or ineffective 2. Test and repair shorted horn switch

horn switch return circuit. return circuit if required.
3. Damaged or ineffective 3. Test and replace the shorted

clockspring. clockspring and stalk unit if required.
4. Damaged or ineffective 4. Test and replace the shorted horn

horn switch. switch, mounting plate and DAB unit if
required.
5. Damaged or ineffective 5. Test the horn relay inputs and outputs

horn relay. of the Power Distribution Center (PDC).
Replace the horn relay if required.
6. Ineffective Body Control 6. Use a diagnostic scan tool to test the

Module (BCM) inputs or BCM inputs and outputs. Refer to the
outputs. appropriate diagnostic information.
HORN SOUNDS 1. Damaged or ineffective 1. Test and repair intermittent shorted

INTERMITTENTLY AS THE horn switch return circuit. horn switch return circuit if required.
STEERING WHEEL IS
2. Test and replace the intermittent open
ROTATED 2. Damaged or ineffective
or shorted horn switch, mounting plate and
horn switch.
DAB unit if required.
1. Damaged or ineffective 1. Test and repair open horn ground circuit

horn ground circuit. if required.
2. Damaged or ineffective 2. Test and repair open horn feed circuit if

horn feed circuit. required.
3. Damaged or ineffective
3. Test and replace open horn if required.
horn.
4. Damaged or ineffective 4. Test and repair open horn switch feed

horn switch feed circuit. circuit if required.
5. Damaged or ineffective 5. Test and repair open horn switch return

horn switch return circuit. circuit if required.
HORN DOES NOT SOUND
6. Damaged or ineffective 6. Test and replace the open clockspring
clockspring. and stalk unit if required.
7. Damaged or ineffective 7. Test and replace the open horn switch,

horn switch. mounting plate and DAB unit if required.
8. Test the horn relay inputs and outputs

8. Damaged or ineffective
of the PDC. Replace the horn relay if
horn relay.
required.
9. Ineffective Body Control 9. Use a diagnostic scan tool to test the

Module (BCM) inputs or BCM inputs and outputs. Refer to the
outputs. appropriate diagnostic information.
HORN > DESCRIPTION AND OPERATION > DESCRIPTION AND OPERATION >
DESCRIPTION
Fig 1: Horn, Bracket & Connector Insulator
Electromagnetic diaphragm-type horns are standard equipment on this vehicle. Each trumpet-style horn
(2) is secured to a stamped metal mounting bracket (3). The horn and mounting bracket unit is then
secured by a single screw to the underside of the left (high note) or right (low note) fender front lower
bracket ahead of each front wheel house splash shield, below each front combination lamp and behind
each outboard end of the front bumper fascia.
The horn includes a single connector insulator (1) with two terminal pins integral to the horn. A dedicated
take out and connector of the headlamp and dash wire harness connects the horn to the vehicle
electrical system.
The horn and the mounting bracket are factory-tuned as a unit and; therefore, are serviced only as a
unit. The horn cannot be adjusted or repaired. If the horn or the mounting bracket is ineffective or
damaged, the entire unit must be replaced.
HORN > DESCRIPTION AND OPERATION > DESCRIPTION AND OPERATION >
OPERATION
The horn has a path to ground at all times through its wire harness connection to an eyelet terminal
secured to the body sheet metal. The horn is completely controlled by a fused B(+) output received
through a fuse and the closed contacts of the horn relay located within the Power Distribution Center
(PDC).
Within the two halves of the horn housing are a flexible diaphragm, a plunger, an electromagnetic coil
and a set of contact points. The diaphragm is secured in suspension around its perimeter by the mating
surfaces of the horn housing. The plunger is secured to the center of the diaphragm and extends into the
center of the electromagnetic coil. The contact points control the current flow through the windings of the
electromagnetic coil.
When the horn is energized, electrical current flows through the closed contact points to the
electromagnetic coil. The resulting electromagnetic field draws the plunger and diaphragm toward it until
that movement mechanically opens the contact points. When the contact points open, the
electromagnetic field collapses allowing the plunger and diaphragm to return to their relaxed positions
and closing the contact points again. This cycle continues repeating at a very rapid rate producing the
vibration and movement of air that creates the sound that is directed through the horn trumpet outlet.
The horn as well as the hard wired input circuit for the horn may be diagnosed using conventional
diagnostic tools and procedures. Refer to the appropriate wiring information.
HORN > DIAGNOSIS AND TESTING > DIAGNOSIS AND TESTING - HORN
and connector repair procedures, details of wire harness routing and retention, connector pin out
1. Disconnect the wire harness connector from the horn. Check for continuity between the horn
ground circuit cavity of the harness connector and a good ground. There should be continuity.
If OK, go to Step 2. If not OK, repair the open ground circuit to ground as required.
2. Check for battery voltage at the horn input circuit cavity of the harness connector. There
should be zero volts. If OK, go to Step 3. If not OK, repair the shorted horn output circuit
between the horn and the horn relay in the Power Distribution Center (PDC) as required.
3. Depress the horn switch. There should now be battery voltage at the horn input circuit cavity of
the harness connector for the horn. If OK, replace the ineffective horn. If not OK, perform
further diagnosis of the horn switch, the clockspring, the horn switch input to the Body Control
Module (BCM) and the BCM output to the horn relay in the PDC as required.
HORN > REMOVAL AND INSTALLATION > REMOVAL AND INSTALLATION >
REMOVAL
Fig 1: Horn, Connector & Screw
from the battery.
3. Disengage the front of the appropriate right or left front wheel house splash shield from the
fender and the front bumper fascia and move it far enough to access the horn and mounting
bracket. Refer to SHIELD, SPLASH, FRONT WHEELHOUSE, REMOVAL AND INSTALLATION
.
4. Reach behind the appropriate right or left outboard end of the front bumper fascia to access
and disconnect the headlamp and dash wire harness connector (1) for the horn from the horn
connector.
5. Remove the screw (2a) that secures the horn (2b) mounting bracket to the underside of the left
(high note) or right (low note) fender front lower bracket.
6. Remove the horn and mounting bracket from the vehicle as a unit.
HORN > REMOVAL AND INSTALLATION > REMOVAL AND INSTALLATION >
INSTALLATION
Fig 1: Horn, Connector & Screw
1. Reach behind the appropriate right or left outboard end of the front bumper fascia to position
the horn and mounting bracket unit (2b) to the underside of the left (high note) or right (low
note) fender front lower bracket. Be certain to engage the anti-rotation tab of the horn mounting
bracket with the anti-rotation clearance hole in the fender front lower bracket.
2. Install and tighten the screw (2a) that secures the horn mounting bracket to the fender front
lower bracket. Tighten the screw securely.
3. Connect the headlamp and dash wire harness connector (1) to the horn connector.
4. Install the front of the appropriate right or left front wheel house splash shield to the fender and
the front bumper fascia. Refer to SHIELD, SPLASH, FRONT WHEELHOUSE, REMOVAL AND
INSTALLATION .
RELAY, HORN > DESCRIPTION AND OPERATION > DESCRIPTION AND OPERATION >
DESCRIPTION
Fig 1: Horn Relay Circuit Diagram
The horn relay (1) is a conventional International Standards Organization (ISO) micro relay. Relays
conforming to the ISO specifications have common physical dimensions, current capacities, terminal
patterns, and terminal functions. This relay is contained within a small, rectangular, molded plastic
housing and is connected to all of the required inputs and outputs through four integral male spade-type
terminals that extend from the relay base plate.
Internally (2), the horn relay is a electromechanical device that consists of an electromagnetic coil, a
resistor and a pair of normally open electrical contacts. One of the two electrical contacts is fixed, while
the other contact is movable. The movable relay contact is held away from the fixed contact by spring
pressure. The horn relay for this vehicle is installed in a cavity within the Power Distribution Center
(PDC), which is located on the left side of the engine compartment and outboard of the battery. Refer to
the layout label on the underside of the PDC cover for specific relay cavity assignment information.
The horn relay cannot be repaired or adjusted and, if ineffective or damaged, the relay unit must be
replaced.
RELAY, HORN > DESCRIPTION AND OPERATION > DESCRIPTION AND OPERATION >
OPERATION
The horn relay within the PDC switches battery current to the horn when the Body Control Module (BCM)
provides a path to ground for the electromagnetic coil of the relay. When the electromagnetic relay coil
is energized, it draws and holds the normally open movable contact of the relay against the fixed relay
contact. The closed relay contacts supply fused battery current from a fuse in the PDC to energize the
horns.
When the BCM de-energizes the electromagnetic relay coil, spring pressure returns the movable contact
to the normally open position, which de-energizes the horns. The resistor within the relay is connected in
parallel with the electromagnetic coil, which helps to dissipate voltage spikes that are produced when the
coil is de-energized.
The hard wired inputs and outputs of the horn relay in the PDC may be diagnosed using conventional
diagnostic tools and procedures. Refer to the appropriate wiring information.
RELAY, HORN > DIAGNOSIS AND TESTING > DIAGNOSIS AND TESTING - HORN
RELAY
The hard wired inputs and outputs of the horn relay in the Power Distribution Center (PDC) may be
diagnosed using conventional diagnostic tools and procedures. Refer to the appropriate wiring
information.
RELAY, HORN > REMOVAL AND INSTALLATION > REMOVAL AND INSTALLATION >
REMOVAL
Fig 1: Battery & Power Distribution Center
from the battery.
2. Remove the cover from the Power Distribution Center (PDC) (2) located on the left side of the
engine compartment near the battery (1) and the washer reservoir filler neck.
NOTE:
Refer to the appropriate wiring information and the fuse and relay layout map on the
underside of the PDC cover for relay identification and cavity location.
3. Remove the horn relay by grasping it firmly and pulling it straight out from the cavity within the
PDC.
RELAY, HORN > REMOVAL AND INSTALLATION > REMOVAL AND INSTALLATION >
INSTALLATION
Fig 1: Battery & Power Distribution Center
NOTE:
Refer to the appropriate wiring information and the fuse and relay layout map on the
underside of the Power Distribution Center (PDC) cover for relay identification and cavity
location.
1. Position the horn relay in the proper cavity within the PDC (2).
2. Align the relay terminals with the terminal cavities in the PDC.
3. Push firmly and evenly on the top of the relay until the terminals are fully seated in the terminal
cavities in the PDC.
4. Install the cover onto the PDC on the left side of the engine compartment near the battery (1)
and the washer reservoir filler neck.
SWITCH, HORN > DESCRIPTION AND OPERATION > DESCRIPTION AND OPERATION
> DESCRIPTION
Fig 1: Driver AirBag, Connector Receptacle, Inflator & Horn Switch
The horn switch (4) for this vehicle consists of four individual sets of normally open contacts wired in
parallel so that all four sets of contacts operate as one switch. The horn switch contacts are secured to,
but insulated from the four coiled springs secured to the molded plastic fixing plate for the Driver AirBag
(DAB) (1). The fixing plate includes an integral connector receptacle (2) on the upper center and integral
routing clips for the contact wiring routed around both sides and the bottom of the plate.
The horn switch and fixing plate unit is secured to the DAB housing by four nuts with washers. Each nut
is secured to a stud that also secures the DAB inflator (3) to the DAB housing. The DAB inflator
protrudes through a clearance hole in the center of the fixing plate. A dedicated take out and connector
of the steering wheel wire harness connects the horn switch to the vehicle electrical system through the
clockspring. A retainer that extends to each outboard side of the fixing plate is secured within the hub of
the steering wheel under a latch formation in the steering wheel hub armature adjacent to each side of
the steering wheel hub cavity.
The components that make up the horn switch cannot be adjusted or repaired. If damaged or ineffective,
the entire DAB, horn switch and fixing plate unit must be replaced.
SWITCH, HORN > DESCRIPTION AND OPERATION > DESCRIPTION AND OPERATION
> OPERATION
The horn switch allows the vehicle operator to actuate the horns by depressing anywhere on the upper
surface of the DAB trim cover in the center of the steering wheel. The four sets of horn switch contacts
are wired in parallel so they perform as a single switch. One wire for each pair of contacts is connected
to a path to ground at all times through the steering wheel wire harness and the clockspring.
When the DAB trim cover is depressed, the DAB trim cover compresses the coil springs isolating the
floating horn switch contacts causing at least one of the four sets of electrically conductive horn switch
contacts to close the horn switch circuits. When the DAB trim cover is released, the coil springs
between the DAB trim cover and the fixing plate return the DAB to its at rest position and open the horn
switch circuit. The closed horn switch circuit provides a ground signal to the Body Control Module
(BCM), which then pulls the control coil of the horn relay located within the Power Distribution Center
(PDC) to ground. The horn relay in the PDC then controls the output to the horns accordingly.
The hard wired circuits between components related to the horn switch may be diagnosed using
SWITCH, HORN > DIAGNOSIS AND TESTING > DIAGNOSIS AND TESTING - HORN
SWITCH
WARNING:
airbag deployment.
1. Remove the Driver AirBag (DAB) from the steering wheel. Refer to AIR BAG, DRIVER,
2. Disconnect the steering wheel wire harness connector from the horn switch connector.
3. With the horn switch contacts released, check for continuity between the two terminals in the
horn switch connector. There should be no continuity. If OK, go to Step 4. If not OK, replace
the ineffective horn switch, mounting plate and DAB unit.
4. With each of the horn switch contacts compressed one at a time, check for continuity between
the two terminals in the horn switch connector. There should now be continuity. If OK, go to
Step 5. If not OK, replace the ineffective horn switch, fixing plate and DAB unit.
5. Check the horn switch ground circuit between the steering wheel wire harness and the ground
source for continuity. If OK, go to Step 6. If not OK, repair the open ground circuit or replace
the clockspring and stalk unit as required.
6. Check the horn switch output circuit between the steering wheel wire harness and the horn
relay coil ground (85) terminal of the Power Distribution Center (PDC) for shorts or opens.
Repair the shorted or open circuit or replace the clockspring and stalk unit as required.
SWITCH, HORN > REMOVAL AND INSTALLATION > REMOVAL AND INSTALLATION >
REMOVAL
The horn switch is serviced only as a unit with the Driver AirBag (DAB). Refer to AIR BAG, DRIVER,
SWITCH, HORN > REMOVAL AND INSTALLATION > REMOVAL AND INSTALLATION >
INSTALLATION
The horn switch is serviced only as a unit with the Driver AirBag (DAB). Refer to AIR BAG, DRIVER,
Service Manual: INSTRUMENT CLUSTER - SERVICE Jeep Renegade
INFORMATION
The Instrument Panel Cluster (IPC) for this vehicle is located in the instrument panel above the steering
column opening. The IPC gauges and indicators are visible through an opening in the cluster bezel and
are protected by a clear plastic cluster lens that is secured to the cluster housing by integral latch
formations.
The molded plastic cluster housing encloses and protects the perimeter of the IPC unit. The cluster
housing serves as the carrier for the instrument cluster circuitry, the gauge set, the indicators, an
electronic display unit as well as an audible tone transducer. Each of the cluster hard indicators as well
as the general cluster illumination is provided by dedicated Light Emitting Diode (LED) units soldered to
the cluster electronic circuit board. A molded plastic rear cover includes clearance holes for the
connector receptacle and is secured to the cluster housing by screws. The connector receptacle on the
back of the IPC electronic circuit board connects the unit to the electrical system of the vehicle through
a dedicated take out and connector of the instrument panel wire harness.
Just behind the cluster lens is the molded plastic cluster mask. The mask serves to separate and define
the layout of the various visible areas of the IPC and also trims the cluster overlay. The mask lays over
the cluster overlay, which is a laminated plastic unit. The dark, visible, outer surface of the overlay is
marked with all of the gauge dial faces and graduations, but this layer is also translucent. The darkness
of this outer layer prevents the cluster from appearing cluttered or busy by concealing the hard indicators
that are not illuminated, while the translucence of this layer allows those hard indicators that are
illuminated to be readily visible. The underlying layer of the overlay is opaque and allows light from the
hard indicator LED units to be visible through the outer layer of the overlay through predetermined
stencil-like cutouts. The defined areas of the IPC are:
Tachometer (1)
- This is the electronic display unit. It includes an odometer display, several trip computer functions,
a message center, numerous predetermined soft indicators and several reconfigurable display
options.
Speedometer (5)
Several versions of the IPC are offered on this vehicle. These versions accommodate all of the
variations of optional equipment and regulatory requirements for the various markets in which the vehicle
is offered. The microcontroller-based IPC utilizes integrated circuitry and information carried on the
Controller Area Network (CAN) data bus along with several hard wired inputs to monitor other sensors
and switches in the vehicle. In response to those inputs, the internal circuitry and programming of the
IPC allow it to monitor many electronic functions and features of the vehicle.
The IPC is mounted behind the steering wheel, is connected to the CAN and includes four gauges:
Tachometer (1)
- This is the electronic display unit. It includes an odometer display, several trip computer functions,
a message center, numerous predetermined soft indicators and several reconfigurable display
options.
Speedometer (5)
At the center is a large display (available in two different versions and is reconfigurable), the Electronic
Vehicle Information Center (EVIC). In the various information positions are located numerous warning
lights, described in the service information of the functions to which they relate.
The IPC receives and manages the messages coming from the compass module and the humidity
sensor (if present) via the LIN line.
The BCM directly controls the door closing red flashing LED, located in the instrument panel.
For the versions in which the "SERVICE" menu is present, a dedicated menu for resetting the SERVICE
will be available in the IPC module diagnosis. The "SERVICE" resetting procedure must be carried out
via diagnosis equipment.
For versions in which the pre-delivery mileage RESET function is present, when the vehicle is new or
with less than 200 km (124 miles) the display shows the letter "H" before mileage. As long as mileage is
below 200 km (124 miles) and the "H" is displayed this can be reset, since it is considered as
pre-delivery movement. Resetting of pre-delivery mileage is carried out through diagnosis equipment in
the IPC module diagnosis.
Within the IPC is placed a chime with the ability to manage reports of different intensity, in order to fulfill
the many functions (described in the diagrams of the functions to which they relate).
The IPC is a module of the CAN through which it exchanges information with the Body Control Module
(BCM) and other electronic control units, in detail:
- Speedometer: the function is to display on the dashboard of the car speed: this information
comes from the Antilock Brake System (ABS) control unit and Powertrain Control Module (PCM),
using the BCM
- Engine RPM: the function is to display on the IPC the rotational speed of the engine by means of
the message sent via the CAN by the PCM
- Odometer: function provides for the display and storage of total and partial information that are
processed by the BCM through a counter that is transmitted via the CAN to the IPC
- Fuel level: the BCM receives the signal from the sensor built into the fuel pump inside the tank
and processes it to ensure an appropriate filtering / damping to the indicator of the IPC and also
controls the lighting of the "reserve" lamp
The IPC indicator circuit is able to detect any anomaly in the wiring or the sensor and provide an
appropriate indication to the IPC:
- Fuel level: in case of system malfunction, the index is placed at the beginning of scale and the
light of the "reserve" flashes.
- Engine coolant temperature: the function is to display on the IPC the coolant temperature and the
indicator light will light of excessive engine temperature by means of messages sent via the CAN
by the PCM. The temperature reading is always guaranteed, even in extreme conditions of
operation.
- Low engine oil pressure: the function includes the lighting on the IPC of minimum engine oil
pressure warning light through a message sent via CAN by the PCM.
- Park Brake: the BCM acquires the status of the parking brake from the switch and communicates
specific activation to the IPC through the CAN, the function includes the lighting on the IPC of the
"brake fluid level too low" warning light; also, if this signal is associated to pass a certain threshold
of speed, an acoustic signal is activated.
- Insufficient brake fluid: the function includes the lighting on the IPC of the "brake fluid level too
low" warning light. The signal is sent via the CAN by the BCM.
The IPC gauges, indicators, LED units, control switches as well as the electronic display unit are all
integral components of the IPC and its electronic circuit board. If any part of the IPC is damaged or
ineffective, the entire IPC assembly must be replaced.
The IPC has the hardware and software to simultaneously monitor multiple inputs. The
microcontroller-based IPC uses these inputs to control the gauges and indicators visible on the face of
the cluster, and to display the appropriate information in the electronic display unit to allow the vehicle
operator to monitor the conditions of many of the vehicle components and operating systems. The IPC
display provides valuable information about the various standard and optional powertrain, fuel and
emissions systems, cooling systems, lighting systems, safety systems and many other convenience
items. The IPC is installed in the instrument panel so that all of these monitors can be easily viewed by
the vehicle operator when driving, while still allowing relative ease of access for service.
Some of the IPC inputs are hard wired, but most are in the form of electronic messages that are
transmitted by other electronic modules over the Controller Area Network (CAN) data bus. The IPC
microcontroller smooths the input data using algorithms to provide gauge readings that are accurate,
stable and responsive to operating conditions. These algorithms are designed to provide gauge readings
during normal operation that are consistent with customer expectations. However, when abnormal
conditions exist such as high coolant temperature, the algorithm can provide an extreme output and the
microcontroller can sound a chime through the on-board audible tone transducer to provide distinct visual
and audible indications of a problem to the vehicle operator. The IPC may also produce audible warnings
for other electronic modules in the vehicle based upon electronic tone request messages received
over the CAN data bus. Each audible warning is intended to provide the vehicle operator with an audible
alert to supplement a visual indication.
The Body Control Module (BCM) stores and compares vehicle configuration data with the IPC as well as
with other Electronic Control Units (ECU) in the vehicle. This process is referred to as PRogramming Of
Configuration of Systems Integrated (PROCSI) (also known as PROXI). If a configuration mismatch is
detected, the BCM sets a DTC. A configuration mismatch DTC will require the performance of a Restore
BCM PROXI Configuration routine, or a PROXI Configuration Alignment routine using a diagnostic scan
tool.
The IPC circuitry operates on battery current received through a fused B(+) fuse on a non-switched
fused B(+) circuit. This arrangement allows the IPC to remain functional regardless of the status of the
ignition switch. The IPC circuitry is grounded through a ground circuit and take out of the instrument
panel wire harness with an eyelet terminal connector that is secured by a ground screw to a ground
location on the instrument panel structural support.
The hard wired circuits between components related to the IPC may be diagnosed using conventional
electronic controls or communication between modules and other devices that provide some features of
the IPC. The most reliable, efficient and accurate means to diagnose the IPC or the electronic controls
and communication related to IPC operation requires the use of a diagnostic scan tool. Refer to the
DIAGNOSIS AND TESTING > DIAGNOSIS AND TESTING - INSTRUMENT CLUSTER
WARNING:
If all of the Instrument Panel Cluster (IPC) gauges and indicators are ineffective, be certain to check the
IPC fused B(+) fuse and the IPC fused B(+) circuit and ground circuit for shorts or opens. The hard wired
circuits between components related to the IPC may be diagnosed using conventional diagnostic tools
and procedures. Refer to the appropriate SYSTEM WIRING DIAGRAMS article. The wiring information
includes wiring diagrams, proper wire and connector repair procedures, details of wire harness routing
and retention, connector pin out information and location views for the various wire harness connectors,
electronic controls or communication between modules and other devices that provide some features of
the IPC. The most reliable, efficient and accurate means to diagnose the IPC or the electronic controls
and communication related to IPC operation requires the use of a diagnostic scan tool. Refer to the
DIAGNOSIS AND TESTING > ABS WARNING LIGHT ON
The Anti-Lock Brake Module (ABM) sends a message to the Body Control Module (BCM) via the CAN-C
network and is then made available to Instrument Panel Cluster via the CAN-B network from the BCM
gateway.
0 PRELIMINARY CHECKS Result OK Result Not OK Action
Connect a diagnostic
scan tool and verify on
INFORMATION
NETWORK CAN:
1. The presence of
Absence of control 1. Proceed as
anomalies on CAN
units inactive indicated by the
network
diagnostic tool
Continue to Step 1 2. ABS control
Absence of control 2. Correctly insert
module connector is
units in error ABS control module
not properly
connector
Correct insertion of connected
the connector of
the ABS control
module
CHECK WITH
DIAGNOSTIC TOOL
With the diagnostic scan

tool still connected, 1. Proceed as
1. system /
check on CAN network indicated by the
component fault
information: diagnostic tool
Continue to Step 2 2. Presence of a
absence of system / 2. Proceed as
fault on the CAN-C
component anomalies indicated by the
network
absence of CAN network diagnostic tool
anomalies
CHECK WITH
DIAGNOSTIC TOOL

tool still connected to the
DLC, verify the absence Proceed as
of anomalies on the Continue to Step 3 Presence of errors indicated by the
instrument panel cluster diagnostic tool
and the presence of
parameters.
CHECK WITH ACTIVE

DIAGNOSIS

tool still connected to the Diagnostic complete The ABS warning Replace instrument
DLC, check the light flashes panel cluster
functionality of the ABS
light by activating it with
the scan tool.
DIAGNOSIS AND TESTING > AIRBAG INDICATOR OFF (DOES NOT CARRY OUT
INITIAL TEST)
When the ignition key is turned on, the Air Bag indicator lights should come on for a few seconds to
indicate the performance of the initial test of the control unit and then go off. The warning lights are
integrated LEDs in the electronic circuit of the instrument panel cluster and therefore are NOT
replaceable. If the LEDs are at fault, the instrument panel cluster must be replaced.
CHECK WITH
DIAGNOSTIC TOOL
1. Restore:
scan tool.
Make sure that you Connection
establish a regular between the Air
communication with the 1. Failure to Bag Module and
Air Bag Module and in communicate with the DLC
particular: Continue to Step
the Air Bag Module
2 power to the Air
2. An error in the Air
no abnormalities in Bag Module Bag Module
Air Bag control unit
plausibility of all 2. Proceed as indicated

parameters by the diagnostic tool
CHECK WITH
DIAGNOSTIC TOOL

DLC, test the functionality Continue to Step Replace instrument
Lamp does not flash
of the Air Bag warning 3 panel cluster
light through active
diagnosis
CHECK PROPER
OPERATION
Verify correct operation of Diagnostic Air bag module not Replace the Air Bag
the air bag module. complete working Module
DIAGNOSIS AND TESTING > AMBIENT TEMPERATURE DOES NOT DISPLAY
The ambient temperature does not display in the Electronic Vehicle Information Center (EVIC).
CHECKING
ELECTRICAL CIRCUIT
Verify the correct

communication 1. Restore the
between the ambient correct connections;
temperature sensor 1. Communication error if necessary replace
and Body Control Continue to Step 2 2. Ambient temperature the wiring.
Module. sensor fault 2. Replace the
Verify proper operation ambient temperature
of the ambient sensor
temperature sensor
CHECK DISPLAY
OPERATION
Check the correct Diagnostic Replace instrument

Display malfunction
operation of the display complete panel cluster
DIAGNOSIS AND TESTING > CLOCK DOES NOT WORK
When the ignition key is turned to the on position, the clock does not display or displays incorrectly.
CHECK INSTRUMENT
PANEL FEATURES
1. The time
Verify: 1. Set the time
displayed is not
The display shows the correctly
correct
correct time 2. Continue to Step
Diagnostic complete 2. You can not
You can adjust the time 2
adjust the time
The clock time 3. Continue to Step
3. The clock time
advances 3
does not advance
CHECK WITH
DIAGNOSTIC TOOL
Connect the diagnostic

scan tool to the DLC. Proceed as
Verify the absence of Continue to Step 3 Presence of errors indicated by the
anomalies on the diagnostic tool
instrument panel cluster.
CHECK WITH
DIAGNOSTIC TOOL
With the diagnostic

scan tool still connected
Replace the
to the DLC, verify the
Diagnostic complete display faulty instrument panel
functionality of the
cluster
display via active
diagnosis.
DIAGNOSIS AND TESTING > DOOR OPEN INDICATOR ALWAYS ON
After performing the initial test, the doors open indicator, located on the Instrument Panel Cluster, is
always on.
Check the correct Doors not properly Ensure the doors

Continue to Step 1
closure of the four doors closed close properly
CHECK WITH
DIAGNOSTIC TOOL
With the diagnostic scan 1. the scan tool

1. Continue to Step
tool, check in the cannot connect to
2
Instrument Panel Cluster the instrument panel
Continue to Step 2 2. Proceed as
the absence of errors cluster
indicated by the
and the presence of the 2. presence of
diagnostic tool
parameters errors
CHECK WITH
DIAGNOSTIC TOOL

tool, check in the Body
Control Module (BCM) for The parameter
the absence of errors Continue to Step 4 values do not Continue to Step 3
and the variation of the change
parameter for the state of
the doors
CHECK ELECTRICAL
CONNECTIONS
Check the operation of

the switches on the door
motors 1. Switch defective
1. Replace switch
Check the ground 2. Wiring with
Continue to Step 4 2. Restore the
insulation of the imperfect ground
wiring insulation
connection between the insulation
switches and door inputs
to the BCM
CHECK WITH ACTIVE

DIAGNOSIS

tool under Instrument
The light check
Panel Cluster, check in Replace instrument
Continue to Step 5 doors open is not
"Active Diagnosis" the panel cluster
activated
correct activation, check
the open doors light
CHECK PROPER
OPERATION
Verify that the fault is no Replace the Body
Diagnostic complete Anomaly persists
longer present Control Module
DIAGNOSIS AND TESTING > ENGINE COOLANT TEMPERATURE LIGHT DOES NOT
WORK
With the ignition key on, the engine coolant temperature warning light on the instrument panel does not
work.
NOTE:
The message comes from the engine coolant temperature sensor signal to the Powertrain
Control Module (PCM) on the CAN-C network and made available to the Instrument Panel
Cluster (IPC) through the Body Control Module (BCM) via the CAN-B network.
CHECK WITH
DIAGNOSTIC TOOL
scan tool. Proceed as indicated
Continue to Step 2 Presence of errors
Verify the absence of by the diagnostic tool
anomalies on the PCM.
CHECK WITH
DIAGNOSTIC TOOL

DLC, test the The lamp does not Replace instrument
Continue to Step 3
functionality of the light in flash. panel cluster
the IPC through active
diagnosis
CHECK ELECTRICAL
CIRCUIT
Check continuity /
insulation of the wiring
Circuit fault / not Restore circuit
between the engine Continue to Step 4
insulated continuity / insulation
coolant temperature
sensor and the PCM.
CHECK ENGINE
4 TEMPERATURE Result OK Result Not OK Action
SENSOR
Check the correct

Replace the engine
operation of the engine
Diagnostic complete faulty sensor coolant temperature
coolant temperature
sensor
sensor
DIAGNOSIS AND TESTING > EVIC NEVER DISPLAYS DANGER ICE WITH LOW
EXTERNAL TEMPERATURE
The Instrument Panel Cluster receives external temperature information from the Body Control Module
(BCM), which in turn receives the value from the ambient temperature sensor in the passenger side
outside mirror.
PRELIMINARY
CHECKS
Check that the

temperature shown on
1. implausible value
the instrument panel
error
cluster display is
2. The value 1. Continue to Step 1
plausible. Also check if Continue to Step 3
returned correctly 2. Continue to Step 3
by power cycling the
with the new key
instrument panel
cycle
cluster the temperature
returns plausible
CHECK WITH ACTIVE

DIAGNOSIS

scan tool to read data
from the BCM.
With the diagnostic The function in
tool test environment in question is not Replace the instrument
Continue to Step 2
active diagnosis, changed by active panel cluster
activate the self-test diagnosis
function for the
instrument panel
cluster
2 CHECK FOR ERRORS Result OK Result Not OK Action
1. Replace the ambient

temperature sensor
2. Restore the correct
wiring
With the diagnostic
scan tool still 1. Ambient
connected to the DLC, temperature sensor NOTE:
go to the environment defective /
Continue to Step 3 The ambient
BCM and verify the incorrectly
absence of any error calibrated temperature sensor is
on the ambient 2. Faulty wiring an integral part of the
temperature sensor passenger outside
mirror and is replaced
with the mirror.
VERIFY PROPER
OPERATION
Verify that the fault is Diagnostic

no longer present complete
DIAGNOSIS AND TESTING > EVIC SIGNALS DANGER ICE WITH ELEVATED
EXTERNAL TEMPERATURE
The Instrument Panel Cluster receives external temperature information from the Body Control Module
(BCM), which in turn receives the value from the ambient temperature sensor in the passenger side
outside mirror.
PRELIMINARY
CHECKS
Check that the

temperature shown on
1. implausible value
the instrument panel
error
cluster display is
2. The value 1. Continue to Step 1
plausible. Also check if Continue to Step 3
returned correctly 2. Continue to Step 3
by power cycling the
with the new key
instrument panel
cycle
cluster the temperature
returns plausible
CHECK WITH ACTIVE

DIAGNOSIS

from the BCM.
With the diagnostic The function in
tool test environment in question is not Replace the instrument
Continue to Step 2
active diagnosis, changed by active panel cluster
activate the self-test diagnosis
function for the
instrument panel
cluster
2 CHECK FOR ERRORS Result OK Result Not OK Action
1. Replace the ambient

With the diagnostic temperature sensor
scan tool still 1. Ambient 2. Restore the correct
connected to the DLC, temperature sensor wiring
go to the environment defective /
Continue to Step 3
BCM and verify the incorrectly
absence of any error calibrated NOTE:
on the ambient 2. Faulty wiring
The ambient
temperature sensor
temperature sensor is
an integral part of the
passenger outside
mirror and is replaced
with the mirror.
VERIFY PROPER
OPERATION
Contact Technical
Verify that the fault is Diagnostic The anomaly Support for more
no longer present complete persists information on the
problem
DIAGNOSIS AND TESTING > FUEL WARNING LIGHT DOES NOT WORK
With the ignition key on, the fuel reserve warning light does not come on when the tank enters the
reserve level.
NOTE:
The message comes from the fuel level signal to the Body Control Module (BCM) and made
available to the Instrument Panel Cluster (IPC) through the CAN-B network.
The BCM also sends a fuel level sensor error message.
CHECK WITH
DIAGNOSTIC TOOL
Sensor with open

circuit, sensor DC, Proceed as
scan tool to the DLC.
Continue to Step 2 value incongruent / indicated by the
Verify the absence of
implausible with diagnostic tool
anomalies in the BCM.
actual fuel level
CHECK WITH
DIAGNOSTIC TOOL
With the diagnostic

scan tool, test the
The light does not Replace instrument
functionality of the fuel Continue to Step 3
come on. panel cluster
reserve light through
active diagnosis.
CHECK FUEL LEVEL

SENSOR
Check the operation of Replace the fuel

Continue to Step 4 Sensor not working.
the fuel level sensor pump assembly
CHECK ELECTRICAL
CIRCUIT
Check continuity /
Restore circuit
insulation of the circuits Circuit fault / not
Continue to Step 5 continuity /
between the fuel level insulated.
insulation
sensor and BCM.
CHECK PROPER
OPERATION
Verify that the fault is Replace the Body

Diagnostic complete Anomaly persists
no longer present Control Module
DIAGNOSIS AND TESTING > GENERATOR LIGHT DOES NOT WORK
Turning the ignition key to run, the generator warning light does not come on.
CHECK WITH
DIAGNOSTIC TOOL
scan tool.
Test the functionality of
The light doesn't Replace instrument
the light in the Continue to Step 2
work. panel cluster
instrument panel cluster
through active
diagnosis.
CHECK ELECTRICAL
SYSTEM
1. Power to the BCM

1. Restore correct
Verify the Body Control incorrect
power to the BCM
Module (BCM) power 2. Signal D +
2. Restore proper
supplies are correct Continue to Step 3 between alternator
wiring
and in particular the and BCM interrupted
3. Replace
signal "D +". or faulty wiring
alternator
3. Faulty alternator
CHECK PROPER
OPERATION
Verify that the fault is

Diagnostic complete
no longer present
DIAGNOSIS AND TESTING > LOW OIL PRESSURE LIGHT DOES NOT WORK
With the ignition key on, the engine low oil pressure warning light on the instrument panel does not work.
NOTE:
The message comes from the engine oil pressure sensor signal to the Powertrain Control
Module (PCM) on the CAN-C network and made available to the Instrument Panel Cluster
(IPC) through the Body Control Module (BCM) via the CAN-B network.
CHECK WITH
DIAGNOSTIC TOOL
scan tool. Presence of
Proceed as indicated
Verify the absence of Continue to Step 2 anomalies in the IPC
by the diagnostic tool
anomalies on the PCM or PCM
and the IPC.
CHECK WITH
DIAGNOSTIC TOOL
1. The light doesn't

With the diagnostic work.
1. Replace
scan tool still 2. The light works -
instrument panel
connected to the DLC, pressure sensor
cluster
test the functionality of Continue to Step 3 defective
2. Replace engine oil
the light in the IPC 3. 3. Engine oil
pressure sensor
through active pressure sensor
3. Restore wiring
diagnosis wiring fault / not
insulated
CHECK PROPER
OPERATION
Replace the Body

Diagnostic complete anomaly persists Control Module and
no longer present
continue to Step 4
CHECK PROPER
OPERATION
Replace the
Diagnostic complete anomaly persists Powertrain Control
no longer present
Module
DIAGNOSIS AND TESTING > MIL WARNING LIGHT FLASHES
The light flashes engine failure with the engine running.
NOTE:
The light may blink in two different modes: when vehicle starts and stops, or when the
vehicle is placed in gear.
CHECK FUEL WARNING
LIGHT
Return the fuel level

Check that the low fuel Low fuel warning above the reserve
Continue to Step 2
light is off. light lit. area and continue to
Step 4
2 CHECK FUEL LEVEL Result OK Result Not OK Action
Proceed as indicated
Verify the correct
Fuel gauge does in FUEL LEVEL
operation of the fuel level Continue to Step 3
not work INDICATOR DOES
indicator.
NOT WORK
CHECK WITH
DIAGNOSTIC TOOL
Error Ignition
scan tool to the DLC. Proceed as indicated
Diagnostic complete Misfiring is
Verify the absence of the by the diagnostic tool
present
error "Ignition failure"
CANCELLATION AND
ERROR CHECKING
Clear the codes in the

powertrain control unit
Error Ignition
using the diagnostic tool. Proceed as indicated
Continue to Step 5 Misfiring is
Perform a road test and by the diagnostic tool
present
verify that the error does
not recur.
CHECK PROPER
OPERATION
Verify that the fault is no

Diagnostic complete
longer present
DIAGNOSIS AND TESTING > ODOMETER DOES NOT WORK
While moving, the odometer does not work, or operates erratically. The speed signal comes from the
Anti-Lock Brake Module to the Body Control Module via the CAN-C network and is then made available
to Instrument Panel Cluster via the CAN-B network from the BCM gateway.
PRELIMINARY
CHECKS
scan tool.
Check that the engine is
Continue to Step 2 Presence of errors Continue to Step 1
running and is not
displayed any error
message
CHECK WITH
DIAGNOSTIC TOOL

from the BCM.
Check on CAN network 1. The presence of
1. Proceed as
information: anomalies on CAN
indicated by the
absence of non-active network
Continue to Step 2 diagnostic tool
units 2. The presence of
2. Continue to Step
absence of control in errors on instrument
2
error; panel cluster
absence of control unit
CAN communication
error
CHECK WITH
DIAGNOSTIC TOOL
With the diagnostic

Errors or failure to Proceed as
Continue to Step 3 communicate with the indicated by the
absence of anomalies
diagnostic scan tool diagnostic tool
on the instrument panel
cluster.
CHECK WITH
DIAGNOSTIC TOOL
With the diagnostic

to the DLC, check the Odometer does not Replace instrument
Diagnostic complete
functionality of the work panel cluster
display by activating it
with the scan tool.
DIAGNOSIS AND TESTING > SPEEDOMETER DOES NOT WORK
While moving, the speedometer does not work, or operates erratically. The speed signal comes from the
Anti-Lock Brake Module to the Body Control Module via the CAN-C network and is then made available
to Instrument Panel Cluster via the CAN-B network from the BCM gateway.
PRELIMINARY
CHECKS
scan tool.
Check that the engine is
Continue to Step 2 Presence of errors Continue to Step 1
running and is not
displayed any error
message
CHECK WITH
DIAGNOSTIC TOOL

from the BCM.
Check on CAN network 1. The presence of
1. Proceed as
information: anomalies on CAN
indicated by the
absence of non-active network
Continue to Step 2 diagnostic tool
units 2. The presence of
2. Continue to Step
absence of control in errors on instrument
2
error; panel cluster
absence of control unit
CAN communication
error
CHECK WITH
DIAGNOSTIC TOOL
With the diagnostic

Errors or failure to Proceed as
Continue to Step 3 communicate with the indicated by the
absence of anomalies
diagnostic scan tool diagnostic tool
on the instrument panel
cluster.
CHECK WITH
DIAGNOSTIC TOOL
With the diagnostic

to the DLC, check the
Speedometer does not Replace instrument
functionality of the Diagnostic complete
work panel cluster
speedometer pointer by
activating it with the
scan tool.
DIAGNOSIS AND TESTING > TACHOMETER DOES NOT WORK
The engine tachometer does not work, or works erratically.
CHECK WITH
DIAGNOSTIC TOOL
scan tool. Proceed as
Verify the absence of Continue to Step 2 Presence of errors indicated by the
instrument panel.
CHECK WITH
DIAGNOSTIC TOOL
With the diagnostic
scan tool still
Tachometer doesn't
connected to the DLC, Replace instrument
Continue to Step 3 work for stepper
test the functionality of panel cluster
motor malfunction
the pointer through
active diagnosis
CHECK WITH
DIAGNOSTIC TOOL
With the diagnostic

scan tool still
connected to the DLC, Proceed as
verify the absence of Diagnostic complete Presence of errors indicated by the
powertrain control
module.
STANDARD PROCEDURE > STANDARD PROCEDURE - ENHANCED SEATBELT

REMINDER PROGRAMMING
The seatbelt indicator also includes a programmable enhanced seatbelt reminder or BELTMINDER
feature that is enabled when the vehicle is shipped from the factory. This BELTMINDER feature provides
extended and modified visual seatbelt indicator and audible chime warning responses to an unbuckled
driver side front seat belt. The BELTMINDER feature may be disabled or enabled by the customer using
the programming sequence that follows, or by the dealer using a diagnostic scan tool.
STANDARD PROCEDURE > STANDARD PROCEDURE - ENHANCED SEATBELT

REMINDER PROGRAMMING > CUSTOMER PROGRAMMING SEQUENCE
NOTE:
The following sequence of events must occur within 60 seconds of the ignition switch being
placed in the ON position in order for the programming to be completed successfully.
1. With all doors closed and the ignition switch in any position except ON or START, buckle the
driver side front seat belt.
2. Turn the ignition switch to the ON position and wait for the seatbelt indicator reminder function
to conclude (about six seconds).
3. Unbuckle and buckle the driver side front seat belt three or more times, ending with the belt
buckled.
4. Turn the ignition switch to any position except ON or START to toggle the BELTMINDER
feature from its current setting (from active to inactive, or from inactive to active). A single
chime tone will provide an audible confirmation that the programming sequence has been
successfully completed.
WARNING:
cable.
2. Lower the steering column to the downward most position.
5. Remove the two fasteners (1a) from the steering column shroud gap hider (1c) and remove the
gap hider from the vehicle.
6. Remove the four fasteners (1a) that secure the instrument panel cluster (1b) to the instrument
panel.
7. Disconnect the instrument panel wiring harness connector (2a) from the receptacle on the back
of the instrument panel cluster (2b).
8. Remove the instrument panel cluster (2b) from the instrument panel.
WARNING:
NOTE:
Make sure that the steering column remains in the lowest position setting.
2. Position the instrument cluster close enough to the instrument panel to access and connect the
instrument panel wire harness connector (2a) to the receptacle on the back of the cluster
housing.
3. Install and securely tighten the four screws (1a) that secure the instrument panel cluster to the
instrument panel.
4. Position the steering column shroud gap hider (1c) to the instrument panel and install the two
fasteners (1a). Be certain the retaining clips (1b) are fully engaged with the instrument panel.
5. Install the instrument cluster bezel onto the instrument panel. Refer to BEZEL, INSTRUMENT
NOTE:
scan tool MUST be used to align the PROXI Configuration data into the new ECU.
Alignment under Miscellaneous Functions for the ECU menu item.
Refer to MODULE, INSTRUMENT PANEL CLUSTER, MODULE PROGRAMMING .
GAUGE PACK, INSTRUMENT CLUSTER > DESCRIPTION AND OPERATION >

The Instrument Panel Cluster (IPC) houses four analog gauges that are standard on all models. The
analog gauges are the speedometer (5), tachometer (1), engine temperature gauge (2) and the fuel
gauge (4). Gauge illumination is provided by dimmer controlled Light Emitting Diode (LED) units soldered
onto the IPC electronic circuit board.
The IPC gauges, indicators, LED units and control switches as well as the electronic display unit (3) are
all integral components of the IPC and its electronic circuit board. If any part of the IPC is damaged or
ineffective, the entire IPC assembly must be replaced.
GAUGE PACK, INSTRUMENT CLUSTER > DESCRIPTION AND OPERATION >

All analog gauges in the Instrument Panel Cluster (IPC) receive battery current on the IPC printed circuit
board only when the status of the ignition switch is ON. When status of the ignition switch is OFF,
battery current is not supplied to any gauges and the IPC is programmed to move all of the gauge
needles back to the low end of their respective scales. Therefore, the gauges do not accurately indicate
any vehicle condition unless the status of the ignition switch is ON.
Each of the analog IPC gauges contains an electronically controlled stepper motor unit. The IPC circuitry
completely controls the activation and deactivation of these stepper motors to position each gauge
needle in the appropriate position based upon IPC programming and electronic messages received from
other electronic modules in the vehicle over the Controller Area Network (CAN) data bus.
The analog gauges are diagnosed using the self-diagnostic IPC actuator test when the ignition is turned
to ON. Proper testing of the CAN data bus and the electronic message inputs that the IPC uses to
control each gauge requires the use of a diagnostic scan tool. Refer to DIAGNOSIS AND TESTING .
INDICATORS, INSTRUMENT CLUSTER > DESCRIPTION AND OPERATION >

Fig 1: Instrument Panel Cluster (IPC) Indicators
The Instrument Panel Cluster (IPC) features a number of soft indicators, which are located within the
electronic display unit in the center of the cluster. The soft indicators are discussed in further detail
within the message center service information. Refer to CENTER, ELECTRONIC VEHICLE
INFORMATION, DESCRIPTION AND OPERATION . Some of the indicators are automatically configured
when the IPC is connected to the electrical system of the vehicle for compatibility with certain optional
equipment or equipment required for regulatory purposes in certain markets. While each IPC may have
provisions for indicators to support every available option, the configurable indicators will not function in
vehicles that do not have the equipment that an indicator supports.
Below are brief explanations of the indicators available on this vehicle. More detailed information may be
available elsewhere in this article, located within the service information covering the system or
component that controls or influences the illumination of that indicator.
The IPC includes provisions for the following indicators:
High Beam Indicator (1)
Park/Headlight ON Indicator (2) - if equipped
Automatic High Beam Indicator (3)
Engine Coolant Temperature Warning Indicator (4)
Anti-Lock Brake Indicator (5)
Electronic Park Brake Warning Indicator (6) - if equipped
Brake Warning Indicator (7)
Electronic Stability Control (ESC) OFF Indicator (8) - if equipped
Electronic Stability Control (ESC) Activation/Malfunction Indicator (9) - if equipped
Lane Sense Indicator (10) - if equipped
Seat Belt Reminder Indicator (11)
Turn Signal (Right and Left) Indicators (12) and (16)
Electronic Power Steering Warning Indicator (13)
Airbag Warning Indicator (14)
Malfunction Indicator Lamp (15) - Malfunction Indicator Lamp (MIL)
Tire Pressure Monitor Indicator (17) - Tire Pressure Monitor (TPM)
Stop / Start Indicator (18) - if equipped
Rear Fog Lamp Indicator (19) - if equipped
Front Fog Lamp Indicator (20) - with optional front fog lamps only
The simultaneous firing of BRAKE light (Red) and the ABS light (Amber) with the engine running indicates
a failure of the Electronic Breakforce Distribution (EBD) system or that the system is not available.
These indicators and LED units are serviced only as a unit with the IPC. If damaged or ineffective, the
entire IPC assembly must be replaced.
INDICATORS, INSTRUMENT CLUSTER > DESCRIPTION AND OPERATION >

Indicators are located in various locations within the Instrument Panel Cluster (IPC) and are all
connected to the electronic circuit board. All of the indicators are completely controlled by the IPC. The
various indicators are controlled by different strategies; some receive fused ignition output from the IPC
circuitry and have a switched ground, while others are grounded through the IPC circuitry and have a
switched battery feed. However, most are controlled by Control Area Network (CAN) or Local Interface
Network (LIN) data bus messages from other electronic modules in the vehicle while others are
controlled by a combination of hard wired inputs, electronic messaging and IPC programming. If the IPC
loses CAN data bus communication, the IPC circuitry will automatically turn ON the Malfunction Indicator
Lamp (MIL) until CAN data bus communication is restored.
In addition, certain indicators in this IPC are automatically or self-configured. This feature allows the
configurable indicators to be enabled by the IPC circuitry for compatibility with certain optional
equipment. These indicators are enabled or disabled by an electronic configuration message sent to
the IPC by the Body Control Module (BCM). The BCM default for the Anti-lock Brake System (ABS) and
the airbag indicators is enabled. The automatically or self-configured indicators remain latent in the IPC
at all times and will be active only when the IPC receives the appropriate CAN or LIN bus message
inputs for that optional system or equipment.
The hard wired indicator inputs may be diagnosed using conventional diagnostic tools and procedures.
However, the IPC circuitry and electronic CAN or LIN data bus message controlled indicators are
diagnosed using a diagnostic scan tool. Proper testing of the CAN or LIN data bus and the electronic
data bus message inputs to the IPC that control each indicator requires the use of a diagnostic scan
tool. Refer to the appropriate Diagnostic & Testing article. Refer to DIAGNOSIS AND TESTING .
POD, SWITCH > DESCRIPTION AND OPERATION > DESCRIPTION AND OPERATION >
DESCRIPTION
Fig 1: Instrument Panel Switch Pod
The instrument panel switch pod is located just between the Radio Receiver Module (RRM) and air
conditioner controls in the center stack area of the instrument panel. This switch is available in multiple
configurations, which vary depending upon the equipment in the vehicle. However, every available
configuration includes the hazard warning push button switch. The switch pod may include the following
switches:
Heated Seat Switches (1) - Driver and Passenger
Heated Steering Wheel Switch (2)
Parallel and Perpendicular Park Assist Activation Switch (3) - EMEA only
ParkSense® Rear Park Assist ON/OFF Switch (4)
Hazard Lamp Switch (5)
Passenger Air Bag Status Indicator (6) - EMEA only
Lane Departure Warning + ON/OFF Switch (7)
The switch housing and the push buttons are constructed of molded plastic. Each push button has a
smooth finish and is clearly identified with the appropriate text and International Control and Display
Symbol icons. Refer to INTERNATIONAL VEHICLE CONTROL AND DISPLAY SYMBOLS,
DESCRIPTION . Several of the push buttons feature Light Emitting Diode (LED) units to give the vehicle
operator an indication when the function of that switch is currently active. Only the hazard warning
switch push button latches, the remaining switches feature momentary operation.
Six retaining clips secure the switch to the back of the instrument panel through integral mounting tabs
that are molded onto the switch housing. The back of the switch housing has an integral connector
receptacle containing terminal pins that connect the switch to the vehicle electrical system through a
dedicated take out and connector of the instrument panel wire harness.
Panel lamps dimmer controlled illumination lamps integral to the circuit board within the switch provide
back lighting for visibility at night, but these lamps are not serviceable. The individual switches in the
upper instrument panel switch pod cannot be repaired and are not serviced individually. If any component
within the switch pod is ineffective or damaged, the entire switch pod must be replaced.
POD, SWITCH > DESCRIPTION AND OPERATION > DESCRIPTION AND OPERATION >
OPERATION
For information covering details of operation for the individual switches and circuits contained within the
instrument panel switch pod, refer to the specific service information covering the system to which that
switch belongs.
POD, SWITCH > REMOVAL AND INSTALLATION > REMOVAL AND INSTALLATION >
REMOVAL
Fig 1: Switch Pod, Wire Harness Connector & Retaining Tabs
cable.
2. Remove the radio from the instrument panel to gain access to the switch pod retaining tabs
(1a). Refer to RADIO, REMOVAL AND INSTALLATION .
3. Using a trim stick C-4755 or equivalent, remove the switch pod (1b) from the instrument panel
while compressing the retaining tabs (1a).
4. Disconnect the switch pod wire harness connector (2) from the switch pod (1b).
5. Remove the switch pod (1b) from the vehicle.
POD, SWITCH > REMOVAL AND INSTALLATION > REMOVAL AND INSTALLATION >
INSTALLATION
Fig 1: Switch Pod, Wire Harness Connector & Retaining Tabs
1. Position the switch pod (1b) to the instrument panel and connect the wire harness (2) to the
switch pod (1b).
2. Install the switch pod (1b) into the instrument panel. Be certain the switch pod retaining tabs
(1a) fully engage the instrument panel.

Service Manual: MESSAGE CENTER - SERVICE Jeep Renegade
INFORMATION
CENTER, ELECTRONIC VEHICLE INFORMATION > DESCRIPTION AND OPERATION >
Two Instrument Panel Cluster (IPC) trim levels can be installed on the car.
Fig 1: 3.5" Electronic Vehicle Information Center
3.5" Electronic Vehicle Information Center (EVIC)
The display is designed using the TFT (Thin Film Transistor) technology and is positioned in the center of
the instrument panel. To access the EVIC menu use the EVIC control switch on the left steering wheel
spoke.
Examples of the possible menus within 3.5" EVIC are shown below:
Menu Submenu Illustration
Digital speed MPH or KM/H
Vehicle
Tire pressure
Information
Vehicle
Information
Water temperature
Vehicle
Information
Fluid Temperature
Vehicle
Information
Battery Voltage
Vehicle
Information
Service
Distance
Trip A Average speed
Time elapsed
Distance
Trip B Average speed
Time elapsed
Instant consumption
Average consumption
Fuel Economy
Mileage from
refueling
Drive assist LDW function display
Source currently
Audio
used
Example: Low fuel

Stored messages
level
Navigation Direction display
Available when the

vehicle is not moving.
Screen set-up Allows you to change
the position of some
values on the EVIC.
Fig 2: 7" Drive Information Display
7" DID (Drive Information Display)
The vehicle can be equipped with a 7" display, made with Liquid Crystal Display (LCD) technology. The
display offers a clear, full-color image and perfectly integrates with the analogue instruments of the
instrument panel. The DID allows a wide range of settings.
Examples of menu available in the Europe-Middle East-Africa (EMEA) market with 7" DID screen is
shown below:
Menu Submenu Illustration

Digital speed MPH or KM/H
Vehicle
Tire pressure
information
Vehicle
Water temperature
information
Vehicle Transmission fluid

information temperature
Vehicle
Fluid temperature
information
Vehicle
Battery voltage
information
Vehicle
Service
information
Display of the active

Driver assist
functions
Instant consumption
Average consumption
Fuel Economy
Mileage from
refuelling
Distance
Trip A Average speed
Time elapsed
Distance
Trip B Average speed
Time elapsed
Stop/Start if present - EMEA
Audio Source currently used
Navigation and
Message reception
phone
Example: "Oil change

Stored messages
request"
Available when the
Screen set-up
vehicle is not moving.
Vehicle settings Available in the menu
The display options of the EVIC can be navigated and selected using the EVIC control switches located
on the left steering wheel spoke. For more information refer to the vehicle's owner manual.
The EVIC electronic display unit is integral to the IPC unit. If the EVIC is damaged or ineffective, the
entire IPC unit must be replaced. Refer to REMOVAL AND INSTALLATION .
CENTER, ELECTRONIC VEHICLE INFORMATION > DIAGNOSIS AND TESTING >

DIAGNOSIS AND TESTING - ELECTRONIC VEHICLE INFORMATION CENTER
The Electronic Vehicle Information Center (EVIC) data is obtained from several components on the
Controller Area Network (CAN) Data Bus circuit. The EVIC will not function properly if the bus messages
from any of these components is not received. If no EVIC data is displayed, check the CAN Data Bus
circuit communications, the Instrument Panel Cluster (IPC) functions and the Body Control Module
(BCM).
The use of a scan tool and the proper diagnostic procedures information are recommended for further
testing of the EVIC and the CAN Data Bus circuit. For complete circuit schematic or connector pin-out
information, refer to appropriate SYSTEM WIRING DIAGRAMS article .
CENTER, ELECTRONIC VEHICLE INFORMATION > STANDARD PROCEDURE >

RESET OIL CHANGE INDICATOR
After performing the needed maintenance, reset the Oil Change Required indicator using the following
procedure:
1. Turn the ignition switch to the ON position, but do not start the engine.
2. For EMEA vehicles only, depress and hold the brake pedal while performing the next step.
3. Fully depress and release the accelerator pedal slowly, three times, within 10 seconds on
NAFTA vehicle and within 30 seconds on EMEA vehicles.
5. For EMEA vehicles only, release the brake pedal.
NOTE:
If the Oil Change Required indicator message illuminates when you start the engine, the
indicator did not reset. If necessary, repeat this procedure.
SWITCH, EVIC CONTROL > DESCRIPTION AND OPERATION > DESCRIPTION AND
The Electronic Vehicle Information Center (EVIC) steering wheel EVIC control switch sends the
commands to the Body Control Module (BCM) via the Local Interface Network (LIN) line. The BCM
translates the controls requested by the driver and sends them via Control Area Network (CAN) to the
Instrument Panel Cluster (IPC) module, to access menus and submenus.
Other display activation requests can come from other systems, to warn the driver when the
corresponding system activates; for instance:
Park Assist function
Seat Belt Reminder
Assisted parking
Fig 1: Steering Wheel EVIC Control Switches

NOTE:
Key:
1. Movements in the menu
2. Selection confirmation button
3. Cruise control buttons
4. Speed limiter and ACC
5. EMEA version
6. NAFTA version
The EVIC control switch cannot be adjusted or repaired. If any function of the switch is ineffective or
damaged, the entire switch unit must be replaced.
Service Manual: NAVIGATION/TELECOMMUNICATION - Jeep Renegade
SERVICE INFORMATION
DESCRIPTION AND OPERATION > HANDS FREE PHONE > DESCRIPTION - HANDS
FREE PHONE
A Uconnect™ Hands Free Phone system is factory-installed optional equipment. This system allows
hands free use of compatible mobile phones for sending and receiving phone calls and text messages as
well as for streaming audio from those devices through the audio system in the vehicle. The Hands Free
Phone system includes the following major components, which are described in further detail elsewhere
in this service information:
Bluetooth™ Antenna - A Bluetooth™ antenna is internal and integral to the Radio Receiver
Module (RRM).
Bluetooth™ Phone - A compatible, customer-supplied and paired Bluetooth™ phone is a required

component of the hands free phone system. A list of suggested phones and providers is available
at: http://www.chrysler.com/uconnect
Body Control Module - The Body Control Module (BCM) is located within the instrument panel on
the driver side of the vehicle. The BCM is the configuration master node for the vehicle. Refer to
MODULE, BODY CONTROL, DESCRIPTION AND OPERATION .
Electronic Vehicle Information Center Switch Pod - The Electronic Vehicle Information Center
(EVIC) switch pod is located in the left horizontal spoke of the steering wheel. In addition to the
EVIC switch buttons the lower part of this switch pod contains the Uconnect™ Voice Recognition
(VR) (also known as Voice Command) switch button and the Uconnect™ Phone switch button of
the Hands Free Phone system. Refer to SWITCH, EVIC CONTROL, DESCRIPTION AND
OPERATION .
Microphone - A microphone is integral to the is integral to the roof lamp unit in the headliner near
the center of the upper windshield opening header panel in vehicles equipped with the Uconnect™
Hands Free Phone system. Refer to MICROPHONE, DESCRIPTION AND OPERATION .
Radio Receiver Module - The RRM is located within the instrument panel and is the primary
component of the hands free phone system in this vehicle. Depending upon selected vehicle
optional equipment the RRM may include a microcontroller, a Bluetooth™ transceiver, a navigation
module, flash memory and sophisticated Advanced Speech Recognition (ASR) input capability
through Voice Recognition (VR) software. The ASR software includes many different available
languages. Each vehicle is equipped with a list of available languages, which are made available
from the factory based upon languages most commonly used for the market destination. Refer to
RADIO, DESCRIPTION AND OPERATION .
The RRM also contains a microcontroller and programming that allows it to communicate with other
electronic modules in the vehicle over the Controller Area Network (CAN) - B data bus. Refer to
The Uconnect™ Hands Free Phone system components cannot be adjusted or repaired. If any Hands
Free Phone system component is damaged or ineffective, that component must be replaced. The Hands
Free Phone system software is flash programmable through the Universal Serial Bus (USB) port.
DESCRIPTION AND OPERATION > HANDS FREE PHONE > OPERATION - HANDS
FREE PHONE
The Uconnect™ Hands Free Phone system relies upon Bluetooth™ technology to enable wireless
connectivity between Bluetooth™ compatible, paired and turned On mobile devices and the on-board
entertainment system components. This system also relies upon ASR software to enable Voice
Commands to control the mobile device as well as the components and features of some other on-board
systems.
The system will recognize up to ten Bluetooth™ compatible devices, each of which is identified within the
system by the name acquired from the device during the pairing process. The Hands Free Phone system
will communicate with a paired device that is anywhere within the vehicle. However, covering the paired
device with a metal object may block the signal.
The Hands Free Phone system is operated in one of two ways: actively or passively. Active operation
begins with the vehicle operator depressing a push button in the EVIC switch pod on the face of the left
horizontal spoke of the steering wheel. The Uconnect™ Voice Recognition (VR ) (also known as Voice
Command) button is depressed for hands free Voice Command access to available features other than
the phone, or the Uconnect™ Phone (Phone is identified by a phone handset icon) button is depressed
for hands free phone access.
The VR or Phone button press provides a resistor multiplexed input to the Local Interface Network
(LIN) slave node integral to the EVIC switch pod. The LIN slave node sends an electronic switch press
message to the LIN master node integral to the microcontroller of the BCM. The BCM is also a gateway
to the CAN - B data bus and relays the message over the CAN - B data bus to the RRM.
When the RRM receives the electronic switch press message, the RRM suppresses any current audio
output and issues an audible beep to indicate that the VR hardware is prepared to receive a Voice
Command. Part of the Uconnect™ Hands Free Phone system hardware includes the VR microphone
integral to the roof lamp unit in the headliner centered between the sun visors near the windshield. The
microphone provides a hard wired input of Voice Commands to the VR engine within the RRM, and the
ASR software converts that input into an electronic instruction message broadcast over the CAN - B
data bus to invoke the appropriate system response. If no appropriate Voice Command is received
within a few seconds following the audible beep , the system will provide an audible verbal output listing
a menu of the available Voice Command options.
Passive operation begins when an incoming cellular call is received. If the Bluetooth™ phone is Short
Message Service (SMS) text message capable and compatible with the Uconnect™ system (see the
Uconnect™ web site), passive operation will also begin when an SMS text message is received. The
call or SMS text message is relayed to the Bluetooth™ transceiver embedded within the RRM. The
Bluetooth™ transceiver then instructs the RRM to announce the incoming call or message. The vehicle
operator presses the Uconnect™ Phone button in the steering wheel switch pod or the soft button that
will appear in the RRM display to accept the call or to accept the message.
The Bluetooth™ transceiver connects the voices of the two phone parties using outputs through the
audio system speakers and inputs through the Uconnect™ hands free microphone. In the case of a text
message, the Bluetooth™ transceiver sends the message to the VR hardware and the ASR software
converts the message from text to voice and plays it through the audio system speakers.
If the RRM integrates the optional High-level Telematic Module (HTM), the text message can then be
replied to by depressing the Uconnect™ VR button and giving an SMS Voice Command to select from
several predetermined short text phrase responses. If the RRM has the Low-level Telematic Module
(LTM) or the Entertainment Telematics Module (ETM), it can receive and display SMS text messages,
but it is not equipped to reply to text messages.
The Hands Free Phone system operates on battery current received through a fused B(+) circuit, but
also monitors the ignition status through electronic messages received over the CAN - B data bus. If a
call is in progress when the status of the ignition transitions to Off, the system will continue to operate
until the call has been completed.
The RRM receives electronic message inputs over the CAN - B data bus related to the Hands Free
Phone system. The RRM is also connected to the CAN - C data bus; however, the RRM is not a CAN
gateway. All electronic message outputs of the RRM are carried over the CAN - B data bus. When the
RRM monitors a problem in any of the audio system circuits and components, or in any of the
Bluetooth™ transceiver circuits, it stores a fault code or Diagnostic Trouble Code (DTC) in its memory
circuit.
The hard wired circuits between components related to the RRM and the Hands Free Phone system may
be diagnosed using conventional diagnostic tools and procedures. Refer to the appropriate wiring
information. The wiring information includes wiring diagrams, proper wire and connector repair
However, conventional diagnostic methods will not prove conclusive in the diagnosis of the RRM or the
of the Hands Free Phone system. The most reliable, efficient and accurate means to diagnose the RRM
or the electronic controls and communication related to Hands Free Phone system operation requires
the use of a diagnostic scan tool. Refer to the appropriate diagnostic information.
DESCRIPTION AND OPERATION > NAVIGATION > DESCRIPTION - NAVIGATION
A factory-installed satellite navigation system based upon the Global Positioning System (GPS) is an
available option on this vehicle. Depending upon the optional touchscreen Radio Receiver Module
(RRM) selected for the vehicle, there are some variations in navigation system features available. Each
system provides the vehicle operator with both visual and audible guidance to a chosen destination. An
available premium navigation system includes such features as one-shot Voice Recognition (VR)
destination entry, three dimensional city models and landmarks, digital terrain modeling, SiriusXM™
Travel Link and SiriusXM™ Traffic.
A RRM color touchscreen electronic display provides a graphical interface for programming, searching
for and selecting destinations. In vehicles also equipped with a Uconnect™ Hands-Free
telecommunication option, the available navigation systems are also equipped with Advanced Speech
Recognition (ASR) input capability allowing hands-free operation. Each system provides visual guidance
through dynamic maps with a turn-by-turn feature that can be enabled or disabled by the vehicle
operator, while voice prompts through the audio system of the vehicle provide the vehicle operator with
audible alerts and directions coordinated with the visual displays. The system also displays and logs
valuable trip information such as speed, posted speed limit, distance and Estimated Time of Arrival
(ETA).
The navigation system includes the following major components, which are described in further detail
Body Control Module - The Body Control Module (BCM) is located within the instrument panel on
the driver side of the vehicle. The BCM is the configuration master node for the vehicle. Refer to
MODULE, BODY CONTROL, DESCRIPTION AND OPERATION .
Combination Antenna - The navigation module acquires GPS position data through a
roof-mounted combination antenna that also receives satellite audio and cellular signals. Refer to
ANTENNA, SATELLITE, AUDIO, DESCRIPTION AND OPERATION .
Electronic Vehicle Information Center - The Electronic Vehicle Information Center (EVIC) is an
electronic display within the Instrument Panel Cluster (IPC). When Turn-By-Turn navigation is
enabled through the EVIC Personal Settings menu, the EVIC displays turn-by-turn directions to the
chosen destination supplemental to the navigation display within the RRM touchscreen unit. Refer
to CENTER, ELECTRONIC VEHICLE INFORMATION, DESCRIPTION AND OPERATION .
Electronic Vehicle Information Center Switch Pod - The EVIC switch pod is located in the left
horizontal spoke of the steering wheel. In addition to the EVIC switch buttons the lower part of this
switch pod contains the Uconnect™ Voice Recognition (VR) (also known as Voice Command)
switch button and the Uconnect™ Phone switch button of the Uconnect™ Hands-Free Phone
system. Refer to CENTER, ELECTRONIC VEHICLE INFORMATION, DESCRIPTION AND
OPERATION .
Microphone - A microphone is integral to the roof lamp unit in the headliner near the center of the
upper windshield opening header panel in vehicles equipped with the Uconnect™ Hands-Free
Phone system. Refer to MICROPHONE, DESCRIPTION AND OPERATION .
Radio Receiver Module - The RRM contains the central components of the navigation system. A
navigation module is internal and integral to each RRM that is equipped with navigation capability.
The navigation module contains all of the navigation system hardware and software. Hardware
includes the GPS receiver, an electronic gyroscope, a microcontroller and flash memory for
system software and map data storage. Refer to RADIO, DESCRIPTION AND OPERATION .
The BCM, the IPC and the RRM each contain a microcontroller and programming that allows them to
communicate with other electronic modules in the vehicle using the Controller Area Network - B (CAN -
B) data bus. Refer to COMMUNICATION, DESCRIPTION AND OPERATION .
The navigation system components cannot be adjusted or repaired. If any of the navigation system
components is damaged or ineffective, that component must be replaced. The external combination
antenna can be repaired separately from the RRM. The navigation system software as well as the map
data is flash programmable through the Universal Serial Bus (USB) port.
DESCRIPTION AND OPERATION > NAVIGATION > OPERATION - NAVIGATION
The optional navigation system is active whenever the Radio Receiver Module (RRM) electronic display
is powered On. If a navigation system menu or map isn't being actively displayed, the system is still
operating in the background. The menu, map or route that was active when the RRM was powered Off
along with all other user-relevant information is saved in nonvolatile memory by the navigation module for
display again the next time the RRM electronic display is powered On and the navigation system is
selected.
Once a destination is selected, the navigation system uses information from stored map data to quickly
calculate a route. As the vehicle is driven along that route, the vehicle operator is guided with visual
displays and voice prompts. Any variances from that route will cause the navigation system to
automatically recalculate and deliver a revised route to the chosen destination.
When Turn-By-Turn Navigation is enabled through the Personal Settings menu of the Electronic Vehicle
Information Center (EVIC), the EVIC supplements the RRM display with a more focused turn-by-turn
display which includes: the name of the approaching crossroad, an arrow indicating the upcoming turn
direction and a countdown to indicate the distance to that turn.
All vehicles have their original map and Points-Of-Interest (POI) data stored in nonvolatile flash memory
integral to the navigation module integral and internal to the RRM. Updated map and POI data as well as
updated navigation software for these vehicles can be uploaded to the system using USB media. The
originally installed data is based upon the market for which the vehicle was manufactured. Navigation
software updates are also uploaded to the system using USB media.
The GPS receiver of the navigation module is capable of acquiring and tracking GPS signal inputs
through the roof-mounted combination antenna from numerous satellites simultaneously to calculate and
display the position and direction of the vehicle. However, when access to satellite signals is blocked by
bridges, tunnels or other obstacles, the navigation module relies upon Dead Reckoning (DR) to aid in
calculating vehicle position and direction. The navigation module uses pulse signals from the wheel
speed sensors, a Reverse gear indicator input and an internal electronic gyroscope sensor to provide
DR vehicle position and direction calculations to supplement GPS satellite signals.
User input mechanisms for the navigation system include the RRM touchscreen and the Uconnect™
Hands-Free VR verbal commands. The VR function uses ASR software. Master control of the VR
function is handled by the VR engine internal and integral to the RRM. The VR recognizes and responds
to certain global commands, while other commands are specific to the RRM or the navigation system.
For safety reasons some input, editing and setting features of the navigation system are restricted when
the vehicle is in motion or when a hands-free phone call is active. This includes many features that
require touchscreen inputs. However, many of those same features disabled for touchscreen inputs
remain enabled for Uconnect™ Hands-Free VR inputs.
The navigation module receives electronic message inputs within the RRM over the Controller Area
Network - B (CAN - B) data bus; however, the RRM is not a CAN gateway. All electronic message
outputs of the navigation module and the RRM are carried over the CAN - B data bus. When the RRM
monitors a problem in any of the audio system circuits and components, or in any of the navigation
system antenna circuits, it stores a fault code or Diagnostic Trouble Code (DTC) in its memory circuit.
The external combination antenna may be diagnosed separately from the RRM.
The hard wired circuits between components related to the RRM and the navigation system may be
diagnosed using conventional diagnostic tools and procedures. Refer to the appropriate wiring
of the navigation system. The most reliable, efficient and accurate means to diagnose the RRM or the
electronic controls and communication related to navigation system operation requires the use of a
diagnostic scan tool. Refer to the appropriate diagnostic information.
DESCRIPTION AND OPERATION > DESCRIPTION AND OPERATION - UCONNECT

ACCESS > DESCRIPTION - UCONNECT ACCESS
A Uconnect™ Access system is factory-installed optional equipment that uses an embedded cellular
module within the Radio Receiver Module (RRM) to enable several mobile connectivity features.
Vehicles equipped with the Uconnect™ Access system can be readily identified by two switch buttons in
the front roof lamp unit identified with ASSIST and 9-1-1 labels.
To enable Uconnect™ Access, a subscription must be completed by the customer. Detailed directions
for subscription along with other information relating to Uconnect™ Access can be found on
www.driveuconnect.com or within the Uconnect™ owner's manual supplement for the supported
radios.
NOTE:
A free trial period of Uconnect™ Access may be offered with the sale of a new vehicle.
Registration will be required to activate the trial subscription.
Subscription to Uconnect™ Access provides many features that allow cellular smart phones to be put
away in favor of the integrated mobile connectivity features and functionality accessible through the use
of the radio, steering wheel and voice controls in the vehicle. All Access features are only available
based on subscription. Features are continually being added or changed and offerings at the time this
information was last updated included:
9-1-1/Assist - The following call features are executed through the embedded cellular module of
the RRM:
9-1-1 - Pressing the 9-1-1 button will initiate an emergency call to a Public Safety Answering
Point (PSAP). The Global Positioning System (GPS) coordinates of the vehicle are made
available to the emergency operator in the event help needs to be sent. In addition it opens a
two way voice channel with the emergency operator allowing communication between the
vehicle occupant and the emergency operator.
Assist - Pressing the ASSIST button will present the customer with three choices.
Uconnect™ Care, Vehicle Care or Roadside Assistance. These selection options are
presented as soft keys in the RRM display. Selecting any one of these choices will place a
call to the selected group. If there are questions about Uconnect™ Services, Uconnect™
Care can be contacted; if there are questions related to vehicle functionality, Vehicle Care
can be contacted; or, if Roadside Assistance is needed, a direct call can be made.
Applications - Some of the Uconnect™ Access applications (apps) presently available include:
Points Of Interest Search - A Points Of Interest (POI) Search app gives the vehicle owner
access to Yelp (POI) local business and destination information previously available on the
Internet or through a mobile app, adapted for use on the radio in their vehicle. The Yelp POI
Search app provides searches using predefined search categories, or custom searches
using keywords and voice recognition.
Via Mobile - The Via Mobile app leverages apps already installed on a compatible and paired
iPhone or Android smart phone to enable accessibility to streaming Internet audio content
through the RRM and audio system components within the vehicle. This app enables one
touch access and a hands-free, radio-like user interface with no expenses besides those
already being incurred to access the same content through the existing smart phone data
plan. There are presently smart phone apps available for streaming audio content such as
Aha Radio, iHeart Radio, Pandora and Slacker. When additional apps are made available
there could potentially be access to streaming news, sports, weather, social media, comedy,
audio books and other content such as special interest podcasts.
Notifications - Customers have the option to sign up for automatic electronic mail (email) or text
message (Short Message Service/SMS) notifications when an Access remote services command
is processed or if their vehicle theft alarm has been triggered. These notifications are set up
through the Mopar® Owner Connect account of the customer (www.MoparOwnerConnect.com ).
Remote Services - The distance of remote services normally available through the Remote
Keyless Entry (RKE) FOB with Integrated Key (FOBIK) can be extended through cellular
connectivity. These services may include remote door Lock/Unlock, remote horn and lights (Panic
Mode) and remote start. An active Access subscription is required and the customer must install
the Uconnect™ Access Via Mobile smart phone app on their phone. The app can be obtained
through the Mopar® Owner Connect account of the customer (www.MoparOwnerConnect.com )
or by downloading it from the play store for their phone. Once the smart phone app is installed, the
remote services can be controlled by the customer on line through their Mopar® Owner Connect
account.
NOTE:
Remote services are only available based on factory installed options. Options
installed at the dealer are not eligible for these services.
Stolen Vehicle Assistance - If the vehicle is stolen, stolen vehicle assistance can be used to
help the police locate the vehicle. This service is based on the request of the customer to
Uconnect™ Care and must first be reported to local authorities and a police report reference
number obtained. Uconnect™ Care will not provide stolen vehicle assistance without a police
report reference number.
Voice Texting - Voice Texting enhances the Voice Text Reply feature of the Uconnect™ Access
subscription. While Voice Text Reply provides pre-formatted messages, it also lets the customer
create custom messages. A message is spoken as if talking to the intended message recipient and
the Uconnect™ Access voice-to-text technology converts the voice message into a text message.
NOTE:
Voice Texting and Voice Text Reply are compatible with most phones that support
Bluetooth Message Access Protocol (MAP) or AT Messaging Protocol. Always check
compatibility by accessing Mobile Device Support at: Uconnectphone.com . These
features are not available in all markets.
Wi-Fi Hot Spot - Vehicles equipped with the Uconnect™ Access system can become a Wi-Fi hot
spot with payment of a daily, weekly or monthly subscription option. This system allows the use of
the vehicle as a Wi-Fi hot spot for connecting consumer Wi-Fi devices to the Internet through a
Wi-Fi antenna and an embedded cellular connection that are internal and integral to the RRM and
the external cellular combination antenna. The external combination antenna can be repaired
separately from the RRM. The Wi-Fi Hot Spot system software is flash programmable through the
Universal Serial Bus (USB) port.
Refer to www.driveuconnect.com for the latest information and helpful videos describing all of the
Uconnect™ services and offerings. The Uconnect™ Access system includes the following major
components, which are described in further detail elsewhere in this service information:
Access Switches - In vehicles equipped with Uconnect™ Access, the front roof lamp unit also
contains two integral push button switches and a Light Emitting Diode (LED) indicator located on
the rearward-facing housing for activation of the ASSIST and 9-1-1 features.
Bluetooth™ Antennas - Bluetooth™ antennas are internal and integral to the RRM.
Bluetooth™ Phone - A customer-supplied and paired Bluetooth™ smart phone is a required

component of the Uconnect™ Access system to enable remote services.
Body Control Module - The Body Control Module (BCM) is the configuration master node for the
vehicle. Refer to MODULE, BODY CONTROL, DESCRIPTION AND OPERATION .
Combination Antenna - The RRM sends and receives cellular data through a roof-mounted
combination antenna that also receives satellite audio and GPS navigation signals. Refer to
ANTENNA, SATELLITE, AUDIO, DESCRIPTION AND OPERATION .
Electronic Vehicle Information Center Switch Pod - The Electronic Vehicle Information Center
(EVIC) switch pod is located in the left horizontal spoke of the steering wheel. In addition to the
EVIC switch buttons the lower portion of this switch pod contains the Voice Recognition (VR)
switch button and the Phone switch button of the hands-free phone system. Refer to SWITCH,
EVIC CONTROL, DESCRIPTION AND OPERATION .
Microphone - A microphone is integral to the roof lamp unit in the headliner near the center of the
upper windshield opening header panel in vehicles equipped with the Uconnect™ Hands Free
Phone system. Refer to MICROPHONE, DESCRIPTION AND OPERATION .
Occupant Restraint Controller - The Occupant Restraint Controller (ORC) module has a
dedicated hard wired circuit that provides an input to the RRM whenever a Supplemental Restraint
System (SRS) deployment occurs in the vehicle. Refer to MODULE, OCCUPANT RESTRAINT,
Radio Frequency Hub Module - The Radio Frequency Hub Module (RFHM) is a key component
of the Uconnect™ Access remote vehicle services feature. The RFHM is located on the upper
liftgate opening header and concealed above the headliner within the passenger compartment.
Refer to MODULE, RADIO FREQUENCY (RF HUB), DESCRIPTION AND OPERATION .
Radio Receiver Module - The RRM is located near the top of the instrument panel center stack
area and is the primary component of the Uconnect™ Access system in this vehicle. The RRM
includes a microcontroller, a Bluetooth™ transceiver, a navigation module, flash memory and
sophisticated Advanced Speech Recognition (ASR) input capability through VR software. The ASR
software includes many different available languages. Each vehicle is equipped with a list of
available languages, which are made available from the factory based upon languages most
commonly used for the market destination. Refer to MODULE, RADIO RECEIVER, DESCRIPTION
AND OPERATION .
Uconnect™ Access Registration And Applications - Uconnect™ Access registration must be

completed before individual RRM apps or Uconnect™ Access subscription packages can be
purchased from the Uconnect™ Store Front. The Uconnect™ Access Via Mobile smart phone app
must also be installed on the user's compatible smart phone for the remote vehicle services
features to operate. Many additional Uconnect™ Access apps are under development for later
release.
Wi-Fi Antenna - The Wireless Local Area Network (WLAN) (also known as Wi-Fi) antenna is
internal and integral to the RRM.
Wi-Fi Device - A customer-supplied Wi-Fi capable device is a required component of the Wi-Fi
Hot Spot system.
The RRM contains a microcontroller and programming that allows it to communicate with other electronic
modules in the vehicle over the Controller Area Network - B (CAN - B) data bus. In vehicles equipped
with Uconnect™ Access, the RRM also uses electronic message communication with other electronic
modules in the vehicle over the CAN - C data bus. Refer to COMMUNICATION, DESCRIPTION AND
OPERATION .
The Uconnect™ Access system components cannot be adjusted or repaired. If any Uconnect™ Access
system component is damaged or ineffective, that component must be replaced. The external
combination antenna can be repaired separately from the RRM. The Uconnect™ Access system
software is flash programmable through the USB port.
DESCRIPTION AND OPERATION > DESCRIPTION AND OPERATION - UCONNECT

ACCESS > OPERATION - UCONNECT ACCESS
Uconnect™ Access capability relies on cellular (telematics) technology and subscribed services that are
controlled through Digital Rights Management (DRM). The management or DRM along with specific
services occur wirelessly through the cloud. Digital rights and a subscription determine the specific
services a customer is eligible to receive. Data feeds between Chrysler assembly plants and its radio
suppliers are provided to the cellular provider to enable initial capability or provisioning. This initial data
must exist in the database of the cellular provider or functionality will be unavailable. Base features are
supported through software that exists within the applicable RRM platform and cellular connectivity is
provided through the embedded cellular module.
Signal strength and data capability is shown adjacent to the Apps orb soft key found at the lower right
corner of the radio touchscreen. Relative signal strength is indicated by a bar graph and data capability
is indicated by the display of either a 3G (full capability), 1X (text capable only) or a 0 with a strike-
through symbol (no data capability). Depending on location and coverage, data capability can change.
Signal strength is a major factor for any wireless connectivity. Third Generation (3G) data is the highest
connectivity available at this time. Remote Service features (Start, Lock, Unlock, etc.) rely on data
capability. If the vehicle is located in an area of no or low coverage, the Remote Services features may
not function. Signal strength and data capability can suffer from the same situations any cellular device
might experience. Parking structures, blocks, drops and dead zones can affect performance at any time.
The two switch buttons on the front roof lamp unit identified with ASSIST and 9-1-1 provide a hard
wired input to the Local Interface Network (LIN) slave node integral to the front roof lamp unit. The LIN
slave node sends an electronic switch press message to the LIN master node integral to the BCM. The
BCM relays the message over the CAN - B data bus, where it is retrieved by the RRM.
If the vehicle has the optional Uconnect™ Access Via Mobile application (also known as app)
downloaded, installed and enabled on their smart phone their Uconnect™ Access subscription can
provide remote services features. In the Uconnect™ Access system the Via Mobile app on the smart
phone calls the RRM in the vehicle. The RRM communicates through electronic messages over the CAN
- C data bus with the RFHM and the RFHM communicates over the CAN - C bus with the BCM to
achieve the requested remote features. While the RRM uses electronic message communication over
both the CAN - C data bus and the CAN - B data bus, the RRM is not a CAN gateway.
If a Bluetooth™ phone is SMS text message capable and compatible with the Uconnect™ Access
system (see the Uconnect™ web site for a phone compatibility list), a Uconnect™ Access subscription
provides an enhanced Voice Texting feature. This SMS text message free form dictation feature is used
to compose a response when a text message is received. The call or SMS text message is relayed to
the Bluetooth™ transceiver embedded within the RRM. The Bluetooth™ transceiver then instructs the
RRM to announce the incoming call or message. The vehicle operator presses the Uconnect™ Phone
button in the EVIC switch pod or the soft button that will appear in the RRM touchscreen display to
accept the message and dictate a response.
The optional Wi-Fi hot spot feature of Uconnect™ Access utilizes the same operating principles and
components as Uconnect™ Access for wireless connectivity. Digital rights to the Wi-Fi hot spot feature
are provided based on a subscription separate from Uconnect™ Access. Several wireless devices can
be supported in vehicles with the Wi-Fi hot spot feature and security to prevent unauthorized access can
be enabled by the customer.
The hard wired circuits between components related to the RRM and the Uconnect™ Access system
may be diagnosed using conventional diagnostic tools and procedures. Refer to the appropriate wiring
of the Uconnect™ Access system. The most reliable, efficient and accurate means to diagnose the RRM
or the electronic controls and communication related to Uconnect™ Access system operation requires
the use of a diagnostic scan tool. Refer to the appropriate diagnostic information.
DIAGNOSIS AND TESTING > DIAGNOSIS AND TESTING - HANDS FREE PHONE
WARNING:
The hard wired circuits between components related to the Radio Receiver Module (RRM) and the
Uconnect™ Hands Free Phone system may be diagnosed using conventional diagnostic tools and
procedures. Refer to the appropriate wiring information. The wiring information includes wiring diagrams,
proper wire and connector repair procedures, details of wire harness routing and retention, connector
pin out information and location views for the various wire harness connectors, splices and grounds.
of the Uconnect™ Hands Free Phone system. The most reliable, efficient and accurate means to
diagnose the RRM or the electronic controls and communication related to Uconnect™ Hands Free
Phone system operation requires the use of a diagnostic scan tool. Refer to the appropriate diagnostic
information.
NOTE:
The MIT019 Multi-Media Interface Tester special tool may also be used for testing
where no Diagnostic Trouble Code (DTC) has been recorded, such as with Bluetooth™
reception and phone pairing issues. Refer to DIAGNOSIS AND TESTING .
NOTE:
Validation and diagnosis of many of the conditions listed below will require access to
both the paired Bluetooth™ device and the PIN required for that device.
HANDS FREE PHONE DIAGNOSIS
1. Bluetooth phone not 1. Be certain that the phone is Bluetooth

paired to the RRM. compatible and is paired to the RRM.
2. Be certain that the paired phone is

2. Bluetooth phone not
present, turned On and that the Bluetooth
present or turned Off.
option is enabled in the phone.
3. At low battery levels, some phones will

3. Bluetooth phone has low turn Off Bluetooth functionality. Be certain
PHONE NOT AVAILABLE battery. that the phone battery is charged to an
adequate level.
4. The boot procedure for

4. Cycle both the RRM and the phone Off,
the RRM, the phone or both
then On again in an attempt to complete a
did not complete
successful boot procedure.
successfully.
5. A phone freeze has 5. Power cycle the phone. Refer to the

occurred. operator's manual for the phone.
1. The Bluetooth transceiver requires that

the cellular phone be Bluetooth enabled. The
1. The phone is not phone must be upgraded to one that is
Bluetooth enabled. Bluetooth enabled. A list of suggested
phones is available at:
http://www.chrysler.com/uconnect .
PHONE PAIRING FAILED
2. The Bluetooth transceiver requires that
the cellular phone support the Hands-Free
2. The phone does not
Profile. The phone must be upgraded to one
support the Bluetooth
that supports the Hands Free Profile. A list of
Hands Free Profile.
suggested phones is available at:
http://www.chrysler.com/uconnect
3. Incorrect discovered 3. Be certain to select Uconnect in the
Bluetooth device selected discovered Bluetooth™ devices in the phone
in phone. for pairing.
4. The PIN of the phone is

not the same as the PIN 4. The PIN assigned by the RRM during
assigned by the RRM during pairing must match the PIN of the phone.
pairing.
5. To unlock phone pairing in the phone, be

5. Phone pairing is locked
certain that password protection is turned
(password protected).
Off.
6. The RRM has reached

6. Remove one of the previously paired
the maximum number of
devices from the paired list of the RRM.
allowed devices paired.
7. Remove one of the previously paired

7. The phone has reached
devices from the paired list of the phone, or
the maximum number of
delete the pairing history from the phone.
allowed devices paired.
Refer to the operator's manual for the phone.
8. The boot procedure for

8. Cycle both the RRM and the phone Off,
did not complete
successfully.
9. Perform a hard reset (power cycle) to the

9. A phone freeze has
phone. Refer to the operator's manual for the
occurred.
phone.
1. Bluetooth settings in phone should be set

1. Bluetooth settings in
to auto-connect or select Uconnect™ as a
phone are incorrect.
trusted device in phone.
2. To unlock phone pairing in the phone, be

2. Phone pairing is locked
certain that password protection is turned
(password protected).
PHONE WILL NOT Off.
RECONNECT AFTER 3. The boot procedure for
PAIRING 3. Cycle both the RRM and the phone Off,
did not complete
successfully.
4. Perform a hard reset (power cycle) to the

4. A phone freeze has
phone. Refer to the operator's manual for the
occurred.
phone.
1. User is not waiting for the

1. Be certain the user knows to wait for the
beep tone
acknowledgment beep tone prior to issuing
acknowledgment before
Voice Commands.
issuing Voice Commands.
POOR VOICE
RECOGNITION 2. Be certain the user is issuing Voice
2. User is not issuing Voice Commands in a normal, smooth and
Commands in a smooth and consistent speaking voice. The Advanced
consistent speaking voice. Speech Recognition (ASR) engine is
designed to recognize normal speech
patterns and at a normal tone. Some users
tend to speak to a computer loud and slow,
which results in reduced performance.
3. User is not using proper 3. User must speak using proper Voice
Voice Command syntax. Command syntax.
4. ASR engine performance is increased

4. High noise levels within when noise conditions in the passenger
the passenger compartment are lowered. Ideal conditions
compartment. include having the windows closed and the
blower fan set to Low or Off.
5. Although designed to focus on sounds

from the driver's seated position, the
5. Passengers are talking
directional microphone will pick up sounds
while the user is attempting
from any seating position in the vehicle. ASR
to issue a Voice Command.
engine performance is increased in low
noise environments.
6. Verify that there are no foreign objects

6. Foreign objects
hanging from the inside rear view mirror that
interfering with microphone
could be interfering with microphone
input.
reception.
7. The front roof lamp unit is 7. The front roof lamp unit must be firmly
not properly attached to the mounted to the mounting location. Be certain
mount. the lamp unit is properly installed.
8. Phone features are accessed using the

Uconnect Phone button on the steering
8. The incorrect Uconnect
wheel or the Phone soft key in the RRM
switch button is being
display. Other Uconnect Voice Command
depressed.
features are accessed using the Uconnect
VR button or soft key.

9. Microphone failure. appropriate diagnostic procedures for further
diagnosis of the microphone.
1. The Uconnect system requires that the

cellular phone support the PBAP profile. To
1. Phone does not support enable the Uconnect phone book download
the Phone Book Access feature, the phone must be upgraded to one
Profile (PBAP). that is PBAP enabled. A list of suggested
phones is available at:
PHONE BOOK DOES NOT
DOWNLOAD 2. Be certain that phone book transfer is
2. Phone book transfer not
accepted or enabled in the phone during
enabled in phone during
pairing to enable the Uconnect phone book
pairing.
download feature.
3. Missing contacts from 3. Only contacts with a phone number are

downloaded phone book. downloaded from phone and the number of
contacts downloaded is limited to 1000.
1. User is not waiting for the

beep tone
Voice Commands.
2. Be certain the user is issuing Voice

Commands in a normal, smooth and
2. User is not issuing Voice consistent speaking voice. The ASR engine
Commands in a smooth and is designed to recognize normal speech
consistent speaking voice. patterns and at a normal tone. Some users
tend to speak to a computer loud and slow,
which results in reduced performance.
3. User must speak using proper Voice

3. User is not using proper
Command syntax (i.e.: say Call - then name,
Voice Command syntax.
or say Dial - then number).
4. For increased performance, it is

4. Phone book names too recommended to use both first and last
short. names for phone book entries. Example:
Daniel Johnson as opposed to Dan .
5. Name not spoken by user

5. Speak the full contact name as it appears
as it appears in the phone
in the phone book. Do not use nicknames.
book.
PHONE BOOK NAMES NOT 6. For increased performance it is
RECOGNIZED 6. Multiple similar sounding
recommended that the user do not enter
CONSISTENTLY names in the phone book.
similar sounding names in the phone book.
7. Depending upon the size of the contact list

on the phone, the download may not have
7. Phone book download had time to complete. If the Phone Book
not yet completed. button on the RRM phone screen appears
grayed out, the contact list download is still
in progress. Wait until download completes.


directional microphones will pick up sounds
noise environments.

10. Foreign objects
input.
reception.
11. The front roof lamp unit 11. The front roof lamp unit must be firmly
is not properly attached to mounted to the mounting location. Be certain
the mount. the lamp unit is properly installed.

Uconnect Phone button on the steering
wheel or the Phone soft key in the RRM
display. Other Uconnect Voice Command
depressed.
features are accessed using the Uconnect
VR button or soft key.



directional microphones will pick up sounds
POOR PHONE AUDIO noise environments.
QUALITY
3. Foreign objects
input.
reception.
4. The front roof lamp unit is 4. The front roof lamp unit must be firmly
not properly attached to the mounted to the mounting location. Be certain
mount. the lamp unit is properly installed.

1. The settings in the phone

1. Route the phone audio to the hands free
NO PHONE AUDIO cause the phone audio to
device.
be routed to a handset.
1. The Uconnect system requires that the

cellular phone support the call log feature. To
enable the Uconnect call log feature, the
1. Call log not supported by
phone must be upgraded to one that is call
phone.
CALL LOG INOPERATIVE log enabled. A list of suggested phones is
OR INACCURATE available at: http://www.chrysler.com
/uconnect
2. The phone is not

2. Refer to the operator's manual for the
providing accurate call log
phone.
data.
1. Volume setting on the 1. Set the volume of the phone or other
Bluetooth device set too Bluetooth device to about three quarters
low. (3/4) of full or maximum volume.
AUDIO OUTPUT TOO LOW
2. Set the volume of the RRM to the desired
2. Volume setting on the
level during an active Uconnect Hands Free
RRM set too low.
Phone call session.
DIAGNOSIS AND TESTING > DIAGNOSIS AND TESTING - NAVIGATION
WARNING:
Uconnect™ Navigation system may be diagnosed using conventional diagnostic tools and procedures.
of the Uconnect™ Navigation system. The most reliable, efficient and accurate means to diagnose the
RRM or the electronic controls and communication related to Uconnect™ Navigation system operation
requires the use of a diagnostic scan tool. Refer to the appropriate diagnostic information.
DIAGNOSIS AND TESTING > DIAGNOSIS AND TESTING - UCONNECT ACCESS
WARNING:
Uconnect™ Access system may be diagnosed using conventional diagnostic tools and procedures.
of the Uconnect™ Access system.
A Light Emitting Diode (LED) indicator integral to the front roof lamp unit push buttons provides an
indication of the status of the Uconnect™ Access embedded cellular device. Any fault indication is
accompanied by a pop up screen in the RRM electronic touchscreen display. The following indications
are provided whenever the status of the ignition is On or Accessory:
Solid Green - No active call.
Flashing Green - A Uconnect™ Access Care or 9-1-1 call is active.
Solid Red - A CAN, embedded cellular device, cellular antenna or wiring fault has been detected.
Off - No power supply to the front roof lamp unit.
In addition to the LED indicator in the push button, one of the following error messages may appear in
the RRM touchscreen display. These error messages will coincide with a solid red push button LED
indication.
Critical VIN Error - This message typically indicates the radio data was not provisioned with the
back end database, or that critical data within the RRM is missing. Diagnosis of this type of failure
will require the assistance of the network provider.
1. Enter the Dealer Mode menu by selecting the temperature up, temperature down and
front defrost buttons simultaneously until the menu appears (about 5 to 8 seconds).
1. Navigate through the System Information menu to the Radio Part

Information menu.
2. Write down the Serial Number listed on the Radio Part Information
menu. The serial number begins with the characters, T00BE .
2. Navigate back to the Dealer Mode menu.
1. Navigate through the ##Menu Basic menu to the ##RTN# menu.
2. Write down the MDN number listed on the ##RTN# menu.
3. Write down the MSID number listed on the ##RTN# menu.
3. Place a call to Uconnect™ Care. Provide your dealer code, name, call back number
and the Vehicle Identification Number (VIN). Request a ticket be opened with the
network engineers to assist with Uconnect™ Access diagnostics. A ticket will be
opened with the network engineers and a call back will occur within 15 minutes for
further assistance and diagnostics.
Vehicle Phone Requires Service - This message can indicate a fault with the antenna, the front
roof lamp unit, communication with the Occupant Restraint Controller (ORC) module or any of the
hard wired circuits between these components. Check for an active or stored Diagnostic Trouble
Code (DTC) for any of the listed components. Follow all of the steps found in the diagnostic
information for the retrieved DTC and fully check the hard wired circuitry associated with the DTC.
If no DTC can be retrieved, an internal failure within the RRM may exist.
The Wi-Fi hot spot feature can only be diagnosed if the customer has subscribed for this additional
feature. The same diagnostic steps associated with Uconnect™ Access will be used for Wi-Fi hot spot
as they share the same network. In addition, each of the wireless devices of the customer must be
properly paired for them to work.
NOTE:
The MIT019 Multi-Media Interface Tester special tool may also be used for testing
where no DTC has been recorded, such as with Bluetooth™ reception and phone
pairing issues. Refer to DIAGNOSIS AND TESTING .
NOTE:
Validation and diagnosis of many of the conditions listed below will require access to
both the paired Bluetooth™ device and the PIN required for that device.
UCONNECT ACCESS DIAGNOSIS
1. User is not waiting for

the beep tone
Voice Commands.
2. Be certain the user is issuing Voice

Commands in a normal, smooth and consistent
2. User is not issuing speaking voice. The Advanced Speech
Voice Commands in a Recognition (ASR) engine is designed to
smooth and consistent recognize normal speech patterns and at a
speaking voice. normal tone. Some users tend to speak to a
computer loud and slow, which results in reduced
POOR VOICE performance.
RECOGNITION
3. User is not using proper 3. User must speak using proper Voice
Voice Command syntax. Command syntax.
4. ASR engine performance is increased when

4. High noise levels within noise conditions in the passenger compartment
the passenger are lowered. Ideal conditions include having the
compartment. windows closed and the blower fan set to Low or
Off.
5. Passengers are talking 5. Although designed to focus on sounds from

while the user is the driver's seated position, the directional
attempting to issue a microphone will pick up sounds from any seating
Voice Command. position in the vehicle. ASR engine performance
is increased in low noise environments.
6. Foreign objects 6. Verify that there are no foreign objects

interfering with hanging from the inside rear view mirror that
microphone input. could be interfering with microphone reception.
7. The front roof lamp unit 7. The front roof lamp unit must be firmly
is not properly attached to mounted to the mounting location. Be certain the
the mount. lamp unit is properly installed.

Uconnect Phone button on the steering wheel
or the Phone soft key in the RRM display. Other
Uconnect Voice Command features are
depressed.
accessed using the Uconnect VR button or soft
key.

1. The Uconnect system requires that the cellular

phone support the Bluetooth MAP for the text
1. The Bluetooth Message
messaging feature. To enable the Uconnect text
Access Profile (MAP) is
messaging feature, the phone must be upgraded
not supported by the
to one that supports Bluetooth MAP. A list of
TEXT MESSAGING phone.
INOPERATIVE http://www.chrysler.com/uconnect
2. The Connect-To-Your-
2. Accept the Connect-To-Your-Messages
Messages setting has not
setting on the phone. Refer to the operator's
been accepted on the
manual for the phone.
phone.
1. Select the Apps soft key in the RRM display,

then select the Uconnect Registration App
1. Uconnect registration soft key from the Apps list. For further
incomplete. assistance press the ASSIST button on the
front roof lamp unit to contact Uconnect
Customer Care.
2. This feature is only available with the

2. Uconnect Access
Uconnect Access Advantage subscription
ENHANCED VOICE- subscription service is
service. Be certain that the subscription service
TO-TEXT (DICTATED) inactive.
account is active in the RRM.
MESSAGING
RESPONSE FEATURE 3. The Uconnect system requires that the cellular
INOPERATIVE phone support the Bluetooth MAP for the text
3. The Bluetooth MAP is messaging feature. To enable the Uconnect text
not supported by the messaging feature, the phone must be upgraded
phone. to one that supports Bluetooth MAP. A list of
4. The Connect-To-Your- 4. Accept the Connect-To-Your-Messages

Messages setting has not setting on the phone. Refer to the operator's
been accepted on the
manual for the phone.
phone.

UNABLE TO PURCHASE
Customer Care.
APPLICATIONS FROM
UCONNECT STORE 2. Set up a valid wallet for the Uconnect store
FRONT 2. Wallet is not set up. front in order to purchase application
subscriptions.
3. Refer to the Audio And Video System service

3. Cellular antenna issue. information for further diagnosis of the cellular
(combination) antenna.

Customer Care.
2. Be certain that the phone is compatible and is

2. Phone is not paired to the RRM. A list of suggested phones is
compatible. available at: http://www.chrysler.com
/uconnect .
3. Download the Uconnect Access Via Mobile

app to the user's smart phone from
www.MoparOwnerConnect.com . Allow
3. Uconnect Access Via
sufficient time for the Uconnect Access Via
REMOTE SERVICES Mobile application (app)
Mobile application (app) download to smart
INOPERATIVE not downloaded or not fully
phone to complete. Download times will vary
installed to smart phone.
widely with the throughput performance of the
user's smart phone and the accessibility of the
user's cellular network services.
4. This feature is only available with the

4. Uconnect Access
Uconnect Access Advantage subscription
subscription service is
inactive in the RRM.

(combination) antenna.
5. Further diagnosis of the RFHM requires the

5. Radio Frequency Hub
use of a diagnostic scan tool and the appropriate
Module (RFHM) issue.
diagnostic procedures.
1. Volume setting on 1. Set the volume of the phone or other

AUDIO OUTPUT TOO
Bluetooth device set too Bluetooth device to about three quarters (3/4) of
LOW
low. full or maximum volume.
2. Set the volume of the RRM to the desired
2. Volume setting on the
level during an active Uconnect Access feature
RRM.
session.
1. Ignition status must be On or Accessory

1. Status of ignition is Off.
during Uconnect Access operation.
UCONNECT ACCESS 2. Front roof lamp unit 2. Be certain the wire harness for the front roof
INOPERATIVE - NO wiring not connected. lamp unit is connected and fully engaged.
GREEN OR RED LED 3. Ineffective ground 3. Test and repair the open front roof lamp unit
INDICATOR circuit. ground circuit if required.
4. Test and repair the open front roof lamp unit

4. Ineffective feed circuit.

Customer Care.
UCONNECT ACCESS
INOPERATIVE - GREEN 2. Many Uconnect Access features are only
2. Uconnect Access
LED INDICATOR available with the Uconnect Access subscription
subscription service is
inactive in the RRM.
3. Uconnect Access 3. Perform the Uconnect Access System

application (app) corrupt Reinstall Applications Standard Procedure. Refer
or improperly installed. to STANDARD PROCEDURE .
1. Further diagnosis of CAN - B or CAN - C

1. Loss of Controller Area
communication requires the use of a diagnostic
Network - B (CAN - B) or
scan tool and the appropriate diagnostic
CAN - C communication.
procedures.
UCONNECT ACCESS 2. Refer to the Audio And Video System service

INOPERATIVE - RED 2. Cellular antenna issue. information for further diagnosis of the cellular
LED INDICATOR (combination) antenna.
3. Further diagnosis of the RRM requires the use

3. Ineffective embedded of a diagnostic scan tool and the appropriate
cellular device. diagnostic procedures. Test and replace the
RRM, if required.

WI-FI HOT SPOT front roof lamp unit to contact Uconnect
INOPERATIVE Customer Care.
2. Uconnect Wi-Fi 2. This feature is only available with the

subscription service is Uconnect Wi-Fi subscription service. Be certain
inactive or expired in the that the subscription service account is active in
RRM. the RRM.
3. Wi-Fi capability is not 3. Confirm Wi-Fi setting in user's Bluetooth
enabled in user's device is enabled. Refer to the user's manual for
Bluetooth device. that device.
4. Selected Wireless 4. Confirm that correct WAP is selected in user's

Access Point (WAP) is Bluetooth device. Refer to the user's manual for
incorrect. that device.
5. Wireless Access Point 5. Use the Application Settings menu of the RRM
(WAP) password or display to confirm or adjust the WAP password
security settings incorrect. and security settings.

antenna.
STANDARD PROCEDURE > NAVIGATION SYSTEM - RESTORE OR UPDATE
Navigation System map and Point-Of-Interest (POI) data updates may become available occasionally
through the Navteq Maps web site (www.navigation.com). The updated information as well as some
additional feature applications can be downloaded and copied to Universal Serial Bus (USB) media for
transfer and installation to the navigation module within the Radio Receiver Module (RRM) in the vehicle.
These are fee-based applications and updates, which are made at the option and expense of the
customer.
However, a new RRM is equipped with only a standard base version of the map and POI data. Before an
original RRM is replaced by the dealer with a new unit, the version of the map and POI data on the
original RRM must be noted. If the version of the map and POI data found on the new RRM is not equal
to or newer than the version that was found on the replaced RRM, updated data will have to be
downloaded and installed to the new RRM at the expense of the dealer.
STANDARD PROCEDURE > UCONNECT ACCESS SYSTEM - REINSTALL

APPLICATIONS
NOTE:
The following procedure may assist the dealer technician in diagnosis by reloading
the applications for which the vehicle owner or operator has valid subscriptions. This
is primarily used to troubleshoot any application provisioning or data corruption
issues. The reinstallation process may take up to 30 minutes, depending upon the
number of apps and the cellular signal strength seen on the Apps orb of the Radio
Receiver Module (RRM). In addition, reinstalling applications may correct a Digital
Rights Management (DRM) concern that is causing a No Subscription error for
customers that were fully registered. This process may also help force DRM
synchronization following a software or firmware update.
The Reinstall Applications procedure can only be initiated from the touchscreen of the RRM.
During this procedure, the subscribed applications are removed from the RRM and reinstalled based
upon data found on the cloud server. The applications reinstalled onto the RRM will be based upon valid
subscriptions and is referred to as Digital Rights.
1. Navigate through the Apps > Uconnect Store > My Apps > Settings on the RRM
touchscreen.
2. Select Reinstall Apps .
3. Press the Continue soft key to initiate the Reinstall Applications procedure, or press the
Help soft key for more information.
4. When the Apps reinstalled. Radio will restart shortly. screen appears, press the OK soft
key.
5. Once the request is processed, a screen will appear alerting the customer with the message,
Important: Application Data Reset Initiated. After Radio Resets, all application data will
be lost. Please Wait. After the RRM reset occurs, the apps will begin to be reinstalled. The
reinstallation process may take up to 30 minutes, depending upon the number of apps and the
cellular signal strength seen with the bar graph on the Apps soft key orb in the lower right
corner of the RRM touchscreen.
NOTE:
One or two ignition cycles (including bus time-outs) may speed the reloading process
following the radio reset.
STANDARD PROCEDURE > UCONNECT ACCESS SYSTEM - REMOVE ACCOUNTS
NOTE:
The following procedure is provided to the dealer technician as INFORMATION ONLY.

This procedure is intended for use by the vehicle owner or operator. This procedure is
used when selling the vehicle or cancelling the Uconnect Access account. Removing
the account will disassociate the Vehicle Identification Number (VIN) from the account
and remove Uconnect Access features from the vehicle. The Uconnect Access
features can be reinstated by repeating the registration process through the Radio
Receiver Module (RRM) and following the directions associated with registering for
Uconnect Access.
The Remove Accounts procedure can be initiated by one of three methods:
Through the touchscreen of the RRM.
Through the Uconnect™ Call Center (ASSIST button in the front roof lamp unit) or under
Uconnect™ Apps selection of the RRM display.
Through the Uconnect™ Owners information accessed through the Mopar® Owner Connect web
site (www.moparownerconnect.com).
The following describes the Remove Accounts procedure accomplished through the RRM touchscreen:
1. Navigate through Apps > Uconnect Store > My Apps > Settings on the RRM touchscreen.
2. Select Remove Uconnect Account .
3. Press the Continue soft key after each of the two Warning screens, or press the Cancel
soft key to abort the procedure.
4. When the Authentication screen is reached, enter the 4 digit Uconnect Access ID .
5. Press the Continue soft key to continue the Remove Accounts procedure, the Help soft key
for additional information or the Cancel soft key to abort the Remove Accounts procedure.
6. When the This vehicle has been removed from your account. screen appears, press the
OK soft key. Once the request is processed, a screen will appear alerting the customer with
the message, Important: Application Data Reset Initiated. After Radio Resets, all
application data will be lost. Please Wait.
7. After the radio reset occurs, Uconnect Access applications will no longer be available and the
Uconnect Registration screen will appear each time the Apps soft key is selected until a
new valid registration has been successfully completed.
ANTENNA, NAVIGATION > DESCRIPTION AND OPERATION > DESCRIPTION AND

The navigation antenna is integrated into a roof-mounted combination antenna that also receives
satellite audio and cellular signals. Refer to ANTENNA, SATELLITE, AUDIO, DESCRIPTION AND
OPERATION .
ANTENNA, NAVIGATION > DESCRIPTION AND OPERATION > DESCRIPTION AND

The navigation module acquires Global Positioning System (GPS) position data through a roof-mounted
combination antenna that also receives satellite audio and cellular signals. Refer to ANTENNA,
SATELLITE, AUDIO, DESCRIPTION AND OPERATION .
ANTENNA, NAVIGATION > DIAGNOSIS AND TESTING > DIAGNOSIS AND TESTING -
NAVIGATION ANTENNA
ANTENNA, NAVIGATION > REMOVAL AND INSTALLATION > REMOVAL AND

The navigation antenna is serviced as a unit with the combination antenna located on the roof panel.
Refer to ANTENNA, SATELLITE, AUDIO, REMOVAL AND INSTALLATION .
ANTENNA, NAVIGATION > REMOVAL AND INSTALLATION > REMOVAL AND

The navigation antenna is serviced as a unit with the combination antenna located on the roof panel.
Refer to ANTENNA, SATELLITE, AUDIO, REMOVAL AND INSTALLATION .
MICROPHONE > DESCRIPTION AND OPERATION > DESCRIPTION AND OPERATION

> DESCRIPTION
Fig 1: Roof Lamp Unit, Push Buttons & Grilles
Vehicles equipped with the optional hands-free system have a microphone mounted above a grille (3) in
the roof lamp unit (1) located between the two sun visors in the headliner near the windshield opening
header. The microphone is powered by and provides a hard wired input to the Radio Receiver Module
(RRM) in the instrument panel whenever the Voice Recognition (VR) feature of the hands-free system is
active. This microphone is connected to the vehicle electrical system through a dedicated pigtail wire
harness and connector to a dedicated take out and connector of the overhead wire harness.
In vehicles equipped with the optional Uconnect™ Access system, the front roof lamp unit also houses
both a 9-1-1 push button and a Assist push button (2).
The microphone cannot be adjusted or repaired and, if damaged or ineffective, it must be replaced.
MICROPHONE > DESCRIPTION AND OPERATION > DESCRIPTION AND OPERATION

> OPERATION
When the hands-free VR control circuitry integral and internal to the RRM detects the appropriate inputs
or requests, it energizes the circuitry of the microphone within the front lamp unit housing. The
microphone remains active until it is deactivated by the hands-free VR control circuitry, or until the status
of the ignition transitions to Off, whichever occurs first.
The inputs from the microphone is processed, filtered and redirected by the VR control circuitry and logic
as appropriate. Those inputs can be redirected to the Advanced Speech Recognition (ASR) engine or to
the audio send circuitry of the Bluetooth™ transceiver. Each of these electronic modules is also integral
and internal to the RRM.
The status of the Uconnect™ Access Assist and 9-1-1 push buttons is relayed by the Local Interface
Network (LIN) slave node integral to the front roof lamp unit via the LIN data bus to the Body Control
Module (BCM), which is a LIN master node. The BCM is also a Controller Area Network (CAN) data bus
gateway and relays the push button status information to the RRM over the CAN - B data bus.
The hard wired inputs and outputs of the microphone in the front lamp unit housing may be diagnosed
using conventional diagnostic tools and procedures. Refer to the appropriate wiring information.
However, conventional diagnostic methods will not prove conclusive in the diagnosis of the microphone
features of the RRM controlled microphone. The most reliable, efficient and accurate means to diagnose
the RRM or the electronic controls and communication related to RRM-controlled microphone operation
requires the use of a diagnostic scan tool. Refer to the appropriate diagnostic information.
MICROPHONE > DIAGNOSIS AND TESTING > DIAGNOSIS AND TESTING -

MICROPHONE
WARNING:
The hard wired inputs and outputs of the microphone in the front lamp unit housing may be diagnosed
using conventional diagnostic tools and procedures. Refer to the appropriate wiring information.
However, conventional diagnostic methods will not prove conclusive in the diagnosis of the microphone
features of the Radio Receiver Module (RRM) controlled microphone. The most reliable, efficient and
accurate means to diagnose the RRM or the electronic controls and communication related to
RRM-controlled microphone operation requires the use of a diagnostic scan tool. Refer to the
MICROPHONE > REMOVAL AND INSTALLATION > REMOVAL AND INSTALLATION >
REMOVAL
Fig 1: Front Roof Lamp Unit & Microphone
from the battery.
2. Remove the front roof lamp unit (1) from the headliner. Refer to LAMP, DOME, REMOVAL AND
INSTALLATION .
3. Release the retainer that secures the microphone (2) to the back of the roof lamp housing.
4. Remove the microphone from the roof lamp.
MICROPHONE > REMOVAL AND INSTALLATION > REMOVAL AND INSTALLATION >
INSTALLATION
Fig 1: Front Roof Lamp Unit & Microphone
1. Position the microphone (2) to the back of the front roof lamp unit housing (1).
2. Firmly press the microphone into the housing until the retainer is fully engaged.
3. Install the roof lamp unit into the headliner. Refer to LAMP, DOME, REMOVAL AND
INSTALLATION .
Jeep Renegade
Service Manual: POWER DISTRIBUTION
Fig 1: Front PDC
FRONT PDC - The front PDC is inserted on the front vehicle wiring harness and fixed to the front left
wing.
Fig 2: Front PDC Fuse And Relay Locations
The location of the fuses and relays fitted on the PDC.
Fuse Type AMP Protection
01 Maxi fuse 70 from +30 for BCM
02 Maxi fuse 70 from +30 for BCM
03 J case 20 from +30 for BCM
04 J case 30 from +30 for ESC valves
05 Maxi fuse 70 from +30 for EPS
06 Maxi fuse 40 / 20 for Engine cooling fan
07 Maxi fuse 30/40/50 for 86 T07 engine cooling fan
08 J case 20 / 30 from +30 for DDCT, GCM / +30 for ATX, GSM
09 Mini fuse 5 from +30 for ECM / DDCT

10 Mini fuse 10 from +30 for horn
11 Mini fuse 10/15 /25 from T09 for secondary engine loads
14 Mini fuse 7.5 / 5 from +30 for blow-by relay / after-run pump
15 Maxi fuse 40 from +30 for ESC pump
16 Mini fuse 5 from kl15 for ECM, ATX, DDCT
17 Mini fuse 10 / 15 from T09 for primary engine loads
18 Mini fuse 20 from +30 for luggage compartment power socket
19 Mini fuse 7.5 from +30 for A/C relay
20 Mini fuse 5 from +30 for DTCM
21 Mini fuse 15 from +30 for fuel pump
22 Mini fuse 7.5 / 20 from T09 for ECM supply
23 Mini fuse 30 from +30 for windscreen heater
24 Mini fuse 7.5 / 15 from KL15 for DDCT / ATX GSM
30 Mini fuse from +30 for power socket setup
81 J case 40 / 60 from +30 from DDCT SDU / Heater plugs
82 J case 40 from +30 for diesel filter heater
83 J case 40 from +30 for HAVC
84 Mini fuse 30 from +30 for AWD
87 Mini Fuse 5 from KL15 for DDCT gear selector unit
88 Mini fuse 7.5 from T17 for mirror heater
89 J case 7.5 from T17 for rear window defroster
90 Mini fuse 5 from KL 15 for IBS
List of T Relays in the front PDC
T Relay Function
03 Horn
05 A/C compressor
06 engine cooling fans
07 Engine cooling fan
08 HVAC fan
09 ECM / Primary and secondary engine loads
10 Rear power socket
17 Rear view mirror heater / Rear window defroster

19 After-Run Pump or Blow-By Heater
20 Starter
31 Fuel pump
89 DIESEL fuel filter heater
90 Windscreen heater
REAR PDC - Some relay switches and a series of fuses are located in the luggage compartment on the
rear left side panel, in a dedicated box called rear PDC. These fuses are used for a series of optional
content: sun roof, electric seat movement, Hi-Fi system, etc.
Fig 3: Rear PDC & Additional PDC
A. Rear PDC
B. Additional PDC for TTM
The rear PDC is wired directly to the rear cable and does not have connections that can be
disconnected; it can only be replaced by disconnecting the individual terminals.
Fig 4: Rear PDC Circuit Diagram
1. +30 Passenger seat movement
2. INT/A supply for electric driver seat movement
3. +30 for Inverter
4. +30 for Hi-Fi

5. +30 for electric roof
6. +30 from F02
7. INT/A from f31
8. INT/A passenger side only electric lumbar adjustment
9. INT from F49
10. INT/A supply for driver / passenger side electric seat movement
11. INT for front seat heater pad control unit
12. Driver side seat movement
13. Lumbar adjustment
14. Heated seats
15. INT/A for driver and passenger side seat movement
Additional PDC for TTM

Fig 5: Additional PDC Circuit Diagram
1. +30
2. +30 TTM
3. +30 TTM
4. +30 TTM for hook connector

5. INT TTM for hook connector
6. INT from BCM
7. Only for EMEA market
DESCRIPTION AND OPERATION > DESCRIPTION AND OPERATION > POWER AND
WIRING
The electrical system is designed to increase the car's safety level and prevent the possibility of fires
and other consequences of electrical malfunctions. State- of- the-art connectors have been introduced
to rule out the possibility of many connection defects.
The power distribution is supplied via control units and / or fuses, connected to the control elements
(relay pressure transducers) to ensure the highest level of power protection and the minimum degree of
wiring complexity.
The main security solutions are adopted:
Power supply protection by maxifuse for the interruption of the electrical system, in case of short
circuit
The lay-out of the entire system is optimized for the reduction of risk of damage in case of damage
or accident
The laying of the cables has been optimized by reducing incorrect placements, and noise due to
vibration
All cables are high abrasion resistance
In the engine compartment cables are of special, high temperature resistance and are protected
with sheaths or pipes
The cables in the passenger compartment are protected by corrugated tubes and tapes with micro-
fleece to reduce noise
The main connections are equipped with anti-slip device terminals (secondary lock) and a safety
lock (lock lever) which avoids any deformation of the terminals.
All systems and electrical systems are supplied by the battery with the voltage of 12 V. The battery in
turn is recharged during operation of the generator.
The versions with Start & Stop, the battery status is monitored continuously by a special sensor battery
(Intelligent Battery Sensor / IBS) located on the negative pole of the battery.
The main supply lines are protected by a "MAXIFUSE", contained in the box on the positive battery
terminal.
Some circuits employ "J-House" fuses: this is a cartridge type fuse with the characteristics to ensure a
lower voltage drop for the protection of circuits that absorb high current.
Other circuits are fed by turning the key in the ignition switch in different positions:
Inserting and turning the key to the first click goes to ON and feeds many circuits, which are, in
fact, called "locked" (line "INT")
The second detent - AVV - instead feeds the starter, however, by disconnecting some circuits
(those that absorb more power), thus ensuring the maximum flow of current to the starter motor
itself (line "INT / A").
MODULE, POWER INVERTER > DESCRIPTION AND OPERATION > DESCRIPTION

Fig 1: Power Inverter Module
The inverter module can be installed as an optional on the car to convert direct current to alternating
current (DC/AC inverter).
The inverter is a device that uses diodes and transistors to create an alternating current. The US market
versions operate at 110 V and the European market versions operate at 220 V. Both inverters are rated
at 150 W. The inverter can provide approximately 300 W for up to two seconds to compensate for the
power surge that may occur as a device is plugged in. To prevent blowing of the fuse, the inverter will
automatically shut down if a device draws more than the rated power. The module transforms the DC
12V voltage in the correct value of output alternating current. The BCM activates the inverter module,
sending it a positive command, when the power status is ON and when the car is started and no errors
can be found on the alternator. The inverter module senses this positive control and switches on the
power to the A/C outlet. The inverter is located behind the front glove compartment.
MODULE, POWER INVERTER > DESCRIPTION AND OPERATION > DESCRIPTION

Fig 1: Power Inverter Module Connector End View
Pin Function
1 CA2 (Output 2 in A.C.)
2 N.C.
3 N.C.
4 +30
5 CA1 (Output 1 in A.C.)

6 EL (enabling pin)
7 N.C.
8 Earth
Fig 2: Power Inverter Module, BCM & Power Socket Circuit Diagram
KEY
1. Inverter module
2. BCM
3. Power socket
MODULE, POWER INVERTER > REMOVAL AND INSTALLATION > REMOVAL AND
INSTALLATION > POWER INVERTER MODULE - REMOVAL
2. Remove the glove box. Refer to GLOVE BOX, INSTRUMENT PANEL, REMOVAL AND
INSTALLATION .
Fig 1: Power Inverter Module, Bracket, Connector & Nuts
3. Working within the storage compartment, remove the nuts (1a) and remove the power inverter
module with support bracket (1b).
4. Disconnect the electrical connection (2) from the power inverter module.
5. Separate the power inverter module from the bracket.

MODULE, POWER INVERTER > REMOVAL AND INSTALLATION > REMOVAL AND
INSTALLATION > POWER INVERTER MODULE - INSTALLATION
1. Check that the power inverter module is not damaged.
2. Connect the module electrical connector.
3. Position the inverter module and tighten the screws.
4. Install the glove box. Refer to GLOVE BOX, INSTRUMENT PANEL, REMOVAL AND
INSTALLATION .
OUTLET, POWER > DIAGNOSIS AND TESTING > DIAGNOSIS AND TESTING -
POWER OUTLET
For complete circuit diagrams, refer to appropriate SYSTEM WIRING DIAGRAMS article. The wiring
harness routing and retention, connector pin-out information and location views for the various wire
1. Check the fused B(+) fuse in the Power Distribution Center (PDC). If not OK, repair the shorted
circuit or component as required and replace the inoperative fuse.
2. Turn the ignition switch to the Run position. Check for battery voltage at the fused B(+) fuse in
the PDC. If not OK, repair the open or short as required.
3. Remove the cigar lighter knob and element from the cigar lighter outlet shell. Check for
continuity between the inside circumference of the cigar lighter outlet shell and a good ground.
There should be continuity.
4. Turn the ignition switch to the Run position. Check for battery voltage at the insulated contact
located at the back of the cigar lighter outlet shell. If OK, replace the inoperative cigar lighter
knob and element.
5. Turn the ignition switch to the Off position. Disconnect and isolate the battery negative cable.
Check for continuity between the ground circuit cavity of the cigar lighter wire harness
connector and a good ground. There should be continuity. If not OK, repair the open ground
circuit to ground as required.
6. Connect the battery negative cable. Turn the ignition switch to the Accessory or Run positions.
Check for battery voltage at the fused B(+) circuit cavity of the cigar lighter wire harness
connector. If OK, replace the inoperative cigar lighter outlet. If not OK, repair the open fused
B(+) circuit to the PDC fuse as required.
OUTLET, POWER > REMOVAL AND INSTALLATION > FRONT POWER OUTLET >
FRONT POWER OUTLET - REMOVAL
2. Remove the floor console portion to gain access to the accessory outlet panel. Refer to
CONSOLE, FLOOR, REMOVAL AND INSTALLATION .
Fig 1: Front Power Outlet & Clips
3. Untie the retaining clips (1a) and remove the front power outlet (1b).
OUTLET, POWER > REMOVAL AND INSTALLATION > FRONT POWER OUTLET >
FRONT POWER OUTLET - INSTALLATION
1. Position the front outlet and install the retaining clips.
2. Connect the electrical connector to the power outlet.
OUTLET, POWER > REMOVAL AND INSTALLATION > MID POWER OUTLET > MID
POWER OUTLET - REMOVAL

2. With the proper tool, remove the floor console rear cover (1b) retainers (1a).
Fig 2: Power Outlet & Retainers
3. Release the retainers (1a) and remove the power outlet (1b).
OUTLET, POWER > REMOVAL AND INSTALLATION > MID POWER OUTLET > MID
POWER OUTLET - INSTALLATION
1. Position the front outlet and install the retaining clips.
2. Connect the electrical connector to the power outlet.
3. Install the floor console rear cover.
OUTLET, POWER > REMOVAL AND INSTALLATION > REAR POWER OUTLET > REAR
POWER OUTLET - REMOVAL

Fig 1: Rear Power Outlet, Cover & Tool
2. Working from the left side of the rear cargo compartment, open the cover (1a) of the outlet
(1b).
3. Engage the appropriate tool (2a) in the socket, then carefully remove the socket (1b) itself.
Fig 2: Rear Power Outlet, Connector & Cover
4. Disconnect the power outlet electrical connection.
5. Remove the socket.
6. If necessary, remove the flange cover.
OUTLET, POWER > REMOVAL AND INSTALLATION > REAR POWER OUTLET > REAR
POWER OUTLET - INSTALLATION
1. Check that the plug is not damaged.
2. If removed, replace the flange cover.
3. Connect the power outlet electrical connection.
4. Install the power outlet.
5. Close the cover of the socket.

Jeep Renegade
Service Manual: SPECIAL TOOLS - ELECTRICAL
SPECIAL TOOLS
LDW system adjusting

2015400000 * Calibration system LDW
tool panel
LDW system adjusting

2021200000 * tool reflective mirror Calibration Radar
support
2021201000 * Strap Calibration Radar
2000040319 9857 Power Outlet Remover Remove Power Outlet
Service Manual: STARTING - NON-DTC BASED Jeep Renegade
DIAGNOSTICS
DIAGNOSIS AND TESTING > NO CRANK (BCM EQUIPPED)
Fig 1: Starting System Circuit Diagram
DIAGNOSIS AND TESTING > NO CRANK (BCM EQUIPPED) > THEORY OF

OPERATION
This vehicle may come equipped with one of two types of ignitions, the IGNM (IGnition Node Module) or
a KIN (Keyless Ignition Node). The KIN uses a Keyless Go Start/Stop push button for cycling the ignition
on/off. The IGNM does not use a Keyless Go Start/Stop push button, instead providing a visible slot for
the FOBIK to fit into for cycling the ignition on/off.
When the operator presses the Start/Stop Button on a KIN or cycles the FOBIK in a IGNM type ignition,
the FOBIK is validated wirelessly by the RF Hub (Radio Frequency Hub Module). If the FOBIK is
recognized as belonging to the vehicle and is inside the vehicle, the system allows the ignition state of
the vehicle to be changed by the operator between the LOCK, ACCESSORY, RUN, and START ignition
states.
LED Operation
The LEDs in the IGNM and Start/Stop Button provide visual indication of the ignition system and button
use to aid the driver. The Logic for LED control is implemented in the IGNM and RF HUB. The IGNM and
Start/Stop Button contain four LEDs:
OFF Indication
ACC Indication (Accessory)
ON Indication (On or Run)
Ignition Switch Indicator (button backlight)
The LEDs indicate the vehicle ignition position and are driven by the CAN bus signals related to the
ignition position. The Center LED (Ignition Switch Indicator) will blink if there is a related concern.
The RF HUB will log a DTC indicating an incorrect Ignition status value is present; in this state the
ignition status is unknown. This will continue until the correct signal is received by the RF Hub.
EVIC Operation
The Keyless Go feature requires the vehicle to be equipped with an EVIC display for prompts and status
information. The display messages are:
Service Keyless System
FOB Not Detected
FOB Left Vehicle
Not in Park
Push Brake Pedal and Push Button to Start
Push Clutch Pedal and Push Button to Start
Vehicle not in Park Warning
BCM/RF Hub Module Interaction
There are a few things that must take place before the starter relay can apply voltage to the starter.
Below are some key points to check when diagnosing a no crank condition.
The BCM requires two signals from the RF HUB to verify the ignition is in the run or start position. The
voltage on the F20 circuit is one of these signals. It can be monitored in both the RF HUB and BCM data
display screens as the Ignition Run/Start under the "Sensor" value. The run or start position voltage on
this circuit should be at or close to battery voltage.
Simultaneously the RF HUB busses the Ignition Run/Start status to the BCM. The BCM monitors the
bussed input information as the secondary verification on the Ignition Run/Start status. The bussed
messages can be monitored with the scan tool in both the RF HUB and BCM data display screens.
The F20 circuit voltage and the bussed ignition run/start status message received by the BCM must
agree to enable starting. Once the vehicle is started, the loss of only one ignition signal will not cause
the vehicle to cycle off as long as the other feed still indicates a "run status".
The RF HUB also requires an input from the Gated park switch (hardwired) and the OK to start CAN Bus
message from the TCM (Crank Enable).
Diagnostic Aids
NOTE:
The No Crank Diagnostic serves as an aid in diagnosing the concern and is intended
to be used as a general guide, since each no crank condition can be unique.
The No Crank Diagnostic Test assumes all of the following to be true:
Communication to all configured modules in the vehicle is possible with the scan tool.
The condition is currently present.
The TCM, PCM, RF HUB, and BCM are at the latest calibration (part number) levels.
There are no active DTCs.
There are no applicable Recalls.
There are no applicable TSBs.
There are no PCM inhibits (i.e. RPM, Trans Range, Clutch).
The FOBIKs complete function and operation is correct.
All battery cables and connections are clean and tight.
There are no open fuses.
The battery is fully charged and can pass a load test from the GR8 tester.
The engine rotates freely.
Any aftermarket equipment/wiring that has been installed is operating correctly.
Starter Relay Operation
In a no crank condition the Starter Relay can be missing power at pin 85, feed at pin 30, controlled
ground at pin 86 or output at pin 87. Further explanation of how a relay operates is listed below:
Pin 85 receives power from the BCM once the parameters for the Ignition Switch position and
status, and all inhibit monitors (i.e. clutch switch, RPM, etc.) are satisfied.
Pin 30 is a constant B+ feed.
Pin 86 is a controlled ground by a module (i.e. PCM or BCM). Once power is sent from the BCM to
the pin 85 of the relay it passes through a coil and leaves the relay through pin 86 to the control
module.
Pin 87 is an output circuit to the Starter solenoid. Once the circuit on pin 86 is grounded by the
control module, the coil winding in the relay magnetically pulls the internal switch closed. When the
internal switch is closed the power at pin 30 is sent to pin 87 of the relay.
DIAGNOSIS AND TESTING > NO CRANK (BCM EQUIPPED) > DIAGNOSTIC TEST
1. STARTER RELAY CHECK
1. When attempting to start the vehicle, listen and if needed feel for a click at the starter
relay in the PDC.
NOTE:
Some starter relays are internal to a module and may not be accessible,
making it more difficult to hear, or feel the clicking response. It is possible
for a poor ground or the Trans Range Sensor position to be lost causing
the starter to click once.
Did you hear an audible click at the relay or starter?
Yes
1. Go To Step 9
No
1. Go To Step 2
2. STARTER RELAY INPUT CHECK
1. Use a 12 volt test light/DVOM to check for power at pin 85 of the starter relay.
Is there Power/12 volts at pin 85?
Yes
1. Go To Step 8
No
1. Go To Step 3
3. RF HUB OPERATION
1. Using the scan tool, confirm the ignition switch status changes in the RF HUB under
the data display screen for the "Sensor" values.
Does the ignition switch status on the data screen match the physical position of the
KIN/IGNM?
Yes
1. Go To Step 5
No
1. Go To Step 4
4. REMOTE START ANTENNA
NOTE:
If the vehicle is not equipped with Remote Start, proceed to the next test step.
1. Cycle the ignition off.
2. Disconnect the Remote Start Antenna from the RF HUB.
3. Using one FOBIK and sitting in the driver's seat, attempt to start the vehicle.
Did the vehicle start?
Yes
1. Replace the Remote Start Antenna in accordance with the Service Information.
2. Perform the BODY VERIFICATION TEST. Refer to BODY VERIFICATION TEST

.
No
1. Go To Step 5
5. BCM IGNITION STATUS
1. Using the scan tool, confirm the ignition switch status changes in the BCM under the
data display screen for the "Bussed Input" and "Sensor" values.
NOTE:
The change of status in the BCM for the "Sensor" value validates the
voltage activity (with very low amperage) of the F20 circuit.
In the BCM, do both values for the ignition switch status match; and do they match
those in the RF HUB?
Yes
1. Go To Step 6
No
1. If the status of the Ignition Switch position is not changing under the "Sensor"
value, check the F20 circuit at the BCM for battery voltage with a DVOM (not a
test light).
2. If there is Battery voltage at the BCM on the F20 circuit verify all power,
ground and bus circuits are OK for the BCM. If no problem found replace the
BCM in accordance with Service Information. (Refer to MODULE, BODY
CONTROL ).
3. If there is NO Battery voltage at the BCM on the F20 circuit, then check for
voltage on the F20 circuit at the RF HUB.
4. If there is Battery voltage coming out of the RF HUB on the F20 circuit ,
check the F20 circuit between the RF HUB and BCM for a short, open condition
or high resistance.
5. If there is NO Battery voltage coming out of the RF HUB on the F20 circuit
verify all power, ground & communication circuits, & connections to the RF HUB
prior to replacing. (Refer to MODULE, RADIO FREQUENCY (RF HUB) ).
6. In the data screen, if the status of the Ignition Switch was not changing under
the "Bussed Input" value, further diagnosis is needed between the RF HUB,
(bus circuits, connections) and the BCM.
6. PCM IGNITION, TRANS RANGE/CLUTCH SWITCH STATUS VERIFICATION
1. Using the scan tool confirm there are no inhibits that have been triggered in the PCM
(i.e. Ignition Switch, Trans Range or Clutch Switch) and any switch inputs (filtered
states) relating to the starting system function and operate correctly under the data
display screen.
Does the PCM show any inhibits (not DTCs ) for starting (not remote starting )?
Yes
1. Correct the inhibit reason listed.
2. If no problem can be found, then verify all power, ground and bus circuits to the
PCM and replace the PCM in accordance with the Service Information. (Refer
to MODULE, POWERTRAIN CONTROL ).
No
1. Go To Step 7
7. BCM TO STARTER RELAY POWER INPUT CHECK
1. At this time if all the correct inputs for the ignition switch status are correct in the RF
HUB, BCM and PCM, verify both power feeds are present (pin 30 and 85) to the
Starter Relay while in the crank position.
Are both power feeds present at the relay when the ignition is in the crank position?
Yes
1. Go To Step 8
No
1. If, there is no power to pin 30 or 85, no DTCs, TSBs, Recalls, or Inhibits

replace the BCM in accordance with Service Information. (Refer to MODULE,
BODY CONTROL ).
8. STARTER RELAY CONTROL CIRCUIT CHECK
1. Using a test light/DVOM determine if the Starter Control circuit at pin 86 of the relay
is missing ground (at the relay if equipped with a removable relay or wiring to the
internal relay) when the ignition is in the crank position.
Was the Starter Control circuit for pin 86 being grounded when the ignition was in the
crank position?
Yes
1. Go To Step 10
No
1. Verify the Starter Relay Control circuit from pin 86, has no shorts, opens or
high resistance on the wiring going from the Starter Relay in the BCM (or PDC)
to the PCM.
2. Verify the cables do not have excessive resistance by performing a voltage

drop on the battery cables.
9. STARTER RELAY OUTPUT CIRCUIT CHECK
NOTE:
At this point in the test, when the key is in the crank position power has been
verified at Pin 30 & 85, along with the control circuit being grounded for pin 86.
1. Remove the Starter Relay Output circuit connector from the Starter solenoid.
2. Using a test light/DVOM and ignition in the crank position check for power at pin 87
(If equipped with a removable relay or wiring to the internal relay) of the relay and at
the connection to the starter.
Was there power at pin 87 for the output circuit?
Yes
1. Go To Step 10
No
1. If power is missing to pin 30 of the starter relay the BCM is suspect. Verify all
power, ground, communication circuits and connections to the BCM before
replacing in accordance with service information.
2. If power is missing at pin 87 of the starter relay and the relay is replaceable,
change out the relay and recheck the concern. If a known good relay causes
no change, check the Starter Output circuit from pin 87 of the relay to the
starter for an open, short, excessive resistance, or poor connections to the
solenoid or starter.
3. Verify and Inspect the Starter to ensure it is free of corrosion, oil, and there is
no damage, or binding conditions.
4. Verify that all wiring, cables and connections are clean and tight.
10. STARTER RELAY OUTPUT CIRCUIT LOAD TEST
1. Load test the Starter Relay output circuit going from the BCM to the Starter.
Does the starter relay output circuit pass the load test?
Yes
1. Verify that all connections are clean, tight and there is no damage to starter
when fully inspected. If no problem found then replace the Starter in
accordance with Service Information. (Refer to STARTER ).
No
1. Adjust the shift cable in accordance with the Service Information. Perform the
POWERTRAIN VERIFICATION TEST. Refer to the appropriate TESTING &
DIAGNOSTICS article in ENGINE PERFORMANCE.
DIAGNOSIS AND TESTING > REMOTE START INOPERATIVE (BCM - RF HUB

EQUIPPED)

EQUIPPED) > THEORY OF OPERATION
The customer may notice that the signal range of the Remote Keyless Entry (RKE) system is reduced.
This condition may be due to the RKE antenna where the RKE key fob may need to be closer than 3
meters (10 feet) before the functions available on the key fob will operate. The diagnostic test is
provided as a diagnostic aid for the dealer technician.
It is necessary to confirm the correct sales code(s) are present in the Standard and Optional Equipment
sections of DealerCONNECT to determine if a factory or a Mopar® Accessory Remote Start kit was
installed. If the vehicle has a Mopar® Accessory Remote Start kit, verify that at least 20 minutes has
elapsed since the sales codes were added to DealerCONNECT. Once it has been confirmed that the
proper sales codes have been added and the allotted time has passed, verify the vehicle has been
configured properly using the scan tool. Also, make sure that the system shows as enabled in the BCM
and that the temporary remote start override is set to disabled.
For any further assistance on diagnosing the installed Mopar® Accessory kit contact the Mopar®
Accessories group at 800-84-MOPAR (66787).

EQUIPPED) > DIAGNOSTIC TEST
1. REMOTE START FUNCTION
NOTE:
In some cases the vehicle will start then stall, indicating a fuel level concern (less
than a quarter of a tank). Before proceeding verify there is enough fuel in the tank
for the vehicle to start and run.
1. Attempt to start the vehicle with the FOBIK.
Does the vehicle start when using the FOBIK?
Yes
1. At this time the Remote Start is functioning properly.
2. Using the scan tool, check for any related Starting, Communication, or Ignition
related DTCs that may inhibit the Remote Starting feature. Check the BCM for
any previous Remote Start Inhibits and mileage that were stored. Inhibits may
be found under the system tests or miscellaneous functions tab.
No
1. Go To Step 2
2. REMOTE START VISUAL CHECK
1. While pressing the remote start button on the FOBIK, observe the exterior lights and
the horn operation.
Does the horn sound and the exterior parking lights flash?
Yes
1. Go To Step 3
No
1. Go To Step 4
3. CHECKING BCM INHIBITS
NOTE:
Since the horn sounds and the parking lights flash, this verifies the BCM is
receiving the CAN BUS message from the RF HUB. It also verifies the RF signal for
Remote Start from the FOBIK to the RF HUB is operating correctly.
1. Using the scan tool, check the Remote Start inhibits of the BCM or any ACTIVE
DTCs listed in all modules.
NOTE:
Inhibits may be found under the system tests or miscellaneous functions

tab. The fuel level may not be a listed inhibit.
Are there any Remote Start inhibits or any ACTIVE DTCs listed in the entire vehicle?
Yes
1. For any inhibits for a complete list of Remote Start inhibits. Refer to
2. For any ACTIVE DTCs, perform the appropriate diagnostic procedure in DTC
INDEX .
No
1. Check for any related TSBs prior to replacing the BCM. If no related TSBs are
found, then replace the BCM in accordance with the Service Information.
(Refer to MODULE, BODY CONTROL ).
4. RKE FUNCTION SHORT RANGE
1. While standing next to the Driver door and using the FOBIK, attempt to lock and
unlock the doors.
Does the RKE function properly?
Yes
1. Go To Step 5
No
1. Go To Step 7
5. RKE FUNCTION MID RANGE
1. While standing 20 feet from the vehicle and using the FOBIK, attempt to lock and
unlock the doors.
Does the RKE function properly at 20 feet?
Yes
1. Go To Step 6
No
1. Go To Step 7
6. RKE FUNCTION LONG RANGE
1. While standing 100 feet from the vehicle and using the FOBIK, attempt to lock and
unlock the doors.
Does the RKE function properly at 100 feet?
Yes
1. Go To Step 9
No
1. Go To Step 7
7. FOBIK SIGNAL STRENGTH
1. Use the RF Tester 9001 to check the signal strength of the FOBIK.
Does the FOBIK pass?
Yes
1. Go To Step 10
No
1. Go To Step 8
8. CHECKING THE FOBIK
1. Replace the battery in the FOBIK with a known good battery and recheck the signal
from the FOBIK with the RF Tester 9001.
Does the FOBIK pass?
Yes
1. Go To Step 9
No
1. Check for any related TSBs prior to replacing the FOBIK. If no related TSBs
are found, then replace the FOBIK in accordance with the Service Information.
9. CHECKING FOR ACTIVE DTCs
NOTE:
The RKE portion of the FOBIK is operational, this verifies that the RF HUB is
capable of receiving signals and communicating to operate the locks.
1. Use the scan tool to check for ACTIVE DTCs.
Did the scan tool show any ACTIVE DTCs in the entire vehicle?
Yes
1. Diagnose the DTCs in accordance with the Service Information before

proceeding with the Remote Start Inoperative concern.
No
1. Go To Step 10
10. CHECKING THE RF HUB
NOTE:
Even though the RKE function of the system may work with no concern, the BCM is
either not receiving a message or is receiving a corrupt message from the RF HUB
for remote start operation.
1. While sitting in the driver seat and using the scan tool, monitor the RF HUB on the
data display screen for changes when the Remote Start button of the FOBIK is
pressed.
Did the status change when the Remote Start button of the FOBIK was pressed?
Yes
1. Go To Step 11
No
1. Go To Step 12
11. CHECKING BCM INHIBITS
NOTE:
The parking lights flash and the horn are inoperative when using the FOBIK, this
indicates a faulty BCM or "Inhibit" that may be preventing the start request from
occurring.
1. Use the scan tool to check for any Remote Start inhibits listed in the BCM. This may
be found under the system tests or miscellaneous functions tab.
Were there any Remote Start inhibits listed in the BCM?
Yes
1. Perform the REMOTE START SYSTEM Diagnosing and Testing. Refer to

No
1. If this has had a Mopar® Accessory kit installed verify the correct Sales Code
for Remote Start has been added to Dealer Connect and a Restore Vehicle
Configuration has been performed.
2. Confirm the system is enabled; and the temporary Remote Start override is set
to disabled in the BCM and contact the Mopar® Accessories group (800-84-
Mopar) for further details before proceeding.
3. If this has a factory installed Remote Start, check for any related TSBs prior to
replacing the BCM. If no related TSBs are found, then replace the BCM in
accordance with the Service Information.
12. CHECKING THE REMOTE START ANTENNA
1. Cycle the ignition off
2. Disconnect the Remote Start antenna from the RF Hub.
3. Using one FOBIK and sitting in the driver's seat, attempt to start the vehicle.
Did the vehicle start?
Yes
1. Replace the Remote Start Antenna in accordance with the Service Information.
2. Perform the BODY VERIFICATION TEST. Refer to BODY VERIFICATION TEST

.
No
1. Verify all power, ground, communication circuits, & connections to the RF HUB
prior to replacing. (Refer to MODULE, RADIO FREQUENCY (RF HUB) ).
Jeep Renegade
Service Manual: STARTING - SERVICE INFORMATION
Starting and recharging wiring diagram with Stop/Start.
Fig 1: Starting & Recharging With Stop/Start - Wiring Diagram

1. Voltage stabilizer
2. Clutch Pedal Switch
3. Gear lever position switch
4. Generator
5. Starter
6. Stop/Start button
NOTE: Stop/Start is not available on NAFTA-version vehicles.
Fig 2: Starting & Recharging Without Stop/Start - Wiring Diagram
Analyzing the wiring diagram of both configurations (with and without Stop/Start), the starter is always
operated by a single relay positioned in the front PDC and activated by the ECM. The activation signal
(+50 with key without remote control or digital signal via CAN line with keyless go system) reaches the
BCM, which will activate an internal relay of its own, which sends +30 to the relay located in the front
PDC and activated by the ECM. When the ECM module activates relay T20, signal 87 (12 V) arrives at
the solenoid of the starter, which will trigger the anchor and activate the starter. In the first moments,
after the engine has started, the ECM reactivates relay T20 to check whether there is voltage at output
87. Should there be voltage at output 87 of relay T20, this would indicate a fault on the internal relay of
the BCM. The ECM will set the correct fault codes and deactivate the Stop & Start function if present.
STOP/START SYSTEM - The STOP & START (S/S) device automatically stops the engine whenever
the vehicle is stopped and restarts it when the driver wants to start driving again. This improves the
efficiency of the vehicle by reducing fuel consumption, the emission of harmful gases and noise pollution.
Fig 3: S/S Button
Manual activation and deactivation - The S/S device can be activated/deactivated through the S/S
button positioned on the central tunnel near the electric parking brake button. The deactivation of the
system is indicated through a message on the instrument panel. When it is deactivated, the button's LED
is off. When the system is active, the LED is on.
Fig 1: Engine Stopping Mode With Manual Gearbox Operation
Engine stopping mode with manual gearbox
With the vehicle stationary, the engine (3) stops with the gearbox in neutral (1) and the clutch pedal (2)
released. The engine can be stopped at speeds below 7 km/h.
Fig 2: Engine Restarting Mode With Manual Gearbox Operation
Engine restarting mode with manual gearbox
Press the clutch pedal (4) to restart the engine (5).
Fig 3: Engine Stopping Mode With Automatic Transmission Operation
Engine stopping mode with automatic transmission
The engine cuts out if the car stops with the brake pedal (1) pressed.
Fig 4: Keeping Engine Stopped With Automatic Transmission Operation

Keeping the engine stopped with automatic transmission
With the brake pedal pressed (3) and the engine at standstill (4), position the gear lever at N (5) and
release the brake pedal (6).
Fig 5: Engine Restarting Mode With Automatic Transmission Operation
Engine restarting mode with automatic transmission
If the gear lever is at N, place it in any gear position (8); otherwise, release the brake pedal (7) or move
the gear lever in a position other than N. The engine starts again (9)
Failed engine cut out conditions
- When the device is operating, due to comfort, emission control and safety reasons, the engine may not
stop in some conditions, among which:
Engine still cold.
Battery not sufficiently charged.
Windscreen wiper at max. speed.
Particulate trap regeneration in progress (only for diesel engines).
Driver's door not shut
Driver's seat belt not fastened.
Reverse engaged (for example parking operation).
With automatic climate control, if a suitable level of thermal comfort has not yet been reached.
4WD low Active
Heated windscreen active
In the above case, an informative message is shown on the panel.
Automatic restarting conditions

- Due to comfort, emission control and safety reasons, the engine can restart automatically without any
intervention by the driver, under special conditions, such as:
Battery not sufficiently charged.
Low braking system vacuum (for example after the brake pedal has been pressed repeatedly).
Car moving (for example on roads with a gradient).
Engine stopped by the S/S for more than three minutes.
With a gear engaged, the automatic restarting of the engine is only permitted by fully depressing the
clutch pedal. This operation is requested through a message on the instrument panel.
NOTE:
If the clutch is not pressed, when three minutes have elapsed since the engine was stopped,
the engine can only be restarted using the key.
In the case of an undesired engine stopping as a result of sudden clutch pedal release with gear
engaged, if the S/S system is active, the engine can be automatically restarted by fully pressing the
clutch pedal or placing the gearbox in neutral.
Safety functions - When the engine is stopped by the S/S system, if the driver releases their seat belt
and opens the driver side or passenger side door, the engine can be restarted only using the key.
"Energy saving" function - If, as a result of the engine automatic restarting, the driver does not
execute any action on the car for a long time, the S/S system stops the engine once and for all, to
prevent fuel consumption. In this case restarting requires the key.
Important
The car should always be left after the key has been removed or turned to the OFF position.
Before opening the hood, make sure that the car is switched off and the key is in the OFF position.
It is advisable to remove the key when there are other people in the car.
When refuelling, make sure that the car is switched off with the key in the OFF position. It is
advisable to remove the key when there are other people in the car.
If you want to make the most of climate comfort, the S/S system can be deactivated to allow
continuous operation of the climate control system.
Irregular operation - In the case of malfunction the system is deactivated. The driver is informed about
the switching on of the warning light for general failure and, where provided, by the information message
and by the icon of system failure on the instrument panel.
Components involved in operation
- The parts or components involved in the operation can be subdivided into four groups as follows:
Additional components: components that are new or have been added to operate this type of
device.
Components with modified hardware.
Components with modified hardware and/or software.
"Carry over" components: components that are not new but have already been used on other cars
or are already fitted on the car.
Fig 6: S/S Function - Block Diagram
The following is a block diagram of the car, divided by area. Each area shows the main components
involved in carrying out the S/S function. In particular, the following are highlighted:
-A: white, additional components;
-M-HW: yellow, components with modified hardware or mechanics as compared to those normally
present;
-M-HW/SW: orange, components with modified hardware and/or software as compared to those
normally present;
-CO: green, components which have not been changed or adapted as compared to the originals.
Key:
A: added components.
HW: components with modified hardware.
HW/SW: components with modified hardware/software.

CO: Carry Over components (not modified).
HMI area (Human Machine Interface)
1: accelerator pedal.
2: clutch pedal.
3: brake pedal.
4: gearbox control.
5: S/S push-button.
6: instrument panel.
PWT area (powertrain)
7: accelerator potentiometer.
8: clutch sensor.
9: brake sensor.
10: gearbox sensor.
11: engine temperature sensor.
12: braking system vacuum sensor.
13: engine rpm sensor.
14: other (handbrake, catalytic converter, etc).
15: flywheel.
16: engine.
ECM: engine control module (engine control node)
CAR area
17: starter
18: Generator.
19: various loads (heated rear window, windscreen wiper, etc.).
20: seat belt fastened sensors.
21: door sensors.
22: outside temperature sensor.
23: battery.
24: voltage stabilizer for radio and Hi-Fi.
25: various electrical loads.

RRM/ HI-FI: radio receiver/Hi-Fi node.
IBS: Intelligent Battery Sensor (battery monitor).
FP: dummy pole.
NCL: Climate control node.
BCM: Body Computer Module (Body Computer Node)
Added components (white)
5: S/S function activation/deactivation button.
10: gearbox sensor.
12: brake servo vacuum sensor.
24: voltage stabilizer for radio and info-telematics supply.
FP: dummy negative battery pole with wiring.
IBS: Intelligent battery sensor (battery monitor control unit).
Components with modified hardware (yellow)
2: clutch pedal with clutch sensor.
13: engine rpm sensor.
16: engine.
15: flywheel.
17: starter.
18: Generator.
23: battery.
Components with modified hardware and/or software (orange)
6: instrument panel.
ECM: (Engine Control Node).
BCM: (Body computer node).
NCL: (Automatic climate control node).
ABS (Braking system control module)
Carry over components (green)
1: accelerator pedal with accelerator sensor.
3: brake pedal with brake sensor.
11: engine coolant temperature sensor.

20: belt sensors.
21: door sensors.
22: outside temperature sensor.
14: other (handbrake, catalytic converter, DPF, heated rear window, windscreen wiper, general
electrical loads, etc.) RRM: Hi-Fi radio.
Fig 7: S/S Activation Button Pinout
S/S activation button
Pinout
1 Ignition-operated power supply
2 LED control for backlighting
3 Earth
4 Switch signal
5 n.c.
6 Switch signal
Sensor for gearbox in neutral:
The gearbox sensor is fitted on the gear lever unit and transmits to the ECM a signal enabling the
system to recognize the position of the lever corresponding to the "gearbox in neutral" condition.
The condition of gearbox in neutral is essential for the engine automatic starting.
The gearbox sensor generates a PWM signal with a duty cycle between 33% and 67% when the
gearbox is in neutral.
Fig 8: Vacuum Sensor On Brake Servo
Vacuum sensor on brake servo - The vacuum sensor on the brake servo informs the system that the
vacuum in the circuit is not enough to guarantee an efficient braking with the engine off, due to the
missing brake servo intervention. In this case the engine is restarted or is not stopped if it was already
running.
The sensor is connected to the ABS module and is provided with a normally closed contact: in other
words the contact is closed if the absolute pressure of the circuit is low enough (about 400-500 mbar).
Fig 9: Clutch Sensor
Clutch sensor - The clutch sensor S (no. 8 in the block diagram) plays a primary role for the Stop &
Start function because, in combination with the gearbox sensor, enables the automatic starting of the
engine. The sensor is fixed directly on the pedal unit. The sensor is rotary type and communicates to the
ECM both whether the pedal is released or pressed and also if the pedal is not fully depressed. In this
way the system can recognize the pedal position unambiguously.
The ECM receives from the rotary sensor associated to the clutch pedal a value which can be HIGH
(pedal not pressed), MIDDLE (pedal partly pressed), LOW (pedal pressed) or ERROR (sensor error).
Fuel pump - When the S/S system is activated, during the engine stopping stages the fuel pump
remains active. This guarantees the supply system filling and a ready start-up. When the engine does
not run for a certain period of time, the pump is switched off.
Fig 10: Voltage Stabilizer - Circuit Diagram
Voltage stabilizer
The voltage stabilizer maintains the supply voltage of some devices (the radio receiver in
particular) within values which guarantee that the supply voltage is maintained during the engine
start-up stages.
The voltage stabilizer consists of an electronic unit directly connected to the battery.
It is positioned under the dashboard, on the right side, as shown in the figure.
Operation - With the key at STOP: the T1 relay switch is closed and the device is completely
bypassed. In these conditions the battery positive is applied to +30 of the radio and to the entire Hi-Fi
system, if present. With the key at MAR (+15 present) and during the start-up stage (+50 present), the
T1 relay switch is opened and the T2 and T3 relay switches are closed. In this way +30 of the battery
can pass through the voltage stabilizer because in this condition a voltage drop can cause a temporary
audio interruption or the stored channels can be lost.
Diagnosis - The diagnosis is performed through the NBC to which the diagnosis cable (DIAG) is
connected. The fault status is signalled to the NBC by means of a low digital signal.
NOTE:
Two types of stabilizers are available: 90 W if the car is only equipped with the radio and
180 W if it has both the radio and the Hi-Fi system.
Fig 11: Intelligent Battery Sensor (IBS)
IBS (Intelligent Battery Sensor or Battery Monitor) and dummy negative pole - The IBS (Intelligent
battery sensor) (A) is an electronic unit which informs the BCM of the battery operating conditions. This
prevents an engine shutdown in the case the charge conditions or health of the battery are inadequate.
The information produced by the IBS and sent to the BCM through the LIN is used for the management of
the Start & Stop function to take the battery starting capacity into consideration. In particular, this
information is used, in conjunction with other information coming from other vehicle devices/control units,
to activate or deactivate the Stop/Start function.
The general concept is that, whilst the engine is on it should not be stopped automatically if the capacity
of the battery is not sufficient to start it and, during an automatic stopping stage, the engine should be
restarted if the battery start-up capacity becomes too low.
The Stop/Start function is also deactivated if a possible IBS fault does not allow the effective battery
status to be determined: an internal error signal is generated in the BCM to this end.
The Stop/Start is primarily managed by the ECM which decides whether to activate/deactivate the
Stop/Start taking a great deal of information into consideration, including data coming from the IBS
(through the BCM).
NOTE:
The BCM and ECM can also deactivate the Stop/Start function as a result of vehicle
conditions not connected to the IBS.
For more details on other conditions that can deactivate an automatic stop or cause automatic restarting
of the engine, refer to the appropriate Service Information .
IBS - Operation
- The IBS performs the following measurements:
Battery voltage (V)
Battery current (A)
Battery temperature (°C)
The control unit processes these values and calculates the following parameters expressing the battery
status:
SOC : (State Of Charge) percentage of the battery residual charge as compared to its rated
capacity. In other words it indicates the charge of the battery.
SOH : (State Of Health) "age" of the battery or, better, percentage of the battery real capacity as
compared to the rated capacity. This condition has to be considered because the battery
undergoes an irreversible ageing process with time, reducing its ability to be fully recharged and
therefore the possibility to supply all the energy it could store when new.
SOF : (State Of Function) minimum voltage peak that can be reached during the start-up stage, in
volt.
These parameters identify the starting capacity of the battery.
In the case of insufficient SOC or SOH, the battery could not be able to restart the engine any more. In
the case of insufficient SOF, the battery voltage during starting may reach such low values that the
standard operating conditions of the various electronic units of the car are no longer guaranteed.
Calibration of the IBS - When the IBS is connected to the power supply for the first time or is
reconnected after a service operation, it enters the recalibration.
During recalibration, the battery efficiency status (SOC, SOH and SOF) is calculated in a less accurate
way and with broader tolerances for a certain period of time during which the IBS must recognize the
type of battery it is connected to, its voltage and its efficiency status. During this period, the S/S system
may not stop/restart the engine to prevent the risk of an insufficient energy level remaining in the battery.
Whenever the IBS is removed from/refitted to the power supply or the battery is replaced, when the
connections are restored a calibration processes is started to store the battery efficiency status again.
The following table illustrates the calibration process logic.
CALIBRATION PROCESS LOGIC TABLE
Restoring supply First start-up First period of 5 time for 8 hours

inactivity > 4 hours of inactivity,
and engine start-up followed by car
starting
SOC Out of range Out of range Tolerance O.K. Tolerance O.K.
SOF Out of range Tolerance O.K. Tolerance O.K. Tolerance O.K.
SOH Out of range Out of range Out of range Tolerance O.K.
CALIBRATION STANDARD OPERATION
When the power supply is restored - all parameters are out of range because the system is not able
to determine the battery status yet.
At the first starting - it performs the SOF calibration, considering immediately the minimum voltage
already reached at the first starting. The other parameters cannot be taken into account yet.
After a period of inactivity longer than 4 hours and at least a starting cycle - the SOC parameter
is also considered, which determines the battery charge status after a certain period of time has
elapsed. The state of health - SOH - is not considered yet because it is still necessary to alternate
start-up cycles and inactivity periods. The real efficiency status of a battery can be determined if also
the elapsed operation time is considered.
After 5 inactivity periods of at least 8 hours, combined with a series of starting attempts - the
cycle ends and the SOH parameter is acquired and stored
If the IBS does not recognize the values of the above mentioned parameters, the system will
appropriately limit the engine stopping and starting cycles to ensure that the battery recharges correctly.
Conclusion: The IBS exits the calibration stage when the SOC and SOF evaluations are within the
tolerances, as shown in CALIBRATION PROCESS LOGIC TABLE . This occurs after a rest stage
(engine off) of at least 4 hours followed by a starting.
Use of information supplied by the IBS
In engine on conditions, the BCM uses the information received from the IBS to activate or deactivate a
possible automatic stop on the basis of the battery starting capacity estimated by the IBS.
As already mentioned, the starting capacity of the battery is usually evaluated through the battery status,
expressed as SOC, SOF, SOH and temperature; when, on the other hand, the IBS is being recalibrated,
some status variables are not reliable and therefore only the SOF and the battery temperature are taken
into account.
The request to enable/disable an automatic stop by the BCM is translated into a signal produced by the
BCM and sent, through the C-CAN, to the ECM.
The following flow-chart describes the strategy used by the BCM to manage the information from the IBS
and the automatic stop enabling/disabling.
When the engine automatic stop is enabled by the BCM, the ECM is enabled to automatically switch off
the engine if the driving conditions (actions on the brake, clutch and accelerator pedals) are satisfied in
the same way as the other conditions controlled by the ECM.
When the engine automatic stop is disabled by the BCM, the ECM is not enabled to automatically switch
off the engine, even if the driving conditions (actions on the brake, clutch and accelerator pedals) are
satisfied in the same way as the other conditions controlled by the ECM.
Engine automatically switched off conditions
When the engine has been automatically switched off for the Stop/Start function, a request can be
generated by a device/control unit, which requires the automatic restarting of the engine.
The BCM collects the information coming from the vehicle and, if necessary, requires the ECM to
automatically restart the engine (the ECM checks first whether safe automatic restarting conditions are
satisfied).
The decision to request or not request an automatic stop by the BCM is translated into a signal produced
by the BCM and sent, through the C-CAN, to the ECM.
The following flowchart describes the strategy used by the BCM to manage the information from the IBS
and the procedure for asking/not asking for an automatic stop.
Fig 12: Automatic Stop System - Flowchart
Cranking
Key start-up is controlled by the user by placing the key in the starting position: under these
circumstances starting is managed by BCM, and by ECM.
Inside the BCM is a relay, R2, the power line of which is in series with the power line of relay R1
managed by the ECM.
When the engine is started, both relays are closed. At the end of starting, the engine management
module opens relay R2 and immediately afterwards orders brief closure of the same relay to diagnose
the body computer relay: if the voltage level downstream of the relay is low, relay R1 has not become
stuck. If instead the level is high, relay R1 has become stuck. A fault code will be set and the stop/start
is disabled.
Starting by stop/start occurs according to the same logic as key starting, with the sole difference that the
starting signal (+50) arrives at the BCM from the CAN and not from the switch.
In normal conditions, both relays are controlled only when the engine is started, both by key and by
Stop/Start.
Failed engine cut out conditions - Conditions managed by the ECM
When the Stop/Start is activated, under certain circumstances the engine does not stop automatically
due to comfort, emission control and safety reasons. These conditions leading to a failed automatic
engine cut-out can be detected and managed by the BCM or by the ECM.
Engine cold : the automatic engine cut-out is not allowed if the signal from the engine coolant
temperature sensor is outside of a range from Temp_H20_min (about 40°C) and Temp_H20_max.: (about
100°C). In this case the consumption and emission reduction derived from the Stop/Start is not
guaranteed. Refer to CALIBRATION PROCESS LOGIC TABLE for the details.
Reverse engaged : if reverse gear is engaged, the Powertrain Control Module does not allow the
automatic stopping of the engine. In this way the driveability during parking maneuvers is not
compromised.
Clutch switch operation check not performed yet : This check takes place following a complete
clutch pedal cycle (release and pressing or pressing and release) with the engine on
Malfunction or fault detected in at least one of the following sensors or systems:
Accelerator pedal.
Brake pedal.
Vacuum sensor on brake servo.
Gearbox control unit.
Water temperature sensor in the engine.
Wheel speed sensors.
Clutch switch.
Engine rpm sensor.
Camshaft sensor.
Reverse switch.
Engine or Powertrain Control Module (with MIL on).
Braking system low vacuum: the ECM prevents the automatic engine cut-out if the vacuum
sensor (see paragraph on the sensors detected by the ECM for details on the sensors) transmits a
LOW value.
The BCM asked to prevent the engine automatic stopping by sending a C_CAN message if one or
more conditions managed by the BCM occur
For Diesel engines only. Particulate filter regeneration in progress; the Powertrain Control
Module does not allow the automatic engine cut-out if the DPF is carrying out the regeneration of
the filter.
Conditions managed by the BCM - Battery not sufficiently charged or flat:
The BCM receives information from the IBS on the status of the battery charge. If the IBS is being
recalibrated, the engine cut-out is not allowed if one of the following conditions occurs:
the battery Function Status (SOF) is below 8.3 V
the battery temperature is below ?23°C
If the IBS is not being recalibrated, the engine cut-out is not allowed if one of the following conditions
occurs:
the battery Charge Status (SOC) is below 75%
the battery Health Status (SOH) is below 60%
the battery temperature is below 23°C
IBS failure: the automatic engine cut-out is not allowed if an IBS malfunction occurs.
Voltage Stabilizer failure: the automatic engine cut-out is not allowed if Voltage Stabilizer malfunction
occurs.
Driver's door not closed: the automatic engine cut-out is not allowed if the driver's door is open
Driver's seat belt unfastened: the engine automatic cut-out is not allowed if the driver's seat belt is
unfastened.
Outside temperature sensor:
when the outside temperature sensor is fitted, the automatic engine cut-out is not allowed if:
the outside temperature is lower than the limit Temp_min_1 (?14°C)
the outside temperature is higher than the limit Temp_max_1 (80°C)
NOTE:
The temperature limits that have been set on the outside temperature sensor are "extreme"
and therefore must always be respected.
Automatic climate control: the automatic engine cut-out is not allowed if the difference between the
climate control temperature set by the customer and the temperature inside the passenger compartment
is greater than ± 4°C. In the case of manual air conditioning, the engine can always be stopped.
Generator fault: the automatic engine cut-out is not allowed in the case of Generator malfunction.
Engine hood open: if the hood switch is fitted, the automatic engine cut-out is not allowed if the hood
is open.
Logistic Mode status active: the automatic engine cut-out is not allowed if the Logistic Mode status is
active.
SPM semi-automatic parking system: when the semi-automatic parking system is fitted, the
automatic engine cut-out is not allowed if the system is active.
Failure on BCM relay: the automatic engine cut-out is not allowed in the case of malfunction of the
start-up circuit relay operated by the BCM.
Automatic restarting - When the Stop/Start is operational, under certain circumstances the engine
may restart automatically without any intervention by the driver due to comfort, emission control and
safety reasons. These conditions leading to the engine automatic restarting can be detected and
managed by the BCM or by the ECM.
Conditions managed by the ECM -
Braking system low vacuum: an automatic engine restart is forced if the vacuum sensor (see
paragraph on the sensors detected by the ECM for details on the individual sensors) transmits a
LOW value. This prevents undesired movements of the car with the engine off on a gradient due to
a possible brake servo failure.
Moving vehicle: An automatic engine restart is forced if the car speed is higher than a certain
threshold, named V_th_start (about 5 km/h). This condition avoids dangerous situations due to a
failure of the engine brake on gradients.
Engine cut-off by the Stop/Start system for a time longer than t_timeout_stop_1 (160
seconds).
Engaged reverse: if the driver engages reverse gear during an engine stop by the Stop/Start, the
Powertrain Control Module automatically restarts the engine. In this way the driveability during
parking maneuvers is not compromised.
Cold engine: the NCM forces the automatic engine restart if the signal from the engine water
temperature sensor is below the threshold Temp_H20_min_ON (about 30°C). In this case the
reduction in consumption and emissions derived from the Stop/Start is not guaranteed.
The BCM requested the automatic engine restart without any action by the driver and
transmitted this information to the ECM by means of a specific message on C_CAN.
(STATUS_B_CAN2.BCMAutoStopStaySts = 0).
Catalytic converter temperature below a given threshold (temp_catalist).
The handbrake is applied whilst the car is moving (either forwards or in reverse) with the
engine stopped at a speed higher than the threshold V_th_start_HndBrk. (about 3 km/h).
This is a further safety measure to avoid dangerous situations due to a failure of the engine brake
on gradients
For Diesel engines only. Particulate filter regeneration in progress: the Powertrain Control
Module automatically reactivates the engine if the DPF is carrying out the regeneration of the filter.
Conditions managed by the BCM
Battery not sufficiently charged or flat:

The BCM receives information from the IBS on the status of the battery charge. If the IBS is being
recalibrated, the engine is automatically restarted without any driver's intervention if one of the following
conditions occurs:
the battery temperature is below ?24°C
If the IBS is not being recalibrated, the engine is automatically restarted if one of the following conditions
occurs:
the battery Charge Status (SOC) is below 70%
the battery Health Status (SOH) is below 59%
the battery temperature is below 24°C
IBS fault: The engine is automatically restarted without any action by driver if an IBS malfunctioning
occurs
Outside temperature sensor:
If an outside temperature sensor is fitted, the engine is automatically restarted without any action by
driver if:
the outside temperature is lower than the limit Temp_min_2 (14°C).
the outside temperature is higher than the limit Temp_max_2 (80°C).
NOTE: the temperature limits that have been set on the outside temperature sensor are
"extreme" and therefore must always be respected.
Automatic climate control: The engine is automatically restarted without any action by the driver if the
difference between the climate control temperature set by the customer and the temperature in the
passenger compartment is greater than ± 7°C.
NOTE: in the case of manual air conditioning, the engine remains off.
Logistic Mode status active: The engine is automatically restarted without any action by driver if the
Logistic Mode status is activated.
Semi-automatic parking system SPM : When the semi-automatic parking system is fitted, the engine
is automatically restarted without any action by driver if the parking system is activated during the
engine stopping stage.
Disabling of automatic restarting (safety function) - In some cases, after an automatic engine
cut-out through the Stop/Start, it is possible that the automatic restart requested by the driver is not
carried out. In these circumstances, restarting is only possible through manual intervention by the driver
on the key, to restore the behavior of the vehicle to that of a traditional car without S/S. The
management of this function is transferred to the ECM and the BCM.
Conditions managed by the ECM -
Too many unsuccessful attempts at automatic starting - The threshold Max_cranking_attempts (5

times) has been exceeded. The threshold indicates the maximum number of failed automatic engine
restart attempts. This threshold is set to prevent damage to the starter by too many start-up attempts
close together. Refer to CALIBRATION PROCESS LOGIC TABLE on the threshold values.
The BCM requested to prevent the engine automatic restart. Malfunction or fault detected in at
least one of the following sensors or systems:
Accelerator pedal
Brake pedal
Brake servo vacuum sensor
Engine coolant temperature sensor
Vehicle speed
Gearbox/transmission control unit
Clutch switch
Neutral sensor
Engine rpm sensor
Camshaft sensor
Reverse switch
Engine or Powertrain Control Module (with MIL on).
The driver has been requested to perform an action but did not perform it in time - Engine at
standstill timeout set by the threshold T_immo (175 seconds). If an automatic engine restart attempt is
unsuccessful as a result of a failure to press the clutch or because the gearbox is not in neutral and the
driver is then requested to allow automatic restart by pressing the clutch or engaging neutral, the engine
can only be restarted using the key after T_immo (175 seconds) has elapsed from the engine restart
attempt.
Conditions managed by the BCM
Engine hood open: when the hood switch is fitted, automatic engine restarting is not allowed if
the hood is open.
Driver's or passenger's door not closed and driver's seat belt unfastened: automatic engine
restarting is not allowed if the driver's door or the passenger's door is open and, at the same time,
the driver's seat belt is not fastened.
Failure on BCM relay: automatic engine restarting is not allowed in the case of malfunction of
relay T20 controlled by the BCM.
OPERATION
1.4L / 2.4L
Module (PCM).
The efficiency of the charging system is controlled by the Body Control Module (BCM):
The PCM sends the voltage signal to the BCM which controls the efficiency of the generator
charging by detecting two parameters: the voltage signal coming from the generator itself, and the
starter motor signal which is also received on the CAN network by the PCM.
The BCM signals the cluster to turn on the insufficient charging warning when the ignition is
switched ON until the voltage is above 5.5 volts. If the voltage drops below 4.5 volts with the
engine above 700 RPMs, the indicator will turn on accompanied by a display message in the
information center of the cluster.
1.6L / 2.0L With STOP / START
Module (PCM).
This engine uses an electronically controlled generator, equipped with a controller that receives
commands from the PCM: in this way you get the best performance in terms of:
Reduction in fuel consumption and emissions
Improvement of powertrain performance and vehicle dynamics
The Start & Stop system automatically shuts down the engine whenever the vehicle is stationary and
restarts it when the driver intends to resume driving.
The system is essentially based on a starter system (battery and starter) being able to perform, quickly
and relatively quiet, the restarting of the engine and to support a number of starts much higher than that
required for a traditional system.
Strategies for implementation and monitoring of the shutdown and restart of the system is managed by
the PCM and the Body Control Module (BCM) directly or via the CAN network.
The starter is upgraded to a heavy duty cycle starter, and the generator is also upgraded increasing the
capabilities of current delivery.
Besides the changes on the battery, in order to incorporate Start & Stop strategies, an Intelligent Battery
Sensor (IBS) is used. The IBS has the function to monitor the status of the battery and communicate it to
the network nodes or to enable an optimal management of the battery in the framework of the Start &
Stop strategies.
The IBS is located on the negative battery terminal.
A Neutral Position Sensor is mounted on the gearbox providing output from the sensor to a controller
concerning gear range position.
Automatic shutdown and restart of the motor are marked by a specific indicator on the instrument cluster.
If the indicator is flashing, this indicates a possible fault with the Start & Stop system.
The device is activated / deactivated manually via the switch between the controls next to the gear
lever.
DIAGNOSIS AND TESTING > STARTING SYSTEM
The battery, starting, and charging systems operate in conjunction with one another, and must be tested
as a complete system. For correct starting/charging system operation, all of the components involved in
these three systems must perform within specifications.
STARTING SYSTEM DIAGNOSIS
CONDITION POSSIBLE CAUSE CORRECTION
STARTER FAILS TO 1. Battery discharged or 1. Charge and test battery (Refer to DIAGNOSIS
OPERATE inoperative AND TESTING ). Replace battery, if required.
2. Test the starter motor and solenoid (Refer to

2. Starter motor or
DIAGNOSIS AND TESTING ). Replace starter
solenoid inoperative
motor, if required.
3. Starter relay 3. See appropriate SYSTEM WIRING

inoperative DIAGRAMS article. Test and replace the starter
relay, if required
4. Clutch pedal position 4. See Clutch Pedal Position Switch. Test and
switch inoperative (if adjust or replace switch, if required.
equipped with manual
transmission)
5. Park/Neutral position 5. See Park/Neutral Position Switch. Test and
switch inoperative (if adjust or replace switch, if required.
equipped with automatic
transmission)
6. Ignition switch 6. Test the Ignition Switch and Key Lock

inoperative Cylinder. Replace ignition switch if required.
7. See appropriate SYSTEM WIRING

7. Starting circuit wiring
DIAGRAMS article. Test and repair starter feed
inoperative
and/or control circuits, if required.
STARTER ENGAGES, 1. Battery discharged or 1. Charge and test battery (Refer to DIAGNOSIS
BUT FAILS TO TURN inoperative AND TESTING ). Replace battery if required.
ENGINE
2. Test the starter motor and solenoid (Refer to
2. Starter motor or
DIAGNOSIS AND TESTING ). Replace starter
motor if required.

3. Starting circuit wiring
DIAGRAMS article. Test and repair starter feed
inoperative
and/or control circuits, if required.
4. Engine seized 4. See 9 - Engine. Test and repair engine as

required.
STARTER ENGAGES, 1. Test the starter motor and solenoid (Refer to

1. Starter motor or
BUT THEN DISENGAGES DIAGNOSIS AND TESTING ). Replace starter
BEFORE ENGINE motor, if required.
STARTS
2. Remove starter motor and inspect starter ring
2. Starter ring gear
gear (Refer to REMOVAL AND INSTALLATION
damaged
). Replace starter ring gear, if required.
STARTER DOES NOT 1. Starter motor 1. Inspect and test the starter motor and
DISENGAGE incorrectly installed or solenoid (Refer to DIAGNOSIS AND TESTING ).
solenoid inoperative Replace starter motor, if required.

2. Starter relay
DIAGRAMS article. Test and replace the starter
inoperative
relay, if required.
3. Ignition switch 3. Test the Ignition Switch and Key Lock

inoperative Cylinder. Replace ignition switch, if required.
SPECIFICATIONS > STARTER

STARTER SPECIFICATIONS TABLE
Hitachi S114-943A
Type Mitsubishi 5450B Bosch S74L Bosch S78M
Bosch SCL70S
Voltage (V) 12
Rated output (kW) 1.0 1.3 - -
Pinion side
clockwise
rotation
Pole number 6 - 6 6

COMPONENT FASTENER Ø VALUE (nm) VALIDITY
Ignition switch in the steering

Trim Screw M8 20 -
column
1.4L Turbo
MultiAir
Starter Screw M8 26
1.6L Turbo Diesel
2.0L Turbo Diesel
Starter-upper screw Screw M10 47 2.4L MultiAir
Starter-lower screw Screw M10 61 2.4L MultiAir
1.4L Turbo
Starter wiring Nut M8 15
MultiAir
1.6L Turbo Diesel

Glow plug - M9 8
2.0L Turbo Diesel
SENSOR, NEUTRAL POSITION > REMOVAL AND INSTALLATION > REMOVAL AND
INSTALLATION > NEUTRAL POSITION SENSOR - REMOVAL
2. Remove the floor console trim. Refer to CONSOLE, FLOOR, REMOVAL AND INSTALLATION .
Fig 1: Removing Neutral Position Sensor
3. Working in front of the transmission shifter control (1a), disconnect the sensor (1c) electrical
connector (1b) of the sensor (1c).
4. Release the retainers (2a) and remove the sensor (1c) by lifting. If necessary, insert a tool
under the bottom of the sensor and apply light pressure to disengage from the seat.
SENSOR, NEUTRAL POSITION > REMOVAL AND INSTALLATION > REMOVAL AND
INSTALLATION > NEUTRAL POSITION SENSOR - INSTALLATION
1. Check that the sensor is not damaged.
2. Position the sensor then engage the retainers.
3. Connect the sensor electrical connector.
4. Connect the diagnostic tool. Go to the ECM "Miscellaneous Functions" menu and launch the
self learning neutral position sensor procedure.
STARTER > REMOVAL AND INSTALLATION > REMOVAL AND INSTALLATION - 1.4L >
REMOVAL

Fig 1: Upper Starter Bolt
3. Remove the upper starter bolt.

Fig 2: Connector Cover
4. Open the connector cover (1).

Fig 3: Wiring Connector & Nut
5. Remove the nut (1) and disconnect the wiring connector from the start motor.
Fig 4: Starter & Lower Starter Bolt
6. Remove the lower starter bolt (1a).
7. Remove the starter (1b).

Fig 5: Starter Bushing
8. Check the integrity of the starter bushing (1).
9. Check that the starter motor is not damaged.
INSTALLATION
Fig 1: Starter Motor & Lower Screw
1. Put into place the starter motor (1a) and tighten the lower screw (1b) to the proper
SPECIFICATIONS .
2. Connect the wiring harness starter motor, tighten the nut and close the connector cover.
Fig 2: Upper Mounting Bolt
3. Install and tighten the upper mounting bolt (1) for the starter to the proper SPECIFICATIONS .
4. Remove the vehicle from the hoist.
REMOVAL

Fig 1: Removing Starter
3. Open the starter connector cover (1a) at the starter motor (1b).
4. Remove the nut (2a) and disconnect the battery (2b) and generator (2c) wiring electrical
connections.
5. Remove the nut and disconnect the electrical connector (3a).
6. Remove the starter bolt (4a). Move the seat support bracket wiring.
7. Remove the starter bolt (5a).
8. Remove the lower starter bolt (6a) and then remove the starter (1b).
INSTALLATION
Fig 1: Installing Starter
1. Position the starter for installation.
2. Install the top (2a) starter bolt.
3. Position the bracket wiring support and install the top (3a) starter bolt.
4. Install the lower starter bolt.

5. Tighten all installed bolts to the proper SPECIFICATIONS .
6. Connect the wiring connection from the battery (6a), from the generator (6b) and secure with
the nut (6c).
7. Close the starter wiring harness connector cover (7a).
REMOVAL

2. Working behind the engine, remove the nut (1a) and position the plug control unit (1b) out of
the way.
Fig 2: Repositioning Particulate Filter Pressure Sensor
3. Disconnect the electrical connections (1a, 1b) of the injection ECU (1c).
4. Open the clamp (2a) of the wiring.
5. Remove the nuts (3a) and reposition the particulate filter pressure sensor (3b), complete with
bracket.
Fig 3: Removing Injection Control Unit Media
6. Disconnect the ground wire from the terminal (1a).
7. Disconnect the electrical connection (2a) from the junction of the PTU power cord.
8. Open the various retainer clips (3a) and free the wiring (3b) from the injection control unit
support (3c).
9. Loosen the nuts (4a) and the screws (4b), then remove the injection control unit media (3c).
Fig 4: Remove/Install Starter
10. Working from the top of the engine, open the starter motor electrical protection cover (1a) of
the starter motor (1b).
11. Remove the nut (2a) and disconnect the wiring electrical connections from the battery (2b) and
from the generator (2c).
12. Disconnect the electrical connector (3a) after removing the nut.
13. Remove the starter bolt (4a). Reposition the wiring support from the seat bracket (4b).
14. Remove the starter bolt (5a).
15. Remove the lower starter bolt (6a).
16. Remove the starter (1b).
17. Remove the spacer (7a).
INSTALLATION
Fig 1: Installing Starter
1. Place the spacer (1a).
2. Place the starter (2a) and pull the screws in the holes (2b).
3. Position the wiring (3b) bracket support (3a) and then tighten the upper starter bolt.
4. Tighten to torque the screws securing the starter motor.

5. Connect the electrical connector (5a) and then tighten the nut.
6. Connect the wiring connection from the battery (6a), from the generator (6b) and secure with
the nut (6c).
7. Close the starter wiring harness connector cover (7a).

Fig 2: Installing Injection Control Unit Media
9. Connect the wiring (2a) to the injection ECU support (1a) and apply various retaining straps
(2b).
10. Connect the PTU power cord electrical connector (3a), and then engage it to its support.
11. Connect the (4a) ground wire and tighten the nut.
Fig 3: Placing Particulate Filter Pressure Sensor
(1b).
14. Connect the injection control unit (3c) electrical connections (3a, 3b).
15. Place the plug unit and tighten.
REMOVAL
2. Disconnect the electrical connectors from the starter motor.
3. Remove the lower starter bolt.
4. Remove and disengage the gear selector retaining bracket (1).
5. Remove the upper starter bolt (2)
6. Remove the starter motor.
INSTALLATION
1. Position the starter and install the top starter retaining bolt. Tighten the bolt to the proper
SPECIFICATIONS .
2. Install the gear shift retaining bracket.
3. Install the lower start bolt and tighten the bolt to the proper SPECIFICATIONS .
4. Connect the start electrical connectors.
5. Lower the vehicle from the hoist.
SWITCH, IGNITION > REMOVAL AND INSTALLATION > REMOVAL AND

NOTE:
For mechanical key ignition, refer to SWITCH, IGNITION, REMOVAL AND INSTALLATION .
Fig 1: Removing Steering Column Bottom Cover
3. Lower the steering wheel position lever (1).
4. Remove the screws (2a) securing the bottom cover (2b) of the steering column.
5. Remove the bottom cover (3a) by disengaging the retainers (3b).
Fig 2: Steering Wheel Bottom Cover & Electrical Connector
6. Disconnect the electrical connector.
7. Remove the bottom cover (2) of the steering column.

Fig 3: Ignition Push Button Switch & Mounting Screws
8. Remove the mounting screws (1).
9. Remove the ignition push button switch (2).

NOTE:
For mechanical key ignition, refer to SWITCH, IGNITION, REMOVAL AND INSTALLATION .
1. Check that the ignition push button switch is not damaged.
2. Place the ignition push button switch and tighten the screws.
3. Connect the switch electrical connector.
4. Install the lower steering column cover.
5. Turn the steering wheel to the middle position and secure it with the position lever.
6. Install the instrument cluster bezel to the instrument panel. Refer to BEZEL, INSTRUMENT

Jeep Renegade
ENGINE
Capacities
U.S. Metric
Cooling System •
MOPAR®
Standard MS.90032.

(1.6L Engine) D3306 9.55523

(2.0L Engine) D3306 9.55523
MOPAR®
Standard MS.90032.

Engine Oil - (1.4L
Engine)



Engine)
Engine Oil Filter
(1.4L Engine)
Engine Oil Filter

(1.6L Engine)
Engine Oil Filter

(2.0L Engine)
Engine Oil Filter

(2.4L Engine)
Fuel

Engine) Ethanol

Engine)

Engine)

Engine) Ethanol

Ethanol
(E85) Models Only
CAUTION:
SPARK PLUGS
Gap
U.S. Metric

TRANSAXLE
Capacity
U.S. Metric
Automatic
Use only MOPAR® ZF

8&9 Speed
ATF™Automatic
Transmission Fluid,
performance of your
transmission.
Manual

C635 Manual
Transaxle
Transmission Fluid
CHASSIS
Capacities
U.S. Metric
Axles
Use synthetic
Rear Differential
(RDM)
75W-90 API GL5
Transfer Case
Use synthetic
Power Transfer Unit
(PTU)
75W-90 API GL5
Chassis Systems
We recommend you
use MOPAR® DOT
then DOT 3 is
acceptable.
FUSES AND RELAYS

F02 70 Amp Tan - -
Controller Power
F03 - 20 Amp Blue -
Brake Control
F04 - 30 Amp Pink -
Electronics Module
F05 70 Amp Tan - -
Steering

40 Amp Orange -
1.4 Without A/C
With A/C And All
2.4 Models
Automatic
F08 - 30 Amp Pink -
Transmission, GSM
10 Amp Red - 1.4

F11 - -
Engines
Pump Power "After

F14 - - 5 Amp Tan
Run"

Pump

Transmission
10 Amp Red - 1.4

Engines
15 Amp Blue - 2.4
Engines

Ignition Powered
Air Conditioner
Compressor
Electronic Power
F20 - - 5 Amp Tan
Four-Wheel Drive

Engine
Equipped

F24 - - 15 Amp Blue

20 Amp Yellow
Powered

Drive

F87 - - 5 Amp Tan
Transmission
IBS Sensor (Battery

F90 - - 5 Amp Tan
State Of Charge)

F31 7.5 Amp Brown

IPC

F49 7.5 Amp Brown


F53 7.5 Amp Brown

Fuse holders no. 1

F7 30 Amp Green
Passenger Side)
Fuse holders no. 2
figure.
NOTE:


STARTING
WARNING:
WARNING:
WARNING:
COLOR.
WARNING:
WARNING:
WARNING:

WARNING:
TO EXCEED 16 VOLTS.
WARNING:
CAUTION:

parts.
replaced.
CAUTION:

accessories.
CAUTION:
vehicle.
battery post.
CAUTION:

20, 40, 60, 80, 100, 120, 140, 160, 180, 200,
Kilometers:
000 000 000 000 000 000 000 000 000 000
Or Years: 1 2 3 4 5 6 7 8 9 10

• • • • • • • • • •
charge (if any).

• • • • • • • • • •
etc.).

• • • • • • • • • •
battery, etc.).


• • • • •

• • • • •

• • • • •
and adjust nozzles.

lubrication.
operation.

operation.



•
timing belt.

(1)

(2)
s. (2)

O • O • O • O • O •
(•)
60, 000 km.

NOTE:
15, 30, 45, 60, 75, 90, 105, 120, 135, 150,
Kilometers:
000 000 000 000 000 000 000 000 000 000
Or Years: 1 2 3 4 5 6 7 8 9 10

• • • • • • • • • •
(if any).


• • • • • • • • • •
etc.).


• • • • •

• • • • •

• • • • •
and adjust nozzles.
lubrication.

operation.

operation.


tensioner).

•
timing belt.

(3)
s. (3)

O • O • O • O • O •
(•)
60, 000 km.

NOTE:
procedure.

NOTE:
CAUTION:
Maintenance Chart
Mileage or time
passed 10, 20, 30, 40, 50, 60, 70, 80, 90, 100, 110, 120, 130, 140, 150,
(whichever 000 000 000 000 000 000 000 000 000 000 000 000 000 000 000
comes first)
Years 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15
16, 32, 48, 64, 80, 96, 112, 128, 144, 160, 176, 192, 208, 224, 240,
Or Kilometers
000 000 000 000 000 000 000 000 000 000 000 000 000 000 000
Check tire
condition/wear
and adjust
pressure, if
• • • • • • • • • • • • • • •
necessary,
check TIRE KIT
expiration date
(if provided).
Check operation
of lighting
system
(headlamps,
direction
indicators,
hazard warning
lights, luggage
• • • • • • • • • • • • • • •
compartment,
passenger
compartment,
glove
compartment,
instrument panel
warning lights,
etc.).
Check and, if
necessary, top
up fluid levels
(brakes/hydraulic
clutch, • • • • • • • • • • • • • • •
windshield
washer, battery,
engine coolant,
etc.).
Check engine
control system
• • • • • • • • • • • • • • •
operation (via
diagnostic tool).
Visually inspect
condition of:
exterior
bodywork,
• • • • • • •
underbody
protection, pipes
and hoses
(exhaust - fuel
system -
brakes), rubber
elements (boots,
sleeves,
bushings, etc.).
Check
windshield/rear
window wiper • • • • • • • •
blade
position/wear.
Check operation
of windshield
and adjust jets if
necessary.
Check
cleanliness of
hood and
and cleanliness
and lubrication of
linkages.
Visually check
the condition and
• • • • • • • • • • • • • • •
wear of the front
and rear brakes.
Check the front

suspension, tie
and replace if
necessary.
Visual inspect
the condition of
• • •
the accessory
drive belt.
Check the
tension of the
• • • • • • •
accessory drive
belt.
Replace the
accessory drive •
belt.
Inspect and
replace PCV
•
valve if
necessary.
Change engine
oil and replace
oil filter (*).
Inspect the PTU

• • •
fluid level.
Inspect the rear

level.
Replace spark
plugs (1.4L
• • • • •
Turbo engine).
(**)
Replace spark
plugs (2.4L •
engine). (**)
Replace engine
• • • • •
air filter. (#)
Replace brake
years.
Replace cabin
• • • • • • • • • • • • • • •
filter.
Change the
manual
transmission
fluid if using your
vehicle for any
of the following:
trailer towing,
heavy loading,
taxi, police,
delivery service
(commercial • •
service),
off-road, desert
operation or
more than 50%
of your driving is
at sustained
speeds during
hot weather,
above 90°F
(32°C).
Flush and
replace the
at 10 years or
150, 000 miles
(240, 000 km)
whichever
comes first.
Replace the
Turbo Engine).
plug replacement.
WARNING:
Brake fluid level;
Dusty roads
(if any).
etc.).
INSTALLATION .
(if any).
etc.).

NOTE:

assembly.
suitable container.


MULTIAIR)
(if any).
etc.).
NOTE:
PLUGS .



(if any).
etc.).

NOTE:

assembly.
suitable container.



MULTIAIR)
(if any).
etc.).


INSTALLATION .
(if any).
etc.).

NOTE:
PLUGS .



NOTE:
(if any).
etc.).
4x4 versions only:
NOTE:

NOTE:

assembly.
suitable container.



(if any).
etc.).

INSTALLATION .
(if any).
etc.).

NOTE:

assembly.
suitable container.


MULTIAIR)
(if any).
etc.).
NOTE:
PLUGS .




(if any).
etc.).

NOTE:

assembly.
suitable container.

NOTE:

assembly.

MULTIAIR)
(if any).
etc.).


INSTALLATION .
(if any).
etc.).

NOTE:
PLUGS .


NOTE:
(if any).
etc.).

NOTE:

assembly.
suitable container.

NOTE:

assembly.

MULTIAIR)
(if any).
etc.).

INSTALLATION .
(if any).
etc.).

4x4 versions only:

NOTE:

assembly.
suitable container.

NOTE:

assembly.

MULTIAIR)
(if any).
etc.).
NOTE:
PLUGS .




(if any).
etc.).

NOTE:

assembly.
suitable container.

NOTE:

assembly.

(if any).
etc.).

NOTE:

assembly.
suitable container.

NOTE:

assembly.

(if any).
etc.).

NOTE:

assembly.
suitable container.


Corporate name
Sincom code
Model
Version
Chassis No.
CONFORMITY
• Accessory check
VEHICLE INTERIOR
• Locks
ENGINE COMPARTMENT
CAR EXTERIOR

FINAL CHECK
• Dry vehicle
NOTE:
removed
Detected faults:
Date:
Operator's name:
VEHICLE READINESS
NOTE:
Description Action
2. Headlights Off;


seconds.
Renegade)
NOTE:


turn off.

180 Days

Process.

installed module.

shipping.


equipped)
UNDERHOOD
Description Action




All Fluid Levels

an full engagement.
ROAD TEST
Description Action

______


Keyless Go
inside vehicle.



does not drag.



Autostick
through the gears.

depressed.

depressed.




Defrost - Rear

detection zone.



disconnected.


suspension system.

flashing/chiming.

INTERIOR
Description Action
damage.

operates properly.

Rear View Mirror
operating properly.

operation.


seat system.

operating properly.




required.


Set Clock(s)




operation.



cooled cup holders.

properly.
EXTERIOR
Description Action

Preparation.


keys.

Needed
operation.

equipped)



VEHICLE STORAGE
Description Action

Description Action

Protective Covers

dings and dents.




placard

equipped)
instrument panel.


FRONT, BASE - EMEA
1.



REAR, EMEA
holder (1a).


FRONT, BASE - NAFTA



REAR, NAFTA
140CV 170CV
Maximum weight
1905 1905 2010/2080 (*) 2080
allowed (kg)
Maximum weight
axles (kg)
Maximum weight
axles (kg)
NOTE:
NOTE:
140CV 170CV
Payload including
585 kg 515 kg 580/550 kg (**) 545 kg
the driver (*)
NOTE:
NOTE:
140CV 170CV
Trailer with brakes

1000 1000 1500/1000 (*) 1500
(kg)
Trailer without
400 400 400 400
brakes (kg)
Cargo on the ball

(kg)
The maximum load

(kg) (**)
NOTE:
NOTE:
140CV 170CV

to 90% and no 1320 1390 1430/1530 (*) 1535
optional equipment)
(kg)
NOTE:

VEHICLE
FRONT
REAR
threaded pin back.
Trail Hawk Version
CAUTION:
improper towing.
CAUTION:
Warranty.
NOTE:
NOTE:
Wheels
OFF the
Ground

must be observed.
ON/RUN position.
Service Manual: 1.6L/2.0L DIESEL - SERVICE Jeep Renegade
INFORMATION
DIAGNOSIS AND TESTING > INTRODUCTION
Engine diagnosis is helpful in determining the causes of malfunctions not detected and remedied by
routine maintenance.
These malfunctions may be classified as either mechanical (e.g., a strange noise), or performance (e.g.,
engine idles rough and stalls).
For Engine Mechanical diagnosis, refer to ENGINE MECHANICAL DIAGNOSTIC TABLE .
For Engine Performance diagnosis, refer to ENGINE PERFORMANCE DIAGNOSTIC TABLE .
For Fuel Delivery system diagnosis, refer to FUEL DELIVERY, DIAGNOSIS AND TESTING .
For Cooling System diagnosis, refer to DIAGNOSIS AND TESTING .
For Engine Lubrication System diagnosis, refer to ENGINE LUBRICATION DIAGNOSTIC TABLE .
Additional tests and diagnostic procedures may be necessary for specific engine malfunctions that
cannot be isolated with the Service Diagnosis tables. Information concerning additional tests and
diagnosis is provided within the following:
Cylinder Compression Pressure Test: Refer to CYLINDER COMPRESSION TEST .
Cylinder Combustion Pressure Leakage Test: Refer to CYLINDER LEAKAGE TEST .
Cylinder Head Gasket Leakage Diagnosis: Refer to CYLINDER HEAD GASKET .
Mechanical Valve Tappet Noise Diagnosis: Refer to LIFTER(S), HYDRAULIC .
Exhaust System leak testing: Refer to CHECKING THE EXHAUST SYSTEM FOR LEAKS .
DIAGNOSIS AND TESTING > ENGINE PERFORMANCE DIAGNOSTIC TABLE
ENGINE WILL NOT START 1. Weak battery. 1. Test the battery. Charge or
replace as necessary. Refer to
BATTERY, DIAGNOSIS AND
TESTING .
2. Corroded or loose battery 2. Clean and tighten the battery

connections. connections. Apply a coat of light
mineral grease to the terminals.
3. Faulty engine starting 3. Test the starting system. Refer

system. to DIAGNOSIS AND TESTING .
4. Faulty coil(s) or control unit. 4. Test and replace as needed.

Refer to DIAGNOSIS AND
TESTING .
5. Incorrect spark plug gap. 5. Set the spark plug gap. Refer to
SPECIFICATIONS .
6. Contamination in fuel system. 6. Clean the fuel system and

replace the fuel filter.
The engine starting should not be

effected if the oil level shows
anywhere on the dipstick. If the oil
7. Incorrect engine oil level and level is off the dipstick, the oil level
oil quality. could be contributing to the
startability issue.
If the oil quality is questionable,
change the oil and filter.
Perform a long start procedure -

Crank engine for 10 seconds, let sit
8. Long Stand Still Parking - for 5 seconds, crank for 10
longer than 35 days. seconds. May be necessary to
continue sequence after a 30
second break.
9. Faulty fuel pump. 7. Test the fuel pump and replace

as needed. Refer to DIAGNOSIS
AND TESTING .
8. Incorrect cam timing. 8. Verify cam timing. Refer to

Replace the Camshaft Position

10. Faulty Camshaft Position (CMP) sensor. Refer to SENSOR,
(CMP) sensor. CAMSHAFT POSITION, REMOVAL
AND INSTALLATION .
Replace the Crankshaft Position

11. Faulty Crankshaft Position (CKP) sensor. Refer to SENSOR,
(CKP) sensor. CRANKSHAFT POSITION,
ENGINE STALLS OR IDLES 1. Idle speed too low. 1. Check for Diagnostic Trouble
ROUGH Codes (DTC). Refer to appropriate
Engine Electrical Diagnostics
article.
2. Incorrect fuel mixture. 2. Check for Diagnostic Trouble

Codes (DTC). Refer to appropriate
article.
3. Vacuum leak. 3. Inspect intake manifold, manifold

gasket, and vacuum hoses.
4. Faulty ignition coil(s). 4. Test and replace the ignition coil.

Refer to COIL, IGNITION,
5. Replace the Crankshaft Position
6. Verify cam timing. Refer to

6. Incorrect cam timing.
ENGINE LOSS OF POWER 1. Dirty or incorrectly gapped 1. Correct as necessary. Refer to

spark plugs. SPARK PLUG, REMOVAL AND
INSTALLATION .

3. Faulty fuel pump. 3. Test and replace the fuel pump.

Refer to MODULE, FUEL PUMP,
4. Leaking cylinder head 4. Replace the cylinder head

gasket. gasket. Refer to CYLINDER HEAD,
5. Low compression. 5. Determine the cause and repair

as necessary. Refer to CYLINDER
COMPRESSION TEST .
6. Burned, warped, or pitted 6. Replace valves as necessary.

valves. Refer to CYLINDER HEAD
7. Plugged or restricted exhaust 7. Perform the exhaust restriction

system. test. Install new parts as
necessary. Refer to DIAGNOSIS
AND TESTING .

9. Incorrect valve timing. 9. Verify cam timing. Refer to

ENGINE MISSES ON 1. Dirty or incorrectly gapped 1. Correct as necessary. Refer to

ACCELERATION spark plugs. SPARK PLUG, REMOVAL AND
INSTALLATION .
2. Contamination in fuel system. 2. Clean fuel system and replace

the fuel filter.

valves. Refer to CYLINDER HEAD .

ENGINE MISSES AT HIGH 1. Dirty or incorrect spark plug 1. Correct as necessary. Refer to
SPEED gap. SPARK PLUG, REMOVAL AND
INSTALLATION .


4. Dirty fuel injector(s). 4. Test and replace as necessary.

TESTING .
DIAGNOSIS AND TESTING > NOISY OPERATION
1. You will hear a noise of high and constant intensity, coming from the engine area and
detectable only within a certain range of RPM.
EVERYTHING PROBLEMS
PRELIMINARY CHECKS RESOLUTION
OK ENCOUNTERED
Check the integrity and Repair or replace

Circuit components
tightness of the circuit intake Continue to Step 2 components as
damaged.
air necessary.
2. Check the engine mounts.
CHECK ENGINE PROBLEMS

EVERYTHING OK RESOLUTION
MOUNTS ENCOUNTERED
1. Restore the
correct fitting.
1. Fixing incorrect 2. Replace the motor
media engine mount on the
2. Support the engine gearbox side.
gearbox side defective 3. Replace the motor
3. Support engine mount side
timing side defective distribution.
Check the correct
4. Support rear motor 4. Replace the rear
mounting and the integrity
defective motor mount.
of:
Continue to Step 3 5. Anchor elastic 5. Replace the
- engine Supports
support front defective elastic block front
- flexible blocks
6. Anchor elastic back support.
- guy reaction
support defective 6. Replace the
7. Anchor elastic elastic block back
support gearbox side support.
defective 7. Replace the
8. Fixing incorrect tie elastic block support
rod reaction. gearbox side.
8. Restore the
correct fixing.
3. Check the engine supports exhaust.

SUPPORTS EXHAUST ENCOUNTERED
1. Restore the
correct fixing of the
Check the correct support 1. Supports loose.
Continue to Step 4 supports.
fixing sewage pipes. 2. Support damaged.
2. Replace the
damaged media.
4. Check the engine exhaust.

EXHAUST ENCOUNTERED
Check the exhaust

system of the engine and 1. Replace the pipe
in particular: 1. Full damaged pipe. complete
- collector 2. Silencer damaged. 2. Replace the rear
End diagnosis
- conduit 3. Seal Front worn or silencer
- Exhaust silencer damaged. 3. Replace the front
- Seal front of the seal
catalytic converter.
DIAGNOSIS AND TESTING > ENGINE MECHANICAL DIAGNOSTIC TABLE
CONDITION POSSIBLE CAUSES CORRECTIONS
NOISY VALVES 1. High or low oil level in 1. Adjust the engine oil level. Refer
crankcase. to FILTER, ENGINE OIL, REMOVAL
AND INSTALLATION .
2. Thin or diluted oil. 2. Change the engine oil and filter.

Refer to FILTER, ENGINE OIL,
3. Low oil pressure. 3. Check the oil pump, if OK, check

the rod and main bearings for
excessive wear. Refer to
4. Dirt in valve lash adjusters. 4. Replace as necessary. Refer to

LIFTER(S), HYDRAULIC, REMOVAL
AND INSTALLATION .
5. Worn rocker arms. 5. Replace as necessary. Refer to

CYLINDER HEAD .
6. Worn valve lash adjusters 6. Replace as necessary. Refer to

AND INSTALLATION .
7. Worn valve guides. 7. Inspect the valve guides for wear,

cracks or looseness. If either
condition exists, replace the cylinder
head. Refer to CYLINDER HEAD,
8. Excessive runout of valve 8. Replace as necessary. Refer to

seats or valve faces. CYLINDER HEAD .
CONNECTING ROD NOISE 1. Insufficient oil supply. 1. Check and adjust the engine oil
level. Refer to FILTER, ENGINE OIL,
2. Low oil pressure. 2. Check the engine oil pump, if OK,

check the rod and main bearings for

4. Excessive bearing 4. Replace as necessary. Refer to

clearance. ENGINE BLOCK .
5. Connecting rod journal 5. Service or replace the crankshaft.

out-of-round, rough surface or Check the crankshaft for plugged oil
debris. Obstructed oil feed feed hole. Refer to ENGINE
hole. BLOCK .
6. Misaligned connecting rods. 6. Replace the bent connecting rods.

Refer to ROD, PISTON AND
CONNECTING, REMOVAL AND
INSTALLATION .
MAIN BEARING NOISE 1. Insufficient oil supply. 1. Check and adjust the engine oil



5. Excessive end play. 5. Check the thrust washers for

wear. Refer to ENGINE BLOCK .
6. Crankshaft journal out-of 6. Service or replace the crankshaft.
round, rough or debris. Check the engine block for plugged
Obstructed oil feed hole. oil feed hole. Refer to ENGINE
BLOCK .
7. Loose flywheel, flexplate or 7. Tighten to the proper

torque converter. specification. Refer to TORQUE
SPECIFICATIONS .
DIAGNOSIS AND TESTING > CYLINDER COMPRESSION TEST
NOTE:
To perform a compression test on a MULTI-AIR equipped engine, the ignition MUST

remain in the "key on" position. If the ignition is in the "off" position, the intake
valves will not actuate and the result will be no compression.
NOTE:
The results of a cylinder compression pressure test can be utilized to diagnose several
engine malfunctions.
NOTE:
Be certain the battery is completely charged and the engine starter motor is in good
operating condition. Otherwise the indicated compression pressures may not be valid for
diagnosis purposes.
1. Clean the spark plug recesses with compressed air.
2. Remove the spark plugs and record the cylinder number of each spark plug for future
reference.
3. Inspect the spark plug electrodes for abnormal firing indicators such as fouled, hot, oily, etc.
4. Disable the fuel system and perform the fuel system pressure release procedure. Refer to
FUEL DELIVERY, STANDARD PROCEDURE .
5. Insert a compression pressure gauge and rotate the engine with the engine starter motor for
three revolutions.
6. Record the compression pressure on the 3rd revolution. Continue the test for the remaining
cylinders.
NOTE:
The recommended compression pressures are to be used only as a guide to

diagnosing engine problems. An engine should not be disassembled to determine
the cause of low compression unless some malfunction is present.
7. Compression should not be less than 689 kPa (100 psi) and not vary more than 25 percent
from cylinder to cylinder.
8. If one or more cylinders have abnormally low compression pressures, repeat the compression
test.
NOTE:
If the same cylinder or cylinders repeat an abnormally low reading on the second
compression test, it could indicate the existence of a problem in the cylinder in
question.
9. If one or more cylinders continue to have abnormally low compression pressures, perform the
cylinder combustion pressure leakage test. Refer to CYLINDER LEAKAGE TEST .
DIAGNOSIS AND TESTING > CYLINDER LEAKAGE TEST
The combustion pressure leakage test provides an accurate means for determining engine condition.
Cylinder leakage testing will detect:
Exhaust and intake valve leaks (improper seating).
Leaks between adjacent cylinders or into water jacket.
Any causes for combustion pressure loss.
1. Check the coolant level and fill as required. DO NOT install the radiator cap.
2. Start and operate the engine until it attains normal operating temperature, then turn the engine
OFF.
3. Remove the spark plugs.
4. Remove the oil filler cap.
5. Remove the air cleaner hose.
6. Calibrate the tester according to the manufacturer's instructions. The shop air source for
testing should maintain a regulated air pressure at 552 kPa (80 psi).
7. Perform the test procedures on each cylinder according to the tester manufacturer's
instructions. Set piston of cylinder to be tested at TDC compression.
8. While testing, listen for pressurized air escaping through the throttle body, tailpipe and oil filler
cap opening. Check for bubbles in the radiator coolant.
All gauge pressure indications should be equal, with no more than 25% leakage.
If leakage is greater then 25%, refer to CYLINDER COMBUSTION PRESSURE LEAKAGE DIAGNOSIS
CHART below.
CYLINDER COMBUSTION PRESSURE LEAKAGE DIAGNOSIS CHART
AIR ESCAPES THROUGH Intake valve bent, burnt, or not Inspect valve and valve seat.
THROTTLE BODY seated properly Reface or replace, as necessary.
Inspect valve springs. Replace as
necessary.
AIR ESCAPES THROUGH Exhaust valve bent, burnt, or not Inspect valve and valve seat.
TAILPIPE seated properly Reface or replace, as necessary.
necessary.
AIR ESCAPES THROUGH Head gasket leaking or cracked Remove cylinder head and inspect.
RADIATOR cylinder head or block Replace defective part
MORE THAN 50% LEAKAGE Head gasket leaking or crack in Remove cylinder head and inspect.
FROM ADJACENT CYLINDERS cylinder head or block between Replace gasket, head, or block as
adjacent cylinders necessary
MORE THAN 25% LEAKAGE Stuck or broken piston rings; Inspect for broken rings or piston.
AND AIR ESCAPES THROUGH cracked piston; worn rings Measure ring gap and cylinder
OIL FILLER CAP OPENING and/or cylinder wall diameter, taper and out-of-round.
ONLY Replace defective part as
necessary
DIAGNOSIS AND TESTING > OIL CONSUMPTION TEST AND DIAGNOSIS
The following diagnostic procedures are used to determine the source of excessive internal oil
Consumption, these procedures and tests apply to vehicles with 50, 000 miles or less.
NOTE:
Engine oil consumption may be greater than normal during engine break-in. Repairs should
be delayed until vehicle has been driven at least 7, 500 miles.
Severe service (high ambient temperature, short trips, heavy loading, trailer towing, taxi,
off-road, or law enforcement use) may result in greater oil consumption than normal.
Sustained high speed driving and high engine RPM operation may result in increased oil
consumption.
Failure to comply with the recommended oil type and viscosity rating, as outlined in the owner's
manual, may impact oil economy as well as fuel economy.
Oil consumption may increase with vehicle age and mileage due to normal engine wear.
NOTE:
Because a few drops of external oil leakage per mile can quickly account for the loss of one
quart of oil in a few hundred miles, ensure no external engine oil leaks are present.
Oil leakage is not the same as oil consumption and all external leakage must be eliminated
before any action can be taken to verify and/or correct oil consumption complaints.
Verify that the engine has the correct oil level dipstick and dipstick tube installed.
Verify that the engine is not being run in an overfilled condition. Check the oil level 15
minutes after a hot shutdown with the vehicle parked on a level surface. In no case should
the level be above MAX or the FULL mark on the dipstick.
DIAGNOSIS AND TESTING > OIL CONSUMPTION TEST AND DIAGNOSIS > OIL
CONSUMPTION TEST
1. Check the oil level at least 15 minutes after a hot shutdown with the vehicle on a level surface.
2. If the oil level is low, top off with the proper viscosity and API service level engine oil. Add one
bottle of MOPAR® 4-In-1 Leak Detection Dye into the engine oil.
3. Tamper proof the oil pan drain plug, oil filter, dipstick and oil fill cap with a black light marking
device (pen) or air conditioning dye applied with a small brush.
NOTE:
The use of a black light marking device is recommended so the marks can only be
seen with a ultraviolet light.
4. Record the vehicle mileage. Note that the oil level at 'full' mark 15 minutes after hot shut-down
and date.
5. Instruct the customer to drive the vehicle as usual.
6. Ask the customer to return to the servicing dealer after accumulating 500 miles, Check the oil
level at least 15 minutes after a hot shutdown on a level surface. If the oil level is half way
between the "FULL" and "ADD" mark or below, continue with the next step.
7. Using a black light, check for any external engine oil leaks, repair as necessary, if no external
engine oil leaks are present, continue with oil consumption diagnosis.
CONSUMPTION DIAGNOSIS
1. Check the Positive Crankcase Ventilation (PCV) system. Make sure the system is not
restricted, (one way by blowing air through it) and the PCV valve is the correct part based on
the part number. Check the hoses and connectors for damage or leaks. It must have correct
vacuum source at intake manifold through the hose- vent assembly. Normal vacuum is
considered to be 18-20 in. Hg at idle, below 3000 ft. above sea level.
2. Perform a cylinder compression test and cylinder leakage test using the standard cylinder
leakage tester and following manufacturers suggested best practices. Refer to CYLINDER
COMPRESSION TEST and CYLINDER LEAKAGE TEST .
NOTE:
Blow the spark plug sockets/bores out with compressed air to remove fluid or
debris before removing the spark plugs.
Verify the spark plugs are not oil saturated.
3. If one or more cylinders have more than 15% leak down further engine tear down and
inspection will be required.
DIAGNOSIS AND TESTING > OIL CONSUMPTION TEST AND DIAGNOSIS > TOP 18
REASONS THAT MAY LEAD TO ENGINE OIL CONSUMPTION
1. Tapered and Out-of-Round Cylinders
The increased piston clearances permit the pistons to rock in the worn cylinders. While tilted
momentarily, an abnormally large volume of oil is permitted to enter on one side of the piston.
The rings, also tilted in the cylinder, permit oil to enter on one side. Upon reversal of the piston
on each stroke, some of this oil is passed into the combustion chamber.
2. Distorted Cylinders
This may be caused by unequal heat distribution or unequal tightening of cylinder head bolts.
This condition presents a surface which the rings may not be able to follow completely. In this
case, there may be areas where the rings will not remove all of the excess oil. When
combustion takes place, this oil will be burned and cause high oil consumption.
3. Improper operation of "PCV" system
The main purpose of the Positive Crankcase Ventilation (PCV) valve is to recirculate blow-by
gases back from the crankcase area through the engine to consume unburned hydrocarbons.
The PCV system usually has a one way check valve and a make up air source. The system
uses rubber hoses that route crankcase blow by gases to the intake manifold. Vacuum within
the engine intake manifold pulls the blow by gases out of the crankcase into the combustion
chamber along with the regular intake air and fuel mixture.
The PCV system can become clogged with sludge and varnish deposits and trap blow by
gases in the crankcase. This degrades the oil, promoting additional formation of deposit
material. If left uncorrected, the result is plugged oil rings, oil consumption, rapid ring wear due
to sludge buildup, ruptured gaskets and seals due to crankcase pressurization.
If equipped with an engine driven vacuum pump, high oil consumption can be caused by
unchecked airflow into the pump. This can be caused by anything that opens the vacuum pump
intake port up to the atmosphere such as a faulty vacuum pump, hose fitting, hose and brake
booster. If there is not a restriction (normally caused by the pump pulling vacuum on the brake
booster), then the vacuum pump will pump a high volume of air. This high volume of air will
pressurize the crankcase and cause excessive oil burning and oil flow through the PCV
system.
4. Worn Piston Ring Grooves
For piston rings to form a good seal, the sides of the ring grooves must be true and flat - not
flared or shouldered. Piston rings in tapered or irregular grooves will not seal properly and,
consequently, oil will pass around behind the rings into the combustion chamber.
5. Worn, Broken or Stuck Piston Rings
When piston rings are broken, worn or stuck to such an extent that the correct tension and
clearances are not maintained, this will allow oil to be drawn into the combustion chamber on
the intake stroke and hot gases of combustion to be blown down the cylinder past the piston on
the power stroke. All of these conditions will result in burning and carbon build up of the oil on
the cylinders, pistons and rings.
6. Cracked or Broken Ring Lands
Cracked or broken ring lands prevent the rings from seating completely on their sides and
cause oil pumping. This condition will lead to serious damage to the cylinders as well as
complete destruction of the pistons and rings. Cracked or broken ring lands cannot be
corrected by any means other than piston replacement.
7. Worn Valve Stems and Guides
When wear has taken place on valve stems and valve guides, the vacuum in the intake
manifold will draw oil and oil vapor between the intake valve stems and guides into the intake
manifold and then into the cylinder where it will be burned.
8. Bent or Misaligned Connecting Rods
Bent or misaligned connecting rods will not allow the pistons to ride straight in the cylinders.
This will prevent the pistons and rings from forming a proper seal with the cylinder walls and
promote oil consumption. In addition, it is possible that a bearing in a bent connect rod will not
have uniform clearance on the connecting rod wrist pin. Under these conditions, the bearing
will wear rapidly and throw off an excessive amount of oil into the cylinder.
9. Fuel Dilution
If raw fuel is allowed to enter the lubrication system, the oil will become thinner and more
volatile and will result in higher oil consumption. The following conditions will lead to higher oil
consumption:
1. Excess fuel can enter and mix with the oil via a leaking fuel injector
2. Gasoline contaminated with diesel fuel
3. Restricted air intake
4. Excessive idling
10. Contaminated Cooling Systems
Corrosion, rust, scale, sediment or other formations in the water jacket and radiator will
prevent a cooling system from extracting heat efficiently. This is likely to cause cylinder
distortion thus leading to higher oil consumption.
11. Oil Viscosity
The use of oil with a viscosity that is too light may result in high oil consumption. Refer to the
vehicle owner's manual for the proper oil viscosity to be used under specific driving conditions
and/or ambient temperatures.
12. Dirty Engine Oil
Failure to change the oil and filter at proper intervals may cause the oil to be so dirty that it will
promote accumulation of sludge and varnish and restrict oil passages in the piston rings and
pistons. This will increase oil consumption; dirty oil by nature is also consumed at a higher rate
than clean oil.
13. Crankcase Overfull
Due to an error in inserting the oil dip stick so that it does not come to a seat on its shoulder, a
low reading may be obtained. Additional oil may be added to make the reading appear normal
with the stick in this incorrect position which will actually make the oil level too high. If the oil
level is so high that the lower ends of the connecting rods touch the oil in the oil pan excessive
quantities of oil will be thrown on the cylinder walls and some of it will work its way up into the
combustion chamber.
14. Excessively High Oil Pressure
A faulty oil pressure relief valve may cause the oil pressure to be too high. The result will be
that the engine will be flooded with an abnormally large amount of oil in a manner similar to that
which occurs with worn bearings. This condition may also cause the oil filter to burst.
15. Aftermarket Performance Chips and Modification
Increasing performance through the use of performance/power enhancement products to a

stock or factory engine will increase the chance of excessive oil consumption.
16. Lugging Engine
Lugging is running the engine at a lower RPM in a condition where a higher RPM (more
power/torque) should be implemented. Especially susceptible on vehicles equipped with a
manual transmission. This driving habit causes more stress loading on the piston and can lead
to increases in engine oil consumption.
17. Turbocharged Engines
There is a possibility for PCV "push-over" due to higher crankcase pressure (as compared to
naturally aspirated engines) which is normal for turbocharged engines. This condition causes
varying amounts of engine oil to enter the intake manifold, charge air cooler and associated
plumbing to and from the charge air cooler, also a leaking turbocharger seal will draw oil into
the combustion chamber where it will burn (blue smoke from tail pipe may be present) and form
carbon deposits which contribute to further oil consumption as they interfere with proper engine
function.
18. Restricted Air Intake
Excessive restriction in the air intake system will increase engine vacuum and can increase oil
consumption, an extremely dirty air filter would be one example of this situation.
DIAGNOSIS AND TESTING > ENGINE LUBRICATION DIAGNOSTIC TABLE
OIL LEAKS 1. Misaligned or damaged 1. Replace as necessary.

gaskets and O-rings.
2. Loose fasteners, broken or 2. Repair or replace metal parts.

porous metal parts. Tighten fasteners to the proper
specification. Refer to TORQUE
SPECIFICATIONS .
3. Crankshaft rear oil seal. 3. Replace the rear crankshaft oil

seal. Refer to SEAL, CRANKSHAFT
OIL, REAR, REMOVAL AND
INSTALLATION .
4. Crankshaft rear oil seal 4. Polish or replace the crankshaft.

surface scratched, nicked or Refer to ENGINE BLOCK .
grooved.
5. Oil pan flange cracked. 5. Replace the oil pan. Refer to PAN,
OIL, REMOVAL AND
INSTALLATION .
6. Damaged or misaligned 6. Replace the front crankshaft oil

crankshaft front oil seal. seal.
7. Scratched or damaged 7. Polish or replace the vibration

vibration damper hub front oil damper. Refer to DAMPER,
seal surface. VIBRATION, REMOVAL AND
INSTALLATION .
OIL PRESSURE DROP 1. Low oil level. 1. Check and correct the engine oil
level. Refer to LUBRICATION .
2. Faulty oil pressure sensor. 2. Replace the oil pressure sensor.
3. Low oil pressure. 3. Check the main crankshaft bearing

clearance. Refer to STANDARD
PROCEDURE .
3. Check the rod bearing clearance.
4. Clogged oil filter. 4. Replace the engine oil filter. Refer
to FILTER, ENGINE OIL, REMOVAL
AND INSTALLATION .
5. Worn oil pump. 5. Replace the engine oil pump.

Refer to PUMP, ENGINE OIL,

Refer to FILTER, ENGINE OIL .
7. Excessive bearing 7. Replace the crankshaft bearings.

clearance. Refer to ENGINE BLOCK .
7. Replace the rod bearings. Refer to
ENGINE BLOCK .
8. Oil pump relief valve stuck. 8. Replace the engine oil pump.
OIL PUMPING AT RINGS; 1. Worn or damaged rings. 1. Hone the cylinder bores and
SPARK PLUGS FOULING replace the piston rings. Refer to
STANDARD PROCEDURE . Refer to
RING(S), PISTON, REMOVAL AND
INSTALLATION .
2. Carbon in oil ring slots. 2. Replace the piston rings. Refer to

INSTALLATION .
3. Worn valve guides. 3. Replace the cylinder head. Refer

to CYLINDER HEAD, REMOVAL
AND INSTALLATION .
4. Leaking valve guide seals. 4. Replace the valve guide seals.

Refer to CYLINDER HEAD .
1. Install new oil filter and test engine

1. Obstructed or incorrect oil
oil pressure. Refer to DIAGNOSIS
filter.
AND TESTING .
2. Change engine oil and test engine

ENGINE OIL FILTER SWOLLEN 2. Engine oil viscosity
oil pressure. Refer to DIAGNOSIS
OR BURST incorrect.
AND TESTING .
3. Replace engine oil pump. Refer to

3. Excessive engine oil
PUMP, ENGINE OIL, REMOVAL AND
pressure.
INSTALLATION .
STANDARD PROCEDURE > DUST COVERS AND CAPS

Fig 1: Covers/Caps
To avoid the possibility of dust, dirt, moisture and other foreign debris being introduced to the engine
during service, cover or cap all openings when hoses and tubes are removed.
Fig 2: Opening Cover
Covers installed over openings will reduce the possibility of foreign materials to entering the engine
systems. Using miller tool Universal Protective Cap Set (special tool #10368, Set, Universal Protective
Cap), select the appropriate cover needed for the procedure.
STANDARD PROCEDURE > ENGINE GASKET SURFACE PREPARATION

Fig 1: Proper Tool Usage For Surface Preparation
1 - ABRASIVE PAD
2 - 3M ROLOC™ BRISTLE DISC
3 - PLASTIC/WOOD SCRAPER
To ensure engine gasket sealing, proper surface preparation must be performed, especially with the use
of aluminum engine components and multi-layer steel cylinder head gaskets.
Never use the following to clean gasket surfaces:
Metal scraper.
Abrasive pad or paper to clean cylinder block and head.
High speed power tool with an abrasive pad or a wire brush (1).
NOTE:
Multi-Layer Steel (MLS) head gaskets require a scratch free sealing surface.
Only use the following for cleaning gasket surfaces:
Solvent or a commercially available gasket remover
Plastic or wood scraper (3).
Drill motor with 3M Roloc™ Bristle Disc (white or yellow) (2).
CAUTION:
Excessive pressure or high RPM (beyond the recommended speed), can damage the
sealing surfaces. The mild (white, 120 grit) bristle disc is recommended. If necessary, the
medium (yellow, 80 grit) bristle disc may be used on cast iron surfaces with care.
STANDARD PROCEDURE > FORM-IN-PLACE GASKETS AND SEALERS
NOTE:
All of the sealants mentioned below are not used on every engine, they are listed as a
general reference guide. See service information for specific sealer usage.
There are numerous places where form-in-place gaskets are used on the engine. Care must be taken
when applying form-in-place gaskets to assure obtaining the desired results.Do not use form-in-place
gasket material unless specified. Bead size, continuity, and location are of great importance. Too thin
a bead can result in leakage while too much can result in spill-over which can break off and obstruct fluid
feed lines. A continuous bead of the proper width is essential to obtain a leak-free gasket. All sealing
surfaces that use form-in-place gaskets and sealers must be free of grease or oil. Surfaces should be
cleaned with Mopar® brake parts cleaner prior to sealer application. After the sealer is applied, the parts
should be assembled within 10 minutes.
There are numerous types of form-in-place gasket materials that are used in the engine area. Each has
different properties and can not be used in place of the other.
SEALANT TYPES
MOPAR® ENGINE SEALANT RTV SILICONE RUBBER ADHESIVE is used to seal components
exposed to engine oil. This material is a specially designed black silicone rubber RTV that retains
adhesion and sealing properties when exposed to engine oil. Moisture in the air causes the
material to cure. This material is available in three ounce tubes and has a shelf life of one year.
After one year this material will not properly cure. Always inspect the package for the expiration
date before use.
MOPAR® ATF-RTV is a specifically designed black silicone rubber RTV that retains adhesion and
sealing properties to seal components exposed to automatic transmission fluid, engine coolants,
and moisture. This material is available in three ounce tubes and has a shelf life of one year. After
one year this material will not properly cure. Always inspect the package for the expiration date
before use.
MOPAR® GASKET MAKER is an anaerobic type gasket material. The material cures in the
absence of air when squeezed between two metallic surfaces. It will not cure if left in the
uncovered tube. The anaerobic material is for use between two machined surfaces. Do not use on
flexible metal flanges.
MOPAR® BED PLATE SEALANT is a unique (green-in-color) anaerobic type gasket material that
is specially made to seal the area between the bed plate and cylinder block without disturbing the
bearing clearance or alignment of these components. The material cures slowly in the absence of
air when torqued between two metallic surfaces, and will rapidly cure when heat is applied.
MOPAR® THREEBOND™ ENGINE RTV is formulated as a high performance temperature

vulcanized silicone with good elasticity, temperature and chemical resistance when cured. It is
resistant to engine oil, transmission fluid and gear lube but not recommended for sealing engine
coolant.
SEALANT APPLICATION
Mopar® Gasket Maker material should be applied sparingly 1 mm (0.040 in.) diameter or less of
sealant to one gasket surface. Be certain the material surrounds each mounting hole. Excess
material can easily be wiped off. Components should be torqued in place within 15 minutes. The
use of a locating dowel is recommended during assembly to prevent smearing material off the
location.
Mopar® Engine Sealant RTV or ATF-RTV gasket material should be applied in a continuous bead
approximately 3 mm (0.120 in.) in diameter. All mounting holes must be circled. For corner sealing
and "T" joint locations, a 3.17 or 6.35 mm (1/8 or 1/4 in.) drop is placed in the center of the gasket
contact area. Uncured sealant may be removed with a shop towel. Components should be torqued
in place while the sealant is still wet to the touch (within 10 minutes). The usage of a locating dowel
is recommended during assembly to prevent smearing material off the location.
Mopar® Threebond™ Engine RTV Sealant gasket material should be applied in a continuous bead
approximately 3 mm (0.120 in.) in diameter. The gasket surfaces should be cleaned with isopropyl
alcohol wipes in preparation for sealant application. All mounting holes must be circled. For corner
sealing and "T" joint locations, a 3.17 or 6.35 mm (1/8 or 1/4 in.) drop is placed in the center of the
gasket contact area. Uncured sealant may be removed with a shop towel. Components should be
assembled within 20 minutes and torqued in place within 45 minutes. The usage of a locating dowel
STANDARD PROCEDURE > HYDROSTATIC LOCKED ENGINE
When an engine is suspected to be hydrostatically locked, regardless of what caused the problem, the
following steps should be used.
CAUTION:
DO NOT use starter motor to rotate the engine, severe damage may occur.
1. Inspect air cleaner, induction system and intake manifold to insure system is dry and clear of
foreign material.
cable.
3. Place a shop towel around the spark plugs when removing them from the engine. This will catch
any fluid that may possibly be in the cylinder under pressure.
4. With all spark plugs removed, rotate engine crankshaft using a breaker bar and socket.
5. Identify the fluid in the cylinder(s) (i.e., coolant, fuel, oil or other).
6. Make sure all fluid has been removed from the cylinders. Inspect engine for damage (i.e.,
connecting rods, pistons, valves, etc.)
7. Repair engine or components as necessary to prevent this problem from re-occurring.
CAUTION:
Squirt approximately one teaspoon of oil into the cylinders, rotate engine to
lubricate the cylinder walls to prevent damage on restart.
8. Install new spark plugs.
9. Drain engine oil and remove oil filter.
10. Install a new oil filter.
11. Fill engine with specified amount of approved oil.
13. Start engine and check for any leaks.
STANDARD PROCEDURE > REPAIR DAMAGED OR WORN THREADS
CAUTION:
Be sure that the tapped holes maintain the original center line.
Damaged or worn threads can be repaired. Essentially, this repair consists of:
Drilling out worn or damaged threads.
Tapping the hole with a special Heli-Coil™ Tap, or equivalent.
Installing an insert into the tapped hole to bring the hole back to its original thread size.
SPECIFICATIONS > ENGINE SPECIFICATIONS

ENGINE TYPE
- 1.6 16V Multijet 1.6 16V Multijet 2.0 16V Multijet 2.0 16V Multijet
120CV 115CV 120/140CV 170CV
Position in vehicle Front Front Front Front
Orientation Transverse Transverse Transverse Transverse
Number of cylinders 4 4 4 4
Cylinder position In line In line In line In line
Fuel Diesel Diesel Diesel Diesel
2 Cams in head 2 Cams in head 2 Cams in head 2 Cams in head

Camshaft
(intake side and (intake side and (intake side and (intake side and
configuration
exhaust side) exhaust side) exhaust side) exhaust side)
ENGINE DATA
- 1.6 16V 2.0 16V 2.0 16V 2.0 16V

1.6 16V
Multijet Multijet Multijet Multijet
Multijet 115CV
120CV 120CV 140CV 170CV
Bore (mm) 79.5 79.5 83.0 83.0 83.0
Stroke (mm) 80.5 80.5 90.4 90.4 90.4
Total displacement
1598 1598 1956 1956 1956
(cm3)
Maximum power (kW

88 85 88 103 125
EEC)
Maximum power (CV

120 115 120 140 170
EEC)
Max. power (RPM) 3750 3750 4000 3750 3750
Maximum torque
320 320 320 350 350
(Nm EEC)
Maximum torque
32.6 32.6 32.6 35.7 35.7
(kgm EEC)
Maximum torque
1750 1750 1250 1500 1750
(RPM)
Idle speed (RPM) 800 ± 30 800 ± 30 850 ± 30 850 ± 30 850 ± 30
Compression ratio 16.5 : 1 16.5 : 1 16.5 : 1 16.5 : 1 16.5 : 1
TIMING ANGLES
- - 1.6 16V Multijet 2.0 16V Multijet
Operation control Intake (•) (•)

clearance (mm) Exhaust (•) (•)
Control timing clearance Intake - -

(mm) Exhaust - -
Opening (BTDC) 10° 10°
Intake Opening (ATDC) - -
Closed (after BDC) 1.5° 2°
Opening (before BDC) 40° 40°
Exhaust Closed (BTDC) - -
Closed (ATDC) 9° 9°
(•) Hydraulic Tappets
CYLINDER BORE
Measure Value Engine
Internal diameter cylinder Bore -

79.500 ÷ 79.510 1.6L Turbo Diesel
Class A (mm)

79.510 ÷ 79.520 1.6L Turbo Diesel
Class B (mm)

79.520 ÷ 79.530 1.6L Turbo Diesel
Class C (mm)

83.000 ÷ 83.010 2.0L Turbo Diesel
Class A (mm)

83.010 ÷ 83.020 2.0L Turbo Diesel
Class B (mm)

83.020 ÷ 83.030 2.0L Turbo Diesel
Class C (mm)
1.6L Turbo Diesel

Cylinder Bore Out of Round (mm) < 0.05
2.0L Turbo Diesel
1.6L Turbo Diesel
Cylinder Bore Taper < 0.005
2.0L Turbo Diesel
Oversize inner diameter cylinder

0.1 -
bore (mm)
CYLINDER HEAD
Cylinder head gasket thickness

protrusion -0.020 ÷ + 0.100
with maximum protrusion piston 1.6L Turbo Diesel
thickness (no hole) 0.82 +/- 0.05
(mm)

protrusion+ 0.101 ÷ + 0.200
thickness (one hole) 0.92 +/- 0.05
(mm)
Cylinder head gasket thickness protrusion + 0.201 ÷ + 0.295

with maximum protrusion piston thickness (two holes) 1.02 +/- 1.6L Turbo Diesel
(mm) 0.05

protrusion -0.110 ÷ + 0.230
thickness (no hole) 0.95 +/- 0.05
(mm)

protrusion -0.231 ÷ + 0.330
thickness (one hole) 0.95 +/- 0.05
(mm)
Cylinder head gasket thickness protrusion + 0.331 ÷ + 0.425

with maximum protrusion piston thickness (two holes) 1.15 +/- 2.0L Turbo Diesel
(mm) 0.05
Nominal cylinder head height 1.6L Turbo Diesel

107 +/- 0.05
(mm) 2.0L Turbo Diesel
Flatness Cylinder Head Surface

< 0.1 -
(mm)
VALVES
1.6L Turbo Diesel

Valve stem diameter- Intake (mm) 4.982 ÷ 5.000
2.0L Turbo Diesel
Valve stem diameter - Exhaust 1.6L Turbo Diesel

4.972 ÷ 4.990
VALVE GUIDES

1.6L Turbo Diesel
Valve stem diameter- Intake (mm) 4.982 ÷ 5.000
2.0L Turbo Diesel
Valve stem diameter - Exhaust 1.6L Turbo Diesel

4.972 ÷ 4.990
VALVE SPRINGS
1.6L Turbo Diesel

Valve spring free length (mm) 44.1
2.0L Turbo Diesel
Valve spring length under load of 1.6L Turbo Diesel

34.0
22.80 ÷ 25.20 daN (mm) 2.0L Turbo Diesel
Valve spring length under load of 1.6L Turbo Diesel

25.5
43.90 ÷ 48.10 daN (mm) 2.0L Turbo Diesel
VALVE SEATS
Outer diameter-intake valve seats

28.355 ÷ 28.365 1.6L Turbo Diesel
(mm)
Outer diameter-exhaust valve

26.100 ÷ 26.111 1.6L Turbo Diesel
seats (mm)
Outer diameter-intake valve seats

29.600 ÷ 29.611 2.0L Turbo Diesel
(mm)
Outer diameter-exhaust valve

26.100 ÷ 26.111 2.0L Turbo Diesel
seats (mm)
Valve seat angle in contact with

45° 0' +/- 1° 1.6L Turbo Diesel
valve
Valve seat angle in contact with

45° 30' +/- 1° 2.0L Turbo Diesel
valve
CRANKSHAFT
1.6L Turbo Diesel

Crankshaft End Play (mm) 0.049 ÷ 0.211
2.0L Turbo Diesel
Journal diameter (mm) 56.705 ÷ 56.718 1.6L Turbo Diesel
Journal diameter (mm) 63.705 ÷ 63.718 2.0L Turbo Diesel
Journal diameter - Class A (mm) 52.994 ÷ 53.000 1.6L Turbo Diesel
Journal diameter - Class B (mm) 52.988 ÷ 52.994 1.6L Turbo Diesel

Journal diameter - Class C (mm) 52.982 ÷ 52.988 1.6L Turbo Diesel
Journal diameter - Class A (mm) 59.995 ÷ 60.002 2.0L Turbo Diesel
Journal diameter - Class B (mm) 59.988 ÷ 59.995 2.0L Turbo Diesel
Journal diameter - Class C (mm) 59.981 ÷ 59.988 2.0L Turbo Diesel
Connecting rod pin diameter -

48.238 ÷ 48.244 1.6L Turbo Diesel
Class A (mm)

48.232 ÷ 48.238 1.6L Turbo Diesel
Class B (mm)

48.226 ÷ 48.232 1.6L Turbo Diesel
Class C (mm)

50.800 ÷ 50.807 2.0L Turbo Diesel
Class A (mm)

50.793 ÷ 50.800 2.0L Turbo Diesel
Class B (mm)

50.786 ÷ 50.793 2.0L Turbo Diesel
Class C (mm)
Journal out of round diameter

0.127 -
(mm)
Diameter connecting rod pins 0.127 -
MAIN BEARINGS/CRANKSHAFT CONNECTING ROD
Thickness of bearing shells - Class

1.831 ÷ 1.837 1.6L Turbo Diesel
To (Red) (mm)

1.836 ÷ 1.844 1.6L Turbo Diesel
B (Blue) (mm)

1.843 ÷ 1.849 1.6L Turbo Diesel
C (Yellow) (mm)

1.832 ÷ 1.836 2.0L Turbo Diesel
To (Red) (mm)

1.835 ÷ 1.839 2.0L Turbo Diesel
B (Blue) (mm)

1.838 ÷ 1.842 2.0L Turbo Diesel
C (Yellow) (mm)
Oversize bearing shells /

1.6L Turbo Diesel
connecting rod - Class A (Brown) 0.127
2.0L Turbo Diesel
(mm)
1.6L Turbo Diesel
connecting rod - Class B (Green) 0.254
2.0L Turbo Diesel
(mm)

1.6L Turbo Diesel
connecting rod - Class C (Black) 0.508
2.0L Turbo Diesel
(mm)
Thickness of connecting rod

1.536 1.6L Turbo Diesel
bearing- Class A (Red) (mm)

bearing - Class B (Blue) (mm)

bearing - Class C (Yellow) (mm)

1.528 ÷ 1.532 2.0L Turbo Diesel
bearing- Class A (Red) (mm)

1.532 ÷ 1.536 2.0L Turbo Diesel
bearing - Class B (Blue) (mm)

1.535 ÷ 1.539 2.0L Turbo Diesel
bearing - Class C (Yellow) (mm)
Clearance of main bearings -

0.011 ÷ 0.071 1.6L Turbo Diesel
crankshaft bearing journals (mm)
Clearance of main bearings -

0.031 ÷ 0.051 2.0L Turbo Diesel
crankshaft bearing journals (mm)
Clearance of rod bearings - 1.6L Turbo Diesel

0.030 ÷ 0.056
crankshaft rod bearings (mm) 2.0L Turbo Diesel
PINS
Diameter of seat pin (mm) 25.991 ÷ 25.996 1.6L Turbo Diesel
Diameter of seat pin (mm) 29.985 ÷ 29.990 2.0L Turbo Diesel
Pin outer diameter (mm) 25.982 ÷ 25.988 1.6L Turbo Diesel
Pin outer diameter (mm) 29.975 ÷ 29.980 2.0L Turbo Diesel
PISTON RINGS
Light 1^ seal ring compression 1.6L Turbo Diesel

0.20 ÷ 0.35
cylinders (mm) 2.0L Turbo Diesel
Light 2^ seal ring compression 1.6L Turbo Diesel

0.60 ÷ 0.80
cylinders (mm) 2.0L Turbo Diesel
Light scraper ring piston engine 1.6L Turbo Diesel
0.25 ÷ 0.50
Clearance of axial engine piston 1.6L Turbo Diesel

0.030 ÷ 0.070
scraper ring (mm) 2.0L Turbo Diesel
Thickness 1^ seal ring compression

1.970 ÷ 2.005 1.6L Turbo Diesel
cylinders (mm)

- 1.6L Turbo Diesel
cylinders (mm)

1.970 ÷ 1.990 1.6L Turbo Diesel
cylinders (mm)

1.470 ÷ 1.495 2.0L Turbo Diesel
cylinders (mm)

1.470 ÷ 1.495 2.0L Turbo Diesel
cylinders (mm)

1.970 ÷ 1.990 2.0L Turbo Diesel
cylinders (mm)
Seat seal on the piston - 1st slot

2.120 ÷ 2.140 1.6L Turbo Diesel
(mm)
Seat seal on the piston - 2nd slot

1.800 ÷ 1.820 1.6L Turbo Diesel
(mm)
Seat seal on the piston - 3rd slot

2.020 ÷ 2.040 1.6L Turbo Diesel
(mm)
Seat seal on the piston - 1st slot

1.620 ÷ 1.640 2.0L Turbo Diesel
(mm)
Seat seal on the piston - 2nd slot

1.550 ÷ 1.570 2.0L Turbo Diesel
(mm)
Seat seal on the piston - 3rd slot

2.020 ÷ 2.040 2.0L Turbo Diesel
(mm)
Axial 1^ seal ring compression

0.115 ÷ 0.170 1.6L Turbo Diesel
cylinders (mm)

0.050 ÷ 0.090 1.6L Turbo Diesel
cylinders (mm)

0.125 ÷ 0.170 2.0L Turbo Diesel
cylinders (mm)

0.055 ÷ 0.100 2.0L Turbo Diesel
cylinders (mm)
PISTONS

Outside diameter pistons - Class
79.440 ÷ 79.450 1.6L Turbo Diesel
A (mm)

79.450 ÷ 79.460 1.6L Turbo Diesel
B (mm)

79.460 ÷ 79.470 1.6L Turbo Diesel
C (mm)

82.930 ÷ 82.940 2.0L Turbo Diesel
A (mm)

82.940 ÷ 82.950 2.0L Turbo Diesel
B (mm)

82.950 ÷ 82.960 2.0L Turbo Diesel
C (mm)
Difference of weight allowed

+/- 5 -
between pistons (g)
Increase piston outer diameter

0.1 -
(mm)
CONNECTING RODS
Difference of weight allowed

1.6L Turbo Diesel
between the complete connecting +/- 2.5
2.0L Turbo Diesel
rods (g)
Inner Diameter small end of

26.006 ÷ 26.014 1.6L Turbo Diesel
bushings (mm)
Inner Diameter small end of

30.006 ÷ 30.014 2.0L Turbo Diesel
bushings (mm)
Inner Diameter big end of bushings

51.354 ÷ 51.366 1.6L Turbo Diesel
(mm)
Inner Diameter big end of bushings

53.897 ÷ 53.909 2.0L Turbo Diesel
(mm)
CAMSHAFTS
1.6L Turbo Diesel

Nominal intake camshaft lift (mm) 8.5
2.0L Turbo Diesel
1.6L Turbo Diesel

Nominal exhaust camshaft lift (mm) 8.0
2.0L Turbo Diesel
Diameter First pin timing shaft 1.6L Turbo Diesel

43.600 ÷ 43.615
Diameter Second pin timing shaft 1.6L Turbo Diesel
43.400 ÷ 43.415
Diameter Third pin timing shaft 1.6L Turbo Diesel

43.200 ÷ 43.215
Diameter Fourth pin timing shaft 1.6L Turbo Diesel

43.000 ÷ 43.015
Diameter Fifth pin timing shaft 1.6L Turbo Diesel

30.000 ÷ 30.015
Diameter first timing shaft support 1.6L Turbo Diesel

43.646 ÷ 43.671
Diameter second timing shaft 1.6L Turbo Diesel

43.446 ÷ 43.471
support (mm) 2.0L Turbo Diesel
Diameter third timing shaft support 1.6L Turbo Diesel

43.246 ÷ 43.271
Diameter fourth timing shaft 1.6L Turbo Diesel

43.046 ÷ 43.071
support (mm) 2.0L Turbo Diesel
Diameter fifth timing shaft support 1.6L Turbo Diesel

30.045 ÷ 30.070

ENGINE MOUNTS
Component Anchorage Ø Value (N.m) Validity
Rigid Support of the

powertrain side Screw M8 25 1.4L MultiAir Turbo
distribution

1.6L Turbo Diesel
powertrain side Screw M10 50
2.0L Turbo Diesel
distribution

powertrain Screw M12 40 + 45° 1.4L MultiAir Turbo
transmission side
Elastic Dowel of the

powertrain support Screw M10 60 + 45° 1.4L MultiAir Turbo
distribution side

powertrain support 1.6L Turbo Diesel
Screw M10 60 + 45°
distribution side - 2.0L Turbo Diesel
bodywork side
Screw M12 90 + 45°
distribution side - rigid 2.0L Turbo Diesel
support side

1.4L MultiAir Turbo
powertrain support
Screw M12 40 + 45° 1.6L Turbo Diesel
transmission side -
2.0L Turbo Diesel
rigid support side

powertrain support
Screw M12 120
transmission side -
bodywork side
Reaction of the lower

bolt gearshift-side Screw M14 90 + 45°
bracket
Reaction of the lower

bolt gearshift-side
Screw M14 90 + 45°
suspension cross
member
1.4L MultiAir Turbo

Bracket for lower tie 1.6L Turbo Diesel
Screw M12 40 + 45°
rod of reaction 2.0L Turbo Diesel
120/140CV
Bracket for lower tie 2.0L Turbo Diesel

Screw M14 90 + 45°
rod of reaction 170 hp

rigid support powertrain
Screw - 68 2.4L MultiAir
group timing to the
bodywork side

rigid support powertrain
Screw - 75 2.4L MultiAir
group timing to the rigid
support side
ENGINE CRANKCASE
Crankcase Central Screw M10 20 + 80° 1.4L MultiAir Turbo
Crankcase Lateral Screw M8 30 1.4L MultiAir Turbo
CYLINDER HEAD

Cover tappets Screw M6 9 1.4L MultiAir Turbo
Cover tappets Screw - 10 2.4L MultiAir
Central Screw (to

Upper head engine M8 25 1.4L MultiAir Turbo
replace)
Upper head engine Lateral Screw M8 25 1.4L MultiAir Turbo
1.6L Turbo Diesel

Upper head engine Screw M8 25
2.0L Turbo Diesel
Engine cylinder head Screw M9 30 + 90° 1.4L MultiAir Turbo
30 + 73 + 73 +
Engine cylinder head Screw - 2.4L MultiAir
90°
65 + 90° + 90° + 1.6L Turbo Diesel

Engine cylinder head Screw M12
90° 2.0L Turbo Diesel
Upper engine cylinder 1.6L Turbo Diesel

Cap M16 14
head caps 2.0L Turbo Diesel
ENGINE COVERS
1.4L MultiAir Turbo

Engine oil drain plug Cap M14 20 1.6L Turbo Diesel
2.0L Turbo Diesel
Crankcase engine Screw M6 9 1.4L MultiAir Turbo
Crankcase engine Nut M6 9 1.4L MultiAir Turbo
Engine oil gearbox Screw M10 40 1.4L MultiAir Turbo
Screws timing side and 1.6L Turbo Diesel

Crankcase M6 9
transmission side 2.0L Turbo Diesel
1.6L Turbo Diesel

Crankcase Lateral screws M8 25
2.0L Turbo Diesel
Front cover oil seal 1.4L MultiAir Turbo

Screw M6 9
crankshaft 2.0L Turbo Diesel
Front cover oil seal 1.6L Turbo Diesel

Screw (to replace) M6 9
Crankcase Screw - 12 2.4L MultiAir
Engine oil -
conditioning Screw - 22 2.4L MultiAir
compressor side
Timing cover Screw M6 9 2.4L MultiAir

1.6L Turbo Diesel
Rear oil seal retainer Screw (to replace) M6 9
2.0L Turbo Diesel
Rear oil seal retainer Screw M6 9 1.4L MultiAir Turbo
CRANKSHAFT AND FLYWHEEL
Flywheel engine Screw (to replace) M9 20 + 50° 1.4L MultiAir Turbo
Flywheel engine Screw - 29 2.4L MultiAir
1.6L Turbo Diesel

Flywheel engine Screw (to replace) M12 160
2.0L Turbo Diesel
Bearing caps Screw M12 20 + 100° 1.6L Turbo Diesel
PISTONS AND CONNECTING RODS
Rod cap Screw M8 20 + 40° 1.4L MultiAir Turbo
Rod cap Screw M9 25 + 60° 1.6L Turbo Diesel
TIMING CONTROL
Mobile tensioner Nut M8 22 - 27 1.4L MultiAir Turbo
Mobile tensioner Screw - 12 2.4L MultiAir
1.6L Turbo Diesel

Mobile tensioner Screw (to replace) M8 25
2.0L Turbo Diesel
1.6L Turbo Diesel

Fixed tensioner Screw M8 25
2.0L Turbo Diesel
Crankshaft pulley Screw M12 120 1.4L MultiAir Turbo
1.6L Turbo Diesel

Crankshaft pulley Screw M12 30 + 40°
2.0L Turbo Diesel
Camshaft pulley Screw M12 20 + 110° 1.4L MultiAir Turbo
1.6L Turbo Diesel

Camshaft pulley Screw (clockwise) M16 340
2.0L Turbo Diesel
Protection cover of 1.6L Turbo Diesel

timing control 2.0L Turbo Diesel
Driving gears
camshafts
Driving gears
camshafts
Tensioners support of
Screw M10 50 1.6L Turbo Diesel
timing belt
timing belt
CAMSHAFT
Timing shaft cap Screw M7 10 1.4L MultiAir Turbo
MultiAir module Screw M8 23 1.4L MultiAir Turbo
1.4L MultiAir Turbo

Oil temperature sensor - - 11
2.4L MultiAir
ENGINE TURBOCHARGER SYSTEM
1.4L MultiAir Turbo

Turbocharger Nut (to replace) M8 25 1.6L Turbo Diesel
2.0L Turbo Diesel
Bracket turbocharger
Screw M8 25 1.4L MultiAir Turbo
support
Nut (to replace) M8 25 1.4L MultiAir Turbo
support
Engine oil pressure

pipe to the Turbo- Fitting M10 26 2.0L Turbo Diesel
turbocharger side
Engine oil pressure

pipe to the Fitting M12 25 2.0L Turbo Diesel
turbocharged
Duct engine oil return

from the turbocharger - Screw M10 50 2.0L Turbo Diesel
base side
Oil return tube

turbocharger engine - Screw M6 9 2.0L Turbo Diesel
turbocharger side
INTAKE AND EXHAUST MANIFOLDS

Exhaust manifold Nut (to replace) M8 15 + 30° 1.4L MultiAir Turbo
Exhaust manifold Screw - 34 2.4L MultiAir
Exhaust manifold Nut - 34 2.4L MultiAir
Intake manifold Screw (to replace) M7 15 1.4L MultiAir Turbo
1.6L Turbo Diesel

Intake manifold Nut M8 25
2.0L Turbo Diesel
Exhaust manifold Nut (to replace) M8 24 1.6L Turbo Diesel
Heat shield of the

exhaust manifold
LUBRICATION SYSTEM
1.4L MultiAir Turbo

Engine oil filter cover - - 25 1.6L Turbo Diesel
2.0L Turbo Diesel
Oil filter support and

heat exchanger - oil Screw M20 45 1.4L MultiAir Turbo
pump side

heat exchanger - base Screw M10 50 1.4L MultiAir Turbo
side
Output pipe from turbo

engine oil

engine oil
Engine oil return pipe

from the turbo-
Fitting M14 33 1.4L MultiAir Turbo
blower-side heat
exchanger
Engine oil pressure

pipe to the Turbo- Junction with filter M12 25 1.4L MultiAir Turbo
turbocharger side
Engine oil pressure

pipe to the turbo-
blower-side heat
exchanger
Engine oil pressure
1.6L Turbo Diesel
pipe to the Turbo- Fitting M10 15
2.0L Turbo Diesel
turbocharger side
Engine oil pressure

pipe to the Turbo- 1.6L Turbo Diesel
Fitting M12 25
cylinder head upper 2.0L Turbo Diesel
side
Switch for engine oil

- M14 32 1.4L MultiAir Turbo
pressure warning light

- - 18 2.4L MultiAir
Switch for engine oil 1.6L Turbo Diesel

- M14 25
pressure warning light 2.0L Turbo Diesel
Engine oil pump

assembly - balance Screw - 15 + 29 + 90° 2.4L MultiAir
module
Engine oil pressure 1.6L Turbo Diesel

- M10 20
switch 2.0L Turbo Diesel
Introducing engine oil 1.6L Turbo Diesel

Screw M6 9
nozzle 2.0L Turbo Diesel
Displacement control 1.6L Turbo Diesel

Screw - 7
valve oil pump motor 2.0L Turbo Diesel
Engine oil pump Screw M6 10 1.4L MultiAir Turbo
MISCELLANEOUS ENGINE PARTS
1.4L MultiAir Turbo

Pulley on crankshaft Screw M8 25 1.6L Turbo Diesel
2.0L Turbo Diesel
Pulley on crankshaft Screw - 210 2.4L MultiAir
Automatic tensioner Screw - 24 2.4L MultiAir
Fixed tensioner Screw - 48 2.4L MultiAir
1.6L Turbo Diesel

2.0L Turbo Diesel
1.6L Turbo Diesel

Mobile tensioner Screw M10 50
2.0L Turbo Diesel
REMOVAL AND INSTALLATION > 1.6L DIESEL WITH MANUAL TRANSMISSION >
REMOVAL
5. Remove the front belly pan. Refer to BELLY PAN, REMOVAL AND INSTALLATION and BELLY
PAN, SIDE, REMOVAL AND INSTALLATION .
6. Remove the front wheel splash shields. Refer to SHIELD, SPLASH, FRONT WHEELHOUSE,
Fig 1: Left & Right Side Support Bolts
8. Remove the bolts (1) left side.
9. Remove the bolts right side.

Fig 2: Left & Right Side Reinforcement Bolts
10. Remove the bolts (1) and the left side reinforcement.
11. Remove the bolts and the right side reinforcement.

Fig 3: Left Side Load Beam & Bolts
12. Remove the bolts (1) and the left side load beam.
14. Remove the air cleaner body.
15. Remove the fuel filter. Refer to FILTER, FUEL, REMOVAL AND INSTALLATION .
Fig 4: Mass Air Flow (MAF) Sensor Wire Harness Connector, MAF Sensor Clamp, Oil Vapor
Hose Clamp & Air Intake Pipe Clamp
16. Disconnect the Mass Air Flow (MAF) sensor wire harness connector (1).
17. Loosen the clamp (2) and remove the MAF sensor from the turbocharger air inlet pipe (4).
18. Loosen the clamp (3) and disconnect the engine oil vapor hose from the tube side.
19. Loosen the clamp (4) and remove the air intake pipe from the turbocharger.
20. Drain the transmission fluid. Refer to FLUID, STANDARD PROCEDURE .
21. Drain the cooling system.
22. Recover the refrigerant from the refrigerant system.
Refer to PLUMBING, STANDARD PROCEDURE .
23. Remove the left front head lamp. Refer to UNIT, FRONT LAMP, REMOVAL AND INSTALLATION
.
24. Remove the right front head lamp. Refer to UNIT, FRONT LAMP, REMOVAL AND
INSTALLATION .

Fig 5: Exhaust Pipe Hanger Bolts
26. Remove the exhaust pipe hanger bolts (1).

Fig 6: Tube Support Bracket Bolt, Tube Nut, Exhaust Flange Nuts & Exhaust Pipe Support
Bracket Bolt
27. Remove the tube support bracket bolt (1).
28. Loosen the tube nut (2) and reposition the tube.
29. Remove the exhaust flange nuts (3).
30. Remove the exhaust pipe support bracket bolt (4).
31. Disconnect the exhaust pipe from the Diesel Particulate Filter (DPF) and remove the flange
gasket.
Fig 7: Rear Engine Mount Isolator To Front Crossmember Bolt, Rear Engine Mount Isolator
Bolt & Rear Engine Mount Isolator Bracket Bolt
32. Remove the rear engine mount isolator to front crossmember bolt (1).
33. Remove the bolt (2) and the rear engine mount isolator.
34. Remove the bolts (3) and the rear engine mount isolator bracket.
35. Remove the left and right half shafts. Refer to REMOVAL AND INSTALLATION .
Fig 8: Brake System/Clutch Fluid Resevoir Cap
36. Unscrew the cap for brake/clutch fluid reservoir and install the 2000001400 Cap Depression
brake system/clutch (1).
Fig 9: Reverse Lamp Switch Wire Harness Connector & Battery Ground Cable Bolt
37. Disconnect the reverse lamp switch wire harness connector (1).
38. Remove the bolt (2) and reposition the battery ground cable.
Fig 10: Coolant Hose Quick Couplings
39. Disconnect the coolant hose quick couplings (1).

Fig 11: Retaining Clip & Hose
40. Lift the retaining clip (1a) and disconnect the hose (1b) from the clutch slave cylinder.
Fig 12: Heater Core Hose Quick Couplings
41. Disconnect the heater core hose quick couplings (1).

Fig 13: Quick Coupling & Air Delivery Pipe At Throttle Body Bolts
42. Disconnect the quick coupling (1) and remove the vacuum hose from the vacuum pump.
43. Remove the screws (2) securing the air delivery pipe to the throttle body.
44. Remove the screw (3a) and remove the air delivery pipe from the throttle body (3b).
Fig 14: Degas Hose & Clamp
45. Loosen the clamp (1) and remove the degas hose from the thermostat.
Fig 15: Quick Coupling At Pressurized Coolant Bottle
46. Disconnect the quick coupling (1) and remove the pressurized coolant bottle.
Fig 16: Glow Plug Control Unit Wire Harness Connector
47. Disconnect the glow plug control unit wire harness connector (1).
Fig 17: DPF Differential Pressure Sensor Wire Harness Connector & Nut
48. Disconnect the DPF differential pressure sensor wire harness connector (1).
49. Unscrew the nut (2) and reposition the DPF differential pressure sensor onto the engine.
Fig 18: Gear Selector Cables & Lock Sliders
50. Open the retaining clips and disengage the gear selector cables (1).
51. Pull back the lock slider (2) and disengage the gear selector cable from the bracket.
Fig 19: Starter Cable & Nut
53. Remove the nut (1) and disconnect the starter cable from the positive battery terminal.
Fig 20: Retaining Clip, Powertrain Control Module (PCM) Wire Harness Connector & Engine
Wire Harness Connector
54. Open the retaining clip (1) and disconnect the Powertrain Control Module (PCM) wire harness
connector.
55. Disconnect the engine wire harness connector (2) and disengage the wiring from the spring
retainer.
Fig 21: Fuel Tank Return Line Quick Coupling, Fuel Supply Line Quick Coupling & Retaining
Bracket Bolt
56. Disconnect the fuel tank return line quick coupling (1).
57. Disconnect the fuel supply line quick coupling (2).
58. Remove the screw (3) and reposition the fuel lines retaining bracket.
Fig 22: Hydraulic Crane & Sling
59. Connect a hydraulic crane and 1871001700 Sling (1) to the lifting brackets.
Fig 23: Right Engine Mount Isolator & Bolts
60. Remove the bolts (1a) and (1b) and remove the right engine mount isolator.
Fig 24: Support Bracket, Left Engine Mount Isolator & Bolts
61. Remove the bolt (1) and the support bracket.
62. Remove the bolts (2a) and (2b) and remove the left engine mount isolator.
63. Remove the powertrain from the engine compartment and place it on a suitable platform.
64. Remove the hydraulic crane and sling form the lifting brackets.
INSTALLATION
1. Install the powertrain in the engine compartment using a hydraulic crane and 1871001700 Sling
connected to the lifting brackets.
Fig 1: Left Engine Mount Isolator, Support Bracket & Bolts
2. Install the left engine mount isolator and tighten the bolts (1a) and (1b) to the proper torque
3. Install the support bracket (2) with the bolt tightened to the proper torque specification. Refer to
4. Install the right engine mount isolator and tighten the bolts (1a) and (1b) to the proper torque
5. Remove the hydraulic crane and sling connected to the powertrain lifting brackets.
6. Install the fuel line retaining bracket with the screw tightened to the proper torque specification.
7. Connect the fuel supply line quick coupling.
8. Connect the fuel tank return line quick coupling.
9. Connect the engine wire harness connector and engage the wiring to the spring retainer.
10. Connect the Powertrain Control Module (PCM) wire harness connector and close the retaining
clip.
11. Install the starter cable to the positive battery terminal and tighten the nut to the proper torque
12. Pull back the lock sliders and engage the gear selector cables to the brackets.
13. Open the retaining clips and engage the gear selector cables to the lever arms.
14. Install the DPF differential pressure sensor with the nut tightened to the proper torque
15. Connect the DPF differential pressure sensor wire harness connector.
16. Connect the glow plug control unit wire harness connector.
17. Install the pressurized coolant bottle and connect the quick coupling.
18. Install the degas hose to the thermostat and tighten the clamp to the proper torque
19. Install the air delivery pipe to the throttle body with the screws tightened to the proper torque
20. Secure the air delivery pipe to the support bracket with the screw tightened to the proper
torque specification. Refer to TORQUE SPECIFICATIONS .
21. Install the vacuum hose to the vacuum pump and connect the quick coupling.
22. Connect the heater core hose quick couplings.
23. Connect the hose to the clutch slave cylinder and engage the retaining clip.
24. Connect the coolant hose quick couplings.
25. Install the battery ground cable with the bolt tightened to the proper torque specification. Refer
26. Connect the reverse lamp switch wire harness connector.
27. Install the left and right half shafts. Refer to REMOVAL AND INSTALLATION .
Fig 3: Rear Engine Mount Isolator Bracket, Rear Engine Mount Isolator, Rear Engine Mount
Isolator To Front Crossmember & Bolts
28. Install the rear engine mount isolator bracket (1) with the bolts tightened to the proper torque
29. Install the rear engine mount isolator (2) with the bolt tightened to the proper torque
30. Install the rear engine mount isolator to front crossmember bolt (3) and tighten to the proper
Fig 4: Exhaust Pipe Support Bracket Bolt, Exhaust Flange Nuts, Tube & Tube Support Bracket
Bolt
31. Install a new flange gasket and connect the exhaust pipe to the Diesel Particulate Filter (DPF).
32. Install the exhaust pipe support bracket bolt (1) and tighten to the proper torque specification.
33. Install the exhaust flange nuts (2) and tighten to the proper torque specification. Refer to
34. Connect the tube (3) and tighten the nut to the proper torque specification. Refer to TORQUE
SPECIFICATIONS .
35. Install the tube support bracket bolt (4) and tighten to the proper torque specification. Refer to
36. Install the exhaust pipe hanger bolts (1) and tighten to the proper torque specification. Refer to

38. Install the right front head lamp. Refer to UNIT, FRONT LAMP, REMOVAL AND INSTALLATION .
39. Install the left front head lamp. Refer to UNIT, FRONT LAMP, REMOVAL AND INSTALLATION .
40. Install the air intake pipe to the turbocharger with the clamp tightened to the proper torque
41. Connect the engine oil vapor hose to the tube side with the clamp tightened to the proper
42. Install the MAF sensor to the turbocharger air inlet pipe with the clamp tightened to the proper
43. Connect the Mass Air Flow (MAF) sensor wire harness connector.
44. Install the fuel filter. Refer to FILTER, FUEL, REMOVAL AND INSTALLATION .
45. Install the air cleaner body.

Fig 6: Left Side Load Beam Bolts
47. Install the left side load beam (1) with the bolts tightened to the proper torque specification.
48. Install the left side reinforcement with the bolts tightened to the proper torque specification.
49. Install the bolts (1) left side and tighten to the proper torque specification. Refer to TORQUE
SPECIFICATIONS .
50. Install the bolts right side and tighten to the proper torque specification. Refer to TORQUE
SPECIFICATIONS .
51. Install the right side reinforcement with the bolts tightened to the proper torque specification.
54. Evacuate and charge the refrigerant system. Refer to PLUMBING, STANDARD PROCEDURE .
55. Fill the cooling system. Refer to STANDARD PROCEDURE .
56. Fill the transmission. Refer to FLUID, STANDARD PROCEDURE .
57. Bleed the clutch hydraulic circuit. Refer to CLUTCH SYSTEM article.
59. Install the front wheel splash shields. Refer to SHIELD, SPLASH, FRONT WHEELHOUSE,
60. Install the front belly pan. Refer to BELLY PAN, REMOVAL AND INSTALLATION and BELLY
62. Remove the vehicle from the lift.
REMOVAL AND INSTALLATION > 2.0L TURBO DIESEL WITH AUTOMATIC

TRANSMISSION > REMOVAL
2. Remove the hood. Refer to HOOD, REMOVAL AND INSTALLATION .
9. Remove the bolts (1) and the left lower load beam.
10. Remove the bolts and the right lower load beam.
Fig 2: Air Intake Pipe At Turbocharger
14. Loosen the clamp and remove the air intake pipe from the turbocharger (1).
.
INSTALLATION .

20. Disconnect the quick coupling (1) and remove the coolant hose from the pressurized coolant
bottle.
21. Loosen the clamp (1), remove the degas hose from the thermostat and remove the pressurized
coolant bottle from the vehicle.

Fig 6: Exhaust Flange Nuts & Exhaust Pipe Support Bracket Bolt
gasket.
Fig 7: Positioning Hydraulic Lift Under Powertrain
26. Position a suitable hydraulic lift under the powertrain (1).

Fig 8: Rear Engine Mount Isolator To Front Crossmember Bolt & Rear Engine Mount Isolator
Bolt
Fig 9: Rear Engine Mount Isolator Bracket & Bolts
29. Remove the bolts and the rear engine mount isolator bracket (1).
Fig 10: Battery Ground Cable & Bolt
31. Remove the bolt and reposition the battery ground cable (1).

Fig 12: Protective Sleeve At Joint
NOTE:
The protective sleeve is included in the service parts package which also includes
new dust covers and snap rings.
33. Mount the protective sleeve (1) as shown in illustration to protect the joint from excessive
bending.
Fig 13: Dust Cover
NOTE:
The dust cover must be replaced whenever the drive shaft is disconnected.
34. Pull back the dust cover (1).

Fig 14: Using Special Tool To Open Snap Ring
NOTE:
The snap ring must be replaced whenever the drive shaft is disconnected.
35. Using tool 2019500030 Retractor (1), open the snap ring.
Fig 15: Positioning Drive Shaft At PTU
36. Using the hydraulic lift, move the powertrain up and forward as much as permitted by the right
and left engine mounts.
37. Pull back the drive shaft to disengage it from the PTU and reposition the shaft on the
crossmember.

Fig 16: Power Transfer Unit (PTU) Actuator Wire Harness Connector
39. Disconnect the power transfer unit actuator wire harness connector (1).

Fig 18: Quick Coupling, Air Delivery Pipe, Throttle Body & Bolts
Fig 21: Gear Change Lever & Lock Slider
47. Disconnect the gear selector cable from the gear change lever (1).
Fig 22: Transmission Control Module (TCM) Wire Harness Connector
49. Open the retaining clip and disconnect the Transmission Control Module (TCM) wire harness
connector (1).
Fig 23: Downstream Oxygen Sensor, Exhaust Gas Temperature Sensor & Exhaust Gas
Temperature Sensor Wire Harness Connectors
50. Open the wire harness retaining clips.
51. Disconnect the downstream oxygen sensor wire harness connector (1).
52. Disconnect the exhaust gas temperature sensor wire harness connector (2).
53. Rotate the connector lock nut and disconnect the transmission wire harness connector (3).
connector.
retainer.
Bracket Bolt
Fig 27: Engine Lifting Bracket & Bolt
60. Install a suitable engine lifting bracket (1).

Fig 28: Engine Lifting Bracket & Bolt
61. Install a suitable engine lifting bracket (1) under the left engine mount bracket bolt.
63. Remove the bolts (1a) and (1b) and remove the right engine mount isolator (1c).
Fig 31: Left Engine Mount Isolator & Bolts
64. Remove the bolts (1) from the left engine mount isolator.
REMOVAL AND INSTALLATION > 2.0L TURBO DIESEL WITH AUTOMATIC

TRANSMISSION > INSTALLATION
2. Install the left engine mount isolator bolts (1) and tighten to the proper torque specification.
3. Install the right engine mount isolator (1a) and tighten the bolts (1b) and (1c) to the proper
clip.
11. Connect the transmission wire harness connector by rotating the connector lock nut.
12. Connect the exhaust gas temperature sensor wire harness connector.
13. Connect the downstream oxygen sensor wire harness connector.

14. Close the wire harness retaining clips.
15. Connect the Transmission Control Module (TCM) wire harness connector and close the wire
harness retaining clip.
16. Pull back the lock slider and engage the gear selector cable to the bracket.
17. Engage the gear selector cable to the lever arm and check its function.
21. Install the air delivery pipe to the throttle body with a new gasket and tighten the screws to the
22. Install the vacuum hose quick coupling to the vacuum pump and engage the retaining clip.
24. Connect the power transfer unit actuator wire harness connector.
25. Install a new drive shaft snap ring.
26. Install a new drive shaft dust cover.
27. Install the drive shaft into the power transfer unit and engage the snap ring.
28. Install the drive shaft dust cover.
29. Remove the drive shaft protective sleeve.
Fig 3: Rear Engine Mount Isolator Bracket & Bolts
Fig 4: Rear Engine Mount Isolator & Bolts
Fig 5: Exhaust Pipe Support Bracket Bolt & Flange Nuts
36. Install a new flange gasket and connect the exhaust pipe to the Diesel Particulate Filter (DPF)
with new nuts.
38. Tightened the new flange nuts (2) to the proper torque specification. Refer to TORQUE
SPECIFICATIONS .

49. Install the left side lower load beam (1) with the bolts tightened to the proper torque
50. Install the right side lower load beam with the bolts tightened to the proper torque specification.
59. Install the hood. Refer to HOOD, REMOVAL AND INSTALLATION .

REMOVAL
8. Remove the bolts (1) left side.
9. Remove the bolts right side.

Fig 2: Left & Right Side Reinforcement Bolts
10. Remove the bolts (1) and the left side reinforcement.
11. Remove the bolts and the right side reinforcement.

12. Remove the bolts (1) and the left side load beam.
Fig 4: Mass Air Flow (MAF) Sensor Wire Harness Connector, MAF Sensor Clamp, Oil Vapor
Hose Clamp & Air Intake Pipe Clamp
17. Loosen the clamp (2) and remove the MAF sensor from the turbocharger air inlet pipe (4).
18. Loosen the clamp (3) and disconnect the engine oil vapor hose from the tube side.
19. Loosen the clamp (4) and remove the air intake pipe from the turbocharger.
.
INSTALLATION .


Fig 6: Exhaust Pipe Support Bracket Bolt & Exhaust Flange Nuts
gasket.
32. Remove the bolts (3) and the rear engine mount isolator bracket.
Fig 8: Brake System/Clutch Fluid Resevoir Cap
34. Unscrew the cap for brake/clutch fluid reservoir and install the 2000001400 Cap Depression
brake system/clutch (1).
Fig 9: Reverse Lamp Switch Wire Harness Connector & Battery Ground Cable Bolt
35. Disconnect the reverse lamp switch wire harness connector (1).

Fig 11: Retaining Clip & Hose
38. Lift the retaining clip (1a) and disconnect the hose (1b) from the clutch slave cylinder.

Fig 13: Quick Coupling & Air Delivery Pipe At Throttle Body Bolts
43. Loosen the clamp (1) and remove the degas hose from the thermostat.
44. Disconnect the quick coupling (1) and remove the pressurized coolant bottle.
Fig 19: Gear Selector Cables & Lock Sliders
49. Open the retaining clips and disengage the gear selector cables (1).
connector.
retainer.
Bracket Bolt
Fig 25: Support Bracket, Left Engine Mount Isolator & Bolts
60. Remove the bolt (1) and the support bracket.
61. Remove the bolts (2a) and (2b) and remove the left engine mount isolator.
INSTALLATION
Fig 1: Left Engine Mount Isolator, Support Bracket & Bolts
2. Install the left engine mount isolator and tighten the bolts (1a) and (1b) to the proper torque
3. Install the support bracket (2) with the bolt tightened to the proper torque specification. Refer to
4. Install the right engine mount isolator and tighten the bolts (1a) and (1b) to the proper torque
clip.
12. Pull back the lock sliders and engage the gear selector cables to the brackets.
13. Open the retaining clips and engage the gear selector cables to the lever arms.
19. Install the air delivery pipe to the throttle body with the screws tightened to the proper torque
20. Secure the air delivery pipe to the support bracket with the screw tightened to the proper
23. Connect the hose to the clutch slave cylinder and engage the retaining clip.
26. Connect the reverse lamp switch wire harness connector.
Fig 4: Exhaust Pipe Nuts & Exhaust Pipe Support Bracket Bolt
31. Install a new flange gasket and connect the exhaust pipe to the Diesel Particulate Filter (DPF)
with new nuts (1) tightened to the proper torque specification. Refer to TORQUE
SPECIFICATIONS .

38. Connect the engine oil vapor hose to the tube side with the clamp tightened to the proper
39. Install the MAF sensor to the turbocharger air inlet pipe with the clamp tightened to the proper

44. Install the left side load beam (1) with the bolts tightened to the proper torque specification.
45. Install the left side reinforcement with the bolts tightened to the proper torque specification.
46. Install the bolts (1) left side and tighten to the proper torque specification. Refer to TORQUE
SPECIFICATIONS .
47. Install the bolts right side and tighten to the proper torque specification. Refer to TORQUE
SPECIFICATIONS .
48. Install the right side reinforcement with the bolts tightened to the proper torque specification.
53. Fill the transmission. Refer to FLUID, STANDARD PROCEDURE .
54. Bleed the clutch hydraulic circuit. Refer to CLUTCH SYSTEM article.
REMOVAL AND INSTALLATION > ENGINE - POSITION ON STAND AND REMOVE -

1.6L > REMOVAL
Fig 1: Flywheel Holder Tool & Clutch Cover Bolts
1. Install the 1860846000 flywheel holder tool (1).
2. Remove the three indicated clutch cover bolts (2).

Fig 2: Clutch Centering Tool & Clutch Compressor Mounting Posts
3. Install the clutch centering tool 2000030800 (1) tool kit.
4. Install the clutch compressor mounting posts (2) from the 2000040925 tool kit into the
previously removed bolt locations.
Fig 3: Clutch Compressor Tool & Clutch Cover Bolts
5. Install the clutch compressor tool (1) from the 1871003100 tool kit and rotate the handwheel to
compress the clutch spring.
6. Remove the remaining clutch cover bolts (2).

Fig 4: Flywheel Holder Tool & Flywheel Bolts
7. Rotate the handwheel to unload the clutch spring.
8. Remove the clutch compressor and centering tools, clutch pressure plate and friction disc.
9. With the 1860846000 flywheel holder tool (1a) installed, remove the bolts (1b) and the flywheel
(1c).
Fig 5: Flywheel Dust Shield & Bolts
10. Remove the bolts (1a) and the flywheel dust shield (1b).
11. Remove the 1860846000 flywheel holder tool.

Fig 6: Engine Block Maintenance Stand
12. With the aid of a hydraulic lift, install the engine block to the 1871000000 maintenance stand
(1).

1.6L > INSTALLATION
1. With the aid of a hydraulic lift, remove the engine from the 1871000000 maintenance stand.
2. Place the engine on a suitable platform.
3. Install the flywheel dust cover with the bolts tightened to the proper torque specification. Refer
Fig 1: Flywheel, Bolts & Flywheel Holder Tool
4. Install the flywheel (1) and hand tighten the bolts (3).
6. Tighten the flywheel bolts (3) to the proper torque specification. Refer to TORQUE
SPECIFICATIONS .
Fig 2: Clutch Friction Disc & Pressure Plate, Clutch Centering Tool, Clutch Compressor
Mounting Posts
NOTE:
The clutch friction disc is identified with a "MOTOR SIDE" marking for correct
assembly.
NOTE:
To avoid contamination, do not touch the friction disc surface with bare hands.
NOTE:
Thoroughly clean the friction disc surface of all corrosion or residue prior to
assembly.
7. Position the clutch friction disc and pressure plate (1a) and install the clutch centering tool
2000030800 (1b) from the tool kit and clutch compressor mounting posts 2000040925 (1c)
tool kit.
9. Install the bolts (2) hand tight.
11. Remove the clutch compressor tool.
12. Install the three remaining clutch cover screws hand tight.
13. Tighten the clutch cover screws in a crisscross pattern to the proper torque specification.
14. Remove the 1860846000 flywheel holder tool and 2000030800 clutch centering tool.

2.0L - 120/140CV > REMOVAL
Fig 1: Flywheel Holder Tool & Clutch Cover Bolts
2. Remove the three indicated clutch cover bolts (2).

Fig 2: Clutch Centering Tool & Clutch Compressor Mounting Posts
3. Install the clutch centering tool (1) from the 2000030800 tool kit.
4. Install the clutch compressor mounting posts (2) from the 2000040925 tool kit, into the
previously removed bolt locations.
6. Remove the remaining clutch cover bolts (2).

Fig 4: Flywheel Holder Tool & Flywheel Bolts
8. Remove the clutch compressor and centering tools, clutch pressure plate and friction disc.
9. With the 1860846000 flywheel holder tool (1a) installed, remove the bolts (1b) and the flywheel
(1c).
Fig 5: Flywheel Dust Shield & Bolts
10. Remove the bolts (1a) and the flywheel dust shield (1b).

(1).

2.0L - 120/140CV > INSTALLATION
3. Install the flywheel dust cover with the bolts tightened to the proper torque specification. Refer
Fig 1: Flywheel, Bolts & Flywheel Holder Tool
4. Install the flywheel (1) and hand tighten the new bolts (3).
6. Tighten the new flywheel bolts (3) to the proper torque specification. Refer to TORQUE
SPECIFICATIONS .
Fig 2: Clutch Friction Disc & Pressure Plate, Clutch Centering Tool, Clutch Compressor
Mounting Posts
NOTE:
The clutch friction disc is identified with a "MOTOR SIDE" marking for correct
assembly.
NOTE:
To avoid contamination, do not touch the friction disc surface with bare hands.
NOTE:
Thoroughly clean the friction disc surface of all corrosion or residue prior to
assembly.
7. Position the clutch friction disc and pressure plate (1a) and install the clutch centering tool (1b)
from the 2000030800 tool kit and the clutch compressor mounting posts (1c) from the
2000040925 tool kit.
9. Install the bolts (2) hand tight.
11. Remove the clutch compressor tool.
12. Install the three remaining clutch cover screws hand tight.
13. Tighten the clutch cover screws in a crisscross pattern to the proper torque specification.
14. Remove the 1860846000 flywheel holder tool and 2000030800 centering tool kit.

2.0L - 170CV > REMOVAL
Fig 1: Flywheel Holder Tool, Flywheel & Bolts
2. Remove the bolts (2a) and the flywheel (2b).

(1).

2.0L - 170CV > INSTALLATION

Fig 1: Flywheel Holder Tool, Flywheel & Bolts
3. Install the flywheel (1) and hand tighten the bolts (3).
5. Tighten the flywheel bolts (3) to the proper torque specification. Refer to TORQUE
SPECIFICATIONS .
6. Remove the 1860846000 flywheel holder (2).
REMOVAL AND INSTALLATION > ENGINE (MANUAL TRANSMISSION) SEPARATION

AND REASSEMBLY - 1.6L TURBO DIESEL > REMOVAL
Fig 1: Rear Oil Pan To Transmission Bolt
1. Connect a hydraulic crane and 1871001700 Sling to the lifting brackets on the powertrain.
2. Remove the rear oil pan to transmission bolt (1).

Fig 2: Front Transmission To Oil Pan Bolt
3. Remove the front transmission to oil pan bolt (1).

Fig 3: Flywheel Dust Cover Nuts
4. Remove the flywheel dust cover nuts (1).

Fig 4: Protective Cover & Battery Positive Cable Nut
5. Open the protective cover (1a), remove the nut and disconnect the battery positive cable (1b).
Fig 5: Ground Cable, Nut & Starter
6. Remove the nut (1) and the ground cable from the starter.
Fig 6: Starter & Bolts
7. Remove the bolts (1a) and the starter (1b).

Fig 7: Exhaust Side Transmission To Engine Nut
8. Remove the exhaust side transmission to engine nut (1).

Fig 8: Upper Transmission To Engine Block Bolts
9. Remove the two upper transmission to engine block bolts (1).

Fig 9: Intake Side Transmission To Engine Nut
10. Remove the intake side transmission to engine nut (1).
11. Remove the transmission from the engine.
12. Remove the flywheel dust cover.

AND REASSEMBLY - 1.6L TURBO DIESEL > INSTALLATION
Fig 1: Intake Side Transmission To Engine Nut
1. Install the flywheel dust cover and transmission to the engine.
2. Install the intake side transmission to engine nut (1) and tighten to the proper torque
3. Install the two upper transmission to engine block bolts (1) and tighten to the proper torque
Fig 3: Exhaust Side Transmission To Engine Nut
4. Install the exhaust side transmission to engine nut (1) and tighten to the proper torque
5. Install the starter and tighten the bolts to the proper torque specification. Refer to TORQUE
SPECIFICATIONS .
6. Connect the ground cable to the starter and tighten the nut to the proper torque specification.
7. Connect the battery positive cable to the starter and tighten the nut to the proper torque
8. Install the flywheel dust cover nuts and tighten to the proper torque specification. Refer to
Fig 4: Rear Transmission To Oil Pan Bolt
9. Install the rear transmission to oil pan bolt (1) and tighten to the proper torque specification.
Fig 5: Front Transmission To Oil Pan Bolt
10. Install the front transmission to oil pan bolt (1) and tighten to the proper torque specification.
REMOVAL AND INSTALLATION > ENGINE (AUTOMATIC TRANSMISSION)

SEPARATION AND REASSEMBLY - 2.0L TURBO DIESEL > REMOVAL
1. Disengage the power transfer unit actuator wire harness connector (1) from the bracket.
Fig 2: Transmission Vent Hose & Retaining Clips
2. Open the retaining clips (1) and reposition the transmission vent hose.
Fig 3: PTU Support Bracket & Bolts
3. Remove the bolts (1a) and (1b) and remove the PTU support bracket (1c).
Fig 4: PTU To Transmission Bolts
4. Remove the PTU to transmission bolts (1).

Fig 5: PTU & Support Bracket
5. Reposition the PTU (1) and remove the PTU support bracket.
Fig 6: PTU & Transmission
6. Remove the PTU (1) from the transmission.

Fig 7: PTU O-Ring Seal
7. Remove the PTU O-ring seal (1).

Fig 8: Battery Positive Cable & Nut
8. Open the protective cover, remove the nut (1a) and disconnect the battery positive cable (1b)
from the starter motor.
Fig 9: Nut & Ground Cable
9. Remove the nut (1) and the ground cable from the starter motor.
Fig 10: Bolts, Bracket & Starter
10. Remove the bolts (1a), bracket (1b) and the starter motor (1c).
11. Remove the starter motor gasket.

Fig 11: Torque Converter Bolt & Torque Converter
12. Remove the torque converter bolts (1).

Fig 12: Turbocharger Heat Shield & Fasteners
13. Remove the fasteners (1) and remove the turbocharger heat shield.
Fig 13: Exhaust Temperature Sensor Wire Harness Connector
14. Disconnect the exhaust temperature sensor wire harness connector (1).
Fig 14: Exhaust Temperature Sensor & Upstream Oxygen Sensor Wire Harness Connectors
15. Disconnect the upstream oxygen sensor wire harness connector (1) and disengage the wire
harness from the support bracket.
16. Disengage the exhaust temperature sensor and upstream oxygen sensor wire harness
connectors (2) from the support bracket.
Fig 15: Differential Pressure Sensor Hoses & Clamps
17. Loosen the clamps (1) and disconnect the differential pressure sensor hoses.
Fig 16: Exhaust Temperature Sensor Wire Harness & Retaining Clip, Turbocharger Air Outlet
Pipe Bolt & Air Outlet Pipe Bolts
18. Open the retaining clip (1) and reposition the exhaust temperature sensor wire harness.
19. Remove the turbocharger air outlet pipe bolt (2).
20. Remove the bolts (3) and remove the air outlet pipe from the turbocharger.
Fig 17: EGR Tube & Clamps
21. Loosen the clamps (1) and remove the EGR tube.
Fig 18: Exhaust Temperature Sensor Wire Harness Connectors
22. Disconnect the exhaust temperature sensor wire harness connectors (1).
Fig 19: Exhaust Temperature Sensor Wire Harness Connectors & Support Bracket
23. Disengage the exhaust temperature sensor wire harness connectors from the support bracket
(1).
Fig 20: Diesel Particulate Filter (DPF) To Turbocharger Clamp
24. Loosen the clamp (1) and reposition the DPF to turbocharger clamp.
Fig 21: Diesel Particulate Filter (DPF) & Nuts
25. Remove the nuts (1) and remove the Diesel Particulate Filter (DPF).
Fig 22: Diesel Particulate Filter (DPF) Mounting Bracket & Bolts
26. Remove the bolts (1) and remove the DPF mounting bracket.
Fig 23: Inspection Cover Bolt & Exhaust Side Transmission To Oil Pan Bolt
27. Remove the bolt (1) and remove the inspection cover.
28. Remove the exhaust side transmission to oil pan bolt (2).
Fig 24: Intake Side Oil Pan To Transmission Bolt
29. Remove the intake side oil pan to transmission bolt (1).
30. Remove the upper transmission to engine block bolts (1).

Fig 26: Exhaust Side Engine To Transmission Bolt
31. Remove the exhaust side engine to transmission bolt (1).

Fig 27: Intake Side Engine To Transmission Bolt & Transmission At Engine
32. Remove the intake side engine to transmission bolt (1a) and remove the transmission (1b)
from the engine.

SEPARATION AND REASSEMBLY - 2.0L TURBO DIESEL > INSTALLATION
Fig 1: Intake Side Engine To Transmission Bolt & Transmission At Engine
1. Install the transmission (1a) to the engine with the intake side engine to transmission bolt (1b)
tightened to the proper torque specification. Refer to TORQUE SPECIFICATIONS .
Fig 2: Exhaust Side Engine To Transmission Bolt
2. Install the exhaust side engine to transmission bolt (1) and tighten to the proper torque
3. Install the upper transmission to engine block bolts (1) and tighten to the proper torque
Fig 4: Intake Side Oil Pan To Transmission Bolt
4. Install the intake side oil pan to transmission bolt (1) and tighten to the proper torque
Fig 5: Inspection Cover Bolt & Exhaust Side Transmission To Oil Pan Bolt
5. Install the exhaust side transmission to oil pan bolt (1) and tighten to the proper torque
6. Install the inspection cover and tighten the bolt (2) to the proper torque specification. Refer to
7. Install the DPF mounting bracket and tighten the bolts to the proper torque specification. Refer
8. Install the DPF to the mounting bracket with a new gasket and tighten the nuts to the proper
9. Install the DPF to turbocharger clamp (1) and tighten the nut to the proper torque specification.
10. Engage the exhaust temperature sensor wire harness connectors to the support bracket.
11. Connect the exhaust temperature sensor wire harness connectors.
12. Install the EGR tube and tighten the clamps to the proper torque specification. Refer to
13. Install the air outlet pipe to the turbocharger with a new gasket and tighten the lower mounting
bolt to the proper torque specification. Refer to TORQUE SPECIFICATIONS .
14. Install the air outlet pipe to turbocharger bolts and tighten to the proper torque specification.
15. Position the exhaust temperature sensor wire harness on the support bracket and close the
retaining clip.
16. Connect the differential pressure sensor hoses and tighten the clamps to the proper torque
17. Engage the exhaust temperature sensor and upstream oxygen sensor wire harness
connectors to the support bracket.
18. Connect the upstream oxygen sensor wire harness connector and engage the wire harness to
the support bracket.
19. Connect the exhaust temperature sensor wire harness connector.
20. Install the turbocharger heat shield and tighten the bolts to the proper torque specification.
21. Install the torque converter bolts and tighten to the proper torque specification. Refer to
Fig 7: Bolts, Bracket & Starter
22. Install the starter motor with a new gasket.
23. Install the bracket (1) with the bolts (2) tightened to the proper torque specification. Refer to
24. Connect the ground cable to the starter motor and tighten the nut to the proper torque
25. Connect the battery positive cable to the starter motor and tighten the nut to the proper torque
Fig 8: PTU To Transmission Bolts
26. Install a new O-ring seal to the PTU.
27. Install the PTU to the transmission together with the PTU support bracket and tighten the bolts
(1) to the proper torque specification. Refer to TORQUE SPECIFICATIONS .
28. Position the PTU support bracket (1a) and tighten the bolts (1b) and (1c) to the proper torque
29. Position the transmission vent hose and close the retaining clips.
30. Engage the power transfer unit actuator wire harness connector to the bracket.

AND REASSEMBLY - 2.0L TURBO DIESEL 120CV/140CV > REMOVAL
Fig 1: PTU Support Bracket, Wire Harness Connector & Bolts
1. Connect a hydraulic crane and 1871001700 Sling to the lifting brackets on the powertrain.
2. Remove the bolts (1a) and (1b) and remove the PTU support bracket (1c).
Fig 2: PTU, Transmission & Bolts
4. Remove the bolts (1a) and remove the PTU (1b) from the transmission.
Fig 3: Exhaust Gas Temperature Sensor Wire Harness Connector
Fig 4: Upstream Oxygen Sensor Wire Harness Connector
6. Disconnect the upstream oxygen sensor wire harness connector (1).

Fig 5: DPF Temperature Sensor Wire Harness Connector
7. Disconnect the DPF temperature sensor wire harness connector (1).

Fig 6: Pressure Sensor Tube, Fitting, Exhaust Gas Hose & Clamp
8. Loosen the fittings (1) and remove the pressure sensor tube.
9. Loosen the clamp (2) and disconnect the exhaust gas hose.
Fig 7: Turbocharger Heat Shield & Bolts
10. Remove the bolts (1) and the turbocharger heat shield.
11. Loosen the nut (1) and reposition the DPF to turbocharger clamp.
12. Remove the nuts (1) and remove the Diesel Particulate Filter (DPF).
Fig 10: Diesel Particulate Filter (DPF) Mounting Bracket & Bolts
13. Remove the bolts (1) and remove the DPF mounting bracket.
Fig 11: Protective Cover & Battery Positive Cable Nut
14. Open the protective cover (1a), remove the nut and disconnect the battery positive cable (1b).
Fig 12: Ground Cable, Nut & Starter
15. Remove the nut (1) and the ground cable from the starter motor.
16. Remove the bolts (1a) and the starter motor (1b).
Fig 14: Transmission To Engine Block Stud, Exhaust Side Nut & Exhaust Side Transmission To
Oil Pan Bolt
17. Remove the nut (1) from the transmission to engine block stud, exhaust side.
18. Remove the exhaust side transmission to oil pan bolt (2).
19. Remove the upper transmission to engine block bolts (1).

Fig 16: Engine Block To Transmission Stud, Intake Side Nut & Oil Pan To Transmission Bolt
20. Remove the nut (1) from the engine block to transmission stud, intake side.
21. Remove the oil pan to transmission bolt (2), intake side.
22. Remove the transmission from the engine.
23. Remove the flywheel dust cover.

AND REASSEMBLY - 2.0L TURBO DIESEL 120CV/140CV > INSTALLATION
Fig 1: Engine Block To Transmission Stud, Intake Side Nut & Oil Pan To Transmission Bolt
1. Install the flywheel dust cover and transmission to the engine.
2. Install the intake side oil pan to transmission bolt (1).
3. Install the nut (2) on the intake side transmission to engine block stud and tighten to the proper
4. Install the upper transmission to engine block bolts (1) and tighten to the proper torque
Fig 3: Transmission To Engine Block Stud, Exhaust Side Nut & Exhaust Side Transmission To
Oil Pan Bolt
5. Install the exhaust side transmission to oil pan bolt (1) and tighten to the proper torque
6. Install the exhaust side nut (2) on the transmission to engine block stud and tighten to the
7. Install the starter (1a) with a new gasket and tighten the bolts (1b) to the proper torque
8. Connect the ground cable to the starter and tighten the nut to the proper torque specification.
9. Connect the battery positive cable to the starter and tighten the nut to the proper torque
10. Install the DPF mounting bracket and tighten the bolts to the proper torque specification. Refer
11. Install the DPF to the mounting bracket with a new gasket and tighten the nuts to the proper
12. Install the DPF to turbocharger clamp (1) and tighten the nut to the proper torque specification.
13. Install the turbocharger heat shield and tighten the bolts to the proper torque specification.
14. Connect the exhaust gas hose and tighten the clamp to the proper torque specification. Refer
15. Install the pressure sensor tube and tighten the fittings to the proper torque specification. Refer
16. Connect the DPF temperature sensor wire harness connector.
17. Connect the upstream oxygen sensor wire harness connector.
18. Connect the exhaust gas temperature sensor wire harness connector.
20. Install the PTU (1a) to the transmission with the bolts (1b) tightened to the proper torque
Fig 7: Power Transfer Unit (PTU) Actuator Wire Harness Connector, PTU Support Bracket &
Bolts
21. Connect the power transfer unit actuator wire harness connector (1).
22. Install the PTU support bracket (2a) with the bolts (2b) and (2c) tightened to the proper torque
DISASSEMBLY AND ASSEMBLY > DISASSEMBLY AND REASSEMBLY FOLLOWING

INSPECTION - 1.6L > DISASSEMBLY
Fig 1: A/C Compressor, Mounting Bracket & Bolts
1. Remove the bolts (1a) and remove the A/C compressor (1b) from its mounting bracket.
2. Remove the bolts (2a) and remove the A/C compressor mounting bracket (2b).
Fig 2: DPF Bracket & Bolts
3. Remove the bolts (1a) and remove the DPF bracket (1b).
Fig 3: Centering Bushing, Bracket & Bolt
4. Remove the bolt (1a), remove the bracket (1b) and the centering bushing (1c).
Fig 4: Crankshaft Position Sensor & Bolt
5. Remove the screw (1a) and remove the crankshaft position sensor (1b).
Fig 5: Engine Oil Filter-Heat Exchanger & Bolts
6. Remove the screws (1a) and remove the engine oil filter-heat exchanger (1b).
Fig 6: Alternator & Bolts
7. Loosen the screw (1a), remove the screws (1b) and remove the alternator (1c).
Fig 7: Fuel Injection Pump, Mounting Bracket & Bolts
8. Remove the screws (1a) and remove the fuel injection pump and mounting bracket (1b).
Fig 8: Crankshaft Pulley, Front Crankshaft Oil Seal Cover, Timing Belt Tensioner & Bolts
9. Remove the bolt (1a) and remove the crankshaft pulley (1b).
10. Remove the screws (2a) and remove the front crankshaft oil seal cover (2b).
11. Unscrew the screws (3a) and remove the timing belt tensioner (3b).
Fig 9: Connecting Rod & Piston, Rod Cap, Lower Connecting Rod Bearing, Upper Connecting
Rod Bearing Shell & Bolts
12. Rotate the crankshaft with the tool previously mounted until the piston is positioned at Bottom
Dead Center (BDC).
13. Remove the screws (1a) and remove the rod cap (1b).
14. Remove the lower connecting rod bearing (2).

15. Remove the connecting rod and piston (3).
16. Remove the upper connecting rod bearing shell (4).
17. Repeat the procedure for removal of the pistons and connecting from the remaining cylinders.
Fig 10: Rear Crankshaft Oil Seal Retainer & Bolts
18. Remove the crankshaft rotation tool.
19. Remove the screws (1a) and remove the rear crankshaft oil seal retainer (1b).
20. Check the crankshaft end play using a magnetic base fitted with a dial indicator. If the
crankshaft end play is not within the required value, adjust the thickness of the crankshaft
thrust bearings. Refer to ENGINE SPECIFICATIONS .
Fig 11: Bearing Caps, Lower Bearing Shells, Crankshaft, Upper Bearing Shells, Thrust
Bearings, Piston Oil Cooling Jets & Bolts
21. Remove the screws (1a) and remove the bearing caps (1b).
22. Remove the lower bearing shells (2).
23. Remove the crankshaft (3).
24. Remove the upper bearing shells (4).
25. Remove the thrust bearings (5).
26. Remove the screws (6a) and remove the piston oil cooling jets (6b).
27. Disassemble the piston and connecting rod assemblies for inspection. Refer to ROD, PISTON
AND CONNECTING, DISASSEMBLY AND ASSEMBLY .
28. Remove the engine block from the maintenance stand, then place on a work bench.
29. Drill and remove the water and oil galley plugs from the engine block to allow cleaning of the
galleys.

INSPECTION - 1.6L > REASSEMBLY
1. Wash the disassembled components.
2. Install the water and oil galley plugs to the engine block, using appropriate tools.
3. Lubricate all internal engine components with clean engine oil.
4. Check that the cylinder head gasket surface of the engine block is absence of cracks or
surface scratches.
5. Check that the flatness of the cylinder head gasket surface is within specification otherwise
resurface the cylinder head gasket surface. Refer to ENGINE SPECIFICATIONS .
Fig 1: Measuring Diameter Of Cylinder Bores
6. Measure the diameter of cylinder bores as shown in illustration.
7. Verify that the taper of the cylinder bores are within specification. Refer to ENGINE
SPECIFICATIONS .
8. Check that the roundness of the cylinder bores are within specification. Refer to ENGINE
SPECIFICATIONS .
9. If the diameter of the cylinder bores are not within the specification, refinish the cylinder bores
to the next prescribed oversize diameter.
NOTE:
In the case of refinishing, all cylinders bores must undergo the same increase.
Fig 2: Main Bearing Caps
NOTE:
The main bearing caps have engraved notches (zero to four from the front of the
engine) which define the mounting position.
10. Temporarily fit the main bearing caps (1).

Fig 3: Bearing Cap Bolts, Tightening Tool & Measuring Crankshaft Main Bearing Journal
Diameters
11. Tighten the bearing cap bolts (1a) using a suitable angle tightening tool (1b) to the proper
12. Verify that the main bearing journal diameters are within specification. Refer to ENGINE
SPECIFICATIONS .
13. Check that the lubrication channels in the crankshaft are free of debris and clogging.
14. Measure the crankshaft main bearing journal diameters and verify that they are within
specification. Refer to ENGINE SPECIFICATIONS .
15. If the crankshaft main bearing journal diameters do not fall within the specifications, correct by
refinishing the diameter of the journal up to an additional 0.127 mm.
NOTE:
Do not attempt to refinish a crankshaft main bearing journal diameter more than
0.127 mm. Diameter adjustments greater than this endanger the structural strength
of the crankshaft. If the adjustment required is greater than 0.127 mm, it is
necessary to replace the crankshaft. The bearing shells used for adjustments
greater than 0.127 mm are no longer available as a spare (although the relative
number is still shown).
16. Measure the crankshaft rod bearing journal diameters and verify that they are within
17. If the crankshaft rod bearing journal diameters do not fall within the specifications, correct by
NOTE:
Do not attempt to refinish a crankshaft rod bearing journal diameter more than 0.127
mm. Diameter adjustments greater than this endanger the structural strength of the
crankshaft. If the adjustment required is greater than 0.127 mm, it is necessary to
replace the crankshaft. The bearing shells used for adjustments greater than 0.127
mm are no longer available as a spare (although the relative number is still shown).
18. Select main bearings to achieve the proper bearing clearance. Do not attempt perform any
adaptation to the bearing shells. If you encounter any scratches or traces of engagement,
replace the bearing shells with bearings from the same scheduled class.
19. Verify the bearing shells are clean and install them in the engine block crankshaft journals.
20. Install the crankshaft into place.

Fig 4: Applying Plastigage Across Surface Of Bearing Journals
21. Apply the calibrated wire (Plastigage) across the surface of the bearing journals (1).
22. Check one journal at a time without moving the crankshaft.

Fig 5: Fitting Bearing Caps With Bearing Shells
NOTE:
23. Fit the bearing caps complete with bearing shells (1).
Fig 6: Bearing Cap Bolts & Tightening Tool
Fig 7: Measuring Bearing Clearance Using Plastigage
25. Remove the bearing caps previously installed and using the graduated measuring guide (1a)
determine the bearing clearance indicated by the calibrated wire (Plastigage) (1b).
NOTE:
If the measured value is not within specification, replace the bearing shells with the
proper dimension of the appropriate class.
Perform the measurement on the remaining journals taking care not to rotate the crankshaft.
26. Check that the diameter of the connecting rod small end bushings are within specification; if
not, replace the connecting rod. Refer to ENGINE SPECIFICATIONS .
27. Verify that the internal diameter of the pistons pin bores are within specification if not, replace
the piston pins. Refer to ENGINE SPECIFICATIONS .
28. Make sure that the outer diameter of the piston pins are within specification; if not, replace the
piston complete with sealing rings, piston pin and bushings. Refer to ENGINE
SPECIFICATIONS .
29. Insert the piston rings in the cylinder bore and check that the end gaps are within specification.
Refer to ENGINE SPECIFICATIONS .
30. Make sure that the piston outer diameter is within specification. Refer to ENGINE
SPECIFICATIONS .
NOTE:
Measure 7 mm up from the bottom edge of the piston skirt, perpendicular to the
piston pin bore.
31. Check that the piston to cylinder bore clearances are within specification. Refer to ENGINE
SPECIFICATIONS .
32. Check that the thickness of the piston rings are within specification. Refer to ENGINE
SPECIFICATIONS .
Fig 8: Checking Axial Clearance Between First & Second Ring & Ring Groove On Piston
33. Check that the axial clearance (1a) between the first and second ring (1b) and ring groove on
the piston (1c) is within specification. Refer to ENGINE SPECIFICATIONS .
34. Check that the axial clearance between the scraper ring and its ring groove on the piston is
within specification. Refer to ENGINE SPECIFICATIONS .
Fig 9: Verifying Diameter Of Connecting Rod Big End
35. Install the connecting rod caps (1b) to the connecting rods (1a) and tighten the bolts (1c) to the
proper specification. Refer to TORQUE SPECIFICATIONS .
36. Verify that the diameter of the connecting rod big end (2) is within specification; if not, replace
the connecting rod. Refer to ENGINE SPECIFICATIONS .
37. Reassemble the piston and connecting rod assemblies. Refer to ROD, PISTON AND
CONNECTING, DISASSEMBLY AND ASSEMBLY .
38. Inspect meshing teeth indications on the ring gear. If unusually worn, replace it.
39. Install the engine block on the 1871000000 maintenance stand.
40. Install the piston oil cooling jets in the engine block and tighten the screws to the proper
41. Place the thrust bearings in their seats on the third main bearing journal.
Fig 10: Crank Pin Identification, Crank Journal Identification & Two Digits
NOTE:
A new crankshaft is provided without bearing shells but is identified with journal and
connecting rod dimensional class values in order to choose the bearing shells to
assemble with "normal" journal and connecting rod bearing clearances.
NOTE:
For the selection of main journal bearing shells the numeric code is printed on the
crankshaft adjacent to the pins.
NOTE:
Use only the codes related to the legend, all other codes present on the tone wheel
must not be used.
42. The following is an example of a class identification of the main journals.
1. Crank pin identification (1): The number on the left refers to the first pin on the timing
side. The "N" at the end is a code not significant for 4-cylinder engines.
2. Crank journal identification (2): the first number on the left refers to the first journal on the
timing side. The "N" at the end is a code not significant for 4-cylinder engines.
3. Number blocks (if any), in groups of two digits (3), indicate the size (thousandth part) of
the main journals: the first two numbers on the left refer to the first journal on the timing
side.
4. For the identification of the class of journals you should refer to the numerical code of
reference (2).
5. In the case of the example, numbers 11111N indicate that all five pins are Class A (red).
43. Another method of identifying the class of the pins is to read the reference (3).
In the case of the number 94 (the first on the left) corresponds to the dimensional value of
52.994 of the first journal that identifies the Class A (red color). The same method should be
applied to other groups of two figures (97 - 95 - 95 - 94).
BEARING CLASS
1. Crankshaft journal class A (normal), 52.994-53.000 mm, RED, code 1 (94 00) *
2. Crankshaft journal class B (normal), 52.988-52.994 mm, BLUE, code 2 (88 94) *
3. Crankshaft journal class C (normal), 52.982-52.988 mm, YELLOW, code 3 (82 88) *
4. Crankshaft journal class D (refinished 0.127 mm), 52.867-52.873 mm, BROWN, code 6
(67 73) *
5. Crankshaft journal class E (refinished 0.127 mm), 52.861-52.867 mm, GREEN, code 7
(61 67) *
6. Crankshaft journal class F (refinished 0.127 mm), 52.855-52.861 mm, BLACK, code 8
(55 61) *
(*): Last two numbers (part thousandth) is the size of the main journals.
NOTE:
When using a crankshaft which has been refinished to the maximum value of 0.127
mm by the operation of grinding and lapping, the class must be chosen by means
of dimensional measurement of the pin diameter as previously described.
NOTE:
The clearance between journal and bearing shell, obtained by the selection method
indicated above, must be within the following values: Minimum: 0.011 mm -
Maximum: 0.071 mm. This value may be measured, as a final check, using the
calibrated wire (Plastic Gauge).
44. Install the lower bearing shells in the engine block.
45. Install the crankshaft onto the bearing shells in the engine block.
NOTE:
46. Install the upper bearing shells into the bearing caps and install the bearing caps.
47. Tighten the bearing cap bolts using a suitable angle tightening tool to the proper specification.
Fig 11: Installing Rod & Piston With Bearing Shell Using Ring Compressor
48. Install the 1860815000 crankshaft rotation tool.
49. Rotate the crankshaft with the tool until the affected cylinder is at BDC.
NOTE:
Position the rod and piston in the engine block so that the discharge on the skirt of
the piston is aligned with the oil jet mounted on the engine block.
NOTE:
Select the appropriate bearing shell class based on the following measurement
procedure.
50. Install the rod and piston (1a) complete with bearing shell using a ring compressor (1b).
51. Repeat the proceeding steps for installation of the remaining rod and piston assemblies into
the engine block.
NOTE:
The connecting rod caps must be assembled so that the number stamped on them
is facing the same side as the one stamped on the big end (intake side).
53. Fit the bearing caps complete with bearing shells.
Fig 13: Using Plastigage To Determine Bearing Clearance
determine the bearing clearance indicated by the calibrated wire (Plastigage) (1b).
NOTE:
NOTE:
56. Fit all bearing caps complete with bearing shells.
57. Tighten all bearing cap bolts using a suitable angle tightening tool to the proper specification.
58. Remove the 1860815000 crankshaft rotation tool.
59. Install the front crankshaft oil seal cover with gasket and tighten the screws to the proper
Fig 14: Installing Front Crankshaft Oil Seal In Cover
60. Install the front crankshaft oil seal (1a) in the cover with the 1860816000 tool (1b).
61. Install the crankshaft position sensor and tighten the screw to the proper specification. Refer
62. Install the timing belt tensioner and tighten the bolts to the proper specification. Refer to
63. Install the rear crankshaft oil seal retainer and tighten the screws to the proper specification.
64. Apply silicone sealant around the entire perimeter of the engine oil pan.
65. Install the engine oil pan.
66. Tighten the side oil pan bolts with tool 1860834000 to the proper specification. Refer to
67. Tighten the front and rear oil pan bolts with tool 1860833000 to the proper specification. Refer
69. Install the crankshaft pulley, hold the crankshaft rotation tool and tighten the bolt to the proper

Fig 15: Measuring Piston Protrusion
71. Measure the protrusion of the pistons at two points 180° apart, on the axis of the pin with the
tool and take the average of the two readings for each piston.
Fig 16: Choosing Thickness Of Cylinder Head Gasket
72. Choose the thickness of the cylinder head gasket to be used, as a function of the maximum
value between the averages of the protrusion of the pistons. Refer to ENGINE
SPECIFICATIONS .
73. Bring the first cylinder to TDC and further rotate the crankshaft counterclockwise the equivalent
of two teeth on the crankshaft sprocket to lower the piston thus avoiding any interference with
the valves during the installation of the cylinder head.
NOTE:
The engine block to cylinder head centering bushings are shorter (12.5 mm)
compared to the cylinder head to cylinder head cover centering bushings, so be
careful not to reverse them as engine damage may occur.
74. Install the cylinder head centering bushings in the engine block.
75. Install the new selected cylinder head gasket.
76. Install the cylinder head.

Fig 17: Cylinder Head Bolt Tightening Sequence
NOTE:
The cylinder head bolts can not be reused more than four times due to elongation
which occurs with each use. In case you do not know the number of uses
performed previously on the cylinder head bolts, it is imperative that they be
replaced.
77. Tighten the cylinder head bolts (1a) in the sequence shown in illustration using a suitable angle
tightening tool (1b) to the proper specification. Refer to TORQUE SPECIFICATIONS .
78. Install the glow plugs and tighten to the proper specification. Refer to TORQUE
SPECIFICATIONS .
79. Install the fuel injection pump with bracket and tighten the bolts to the proper specification.
80. Install the alternator and tighten the bolts to the proper specification. Refer to TORQUE
SPECIFICATIONS .
81. Install the engine oil filter-heat exchanger with new O-ring seals and tighten the screws to the
82. Install the centering bushing and bracket with the bolt tightened to the proper specification.
83. Install the DPF bracket and tighten the bolts to the proper specification. Refer to TORQUE
SPECIFICATIONS .
84. Install the A/C compressor mounting bracket and tighten the bolts to the proper specification.
85. Install the A/C compressor and tighten the bolts to the proper specification. Refer to TORQUE
SPECIFICATIONS .
86. Install the engine oil cooler coolant outlet hose and connect the quick couplings.
87. Install the engine oil cooler coolant inlet hose, connect the quick couplings and secure the
hose to the support bracket.
88. Connect the fuel return hose to the fuel injection pump and tighten the clamp to the proper
Fig 18: Locating Caps & Camshaft Timing Tools In Cylinder Head Cover
89. If not already done during inspection of the cylinder head, remove the caps (1a) and install the
1870896900 camshaft timing tools (1b) in the cylinder head cover.
NOTE:
Verify proper installation of the 1870896900 camshaft timing tools.
90. Remove the intake side camshaft timing tool, install the cap and tighten to the proper
NOTE:
The cylinder head to cylinder head cover centering bushings are longer (16.0 mm)
compared to the engine block to cylinder head centering bushings, so be careful
not to reverse them as engine damage may occur.
91. Install the cylinder head cover centering bushings in the cylinder head.
92. Install the rocker arms.

93. Install the cylinder head cover gasket.
94. Install the cylinder head cover and tighten the bolts to the proper specification. Refer to
95. If not already done during inspection of the cylinder head, loosen the exhaust camshaft pulley
bolt.
Fig 19: Exhaust Camshaft Pulley Bolt
96. Remove the bolt (1).
NOTE:
To allow insertion of the dowel pin through the hole in the tool into the engine, turn
the crankshaft with small movements.
Fig 20: Avoiding Bending Timing Belt At Acute Angle
NOTE:
When handling the timing belt, avoid creating bends at an acute angle so as not to
compromise the structure of the belt, as the stresses induced by excessive bending
could result in damage not visible to the fibers inside, which could cause premature
failure of the belt during operation of the engine.
Fig 21: Timing Belt, Crankshaft Sprocket, Yellow Reference Mark, Notch & Arrows
97. Install the 2000003000 engine timing tool (2).
98. Remove the 2000003000 engine timing tool (2).
NOTE:
The yellow reference mark (1c) on the timing belt is the one that is in close
proximity to the two yellow arrows (a).
Fig 22: Timing Belt, Yellow Reference Mark, Hole, Tensioner & Tensioner Bolt
99. Position the timing belt (1a) on the crankshaft sprocket (1b), taking care to match the yellow
reference mark (1c) with the notch (1d).
100. Complete installation of the timing belt (1a), taking care to match the yellow reference mark
(1b) with the notch on the pulley.
NOTE:
The hole "a" is the reference for the final tensioning of the timing belt as described
below.
101. Insert a screwdriver into the hole (2a) and position the index of the tensioner (2b) in maximum
tension. In this position tighten the tensioner bolt (2c) to the proper specification. Refer to
102. Tighten the exhaust camshaft pulley bolt to the proper specification. Refer to TORQUE
SPECIFICATIONS .
103. Remove the 1860815000 and 1870836000 tools.
104. Rotate the crankshaft two complete revolutions.
105. Loosen the timing tensioner bolt.
106. Use a screwdriver to position the index of the tensioner at the reference hole. In this position
tighten the tensioner bolt to the proper specification. Refer to TORQUE SPECIFICATIONS .
107. Recheck the engine timing using the 1870896900 and 2000003000 timing tools.
108. Remove the 2000003000 timing tool, install the bolt and tighten to the proper specification.
109. Remove the 187086900 camshaft timing tools, install the caps and tighten to the proper
Fig 23: Fuel Injectors, Brackets & Nuts
NOTE:
Install the fuel injector into the 4th cylinder first and continue with the 3rd, 2nd and
1st cylinder.
110. Install the fuel injectors (1a) complete with brackets (1b) and tighten the nuts (1c) to the proper
111. Connect the vacuum hose to the vacuum pump.
112. Install the intake manifold support bracket and tighten the bolts to the proper specification.
113. Install the right engine mount bracket and tighten the bolts to the proper specification. Refer to
114. Install the timing belt cover and tighten the screws to the proper specification. Refer to
115. Install the accessory drive belt tensioner and tighten the bolt to the proper specification. Refer
116. Install the accessory drive belt idler pulley and tighten the screw to the proper specification.
117. Install the crankshaft pulley and tighten the bolts to the proper specification. Refer to TORQUE
SPECIFICATIONS .
118. Rotate the tensioner to relieve drive belt tension and install the accessory drive belt.
119. Connect the fuel injector return line to the fuel injectors and install the clips.
120. Connect the fuel injector return line to the fuel injection pump.
121. Install the fuel manifold and tighten the bolts to the proper specification. Refer to TORQUE
SPECIFICATIONS .
122. Install the fuel injection pump to fuel manifold pipe and tighten the fittings to the proper
123. Install the fuel manifold to fuel injector pipes and tighten the fittings to the proper specification.
124. Install the oil vapor separator with the oil vapor recovery pipe attached and tighten the bolts to
the proper specification. Refer to TORQUE SPECIFICATIONS .
125. Install the oil vapor recovery pipe bolts and tighten to the proper specification. Refer to
126. Position a new exhaust manifold gasket on the cylinder head.
127. Install the exhaust manifold with the turbocharger attached using new nuts tightened to the
128. Install the oil level indicator tube with a new O-ring seal and tighten the bolt to the proper
129. Position a new gasket on the turbocharger end of the turbocharger oil return tube and engage
the retaining tabs on the fitting.
130. Install the turbocharger oil return tube and tighten the bolts to the proper specification. Refer to
131. Install the turbocharger oil supply tube with new gaskets and tighten the fittings to the proper
132. Install the DPF and secure with the bracket and nuts tightened to the proper specification.
133. Position the DPF to turbocharger clamp and tighten the nut to the proper specification. Refer to
134. Install the DPF heat shield and tighten the nuts to the proper specification. Refer to TORQUE
SPECIFICATIONS .
135. Install the turbocharger heat shield and tighten the bolts to the proper specification. Refer to
136. Engage the oxygen sensor connector to the retaining bracket.
137. Position the wire harness on the engine and make the following connections:
1. Connect the fuel pressure regulator wire harness connector
2. Connect the manifold pressure and temperature sensor wire harness connector
3. Connect the glow plug wire harness connectors
4. Connect the fuel pressure sensor wire harness connector
5. Connect the alternator ground wire and tighten the nut to the proper specification. Refer
6. Connect the engine oil pressure sensor wire harness connector
7. Connect the EGR solenoid wire harness connector
8. Connect the crankshaft position sensor wire harness connector
9. Install the bolt in the engine wire harness tray and tighten to the proper specification.
10. Connect the EGR heat exchanger coolant solenoid wire harness connector
11. Connect the coolant temperature sensor wire harness connector
12. Connect the throttle body wire harness connector
13. Connect the fuel injector wire harness connectors
14. Connect the camshaft position sensor wire harness connector
16. Connect the A/C compressor wire harness connector
138. Install the oil drain plug and tighten to the proper specification. Refer to TORQUE
SPECIFICATIONS .
139. Service the engine with the proper quality and quantity of engine oil. Refer to CAPACITIES
AND RECOMMENDED FLUIDS, SPECIFICATIONS .

INSPECTION - 2.0L 120/140CV > DISASSEMBLY
Dead Center (BDC).

28. Remove the engine block from the maintenance stand.

galleys.

INSPECTION - 2.0L 120/140CV > REASSEMBLY
surface scratches.
SPECIFICATIONS .
SPECIFICATIONS .
NOTE:
NOTE:

Diameters
SPECIFICATIONS .
NOTE:
NOTE:


NOTE:
determine the bearing clearance indicated by the calibrated wire (1b).
NOTE:
26. Check that the diameter of the connecting rod small end bushings are within specification.
27. Verify that the internal diameter of the pistons pin bores are within specification. Refer to
ENGINE SPECIFICATIONS .
28. Make sure that the outer diameter of the piston pins are within specification. Refer to ENGINE
SPECIFICATIONS .
SPECIFICATIONS .
NOTE:
piston pin bore.
SPECIFICATIONS .
SPECIFICATIONS .
36. Verify that the diameter of the connecting rod big end (2) is within specification. Refer to
NOTE:
NOTE:
NOTE:
must not be used.
side.
reference (2).
BEARING CLASS
(67 73) *
(61 67) *
(55 61) *
NOTE:
NOTE:
NOTE:
NOTE:
NOTE:
procedure.
the engine block.
NOTE:
NOTE:
NOTE:
59. Using the tool with dial gauge, check the gear clearance of the engine balancing shaft unit to
determine the thickness of the corresponding spacers.
70. Install the crankshaft pulley, hold the crankshaft rotation tool and tighten the bolt to the proper

SPECIFICATIONS .
NOTE:

NOTE:
replaced.
SPECIFICATIONS .
SPECIFICATIONS .
SPECIFICATIONS .
86. Install the A/C compressor and tighten the bolts to the proper specification. Refer to
SPECIFICATIONS .
NOTE:
NOTE:

bolt.
NOTE:
99. Place the engine balancing module in its housing, complete with spacers, and tighten the
corresponding screws.
100. Remove the balancing shaft locking pin 2016000090 and the crankshaft timing template fitted
previously.
101. Apply silicone sealant to the entire perimeter of the engine oil sump.
102. Place the engine oil sump back in its housing.
103. Tighten the side bolts fixing the engine oil sump to the proper specification using the
1860834000 tool. Refer to TORQUE SPECIFICATIONS .
104. Tighten the front and rear bolts fixing the engine oil sump to the proper specification using
1860833000 tool. Refer to TORQUE SPECIFICATIONS .
NOTE:
105. Remove the 2000003000 engine timing tool (2).

NOTE:

NOTE:
below.
109. Using the 1860815000 and 1870836000 tools, tighten the exhaust camshaft pulley bolt to the
NOTE:
1st cylinder.
118. Place the camshaft housing to air chamber connecting bracket in position and tighten the
screws.

SPECIFICATIONS .
SPECIFICATIONS .
136. Install the oil level indicator tube with a new O-ring seal and tighten the bolt to the proper
SPECIFICATIONS .
1. Connect the fuel pressure regulator wire harness connector.
2. Connect the manifold pressure and temperature sensor wire harness connector.
3. Connect the glow plug wire harness connectors.
4. Connect the fuel pressure sensor wire harness connector.
6. Connect the engine oil pressure sensor wire harness connector.
7. Connect the EGR solenoid wire harness connector.
8. Connect the crankshaft position sensor wire harness connector.
10. Connect the EGR heat exchanger coolant solenoid wire harness connector.
11. Connect the coolant temperature sensor wire harness connector.
12. Connect the throttle body wire harness connector.
13. Connect the fuel injector wire harness connectors.
14. Connect the camshaft position sensor wire harness connector.
16. Connect the A/C compressor wire harness connector.
SPECIFICATIONS .
INSPECTION - 2.0L 170CV > DISASSEMBLY
Dead Center (BDC).

28. Remove the engine block from the maintenance stand.

galleys.

INSPECTION - 2.0L 170CV > REASSEMBLY
surface scratches.
SPECIFICATIONS .
SPECIFICATIONS .
NOTE:
NOTE:

Diameters
SPECIFICATIONS .
NOTE:
NOTE:
18. Select main bearings to achieve the proper bearing clearance. Do not attempt to perform any


NOTE:
NOTE:
26. Check that the diameter of the connecting rod small end bushings are within specification.
27. Verify that the internal diameter of the pistons pin bores are within specification. Refer to
28. Make sure that the outer diameter of the piston pins are within specification. Refer to ENGINE
SPECIFICATIONS .
SPECIFICATIONS .
NOTE:
piston pin bore.
SPECIFICATIONS .
SPECIFICATIONS .
36. Verify that the diameter of the connecting rod big end (2) is within specification. Refer to
NOTE:
NOTE:
NOTE:
must not be used.
side.
reference (2).
BEARING CLASS
(67 73) *
(61 67) *
(55 61) *
NOTE:
NOTE:
NOTE:
NOTE:
NOTE:
procedure.
the engine block.
NOTE:
NOTE:
NOTE:
Fig 14: Measuring Thickness Of Balance Shaft Module Spacers
59. Use the 2019600090 tool (1) to determine the thickness of the balance shaft module spacers.

70. Install the crankshaft sprocket, hold the crankshaft rotation tool and tighten the bolt to the

SPECIFICATIONS .
NOTE:

NOTE:
replaced.
SPECIFICATIONS .
SPECIFICATIONS .
SPECIFICATIONS .
86. Install the A/C compressor and tighten the bolts to the proper specification. Refer to TORQUE
SPECIFICATIONS .
NOTE:
NOTE:

bolt.
NOTE:
99. Install the balance shaft module and spacers over the centering bushings on the engine block.
Tighten the bolts to the proper specification. Refer to TORQUE SPECIFICATIONS .
NOTE:
100. Remove the 2000003000 engine timing tool and the 201600090 balance shaft module lock pin.
NOTE:

NOTE:
below.
104. Tighten the exhaust camshaft pulley bolt to the proper specification. Refer to TORQUE
SPECIFICATIONS .
NOTE:
1st cylinder.
SPECIFICATIONS .
SPECIFICATIONS .
128. Install the degas hose to the thermostat and tighten the clamp to the proper specification.
131. Install a new O-ring seal on the engine block end of the turbocharger oil return tube.
SPECIFICATIONS .
1. Connect the fuel pressure regulator wire harness connector
2. Connect the manifold pressure and temperature sensor wire harness connector
3. Connect the glow plug wire harness connectors
4. Connect the fuel pressure sensor wire harness connector
7. Connect the EGR solenoid wire harness connector
9. Connect the oil level sensor wire harness connector
11. Connect the EGR heat exchanger coolant solenoid wire harness connector
15. Connect the camshaft position sensor wire harness connector
17. Connect the turbocharger actuator wire harness connector
SPECIFICATIONS .
DISASSEMBLY AND ASSEMBLY > REMOVE CYLINDER HEAD AND OIL PAN FOR
INSPECTION - 1.6L
Fig 1: Oil Pan Drain Plug
1. Remove the oil pan drain plug (1) and drain the engine oil.
Fig 2: Engine Wire Harness Tray Bolt, Camshaft Position Sensor & Fuel Injector Wire Harness
Connectors
2. Disconnect the A/C compressor wire harness connector.
3. Remove the bolt (1) from the engine wire harness tray.
4. Disconnect the camshaft position sensor wire harness connector (2).
5. Disconnect the fuel injector wire harness connectors (3).

Fig 3: Throttle Body, Coolant Temperature Sensor, EGR Heat Exchanger Coolant Solenoid
Wire Harness Connectors & Engine Wire Harness Tray Bolt
6. Disconnect the throttle body wire harness connector (1).
7. Disconnect the coolant temperature sensor wire harness connector (2).
8. Disconnect the EGR heat exchanger coolant solenoid wire harness connector (3).
Fig 4: Crankshaft Position Sensor & EGR Solenoid Wire Harness Connectors
10. Disconnect the crankshaft position sensor wire harness connector (1).
11. Disconnect the EGR solenoid wire harness connector (2).

Fig 5: Oil Pressure Sensor Wire Harness Connector, Alternator Ground Wire & Nut
12. Disconnect the engine oil pressure sensor wire harness connector (1).
13. Loosen the nut (2) and disconnect the alternator ground wire.
Fig 6: Fuel Pressure Sensor & Glow Plug Wire Harness Connectors
14. Disconnect the fuel pressure sensor wire harness connector (1).
15. Disconnect the glow plug wire harness connectors (2).

Fig 7: Manifold Pressure & Temperature Sensor, Fuel Pressure Regulator Wire Harness
Connectors, Engine Wire Harness & Bolt
16. Disconnect the manifold pressure and temperature sensor wire harness connector (1).
17. Disconnect the fuel pressure regulator wire harness connector (2).
18. Remove the bolt (3) and remove the wire harness from the engine.
Fig 8: Oxygen Sensor Connector Retaining Bracket, Turbocharger Heat Shield, DPF Heat
Shield & Bolts
19. Disengage the oxygen sensor connector from the retaining bracket (1).
20. Remove the bolts (2a) and remove the turbocharger heat shield (2b).
21. Remove the nuts (3a) and remove the DPF heat shield (3b).
Fig 9: Turbocharger Clamp, Nut, Bracket & DPF
23. Remove the nuts (2a), remove the bracket (2b) and remove the DPF (2c).
Fig 10: Turbocharger Oil Supply Tube & Fittings
24. Remove the fittings (1a) and remove the turbocharger oil supply tube (1b).
Fig 11: Turbocharger Oil Return Tube & Bolt
25. Remove the bolt (1a) and disconnect the turbocharger oil return tube (1b) from the
turbocharger.
Fig 12: Oil Level Indicator Tube Bolt, & Exhaust Manifold And Turbocharger Bolts
26. Remove the bolt (1) and remove the oil level indicator tube.
27. Remove the bolts (2a) and remove the Exhaust manifold and turbocharger (2b).
28. Remove the exhaust manifold gasket.

Fig 13: Oil Vapor Recovery Pipe Bolts
29. Remove the bolt (1) from the oil vapor recovery pipe.
30. Remove the bolts (2) from the oil vapor recovery pipe.
Fig 14: Oil Vapor Separator Bolts & Oil Vapor Recovery Pipe
31. Remove the bolts (1a) and remove the oil vapor separator with the oil vapor recovery pipe
attached.
Fig 15: Fuel Manifold To Fuel Injector Pipes Fittings, Fuel Injection Pump To Fuel Manifold Pipe
Fittings, Fuel Manifold & Bolts
32. Loosen the fittings (1) and remove the fuel manifold to fuel injector pipes.
33. Loosen the fittings (2) and remove the fuel injection pump to fuel manifold pipe.
34. Remove the bolts (3) and remove the fuel manifold.
Fig 16: Fuel Injector Return Line, Clips & Fuel Injector Return Line At Fuel Injectors
35. Disconnect the fuel injector return line (1) from the fuel injection pump.
36. Remove the clips (2a), disconnect the fuel injector return line from the fuel injectors (2b) and
remove the fuel injector return line.
Fig 17: Removing Fuel Injector
NOTE:
When installing the fuel injectors, use the diagnostic tool to register the
identification code of the fuel injectors with the powertrain control module.
NOTE:
Remove the number 1 fuel injector first, followed by number 2, number 3 and
number 4.
37. Remove the nut (1) from the fuel injector.
38. Remove the fuel injector (2a) using 1870739000 extractor (2b) and 1870897300 adapter (2c).
Fig 18: Installing Crankshaft Rotation Tool
39. Install the 1860815000 crankshaft rotation tool (1).

Fig 19: Tensioner, Accessory Drive Belt, Crankshaft Pulley Bolts, Idler Pulley Bolt & Tensioner
Bolt
40. Rotate the tensioner (1a) to relieve drive belt tension and remove the accessory drive belt
(1b).
41. Remove the bolts (2) and remove the crankshaft pulley.
42. Remove the bolt (3) and remove the idler pulley.
43. Remove the bolt (4) and remove the tensioner.

Fig 20: Timing Belt Cover, Right Engine Mount Bracket & Bolts
44. Remove the screws (1a) and remove the timing belt cover (1b).
45. Remove the bolts (2a) and remove the right engine mount bracket (2b).
Fig 21: Tensioner Bolt & Timing Belt
46. Loosen the tensioner bolt (1a) and remove the timing belt (1b).
Fig 22: Vacuum Hose, Intake Manifold Support Bracket, Cylinder Head Cover & Bolts
47. Disconnect the vacuum hose (1) from the vacuum pump.
48. Remove the bolts (2) and remove the intake manifold support bracket.
49. Remove the bolts (3a) and remove the cylinder head cover (3b).
50. Remove the cylinder head cover gasket.

Fig 23: Fuel Return Hose Clamp, Engine Oil Cooler Coolant Inlet & Outlet Hoses & Quick
Couplings
51. Loosen the clamp (1) and disconnect the fuel return hose from the fuel injection pump.
52. Disconnect the quick couplings (2a) and remove the engine oil cooler coolant outlet hose (2b).
53. Disconnect the quick couplings (3a) and remove the engine oil cooler coolant inlet hose (3b).
Fig 24: Fuel Injection Pump Mounting Bolt
54. Remove the fuel injection pump mounting bolt (1).

Fig 25: Removing Cylinder Head, Intake Manifold & Bolts
55. Remove the bolts (1a) and remove the cylinder head (1b) and intake manifold.
56. Remove the cylinder head gasket.

Fig 26: Removing Oil Pan
57. Rotate the engine 180°.
58. Using the 1860834000 tool (1a) remove the side screws (1b).
59. Using the 1860833000 tool (2a) remove the timing side and gearbox side screws (2b).
60. Use the 1870718000 tool to cut the sealant along the perimeter of the engine oil pan.
61. Remove the oil pan.
62. Carefully clean the contact surfaces between the crankcase and oil pan.
INSPECTION - 2.0L 120/140CV
Fig 2: Engine Wire Harness Tray Bolt, Camshaft Position Sensor & Fuel Injector Wire Harness
Connectors
2. Disconnect the A/C compressor wire harness connector.

Fig 3: Throttle Body, Coolant Temperature Sensor, EGR Heat Exchanger Coolant Solenoid
Wire Harness Connectors & Engine Wire Harness Tray Bolt
7. Disconnect the coolant temperature sensor wire harness connector (2).
8. Disconnect the EGR heat exchanger coolant solenoid wire harness connector (3).
Fig 4: Crankshaft Position Sensor & EGR Solenoid Wire Harness Connectors
11. Disconnect the EGR solenoid wire harness connector (2).

Fig 5: Oil Pressure Sensor Wire Harness Connector, Alternator Ground Wire & Nut
12. Disconnect the engine oil pressure sensor wire harness connector (1).
13. Loosen the nut (2) and disconnect the alternator ground wire.
Fig 6: Fuel Pressure Sensor & Glow Plug Wire Harness Connectors

Fig 7: Manifold Pressure & Temperature Sensor, Fuel Pressure Regulator Wire Harness
Connectors, Engine Wire Harness & Bolt
16. Disconnect the manifold pressure and temperature sensor wire harness connector (1).
18. Remove the bolt (3) and remove the wire harness from the engine.
Fig 8: Oxygen Sensor Connector Retaining Bracket, Turbocharger Heat Shield, DPF Heat
Shield & Bolts
19. Disengage the oxygen sensor connector from the retaining bracket (1).
20. Remove the bolts (2a) and remove the turbocharger heat shield (2b).
21. Remove the nuts (3a) and remove the DPF heat shield (3b).
Fig 9: Turbocharger Clamp, Nut, Bracket & DPF
23. Remove the nuts (2a), remove the bracket (2b) and remove the DPF (2c).
Fig 10: Turbocharger Oil Supply Tube & Fittings
24. Remove the fittings (1a) and remove the turbocharger oil supply tube (1b).
Fig 11: Turbocharger Oil Return Tube & Bolt
25. Remove the bolt (1a) and disconnect the turbocharger oil return tube (1b) from the
turbocharger.
Fig 12: Oil Level Indicator Tube Bolt, & Exhaust Manifold And Turbocharger Bolts
27. Remove the bolts (2a) and remove the exhaust manifold and turbocharger (2b).
28. Remove the exhaust manifold gasket.

Fig 13: Oil Vapor Recovery Pipe Bolts
29. Remove the bolt (1) from the oil vapor recovery pipe.
Fig 14: Oil Vapor Separator Bolts & Oil Vapor Recovery Pipe
31. Remove the bolts (1a) and remove the oil vapor separator (1b) with the oil vapor recovery pipe
attached.
Fig 15: Fuel Manifold To Fuel Injector Pipes Fittings, Fuel Injection Pump To Fuel Manifold Pipe
Fittings, Fuel Manifold & Bolts
32. Loosen the fittings (1) and remove the fuel manifold to fuel injector pipes.
33. Loosen the fittings (2) and remove the fuel injection pump to fuel manifold pipe.
34. Remove the bolts (3) and remove the fuel manifold.
Fig 16: Fuel Injector Return Line, Clips & Fuel Injector Return Line At Fuel Injectors
35. Disconnect the fuel injector return line (1) from the fuel injection pump.
36. Remove the clips (2a), disconnect the fuel injector return line from the fuel injectors (2b) and
remove the fuel injector return line.
NOTE:
When installing the fuel injectors, use the diagnostic tool to register the
identification code of the fuel injectors with the powertrain control module.
NOTE:
Remove the number 1 fuel injector first, followed by number 2, number 3 and
number 4.
37. Remove the nut (1) from the fuel injector.
38. Remove the fuel injector (2a) using 1870739000 extractor (2b) and 1870897300 adapter (2c).
Fig 18: Installing Crankshaft Rotation Tool
39. Install the 1860815000 crankshaft rotation tool (1).

Fig 19: Tensioner, Accessory Drive Belt, Crankshaft Pulley Bolts, Idler Pulley Bolt & Tensioner
Bolt
40. Rotate the tensioner (1a) to relieve drive belt tension and remove the accessory drive belt
(1b).

Fig 20: Timing Belt Cover, Right Engine Mount Bracket & Bolts
44. Remove the screws (1a) and remove the timing belt cover (1b).
45. Remove the bolts (2a) and remove the right engine mount bracket (2b).
46. Loosen the tensioner bolt (1a) and remove the timing belt (1b).
Fig 22: Vacuum Hose, Intake Manifold Support Bracket, Cylinder Head Cover & Bolts
47. Disconnect the vacuum hose (1) from the vacuum pump.
49. Remove the bolts (3a) and remove the cylinder head cover (3b).

Fig 23: Fuel Return Hose Clamp, Engine Oil Cooler Coolant Inlet & Outlet Hoses & Quick
Couplings
51. Loosen the clamp (1) and disconnect the fuel return hose from the fuel injection pump.
52. Disconnect the quick couplings (2a) and remove the engine oil cooler coolant outlet hose (2b).
53. Disconnect the quick couplings (3a) and remove the engine oil cooler coolant inlet hose (3b).

Fig 25: Removing Cylinder Head, Intake Manifold & Bolts
55. Remove the bolts (1a) and remove the cylinder head (1b) and intake manifold.

Fig 26: Removing Oil Pan
57. Rotate the engine 180°.
58. Using the 1860834000 tool (1a) remove the side screws (1b).
59. Using the 1860833000 tool (2a) remove the timing side and gearbox side screws (2b).
60. Use the 1870718000 tool to cut the sealant along the perimeter of the engine oil pan.
61. Remove the oil pan.
Fig 27: Balance Shaft Module & Special Tool To Lock Balance Shaft In Timed Position
63. With the 2000003000 tool fitted previously (1a) install the 2016000090 tool (1b) to lock the
balance shaft in a timed position.
64. Remove the bolts and the balance shaft module (2).
Fig 28: Spacers On Engine Block
65. Remove the spacers (1) and check the condition of the locating bushes.
INSPECTION - 2.0L 170CV
Fig 2: PTU Actuator Wire Harness
2. Disconnect and remove the PTU actuator wire harness (1).

Fig 3: Oil Pressure Regulator Wire Harness Connector
3. Disconnect the oil pressure regulator wire harness connector (1).

Fig 4: Rear A/C Compressor Wire Harness Connector
4. Disconnect the rear A/C compressor wire harness connector (1).

Fig 5: Front A/C Compressor, Upstream & Downstream Exhaust Gas Temperature Sensor
Wire Harness Connectors
5. Disconnect the front A/C compressor wire harness connector (1).
6. Disconnect the upstream exhaust gas temperature sensor wire harness connector (2).
7. Disconnect the downstream exhaust gas temperature sensor wire harness connector (3).
Fig 6: EGR Temperature Sensor Wire Harness Connector
8. Disconnect the EGR temperature sensor wire harness connector (1).

Fig 7: EGR Temperature Sensor Wire Harness Retainer
9. Disengage the EGR temperature sensor wire harness retainer (1).

Fig 8: Camshaft Position Sensor & Turbocharger Actuator Wire Harness Connectors
11. Disconnect the turbocharger actuator wire harness connector (2).

Fig 9: Fuel Injector Wire Harness Connectors, Exhaust Gas Temperature Sensor Wire
Harness Connectors & Wire Harness Tray Bolts
14. Remove the bolts and reposition the wire harness tray (3).
Fig 10: Upstream Oxygen Sensor Wire Harness Connector & Engine Coolant Temperature
Sensor Wire Harness Connector
16. Disconnect the engine coolant temperature sensor wire harness connector (2).
Fig 11: Fuel Rail Pressure Sensor Wire Harness Connector & Glow Plug Wire Harness
Connectors
17. Disconnect the fuel rail pressure sensor wire harness connector (1).

Fig 12: Throttle Body Wire Harness Connector

Fig 13: Air Intake Pressure And Temperature Sensor Wire Harness Connector & Wire Harness
Tray Bolt
20. Disconnect the air intake pressure and temperature sensor wire harness connector (1).
21. Remove the bolt (2) from the wire harness tray.
Fig 14: Fuel Pressure Regulator Wire Harness Connector & Wire Harness Tray Bolt
23. Remove the bolt (2) from the wire harness tray.
Fig 15: Alternator Wire Harness Connector & Low Oil Pressure Switch Wire Harness
Connector
24. Disconnect the alternator wire harness connector (1).
25. Disconnect the low oil pressure switch wire harness connector (2).
Fig 16: High Oil Pressure Switch Wire Harness Connector & Crankshaft Position Sensor Wire
Harness Connector
26. Disconnect the high oil pressure switch wire harness connector (1).
Fig 17: Swirl Actuator Wire Harness Connector
28. Disconnect the swirl actuator wire harness connector.

Fig 18: EGR Wire Harness Connector
29. Disconnect the EGR wire harness connector.

30. Remove the fasteners (1) and remove the turbocharger heat shield.
Fig 20: Upstream Oxygen Sensor Wire Harness & Retainer
31. Disengage the upstream oxygen sensor wire harness from the retainer (1).
Fig 21: Differential Pressure Sensor Hoses & Clamps
32. Loosen the clamps (1) and disconnect the differential pressure sensor hoses.
Fig 22: Exhaust Gas Temperature Sensor Wire Harness & Clip
33. Open the clip (1) and disengage the exhaust gas temperature sensor wire harness.
Fig 23: EGR Clamp & Bolt
34. Loosen the bolt (1) and reposition the EGR clamp.
Fig 24: Turbocharger To DPF Clamp & Nut
35. Loosen the nut (1) and reposition the turbocharger to DPF clamp.
36. Remove the nuts (1a) and remove the Diesel particulate filter (DPF) (1b) complete with
gaskets.
Fig 26: Oil Level Indicator Tube & Bolt
Fig 27: Oil Return Tube, Turbocharger & Bolts
38. Remove the bolts (1) and disconnect the oil return tube from the turbocharger.
39. Remove the bolts (2) and remove the turbocharger oil return tube.
Fig 28: EGR Cooler Mounting Nuts
40. Remove the EGR cooler mounting nuts (1).

Fig 29: EGR Cooler Mounting Nuts
41. Remove the EGR cooler mounting nuts (1).

Fig 30: Engine Oil Vapor Hose & Clamp
42. Loosen the clamp (1) and disconnect the engine oil vapor hose.
Fig 31: EGR Components & Bolts
43. 1. Remove the bolts (1) and remove the EGR components.
Fig 32: Turbocharger Air Outlet Pip & Bolts
44. Remove the bolts (1a) and remove the turbocharger air outlet pipe (1b) with gasket from the
turbocharger.
Fig 33: Turbocharger Oil Inlet Tube Fitting
45. Remove the fitting (1) from the turbocharger oil inlet tube.
Fig 34: Heat Shield & Nuts
46. Remove the nuts (1) and remove the heat shield.
Fig 35: Exhaust Manifold And Turbocharger & Nuts
47. Remove the nuts (1) and remove the exhaust manifold and turbocharger.
48. Remove the gasket.

Fig 36: EGR Coolant Tube Mounting Flange & Nuts
49. Remove the nuts (1) from the EGR coolant tube mounting flange.
Fig 37: EGR Heat Exchanger & Bolts
50. Remove the bolts (1) and remove the EGR heat exchanger complete with tubes and gaskets.
Fig 38: Oil Cooler Coolant Hose & Quick Coupling
51. Disconnect the quick coupling (1) of the engine oil cooler coolant hose.
Fig 39: Oil Cooler Coolant Hoses & Quick Coupling
52. Disconnect the quick couplings (1) of the engine oil cooler coolant hoses.
Fig 40: Complete Coolant Hose Assembly & Quick Coupling
53. Disconnect the quick coupling (1) and remove the complete coolant hose.
Fig 41: High Pressure EGR Housing & Bolts
54. Remove the bolts (1) from the high pressure EGR housing.
Fig 42: EGR Tube & Bolts
55. Remove the bolts (1) and remove the EGR tube.
Fig 43: High Pressure EGR Components & Bolts
56. Remove the bolts (1) and remove the high pressure EGR components.
Fig 44: Oil Vapor Recovery Pipe & Bolts
Fig 45: Oil Return Tube & Bolt
58. Remove the bolt and disconnect the oil return tube.
Fig 46: Oil Vapor Separator & Bolts
59. Remove the bolts (1) and remove the oil vapor separator.
Fig 47: Fuel Injection Pump To Fuel Rail Tube & Fittings
60. Loosen the fittings (1) and remove the fuel injection pump to fuel rail tube.
Fig 48: Fuel Rail To Fuel Injector Tubes & Fittings
61. Loosen the fittings (1) and remove the fuel rail to fuel injector tubes.
Fig 49: Fuel Injector Return Line At Fuel Injectors & Clips
62. Remove the clips (1) and disconnect the fuel injector return line from the fuel injectors.
Fig 50: Fuel Injection Return Line, Fuel Return Manifold, Clamp & Bolts
63. Loosen the clamp (1) and remove the fuel injection return line from the fuel return manifold.
64. Remove the bolts (2) and remove the fuel return manifold.
Fig 51: Fuel Rail & Bolts
65. Remove the bolts (1) and remove the fuel rail.
Fig 52: Tensioner & Accessory Drive Belt
66. Rotate the tensioner (1) to relieve drive belt tension and remove the accessory drive belt.
Fig 53: Crankshaft Pulley & Bolts
Fig 54: Tensioner, Idler Pulley & Bolts
Fig 55: Right Engine Mount Bracket & Bolts
70. Remove the bolts (1) and (2) and remove the right engine mount bracket.
Fig 56: Timing Belt Cover & Bolts
71. Remove the bolts (1) and remove the timing belt cover.
NOTE:
The crankshaft timing tool must remain mounted until the balance shaft module is
removed.
72. Remove the cap and fit the 2000003000 timing tool.
73. Fit the 2000003000 timing tool and check the timing of the engine.
Fig 58: Fuel Injector Retaining Brackets & Nuts
74. Remove the nuts (1) from the fuel injector retaining brackets.
75. Remove the fuel injector using 1870739000 extractor (1a) and 1870897300 adapter (1b).
Fig 60: Support Bracket & Bolts
Fig 61: Cylinder Head Cover & Bolts
77. Remove the bolts (1) and remove the cylinder head cover.


Fig 63: Threaded Bushing
80. Remove the threaded bushing (1).

Fig 64: Cylinder Head & Bolts
81. Remove the bolts (1) and remove the cylinder head.

Fig 65: Engine Oil Pan & Bolts
83. Remove the bolts (1), cut the sealant and remove the engine oil pan.
Fig 66: Balance Shaft Module & Special Tool To Lock Balance Shaft In Timed Position
84. With the previously installed 2000003000 timing tool (1a) in place, install the 2016000090 lock
pin (1b) in the balance shaft module.
85. Remove the bolts (2) and remove the balance shaft module.
Fig 67: Spacers On Engine Block
86. Remove the spacers (1) and verify the integrity of the centering bushings.

ENGINE DIAGNOSIS AND TESTING
Transducers Examiner Test compression

1806338000 *
Kit 2 cylinders
Check the engine

1860969000 * Fitting lubrication system
pressure
1870811001 * Fitting Cylinder compression
Check cylinder
1870897400 * Incorrect injector
compression
Check the engine

Connection tube
2000015600 * lubrication system
manometer
pressure
Check the engine

2000018801 * Tee lubrication system
pressure
Check the engine

pressure
ENGINE PROCEDURES
1823015000 C-4829A Pry retainer -
1860470000 * Cylinder head overhaul -
1860815000 * Rotating crankshaft -
1860816000 * Introduction oil pump sealing ring 1.6L/2.0L Turbo

Diesel
1860833000 * Loosen/tighten screws side stand 1.6L/2.0L Turbo

Cup distribution and Exchange side Diesel
1860834000 * Loosen/tighten screws on the side 1.6L/2.0L Turbo

sump Diesel
1860846000 * Flywheel retainer -
1860854001 * Pulley extraction pressure pump 1.6L/2.0L Turbo

control Diesel
1860898000 10272 Flywheel retainer Transmission 948TE
1860898000 10272 Flywheel retainer -

1867030000 * Flywheel retainer 2.0L Turbo Diesel
170 CV
1870718000 * Cut sealing -
1870739000 * Electroinjectors removal 1.6L/2.0L Turbo

Diesel
1870815000 6847 Loosen/tighten fixing screw pulley 1.6L/2.0L Turbo

distribution policy Diesel
1870836000 * Loosen/tighten fixing screw pulley 1.6L/2.0L Turbo

distribution policy Diesel
1870896800 20131 Introduction front oil seal camshaft 1.6L/2.0L Turbo

exhaust Diesel
1870896900 20132 Engine timing 1.6L/2.0L Turbo

Diesel
1870897100 * Introduction oil seals valve guides 1.6L/2.0L Turbo

Diesel
1870897300 * Electro injectors removal 1.6L/2.0L Turbo

Diesel
1871000000 * Engine placement on tripod for -

review
1871000600 * Extracting/Introduction tappets 1.6L/2.0L Turbo

Diesel
1871001700 * Removing/installing the power plant -
1871003100 * Clutch disassembly/reassembly 1.6L/2.0L Turbo

mechanism Diesel
1871008501 * Extracting/Introduction tappets 1.6L/2.0L Turbo

Diesel
1871008601 * Removing/installing dismissal 1.6L/2.0L Turbo

gears shafts distribution Diesel
2019500031 * Removing rear drive shaft 4x4

mechanism Diesel
2000026900 20150 Removing/Installing pressure pump 1.6L/2.0L Turbo

Diesel
2000032400 * Tappets extraction/Introduction oil 2.0L Turbo Diesel

seal

mechanism Diesel
2000039800 * Capless fuel inlet pipe fastening 1.6L/2.0L Turbo

Diesel
2000040436 8534B Shaft supporting powerplant -
2000042900 * Capless fuel inlet pipe fastening 1.6L/2.0L Turbo

Diesel
2000043000 * Front suspension cross positioning -
2000001400 * Brake/clutch system depression -
2000002100 9340 Loosen / tighten the fuel pump -

mounting ring
2000003000 * Engine timing 1.6L/2.0L Turbo

Diesel
2000004100 20145 Introduction front oil seal 1.6L/2.0L Turbo

crankshaft Diesel
2016000090 * Balancing shaft lock motor 2.0L Turbo Diesel
2019600090 * Control engine balancing shafts 2.0L Turbo Diesel
2000040488 * Extraction driveshafts 2.0L Turbo Diesel
COVER, ENGINE > REMOVAL AND INSTALLATION > REMOVAL AND INSTALLATION
> REMOVAL - 1.6L TURBO DIESEL
Fig 1: Engine Cover
1. Unlock and remove the engine cover (1a) from the mounting pins.
> INSTALLATION - 1.6L TURBO DIESEL
1. Check that the engine cover is not damaged.
2. Install the engine cover by engaging the mounting pins.
> REMOVAL - 2.0L TURBO DIESEL 170 CV
Fig 1: Engine Cover
> INSTALLATION - 2.0L TURBO DIESEL 170 CV
> REMOVAL - 2.0L TURBO DIESEL 120CV/140CV
Fig 1: Engine Cover
> INSTALLATION - 2.0L TURBO DIESEL 120CV/140CV
CYLINDER HEAD > DESCRIPTION AND OPERATION > DESCRIPTION AND

OPERATION
Fig 1: Cylinder Head
Opening for intake-side second water pump inlet
"Internal" EGR circulation channels
Valves with stem 5 mm stem and 28 mm top (intake) and 24.5 mm (exhaust) head. The intake valve
heads have a layer of Eatonite to give them dimensional stability.
The cylinder head is one-piece and made of aluminum alloy.
The four valves per cylinder are fitted in the guides and are operated by two camshafts by means of
hydraulic tappets.
The valve guides are driven into the relative cylinder head seats by interference.
A special reamer is used to produce the correct bore after fitting.
The gasket between cylinder head and block is multi-layer metal type and is supplied by Spare Parts in
three different thicknesses
Fig 2: Cylinder Head Gasket & Sizes
CYLINDER HEAD > DIAGNOSIS AND TESTING > CYLINDER HEAD GASKET
A cylinder head gasket leak can be located between adjacent cylinders or between a cylinder and the
adjacent water jacket.
Possible indications of the cylinder head gasket leaking between adjacent cylinders are:
Loss of engine power
Engine misfiring
Poor fuel economy
Possible indications of the cylinder head gasket leaking between a cylinder and an adjacent water jacket
are:
Engine overheating
Loss of coolant
Excessive steam (white smoke) emitting from exhaust
Coolant foaming
CYLINDER HEAD > CLEANING > CLEANING
CAUTION:
When cleaning cylinder head and cylinder block surfaces, DO NOT use a metal scraper
because the surfaces could be cut or ground. Use ONLY a wooden or plastic scraper.
NOTE:
1. Remove all gasket material from cylinder head and block. Refer to ENGINE GASKET
SURFACE PREPARATION . Do not damage the aluminum head sealing surface.
2. Clean all the engine oil passages.
3. Clean out the cylinder head bolt holes in the engine block.
CYLINDER HEAD > INSPECTION > INSPECTION
Fig 1: Checking Cylinder Head Flatness

NOTE:
Typical Cylinder Head shown in illustration.
1. Check the cylinder head for warping with a straight edge (2) and a feeler gauge (1).
2. The cylinder head must be flat within specification. Refer to ENGINE SPECIFICATIONS .
3. Remove any carbon or varnish deposits from inside of valve guides with a reliable guide
cleaner.
4. Inspect the following components and verify that they are within specification.
1. Valve Springs
2. Valve Seats
3. Valve Guides
4. Valves
CYLINDER HEAD > REMOVAL AND INSTALLATION > 1.6L AND 2.0L-120/140CV >
REMOVAL
5. Remove the throttle body. Refer to THROTTLE BODY, REMOVAL AND INSTALLATION .
8. Remove the EGR cooler. Refer to COOLER, EXHAUST GAS RECIRCULATION (EGR),
9. Remove the diesel particulate filter. Refer to FILTER, DIESEL PARTICULATE, REMOVAL AND
INSTALLATION .
10. Remove the turbocharger. Refer to TURBOCHARGER, REMOVAL AND INSTALLATION .
12. Remove the right front wheelhouse splash shield. Refer to SHIELD, SPLASH, FRONT
13. Remove the accessory drive belt. Refer to BELT, SERPENTINE, REMOVAL AND
INSTALLATION .
14. Remove the engine vibration damper. Refer to DAMPER, VIBRATION, REMOVAL AND
INSTALLATION .
15. Remove the air cleaner.
16. Remove the timing belt. Refer to BELT, TIMING, REMOVAL AND INSTALLATION .
17. Temporarily install the rigid support and elastic powerplant block on the distribution side.
18. Remove the fuel injectors. Refer to INJECTOR(S), FUEL, REMOVAL AND INSTALLATION .
19. Remove the cylinder head cover. Refer to REMOVAL AND INSTALLATION .
Fig 1: Glow Plugs Wire Harness Connectors
20. Disconnect the wire harness connectors (1) from the glow plugs.
Fig 2: Intake Air Pressure/Temperature Sensor Wire Harness Connector
21. Disconnect the wire harness connector (1) from the intake air pressure/temperature sensor.
Fig 3: Conduit Trays & Screw
22. Remove the front screw (1) and move the conduit trays (1) to side.
Fig 4: Return Pipe To The Water Pump Quick Coupling
23. Disconnect the quick coupling of the return pipe to the water pump, airbox side.
Fig 5: Oil Vapor Separator, Bolt & Clamp
24. Remove the upper screw (1) securing the oil vapor separator to the airbox.
25. Loosen the clamp (2) and disconnect the hose from the oil vapor separator.
Fig 6: Radiator Hose & Clamp
26. Loosen the clamp (1) and disconnect the radiator hose (1), water pump side.
Fig 7: Dipstick Tube & Bolt
27. Remove the screw (1) and remove the dipstick tube (1) from the engine.
Fig 8: Pressure Pump Support Retaining Bolt
28. Remove the retaining screw (1) for pressure pump support to the cylinder head.
Fig 9: Hydraulic Lifters With Rocker
29. Remove the hydraulic lifters complete with rockers.
30. Remove the bolts (1a) and remove the cylinder head complete (1b).
Fig 10: Cylinder Head Gasket
31. Remove and discard the cylinder head gasket.
32. If it is necessary to disassemble any of the remaining components, refer to DISASSEMBLY

AND ASSEMBLY
33. Clean the bottom of the cylinder head from old gasket residue.
34. Check that the flatness of the bottom of the cylinder head is within the prescribed limit.
NOTE:
If the flatness of the bottom of the cylinder head does not fall within the
required limit, correct not to exceed the minimum height allowed.
CYLINDER HEAD > REMOVAL AND INSTALLATION > 1.6L AND 2.0L-120/140CV >
INSTALLATION
NOTE:
The centering bushings between the crankcase and cylinder head are shorter (12.5
mm) compared to those between the cylinder head and cylinder head cover; so be
careful not to reverse them as it may impair the efficiency of the engine.
Fig 1: Centering Bushing - Gearbox Side
1. Install in the engine block the cylinder head centering bushing, gearbox side.
Fig 2: Centering Bushing - Timing Gear Side
2. Install in the engine block the cylinder head centering bushing, timing gear side.
NOTE:
In case it was not necessary to proceed to the flattening of the cylinder head,
use a new gasket having the same thickness of the removed. Otherwise it is
necessary to determine the thickness of the new cylinder head gasket (see
operation 1004E20).
3. Put into place a new cylinder head gasket.
NOTE:
Move the cylinder to the 1st P.M.S.; further rotate the crankshaft of two teeth
of the pulley driving gear so as to lower the pistons, thus avoiding any
interference with the valves during the assembly of the cylinder head.
4. Place the cylinder head on the engine block.

NOTE:
The cylinder head bolts, due to the permanent elongation which happens at
during installation, can not be reused more than four times. Therefore, if you
do not know the number of previous cylinder head bolt installations, it is
imperative to replace them.
5. In the order shown in illustration, tighten the cylinder head bolts to the proper specification.
NOTE:
The value of 65 N.m (48 Lb/Ft) must be done with a combination of 20 N.m
(14.75 Lb/Ft) and subsequently an increase of 45 N.m (33 Lb/Ft).
6. Install the hydraulic lifters in their bores complete with rockers.

7. Install the retaining screw (1) for pressure pump support to the cylinder head and tighten to the
8. Position the dipstick tube to the engine and install the screw. Tighten the screw securely.
9. Connect the radiator hose, water pump side and securely tighten the clamp.
10. Connect the hose to the oil vapor separator and securely tighten the clamp.
11. Install the upper screw securing the oil vapor separator to the airbox.
12. Connect the quick coupling of the return pipe to the water pump, airbox side.
13. Position the conduit trays and install the front screw.
14. Connect the wire harness connector to the intake air pressure / temperature sensor.
15. Connect the wire harness connectors to the glow plugs.
16. Install the cylinder head cover. Refer to REMOVAL AND INSTALLATION .
17. Install the fuel injectors. Refer to INJECTOR(S), FUEL, REMOVAL AND INSTALLATION .
18. Install the timing belt. Refer to BELT, TIMING, REMOVAL AND INSTALLATION .
19. Install the air cleaner.
20. Install the engine vibration damper. Refer to DAMPER, VIBRATION, REMOVAL AND
INSTALLATION .
21. Install the accessory drive belt. Refer to BELT, SERPENTINE, REMOVAL AND INSTALLATION
.
22. Install the right front wheelhouse splash shield. Refer to SHIELD, SPLASH, FRONT
24. Install the turbocharger. Refer to TURBOCHARGER, REMOVAL AND INSTALLATION .
25. Install the diesel particulate filter. Refer to FILTER, DIESEL PARTICULATE, REMOVAL AND
INSTALLATION .
26. Install the EGR cooler. Refer to COOLER, EXHAUST GAS RECIRCULATION (EGR),
29. Install the throttle body. Refer to THROTTLE BODY, REMOVAL AND INSTALLATION .
CYLINDER HEAD > REMOVAL AND INSTALLATION > 2.0L DIESEL 170CV >
REMOVAL
5. Recover the A/C system refrigerant. Refer to PLUMBING, STANDARD PROCEDURE .
6. Remove the front bumper. Refer to FASCIA, FRONT, REMOVAL AND INSTALLATION .
7. Remove the engine cooling fan. Refer to FAN, COOLING, REMOVAL AND INSTALLATION .
8. Remove the radiator. Refer to RADIATOR, ENGINE COOLING, REMOVAL AND

INSTALLATION .
9. Remove the diesel particulate filter. Refer to FILTER, DIESEL PARTICULATE, REMOVAL AND
INSTALLATION .
11. Remove the low pressure EGR valve. Refer to VALVE, EXHAUST GAS RECIRCULATION
(EGR), REMOVAL AND INSTALLATION .
14. Remove the air cleaner. (Refer to 09 - Engine/Air Intake System/AIR CLEANER/Removal and
Installation)
INSTALLATION .
INSTALLATION .
19. Remove the fuel injectors. Refer to INJECTOR(S), FUEL, REMOVAL AND INSTALLATION .
20. Remove the cylinder head cover. Refer to REMOVAL AND INSTALLATION .
21. Remove the starter. Refer to STARTER, REMOVAL AND INSTALLATION .

Fig 1: Oil Vapor Separator Upper Bolt
22. Temporarily install the rigid support and elastic powerplant block on the distribution side.
23. Remove the upper screw (1) securing the oil vapor separator to the airbox.
Fig 2: Oil Vapor Separator Lower Bolt
24. Remove the lower bolt (1) securing the engine oil vapor separator to airbox.
Fig 3: Oil Vapor Separator & Bolt
25. Remove the bolt (1a) and remove the engine oil vapor separator (1b).
Fig 4: Engine RPM Sensor & EGR High Pressure Electric Fan Wire Harness Connectors
26. Disconnect the wire harness connector (1) from the engine RPM sensor.
27. Disconnect the wire harness connector (2) from the EGR high pressure electric fan.
Fig 5: Intake Air Pressure/Temperature Sensor Wire Harness Connector
28. Disconnect the wire harness connector (1) from the intake air pressure/temperature sensor.
Fig 6: Throttle Body Wire Harness Connector
29. Disconnect the wire harness connector (1) from the throttle body.
Fig 7: Swirl Actuator Wire Harness Connector
30. Disconnect the wire harness connector (1) from the swirl actuator.
Fig 8: Oil High Pressure Sensor Wire Harness Connector
31. Disconnect the wire harness connector (1) from the engine oil high pressure sensor.
Fig 9: Alternator & Low Oil Pressure Switch Wire Harness Connectors
32. Disconnect the wire harness connector (1) from the alternator.
33. Disconnect the wire harness connector (2) from the engine low oil pressure switch.
Fig 10: Engine Oil Heat Exchanger Liquid-Cooled Discharge Line Quick Coupling
34. Disconnect the quick coupling (1) liquid-cooled discharge line to the engine oil heat exchanger.
Fig 11: Engine Coolant Temperature Sensor Wire Harness Connector
35. Disconnect the wire harness connector (1) from the engine coolant temperature sensor.
Fig 12: Glow Plug Preheat Control Module Electrical Connection
36. Disconnect the electrical connection of the glow plug preheat control module.
Fig 13: Locating Glow Plugs
37. Unscrew and remove the glow plugs.

Fig 14: Engine Harness Front Junction Connector
38. Disconnect the engine harness front junction connector (1).
39. Disconnect the engine wiring harness retainers from the junction connector and remove it.
Fig 15: Heater Hose & Clamp
40. Loosen the clamp (1) and disconnect the heater hose (1).
Fig 16: Return Connection To Water Pump & Clamp
41. Turn the clamp (1) and disconnect the return connection (1) to the water pump.
Fig 17: Radiator Hose, Thermostat Venting Port Hose & Clamps
42. Loosen the clamp (1) and remove the radiator hose (1) from the thermostat housing.
43. Loosen the clamp (2) and disconnect the hose (2) from the thermostat venting port.
Fig 18: Return Connection To Water Pump & Bolts
44. Remove the screws (1) and remove the return connection to the water pump. Remove and
discard the gasket.
Fig 19: Engine Coolant Reservoir & Clips
45. Release the clips and remove the engine coolant reservoir fully.
Fig 20: EGR High Pressure/EGR Low Pressure Duplex Flow & Return Water Pipe, Bolts &
Nuts
46. Remove the screws (1a) and nuts (1b) and remove the duplex flow and return water pipe from
the EGR High pressure/EGR low pressure (1c).
Fig 21: Heat Exchanger For Low Pressure Exhaust Gas & Nuts
47. Remove the nuts (1) and remove the heat exchanger (1) for low pressure exhaust gas.
48. Remove the retaining screw (1) for the pressure pump support to the cylinder head.
Fig 23: Removing Cylinder Head & Bolts
49. Remove the cylinder head bolts (1a) and remove the cylinder head complete (1b).
50. Remove and discard the cylinder head gasket.
51. If it is necessary to disassemble any of the remaining components, refer to DISASSEMBLY

AND ASSEMBLY .
52. Clean the bottom of the cylinder head from old gasket residue.
53. Check that the flatness of the bottom of the cylinder head is within the prescribed limit.
NOTE:
If the flatness of the bottom of the cylinder head does not fall within the
required limit, correct not to exceed the minimum height allowed.
CYLINDER HEAD > REMOVAL AND INSTALLATION > 2.0L DIESEL 170CV >
INSTALLATION
Fig 1: Centering Bushing - Gearbox Side

NOTE:
The centering bushes between the crankcase and cylinder head are shorter (12.5 mm)
compared to those between the cylinder head and cylinder head cover; so be careful
not to reverse them as it may impair the efficiency of the engine.
1. Install in the engine block the cylinder head centering bushing, gearbox side.
Fig 2: Centering Bushing - Timing Gear Side
2. Install in the engine block the cylinder head centering bushing, timing gear side.
NOTE:
In case it was not necessary to proceed to the flattening of the cylinder head,
use a new gasket having the same thickness of the removed. Otherwise it is
necessary to determine the thickness of the new cylinder head gasket (see
operation 1004E20).
3. Put into place a new cylinder head gasket.

NOTE:
Move the cylinder to the 1st P.M.S.; further rotate the crankshaft of two teeth
of the pulley driving gear so as to lower the pistons, thus avoiding any
interference with the valves during the assembly of the cylinder head.
4. Place the cylinder head on the engine block.


NOTE:
The cylinder head bolts, due to the permanent elongation which happens at
during installation, can not be reused more than four times. Therefore, if you
do not know the number of previous cylinder head bolt installations, it is
imperative to replace them.
5. In the order shown in illustration, tighten the cylinder head bolts to the proper specification.
NOTE:
The value of 65 N.m (48 Lb/Ft) must be done with a combination of 20 N.m
(14.75 Lb/Ft) and subsequently an increase of 45 N.m (33 Lb/Ft).
6. Install the hydraulic lifters in their bores complete with rockers.

7. Install the retaining screw (1) for pressure pump support to the cylinder head and tighten to the
Fig 5: Heat Exchanger For Low Pressure Exhaust Gas & Nuts
8. Position the heat exchanger for low pressure exhaust gas and install the nuts. Tighten the nuts
Fig 6: EGR High Pressure/EGR Low Pressure Duplex Flow & Return Water Pipe, Bolts & Nuts
9. Position the duplex flow and return water pipe from EGR High pressure to the EGR low
pressure (1a), tighten the nuts (1b) and bolts (1c) to the proper specification. Refer to
10. Install the engine coolant tank complete and attach the retaining clips.
11. Position the return connection back to the water pump, complete with new gasket and tighten
the screws securely.
12. Connect the vent hose to the thermostat housing and tighten its strap.
13. Connect the radiator hose to the thermostat housing and tighten its strap.
14. Connect the return connection to the water pump by turning its connector.
15. Connect the water heater hose and tighten the clamp.
16. Connect the engine wiring harness retainers for the engine wire harness junction connector.
17. Connect the engine harness front junction connector.

Fig 7: Locating Glow Plugs
18. Install the glow plugs and torque to the proper specification. Refer to TORQUE
SPECIFICATIONS .
19. Connect the wire harness connector to the glow plug control unit.
20. Connect the wire harness connector to the engine coolant temperature sensor.
21. Connect the quick coupling of the outlet pipe to the engine oil cooler.
22. Connect the wire harness connector to the engine low oil pressure switch.
23. Connect the wire harness connector to the alternator.
24. Connect the wire harness connector to the engine oil high pressure sensor.
25. Connect the wire harness connector to the swirl actuator.
26. Connect the wire harness connector to the throttle body.
27. Connect the wire harness connector to the intake air pressure / temperature sensor.
28. Connect the wire harness connector to the EGR valve high pressure solenoid.
29. Connect the wire harness connector to the engine RPM sensor.
30. Install the engine oil vapor separator and securely tighten the bolts.
31. Securely tighten the bolts mounting the engine oil vapor separator base and to the air cleaner
box.
32. Install the starter. Refer to STARTER, REMOVAL AND INSTALLATION .
33. Install the cylinder head cover. Refer to REMOVAL AND INSTALLATION .
34. Install the fuel injectors. Refer to INJECTOR(S), FUEL, REMOVAL AND INSTALLATION .
INSTALLATION .
.
39. Install the air cleaner.
42. Install the low pressure EGR valve. Refer to VALVE, EXHAUST GAS RECIRCULATION (EGR),
44. Install the diesel particulate filter. Refer to FILTER, DIESEL PARTICULATE, REMOVAL AND
INSTALLATION .
45. Install the radiator. Refer to RADIATOR, ENGINE COOLING, REMOVAL AND INSTALLATION .
46. Install the engine cooling fan. Refer to FAN, COOLING, REMOVAL AND INSTALLATION .
47. Install the front bumper. Refer to FASCIA, FRONT, REMOVAL AND INSTALLATION .
48. Evacuate and charge the A/C system refrigerant. Refer to PLUMBING, STANDARD
PROCEDURE .
CYLINDER HEAD > CAMSHAFT, ENGINE > INSPECTION > INSPECTION

Fig 1: Inspecting Camshaft Bearing Journals, Checking Surface Of Cam Lobes For Abnormal Wear &
For Worn Or Unworn Areas Of Camshaft
1. Inspect the camshaft bearing journals (4) for damage and binding. If the journals are binding,
check the cylinder head for damage. Also check the oil supply ports for obstructions.
2. Check the surface of the cam lobes (5) for abnormal wear (1). Measure and compare the
unworn area (3) to the worn area (2). Replace the camshaft if it is not within specification.
CYLINDER HEAD > CAMSHAFT, ENGINE > REMOVAL AND INSTALLATION >
1.6L-2.0L > REMOVAL
Fig 1: Positioning Cylinder Head Cover In Vise Using Special Tool
1. Position the cylinder head cover (1a) in a vice and using support 1860470000 (1b).
Fig 2: Oil Filler To Cylinder Head Cover Bolts, Oil Filler Housing, Vacuum Pump To Cylinder
Head Cover Bolts & Vacuum Pump
2. Remove the oil filler to cylinder head cover bolts (1a) and remove the oil filler housing (1b).
3. Remove the vacuum pump to cylinder head cover bolts (2a) and remove the vacuum pump
(2b).
Fig 3: Camshaft Position Sensor & Bolt
4. Remove the camshaft position sensor bolt (1a) and remove the camshaft position sensor (1b).
Fig 4: Exhaust Camshaft Bolt & Gear
5. Remove the exhaust camshaft gear to camshaft bolt (1a) and remove the gear (1b).
Fig 5: Intake Idler Gear Bolt & Holding Tool
6. While using holding tool 1871008600 (1a) remove the intake idler gear bolt (1b).
Fig 6: Exhaust Idler Gear Bolt & Holding Tool
7. While using holding tool 1871008600 (1a) remove the exhaust idler gear bolt (1b).
Fig 7: Camshaft Idler Gears
8. Remove the idler gears (1) from the camshafts.

Fig 8: Intake Camshaft, Relative Cap, Exhaust Camshaft & Oil Seal
9. Using a suitable punch, extract the intake camshaft (1a) and the relative cap (1b).
10. Using a suitable punch, extract the exhaust camshaft (2a) and the oil seal (2b).
11. To determine if the upper head has to be replaced, or the camshafts are worn, take the
measurements shown in chart below.
1. Check that the diameter of the pins of the camshaft is within the prescribed values;
otherwise, replace the camshaft due to being worn.
Pin diameter measurement Specification Range (mm)
1 43.600 - 43.615
2 43.400 - 43.415
3 43.200 - 43.215
4 43.000 - 43.015
5 30.000 - 30.015
2. Check that the nominal lift of the camshafts is within the prescribed values; otherwise,
replace the camshaft due to being worn.
Camshaft lobes measurement Specification (mm)
Intake 8.5
Exhaust 8.0
Fig 9: Measuring Camshaft Journals
12. Make sure the camshaft journals (1) is within the prescribed values; otherwise, replace the
upper head only.
Camshaft journal measurement Specifications Range (mm)
1 43.646 - 43.671
2 43.446 - 43.471
3 43.246 - 43.271
4 43.046 - 43.071
5 30.045 - 30.070
1.6L-2.0L > INSTALLATION
Fig 1: Exhaust Idler Gear & Special Tool
1. Install the camshafts into the cylinder head cover.
2. Install the exhaust idler gear (1a) and using the tool 1871008600 (1b) tighten the bolt to the
Fig 2: Intake Idler Gear & Special Tool
3. Install the intake idler gear (1a) and using the tool 1871008600 (1b) tighten the bolt to the
Fig 3: Installing Front Oil Seal Camshaft On Exhaust Side
4. Mount the plug of camshaft on the intake side.
5. Install the front oil seal camshaft on the exhaust side (1a) with the tool 1870896800 (1b).
6. Install the camshaft drive pulley on the exhaust side and secure it with the bolt but do not
tighten at this time .
Fig 4: Camshaft Position Sensor & Bolt
7. Install the camshaft position sensor (1a) and tighten the camshaft position sensor bolt (1b) to
Fig 5: Oil Filler To Cylinder Head Cover Bolts, Oil Filler Housing, Vacuum Pump To Cylinder
Head Cover Bolts & Vacuum Pump
8. Install the vacuum pump (1a) with gasket and tighten the vacuum pump to cylinder head cover
bolts (1b) to the proper specification. Refer to TORQUE SPECIFICATIONS .
9. Install the engine oil filler housing and seal (2a) and tighten the oil filler housing to cylinder head
cover bolts (2b) to the proper specification. Refer to TORQUE SPECIFICATIONS .
10. Remove the tool holder with the cylinder head top and separate from the holding tool.
CYLINDER HEAD > LIFTER(S), HYDRAULIC > REMOVAL AND INSTALLATION > 1.6L -
2.0L > REMOVAL
Fig 1: Hydraulic Lifters With Rocker
1. Remove the hydraulic tappet (1).
2. If required, remove the clip and separate the bar from the hydraulic tappets.
CYLINDER HEAD > LIFTER(S), HYDRAULIC > REMOVAL AND INSTALLATION > 1.6L -
2.0L > INSTALLATION
1. Install the new hydraulic tappets in the seat of the rocker arm and secure it with a NEW
retaining clip.
2. Install the hydraulic tappet.
ENGINE BLOCK > STANDARD PROCEDURE > CYLINDER BORE DEGLAZING
Before deglazing, mask the crankcase area to keep abrasive materials from entering the engine lower
end. Tape off any openings to prevent abrasive material from entering the coolant and oil circuits.
CAUTION:
DO NOT use rigid type hones to remove cylinder wall glaze.
1. Select an appropriate size flexible ball hone.
CAUTION:
DO NOT use engine or transmission oil, mineral spirits, or kerosene.
2. Deglazing of the cylinder walls may be done if the cylinder bore is straight and round. About
20-60 strokes, depending on the condition of the cylinder bore, will be sufficient to provide a
satisfactory surface. Use a light honing oil, available from major oil distributors.
Fig 1: Identifying Cylinder Bore Crosshatch Pattern
3. Deglazing should be done by moving the hone up and down fast enough to get a crosshatch
pattern. The hone marks should intersect at 30° to 60° inclusive angle for proper seating of
rings.
4. A controlled hone motor speed between 200 and 300 RPM is necessary to obtain the proper
crosshatch angle (1). The number of up and down strokes per minute can be regulated to get
the desired 30° to 60° inclusive angle (2). Faster up and down strokes increase the crosshatch
angle.
5. After deglazing, it is necessary that the block be cleaned to remove all traces of abrasive. Use
a brush to wash parts with a solution of hot water and detergent. Dry parts thoroughly. Use a
clean, white, lint-free cloth to check that the bore is clean. Oil the bores after cleaning to
prevent rusting. Upon completion, perform a visual inspection of the cylinder block passages to
inspect for abrasive debris. If any debris is found, repeat the cleaning process.
NOTE:
Cylinder bore diameter should not increase more than 20 microns during deglazing
process from original nominal bore diameter, if the maximum of 20 microns is
exceeded, the cylinder block must be replaced. If deglazing the cylinder bore
cannot remove the light scratches and scuffs the cylinder block should be replaced.
ENGINE BLOCK > STANDARD PROCEDURE > MEASURING BEARING CLEARANCE

USING PLASTIGAGE
Fig 1: Plastigage Placed In Lower Shell-Typical

NOTE:
Typical crankshaft journal shown in illustration.
Engine crankshaft and connecting rod bearing clearances can be determined by the use of Plastigage or
equivalent. The following is the recommended procedure for the use of Plastigage:
1. Remove the oil film from surface to be checked. Plastigage is soluble in oil.
2. Place a piece of Plastigage (1) across the entire width of the journal (In addition, suspected
areas can be checked by placing the Plastigage in the suspected area). Plastigage must not
crumble in use. If brittle, obtain fresh stock.
NOTE:
DO NOT rotate the crankshaft. Plastigage will smear, causing inaccurate results.
3. Torque the bearing cap bolts of the bearing being checked to the proper specification. Refer to
Fig 2: Measuring Bearing Clearance With Plastigage
NOTE:
Typical connecting rod cap shown in illustration.
4. Remove the bearing cap and compare the width of the flattened Plastigage (2) with the scale
provided on the package (1). Locate the band closest to the same width. This band shows the
amount of clearance. Differences in readings between the ends indicate the amount of taper
present or the possibility of foreign material trapped under the bearing insert.
5. Record all readings taken. Compare clearance measurements to specification. Refer to

Fig 3: Checking Connecting Rod Bearing Clearance-Typical
NOTE:
Typical connecting rod journal shown in illustration.
NOTE:
Plastigage is available in a variety of clearance ranges. Use the most appropriate

range for the specifications you are checking. Plastigage generally is
accompanied by two scales. One scale is in inches, the other is a metric
scale.
6. Install the proper bearings to achieve the specified bearing clearances.
7. Repeat the Plastigage measurement to verify your bearing selection prior to final assembly.
ENGINE BLOCK > MODULE, BALANCE SHAFT > REMOVAL AND INSTALLATION >
2.0L > REMOVAL - 2.0L TURBO DIESEL 120CV/140CV
5. Remove the front suspension crossmember. Refer to CROSSMEMBER, FRONT

SUSPENSION, REMOVAL AND INSTALLATION .
6. Drain the engine oil.
12. Remove the transfer case, if equipped. Refer to REMOVAL AND INSTALLATION .
13. Remove the clutch, if equipped. Refer to DISC, CLUTCH, REMOVAL AND INSTALLATION .
14. Remove the flywheel on vehicles with manual gearbox and 4x4. Refer to FLYWHEEL,
15. Remove the oil pan. Refer to PAN, OIL, REMOVAL AND INSTALLATION .
16. Remove the serpentine belt. Refer to BELT, SERPENTINE, REMOVAL AND INSTALLATION .
17. Remove the vibration damper. Refer to DAMPER, VIBRATION, REMOVAL AND
INSTALLATION .
Fig 1: Fuel Pressure Sensor Electrical Connector & Cap
18. Disconnect the electrical connector (1) from the fuel pressure sensor.
19. Unscrew the cap (2) on the timing cover.

Fig 2: Balancer Shaft Locking Tool
20. Insert the balancer shaft locking tool (1).
21. Fit the balancer shaft locking tool in phase with the engine.
Fig 3: Crankshaft Timing Template
22. Remove the crankshaft cover and fit the crankshaft timing template (1).
Fig 4: Balancer Shaft Locking Tool, Balance Shaft & Bolts
23. Fit the balancer shaft locking tool (1) in phase with the engine.
24. Remove the bolts (2) and remove the balance shaft.
25. Remove the spacers and verify the integrity of the centering bushings.
NOTE:
The balancer can only be serviced with engine removed first.
2.0L > INSTALLATION - 2.0L TURBO DIESEL 120CV/140CV
1. Install the balance shaft and tighten the bolts to the proper specification. Refer to TORQUE
SPECIFICATIONS .
2. Remove the balancer shaft locking tool.
3. Remove the crankshaft timing template and install the front crankshaft cover.
4. Install the cap into the timing cover.
5. Connect the electrical connector to the fuel pressure sensor.
6. Install the serpentine belt. Refer to BELT, SERPENTINE, REMOVAL AND INSTALLATION .
7. Install the oil pan. Refer to PAN, OIL, REMOVAL AND INSTALLATION .
8. Install the flywheel on vehicles with manual gearbox and 4x4. Refer to FLYWHEEL, REMOVAL
AND INSTALLATION .
9. Install the clutch, if equipped. Refer to DISC, CLUTCH, REMOVAL AND INSTALLATION .
10. Install the transfer case, if equipped. Refer to REMOVAL AND INSTALLATION .
16. Fill the engine oil.
17. Install the front suspension crossmember. Refer to CROSSMEMBER, FRONT SUSPENSION,
2.0L > REMOVAL - 2.0L TURBO DIESEL 170CV
NOTE: The balancer can only be serviced with engine removed first.
ENGINE BLOCK > DAMPER, VIBRATION > REMOVAL AND INSTALLATION > 1.6L
DIESEL > REMOVAL

2. Remove the right front tire and wheel assembly. Refer to REMOVAL AND INSTALLATION .
Fig 1: Nuts At Lower Flywheel Cover
6. Remove the nuts (1) and the lower flywheel cover.

Fig 2: Installing Special Tool
7. Install the 1860898000 tool (1).

Fig 3: Vibration Damper & Bolts
8. Remove bolts (1a) and the vibration damper (1b).
DIESEL > INSTALLATION
1. Install the vibration damper (1a). Tighten bolts (1b) to the proper specification. Refer to
2. Remove the 1860898000 tool.
3. Install the lower flywheel cover and securely tighten the nuts.
4. Installed the serpentine belt. Refer to BELT, SERPENTINE, REMOVAL AND INSTALLATION .
7. Install the right front tire and wheel assembly. Refer to REMOVAL AND INSTALLATION .
DIESEL > REMOVAL

5. Remove bolts (1a) and the vibration damper (1b).
1. Install the vibration damper (1a). Tighten bolts (1b) to the proper specification. Refer to
2. Installed the serpentine belt. Refer to BELT, SERPENTINE, REMOVAL AND INSTALLATION .
ENGINE BLOCK > RING(S), PISTON > REMOVAL AND INSTALLATION > 1.6L DIESEL
> REMOVAL
Fig 1: Connecting Rod, Pin, Piston & Snap Rings
1. Remove the snap rings (1).
2. Slide the pin (2a) and separate the connecting rods (2b) from the pistons (2c).
Fig 2: Removing/Installing Piston Rings Using Special Tool
3. Using a suitable tool (1b), remove the piston rings (1a).
4. Check the straightness of the connecting rods using suitable equipment; if out of specification
replace the connecting rod. Refer to ENGINE SPECIFICATIONS .
Fig 3: Arrows In Illustration Indicate Zones Where It Is Possible To Remove Material From
Piston & Connecting Rod To Achieve Equality Of Weight
5. Check that the weight difference between the pistons are within the specified limits. Refer to
NOTE:
The arrows in the figure indicate the zones from which it is possible to remove the
material to achieve the equality of weight.
6. Check that the difference in weight between the connecting rods complete with bearing shells,
caps and screws are within the specified limits. Refer to ENGINE SPECIFICATIONS .
NOTE:
> INSTALLATION
1. Using a suitable tool (1b), install the piston rings (1a).

Fig 2: Number Stamped On Connecting Rod Is Facing Notch
2. Install the piston-connecting rod relative to the piston so that the number (1a) stamped on the
connecting rod is facing the notch (1b) formed on the skirt of the piston.
3. Install the piston pin and the snap rings.
> PISTON ROD BUSHING
NOTE:
The piston rod bushing cannot be replaced, the entire piston rod must be replaced.
> REMOVAL
2. Slide the pin (2a) and separate the connecting rods (2b) from the pistons (2c).
3. Using a suitable tool (1b), remove the piston rings (1a).
4. Check the straightness of the connecting rods using suitable equipment; if out of specification
replace the connecting rod. Refer to ENGINE SPECIFICATIONS .
Fig 3: Arrows In Illustration Indicate Zones Where It Is Possible To Remove Material From
Piston & Connecting Rod To Achieve Equality Of Weight
5. Check that the weight difference between the pistons are within the specified limits. Refer to
NOTE:
6. Check that the difference in weight between the connecting rods complete with bearing shells,
caps and screws are within the specified limits. Refer to ENGINE SPECIFICATIONS .
NOTE:
> INSTALLATION
1. Using a suitable tool (1b), install the piston rings (1a).

2. Install the piston-connecting rod relative to the piston so that the number (1a) stamped on the
connecting rod is facing the notch (1b) formed on the skirt of the piston.
3. Install the piston pin and the snap rings.
> PISTON ROD BUSHING
NOTE:
The piston rod bushing cannot be replaced, the entire piston rod must be replaced.
ENGINE BLOCK > ROD, PISTON AND CONNECTING > REMOVAL AND
INSTALLATION > 1.6L > REMOVAL
1. Remove the cylinder head. Refer to CYLINDER HEAD, REMOVAL AND INSTALLATION .
Fig 1: Connecting Rod Cap & Bolts
2. Rotate the crankshaft to bring the piston rod No. 1 to the position shown in the figure, remove
the screws (1a) and remove the connecting rod cap (1b) together.
Fig 2: Piston & Connecting Rod Assembly
3. Pull out and remove the piston-connecting rod assemblies complete with bearing (1).
INSTALLATION > 1.6L > INSTALLATION
Fig 1: Installing Piston & Connecting Rod Assembly Using Special Tool
1. Install the piston-connecting rod assemblies complete with bearing using an appropriate tool
(1).
NOTE:
The piston-connecting rod assemblies are installed in the crankcase so that the
discharge on the skirt of the piston is in correspondence with the oil jet mounted on
the crankcase.
NOTE:
The rod caps must be installed such to the number stamped on them is facing the
same side of that stamped on the rod.
NOTE:
Each connecting rod must be coupled with the respective cap respecting the
numerical references stamped on them; connecting rods and rod caps are not
interchangeable.
2. Install the rod caps (1a) complete with bearing and tighten the bolts (1b) to the proper
3. Install the cylinder head. Refer to CYLINDER HEAD, REMOVAL AND INSTALLATION .
NOTE:
The piston with connecting rod is removed only with engine removed first. Refer to
ENGINE BLOCK > ROD, PISTON AND CONNECTING > DISASSEMBLY AND
ASSEMBLY > DISASSEMBLY AND ASSEMBLY - 1.6L TURBO DIESEL & 2.0L TURBO
DIESEL > DISASSEMBLY
2. Slide the pin (2a) and remove the connecting rods (2b) from the pistons (2c).
ENGINE BLOCK > ROD, PISTON AND CONNECTING > DISASSEMBLY AND
ASSEMBLY > DISASSEMBLY AND ASSEMBLY - 1.6L TURBO DIESEL & 2.0L TURBO
DIESEL > ASSEMBLY
1. Combine the connecting rods relative to the pistons so that the number stamped on the
connecting rod head (1a) is facing the notch (1b) formed on the skirt of the piston to the
housing of the oil jet.
2. Insert the pins and secure with its snap rings.
ENGINE BLOCK > SEAL, CRANKSHAFT OIL, REAR > REMOVAL AND INSTALLATION
> 1.6L > REMOVAL - 1.6L TURBO DIESEL
Fig 1: Flywheel Stop Tool, Flywheel & Bolts
2. Fit the 1860846000 flywheel stop tool (1).
3. Remove the bolts (2a) and remove the flywheel (2b).
4. Remove the 1860846000 flywheel stop tool.

Fig 2: Oil Seal Retainer (Flywheel Side) & Bolts
5. Remove the bolts (1a) and remove the oil seal retainer on the flywheel side (1b).
6. Clean the residual sealant from the mating surface of the oil seal retainer on the flywheel side
oil sump.
> 1.6L > INSTALLATION - 1.6L TURBO DIESEL
1. Install the oil seal retainer (1a), flywheel side first, and tighten the bolts (1b) to the proper
2. Install and secure the flywheel (1) with new bolts (3) without tightening torque.
3. Install the 1860846000 flywheel stop tool (2).
4. Tighten the flywheel mounting bolts (3) to the proper specification. Refer to TORQUE
SPECIFICATIONS .
> 2.0L > REMOVAL - 2.0L TURBO DIESEL 170 CV
.
INSTALLATION .

18. Remove the engine and transmission from the vehicle. Refer to REMOVAL AND
INSTALLATION .
19. Remove the transmission from the engine. Refer to REMOVAL AND INSTALLATION .
21. Remove the bolts (2a) and remove the flywheel (2b).

23. Remove the bolts (1a) and remove the oil seal retainer on the flywheel side (1b).
24. Clean the residual sealant from the mating surface of the oil seal retainer on the flywheel side
oil sump.
> 2.0L > INSTALLATION - 2.0L TURBO DIESEL 170 CV
1. Install the oil seal retainer (1a), flywheel side first, and tighten the bolts (1b) to the proper
2. Install the engine flywheel (1) and partially tighten the bolts (3).
SPECIFICATIONS .
6. Install the transmission to the engine.
Refer to REMOVAL AND INSTALLATION .
7. Install the engine and transmission in the vehicle. Refer to REMOVAL AND INSTALLATION .

MANIFOLDS > MANIFOLD, EXHAUST > REMOVAL AND INSTALLATION > 1.6L
DIESEL > REMOVAL
2. Remove the Diesel Particulate Filter (DPF). Refer to FILTER, DIESEL PARTICULATE,

Fig 1: Lower Oil Dipstick Tube Bolt
4. Remove the lower oil dipstick tube bolt (1).

Fig 2: Oil Dipstick, Oil Indicator Tube & Bolt
5. Remove the engine oil dipstick (1).
6. Remove the bolt (2) and the oil indicator tube.

Fig 3: Exhaust Manifold, Spacers & Nuts
7. Remove the nuts (1a), the spacers and the exhaust manifold (1b).
1. Install a NEW exhaust manifold gasket.
2. Install the exhaust manifold with spacers and tighten the NEW nuts to the proper specification.
3. Install the oil dipstick tube and securely tighten the upper bolt.
4. Install the engine oil dipstick.
5. Install the lower oil dipstick tube bolt and securely tighten.
7. Install the Diesel Particulate Filter (DPF). Refer to FILTER, DIESEL PARTICULATE, REMOVAL
AND INSTALLATION .
DIESEL 120/140 CV > REMOVAL
5. Remove the upstream exhaust temperature sensor from the Diesel Particulate Filter (DPF).
Refer to SENSOR, EXHAUST TEMPERATURE, REMOVAL AND INSTALLATION .
Fig 1: Upper Oil Indicator Tube Bolt
6. Remove the upper oil indicator tube bolt (1).

Fig 2: Oil Indicator Tube & Bolt
7. Remove the bolt (1) and the oil indicator tube.

Fig 3: Lower Exhaust Manifold Nuts
8. Remove the lower exhaust manifold nuts (1).

Fig 4: Upper Exhaust Manifold Nuts & Manifold
9. Remove the upper exhaust manifold nuts (1a) and the exhaust manifold.
10. Remove and discard the gasket.
11. If required, remove the exhaust gas temperature sensor.
DIESEL 120/140 CV > INSTALLATION
Fig 1: Upper Exhaust Manifold Nuts & Manifold
1. Using a NEW gasket, install the exhaust manifold (1a). Tighten the NEW upper nuts (1b) to
Fig 2: Lower Exhaust Manifold Nuts
2. Install NEW lower exhaust manifold nuts (1) and tighten to the proper specification. Refer to
3. Install the oil indicator tube and securely tighten the bolt.
4. Install the oil indicator tube upper bolt and securely tighten.
5. Install the upstream exhaust temperature sensor into the Diesel Particulate Filter (DPF). Refer
to SENSOR, EXHAUST TEMPERATURE, REMOVAL AND INSTALLATION .
DIESEL 170 CV > REMOVAL


INSTALLATION .

Fig 1: Air Tube & Clamp
8. Loosen the hose clamps and remove the air tube (1).
Fig 2: Disconnecting Air Delivery Hose To Turbocharger From EGR Valve
9. Disconnect the air delivery hose to the turbocharger from the EGR valve of low pressure.
Fig 3: Low Pressure EGR Valve & Exhaust Gas Temperature Sensor Wire Harness
Connectors
10. Disconnect the low pressure EGR valve wire harness connector (1).
Fig 4: Low Pressure EGR Cooler & Nuts
12. Remove the nuts (1) securing the low pressure EGR cooler.
Fig 5: Low Pressure EGR Valve & Bolts
13. Remove bolts (1a) and the low pressure EGR valve (1b).
Fig 6: Exhaust Manifold Heat Shield & Nuts
14. Remove the nuts (1) and the exhaust manifold heat shield.
Fig 7: Exhaust Manifold & Nuts
15. Remove the nuts (1a) and the exhaust manifold (1b).
17. If required, remove the exhaust temperature sensor.
DIESEL 170 CV > INSTALLATION
Fig 1: Exhaust Manifold & Nuts
1. Using a NEW gasket, install the exhaust manifold (1a). Tighten the NEW nuts (1b) to the
Fig 2: Gasket Seals
2. Install a NEW gasket onto the low pressure EGR cooler manifold.
Fig 3: Low Pressure EGR Valve & Bolts
3. Install the low pressure EGR valve (1a) and tighten the bolts (1b) to the proper specification.
Fig 4: Low Pressure EGR Cooler & Bolts
4. Install the nuts (1) securing the low pressure EGR cooler and securely tighten.
5. Connect the exhaust temperature sensor wire harness connector.
6. Connect the low pressure EGR valve wire harness connector.
7. Connect the air delivery hose to the turbocharger and the EGR valve of low pressure and
tighten the clamp.
AND INSTALLATION .

MANIFOLDS > MANIFOLD, INTAKE > REMOVAL AND INSTALLATION > 1.6L DIESEL
> REMOVAL
6. Drain the cooling system. Refer to STANDARD PROCEDURE .
10. Remove the fuel filter/water separator assembly. Refer to FILTER, FUEL, REMOVAL AND
INSTALLATION .
11. Remove the fuel injection pump. Refer to PUMP, FUEL INJECTION, REMOVAL AND
INSTALLATION .
12. Remove the EGR air flow control valve. Refer to VALVE, EXHAUST GAS RECIRCULATION
14. Remove the EGR cooler and manifold. Refer to COOLER, EXHAUST GAS RECIRCULATION
Fig 1: Oil Vapor Pipe & Oil Vapor Separator Bolt
15. Remove the clamp and the oil vapor pipe (1).
16. Remove the bolt (2) securing the oil vapor separator to the intake manifold.
Fig 2: Oil Vapor Recovery Pipe & Bolt
17. Remove the lower bolt (1) securing the engine oil vapor recovery pipe to the engine block.
Fig 3: Oil Recovery Pipe Bolt
18. Remove the bolt (1) securing the oil recovery pipe to the oil pan.
Fig 4: Oil Vapor Separator Assembly
19. Remove the oil vapor separator assembly complete with O-ring.
Fig 5: Glow Plug, Fuel Pressure Sensor & Pressure Sensor Wire Harness Connectors & Wire
Harness Assembly Bolt
20. Disconnect the glow plug wire harness connector (1) from each glow plug.
22. Remove the bolt (3) securing the wire harness assembly to the intake manifold and position
aside.
23. Disconnect the pressure sensor wire harness connector (4).

Fig 6: Oil Vapor Pipe & Bolts
24. Remove the bolts (1a) securing the oil vapor pipe (1b) and position aside.
Fig 7: Wire Harness & Intake Manifold Support Bracket Bolts
25. Remove the bolt (1) securing the wire harness to the intake manifold.
26. Remove the bolt (2) and the intake manifold support bracket.
Fig 8: Bottom Mounting Stud At Fuel Injection Pump
27. Remove the bottom mounting stud (1) securing the fuel injection pump.
Fig 9: Intake Manifold Mounting Nuts
28. Remove the intake manifold mounting nuts (1).

Fig 10: Intake Manifold With Gasket
29. Remove the intake manifold with gasket (1).

Fig 11: Pressure Sensor & Bolt
30. If necessary, remove the screw (1) and the pressure sensor.
> INSTALLATION
1. Using a NEW gasket, install the intake manifold and pressure sensor (1).
2. Tighten the nuts (1) to the proper specification. Refer to TORQUE SPECIFICATIONS .
3. Install the bottom mounting stud securing the fuel injection pump and securely tighten.
4. Install the support bracket securing the intake manifold and securely tighten.
5. Install the bolt securing the wire harness to the intake manifold.
6. Install the oil vapor pipe and securely tighten the bolt.
7. Connect the pressure sensor wire harness connector.
8. Install the wire harness assembly the intake manifold and securely tighten bolt.
10. Connect the glow plug wire harness connector to each glow plug.
11. Using a NEW O-ring seal, install vapor separator assembly.
12. Install the bolt (1) securing the oil recovery pipe to the oil pan and securely tighten.
13. Install the lower bolt (1) securing the engine oil vapor recovery pipe to the engine block and
securely tighten.
14. Install the bolt (2) securing the oil vapor separator to the intake manifold and securely tighten.
15. Install the oil vapor pipe and tighten the clamp.
16. Install the EGR cooler and manifold. Refer to COOLER, EXHAUST GAS RECIRCULATION
18. Install the EGR air flow control valve. Refer to VALVE, EXHAUST GAS RECIRCULATION
19. Install the fuel injection pump. Refer to PUMP, FUEL INJECTION, REMOVAL AND
INSTALLATION .
20. Install the fuel filter/water separator assembly. Refer to FILTER, FUEL, REMOVAL AND
INSTALLATION .
> REMOVAL
10. Remove the fuel filter/water separator assembly. Refer to FILTER, FUEL, REMOVAL AND
INSTALLATION .
11. Remove the fuel injection pump. Refer to PUMP, FUEL INJECTION, REMOVAL AND
INSTALLATION .
NOTE:
The following step applies to 120/140 CV.
13. Remove the EGR cooler and manifold. Refer to COOLER, EXHAUST GAS RECIRCULATION
NOTE:
The following step applies to 170 CV.
14. Remove the EGR valve and manifold. Refer to VALVE, EXHAUST GAS RECIRCULATION
Fig 1: Oil Vapor Pipe & Oil Vapor Separator Bolt
15. Remove the clamp and the oil vapor pipe (1).
16. Remove the bolt (2) securing the oil vapor separator to the intake manifold.
Fig 2: Swirl Valve Actuator Wire Harness Connector, Oil Vapor Recovery Pipe & Bolt
17. Remove the lower bolt (1) securing the engine oil vapor recovery pipe to the engine block.
18. Disconnect the swirl valve actuator wire harness connector (2).
Fig 3: Oil Recovery Pipe Bolt
19. Remove the bolt (1) securing the oil recovery pipe to the oil pan.
Fig 4: Oil Vapor Separator Assembly
20. Remove the oil vapor separator assembly complete with O-ring.
Fig 5: Glow Plug, Fuel Pressure Sensor & Pressure Sensor Wire Harness Connectors & Wire
Harness Assembly Bolt
21. Disconnect the glow plug wire harness connector (1) from each glow plug.
23. Remove the bolt (3) securing the wire harness assembly to the intake manifold and position
aside.
24. Disconnect the pressure sensor wire harness connector (4).

Fig 6: Oil Vapor Pipe & Bolts
25. Remove the bolts (1a) securing the oil vapor pipe (1b) and position aside.
Fig 7: Wire Harness & Intake Manifold Support Bracket Bolts
26. Remove the bolt (1) securing the wire harness to the intake manifold.
27. Remove the bolt (2) and the intake manifold support bracket.
Fig 8: Bottom Mounting Stud At Fuel Injection Pump
28. Remove the bottom mounting stud (1) securing the fuel injection pump.
29. Remove the intake manifold mounting nuts (1).

Fig 10: Intake Manifold With Gasket
30. Remove the intake manifold with gasket (1).

Fig 11: Pressure Sensor & Bolt
31. If necessary, remove the screw (1) and the pressure sensor.
> INSTALLATION
1. Using a NEW gasket, install the intake manifold and pressure sensor.
2. Tighten the nuts (1) to the proper specification. Refer to TORQUE SPECIFICATIONS .
3. Install the bottom mounting stud (1) securing the fuel injection pump and securely tighten.
4. Install the support bracket securing the intake manifold and securely tighten.
5. Install the bolt securing the wire harness to the intake manifold.
6. Install the oil vapor pipe and securely tighten the bolt.
7. Connect the pressure sensor wire harness connector.
8. Install the wire harness assembly the intake manifold and securely tighten bolt.
10. Connect the glow plug wire harness connector to each glow plug.
11. Using a NEW O-ring seal, install vapor separator assembly.
12. Install the bolt (1) securing the oil recovery pipe to the oil pan and securely tighten.
13. Connect the swirl valve actuator wire harness connector.
14. Install the lower bolt (1) securing the engine oil vapor recovery pipe to the engine block and
securely tighten.
15. Install the bolt (2) securing the oil vapor separator to the intake manifold and securely tighten.
16. Install the oil vapor pipe and tighten the clamp.
NOTE:
The following step applies to 170 CV.
17. Install the EGR valve and manifold. Refer to VALVE, EXHAUST GAS RECIRCULATION (EGR),
NOTE:
The following step applies to 120/140 CV.
18. Install the EGR cooler and manifold. Refer to COOLER, EXHAUST GAS RECIRCULATION
20. Install the fuel injection pump. Refer to PUMP, FUEL INJECTION, REMOVAL AND
INSTALLATION .
21. Install the fuel filter/water separator assembly. Refer to FILTER, FUEL, REMOVAL AND
INSTALLATION .
LUBRICATION > DIAGNOSIS AND TESTING > CHECKING ENGINE OIL PRESSURE
1. Run the engine until it reaches normal operating temperature.

5. Disconnect the oil pressure switch wire harness connector.
6. Remove the oil pressure switch.

Fig 1: Installing Fittings & Tee Into Engine Oil Pressure Switch Port
7. Install the 1860969000 Fitting (1a), 2000024300 Fitting (1b), and 2000018801 Tee (1c) into
the engine oil pressure switch port.
Fig 2: Installing Connection Tube Manometer & Pressure Gauge Into Fittings
8. Install the 2000015600 Connection Tube Manometer (1) into the previously installed fittings.
9. Install a suitable pressure gauge (1) and check to see if the engine oil is within the prescribed
limits.
Delivery pressure Engine oil

l.6L/2.0L Diesel 1.0 bar
(Idle)
Delivery pressure engine oil

l.6L/2.0L Diesel 4.0 - 4.2 bar
(4000 RPM)
10. Remove the pressure gauge and fittings.
11. Install the oil pressure switch and tighten to the proper specification. Refer to TORQUE
SPECIFICATIONS .
12. Connect the oil pressure switch wire harness connector.

LUBRICATION > COOLER, OIL > REMOVAL AND INSTALLATION > 1.6L > REMOVAL
2. Remove the engine beauty cover. Refer to COVER, ENGINE, REMOVAL AND
INSTALLATION .
4. Remove the right front wheel and splash shield. Refer to SHIELD, SPLASH, FRONT
Fig 1: Connecting Collar Exhaust Pipes Nut & Discharge Pipe Support Brackets Bolts
5. Unscrew (1) the nut of the connecting collar exhaust pipes.
6. Remove the screws (2) fastening the discharge pipe support brackets, the side of the
suspension cross member.
Fig 2: Drain Pipe Support Bracket Collar Screw, Exhaust Gas Downstream Outlet Pressure
Pipe & Discharge Pipe Nuts
7. Remove the collar screw (1) to the drain pipe support bracket.
8. Remove the connection and disconnect the exhaust gas downstream outlet pressure pipe (2)
to the DPF.
9. Remove the nuts (3) and disconnect the discharge pipe from the DPF.

Fig 3: Locating Bolt

Fig 4: Coolant Flow & Return Cooler Pipes
12. Pull back the clips and disconnect the coolant flow and return cooler pipes (1).
Fig 5: High Pressure Engine Oil Electrical Connector & Engine Oil Pressure Switch Electrical
Connector
13. Disconnect the high pressure engine oil electrical connector (1).
14. Disconnect the engine oil pressure switch electrical connector (2).
Fig 6: Placing Hydraulic Lift Under Gearbox
15. Place a suitable hydraulic lift (1) under the gearbox and remove the suspension cross member.
Fig 7: Engine Oil Cooler & Bolts
16. Remove the screws (1) and remove the engine oil cooler.
Fig 8: Engine Oil Cooler O-Rings
17. Remove inlet and output O-rings (1) from the engine oil cooler.
Fig 9: Oil Pressure Switch, Oil Filter Cover & Oil High Pressure Switch
18. If required, loosen and remove the engine oil pressure switch (1).
19. If required, unscrew and remove the engine oil filter cover (2) complete with filter element.
20. If required, loosen and remove the engine oil high pressure switch (3).
LUBRICATION > COOLER, OIL > REMOVAL AND INSTALLATION > 1.6L >
INSTALLATION
1. Insert a new filter into the engine oil filter cover.
2. Screw the engine oil filter cover complete with new O-ring and tighten to the proper
3. Install the engine oil high-pressure switch and tighten it to the proper specification. Refer to
4. Install the engine oil pressure switch and tighten it to the proper specification. Refer to
5. Install engine oil cooler support complete with O-rings and tighten the screws.
NOTE:
Before tightening the screws check the complete insertion of the engine oil cooler
fittings are into the holes of the base.
6. Remove the hydraulic lift from the gearbox.
7. Connect the electrical connection of the engine oil pressure switch.
8. Connect the electrical connection of the engine oil high-pressure.
9. Connect the quick couplings of the coolant flow and return cooler pipe.
Fig 1: Rigid Support Rod Less Reaction Bolt
10. Tighten the rigid support rod less reaction screw (1) to the proper specification. Refer to
Fig 2: Drain Pipe & Nuts, Exhaust Gas Downstream Pressure Pipe Fitting & Drain Pipe
Support Collar Bolt
11. Connect the drain pipe (1) to the DPF, using a new gasket and tighten the nuts to the proper
12. Tighten the fitting of the exhaust gas downstream pressure pipe (2) to the DPF.
13. Tighten drain pipe support collar screw (2) to the proper specification. Refer to TORQUE
SPECIFICATIONS .
Fig 3: Connecting Collar Exhaust Pipes Nut & Discharge Pipe Support Brackets Bolts
14. Tighten the fastening screws of the drain pipe brackets support (1), cross member suspension
15. Tighten connecting pipes collar nut (2) to the proper specification. Refer to TORQUE
SPECIFICATIONS .
16. Install the right front wheel and splash shield. Refer to SHIELD, SPLASH, FRONT
INSTALLATION .

Fig 1: Coolant Flow & Return Cooler Pipes
4. Pull back the clips and disconnect the coolant flow and return cooler pipe (1).
Fig 2: Return Line To Water Pump
5. Disconnect the return line (1) to the water pump.

Fig 3: Oil Pressure Switch & Oil High Pressure Sensor Electrical Connections
6. Disconnect the electrical connection of the engine oil pressure switch (1).
7. Disconnect the electrical connection of the engine oil high pressure sensor (2).
8. Disconnect the electrical connection of the engine oil high pressure sensor (3).
Fig 4: Engine Oil Cooler O-Rings
9. Remove the inlet and output o-rings (1) from the engine oil cooler.
Fig 5: Oil Pressure Switch, Oil Filter Cover & Oil High Pressure Switch
10. If required, loosen and remove the engine oil pressure switch (1).
11. If required, unscrew and remove the engine oil filter cover (2) complete with filter element.
12. If required, loosen and remove the high pressure engine oil sensor (3).
INSTALLATION
1. Insert a new filter into the engine oil filter cover.
2. Screw the engine oil filter cover complete with new O-ring and tighten to the proper
3. Install the engine oil high-pressure switch and tighten it to the proper specification. Refer to
4. Install the engine oil pressure switch and tighten it to the proper specification. Refer to
5. Connect the electrical connection of the engine oil pressure switch.
6. Connect the electrical connection of the engine oil high-pressure.

7. Connect the quick couplings of the coolant flow and return cooler pipe.
8. Connect the drain pipe (1) to the DPF, using a new gasket and tighten the nuts to the proper
LUBRICATION > COOLER, OIL > REMOVAL AND INSTALLATION > OIL COOLER
LINES > REMOVAL

Fig 1: Upper Oxygen Sensor Wire Harness Connector
4. Disconnect the upper oxygen sensor wire harness connector (1).
5. Disengage the top oxygen sensor wiring harness, and loosen the bolt (1) and remove the
bracket.
Fig 2: Exhaust Manifold Heat Shield & Bolts
6. Remove the bolts (2) and the exhaust manifold heat shield.
Fig 3: Bottom Exhaust Manifold Heat Shield & Nuts
7. Remove the nuts and the bottom exhaust manifold heat shield.
Fig 4: Upper Oxygen Sensor Wiring Retainer & Coolant Tube Assembly Rear Bracket Bolt
8. Detach the retainer (1) securing the upper oxygen sensor wiring.
9. Remove the rear bracket bolt (2) securing the coolant tube assembly.
Fig 5: Front Bracket Nut Securing Coolant Tube Assembly
10. Remove the front bracket nut (1) securing the coolant tube assembly.
Fig 6: Water Supply & Return Hoses Hose Clamps
11. Loosen the hose clamps (1) and disconnect the water supply and return hoses.
Fig 7: Disconnecting Coolant Hoses & Removing Coolant Tubes
12. Disconnect the coolant hoses (1) and remove the coolant tubes.
LINES > INSTALLATION
1. Install the coolant tubes and tighten the clamps.
2. Connect the water supply and return hoses and tighten the clamps.
3. Install the front bracket nut securing the tubes assembly and securely tighten.
4. Install the rear bracket bolt securing the tubes assembly and securely tighten.
5. Engage the retaining clip oxygen sensor harness
6. Install the lower exhaust manifold heat shield and securely tighten the nuts.
7. Install the top exhaust manifold heat shield and securely tighten the bolts.
8. Install the top oxygen sensor wiring bracket and securely tighten the bolt and engage the wiring
retaining clip.
9. Connect the upper oxygen sensor wire harness connector.
LUBRICATION > FILTER, ENGINE OIL > REMOVAL AND INSTALLATION > 1.6L
TURBO DIESEL & 2.0L TURBO DIESEL
NOTE:
Following a complete replacement of the engine oil, update the "change engine oil" function
in the specific engine Control Module using the diagnostic tool.
NOTE:
Minimize skin contact with engine oil. Engine oil is harmful to the skin. In case of contact,
wash with soap and water.

Fig 1: Oil Filler Cap & Dipstick
2. When the engine is warm, remove the engine oil filler cap (1).
3. Pull out the dipstick (2) to check the engine oil level.
NOTE:
When removing the drain plug, use caution as the oil may be very hot.
NOTE:
Do not spill any oil, as the indiscriminate dispersal of the product causes pollution.
5. Unscrew the drain plug (1) from the oil pan and allow the engine oil to completely drain into a
suitable container.
6. Clean the engine oil drain plug (1) and tighten it with the gasket to the proper specification.
Fig 4: Oil Filter Housing Fitting
7. Remove the cap and insert a suitable drain hose onto the fitting (1) on the oil filter housing for
the recovery of oil that comes out when you remove the oil filter cover.
Fig 5: Oil Filter Cartridge Cover
8. Unscrew and remove the engine oil filter cartridge cover (1).
Fig 6: Oil Filter Element & Oil Filter Cover O-Ring
9. Remove the oil filter element (1) from the oil filter cover.
10. Remove the O-ring (2) from the oil filter cover.
Fig 7: Oil Filter Element, Retaining Clips & Oil Filter Cover O-Ring
11. Install a new oil filter element (1a) engaging the retaining clips (1b).
12. Install a new O-ring (2) on the oil filter cover.
13. Install the oil filter cover and tighten to the proper specification. Refer to TORQUE
SPECIFICATIONS .
14. Remove the drain hose used for oil recovery and install the cap on the fitting.
15. Refill the engine lubrication system with the proper quality and quantity of engine oil. Refer to
CAPACITIES AND RECOMMENDED FLUIDS, SPECIFICATIONS .
NOTE:
In the table is shown the amount for periodic replacement.
16. Check the engine oil level with the dipstick.
NOTE:
Checking the oil level should be carried out with the vehicle on level ground.
17. Install the oil filler cap, run the engine at idle speed for about 2 minutes, turn off the engine and
wait a few minutes.
18. When the engine is cold, check the oil level and check for leakage.
LUBRICATION > PAN, OIL > REMOVAL AND INSTALLATION > 1.6L DIESEL >
REMOVAL
4. Remove and the belly pan. Refer to BELLY PAN, REMOVAL AND INSTALLATION and BELLY
5. Drain engine oil and remove the oil filter. Refer to FILTER, ENGINE OIL, REMOVAL AND
INSTALLATION .
6. Drain the transmission oil. Refer to FLUID, STANDARD PROCEDURE .
7. Remove the engine oil dipstick.
8. Remove fasteners and the oil dipstick tube.

9. Remove the bolts (1) securing the exhaust isolator bracket.

Fig 2: Tube Support Bracket Bolt, Tube Nut, Exhaust Flange Nuts & Exhaust Pipe Support
Bracket Bolt
10. Remove the nut (1) securing the outlet pressure tube from the Diesel Particulate Filter (DPF).
11. Loosen the nut (2) and remove the outlet pressure tube.
12. Remove the nuts (3) securing the exhaust pipe to the DPF.
14. Disconnect the exhaust pipe from the DPF and position aside.

Fig 3: Right Side Tie Rod Nut
16. Remove the right side tie rod nut (1).

Fig 4: Disconnecting Tie Rod From Steering Knuckle Using Special Tool
17. Using the 1871000700 tool (1a), disconnect the tie rod (1b) from the steering knuckle.
Fig 5: Lower Control Arm Nut & Bolt
18. Remove the nut (1) and bolt and disconnect the lower control arm from the steering knuckle.
19. Remove nut (1a) and the stabilizer bar link (1b) from the shock.
Fig 7: Intermediate Halfshaft Bearing Support Bolts
20. Remove the bolts (1) securing the intermediate halfshaft bearing support.
21. Remove the right halfshafts and intermediate shaft from the transmission.
Fig 8: Intermediate Halfshaft Bearing Support To Oil Pan Upper Bolt
22. Remove the upper bolt (1) securing the intermediate halfshaft bearing support to the oil pan.
Fig 9: Intermediate Halfshaft Bearing Support To Oil Pan Bottom Bolts
23. Remove the bottom bolts (1a) securing the intermediate halfshaft bearing support to the oil pan
(1b).
Fig 10: Oil Vapor Recovery Hose Bolt
24. Remove bolt (1) and the oil vapor recovery hose.
Fig 11: Oil Pan To Transmission Bolts
25. Remove bolts (1a) and (1b) securing the oil pan to the transmission.
Fig 12: Removing/Installing Oil Pan Bolts Using Special Tool
26. Using the 1860834000 tool (1a), remove the bolts (1b) securing the oil pan.
Fig 13: Removing/Installing Front & Rear Oil Pan Bolts Using Special Tool
27. Using the 1860833000 tool (1a), remove the front and rear oil pan bolts (1b).
Fig 14: Cutting Sealer & Removing Oil Pan Using Special Tool
NOTE:
Turn the flywheel up to match the groove with the mounting screws engine oil pan
gearbox side.
28. Using a suitable tool (1a) cut the sealer and remove the oil pan (1b).
Fig 15: Oil Pump Intake Connector Gasket
29. Remove the oil pump intake connector gasket (1).
30. With a suitable tool remove residual sealant from the engine block sealing surface.
Fig 16: Removing Residual Sealant From Engine Oil Pan
31. With suitable tool remove residual sealant from the engine oil pan.
INSTALLATION
1. Clean oil pan and all sealing surfaces. Refer to ENGINE GASKET SURFACE PREPARATION .
2. Install a NEW gasket seal onto the oil pump intake.
NOTE:
No interruptions in the bead of sealant.
3. Apply a bead of silicone sealant to the oil pan.

NOTE:
During assembly of the engine oil sump careful not to damage the bead of sealant.
NOTE:
Complete assembly operations within 10 minutes of applying the sealant.
4. Install the oil pan and tighten bolts finger tight.

Fig 1: Removing/Installing Front & Rear Oil Pan Bolts Using Special Tool
5. Using the 1860833000 tool (1a), install the front and rear oil pan bolts (1b) and tighten to the
Fig 2: Removing/Installing Oil Pan Bolts Using Special Tool
6. Using the 1860834000 tool (1a), tighten the oil pan bolts (1b) to the proper specification. Refer
Fig 3: Oil Pan To Transmission Bolts
7. Install the oil pan-to-the transmission bolts (1a) and (1b) and tighten to the proper specification.
8. Using a NEW gasket seal, install the oil vapor recovery hose and tighten the bolt to the proper
Fig 4: Intermediate Halfshaft Bearing Support To Oil Pan Bottom Bolts
9. Install intermediate halfshaft bearing support (1a) to the oil pan and tighten the lower bolts (1b)
Fig 5: Intermediate Halfshaft Bearing Support To Oil Pan Upper Bolt
10. Install the upper bolt (1) securing the intermediate halfshaft bearing support to the oil pan and
tighten to the proper specification. Refer to TORQUE SPECIFICATIONS .
11. Install the right halfshafts and intermediate shaft from the transmission.
Fig 6: Intermediate Halfshaft Bearing Support Bolts
12. Install the intermediate halfshaft bearing support bolts (1) and tighten to the proper
13. Install the stabilizer bar link (1a) to the shock and tighten the NEW nut (1b) to the proper
Fig 8: Lower Control Arm Nut & Bolt
14. Install the lower control arm from the steering knuckle. Tighten the NEW bolt and nut to the
Fig 9: Right Side Tie Rod Nut
15. Install the tie rod to the steering knuckle. Tighten the NEW nut to the proper specification.
Refer to FRONT, SPECIFICATIONS .
Fig 10: Exhaust Pipe Support Bracket Bolt, Exhaust Flange Nuts, Tube & Tube Support Bracket
Bolt
16. Using a NEW gasket, connect the exhaust pipe to the Diesel Particulate Filter (DPF).
17. Install the exhaust pipe support bracket bolt (1) and tighten to the proper specification. Refer to
SPECIFICATIONS .
18. Install NEW nuts (2) securing the exhaust pipe to the DPF and tighten to the proper
19. Install the outlet pressure tube to the DPF and securely tighten the nut (3)
20. Install the nut (4) securing the outlet pressure tube to the DPF and securely tighten.
21. Install the bolts (1) securing the exhaust isolator bracket and tighten to the proper
22. Install the oil dipstick tube and securely tighten fasteners.
23. Install the engine oil dipstick.
24. Install a NEW engine oil filter. Refer to FILTER, ENGINE OIL, REMOVAL AND
INSTALLATION .
25. Install the belly pan and securely tighten bolts.
28. Fill the engine with recommended oil. Refer to CAPACITIES AND RECOMMENDED FLUIDS,
SPECIFICATIONS .
REMOVAL
3. Remove the right and left front tire and wheel assembly. Refer to REMOVAL AND
INSTALLATION .
6. Remove the left front wheelhouse splash shield. Refer to SHIELD, SPLASH, FRONT
8. Remove the front suspension crossmember. Refer to CROSSMEMBER, FRONT

SUSPENSION, REMOVAL AND INSTALLATION .
9. Drain engine oil using a new sealing washer tighten drain plug to the proper specification.
11. Remove the left side half shaft. Refer to REMOVAL AND INSTALLATION .
12. Remove the right side half shaft. Refer to REMOVAL AND INSTALLATION .
13. Remove the Power Transfer Unit (PTU). Refer to REMOVAL AND INSTALLATION .
18. Remove the clutch assembly. Refer to FILTER, DIESEL PARTICULATE, REMOVAL AND
INSTALLATION .
19. Remove the flywheel. Refer to FLYWHEEL, REMOVAL AND INSTALLATION .

Fig 1: Oil Vapor Recovery Hose Bolt, Oil Pan Bolts & Oil Pan
20. Remove the bolt (1) and the oil vapor recovery hose.
21. Remove the oil pan bolts (2).
22. Using a suitable tool cut the sealer and remove the oil pan (3).
23. Remove the oil pump intake connector gasket.
24. Clean the residual sealant from the oil pan and engine block sealing surfaces.
INSTALLATION
1. Install a NEW gasket seal onto the oil pump intake.
NOTE:
No interruptions in the bead of sealant.
2. Apply a bead of silicone sealant to the oil pan.

NOTE:
During assembly of the engine oil sump careful not to damage the bead of sealant.
NOTE:
Complete assembly operations within 10 minutes of applying the sealant.
Fig 1: Oil Vapor Recovery Hose Bolt, Oil Pan Bolts & Oil Pan
3. Install the oil pan and tighten the bolts (1) finger tight.
4. Tighten the oil pan bolts (1) to the proper specification. Refer to TORQUE SPECIFICATIONS .
5. Install the oil vapor recovery hose. Tighten bolt (2) to the proper specification. Refer to
6. Install the flywheel. Refer to FLYWHEEL, REMOVAL AND INSTALLATION .
7. Install the clutch assembly. Refer to FILTER, DIESEL PARTICULATE, REMOVAL AND
INSTALLATION .
AND INSTALLATION .
12. Install the Power Transfer Unit (PTU). Refer to REMOVAL AND INSTALLATION .
13. Install the right side halfshafts. Refer to REMOVAL AND INSTALLATION .
14. Install the left side half shaft. Refer to REMOVAL AND INSTALLATION .
15. Install the front suspension crossmember. Refer to CROSSMEMBER, FRONT SUSPENSION,
16. Fill the transmission fluid. Refer to FLUID, STANDARD PROCEDURE .
17. Fill the engine with recommended oil. Refer to CAPACITIES AND RECOMMENDED FLUIDS,
SPECIFICATIONS .
18. the front fascia. Refer to FASCIA, FRONT, REMOVAL AND INSTALLATION .
19. Install the left front wheelhouse splash shield. Refer to SHIELD, SPLASH, FRONT
LUBRICATION > SENSOR, OIL PRESSURE > REMOVAL AND INSTALLATION > 1.6L
DIESEL WARNING LIGHT > REMOVAL

Fig 1: Engine Oil Cooler Coolant Hoses
5. Disconnect the engine oil cooler coolant hoses (1).

Fig 2: Oil Pressure Sensor & Harness Connector
6. Disconnect oil pressure sensor harness connector (1).
7. Remove the oil pressure sensor (2).
DIESEL WARNING LIGHT > INSTALLATION
1. Install the oil pressure sensor (2) and tighten to the proper specification. Refer to TORQUE
SPECIFICATIONS .
2. Connect oil pressure sensor wire harness connector (1).

3. Connect the engine oil cooler coolant hoses.
DIESEL HIGH PRESSURE > REMOVAL
2. Remove the belly pan. Refer to BELLY PAN, REMOVAL AND INSTALLATIONBELLY PAN,
Fig 1: Oil Pressure Sensor Harness Connector

Fig 2: Oil Pressure Sensor
DIESEL HIGH PRESSURE > INSTALLATION
Fig 1: Oil Pressure Sensor
SPECIFICATIONS .
2. Connect oil pressure sensor wire harness connector.
DIESEL WARNING LIGHT > REMOVAL
Fig 1: Glow Plug Module & Nut
3. Remove the nut (1a) and position aside the glow plug module (1b).
Fig 2: Powertrain Control Module (PCM) Wire Harness Connectors, Differential Pressure
Sensor & Nuts
4. Disconnect the Powertrain Control Module (PCM) wire harness connectors (1a, 1b).
5. Remove the nuts (3a) and position aside the Differential Pressure Sensor (DPS) (3b) with
bracket.
Fig 3: Ground Wire Nut, Power Transfer Unit (PTU) Wire Harness Connector, PCM Wire
Harness & Clamps, PCM Mounting Bracket & Bolts/Nuts
6. Remove the nut (1a) and the ground wire.
7. Disengage from the holder and disconnecting the Power Transfer Unit (PTU) wire harness
connector (2a).
8. Open the clamps (3a) and unhook the PCM wire harness (3b) from the PCM mounting bracket
(3c).
9. Remove the nuts (4a) and the bolts (4b) and the PCM with mounting bracket (3c).
10. Disconnect oil pressure sensor harness connector (1a).
11. Remove oil pressure sensor (1b).
DIESEL WARNING LIGHT > INSTALLATION
SPECIFICATIONS .
3. Install the PCM with mounting bracket and securely tighten the nuts and bolts.
4. Install the PCM wire harness into the PCM mounting bracket wire harness retainer and close
the clamp.
5. Connecting the PTU wire harness connector and attach to holder.
6. Install the ground wire and securely tighten the nut.
7. Connect the PCM wire harness connectors.
8. Install the DPS with bracket and securely tighten the nut.
9. Install the glow plug module and securely tighten the nut.

DIESEL HIGH PRESSURE > REMOVAL

6. Remove oil pressure sensor (2).
DIESEL HIGH PRESSURE > INSTALLATION
SPECIFICATIONS .
LUBRICATION > PUMP, ENGINE OIL > REMOVAL AND INSTALLATION > 1.6L-2.0L >
REMOVAL
1. Remove the timing drive gear. Refer to CHAIN AND SPROCKETS, TIMING, REMOVAL AND
INSTALLATION .
Fig 1: Oil Pump Solenoid Electrical Connector, Oil Pump To Engine Block Bolts & Oil Pump
2. Disconnect the oil pump solenoid electrical connector (1).
3. Remove the oil pump to engine block bolts (2a) and remove the oil pump (2b).
Fig 2: Oil Pump Front Oil Seal
4. Remove the oil pump front oil seal (1).

Fig 3: Oil Pump Gasket & Oil Pump Intake Seal
5. Remove the oil pump gasket (1).
6. Remove the oil pump intake seal (2).
LUBRICATION > PUMP, ENGINE OIL > REMOVAL AND INSTALLATION > 1.6L-2.0L >
INSTALLATION
Fig 1: Oil Pump Gasket & Oil Pump Intake Seal
1. Install a NEW oil pump gasket (1) and intake seal (2).
2. Install the oil pump onto the engine and tighten the oil pump to engine block bolts to the proper
3. Install a NEW front oil seal with tool 2000004100.
4. Connect the oil pump solenoid electrical connector.
5. Install the timing drive gear. Refer to CHAIN AND SPROCKETS, TIMING, REMOVAL AND
INSTALLATION .
LUBRICATION > REGULATOR, OIL PRESSURE > REMOVAL AND INSTALLATION >
1.6L/2.0L DIESEL > REMOVAL
2. Remove the support and lower the vehicle. Refer to HOISTING, STANDARD PROCEDURE .
4. Remove the right wheel house splash shield. Refer to SHIELD, SPLASH, FRONT

INSTALLATION .
Fig 1: Oil Pressure Regulator & Wire Harness Connector

7. Disconnect oil pressure regulator wire harness connector (1).
8. Remove bolt (2a) and oil pressure regulator (2b).
LUBRICATION > REGULATOR, OIL PRESSURE > REMOVAL AND INSTALLATION >
1.6L/2.0L DIESEL > INSTALLATION
1. Replace the oil pressure regulator (1) and clean and inspect the inlet screen (3).
2. Using a NEW O-ring seal, install oil pressure regulator and tighten the bolt to the proper
3. Connect oil pressure regulator wire harness connector.
4. Install the vibration damper. Refer to DAMPER, VIBRATION, REMOVAL AND INSTALLATION .
6. Install the right wheel house splash shield. Refer to SHIELD, SPLASH, FRONT
7. Install the right front wheel and tire. Refer to REMOVAL AND INSTALLATION .
TURBOCHARGER SYSTEM > COOLER AND HOSES, CHARGE AIR > REMOVAL AND
INSTALLATION > 2.0L DIESEL 120/140 CV > REMOVAL
2. Remove the from bumper fascia. Refer to FASCIA, FRONT .

Fig 1: Bumper Reinforcement, Bolts & Nuts
3. Remove the bolts (1a) and nuts (1b) bumper reinforcement (1c).
Fig 2: Charge Air Cooler (CAC) & Bolts
4. Remove bolts (1) from Charge Air Cooler (CAC).

Fig 3: Air Duct & Tabs
5. Release the tabs (1) to disengage and remove the air duct.
Fig 4: Right Charge Air Cooler (CAC) Hose & Clamp
6. Loosen clamp (1) and remove right the CAC hose.

Fig 5: Left Charge Air Cooler (CAC) Hose Quick Connect Fitting
7. Disconnect the left CAC hose quick connect fitting (1).

Fig 6: A/C Lines & Retaining Clips
8. Open the retaining clips and disconnect the A/C lines.

Fig 7: Air Cleaner Outlet Tube & Nut
9. Remove the nut (1) and the air cleaner tube.

Fig 8: Tabs Located At A/C Condenser
10. Release the tabs (1) and position aside the A/C condenser without disconnecting the lines.
Fig 9: Charge Air Cooler (CAC) & Tabs
11. Disengage the tabs and remove the CAC (1).
12. Remove the isolator blocks.
INSTALLATION > 2.0L DIESEL 120/140 CV > INSTALLATION
1. Install NEW isolator blocks.
2. Install the CAC and engage the lock tabs.
3. Install the A/C condenser and engage the lock tabs.
4. Install the air cleaner tube and securely tighten the nut.
5. Connect the A/C lines into retaining clips and close the clips.
6. Connect the left CAC hose quick connect fitting.
7. Install the right CAC hose and securely tighten the clamp.
8. Install the air duct and engage the lock tabs.

9. Install the CAC bolts and securely tighten.
Fig 1: Bumper Reinforcement, Bolts & Nuts
10. Install the bumper reinforcement (1a) and tighten the bolts (1c) and nuts (1b) to the proper
11. Install the front fascia. Refer to FASCIA, FRONT ,
INSTALLATION > 2.0L DIESEL 170 CV > REMOVAL
NOTE:
The cooling fan is integrated into the front radiator closure panel and can be removed
separately.

4. Recover the A/C refrigerant. Refer to PLUMBING, STANDARD PROCEDURE .
5. Remove the front bumper fascia. Refer to FASCIA, FRONT, REMOVAL AND INSTALLATION .
Fig 1: Air Tube & Nut
6. Working on the right side, remove the nut (1a) and the air tube (1b).
Fig 2: Front Energy Absorber & Bolts, Front Bumper Reinforcement & Nuts
7. Remove the bolts (1a) and front energy absorber (1b).
8. Remove the three nuts (2a) and the front bumper reinforcement (1b).
Fig 3: Air Duct & Bolts, Seats & Retainers & Air Cooler
9. Remove the bolts (1a) securing the air duct (1b).
10. Release the retainers (2a) from the seats (2b) of the front end.
11. Remove the air cooler (1b).

Fig 4: Transmission Oil Cooler Pipes & Retaining Clamps, Transmission Oil Cooler & Retaining
Clips
12. Open the retaining clamps (1a) securing the transmission oil cooler pipes (1b).
NOTE:
Install plugs to seal the fittings disconnected to prevent the entrance of moisture
and impurities in the system.
13. Carefully disengage the retainer clips (2a) and disconnect the pipes (1b) from the transmission
oil cooler (2c). Recover oil drops leaking from the pipes and fittings.
Fig 5: Bolts, Fitting, Pipes & Connections At Condenser
NOTE:
14. Unscrew the bolts (1a) and disconnect the fittings (1b) and (1c) of the pipes (1d) connection to
the condenser (1e).
Fig 6: Transmission Cooler, Mounts & Bolts
15. Remove the bolts (1a) and the transmission cooler (1b) from mounts (1c).
Fig 7: A/C Condenser, Mounts & Bolts
16. Remove the bolts (1a) and the A/C condenser (1b) from the mounts (1c).
Fig 8: Hose & Clamp At Charge Air Cooler (CAC)
17. Working on the lower right side of the radiators, open the clamp (1a) and disconnect the hose
(1b) from the Charge Air Cooler (CAC).
Fig 9: Spring Retainer, Quick Connect Coupling & Charge Air Cooler (CAC) Hose
18. Working on the lower right side of the radiators, disengage the spring retainer (1a) and
disconnect the quick connect coupling (1b) and remove the CAC hose (1c).
Fig 10: Charge Air Cooler (CAC), Bolts & Retaining Pins
19. Remove the bolts (1a) securing the CAC.
20. Lift up on CAC to disengage retaining pins (2a) and remove the CAC.
INSTALLATION > 2.0L DIESEL 170 CV > INSTALLATION
1. Inspect the CAC for damage
2. Install the CAC into the lower retaining pins.
3. Install the bolts securing the CAC and securely tighten.
4. Working on the lower left side of the radiator, connect the CAC quick coupling cooler hose onto
the CAC, then engage the retaining clip.
5. Working on the lower right side of the radiator, connect the CAC cooler hose to the CAC and
securely tighten the clamp.
Fig 1: A/C Condenser, Mounts & Bolts
6. Install the A/C condenser (1b) into the mounts (1c) and securely tighten the bolts (1a).
Fig 2: Transmission Cooler, Mounts & Bolts
7. Install the transmission cooler (1b) from mounts (1c) and securely tighten the bolts (1a).
NOTE:
Replace the O-ring sealing fittings. Use only O-ring seal washer with part HNBR
elastomeric material resistant to refrigerant R1234 yf. The use of rings seal washer
with other elastomeric material is liable to give serious losses of refrigerant from the
air conditioner.
8. Using NEW O-ring sealing washers, connect the fittings (1a) and (1b) of the pipes (1c) to the
condenser (1d). Tighten the bolts (1e) to the proper specification. Refer to SPECIFICATIONS .
Clips
9. Connect the pipes (1a) to the fittings (1b) on the transmission oil cooler (1c), then engage the
retaining clips (1d).
10. Close the retainer clips (2a) securing the transmission oil cooler pipes (1a).
11. Install the air cooler (1a) and engage the retainers (1b) in the seats (1c).
12. Install the bolts (2a) securing the air cooler (1a) and securely tighten the bolts.
13. Install the front energy absorber (1a) and securely tighten the three nuts (1b).
14. Tighten the front bumper reinforcement bolts (2a) to the proper specification. Refer to
SPECIFICATIONS .
15. Working on the right side, install the tube and securely tighten the nut.
16. Check the automatic transmission fluid level and fill with the recommended transmission fluid.
Refer to CAPACITIES AND RECOMMENDED FLUIDS, SPECIFICATIONS .
17. Install the front bumper cover.
18. Remove support and lower the vehicle.
19. Evacuate and charge the A/C system. Refer to PLUMBING, STANDARD PROCEDURE .
TURBOCHARGER SYSTEM > SENSOR, TURBO BOOST PRESSURE > REMOVAL AND
INSTALLATION .
2. Disconnect the electrical connection of the turbo boost pressure sensor (1).
Fig 1: Turbo Boost Pressure Sensor & Bolt
3. Remove the screw and remove the turbo boost pressure sensor (1).
TURBOCHARGER SYSTEM > SENSOR, TURBO BOOST PRESSURE > REMOVAL AND
Fig 1: Turbo Boost Pressure Sensor Electrical Connection
1. Install the pressure sensor to the seat and tighten the screw.
2. Connect the electrical connector to the pressure sensor.
TURBOCHARGER SYSTEM > TURBOCHARGER > REMOVAL AND INSTALLATION >

TURBOCHARGER 1.6L > REMOVAL
1. Remove the air intake tube.
Fig 1: Turbocharger Oil Drain Tube To Turbo Bolts
3. Remove the turbocharger oil drain tube to turbo bolts (1).

Fig 2: Turbocharger Oil Drain Tube To Engine Block Bolts
4. Remove the turbocharger oil drain tube to engine block bolts (1), and remove the tube.
Fig 3: Air Outlet Tube To Intercooler, Air Outlet Tube Support Bracket Bolt & Turbocharger Air
Outlet Tube Bolts
5. Disconnect the air outlet tube to the intercooler (1).
6. Remove the air outlet tube support bracket bolt (2).
7. Remove the turbocharger air outlet tube bolts and disconnect tube (3).
Fig 4: Turbocharger Vanes Actuator Hose & Turbocharger Variable Geometry Vanes Position
Sensor Electrical Connector
8. Disconnect the turbocharger vanes actuator hose (1).
9. Disconnect the turbocharger variable geometry vanes position sensor electrical connector (2).
Fig 5: Lower Turbocharger To Exhaust Manifold Nuts
10. Remove the lower turbocharger to exhaust manifold nuts (1).

Fig 6: Injector Wiring Loom Bolts & Fuel Injector Electrical Connectors
11. Remove the injector wiring loom bolts (1a), and disconnect the fuel injector electrical
connectors (1b).
Fig 7: Turbocharger Oil Feed Line Banjo Bolts
12. Remove the turbocharger oil feed line banjo bolts (1), and remove the turbo oil feed line.
Fig 8: Upper Turbocharger To Exhaust Manifold Nut
13. Remove the upper turbocharger to exhaust manifold nut (1), and remove the turbo.

TURBOCHARGER 1.6L > INSTALLATION
Fig 1: Upper Turbocharger To Exhaust Manifold Nut
1. Install a NEW turbocharger to exhaust manifold gasket.
2. Install the turbocharger onto the exhaust manifold, and tighten the upper turbocharger to
exhaust manifold nut (1) to the proper specification. Refer to TORQUE SPECIFICATIONS .
Fig 2: Turbocharger Oil Feed Line Banjo Bolts
3. Install and tighten the turbocharger oil feed line banjo bolts to the proper specification. Refer to
4. Connect the fuel injector electrical connectors, and tighten the injector wiring loom bolts.
5. Install and tighten the lower turbocharger to exhaust manifold nuts to the proper specification.
6. Connect the turbocharger variable geometry vanes position sensor electrical connector.
7. Connect the turbocharger vanes actuator hose.
8. Install the turbocharger air outlet tube and tighten the bolts.
9. Install and tighten the air outlet tube support bracket bolt.
10. Connect the air outlet tube quick connect coupling.

11. Install a NEW O-ring on the turbo oil drain tube at the block.
12. Install and tighten the turbocharger oil drain tube to engine block bolts (1b) to the proper
13. Install a NEW flange gasket on the turbo oil drain tube at the turbocharger.
14. Install and tighten the turbocharger oil drain tube to turbo bolts (1b) to the proper specification.
AND INSTALLATION .
16. Install the air intake tube.

TURBOCHARGER 2.0L 120CV/140CV > REMOVAL
3. Remove the turbocharger oil drain tube to turbo bolts (1a).

4. Remove the turbocharger oil drain tube to engine block bolts (1a), and remove the tube (1b).
Fig 3: Turbocharger Air Outlet Tube & Bolts

Fig 4: Turbocharger Oil Feed Line Banjo Bolt & Upper Turbocharger To Exhaust Manifold Nut
7. Remove the turbocharger oil feed line banjo bolt (1).
8. Remove the upper turbocharger to exhaust manifold nut (2).

Fig 5: Variable Geometry Actuator Electrical Connector
9. Disconnect the variable geometry actuator electrical connector (1).

Fig 6: Turbocharger & Gasket
10. Remove the turbocharger (1).
11. Remove the gasket (2).

TURBOCHARGER 2.0L 120CV/140CV > INSTALLATION
1. Install the turbocharger with NEW gasket onto the exhaust manifold.
2. Connect the variable geometry actuator electrical connector.

Fig 1: Turbocharger Oil Feed Line Banjo Bolt & Upper Turbocharger To Exhaust Manifold Nut
3. Tighten the upper turbocharger to exhaust manifold nut (1) to the proper specification. Refer to
4. Install and tighten the turbocharger oil feed line banjo bolt (2) to the proper specification. Refer
5. Tighten the lower turbocharger to exhaust manifold nuts to the proper specification. Refer to
6. Connect the turbocharger air outlet tube and tighten bolts.

8. Install and tighten the turbocharger oil drain tube to engine block bolts (1b) to the proper
10. Install and tighten the turbocharger oil drain tube to turbo bolts (1b) to the proper specification.
AND INSTALLATION .

TURBOCHARGER 2.0L 170CV > REMOVAL
Fig 1: Variable Geometry Actuator Electrical Connector
3. Disconnect the variable geometry actuator electrical connector (1).

Fig 2: Turbocharger Oil Feed Line & Banjo Bolts
4. Remove the turbocharger oil feed line banjo bolts (1), and remove the line.
5. Remove the engine oil dipstick tube.

Fig 3: Air Outlet Tube Support Bracket Bolt & Turbocharger Air Outlet Tube Bolts
6. Remove the air outlet tube support bracket bolt (1).
Fig 4: Turbocharger Oil Drain Tube To Turbo Bolts & Engine Block Bolts
8. Remove the turbocharger oil drain tube to turbo bolts (1).
9. Remove the turbocharger oil drain tube to engine block bolts (2), and remove the tube.

Fig 6: Upper Turbocharger To Exhaust Manifold Nuts
11. Remove the upper turbocharger to exhaust manifold nuts (1).

Fig 7: Turbocharger At Exhaust Manifold
12. Remove the turbocharger from the exhaust manifold (1).

Fig 8: Turbocharger To Exhaust Manifold Gasket
13. Remove the turbocharger to exhaust manifold gasket.

TURBOCHARGER 2.0L 170CV > INSTALLATION
Fig 1: Upper Turbocharger To Exhaust Manifold Nuts
1. Install a NEW turbocharger to exhaust manifold gasket.
2. Install the turbocharger onto the exhaust manifold, and tighten the upper turbocharger to
exhaust manifold nut (1) to the proper specification. Refer to TORQUE SPECIFICATIONS .
Fig 2: Lower Turbocharger To Exhaust Manifold Bolts
3. Install and tighten the lower turbocharger to exhaust manifold bolts (1) to the proper
Fig 3: Turbocharger Oil Drain Tube To Turbo Bolts & Engine Block Bolts
5. Install and tighten the turbocharger oil drain tube to engine block bolts (1) to the proper
7. Install and tighten the turbocharger oil drain tube to turbo bolts (2) to the proper specification.
8. Install the turbocharger air outlet tube and tighten the bolts.
9. Install and tighten the air outlet tube support bracket bolt.
10. Install the engine oil dipstick tube.

Fig 4: Turbocharger Oil Feed Line & Banjo Bolts
11. Install and tighten the turbocharger oil feed line banjo bolts to the proper specification. Refer to
12. Connect the variable geometry actuator electrical connector.
AND INSTALLATION .
VALVE TIMING > STANDARD PROCEDURE > 1.6L-2.0L - VALVE TIMING

VERIFICATION
2. Remove the tool used to loosen the screws securing the crankshaft pulley.
Fig 1: Threaded Cap On Cylinder Head Cover
3. Remove the threaded cap (2) from the cylinder head cover.
Fig 2: Installing Camshaft Timing Tool At Intake Side
4. Install the tool 1870896900 timing camshafts, intake side (1).
NOTE:
Check the correct insertion of the tool into its seat on the intake side by rotating the
crankshaft until the tools spring pin clicks into the correct location on the camshaft.
Fig 3: Locating Bolt At Bottom Right Location Of Engine Front Cover
5. Remove the screw (1) from the bottom right location of the engine front cover.
Fig 4: Mounting Special Tool To Verify Engine Timing
6. Mount the tool 2000003000 (1) to verify the engine timing.
NOTE:
Rotate the crankshaft timing belt pulley with small movements to allow insertion of
the dowel pin through the hole on the tool.
7. Remove the engine timing tools.
8. Install a new bolt in the bottom right location of the engine front cover and tighten to the proper
9. Mount the screw cap complete with new O-ring on the cylinder head cover and tighten to the
VALVE TIMING > BELT, TIMING > REMOVAL AND INSTALLATION > 1.6L REMOVAL
NOTE:
When replacing the timing belt, connect the diagnostic tool, enter "Diagnosis active" and run
the self-learning procedure.
INSTALLATION .
6. Remove the crank pulley. Refer to DAMPER, VIBRATION, REMOVAL AND INSTALLATION .
Fig 1: Accessory Drive Belt Tensioner, Accessory Drive Belt Pulley & Bolts
7. Disconnect the quick coupling of the discharge pipe to the turbocharger oil vapor.
8. Loosen the air hose clamp and remove the suction hose from the turbocharger.
9. Remove the bolt (1) and remove the accessory drive belt tensioner.
10. Remove the bolt (2) and remove the accessory drive belt pulley.
11. Place a hoist arm under the engine.
12. Remove the screws (1a), (1b) and remove the right engine mount isolator (1c).
13. Remove the screws (1a) and remove the right engine mount bracket (1b).
Fig 4: Protective Cover & Bolts
14. Remove the screws (1a) and remove the protective cover (1b).
Fig 5: Fuel Pressure Sensor Electrical Connection & Screw Cap
15. Remove the tool used to remove the fastening screws on the crankshaft pulley services.
16. Disconnect the electrical connection of the fuel pressure sensor (1).
17. Remove the screw cap from the top head to gauge timing.
Fig 6: Oil Vapor Discharge Rigid Pipe Fixing Bolts
18. Remove the engine oil vapor discharge rigid pipe fixing screws (1).
19. Fit the camshafts timing tool 187096900 (1), intake side.
NOTE:
Check the correct insertion of the tool in its seat on the suction distribution side,
rotating the crankshaft until it clicks the correct insertion of the pin spring on the
shaft of the seated tool.
Fig 8: Front Cover Bottom Right Base Bolt
20. Remove the front cover bottom right base screw (1).
Fig 9: Temporarily Installing Special Tool To Verify Engine Timing
21. Temporarily install the tool 2000003000 to verify the timing of the engine.
NOTE:
When inserting the timing belt dowel pin in the hole on the tool, turn the crankshaft
pulley with small movements.
22. Remove the special tool 1870815000 for placing the crankshaft in time.
Fig 10: Timing Belt Tensioner, Bolt & Timing Belt
23. Loosen the screw securing timing belt tensioner (1).
24. Pry off and remove the timing belt (2).

Fig 11: Loosening Bolt Securing Pulley Using Special Tool
25. With tool 1870836000 (1a) loosen the screw (1b) securing pulley (1c).
NOTE:
When the belt must be handled and mounted, avoid creating bends at an acute angle. This
can compromise the structure of the belt, as the stresses induced by excessive bending
could result in damage to the fibers inside the belt, which could cause premature failure of
the belt during operation of the engine.
NOTE:
NOTE:
NOTE:
With crankshaft timed, fit the timing belt as described below.

Fig 2: Positioning Timing Belt On Crankshaft Gear, Ensuring To Align Notch With Yellow Reference,
Located Near Two Yellow Arrows On Timing Belt
1. Position the timing belt (1a) on the crankshaft gear, making sure to align the notch (1b) with the
yellow reference (1c). The yellow reference (1c) is located near the two yellow arrows (a) on
the timing belt.
Fig 3: Fitting Timing Belt On Pressure Pump Gear, Taking Care To Match Yellow Reference
With Notch On Gear
2. Fit the timing belt on pressure pump gear, taking care to match the yellow reference (1a) with
the notch (1b).
Fig 4: Fitting Timing Belt On Gear, Taking Care To Match Yellow Reference With Notch On
Gear
3. Completely fit the timing belt on the gear, taking care to match the yellow reference (1a) with
the notch (1b).
4. Fit the tool 187096900 for the timing of the engine.

Fig 5: Spring, Tensioner & Bolt
5. Pry with a screwdriver on the spring (1a) until the index of the tensioner (1b) is in the position
of maximum tension and then tighten the new bolt (1c) to the proper specification. Refer to
6. Remove timing gear tool.
7. Tighten the screw securing the pulley to the proper specification. Refer to TORQUE
SPECIFICATIONS .
8. Turn the crankshaft two turns to seat the timing belt.
9. Loosen the screw securing the timing belt tensioner.

Fig 6: Spring, Index, Hole & Bolt
10. Pry with a screwdriver on the spring (1a) until the index (1b) position is at the hole (1c) and
tighten the new bolt (1d) to the proper specification. Refer to TORQUE SPECIFICATIONS .
11. Make two turns of the crankshaft to seat the timing belt.
12. Recheck for correct engine gear timing.
13. Tighten the new bolt at the bottom right of the front cover base to the proper specification.
14. Tighten the engine oil vapor discharge rigid pipe to the turbocharger mounting screws.
15. Install the suction hose air from the turbocharger and tighten the clamps.
16. Connect the discharge pipe quick coupling to the turbocharger oil vapor.
17. Install the threaded plug complete with new O-ring on the upper head template for timing and
tighten it to the proper specification. Refer to TORQUE SPECIFICATIONS .
18. Connect the fuel pressure sensor electrical connector.

19. Install the right engine mounting bracket (1a). Tighten the screws (1b) to the proper
20. Install the protective cover and tighten the screws.

21. Install the right engine mount isolator (1a), tighten the screws (1b) and (1c) to the proper
22. Remove the hoist arm.

Fig 9: Accessory Drive Belt Tensioner, Accessory Drive Belt Pulley & Bolts
23. Install the accessory drive belt tensioner (1) and tighten the bolt to the proper specification.
24. Install the accessory drive belt pulley (2) and tighten the bolt to the proper specification. Refer
25. Install the air suction from the turbocharger and tighten the clamps.
26. Connect the quick coupling of the oil vapor discharge pipe to the turbocharger.
.
28. Install the crank pulley. Refer to DAMPER, VIBRATION, REMOVAL AND INSTALLATION .
NOTE:
5. Remove the accessory drive belt Refer to BELT, SERPENTINE, REMOVAL AND
INSTALLATION .
7. Disconnect the quick coupling of the discharge pipe to the turbocharger oil vapor.
8. Loosen the air hose clamp and remove the suction hose from the turbocharger.
Fig 1: Timing Belt Lower Guard & Bolts
9. Remove the screws (1a) and remove the timing belt lower guard (1b).
Fig 2: Accessory Drive Belt Pulley, Accessory Drive Belt Tensioner & Bolts
10. Remove the bolt (1a) and remove the accessory drive belt pulley (1b).
11. Remove the bolt (2a) and remove the accessory drive belt tensioner (2b).
12. Place a suitable hydraulic lift under the engine.
13. Remove the screws (1a), (1b) and remove the right engine mount isolator (1c).
Fig 4: Timing Belt Top Cover & Bolts
14. Remove the screws (1) and remove the top cover of the timing belt.
15. Remove the screws (1a) and remove the engine mounting bracket, timing side (1b).
16. Remove the fastening screws on crankshaft pulley using special tool 2000003000.
Fig 6: Fuel Pressure Sensor Electrical Connection & Cap
18. Remove the cap (2) for mounting the camshaft timing template, intake side.
Fig 7: Oil Vapor Discharge Rigid Pipe Fixing Bolts
19. Remove the engine oil vapor discharge rigid pipe fixing screws (1).
20. Fit the camshafts timing tool 187096900 (1), intake side.
NOTE:
Check the correct insertion of the tool in its seat on the suction distribution side,
rotating the crankshaft until it clicks the correct insertion of the pin spring on the
shaft of the seated tool.
Fig 9: Temporarily Installing Special Tool To Verify Engine Timing
21. Unscrew the crankshaft bolt and mount special tool 2000003000 to keep the correct timing of
the crankshaft.
22. Temporarily install the tool 2000003000 to verify the timing of the engine.
NOTE:
When inserting the timing belt dowel pin in the hole on the tool, turn the crankshaft
pulley with small movements.
23. Remove the special tool 1870815000 for placing the crankshaft in time.
Fig 10: Timing Belt Tensioner Bolt & Timing Belt
24. Loosen the screw securing timing belt tensioner (1).
25. Pry off and remove the timing belt (2).

Fig 11: Loosening Bolt Securing Pulley Using Special Tool
26. With tool 1870836000 (1a) loosen the screw (1b) securing pulley (1c).
NOTE:
NOTE:
NOTE:
NOTE:
With crankshaft timed, fit the timing belt as described below.

Fig 2: Positioning Timing Belt On Crankshaft Gear, Ensuring To Align Notch With Yellow Reference,
Located Near Two Yellow Arrows On Timing Belt
1. Position the timing belt (1a) on the crankshaft gear, making sure to align the notch (1b) with the
yellow reference (1c). The yellow reference (1c) is located near the two yellow arrows (a) on
the timing belt.
Fig 3: Fitting Timing Belt On Pressure Pump Gear, Taking Care To Match Yellow Reference
With Notch On Gear
2. Fit the timing belt on pressure pump gear, taking care to match the yellow reference (1a) with
the notch (1b).
Fig 4: Fitting Timing Belt On Gear, Taking Care To Match Yellow Reference With Notch On
Gear
3. Completely fit the timing belt on the gear, taking care to match the yellow reference (1a) with
the notch (1b).
4. Fit the tool 187096900 for the timing of the engine.

Fig 5: Spring, Tensioner & Bolt
5. Pry with a screwdriver on the spring (1a) until the index of the tensioner (1b) is in the position
of maximum tension and then tighten the new bolt (1c) to the proper specification. Refer to
6. Remove timing gear tool.
7. Tighten the screw securing the pulley to the proper specification. Refer to TORQUE
SPECIFICATIONS .
8. Turn the crankshaft two turns to seat the timing belt.
9. Loosen the screw securing the timing belt tensioner.

Fig 6: Spring, Index, Hole & Bolt
10. Pry with a screwdriver on the spring (1a) until the index (1b) position is at the hole (1c) and
tighten the new bolt (1d) to the proper specification. Refer to TORQUE SPECIFICATIONS .
11. Make two turns of the crankshaft to seat the timing belt.
12. Recheck for correct engine gear timing.
13. Tighten the new bolt at the bottom right of the front cover base to the proper specification.
14. Tighten the engine oil vapor discharge rigid pipe to the turbocharger mounting screws.
15. Install the suction hose air from the turbocharger and tighten the clamps.
16. Connect the discharge pipe quick coupling to the turbocharger oil vapor.
17. Install the threaded plug complete with new O-ring on the upper head template for timing and
tighten it to the proper specification. Refer to TORQUE SPECIFICATIONS .
18. Connect the fuel pressure sensor electrical connector.

Fig 7: Engine Mounting Bracket & Bolts
19. Install the engine mounting bracket (1a), timing side (1a). Tighten the screw (1b) to the proper
20. Install the protective cover and tighten the screws.

21. Install the right engine mount isolator (1a), tighten the screws (1b) and (1c) to the proper
24. Install the accessory drive belt pulley and tighten the bolt to the proper specification. Refer to
25. Install the timing belt lower guard and tighten the screws.
26. Install the air suction from the turbocharger and tighten the clamps.
27. Connect the quick coupling of the oil vapor discharge pipe to the turbocharger.
.
VALVE TIMING > CHAIN AND SPROCKETS, TIMING > REMOVAL AND INSTALLATION
> 1.6L - 2.0L CAMSHAFT SPROCKET > REMOVAL
Fig 1: Camshaft Gear & Bolt
1. The screw (1a) was loosened during the procedure of the timing belt, so unscrew it completely
and then remove the camshaft gear (1b).
Fig 2: Front Camshaft Oil Seal
2. Pry and remove the front camshaft oil seal (1).
NOTE:
The operation to remove the oil seal is destructive, so it is always necessary to

replace it. Be careful not to damage the seat of the oil seal during its removal.
> 1.6L - 2.0L CAMSHAFT SPROCKET > INSTALLATION
Fig 1: Installing New Front Camshaft Oil Seal Using Special Tool
1. Install a new front camshaft oil seal (1a) using the special tool 1870896800 (1b).
2. Install the camshaft gear pulley (1a) and secure it with the screw (1b) without tightening the
screw. The screw will be tightened during the timing belt procedure.

2. The screw (1a) was loosened during the procedure of the timing belt, so unscrew it completely
and then remove the camshaft gear (1b).
Fig 4: Front Camshaft Oil Seal
3. Pry and remove the front camshaft oil seal (1).
NOTE:
The operation to remove the oil seal is destructive, so it is always necessary to

replace it. Be careful not to damage the seat of the oil seal during its removal.
> 1.6L CRANKSHAFT SPROCKET > REMOVAL
1. Temporarily install the engine mounting bracket, timing side and remove the lift arm used for the
detachment of the timing belt.
Fig 1: Lower Flywheel Guard & Bolts
3. Remove the nuts and remove the lower flywheel guard (1).
4. Install the tool 1860898000 (1).

Fig 3: Crankshaft Pulley & Bolt
5. Remove the screw clockwise (1a) and remove the crankshaft pulley (1b).
Fig 4: Crankshaft Front Cover Oil Seal
6. Pry and remove the crankshaft front cover oil seal (1).
NOTE:
Be careful not to damage the seat of the oil seal during its removal. The operation
to remove the oil seal is destructive, so it is always necessary to replace it.
> 1.6L CRANKSHAFT SPROCKET > INSTALLATION
1. Using tool 1870896800, install a new crankshaft front cover oil seal.
2. Put into place the crankshaft pulley (1a) and tighten the screw (1b) to the proper specification.
4. Install the flywheel lower guard and tighten the nuts.
> 2.0L 120CV - 140CV CRANKSHAFT SPROCKET > REMOVAL

NOTE:
> 2.0L 120CV - 140CV CRANKSHAFT SPROCKET > INSTALLATION
> 2.0L 170CV CRANKSHAFT SPROCKET > REMOVAL
3. Remove the hydraulic jack previously placed under the engine.


NOTE:
> 2.0L 170CV CRANKSHAFT SPROCKET > INSTALLATION
VALVE TIMING > CHAIN AND SPROCKETS, TIMING > INSPECTION > INSPECTION
Fig 1: Measuring Distance From Tensioner Body To Edge Of Chain Guide
Inspect the timing chain for stretching prior to removal.
Rotate the engine while watching timing chain tensioner plunger. When the plunger reaches its
maximum extension, stop rotating engine.
Measure the distance from the tensioner body to the edge of the chain guide as shown in
illustration.
If the distance is greater than 20.5 mm (0.81 in.) inspect the guide shoes for excessive wear.
If the guide shoes are not excessively worn, replace the timing chain.
VALVE TIMING > PULLEY, TIMING BELT IDLER > REMOVAL AND INSTALLATION >
2.0L TIMING BELT IDLER PULLEY > REMOVAL
Fig 1: Tensioner & Bolt
2. Remove the screw (1a) and remove the tensioner (1b).
VALVE TIMING > PULLEY, TIMING BELT IDLER > REMOVAL AND INSTALLATION >
2.0L TIMING BELT IDLER PULLEY > INSTALLATION
1. Install the tensioner (1a) and tighten the screw (1b) to the proper specification. Refer to
VALVE TIMING > TENSIONER, ENGINE TIMING > REMOVAL AND INSTALLATION >
1.6L - 2.0L TIMING BELT TENSIONER > REMOVAL
2. Fully unscrew the screw (1a) previously loose and remove the tensioner (1b).
1.6L - 2.0L TIMING BELT TENSIONER > INSTALLATION
1. Install the tensioner and secure it with the screw without tightening it to torque. Leave the
screw loose.
Service Manual: 1.6L GASOLINE ENGINE - SERVICE Jeep Renegade
INFORMATION
Fig 1: 4-Cylinder In-Line 1598 CC Engine
DESCRIPTION > DESCRIPTION > 1.6 TORQUE ENGINE
The 4-cylinder in-line 1598 cc engine, with 4 valves per cylinder, delivers a power of 110 HP and a toque
of 15 kgm.
The engine management with integrated electronic injection-ignition system is by Magneti Marelli.
The engine features the following characteristics:
Tappet cover made of plastic

Aluminum alloy head
Single overhead camshaft
Roller rocker arms
Cast-iron block
Cast-iron under-block
Oil sump made of aluminum alloys
Timing controlled by chain
Variable valve timing system
Hydraulic tappets

ENGINE PERFORMANCE DIAGNOSTIC TABLE
TESTING .

3. Faulty engine starting system. 3. Test the starting system. Refer


TESTING .
SPECIFICATIONS .

replace the fuel filter. Refer to
FILTER, FUEL, REMOVAL AND
INSTALLATION .
7. Incorrect engine oil level and The engine starting should not be
oil quality. effected if the oil level shows
level is off the dipstick, the oil
level could be contributing to the
startability issue.
change the oil and filter. Refer to
FILTER, ENGINE OIL, REMOVAL
AND INSTALLATION .
8. Long Stand Still Parking - Perform a long start procedure -

longer than 35 days. Crank engine for 10 seconds, let
sit for 5 seconds, crank for 10
seconds. May be necessary to
second break.

AND TESTING .

VALVE TIMING .
10. Faulty Camshaft Position Replace the Camshaft Position

(CMP) sensor. (CMP) sensor. Refer to SENSOR,
CAMSHAFT POSITION,
11. Faulty Crankshaft Position Replace the Crankshaft Position

(CKP) sensor. (CKP) sensor. Refer to SENSOR,
CRANKSHAFT POSITION,
ROUGH Codes (DTC). Refer to
appropriate Engine Electrical
Diagnostics article.

Codes (DTC). Refer to
appropriate Engine Electrical
Diagnostics article.
3. Vacuum leak. 3. Inspect intake manifold,

manifold gasket, and vacuum
hoses.
4. Faulty ignition coil(s). 4. Test and replace the ignition

coil. Refer to COIL, IGNITION,
5. Faulty Crankshaft Position 5. Replace the Crankshaft

(CKP) sensor. Position (CKP) sensor. Refer to
SENSOR, CRANKSHAFT
POSITION, REMOVAL AND
INSTALLATION .

VALVE TIMING .
INSTALLATION .

INSTALLATION .

4. Leaking cylinder head gasket. 4. Replace the cylinder head

gasket. Refer to CYLINDER
HEAD, REMOVAL AND
INSTALLATION .

as necessary. Refer to ENGINE
MECHANICAL DIAGNOSTIC
TABLE .

valves.

AND TESTING .


VALVE TIMING .

INSTALLATION .

the fuel filter. Refer to FILTER,
FUEL, REMOVAL AND
INSTALLATION .

valves.

INSTALLATION .

INSTALLATION .

TESTING .

ENGINE MECHANICAL DIAGNOSTIC TABLE
NOISY VALVES 1. High or low oil level in 1. Adjust the engine oil level.
crankcase. Refer to FILTER, ENGINE OIL,
2. Thin or diluted oil. 2. Change the engine oil and

filter. Refer to FILTER, ENGINE
OIL, REMOVAL AND
INSTALLATION .
3. Low oil pressure. 3. Check the oil pump. If OK,

check the rod and main bearings
for excessive wear. Refer to
4. Dirt in valve lash adjusters. 4. Replace as necessary. Refer

to LIFTER(S), HYDRAULIC,
5. Worn rocker arms. 5. Replace as necessary.
6. Worn valve lash adjusters 6. Replace as necessary. Refer

to LIFTER(S), HYDRAULIC,
7. Worn valve guides. 7. Inspect the valve guides for

wear, cracks or looseness. If
either condition exists, replace
the cylinder head. Refer to
CYLINDER HEAD, REMOVAL
AND INSTALLATION .
8. Excessive runout of valve 8. Replace as necessary.

seats or valve faces.
level. Refer to FILTER, ENGINE
OIL, REMOVAL AND
INSTALLATION .
2. Low oil pressure. 2. Check the engine oil pump. If

OK, check the rod and main
bearings for excessive wear.
Refer to STANDARD
PROCEDURE .

OIL, REMOVAL AND
INSTALLATION .
4. Excessive bearing clearance. 4. Replace as necessary).
5. Connecting rod journal out-of- 5. Service or replace the

round, rough surface or debris. crankshaft. Check the crankshaft
Obstructed oil feed hole. for plugged oil feed hole.
6. Misaligned connecting rods. 6. Replace the bent connecting

rods. Refer to ROD, PISTON
AND CONNECTING, REMOVAL
AND INSTALLATION .
level. Refer to FILTER, ENGINE
OIL, REMOVAL AND
INSTALLATION .
2. Low oil pressure. 2. Check the engine oil pump. If

OK, check the rod and main
bearings for excessive wear.
Refer to STANDARD
PROCEDURE .

OIL, REMOVAL AND
INSTALLATION .
4. Excessive bearing clearance. 4. Replace as necessary.

wear.
6. Crankshaft journal out-of round, 6. Service or replace the

rough or debris. Obstructed oil crankshaft. Check the engine
feed hole. block for plugged oil feed hole.
7. Loose flywheel, flexplate or 7. Tighten flexplate to the proper

SPECIFICATIONS . Tighten
flywheel to the proper
specification. Refer to
SPECIFICATIONS . Tighten
torque converter to the proper
specification. Refer to
SPECIFICATIONS .
NOTE:

NOTE:
NOTE:
diagnosis purposes.
1. If possible, for best results, the compression test should be performed on a warm engine.
reference.
three revolutions.
cylinders.
NOTE:
test.
NOTE:
question.
OFF.
CHART below.
necessary.
necessary.
AIR ESCAPES THROUGH Head gasket leaking or cracked Remove cylinder head and
RADIATOR cylinder head or block inspect. Replace defective part
MORE THAN 50% LEAKAGE Head gasket leaking or crack in Remove cylinder head and
FROM ADJACENT CYLINDERS cylinder head or block between inspect. Replace gasket, head, or
adjacent cylinders block as necessary
AND AIR ESCAPES THROUGH cracked piston; worn rings and/or Measure ring gap and cylinder
OIL FILLER CAP OPENING cylinder wall diameter, taper and out-of-round.
necessary
consumption, these procedures and tests apply to vehicles with 50,000 miles or less.
NOTE:
be delayed until vehicle has been driven at least 7,500 miles.
consumption.
NOTE:
CONSUMPTION TEST
NOTE:
and date.
leakage tester and following manufacturers suggested best practices. Refer to CYLINDER
COMPRESSION TEST and CYLINDER LEAKAGE TEST .
NOTE:
system.
9. Fuel Dilution
consumption:
4. Excessive idling
11. Oil Viscosity
than clean oil.
combustion chamber.

16. Lugging Engine
function.

ENGINE LUBRICATION DIAGNOSTIC TABLE


SPECIFICATIONS .

seal.
4. Crankshaft rear oil seal 4. Polish or replace the

surface scratched, nicked or crankshaft).
grooved.
5. Oil pan flange cracked. 5. Replace the oil pan. Refer to

PAN, OIL, REMOVAL AND
INSTALLATION .

crankshaft front oil seal. seal.

vibration damper hub front oil seal damper. Refer to DAMPER,
surface. VIBRATION, REMOVAL AND
INSTALLATION .
OIL PRESSURE DROP 1. Low oil level. 1. Check and correct the engine
oil level.
2. Faulty oil pressure sensor. 2. Replace the oil pressure

sensor. Refer to SENSOR, OIL
PRESSURE, REMOVAL AND
INSTALLATION .
3. Low oil pressure. 3. Check the main crankshaft

bearing clearance. Refer to
3. Check the rod bearing
clearance. Refer to STANDARD
PROCEDURE .
4. Clogged oil filter. 4. Replace the engine oil filter.


filter.
7. Excessive bearing clearance. 7. Replace the crankshaft

bearings.
7. Replace the rod bearings.
OIL PUMPING AT RINGS; SPARK 1. Worn or damaged rings. 1. Hone the cylinder bores and
PLUGS FOULING replace the piston rings. Refer to
Refer to RING(S), PISTON,
2. Carbon in oil ring slots. 2. Replace the piston rings. Refer

to RING(S), PISTON, REMOVAL
AND INSTALLATION .
3. Worn valve guides. 3. Replace the cylinder head.

Refer to CYLINDER HEAD,

Refer to VALVE GUIDES .
ENGINE OIL FILTER SWOLLEN 1. Obstructed or incorrect oil 1. Install new oil filter and test
OR BURST filter. engine oil pressure. Refer to
2. Engine oil viscosity incorrect. 2. Change engine oil and test

engine oil pressure. Refer to
3. Excessive engine oil pressure. 3. Replace engine oil pump. Refer

to PUMP, ENGINE OIL,

Fig 1: Covers/Caps

1 - ABRASIVE PAD
Metal scraper.
NOTE:
CAUTION:
NOTE:
SEALANT TYPES
date before use.
before use.

coolant.
SEALANT APPLICATION
location.
CAUTION:
foreign material.
cable.
7. Repair engine or components as necessary to prevent this problem from reoccurring.
CAUTION:
CAUTION:

GENERAL SPECIFICATIONS
SPECIFICATION
DESCRIPTION
Metric Standard
Type In-Line OHV, SOHC
Number of Cylinders 4
Firing Order 1-3-4-2
Compression Ratio 11.0:1
Maximum Engine Speed 5500 RPM
Displacement 1.6 L E-Torque (1598 cc) 97.6 cu. in.
Oil Capacity 4.3 L 4.5 qt.
Coolant Capacity 5.6 L 5.9 qt.
Maximum Power 81 kw @ 5500 RPM 110 hp @ 5500 RPM
Maximum Torque 152 N.m @ 4500 RPM 112 ft. lbs. @ 4500 RPM
Maximum Torque 15.5 Kg @ 4500 RPM 112 ft. lbs. @ 4500 RPM
Bore 77 mm 3.03 in.
Stroke 85.8 mm 3.37 in.
CYLINDER BLOCK
Metric Standard
Material Cast Aluminum
Cylinder Bore Diameter
Cylinder Bore Internal Diameter 76.993 - 77.007 mm 3.0312 - 3.0317 in.
Oversize inner diameter cylinder 0.010 mm 0.0003 in.

bore
Cylinder Bore Out-of-Round ± 0.005 mm ± 0.0001 in.
Cylinder Bore Taper ± 0.005 mm ± 0.0001 in.
Cylinder liner inner diameter 0.010 mm 0.0003 in.

oversize
CRANKSHAFT
SPECIFICATION
DESCRIPTION
Metric Standard
Connecting Rod Journal Diameter
Journal Grade
A (red) 1.480 - 1.484 mm 0.0582 - 0.0584 in.
B (blue) 1.485 - 1.489 mm 0.05846 - 0.0586 in.
C (yellow) 1.490 - 1.494 mm 0.0586 - 0.0588 in.
Oversized Connecting Rod

1.541 - 1.547 mm 0.0606 - 0.0609 in.
Half-Bearing Thickness
Main Bearing Journal Diameter
Journal Grade
1 1.980 - 1.984 mm 0.0779 - 0.0781 in.
2 1.984 - 1.988 mm 0.0781 - 0.0782 in.
3 1.989 - 1.993 mm 0.0783 - 0.0784 in.
Oversized Main Half-Bearing 2.105 - 2.111 mm 0.0828 - 0.0831 in.

Thickness
Clearance Between Main 0.015 - 0.034 mm

Bearings - Crankshaft Main 0.0005 - 0.0013 in.
Journals
Thrust Half-Washer Thickness 2.08 - 2.18 mm 0.0818 - 0.0858 in.
Crankshaft End Float 0.033 - 0.050 mm 0.00129 - 0.00196 in.
Main Journal Seat Diameter 51.997 - 52.007 mm 2.0471 - 2.0475 in.
Crankshaft Main Journal

47.992 - 48.008 mm 1.8894 - 1.8900 in.
Diameter
Crankshaft Diameter 43.992 - 44.008 mm 1.7319 - 1.7325 in.
Main Journal Diameter Undersize 0.127 mm 0.0049 in.
Crankshaft Diameter Undersize 0.127 mm 0.0049 in.
CONNECTING ROD
Metric Standard
Bearing Clearance Connecting

Rod Bearings - Crankshaft 0.021 - 0.037 mm 0.0008 - 0.0014 in.
Crankpins
Big End Inner Diameter 46.991 - 47.005 mm 1.8500 - 1.8505 in.
PISTONS
Metric Standard
Piston Diameter
Piston Outer Diameter 76.965 - 76.974 mm 3.0301 - 3.0304 in.
Piston Outer Diameter Oversize 0.40 mm 0.0157 in.
Permitted Weight Difference

±5g ± 0.1763 oz.
Between Pistons
Piston Outer Diameter Oversize 0.1 mm 0.0039 in.
PISTON RINGS
Metric Standard
Cylinder Compression 1st Sealing

0.2 mm 0.0070 in.
Ring Gap
Cylinder Compression 2nd

0.2 mm 0.0070 in.
Sealing Ring Gap
Engine Piston Oil Scraper Ring

0.25 mm 0.0088 in.
Gap

1.170 - 1.230 mm 0.0412 - 0.0433 in.
Ring Thickness

1.172 - 1.210 mm 0.0413 - 0.0426 in.
Sealing Ring Thickness
Piston Oil Scraper Ring

2.340 - 2.480 mm 0.0825 - 0.0874 in.
Thickness
Sealing Ring Seat in Piston - 1st

1.220 - 1.250 mm 0.0430 - 0.0440 in.
Groove
Sealing Ring Seat in Piston - 2nd
1.215 - 1.235 mm 0.0428 - 0.0435 in.
Groove
Sealing Ring Seat in Piston - 3rd

2.521 - 2.541 mm 0.0889 - 0.0896 in.
Groove

0.010 - 0.080 mm 0.0003 - 0.0028 in.
Ring End Float

0.025 - 0.063 mm 0.0008 - 0.0022 in.
Sealing Ring End Float
Engine Piston Oil Scraper Ring

0.041 - 0.201 mm 0.0014 -0.0070 in.
End Float
PISTON PINS
SPECIFICATION
DESCRIPTION
Metric Standard
Small End Piston Pin Housing

18.96 - 18.98 mm 0.7464 - 0.7472 in.
Diameter
Piston Pin-Small End Interference 0.020 - 0.045 mm 0.0007 - 0.0017 in.
Diameter of Piston Pin Housing

18.992 - 19.012 mm 0.7477 - 0.74850 in.
on the Piston
Gudgeon Pin Outer Diameter 18.995 - 19.000 mm 0.7478 - 0.7480 in.
Piston to Piston Pin Clearance 0.008 - 0.017 mm 0.0003 - 0.0006 in.
CYLINDER HEAD
Metric Standard
Material Cast Aluminum - Heat Treated
Cylinder head height 97 mm 3.4215 in.
Combustion chamber volume (cc) 31.6 - 33.0 cc
VALVE SEAT
Metric Standard
Valve Seat Band Angle in Contact

44°30' - 44°
With Inlet Valves
Valve Seat Band Angle in Contact
44°30' - 45°
With Exhaust Valves
VALVE GUIDE
Metric Standard
Valve Guide Seat Diameter 11.000 - 11.020 mm 0.4330 - 0.4338 in.
Valve Guide Inner Diameter 5.975 - 6.000 mm 0.2352 - 0.2362 in.
Valve Guide Outer Diameter 11.049 - 11.064 mm 0.4349 - 0.4355 in.
Valve Guide Outer Diameter

0.05/0.10/0.25 mm 0.0019/0.0039/0.0098 in.
Oversizes
Intake Valve/Valve Guide

0.023 - 0.066 mm 0.0009 - 0.0025 in.
Clearance
Exhaust Valve/Valve Guide

0.051 - 0.094 mm 0.0020 - 0.0037 in
Clearance
Interference Between Valve

0.029 - 0.064 mm 0.0011 - 0.0025 in.
Guides and Valve Guide Seats
VALVES
Metric Standard
Valve Outer Diameter
Intake 30.60 - 30.86 mm 1.2047 - 1.2149 in.
Exhaust 23.13 - 23.39 mm 0.9106 -0.9208 in.
Valve Stem Diameter
Intake 5.934 - 5.952 mm 0.2336 - 0.2343 in.
Exhaust 5.906 - 5.924 mm 0.2325 - 0.2332 in.
VALVE SPRINGS
- Metric Standard
Valve Spring Free Length 51.3 mm 2.0196 in.
Length of Valve Springs Under a

43.0 mm 1.6929 in.
Load of 285 - 319 N
Length of Valve Springs Under a
34.45 mm 1.3562 in.
Load of 759 - 833 N
CAMSHAFT
Metric Standard
Cam Journal Diameter 25.29 - 25.30 mm 0.9956 - 0.9960 in.
Cam Support Diameter 25.359 - 25.380 mm 0.9983 - 0.9992 in.
Cam Pin/Support Clearance 0.050 - 0.070 mm 0.0019 -0.0027 in.
End Play 0.013 - 0.023 mm 0.0005 - 0.0009 in.
Intake Camshaft Total Lift 35.33 mm 1.3909 in.
Exhaust Camshaft Total Lift 35.76 mm 1.4078 in.
Nominal Intake Camshaft Lift 5.1429 mm 0.2024 in.
Nominal Exhaust Camshaft Lift 5.5701 mm 0.2192 in.
OIL PRESSURE
Metric Standard
Engine Oil Delivery Pressure at

1.0 bar 14.5 psi
Idle
Engine Oil Supply Pressure At 2.8 - 3.8 bar 40.6 - 55.1 psi.
4000 RPM

A/C Lines to Compressor 20 15 - -
A/C Compressor Mounting Bracket 25 18 - -

Bolts
A/C Compressor Bolts 25 18 - -
Belt Tensioner Bolts 9 - 80 -
Camshaft Position Sensor 9 - 80 -

Camshaft Sprocket VVT Bolt 115 85 - -
Coolant Connector Pipe Bolts 12 9 - -
Coolant Chamber Cover Bolts 12 9 - -
Connecting Rod Caps 16 + 90° 12 + 90° - X
Crankshaft Position Sensor Bolt 9 - 80 -
Cylinder Head Bolts Refer to CYLINDER HEAD, REMOVAL AND -

INSTALLATION .
Cylinder Head Cover Bolts 12 9 - -
Cylinder Head Access Caps 18 13 - -
Engine Timing Cover Bolts 13 10 - -
Exhaust Manifold/Catalytic 25 18 - X
Converter to Cylinder Head Bolts
Engine to Transmission Bolts 60 44 - -
Exhaust Manifold Heat Shield Bolts 8 - 71 -
Exhaust Manifold/Catalytic 25 18 - -
Converter Lower Bracket Bolts
Exhaust Pipe to Exhaust 20 15 - -

Manifold/Catalytic Converter Bolts
Exhaust Pipe Bracket Bolts 25 18 - -
Flywheel Bolt 40 + 40° 30 + 30° - -
Flywheel Lower Guide Bolts 60 44 - -
Flywheel Upper Guide Bolts 60 44 - -
Generator Bolts 25 18 - -
Idler Pulley Bolt 35 26 - -
Ignition Coils 9 - 80 -
Intake Manifold Bolts 28 21 - X
Knock Sensor Bolt 25 18 - -
Ladder Frame to Block Bolts -
M8 Bolts 26 19 - -
M10 Bolts 61 45 - -
Left Engine Mount - -
M8 Bolts 35 26 - -
M10 Bolts 67 49 - -
Left Engine Mount to Adapter 40 + 45° 30 + 45° - -
Bracket Bolts
Left Engine Mount to Frame Rail 120 89 - -

Bolts
Oil Filter Cap 25 18 - -
Oil Filter Housing 27 20 - -
Oil Jet Bolt 12 9 - -
Oil Pan Bolts 31 23 - -
Oil Pan to Transmission Bolts 60 44 - -
Oil Pan Drain Plug 20 15 - -
Oil Pressure Sensor 32 24 - -
Oil Pump Pick-up Tube Bolts 12 9 - -
Oxygen Sensor 45 32 - -
Rocker Arm Shaft Bolt 28 21 - -
Rear Engine Mount to 90 + 45° 66 + 45° - X

Transmission Bolt
Rear Engine Mount to Cradle Bolt 90 + 45° 66 + 45° - -
Rear Engine Mount to Pivot 40 + 45° 30 + 45° - -

Bracket Bolt (Transmission Side)
Rear Engine Mount to Pivot

40 + 45° 30 + 45° - -
Bracket Bolt (Cradle Side)
Right Engine Mount Bracket Bolts 100 74 - -
Right Engine Mount to Frame Rail 60 + 45° 44 + 45° - -
Right Engine Mount to Engine 90 + 45° 66 + 45° - -

Mount Bracket
Spark Plugs 30 22 - -
Starter Motor Bolts 38 28 - -
Thermostat Housing Bolts 14 10 - -
Throttle Body Bolts 9 - 80 -
Timing Chain Tensioner 63 46 - -
Timing Chain Guide Bolt 23 17 - -
Transmission to Engine Bolts 60 44 - -
Transmission to Oil Pan 60 44 - -
Vibration Damper Bolt 40 + 55° 30 + 55° - -
Water Pump Bolts 28 21 - -

2025300090 - Alignment Pins, Multiair to Cylinder

Head
2029400090 - Tool, Engine Mount Alignment
10224 - Adapter, Valve Spring

(Originally Shipped In Kit Number(s) 10223.)
10368 - Set, Universal Protective Cap

7700-A - Tester, Cooling System
8189 - Guide Pins

(Originally Shipped In Kit Number(s) 8180, 8180CC,
8263, 8263CC.)
9506 - Installer, Oil Seal

(Originally Shipped In Kit Number(s) 9610, 9970.)
9509 - Installer, Oil Seal

9703 - Pin, Tensioner

9706 - Installer, Crankshaft Rear Oil Seal

9707 - Holder, Vibration Damper
9879 - Adapter, Oil Pressure Test

C-3685-A - Bloc-Chek Kit
C-4171 - Driver Handle, Universal

(Originally Shipped In Kit Number(s) 9202,
9202A-CAN, 9202CC, 9299, 9299CC, 9299CC,
9300A-CAN.)
C-4597 - Socket, Oil Pressure

MD998772A - Compressor, Valve Spring
(Originally Shipped In Kit Number(s) 8678, 8853,
8854.)
10288 - Pliers, Hose Clamp
10259B - Compressor, MultiAir® Spring
8534B - Fixture, Driveline Support

(Originally Shipped In Kit Number(s) 8534, 8534B,
8849, 9565.)
1. Open the fuse box casing lid in the engine compartment and remove fuse F21 (15 Amp) from
the fuel pump.
2. Start-up several times until all the pressure in the fuel distribution manifold has discharged.
3. Fit the fuse removed previously and close the fuse box casing.
4. Remove the left and right front tire and wheel. Refer to REMOVAL AND INSTALLATION .
9. Drain the manual transmission gear oil. Refer to appropriate Transmission Service Information
article.
11. Recover the refrigerant from the A/C system. Refer to PLUMBING, STANDARD PROCEDURE
.
12. Remove the left front half shaft. Refer to REMOVAL AND INSTALLATION .
13. Remove the right front half shaft. Refer to REMOVAL AND INSTALLATION .
15. Remove the left front head lamp unit. Refer to UNIT, FRONT LAMP, REMOVAL AND
INSTALLATION .
16. Remove the right front head lamp unit. Refer to UNIT, FRONT LAMP, REMOVAL AND
INSTALLATION .
17. Remove the head lamp cross member. Refer to CROSSMEMBER, HEADLAMP MOUNTING,
18. Remove the air cleaner body. Refer to BODY, AIR CLEANER, REMOVAL AND
INSTALLATION .
19. Remove the air cleaner hose. Refer to HOSE, CLEAN AIR, REMOVAL AND INSTALLATION .
Fig 1: Exhaust Pipe Mounting Bracket Screws
20. Loosen the screws (1) fixing the exhaust pipe mounting bracket.
Fig 2: Exhaust Pipe To Catalytic Converter Nut
21. Undo the nuts and disconnect the exhaust pipe from the catalytic converter.

Fig 3: Lower Reaction Rod To Bracket Bolt, Lower Reaction Rod & Bolt
23. Position a suitable hydraulic lift underneath the gearbox.
24. Undo the bolt (1) securing the lower reaction rod to the bracket on the differential.
25. Undo the bolt (2a) and remove the lower reaction rod (2b) from the front suspension
crossmember.

Fig 4: Quick Coupling At Degassing Pipe - Thermostat Side
27. Disconnect the quick coupling for the degassing pipe (1), thermostat side.
Fig 5: Return Pipe To Water Pump & Band
28. Loosen the band and remove the return pipe (1) to the water pump, complete with the
reservoir.
Fig 6: Quick Couplings At Heater Supply & Return Pipes
29. Disconnect the quick couplings for the heater supply and return pipes (1).
Fig 7: Starter Supply Cable & Nut
30. Undo the nut and disconnect the starter supply cable (1).
31. Undo the nut and disconnect the starter cable (1).
Fig 9: Front Fuel Vapor Pipe & Band At Solenoid Valve Side, Quick Coupling At Fuel Manifold
Supply Pipe At Rail Side, Pipe Retaining Clips & Vacuum Air Pipe & Band At Throttle Body
32. Loosen the band and disconnect the front fuel vapor pipe, solenoid valve side (1).
33. Disconnect the quick coupling for the fuel manifold supply pipe, rail side (2).
34. Open the clips retaining the pipes previously disconnected (3).
35. Loosen the band and disconnect the vacuum air pipe from the throttle body (4).
Fig 10: Quick Coupling At Front Coolant Return Pipe At Evaporator
36. Disconnect the quick coupling for the front coolant return pipe (1) from the evaporator.
Fig 11: Coolant Pipes At Compressor & Screw
37. Undo the screw (1a), disconnect and remove the coolant pipes (1b) from the compressor.
Fig 12: Lifting Bracket & Screw
38. Using the rigid power unit support front fixing screw, timing side, fit the lifting bracket (1).
Fig 13: Lifting Bracket & Screw
39. Using the rigid power unit support rear opening, timing side, fit the lifting bracket (1).
Fig 14: Injection Control Unit Wire Harness Connectors & Retaining Clips
40. Disconnect the injection control unit wire harness connectors (1, 2).
41. Disconnect the engine front coupling.
42. Open the retaining clips (3) and release the wiring.
Fig 15: Special Tool On Reservoir
43. Unscrew the cap and fit the tool 2000001400 (1).
Fig 16: Gear Engagement Cable & Gear Selection Cable
44. Release the terminal, retract the bush and move the gear engagement cable to the side (1).
45. Release the terminal, retract the bush and move the gear selection cable to the side (2).
Fig 17: Oil Supply Pipe At Clutch Control Actuator, Battery Earth Cable Screw & Wiring
Retaining Clip
46. Compress the clip and disconnect the oil supply pipe (1) to the clutch control actuator.
47. Undo the screw (2) and disconnect the battery earth cable.
48. Open the retaining clip and release the wiring (3).
Fig 18: Reversing Light Switch Wire Harness Connector
49. Disconnect the reversing light switch wire harness connector (1).
Fig 19: Special Tool Used To Secure Brackets
50. Use a suitable hydraulic lift and the tool 1871001700 to secure the brackets fitted previously
and the gearbox side power unit rigid support.
Fig 20: Heat Shield & Bolt
51. Undo the bolt and remove heat shield (1).

Fig 21: Power Unit Support Flexible Mounting (Gearbox Side) & Bolts
52. Undo the bolts (1) securing the gearbox side power unit support flexible mounting to the rigid
support.
Fig 22: Power Unit Support Flexible Mounting (Timing Side) & Bolts
53. Undo the bolts (1a), (1b) and remove the timing side power unit support flexible mounting (1c).
54. Remove the power unit from the engine compartment and position it on a suitable platform.
55. Release the power unit from the support tools.
1. Fit the support tools to the power unit.
2. Place the power unit in its housing using a suitable hydraulic hoist.
Fig 1: Power Unit Support Flexible Mounting (Timing Side) & Bolts
3. Place the timing side power unit support flexible mounting (1a) in its housing and tighten the
screws (1b) and (1c) to the proper specification. Refer to TORQUE SPECIFICATIONS .
Fig 2: Power Unit Support Flexible Mounting (Gearbox Side) & Bolts
4. Tighten the screws securing the gearbox side power unit support flexible mounting to the rigid
support to the proper specification. Refer to TORQUE SPECIFICATIONS .
5. Place the heat shield in its housing and tighten the screw.
6. Remove the hydraulic hoist and the equipment used for supporting the power unit.
7. Remove the rear lifting bracket.
8. Remove the front lifting bracket.
9. Connect the reverse light switch wire harness connector.
10. Engage the starter wiring with the intermediate retaining clip.
11. Connect the battery earth cable and tighten the screw.
12. Connect the oil delivery pipe to the clutch control actuator and engage the fixing clip.
13. Place the gear selection cable in its housing, engage the bush and the terminal.
14. Place the gear engagement cable in its housing, engage the bush and the terminal.
15. Connect the engine front coupling.
16. Connect the injection control unit wire harness connectors.

17. Engage the wiring retaining clips.
Fig 3: A/C lines & Screw
18. Connect the A/C lines (1a), complete with NEW gaskets and tighten the screw (1b) to the
19. Connect the quick coupling for the front coolant return pipe from the evaporator.
20. Connect the vacuum air pipe to the throttle body and tighten the band.
21. Connect the quick coupling for the fuel manifold supply pipe, rail side.
22. Connect the front fuel vapor pipe, solenoid valve side, and tighten the band.
23. Engage the pipes connected previously to the intermediate retaining clips.
24. Connect the starter cable and tighten the nut.
25. Connect the starter supply cable and tighten the nut.
26. Connect the quick couplings for the heater supply and return pipes.
27. Place the water pump return pipe complete with reservoir in its housing and tighten the band.
28. Connect the quick coupling for the degassing pipe, thermostat side.
Fig 4: Exhaust Pipe To Catalytic Converter Nut
29. Place the exhaust pipe back in its housing complete with NEW gasket. Connect it to the
catalytic converter and tighten the new nuts to the proper specification. Refer to TORQUE
SPECIFICATIONS .
Fig 5: Exhaust Pipe Mounting Bracket Screws
30. Tighten the screws securing the exhaust pipe mounting bracket to the proper specification.
Fig 6: Lower Reaction Rod To Bracket Bolt, Lower Reaction Rod & Bolt
31. Place the rear mount (1a) in its housing and tighten the bolt (1b) to the proper specification.
32. Tighten the rear mount to the bracket bolt (2) to the proper specification. Refer to TORQUE
SPECIFICATIONS .
33. Install the air cleaner hose. Refer to HOSE, CLEAN AIR, REMOVAL AND INSTALLATION .
34. the air cleaner body. Refer to BODY, AIR CLEANER, REMOVAL AND INSTALLATION .
35. Install the head lamp cross member. Refer to CROSSMEMBER, HEADLAMP MOUNTING,
36. Install the right front head lamp unit. Refer to UNIT, FRONT LAMP, REMOVAL AND
INSTALLATION .
37. Install the left front head lamp unit. Refer to UNIT, FRONT LAMP, REMOVAL AND
INSTALLATION .
39. Install the right front half shaft. Refer to REMOVAL AND INSTALLATION .
40. Install the left front half shaft. Refer to REMOVAL AND INSTALLATION .
44. Fill the manual transmission gear oil. Refer to appropriate Transmission Service Information
article.
45. Bleed the hydraulic clutch. Refer to STANDARD PROCEDURE .
49. Install the left and right front tire and wheel. Refer to REMOVAL AND INSTALLATION .
REMOVAL AND INSTALLATION > ENGINE - POSITION ON STAND AND REMOVE
REST THE ENGINE ON THE STAND

Fig 1: Flywheel Locking Tool, Clutch Centering Tool & Clutch Mechanism Assembly & Bolts
1. Fit the flywheel locking tool 1860846000 (1).
2. Fit a suitable clutch centering tool (2).
3. Remove the bolts and the clutch mechanism assembly (3).

Fig 2: Flywheel Locking Tool, Flywheel & Bolts
4. Make sure that the flywheel locking tool 1860846000 (1) has been fitted properly.
5. Remove the bolts (2a) and remove the engine flywheel (2b).
6. Remove the flywheel locking tool 1860846000 (1).

Fig 3: Positioning Engine On Overhaul Stand
7. With a suitable hydraulic hoist, place the engine on the overhaul stand 1871000000 (1).
8. Removal of engine from the stand
9. Support the engine using the mounting tools and a suitable hydraulic hoist.
10. Undo the fastenings securing the engine block to the overhaul stand bracket.
11. Place the engine on a suitable board.

Fig 4: Flywheel Locking Tool, Flywheel & Bolts
12. Fit the flywheel locking tool 1860846000 (1).
13. Install the engine flywheel (2a) in its housing and tighten the NEW screws (2b) to the proper
Fig 5: Flywheel Locking Tool, Clutch Centering Tool & Clutch Mechanism Assembly & Bolts
14. Using a suitable clutch centering tool, position the complete clutch mechanism (1a) and tighten
15. Remove the flywheel lock 1860846000 (2).

INSPECTION > DISASSEMBLY
Fig 1: Front & Rear O2 Sensors Wire Harness Retaining Clips & Exhaust Manifold Heat Shield &
Screws
1. Disconnect the front oxygen sensor wire harness connector and release the wiring from the
retaining clip (1).
2. Disconnect the rear oxygen sensor wire harness connector and release the wiring from the
retaining clip (2).
3. Undo the screws and remove the exhaust manifold heat shield (3).
Fig 2: Catalytic Converter Mounting Bracket (At Engine Oil Sump Side) & Screws
4. Undo the screws securing the catalytic converter mounting bracket (1), engine oil sump side.
Fig 3: Exhaust Manifold And Catalytic Converter & Nuts
5. Undo the nuts (1a) and remove the exhaust manifold and catalytic converter (1b).
Fig 4: Starter Wiring & Nut
6. Undo the nut and disconnect the starter wiring (1).

Fig 5: Starter & Screws
7. Undo the screws (1a) and remove the starter (1b).

Fig 6: Wiring Attached To Bracket At Gearbox
8. Release the wiring from the bracket on the gearbox (1).

Fig 7: Gearbox To Engine Upper Bolts
9. Remove the upper bolts (1) securing the gearbox to the engine.
Fig 8: Flywheel Lower Guard, Bolts, Gearbox To Engine Oil Sump Bolts
10. Remove the bolts (1a) and remove the engine flywheel lower guard (1b).
11. Remove the front bolts (2) fixing the gearbox to the engine oil sump.
Fig 9: Gearbox To Engine Bolt & Flywheel Upper Guard
12. Remove the side screws bolts fixing the gearbox to the engine (1a) and the engine flywheel
upper guard (1b).
Fig 10: Gearbox To Engine Oil Sump Rear Bolts
13. Remove the rear bolts (1) securing the gearbox to the engine oil sump.
Fig 11: Gearbox To Engine Side Bolt
14. Remove the side bolt fixing the gearbox to the engine.
15. Remove the gearbox from the engine.

INSPECTION > REASSEMBLY
Fig 1: Gearbox To Engine Side Bolt
1. Fit the gearbox in its seat and tighten the side bolt fixing the gearbox to the engine to the
Fig 2: Gearbox To Engine Oil Sump Rear Bolts
2. Tighten the bolts securing the rear upper screws fixing the gearbox to the engine oil sump to
Fig 3: Gearbox To Engine Bolt & Flywheel Upper Guard
3. Place the engine flywheel upper guard (1a) back in its housing and tighten the screws (1b) to
Fig 4: Flywheel Lower Guard, Bolts, Gearbox To Engine Oil Sump Bolts
4. Place the engine flywheel lower guard (1a) in its housing and tighten the corresponding bolts
(1b).
5. Tighten the front bolt securing the gearbox to the engine oil sump to the proper specification.
Fig 5: Gearbox To Engine Upper Bolts
6. Tighten the upper screws fixing the gearbox to the engine to the proper specification. Refer to
7. Engage the wiring in the bracket on the gearbox.

Fig 6: Starter & Screws
8. Place the starter (1a) in its housing and tighten the screws (1b) to the prescribed torque.
9. Connect the starter wiring and tighten the nut.

Fig 7: Exhaust Manifold With Catalytic Converter & Nuts
10. Place the exhaust manifold with catalytic converter (1a), complete with a NEW gasket, back in
its housing and tighten the NEW nuts (1b) to the proper specification. Refer to TORQUE
SPECIFICATIONS .
Fig 8: Catalytic Converter Mounting Bracket (At Engine Oil Sump Side) & Screws
11. Tighten the fixing screws for the catalytic converter mounting bracket, engine sump side, to the
12. Refit the exhaust manifold heat shield back in its housing and tighten the screws.
13. Connect the rear oxygen sensor wire harness connector for the and engage the wiring with the
retaining clip.
14. Connect the front oxygen sensor wire harness connector for the and engage the wiring with
the retaining clip.
INSPECTION
Fig 1: Engine Oil Pan Drain Plug
1. Remove the plug (1) and drain the engine oil into a suitable container.
Fig 2: Oil Pressure Switch Wire Harness Connector
2. Disconnect the minimum engine oil pressure switch wire harness connector and release the
wiring.
Fig 3: Camshaft Position (CMP) Sensor Wire Harness Connector, Variable Valve Timing
System Electromagnet Wire Harness Connector & Wiring Duct To Tappet Cover (Timing Side)
Bolt
3. Disconnect the Camshaft Position (CMP) sensor wire harness connector (1).
4. Disconnect the variable valve timing system electromagnet wire harness connector (2).
5. Remove the bolt (3) securing the wiring duct to the tappet cover, on the timing side.
Fig 4: Intake Air Temperature And Pressure Sensor Wire Harness Connector & Generator
6. Disconnect the intake air temperature and pressure sensor wire harness connector (1).
7. Disconnect the generator wire harness connector (2).

Fig 5: A/C Compressor Wire Harness Connector
8. Disconnect the A/C compressor wire harness connector (1).

Fig 6: Wiring Retaining Clips At Air Chamber Side
9. Release the wiring retaining clips (1), air chamber side.

Fig 7: Wiring Duct To Tappet Cover (Intake Side) Bolt
10. Remove the bolt (1) securing the wiring duct to the tappet cover, on the intake side.
Fig 8: Ignition Coils & Fuel Injector Wire Harness Connectors & Wiring At Mounting Brackets
11. Disconnect the ignition coils wire harness connector (1).
12. Detach the fuel injectors wire harness connector (2).
13. Release the wiring from the mounting brackets (3).

Fig 9: Fuel Vapor Recovery Solenoid, Throttle Body & Knock Sensor Wire Harness
Connectors
14. Detach the fuel vapor recovery solenoid wire harness connector (1).
15. Detach the throttle body wire harness connector (2)
16. Disconnect the knock sensor wire harness connector.

Fig 10: Crankshaft Position (CKP) Sensor Wire Harness Connector
17. Disconnect the Crankshaft Position (CKP) sensor wire harness connector (1).
Fig 11: Engine Water Temperature Sensor Wire Harness Connector & Wiring At Bracket
18. Disconnect the engine water temperature sensor wire harness connector (1a) and release the
wiring from the bracket (1b).
19. Remove the engine wiring.

Fig 12: Positive Crankcase Valve (PCV)
20. Disconnect the Positive Crankcase Valve (PCV) (1), single-acting valve side.
Fig 13: Engine Oil Vapor Inlet Pipe & Retaining Clip
21. Open the retaining clip (1a), disconnect the idling engine oil vapor inlet pipe (1b) from the air
chamber and remove it.
Fig 14: Engine Oil Dipstick, Tube & Bolt
22. Remove the engine oil dipstick (1).
23. Remove the bolt (2a) and the engine oil dipstick tube (2b).
Fig 15: Air Chamber To Mounting Bracket Bolt
24. Remove the bolt (1) securing the air chamber to the mounting bracket.
Fig 16: Air Intake Chamber With Throttle Body And Fuel Distribution Manifold & Bolts
25. Remove the bolts (1a) and remove the air intake chamber (1b) complete with throttle body and
fuel distribution manifold.
Fig 17: Engine Wiring & Nut
26. Remove the nut (1a) and remove the engine wiring (1b).
Fig 18: Heater To Thermostat Return Pipe & Bolt
27. Remove the fixing bolt (1) for the return pipe from the heater to the thermostat.
Fig 19: Return Pipe & Retaining Band
28. Use the tool 1881138000 to release the retaining band (1) for the return pipe (2) from the
heater, water pump side.
29. Disconnect the return pipe (2) from the heater from the water pump and remove it.
Fig 20: Thermostat Complete With Pipes & Bolts
30. Remove the bolts (1a) and the thermostat (1b) complete with pipes.
Fig 21: Ignition Coils & Bolts
31. Remove the bolts (1a) and the ignition coils (1b).
Fig 22: Removing/Installing Spark Plugs
32. Remove the spark plugs (1) using a suitable tool.

Fig 23: Tappet Cover & Bolts
33. Remove the bolts (1a) and remove the tappet cover (1b) complete with variable valve timing
electromagnet.
Fig 24: Tensioner & Serpentine Belt Routing
34. Use the moving tensioner (1a) and remove the serpentine belt (1b).
Fig 25: Generator Guard & Nuts
35. Remove the nuts and the generator guard (1).

Fig 26: Generator & Bolts
36. Remove the bolts (1a) and the generator (1b).

Fig 27: A/C Compressor & Bolts
37. Remove the bolts (1a) and the A/C compressor (1b).
Fig 28: A/C Compressor Mounting & Bolts
38. Remove the bolts (1a), the bolt (1b) and the A/C compressor mounting (1c).
Fig 29: Compressor Mounting Bushes
39. Check that the compressor mounting bushes (1) are intact.
Fig 30: Water Delivery Pipe To Engine Block, Water Pump Assembly & Bolts
40. Remove the bolts (1) securing the water delivery pipe to the engine block.
41. Remove the bolts (2a) and the water pump assembly (2b).
Fig 31: Accessory Drive Belt Automatic Tensioner, Accessory Drive Belt Fixed Tensioner &
Bolts
42. Remove the bolts (1a) and the accessory drive belt automatic tensioner (1b).
43. Remove the bolts (2a) and the engine accessory drive belt fixed tensioner (2b).
Fig 32: Using Special Tool At Crankshaft Pulley & Bolt
44. Use the tool 2000040944 (1a) to remove the bolt securing the crankshaft pulley (1b).
Fig 33: Inserting Special Tool In Crankshaft Pulley Hub
45. Insert the tool 2000040942 (1) in the crankshaft pulley hub as shown in the figure.
Fig 34: Removing Crankshaft Pulley Using Extractor
46. Apply a suitable extractor (1) as shown in the figure and proceed with the removal of the
crankshaft pulley.
47. Remove the crankshaft oil seal and the gaskets from the timing drive chain cover.
Fig 35: Timing Drive Chain Cover & Bolts
48. Remove the bolts (1a), (1b), (1c) and the timing drive chain cover (1d) complete with gasket
and engine oil pump.
Fig 36: Centre Fixing Screw For Timing Drive Chain Cover & Gasket
49. The centre fixing screw for the timing drive chain cover must be replaced at every removal,
since it includes a gasket (a) in the position shown in the figure.
Fig 37: Timing Side Power Unit Rigid Support & Bolts
50. Remove the bolts (1a) and the timing side power unit rigid support (1b).
Fig 38: Applying Counter-Torque On Rear Stem Of Camshaft To Remove Bolt Securing Variable
Valve Timing System
51. Applying a counter-torque on the rear stem of the camshaft (1a) remove the bolt securing the
variable valve timing system (1b).
Fig 39: Variable Valve Timing System And Toothed Wheel For Timing Sensor & Bolt
52. Remove the bolt (1a) securing the variable valve timing system and the toothed wheel for the
timing sensor (1b).
Fig 40: Timing Drive Chain Moving Tensioner & Bolt
53. Remove the bolt (1a) complete with gasket and the timing drive chain moving tensioner (1b).
Fig 41: Variable Valve Timing System With Timing Control Chain
54. Remove the variable valve timing system along with the timing control chain (1).
Fig 42: Access Caps For Timing Drive Chain Pad Fixing Screws
55. Remove the access caps (1) for the timing drive chain pad fixing screws, complete with
O-rings.
Fig 43: Timing Drive Chain Moving Pad & Fixed Pad Fixing Bolts
56. Remove the timing drive chain moving pad fixing bolt (1).
57. Remove the timing drive chain fixed pad fixing bolt (1).
Fig 44: Timing Drive Chain Moving Pad
58. Remove the timing drive chain moving pad (1).

Fig 45: Timing Drive Chain Fixed Pad
59. Remove the timing drive chain fixed pad (1).

Fig 46: Intake & Exhaust Rocker Arms & Bolts
60. Remove the bolts (1a) and the rocker arms on exhaust side (1b).
61. Remove the bolts (2a) and the rocker arms on intake side (2b).
Fig 47: Camshaft Caps
62. Remove the camshaft caps (1).

Fig 48: Camshaft
63. Remove the camshaft.

64. Remove the bolts (1a), (1b) and cylinder head (1c).

Fig 50: Engine Oil Sump & Bolts
66. Remove the bolts (1a) and the engine oil sump (1b).
DISASSEMBLY AND ASSEMBLY > DISASSEMBLE-REASSEMBLE-FOLLOWING-

INSPECTION
Fig 1: Engine Oil Pick-Up Tube With O-Ring & Screws
1. Undo the screws (1a) and remove the engine oil pick-up tube (1b) complete with O-ring.
Fig 2: Special Tool Installed To Rotate Crankshaft
2. Fit the tool 1860815000 (1) for rotating the crankshaft.

Fig 3: Connecting Rod Cap With Half-Bearing & Bolts
3. Remove the bolts (1a) and the connecting rod cap (1b) complete with half-bearing (1c).
Fig 4: Piston-Connecting Rod Assembly With Half-Bearing
4. Remove the piston-connecting rod assembly (1a) complete with half-bearing (1b).
5. Proceed in the same way for the removal of the remaining pistons.
Fig 5: Arrow On Piston Crown Facing Timing Side Indicates Piston Fitting Direction
6. The arrow (a) on the piston crown facing the timing side indicates the fitting direction. The
connecting rod-cap matching is "BREAK" type and can only be fitted in one position.
7. Remove the piston pin, connecting rod, and rings. Refer to ROD, PISTON AND CONNECTING,
Fig 6: Intermediate Shaft Mounting Bracket & Bolts
8. Remove the bolts (1a) and remove the intermediate shaft mounting bracket (1b).
Fig 7: Crankshaft Position (CMP) Sensor With O-Ring & Bolt
9. Remove the bolt (1a) and the Crankshaft Position (CMP) sensor (1b) complete with O-ring
(1c).
Fig 8: Fitting Central Pin And Half-Casing Of Special Tool To Remove Timing Chain Drive Gear
10. Remove the timing chain drive gear using the tool 2000040946 (1).
11. Fit the central pin and the half-casing as shown in the figure (1).
Fig 9: Fitting Half-Casing Of Special Tool
12. Fit the half-casing as shown in the figure (1).

Fig 10: Fitting Retaining Cylinder Of Special Tool
13. Fit the retaining cylinder as shown in the figure.

Fig 11: Removing Timing Chain Drive Gear
14. Proceed with the removal of the timing chain drive gear.
Fig 12: Internal & External Bolts Securing Lower Block
15. Remove the external bolts (1a) and the internal bolts (1b) securing the lower block.
Fig 13: Releasing Lower Block Using Suitable Tool In Designated Areas
16. Use a suitable tool (1) to release the lower block, operating in the areas shown in the figure,
intake side and exhaust side.
17. Remove the lower block complete with main half-bearings.

Fig 14: Lower Main Half-Bearings & Locating Bushes
18. Remove the lower main half-bearings (1).
19. Remove the locating bushes (2).
20. Remove all sealant residues.

Fig 15: Crankshaft
21. Check that the crankshaft end float corresponds to the prescribed figures using a magnetic
base and dial gauge.
0.050 ÷ 0.033 (mm)
22. If the value for the crankshaft end float is not within the prescribed limits, when refitting use
suitable oversize thrust half-washers.
24. Remove the crankshaft oil seal, flywheel side.

Fig 16: Tone Wheel & Bolts
25. Remove the bolts (1a) and tone wheel (1b).

Fig 17: Upper Main Half-Bearings, Thrust Washers & Locating Bushing
26. Remove the upper main half-bearings (1).
27. Remove the thrust washers (2).
28. Remove the locating bush (3).
29. Remove all sealant residues.

Fig 18: Engine Oil Jets & Bolts
30. Remove the bolt and the engine oil jets (1).
Fig 19: Oil Filter Mounting & Bolts
NOTE:
Place the engine oil filter mounting in a vice, undo the cover and remove the filter
element.
31. Remove the bolts (1a) and the engine oil filter mounting (1b) complete with gasket.
Fig 20: Knock Sensor & Bolt
32. Remove the bolt (1a) and the knock sensor (1b).
Fig 21: Locating Coolant Plugs
33. Use a suitable tool to remove the plugs from the engine coolant chambers.
Fig 22: Closing Flange & Bolts
34. Remove the bolts and the closing flange (1) for the engine coolant chambers complete with
gasket.
35. Wash and check the appearance of all components removed.
36. Place the engine block on the overhaul stand.

Fig 23: Installing Coolant Plugs Using Special Tool
37. Use the tool 2000040940 (1a) to fit the NEW plugs of the engine coolant chambers (1b).
Fig 24: Closing Flange & Bolts
38. Place the engine coolant chambers closing flange in its housing, complete with a NEW gasket,
and tighten the bolts (1) to the proper specification. Refer to TORQUE SPECIFICATIONS .
39. Use a calibrated metal rule and a feeler gauge to check the planarity of the cylinder head -
engine block support surface. Refer to ENGINE SPECIFICATIONS .
40. If the measurement does not correspond to the prescribed values, regrind the cylinder head
support surface.
41. Measure the diameter of the cylinder liners and check that they correspond to the prescribed
values. Refer to ENGINE SPECIFICATIONS .
42. Check that the roundness of the cylinder liners is within the prescribed limit. Refer to ENGINE
SPECIFICATIONS .
43. Check that the taper of the cylinder liners is within the prescribed limits. Refer to ENGINE
SPECIFICATIONS .
44. If the cylinder liner taper or roundness measurements are not within the prescribed values,
ream the cylinder liners following the prescribed oversizes. Refer to ENGINE
SPECIFICATIONS .
45. If reaming, ensure all the liners have the same oversize. Refer to ENGINE SPECIFICATIONS .
46. Fit the locating bushes for the lower/upper block.

47. Provisionally fit the lower block to measure the main journal seats and then remove it.
Fig 25: Lower Block Bolt Tightening Sequence
48. Using the tightening sequence shown in illustration, tighten the lower block fixing bolts to:
1. M8 bolts 26 N.m (19 ft. lbs.).
2. M10 bolts 61 N.m (45 ft. lbs.).
49. Check that the diameter of the main journal seats is within the prescribed limits (without fitting
the half-bearings).
51.997 ÷ 52.007 (mm)
50. Check that the diameter of the main journals is within the prescribed limits.
47.992 ÷ 48.008 (mm)
51. Check that the diameter of the crankpins is within the prescribed limits.
43.992 ÷ 44.008 (mm)
52. Check the crankshaft and connecting rod bearings, keeping in mind that no adjustment
operations should be carried out on the half-bearings.
53. Replace them if scoring or signs of binding are noted.
54. The size of the main half-bearings is given.

- mm in.
Class 1 1.980 ÷ 1.984 0.0779 ÷ 0.0781
Class 2 1.984 ÷ 1.988 0.0781 ÷ 0.0782
Class 3 1.989 ÷ 1.993 0.0783 ÷ 0.0784
Bearing shells thickness of

2.105 ÷ 2.111 0.0828 ÷ 0.0831
counter increased
55. The size of the connecting rod half-bearings is given.
- (mm) in.
Class A (Red) 1.480 ÷ 1.484 0.05826 ÷ 0.05842
Class B (Blue) 1.485 ÷ 1.489 0.05846 ÷ 0.05862
Class C (Yellow) 1.490 ÷ 1.494 0.05866 ÷ 0.05881
56. The thrust half-washer thickness is given.
- (mm) in.
Thickness big end bearings 2.08 ÷ 2.18 0.0818 ÷ 0.0858

plus
57. Place the upper and lower main half-bearings in their seats taking great care over cleanliness.
58. Position the tone wheel in its housing and securely tighten the NEW screws, pre-treated type.
59. Fit the crankshaft into its housing on the upper block.
Fig 26: Using Plastigage To Measure Main Journal Clearance
60. Fit the calibrated wire (Plastigage) (1) for measuring the main journal clearance.
61. Provisionally fit the lower block to measure the main journal clearance and then remove it.
62. Using the tightening sequence shown in illustration, tighten the lower block fixing bolts to:
1. M8 bolts 26 N.m (19 ft. lbs.).
2. M10 bolts 61 N.m (45 ft. lbs.).

Fig 28: Measuring Journal Clearance
63. Remove the ladder frame complete with main half-bearings and, using a graduated measuring
instrument (1a), measure the clearance shown in illustration by the calibrated wire (1b).
64. Check one journal at a time, without rotating the crankshaft.
bearings - journals crankshaft (mm) 0.015 ÷ 0.034
65. If the figure measured is outside of the tolerance, replace the main half-bearings with ones of
the correct size and category.
66. Apply a 1.5-2.0 mm thick continuous bead of sealant (LOCTITE 5205) to the lower block
surface.
67. Using the tightening sequence shown in illustration, tighten the ladder frame bolts to:
1. M8 bolts the proper specification. Refer to TORQUE SPECIFICATIONS .
2. M10 bolts the proper specification. Refer to TORQUE SPECIFICATIONS .
68. Check the piston pin housing diameter on the small end.
- (mm) in.
Connecting rod 18.96 ÷ 18.98 0.7464 ÷ 0.7472
Pin 0.045 ÷ 0.020 0.00177 ÷ 0.0007
Based on the piston pin 18.992 ÷ 19.012 0.7477 ÷ 0.7485

diameter
69. Check that the diameter of the piston pin housing in the piston is within the prescribed values.
70. If the piston pin housing diameter is not within prescribed values, replace the piston complete
with its piston pin.
71. Check that the outer diameter of the piston pin is within the prescribed limits; if not, replace the
worn piston pin.
- (mm) in.
Pin outer diameter 18.995 ÷ 19.000 0.7478 ÷ 0.7480
piston pin 0.008 ÷ 0.017 0.0003 ÷ 0.0006
72. Fit the piston rings in the cylinder bore and check that the opening between the ends is within
the recommended values; if this is not the case, replace the circlips.
- (mm) in.
Ring 1 seal ring compression 0.2 0.007

cylinders
Ring 2 seal ring compression 0.2 0.007

cylinders
Light scraper ring piston (mm) 0.25 0.009
73. Check that the thickness of the sealing rings is within the prescribed limits.
- (mm) in.
Thickness 1 ^ seal ring 1.170 ÷ 1.230 0.046 ÷ 0.048

compression cylinders
Thickness 2 ^ seal ring 1.172 ÷ 1.210 0.046 ÷ 0.047

compression cylinders (mm)
Scraper piston ring thickness 2.340 ÷ 2.480 .0.092 ÷ 0.097

(mm)
74. Check that the housing of the sealing rings on the pistons is within the prescribed limits.
- (mm) in.
Ring seats on the piston - 1st 1.220 ÷ 1.250 1.963 ÷ 2.011
Ring seats on the piston - 2nd 1.215 ÷ 1.235 1.955 ÷ 1.987
Ring seats on the piston - 3rd 2.521 ÷ 2.541 4.057 ÷ 4.089
75. Check that the outer diameter of the pistons corresponds to the prescribed figures; if not,
replace the piston complete with piston rings and piston pin.
- (mm) in.
Outside diameter pistons 76.956 ÷ 76.974 123.849 ÷ 123.878
Increase outside diameter 0.40 0.643

pistons
76. Measure perpendicular to the gudgeon pin axis, 10 mm from the lower edge of the skirt.
77. Check that the axial clearance between the pistons rings and the seats on the piston
corresponds to the prescribed values.
- (mm) in.
Axial play 1st ring 0.010 ÷ 0.080 0.0160 ÷ 0.1287

compression cylinder
Axial clearance 2nd ring 0.025 ÷ 0.063 0.0402 ÷ 0.1013

compression cylinder (mm)
Axial piston motor scraper ring 0.041 ÷ 0.201 0.0659 ÷ 0.3234
78. Fit the caps on the connecting rods and secure them by tightening the screws to the proper
79. The connecting rods are preset fracture rods and are supplied already fractured by parts
together with the cap screws. The connecting rod caps are not interchangeable because the
fracture profile differs from part to part.
80. Check that the big end diameter (without fitting the half-bearings) is within the prescribed limits;
if not, replace the connecting rods.
- (mm) in.
Big end inside diameter 46.991 ÷ 47.005 75.624 ÷ 75.647
81. Assemble the piston pin, connecting rod, and rings. Refer to ROD, PISTON AND
CONNECTING, REMOVAL AND INSTALLATION .
82. Install the tool 1860815000 for crankshaft rotation.

Fig 30: Compressing Sealing Rings To Install Piston Assemblies
83. Fit the connecting rod-piston assemblies with half-bearings using a suitable tool (1) to
compress the sealing rings and then fit the piston into the cylinder liner.
Fig 31: Installing Piston With Arrow On Piston Crown Facing Timing Side
84. The arrow (a) on the piston crown facing the timing side indicates the fitting direction.
85. Apply the calibrated wire (plastigage) for measuring the crankpin clearance.
86. Refit the caps complete with half-bearings on the connecting rods and secure them by
tightening the screws to the proper specification. Refer to TORQUE SPECIFICATIONS .
87. The connecting rods are preset fracture rods and are supplied already fractured by Parts
together with the cap screws. The connecting rod caps are not interchangeable because the
fracture profile differs from part to part.
Fig 32: Locating Notches On Connecting Rod Cap & Connecting Rod
88. A notch (a) is present on the connecting rod caps, which should be aligned with the notch (b)
on the connecting rod.
These reference notches should be facing the intake side.
89. Remove the connecting rod caps and check the crankshaft backlash. Use an appropriate
gauge to measure the width of the plastigage.
90. Check one crankshaft at a time, without rotating the crankshaft.
- (mm) in.
rod bearings - crankpins 0.021 ÷ 0.037 0.0337 ÷ 0.0595

crankshaft
91. If the measured value is outside of the prescribed limits, replace the connecting rod
half-bearings with appropriately sized half-bearings.
Fig 33: Connecting Rod Caps Bolts
92. Proceed with final fitting of the connecting rod caps complete with half-bearings, tightening the
fixing bolts (1) to the proper specification. Refer to TORQUE SPECIFICATIONS .
Fig 34: Knock Sensor & Bolt
93. Install the knock sensor (1a) in its housing and tighten the bolt (1b) to the proper specification.
Fig 35: Oil Filter Mounting & Bolts
94. Place the engine oil filter mounting (1a) complete with new gasket back in its housing and
tighten the screws (1b) to the proper specification. Refer to TORQUE SPECIFICATIONS .
95. Install a NEW filter element and tighten the cover (2) complete with a NEW gasket to the
Fig 36: Installing Engine Oil Jets Back In Their Housings Using Special Tool
96. Using the tool 2000040951 (1a) to place the engine oil jets (1b) back in their housings, and
tighten the screws to the proper specification. Refer to TORQUE SPECIFICATIONS .
Fig 37: Installing Timing Chain Drive Gear Ensuring Pin Is Aligned With Groove
97. Place the timing chain drive gear back in its housing, making sure the pin (1a) is aligned with
the groove (1b).
Fig 38: Fitting Retaining Cylinder Of Special Tool
98. Install the tool 2000040941 as shown in illustration.

Fig 39: Using Special Tool To Complete Fitting Of Timing Chain Drive Gear
99. Use the tool 2000040941 (1a) to complete fitting of the timing chain drive gear (1b).
Fig 40: RPM Sensor & Bolt
100. Install the RPM sensor (1a) back in its housing complete with NEW O-ring and tighten the
screw (1b) to the proper specification. Refer to TORQUE SPECIFICATIONS .
101. Place the intermediate shaft mounting in its housing and securely tighten the bolts.
Fig 41: Engine Oil Pick-Up Tube With O-Ring & Screws
102. Using a NEW O-ring seal, install the oil pick-up tube (1a). Tighten the bolts (1b) to the proper
Fig 42: Engine Oil Sump & Bolts
103. Using a NEW gasket, install the engine oil pan and tighten the bolts (1b) finger tight.
Fig 43: Oil Pan Bolt Tightening Sequence
104. Using the tighten sequence shown in illustration, tighten the oil pan bolts to the to the proper
105. Using a NEW O-ring seal, Install the dipstick tube and securely tighten the bolt.
106. Install a NEW cylinder head gasket in position engaging the locating bushes on the engine
block.
107. Install the cylinder head (1a) back in its housing, engaging the locating bushes, then tighten the
NEW bolts (1b) and (1c) finger tight.
108. Using the tightening sequence shown in illustration, tighten the bolts:
1. Tighten bolts 1 - 10 to 20 N.m (15 ft. lbs.)
4. Tighten bolts 1 - 10 an additional 90° turn
5. Tighten bolts 1 - 10 an additional 90° turn
6. Tighten bolts 11 - 12 to 30 N.m (22 ft. lbs.).

Fig 46: Placing Camshaft Caps & Camshaft In Housing And Positioning Camshaft So That 2
Pins Of Timing Side Stem Are Vertical And Face Exhaust Side
109. Place the camshaft in its housing and position it so that the two pins of the timing side stem
are vertical and face the exhaust side, as shown in illustration.
110. Place the camshaft caps in their housings engaging the locating bushings and complying with
the numbers printed on the top, from 1 to 5. The assembly direction goes from number 1, timing
side, to number 5, flywheel side.
NOTE:
Each camshaft cap has two teeth (1) that must be facing towards the timing drive
chain side, so that the lubrication hole is facing towards the exhaust side.
Fig 47: Positioning Two Bevels Of Flywheel Side Stem Of Camshaft
111. Position the camshaft as described, then make sure that the two bevels (a) of the flywheel side
stem are in the position shown in figure, for an easier fitting of a spanner to use as counter-
torque in the following tightening of the variable valve timing system.
Fig 48: Intake & Exhaust Rocker Arms & Bolts
112. Install the rocker arms in their housings on the intake side (1a), exhaust side (1b) and the bolts
(2).
113. Check that matching of each hydraulic tappet with the relevant valve is correct.
114. Tighten the intake and exhaust rocker arm shaft bolts (2) to the proper specification. Refer to
115. Install the timing drive chain fixed guide in its housing.
116. Install the timing drive chain moving guide in its housing.
Fig 49: Rotating Crankshaft To Position Pin At Bottom To Ensure Triangles On Timing Chain
Control Gear Are In Correct Position
117. Rotate the crankshaft to position the pin (1a) at the bottom, so that the two triangles (1b) on
the timing chain control gear are in the position shown in the figure.
Fig 50: Placing Timing Chain In Position & Engaging Teeth Of Drive Gear To Ensure Yellow
References Correspond To Triangles
118. Place the timing chain (1a) in position, engaging the teeth of the drive gear, so that the two
yellow references (1b) correspond to the two triangles (1c).
Fig 51: Engaging Upper Branch Of Timing Drive Chain With Variable Valve Timing System
Teeth To Ensure Yellow Reference On Chain Corresponds To Reference Cut Into Back Of
Variable Valve Timing System
119. Engage the upper branch of the timing drive chain with the variable valve timing system teeth,
so that the yellow reference (1a) on the chain corresponds to the reference (1b) cut into the
back of the variable valve timing system.
Fig 52: Ensuring Notch Cut Into Toothed Wheel Corresponds To Yellow Notch Of Timing Drive
Chain
120. Place the variable valve timing system with chain in its housing, engaging the two pins of the
camshaft stem.
121. Place the timing sensor toothed wheel in its housing, engaging the variable valve timing system
pin.
122. Check that the notch (a) cut into the toothed wheel corresponds to the yellow notch (b) of the
timing drive chain.
123. Install the variable valve timing system fixing screw, without tightening it.
Fig 53: Timing Drive Chain Moving Pad & Fixed Pad Fixing Bolts
124. Tighten the bolt (2) securing the timing chain fixed guide to the proper specification. Refer to
125. Tighten the bolt (1) securing the timing chain moving guide to the proper specification. Refer to
Fig 54: Moving Tensioner For Timing Drive Chain Cover
126. Remove the cover (1) of the moving tensioner for the timing drive chain.
Fig 55: Engaging Moving Tensioner For Timing Drive Chain
127. Engage the moving tensioner for the timing drive chain as shown in the figure.
128. Fit the cover on the moving tensioner for the timing drive chain.
Fig 56: Timing Drive Chain Moving Tensioner & Bolt
129. Using a NEW gasket, install the timing chain tensioner and tighten to the proper specification.
Fig 57: Releasing Piston Of Timing Drive Chain Mobile Tensioner
130. Work on the mobile pad to release the piston of the timing drive chain mobile tensioner.
Fig 58: Ensuring Piston Of Mobile Tensioner Touches Mobile Pad
131. Check that the piston of the mobile tensioner (1a) touches the mobile pad (1b).
132. Using NEW O-rings, Install the access caps and tighten to the proper specification. Refer to
Fig 60: Applying A Counter-Torque On Rear Stem Of Camshaft & Tightening Screw Securing
Variable Valve Timing System
133. Applying a counter-torque on the rear stem of the camshaft (1a) tighten the screw securing the
variable valve timing system (1b) to the proper specification. Refer to TORQUE
SPECIFICATIONS .
Fig 61: Timing Side Power Unit Rigid Support & Bolts
134. Install the engine mount bracket (1a) complete with NEW gasket in its housing and tighten the
bolts (1b) to the proper specification. Refer to TORQUE SPECIFICATIONS .
Fig 62: Applying Bead Of Sealant In Upper Block/Lower Block Joining Area Of Engine
135. Lay a bead of sealant (Loctite ultra-black) (1) in the upper block/lower block joining area of the
engine, as shown in the figure.
Fig 63: Timing Drive Chain Cover & Bolts

Fig 64: Centre Fixing Screw For Timing Drive Chain Cover & Gasket
136. Using a NEW gaskets, install the timing chain cover (1a) and tighten the bolts (1b), (1c) finger
tight.
137. Using a NEW bolt in location (1d) gasket (a) with gasket tighten finger tight.
Fig 65: Timing Drive Chain Cover Bolt Tightening Sequence
138. Using the tightening sequence shown in illustration, tighten the bolts:
1. M6 bolts 13 N.m (10 ft. lbs.).
2. M8 bolts 13 N.m (10 ft. lbs.).

Fig 66: Using Special Tool To Install Crankshaft Oil Seal
139. Using the 2000040939 tool, install a NEW crankshaft oil seal.
Fig 67: Using Special Tool To Install Crankshaft Pulley Into Housing
140. Install the crankshaft pulley (1a) in its housing and use the 2000040941 tool (1b).
Fig 68: Using Special Tool At Crankshaft Pulley & Bolt
141. Using the 2000040944 tool (1a) tighten the vibration damper bolt (1b) to the proper
Fig 69: Accessory Drive Belt Automatic Tensioner, Accessory Drive Belt Fixed Tensioner &
Bolts
142. Install the idler pulley (1a) and tighten the bolt (1b) to the proper specification. Refer to
143. Install the serpentine belt tensioner (2a) and tighten the bolts (2b) to the proper specification.
Fig 70: Water Delivery Pipe To Engine Block, Water Pump Assembly & Bolts
144. Replace the gasket on the connector of the water delivery pipe to the engine block.
145. Install the water pump (1a) and tighten the bolts (1b) to the proper specification. Refer to
146. Tighten the bolts (2) securing the water delivery pipe connector to the engine block to the
Fig 71: A/C Compressor Mounting & Bolts
147. Install the A/C compressor mounting bracket (1a). Tighten the bolts (1b) and the bolt (1c) to the
148. Install the A/C compressor (1a) in its housing and tighten the screws (1b) to the proper
149. Install the generator (1a) in its housing and tighten the screws (1b) to the proper specification.
150. Fit the alternator guard in its housing and tighten the nuts.
151. Adjust the moving tensioner and fit the accessory drive belt.
Fig 74: Tappet Cover & Bolts
152. Install the cylinder head cover (1a) complete with NEW gasket and variable valve timing
electromagnet in its housing and tighten the bolts (1b) to the proper specification. Refer to
Fig 75: Removing/Installing Spark Plugs
153. Install the spark plugs (1) and tighten to the proper specification. Refer to TORQUE
SPECIFICATIONS .
154. Install the ignition coils (1a) in place and tighten the screws (1b) to the proper specification.
Fig 77: Thermostat Complete With Pipes & Bolts
155. Install the thermostat housing (1a) and tighten the screws (1b) to the proper specification.
156. Place the return pipe from the heater to the water pipe in its housing and tighten the fixing
screw to the thermostat.
157. Connect the return pipe from the heater to the water pump and engage the retaining clip using
the 1881138000 tool.
Fig 78: Air Intake Chamber With Throttle Body And Fuel Distribution Manifold & Bolts
158. Install the intake manifold (1a) complete with throttle body and fuel rail and tighten the bolts (1b)
159. Tighten the screw securing the air chamber to the mounting bracket.
160. Place the engine oil dipstick tube in its housing and tighten the fixing bolt.
161. Place the idling engine oil vapor intake pipe in its housing and press-fit it, air chamber and
single-acting valve side.
162. Place the engine wiring in its housing and engage the retaining clips.
163. Connect the engine temperature sensor wire harness connector and engage the wiring retainer
with the bracket.
164. Connect the Crankshaft Position (CKP) sensor wire harness connector.
165. Connect the knock sensor wire harness connector.
167. Connect and secure the fuel vapor recovery solenoid wire harness connector.
168. Connect the fuel injectors wire harness connector.
169. Connect the ignition coils wire harness connector.

170. Tighten the screw securing the wiring duct to the tappet cover, intake side.
171. Engage the wire harness retaining clips on the intake manifold side.
172. Connect the A/C compressor wire harness connector.
173. Connect the generator wire harness connector.
174. Connect the intake air temperature and pressure sensor wire harness connector.
175. Tighten the screw securing the wiring duct to the cylinder head cover, timing side.
176. Connect the variable valve timing system electromagnet wire harness connector.
177. Connect the Camshaft Position (CMP) sensor wire harness connector.
178. Connect the minimum engine oil pressure switch wire harness connector.
179. Install the engine oil plug and tighten to the proper specification. Refer to TORQUE
SPECIFICATIONS .
180. Remove the engine from the overhaul stand and place it on a suitable platform.
> REMOVAL
Fig 1: Engine Cover
1. Raise and remove the sound insulation cover (1a) releasing it from the four inner retainers.
> INSTALLATION
1. Check that the sound insulation cover is not damaged.
2. Position the sound insulation cover and secure it engaging the four inner retainers.
AIR INTAKE SYSTEM > BODY, AIR CLEANER > REMOVAL AND INSTALLATION >
Fig 1: Cover At Wheel Arch & Screws
2. Remove the screws and the cover from the wheel arch.
Fig 2: Resonator
3. Remove the resonator (1).

Fig 3: Cold Air Intake Nut
4. Remove the nut (1) fixing the cold air intake to the front end.
Fig 4: Air Cleaner Body
5. Remove the air cleaner body (1) from the flexible mountings.
Fig 5: Clips At Cold Air Intake
6. Release the clips to disconnect the cold air intake (1).
1. Install the cold air intake to the air cleaner and engage the clips.
2. Place the air cleaner assembly back in its housing and engage the flexible mountings.
3. Tighten the nut fixing the cold air intake to the front end.
4. Tighten the resonator to the cold air intake.
5. Install the cover from the wheel arch and securely tighten the screws.
AIR INTAKE SYSTEM > HOSE, CLEAN AIR > REMOVAL AND INSTALLATION >
Fig 1: Oil Vapor Pipe Quick Coupling, Air Tube To Throttle Body Band & Air Tube Bolt
2. Disconnect the oil vapor pipe quick coupling (1).
3. Loosen the band securing the air tube to the throttle body (2).
4. Remove the bolt securing the air tube (3).

Fig 2: Air Tube Band At Air Cleaner Body
5. Loosen the band and remove the air tube from air cleaner body.
AIR INTAKE SYSTEM > HOSE, CLEAN AIR > REMOVAL AND INSTALLATION >
1. Install the air tube to the air cleaner body and tighten the band clamp.
2. Tighten the fixing screw of the sleeve intermediate bracket.
3. Install the air tube to the throttle body and securely tighten the band clamp.
4. Connect the oil vapor pipe quick coupling.
CYLINDER HEAD > DESCRIPTION AND OPERATION > DESCRIPTION

Fig 1: Cylinder Head
The cylinder head (1) is one-piece and made of aluminum alloy. The 4 valves per cylinder are
interference fit in their respective valve guides in the respective cylinder head housings.
The 16 valves of the cylinder head are operated by roller rocker arms controlled through a single
camshaft.
In the cylinder head is a frame which acts as a support for the camshaft. The upper half cap of the
camshaft in turn supports another two shafts, which support the automatic clearance recovery
rocker arms.
The cylinder head is 97 mm in height.
Engine misfiring
Poor fuel economy
are:
Engine overheating
Loss of coolant
Coolant foaming
CYLINDER HEAD > DIAGNOSIS AND TESTING > HYDRAULIC LASH ADJUSTER
A tappet-like noise may be produced from several sources. Check the following items:
Engine oil level too high or too low. This may cause oil aeration. Aerated oil entering the adjusters
may cause them to be spongy.
Insufficient running time after rebuilding the cylinder head. Low speed running up to one hour may
be required. Turn the engine off and let set for a few minutes before restarting. Repeat this several
times after the engine has reached normal operating temperature.
Low oil pressure.
The oil screen in cylinder head or the oil passage to the cylinder head is plugged with debris.
Air ingested into oil due to broken or cracked oil pump pick-up.
Worn valve guides.
Rocker arm ears contacting valve spring retainer.
Rocker arm loose, adjuster stuck or at maximum extension and still leaves lash in the system.
Oil leak or excessive cam bearing wear in the cylinder head.
Faulty lash adjuster. Check lash adjusters for "sponginess" while installed in the cylinder head and
cam lobe at base circle. Depress part of rocker arm over the adjuster. Normal adjusters should feel
firm when pressed quickly. When pressed very slowly, lash adjusters should collapse. Remove
suspected lash adjusters, and replace. Before installation, make sure adjusters are full of oil. This
can be verified by little plunger travel when lash adjuster is depressed quickly.

CAUTION:
NOTE:

NOTE:
cleaner.
1. Valve Springs
2. Valve Seats
3. Valve Guides
4. Valves
CYLINDER HEAD > REMOVAL AND INSTALLATION > REMOVAL AND INSTALLATION
> REMOVAL
2. Remove the cylinder head cover. Refer to COVER(S), CYLINDER HEAD, REMOVAL AND
INSTALLATION .

INSTALLATION .
10. Remove the A/C compressor. Refer to COMPRESSOR, A/C, REMOVAL AND INSTALLATION .
11. Remove the engine timing cover. Refer to COVER(S), ENGINE TIMING, REMOVAL AND
INSTALLATION .
12. Remove the engine timing tensioner. Refer to TENSIONER, ENGINE TIMING, REMOVAL AND
INSTALLATION .
INSTALLATION .
14. Remove the clean air hose. Refer to HOSE, CLEAN AIR, REMOVAL AND INSTALLATION .
15. Remove the timing chain and sprocket. Refer to CHAIN AND SPROCKETS, TIMING,
16. Remove the front oxygen sensor. Refer to SENSOR, OXYGEN, REMOVAL AND
INSTALLATION .
17. Remove the rear oxygen sensor. Refer to SENSOR, OXYGEN, REMOVAL AND
INSTALLATION .
18. Remove the exhaust manifold. Refer to MANIFOLD, EXHAUST, REMOVAL AND
INSTALLATION .
19. Remove the intake manifold. Refer to MANIFOLD, INTAKE, REMOVAL AND INSTALLATION .
Fig 1: Powertrain Control Module (PCM) Wire Harness Connector, Engine Front Wire Harness
& Clip
20. Disconnect the Powertrain Control Module (PCM) wire harness connector (1).
21. Disconnect the engine front wire harness (2).
22. Open the clip (3) and release the wiring.

Fig 2: Water Supply Hose Band & Degassing Pipe Quick Coupling
23. Loosen the band and disconnect the water supply hose (1) to the radiator, thermostat side.
24. Disconnect the quick coupling for the degassing pipe (2), thermostat side.
Fig 3: Water Return Pipe, Water Supply Pipe, Bands & Engine Coolant Temperature Sensor
25. Loosen the band and disconnect the water return pipe (1) from the heater, pipe side.
26. Loosen the band and disconnect the water supply pipe (2) to the heater, thermostat side.
27. Detach the engine coolant temperature sensor wire harness connector (3).
Fig 4: Ground Cable & Bolt
28. Remove the bolt and the ground cable.

Fig 5: Water Pump Return Pipe & Bolt
29. Remove the bolt and position aside the water pump return pipe.
Fig 6: Cylinder Head Bolts
30. Remove the bolts (1a) and the cylinder head (1b).
31. Remove the gasket and check the condition of the locating bushes on the engine block.
> INSTALLATION
1. Fit a new cylinder head gasket engaging the locating bushes on the engine block.
2. Place the cylinder head in position engaging the locating bushes on the engine block.
3. PROCEED TIGHTENING THE CYLINDER HEAD SCREWS TO THE ENGINE BLOCK,

FOLLOWING THE ORDER SHOWN IN THE FIGURE
4. The tightening stages are as follows:
1. a - Tighten the bolts from 1 to 12 finger tight
2. b - Tighten the bolts 1 to 10 to 20 N.m (15 ft. lbs.)
3. c - Tighten the bolts 1 to 10 to 40 N.m (30 ft. lbs.)
4. d - Tighten the bolts 11 to 12 to 15 N.m (11 ft. lbs.)
5. e - Tighten the bolts 1 to 10 an additional 90° turn
6. f - Tighten the bolts 1 to 10 an additional 90° turn
7. g - Tighten the bolts 11 to 12 to 30 N.m (22 ft. lbs.).
5. Install the return pipe to the water pump in its housing and tighten the bolt to the proper
6. Install the ground cable and securely tighten the bolt.
7. Connect the engine coolant temperature sensor wire harness connector.

8. Connect the water delivery pipe to the heater, thermostat side, and tighten the band.
9. Connect the water return pipe from the heater, pipe side and tighten the band.
10. Connect the quick coupling for the degassing pipe, thermostat side.
11. Connect the radiator coolant supply hose, thermostat side, and tighten the band.
12. Connect the engine front wire harness.
13. Connect the Powertrain Control Module (PCM) wire harness connector.
14. Engage the wiring retaining clip.
15. Install the intake manifold. Refer to MANIFOLD, INTAKE, REMOVAL AND INSTALLATION .
16. Install the exhaust manifold. Refer to MANIFOLD, EXHAUST, REMOVAL AND INSTALLATION .
17. Install the rear oxygen sensor. Refer to SENSOR, OXYGEN, REMOVAL AND INSTALLATION .
18. Install the front oxygen sensor. Refer to SENSOR, OXYGEN, REMOVAL AND INSTALLATION .
19. Install the timing chain and sprocket. Refer to CHAIN AND SPROCKETS, TIMING, REMOVAL
AND INSTALLATION .
20. Install the clean air hose. Refer to HOSE, CLEAN AIR, REMOVAL AND INSTALLATION .
21. Install the air cleaner body. Refer to BODY, AIR CLEANER, REMOVAL AND INSTALLATION .
22. Install the engine timing tensioner. Refer to TENSIONER, ENGINE TIMING, REMOVAL AND
INSTALLATION .
23. Install the engine timing cover. Refer to COVER(S), ENGINE TIMING, REMOVAL AND
INSTALLATION .
24. Install the A/C compressor. Refer to COMPRESSOR, A/C, REMOVAL AND INSTALLATION .
32. Install the cylinder head cover. Refer to COVER(S), CYLINDER HEAD, REMOVAL AND
INSTALLATION .
CYLINDER HEAD > REMOVAL AND INSTALLATION > DISASSEMBLY AND
REASSEMBLY > DISASSEMBLY
Fig 1: Placing Cylinder Head In A Vise Using Support Tool
1. Position the cylinder head (1a) in the vice, supporting it using the support tool (1b).
Fig 2: Fitting Valve Retaining Tool & Camshaft Front Support Tool
2. Fit the valve retaining tool (1).
3. Fit the tool on the camshaft front support (2).

Fig 3: Compressing Valve Spring Using Special Tools
4. Using the tools (1a), (1b) and (1c), compress the spring and remove the valve spring upper
shim retaining half-cones.
Fig 4: Upper Shim & Valve Spring
5. Remove the upper shim (1a) and the valve spring (1b).
Fig 5: Removing Oil Sealing Ring Using Special Tool
6. Using the tool (1a), remove the oil sealing rings (1b) with built-in spring lower shim.
7. Proceed in the same way for the remaining three valves of the cylinder.
8. Remove the valve retaining tool and keep the intake and exhaust valves.
9. Proceed in the same way for removing the valves of the remaining pistons.
10. Replace the valve guides. Refer to VALVE GUIDES, REMOVAL AND INSTALLATION .
CYLINDER HEAD > REMOVAL AND INSTALLATION > DISASSEMBLY AND

REASSEMBLY > ASSEMBLY
1. Clean any residues of the gasket from the lower cylinder head plane.
2. Check that the flatness of the cylinder head lower surface corresponds to the recommended
values.
3. If necessary, flatten the lower cylinder head surface; it is permitted to remove 0.1 mm of
material from the minimum cylinder head height (factory value).
4. Check the volume of all combustion chambers proceeding as described below.
5. Fit the valves and spark plugs provisionally. Take a graduated burette containing a known
amount of engine oil.
6. Rest a glass plate on the cylinder head with holes corresponding to the combustion chambers.
Fig 1: Filling Combustion Chamber On Cylinder Head With Oil
7. Fill the combustion chamber completely, taking care not to pour oil outside of the combustion
chamber.
8. Wait about 10 minutes to allow the oil to decant.
9. Measure the amount of oil remaining in the burette and then calculate the difference between
this and the amount of oil used initially with the burette full. The difference is the volume of the
combustion chamber in the cylinder head.
10. Check that this value is within the specified values; if it is not, replace the cylinder head.
11. Check that the valve stem does not show signs of grooves or seizing.
12. Check that the diameter of the valve stems corresponds to the recommended figures; if not,
replace the worn valves.
13. Check that the diameter of the valve head corresponds to the prescribed figures; if not, replace
the worn valves.
14. Check that the inner diameter of the valve guide and the clearance between it and the valve
are within specified values, otherwise replace the valve guide.
15. If necessary, replace the valve guides. Refer to VALVE GUIDES, REMOVAL AND
INSTALLATION .
16. Check that the length of the valve springs released is within the prescribed values.
17. Using a suitable tool, check that the valve spring specifications correspond to the prescribed
figures; if not, replace the worn components.
18. Check that the diameter of the camshaft bearings corresponds to the recommended figures; if
not, replace the worn camshaft.
19. Check that the diameter of the camshaft supports corresponds to the prescribed figures; if not,
replace the cylinder head.
20. Check that the clearance between the pins and the camshaft supports is within the prescribed
values.
21. Check that the camshaft end float is within the prescribed values.
22. Check that the nominal camshaft cam lift corresponds to the recommended figures; if not,
replace the worn camshaft.
23. Check that the total height of the shaft plus cam is within the prescribed values.
Fig 2: Grinding Valve Seat
24. Grind the valve seats to the prescribed size.
25. Grind the valve seats using a suitable tool.
26. Position the cylinder head in the vice using the tool.
27. Fit the valves in the seats, then support them using the valve retaining tool.
Fig 3: Positioning Fitting Tool For Installation Of Valve Guide Oil Seal
28. Position the fitting tool (1) for the installation of the valve guide oil seal as shown in the figure.
Fig 4: Fitting Valve Guide Oil Seal With Built-In Lower Shim Using Special Tool
29. Fit the valve guide oil seal with built-in lower shim using the tool (1) as shown in the figure.
30. Place the valve spring and the upper shim back in the housing.
31. Place the upper shim retaining half-cones back in their housings with the tools used for the
removal.
32. Proceed in a similar way for the other valves.
33. Remove the tools used for fitting the valves.
34. Undo the nuts and remove the cylinder head from the support tool.
CYLINDER HEAD > CAMSHAFT, ENGINE > DESCRIPTION > DESCRIPTION

Fig 1: Camshaft
The cast-iron camshaft has three cams for each cylinder:
Two - smaller - cams operate the rocker arms that move the intake valves.
The cam - larger - operates a specific rocker arm that moves the exhaust valves.
The camshaft has 4 oil entry holes in the area with the first timing side bearing at the height where the
variable valve timing unit is fixed on the camshaft. The holes are filled and pressurized with the engine oil
from the cylinder head.
Fig 2: Variable Valve Timing (VVT) Unit, Fixing Screw & Oil Filling Duct
The engine oil is used both to lubricate the mounting and also for filling and the operation of the Variable
Valve Timing (VVT) unit through the VVT unit fixing screw (2) and oil filling duct (1), which is hollow
precisely in order to permit the transfer of oil to the VVT unit (3).
INSTALLATION .

INSTALLATION .
INSTALLATION .
INSTALLATION .
INSTALLATION .
14. Remove the timing chain and sprocket. Refer to CHAIN AND SPROCKETS, TIMING,
Fig 1: Camshaft Caps
15. Remove the camshaft caps (1).

Fig 2: Camshaft In Cylinder Head
16. Remove the camshaft.
Fig 1: Placing Camshaft Caps & Camshaft In Housing And Positioning Camshaft So That 2
Pins Of Timing Side Stem Are Vertical And Face Exhaust Side
1. Place the camshaft in its housing and position it so that the two pins (1) of the timing side stem
are vertical and face the exhaust side, as shown in illustration.
2. Place the camshaft caps (2) in their housings engaging the locating bushings and complying
with the numbers printed on the top, from 1 to 5. The assembly direction goes from number 1,
timing side, to number 5, flywheel side.
3. Each camshaft cap has two teeth that must be facing towards the timing drive chain side, so
that the lubrication hole is facing towards the exhaust side.
Fig 2: Positioning Two Bevels Of Flywheel Side Stem Of Camshaft
4. Position the camshaft as described, then make sure that the two bevels of the flywheel side
stem are in the position shown in figure, for an easier fitting of a spanner to use as counter-
AND INSTALLATION .
INSTALLATION .
INSTALLATION .
INSTALLATION .
CYLINDER HEAD > COVER(S), CYLINDER HEAD > DESCRIPTION > DESCRIPTION
Fig 1: Tappet Cover & Gasket
The tappet cover is made of plastic. A dedicated rubber seal is fitted in the part in contact with the
cylinder head.
On the tappet cover are holes for inserting the ignition coils and timing sensor. Positioned between the
coils and the timing sensor are specific rubber seals to prevent engine oil leaks.
Also on the tappet cover are two oil vapor recovery systems.
CYLINDER HEAD > COVER(S), CYLINDER HEAD > REMOVAL AND INSTALLATION >
Fig 1: Ignition Coils, Screws & Wire Harness Connectors
2. Disconnect the ignition coils wire harness connectors (1).
3. Undo the screws (2a) and remove the ignition coils (2b).
Fig 2: Oil Vapor Pipe At Tappet Cover & Band
4. Disconnect the oil vapor pipe from the tappet cover (1).
5. Loosen the band and disconnect the oil vapor pipe from the tappet cover (2).
Fig 3: Timing Sensor Electrical Connection & Screws Attaching Wiring Duct To Tappet Cover
6. Detach the timing sensor electrical connection (1).
7. Undo the screws fixing the wiring duct to the tappet cover (2).
Fig 4: Wiring Retaining Clips
8. Release the wiring retaining clips (1).

Fig 5: Variable Valve Timing System Wire Harness Connector
9. Disconnect the variable valve timing system wire harness connector (1).
10. Release the wiring from the intermediate retaining clips.

Fig 6: Tappet Cover & Screws
11. Undo the screws (1a) and remove the tappet cover (1b) complete with seal.
Fig 7: Variable Valve Timing System & Screws
12. If necessary:
13. Undo the screws (1a) and remove the variable valve timing system (1b) complete with gasket.
Fig 8: Camshaft Position (CMP) Sensor, Positive Crankcase Ventilation (PCV) Valve & Engine
Oil Filler Plug
14. Remove the screw and the Camshaft Position (CMP) sensor (1).$
15. Remove the Positive Crankcase Ventilation (PCV) valve (2).
16. Remove the engine oil filler plug (3).
Fig 1: Tappet Cover & Screws
1. Install the tappet cover (1a) complete with NEW gasket in its housing and tighten the screws
(1b) to the proper specification. Refer to TORQUE SPECIFICATIONS .
2. Connect the variable valve timing system wire harness connector and engage the wiring
retaining clips.
3. Tighten the screws fixing the wiring duct to the tappet cover.
4. Connect the Camshaft Position (CMP) sensor wire harness connector and engage the wiring
retaining clips.
5. Connect the oil vapor pipe to the tappet cover and tighten the band.
6. Connect the oil vapor pipe to the tappet cover.

Fig 2: Ignition Coils, Screws & Wire Harness Connectors
7. Fit the ignition coils (1a) in place and tighten the screws (1b) to the proper specification. Refer
to SPECIFICATIONS .
8. Connect the ignition coils wire harness connectors (2).
CYLINDER HEAD > LIFTER(S), HYDRAULIC > DESCRIPTION > DESCRIPTION
INTAKE
Fig 1: Intake Side Rocker Arm & Hydraulic Tappet
There are two intake side rocker arms (1), one per valve, and they have a specific form according
to the valve to be operated.
They contain the hydraulic tappet (2) and oil transfer channels for lubricating and filling the tappet
and act as supports for the roller bearing (3).
EXHAUST
Fig 2: Exhaust Side Rocker Arm, Roller Bearing & Hydraulic Tappet
There is a single exhaust side rocker arm (2), but it acts on both exhaust valves simultaneously. It
contains the hydraulic tappets (3) and oil transfer channels for lubricating and filling the tappets and
acts as support for the roller bearing (1).
Fig 3: Locating Holes In Shaft Body For Rocker Arm Bearing & Hydraulic Tappet Lubrication
There are two rocker arm supports, one per side. They are hollow and made of steel. Along the
body of the shaft are the holes (1) used for lubricating the bearings for the rocker arms and the
corresponding hydraulic lifters. Also on the shafts are other holes used for fixing them, with screws,
to the cylinder head.
CYLINDER HEAD > LIFTER(S), HYDRAULIC > REMOVAL AND INSTALLATION >
EXHAUST SIDE TAPPETS

Fig 1: Exhaust Side Rockers With Tappets
1. Take out the rockers (1a) with tappets (1b) from the rocker axle.
INTAKE SIDE TAPPETS
1. Remove the spacers (1a) and take out the rockers (1b) with tappets (1c) from the rocker axle.
Fig 2: Intake Side Spacers & Rockers With Tappets
CYLINDER HEAD > LIFTER(S), HYDRAULIC > REMOVAL AND INSTALLATION >
INTAKE SIDE TAPPETS

Fig 1: installing Intake Side Tappets
1. Place the rockers with tappets in their housings on the rocker axle.
2. The tappets of each cylinder must be installed with the tappet housings (a) reciprocally
converging.
Fig 2: Intake Side Spacers Must Be Fitted Next To Grooves
3. Install the spacers in the housings on the rocker axle.
4. The spacers (a) must be fitted next to the grooves (b) on the rocker axle, as shown in the
figure.
EXHAUST SIDE TAPPETS
1. Place the rockers with tappets in their housings on the rocker axle.
CYLINDER HEAD > VALVE GUIDES > REMOVAL AND INSTALLATION > REMOVAL
Fig 1: Removing Valve Guide Using Special Tool
1. Remove the valve guide using the tool as shown in the figure.
CYLINDER HEAD > VALVE GUIDES > REMOVAL AND INSTALLATION > REMOVAL
1. Check that the diameter of the valve guide housing is within the prescribed values.
2. Check that the outer diameter of the new valve guide is within the prescribed values.
3. Check that the interference between the valve guide and the seat is within the prescribed
values.
4. Before fitting the new valve guide, the cylinder head must be heated to a temperature of
around 100°C (212°F).
Fig 1: Installing Valve Guide Using Special Tool
5. Fit the NEW valve guide using the tool (1) as shown in the figure.
6. If the valve guide is slightly distorted during fitting, ream the inner surface using a suitable size
reamer.
7. Measure the inner diameter of the valve guide after refacing and the clearance with the valve;
check that they are within the prescribed values.
ENGINE BLOCK > DESCRIPTION > DESCRIPTION

Fig 1: Cylinder Block
The block is made of cast iron, and features high mechanical resistance.
Special channels in the block walls carry coolant and lubrication fluid.
The lower part of each cylinder contains a jet that sprays engine oil onto the piston crown to cool it
and to ensure that the gudgeon pin is lubricated by the oil dripping from above.
In addition to housing the cylinder liners/bores, the engine block supports the moving assemblies in
the engine (pistons, connecting rods, crankshaft, etc.), the fixed elements (cylinder heads, oil
sump, timing cover) and the auxiliary components (alternator, starter, climate control compressor,
etc.).
ENGINE BLOCK > DESCRIPTION > LOWER BLOCK

Fig 1: Lower Block
The lower block is made of cast iron, as are the 5 main bearings. The lower engine block is joined
to the upper engine block by means of screws and locating dowels, to guarantee a precise fit.
There is a bead of sealant between the two blocks to prevent oil leaks.
The lower block helps to reduce the level of vibration and engine noise.
The lower block carries out the following functions:
Acts as a bearing structure with the upper engine block.
Supports the crank gear reactions and loads.
Supports the oil pan and lubrication oil.
Acts as a support for the main half bearings.

CAUTION:
CAUTION:
rings.
angle.
NOTE:

USING PLASTIGAGE

NOTE:
NOTE:
NOTE:

NOTE:
NOTE:

scale.
ENGINE BLOCK > DAMPER, VIBRATION > REMOVAL AND INSTALLATION >
2. Remove the starter motor. Refer to STARTER, REMOVAL AND INSTALLATION .
3. Remove the right front wheel house splash shield. Refer to SHIELD, SPLASH, FRONT
Fig 1: Installing Flywheel Locking Tool In Starter Housing
5. Install the flywheel locking tool 2000041300 in the housing of the starter.
Fig 2: Vibration Damper Bolt
6. Remove the vibration damper bolt (1).

Fig 3: Removing Vibration Damper
7. Using the tool 2000040942 (1a) and suitable extractor (1b), remove the vibration damper (1c).
Fig 4: Front Crankshaft Oil Seal At Timing Cover
8. Remove the front crankshaft oil seal from the timing cover taking care not to damage its
housing.
Fig 1: Installing Front Crankshaft Oil Seal Using Special Tool
1. Using the fitting tool 2000040939 (1), install the NEW front crankshaft oil seal.
Fig 2: Installing Vibration Damper Using Special Tool
2. Using the tool 2000040941 (1b), install the vibration damper (1a).
3. Install a NEW vibration damper and tighten to the proper specification. Refer to TORQUE
SPECIFICATIONS .
4. Remove the flywheel locking tool 2000041300.
6. Install the right front wheel house splash shield. Refer to SHIELD, SPLASH, FRONT
7. Install the starter motor. Refer to STARTER, REMOVAL AND INSTALLATION .
ENGINE BLOCK > RING(S), PISTON > REMOVAL AND INSTALLATION > REMOVAL
1. Position the connecting rod-piston assembly in a vice fitted with protective jaws.
Fig 1: Removing Sealing Rings From Piston
2. Remove the sealing rings from the piston using a suitable tool (1).
Fig 2: Removing Gudgeon Pin Using Hydraulic Press And Special Tools
3. On the hydraulic press, with the tools positioned as shown in the figure, remove the gudgeon
pin.
ENGINE BLOCK > RING(S), PISTON > REMOVAL AND INSTALLATION > REMOVAL
1. Clean any carbon residues from the piston crown.
2. Heat the connecting rod in an oven to a temperature of 240 °C to allow the fitting of the
gudgeon pin.
Fig 1: Joining Connecting Rod To Piston With Notch On Connecting Rod Positioned Next To
Two Marks On Piston Crown For Intake Valves
3. Join the connecting rod to the piston so that the notch (a) on the connecting rod is next to the
two marks (b) on the piston crown for the intake valves.
Fig 2: Installing Gudgeon Pin Using Hydraulic Press And Special Tools
4. On the hydraulic press, fit the gudgeon pin (1b) using the tool (1a) as shown in the figure.
5. Position the connecting rod-piston assembly in a vice fitted with protective jaws.
6. Fit the seals on the piston using a suitable tool.
7. All the sealing rings must be fitted with the word TOP upwards.
8. When the fitting is complete, position the references on the sealing rings so that they are not
aligned with the gudgeon pin axis and are 120° offset from one another.
ENGINE BLOCK > ROD, PISTON AND CONNECTING > DESCRIPTION >
DESCRIPTION
Fig 1: Piston Components
PISTON
The pistons are made of aluminum alloys and have a graphite coating on the skirt, imprints for the
valves and a small hollow for the combustion chamber on the crown. The pistons are further cooled
by an oil jet; the compression seal is ensured by two piston rings, while the oil seal is provided by
a third oil scraper ring.
Fig 2: Connecting Rod
CONNECTING ROD
The connecting rods (1) are made of steel. The piston pin is the floating type and works inside the
bush inserted in the small end and is kept in place by two circlips on the piston. The last two digits
of the external diameter of the big end are shown on the connecting rod cap. The weight of each
individual connecting rod is approximately 420 g.
INSTALLATION .
6. Drain the engine oil and replace the oil filter. Refer to FILTER, ENGINE OIL, REMOVAL AND
INSTALLATION .
INSTALLATION .
INSTALLATION .
INSTALLATION .
INSTALLATION .
16. Remove the timing chain and sprocket. Refer to CHAIN AND SPROCKETS, TIMING .
17. Remove the front oxygen sensor. Refer to SENSOR, OXYGEN, REMOVAL AND
INSTALLATION .
18. Remove the rear oxygen sensor. Refer to SENSOR, OXYGEN, REMOVAL AND
INSTALLATION .
19. Remove the exhaust manifold. Refer to MANIFOLD, EXHAUST, REMOVAL AND
INSTALLATION .
20. Remove the intake manifold. Refer to MANIFOLD, INTAKE, REMOVAL AND INSTALLATION .
21. Remove the cylinder head. Refer to CYLINDER HEAD, REMOVAL AND INSTALLATION .
23. Remove the bolts (1a) and the connecting rod cap (1b) complete with half-bearing.
Fig 2: Arrow On Piston Crown Facing Timing Side Indicates Fitting Direction
24. Remove the piston with connecting rod and half-bearing.
25. The arrow (a) on the piston crown facing the timing side indicates the fitting direction. The
connecting rods are pre-set fracture rods and are supplied already fractured by parts together
with the cap screws. The connecting rod caps are not interchangeable because the fracture
profile differs from part to part.
Fig 1: Aligning Notch On Connecting Rod Cap With Notch On Connecting Rod
1. A notch (a) is present on the connecting rod caps, which should be aligned with the notch (b)
on the connecting rod. These reference notches should be facing the intake side.
Fig 2: Installing Piston Assembly Into Cylinder Using Special Tool
2. Fit the connecting rod-piston assembly with half-bearings using a suitable tool (1) to compress
the sealing rings and then fit the piston into the cylinder liner.
Fig 3: Arrow On Piston Crown Facing Timing Side Indicates Fitting Direction
3. The arrow (a) on the piston crown facing the timing side indicates the fitting direction.
4. Place the bearing cap (1a), complete with half-bearing, back in its housing and tighten the
screws (1b) to the proper specification. Refer to TORQUE SPECIFICATIONS .
6. Install the cylinder head. Refer to CYLINDER HEAD, REMOVAL AND INSTALLATION .
7. Install the intake manifold. Refer to MANIFOLD, INTAKE, REMOVAL AND INSTALLATION .
8. Install the exhaust manifold. Refer to MANIFOLD, EXHAUST, REMOVAL AND INSTALLATION .
9. Install the rear oxygen sensor. Refer to SENSOR, OXYGEN, REMOVAL AND INSTALLATION .
10. Install the front oxygen sensor. Refer to SENSOR, OXYGEN, REMOVAL AND INSTALLATION .
AND INSTALLATION .
INSTALLATION .
INSTALLATION .
INSTALLATION .
25. Fill the engine with oil and replace the oil filter. Refer to FILTER, ENGINE OIL, REMOVAL AND
INSTALLATION .
MANIFOLDS > MANIFOLD, INTAKE > REMOVAL AND INSTALLATION > REMOVAL
2. Open the fuse box cover in the engine compartment, remove the fuse F21 and start the engine
several times until the pressure in the distribution manifold is discharged.
Fig 1: Air Chamber To Bracket Bolt
6. Remove the bolt (1) securing the air chamber to the bracket.
Fig 2: Fuel Vapor Pipe Retaining Clips
7. Release the retaining clips and remove the fuel vapor pipe (1).
Fig 3: Fuel Supply Line Quick Coupling
8. Disconnect the quick coupling for the fuel supply line (1).
Fig 4: Fuel Injector Wire Harness Connectors & Wiring Retaining Clips
9. Disconnect the fuel injector wire harness connectors (1a) and release the wiring retaining clips
(1b).
Fig 5: Knock Sensor Wire Harness Connector
10. Disconnect the knock sensor wire harness connector (1).

Fig 6: Knock Sensor
11. Remove the knock sensor (1).

Fig 7: Throttle Body Wire Harness Connector, Brake Servo Vacuum Air Pipe & Band
13. Loosen the band and disconnect the brake servo vacuum air pipe (2).
Fig 8: Degassing Pipe, Oil Vapor Pipe At Intake Manifold, Vacuum Air Pipe For Brake Servo &
Clips
14. Open the clip and release the degassing pipe (1).
15. Open the clip and disconnect the oil vapor pipe from the intake manifold (2).
16. Open the clip and release the vacuum air pipe for brake servo (3).
Fig 9: Fuel Vapor Recovery Solenoid Wire Harness Connector, Fuel Vapor Recovery Solenoid
Valve & Clip
18. Open the clip (2a) and disconnect the fuel vapor recovery solenoid valve (2b) complete with
O-ring.
Fig 10: Air Pressure And Temperature Sensor Wire Harness Connector & Wiring Retaining
Clips
19. Disconnect the air pressure and temperature sensor (1a) wire harness connector and release
the wiring retaining clips (1b).
Fig 11: Engine Oil Dipstick Tube, Intake Manifold & Bolts
20. Remove the bolt securing the engine oil dipstick tube (1).
21. Remove the bolts (2a) and the intake manifold (2b).
Fig 12: Intake Manifold Gaskets
22. Remove the intake manifold gaskets (1).

Fig 13: Throttle Body & Screws
23. Remove the screws (1a) and the throttle body (1b) complete with bracket.
Fig 14: Fuel Rail, Injectors & Screws
24. Remove the screws and the fuel rail complete with injectors.
Fig 15: Air Pressure And Temperature Sensor & Screws
25. Remove the screw and the air pressure and temperature sensor.
MANIFOLDS > MANIFOLD, INTAKE > REMOVAL AND INSTALLATION > REMOVAL
1. Install the air pressure and temperature sensor in its housing and secure it using the screw.
2. Install the fuel rail and securely tighten the screws.
3. Install the throttle body assembly and tighten the screws to the proper specification. Refer to
FUEL INJECTION, SPECIFICATIONS .
4. Install NEW gaskets on the intake manifold.
5. Install the intake manifold and tighten the NEW bolts to the proper specification. Refer to
6. Install the engine oil dipstick tube bolt and securely tighten.
7. Connect the air pressure and temperature sensor wire harness connector and close the wiring
retaining clips.
8. Using a New O-ring, connect the fuel vapor recovery solenoid valve and close the retaining
clip.
9. Connect the fuel vapor recovery solenoid wire harness connector.
10. Engage the fuel vapor pipe retaining clips.
11. Engage the brake servo vacuum air pipe retaining clip.
12. Connect the oil vapor pipe to the intake manifold and engage the retaining clip.
13. Engage the degassing pipe retaining clip.
14. Connect the brake servo vacuum air pipe to the throttle body and tighten the band.
16. Install the knock sensor.
18. Connect the fuel injector wire harness connector and engage the wiring retaining clips.
19. Connect the quick coupling for the fuel supply pipe.
20. Install the bolt securing the air chamber to the bracket and securely tighten.
MANIFOLDS > MANIFOLD, EXHAUST > REMOVAL AND INSTALLATION > REMOVAL
2. Open the fuse box cover in the engine compartment, remove the fuse F21 and start the engine
several times until the pressure in the distribution manifold is discharged.
Fig 1: Air Chamber To Bracket Bolt
6. Remove the bolt (1) securing the air chamber to the bracket.
Fig 2: Fuel Vapor Pipe Retaining Clips
7. Release the retaining clips and remove the fuel vapor pipe (1).
Fig 3: Fuel Supply Line Quick Coupling
8. Disconnect the quick coupling for the fuel supply line (1).
Fig 4: Fuel Injector Wire Harness Connectors & Wiring Retaining Clips
9. Disconnect the fuel injector wire harness connectors (1a) and release the wiring retaining clips
(1b).
Fig 5: Knock Sensor Wire Harness Connector
10. Disconnect the knock sensor wire harness connector (1).

Fig 6: Knock Sensor

Fig 7: Throttle Body Wire Harness Connector, Brake Servo Vacuum Air Pipe & Band
13. Loosen the band and disconnect the brake servo vacuum air pipe (2).
Fig 8: Degassing Pipe, Oil Vapor Pipe At Intake Manifold, Vacuum Air Pipe For Brake Servo &
Clips
14. Open the clip and release the degassing pipe (1).
15. Open the clip and disconnect the oil vapor pipe from the intake manifold (2).
16. Open the clip and release the vacuum air pipe for brake servo (3).
Fig 9: Fuel Vapor Recovery Solenoid Wire Harness Connector, Fuel Vapor Recovery Solenoid
Valve & Clip
18. Open the clip (2a) and disconnect the fuel vapor recovery solenoid valve (2b) complete with
O-ring.
Fig 10: Air Pressure And Temperature Sensor Wire Harness Connector & Wiring Retaining
Clips
19. Disconnect the air pressure and temperature sensor (1a) wire harness connector and release
the wiring retaining clips (1b).
Fig 11: Engine Oil Dipstick Tube, Intake Manifold & Bolts
20. Remove the bolt securing the engine oil dipstick tube (1).
21. Remove the bolts (2a) and the intake manifold (2b).
Fig 12: Intake Manifold Gaskets
22. Remove the intake manifold gaskets (1).

23. Remove the screws (1a) and the throttle body (1b) complete with bracket.
Fig 14: Fuel Rail, Injectors & Screws
24. Remove the screws and the fuel rail complete with injectors.
Fig 15: Air Pressure And Temperature Sensor & Screws
25. Remove the screw and the air pressure and temperature sensor.
MANIFOLDS > MANIFOLD, EXHAUST > REMOVAL AND INSTALLATION > REMOVAL
1. Install the air pressure and temperature sensor in its housing and secure it using the screw.
2. Install the fuel rail and securely tighten the screws.
3. Install the throttle body assembly and tighten the screws to the proper specification. Refer to
4. Install NEW gaskets on the intake manifold.
5. Install the intake manifold and tighten the NEW bolts to the proper specification. Refer to
6. Install the engine oil dipstick tube bolt and securely tighten.
7. Connect the air pressure and temperature sensor wire harness connector and close the wiring
retaining clips.
8. Using a New O-ring, connect the fuel vapor recovery solenoid valve and close the retaining
clip.
9. Connect the fuel vapor recovery solenoid wire harness connector.
10. Engage the fuel vapor pipe retaining clips.
11. Engage the brake servo vacuum air pipe retaining clip.
12. Connect the oil vapor pipe to the intake manifold and engage the retaining clip.
13. Engage the degassing pipe retaining clip.
14. Connect the brake servo vacuum air pipe to the throttle body and tighten the band.
16. Install the knock sensor.
18. Connect the fuel injector wire harness connector and engage the wiring retaining clips.
19. Connect the quick coupling for the fuel supply pipe.
20. Install the bolt securing the air chamber to the bracket and securely tighten.
LUBRICATION > DESCRIPTION > DESCRIPTION

Fig 1: Engine Oil Flow In Engine Block
The engine oil is drawn up from the sump through the suction head connected to the oil pump. The
engine oil pressure and hydraulic chain tensioner are positioned on the engine oil delivery duct,
inside the monobloc.
The bearing unit and engine oil filter are fixed on the exhaust side engine block.
Fig 2: Oil Supply Duct & Engine Oil Jets
The same oil supply duct (1) through specific channels in the monobloc, allows the engine oil to
reach the main bearings, crankshaft and crankpins in order to lubricate them.
The oil also reaches four jets (2), in the block, which spray oil under the piston crowns in order to
cool them.
Fig 3: Engine Oil Flow In Cylinder Head
When the engine oil has passed through the block via a specific duct, it arrives at the cylinder
head.
The ducts in the cylinder head allow the engine oil to arrive at the supports for the camshaft, rocker
arms and hydraulic tappets, and through the ducts on the camshaft it arrives at the Variable Valve
Timing (VVT) unit to permit its operation.
The oil that collects in the cylinder head returns to the block and then to the oil sump through
dedicated channels both on the cylinder head and the block.
LUBRICATION > DIAGNOSIS AND TESTING > ENGINE OIL LEAK
Begin with a thorough visual inspection of the engine, particularly at the area of the suspected leak. If an
oil leak source is not readily identifiable, the following steps should be followed:
1. Do not clean or de-grease the engine at this time because some solvents may cause rubber to
swell, temporarily stopping the leak.
2. Add an oil soluble dye (use as recommended by the manufacturer). Start the engine and let idle
for approximately 15 minutes. Check the oil dipstick to make sure the dye is thoroughly mixed
as indicated with a bright yellow color under a black light.
3. Using a black light, inspect the entire engine for fluorescent dye, particularly at the suspected
area of the oil leak. If the oil leak is found and identified, repair per service information
instructions.
4. If dye is not observed, drive the vehicle at various speeds for approximately 24 km (15 miles),
and repeat the inspection.
If the oil leak source is not positively identified at this time, proceed with the air leak detection
test method.
LUBRICATION > FILTER, ENGINE OIL > REMOVAL AND INSTALLATION > REMOVAL
AND INSTALLATION
1. Engine oil is dangerous for the skin: keep contact with skin to a minimum and if there is contact
Fig 1: Engine Oil Filler Cap & Oil Dipstick
6. With the engine hot, remove the engine oil filler cap (1).
7. Take out the engine oil dipstick (2).

8. Remove the drain plug (1) and drain oil completely into a suitable container.
9. Be very careful when removing the draining plug; the oil could be very hot.
10. Do not dispose of oil into the environment as indiscriminate dispersion of this product causes
pollution.
11. Clean the engine oil drain plug and tighten it with the gasket to the proper specification. Refer
Fig 4: Engine Oil Filter Cover With Filter Element
12. Remove the engine oil filter cover complete with filter element.
Fig 5: Oil Filter Element
13. Remove the filter element and the O-ring (1).

Fig 6: Oil Filter Cover O-Ring & Filter Element
14. Fit a NEW O-ring (1) on the engine oil filter cover.
15. Press fit a NEW filter element (2) in the cover fitting the retaining clips.
Fig 7: Engine Oil Filter Cover With Filter Element
16. Place the engine oil filter in position and tighten the cover to the proper specification. Refer to
17. Refill the engine lubrication circuit with the prescribed oil. Refer to CAPACITIES AND
RECOMMENDED FLUIDS, SPECIFICATIONS .
18. The table shows the quantity for periodic replacement.
19. Check that the engine oil level is correct using the dipstick.
20. The oil level is checked with the vehicle on a flat surface.
21. Fit the filler cap, let the engine idle for about 2 minutes, switch off the engine and then wait for
several minutes.
22. With engine cold, check the oil level and make sure there are no leaks.
LUBRICATION > PAN, OIL > DESCRIPTION > DESCRIPTION
Fig 1: Engine Oil Pan & Gasket
The oil pan (2) contains the engine lubrication oil and is made of aluminum; it includes a threaded
oil drainage opening with plug.
Block seal is achieved through a rubber seal gasket (1).
The sump is fixed to the engine block and front cover (timing side) with screws.
LUBRICATION > PAN, OIL > REMOVAL AND INSTALLATION > REMOVAL AND
1. Remove the right tire and wheel assembly. Refer to REMOVAL AND INSTALLATION .
2. Remove the right front wheel house. Refer to SHIELD, SPLASH, FRONT WHEELHOUSE,
.
7. Drain the engine oil and remove the oil filter. Refer to FILTER, ENGINE OIL, REMOVAL AND
INSTALLATION .
Fig 1: Catalytic Converter Mounting Bracket & Bolts
8. Remove the bolts (1a), (1b) and the catalytic converter mounting bracket (1c).
Fig 2: Front End Reinforcement & Bolts
9. Remove the bolts (1) and the front end reinforcement.

Fig 3: Air Conditioning Compressor Mounting & Bolts
10. Remove the bolts (1a), (1b) and the air conditioning compressor mounting (1c).
Fig 4: Gearbox To Engine Oil Sump Bolt
11. Remove the front and rear bolts securing the gearbox to the engine oil sump.
12. Remove the bolts (1) and the engine oil pan complete with gasket.
LUBRICATION > PAN, OIL > REMOVAL AND INSTALLATION > REMOVAL AND
1. Using a NEW gasket, install the engine oil pan. Tighten the bolts (1) finger tight.
Fig 2: Gearbox To Engine Oil Sump Bolt
2. Install the front and rear bolts (1) securing the transmission to the engine oil pan and tighten to
Fig 3: Engine Oil Pan Bolt Tightening Sequence
3. Using the tightening sequence shown in illustration, tighten the bolts to the proper specification.
Fig 4: Air Conditioning Compressor Mounting & Bolts
4. Install the air conditioning compressor mount (1a). Tighten the bolt (1b), (1c) to the proper
5. Install the front end reinforcement and securely tighten the bolts.
Fig 5: Installing Catalytic Converter Mounting Bracket
6. Install the catalytic converter mounting bracket (1a) Tighten the bolts (1b) and (1c) to the
10. Install a NEW oil filter and fill the engine with the recommended engine oil. Refer to FILTER,
ENGINE OIL, REMOVAL AND INSTALLATION .
12. Install the right front wheel house. Refer to SHIELD, SPLASH, FRONT WHEELHOUSE,
13. Install the right tire and wheel assembly. Refer to REMOVAL AND INSTALLATION .
LUBRICATION > SENSOR, OIL PRESSURE > REMOVAL AND INSTALLATION >
2. Position a suitable container to collect the oil that will come out of the housing for the engine oil
pressure warning light switch.
Fig 1: Engine Oil Warning Light Switch & Wire Harness Connector
3. Disconnect the engine oil warning light switch (1b) wire harness connector (1a).
4. Remove the engine oil warning light switch (1b).

Fig 2: Bolt, Fitting & Gaskets
5. If necessary, remove the bolt and the fitting complete with gaskets.
LUBRICATION > SENSOR, OIL PRESSURE > REMOVAL AND INSTALLATION >
1. If removed, install the fitting complete with NEW gaskets and securely tighten.
Fig 1: Engine Oil Warning Light Switch & Wire Harness Connector
2. Install the engine oil warning light switch (1) in its housing and tighten it to the proper
3. Connect the engine oil warning light switch wire harness connector (2).
LUBRICATION > PUMP, ENGINE OIL > DESCRIPTION AND OPERATION >
Fig 1: Timing Cover & Oil Pump
The oil pump (2) is coupled to the timing cover (1) using screws. Engine oil is drawn up from the
sump via the vacuum created by the rotation of vane rotor fitted to the crankshaft.
The pump features specific springs that vary the pump displacement according to the stator
position and engine operating conditions. Varying the displacement allows a reduction in
consumption and, as a consequence, a reduction in CO? emissions. The lower displacement
allows the pump to process a lower oil quantity, reducing the pump power uptake from the engine.
In this way consumption and emissions are reduced.
LUBRICATION > PUMP, ENGINE OIL > DESCRIPTION AND OPERATION >
Fig 1: Oil Pump Components
Inside the engine oil pump, in addition to the relief or overpressure valve (12), there are two
springs (10, 11) of different forces and lengths positioned in contact with the pump's stator.
The stator pivots (4) on one side on a pin (9) and on the other is positioned in contact with two
springs (10, 11). The link created between pin (9) and stator (4) permits minor rotation to increase
or decrease the eccentricity with respect to the crankshaft axis. The rotor (3), on the other hand, is
on the crankshaft and has little vanes free to exit from and return inside the rotor, so as to adapt to
the configuration of stator movement.
The stator (4) pivots on one side on a pin (9) and on the other is positioned in contact with two
springs (10, 11). The link created between pin (9) and stator (4) permits minor rotation to increase
or decrease the eccentricity with respect to the crankshaft axis. The rotor (3), on the other hand, is
on the crankshaft and has little vanes (6) free to exit from and return inside the rotor (3), so as to
adapt to the configuration of stator movement.
When the engine oil pressure exceeds a value of 5.0 bar and overcomes the reaction of the relief
or overpressure valve (12), the pressure moves the valve to the extent that it opens the
connecting duct between pressure chamber and oil filter delivery duct, so as to limit the maximum
pressure value in the circuit to a preset limit.
LUBRICATION > PUMP, ENGINE OIL > REMOVAL AND INSTALLATION > REMOVAL
AND INSTALLATION
1. For oil pump removal, refer to the engine timing cover service procedure. Refer to COVER(S),
ENGINE TIMING, REMOVAL AND INSTALLATION .
VALVE TIMING > DESCRIPTION AND OPERATION > DESCRIPTION-AND-OPERATION
> DESCRIPTION
Fig 1: Valve Timing Components
1. Oil Pressure Switch, 2. Hydraulic Chain Tensioner, 3. Moving Pad, 4. Fixed Pad, 5. Crankshaft Gear,
6. Camshaft Pulley on Variable Valve Timing (VVT) unit.
The timing control comprises a chain controlled via the gear, splined on the crankshaft, which transmits
the drive to the gear of the VVT unit fixed to the camshaft.
The chain is guided by a fixed pad and the mobile pad. It is tensioned by the hydraulic tensioner acting
on the mobile pad, which ensures a reduction in noise during operation and the correct gear control,
maintaining the tension on the loose section of the chain.
The two guide/pads are secured to the engine block with bolts.
Fig 2: Variable Valve Timing System Components
The VVT system consists of: VVT unit fixing screw head (1), Slider valve (2), Toothed timing wheel (3),
Camshaft ring gear (4), VVT unit default position recall spring (5), VVT unit fixing screw body (6).
The "continuous" VVT unit is capable of modifying the position of the camshaft in relation to the
crankshaft by approximately 45°.
In this way the engine is working with optimum timing in all operating points.
The variable valve timing is managed entirely by the Powertrain Control Module, which:
Detects the camshaft position via the timing sensor
Alters this position according to the engine operation on the basis of a calibrated map
Keeps the camshaft position under control.
The variable valve timing actuator comprises a rotor integral with the camshaft, which is able to rotate
with respect to the ring gear moved by the crankshaft via chain. The rotor is equipped with vanes and is
moved by the pressure of the engine oil acting on these vanes.
There are two compartments (the advance compartment and the delay compartment) created at
the two sides of each of these vanes: the oil can flow into one compartment or the other.
The pressure of the oil entering one compartment, pushes the vane to one side and the oil in the
other compartment is discharged. This rotates the rotor and thereby also the camshaft in a certain
direction (advance or delay).
If the engine oil alternatively enters one compartment and the other continuously for the same time,
the pressures at the two sides of the rotor are dynamically balanced and it remains still.
Engine oil flow is effected through a slider valve that brings the oil channels on the cylinder fixing
screw into communication with the advance or delay compartments created inside the VVT unit
itself, all of which is managed by an actuator fixed on the tappet cover.
The slider valve that manages the distribution of oil for the VVT unit compartments is inside the
screw used to fix the VVT unit to the camshaft.
The VVT unit is also fitted with a locking pawl that integrates the stator with the rotor when there is
no oil pressure. This measure prevents unnecessary motion of the stator in the engine starting
stage, which would begin with a considerable timing valve opening/closing delay.
The position of the VVT unit is altered by changing the oil pressure through the slider valve. A voltage
signal is applied to the VVT actuator solenoid (1) to start the VVT movement. The solenoid plunger (4)
either extends or retracts. The plunger pushes against the slider valve (2), pushing the valve backwards
and forwards to direct the flow of oil one way or another.
When the engine is being started, the pressure in the system overcomes the pressure of the spring and
releases the locking pin of the variable valve timing unit (1). The VVT remains in this position until it
receives a signal from the Powertrain Control Module to the actuator solenoid. When the engine stops,
with the reduction in oil pressure, the VVT unit locking pin returns to its original position, also assisted by
a spring inside the VVT unit itself.
The position of the slider valve (1) inside the fixing screw (2) determines which openings and chambers
inside the VVT are supplied to anticipate (3), maintain (4) or delay (5) crankshaft pinion timing with
respect to the camshaft. The valve contributes towards bringing oil from the chambers to the sump (6).
The timing sensor controls the position of the camshaft with respect to the crankshaft and provides
feedback to the Powertrain Control Module. The stator starts moving when the oil pressure pushes
against the blades (6) of the VVT body. The component is physically fixed to the camshaft and for this
reason the rotation of this component turns the camshaft with respect to the standard position of the
gear (7).
VALVE TIMING > DESCRIPTION AND OPERATION > DESCRIPTION-AND-OPERATION

> OPERATION
Fig 1: Variable Valve Timing System Operation
The position of the VVT unit is altered by changing the oil pressure through the slider valve. A
voltage signal is applied to the VVT actuator solenoid (1) to start the VVT movement. The solenoid
plunger (4) either extends or retracts. The plunger pushes against the slider valve (2), pushing the
valve backwards and forwards to direct the flow of oil one way or another.
Fig 2: Locking Pin Of Variable Valve Timing Unit
When the engine is being started, the pressure in the system overcomes the pressure of the
spring and releases the locking pin of the variable valve timing unit (1). The VVT remains in this
position until it receives a signal from the Powertrain Control Module to the actuator solenoid.
When the engine stops, with the reduction in oil pressure, the VVT unit locking pin returns to its
original position, also assisted by a spring inside the VVT unit itself.
Fig 3: Variable Valve Timing System Component Operation
The position of the slider valve (1) inside the fixing screw (2) determines which openings and
chambers inside the VVT are supplied to anticipate (3), maintain (4) or delay (5) crankshaft pinion
timing with respect to the camshaft. The valve contributes towards bringing oil from the chambers
to the sump (6). The timing sensor controls the position of the camshaft with respect to the
crankshaft and provides feedback to the Powertrain Control Module. The stator starts moving when
the oil pressure pushes against the blades (6) of the VVT body. The component is physically fixed
to the camshaft and for this reason the rotation of this component turns the camshaft with respect
to the standard position of the gear (7).
INSTALLATION .

INSTALLATION .
INSTALLATION .
INSTALLATION .
INSTALLATION .
14. Position a floor jack under the engine to support the engine.
Fig 1: Right Side Engine Mount & Bolts
15. Remove the bolts (1a), (1b), and the right side engine mount (1c).
Fig 2: Right Side Engine Mount Bracket & Bolts
16. Remove the bolts (1a) and the right side engine mount bracket (1b).
17. Remove the plugs (1) with seals.

Fig 4: Chain Tensioning Pads Bolts
18. Remove the bolts (1) for the chain tensioning pads to the cylinder head.
Fig 5: Positioning Wrench On Rear Stem Of Camshaft
19. Position a suitable wrench (1) on the rear stem of the camshaft.
Fig 6: Removing Bolt Fixing Variable Valve Timing System & Toothed Wheel
20. Apply counter-torque using the wrench previously placed on the rear stem of the camshaft,
remove the bolt (1a) fixing the variable valve timing system and the toothed wheel (1b).
Fig 7: Variable Valve Timing System & Chain
21. Remove the variable valve timing system from the camshaft with its chain (1).
Fig 8: Exhaust Side Rocker Assembly & Bolts
22. Remove the bolts (1a) and the exhaust side rocker assembly (1b).
23. Remove the bolts (2a) and the intake side rocker assembly (2b).
Fig 9: Timing Chain Tensioning Fixed Pad
24. If necessary, remove the chain tensioning pads proceeding as described below.
25. Remove the timing chain tensioning fixed pad (1).

Fig 10: Timing Chain Tensioning Pad
26. Remove the timing chain tensioning pad (1).

Fig 11: Removing Timing Drive Chain Toothed Drive Pulley Using Special Tool
27. If necessary, remove the timing drive chain toothed drive pulley, proceeding as described
below.
28. Temporarily fit the rigid support and the flexible mounting for the engine support, timing side.
29. Fit the 2000040946 tool (1), following the sequence described below.
30. Fit the centre pin of the equipment.

Fig 12: Installing First Half Casing Of Special Tool
31. Fit the first half-casing of the equipment.

Fig 13: Installing Second Half Casing Of Special Tool
32. Fit the second half-casing of the equipment (1).

Fig 14: Installing Retaining Cylinder Of Special Tool
33. Fit the retaining cylinder (1).

Fig 15: Flywheel Locking Tool & Toothed Drive Pulley
34. Use the wrenches (1a) to remove the toothed drive pulley (1b).
35. Remove the flywheel locking tool 2000041300 used previously to remove the service pulley.

Fig 1: Aligning Crankshaft Pin In Groove
1. If it was previously removed, place the timing chain drive gear back in its housing, making sure
the pin (1a) of the crankshaft is aligned with the groove (1b).
Fig 2: Installing Toothed Drive Pulley Using Special Tools
2. Use the 2000040943 tools (1a) and 2000040941 (1b) to install the toothed drive pulley (1c).
Fig 3: Rotating Crankshaft To Position Pin At Bottom To Ensure Two Triangles Printed On Gear
Correspond As Shown
3. Rotate the crankshaft to position the pin (1a) at the bottom, so that the two triangles (1b)
printed on the gear correspond to the position shown in the figure.
4. Install the timing chain tensioner pads.
5. Install the timing chain tensioner pads bolts and tighten the to the proper specification. Refer to
6. Using NEW seals, install the plugs and tighten to the proper specification. Refer to TORQUE
SPECIFICATIONS .
Fig 4: Ensuring Two Pins Of Camshaft Front Stem Are Vertical And Face Exhaust Side
7. Check that the two pins (1) of the camshaft front stem are vertical and face the exhaust side,
as shown in illustration.
Fig 5: Ensure Two Bevels Of Rear Stem Are In Position Shown
8. Position the camshaft as described, then make sure that the two bevels (a) of the rear stem
are in the position shown in figure, for an easier fitting of a suitable wrench to use as counter-
Fig 6: Installing Rocker Arm Assembly & Bolts
9. Install the rocker arm assembly in their housings on the intake side (1a), exhaust side (1b) and
tighten the bolts (2) finger tight.
10. Check that each hydraulic tappet matches with the relevant valve correctly.
11. Tighten the rocker arm assembly bolts (2) to the proper specification. Refer to TORQUE
SPECIFICATIONS .
Fig 7: Placing Timing Drive Chain In Position To Ensure Yellow References Correspond To Two
Triangles
12. Place the timing drive chain (1a) in position, engaging the teeth of the drive gear, so that the
two yellow references (1b) correspond to the two triangles (1c).
Fig 8: Engaging Upper Branch Of Timing Drive Chain In Variable Valve Timing System Teeth To
Ensure Yellow Reference Corresponds To Reference Printed At Back Of Variable Valve Timing
System
13. Engage the upper branch of the timing drive chain in the variable valve timing system teeth, so
that the yellow reference (1a) corresponds to the reference (1b) printed at the back of the
variable valve timing system (2).
14. Place the variable valve timing system (2) with chain in its housing, engaging the two pins of
the camshaft stem.
Fig 9: Ensuring Notch Cut Into Toothed Wheel Corresponds To Yellow Notch Of Timing Drive
Chain
15. Place the toothed wheel in position, engaging the variable valve timing system pin.
16. Check that the notch (a) cut into the toothed wheel corresponds to the yellow notch (b) of the
timing drive chain.
17. Install the variable valve timing system fixing screw, without tightening it.
18. Applying counter-torque with a suitable wrench on the rear stem of the camshaft, tighten the
variable valve timing system fixing bolt (2) to the proper specification. Refer to TORQUE
SPECIFICATIONS .
Fig 10: Engine Mount Bracket & Bolts
19. Install the engine mount bracket (1a) and tighten the bolts (1b) to the proper specification.
Fig 11: Right Side Engine Mount & Bolts
20. Install the right side engine mount (1a) and tighten the bolts (1b) and (1c) to the proper
21. Remove the floor jack from supporting the engine.
INSTALLATION .
INSTALLATION .
30. Evacuate and charge the A/C system with refrigerant. Refer to PLUMBING, STANDARD
PROCEDURE .
INSTALLATION .
VALVE TIMING > COVER(S), ENGINE TIMING > REMOVAL AND INSTALLATION >
2. Remove the wheelhouse splash shield. Refer to SHIELD, SPLASH, FRONT WHEELHOUSE,

INSTALLATION .
Fig 1: Idler Pulley & Bolt
8. Remove the bolt (1a) and the idler pulley (1b).

Fig 2: Belt Tensioner & Bolts
9. Remove the bolts (1a) and the belt tensioner (1b).

Fig 3: Generator Shield & Nuts
10. Remove the nuts (1a) and the generator shield (1b).
11. Loosen the bolts (1) securing the generator.

Fig 5: Water Pump Lower Bolts
12. Loosen the lower bolts securing the water pump.

Fig 6: Timing Cover, Torx Bolts & Bolts
13. Remove the Torx bolts (1a), (1b) and the remaining bolts (1c) securing the timing cover.
14. Separate the alternator and the water pump to the engine block to remove the timing cover,
with oil pump.
15. Remove the residues of sealant, the oil seal and the gaskets of the timing cover.
Fig 1: Timing Cover & Gaskets
1. Install the NEW gaskets (1a), (1b) and (1c) on the timing cover.
Fig 2: Applying A Bead Of Sealant In Specified Areas
2. Apply a bead of sealant (1) in the areas shown in the figure.

Fig 3: Timing Cover & Bolts
3. Install the timing cover and tighten the bolts (1a), (1b) and (1c) finger tight.
Fig 4: Timing Cover Bolt Tightening Sequence
Using the tightening sequence shown in illustration, tighten the bolts to the proper specification.
Fig 5: Central Screw & Sealing Ring
4. The central screw shown in the figure passes through the oil pump and is therefore equipped
with a sealing ring. Tighten the bolts to the proper specification. Refer to TORQUE
SPECIFICATIONS .
Fig 6: Water Pump Lower Bolts
5. Tighten the lower water pump bolts to the proper specification. Refer to TORQUE
SPECIFICATIONS .
Fig 7: Generator Bolt
6. Tighten the generator bolts to the proper specification. Refer to TORQUE SPECIFICATIONS .
7. Install the generator shield and securely tighten the nuts.

Fig 8: Belt Tensioner & Bolts
8. Install the belt tensioner (1a) and tighten the bolts (1b) to the proper specification. Refer to
SPECIFICATIONS .
Fig 9: Idler Pulley & Bolt
9. Install the idler pulley (1a) and tighten the bolt (1b) to the proper specification. Refer to
SPECIFICATIONS .
10. Using the 2000040939 tool (1), install a NEW front crankshaft oil seal.
15. Evacuate and fill the A/C system refrigerant. Refer to PLUMBING, STANDARD PROCEDURE .
16. Install the wheelhouse splash shield. Refer to SHIELD, SPLASH, FRONT WHEELHOUSE,
VALVE TIMING > TENSIONER, ENGINE TIMING > DESCRIPTION > DESCRIPTION
Fig 1: Hydraulic Engine Timing Tensioner
The hydraulic tensioner ensures the correct tensioning of the timing chain. It is hydraulic and acts on the
mobile pad.

INSTALLATION .
INSTALLATION .
INSTALLATION .
Fig 1: Engine Timing Tensioner & Cap
11. Remove the cap (1a) and the engine timing tensioner (1b).
Fig 1: Moving Tensioner Cover
1. Remove the cover (1) of the moving tensioner for the timing control.
Fig 2: Engaging Moving Tensioner For Timing Drive Chain
2. Push down the engine timing tensioner (1) as shown in the figure.
Fig 3: Timing Tensioner & Cover
3. Install the cover (1b) on the timing tensioner (1a).
4. Install the timing tensioner (1a) complete with gasket and tighten the cap (1b) to the proper
Fig 4: Releasing Piston Of Timing Drive Chain Mobile Tensioner
5. Press on the timing chain tensioner pad to release the piston of the timing chain tensioner.
Fig 5: Ensuring Piston Of Mobile Tensioner Touches Mobile Pad
6. Check that the piston of the timing chain tensioner (1a) touches the timing chain tensioner pad
(1b).
INSTALLATION .
INSTALLATION .
14. Evacuate and charge the A/C system with refrigerant. Refer to PLUMBING, STANDARD
PROCEDURE .
Jeep Renegade
Service Manual: 2.4L ENGINE - SERVICE INFORMATION
DIAGNOSIS AND TESTING > INTRODUCTION
Engine diagnosis is helpful in determining the causes of malfunctions not detected and remedied by
routine maintenance.
These malfunctions may be classified as either mechanical (e.g., a strange noise), or performance (e.g.,
engine idles rough and stalls).
For Engine Mechanical diagnosis, refer to ENGINE MECHANICAL DIAGNOSTIC TABLE .
For Engine Performance diagnosis, refer to ENGINE PERFORMANCE DIAGNOSTIC TABLE .
For Fuel Delivery system diagnosis, refer to FUEL DELIVERY, DIAGNOSIS AND TESTING .
For Cooling System diagnosis, refer to DIAGNOSIS AND TESTING .
For Engine Lubrication System diagnosis, refer to ENGINE LUBRICATION DIAGNOSTIC TABLE .
Additional tests and diagnostic procedures may be necessary for specific engine malfunctions that
cannot be isolated with the Service Diagnosis tables. Information concerning additional tests and
diagnosis is provided within the following:
Cylinder Compression Pressure Test: Refer to CYLINDER COMPRESSION TEST .
Cylinder Combustion Pressure Leakage Test: Refer to CYLINDER LEAKAGE TEST .
Cylinder Head Gasket Leakage Diagnosis: Refer to CYLINDER HEAD GASKET .
Mechanical Valve Tappet Noise Diagnosis: Refer to DIAGNOSIS AND TESTING - LASH
ADJUSTER (TAPPET) NOISE .
Exhaust System leak testing: Refer to CHECKING THE EXHAUST SYSTEM FOR LEAKS .
TESTING .

3. Faulty engine starting 3. Test the starting system. Refer

system. to DIAGNOSIS AND TESTING .

TESTING .
SPECIFICATIONS .

The engine starting should not be

effected if the oil level shows
7. Incorrect engine oil level and level is off the dipstick, the oil level
oil quality. could be contributing to the
startability issue.
change the oil and filter.
Perform a long start procedure -

Crank engine for 10 seconds, let sit
8. Long Stand Still Parking - for 5 seconds, crank for 10
longer than 35 days. seconds. May be necessary to
second break.

AND TESTING .

Replace the Camshaft Position

10. Faulty Camshaft Position (CMP) sensor. Refer to SENSOR,
(CMP) sensor. CAMSHAFT POSITION, REMOVAL
AND INSTALLATION .
Replace the Crankshaft Position

ROUGH Codes (DTC). Refer to appropriate
article.

Codes (DTC). Refer to appropriate
article.
3. Vacuum leak. 3. Inspect intake manifold, manifold

gasket, and vacuum hoses.

5. Replace the Crankshaft Position
6. Verify cam timing. Refer to

6. Incorrect cam timing.

INSTALLATION .


4. Leaking cylinder head 4. Replace the cylinder head

gasket. gasket. Refer to CYLINDER HEAD,

as necessary. Refer to CYLINDER
COMPRESSION TEST .


AND TESTING .



INSTALLATION .

the fuel filter.


INSTALLATION .



TESTING .
DIAGNOSIS AND TESTING > NOISY OPERATION
1. You will hear a noise of high and constant intensity, coming from the engine area and
detectable only within a certain range of RPM.
PROBLEMS
PRELIMINARY CHECKS EVERYTHING OK RESOLUTION
ENCOUNTERED
Check the integrity and Repair or replace

Circuit components
tightness of the circuit Continue to Step 2 components as
damaged.
intake air necessary.
2. Check engine mounts.

MOUNTS ENCOUNTERED
1. Restore the
1. Fixing incorrect correct fitting.
media engine 2. Replace the motor
2. Support the engine mount on the
gearbox side defective gearbox side.
3. Support engine 3. Replace the motor
timing side defective mount side
Check the correct
4. Support rear motor distribution.
mounting and the integrity
defective 4. Replace the rear
of:
Continue to Step 3 5. Anchor elastic motor mount.
- engine Supports
support front defective 5. Replace the
- flexible blocks
6. Anchor elastic back elastic block front
- guy reaction
support defective support.
7. Anchor elastic 6. Replace the
support gearbox side elastic block back
defective support.
8. Fixing incorrect tie 7. Replace the
rod reaction. elastic block support
gearbox side.
8. Restore the
correct fixing.
3. Check engine exhaust supports.

SUPPORTS EXHAUST ENCOUNTERED
1. Restore the
correct fixing of the
Check the correct support 1. Supports loose.
Continue to Step 4 supports.
fixing sewage pipes. 2. Support damaged.
2. Replace the
damaged media.
4. Check engine exhaust.

EXHAUST ENCOUNTERED
Check the exhaust

system of the engine and 1. Replace the pipe
in particular: 1. Full damaged pipe. complete
- collector 2. Silencer damaged. 2. Replace the rear
End diagnosis
- conduit 3. Seal Front worn or silencer
- Exhaust silencer damaged. 3. Replace the front
- Seal front of the seal
catalytic converter.
NOISY VALVES 1. High or low oil level in 1. Adjust the engine oil level. Refer
crankcase. to FILTER, ENGINE OIL, REMOVAL
AND INSTALLATION .

3. Low oil pressure. 3. Check the oil pump, if OK, check

the rod and main bearings for
4. Dirt in valve lash adjusters. 4. Replace as necessary. Refer to

AND INSTALLATION .
5. Worn rocker arms. 5. Replace as necessary. Refer to

CYLINDER HEAD .
6. Worn valve lash adjusters 6. Replace as necessary. Refer to
AND INSTALLATION .
7. Worn valve guides. 7. Inspect the valve guides for wear,

cracks or looseness. If either
condition exists, replace the cylinder
head. Refer to CYLINDER HEAD,
8. Excessive runout of valve 8. Replace as necessary. Refer to

seats or valve faces. CYLINDER HEAD .



5. Connecting rod journal 5. Service or replace the crankshaft.

out-of-round, rough surface or Check the crankshaft for plugged oil
debris. Obstructed oil feed feed hole. Refer to ENGINE
hole. BLOCK .
6. Misaligned connecting rods. 6. Replace the bent connecting rods.

Refer to ROD, PISTON AND
CONNECTING, REMOVAL AND
INSTALLATION .




wear. Refer to ENGINE BLOCK .
6. Crankshaft journal out-of 6. Service or replace the crankshaft.
round, rough or debris. Check the engine block for plugged
Obstructed oil feed hole. oil feed hole. Refer to ENGINE
BLOCK .
7. Loose flywheel, flexplate or 7. Tighten to the proper

SPECIFICATIONS .
NOTE:

NOTE:
NOTE:
diagnosis purposes.
reference.
three revolutions.
cylinders.
NOTE:

test.
NOTE:
question.
OFF.
CHART below.
necessary.
necessary.
AIR ESCAPES THROUGH Head gasket leaking or cracked Remove cylinder head and inspect.
RADIATOR cylinder head or block Replace defective part
MORE THAN 50% LEAKAGE Head gasket leaking or crack in Remove cylinder head and inspect.
FROM ADJACENT CYLINDERS cylinder head or block between Replace gasket, head, or block as
adjacent cylinders necessary
AND AIR ESCAPES THROUGH cracked piston; worn rings Measure ring gap and cylinder
OIL FILLER CAP OPENING and/or cylinder wall diameter, taper and out-of-round.
necessary
Consumption, these procedures and tests apply to vehicles with 50,000 miles or less.
NOTE:
be delayed until vehicle has been driven at least 7,500 miles.
consumption.
NOTE:
CONSUMPTION TEST
NOTE:
and date.
leakage tester and following manufacturers suggested best practices.
NOTE:
system.
9. Fuel Dilution
consumption:

4. Excessive idling
11. Oil Viscosity
than clean oil.
combustion chamber.

16. Lugging Engine
function.


SPECIFICATIONS .

seal. Refer to SEAL, CRANKSHAFT
OIL, REAR, REMOVAL AND
INSTALLATION .
4. Crankshaft rear oil seal 4. Polish or replace the crankshaft.

surface scratched, nicked or Refer to ENGINE BLOCK .
grooved.
5. Oil pan flange cracked. 5. Replace the oil pan. Refer to PAN,
OIL, REMOVAL AND
INSTALLATION .

crankshaft front oil seal. seal. Refer to SEAL, CRANKSHAFT
OIL, FRONT, REMOVAL AND
INSTALLATION .

vibration damper hub front oil damper. Refer to DAMPER,
seal surface. VIBRATION, REMOVAL AND
INSTALLATION .
OIL PRESSURE DROP 1. Low oil level. 1. Check and correct the engine oil
level. Refer to LUBRICATION .
2. Faulty oil pressure sensor. 2. Replace the oil pressure sensor.
3. Low oil pressure. 3. Check the main crankshaft bearing

clearance. Refer to ENGINE
BLOCK .
3. Check the rod bearing clearance.
Refer to ENGINE BLOCK .
4. Clogged oil filter. 4. Replace the engine oil filter. Refer
to FILTER, ENGINE OIL, REMOVAL
AND INSTALLATION .


Refer to LUBRICATION .
7. Excessive bearing 7. Replace the crankshaft bearings.

clearance. Refer to ENGINE BLOCK .
7. Replace the rod bearings. Refer to
ENGINE BLOCK .
OIL PUMPING AT RINGS; 1. Worn or damaged rings. 1. Hone the cylinder bores and
SPARK PLUGS FOULING replace the piston rings. Refer to
ENGINE BLOCK . Refer to RING(S),
PISTON, REMOVAL AND
INSTALLATION .
2. Carbon in oil ring slots. 2. Replace the piston rings. Refer to

INSTALLATION .
3. Worn valve guides. 3. Replace the cylinder head. Refer

to CYLINDER HEAD, REMOVAL
AND INSTALLATION .

1. Install new oil filter and test engine

1. Obstructed or incorrect oil
oil pressure. Refer to
filter.
LUBRICATION .
2. Change engine oil and test engine

ENGINE OIL FILTER SWOLLEN 2. Engine oil viscosity
oil pressure. Refer to
OR BURST incorrect.
LUBRICATION .
3. Replace engine oil pump. Refer to

3. Excessive engine oil
PUMP, ENGINE OIL, REMOVAL AND
pressure.
INSTALLATION .

Fig 1: Covers/Caps

1 - ABRASIVE PAD
Metal scraper.
NOTE:
CAUTION:
NOTE:
SEALANT TYPES
date before use.
before use.

coolant.
SEALANT APPLICATION
location.
CAUTION:
foreign material.
cable.
7. Repair engine or components as necessary to prevent this problem from reoccurring.
CAUTION:
CAUTION:

ENGINE TYPE
- 2.4 MultiAir2
Position in vehicle Front
Orientation Transverse
Number of cylinders 4
Cylinder position In line
Fuel Gas
1 Cam in head (exhaust side) + MultiAir actuator

Camshaft configuration
module (intake side)
ENGINE DATA
- 2.4 MultiAir2
Bore (mm) 88.0
Stroke (mm) 97.0
Total displacement (cm3) 2360
Maximum power (kW EEC) 132
Maximum power (CV EEC) 175
Max. power (RPM) 6400
Maximum torque (Nm EEC) 224
Maximum torque (kgm EEC) 22.8
Maximum torque (RPM) 3900

ENGINE MOUNTS
Rigid Support of the Screw M8 25 1.4L MultiAir Turbo

powertrain side
distribution
Rigid Support of the Screw M10 50 1.6L Turbo Diesel

powertrain side 2.0L Turbo Diesel
distribution
Rigid Support of the Screw M12 40 + 45° 1.4L MultiAir Turbo

powertrain
transmission side
Elastic Dowel of the Screw M10 60 + 45° 1.4L MultiAir Turbo

powertrain support
distribution side
Elastic Dowel of the Screw M10 60 + 45° 1.6L Turbo Diesel

distribution side -
bodywork side
Elastic Dowel of the Screw M12 90 + 45° 1.6L Turbo Diesel

distribution side - rigid
support side
Elastic Dowel of the Screw M12 40 + 45° 1.4L MultiAir Turbo

transmission side - 2.0L Turbo Diesel
rigid support side
Elastic Dowel of the Screw M12 120 -

powertrain support
transmission side -
bodywork side
Reaction of the lower Screw M14 90 + 45° -

bolt gearshift-side
bracket
Reaction of the lower Screw M14 90 + 45° -

bolt gearshift-side
suspension cross
member
Bracket for lower tie Screw M12 40 + 45° 1.4L MultiAir Turbo
rod of reaction 1.6L Turbo Diesel
2.0L Turbo Diesel
120/140CV
Bracket for lower tie Screw M14 90 + 45° 2.0L Turbo Diesel
rod of reaction 170 hp
Elastic Dowel of the Screw - 68 2.4L MultiAir

rigid support
powertrain group
timing to the
bodywork side
Elastic Dowel of the Screw - 75 2.4L MultiAir

rigid support
powertrain group
timing to the rigid
support side
ENGINE CRANKCASE
Crankcase Central Screw M10 20 + 80° 1.4L MultiAir Turbo
Crankcase Lateral Screw M8 30 1.4L MultiAir Turbo
CYLINDER HEAD
Cover tappets Screw M6 9 1.4L MultiAir Turbo
Cover tappets Screw - 10 2.4L MultiAir
Central Screw (to

Upper head engine M8 25 1.4L MultiAir Turbo
replace)
Upper head engine Lateral Screw M8 25 1.4L MultiAir Turbo
1.6L Turbo Diesel

Upper head engine Screw M8 25
2.0L Turbo Diesel
Engine cylinder head Screw M9 30 + 90° 1.4L MultiAir Turbo
30 + 73 + 73 +
Engine cylinder head Screw - 2.4L MultiAir
90°
65 + 90° + 90° + 1.6L Turbo Diesel

Engine cylinder head Screw M12
90° 2.0L Turbo Diesel
Upper engine cylinder 1.6L Turbo Diesel

Cap M16 14
head caps 2.0L Turbo Diesel
ENGINE COVERS
1.4L MultiAir Turbo

Engine oil drain plug Cap M14 20 1.6L Turbo Diesel
2.0L Turbo Diesel
Crankcase engine Screw M6 9 1.4L MultiAir Turbo

Crankcase engine Nut M6 9 1.4L MultiAir Turbo
Engine oil gearbox Screw M10 40 1.4L MultiAir Turbo
Screws timing side and 1.6L Turbo Diesel

Crankcase M6 9
transmission side 2.0L Turbo Diesel
1.6L Turbo Diesel

Crankcase Lateral screws M8 25
2.0L Turbo Diesel
Front cover oil seal 1.4L MultiAir Turbo

Screw M6 9
Front cover oil seal 1.6L Turbo Diesel

Crankcase Screw - 12 2.4L MultiAir
Engine oil -
conditioning Screw - 22 2.4L MultiAir
compressor side
1.6L Turbo Diesel

Rear oil seal retainer Screw (to replace) M6 9
2.0L Turbo Diesel
Rear oil seal retainer Screw M6 9 1.4L MultiAir Turbo
CRANKSHAFT AND FLYWHEEL
Flywheel engine Screw (to replace) M9 20 + 50° 1.4L MultiAir Turbo
Flywheel engine Screw - 29 2.4L MultiAir
1.6L Turbo Diesel

Flywheel engine Screw (to replace) M12 160
2.0L Turbo Diesel
PISTONS AND CONNECTING RODS
Rod cap Screw M8 20 + 40° 1.4L MultiAir Turbo
TIMING CONTROL
Mobile tensioner Nut M8 22 - 27 1.4L MultiAir Turbo
Mobile tensioner Screw - 12 2.4L MultiAir
1.6L Turbo Diesel

Mobile tensioner Screw (to replace) M8 25
2.0L Turbo Diesel
1.6L Turbo Diesel

2.0L Turbo Diesel
Crankshaft pulley Screw M12 120 1.4L MultiAir Turbo
1.6L Turbo Diesel

Crankshaft pulley Screw M12 30 + 40°
2.0L Turbo Diesel
Camshaft pulley Screw M12 20 + 110° 1.4L MultiAir Turbo
1.6L Turbo Diesel

Camshaft pulley Screw (clockwise) M16 340
2.0L Turbo Diesel
Protection cover of 1.6L Turbo Diesel

timing control 2.0L Turbo Diesel
Driving gears
camshafts
Driving gears
camshafts
timing belt
timing belt
CAMSHAFT
Timing shaft cap Screw M7 10 1.4L MultiAir Turbo
MultiAir module Screw M8 23 1.4L MultiAir Turbo
1.4L MultiAir Turbo

Oil temperature sensor - - 11
2.4L MultiAir
ENGINE TURBOCHARGER SYSTEM
1.4L MultiAir Turbo

Turbocharger Nut (to replace) M8 25 1.6L Turbo Diesel
2.0L Turbo Diesel
support
support
Engine oil pressure

pipe to the Turbo- Fitting M10 26 2.0L Turbo Diesel
turbocharger side
Engine oil pressure

pipe to the Fitting M12 25 2.0L Turbo Diesel
turbocharged
Duct engine oil return

from the turbocharger - Screw M10 50 2.0L Turbo Diesel
base side
Oil return tube

turbocharger engine - Screw M6 9 2.0L Turbo Diesel
turbocharger side
INTAKE AND EXHAUST MANIFOLDS
Exhaust manifold Nut (to replace) M8 15 + 30° 1.4L MultiAir Turbo
Exhaust manifold Screw - 34 2.4L MultiAir
Exhaust manifold Nut - 34 2.4L MultiAir
Intake manifold Screw (to replace) M7 15 1.4L MultiAir Turbo
1.6L Turbo Diesel

Intake manifold Nut M8 25
2.0L Turbo Diesel
Heat shield of the

exhaust manifold
LUBRICATION SYSTEM
1.4L MultiAir Turbo

Engine oil filter cover - - 25 1.6L Turbo Diesel
2.0L Turbo Diesel

heat exchanger - oil Screw M20 45 1.4L MultiAir Turbo
pump side
heat exchanger - base Screw M10 50 1.4L MultiAir Turbo
side

engine oil

engine oil
Engine oil return pipe

from the turbo-
blower-side heat
exchanger
Engine oil pressure

pipe to the Turbo- Junction with filter M12 25 1.4L MultiAir Turbo
turbocharger side
Engine oil pressure

pipe to the turbo-
blower-side heat
exchanger
Engine oil pressure

1.6L Turbo Diesel
pipe to the Turbo- Fitting M10 15
2.0L Turbo Diesel
turbocharger side
Engine oil pressure

pipe to the Turbo- 1.6L Turbo Diesel
Fitting M12 25
cylinder head upper 2.0L Turbo Diesel
side

- M14 32 1.4L MultiAir Turbo

- - 18 2.4L MultiAir
Switch for engine oil 1.6L Turbo Diesel

- M14 25
pressure warning light 2.0L Turbo Diesel
Engine oil pump

assembly - balance Screw - 15 + 29 + 90° 2.4L MultiAir
module
Engine oil pressure 1.6L Turbo Diesel

- M10 20
switch 2.0L Turbo Diesel
Introducing engine oil 1.6L Turbo Diesel

Screw M6 9
nozzle 2.0L Turbo Diesel
Displacement control 1.6L Turbo Diesel

Screw - 7
valve oil pump motor 2.0L Turbo Diesel
Engine oil pump Screw M6 10 1.4L MultiAir Turbo
MISCELLANEOUS ENGINE PARTS

1.4L MultiAir Turbo

2.0L Turbo Diesel
Pulley on crankshaft Screw - 210 2.4L MultiAir
Automatic tensioner Screw - 24 2.4L MultiAir
Fixed tensioner Screw - 48 2.4L MultiAir
1.6L Turbo Diesel

2.0L Turbo Diesel
1.6L Turbo Diesel

Mobile tensioner Screw M10 50
2.0L Turbo Diesel

ENGINE DIAGNOSIS AND TESTING
Transducers Examiner Test compression

1806338000 *
Kit 2 cylinders
Check the engine

pressure
1870811001 * Fitting Cylinder compression
Check cylinder
1870897400 * Incorrect injector
compression
Check the engine

Connection tube
2000015600 * lubrication system
manometer
pressure
Check the engine

2000018801 * Tee lubrication system
pressure
Check the engine

pressure
ENGINE PROCEDURES
1823015000 C-4829A Pry retainer -
1860313000 * Introducing engine oil sprayers 1.4L MultiAir Turbo
1860395000 * Removing engine oil sprayers 1.4L MultiAir Turbo
1860470000 * Cylinder head overhaul -
1860644000 * Valve disassembly/reassembly 1.4L MultiAir Turbo
1860741000 * Flywheel retainer 2.4L MultiAir
1860786000 * Valve check 1.4L MultiAir Turbo
1860815000 * Rotating crankshaft -
1860987000 * Timing belt tension distribution 1.4L MultiAir Turbo

command
1860990000 10273 Crankshaft oil seal installation 1.4L MultiAir Turbo
1860993000 * Introduction oil seal ring valve 1.4L MultiAir Turbo

guides
1860994000 * Extraction/introduction of valve 1.4L MultiAir Turbo

guides
1870718000 * Cut sealing -
1870890000 * Valve removal 1.4L MultiAir Turbo
1870894000 * Oil seal removal 1.4L MultiAir Turbo
1871000000 * Engine placement on tripod for -

review
1871001700 * Removing/installing the power plant -
2019500031 * Removing rear drive shaft 4x4
2000024700 * Extracting/Introduction tappets 1.4L MultiAir Turbo
2000034400 10277 Distribution shaft timing 1.4L MultiAir Turbo
2000034500 * Compression plates UNIAIR 1.4L MultiAir Turbo
2020000090 10259B Compression plates UNIAIR 2.4L MultiAir
2000034600 10278 Camshaft oil seal assembly 1.4L MultiAir Turbo
2000034800 * Disassembly/reassembly of oil 1.4L MultiAir Turbo

temperature sensor module UNIAIR
2.4L MultiAir
2000039800 * Capless fuel inlet pipe fastening 1.4L MultiAir Turbo

-
1.6L Turbo Diesel
2.0L Turbo Diesel
2000040245 9506 Mounting front cover oil seal 2.4L MultiAir

crankshaft
2000040246 9509 Flywheel side mounting seal 2.4L MultiAir
2000040298 9706 Flywheel side mounting seal 2.4L MultiAir
2000040299 9707 Loosen/tighten pulley bolt on 2.4L MultiAir

crankshaft services
2000040436 8534B Shaft supporting powerplant -
2000040586 C-4171 Flywheel side mounting seal 2.4L MultiAir
2000042900 * Capless fuel inlet pipe fastening 1.4L MultiAir Turbo
2000001400 * Brake/clutch system depression -
2000004500 10276 Crankshaft timing 1.4L MultiAir Turbo
REMOVAL AND INSTALLATION > 2.4L WITH AUTOMATIC TRANSMISSION >

REMOVAL
2. Place the gear selector lever in "N" (neutral).
3. Remove fuse F21 from the Power Distribution Center (PDC).
4. Start and run the engine until it stalls from fuel starvation.
5. Return fuse F21 to the PDC.
8. Remove the right front wheel splash shield. Refer to SHIELD, SPLASH, FRONT
.
INSTALLATION .

INSTALLATION .

Fig 2: Exhaust Pipe Hanger Bolts, Exhaust Pipe Support Bracket Bolt & Exhaust Flange Nuts
24. Remove the exhaust flange nuts (3), disconnect the exhaust pipe from the catalytic converter
and remove the flange gasket.
25. Remove the bolts (1a) and (1b) and remove the rear engine mount isolator (1c).
Fig 4: Left & Right Side Lower Load Beam & Bolts
26. Remove the bolts (1) and the left side lower load beam.
27. Remove the bolts and the right side lower load beam.
Fig 5: Quick Coupling, Pressurized Coolant Bottle & Degas Hose Clamp
bottle.
29. Loosen the clamp (2) and remove the degas hose, disengage the retaining clips and remove
the pressurized coolant bottle.
Fig 6: A/C Evaporator Quick Coupling
30. Disconnect the A/C evaporator quick coupling (1).

Fig 7: Vacuum Hose & Quick Coupling

Fig 9: Fuel Supply Hose & Vapor Purge Hose Quick Couplings
33. Disconnect the fuel supply hose and vapor purge hose quick couplings (1).
Fig 10: Wire Harness Retaining Clip & Transmission Wire Harness Connector
34. Open the wire harness retaining clip (1).
Fig 11: Engine Wire Harness Connector
36. Disconnect the engine wire harness connector (1).

Fig 12: Gear Selector Cable At Gear Change Lever & Lock Slider
connector (1).
Fig 15: Upstream Oxygen Sensor Wire Harness Connector, Exhaust Manifold Heat Shield,
Wire Harness Bracket & Bolts
41. Disconnect the upstream oxygen sensor wire harness connector (1a) and remove the bolt (1b)
and wire harness bracket.
Fig 16: Engine Lifting Bracket & Exhaust Manifold Nut
43. Install a suitable engine lifting bracket (1) under the exhaust manifold nut.
Fig 17: Camshaft Position Sensor Heat Shield & Nut
44. Remove the nut and the Camshaft Position sensor heat shield (1).
Fig 18: Camshaft Position Sensor & Studbolt
45. Remove the studbolt and the Camshaft Position sensor (1).
Fig 20: Engine Lifting Bracket & Engine Timing Cover Bolt
47. Install a suitable engine lifting bracket (1) under the engine timing cover bolt.
49. Remove the bolts (1a) and (1b) and remove the left engine mount isolator (1c).
REMOVAL AND INSTALLATION > 2.4L WITH AUTOMATIC TRANSMISSION >

INSTALLATION
3. Install the left engine mount isolator (1a) and tighten the bolts (1b) and (1c) to the proper torque
5. Remove the powertrain lifting brackets from the engine and tighten the exhaust manifold nuts to
the proper torque specification. Refer to TORQUE SPECIFICATIONS .
6. Install the Camshaft Position sensor to the cylinder head and tighten the studbolt to the proper
7. Install the Camshaft Position sensor heat shield with the nut tightened to the proper torque
8. Install the exhaust manifold heat shield with the bolts tightened to the proper torque
9. Install the wire harness bracket to the exhaust manifold heat shield with the bolt tightened to
15. Connect the engine wire harness connector.
17. Close the wire harness retaining clip near the transmission wire harness connector.
18. Connect the fuel supply hose quick coupling and vapor purge hose quick coupling.
21. Connect the A/C evaporator quick coupling.
23. Install the degas hose to the pressurized coolant bottle and tighten the clamp to the proper
24. Install the left side load beam with the bolts tightened to the proper torque specification. Refer
25. Install the right side load beam with the bolts tightened to the proper torque specification. Refer
26. Install the rear engine mount isolator (1a) with the bolts (1b) and (1c) tightened to the proper
27. Install a new flange gasket and connect the exhaust pipe to the catalytic converter with new
nuts (1) tightened to the proper torque specification. Refer to TORQUE SPECIFICATIONS .

43. Install the right front wheel splash shield. Refer to SHIELD, SPLASH, FRONT WHEELHOUSE,
REMOVAL AND INSTALLATION > 2.4L WITH AUTOMATIC TRANSMISSION - 4X4 >
REMOVAL
3. Remove the fuel pump fuse F21 (15A) from the Power Distribution Center (PDC).
.
INSTALLATION .

INSTALLATION .

24. Remove the exhaust flange nuts (3), disconnect the exhaust pipe from the catalytic converter
and remove the flange gasket.
NOTE:
bending.
Fig 4: Locating Hydraulic Lift Under Powertrain
26. Position a suitable hydraulic lift under the powertrain (1).

27. Remove the bolts (1a) and (1b) and remove the rear engine mount isolator (1c).
Fig 6: Dust Cover
NOTE:
The dust cover must be replaced whenever the drive shaft is disconnected.
28. Using the hydraulic lift, move the powertrain up and forward as much as permitted by the right
and left engine mounts.
29. Pull back the dust cover (1).

Fig 7: Using Retractor Tool To Open Snap Ring
NOTE:
The snap ring must be replaced whenever the drive shaft is disconnected.
30. Using tool 2019500030 Retractor (1), open the snap ring.
Fig 8: Positioning Drive Shaft At PTU
31. Pull back the drive shaft to disengage it from the PTU and reposition the shaft on the
crossmember.

Fig 9: Left & Right Side Lower Load Beam & Bolts
33. Remove the bolts (1) and the left side lower load beam.
34. Remove the bolts and the right side lower load beam.
Fig 10: Quick Coupling, Pressurized Coolant Bottle & Degas Hose Clamp
bottle.
36. Loosen the clamp (2) and remove the degas hose, disengage the retaining clips and remove
the pressurized coolant bottle.
Fig 11: A/C Evaporator Quick Coupling
37. Disconnect the A/C evaporator quick coupling (1).

Fig 12: Vacuum Hose & Quick Coupling

Fig 14: Fuel Supply Hose & Vapor Purge Hose Quick Couplings
40. Disconnect the fuel supply hose and vapor purge hose quick couplings (1).
Fig 15: Power Transfer Unit Actuator Wire Harness Connector
Fig 16: Wire Harness Retaining Clip & Transmission Wire Harness Connector
42. Open the wire harness retaining clip (1).
Fig 17: Engine Wire Harness Connector
44. Disconnect the engine wire harness connector (1).

Fig 18: Gear Selector Cable At Gear Change Lever & Lock Slider
connector (1).
Fig 21: Upstream Oxygen Sensor Wire Harness Connector, Exhaust Manifold Heat Shield,
Wire Harness Bracket & Bolts
49. Disconnect the upstream oxygen sensor wire harness connector (1a) and remove the bolt (1b)
and wire harness bracket.
Fig 23: Camshaft Position Sensor Heat Shield & Nut
52. Remove the nut and the Camshaft Position sensor heat shield (1).
Fig 24: Camshaft Position Sensor & Studbolt
53. Remove the studbolt and the Camshaft Position sensor (1).
57. Remove the bolts (1a) and (1b) and remove the left engine mount isolator (1c).
59. Remove the power train from the engine compartment and place it on a suitable platform.
REMOVAL AND INSTALLATION > 2.4L WITH AUTOMATIC TRANSMISSION - 4X4 >
INSTALLATION
3. Install the left engine mount isolator (1a) and tighten the bolts (1b) and (1c) to the proper torque
5. Remove the powertrain lifting brackets from the engine and tighten the exhaust manifold nuts to
6. Install the Camshaft Position sensor to the cylinder head and tighten the studbolt to the proper
7. Install the Camshaft Position sensor heat shield with the nut tightened to the proper torque
8. Install the exhaust manifold heat shield with the bolts tightened to the proper torque
9. Install the wire harness bracket to the exhaust manifold heat shield with the bolt tightened to
15. Connect the engine wire harness connector.
17. Close the wire harness retaining clip near the transmission wire harness connector.
18. Connect the power transfer unit actuator wire harness connector.
19. Connect the fuel supply hose quick coupling and vapor purge hose quick coupling.
22. Connect the A/C evaporator quick coupling.
24. Install the degas hose to the pressurized coolant bottle and tighten the clamp to the proper
25. Install the left side lower load beam with the bolts tightened to the proper torque specification.
26. Install the right side lower load beam with the bolts tightened to the proper torque specification.
27. Install the rear engine mount isolator (1a) with the bolts (1b) and (1c) tightened to the proper
NOTE:
bending.
Fig 5: Drive Shaft Snap Ring & Dust Cover
29. Install a new drive shaft snap ring (1).
30. Install a new drive shaft dust cover (2).
31. Install the drive shaft into the power transfer unit and engage the snap ring.
32. Install the drive shaft dust cover.
33. Remove the drive shaft protective sleeve.

34. Install a new flange gasket and connect the exhaust pipe to the catalytic converter with new
nuts (1) tightened to the proper torque specification. Refer to TORQUE SPECIFICATIONS .


SEPARATION AND REASSEMBLY - 2.4L MULTIAIR > REMOVAL
Fig 1: Exhaust Pipe Support Bracket Bolt & Intake Side Oil Pan To Transmission Bolts
1. Remove the bolt (1) and remove the exhaust pipe support bracket.
2. Remove the two intake side oil pan to transmission bolts (2).
Fig 2: Exhaust Side Oil Pan To Transmission Bolt
3. Remove the exhaust side oil pan to transmission bolt (1).

Fig 3: Alternator Wiring Harness Retaining Clips & Engine Wire Harness Connector
4. Open the retaining clips (1) and reposition the alternator wiring harness.
5. Disengage the engine wire harness connector (2) from the bracket.
Fig 4: Bracket, Bolt & Upper Starter Bolt
6. Remove the bolt (1) and the bracket.
7. Remove the upper starter bolt (2).

Fig 5: Starter Motor Wire Harness Connector & Lower Starter Bolt
8. Disconnect the starter motor wire harness connector (1).
9. Remove the lower starter motor bolt (2) and remove the starter motor with the battery positive
cable attached.
Fig 6: Inspection Cover Bolt
Fig 7: Special Tool & Torque Converter Bolt
11. Install the 1860898000 tool (1).

Fig 8: Intake Side Upper Transmission To Engine Block Bolt
13. Remove the intake side upper transmission to engine block bolt (1).
Fig 9: Exhaust Side Upper Transmission To Engine Block Bolt
14. Remove the exhaust side upper transmission to engine block bolt (1).
Fig 10: Wire Harness At Transmission, Side Transmission To Engine Block Bolt &
Transmission
15. Disengage the wire harness from the transmission (1).
16. Remove the side transmission to engine block bolt (2a) and remove the transmission (2b) from
the engine.
SEPARATION AND REASSEMBLY - 2.4L MULTIAIR > INSTALLATION
Fig 1: Wire Harness At Transmission, Side Transmission To Engine Block Bolt & Transmission
1. Install the transmission (1a) to the engine with the side transmission to engine bolt (1b)
2. Engage the wire harness to the transmission (2).

3. Install the exhaust side upper transmission to engine block bolt (1) and tighten to the proper
4. Install the intake side upper transmission to engine block bolt (1) and tighten to the proper
5. Install the torque converter bolts (1) and tighten to the proper torque specification. Refer to
6. Remove the 1860898000 tool (2).
7. Install the inspection cover and tighten the bolt to the proper torque specification. Refer to
8. Install the starter motor (1) with the battery positive cable attached and tighten the lower
starter motor bolt to the proper torque specification. Refer to TORQUE SPECIFICATIONS .
9. Connect the starter motor wire harness connector (2).

10. Install the upper starter bolt (1) and tighten to the proper torque specification. Refer to
11. Install the bracket (2) with the bolt tightened to the proper torque specification. Refer to
12. Engage the engine wire harness connector to the bracket.
13. Position the alternator wiring harness and close the retaining clips.
14. Install the exhaust side oil pan to transmission bolt (1) and tighten to the proper torque
15. Install the two intake side oil pan to transmission bolts (1) and tighten to the proper torque
16. Install the exhaust pipe support bracket (2) and tighten the bolt to the proper torque

SEPARATION AND REASSEMBLY - 2.4L MULTIAIR 4X4
Fig 1: Lower Intake Manifold Support Bracket & Fasteners

SEPARATION AND REASSEMBLY - 2.4L MULTIAIR 4X4 > REMOVAL
1. Remove the fasteners (1) and the lower intake manifold support bracket.
2. Remove the bolts (1) and remove the PTU support bracket.
Fig 2: Locating Stud
3. Remove the stud (1).

4. Remove the bolts (1) and remove the PTU from the transmission.
5. Remove the bolt (1) and remove the exhaust pipe support bracket.
6. Remove the two intake side oil pan to transmission bolts (2).
7. Remove the exhaust side oil pan to transmission bolt (1).

Fig 6: Alternator Wiring Harness Retaining Clips & Engine Wire Harness Connector
8. Open the retaining clips (1) and reposition the alternator wiring harness.
9. Disengage the engine wire harness connector (2) from the bracket.
10. Remove the bolt (1) and the bracket.
11. Remove the upper starter motor bolt (2).

12. Disconnect the starter motor wire harness connector (1).
13. Remove the lower starter motor bolt (2) and remove the starter motor with the battery positive
cable attached.
Fig 9: Inspection Cover Bolt
15. Install the 1860898000 tool (1).

17. Remove the intake side upper transmission to engine block bolt (1).
18. Remove the exhaust side upper transmission to engine block bolt (1).
Fig 13: Wire Harness At Transmission, Side Transmission To Engine Block Bolt &
Transmission
19. Disengage the wire harness from the transmission (1).
20. Remove the side transmission to engine block bolt (2a) and remove the transmission (2b) from
the engine.
SEPARATION AND REASSEMBLY - 2.4L MULTIAIR 4X4 > INSTALLATION
Fig 1: Wire Harness At Transmission, Side Transmission To Engine Block Bolt & Transmission
1. Install the transmission (1a) to the engine with the side transmission to engine bolt (1b)
2. Engage the wire harness to the transmission (2).

3. Install the exhaust side upper transmission to engine block bolt (1) and tighten to the proper
4. Install the intake side upper transmission to engine block bolt (1) and tighten to the proper
5. Install the torque converter bolts (1) and tighten to the proper torque specification. Refer to
6. Remove the 1860898000 tool (2).
7. Install the inspection cover and tighten the bolt to the proper torque specification. Refer to
8. Install the starter motor (1) with the battery positive cable attached and tighten the lower
starter bolt to the proper torque specification. Refer to TORQUE SPECIFICATIONS .
9. Connect the starter motor wire harness connector (2).

10. Install the upper starter bolt (1) and tighten to the proper torque specification. Refer to
11. Install the bracket (2) with the bolt tightened to the proper torque specification. Refer to
12. Engage the engine wire harness connector to the bracket.
13. Position the alternator wiring harness and close the retaining clips.
14. Install the exhaust side oil pan to transmission bolt (1) and tighten to the proper torque
15. Install the two intake side oil pan to transmission bolts (1) and tighten to the proper torque
16. Install the exhaust pipe support bracket (2) and tighten the bolt to the proper torque
18. Install the PTU (1) to the transmission and tighten the bolts to the proper torque specification.
Fig 10: Locating Stud
19. Install the stud (1) to the intake manifold and tighten to the proper torque specification. Refer to
20. Install the PTU support bracket (1) and tighten the bolts to the proper torque specification.
21. Install the lower intake manifold support bracket and tighten the fasteners to the proper torque

2.4L > REMOVAL
Fig 1: Flywheel Stop Tool, Flexplate & Bolts
1. Fit the 1860741000 (EMEA) flywheel stop tool (1).
2. Remove the bolts (2a) and remove the flexplate (2b) with spacer.
3. Remove the 1860741000 (EMEA) flywheel stop tool.

Fig 2: Installing Mounting Bracket On Engine Block
4. Install the 1871000000 mounting bracket on the engine block (1).

Fig 3: Installing Engine Block & Mounting Bracket To Maintenance Stand
5. With the aid of a hydraulic lift, install the engine block and mounting bracket to the 1871000000
maintenance stand (1).

2.4L > INSTALLATION

3. Install the engine flexplate with spacer (1) and partially tighten the bolts (3).
SPECIFICATIONS .
INSPECTION - 2.4L
1. Unscrew the plug (1) and drain the engine oil.

Fig 2: Lower Exhaust Manifold Heat Shield & Screws
2. Remove the screws (1) and remove the heat shield (1) below the exhaust manifold.
Fig 3: Knock Sensor & Electrical Connector
3. Disconnect the knock sensor electrical connector (1).

Fig 4: Crankshaft Position (CKP) Sensor, Wire Harness Connector & Bolt
4. Unlock and disconnect the Crankshaft Position (CKP) sensor wire harness connector (2).
Fig 5: Alternator Wire Harness Connector, Bolts, Cap & Nut
5. Disengage cap (1), unscrew the nut (1) and disconnect the alternator wiring.

Fig 6: Wiring Retaining Bracket To Cylinder Head & Bolt
7. Remove the screw (1) from the wiring retaining bracket to the cylinder head.
Fig 7: A/C Compressor Wire Harness Connectors
8. Disconnect the wire harness connectors (1a and 1b) from the A/C compressor.
Fig 8: Manifold Air Pressure (MAP) Sensor
9. Disconnect the manifold air pressure sensor electrical connection (1) and disengage the
retaining clips (2).
Fig 9: Oil Temperature Sensor & Connector
10. Unlock and disconnect the engine oil pressure sensor wire harness connector (4).
Fig 10: Throttle Body Electrical Connection
11. Disconnect the electrical connection of the throttle body (2).

Fig 11: Engine Coolant Temperature (ECT) Sensor Wire Harness Connector & Coolant Hose
Quick-Connect Coupling
12. Disconnect the Engine Coolant Temperature (ECT) sensor wire harness connector (1).
Fig 12: Fuel Vapors Solenoid Wire Harness Connector & Fuel Vapors Solenoid
13. Disconnect the fuel vapors solenoid wire harness connector (2) and remove fuel vapors
solenoid.
Fig 13: Fuel Injectors & Wire Harness Connectors
14. Disconnect the wire harness connectors (1) of the fuel injectors (2).
Fig 14: Oil Temperature Electrical Connector & MULTIAIR Actuator Electrical Connectors
15. Disconnect the oil temperature electrical connector (1) at the MULTIAIR actuator.
16. Disconnect the MULTIAIR actuator electrical connectors (2).

Fig 15: Wiring Duct On Intake Side & Bolts
17. Remove the screws (1) securing the wiring duct on the intake side.
Fig 16: Ignition Coils Wire Harness Connectors, Wiring Duct On Exhaust Side Bolts & Ground
Terminal
18. Disconnect the wire harness connectors (1) from the ignition coils.
19. Remove the screws (2) securing the wiring duct on the exhaust side.
20. Disconnect the ground terminal (5).
21. Remove the wire harness from the engine.

Fig 17: Vacuum Pump Mounting Bolts
22. Remove the vacuum pump mounting bolts (1) and the vacuum pump.
Fig 18: Vacuum Pump O-Ring Seals
23. Remove and discard the vacuum pump O-ring seals (1, 2).
Fig 19: Oil Vapor To Air Capacity Airbox Pipe
24. Disconnect the pipe (1) that delivers oil vapor to the air capacity airbox.
25. Remove the screws (1) and remove the ignition coils.
Fig 21: Valve Cover Bolts
26. Remove the screws (1) and remove the valve cover and discard the valve cover gasket.
NOTE:
Before removing the valve cover, mark the position of the studded screws for ease
of installation.
Fig 22: Lower Heat Shield & Bolts
27. Remove the bolts (1) and the lower heat shield.
Fig 23: Catalytic Converter Support Bracket Bolts
28. Remove the bolts (1) and the catalytic converter support bracket.
Fig 24: Exhaust Manifold Catalyst, Nuts & Bolts
29. Remove the nuts (1a) and the bolts (1b) and the exhaust manifold catalyst (1c).
30. Remove and discard the manifold gasket.

Fig 25: Reinforcement Bracket At Throttle Body & Fastener
31. Remove the fastener and the reinforcement bracket from the throttle body (1).
Fig 26: Throttle Body & Fasteners
32. Remove the fasteners (1a) and remove the throttle body (1b).
Fig 27: Centering Pins & Gasket
33. Remove the gasket (1a) and verify the integrity of the centering pins (1b).
Fig 28: Fuel Injectors & Fuel Rail
34. Remove the fuel rail (1) and fuel injectors. Refer to INJECTOR(S), FUEL, REMOVAL AND
INSTALLATION .
Fig 29: Intake Manifold Silencer Cover
35. Remove the four screws (1) and the intake manifold silencer cover.
Fig 30: Intake Manifold Support Bracket & Bolt
36. Remove the bolt (1) securing the intake manifold support bracket.
Fig 31: Vacuum Pump Support Bracket & Fasteners
37. Remove the fasteners (1a) and the vacuum pump support bracket (1b).
Fig 32: Intake Manifold & Fasteners
38. Remove the fasteners (1) and the intake manifold.
39. Remove and discard the gasket seals

Fig 33: Belt Tensioner, Bolt & Serpentine Belt
40. Using a suitable removal tool, rotate belt tensioner (1b) to release the tension and remove the
serpentine belt (1c).
Fig 34: Vibration Damper & Aligning Timing Marks
41. Turn the vibration damper to align the timing marks (1).
Fig 35: Special Tool, Bolt & Vibration Damper
42. Using the 2000040299 (EMEA) or (special tool #9707, Holder, Vibration Damper) (NAFTA) tool
(1a), remove the bolt (1b) and the vibration damper (1c).
Fig 36: Water Pump Pulley & Bolts
43. Remove the bolts (1a) and the water pump pulley (1b).
Fig 37: Accessory Drive Belt Idler Pulley & Bolt
44. Remove the bolt (1) and remove the accessory drive belt idler pulley.
Fig 38: Engine Oil Dipstick Tube & Bolt
45. Remove the bolt (1) and remove the engine oil dipstick tube.
Fig 39: Accessory Drive Belt Tensioner Top Bolt
46. Remove the top bolt (1) from the accessory drive belt tensioner.
Fig 40: Accessory Drive Belt Tensioner & Bolt
Fig 41: Engine Timing Cover To Cylinder Head Upper Bolts
48. Remove the upper bolts (1) securing the engine timing cover to the cylinder head.
Fig 42: Engine Timing Cover To Engine Block & Engine Oil Pan Bolts
49. Remove the bolts (1) securing the engine timing cover to the engine block.
50. Remove the bolts (2) securing the engine timing cover to the engine oil pan.
Fig 43: A/C Compressor And Support Bracket Bolts
51. Remove the bolts (1) and remove the A/C compressor and support bracket.
Fig 44: Cutting Sealant Between Engine Timing Cover & Engine Oil Pan Using Special Tool
52. With the 1870718000 tool (1) cut the sealant from between the engine timing cover and the
engine oil pan.
Fig 45: Engine Timing Cover
53. Remove the engine timing cover (1).
54. Remove the residual silicone gasket material from the cover and check the integrity of the
centering bushings.
55. Pry off and remove the front crankshaft oil seal from the timing cover.
Fig 46: Tensioner & Bolts
56. Remove the screws (1) and remove the tensioner.

Fig 47: Timing Chain Tensioner Guide & Bolt
57. Remove the screw (1a) and remove the timing chain tensioner guide (1b) complete with
bushing.
58. Remove the screw (1a) and remove the timing chain tensioner guide (1b).
Fig 49: Positioning Crankshaft Key At "9" O-Clock Position & Marking Chain Link At Point
Marked On Crankshaft Gear
59. Check that the crankshaft key is in the "9 o'clock" position (1).
60. Using the same chain, mark the link of the chain that is at the point marked (2) on the drive
gear.
Fig 50: Positioning Camshaft Centering Pin At "12" O-Clock Position & Marking Chain Link At
Point Marked On Camshaft Sprocket
61. Check that the camshaft centering pin (1) is in the "12 o'clock" position".
62. Using the same chain, mark the link of the chain (2) that corresponds with the notch on the
camshaft sprocket.
Fig 51: Camshaft Sprocket & Bolt
63. Remove the camshaft sprocket screw (1).

Fig 52: Camshaft Sprocket & Chain
64. Disengage the camshaft sprocket (1) from the shaft and remove it along with the chain.
65. Loosen the clamp and remove the radiator hose (1) from the thermostat housing.
66. Disconnect the quick-connect coupling and remove the coolant hose (2) from the thermostat
housing
Fig 55: Coolant Tube To Thermostat Housing Lock Tab & Bolt
67. Release the lock tab (1a) and remove the bolt (1b) securing the coolant tube to the thermostat
housing.
Fig 56: Thermostat Housing & Bolt
68. Remove the bolts (1) securing the thermostat housing.

Fig 57: Thermostat Housing
69. Remove the thermostat housing (1).

Fig 58: Thermostat Housing Gasket
70. Remove and discard the thermostat housing gasket (1).

Fig 59: Rear MULTIAIR Actuator To Cylinder Head Bolt
71. Remove the rear MULTIAIR actuator to cylinder head bolts (1).
Fig 60: Compressing MULTIAIR Actuator Spring Using Special Tool & Locating Front MULTIAIR
Actuator To Cylinder Head Bolt
72. Install the 2020000090 (EMEA) or (special tool #10259B, Compressor, MultiAir® Spring)
(NAFTA) tool (1) on the MULTIAIR actuator and compress the springs.
73. Remove the front MULTIAIR actuator to cylinder head bolts (2), and remove the complete
module from the cylinder head.
74. Remove the metal seal and the centering bushings.

Fig 61: MULTIAIR Actuator, Camshaft & Camshaft Caps
NOTE:
For engine specifications, refer to DISASSEMBLY AND ASSEMBLY . Also refer to

75. Using a dial gauge and a suitable magnetic base, check that the camshaft end play is within
the specified values.
76. Remove the camshaft cap to cylinder head bolts (2), and remove the camshaft caps.
77. Remove the camshaft (3) and oil seal.

Fig 62: Hydraulic Tappets
78. Remove the hydraulic tappets (1).

Fig 63: Heat Shield & Nut
79. Remove the nut (1) and remove the heat shield (1) of the ground terminal.
Fig 64: Ground Terminal & Stud
80. Remove the screw (1) and remove the ground terminal (1).
81. Remove the alternator bolts (3).

Fig 66: Alternator
82. Remove the alternator (1) with centering sleeve.

83. Remove the bolts (1) and remove the cylinder head.
Fig 68: Cylinder Head Gasket & Locating Dowels
84. Remove the gasket (2) and the centering bushings (1).
Fig 69: Locating Variable Valve Actuation Assembly (VVAA) Oil Supply Filter
85. Remove the Variable Valve Actuation Assembly (VVAA) oil supply filter (1) from the engine
block.
86. Remove the bolts (2) securing oil pan.

Fig 71: Cutting Sealant Around Perimeter Of Engine Oil Pan Using Special Tool
87. Use the 1870718000 tool (1) to cut the silicone sealant around the entire perimeter of the
engine oil pan.
88. Remove the engine oil pan.

INSPECTION - 2.4L
NOTE:
If the timing chain plated links (1) can no longer be seen, the timing chain links
corresponding to the timing marks (2) must be marked prior to removal if the chain is to be
reused.

INSPECTION - 2.4L > DISASSEMBLY
Fig 1: Marking Chain Link Corresponding To Crankshaft Sprocket Timing Mark
1. Mark chain link (1) corresponding to crankshaft sprocket timing mark (2).
Fig 2: Marking Chain Link Corresponding To Balance Shaft/Oil Pump Sprocket Timing Mark
2. Mark the chain link (1) corresponding to balance shaft/oil pump sprocket timing mark.
Fig 3: Oil Pump Tensioner Reset
3. Reset the balance shaft/oil pump chain tensioner by pushing the plunger inward and installing a
pin to hold the plunger in the retracted position.
Fig 4: Tensioner, Tension Arm, Chain Guide & Bolts
4. Remove the two bolts (4) and the tensioner (3).
5. Remove the tensioner arm bolt (2) and the tensioner arm (1).
6. Remove the fixed chain guide bolts (5) and the chain guide (6).
Fig 5: Oil Pump Assembly - Balancing Assembly & Bolts
7. Remove the screws (1a), disengage the chain from the engine oil pump control and remove the
oil pump assembly - balancing assembly (1b).
Fig 6: Crankshaft Sprocket & Keys
8. Remove the crankshaft sprocket (1).

Fig 7: Rear Crankshaft Oil Seal - Removal
9. Insert a flat bladed screwdriver (7) between the dust lip (8) and the metal case (4) of the
crankshaft seal (1). Angle the screwdriver through the dust lip against the metal case of the
seal. Pry out the seal.
CAUTION:
Do not permit the screwdriver blade to contact crankshaft seal surface. Contact of
the screwdriver blade against crankshaft edge (chamfer) is permitted.
10. Check to make sure the seals garter spring is also removed and is not on the crankshaft.
Fig 8: Water Supply And Return Hoses & Clamps
11. Loosen the clamps and disconnect the water supply and return hoses (1) to the engine oil
cooler.
Fig 9: Removing Oil Filter Using Oil Filter Wrench
12. Unlock the engine oil filter and remove it using an appropriate oil filter wrench (1).
Fig 10: Heat Shield & Bolts
13. Remove the screws and remove the heat shield (1).
Fig 11: Filter Housing & Motor Oil Cooler
14. Unscrew the filter (1) and remove the motor oil cooler.
Fig 12: Knock Sensor & Mounting Bolt
15. Remove the mounting bolt (2) and remove the knock sensor (1).
Fig 13: Crankshaft Position (CKP) Sensor, Wire Harness Connector & Bolt
16. Remove the mounting bolt (3) and remove the Crankshaft Position (CKP) sensor (1).
Fig 14: Oil Temperature Sensor & Connector

Fig 15: Coolant Tube, Water Pump Body, Nuts & Bolts
18. Remove the nuts (1) securing the coolant tube to the water pump body (2b).
19. Remove the bolts (2a) and the water pump body (2b).

Fig 16: Water Pump & Bolts
21. If necessary, remove the bolts (1) and the water pump.
Fig 17: Generator Mounting Bracket, Accessory Belt Tensioner & Bolts
22. Remove the three bolts (2) and the generator mounting bracket (1) from the engine.
Fig 18: Intermediate Shaft Bearing Housing & Bolts
23. Remove the three bolts (2) and the intermediate shaft bearing support (1) from the engine, if
equipped.
Fig 19: Ladder Frame Bolts Tightening Sequence
24. Remove the ladder frame bolts and separate the ladder frame from the engine block.
Fig 20: Main Bearing Cap Bolts Removal & Tightening Sequence
25. Loosen the ten main bearing cap bolts.
26. Remove the bearing beam bolts (1 - 6) and remove the bearing beam. Temporarily install main
bearing cap bolts (M10 x 1.25 x 76.5) into the unsupported No. 2, 3 and 5 main bearing caps
hand tight.
Fig 21: Connecting Rod To Cylinder Identification
NOTE:
Connecting rods and bearing caps are not interchangeable and should be marked
before removing to ensure correct reassembly.
CAUTION:
DO NOT use a number stamp or a punch to mark connecting rods or caps, as

damage to connecting rods could occur
27. Mark connecting rod and bearing cap positions (1) using a permanent ink marker or scribe tool.
Fig 22: Piston, Connecting Rod Cap, Bolts, Plastic Guide Plates & Guide Pins
NOTE:
Typical I4 engine configuration shown in illustration.
28. If necessary, remove the top ridge of the cylinder bores with a reliable ridge reamer before
removing the pistons from the engine block. Be sure to keep the tops of pistons covered
during this operation. Pistons and connecting rods must be removed from the top of the
engine block. When removing piston and connecting rod assemblies from the engine, rotate the
crankshaft CW so that each connecting rod is centered in the cylinder bore.
29. Remove the connecting rod cap bolts (4) and the connecting rod cap (3). Discard the cap bolts
(4).
CAUTION:
Care must be taken not to nick crankshaft journals, as engine damage may occur.
30. Install the (special tool #10281, Pins, Connecting Rod Guide) (6) on the connecting rod being
removed.
CAUTION:
Avoid contact with the piston oil cooler jet(s). Positioning of the oil cooler jet(s) is
critical for proper engine operation.
31. Remove the connecting rod and piston assembly (1) complete with upper bearing shell (7) from
the cylinder bore.
32. Repeat the previous steps for each piston being removed.
33. Immediately after piston and connecting rod removal, reinstall the bearing cap (3) on the mating
connecting rod to prevent damage to the fractured cap and rod surfaces.
34. If required, remove the piston rings. Refer to RING(S), PISTON, REMOVAL AND
INSTALLATION .
Fig 23: Checking Crankshaft End Play
35. Measure the crankshaft end play and compare it to the specification. Refer to ENGINE
SPECIFICATIONS .
NOTE:
Crankshaft thrust bearings are not selectable and are only available in a single
thickness.
CAUTION:
DO NOT use a number stamp or a punch to mark main bearing caps, as damage to
main bearings could occur.
36. Mark the main bearing cap positions using a permanent ink marker or a scribe tool.
NOTE:
Main bearing caps are not interchangeable and are marked to insure correct
assembly.
37. Remove the main bearing cap bolts and remove the main bearing caps.
Fig 24: Target Wheel & Bolts
CAUTION:
Do not rest the crankshaft on the target wheel (1). Damaged or bent target wheel
teeth will destroy the target wheels ability to correctly relay crankshaft position to the
crankshaft position sensor.
38. Lift the crankshaft from the cylinder block. Do not damage the main bearings or journals when
removing the crankshaft.
39. If required, remove the four screws (2) and the target wheel (1) from the crankshaft.
40. Remove the lower main bearing shells from the main bearing caps.
41. Remove the upper main bearing shells from the engine block.
42. Remove the crankshaft thrust bearings.

Fig 25: Gallery Plug
NOTE:
Rear plug shown in illustration, other plugs are similar.
43. Remove the water galley and oil galley plugs (2).
Fig 26: Oil Jet Fastener & Oil Jet
44. Remove the bolt (1) and the piston oil cooler jets (2).

INSPECTION - 2.4L > REASSEMBLY
1. Wash and inspect the disassembled components.
2. Install the engine block on the 1871000000 (EMEA) maintenance stand.

Fig 1: Oil Jet Fastener & Oil Jet
5. Install the piston oil cooler jets (2) with the bolt (1) tightened to the proper specification. Refer
Fig 2: Measuring Flatness Of Cylinder Head Mounting Surface On Engine Block Using A
Straight Edge & Feeler Gauge
6. Measure the flatness of the cylinder head mounting surface of the engine block using a straight
edge (1a) and a feeler gauge (1b) and compare it to the specification. Refer to ENGINE
SPECIFICATIONS .
NOTE:
If the flatness is not within specification, resurface the cylinder head mounting
surface.
7. Measure the diameter of the cylinder bores and compare it to the specification. Refer to
NOTE:
If the diameters are not within specification, bore the cylinders to the appropriate
oversize.
NOTE:
8. Measure the roundness of the cylinder bores and compare it to the specification. Refer to
NOTE:
If the roundness is not within specification, bore the cylinders to the appropriate
oversize.
NOTE:
9. Measure the taper of the cylinder bores and compare it to the specification. Refer to ENGINE
SPECIFICATIONS .
NOTE:
If the taper is not within specification, bore the cylinders to the appropriate oversize.
NOTE:
refinishing the diameter of the journal to the appropriate undersize.
NOTE:
The crankshaft has a nitride treatment; Therefore, after refinishing the crankshaft
should again be nitrided and subjected to a subsequent dimensional inspection.
refinishing the diameter of the journal to the appropriate undersize.
NOTE:
The crankshaft has a nitride treatment; Therefore, after refinishing the crankshaft
should again be nitrided and subjected to a subsequent dimensional inspection.
replace the bearing shells.
Fig 3: Target Wheel
15. If removed, install the target wheel to the crankshaft with four new screws. Ensure the
threaded holes in the crankshaft are free of residual thread lock adhesive. Tighten the screws
in the sequence shown in illustration to the proper specification. Refer to TORQUE
SPECIFICATIONS .
Fig 4: Bearing Identification
NOTE:
The upper main bearing shells (2) have oil lubrication holes, the lower main bearing
shells (1) do not. Crankshaft thrust washers (3) are located on the second main
bearing journal.
16. Lubricate the upper main bearing shells with clean engine oil and install the upper main bearing
shells and crankshaft into the engine block.
NOTE:
The thrust bearings must be installed with the notches facing the crankshaft.
17. When installing thrust bearings at the second main bearing location, use the following
procedure:
1. Move the crankshaft forward to the limit of travel. Lubricate and install the front thrust
bearing by rolling the bearing onto the machined shelf between the second upper main
bulk head and crankshaft thrust surface.
2. Move the crankshaft rearward to the limit of travel. Lubricate and install the rear thrust
bearing by rolling the bearing onto the machined shelf between the second upper main
bulk head and crankshaft thrust surface.
18. Remove oil film from the surface to be checked by the use of Plastigage or equivalent.
Plastigage is soluble in oil.
19. Place a piece of Plastigage (1) across the entire width of the bearing journal (2). In addition,
suspected areas can be checked by placing the Plastigage in the suspected area. Plastigage
must not crumble in use. If brittle, obtain fresh stock.
NOTE:
20. Install the lower main bearing shells into the main bearing caps.
21. Install the main bearing caps with the main bearing cap bolts. Use the temporarily installed
main bearing cap bolts (M10 x 1.25 x 76.5) at the No. 2, 3 and 5 main bearing caps in place of
the bearing beam for this dimensional check.
22. Tighten the ten main bearing cap bolts in the sequence shown in illustration, following this 3
step torque plus angle method. Tighten according to the following torque values:
1. Step 1: All to 15 N.m (11 ft. lbs.)
3. Step 3: All an additional 45° Turn Do not use a torque wrench for this step.
Fig 7: Using A Graduated Measuring Guide To Determine Bearing Clearance
23. Remove the main bearing caps and using a graduated measuring guide (1) determine the
bearing clearance indicated by the Plastigage.
24. Perform the measurement on the remaining journals taking care not to rotate the crankshaft.
25. After verifying all main bearing clearances are within specification, lubricate and reinstall the
main bearing caps with the main bearing cap bolts only hand tight at this time.
Fig 8: Measuring Piston Ring End Gap In Cylinder Bore Using A Feeler Gauge
SPECIFICATIONS .
27. Insert the piston rings (1a) in the cylinder bore and using a feeler gauge (1b), check that the
end gaps are within specification. Refer to ENGINE SPECIFICATIONS .
NOTE:
Piston rings not within specification should be replaced.

Fig 9: Using A Feeler Gauge To Check Axial Clearance Between Rings & Ring Grooves
28. Using a feeler gauge (1a), check that the axial clearance between the rings (1b) and ring
grooves on the piston are within specification. Refer to ENGINE SPECIFICATIONS .
NOTE:
piston pin bore.
29. Using a feeler gauge, check that the piston to cylinder bore clearances are within specification.
30. Verify that the diameter of the connecting rod big end is within specification. Refer to ENGINE
SPECIFICATIONS .
31. Install the piston rings on the pistons. Refer to RING(S), PISTON, REMOVAL AND
INSTALLATION .
Fig 10: Using A Ring Compressor To Install Rod & Piston With Bearing Shell
32. Install the rod and piston complete with bearing shell using a ring compressor (1).
Fig 11: Locating Arrow On Piston Crown For Piston Installation Direction
33. The pistons crowns are stamped with an arrow (1). The piston and connecting rod assemblies
must be installed so the arrow points toward the front of the engine.
Fig 12: Placing Plastigage Across Surface Of Bearing Journal
34. Check that the components are free of burrs, stamps, scratches or any other surface defects.
Thoroughly clean and dry the pieces before assembly.
35. Apply the Plastigage across the surface of the rod bearing journals (1).
NOTE:
is facing the same side as the one stamped on the big end.
Fig 13: Using Graduated Measuring Guide To Determine Bearing Clearance
36. Fit the bearing caps complete with bearing shells and tighten the bearing cap bolts to the
37. Remove the bearing caps previously installed and using the graduated measuring guide (1)
determine the bearing clearance indicated by the Plastigage.
38. Perform the measurement on the remaining journals taking care not to rotate the crankshaft.
NOTE:
proper dimension.
CAUTION:
The connecting rod bolts must not be reused. Always replace the connecting rod
bolts whenever they are loosened or removed.
39. Lubricate the rod bearing surface with clean engine oil. Fit all bearing caps complete with
bearing shells and tighten all bearing cap bolts to the proper specification. Refer to TORQUE
SPECIFICATIONS .
Fig 14: Checking Cylinder Head Bolts For Stretching (Necking)
CAUTION:
The main bearing cap bolts are tightened using a torque plus angle procedure. The
bolts must be examined BEFORE reuse. If the threads are necked down the bolts
must be replaced.
40. After verifying all main and rod bearing clearances are within specification, check the main
bearing cap bolts for necking by holding a scale or straight edge against the threads. If all the
threads do not contact the scale (2) the bolt must be replaced.
Fig 15: Bearing Beam Installed With Indication Pointing To Front Of Engine
41. Remove the temporarily installed main bearing cap bolts from main bearing caps 2, 3 and 5.
Install the bearing beam (1) with its longer bolts so that the <FRT indication (2) is pointing to
the front of the engine.
Fig 17: Checking Crankshaft End Play
43. Measure the crankshaft end play and compare it to the specification. Refer to ENGINE
SPECIFICATIONS .
NOTE:
Crankshaft thrust bearings are not selectable and are only available in a single
thickness.
Fig 18: Sealing Ladder Frame
44. Clean the ladder frame sealing surfaces with isopropyl alcohol in preparation for sealant
application.
CAUTION:
Engine assembly requires the use of a unique sealant that is compatible with
engine oil. Using a sealant other than Mopar® Engine Sealant RTV Silicone Rubber
Adhesive may result in engine fluid leakage.
CAUTION:
Following the application of Mopar® Engine Sealant RTV Silicone Rubber Adhesive
to the gasket surfaces, the components must be assembled within 10 minutes and
the attaching fasteners must be tightened to specification within the next 10 minutes.
Prolonged exposure to the air prior to assembly may result in engine fluid leakage.
45. Apply a 2 mm bead of Mopar® Engine Sealant RTV Silicone Rubber Adhesive as shown in
illustration.
46. Install the ladder frame and tighten the twelve bolts in the sequence shown in illustration,
following this 2 step method. Tighten according to the following torque values:
1. Step 1: All to 10 N.m (89 in. lbs.).
2. Step 2: All to 26 N.m (19 ft. lbs.).

47. If removed, install the crankshaft sprocket key (2) in the crankshaft.
48. Install the crankshaft sprocket (1).

49. Align the timing chain onto the crank sprocket mark (2) using the painted link (1) as a guide.
CAUTION:
The balance shaft/oil pump assembly bolts are tightened using a torque plus angle
procedure. The bolts must be examined BEFORE reuse. If the threads are necked
down the bolts must be replaced.
50. Check the balance shaft/oil pump bolts for necking by holding a scale or straight edge against
the threads. If all the threads do not contact the scale (2) the bolt must be replaced.
51. Align the timing chain onto the balance shaft/oil pump sprocket mark using the painted link (1)
as a guide.
52. With the rear of the balance shaft/oil pump assembly on a slight angle, position the gear into
the chain links and install the balance shaft/oil pump assembly on the ladder frame. Make sure
the paint marks are aligned.
Fig 24: BSM Mounting Bolts Tightening Sequence
53. Install the four balance shaft/oil pump bolts finger tight.
54. Tighten the balance shaft/oil pump bolts in the sequence shown in illustration, following the 3
step torque plus an ending torque angle method. Tighten according to the following torque
values:
3. Step 3: All an additional 90° Do not use a torque wrench for this step.
56. Install the fixed chain guide (7) with two bolts (6) tightened to the proper specification. Refer to
57. Install the tensioner arm (1) with the bolt (2) tightened to the proper specification. Refer to
58. Install the tensioner (4) with the two bolts (5) tightened to the proper specification. Refer to
59. Remove the tensioner pin (3) from the tensioner (4).
Fig 27: Installing Crankshaft Oil Seal Flywheel Side Using Special Tool
60. Using the 2000040586 (EMEA) or C-4171 (NAFTA), 2000040298 (EMEA) or (special tool
#9706, Installer, Crankshaft Rear Oil Seal) (NAFTA) and 2000040246 (EMEA) or (special tool
#9509, Installer, Oil Seal) (NAFTA) tools (1), install a new crankshaft oil seal, flywheel side.
61. If equipped, install the intermediate shaft bearing housing (1) with three bolts (2) tightened to
Fig 29: Water Pump Gasket
62. If removed, install a NEW gasket (1) onto the water pump.
63. If removed, install the water pump. Tightened the five bolts (1) in a crisscross pattern to the
Fig 31: Coolant Tube, Water Pump Body, Nuts & Bolts
64. Using a NEW gasket, install the water pump body (1a). Tighten the bolts (1b) to the proper
65. Install the nuts (2) securing the coolant tube to the water pump body (1b) and tighten to the
66. Install the oil pressure sensor and tighten to the proper specification. Refer to TORQUE
SPECIFICATIONS .
67. Install the crankshaft position (CKP) sensor and tighten the mounting bolt to the proper
68. Install the knock sensor with a new mounting bolt tightened to the proper specification. Refer to
Fig 32: Installing Motor Oil Cooler By Engaging Reference Centering With Tab
69. Install the motor oil cooler, engaging the reference centering with the tab (a) shown in the
figure and tighten the union.
70. Install the heat shield and tighten the screws.
71. Lubricate the seal with engine oil and mount the engine oil filter tightening it completely by
hand.
72. Connect the water flow and return pipes to the engine oil cooler and tighten the clamps.
73. Install the Variable Valve Actuation Assembly (VVAA) oil supply filter (1) in the engine block.
Fig 34: Placing Sealant On Cylinder Head Gasket At Specified Locations
74. Position the cylinder head gasket engaging the centering bushings.
75. Place sealant on the cylinder head gasket at the points indicated (1) in the figure.
Fig 35: Cylinder Head Bolts Tightening Sequence
NOTE:
For each tightening sequence, follow the order shown in illustration.
76. Install the cylinder head and bolts securing the cylinder head. Torque all bolts to the proper
77. Install the hydraulic tappets (1).

78. Install the camshaft (1) into the cylinder head.
79. Install the bearing caps (2), respecting the numbering of the cylinders stamped at the top of
each cap, and tighten the camshaft cap to cylinder head bolts to the proper specification.
NOTE:
The arrow on the bearing cap "a" must point to the timing side.
NOTE:
During all the handling operations, the MUTIAIR actuator should not be overturned
with hydraulic tappets above.
80. Install a NEW metal gasket on the cylinder head top.
81. Position the MULTIAIR actuator into the vehicle, and tighten the front MULTIAIR actuator to
cylinder head bolts to the proper specification. Refer to TORQUE SPECIFICATIONS .
82. Remove the 2020000090 (EMEA) or (special tool #10259B, Compressor, MultiAir® Spring)
(NAFTA) tool from the MULTIAIR actuator.
83. Install and tighten the rear MULTIAIR actuator to cylinder head bolts to the proper
84. Clean the gasket mating surfaces.
85. Install a NEW thermostat housing gasket (1).

86. Install the thermostat housing (1) and tighten bolt finger tight.
87. Install the vacuum pump support bracket (1b) and securely tighten fasteners (1a).
Fig 42: Thermostat Housing Bolts
88. Tighten the thermostat housing bolts (1) in a crisscross pattern to the proper specification.
89. Install the bolt (1b) securing the coolant tube to the thermostat housing and tighten to the
proper specification then bend lock tab to secure bolt (1a). Refer to SPECIFICATIONS .
Fig 44: Timing Chain Guide, Guide Bolts, Tensioner Arm & Bolt
90. Install the timing chain guide (1) with three bolts (2) tightened to the proper specification. Refer
91. Install the tensioner arm (4) with the bushing and bolt (3) tightened to the proper specification.
92. Verify that the crankshaft key is in the "9 o'clock" in correspondence with the surfaces of
contact between the lower and upper crankcase.
93. Install the chain, align the drive gear with the painted link. If you mount a new chain, the
alignment reference is yellow.
Fig 46: Placing Alignment Mark In "12" O-Clock Position
94. Check that the alignment mark (1) is in the "12 o'clock" position.
Fig 47: Matching Camshaft Sprocket Gear Notch To Marked Link
95. Fit the chain on the camshaft sprocket by matching the gear notch (1a) with the marked link
(1b). If you mount a new chain, the alignment reference is yellow.
96. Align the pin (2) and install the camshaft sprocket.
Fig 48: Camshaft Sprocket Bolt
97. Tighten the camshaft sprocket bolt (1) to the proper specification. Refer to SPECIFICATIONS .
Fig 49: Pawl & Piston & Pin Lock
98. Disengage the pawl (1a) from the rack, compress the piston (1b) and insert the pin lock (1c).
Fig 50: Tensioner & Locking Plunger Pin
99. Install the tensioner (1) and tighten the screws to the proper specification. Refer to TORQUE
SPECIFICATIONS .
100. Remove the locking plunger pin (2).

Fig 51: Applying Sealant To Engine Timing Cover To Engine Block Gasket Surface
101. Apply a suitable silicone sealant to the engine timing cover to engine block gasket surface (1)
as shown in the figure.
Fig 52: Applying Sealant To Indicated Surfaces
102. Apply a bead (2 mm) of a suitable silicone sealant (1a) and (1b) to the surfaces indicated in the
figure.
Fig 53: Engine Timing Cover & Mounting Bolts
103. Install the engine timing cover and tighten the mounting bolts (1) to the proper specification.
Fig 54: Applying Sealant To Oil Pan
104. Apply a 2 mm bead of Mopar® Engine Sealant RTV Silicone Rubber Adhesive around the oil
pan as shown in illustration.
105. Install the oil pan and tighten the bolts (1) to the proper specification. Refer to TORQUE
SPECIFICATIONS .
106. Install the A/C compressor mounting bracket and tighten the bolts (2) to the proper
107. Install the A/C compressor with three bolts (1) and tighten the bolts to the proper specification.
108. Install a new front crankshaft oil seal with the 2000040245 (EMEA) or (special tool #9506,
Installer, Oil Seal) (NAFTA) tool (1).
109. Install the generator mounting bracket (1) with three bolts (2) tightened to the proper
Fig 59: Accessory Drive Belt Tensioner & Bolts
110. If removed, install the accessory drive belt tensioner (1) and tighten the bolts to the proper
111. Install the accessory drive belt idler pulley (1) and tighten the bolt to the proper specification.
112. Install the water pump pulley (1a). Tighten the three bolts (1b) to the proper specification. Refer
to SPECIFICATIONS .
113. Install the vibration damper onto the crankshaft (1c).
(1a), Install the vibration damper bolt (1b) and tighten to the proper specification. Refer to
115. Install the alternator, engaging the centering bushing and tighten the bolts (1) to the proper
116. Connect the alternator wiring with the nut (3) and engage the cap (3).
117. Connect the wire harness connector (2) to the alternator.

118. Install the wiring retaining bracket to the cylinder head with the screw (1) tighten to the proper
119. Rotate the belt tensioner (1b) and install the serpentine belt (1c).
Fig 66: Valve Cover Seals
120. Install new seals (1) on the valve cover.

Fig 67: Placing Sealant On Cylinder Head At Specified Locations
121. Apply sealant in the points shown in illustration (1).

Fig 68: Valve Cover Bolts Tightening Sequence
NOTE:
Place the studded screws in the positions previously marked for installation.
122. Put into place the valve cover and tighten the screws in the order shown in illustration. Tighten
the screws to the proper specification. Refer to TORQUE SPECIFICATIONS .
123. Install the ignition coils (1) and tighten the screws (1) to the proper specification. Refer to
124. Using NEW gaskets, install the intake manifold and tighten the fasteners to the proper
125. Install the intake manifold support bracket nuts and securely tighten.
126. Install the intake manifold lower support bracket bolt and securely tighten.
127. Install the intake manifold silencer cover and securely tighten the four screws.
128. Install the fuel rail with injectors and securely tighten the retaining screws.
129. Install the fuel vapor solenoid.
130. Connect the fuel vapor delivery pipe to the air box.
131. Install the sound absorber.
132. Install a new gasket on the inlet plenum.
133. Install the throttle body, positioning it correctly on the centering pin.
134. Install the throttle body fasteners and tighten to the proper specification. Refer to FUEL
INJECTION, SPECIFICATIONS .
135. Install the throttle body reinforcement bracket and tighten the fastener to the proper
specification. Refer to FUEL INJECTION, SPECIFICATIONS .
136. Connect the pipe (1) that delivers oil vapor to the air capacity airbox.
137. Install new vacuum pump O-ring seals (1, 2).

138. Install the vacuum pump into the cylinder head opening with two bolts (1) tightened to the
139. Install the oil dipstick tube (1) to the engine with the bolt (2) tightened to the proper
Fig 74: Ensure Arrow On Exhaust Manifold Gasket Is Pointing Downward
140. Install a new exhaust manifold gasket onto the cylinder head, taking care that the arrow (a)
shown in the figure is pointing downwards.
141. Install the manifold catalyst (1c). Tighten the bolts (1b) and the nuts (1a) to the proper
142. Install the catalytic converter support bracket and tighten the bolts (1) to the proper
146. Install the ground terminal (1) and tighten the bolt securely.
147. Install the heat shield of the ground terminal (1) and tighten the nut securely.
1. Install the screws securing the wiring duct on the intake side.
2. Install the screws securing the wiring duct on the exhaust side.
3. Connect the knock sensor wire harness connector
6. Connect the manifold pressure and temperature sensor wire harness connector and
engage the retaining clips
10. Connect the purge solenoid wire harness connector

12. Connect the engine oil temperature sensor wire harness connector
13. Connect the variable valve actuator wire harness connectors
14. Connect the ignition coil wire harness connectors
15. Connect the ground terminal wire harness connector
149. Install the lower heat shield onto the exhaust manifold and securely tighten the bolts.
150. Install the upper heat shield and securely tighten the nuts.
151. Install the upstream oxygen sensor support bracket and securely tighten the bolts then engage
the wire harness retainer.
154. Install a new oil drain plug and tighten to the proper specification. Refer to TORQUE
SPECIFICATIONS .
> REMOVAL - 2.4L MULTIAIR
1. Unlock and remove the engine cover from the mounting pins.
Fig 1: Engine Cover
> INSTALLATION - 2.4L MULTIAIR
REMOVAL - 2.4L MULTI AIR
Fig 1: Access Panel Retainers
5. Remove the retainers (1) and the access panel.

Fig 2: Resonator
6. Unscrew and remove the resonator (1).

7. Remove the nut (1) securing the air tube.

Fig 4: Mass Air Flow (MAF) Sensor Wire Harness Connector, Air Tube Clamp & Air Cleaner
Body
9. Loosen the clamp (2) and disconnect the air tube from the air cleaner body.
10. Disengage the ball stud mounts, then lift up and remove the air cleaner body (3).
11. Release the tabs (1) and remove the intake air tube from the air cleaner body.
INSTALLATION
1. Install the air cleaner body and press down to engage the ball stud mount.
2. Install the air tube onto the air cleaner body and securely tighten the clamps.
4. Install the nut securing the air tube and securely tighten.
5. Install and attach the resonator.
6. Install the access panel and the retainers.

Engine misfiring
Poor fuel economy
are:
Engine overheating
Loss of coolant
Coolant foaming
CYLINDER HEAD > DIAGNOSIS AND TESTING > HYDRAULIC LASH ADJUSTER
A tappet-like noise may be produced from several sources. Check the following items:
Engine oil level too high or too low. This may cause oil aeration. Aerated oil entering the adjusters
may cause them to be spongy.
Insufficient running time after rebuilding the cylinder head. Low speed running up to one hour may
be required. Turn the engine off and let set for a few minutes before restarting. Repeat this several
times after the engine has reached normal operating temperature.
Low oil pressure.
The oil screen in cylinder head or the oil passage to the cylinder head is plugged with debris.
Air ingested into oil due to broken or cracked oil pump pick-up.
Worn valve guides.
Rocker arm ears contacting valve spring retainer.
Rocker arm loose, adjuster stuck or at maximum extension and still leaves lash in the system.
Oil leak or excessive cam bearing wear in the cylinder head.
Faulty lash adjuster. Check lash adjusters for "sponginess" while installed in the cylinder head and
cam lobe at base circle. Depress part of rocker arm over the adjuster. Normal adjusters should feel
firm when pressed quickly. When pressed very slowly, lash adjusters should collapse. Remove
suspected lash adjusters, and replace. Before installation, make sure adjusters are full of oil. This
can be verified by little plunger travel when lash adjuster is depressed quickly.
CAUTION:
NOTE:

NOTE:
cleaner.
1. Valve Springs
2. Valve Seats
3. Valve Guides
4. Valves
> REMOVAL - 2.4L MULTIAIR2
9. Remove the valve cover. Refer to COVER(S), CYLINDER HEAD, REMOVAL AND
INSTALLATION .
10. Remove the exhaust manifold and catalytic converter. Refer to MANIFOLD, EXHAUST,
12. Remove the air capacity airbox. Refer to MANIFOLD, INTAKE, REMOVAL AND
INSTALLATION .
13. Remove the air cleaner. Refer to BODY, AIR CLEANER .
INSTALLATION .
INSTALLATION .
16. Remove the water pump pulley. Refer to PUMP, WATER, REMOVAL AND INSTALLATION .
17. Remove the timing chain cover. Refer to COVER(S), ENGINE TIMING, REMOVAL AND
INSTALLATION .
18. Remove the timing chain tensioner. Refer to TENSIONER, ENGINE TIMING, REMOVAL AND
INSTALLATION .
19. Remove the timing chain guides. Refer to GUIDES, TIMING CHAIN, REMOVAL AND
INSTALLATION .
20. Remove the timing chain and sprockets. Refer to CHAIN AND SPROCKETS, TIMING,
21. Remove the thermostat. Refer to THERMOSTAT, REMOVAL AND INSTALLATION .
22. Remove the variable valve actuation assembly. Refer to ASSEMBLY, VARIABLE VALVE
ACTUATION, REMOVAL AND INSTALLATION .
23. Remove the camshaft. Refer to CAMSHAFT, ENGINE, REMOVAL AND INSTALLATION .
24. Remove the nut (1) and remove the heat shield (1) of the ground terminal.
25. Remove the screw (1) and remove the ground terminal (1).
Fig 3: Cam Angle Sensor Heat Shield & Nut
26. Remove the nut (1) and remove the heat shield (1) of the cam angle sensor.
Fig 4: Cam Angle Sensor & Bolt
27. Remove the screw (1) and remove the cam angle sensor (1).
28. Disengage cap (1), unscrew the nut (1) and disconnect the wiring.
30. Remove the alternator bolts (3).

Fig 6: Alternator
31. Remove the alternator (1) with centering sleeve.

32. Remove the screw (1) from the wiring retaining bracket to the cylinder head.
Fig 8: Engine Support Tool Bracket At Upper Alternator Mounting Hole
33. Mount the engine support tool bracket (1) to the upper alternator mounting hole.
Fig 9: Positioning Engine Support Special Tool
34. Supporting the engine with the 2000040436 tool (1) positioned as shown in illustration.
35. Remove the bolts (1) and remove the cylinder head (1).
36. Remove the seal and verify integrity of centering sleeves.
37. Remove any residual sealant.
> INSTALLATION - 2.4L MULTIAIR2

NOTE:
4. Remove the engine support tool.
5. Install the screw for the wiring retaining bracket to the cylinder head.
8. Connect the alternator wire (3), tighten the nut securely and engage the cap.
9. Install the cam angle sensor and tighten the screw securely.
10. Install the heat shield of the cam angle sensor and tighten the nut securely.
11. Install the ground terminal and tighten the bolt securely.
12. Install the heat shield of the ground terminal and tighten the nut securely.
13. Install the camshaft. Refer to CAMSHAFT, ENGINE, REMOVAL AND INSTALLATION .
14. Install the variable valve actuation assembly. Refer to ASSEMBLY, VARIABLE VALVE
ACTUATION, REMOVAL AND INSTALLATION .
15. Install the thermostat. Refer to THERMOSTAT, REMOVAL AND INSTALLATION .
16. Install the timing chain and sprockets. Refer to CHAIN AND SPROCKETS, TIMING, REMOVAL
AND INSTALLATION .
17. Install the timing chain guides. Refer to GUIDES, TIMING CHAIN, REMOVAL AND
INSTALLATION .
18. Install the timing chain tensioner. Refer to TENSIONER, ENGINE TIMING, REMOVAL AND
INSTALLATION .
19. Install the timing chain cover. Refer to COVER(S), ENGINE TIMING, REMOVAL AND
INSTALLATION .
20. Install the water pump pulley. Refer to PUMP, WATER, REMOVAL AND INSTALLATION .
INSTALLATION .
.
23. Install the air cleaner. Refer to BODY, AIR CLEANER .
24. Install the air capacity airbox. Refer to MANIFOLD, INTAKE, REMOVAL AND INSTALLATION .
26. Install the exhaust manifold and catalytic converter. Refer to MANIFOLD, EXHAUST,
27. Install the valve cover. Refer to COVER(S), CYLINDER HEAD, REMOVAL AND
INSTALLATION .
CYLINDER HEAD > CAMSHAFT, ENGINE > INSPECTION > INSPECTION
Fig 1: Inspecting Camshaft Bearing Journals, Checking Surface Of Cam Lobes For Abnormal Wear &
For Worn Or Unworn Areas Of Camshaft
1. Inspect the camshaft bearing journals (4) for damage and binding. If the journals are binding,
check the cylinder head for damage. Also check the oil supply ports for obstructions.
2. Check the surface of the cam lobes (5) for abnormal wear (1). Measure and compare the
unworn area (3) to the worn area (2). Replace the camshaft if it is not within specification.
REMOVAL - 2.4L
3. Remove the air cleaner assembly. Refer to BODY, AIR CLEANER, REMOVAL AND
INSTALLATION .
4. Remove the Powertrain Control Module (PCM). Refer to MODULE, POWERTRAIN CONTROL,
5. Remove the vacuum pump. Refer to PUMP, ELECTRIC VACUUM, REMOVAL AND
INSTALLATION .
INSTALLATION .
7. Remove the timing belt. Refer to CHAIN AND SPROCKETS, TIMING .

(NAFTA) tool on the MULTIAIR actuator (1).
9. Remove the camshaft cap to cylinder head bolts (2), and remove the camshaft caps.
10. Remove the camshaft (3) and oil seal.
INSTALLATION - 2.4L
NOTE:
(NAFTA) tool (3) from the MULTIAIR actuator.
4. Install the timing belt. Refer to CHAIN AND SPROCKETS, TIMING .
INSTALLATION .
6. Install the vacuum pump. Refer to PUMP, ELECTRIC VACUUM, REMOVAL AND
INSTALLATION .
7. Install the Powertrain Control Module (PCM). Refer to MODULE, POWERTRAIN CONTROL,
8. Install the air cleaner assembly. Refer to BODY, AIR CLEANER, REMOVAL AND
INSTALLATION .
REMOVAL - 2.4L MULTIAIR2
Fig 1: Clean Air Hose Bolt, Clamp & Engine Oil Vapor Hose Quick Coupling
2. Remove the retaining screw (1) for the clean air hose.
3. Disconnect the engine oil vapor hose quick coupling (2).
4. Loosen the clamp (3) and disconnect the clean air hose (3) from the air filter housing.
Fig 2: Intake Air Temperature Sensor Wire Harness Connector, Clean Air Hose & Clamp
5. Disconnect the wire harness connector (1) from the intake air temperature sensor.
6. Loosen the clamp (2) and remove the clean air hose from the engine compartment.
Fig 3: Air Filter To Valve Cover Hose & Clamp
7. Loosen the clamp (1) and remove the hose that delivers clean air from the air filter to the valve
cover.
8. Disconnect the pipe (1) that delivers oil vapor to the air capacity airbox.
9. Disconnect the wire harness connectors (1) of the fuel injectors.
10. Disconnect the wire harness connector (2) of the module UniAir.
11. Remove the screws (1) securing the wiring duct on the intake side.
Terminal
12. Disconnect the wire harness connectors (1) from the ignition coils.
13. Remove the screws (2) securing the wiring duct on the exhaust side.
14. Disconnect the brake booster vacuum pipe quick coupling (3) from the vacuum pump.
15. Disconnect the wire harness connector (4) from the phase sensor.
16. Disconnect the ground terminal (5) and position the wire harness aside.
17. Remove the screws (1) and remove the ignition coils.
Fig 9: Valve Cover Bolts
18. Remove the screws (1) and remove the valve cover and discard the valve cover gasket.
NOTE:
Before removing the valve cover, mark the position of the studded screws for ease
of installation.
INSTALLATION - 2.4L MULTIAIR2
1. Install new seals on the valve cover.


NOTE:
Terminal
5. Put the engine wiring harness in place and connect the wire harness connectors for the ground
terminal (5) and the phase sensor (4).
6. Connect the brake booster vacuum pipe quick coupling (3) to the vacuum pump.
7. Install the screws (2) securing the wiring duct on the exhaust side.
8. Connect the wire harness connectors (1) to the ignition coils.

9. Install the screws (1) securing the wiring duct on the intake side.
10. Connect the wire harness connector (2) to the module UniAir.
11. Connect the wire harness connectors (1) to the fuel injectors.
Fig 9: Air Filter To Valve Cover Hose & Clamp
13. Connect the hose that delivers clean air from the air filter to the valve cover and tighten the
clamp (1) securely.
Fig 10: Intake Air Temperature Sensor Wire Harness Connector, Clean Air Hose & Clamp
14. Connect the clean air hose from the engine compartment and tighten the clamp (2) securely.
15. Connect the wire harness connector (1) to the intake air temperature sensor.
Fig 11: Clean Air Hose Bolt, Clamp & Engine Oil Vapor Hose Quick Coupling
16. Connect the clean air hose (3) to the air filter housing and tighten the clamp (3) securely.
17. Connect the engine oil vapor hose quick coupling (2).
18. Install the retaining screw (1) for the clean air hose.
CYLINDER HEAD > LIFTER(S), HYDRAULIC > DIAGNOSIS AND TESTING >
DIAGNOSIS AND TESTING - LASH ADJUSTER (TAPPET) NOISE
Proper noise diagnosis is essential in locating the source of an NVH complaint. Locating a hydraulic lash
adjuster (tappet) type noise can sometimes be difficult. As a result, an initial misdiagnosis may occur.
Refer to the following chart for possible causes and correction of a lash adjuster (tappet) type noise.
LASH ADJUSTER (TAPPET) NOISE CHART
POSSIBLE CAUSES CORRECTION
1. Engine oil level-too high or too low. This may 1. Check and correct the engine oil level.
allow aerated oil to enter the adjusters and
cause them to be spongy.
2. Insufficient running time after rebuilding a 2. Low speed running of up to 1 hour may be required
cylinder head. to fully evacuate trapped air from the valve train
system. During this time, turn engine off and let set for
a few minutes before restarting. Repeat this several
times after engine has reached normal operating
temperature.
3. Air trapped in the lash adjuster (after 1 hour of 3. See below:

run time) or possible faulty lash adjuster.
(a) Check lash adjusters for sponginess while
installed in the cylinder head. Depress the lash
adjuster. Normal adjusters should feel very firm. Very
spongy adjusters can be bottomed out easily.
(b) If the lash adjuster(s) are still spongy, replace the

lash adjuster(s). Refer to LIFTER(S), HYDRAULIC,
4. Low oil pressure. 4. See below:
(a) Check and correct the engine oil level.
(b) Check the engine oil pressure. Refer to

LUBRICATION .
(c) Check for excessive main bearing clearance and

correct. Refer to ENGINE BLOCK .
(d) Check for a worn oil pump.
5. Oil screen in the cylinder head or oil passage 5. Check cylinder head oil passages for blockage.
to the cylinder head(s) plugged with debris. Clean or replace as necessary.
6. Measure valve stem-to-guide clearance. Refer to

6. Worn valve guide(s).
CYLINDER HEAD .
7. Visually inspect the alignment of the Variable Valve

7. Rocker arm ears contacting valve spring Actuation (VVAA) plungers. Refer to ASSEMBLY,
retainer. VARIABLE VALVE ACTUATION, REMOVAL AND
INSTALLATION .
8. Rocker arm loose, adjuster stuck or at

8. Check for bent valve stem or sticking valve guide.
maximum extension and still leaves lash in the
system.
9. Oil leak or excessive cam bearing wear in the 9. Check camshaft lobe and bearing journal
cylinder head. diameters. Refer to INSPECTION .
10. Collapsed lash adjuster due to debris

ingestion. Check lash adjuster while in the cylinder head. A
normal lash adjuster will feel very firm. A lash
adjuster with debris will be collapsed and will be
very spongy.
If the lash adjusters are easily collapsed, clean

debris from the engine and replace the lash
adjusters. Refer to LIFTER(S), HYDRAULIC,
CYLINDER HEAD > LIFTER(S), HYDRAULIC > REMOVAL AND INSTALLATION > 2.4L
> REMOVAL
1. Remove the camshaft. Refer to CAMSHAFT, ENGINE, REMOVAL AND INSTALLATION .

2. Remove the hydraulic tappets (1).
CYLINDER HEAD > LIFTER(S), HYDRAULIC > REMOVAL AND INSTALLATION > 2.4L
> INSTALLATION
1. Install the hydraulic tappets.
2. Install the camshaft. Refer to CAMSHAFT, ENGINE, REMOVAL AND INSTALLATION .

CYLINDER HEAD > ASSEMBLY, VARIABLE VALVE ACTUATION > INSPECTION >
INSPECTION
Because variable valve actuation is so closely monitored, the diagnostics of the system are strongly
Diagnostic Trouble Code (DTC) driven. If the system does not perform according to design, many DTC's
may be produced from a condition in the variable valve actuation system.
The variable valve actuation module includes very few serviceable components. The module has no
internal components that are serviceable. The following components are serviceable:
Valve rocker arms.
Oil temperature sensor.
Assembly gasket.
Locating dowels.
CYLINDER HEAD > ASSEMBLY, VARIABLE VALVE ACTUATION > REMOVAL AND
NOTE:
During all the handling operations, the MUTIAIR actuator should not be overturned with
hydraulic tappets above.
INSTALLATION .
Fig 1: Oil Temperature Electrical Connector & MULTIAIR Actuator Electrical Connectors
2. Disconnect the oil temperature electrical connector (1) at the MULTIAIR actuator.
3. Disconnect the MULTIAIR actuator electrical connectors (2).

Fig 2: Rear MULTIAIR Actuator To Cylinder Head Bolt
4. Remove the rear MULTIAIR actuator to cylinder head bolts (1).

(NAFTA) tool (1) on the MULTIAIR actuator and compress the springs.
6. Remove the front MULTIAIR actuator to cylinder head bolts (2), and remove the complete
module from the cylinder head.
7. Remove the metal seal.
CYLINDER HEAD > ASSEMBLY, VARIABLE VALVE ACTUATION > REMOVAL AND
NOTE:
During all the handling operations, the MUTIAIR actuator should not be overturned with
hydraulic tappets above.

5. Connect the MULTIAIR actuator electrical connectors.
6. Connect the oil temperature electrical connector.
INSTALLATION .
CAUTION:
CAUTION:
rings.
angle.
NOTE:

USING PLASTIGAGE

NOTE:
NOTE:
NOTE:

NOTE:
NOTE:

scale.
REMOVAL - 2.4L MULTI AIR
Fig 1: Vibration Damper & Aligning Timing Marks
5. Turn the vibration damper to align the timing marks (1).

(1a), remove the bolt (1b) and the vibration damper (1c).
INSTALLATION - 2.4L MULTI AIR
5. Install the right front tire and wheel assembly Refer to REMOVAL AND INSTALLATION .
ENGINE BLOCK > RING(S), PISTON > REMOVAL AND INSTALLATION > REMOVAL -
2.4L MULTIAIR
Fig 1: Piston Ring Removal/Installation Sequence
CAUTION:
To avoid damage to the piston rings, they must be removed in the following order:
No. 1 (upper) piston ring (1)
No. 2 (intermediate) piston ring (2)
Oil ring upper side rail (3)
Oil ring lower side rail (4)
Oil ring expander (5)

Fig 2: Installing Intermediate Piston Ring
1. Remove the No. 1 (upper) piston ring using a ring expander tool.
2. Remove the No. 2 (intermediate) piston ring using a ring expander tool.
Fig 3: Installing Piston Ring Side Rail
NOTE:
Do not use a piston ring expander to remove the oil ring side rails.
3. Remove the oil ring upper side rail.
4. Remove the oil ring lower side rail.
5. Remove the oil ring expander (1).
ENGINE BLOCK > RING(S), PISTON > REMOVAL AND INSTALLATION >
INSTALLATION - 2.4L MULTIAIR
Fig 1: Piston Ring Removal/Installation Sequence
NOTE:
The No. 1 (upper) piston ring (1) and No. 2 (intermediate) piston ring (2) can be identified by
their configuration. The No. 2 (intermediate) piston ring (2) is a micro Napier design (hook
edge) while the No. 1 (upper) piston ring (1) has a square edge.
CAUTION:
To avoid damage to the piston rings, they must be installed in the following order:
Oil ring expander (5)
Oil ring lower side rail (4)
Oil ring upper side rail (3)

No. 2 (intermediate) piston ring (2)
No. 1 (upper) piston ring (1)
Fig 2: Installing Piston Ring Side Rail
NOTE:
Do not use a piston ring expander to install the oil ring side rails.
1. Install the oil ring expander (1).
2. Install the oil ring lower side rail by placing one end between the piston ring groove and the oil
ring expander. Hold this end firmly and press down the portion to be installed until the side rail
is in position.
3. Install the oil ring upper side rail in the same manner as the lower side rail.
Fig 3: Identifying Dot Marks On Piston Rings
NOTE:
Install the rings with manufacturers I.D. mark (2) facing up, towards the top of the
piston. The No. 2 (intermediate) piston ring (3) is a micro Napier design (hook
edge) while the No. 1 (upper) piston ring (1) has a square edge.
Fig 4: Installing Intermediate Piston Ring
4. Install the No. 2 (intermediate) piston ring using a ring expander tool.
5. Install the No. 1 (upper) piston ring using a ring expander tool.
6. Rotate the rings around the piston, the rings must rotate in the grooves with out binding.
ENGINE BLOCK > ROD, PISTON AND CONNECTING > DESCRIPTION AND
OPERATION > DESCRIPTION AND OPERATION
Fig 1: Piston Components
CAUTION:
Do not use a metal stamp to mark connecting rods as damage may result, instead use ink or
a scratch awl.
The pistons are a lightweight design with ultra low tension piston rings for improved fuel economy:
The pistons are made of a high strength aluminum alloy and the piston skirt (6) has a MolyT®
coating.
The top piston ring land has an anodized coating for improved wear performance.
The piston is connected to the rod using a full floating pin (5) with a locking clip (4) on both sides.
The connecting rod is powder-forged steel with a bolted cracked cap design. The connecting rod
bolts are not reusable.
Pistons are available in three diameters (A, B and C) with grade markings for each bore indicated
on the side of the cylinder block.
The upper compression ring (1) is a 1.2 mm steel ring with Physical Vapor Deposition (PVD)
coating.
The intermediate compression ring (2) is 1.2 mm micro Napier design and has a greater radial wall
thickness than the upper compression ring.
Both compression rings have a dot or a mark on the piston ring. The marked side of the ring must
face the top of the piston.
The 2 mm three piece oil control ring (3) is very thin. Both the rail segments and the expander are
nitride steel.
ENGINE BLOCK > ROD, PISTON AND CONNECTING > STANDARD PROCEDURE >
PISTON FITTING
Fig 1: Upper Main Bearing Journal Diameter Grade Markings & Cylinder Bore Diameter Grade Markings

The pistons are "select fit" to achieve proper oil clearance. Engine block cylinder bore diameter grade
markings (2) are stamped into the right side of the engine block. These marks are read from right to left
(top to bottom), corresponding with cylinder number 1, 2, 3, 4.
Engine block cylinder bore diameter grade markings correspond to specific cylinder bore diameters. The
chart below identifies the three engine block grade markings and their associated cylinder bore
diameters.
Engine Block Marking Cylinder Bore Size mm (in.)
Metric Standard
A 88.000 - 88.010 mm 3.4645 - 3.4649 in.
B 88.010 - 88.020 mm 3.4649 - 3.4653 in.
C 88.020 - 88.030 mm 3.4653 - 3.4657 in.
Fig 2: Piston Size Marked On Piston Crown

The piston is marked with the piston size (1) on the piston crown. The pistons are available in three
different sizes in order to achieve the desired oil clearance. Select the piston size that corresponds to
the engine block cylinder bore diameter grade markings for each cylinder.
Pistons are available in three sizes. The chart below identifies the three piston sizes.
Piston Marking Piston Size mm (in.)
Metric Standard
A 87.975 - 87.985 mm 3.4636 - 3.4640 in.
B 87.985 - 87.995 mm 3.4640 - 3.4644 in.
C 87.995 - 88.005 mm 3.4644 - 3.4648 in.
Fig 3: Identifying Coating Material On Piston

NOTE:
Typical coated piston shown in illustration.
The coated pistons are serviced with the piston pin and connecting rod pre-assembled. The coating
material (1 and 2) is applied to the piston after the final piston machining process. Piston installation into
the cylinder bore requires slightly more pressure than that required for non-coated pistons. The bonded
coating on the piston will give the appearance of a line-to-line fit with the cylinder bore.
CONNECTING ROD SIDE CLEARANCE > DIAL INDICATOR
Fig 1: Measuring Connecting Rod Side Clearance

1. Mount the Dial Indicator Set (special tool #C-3339A, Set, Dial Indicator) to a stationary point
on the engine. Locate the probe perpendicular to and resting against the connecting rod cap
being checked.
2. Move the connecting rod all the way to the rear of its travel.
3. Zero the dial indicator.
4. Move the connecting rod forward to the limit of travel and read the dial indicator. Compare the
measured side clearance to the specification. Refer to ENGINE SPECIFICATIONS .
5. Repeat this procedure for each connecting rod. Rotate the crankshaft for connecting rod
accessibility.
CONNECTING ROD SIDE CLEARANCE > FEELER GAUGE
Fig 1: Connecting Rod Side Clearance
NOTE:
Typical four cylinder engine shown in illustration.
1. Slide a snug-fitting feeler gauge between the connecting rod and crankshaft journal flange.
Compare the measured side clearance to the specification. Refer to ENGINE
SPECIFICATIONS .
2. Repeat this procedure for each connecting rod. Rotate the crankshaft for connecting rod
accessibility.
ENGINE BLOCK > ROD, PISTON AND CONNECTING > CLEANING > CLEANING
CAUTION:
DO NOT use a wire wheel or other abrasive cleaning devise to clean the pistons or
connecting rods. The pistons have a Moly coating, this coating must not be damaged.
CAUTION:
Do not remove the piston pin from the piston and connecting rod assembly.
1. Clean the pistons in warm water using a suitable cleaning solvent and then towel dry.
2. Use a wood or plastic scraper to clean the ring land grooves.
ENGINE BLOCK > ROD, PISTON AND CONNECTING > INSPECTION > INSPECTION
Fig 1: Inserts
1. Wipe the inserts (1) clean.
2. Inspect the inserts for abnormal wear patterns, scoring, grooving, fatigue, pitting and for metal
or other foreign material imbedded in the lining.
3. Inspect the back of the inserts for fractures, scrapes, or irregular wear patterns.
4. Inspect the insert locking tabs for damage.
5. Replace any bearing that shows abnormal wear.

6. Inspect the connecting rod bearing bores for signs of scoring, nicks and burrs.
NOTE:
Misaligned or bent connecting rods can cause abnormal wear on pistons, piston
rings, cylinder walls, connecting rod bearings and crankshaft connecting rod
journals. If wear patterns or damage to any of these components indicate the
probability of a misaligned connecting rod, inspect it for correct rod alignment.
7. Replace any misaligned, bent or twisted connecting rods.

NOTE:
Connecting rods are serviced with the piston pre-assembled. The pistons are
"select fit" to achieve proper oil clearance. Refer to ROD, PISTON AND
CONNECTING, STANDARD PROCEDURE .
Fig 3: Identifying Coating Material On Piston
NOTE:
Typical coated piston shown in illustration.
8. Inspect the piston for scoring or scraping marks in the piston skirts. Check the ring lands for
cracks and/or deterioration.
NOTE:
The coating material (1 and 2) is applied to the piston after the final piston
machining process. This coating may affect the outside diameter measurement of a
coated piston may not provide accurate results.
9. Check the piston for taper and out of round shape.
NOTE:
Piston installation into the cylinder bore may require slightly more pressure than that
required for non-coated pistons. The bonded coating on the piston will give the appearance
of a line-to-line fit with the cylinder bore.
NOTE:
The coated pistons will be serviced with the piston pin and connecting rod pre-assembled.
1. Remove the engine from the vehicle and separate the transmission and flexplate from the
engine. Refer to REMOVAL AND INSTALLATION .
2. Remove the cylinder head and oil pan for inspection. Refer to DISASSEMBLY AND
ASSEMBLY .
NOTE:
If the timing chain plated links (1) can no longer be seen, the timing chain links
corresponding to the timing marks (2) must be marked prior to removal if the chain
is to be reused.
3. Mark chain link (1) corresponding to crankshaft sprocket timing mark (2).
4. Mark the chain link (1) corresponding to balance shaft/oil pump sprocket timing mark.
6. Remove the two bolts (4) and the tensioner (3).
7. Remove the tensioner arm bolt (2) and the tensioner arm (1).
8. Remove the fixed chain guide bolts (5) and the chain guide (6).
10. Remove the crankshaft sprocket (1).

Fig 7: Rear Crankshaft Oil Seal - Removal
11. Insert a flat bladed screwdriver (7) between the dust lip (8) and the metal case (4) of the
crankshaft seal (1). Angle the screwdriver through the dust lip against the metal case of the
seal. Pry out the seal.
CAUTION:
Do not permit the screwdriver blade to contact crankshaft seal surface. Contact of
the screwdriver blade against crankshaft edge (chamfer) is permitted.
12. Check to make sure the seals garter spring is also removed and is not on the crankshaft.
cooler.
17. Remove the three bolts (2) and the generator mounting bracket (1) from the engine.
18. Remove the three bolts (2) and the intermediate shaft bearing support (1) from the engine, if
equipped.
19. Remove the ladder frame bolts and separate the ladder frame from the engine block.
20. Loosen the ten main bearing cap bolts.
21. Remove the bearing beam bolts (1 - 6) and remove the bearing beam. Temporarily install main
bearing cap bolts (M10 x 1.25 x 76.5) into the unsupported No. 2, 3 and 5 main bearing caps
hand tight.
NOTE:
Connecting rods and bearing caps are not interchangeable and should be marked
before removing to ensure correct reassembly.
CAUTION:
DO NOT use a number stamp or a punch to mark connecting rods or caps, as

damage to connecting rods could occur
22. Mark connecting rod and bearing cap positions (1) using a permanent ink marker or scribe tool.
NOTE:
23. If necessary, remove the top ridge of the cylinder bores with a reliable ridge reamer before
removing the pistons from the engine block. Be sure to keep the tops of pistons covered
during this operation. Pistons and connecting rods must be removed from the top of the
engine block. When removing piston and connecting rod assemblies from the engine, rotate the
crankshaft CW so that each connecting rod is centered in the cylinder bore.
24. Remove the connecting rod cap bolts (4) and the connecting rod cap (3). Discard the cap bolts
(4).
CAUTION:
25. Install the (special tool #10281, Pins, Connecting Rod Guide) (6) on the connecting rod being
removed.
CAUTION:
26. Remove the connecting rod and piston assembly (1) complete with upper bearing shell (7) from
the cylinder bore.
27. Repeat the previous steps for each piston being removed.
28. Immediately after piston and connecting rod removal, reinstall the bearing cap (3) on the mating
connecting rod to prevent damage to the fractured cap and rod surfaces.
29. If required, remove the piston rings. Refer to RING(S), PISTON, REMOVAL AND
INSTALLATION .
1. If required, select and fit new piston and connecting rod assemblies to the engine block. Refer
to ROD, PISTON AND CONNECTING, STANDARD PROCEDURE .
2. If required, hone the cylinder bores. Refer to STANDARD PROCEDURE .
3. If removed, install the piston rings. Refer to RING(S), PISTON, REMOVAL AND
INSTALLATION .
Fig 1: Piston Ring End Gap Position
4. Position the piston ring end gaps as follows:
1. Oil ring expander gap (5)
2. Oil ring lower side rail end gap (4)
3. Oil ring upper side rail end gap (1)
4. No. 2 (intermediate) ring end gap (5)
5. No. 1 (upper) ring end gap (2)

NOTE:
NOTE:
Ensure the position of the ring end gaps does not change when installing the ring
compressor (2).
5. Lubricate the piston rings with clean engine oil. Position the (special tool #C-385, Compressor,
Piston) (2) over the piston and rings. Tighten the compressor (2).
NOTE:
Install the rod bearings in pairs. Do not mix sizes or use a new bearing half with an
old bearing half.
6. Install the bearing shell (7) on the connecting rod with the tang inserted into the machined
groove in the rod. Lubricate the bearing surface with clean engine oil.
7. Install the (special tool #10281, Pins, Connecting Rod Guide) (6) on the connecting rod.
CAUTION:
Fig 3: Locating Arrow Stamped On Piston Crown
8. The pistons crowns are stamped with an arrow (1). The piston and connecting rod assemblies
must be installed so the arrow points toward the front of the engine.
9. Wipe the cylinder bore clean and lubricate with clean engine oil.
10. Rotate the crankshaft until the connecting rod journal is on the center of cylinder bore.
CAUTION:
11. Insert the piston and connecting rod into the cylinder bore and carefully position the guide pins
over the crankshaft journal.
12. Tap the piston down in the cylinder bore using a hammer handle while guiding the connecting
rod into position over the rod journal.
NOTE:

CAUTION:
The connecting rod bolts must not be reused. Always replace the connecting rod
bolts whenever they are loosened or removed.
13. Install the bearing shell (5) on the connecting rod cap (3) with the tang inserted into the
machined groove in the cap. Lubricate the bearing surface with clean engine oil.
NOTE:
Do not lubricate the threads of the connecting rod cap bolts (4).
14. Install the connecting rod cap and bearing with the tang on the same side as the rod. Tighten
the NEW connecting rod cap bolts (4) to the proper specification. Refer to TORQUE
SPECIFICATIONS .
15. If required, check the connecting rod side clearance. Refer to ROD, PISTON AND
CONNECTING, STANDARD PROCEDURE .
16. Repeat the previous steps for each piston being installed.
CAUTION:
The main bearing cap bolts are tightened using a torque plus angle procedure. The
bolts must be examined BEFORE reuse. If the threads are necked down the bolts
must be replaced.
17. Check the main bearing cap bolts for necking by holding a scale or straight edge against the
threads. If all the threads do not contact the scale (2) the bolt must be replaced.
Fig 6: Bearing Beam Installed With Indication Pointing To Front Of Engine
18. Remove the temporarily installed cap bolts from main bearing caps 2, 3 and 5. Install the
bearing beam (1) with its longer bolts so that the <FRT indication (2) is pointing to the front of
the engine.
Fig 8: Sealing Ladder Frame
20. Clean the ladder frame sealing surfaces with isopropyl alcohol in preparation for sealant
application.
CAUTION:
Engine assembly requires the use of a unique sealant that is compatible with
engine oil. Using a sealant other than Mopar® Engine Sealant RTV Silicone Rubber
Adhesive may result in engine fluid leakage.
CAUTION:
Following the application of Mopar® Engine Sealant RTV Silicone Rubber Adhesive
to the gasket surfaces, the components must be assembled within 10 minutes and
the attaching fasteners must be tightened to specification within the next 10 minutes.
Prolonged exposure to the air prior to assembly may result in engine fluid leakage.
21. Apply a 2 mm bead of Mopar® Engine Sealant RTV Silicone Rubber Adhesive as shown in
illustration.
22. Install the ladder frame and tighten the twelve bolts in the sequence shown in illustration,
following this 2 step method. Tighten according to the following torque values:
1. Step 1: All to 10 N.m (89 in. lbs.).
2. Step 2: All to 26 N.m (19 ft. lbs.).

23. If removed, install the crankshaft sprocket key (2) in the crankshaft.
24. Install the crankshaft sprocket (1).

25. Align the timing chain onto the crank sprocket mark (2) using the painted link (1) as a guide.
CAUTION:
The balance shaft/oil pump assembly bolts are tightened using a torque plus angle
procedure. The bolts must be examined BEFORE reuse. If the threads are necked
down the bolts must be replaced.
26. Check the balance shaft/oil pump bolts for necking by holding a scale or straight edge against
the threads. If all the threads do not contact the scale (2) the bolt must be replaced.
27. Align the timing chain onto the balance shaft/oil pump sprocket mark using the painted link (1)
as a guide.
28. With the rear of the balance shaft/oil pump assembly on a slight angle, position the gear into
the chain links and install the balance shaft/oil pump assembly on the ladder frame. Make sure
the paint marks are aligned.
Fig 14: BSM Mounting Bolts Tightening Sequence
29. Install the four balance shaft/oil pump bolts finger tight.
30. Tighten the balance shaft/oil pump bolts in the sequence shown in illustration, following the 3
step torque plus an ending torque angle method. Tighten according to the following torque
values:
3. Step 3: All an additional 90° Do not use a torque wrench for this step.
32. Install the fixed chain guide (7) with two bolts (6) tightened to the proper specification. Refer to
33. Install the tensioner arm (1) with the bolt (2) tightened to the proper specification. Refer to
34. Install the tensioner (4) with the two bolts (5) tightened to the proper specification. Refer to
35. Remove the tensioner pin (3) from the tensioner (4).
37. If equipped, install the intermediate shaft bearing housing (1) with three bolts (2) tightened to
hand.
42. Install the Variable Valve Actuation Assembly (VVAA) oil supply filter (1) in the engine block.
NOTE:
46. Install the hydraulic tappets (1).

NOTE:
NOTE:
During all the handling operations, the MUTIAIR actuator should not be overturned
with hydraulic tappets above.

57. Tighten the thermostat housing bolts (1) in a crisscross pattern to the proper specification.
proper then bend lock tab to secure bolt (1a). Refer to SPECIFICATIONS .
Fig 31: Timing Chain Guide, Guide Bolts, Tensioner Arm & Bolt
59. Install the timing chain guide (1) with three bolts (2) tightened to the proper specification. Refer
60. Install the tensioner arm (4) with the bushing and bolt (3) tightened to the proper specification.
65. Align the pin (2) and install the camshaft sprocket.
SPECIFICATIONS .

figure.
72. Install the engine timing cover and tighten the mounting bolts (1) to the proper specification.
SPECIFICATIONS .
76. Install the A/C compressor with three bolts (1) and tighten the bolts to the proper specification.
78. Install the generator mounting bracket (1) with three bolts (2) tightened to the proper
79. If removed, install the accessory drive belt tensioner (1) and tighten the bolts to the proper
to SPECIFICATIONS .
85. Connect the alternator wiring with the nut (3) and engage the cap (3).

87. Install the wiring retaining bracket to the cylinder head with the screw (1) tighten to the proper
89. Install new seals on the valve cover.


NOTE:
103. Install the throttle body fasteners and tighten to the proper specification. Refer to FUEL
104. Install the throttle body reinforcement bracket and tighten the fastener to the proper
106. Install new vacuum pump O-ring seals (1, 2).

107. Install the vacuum pump into the cylinder head opening with two bolts (1) tightened to the
108. Install the oil dipstick tube (1) to the engine with the bolt (2) tightened to the proper
111. Install the catalytic converter support bracket and tighten the bolts (1) to the proper
115. Install the ground terminal (1) and tighten the bolt securely.
116. Install the heat shield of the ground terminal (1) and tighten the nut securely.
1. Install the screws securing the wiring duct on the intake side.
2. Install the screws securing the wiring duct on the exhaust side.
3. Connect the knock sensor wire harness connector
6. Connect the manifold pressure and temperature sensor wire harness connector and
engage the retaining clips
10. Connect the purge solenoid wire harness connector

12. Connect the engine oil temperature sensor wire harness connector
13. Connect the variable valve actuator wire harness connectors
14. Connect the ignition coil wire harness connectors
15. Connect the ground terminal wire harness connector
118. Install the lower heat shield onto the exhaust manifold and securely tighten the bolts.
119. Install the upper heat shield and securely tighten the nuts.
120. Install the upstream oxygen sensor support bracket and securely tighten the bolts then engage
the wire harness retainer.
123. Install a new oil drain plug and tighten to the proper specification. Refer to TORQUE
SPECIFICATIONS .
125. Install the flexplate and transmission to the engine and install the engine in the vehicle. Refer to
126. Fill the transmission. Refer to FLUID AND FILTER, STANDARD PROCEDURE .
130. Start engine and check for leaks.
131. Run the engine until it reaches normal operating temperature. Check cooling system for correct
fluid level. Refer to STANDARD PROCEDURE .
ENGINE BLOCK > SEAL, CRANKSHAFT OIL, FRONT > REMOVAL AND
INSTALLATION > 2.4L MULTI AIR > REMOVAL

INSTALLATION .
Fig 1: Locating Front Crankshaft Oil Seal
2. Using a screwdriver, remove the front crankshaft oil seal (1).
ENGINE BLOCK > SEAL, CRANKSHAFT OIL, FRONT > REMOVAL AND
INSTALLATION > 2.4L MULTI AIR > INSTALLATION
1. Using the 2000040245 (EMEA) or (special tool #9506, Installer, Oil Seal) (NAFTA) tool (1),
Install the NEW front crankshaft oil seal (1) onto the front cover.
> REMOVAL - 2.4L
3. Remove fuse F21 from the Power Distribution Center (PDC).

.
INSTALLATION .

INSTALLATION .
20. Remove the engine and transmission from the vehicle. Refer to REMOVAL AND
INSTALLATION .
21. Remove the transmission from the engine. Refer to REMOVAL AND INSTALLATION .
23. Remove the bolts (2a) and remove the flywheel (2b) with spacer.

Fig 2: Crankshaft Oil Seal, Flywheel Side
NOTE:
Be careful not to damage the oil seal seat during its removal.
25. Remove the crankshaft oil seal (1), flywheel side.
> INSTALLATION - 2.4L
2. Install the engine flywheel (1) and partially tighten the bolts (3).
SPECIFICATIONS .
6. Install the transmission to the engine.
Refer to REMOVAL AND INSTALLATION .
7. Install the engine and transmission in the vehicle. Refer to REMOVAL AND INSTALLATION .

MANIFOLDS > MANIFOLD, EXHAUST > REMOVAL AND INSTALLATION > 2.4L MULTI
AIR > REMOVAL
Fig 1: Downstream Oxygen Sensor Wire Harness Connector
5. Disconnect the downstream oxygen sensor wire harness connector (1).


Fig 3: Upper Heat Shield, Nuts & Wire Harness Retainer
7. Disengage the upstream oxygen sensor wire harness from the retainer (1) and remove the bolt
and bracket.
8. Remove the nuts (2) and the upper heat shield from the exhaust manifold.
Fig 4: Lower Heat Shield & Bolts
9. Remove the bolts (1) and the lower heat shield.

Fig 5: Exhaust Pipe To Transmission Bracket Bolt & Exhaust Pipe At Catalyst Nuts
10. Remove the bolt (1) securing the exhaust pipe to the transmission bracket.
11. Remove the nuts (2) and disconnect the exhaust pipe from the catalyst.

13. Remove the bolts (1) and the catalytic converter support bracket.
14. Remove the nuts (1a) and the bolts (1b) and the exhaust manifold catalyst (1c).
15. Remove and discard the manifold gasket.
MANIFOLDS > MANIFOLD, EXHAUST > REMOVAL AND INSTALLATION > 2.4L MULTI
AIR > INSTALLATION
Fig 3: Exhaust Pipe To Transmission Bracket Bolt & Exhaust Pipe At Catalyst Nuts
3. Install the catalytic converter lower support bracket and securely tighten the bolts.
4. Using a NEW gasket, install the exhaust pipe (2) to the catalyst flange. Using NEW nuts
install and tighten the nuts to the proper specification. Refer to TORQUE SPECIFICATIONS .
5. Install the bolt (1) securing the exhaust pipe to the transmission bracket and tighten to the
6. Install the lower heat shield and securely tighten the bolts.
7. Install the upper heat shield onto the exhaust manifold and securely tighten the nuts.
8. Install the front oxygen sensor support bracket and securely tighten the bolts then engage the
wire harness retainer.
9. Connect the front oxygen sensor wire harness connectors.
10. Connect the lambda sensor wire harness connector.

MANIFOLDS > MANIFOLD, INTAKE > REMOVAL AND INSTALLATION > 2.4L MULTI
AIR > REMOVAL
INSTALLATION .

Fig 1: Retaining Clip & Fuel Vapor Hose Quick Connect Fitting
8. Open the retaining clip (1a) and disconnect the fuel vapor hose quick connect fitting (1b).
Fig 2: Fuel Vapor Hose Quick Connect Fitting & Fuel Vapor Hose
9. Disconnect the fuel vapor hose quick connect fitting (1) and remove the fuel vapor hose.
Fig 3: Precut Sound Absorbing Panel & Panel Edges
10. Separate the two edges of the precut sound absorbing panel (1).
11. Remove the sound absorbing panel (2).

Fig 4: Fuel Vapors Solenoid Wire Harness Connector & Fuel Vapors Solenoid
12. Disconnect the fuel vapor hose quick connect fitting (1).
13. Disconnect the fuel vapors solenoid wire harness connector (2) and remove fuel vapors
solenoid.
Fig 5: A/C lines & Retaining Clips
14. Open the retaining clips and detach the A/C lines (1).
Fig 6: Coolant Hoses & A/C Lines Nuts
15. Remove the nuts (1) and disconnect the A/C lines.
16. Remove the coolant hoses (2) from the heater.

Fig 7: Fuel Injectors & Fuel Rail
17. Remove the fuel rail (1) and fuel injectors. Refer to INJECTOR(S), FUEL, REMOVAL AND
INSTALLATION .
Fig 8: Intake Manifold Silencer Cover
18. Remove the four screws (1) and the intake manifold silencer cover.
Fig 9: Intake Manifold Support Bracket & Bolt
19. Remove the bolt (1) securing the intake manifold support bracket.
Fig 10: Intake Manifold Support Bracket Nuts
20. Remove the intake manifold support bracket nuts (1).

Fig 11: Intake Manifold & Fasteners
21. Remove the fasteners (1) and the intake manifold.
22. Remove and discard the gasket seals
MANIFOLDS > MANIFOLD, INTAKE > REMOVAL AND INSTALLATION > 2.4L MULTI
AIR > INSTALLATION
5. Install the fuel rail and fuel injectors. Refer to INJECTOR(S), FUEL, REMOVAL AND
INSTALLATION .
6. Install the coolant hoses (2) to the heater.
7. Using NEW gasket seals, connect the A/C lines and securely tighten the nuts.
8. Attach the A/C lines into retaining clip and close the clip.
9. Install the fuel vapor solenoid and connect the wire harness connector.
10. Connect the fuel vapor hose quick connect fitting.
11. Install the sound absorbing panel.
12. Install the fuel vapor hose and connect the fuel vapor hose quick connect fitting.
13. Connect the fuel vapor hose quick connect fitting and close the retaining clip.
14. Evacuate the refrigerant system. Refer to PLUMBING, STANDARD PROCEDURE .
15. Charge the refrigerant system. Refer to PLUMBING, STANDARD PROCEDURE .
INSTALLATION .
INSTALLATION .

cooler.
5. Remove the engine oil filter (1). Recover engine oil that comes out in a suitable container.

INSTALLATION
hand.
LINES > REMOVAL

4. Disconnect the electrical connection of the upper oxygen sensor.
5. Disengage the top oxygen sensor wiring harness, and loosen the bolt (1) and remove the
bracket.
Fig 4: Bottom Exhaust Manifold Heat Shield & Nuts
7. Remove the nuts and the bottom exhaust manifold heat shield.
Fig 5: Upper Oxygen Sensor Wiring & Retainer
8. Detach the retainer (1) securing the upper oxygen sensor wiring.
9. Remove the rear bracket bolt (2) securing the coolant tube assembly.
Fig 6: Coolant Tube Assembly Front Bracket Nut
10. Remove the front bracket nut (1) securing the coolant tube assembly.
Fig 7: Water Supply And Return Hoses & Hose Clamps
11. Loosen the hose clamps (1) and disconnect the water supply and return hoses.
Fig 8: Coolant Hoses & Clamps
12. Disconnect the coolant hoses (1) and remove the coolant tubes.
LINES > INSTALLATION
1. Install the coolant tubes and tighten the clamps.
2. Connect the water supply and return hoses and tighten the clamps.
3. Install the front bracket nut securing the tubes assembly and securely tighten.
4. Install the rear bracket bolt securing the tubes assembly and securely tighten.
5. Engage the retaining clip oxygen sensor harness.
6. Install the lower exhaust manifold heat shield and securely tighten the nuts.
7. Install the top exhaust manifold heat shield and securely tighten the bolts.
8. Install the top oxygen sensor wiring bracket and securely tighten the bolt and engage the wiring
retaining clip.
9. Connect the electrical connection of the upper oxygen sensor.
MULTIAIR TURBO
NOTE:
1. Raise and support the vehicle Refer to HOISTING, STANDARD PROCEDURE .

Fig 1: Dipstick & Engine Oil Filler Cap
NOTE:
NOTE:
suitable container.
Fig 3: Oil Pan Drain Plug Seal
6. Check the integrity of the seal (1) on the engine oil drain plug.
Fig 5: Air Inlet Hose & Clamp
8. Loosen the clamp (1) and disconnect the air inlet hose from the air filter cover.
Fig 6: Waste-Gate Actuator Air Control Hose, Engine Oil Vapor Hoses, Clip & Clamps
9. Open the clip (1) and release the Waste-Gate actuator air control hose.
10. Loosen the hose clamps (2) and disconnect the engine oil vapor hoses.
Fig 7: Air Control Hose, Clip & Clamp
11. Open the clip (1), loosen the clamp and disconnect the air control hose from the Waste-Gate
actuator.
12. Loosen the clamp (2) and remove the air inlet hose from the turbocharger.
Fig 8: Engine Oil Filter Cover
13. Unscrew the engine oil filter cover (1).

Fig 9: Oil Filter Element
14. Remove the oil filter element (1).
15. Install a new oil filter element.
SPECIFICATIONS .
17. Install the air inlet hose to the turbocharger and tighten the clamps at the air filter cover and
turbocharger.
18. Connect the air control hose to the Waste-Gate actuator, tighten the clamp and engage the
retaining clip.
19. Connect the engine oil vapor hoses and tighten the clamps.
20. Engage the spring retaining clip to the Waste-Gate actuator air control hose.
NOTE:
NOTE:
wait a few minutes.
TURBO DIESEL/1.6L TURBO DIESEL
NOTE:
Following a complete replacement of the engine oil, update the "change engine oil" function
in the specific engine Control Module using the diagnostic tool.
NOTE:

Fig 1: Dipstick & Engine Oil Filler Cap
NOTE:
NOTE:
suitable container.
Fig 4: Fitting On Oil Filter Housing
7. Remove the cap and insert a suitable drain hose onto the fitting (1) on the oil filter housing for
the recovery of oil that comes out when you remove the oil filter cover.
Fig 5: Engine Oil Filter Cartridge Cover
8. Unscrew and remove the engine oil filter cartridge cover (1).
Fig 6: Oil Filter Element & Oil Filter Cover O-Ring
9. Remove the oil filter element (1) from the oil filter cover.
10. Remove the O-ring (2) from the oil filter cover.
Fig 7: Oil Filter Element, O-Ring & Retaining Clips
11. Install a new oil filter element (1a) engaging the retaining clips (1b).
12. Install a new O-ring (2) on the oil filter cover.
SPECIFICATIONS .
14. Remove the drain hose used for oil recovery and install the cap on the fitting.
NOTE:
NOTE:
wait a few minutes.
MULTIAIR2
NOTE:

Fig 1: Engine Oil Filler Cap & Dipstick

NOTE:
NOTE:
5. Unscrew the oil pan drain plug (1) and allow the engine oil to completely drain into a suitable
container.
6. Clean the engine oil drain plug and tighten it with the gasket to the proper specification. Refer
8. Lubricate the gasket on the new oil filter with engine oil and tighten it by hand.
NOTE:
NOTE:
wait a few minutes.
LUBRICATION > PAN, OIL > REMOVAL AND INSTALLATION > 2.4L MULTI AIR >
REMOVAL
5. Drain the engine oil and remove the oil filter. Refer to FILTER, ENGINE OIL, REMOVAL AND
INSTALLATION .

INSTALLATION .
Fig 1: Front Fascia To Front Bumper Bolts
8. Remove the bolts (1) securing the front fascia to the front bumper.
Fig 2: Front Bumper Support Bracket & Bolts
9. Remove the bolts (1) and the front bumper support bracket.
10. Remove the bolts (1) and the lower A/C compressor mounting bracket.
11. Remove the bolts (2) securing oil pan.

Fig 4: Cutting Sealant Around Perimeter Of Engine Oil Pan Using Special Tool
12. Using the 1870718000 tool (1) to loosen the seal and remove the oil pan from the engine.
13. Remove all residual sealant from the oil pan and engine block.
LUBRICATION > PAN, OIL > REMOVAL AND INSTALLATION > 2.4L MULTI AIR >
INSTALLATION
SPECIFICATIONS .
4. Install the front bumper support bracket and securely tighten the bolts.
5. Install the bolts (1) securing the front fascia to the front bumper and securely tighten.
8. Install the oil filter and fill the engine crankcase with the proper oil to the correct level. Refer to
FILTER, ENGINE OIL, REMOVAL AND INSTALLATION .
MULTI AIR > REMOVAL
4. Remove the wheelhouse splash shield. Refer to SHIELD, SPLASH, FRONT WHEELHOUSE,
Fig 1: Oil Pressure Sensor Wire Harness Connector & Oil Pressure Sensor
5. Disconnect the oil pressure sensor wire harness connector (1).
MULTI AIR > INSTALLATION
Fig 1: Oil Pressure Sensor Wire Harness Connector & Oil Pressure Sensor
SPECIFICATIONS .
2. Connect the oil pressure sensor wire harness connector (2).

3. Install the wheelhouse splash shield. Refer to SHIELD, SPLASH, FRONT WHEELHOUSE,
LUBRICATION > PUMP, ENGINE OIL > REMOVAL AND INSTALLATION > 2.4L >
REMOVAL
NOTE:
The engine oil pump is integrated in the front crankshaft cover, refer to the following:
3. Remove the engine oil pan. Refer to PAN, OIL, REMOVAL AND INSTALLATION .
4. Remove the serpentine belt tensioner.
Fig 1: Lower Front Of Oil Pump Chain Control & Bolts
6. Remove the screws (1) and remove the lower front of the oil pump chain control.
7. Mark the link of the oil pump chain (1) at the point marked on the oil pump pulley.
Fig 3: A/C Conditioning Compressor, Oil Pump Chain Link, Clamp & Bolt
8. Remove the screw at the conditioning compressor at the point shown in illustration (1).
9. With suitable clamp (2a) hook the oil pump chain link (2b) closest to the engine block, and
fasten the screw (1). With this operation, the plunger of the automatic tensioner is fully
compressed.
LUBRICATION > PUMP, ENGINE OIL > REMOVAL AND INSTALLATION > 2.4L >
INSTALLATION
Fig 1: Oil Pump Chain & Shoe
1. Check that the oil pump chain and shoe (1) are in the position shown in the figure.
Fig 2: Ensure Point Marked On Oil Pump Gear Is Aligned With Notch On Inside Cover
2. Check that the point marked on oil pump gear is in aligned (1) with the notch on the inside
cover.
Fig 3: Oil Pump Motor - Balancing Assembly & Bolts
3. Install the complete oil pump motor - balancing assembly (1a) engaging the chain and tightening
the screws (1b) to the proper specification. Refer to TORQUE SPECIFICATIONS .
Fig 4: Oil Pump - Balancing Assembly Bolt Tightening Sequence
4. To tighten the screws of the complete oil pump - balancing assembly, follow the order as shown
in illustration.
Fig 5: Ensuring Timing Marks Between Oil Pump Gear And Oil Pump Chain Motor Are Aligned
5. Check that the timing marks between the oil pump gear and oil pump chain motor are aligned
(1).
6. Remove the clamp and the screw used to draw back the piston of the automatic tensioner.
7. Install the oil pump chain motor front cover and tighten the screws.
8. Install the engine oil pan. Refer to PAN, OIL, REMOVAL AND INSTALLATION .
10. Install the serpentine drive belt tensioner.
14. Install the front cover crankshaft oil seal. Refer to SEAL, CRANKSHAFT OIL, FRONT,
LUBRICATION > SENSOR, OIL TEMPERATURE > REMOVAL AND INSTALLATION >
2.4L > REMOVAL
3. Remove the clean air tube assembly.

Fig 1: Oil Temperature Sensor Electrical Connector
4. Disconnect the oil temperature sensor electrical connector (1).

Fig 2: Removing & Installing Oil Temperature Sensor At MULTIAIR Actuator
5. With tool 2000034800, unscrew and remove the oil temperature sensor from the MULTIAIR
actuator (1).
LUBRICATION > SENSOR, OIL TEMPERATURE > REMOVAL AND INSTALLATION >
2.4L > INSTALLATION
Fig 1: Removing & Installing Oil Temperature Sensor At MULTIAIR Actuator
1. With tool 2000034800 mount the oil temperature sensor in the MULTIAIR actuator and tighten
2. Connect the oil temperature sensor electrical connector.
3. Install the clean air tube assembly.
VALVE TIMING > STANDARD PROCEDURE > 2.4L - VALVE TIMING VERIFICATION
CAUTION:
Painted or colored chain links are used during initial engine assembly and can not be relied
upon for valve timing verification. Only use top-dead-center marks, cylinder head cover
mounting surface and camshaft sprocket marks to verify valve timing or engine damage may
result.
Fig 1: Timing Cover Mark & Notch
Correct timing is critical for the NON free-wheeling designed engine. Engine timing can be verified by
using the following procedures:
1. Remove the cylinder head cover. Refer to COVER(S), CYLINDER HEAD .
2. Remove the spark plugs. Refer to SPARK PLUG, REMOVAL AND INSTALLATION .
CAUTION:
When aligning timing marks, always rotate engine by turning the crankshaft. Failure
to do so will result in valve and/or piston damage.
3. Rotate the crankshaft clockwise (as viewed from the front) to align the timing cover mark (1)
with the damper notch (2) to place the number one cylinder piston at top-dead-center on the
compression stroke.
Fig 2: Vertical Center Line Of Camshaft, Dowel & Cylinder Head
4. While maintaining this alignment, verify that the dowel window (2) on the camshaft sprocket
point toward 12 o'clock.
5. Using a straightedge tool (1), place the tool vertically at the center of the cam gear. Using the
top edge of the cylinder head (3) as a reference point, the angle between the straightedge and
the cylinder head needs to be 90°.
6. If the engine timing is not correct, proceed to CHAIN AND SPROCKETS, TIMING for service
procedures.
> TIMING CHAIN > REMOVAL
INSTALLATION .
3. Remove the engine cylinder head cover. Refer to COVER(S), CYLINDER HEAD, REMOVAL
AND INSTALLATION .
INSTALLATION .
5. Remove the water pump pulley bolts and remove the pulley. Refer to PUMP, WATER,

INSTALLATION .
INSTALLATION .
8. Remove the timing chain tensioner. Refer to TENSIONER, ENGINE TIMING, REMOVAL AND
INSTALLATION .
9. Remove the timing chain fixed and movable tensioner guides. Refer to GUIDES, TIMING
CHAIN, REMOVAL AND INSTALLATION .
10. Check that the crankshaft key is in the "9 o'clock" position (1).
11. Using the same chain, mark the link of the chain that is at the point marked (2) on the drive
gear.
Fig 2: Positioning Camshaft Centering Pin At "12" O-Clock Position & Marking Chain Link At
Point Marked On Camshaft Sprocket
12. Check that the camshaft centering pin (1) is in the "12 o'clock" position".
13. Using the same chain, mark the link of the chain (2) that corresponds with the notch on the
camshaft sprocket.
Fig 3: Camshaft Sprocket & Bolt
14. Remove the camshaft sprocket screw (1).

Fig 4: Camshaft Sprocket & Chain
15. Disengage the camshaft sprocket (1) from the shaft and remove it along with the chain.
> TIMING CHAIN > INSTALLATION
5. Install the camshaft sprocket pin.

7. Install the timing chain fixed and movable tensioner guides. Refer to GUIDES, TIMING CHAIN,
8. Install the timing chain tensioner. Refer to TENSIONER, ENGINE TIMING, REMOVAL AND
INSTALLATION .
INSTALLATION .
10. Install the crankshaft pulley. Refer to DAMPER, VIBRATION, REMOVAL AND INSTALLATION .
INSTALLATION .
13. Install the engine cylinder head cover. Refer to COVER(S), CYLINDER HEAD, REMOVAL AND
INSTALLATION .
VALVE TIMING > CHAIN AND SPROCKETS, TIMING > INSPECTION > INSPECTION
Fig 1: Measuring Distance From Tensioner Body To Edge Of Chain Guide
Inspect the timing chain for stretching prior to removal.
Rotate the engine while watching timing chain tensioner plunger. When the plunger reaches its
maximum extension, stop rotating engine.
Measure the distance from the tensioner body to the edge of the chain guide as shown in
illustration.
If the distance is greater than 20.5 mm (0.81 in.) inspect the guide shoes for excessive wear.
If the guide shoes are not excessively worn, replace the timing chain.
VALVE TIMING > GUIDES, TIMING CHAIN > REMOVAL AND INSTALLATION > 2.4L
TIMING CHAIN GUIDE SHOE > REMOVAL
INSTALLATION .
INSTALLATION .
INSTALLATION .
INSTALLATION .
INSTALLATION .
12. Remove the screw (1a) and remove the timing chain tensioner guide (1b) complete with
bushing.
TIMING CHAIN GUIDE SHOE > INSTALLATION
1. Install the timing chain tensioner guide complete with bushing and tighten the screw.
INSTALLATION .
INSTALLATION .
.
INSTALLATION .
INSTALLATION .
TIMING CHAIN GUIDE TENSIONER > REMOVAL
INSTALLATION .
INSTALLATION .
INSTALLATION .
INSTALLATION .
INSTALLATION .

12. Remove the screw (1a) and remove the timing chain tensioner guide (1b).
TIMING CHAIN GUIDE TENSIONER > INSTALLATION
1. Install the timing chain tensioner guide and tighten the screw.
INSTALLATION .
INSTALLATION .
.
INSTALLATION .
INSTALLATION .
REMOVAL
INSTALLATION .
INSTALLATION .
INSTALLATION .

INSTALLATION .
9. Disconnect the electrical connection from the upstream oxygen sensor (1).
10. Disengage the wiring of the upstream oxygen sensor (1), loosen the screw and remove the
bracket.
11. Remove the bolts (2) and remove the top cover of the exhaust manifold.
12. Remove the bolt (1) and remove the accessory drive belt idler pulley.
Fig 4: Engine Oil Dipstick Tube & Bolt
13. Remove the bolt (1) and remove the engine oil dipstick tube.
Fig 5: Accessory Drive Belt Tensioner Top Bolt
14. Remove the top bolt (1) from the accessory drive belt tensioner.
Fig 6: Accessory Drive Belt Tensioner & Bolt
Fig 7: Center Exhaust Manifold Bolt & Bracket
16. Remove the center exhaust manifold bolt (1) and install the bracket from the 2000040436
powertrain support tool.
Fig 8: Driveline Support Fixture
17. Assemble the 2000040436 (EMEA) or (special tool #8534B, Fixture, Driveline Support)
(NAFTA) tool (1).
Fig 10: Engine Timing Cover To Cylinder Head Upper Bolts
19. Remove the upper bolts (1) securing the engine timing cover to the cylinder head.
Fig 11: Engine Timing Cover To Engine Block & Engine Oil Pan Bolts
20. Remove the bolts (1) securing the engine timing cover to the engine block.
21. Remove the bolts (2) securing the engine timing cover to the engine oil pan.
Fig 12: A/C Compressor And Support Bracket Bolts
22. Remove the bolts (1) and remove the A/C compressor support bracket.
Fig 13: Cutting Sealant Between Engine Timing Cover & Engine Oil Pan Using Special Tool
23. With the tool (1) cut the sealant from between the engine timing cover and the engine oil pan.
Fig 14: Engine Timing Cover
24. Remove the engine timing cover (1).
25. Remove the residual silicone gasket material from the cover and check the integrity of the
centering bushings.
26. Pry off and remove the front crankshaft oil seal from the timing cover.
INSTALLATION
Fig 2: Applying Sealant To Engine Timing Cover To Engine Block Gasket Surface & Oil Pan
3. Apply a bead (2 mm) of suitable silicone sealant to the oil pan (2) as shown in the figure.
figure.
Fig 4: Installing Engine Timing Cover & Bolts
5. Working from the wheel well, install the engine timing cover and tighten the lower mounting
bolts (1) to the proper specification. Refer to TORQUE SPECIFICATIONS .
6. Install the A/C compressor support bracket and tighten the bolts to the proper specification.
7. Tighten the engine timing cover to oil pan bolts (2) to the proper specification. Refer to
8. Tighten the engine timing cover to cylinder head bolts (1) to the proper specification. Refer to
10. Install the right engine mount isolator and tighten the bolts (1a) and (1b) to the proper
11. Remove the 2000040436 (EMEA) or (special tool #8534B, Fixture, Driveline Support) (NAFTA)
tool and tighten the center exhaust manifold bolt to the proper specification. Refer to TORQUE
SPECIFICATIONS .
12. Install the accessory drive belt tensioner (1) and tighten the bolts to the proper specification.
14. Install the top cover of the exhaust manifold and tighten the bolts to the proper specification.
15. Install the upstream oxygen sensor wiring bracket, tighten the bolt and engage the wire
harness in the retaining clip.
16. Connect the electrical connection of the upstream oxygen sensor.
.
INSTALLATION .
24. Install the right front splash shield and wheel. Refer to SHIELD, SPLASH, FRONT
2.4L ENGINE TIMING TENSIONER > REMOVAL
INSTALLATION .
INSTALLATION .
INSTALLATION .

Fig 1: Tensioner & Bolts
10. Remove the screws (1) and remove the tensioner.
2.4L ENGINE TIMING TENSIONER > INSTALLATION
SPECIFICATIONS .
.
INSTALLATION .
INSTALLATION .
Jeep Renegade
Service Manual: ENGINE COOLING SYSTEM
AND OPERATION
The cooling system regulates engine operating temperature. It allows the engine to reach normal
operating temperature as quickly as possible, maintains normal operating temperature and prevents
overheating.
The cooling system also provides a means of heating the passenger compartment and cooling the
engine oil. The cooling system is pressurized and uses a centrifugal water pump to circulate coolant
throughout the system. A separate and remotely mounted, pressurized coolant bottle is used.
When the engine is cold the thermostat is closed. The cooling system has no flow through the
radiator or engine oil cooler. The coolant flows through the engine, water pump, and passenger
compartment heater core.
When the engine is warm the thermostat is full open. Coolant flows through the engine, radiator,
engine oil cooler, passenger compartment heater core, and water pump.
The cooling system consists of:
Electric cooling fan
Radiator
A pressurized coolant de-aeration bottle
Thermostat
Water pump
Engine Coolant Temperature (ECT) sensor
Cooling system pressure cap
Coolant
Engine oil cooler
Hoses and hose clamps
Thermostat housing assembly
DIAGNOSIS AND TESTING > COOLING SYSTEM DIAGNOSIS
TEMPERATURE GAUGE READS 1. Diagnostic Trouble Code 1. Replace the thermostat, if

LOW (DTC) has been set indicating directed by DTC diagnosis.
a stuck open engine Refer to THERMOSTAT,
thermostat. REMOVAL AND
INSTALLATION . If a DTC has
not been set, the problem may
be with the temperature gauge.
2. Engine Coolant Temperature 2. Check connector at Engine

(ECT) sensor. Coolant Temperature (ECT)
sensor. Repair as necessary.
3. Inoperative temperature 3. Check gauge operation.

gauge. Refer to DESCRIPTION AND
OPERATION .
4. Coolant level low during cold 4. Check coolant level in the

ambient temperature, pressurized coolant bottle.
accompanied by poor heater Inspect the system for leaks.
performance. Refer to LEAK TESTING .
Repair as necessary. Refer to
all WARNINGS in this Service
Information before removing the
pressure cap.
TEMPERATURE GAUGE READS 1. Trailer being towed, a steep 1. This may be a temporary
HIGH OR ENGINE COOLANT hill being climbed, vehicle being condition and repair is not
WARNING LAMP ILLUMINATES. operated in slow moving traffic, necessary. Turn off the air
COOLANT MAY OR MAY NOT BE or engine idling during high conditioning and drive the
LOST FROM SYSTEM. ambient (outside) temperatures vehicle without any of the
with air conditioning on. High previous conditions. Observe
altitudes could also cause the temperature gauge. The
these conditions. gauge should return to the
normal range. If the gauge does
not return to the normal range,
determine the cause of the
overheating and repair.
2. Inoperative temperature 2. Check gauge operation.

gauge. Refer to DESCRIPTION AND
OPERATION .
3. Is temperature warning lamp 3. Check warning lamp

(if equipped) illuminating operation. Refer to
unnecessarily? DESCRIPTION AND
OPERATION .
4. Coolant level low in 4. Check for coolant leaks and

pressurized coolant bottle? repair as necessary. Refer to
LEAK TESTING .
5. Pressure cap not installed 5. Tighten cap.

tightly. If cap is loose, boiling
point of coolant will be
lowered. Also refer to the
following step 6.
6. Poor seals at pressure cap. 6. (a) Check condition of cap

and cap seals. Refer to CAP,
RADIATOR, DIAGNOSIS AND
TESTING . Replace cap if
necessary.
(b) Check condition of filler

neck. If neck is warped or
damaged, replace the
pressurized coolant bottle. Refer
to BOTTLE, PRESSURIZED
COOLANT, REMOVAL AND
INSTALLATION .
7. Freeze point of coolant not 8. Check coolant concentration.

correct. Mixture ratio may be Refer to COOLANT,
too rich. DIAGNOSIS AND TESTING .
Adjust glycol-to-water ratio as
required.
8. Coolant not flowing through 9. Check for coolant flow in the

system. pressurized coolant bottle with
some coolant removed, engine
warm, and thermostat open.
Coolant should be observed
flowing into the bottle. If flow is
not observed, determine the
reason for lack of flow and
repair as necessary.
9. Radiator air seals missing 10. Inspect air seals. Correct as

or improperly installed. necessary.
10. Radiator or A/C condenser 11. Clean obstruction from fins.

fins are dirty or clogged.
11. Radiator core is plugged or 12. Clean or replace the

corroded. radiator. Refer to RADIATOR,
ENGINE COOLING, REMOVAL
AND INSTALLATION .
12. Fuel or ignition system 1. Refer to appropriate

problems. Powertrain Diagnostic
Procedures. Repair as
necessary.
13. Dragging Brakes. 14. Inspect the brake system

and repair as necessary. Refer
14. Bug screen or other 15. Remove bug screen or

aftermarket accessory is being accessory.
used causing reduced air flow.
15. Thermostat partially or 16. Check thermostat operation

completely closed. and replace as necessary.
Refer to THERMOSTAT,
REMOVAL AND
INSTALLATION .
16. Cooling fan not operating 17. Check electric fan operation
properly. and repair as necessary.
17. Cylinder head gasket 18. Check cylinder head gasket

leaking. for leaks. Refer to LEAK
TESTING .
18. Heater core leaking. 19. Check heater core for leaks.
TEMPERATURE GAUGE READING 1. The gauge may cycle up and 1. A normal condition. No
IS INCONSISTENT (FLUCTUATES, down. This is due to the correction is necessary. If
CYCLES OR IS ERRATIC) cycling of the electric radiator gauge cycling is the hot zone,
fan. check electric fan operation and
repair as necessary.
2. During cold weather 2. A normal condition. No

operation with the heater correction is necessary.
blower in the high position, the
gauge reading may drop
slightly.
3. Temperature gauge or 3. Check gauge operation.

Engine Coolant Temperature Refer to DESCRIPTION AND
(ECT) sensor is defective or OPERATION .
shorted.
4. Gauge reading rises when 4. A normal condition. No

vehicle is brought to a stop correction is necessary. The
after heavy use (engine still gauge should return to normal
running). range after vehicle is driven.
5. Gauge reading high after 5. A normal condition. No

restarting a warmed-up (hot) correction is necessary. The
engine. gauge should return to normal
range after a few minutes of
engine operation.
6. Coolant level low in radiator 6. Check and correct coolant

(air will build up in the cooling leaks. Refer to LEAK TESTING
system causing the thermostat .
to open late).
7. Cylinder head gasket 7. (a) Check for cylinder head

leaking allowing exhaust gas to gasket leaks. Refer to LEAK
enter cooling system. This will TESTING . Repair as
cause thermostat to open late. necessary.
(b) Check for coolant in the

engine oil. Inspect for white
steam emitting from exhaust
system. Repair as necessary.
8. Water pump impeller loose 8. Check water pump and

on shaft. replace as necessary. Refer to
PUMP, WATER, REMOVAL AND
INSTALLATION .
9. Air leak on the suction side 9. Locate leak and repair as
of water pump allows air to necessary.
build up in cooling system. This
will cause the thermostat to
open late.
PRESSURE CAP IS BLOWING OFF 1. Pressure relief valve in 1. Check condition of pressure
STEAM AND/OR COOLANT pressure cap is defective. cap and seals. Refer to CAP,
FLOWING INTO PRESSURIZED RADIATOR, DIAGNOSIS AND
COOLANT BOTTLE. TEMPERATURE TESTING . Replace as
GAUGE READING MAY BE ABOVE necessary.
NORMAL, BUT NOT HIGH. COOLANT
LEVEL MAY BE HIGH IN THE
BOTTLE.
COOLANT LOSS TO THE GROUND 1. Coolant leaks in radiator, 1. Pressure test cooling system
WITHOUT PRESSURE CAP cooling system hoses, water and repair as necessary. Refer
BLOWOFF. GAUGE IS READING pump or engine. to LEAK TESTING .
HIGH OR HOT.
DETONATION OR PRE-IGNITION 1. Engine overheating. 1. Check reason for overheating

(NOT CAUSED BY IGNITION and repair as necessary.
SYSTEM). GAUGE MAY OR MAY
NOT BE READING HIGH.
2. Freeze point of coolant not 2. Check the freeze point of the

correct. coolant. Refer to COOLANT,
Adjust glycol-to-water ratio as
required.
HOSE OR HOSES COLLAPSE 1. Vacuum created in cooling 1. (a) Pressure cap relief valve
WHEN ENGINE IS COOLING system on engine cool-down is stuck. Refer to CAP, RADIATOR,
not being relieved through the DIAGNOSIS AND TESTING .
pressure cap relief valve. Replace as necessary.
(b) Vent in pressure cap is

plugged. Clean vent and repair
as necessary.
(c) Pressurized coolant bottle is

internally blocked or plugged.
Check for blockage and repair
as necessary.
RADIATOR FAN OPERATES ALL THE 1. Malfunctioning electrical 1. Refer to appropriate

TIME component or circuit. Powertrain Diagnostic
Procedures. Repair as
necessary.
2. Check for low coolant level. 2. Repair as necessary.
RADIATOR FAN WILL NOT 1. Fan motor defective. 1. Refer to appropriate

OPERATE, GAUGE READING HIGH Powertrain Diagnostic
OR HOT information for operation of the
scan tool. Repair as necessary.
2. Fan control circuit, 2. Refer to appropriate
powertrain control module Powertrain Diagnostic
(PCM) or engine coolant information for operation of the
temperature sensor defective. scan tool. Repair as necessary.
3. Blown fuse in power 3. Determine cause for blown

distribution center (PDC). fuse and repair as necessary.
NOISY FAN 1. Fan blade loose. 1. Replace the engine cooling

fan assembly. Refer to FAN,
COOLING, REMOVAL AND
INSTALLATION .
2. Fan blade striking a 2. Locate point of fan blade

surrounding object. contact and repair as
necessary.
3. Air obstructions at radiator 3. Remove obstructions and/or

or A/C condenser. clean debris from radiator and/or
A/C condenser.
4. Electric fan motor defective. 4. Replace the engine cooling

fan assembly. Refer to FAN,
COOLING, REMOVAL AND
INSTALLATION .
INADEQUATE AIR CONDITIONER 1. Electric radiator fan not 1. Refer to appropriate

PERFORMANCE (COOLING operating when A/C is on. Powertrain Diagnostic
SYSTEM SUSPECTED) information for operation of the
2. Radiator and/or air 2. Remove restriction and/or

conditioning condenser is clean as necessary.
restricted, obstructed or dirty.
3. Radiator air seals missing 3. Inspect air seals. Repair as

or improperly installed. necessary.
4. Engine is overheating (heat 4. Correct overheating

may be transferred from condition. Refer to ENGINE
radiator to A/C condenser). COOLING SYSTEM
High underhood temperature OVERHEATING .
due to engine overheating may
also transfer heat to A/C
components.
INADEQUATE HEATER 1. Has a diagnostic trouble 1. Refer to appropriate

PERFORMANCE code (DTC) been set? Powertrain Diagnostic
Procedures.
2. Coolant level low. 2. Check cooling system for

leaks. Refer to LEAK TESTING
. Repair as necessary.
3. Obstructions in heater hose 3. Remove heater hoses at both

fittings at engine. ends and check for obstructions.
Repair as necessary.
4. Heater hose kinked. 4. Locate kinked area and repair
as necessary.
5. Water pump is not pumping 5. Check accessory drive belt

coolant through the heater operation. Repair as necessary.
core. When the engine is fully
warmed up, both heater hoses
should be hot to the touch.
HEAT ODOR 1. Various heat shields are 1. Locate missing shields and
used at certain components. replace or repair as necessary.
One or more of these shields
may be missing.
2. Is temperature gauge 2. Check gauge operation.

reading above the normal Refer to DESCRIPTION AND
range? OPERATION .
3. Is cooling fan operating 3. Repair as necessary.

correctly?
4. Has undercoating been 4. Clean undercoating as

applied to any unnecessary necessary.
component.
5. Engine may be running rich 5. Refer to appropriate

causing the catalytic converter Powertrain Diagnostic
to overheat. information for operation of the
POOR DRIVEABILITY 1. Has a diagnostic trouble 1. Refer to the Powertrain

(THERMOSTAT POSSIBLY STUCK code (DTC) been set? Diagnostic information for
OPEN). GAUGE MAY BE READING checking a DTC related to the
LOW thermostat.
STEAM IS COMING FROM FRONT 1. During wet weather, 1. Occasional steam emitting
OF VEHICLE NEAR GRILLE AREA moisture (snow, ice or rain from this area is normal. No
WHEN WEATHER IS WET, ENGINE condensation) on the radiator repair is necessary.
IS WARMED UP, RUNNING, AND will evaporate when the
VEHICLE IS STATIONARY. thermostat opens. This
TEMPERATURE GAUGE IS IN opening allows heated water
NORMAL RANGE. into the radiator. When the
moisture contacts the hot
radiator, steam may be
emitted. This usually occurs in
cold weather with no fan or
airflow to blow it away.
COOLANT COLOR 1. Coolant color is not 1. Check the freeze point of the
necessarily an indication of coolant. Refer to COOLANT,
adequate corrosion or DIAGNOSIS AND TESTING .
temperature protection. Do not Adjust the glycol-to-water ratio
rely on coolant color for as required.
determining condition of
coolant.
COOLANT LEVEL CHANGES IN 1. Level changes are to be 1. A normal condition. No repair
COOLANT RECOVERY/RESERVE expected as coolant volume is necessary.
BOTTLE fluctuates with engine
temperature. If the level in the
bottle was between the FULL
HOT and ADD marks at normal
engine operating temperature,
the level should return to within
that range after operation at
elevated temperatures.
DIAGNOSIS AND TESTING > AERATION
If coolant level drops below a certain point, aeration will occur drawing air into the water pump resulting
in the following:
High reading shown on the temperature gauge.
Loss of coolant flow through the heater core.
Corrosion in the cooling system.
Water pump seal may run dry, increasing the risk of premature seal failure.
NOTE:
Combustion gases leaking into the coolant can also cause the above problems.
DIAGNOSIS AND TESTING > DEAERATION
As air is removed from the cooling system, it gathers in the pressurized coolant bottle. This pressure is
released into the atmosphere through the pressure valve located in the radiator pressure cap when
pressure reaches 1.4 bar (20.3 psi).
NOTE:
Deaeration does not occur at engine idle, higher engine speeds are required. Normal
driving will deaerate the cooling system.
To effectively deaerate the system, multiple thermal cycles of the system may be required.
DIAGNOSIS AND TESTING > ENGINE COOLING SYSTEM OVERHEATING

Establish what driving conditions caused the complaint. Abnormal loads on the cooling system such as
the following may be the cause:
Prolonged idle in a confined location
Very high ambient temperature
Slow traffic
Traffic jams
High speed or steep grades
Trailer towing
Debris on front of the grill or the cooling module that are restricting airflow
NOTE:
Idling the engine with A/C off may be a driving technique that avoids overheating.
DIAGNOSIS AND TESTING > LEAK TESTING > ULTRAVIOLET LIGHT METHOD
Fig 1: Ultraviolet Light
1 - TYPICAL BLACK LIGHT TOOL
A leak detection additive is available through the parts department that can be added to cooling system.
The additive is highly visible under ultraviolet light (black light) (1). Pour one ounce of additive into
cooling system. Place heater control unit in HEAT position. Start and operate the engine until the radiator
upper hose is warm to the touch. Aim the commercially available black light tool at the components to be
checked. If leaks are present, the black light will cause the additive to glow a bright green color.
The black light can be used in conjunction with a pressure tester to determine if any external leaks exist.
DIAGNOSIS AND TESTING > LEAK TESTING > PRESSURE TESTER METHOD
Fig 1: Cooling Pressure Tester & Pressurized Coolant Bottle
The engine should be at normal operating temperature. Recheck the system cold if cause of coolant loss
is not located during the warm engine examination.
WARNING:
Hot, pressurized coolant can cause injury by scalding.
Carefully remove the pressure cap. Wipe inside of filler neck and examine lower inside sealing seat for
nicks, cracks, paint, dirt and residue.
Inspect the outside of the filler neck. If damaged, seating of the pressure cap valve and tester seal will
be affected.
Attach (special tool #7700, Tester, Cooling System) (1) or an equivalent to the pressurized coolant bottle
(2).
Operate tester pump to apply 103.4 kPa (15 psi) pressure to system. If hoses enlarge excessively or
bulges while testing, replace as necessary. Observe gauge pointer and determine condition of cooling
system according to following criteria:
Holds Steady: If pointer remains steady for two minutes, serious coolant leaks are not present in
system. However, there could be an internal leak that does not appear with normal system test pressure.
If it is certain that coolant is being lost and leaks cannot be detected, inspect for interior leakage or
perform the Internal Leakage Test. Refer to INTERNAL LEAKAGE INSPECTION .
Drops Slowly: Indicates a small leak or seepage is occurring. Examine all connections for seepage or
slight leakage with a flashlight. Inspect radiator, hoses, gasket edges and heater. Seal small leak holes
with a Sealer Lubricant (or equivalent). Repair leak holes and inspect system again with pressure
applied.
Drops Quickly: Indicates that serious leakage is occurring. Examine system for external leakage. If
leaks are not visible, inspect for internal leakage.
DIAGNOSIS AND TESTING > LEAK TESTING > INTERNAL LEAKAGE INSPECTION
Remove the engine oil pan drain plug and drain a small amount of engine oil. If coolant is present in the
pan, it will drain first because it is heavier than oil. An alternative method is to operate the engine for a
short period to churn the oil. After this is done, remove the engine dipstick and inspect for water
globules.
WARNING:
With radiator pressure tester tool installed on radiator, do not allow pressure to exceed 145
kPa (21 psi). Pressure will build up quickly if a combustion leak is present. To release
pressure, rock tester from side to side. When removing tester, do not turn tester more than
1/2 turn if system is under pressure.
Operate the engine without the pressure cap on the pressurized coolant bottle until the thermostat
opens. Attach a Pressure Tester to the filler neck. If pressure builds up quickly it indicates a combustion
leak exists. This is usually the result of a cylinder head gasket leak or a crack in the engine. Repair as
necessary.
If there is not an immediate pressure increase, pump the Pressure Tester. Do this until indicated
pressure is within the system range of 110 kPa (16 psi). Fluctuation of the gauge pointer indicates
compression or combustion leakage into the cooling system.
Because the vehicle is equipped with a catalytic converter, do not short out cylinders to isolate the
compression leak.
If the needle on the dial of the pressure tester does not fluctuate, race engine a few times to check for
an abnormal amount of coolant or steam. This would be emitting from the exhaust pipe. Coolant or steam
from the exhaust pipe may indicate a faulty cylinder head gasket, cracked engine cylinder block or
cylinder head.
STANDARD PROCEDURE > DRAINING AND FILLING THE COOLING SYSTEM >
DRAINING - 1.4L MULTIAIR TURBO
NOTE:
Make sure the coolant is not HOT and under pressure.
NOTE:
DO NOT WASTE reusable coolant. If the solution is clean, drain the coolant into a clean
container for reuse.
3. When the engine is cold, remove the filler cap from the pressurized coolant bottle.
Fig 1: Quick-Connect Coupling
NOTE:
Recover the coolant into a suitable container.
4. Disengage the quick-connect coupling (1) and carefully remove the lower radiator inlet hose
from the radiator.
Fig 2: Drain Valve
5. Open the drain valve (1) on the right rear of the radiator.
FILLING - 1.4L MULTIAIR TURBO
1. Install the lower radiator outlet hose to the radiator and engage the quick-connect coupling.
2. Slowly add the engine coolant through the filler neck until the fluid begins to leak from the bleed
screw.
3. Close the bleed screw.

Fig 1: MIN & MAX Levels
4. Continue to add coolant to the MAX level of the tank.
5. Tighten the cap on the pressurized coolant bottle.
6. Start the engine and run it at idle for about 2 minutes.
7. Bleed the circuit by performing a quick accel to an engine speed of 3000 RPM followed by a
gradual decel (every 30 seconds). The operation must be performed in order to obtain the
opening of the thermostat and operation of the electric fan.
NOTE:
In the course of this operation, keep the air conditioning system switched off to
avoid operation of the electric fan that is not due to heating of the coolant. If at this
stage there has been a dramatic drop in the level in the tank, return the engine
speed to idle and open the cap very carefully, topping up the liquid to the MAX
mark; then install the cap and complete deaeration.
8. Stop the engine and after it has cooled check that the fluid level is positioned at the MAX mark
on the tank.
9. Upon completion of this procedure, be sure the quantity of fluid added is at least equal to that
recovered during the emptying phase.
DRAINING - 1.6L TURBO DIESEL
NOTE:
NOTE:
NOTE:
from the radiator.
Fig 2: Drain Valve
Fig 3: Bleed Valve On Return Line
6. Open the bleed valve (1) on the return line from the heater core.
Fig 4: Bleed Valve On Thermostat
7. Open the bleed valve (1) on the thermostat.
FILLING - 1.6L TURBO DIESEL
2. Slowly add the engine coolant through the filler neck until the fluid begins to leak from the
radiator and thermostat bleed screws.
3. Close the radiator and thermostat bleed screws.
4. Continue adding coolant until fluid begins to leak from the bleed valve located on the return line
from the heater core.

NOTE:
on the tank.
DRAINING - 2.0L TURBO DIESEL
NOTE:
NOTE:
NOTE:
from the radiator.
Fig 2: Drain Valve
7. On 120/140CV engines, open the bleed valve (1) on the thermostat.

8. On 170CV engines, open the bleed valve (1) on the thermostat.
FILLING - 2.0L TURBO DIESEL
radiator and thermostat bleed screws.
3. Close the radiator and thermostat bleed screws.

NOTE:
on the tank.
DRAINING - 2.4L MULTIAIR2
NOTE:
NOTE:
NOTE:
from the radiator.
Fig 2: Drain Valve
FILLING - 2.4L MULTIAIR2
radiator bleed screw.
3. Close the radiator bleed screw.

NOTE:
on the tank.
STANDARD PROCEDURE > STANDARD PROCEDURE - COOLANT AIR EVACUATION
CAUTION:
Failure to purge air from the cooling system can result in an overheating condition and
severe engine damage.
NOTE:
The preferred method to remove air from the cooling system is to use (special tool
#399-550000, Tool, UView Airlift™ Cooling System Refill).
Fig 1: Pressurized Air Operated Vacuum Generator
Evacuating or purging air from the cooling system involves the use of a pressurized air operated vacuum
generator. The vacuum created allows for a quick and complete coolant refilling while removing any
airlocks present in the system components.
NOTE:
To avoid damage to the cooling system, ensure that no component would be susceptible to
damage when a vacuum is drawn on the system.
WARNING:
ANTIFREEZE IS AN ETHYLENE GLYCOL BASE COOLANT AND IS HARMFUL IF

SWALLOWED OR INHALED. IF SWALLOWED, DRINK TWO GLASSES OF WATER AND
INDUCE VOMITING. IF INHALED, MOVE TO FRESH AIR AREA. SEEK MEDICAL
ATTENTION IMMEDIATELY. DO NOT STORE IN OPEN OR UNMARKED CONTAINERS.
WASH SKIN AND CLOTHING THOROUGHLY AFTER COMING IN CONTACT WITH
ETHYLENE GLYCOL. KEEP OUT OF REACH OF CHILDREN. DISPOSE OF GLYCOL
BASED COOLANT PROPERLY. CONTACT YOUR DEALER OR GOVERNMENT AGENCY
FOR LOCATION OF COLLECTION CENTER IN YOUR AREA. DO NOT OPEN A COOLING
SYSTEM WHEN THE ENGINE IS AT OPERATING TEMPERATURE OR HOT UNDER
PRESSURE; PERSONAL INJURY CAN RESULT. AVOID RADIATOR COOLING FAN WHEN
ENGINE COMPARTMENT RELATED SERVICE IS PERFORMED; PERSONAL INJURY CAN
RESULT.
WARNING:
WEAR APPROPRIATE EYE AND HAND PROTECTION WHEN PERFORMING THIS

PROCEDURE.
NOTE:
The service area where this procedure is performed should have a minimum shop air
requirement of 80 PSI (5.5 bar) and should be equipped with an air dryer system.
NOTE:
For best results, the radiator should be empty. The vehicle's heater control should be set to
the heat position (ignition may need to be turned to the on position but do not start the
engine).
1. Refer to the service equipment tool's operating manual for specific assembly steps.
2. Choose an appropriate adapter cone that will fit the vehicle's cooling system filler neck.
3. Attach the adapter cone (2) to the vacuum gauge (1).

Fig 2: Vacuum Generator/Venturi Ball Valve
4. Make sure the vacuum generator/venturi ball valve (3) is closed and attach an airline hose (2)
(minimum shop air requirement of 80 PSI/5.5 bar) to the vacuum generator/venturi (1).
5. Position the adaptor cone/vacuum gauge assembly into the filler neck. Ensure that the adapter
cone is sealed properly.
Fig 3: Vacuum Generator/Venturi
6. Connect the vacuum generator/venturi (2) to the positioned adaptor cone/vacuum gauge
assembly (1).
7. Open the vacuum generator/venturi ball valve.
NOTE:
Do not bump or move the assembly as it may result in loss of vacuum.
8. Let the system run until the vacuum gauge shows a good vacuum through the cooling system.
Refer to the tool's operating manual for appropriate pressure readings.
NOTE:
If a strong vacuum is being created in the system, it is normal to see the radiator
hoses collapse.
9. Close the vacuum generator/venturi ball valve.
Fig 4: Vacuum Generator/Venturi And Air Line
10. Disconnect the vacuum generator/venturi and airline (1) from the adaptor cone/vacuum gauge
assembly (2).
11. Wait approximately 20 seconds, if the pressure readings do not move, the system has no
leaks. If the pressure readings move, a leak could be present in the system. Check for leaks
and repeat the procedure.
12. Place the tool's suction hose into the coolant's container.
NOTE:
Ensure there is a sufficient amount of coolant, mixed to the required

strength/protection level available for use. For best results and to assist the refilling
procedure, place the coolant container at the same height as the filler neck. Always
draw more coolant than required. If the coolant level is too low, it will pull air into the
cooling system which could result in airlocks within the system.
13. Connect the tool's suction hose (1) to the adaptor cone/vacuum gauge assembly (2).
Fig 5: Refilling Cooling System
NOTE:
View typical
14. Open the suction hose's ball valve to begin filling the cooling system.
15. When the vacuum gauge reads zero, the system is filled.
NOTE:
If filling through a pressurized coolant bottle, stop filling when the proper level is
reached.
16. Close the suction hose's ball valve and remove the suction hose from the adaptor
cone/vacuum gauge assembly.
17. Remove the adaptor cone/vacuum gauge assembly from the filler neck.
18. Install the cap on the filler neck.
19. Start and run the engine with the heater control unit in the HEAT position.
20. After the engine has reached normal operating temperature, shut the engine off and allow it to
cool. When the engine is cooling down, coolant will be drawn into the radiator.
21. Add coolant to the pressurized coolant bottle or reservoir tank as necessary. Only add
coolant to the container when the engine is cold. Coolant level in a warm engine will be
higher due to thermal expansion. Add necessary coolant to raise container level to the
COLD MINIMUM mark after each cool down period.
22. Once the appropriate coolant level is achieved, install the cap on the filler neck.
STANDARD PROCEDURE > ADDING ADDITIONAL COOLANT
WARNING:
ANTIFREEZE IS AN ETHYLENE GLYCOL BASE COOLANT AND IS HARMFUL IF

SWALLOWED OR INHALED. IF SWALLOWED, DRINK TWO GLASSES OF WATER AND
INDUCE VOMITING. IF INHALED, MOVE TO FRESH AIR AREA. SEEK MEDICAL
ATTENTION IMMEDIATELY. DO NOT STORE IN OPEN OR UNMARKED CONTAINERS.
WASH SKIN AND CLOTHING THOROUGHLY AFTER COMING IN CONTACT WITH
ETHYLENE GLYCOL. KEEP OUT OF REACH OF CHILDREN. DISPOSE OF GLYCOL
BASED COOLANT PROPERLY. CONTACT YOUR DEALER OR GOVERNMENT AGENCY
FOR LOCATION OF COLLECTION CENTER IN YOUR AREA. DO NOT OPEN A COOLING
SYSTEM WHEN THE ENGINE IS AT OPERATING TEMPERATURE OR HOT UNDER
PRESSURE; PERSONAL INJURY CAN RESULT. AVOID RADIATOR COOLING FAN WHEN
ENGINE COMPARTMENT RELATED SERVICE IS PERFORMED; PERSONAL INJURY CAN
RESULT.
When additional coolant is needed, it should be added to the Pressurized Coolant Bottle. With the
engine cold, add enough coolant to set the level between the add (MIN) and full (MAX) indicators on the
bottle.
Only use the type of coolant specified for this vehicle. Refer to CAPACITIES AND RECOMMENDED
FLUIDS, SPECIFICATIONS .
STANDARD PROCEDURE > CLIC© HOSE CLAMP PLIERS - USAGE
When CLIC© style clamps are used. It requires that miller tool (special tool #10288, Pliers, Hose Clamp)
be used for proper installation and removal.
Fig 1: Flat Blade Of Pliers
Installation of the hose clamp requires the flat blade of the pliers to rest against the latch lock side of the
clamp. The notched end of the pliers will be positioned on the protruded guide on the latch side. Squeeze
the pliers until a CLICK sound is heard.
Fig 2: Notched End Of Pliers
Removal of the hose clamp requires the notched end of the pliers to rest against the latch side of the
clamp. Squeezing the pliers will cause the hook of the latch lock to ride up the beveled edging of the
notched side, releasing itself from the lock.
STANDARD PROCEDURE > REVERSE FLUSHING
CAUTION:
The cooling system normally operates at 97-124 kPa (14-18 psi) pressure. Exceeding this
pressure may damage the radiator or hoses.
Reverse flushing of the cooling system is the forcing of water through the cooling system. This is done
using air pressure in the opposite direction of normal coolant flow. It is usually only necessary with very
dirty systems with evidence of partial plugging.
STANDARD PROCEDURE > REVERSE FLUSHING > CHEMICAL CLEANING
If visual inspection indicates the formation of sludge or scaly deposits, use a radiator cleaner (Mopar
Radiator Kleen or equivalent) before flushing. This will soften scale and other deposits and aid the
flushing operation.
CAUTION:
Be sure instructions on the container are followed.
STANDARD PROCEDURE > REVERSE FLUSHING > REVERSE FLUSHING RADIATOR
Disconnect the radiator hoses from the radiator fittings. Attach a section of radiator hose to the radiator
bottom outlet fitting and insert the flushing gun. Connect a water supply hose and air supply hose to the
flushing gun.
CAUTION:
The cooling system normally operates at 97-124 kPa (14-18 psi) pressure. Exceeding this
pressure may damage the radiator or hoses.
Allow the radiator to fill with water. When radiator is filled, apply air in short blasts allowing radiator to
refill between blasts. Continue this reverse flushing until clean water flows out through rear of radiator
cooling tube passages. For more information, refer to operating instructions supplied with flushing
equipment. Have radiator cleaned more extensively by a radiator repair shop.
STANDARD PROCEDURE > REVERSE FLUSHING > REVERSE FLUSHING ENGINE
Drain the cooling system. Refer to STANDARD PROCEDURE . Remove the thermostat housing. Refer
to THERMOSTAT, REMOVAL AND INSTALLATION . Install a thermostat housing that has had the
thermostat removed. Disconnect the radiator upper hose from the radiator and attach the flushing gun to
the radiator upper hose. Disconnect the radiator lower hose from the radiator and attach the lead away
hose to the lower radiator hose.
Connect the water supply hose and air supply hose to the flushing gun. Allow the engine to fill with water.
When the engine is filled, apply air in short blasts, allowing the system to fill between air blasts. Continue
until clean water flows through the lead away hose. For more information, refer to operating instructions
supplied with flushing equipment.
Remove the lead away hose, flushing gun, water supply hose and air supply hose. Remove the
thermostat housing that has had the thermostat removed and install a new thermostat and housing with a
replacement gasket. Refer to THERMOSTAT, REMOVAL AND INSTALLATION . Connect the radiator
hoses. Refill the cooling system with the correct antifreeze/water mixture. Refer to STANDARD
PROCEDURE .
SPECIFICATIONS > FILL VOLUME
US METRIC
1.4L Multi Air 5.5 Quarts 5.2 Liters
1.6L Gas 5.9 Quarts 5.6 Liters
1.6L Diesel 6.4 Quarts 6.1 Liters
2.0L 6.8 Quarts 6.5 Liters
2.4L Multi Air 7.2 Quarts 6.8 Liters
Use only MOPAR OAT coolant.
* 2.0 Diesel Engine uses Parafull coolant
SPECIFICATIONS > TORQUE SPECIFICATIONS - DIESEL ENGINE

TORQUE SPECIFICATIONS - DIESEL ENGINE
DESCRIPTION N.m Ft. Lbs. In. Lbs. NEW

FASTENER *
EGR Tube Bolts 9 - 80
Engine Cooling Temperature (ECT) Sensor 20 15 -
Thermostat Housing Bolts (1.6L) 25 18 -
Water Pump Bolts 25 18 -
* NEW FASTENERS: Do not reuse these fasteners. If removed, a new fastener must be installed and
tighten to specifications.
SPECIFICATIONS > TORQUE SPECIFICATIONS - GAS ENGINE

TORQUE SPECIFICATIONS - GAS ENGINE

FASTENER *
Engine Coolant Temperature Sensor (1.4L) 20 15 -
Engine Coolant Temperature Sensor (2.4L) 18 13 -
Idler Pulley Bolt (2.4L) 50 37 -
Oil Cooler Pipe Bolts 8 - 71
Thermostat Housing Bolts (1.4L) 10 - 89
Water Pump (1.4L)
M6 Nut 9 - 80
M6 Bolts 9 - 80
Water Pump Bolts (2.4L) 22 16 -
Water Pump Inlet Tube-to-Block Bolts (2.4L) 24 18 -
Water Pump Inlet Tube-to-Water Pump Housing

24 18 -
Nuts (2.4L)
Water Pump-to-Water Pump Adapter Bolts

22 16 -
(2.4L)
Water Pump Pulley Bolts (2.4L) 9 - 80
* NEW FASTENERS: Do not reuse these fasteners. If removed, a new fastener must be installed and
tighten to specifications.
Engine cooling system Test sealing of the

1895377001 *
leak test kit engine cooling system
Test capacity of the

2000030200 * Fitting
cooling system
ACCESSORY DRIVE > BELT, SERPENTINE > DIAGNOSIS AND TESTING >
DIAGNOSIS AND TESTING - SERPENTINE BELT
Fig 1: Serpentine Accessory Drive Belt Wear Patterns
1 - NORMAL CRACKS, BELT OK
2 - ABNORMAL CRACKS, REPLACE BELT
When diagnosing serpentine drive belts, small cracks (1) that run across ribbed surface of belt from rib
to rib, are considered normal. These are not a reason to replace belt. However, cracks running along a
rib (not across) are not normal. Any belt with cracks running along a rib must be replaced. Also replace
belt if it has excessive wear, frayed cords or severe glazing.
SERPENTINE DRIVE BELT DIAGNOSIS CHART

BELT SEPARATION (ONE OR 1. Foreign objects imbedded in 1. Remove foreign objects from
MORE RIBS HAS SEPARATED pulley grooves. pulley grooves. Replace belt.
FROM BELT BODY) Correct the root cause of the
foreign objects in the belt/pulley
system.
2. Fluids contacting the belt. 2. Identify the source of the fluid

and correct as necessary.
RIB OR BELT WEAR 1. Pulley(s) misaligned. 1. Align pulley(s).
2. Fluid contamination. 2. Clean pulley(s). Replace belt if

necessary.
3. Rusted pulley(s). 3. Clean rust from pulley(s).
4. Sharp or jagged pulley groove 4. Replace pulley.

tips.
5. Rubber deteriorated. 5. Replace belt.
LONGITUDINAL BELT CRACKING 1. Belt has clashed with the 1. Replace belt. Align pulley(s),
(CRACKS BETWEEN TWO RIBS) pulley grooves. components as necessary.
2. Pulley groove tip has worn 2. Replace belt.

away rubber to tensile member.
BELT SLIPS 1. Belt slipping because of 1. Replace automatic belt

insufficient tension. tensioner.
2. Belt routed incorrectly. 2. Verify belt routing.
3. Incorrect belt. 3. Replace belt.
4. Belt or pulley subjected to 4. Replace belt and clean

substance (belt dressing, oil pulleys.
ethylene glycol) that has reduced
friction.
5. Driven component bearing 5. Replace faulty component

failure. bearing.
6. Belt glazed and hardened from 6. Replace belt.

heat and excessive slippage.
"GROOVE JUMPING" (BELT 1. Belt tension either too high or 1. Replace automatic belt
DOES NOT MAINTAIN CORRECT too low. tensioner.
POSITION ON PULLEY)
2. Belt routed incorrectly. 2. Verify belt routing.
4. Pulley(s) not within design 4. Replace pulley(s).

tolerance.
5. Foreign object(s) in grooves. 5. Remove foreign objects from

grooves.
6. Pulley misalignment. 6. Inspect pulleys and
accessories. Inspect the
mounting components. Apply
chalk to the edges of the belt and
rotate the engine 2-3 revolutions
to transfer the chalk to the
misaligned pulley. Adjust or
replace as necessary.
7. Belt cord line is broken. 7. Replace belt.
BELT BROKEN (NOTE: IDENTIFY 1. Excessive tension. 1. Replace belt and automatic
AND CORRECT PROBLEM belt tensioner.
BEFORE NEW BELT IS
INSTALLED)
3. Tensile member damaged 3. Replace belt.
during belt installation.
4. Severe misalignment. 4. Check and replace.
5. Bracket, pulley, or bearing 5. Replace defective component

failure. and belt.
6. Inspect for smooth rotation of

6. Component failure/locked up
all component pulleys. Repair
pulley.
failed component.
NOISE (OBJECTIONABLE 1. Belt slippage. 1. Replace belt or automatic belt

SQUEAL, SQUEAK, OR RUMBLE tensioner.
IS HEARD OR FELT WHILE
2. Bearing noise. 2. Locate and repair.
DRIVE BELT IS IN OPERATION)
3. Belt misalignment. 3. Replace belt.
4. Belt-to-pulley mismatch. 4. Install correct belt.
ACCESSORY DRIVE > BELT, SERPENTINE > REMOVAL AND INSTALLATION > 1.4L
MULTIAIR > REMOVAL
Fig 1: Belt Tensioner, Serpentine Belt & Bolt
3. Using a suitable removal tool, rotate belt tensioner to release the tension and remove the
MULTIAIR > INSTALLATION
1. Inspect the serpentine belt and pulleys for damage.
2. Rotate the belt tensioner and install the serpentine belt (1c).
ACCESSORY DRIVE > BELT, SERPENTINE > REMOVAL AND INSTALLATION >
1.6L/2.0L DIESEL > REMOVAL
3. Using a suitable tool, rotate the belt tensioner (1b) and insert the locking pin.
4. Remove the serpentine belt (1c).
ACCESSORY DRIVE > BELT, SERPENTINE > REMOVAL AND INSTALLATION >
1.6L/2.0L DIESEL > INSTALLATION
1. Inspect the serpentine belt for damage or wear.
2. Inspect the pulleys for damage.
3. Install the serpentine belt (1c) over all pulleys.
4. Using a suitable tool, rotate the belt tensioner (1b) and remove the locking pin.
5. Check the serpentine belt (1c) for proper alignment.
170 CV DIESEL > REMOVAL
cable.
3. Remove the right side front wheel.
4. Remove fasteners and the inner fender splash shield (1).
CAUTION:
Do not allow the tensioner to snap back to the unloaded position. Damage to the
tensioner may occur.
Fig 1: Accessory Drive Belt Routing - 2.0L Diesel
5. Using a wrench, rotate the belt tensioner until the locking pin can be installed.
6. Remove the accessory drive belt (1).
170 CV DIESEL > INSTALLATION
Fig 1: Accessory Drive Belt Routing - 2.0L Diesel
1. Install belt over all pulleys.
2. Using a wrench, rotate the cam tensioner (5) until the locking pin can be removed from the
tensioner (8).
3. Check the belt for proper alignment.

4. Install the lower belt splash shield (2).
5. Install the right side front wheel.
MULTIAIR > REMOVAL
3. Using a suitable removal tool, rotate belt tensioner (1b) to release the tension and remove the
1. Inspect the serpentine belt and pulleys for damage.
ENGINE > BOTTLE, PRESSURIZED COOLANT > REMOVAL AND INSTALLATION >
1.4L MULTI AIR 1.6L/2.0L DIESEL > REMOVAL
Fig 1: Degas Hose & Coolant Hose
1. Remove the engine cover. For 1.6/2.0L, refer to COVER, ENGINE, REMOVAL AND
4. Loosen the clamp and remove the degas hose (1) from the pressurized coolant bottle.
5. Release the clip remove the coolant hose (2) from the pressurized coolant bottle.
Fig 2: Retaining Clips
6. Lift the clips (1a) and slide the pressurized coolant bottle to the left and disengage the retaining
clips (1b).
Fig 3: Pressurized Coolant Bottle & Clips
7. Squeeze the clips (1a) and remove pressurized coolant bottle (1b).
1.4L MULTI AIR 1.6L/2.0L DIESEL > INSTALLATION
1. Install the pressurized coolant bottle (1b) and engage the retaining clips (1a).
2. Slide the pressurized coolant bottle to the right and engage the retaining clips (1b). Push the
clip (1a) to lock.
3. Install the coolant hose (2) onto the pressurized coolant bottle and engage the clip.
4. Install the degas hose (1) onto the pressurized coolant bottle and tighten the clamp.
6. Install the engine cover. For 1.6/2.0L, refer to COVER, ENGINE, REMOVAL AND
8. Run the engine until it reaches normal operating temperature. Check cooling system for leaks
and correct fluid level. Refer to STANDARD PROCEDURE .
2.4L MULTI AIR > REMOVAL
3. Loosen the clamp and remove the degas hose (1) from the pressurized coolant bottle.
4. Release the clip remove the coolant hose (2) from the pressurized coolant bottle.
5. Lift the clips (1a) and slide the pressurized coolant bottle to the left and disengage the retaining
clips (1b).
6. Squeeze the clips (1a) and remove pressurized coolant bottle (1b).
2.4L MULTI AIR > INSTALLATION
1. Install the pressurized coolant bottle (1b) and engage the retaining clips (1a).
2. Slide the pressurized coolant bottle to the right and engage the retaining clips (1b). Push the
clip (1a) to lock.
3. Install the coolant hose (2) onto the pressurized coolant bottle and engage the clip.
4. Install the degas hose (1) onto the pressurized coolant bottle and tighten the clamp.
7. Run the engine until it reaches normal operating temperature. Check cooling system for leaks
and correct fluid level. Refer to STANDARD PROCEDURE .
ENGINE > CAP, RADIATOR > DESCRIPTION AND OPERATION > DESCRIPTION AND
OPERATION
Fig 1: Radiator Cap
The pressure cap is located on top of the pressurized coolant bottle. The cap releases pressure at 1.4
bar (20.3 psi). The pressure relief point (in bar) is noted on top of the cap (1).
The cooling system will operate at pressures slightly above atmospheric pressure. This results in a
higher coolant boiling point allowing increased radiator cooling capacity. The cap contains a spring-
loaded pressure relief valve. This valve opens when system pressure reaches 1.4 bar (20.3 psi).
An O-ring gasket seals the pressurized coolant bottle. This is done to maintain vacuum during coolant
cool-down and to prevent leakage when system is under pressure.
ENGINE > CAP, RADIATOR > DIAGNOSIS AND TESTING > RADIATOR CAP
Remove the cap. Be sure that the sealing surfaces are clean. Moisten the rubber gasket with water and
install the cap on a commercially available pressure tester.
Using the cooling system tester, bring the pressure up to the pressure prescribed on cap. If the pressure
cap fails to hold up to 20 psi, replace the cap.
NOTE:
The cap is designed to hold up to 20 psi. If during the test, the pressure rapidly bleeds off
prior to 20 psi, the cap has failed.
The pressure cap may test properly while positioned on the pressure test tool. It may not hold pressure
or vacuum when installed on the pressurized coolant bottle. If the test passes on the tool but there is
sufficient evidence that the cap fails on the bottle, inspect the coolant bottle neck for damage or debris
that may prevent the cap from sealing properly.
CAUTION:
Radiator pressure testing tools are very sensitive to small air leaks which will not cause
cooling system problems. A pressure cap that does not have a history of coolant loss
should not be replaced just because it leaks slowly when tested with this tool. Add water to
tool. Turn tool upside down and recheck pressure cap to confirm that cap needs
replacement.
ENGINE > CAP, RADIATOR > INSPECTION > INSPECTION

Fig 1: Radiator Cap O-Ring
The vent valve in the cap is normally closed.
If the O-ring seal (1) is damaged, replace the cap.
A replacement cap must be the type designed for use on a pressurized coolant bottle.
ENGINE > COOLANT > DESCRIPTION AND OPERATION > DESCRIPTION AND
OPERATION
WARNING:
Antifreeze is an ethylene-glycol base coolant and is harmful if swallowed or inhaled. If

swallowed, drink two glasses of water and induce vomiting. If inhaled, move to fresh air
area. Seek medical attention immediately. Do not store in open or unmarked containers.
Wash skin and clothing thoroughly after coming in contact with ethylene-glycol. Keep out of
reach of children. Dispose of glycol base coolant properly, contact your dealer or
government agency for location of collection center in your area. Do not open a cooling
system when the engine is at operating temperature or hot under pressure, personal injury
can result. Avoid radiator cooling fan when engine compartment related service is
performed, personal injury can result.
CAUTION:
Mopar® Antifreeze/Coolant, is a Lifetime of Engine Formula. IT MAY NOT BE MIXED WITH

ANY OTHER TYPES OF ANTIFREEZE. Mixing of coolants other than specified (non-OAT
or other OAT), may result in engine damage that may not be covered under the new vehicle
warranty, and decreased corrosion protection.
CAUTION:
Mixing of engine coolant (antifreeze) other than specified Organic Additive Technology
(OAT) engine coolant (antifreeze), may result in engine damage and may decrease
corrosion protection. Organic Additive Technology (OAT) engine coolant is different and
should not be mixed with Hybrid Organic Additive Technology (HOAT) engine coolant
(antifreeze). If a non-OAT engine coolant (antifreeze) is introduced into the cooling system in
an emergency, it should be replaced with the specified engine coolant (antifreeze) as soon
as possible.
Only use the coolant specified for this vehicle. Refer to CAPACITIES AND RECOMMENDED FLUIDS,
SPECIFICATIONS .
The cooling system is designed around the coolant. The coolant must accept heat from engine metal, in
the cylinder head area near the exhaust valves and engine block. Then coolant carries the heat to the
radiator where the tube/fin radiator can transfer the heat to the air.
The use of aluminum cylinder blocks, cylinder heads, and water pumps requires special corrosion
protection. Mopar® Antifreeze/Coolant, or the equivalent ethylene-glycol base coolant with organic
corrosion inhibitors (called OAT, for Organic Additive Technology) is recommended. This coolant offers
the best engine cooling without corrosion when mixed with 50% ethylene-glycol and 50% distilled water
to obtain a freeze point of -37°C (-35°F). If it loses color or becomes contaminated, drain, flush, and
replace with fresh properly mixed coolant solution.
OAT coolant is a Life of the Engine coolant. Maintenance of the cooling system is not required unless
a repair has been made with loss of coolant or the coolant has been contaminated.
CAUTION:
Richer antifreeze mixtures cannot be measured with normal field equipment and can cause
problems associated with 100 percent ethylene-glycol.
The required ethylene-glycol (antifreeze) and water mixture depends upon climate and vehicle operating
conditions. The coolant performance of various mixtures follows:
Pure Water- Water can absorb more heat than a mixture of water and ethylene-glycol, but this is not
suitable for use in a cooling system. Water also freezes at a lower temperature, boils at a higher
temperature and allows corrosion.
100 percent Ethylene-Glycol - The corrosion inhibiting additives in ethylene-glycol need the presence
of water to dissolve. Without water, additives form deposits in the system. These deposits act as
insulation causing the temperature to rise as high as 149°C (300°F). This temperature is hot enough to
melt plastic and soften solder. The increased temperature can result in engine detonation. In addition,
100 percent ethylene-glycol freezes at -22°C (-8°F).
50/50 Ethylene-Glycol and Water - Is the recommended mixture, it provides protection against
freezing to -37°C (-34°F). The antifreeze concentration must always be a minimum of 44 percent,
year-round in all climates. If the percentage is lower, engine parts may be eroded by cavitation.
Maximum protection against freezing is provided with a 68 percent antifreeze concentration, which
prevents freezing down to -67.7°C (-90°F). A higher percentage will freeze at a warmer temperature.
Also, a higher percentage of antifreeze can cause the engine to overheat because specific heat of
antifreeze is lower than that of water.
CAUTION:
Do not use coolant additives that are claimed to improve engine cooling.
ENGINE > COOLANT > DIAGNOSIS AND TESTING > DIAGNOSIS AND TESTING -
COOLANT CONCENTRATION TESTING
Check coolant concentration when any additional coolant is added to the system, or after a coolant
drain, flush and refill. Use of a hydrometer or the (special tool #8286, Refractometer) can be used to test
coolant concentration.
A hydrometer tests the amount of glycol in a mixture by measuring the specific gravity of the mixture. The
higher the concentration of ethylene glycol, the larger the number of balls that will float, and the higher
the freeze protection (up to a maximum of 60% by volume glycol).
The (special tool #8286, Refractometer) tests the amount of glycol in a coolant mixture by measuring the
amount a beam of light bends as it passes through the fluid.
Some coolant manufacturers use other types of glycols in their coolant formulations. Propylene glycol is
the most common new coolant. However, propylene glycol based coolants do not provide the same
freezing protection and corrosion protection and are not recommended.
CAUTION:
Do not mix types of coolant - corrosion protection will be severely reduced.

ENGINE > FAN, COOLING > REMOVAL AND INSTALLATION > 1.4 MULTIAIR TURBO >
REMOVAL
Fig 1: Front Bumper Beam, Bolts & Nuts
4. Remove the bolts (1a), nuts (1b) and the front bumper beam (1c).
Fig 2: Charge Air Cooler Quick Coupling Sleeve
5. Disconnect the quick coupling sleeve (1) from the Charge Air Cooler (CAC).
Fig 3: Cooling Fan Bolts
6. Remove the cooling fan bolts (1).

Fig 4: Cooling Fan Wire Harness Connectors & Clips
7. Disconnect the resistor wire harness connector (1).
8. Disconnect the cooling fan wire harness connector (1).
9. Open the retaining clips (3) and detach the wire harness.
Fig 5: Coolant Pipe Retaining Clips
10. Open the retaining clips (1) and remove the coolant pipe.
Fig 6: Cooling Fan Upper Retaining Clips
11. Detach the cooling fan upper retaining clips.

Fig 7: Lower Bracket & Bolt
12. Support the radiator to the vehicle.
13. Remove the bolts (1) and the lower brackets that supports the radiator.
Fig 8: Cooling Fan
14. Unhook and remove the cooling fan (1).
ENGINE > FAN, COOLING > REMOVAL AND INSTALLATION > 1.4 MULTIAIR TURBO >
INSTALLATION
Fig 1: Cooling Fan
1. Install the cooling fan, and engage the retaining clips.

2. Install the lower radiator support brackets and securely tighten the bracket bolts (1).
3. Remove the support for the radiator.

4. Attach the cooling fan upper retaining clips.

5. Install the coolant pipe and close the retaining clips (1).
6. Attach the wire harness and close the retainer clips (3).
7. Connect the cooling fan wire harness connector (1).
8. Connect the resistor wire harness connector (1).

9. Install the cooling fan bolts (1) and securely tighten.

10. Connect the quick coupling sleeve (1) to the Charge Air Cooler (CAC).
11. Install the front bumper beam (1a) and tighten the nuts (1b) and bolts (1c) to the proper
12. Install the front bumper fascia. Refer to FASCIA, FRONT, REMOVAL AND INSTALLATION .
ENGINE > FAN, COOLING > REMOVAL AND INSTALLATION > 1.6L DIESEL >
REMOVAL
5. Remove the left side Charge Air Cooler (CAC) hose (1) from the CAC.
NOTE:
Left side shown in illustration, right side similar.
6. Remove the lower cooling fan mounting bolts (1)

8. Disconnect the cooling fan wire harness connectors (1 and 2).
9. Remove the wiring harness retaining clip and detach the wire harness (3).
10. Unlock retainer clips (1) and remove the coolant hose from fan shroud.
11. Disengage the upper cooling fan retaining clips.

13. Support the radiator to hold in place.
14. Remove the bolt and the lower radiator support bracket (1).
Fig 8: Cooling Fan
15. Unhook and remove the cooling fan (1) from the vehicle.
ENGINE > FAN, COOLING > REMOVAL AND INSTALLATION > 1.6L DIESEL >
INSTALLATION
Fig 1: Cooling Fan
1. Install the cooling fan (1) onto the radiator.

2. Install the lower radiator support bracket and securely tighten the bolts (1).
3. Remove the support holding the radiator in place.

5. Engage the upper cooling fan retaining clips (1).

6. Install the coolant hose onto the fan shroud and lock the retaining clips (1).
7. Attach the wiring harness and install the retaining clip (3).
8. Connect the cooling fan wire harness connector (1 and 2).

NOTE:
10. Install the lower cooling fan mounting bolts (1) and securely tighten.
11. Install the left side Charge Air Cooler (CAC) hose (1) to the CAC.
12. Install the front bumper (1c) with bolts (1a) and nuts (1b) tightened to the proper specification.
ENGINE > FAN, COOLING > REMOVAL AND INSTALLATION > 2.0L DIESEL 120/140
CV > REMOVAL
5. Remove the left side Charge Air Cooler (CAC) hose (1) from the CAC.
NOTE:
6. Remove the lower cooling fan mounting bolts (1)

7. Disconnect the resister wire harness connectors (1).
8. Disconnect the cooling fan wire harness connectors (2).
9. Remove the wiring harness retaining clip and detach the wire harness (3).
10. Unlock retainer clips (1) and remove the coolant hose from fan shroud.
11. Disengage the upper cooling fan retaining clips.

13. Support the radiator to hold in place.
14. Remove the bolt and the lower radiator support bracket (1).
Fig 8: Cooling Fan
15. Unhook and remove the cooling fan (1) from the vehicle.
ENGINE > FAN, COOLING > REMOVAL AND INSTALLATION > 2.0L DIESEL 120/140
CV > INSTALLATION
Fig 1: Cooling Fan
1. Install the cooling fan (1) onto the radiator.

2. Install the lower radiator support bracket and securely tighten the bolts (1).
3. Remove the support holding the radiator in place.

5. Engage the upper cooling fan retaining clips (1).

6. Install the coolant hose onto the fan shroud and lock the retaining clips (1).
7. Attach the wiring harness and install the retaining clip (3).
8. Connect the cooling fan wire harness connector (1 and 2).

NOTE:
10. Install the lower cooling fan mounting bolts (1) and securely tighten.
11. Install the left side Charge Air Cooler (CAC) hose (1) to the CAC.
12. Install the front bumper (1c) with bolts (1a) and nuts (1b) tightened to the proper specification.
ENGINE > FAN, COOLING > REMOVAL AND INSTALLATION > 2.0L DIESEL 170 CV >
REMOVAL
NOTE:
The cooling fan is integrated into the front radiator closure panel and can be removed
separately.

6. Working on the right side, remove the nut (1a) and slightly remove the Charge Air Cooler
(CAC) inlet tube (1b).
7. Remove the bolts (1a) and front energy absorber (1b).
8. Remove the three nuts (2a) and the front energy absorber (1b).
9. Remove the bolts (1a) securing the air cooler (1b).
10. Release the retainers (2a) from the seats (2b) of the front end
11. Remove the air cooler (1b).

Clips
12. Open the retaining clamps (1a) securing the transmission oil cooler pipes (1b).
13. Carefully disengage the retainer clips (2a) and disconnect the pipes (1b) from the transmission
oil cooler (2c). Recover oil drops leaking from the pipes and fittings.
NOTE:
14. Unscrew the screws (1a) and disconnect the fittings (1b) and (1c) of the pipes (1d) connection
to the condenser (1e).
Fig 6: Hose, Pipe, Clamp, Quick Coupling & Spring Retainer
15. Working on the lower right side of the radiators, disengage the spring retainer (1a) and
disconnect the quick coupling (1b) of the pipe (1c) of the engine coolant from the radiator.
16. Open the clamp (2a) and disconnect pipe (2b) from the Charge Air Cooler (CAC).
Fig 7: Quick Coupling, Pipe & Spring Retainer
17. Working on the lower left side of the radiators, disengage the spring retainer (1a) and
disconnect the quick coupling (1b) of the pipe (1c) from the CAC.
Fig 8: Pressurized Coolant Bottle, Retainers & Bracket
18. Lift and disengage the retainers (1a) and slide in the direction of the arrow brackets (1b) of the
pressurized coolant bottle (1c) of the engine coolant, by disengaging the retainers (1d).
19. Remove the pressurized coolant bottle (1c) after having disengaged its lower restraint.
Fig 9: Coolant Tube & Retainers
20. Disengage from the retainers (1a) and the coolant tube (1b).
Fig 10: Pipe, Quick Coupling, Retainer & Connector
21. Working on the upper left side of the radiators, disengage the spring retainer (1a) and
disconnect the quick coupling (1b) of the pipe (1c) of the engine coolant in the radiator inlet.
22. Disconnect the resistor wire harness connector (2a).

Fig 11: Covers & Retainers
23. Remove the covers (1a) for retaining the upper radiator, after having disengaged the central
retaining (1b) and upper retainers (1c) and lower (1d).
Fig 12: Radiator & Supports
24. Move the upper part of the radiator (1a) forward to disengage the supports (1b) from the seats.
Fig 13: Cooling Fan Wire Harness Connectors
25. Disconnect the cooling fan wire harness connectors (1a, 1b, 1c).
Fig 14: Radiator, Pins & Seats
26. Lift and remove the radiator with cooling fan (1a) disengaging its lower pins (1b) from the seats
(1c) of the front-end.
Fig 15: Cooling Fan, Retainers & Screws
27. Remove the screws (1a) of the lower fixing of the cooling fan (1b).
28. Disengage the retainer (2a), and slide the fan (1b) in the direction of the arrow (2b), then
disengage the retainer (2c).
29. Remove the cooling fan (1b) from the radiator.

ENGINE > FAN, COOLING > REMOVAL AND INSTALLATION > 2.0L DIESEL 170 CV >
INSTALLATION
Fig 1: Cooling Fan, Retainers & Screws
1. Check that the cooling fan is not damaged.
2. Position the cooling fan (1a) onto radiator unit.

3. Engage the retainer (2a), and slide the fan (1a) in the direction of the arrow (2b).
4. Engage the retainer (3a).
5. Securely tighten the screws (4a) of the lower fixing the electric fan (1a).
Fig 2: Radiator, Pins & Seats
6. Position and engage the lower pins (1a) of the radiator with cooling fan (1b) in the seats (1c) of
the front-end.
7. Working on the inner side of the radiator unit, connect the cooling fan wire harness connectors
(1a, 1b, 1c).
Fig 4: Radiator & Supports
8. Position the upper part of the radiator (1a) in the seats (1b) and engage the elastic supports.
Fig 5: Covers & Retainers
9. Install the cover (1a) for retaining the upper radiator, and then engage the central retaining (1b)
and upper retainers (1c) and lower (1d).
Fig 6: Pipe, Quick Coupling, Retainer & Connector
10. Connect the resistor wire harness connector (1a).
11. Connect the quick coupling (2a) of the pipe (2b) of the engine coolant in the radiator inlet, and
then engage the clip retainer (2c).
Fig 7: Coolant Tube & Retainers
12. Engage the coolant tube (1b) and the retainers (1a).
Fig 8: Pressurized Coolant Bottle, Retainers & Bracket
13. Install the pressurized coolant bottle (1a) and engage the lower retainer
14. Slide in the direction of the arrow brackets (2a) of the pressurized coolant bottle (1a), by
engaging the retainers (2b), then engage the retainers (2c).
Fig 9: Quick Coupling, Pipe & Spring Retainer
15. Working on the lower left side of the radiator, connect the quick coupling (1b) of the pipe (1c)
to the Charge Air Cooler (CAC), then engage the retaining clip (1a).
Fig 10: Hose, Pipe, Clamp, Quick Coupling & Spring Retainer
16. Working on the lower right side of the radiator, connect the quick coupling (1b) of the pipe (1c)
onto the radiator, then engage the retaining clip (1a).
17. Connect the pipe (2b) to the CAC, then apply the clamp (2a).
NOTE:
Replace the O-ring sealing fittings. Use only O-ring seal washer with part HNBR
elastomeric material resistant to refrigerant R1234 yf. The use of rings seal washer
with other elastomeric material is liable to give serious losses of refrigerant from the
air conditioner.
18. Using NEW O-ring sealing washers, connect the fittings (1a) and (1b) of the pipes (1c) to the
condenser (1d). Tighten the bolts (1e) to the proper specification. Refer to SPECIFICATIONS .
Fig 12: Transmission Oil Cooler Pipes & Retaining Clamps, Transmission Oil Cooler &
Retaining Clips
19. Connect the pipes (1a) to the fittings (1b) on the transmission oil cooler (1c), then engage the
retaining clips (1d).
20. Close the retainer clips (2a) securing the transmission oil cooler pipes (1a).
21. Install the air cooler (1a) and engage the retainers (1b) in the seats (1c).
22. Install the bolts (2a) securing the air cooler (1a) and securely tighten the bolts.
23. Install the front energy absorber (1a) and securely tighten the three nuts (1b).
24. Tighten the front bumper reinforcement to the proper specification. Refer to SPECIFICATIONS
.
25. Working on the right side, Install the nut securing the CAC tube (1b).
26. Install the front bumper cover.
30. Check the automatic transmission fluid level and fill with the recommended transmission fluid.
Refer to CAPACITIES AND RECOMMENDED FLUIDS, SPECIFICATIONS .
ENGINE > FAN, COOLING > REMOVAL AND INSTALLATION > 2.4L MULTI AIR >
REMOVAL
Fig 1: Exhaust Heat Shield, Nuts & Bolts
2. Remove the bolts (1a) and nuts (1b) and the exhaust heat shield (1c).
Fig 2: Transmission Oil Cooler Lines & Clips
3. Remove the retaining clips (1a) and disconnect the transmission oil cooler line (1b).
4. Plug and seal the ends of the transmission cooler lines and lines disconnected, to prevent
leakage of oil or moisture, contaminates, or impurities entering into the system.
Fig 3: Pressurized Coolant Bottle & Fasteners
5. Remove the fasteners (1a) and the pressurized coolant bottle (1b).
Fig 4: Cooling Fan Wire Harness Connectors & Retainers
6. Disconnect the resistor wire harness connector (1a).
7. Disconnect the cooling fan wire harness connector (1b).
8. Detach the wire harness retainer (1c) from fan shroud.
9. Open the retainer (2b) detach the cooler lines from retainer.
Fig 5: Cooling Fan & Brackets
10. Release the retaining brackets (1a) and remove the cooling fan (1b).
ENGINE > FAN, COOLING > REMOVAL AND INSTALLATION > 2.4L MULTI AIR >
INSTALLATION
Fig 1: Cooling Fan & Brackets
1. Install the cooling fan (1b) and engage the retaining brackets (1a).
Fig 2: Cooling Fan Wire Harness Connectors & Retainers
2. Attach the cooler lines to the retainer and close the retainer (2b).
3. Attach the wire harness retainer (1c) from fan shroud.
4. Connect the cooling fan wire harness connector (1b).
5. Connect the resistor wire harness connector (1a).

Fig 3: Pressurized Coolant Bottle & Fasteners
6. Install the pressurized coolant bottle (1b) and the fasteners (1a).
Fig 4: Transmission Oil Cooler Lines & Clips
7. Remove the plugs from the cooler lines an cooler.
8. Connect the transmission oil cooler line (1b) and the retaining clips (1a).
Fig 5: Exhaust Heat Shield, Nuts & Bolts
9. Install he exhaust heat shield (1c) and securely tighten the nuts (1b) and bolts (1a).
ENGINE > PUMP, WATER > REMOVAL AND INSTALLATION > 1.4L MULTI AIR 4X2
PRIMARY > REMOVAL
7. Remove the vibration damper. Refer to DAMPER, VIBRATION, REMOVAL AND INSTALLATION
.
8. Remove the engine cover.
9. Remove the air cleaner body. Refer to BODY, AIR CLEANER, REMOVAL AND INSTALLATION
.
Fig 1: Waste-Gate Actuator Air Control Valve Piping, Inlet Air Hose, Return Line & Couplings
11. Disconnect the fuel vapor pipe quick coupling (1).
12. Disconnect the engine oil vapor pipe quick coupling (2).
13. Loosen the clamp and disconnect the Waste-Gate actuator air control valve piping (3).
14. Loosen the clamp and disconnect the waste-gate air solenoid return line (4).
15. Loosen the clamp and remove the inlet air hose (5) to the turbocharger.
Fig 2: Inner Timing Belt Cover, Water Pump, Nuts & Bolts
16. Remove the bolt and the inner timing belt cover (1).
17. Remove the nut (2a) and the bolts (2b) and the water pump (2c).
PRIMARY > INSTALLATION

Fig 1: Sealant
2. Apply a bead of sealant in the groove shown in the illustration of the new water pump (1).
3. Install the water pump (1a). Tighten the bolts (1b) and nut (1c) to the proper specification.
4. Install the inner timing belt cover (2). Tighten the bolt to the proper specification. Refer to
SPECIFICATIONS .
Fig 3: Waste-Gate Actuator Air Control Valve Piping, Inlet Air Hose, Return Line & Couplings
5. Install the inlet air hose (5) onto the turbocharger and securely tighten the clamp.
6. Connect the wastegate air solenoid return line (4) and securely tighten the clamp.
7. Connect the wastegate actuator air control valve piping (3) and securely tighten the clamp.
8. Connect the engine oil vapor pipe quick coupling (2).
9. Connect the fuel vapor pipe quick coupling (1).
12. Install the engine cover.
15. Evacuate air and fill the cooling system. Refer to STANDARD PROCEDURE .
PRIMARY > REMOVAL
7. Remove the vibration damper. Refer to DAMPER, VIBRATION, REMOVAL AND INSTALLATION
.
.
Fig 1: Waste-Gate Actuator Air Control Actuator Tube, Engine Oil Vapor Pipe Quick Coupling &
Clip
11. Open the retaining clip (1) and disengage the Waste-Gate actuator air control actuator tube.
12. Disconnect the engine oil vapor pipe quick coupling (2).
Fig 2: Inlet Air Hose To The Turbocharger, Solenoid Hose, Retainer & Clamp
13. Open the clip retainer (1a) Loosen the clamp and disconnect the Waste-Gate air control
solenoid hose (1b).
14. Loosen the clamp (2a) and remove the inlet air hose to the turbocharger (2b).
15. Remove the bolt and the inner timing belt cover (1).
16. Remove the nut (2a) and the bolts (2b) and the water pump (2c).
PRIMARY > INSTALLATION

Fig 1: Sealant
2. Apply a bead of sealant (1) in the groove shown in the illustration of the new water pump.
3. Install the water pump (1a). Tighten the bolts (1b) and nut (1c) to the proper specification.
Fig 3: Inlet Air Hose To The Turbocharger, Solenoid Hose, Retainer & Clamp
4. Install the inlet air hose onto the turbocharger (2b) and securely tighten the clamp (2a).
5. Connect the wastegate air control solenoid hose (1b) and securely tighten the clamp and close
the clip retainer (1a).
Fig 4: Waste-Gate Actuator Air Control Actuator Tube, Engine Oil Vapor Pipe Quick Coupling &
Clip
6. Connect the engine oil vapor pipe quick coupling (2).
7. Engage the Waste-Gate actuator air control actuator tube and close the retaining clip (1).
13. Evacuate air and fill the cooling system. Refer to STANDARD PROCEDURE .

SECONDARY > REMOVAL

Fig 1: Water Pump Retaining Collar & Clip
4. Release the clip (1a) and remove the water pump retaining collar (1b).
Fig 2: Secondary Water Pump, Wire Harness Connector, Hoses & Clamps
5. Disconnect the secondary water pump wire harness connector (1).
6. Undo the clamps and remove the coolant hoses (2) from the secondary water pump (3) and
remove the secondary water pump (3).
SECONDARY > INSTALLATION
Fig 1: Secondary Water Pump, Wire Harness Connector, Hoses & Clamps
1. Install the coolant hoses (2) to the secondary water pump (3) and tighten the clamps.
2. Connect the secondary water pump wire harness connector (1).

Fig 2: Water Pump Retaining Collar & Clip
3. Install the water pump retaining collar (1b) and engage the spring lock (1a).
ENGINE > PUMP, WATER > REMOVAL AND INSTALLATION > 1.6L DIESEL >
REMOVAL
6. Remove the bolts (1a) and the water pump (1b).
7. Remove and discard the water pump gasket.
INSTALLATION
1. Install a NEW gasket seal on the water pump by folding the retaining tabs (1).
2. Install the water pump (1a). Tighten the bolts (1b) to the proper specification. Refer to
SPECIFICATIONS .
6. Evacuate the air and fill the cooling system. Refer to STANDARD PROCEDURE .
8. Check cooling system for leaks. Refer to LEAK TESTING .
REMOVAL

6. Remove the bolts (1a) and the water pump (1b).
7. Remove and discard the water pump gasket.
INSTALLATION
1. Install a NEW gasket seal on the water pump by folding the retaining tabs (1).
2. Install the water pump (1a). Tighten the bolts (1b) to the proper specification. Refer to
SPECIFICATIONS .
6. Evacuate the air and fill the cooling system. Refer to STANDARD PROCEDURE .
8. Check cooling system for leaks. Refer to LEAK TESTING .
ENGINE > PUMP, WATER > REMOVAL AND INSTALLATION > 2.4L MULTI AIR >
REMOVAL
8. Remove the bolts (1a) and the water pump (1b) and the gasket.
9. Clean the water pump mounting surface (1).
ENGINE > PUMP, WATER > REMOVAL AND INSTALLATION > 2.4L MULTI AIR >
INSTALLATION
1. Install a NEW gasket (1) onto the water pump.

2. Install the water pump (1a). Tightened the five bolts (1b) in a criss-cross pattern to the proper
to SPECIFICATIONS .
9. Run the engine until it reaches normal operating temperature. Check the cooling system for
correct fluid level or leaks. Refer to STANDARD PROCEDURE .
ENGINE > PUMP, WATER > REMOVAL AND INSTALLATION > 2.4L MULTI AIR WATER
PUMP BODY > REMOVAL

.
Fig 2: Water Pump Body, Nuts & Bolts
12. Remove the nuts (1) securing the coolant tube to the water pump body (2b).
13. Remove the bolts (2a) and the water pump body (2b).

15. If necessary, remove the bolts (1) and the water pump.
ENGINE > PUMP, WATER > REMOVAL AND INSTALLATION > 2.4L MULTI AIR WATER
PUMP BODY > INSTALLATION
1. If removed, install a NEW gasket (1) onto the water pump.

2. If removed, install the water pump. Tightened the five bolts (1) in a criss-cross pattern to the
Fig 3: Water Pump Body, Nuts & Bolts
3. Using a NEW gasket, install the water pump body (1a). Tighten the bolts (1b) to the proper
4. Install the nuts (2) securing the coolant tube to the water pump body (1b) and tighten to the
to SPECIFICATIONS .
correct fluid level or leaks. Refer to STANDARD PROCEDURE .

ENGINE > RADIATOR, ENGINE COOLING > REMOVAL AND INSTALLATION > 1.4L
MULTIAIR TURBO > REMOVAL
6. Working on both sides, Remove the bolts (1a), nuts (1b) and the front bumper reinforcement
(1c).
Fig 2: Upper Radiator Hose & Clip
7. Release spring clip and remove the upper radiator hose (1).
Fig 3: Charge Air Cooler Hose & Clip
8. Release spring clip and remove the Charge Air Cooler (CAC) hose (1).
10. Disconnect the cooling fan resistor wire harness connector (2).
Fig 5: Coolant Hose Clips
11. Open the retaining clips (1) and remove the coolant hose.
Fig 6: A/C Lines, Clips & Bolts
12. Open the retaining clips (1a) then remove the bolts (1b) and the A/C lines from the condenser.
Fig 7: Lower Radiator Hose Clip & CAC Hose Clamp
13. Release spring clip and remove the lower radiator hose (1).
14. Loosen the clamp (2) and remove the CAC hose.
Fig 8: Clips
15. Lift the spring clip (1a) and disengage the clips (1b).
Fig 9: Radiator Retaining Block & Spring
16. Working on both sides, to compress the spring (1a) to disengage and remove the radiator
retaining block (1b).
Fig 10: Radiator & Tab
17. Working on both sides, disengage the upper tabs and remove the radiator assembly (1).
Fig 11: Air Deflector Bolts
18. Remove the bolts (1) and the air deflector.

Fig 12: Air Duct Clips
19. Detach the retaining clips and remove the air duct (1).
Fig 13: Condenser & Clips
20. Compress the clips and remove the condenser (1).

Fig 14: Charge Air Cooler
21. Unlock tabs and remove the CAC (1).

Fig 15: Cooling Fan, Clips & Bolts
23. Unhook the clips and remove the cooling fan (2) from the radiator.
MULTIAIR TURBO > INSTALLATION
1. Install the cooling fan (2) onto the radiator and engage the retaining clips.

3. Install the Charge Air Cooler (1) and engage the retainers.
4. Install the condenser (1) to the radiator and engage the retaining clips.
5. Install the air duct (1) and engage the retaining clips.
6. Install the CAC air deflector and securely tighten the bolts (1).
7. Install the radiator assembly (1) and engage the upper tabs on both sides.
8. Install the radiator retaining block (1b) and engage the spring clips on both sides.
Fig 8: Clips
9. Engage the clips (1b) and lock the spring clip (1a).
10. Install the CAC hose and securely tighten the clamp (2).
11. Install the lower radiator hose (1) and engage the spring clip.
12. Install the A/C lines to the condenser and securely tighten the bolts (1b) and close the retainer
clips (1a).
13. Install the coolant hose and close the retaining clips (1).
14. Connect the cooling fan resistor wire harness connector (2).

16. Install the CAC hose (1) and engage the spring clip.
17. Install the upper radiator hose (1) and engage the spring clip.
18. Install the front bumper crossbar (1a) and working from both sides, tighten the bolts (1c) and
the nuts (1b) to the proper specification. Refer to SPECIFICATIONS .
DIESEL > REMOVAL

6. Working on both sides, remove the bolts (1a), nuts (1b) and the front bumper reinforcement
(1c).
7. Remove the upper radiator hose (1).

8. Remove the left side Charge Air Cooler (CAC) hose (1).
10. Disconnect the cooling fan resistor wire harness connector (2).
11. Unlock retaining clips (1) and remove the coolant hose from fan shroud.
12. Open the retaining clips (1a), remove the bolts (1b) and the A/C lines from the condenser.
13. Remove the lower radiator hose (1).
14. Loosen clamp (2) and remove the right side CAC hose.
Fig 8: Clips
15. Lift the spring (1a) and disengage the clips (1b).
16. Working on both sides, to compress the spring (1a) and remove the retaining block (1b).
17. Working on both sides, disengage the upper tabs and remove the radiator assembly (1).
18. Remove the bolts (1) and the air deflector.

19. Detach the retaining clips and remove the air duct (1).
20. Compress the clips and remove the condenser (1).

21. Unlock tabs and remove the CAC (1).

23. Unhook the clips and remove the cooling fan (2) from the radiator.
1. Install the cooling fan (2) onto the radiator and engage the retaining clips.

3. Install the Charge Air Cooler (1) and engage the retainers.
4. Install the condenser (1) to the radiator and engage the retaining clips.
5. Install the air duct (1) and engage the retaining clips.
6. Install the CAC air deflector and securely tighten the bolts (1).
7. Install the radiator assembly (1) and engage the upper tabs on both sides.
8. Install the radiator retaining block (1b) and engage the spring clips on both sides.
Fig 8: Clips
9. Engage the clips (1b) and lock the spring clip (1a).
10. Install the CAC hose and securely tighten the clamp (2).
11. Install the lower radiator hose (1) and engage the spring clip.
12. Install the A/C lines to the condenser and securely tighten the bolts (1b) and close the retainer
clips (1a).
13. Install the coolant hose and close the retaining clips (1).
14. Connect the cooling fan resistor wire harness connector (2).

16. Install the CAC hose (1) and engage the spring clip.
17. Install the upper radiator hose (1) and engage the spring clip.
18. Install the front bumper crossbar (1a) and working from both sides, tighten the bolts (1c) and
the nuts (1b) to the proper specification. Refer to SPECIFICATIONS .
DIESEL 120/140 CV > REMOVAL

6. Working on both sides, remove the bolts (1a), nuts (1b) and the front bumper reinforcement
(1c).
7. Disengage the retaining clip and remove the upper radiator hose (1).
8. Disengage the retaining clip and remove the Charge Air Cooler (CAC) hose (1).
9. Disconnect the cooling fan resister wire harness connectors (2).

11. Open retainer clips (1) and remove the coolant hose from fan shroud.
12. Open the retaining clips (1a) then remove the bolts (1b) and the A/C lines from the A/C
condenser.
13. Disengage the retaining clip and remove the lower radiator hose (1).
14. Loosen the clamp and remove the CAC hose (2).
Fig 8: Clips
15. Lift the spring (1a) and disengage the clips (1b) securing the block to the radiator.
16. Working on both sides, compress the spring (1a) then disengage and remove the cover block
(1b) securing the radiator.
17. Working on both sides, disengage the upper mount and remove the radiator (1).
18. Remove the bolts (1) securing the air duct.

19. Detach the clips above and remove the air duct (1).
20. Release the clips and remove the A/C condenser (1).
21. Unlock and remove the CAC (1).

22. Remove lower bolts (1) securing the cooling fan to the radiator.
23. Unhook the clips (2) and remove the cooling fan from the radiator.
DIESEL 120/140 CV > INSTALLATION
1. Care must be taken not to damage the radiator cooling fins and tubes during installation.
2. Install the cooling fan onto radiator and engage the upper retaining clips (2).
3. Install the lower cooling fan bolts (1) and securely tighten.
4. Install and lock the Charge Air Cooler (CAC) (1).

5. Install the A/C condenser (1) and engage the retaining clips.
6. Install the air duct (1) and attach the retaining clips.
7. Install the air duct bolt (1) and securely tighten.

8. Install the radiator (1) and engage the upper mounts.

9. Working on both sides, install the cover block (1b) securing the radiator and engage the
retaining clip (1a).
Fig 8: Clips
10. Engage the clips (1b) securing the block to the radiator and engage spring (1a).
11. Install the CAC hose and secure tighten the clamp (2).
12. Install the lower radiator hose and engage the retaining clip (1).
13. Using new gasket seals, install the A/C lines and securely tighten the bolts (1b) then close the
retaining clips (1a).
14. Install the coolant hose onto the fan shroud and close the retaining clips.
16. Connect the cooling fan resister wire harness connectors (2).
17. Install the CAC hose (1) and engage the retaining clip.
18. Install the upper radiator hose (1) and engage the retaining clip.
19. Install the front bumper reinforcement (1c). Tighten the bolts (1a) and the nuts (1b) to the
25. Operate the engine until it reaches normal operating temperature. Check the cooling system for
correct fluid level.
DIESEL 170 CV > REMOVAL
2. Remove the cooling fan. Refer to FAN, COOLING, REMOVAL AND INSTALLATION .
Fig 1: Cooler Bolts & Retaining Tab
3. Remove the upper bolts (1a) and retaining tab (1b) securing the cooler.
Fig 2: A/C Condenser/Transmission Oil Cooler & Pins
4. Disengage the lower pins (1b) and remove the A/C condenser/transmission oil cooler (1a).
Fig 3: Radiator
5. Remove the radiator (1).
DIESEL 170 CV > INSTALLATION
Fig 1: Radiator
1. Inspect the radiator for damage (1). Remove the bolts (1a) and retaining tab (1b) securing the
cooler.
Fig 2: A/C Condenser/Transmission Oil Cooler & Pins
2. Install the A/C condenser/transmission oil cooler (1a) and engage the lower pins (1b).
Fig 3: Cooler Bolts & Retaining Tab
3. Install the upper bolts (1a) securing the cooler and securely tighten.
4. Install the cooling fan. Refer to FAN, COOLING, REMOVAL AND INSTALLATION .

MULTIAIR > REMOVAL

Fig 1: Air Cleaner Inlet Tube & Nut
5. Remove the nut (1a) and the air cleaner inlet tube (1b).
Fig 2: Front Bumper Reinforcement, Bolts & Nuts
6. Remove the bolts (1a) and the nuts (1b) and the front bumper reinforcement (1c).
Fig 3: Radiator Air Deflector, Retainers & Bolts
7. Remove the bolts (1a) and disengage the retainers side (1b) and remove the radiator air
deflector (1c).
Fig 4: Transmission Cooler, Lines & Clips
NOTE:
Plug and seal the ends of the transmission cooler and the transmission cooler lines
to prevent leakage of oil, or moisture, contaminates, or impurities from entering into
the system.
NOTE:
Clean any transmission fluid the may have leaked out during the removal process.
8. Remove the retaining clips (1a) and the transmission cooler lines (1b) from the transmission
cooler (1c).
Fig 5: Transmission Oil Cooler & Retainers
9. Disengage the retainers (1a) and remove the transmission oil cooler (1b).
Fig 6: A/C Lines & Bolts
10. Remove the bolt (1a) and the A/C line (1b) from the condenser.
11. Remove the bolt (2a) and the A/C line (2b) from the condenser.
Fig 7: A/C Condenser & Clips
12. Remove the retaining clips (1a) and the A/C condenser (1b).
Fig 8: Wiring Harnesses, Connectors & Clip
13. Disconnect the cooling fan wire harness connector (1b) and the cooling fan resistor wire
harness connector (1a). and detach the wire harness (1c).
14. Open the retaining clip (2b) and detach the lines.
Fig 9: Upper And Lower Radiator Hoses
15. Remove the upper radiator hose (1).
16. Remove the lower radiator hose (2).

Fig 10: Radiator/Cooling Fan Assembly & Brackets
NOTE:
Recover any coolant that may have spilled.
17. Remove the covers.

18. Remove the retaining brackets (2a) and the radiator/cooling fan assembly (2b).
Fig 11: Cooling Fan & Tabs
19. Disengage the retaining tabs (1a) and remove the cooling fan (1b).
1. Inspect the radiator for damage.
Fig 1: Cooling Fan & Tabs
2. Install the cooling fan (1b) onto the radiator and engage retaining tabs (1a).
Fig 2: Radiator/Cooling Fan Assembly & Brackets
3. Install the radiator/cooling fan assembly (2b) and the retaining brackets (2a).
4. Install the covers.

Fig 3: Upper And Lower Radiator Hoses
5. Install the lower radiator hose (2).
6. Install the upper radiator hose (1).

Fig 4: Wiring Harnesses, Connectors & Clip
7. Attach the lines and close the retaining clips (2b).
8. Attach the wire harness (1c) and connect the cooling fan resistor wire harness connector (1a)
and the cooling fan wire harness connector (1b).
Fig 5: A/C Condenser & Clips
9. Install the A/C condenser (1b) and the retaining clips (1a).
Fig 6: A/C Lines & Bolts
10. Using NEW gasket seals, install the A/C line (2b) to the condenser and securely tighten the
bolt (2a)
11. Using NEW gasket seals, install the A/C line (1b) to the condenser and securely tighten the
bolt (1a). Tighten the bolts (2) to 8 N.m (70 in. lbs.).
12. Install the transmission oil cooler (1b) and engage the retainers (1a).
13. Remove the seal and plug from the transmission cooler and the transmission cooler lines.
14. Using NEW gasket seals, install the transmission cooler lines (1b) to the transmission cooler
(1c) and the retaining clips (1a).
15. Install the radiator air deflector (1c) and engage the retainers side (1b) and securely tighten the
bolts (1a).
16. Instal the front bumper reinforcement (1c). Tighten the bolts (1a) and the nuts (1b) to the proper
17. Install the air cleaner inlet tube (1b) and securely tighten the nut (1a).
ENGINE > SENSOR, COOLANT TEMPERATURE > REMOVAL AND INSTALLATION >
1.4L TURBO MULTI AIR > REMOVAL
CAUTION:
Do not loosen radiator draincock with system hot and pressurized. Serious burns from
coolant can occur.

Fig 1: Coolant Temperature Sensor Connector
Fig 2: Coolant Temperature Sensor
6. Remove the engine coolant temperature sensor (1).
1.4L TURBO MULTI AIR > INSTALLATION
Fig 1: Coolant Temperature Sensor
1. Install the engine coolant temperature sensor (2) and tighten the sensor to the proper
Fig 2: Coolant Temperature Sensor Connector
2. Connect the engine coolant temperature sensor wire harness connector (1).
1.6L DIESEL > REMOVAL
1. Remove the thermostat housing. Refer to THERMOSTAT, REMOVAL AND INSTALLATION .

Fig 1: Engine Cooling Temperature Sensor & Connector
2. Disconnect the Engine Cooling Temperature (ECT) sensor wire harness connector (1).
3. Remove the ECT sensor (2).
1.6L DIESEL > INSTALLATION
1. Install the Engine Cooling Temperature (ECT) sensor (1) and tighten to the proper
2. Install the ECT sensor wire harness connector (2).
3. Install the thermostat housing. Refer to THERMOSTAT, REMOVAL AND INSTALLATION .
2.0L DIESEL 120/140 CV > REMOVAL
1. Remove the thermostat housing. Refer to THERMOSTAT, REMOVAL AND INSTALLATION .

2. Disconnect the Engine Cooling Temperature (ECT) sensor wire harness connector (1).
3. Remove the ECT sensor (2).
2.0L DIESEL 120/140 CV > INSTALLATION
1. Install the Engine Cooling Temperature (ECT) sensor (1) and tighten to the proper
2. Install the ECT sensor wire harness connector (2).
3. Install the thermostat housing. Refer to THERMOSTAT, REMOVAL AND INSTALLATION .
2.0L DIESEL 170 CV > REMOVAL

5. Open the retaining clip and disconnect the vacuum brake booster hose quick connect fitting.
Fig 1: Engine Cooling Temperature (ECT) Sensor & Clip
6. Lift the spring retainer and remove the Engine Coolant Temperature (ECT) sensor (1) from the
thermostat housing.
Fig 2: (ECT) Sensor Wire Harness Connector
7. Disconnect the wire harness connector.
2.0L DIESEL 170 CV > INSTALLATION
Fig 1: (ECT) Sensor Wire Harness Connector
1. Connect the Engine Cooling Temperature (ECT) sensor wire harness connector (1).
Fig 2: Engine Cooling Temperature (ECT) Sensor & Clip
2. Using a NEW O-ring seal, install the ECT sensor (1) into thermostat housing and push down
on spring retainer to lock in place.
3. Connect the vacuum brake booster hose quick connect fitting and close the retaining clip.
4. Fill the coolant system. Refer to STANDARD PROCEDURE .
2.4LTURBO MULTI AIR > REMOVAL
CAUTION:
coolant can occur.

Fig 1: Engine Coolant Temperature Sensor & Connector
6. Remove the engine coolant temperature sensor (2).
2.4LTURBO MULTI AIR > INSTALLATION
Fig 1: Engine Coolant Temperature Sensor & Connector

1. Install the engine coolant temperature sensor (2) and tighten the sensor to the proper
ENGINE > THERMOSTAT > DESCRIPTION AND OPERATION > DESCRIPTION AND
OPERATION
CAUTION:
Do not operate an engine without a thermostat, except for servicing or testing.
A pellet-type thermostat controls the operating temperature of the engine by controlling the amount of
coolant flow to the radiator and engine oil cooler. The thermostat is closed below, see table below for
correct engine application. Above this temperature, coolant is allowed to flow to the radiator and engine
oil cooler. This provides quick engine warm up and overall temperature control.
1.4 MultiAir Turbo 1.6 16V Multijet 2.0 16V Multijet 2.4 MultiAir Turbo
176°F (80°C) 190°F (88°C) 190°F (88°C) 195°F (90°C)
ENGINE > THERMOSTAT > REMOVAL AND INSTALLATION > 1.4L MULTI AIR TURBO
> REMOVAL
CAUTION:
coolant can occur.
CAUTION:
The Thermostat and housing is serviced as an assembly. Do not remove the thermostat from
the housing, damage to the thermostat may occur.
3. Disconnect and isolate the battery cables.
Fig 1: Secondary Water Pump, Retaining Collar & Clip
6. On 4x4 models, release the clip (1a) and remove the water pump retaining collar (1b). and
position aside the secondary water pump (2).
Fig 2: Coolant Hose & Clamp
7. Loosen the clamp and remove the coolant hose (1).

Fig 3: Coolant Temperature Sensor & Quick Connect Coupling
9. Disconnect the degassing hose quick connect coupling (2).

10. Loosen the clamp and remove the radiator hose (1).
Fig 5: Oil Cooler Pipe & Bolt
11. Remove the bolts and the oil cooler pipe (1) and discard the O-ring seal.
Fig 6: Thermostat Housing & Bolts
12. Remove the bolts (1a) and the thermostat housing (1b).
Fig 7: O-Ring Gasket
13. Remove and discard the O-ring gasket seal (1).
ENGINE > THERMOSTAT > REMOVAL AND INSTALLATION > 1.4L MULTI AIR TURBO
> INSTALLATION
Fig 1: O-Ring Gasket
1. Clean the mating surfaces on the engine block and thermostat housing.
2. Install NEW O-ring gasket seal (1) onto the thermostat housing.
3. Install the thermostat housing mounting bolts (2). Tighten bolts to the proper specification.
Fig 3: Oil Cooler Pipe & Bolt
4. Using a NEW O-ring seal, install the oil cooler pipe (1). Tighten the bolt to the proper
5. Install the radiator hose (1) and tighten the clamp.

Fig 5: Coolant Temperature Sensor & Quick Connect Coupling
6. Connect the degassing hose quick connect coupling (2).
Fig 6: Coolant Hose & Clamp
8. Install the coolant hose and tighten the clamp (3).

Fig 7: Secondary Water Pump, Retaining Collar & Clip
9. On 4x4 models, install the secondary water pump (2) and the retaining collar (1b) and engage
the spring lock (1a).
13. Connect the battery cables.
ENGINE > THERMOSTAT > REMOVAL AND INSTALLATION > 1.6L DIESEL >
REMOVAL

Fig 1: Bolt
5. Remove the bolt (1) securing the left Charge Air Cooler (CAC) tube.
Fig 2: Retaining Clip & Quick-Disconnect Fitting
6. Open the retaining clip (1a) and disconnect the vacuum brake booster hose (1b) quick-
disconnect fitting (1b).
Fig 3: Bolts & CAC Tube
7. Remove the bolts (1a) and the CAC tube (1b).

Fig 4: Thermostat Housing, Bolts, Hoses & Clamps
8. Loosen the clamp and remove the coolant hose (1) from the thermostat housing.
10. Remove bolts (3a) and the thermostat housing (3b).

INSTALLATION
Fig 1: Thermostat Housing, Bolts, Hoses & Clamps
1. Using a NEW gasket, install the thermostat housing (1a) Tighten the bolts (1b) to the proper
2. Install the radiator hose (2) onto the thermostat housing and tighten the clamp.
3. Install the coolant hose (3) onto the thermostat housing and tighten the clamp.
4. Using a NEW O-ring seal, install the left charge Air Cooler (CAC) tube (1b). Tighten the bolts
5. Connect the vacuum brake booster hose (1b) quick-disconnect fitting (1b) and close the
Fig 4: Bolt
6. Install the bolt securing the left CAC tube. Tighten the bolts to the proper specification. Refer to
10. Run engine to operating temperature and check for leaks.
REMOVAL

Fig 1: Bolt
5. Remove the bolt (1) securing the left Charge Air Cooler (CAC) tube.
6. Open the retaining clip (1a) and disconnect the vacuum brake booster hose (1b) quick-
disconnect fitting (1b).
7. Remove the bolts (1a) and the CAC tube (1b).

Fig 4: Clamp & Coolant Hose
8. Loosen clamp and remove the coolant hose (1).

Fig 5: Degas Hose, Upper Radiator Hose & Clamps
9. Loosen the clamp and remove the degas hose (1) from the thermostat housing.
10. Loosen clamp and remove the upper radiator hose (2) from the thermostat housing.
Fig 6: Front Oxygen Sensor Wire Connector
11. Disconnect the front oxygen sensor wire connector (1) and detach wire harness connector
from the bracket.
Fig 7: Coolant Temperature Sensor Wire Harness Connector
12. Disconnect the coolant temperature sensor wire harness connector wire harness connector
(1).
Fig 8: Bolts
13. Remove the bolts (1) and the EGR tubes from the thermostat housing.
Fig 9: Bolts & Thermostat Housing Assembly
14. Remove bolts (1a) and the thermostat housing assembly (1b).
Fig 10: Gasket Seals
15. Remove and discard the gasket seals (1).
INSTALLATION
Fig 1: Gasket Seals
1. Install NEW gasket seals (1).

2. Install the thermostat housing (1a). Tighten the bolts (1b) to the proper specification. Refer to
SPECIFICATIONS .
Fig 3: Bolts
3. Install the bolts (1) securing the EGR tubes to the thermostat housing and tighten to the proper
Fig 4: Coolant Temperature Sensor Wire Harness Connector
4. Connect the coolant temperature sensor wire harness connector wire harness connector (1).
Fig 5: Front Oxygen Sensor Wire Connector
5. Attach the wire harness connector to the bracket and connect the front oxygen sensor wire
connector (1).
Fig 6: Degas Hose, Upper Radiator Hose & Clamps
6. Install the upper radiator hose (2) onto the thermostat housing and tighten the clamp.
7. Install the degas hose (1) onto the thermostat housing and tighten the clamp.
Fig 7: Clamp & Coolant Hose
8. Install the coolant hose (1) and tighten the clamp.

9. Using a NEW O-ring seal, install the left charge Air Cooler (CAC) tube (1b). Tighten the bolts
10. Connect the vacuum brake booster hose (1b) quick-disconnect fitting (1b) and close the
Fig 10: Bolt
11. Install the bolt securing the left CAC tube. Tighten the bolts to the proper specification. Refer to
15. Run engine to operating temperature and check for leaks.
ENGINE > THERMOSTAT > REMOVAL AND INSTALLATION > 2.4L MULTI AIR >
REMOVAL
2. Remove the battery and battery tray. Refer to TRAY, BATTERY, REMOVAL AND
INSTALLATION .

5. Disconnect the Engine Coolant Temperature (ECT) sensor wire harness connector (1).
6. Disconnect the quick-connect coupling and remove the coolant hose (2) from the thermostat
housing
Fig 3: Degas Hose Quick-Connect Coupling
7. Disconnect the quick-connect coupling and remove the degas hose (1) from the thermostat
housing.
8. Release the lock tab (1a) and remove the bolt (1b) securing the coolant tube to the thermostat
housing.
Fig 5: Thermostat Housing & Bolt
9. Remove the bolts (1) securing the thermostat housing.

10. Remove the fasteners (1a) and the vacuum pump support bracket (1b).
11. Remove the thermostat housing (1).

12. Remove and discard the thermostat housing gasket (1).
ENGINE > THERMOSTAT > REMOVAL AND INSTALLATION > 2.4L MULTI AIR >
INSTALLATION

5. Tighten the thermostat housing bolts (1) in a criss-cross pattern to the proper specification.
Refer to SPECIFICATIONS . 18 N.m 13 ft. lbs.
proper specification, then bend lock tab to secure bolt (1a) 18 N.m. Refer to
SPECIFICATIONS .
Fig 6: Degas Hose Quick-Connect Coupling
7. Install the degas hose (1) to the thermostat housing and connect the quick-connect fitting.
8. Install the coolant hose to the thermostat housing and engage the quick-connect coupling (2).
9. Connect and lock the Engine Coolant Temperature (ECT) sensor wire harness connector (1).
10. Install the radiator hose (1) to the thermostat housing and securely tighten the clamp.
11. Install the battery tray and battery. Refer to TRAY, BATTERY, REMOVAL AND INSTALLATION .
14. Start engine and check for leaks.
correct fluid level. Refer to STANDARD PROCEDURE .
TRANSMISSION > COOLER, TRANSMISSION OIL > DESCRIPTION AND OPERATION

> DESCRIPTION AND OPERATION > DESCRIPTION
The automatic transmission cooler is located in the front of the condenser and behind the front fascia.
The transmission cooler is a heat exchanger that allows heat in the transmission fluid to be transferred
to the air passing over the cooler fins.
The transmission oil cooler assembly is equipped with a thermal bypass valve that incorporates the
quick connect fitting for the transmission oil cooler lines.
TRANSMISSION > COOLER, TRANSMISSION OIL > DESCRIPTION AND OPERATION
> DESCRIPTION AND OPERATION > OPERATION
Transmission oil is routed through the cooler where heat is removed from the transmission oil before
returning to the transmission. The transmission oil cooler bypass valve aids in achieving desired
transmission oil operating temperature, it does this by recirculating the oil back to the transmission
without flowing through the transmission oil cooler at low oil temperatures.
TRANSMISSION > COOLER, TRANSMISSION OIL > REMOVAL AND INSTALLATION >
cable.
3. Remove the nut (1a) and the air cleaner inlet tube (1b).
4. Remove the bolts (1a) and the nuts (1b) and the front bumper reinforcement (1c).
5. Remove the bolts (1a) and disengage the retainers side (1b) and remove the radiator air
deflector (1c).
NOTE:
Plug and seal the ends of the transmission cooler and the transmission cooler lines
to prevent leakage of oil, or moisture, contaminates, or impurities from entering into
the system.
NOTE:
Clean any transmission fluid the may have leaked out during the removal process.
6. Remove the retaining clips (1a) and the transmission cooler lines (1b) from the transmission
cooler (1c).
7. Disengage the retainers (1a) and remove the transmission oil cooler (1b).
TRANSMISSION > COOLER, TRANSMISSION OIL > REMOVAL AND INSTALLATION >
1. Install the transmission oil cooler (1b) and engage the retainers (1a).
2. Remove the seal and plug from the transmission cooler and the transmission cooler lines.
3. Using NEW gasket seals, install the transmission cooler lines (1b) to the transmission cooler
(1c) and the retaining clips (1a).
4. Install the radiator air deflector (1c) and engage the retainers side (1b) and securely tighten the
bolts (1a).
5. Install the front bumper reinforcement (1c). Tighten the bolts (1a) and the nuts (1b) to the
6. Install the air cleaner inlet tube (1b) and securely tighten the nut (1a).
9. Check transmission fluid level and correct as necessary. Refer to FLUID AND FILTER,
TRANSMISSION > TUBES AND HOSES, TRANSMISSION OIL COOLER > STANDARD
PROCEDURE > STANDARD PROCEDURE - TRANSMISSION COOLER LINE QUICK
CONNECT FITTING DISASSEMBLY/ASSEMBLY > DISCONNECT
TRANSMISSION END
Fig 1: Oil Cooler Line Quick Connect Fitting - Disassembly
1 - QUICK CONNECT FITTING
2 - DUST CAP
3 - OIL COOLER LINE
4 - SPECIAL TOOL 8875A for 3/8" Line or 9546 for 1/2" Line.
1. Remove dust cap by pulling it straight back off of quick connect fitting
2. Place disconnect Special Tool (special tool #8875A, Disconnect, Transmission Cooler Line)
onto a 3/8 inch transmission cooler lines or Special Tool (special tool #9546, Disconnect Tool)
onto a 1/2 inch transmission cooler lines with the fingers of the tool facing the quick connect
fitting.
3. Slide disconnect tool down the transmission line and engage the fingers of the tool into the
retaining clip. When properly engaged in the clip, the tool will fit flush against the quick connect
fitting.
4. Rotate the disconnect tool 60° to expand the retaining clip.
5. While holding the disconnect tool against the quick connect fitting, pull back on the
transmission cooler line to remove.
TRANSMISSION OIL COOLER END
Fig 2: Removing Spring Clips
1. Using a suitable tool (1), remove the spring clips (2) from the connectors.
2. Pull the transmission oil cooler lines out from the transmission oil cooler.
TRANSMISSION > TUBES AND HOSES, TRANSMISSION OIL COOLER > STANDARD
PROCEDURE > STANDARD PROCEDURE - TRANSMISSION COOLER LINE QUICK
CONNECT FITTING DISASSEMBLY/ASSEMBLY > CONNECT
TRANSMISSION END
Fig 1: Connecting Transmission Cooler Line Quick Connect Fitting
1 - QUICK CONNECT FITTING
2 - CLIP
3 - OIL COOLER LINE
4 - DUST CAP
1. Align transmission cooler line (3) with quick connect fitting while pushing straight into the fitting.
2. Push in on transmission cooler line until a "click" is heard or felt.
3. Slide dust cap (4) down the transmission cooler line and snap it over the quick connect fitting
until it is fully seated and rotates freely. Dust cap will only snap over quick connect fitting when
the transmission cooler line is properly installed.
NOTE:
If dust cap will not snap into place, repeat assembly step #2.
TRANSMISSION OIL COOLER END
Fig 2: Quick Connect Fitting & Locking Tabs
1. Position the spring clip In the quick connect fitting (1) so that the three locking Tabs (2) appear
as shown in illustration.
Fig 3: Connecting Transmission Oil Cooler Lines
NOTE:
Lubricate the end of the transmission cooler oil line with the appropriate fluid to
ease installation.
2. Push the transmission oil cooler lines (2) into the fittings (3) until a "click" is heard or felt.
3. Check that the transmission oil cooler line is locked into the fitting by attempting to pull the line
out. If the line comes out, inspect the spring clip for correct installation and repeat steps 2 and
3.
TRANSMISSION > TUBES AND HOSES, TRANSMISSION OIL COOLER > REMOVAL
Fig 1: Transmission Oil Cooler Lines & Routing Clip
2. Release the transmission oil cooler lines (2) from the routing clip (1) located at the radiator fan
shroud.
3. Disconnect the transmission oil cooler lines from the transmission oil cooler.
4. Disconnect the transmission oil cooler lines from the transmission. Refer to TUBES AND
HOSES, TRANSMISSION OIL COOLER, STANDARD PROCEDURE .
5. Remove the transmission oil cooler lines from the vehicle.
TRANSMISSION > TUBES AND HOSES, TRANSMISSION OIL COOLER > REMOVAL
1. Position transmission cooler lines in vehicle.
2. Install transmission cooler line at transmission fittings. Refer to TUBES AND HOSES,
TRANSMISSION OIL COOLER, STANDARD PROCEDURE .
3. Install transmission cooler lines at transmission oil cooler. Refer to TUBES AND HOSES,
TRANSMISSION OIL COOLER, STANDARD PROCEDURE .
Fig 1: Transmission Oil Cooler Lines & Routing Clip
4. Secure the transmission oil cooler lines (2) to the routing clip (1) at the radiator fan shroud.
6. Check transmission fluid level. Refer to FLUID AND FILTER, STANDARD PROCEDURE .
Jeep Renegade
Service Manual: EXHAUST SYSTEM
DIAGNOSIS AND TESTING > EXHAUST EMISSION TESTING
1.4L MultiAir Turbo / 1.6L Turbo Diesel / 2.0L Turbo Diesel / 2.4L MultiAir2
- Execute the relief with all anti-emission devices activated and to the idle speed specified.
NOTE:
If the shape of the exhaust pipe does not allow the full introduction of the probe, it is
necessary to add a special extension tube that ensures the seal in the junction area.
Place the appropriate exhaust gas analyzer probe into the end of the exhaust pipe for no less than
30 cm.
Wait for the indication that the exhaust gas analyzers are stabilized.
With the engine idling check that the CO2 content is within the prescribed values. Refer to
SPECIFICATIONS for 1.4L, SPECIFICATIONS for 1.6L/2.0L Diesel or SPECIFICATIONS for 2.4L .
ADJUSTMENTS > ADJUSTMENTS
A misaligned exhaust system is usually indicated by a vibration, rattling noise, or binding of exhaust
system components. These noises are sometimes hard to distinguish from other chassis noises. Inspect
exhaust system for broken or loose clamps, heat shields, isolators, and brackets. Replace or tighten as
necessary. It is important that exhaust system clearances and alignment be maintained.
Perform the following procedures to align the exhaust system:
1. Loosen clamps and support brackets.
2. Align the exhaust system starting at the front, working rearward.
3. Tighten all clamps and brackets once alignment and clearances are achieved.

Bracket exhaust pipe screw 25 18 -
Exhaust clamp pipe nut 25 18 -
Exhaust clamp pipe screw 25 18 -

Exhaust pipe to engine oil sump 25 18 -
Exhaust pipe to catalytic

25 18 -
converter
INSPECTION > INSPECTION
Inspect the exhaust pipe, catalytic converter and muffler for cracked joints, broken welds and corrosion
damage that would result in a leaking exhaust system. Inspect the clamps, support brackets and
insulators for cracks and corrosion damage.
CONVERTER, CATALYTIC > INSPECTION > INSPECTION
WARNING:
The normal operating temperature of the exhaust system is very high. Therefore, never
attempt to service any part of the exhaust system until it is cooled. Special care should be
taken when working near the catalytic converter. The temperature of the converter rises to a
high level after a short period of engine operation time.
Visually inspect the catalytic converter element by using a borescope or equivalent. Remove oxygen
sensor(s) and insert borescope. If borescope is not available, remove converter and inspect element
using a flashlight. Inspect element for cracked or melted substrate.
NOTE:
Before replacing a catalytic converter, determine the root cause of failure. Most catalytic
converter failures are caused by air, fuel or ignition problems. (Refer to Appropriate
Diagnostic Information) for test procedures.
CONVERTER, CATALYTIC > REMOVAL AND INSTALLATION > 1.4L > REMOVAL 4.1L
2. Remove the engine beauty cover. Refer to COVER, ENGINE, REMOVAL AND INSTALLATION
for 1.6L/2.0L Diesel, COVER, ENGINE, REMOVAL AND INSTALLATION for 1.4L or COVER,
ENGINE, REMOVAL AND INSTALLATION for 2.4L.

Fig 1: Ignition Coil Heat Shield & Nuts
4. Remove the clamps (1a) and remove the ignition coils heat shield (1b).
Fig 2: Turbocharger Support Bracket, Nut & Screws
5. Remove the screws (1a), the nut (1b) and remove the turbocharger support bracket (1c).
Fig 3: Turbocharger Heat Shield & Nuts
6. Remove the clamps (1a) and remove the turbocharger heat shield (1b).
Fig 4: Upper Retaining Clip
7. Disconnect the upstream oxygen sensor wiring to the catalytic converter from the upper
retaining clip (1).
Fig 5: Catalytic Converter To The Turbocharger Securing Screw
8. Loosen the screw (1) securing the catalytic converter to the turbocharger.
Fig 6: Spring Retainer & Electrical Connection Of The Oxygen Sensor
9. Detach the wiring from the spring retainer (1).
10. Disconnect the electrical connection of the oxygen sensor (2).

Fig 7: Spring Retainer & Electrical Connection
12. Disconnect the electrical connection (2) of the front oxygen sensor at the catalytic converter.
Fig 8: Rear Bracket Screws
13. Remove the rear bracket screws (1) supporting the exhaust pipe.
Fig 9: Locating Securing Screws
14. Remove the screws (1) securing the front exhaust support bracket.
15. Unscrew the screw (2) supporting the discharge pipe to the engine oil sump.
Fig 10: Catalytic Converter & Nuts
16. Remove the nuts and disengage the discharge pipe from the catalytic converter (1).

Fig 11: Brackets & Screws
18. Remove the screws (1a) and remove the catalytic converter with brackets (1b).
19. Remove the gasket from the metal collar connection to the turbocharger.
Fig 12: Catalytic Converter Brackets & Screws
20. Remove the screws (1a) and remove the catalytic converter brackets (1b).
21. Remove the nuts (1a) and remove the heat shield (1b) from the catalytic convertor.
Fig 14: Upstream Oxygen Sensor
22. Unscrew and remove the upstream oxygen sensor (1) at the catalytic converter.
CONVERTER, CATALYTIC > REMOVAL AND INSTALLATION > 1.4L > INSTALLATION
1.4L
1. Install the upstream oxygen sensor (1) at the catalytic converter. Tighten to the proper torque
Fig 2: Catalytic Converter Support Brackets & Screws
2. Install the heat shield to the catalytic convertor and tighten the nuts.
3. Install the catalytic converter support brackets (1a) and tighten the screws (1b) to the proper
Fig 3: Metal Gasket
4. Install a new metal gasket matching the references indicated in the illustration (1).
Fig 4: Brackets & Screws
5. Install the catalytic converter with brackets (1a) and tighten the screws (1b) to the proper
Fig 5: Drain Pipe
6. Connect the drain pipe (1) to the catalytic converter, complete with new gasket and tighten the
new nuts to the proper torque specification. Refer to SPECIFICATIONS .
Fig 6: Discharge Pipe Screws
7. Tighten screws (1) for the front exhaust pipe support bracket to the proper torque specification.
8. Tighten the discharge pipe screw (2) to the proper torque specification. Refer to
SPECIFICATIONS .
Fig 7: Rear Bracket Screws
9. Tighten the screws (1) of the rear bracket supporting the exhaust pipe. Tighten to the proper
10. Connect the electrical connection of the upstream oxygen sensor and engage the harness with
the clip retainer.
11. Connect the electrical connection of the downstream oxygen sensor and engage the harness
with the clip retainer.
Fig 8: Catalytic Converter To The Turbocharger Retaining Screw
12. Install the screw retaining the catalytic converter to the turbocharger. Tighten to the proper
13. Engage the upstream oxygen sensor wiring harness to the wiring retaining clip.
14. Install the turbocharger heat shield.

15. Install the turbocharger support bracket (1a), tighten the new nut (1b) and screws (1c) to the
proper torque specification. Refer to SPECIFICATIONS .
16. Install the ignition coils heat shelter and tighten its hardware.
18. Install the engine beauty cover. Refer to COVER, ENGINE, REMOVAL AND INSTALLATION for
1.6L/2.0L Diesel, COVER, ENGINE, REMOVAL AND INSTALLATION for 1.4L or COVER,
CONVERTER, CATALYTIC > REMOVAL AND INSTALLATION > 2.4L > REMOVAL 2.4L
The catalytic converter is integrated into the exhaust manifold. Refer to MANIFOLD, EXHAUST,
REMOVAL AND INSTALLATION for 1.6L/2.0L Diesel or MANIFOLD, EXHAUST, REMOVAL AND
INSTALLATION for 2.4L.
CONVERTER, CATALYTIC > REMOVAL AND INSTALLATION > 2.4L > INSTALLATION
2.4L
The catalytic converter is integrated into the exhaust manifold. Refer to MANIFOLD, EXHAUST,
REMOVAL AND INSTALLATION for 1.6L/2.0L Diesel or MANIFOLD, EXHAUST, REMOVAL AND
INSTALLATION for 2.4L.
FILTER, DIESEL PARTICULATE > REMOVAL AND INSTALLATION > 1.6L DIESEL >
REMOVAL
2. Remove the engine cover. Refer to COVER, ENGINE, REMOVAL AND INSTALLATION for
Fig 1: Heat Shield & Screws
3. Remove the screws (1a) and remove the heat shield top of the turbocharger (1b).
Fig 2: Heat Shield, Clamps & Electrical Connection
4. Disconnect the electrical connection (1) of the oxygen sensor.
5. Remove the clamps (2) and remove the heat shield from bottom of the turbocharger.
Fig 3: Clamp Securing Nut
6. Unscrew the nut (1) securing clamp to the particulate filter to turbocharger.
Fig 4: Exhaust Gas Temperature Sensor Union Nut
7. Unscrew the union (1) and disconnect the exhaust gas temperature sensor from the particulate
filter.
Fig 5: Upstream Pressure Sensor Pipe Fittings
8. Unscrew the fittings (1) and remove the pipe fitting to the upstream pressure sensor of the
particulate filter.
Fig 6: Screw Clamp, Fitting & Nuts
9. Unscrew the screw clamp (1) to the support bracket exhaust pipe.
10. Unscrew the fitting (2) and disconnect the intake piping to the pressure sensor for exhaust gas,
downstream of the particulate filter.
11. Unscrew the nuts (3) and disconnect the exhaust pipe from the particulate filter.

Fig 7: Particulate Filter Nuts
13. Unscrew the nuts (1) and remove the particulate filter with the oxygen sensor and heat shield.
FILTER, DIESEL PARTICULATE > REMOVAL AND INSTALLATION > 1.6L DIESEL >
INSTALLATION
1. Put into place the particulate filter with the oxygen sensor, heat shield and tighten its nuts.
Fig 1: Exhaust Pipe Support Bracket Bolt, Fitting & Nuts
2. Connect the exhaust pipe to the particulate filter, using a new gasket and tighten the nuts (1) to
3. Tighten the fitting (2) of the downstream exhaust pressure sensor of the particulate filter.
4. Tighten the exhaust pipe support bracket bolt (3) to the proper torque specification. Refer to
SPECIFICATIONS .
5. Put into place the tube for outlet of the upstream pressure sensor of the particulate filter and
tighten its fittings.
6. Put into place the exhaust gas temperature sensor on the particulate filter and tighten the
connector to the proper torque specification. Refer to SPECIFICATIONS .
Fig 2: Particulate Filter Collar
7. Tighten the turbocharger to particulate filter fixing collar (1) to the proper torque specification.
8. Put into place the bottom of the turbocharger heat shield and tighten its hardware.
9. Connect the electrical connection of the oxygen sensor.
10. Put into place on top of the turbocharger the heat shield and tighten the screws.
11. Install the engine cover. Refer to COVER, ENGINE, REMOVAL AND INSTALLATION for
FILTER, DIESEL PARTICULATE > REMOVAL AND INSTALLATION > 2.0L DIESEL
120/140CV > REMOVAL
3. Remove the right front splash shield. Refer to SHIELD, SPLASH, FRONT WHEELHOUSE,
4. Remove the engine belly pan. Refer to BELLY PAN, REMOVAL AND INSTALLATION or BELLY
6. Remove the upstream exhaust gas temperature sensor. Refer to SENSOR, EXHAUST
TEMPERATURE, REMOVAL AND INSTALLATION .
Fig 1: Turbocharger Heat Shield & Nuts
7. Remove the clamps (1) and remove the turbocharger heat shield.
8. Disconnect the electrical connection (1) of the oxygen sensor upstream of the catalyst and
unhook the harness from retaining clip.
Fig 3: Exhaust Pipe, Bracket Bolt & Nuts
9. Remove the bolt (1) from the exhaust pipe bracket.
10. Remove the nuts (2a) and disconnect the exhaust pipe (2b) from the DPF.

Fig 4: Downstream Exhaust Gas Temperature Sensor & Oxygen Sensor Electrical Connection
12. Disconnect the electrical connection (1) of the downstream exhaust gas temperature sensor of
the DPF.
13. Disconnect the electrical connection (2) of the oxygen sensor downstream of the DPF.
Fig 5: Turbocharger, Clamp & Nut
14. Unscrew the nut clamp (1a) connecting DPF (1b) to the turbocharger (1c).
Fig 6: Fittings & Clamp
15. Unscrew the fittings (1) and remove the rigid pressure pipe for the upstream DPF.
16. Loosen the clamp (2) and disconnect the hose intermediate on the pressure sampling pipe
downstream of the DPF.
Fig 7: Upstream Exhaust Gas Temperature Sensor Electrical Connection
17. Disconnect the electrical connection (1) of the upstream exhaust gas temperature sensor of
the DPF.
Fig 8: DPF, Support Bracket & Nuts
18. Unscrew the nuts (1a) securing DPF (1b) to the support bracket (1c) and remove it.
FILTER, DIESEL PARTICULATE > REMOVAL AND INSTALLATION > 2.0L DIESEL
120/140CV > INSTALLATION
1. Put into place the DPF complete with new gasket and tighten the mounting nuts to the support
bracket.
2. Connect the electrical connection of the upstream exhaust gas temperature sensor of the DPF.
3. Connect the hose intermediate pressure sampling pipe downstream of the DPF and tighten its
clamp.
4. Put into place the rigid pressure pipe for sampling to the upstream DPF and tighten their
connectors.
Fig 1: Turbocharger, Clamp & Nut
5. Tighten to torque the nut clamp (1a) connecting DPF (1b) to the turbocharger (1c).
6. Connect the electrical connection of the downstream oxygen sensor to the DPF.
7. Connect the electrical connection of the downstream exhaust gas temperature sensor of the
DPF.
Fig 2: Exhaust Pipe, Nuts & Bracket Bolt
8. Put into place the exhaust pipe (1a) complete with new gasket and tighten the new nuts (1b) to
9. Tighten the exhaust pipe bracket bolt (2) to the proper torque specification. Refer to
SPECIFICATIONS .
10. Connect the electrical connection of the upstream oxygen sensor and engage the retaining clip
wiring.
11. Put into place the heat shield of the turbocharger and tighten its hardware.
12. Install the upstream exhaust temperature sensor. Refer to SENSOR, EXHAUST
TEMPERATURE, REMOVAL AND INSTALLATION .
14. Install the right front splash shield. Refer to SHIELD, SPLASH, FRONT WHEELHOUSE,
FILTER, DIESEL PARTICULATE > REMOVAL AND INSTALLATION > 2.0 DIESEL
170CV > REMOVAL
PROCEDURE .
7. Remove the cooling fan. Refer to FAN, COOLING, REMOVAL AND INSTALLATION .

INSTALLATION .
9. Remove the clamps (1) and remove the turbocharger heat shield.
10. Disconnect the electrical connection (1) of the oxygen sensor upstream of the catalyst and
unhook the harness from retaining clip.
Fig 3: Upper Lambda Probe Wiring And Electrical Connection
11. Disengage the wiring (1a) and disconnect the electrical connection of the upper lambda probe
(1b).
Fig 4: Lower Oxygen Sensor & Downstream Particulate Filter Temperature Sensor Electrical
Connection
12. Disconnect the electrical connection (1) of the lower oxygen sensor.
13. Disconnect the electrical connection (2) of the particulate filter temperature sensor
Fig 5: Wiring Harness
14. Disengage the wiring harness (1) oxygen sensor and temperature sensor particulate filter
Fig 6: Electrical Connection
15. Disconnect the electrical connection (1) of the sensor temperature particulate filter upstream of
the DPF and disengage the wiring from the retaining clips.
Fig 7: Exhaust Gas Outlet Clamps
16. Loosen the clamps (1) and disconnect the duct of the exhaust gas outlet for the differential
pressure sensor.
Fig 8: Low Pressure EGR Exhaust Gas Outlet Tube Collars
17. Loosen the collars (1) and remove the low pressure EGR exhaust gas outlet tube.
Fig 9: Exhaust Pipe, Bracket, Nuts & Bolt
18. Remove the bolt (1) from the exhaust pipe bracket.
19. Remove the nuts (2) and disconnect the exhaust pipe from the DPF.
Fig 10: Particulate Filter To The Turbocharger Collar Nut
20. Unscrew the nut (1) securing collar particulate filter to the turbocharger.
Fig 11: Particulate Filter Nuts
21. Unscrew the nuts (1) and remove the particulate filter full.
FILTER, DIESEL PARTICULATE > REMOVAL AND INSTALLATION > 2.0 DIESEL
170CV > INSTALLATION
1. Put into place the particulate filter equipped with oxygen sensors and exhaust gas temperature
sensor and tighten its bolts.
Fig 1: Turbocharger To The Particulate Filter Locking Collar
2. Tighten the turbocharger to the particulate filter locking collar to the proper torque specification.
Fig 2: Exhaust Pipe & Bracket Bolts
3. Put into place the exhaust pipe (1) complete with new gasket and tighten the new nuts to the
4. Tighten the exhaust pipe bracket bolt (2) to the proper torque specification. Refer to
SPECIFICATIONS .
5. Install the low pressure EGR exhaust gas outlet tube and tighten the related fastening collars.
6. Connect the outlet pipes of the exhaust gas to the differential pressure sensor and tighten the
clamps.
7. Connect the electrical connection of the upstream particulate filter temperature sensor and
engage in the wiring retaining clips.
8. Engage the oxygen sensor and temperature sensor wiring harness downstream of the DPF
particulate filter.
9. Connect the electrical connection of the particulate filter temperature sensor downstream of
the DPF.
10. Connect power supply to the lower oxygen sensor.
11. Connect the electrical connection of the oxygen sensor wiring and engage the retaining clip.
12. Connect the electrical connection of the exhaust gas temperature sensor upstream of the
particulate filter and engage the wiring in the retaining clips.
14. Install the cooling fan. Refer to FAN, COOLING, REMOVAL AND INSTALLATION .
17. Fill the engine cooling system. Refer to STANDARD PROCEDURE .
18. Install the engine belly pan. Refer to BELLY PAN, REMOVAL AND INSTALLATION or BELLY
19. Install the engine cover. Refer to COVER, ENGINE, REMOVAL AND INSTALLATION 1.6L/2.0L
Diesel, COVER, ENGINE, REMOVAL AND INSTALLATION for 1.4L or COVER, ENGINE,
REMOVAL AND INSTALLATION for 2.4L.
MUFFLER, EXHAUST > REMOVAL AND INSTALLATION > REAR > 1.4L TURBO
MULTIAIR REMOVAL
Fig 1: Clamp & Nut
2. Unscrew the nut and loosen the clamp connecting the pipes.
Fig 2: Hydraulic Lift, Muffler & Screws
3. Place a suitable hydraulic lift under the muffler.
4. Unscrew the center screws securing the rear bumper.
5. Unscrew the screws and remove the exhaust isolators.

Fig 3: Rear Exhaust Muffler, Clamp & Nut
6. Unscrew the nut (1a), loosen the clamp and disconnect the rear exhaust muffler (1b) from front
to rear (1c).
MULTIAIR INSTALLATION
1. Connect the muffler back to the front and tighten the nut to the specified torque. Refer to
SPECIFICATIONS .
2. Using a suitable hydraulic lift put in the muffler linking them to the front section of the pipe.
3. Tighten and torque the screws fixing the muffler to the rear section. Refer to
SPECIFICATIONS .
4. Tighten the center screws securing the rear bumper.

Fig 1: Clamp & Nut
5. Tighten and torque the exhaust clamps connecting the pipes. Refer to SPECIFICATIONS .
MUFFLER, EXHAUST > REMOVAL AND INSTALLATION > REAR > 2.4L MULTIAIR2
REMOVAL

Fig 1: Clamp & Nut
2. Unscrew the nut and loosen the clamp connecting pipes.

Fig 2: Muffler, Hydraulic Lift & Screws

Fig 3: Rear Exhaust Muffler & Nut
6. Unscrew the nut (1a), loosen the collar and disconnect the rear exhaust muffler (1b) from front
to rear (1c).
MUFFLER, EXHAUST > REMOVAL AND INSTALLATION > REAR > 2.4L MULTIAIR2
INSTALLATION
1. Connect the muffler back to the front and tighten the clamp nut to the specified torque. Refer to
SPECIFICATIONS .
2. Using a suitable hydraulic lift put in their seats the silencers linking them to the front section of
the drain pipe.
3. Tighten and torque the screws fixing the muffler to the rear section. Refer to
SPECIFICATIONS .

Fig 1: Clamp & Nut
5. Tighten and torque the exhaust clamp nut connecting pipes. Refer to SPECIFICATIONS .
DIESEL/1.6L TURBO DIESEL REMOVAL
NOTE:
Only for 2.0L Turbo Diesel 170 hp:
Fig 1: Nuts & Shield
1. Unscrew the nuts and remove the lower shield .

Fig 2: Hydraulic Lift, Muffler & Screws

Fig 3: Rear Exhaust Muffler, Exhaust Pipe Center & Nut
5. Unscrew the nut (1a), loosen the collar and disconnect the rear exhaust muffler (1b) from the
exhaust pipe center (1c).
DIESEL/1.6L TURBO DIESEL INSTALLATION
Fig 1: Clamp & Nut
1. Connect the exhaust muffler to the rear exhaust pipe central and tighten the exhaust clamp nut
to the specified torque. Refer to SPECIFICATIONS .
2. Using a suitable hydraulic lift put in their seats the isolators linking them to the front section of
the exhaust pipe.
3. Tighten the mounting screws to the muffler back to the body.
5. Tighten and torque the exhaust clamp connecting pipes. Refer to SPECIFICATIONS .
NOTE:
Only for 2.0L Turbo Diesel 170 hp:
6. Install and seat the transmission shaft guard and tighten the nuts.
MUFFLER, EXHAUST > REMOVAL AND INSTALLATION > FRONT > 2.4L MULTIAIR2 /
1.4L TURBO MULTIAIR
1. The exhaust muffler front is removed together with the exhaust muffler rear and therefore, refer
to MUFFLER, EXHAUST, REMOVAL AND INSTALLATION .
MUFFLER, EXHAUST > REMOVAL AND INSTALLATION > CENTER PIPE > 2.0L
TURBO DIESEL/1.6L TURBO DIESEL
1. Refer to MUFFLER, EXHAUST, REMOVAL AND INSTALLATION .
PIPE, EXHAUST > REMOVAL AND INSTALLATION > 1.4L > REMOVAL
2. Remove engine belly pan. Refer to BELLY PAN, REMOVAL AND INSTALLATION or BELLY
Fig 1: Steering Column To Pinion Steering Box Screw

4. Unscrew the screw (1) securing the steering column to the pinion steering box.
Fig 2: Right Load Beam Extension Screws
5. Remove the screws (1) securing the right load beam extension at the front end.
Fig 3: Reinforcement Bracket Screws
6. Unscrew the screws (1) and remove the reinforcement bracket of the front-end.
Fig 4: Right Lower Load Beam Screws
7. Unscrew the screws (1a) and remove the right lower load beam (1b).
8. On the left side, do the same for the removal of the load beam extension, reinforcement
bracket and lower load beam.
9. Holding the stem of the link, loosen the fixing nut (1) on right stabilizer bar link and disconnect it
from the shock.
10. On the left side, proceed similarly to disconnect the stabilizer bar link.
Fig 6: Wiring & Connector
11. Disengage the wiring (1) and disconnect the electrical connection of the lambda probe back to
the catalytic converter.
Fig 7: Rear Bracket To Support The Exhaust Pipe Screws & Sleeve Connecting Pipes Nut
12. Remove the screws (1) securing the rear bracket to support the exhaust pipe.
13. Unscrew the nut (2) and loosen the sleeve connecting pipes.
Fig 8: Screws & Clamp
14. Remove the screws (1) securing the support bracket front exhaust.
15. Unscrew the screw (2) collar support the discharge pipe to the engine oil sump.
Fig 9: Exhaust Pipe From The Catalytic Converter Nuts
16. Unscrew the nuts (1) and disengage the exhaust pipe from the catalytic converter.

Fig 10: Rear Engine Mount Isolator To Bracket Bolt
18. Remove the rear engine mount isolator to bracket bolt (1).
Fig 11: Crossmember To Body Screws
19. Place a suitable hydraulic lift under the crossmember of the suspension.
20. Remove the screws (1) securing the rear of the suspension crossmember to the body.
Fig 12: Crossmember Fixing Screws
21. Unscrew the crossmember fixing screws (1) from the left and right side panels.
Fig 13: Front Flex Pipe
22. Turn the hydraulic lift controls to lower the bar and remove the exhaust pipe with front flex pipe
(1) from the exhaust silencer front.
PIPE, EXHAUST > REMOVAL AND INSTALLATION > 1.4L > INSTALLATION
1. Put into place the exhaust pipe with front flex pipe and connect it to the exhaust silencer front.
Fig 1: Side Panel Mounting Screws
2. Using a hydraulic lift put into place the crossmember of the suspension and tighten the left and
right side panel mounting screws (1) to the proper torque specification. Refer to
SPECIFICATIONS .
Fig 2: Suspension Crossmember To Body Screws
3. Tighten and torque the screws (1) fixing rear of the suspension crossmember to the body.

Fig 3: Rear Engine Mount Isolator Bolt
5. Install the rear engine mount isolator bolt (1) and tighten it to the proper torque specification.
Fig 4: Exhaust Pipe To Catalytic Converter Nuts
6. Connect the exhaust pipe to the catalytic converter, complete with new gasket and tighten the
new nuts (1) to the proper torque specification. Refer to SPECIFICATIONS .
Fig 5: Fastening Screws
7. Tighten the fastening screws (1) of the support bracket to front exhaust pipe to the proper
8. Tighten the screw (2) clamp support to the exhaust pipe to the engine oil sump to the proper
Fig 6: Fastening Screws & Nut
9. Tighten the fastening screws (1) of the rear bracket supporting the exhaust pipe to the proper
10. Tighten the nut (2) of clamp to connecting pipes.
11. Connect the electrical connection of the rear oxygen sensor and catalytic converter to engage
the wiring.
12. Connect the right joint stabilizer link and tighten the nut to the proper torque specification. Refer
to SPECIFICATIONS .
13. On the left side, do the same to connect the stabilizer bar link.
Fig 7: Lower Load Beam & Screws
14. Put into place the lower load beam (1a) and tighten the screws (1b) to the proper torque
Fig 8: Load Beam Extension Mounting Screws
15. Put into place the reinforcement bracket and tighten the screws.
16. Tighten and torque the load beam extension mounting screws (1) to the proper torque
17. On the left side, proceed similarly for the reattachment of the lower load beam, reinforcement
bracket and load beam extension.
18. Tighten and torque the new screw steering column to the pinion steering box. Refer to
SPECIFICATIONS .
PIPE, EXHAUST > REMOVAL AND INSTALLATION > 2.4L > REMOVAL
5. Remove the right half-shaft. Refer to REMOVAL AND INSTALLATION for front half shaft or
REMOVAL AND INSTALLATION for rear half shaft.
Fig 1: Screws & Nut
7. Unscrew the nut (2) and loosen the clamp connecting the pipes.
Fig 2: Screws, Clamp & Nuts
8. Unscrew the fixing screws (1) of the front bracket supporting the exhaust pipe.
9. Unscrew the screw clamp (2) support the exhaust pipe to the bracket on the engine.

Fig 3: Hydraulic Lift
12. Place a suitable hydraulic lift (1) under the exhaust pipe.
Fig 4: Isolators
13. Unhook and remove the two isolators (1) that support the front exhaust pipe.
14. Place a suitable hydraulic lift (1) under the transmission as shown in the illustration.
16. Turn the hydraulic lift control to move the powertrain from the crossmember of the suspension.
Fig 7: Exhaust Pipe
17. Remove the exhaust pipe (1) with intermediate flexible portion from the front exhaust silencer.
PIPE, EXHAUST > REMOVAL AND INSTALLATION > 2.4L > INSTALLATION
1. Put in place the exhaust pipe with intermediate flexible portion and connect it to the exhaust
silencer front.
2. Turn the hydraulic lift control to bring the powertrain to crossmember.

3. Tighten the rear engine mount isolator to bracket bolt (1) to the proper torque specification.
5. Engage the two isolators supporting the front exhaust pipe.

Fig 2: Exhaust Pipe Mounting Screws, Nuts & Clamp
7. Tighten the fastening screws (2) of the support bracket to front exhaust pipe to the proper
8. Tighten the exhaust pipe support bracket screw to the proper torque specification. Refer to
SPECIFICATIONS .
Fig 3: Fastening Screws, Nut & Clamp
10. Tighten the nut (2) to clamp connecting the pipes.
11. Remove the hydraulic lift under the exhaust pipe.
12. Install the right half shaft. Refer to REMOVAL AND INSTALLATION for front half shaft or
PIPE, EXHAUST > REMOVAL AND INSTALLATION > 2.4L 4X4 > REMOVAL

5. Remove the right half-shaft. Refer to REMOVAL AND INSTALLATION for front half shaft or
Fig 2: Lower Load Beam Extension & Screws
7. Remove the screws (1) securing the lower load beam extension right at the front end.
8. Loosen the bolts and remove the reinforcement of front-end.
9. Loosen the bolts and remove the right strut.
10. On the left side, do the same for the removal of the reinforcement of the front-end and the
strut.
Fig 3: Right Stabilizer Bar Link Nut
11. Holding the stem of the link, loosen the fixing nut (1) from right stabilizer bar link and disconnect
it from the shock.
12. On the left side, proceed similarly to disconnect the joint stabilizer bar.
Fig 4: Exhaust Pipe Screws & Nut
Fig 5: Exhaust Pipe Screws, Clamp & Nuts
16. Unscrew the screw clamp (2) to support the of exhaust pipe to the bracket on the engine.

19. Place a suitable hydraulic lift (1) under the transmission as shown in the figure.
22. Remove the bolts securing the rear of the suspension crossmember to the body.
Fig 8: Suspension Crossmember To Side Panel Screws
23. Remove the screws (1) fastening the suspension crossmember to the left and right side
panels.
Fig 9: Exhaust Pipe
24. Turn the hydraulic lift control to lower the crossmember and remove the exhaust pipe (1) with
intermediate flexible portion from the front exhaust silencer.
PIPE, EXHAUST > REMOVAL AND INSTALLATION > 2.4L 4X4 > INSTALLATION
1. Put in place the exhaust pipe with intermediate flexible portion and connect it to the exhaust
silencer front.
2. Using a hydraulic lift put into place the crossmember of the suspension and tighten the left and
right side panel mounting screws (1) to the proper torque specification. Refer to
SPECIFICATIONS .
3. Tighten the screws securing the rear of the suspension crossmember to the proper torque

5. Tighten the rear engine mount isolator to bracket bolt (1) to the proper torque specification.

Fig 3: Exhaust Pipe Mounting Screws, Nuts & Clamp
8. Tighten the fastening screws (2) of the support bracket front exhaust pipe to the proper torque
9. Tighten the screw clamp (3) to support the exhaust pipe to the bracket on the engine to the
Fig 4: Fastening Screws & Nuts
11. Tighten the nut (2) to clamp connecting pipes to the proper torque specification. Refer to
SPECIFICATIONS .
Fig 5: Stabilizer Link To Shock Nut
12. Connect the right stabilizer link to shock and tighten the nut (1) to the proper torque
14. Put into place the right strut and tighten the screws to the proper torque specification. Refer to
15. Install the reinforcement of the front-end and tighten the screws to the proper torque
16. Tighten the right load beam extension mounting screws (1) at the front end to the proper torque
17. On the left side, proceed similarly for the reattachment of the load beam extension.
18. Tighten the new screw (1) steering column to the pinion steering box to the proper torque
19. Install the right half shaft. Refer to REMOVAL AND INSTALLATION for front half shaft or
PIPE, EXHAUST > REMOVAL AND INSTALLATION > 1.6L DIESEL > REMOVAL
Fig 2: Load Beam Extension Bolts
5. Unscrew the load beam extension fixing screws, the left side.
Fig 3: Reinforcement Bracket Bolts
6. Unscrew the screws (1) and remove the reinforcement bracket, the left side.
7. Unscrew the screws (1) and remove the lower load beam, the left side.
8. On the right side, do the same for the removal of the load beam extension, reinforcement
9. Holding the stem of the link, loosen the fixing nut (1) from left stabilizer bar link and disconnect
it from the shock.
10. On the right side, proceed similarly to disconnect the stabilizer bar link.
Fig 6: Pipe Support Brackets Screws, Clamp & Nut
11. Unscrew the nut (1) and loosen the clamp connecting pipes.
12. Disconnect the fixing screws (2) of the pipe support brackets on the side of suspension
crossmember.
Fig 7: Screws, Connection & Nut
13. Unscrew the screws (1) securing the support bracket clamp to the exhaust pipe.
14. Unscrew the connection (2) and disconnect the pipe outlet pressure gas downstream of the
DPF.
15. Unscrew the nuts (3) and disconnect the exhaust pipe from the DPF.

19. Remove the screws (1) securing the rear of the suspension crossmember to the body.
Fig 10: Suspension Crossmember To Side Panel Screw
20. Remove the screw (1) fastening the suspension crossmember to the left and right side panels.
Fig 11: Exhaust Pipe With Front Flex Pipe
21. Act on the hydraulic lift to lower the bar and remove the exhaust pipe (1) with front flex pipe
from the exhaust silencer front.
PIPE, EXHAUST > REMOVAL AND INSTALLATION > 1.6L DIESEL > INSTALLATION
2. Using a hydraulic lift put into place the crossmember of the suspension and tighten the
mounting screws (1) to the left and right side panels to the proper torque specification. Refer to
SPECIFICATIONS .
Fig 2: Suspension Crossmember To Body Bolts
3. Tighten the screws (1) fixing the rear of the suspension crossmember to the proper torque
5. Tighten the rear engine mount isolator bolt (1) to the proper torque specification. Refer to
SPECIFICATIONS .
Fig 4: Exhaust Pipe Support Bracket Screw, Fitting & Nuts
6. Connect the exhaust pipe to the DPF, using a new gasket and tighten the nuts (1) to the proper
7. Tighten the fitting (2) of the pipe for the downstream DPF pressure sensor.
8. Tighten the exhaust pipe support bracket screw (3) to the proper torque specification. Refer to
SPECIFICATIONS .
Fig 5: Exhaust Pipe Support Bracket To Suspension Crossmember Bolts
9. Tighten the fastening screws (1) of the exhaust pipe support brackets at the side of the
suspension cross member to the proper torque specification. Refer to SPECIFICATIONS .
10. Tighten the nut clamp (2) for connecting pipes to the proper torque specification. Refer to
SPECIFICATIONS .
Fig 6: Stabilizer Link To Shock And Nut
11. Connect the left stabilizer link (1) to shock and tighten the nut to the proper torque
12. On the right side, do the same to connect the stabilizer bar link.
Fig 7: Lower Load Beam And Bolts
13. Put into place the lower load beam, the left side and tighten the screws to the proper torque
14. Put into place the reinforcement bracket of the front-end, the left side and tighten the screws.
15. Tighten load beam extension mounting screws (1), the left side to the proper torque
16. On the right side, proceed similarly for the reattachment of the lower load beam, reinforcement
17. Tighten the new screw steering column to the pinion steering box to the proper torque
PIPE, EXHAUST > REMOVAL AND INSTALLATION > 2.0L DIESEL 120/140CV >
REMOVAL
4. Unscrew the screw securing the steering column to the pinion steering box.
Fig 2: Load Beam Extension Bolts
5. Remove the bolts (1) securing the load beam extension, left side.
Fig 3: Reinforcement Bracket Bolts
6. Remove the bolts (1) and remove the reinforcement bracket, left side.
7. Remove the bolts and remove the lower load beam, left side.
8. On the right side, do the same for the removal of the load beam extension, reinforcement
9. Holding the stem of the link, loosen the fixing nut from left stabilizer bar link and disconnect it
from the shock.
10. On the right side, proceed similarly to disconnect the link on stabilizer bar.
Fig 6: Pipe Support Brackets Screws, Clamp & Nut
12. Disconnect the fixing screws of the pipe support brackets (2) on the side of the suspension
crossmember.
Fig 7: Exhaust Pipe Support Bracket Bolt & Exhaust Flange Nuts
13. Unscrew the screw (1) on the clamp to the bracket support of the exhaust pipe.
14. Unscrew the nuts (2) and disconnect the exhaust pipe from the DPF.

17. Place a suitable hydraulic lift under the crossbar of the suspension.
18. Remove the screws securing the rear of the suspension crossmember to the body.
19. Remove the screws fastening the suspension crossmember to the left and right side panels.
Fig 11: Exhaust Pipe With Front Flex Pipe
20. Turn the hydraulic lift control to lower the suspension crossmember and remove the exhaust
pipe with front flex pipe from the exhaust silencer on front.
PIPE, EXHAUST > REMOVAL AND INSTALLATION > 2.0L DIESEL 120/140CV >
INSTALLATION
1. Put into place the pipe with front flex pipe and connect it to the exhaust silencer on front.
2. Using a hydraulic lift, put into place the suspension crossmember and tighten the mounting
bolts to the proper torque specification. Refer to SPECIFICATIONS .
3. Install and tighten the rear suspension crossmember to the body bolts (1) to the proper torque
5. Install the rear engine mount isolator to bracket bolt (1) and tighten to the proper torque
Fig 4: Exhaust Pipe Nuts & Exhaust Pipe Support Bracket Bolt
6. Connect the exhaust pipe to the DPF, using a new gasket and tighten the nuts (1) to the proper
7. Install the exhaust pipe support bracket bolt (2) and tighten screw to the to the proper torque
Fig 5: Exhaust Pipe Support Bracket To Suspension Crossmember Bolts
8. Install the exhaust pipe support bracket to suspension crossmember bolts (1) and tighten to the
9. Tighten the nut on the clamp connecting the pipes to the proper torque specification. Refer to
SPECIFICATIONS .
Fig 6: Stabilizer Link To Shock And Nut
10. Connect the left stabilizer link to shock and tighten the nut to the proper torque specification.
11. On the right side, do the same to connect the stabilizer bar link.
Fig 7: Lower Load Beam And Bolts
12. Put into place the left side lower load beam and tighten the bolts (1) to the proper torque
Fig 8: Load Beam Extension Mounting Bolts
13. Put into place the left side reinforcement bracket and tighten the bolts to the proper torque
14. Tighten the load beam extension mounting bolts (1) to the proper torque specification. Refer to
SPECIFICATIONS .
15. On the right side, proceed similarly for the reattachment of the lower load beam, reinforcement
16. Install and tighten a new bolt (1) for steering column to the pinion steering box to the proper
PIPE, EXHAUST > REMOVAL AND INSTALLATION > 2.0L DIESEL 170CV > REMOVAL
Fig 2: Front Lower Load Beam Bolt
5. Unscrew the front lower load beam bolt (1).
6. On the right side, proceed similarly for the removal of the front lower load beam bolt.
7. Unscrew the screws (2) and remove the lower load beam left side.
8. On the right side, do the same for the removal of the lower load beam.
9. Holding the stem of the link, loosen the fixing nut (1) from left stabilizer bar link and disconnect
it from the shock.
10. On the left side, proceed similarly to disconnect the stabilizer bar link.
Fig 4: Screws & Nut
12. Remove the screws (2) fixing the rear bracket supporting the exhaust pipe.
13. Unscrew the nut (3) and loosen the clamp connecting the exhaust pipe.
Fig 5: Clamp & Nuts
14. Unscrew the screw clamp (1) support the exhaust pipe to the engine oil sump.

17. Remove the rear engine mount isolator to bracket bolt.
19. Remove the screws securing the rear of the suspension crossmember to the body.
20. Unscrew the crossmember fixing screws (1) from the left and right side panels.
21. Act on the hydraulic lift to lower the crossmember and remove the crossmember fixing screws
(1) with front flex pipe from the exhaust silencer front.
PIPE, EXHAUST > REMOVAL AND INSTALLATION > 2.0L DIESEL 170CV >
INSTALLATION
2. Using a hydraulic lift put into place the crossmember of the suspension and tighten the
mounting screws (1) to the left and right side panels to the proper torque specification. Refer to
SPECIFICATIONS .
Fig 2: Suspension Crossmember Screws
3. Tighten the screws (1) fixing rear of the suspension crossmember to the proper torque

5. Install the rear engine mount isolator to bracket bolt (1) to the proper torque specification.
Fig 4: Screw Clamp & Nuts
7. Tighten the screw clamp (2) to support the exhaust pipe to the engine oil sump to the proper
Fig 5: Nut, Clamp, & Screws
8. Tighten the nut clamp (1) connecting the exhaust pipe to the proper torque specification. Refer
to SPECIFICATIONS .
10. Tighten the fastening screws (3) of the front bracket for supporting the exhaust pipe to the
11. Connect the right stabilizer link to shock and tighten the nut to the proper torque specification.
Fig 6: Lower Load Beam & Screws
13. Put into place the left lower load beam (1) and tighten the screws to the proper torque
14. Tighten the bolt (2) at the front of the lower load beam to the proper torque specification. Refer
to SPECIFICATIONS .
15. On the right side, proceed similarly for the reattachment of the lower load beam.
16. Tighten the new screw (1) steering column to the pinion steering box to the proper torque
Remove the vehicle from the lift.
SENSOR, DIFFERENTIAL PRESSURE > REMOVAL AND INSTALLATION > 1.6L AND
2.0L > REMOVAL
NOTE:
It is necessary to restore operations using the diagnostic tool when replacing the DPF
differential pressure sensor.

Fig 1: Differential Pressure Sensor, Electrical Connection & Hoses
3. Disconnect the electrical connection (1) from the differential pressure sensor.
4. Loosen the clamps and disconnect the hoses (2) from the differential pressure sensor.
5. Remove the nut and remove the differential pressure sensor (3).
SENSOR, DIFFERENTIAL PRESSURE > REMOVAL AND INSTALLATION > 1.6L AND
2.0L > INSTALLATION
1. Connect the hoses to the differential pressure sensor and tighten the clamps.
2. Install the differential pressure sensor and tighten the nut.
3. Connect the differential pressure sensor electrical connector.
SENSOR, EXHAUST TEMPERATURE > REMOVAL AND INSTALLATION > EXHAUST

TEMPERATURE SENSOR > 1.6L TURBO DIESEL REMOVAL
Fig 1: Exhaust Temperature Sensor Electrical Connector
3. Disconnect the exhaust temperature sensor electrical connector (1).

Fig 2: Temperature Sensor & Fitting
4. Remove the fitting (1a) and remove the temperature sensor (1b).
SENSOR, EXHAUST TEMPERATURE > REMOVAL AND INSTALLATION > EXHAUST

TEMPERATURE SENSOR > 1.6L TURBO DIESEL INSTALLATION
Fig 1: Exhaust Gas Particulate Filter & Fitting
1. Install the exhaust temperature sensor to the exhaust gas particulate filter (1a) and tighten the
fitting (1b) to the proper torque specification. Refer to SPECIFICATIONS .
2. Connect the electrical connector to the exhaust temperature sensor.
3. Install the right front splash shield and wheel. Refer to SHIELD, SPLASH, FRONT
SENSOR, EXHAUST TEMPERATURE > REMOVAL AND INSTALLATION > TURBO

INLET TEMPERATURE SENSOR > REMOVAL
NOTE:
2.0L Turbo Diesel 170 CV
2. Remove the front belly pan. Refer to BELLY PAN, REMOVAL AND INSTALLATION or BELLY
PROCEDURE .
6. Remove the radiator cooling fan. Refer to FAN, COOLING, REMOVAL AND INSTALLATION .

INSTALLATION .
Fig 1: Sensor Temperature Particulate Filter Electrical Connection
8. Disconnect the electrical connection (1) of the sensor temperature particulate filter, upstream
of the DPF.
Fig 2: Exhaust Gas Turbocharger Inlet Temperature Sensor Electrical Connection
9. Disconnect the electrical connection (1) of the exhaust gas turbocharger inlet temperature
sensor.
Fig 3: Turbocharger Exhaust Gas Inlet Temperature Sensor & Fitting
10. Unscrew the fitting and remove the turbocharger exhaust gas inlet temperature sensor (1).
SENSOR, EXHAUST TEMPERATURE > REMOVAL AND INSTALLATION > TURBO

INLET TEMPERATURE SENSOR > INSTALLATION
NOTE:
2.0L Turbo Diesel 170 CV
Fig 1: Turbocharger Exhaust Gas Inlet Temperature Sensor & Fitting
1. Put into place the turbocharger exhaust gas inlet temperature sensor (1) and tighten to the
2. Connect the electrical connection of the exhaust gas turbocharger inlet temperature sensor.
3. Connect the electrical connection of the sensor temperature particulate filter, upstream of the
DPF.
5. Install the radiator cooling fan. Refer to FAN, COOLING, REMOVAL AND INSTALLATION .
9. Install the front belly pan. Refer to BELLY PAN, REMOVAL AND INSTALLATION or BELLY PAN,
Jeep Renegade
Service Manual: FUEL SYSTEM
FUEL DELIVERY > DESCRIPTION AND OPERATION > 1.4L MULTIAIR TURBO
Fig 1: Fuel Supply System Components
The fuel supply system provides fuel at the correct operating pressure to the injector assembly.
The system consists of:
A fuel pump/level gauge unit submerged in the tank
A delivery pipe
An injector rail
A recirculation pipe
The electric pump unit consists of:
Fuel pump
Fuel filter
Maximum pressure regulator
Fuel level sensor
The fuel pump is controlled by the Engine Management Module through a special supply relay.
The fuel filter is fitted inside the pump unit and does not require maintenance.
A maximum pressure regulator is built into the pump unit between the pump and the supply pipe; this
ensures fuel recirculation for safety reasons if the pressure exceeds 6.9 -9.8 bar.
A fuel level sensor is also fitted in the pump unit; this is connected directly to the Body Computer Module.
The fuel supply pipe connects the tank with the injector-carrier rail; the pipe is connected through quick
couplings.
The injector rail ensures the supply of fuel to the injectors and is made from metal for turbocharged
versions:
Inlet connector, connected to the delivery pipe
Approx. fuel pressure value:
3.5 bar
FUEL DELIVERY > SPECIFICATIONS > TORQUE SPECIFICATIONS

Fuel Delivery Pipe to Fuel

23 17 -
Injection Pump
Fuel Pipe to Fuel Rail 19 14 -
Fuel Rail Pressure Sensor 70 52 -
Fuel Tank Strap Bolts 35 26 -
Injection Pump Pulley Nut 50 37 -
Injection Pump Retaining Nuts 25 18 -
FUEL DELIVERY > DIAGNOSIS AND TESTING > DIAGNOSIS AND TESTING - HARD
TO FILL WITH FUEL
1. CHECK FOR AN OBSTRUCTED RECIRCULATION TUBE NEAR THE FUEL TANK

Fig 1: EVAP System Component Identification & Location
CALL OUT DESCRIPTION
1 Filter - Fresh Air Inlet
2 Filter Hose (Filter to ESIM)
3 Evaporative System Integrity Monitor (ESIM)
4 Evaporative Canister
5 Canister Tube (Fuel Tank to Canister)
6 Purge Tube (Purge Solenoid to Canister)
7 Purge Solenoid
8 Manifold Hose (Purge Solenoid to Engine Manifold)
9 Recirculation Tube (Fuel Tank to FTPS)
10 Fuel Tank Pressure Sensor (FTPS)
Recirculation Tube (metal portion) (FTPS to Fuel

11
Filler Tube)
12 Gas Cap or Cap-less Refueling Unit (if equipped)
13 Fuel Filler Tube
14 Fill Limit Vent Valve (FLVV) / Control Valve (CV)
15 GVV Tube (GVV to MFCV)
16 Grade Vent Valve (GVV)
17 Fuel Tank
18 Inlet Check Valve (ICV)
19 Hose - Fuel Filler Tube to ICV
We are all familiar with the handle we squeeze to get fuel to exit the nozzle. The shut off is
created by an aspirator or sensing port located underneath the end of the nozzle and when fuel
covers the sensing port, the nozzle shuts off.
When the fuel pump nozzle is placed in the filler cup and triggered on, fuel flows down the fill
pipe. Air from the outside of the filler cup is also drawn into the filler cup due to vacuum created
by the fuel flow. The air and fuel flow into the fuel tank through the inlet check valve (ICV), the
valve that is welded to the fuel tank and creates the connection between the fill hose and fuel
tank shell. Fuel displaces the vapor in the fuel tank, fuel vapor and the entrained air from the
outside flow out of the fuel tank through the Fill Limit Vent Valve (FLVV) or a Control Valve (CV)
if so equipped. The Control Valve has an internal component (diaphragm) that communicates
with atmosphere through the recirculation line when the fuel cap is removed prior to refueling.
The recirculation line must be free of debris, liquid or any other type of blockage in order to
create the communication link. The confirmation of this link will permit the diaphragm to rise off
of the main venting orifice allowing fuel vapor to exit the fuel tank.
That fuel vapor flows from the FLVV / CV through the canister line and into the evaporative
canister where the hydrocarbons attach to the charcoal in the evaporative canister and fresh
air exits the evaporative canister. The fresh air travels past the Evaporative System Integrity
Monitor (ESIM) and through the air line and exiting the fuel system through the fresh air filter.
Once the fuel level reaches full, there is a refueling float in the FLVV / CV which closes the
main vapor venting orifice. The closure of this orifice prevents fuel vapor from exiting the fuel
tank. The pressure in the fuel tank rises rapidly and fuel fills the filler pipe. When the fuel hits
the aspirator valve in the fuel fill nozzle the fuel flow is shut off.
Every element that fuel and vapor flow through results in additional back pressure during
refueling. When functioning properly, the back pressure is low enough that the fuel in the filler
pipe does not rise high enough to cover the sensing port and shut off the refueling nozzle.
When a hard to fill condition is present, something has happened to cause an increase in
system back pressure. The back pressure rises to the point where the fuel height in the filler
pipe covers the aspirator and shuts off the fuel nozzle, or the customer can only get fuel into
the tank at a very slow rate due to the additional back pressure restriction.
The "Hard to Fill" diagnostic procedure focuses on trying to efficiently identify what has created
the increase in back pressure creating the hard to fill condition.
There can also be problems with fuel station nozzles and operator procedure, such as not
putting the nozzle into the filler pipe properly. This can result in a hard to fill condition where
constant fuel flow is not able to be established. As the customer gets used to their vehicle, the
owner typically figures out the proper nozzle insertion. An issue with the fuel pump nozzle would
be intermittent when they pull up to a pump with a bad nozzle, unless they always refuel at the
same station / same pump and it happens to have a bad nozzle.
FUEL DELIVERY > DIAGNOSIS AND TESTING > DIAGNOSIS AND TESTING - HARD
TO FILL WITH FUEL > DIAGNOSTIC PROCEDURE
1. Verbally confirm customer complaint.
1. Has the vehicle always had this issue, or is it recent?
2. Does it occur on all fill ups or is it intermittent?
3. Is the issue only on high flow and is it okay on low flow of the fuel pump?
2. Scan and record any fuel related P Codes.
3. Line Check - Put vehicle up on hoist and examine visually, by feel or mirror to look for a kink,
bend, or twist condition in the Fill Hose, Air Line, Recirc Line, or Canister Line. Check that the
Air Line is connected to both the ESIM and the Air Filter.
1. Were any problems found?
2. No - Continue to Step 4
3. Yes - For a disconnected Air Line, replace the ESIM and Canister and proceed to Step
10. For a kink, bend or twist, straighten or replace as necessary, document on the repair
order, and proceed to Step 10 - Fuel Fill Verification
4. Air Filter Check - Disconnect the air filter and tap it on a table to determine if the air filter is
dirty or plugged.
3. Yes - Replace Air Filter. Remove the gas cap and tap it on the table to see if it is dirty
and replace it if it is. Proceed to Step 10 - Fuel Fill Verification
5. Recirculation Line Check - Remove the recirc line from the fill neck and remove the large fill
hose at the fuel tank. The gas cap should still be on. Blow air into the recirc line and air with no
contamination should flow freely out of the fill large fill hose.
3. Yes - Replace fuel filler neck and proceed to Step 10 - Fuel Fill Verification
6. Fuel Tank Inlet Check Valve (ICV) Check - The fill hose should already be removed from the
ICV. Visually look inside the ICV for an obstruction. If obstructed, remove the object if possible.
Using a long thin object (not a screwdriver) that will not damage the seal on the check valve or
the antisiphon features inside the ICV, push the object into the ICV to verify that it is free of
obstruction. There is a spring behind it, so there will be a little resistance, but it should move
freely and not be sticky.
3. Yes - If an obstruction was found , but the ICV moves freely proceed to Step 10 Fuel Fill
Verification. If the ICV does not move freely, replace the fuel tank and proceed to Step
10 - Fuel Fill Verification
7. Reassemble the components removed in earlier steps.
8. Canister Weight Check - Remove the heat shield and take the lines off the canister,
disconnect the electrical and take the canister and ESIM assembly off the tank. Use a weight
scale such as one for shipping parts or mail to weigh the assembly. A canister on a 26 gallon
tank assembly should weigh less than 2700 grams (5.9 pounds). A canister on a 32 gallon
assembly should weigh less than 2500 grams (5.5 pounds).
3. Yes - Look into the ESIM ports to see if the ESIM floats have any appearance of rust or
dirt. If the ESIM float is clean, replace the canister. If the ESIM appears to have rust or
dirt, replace both Canister and ESIM. Proceed to Step 10 - Fuel Fill Verification
9. Nothing found in Step 1 through 7, reassemble and components removed in earlier steps and
proceed to step 11.
10. Fuel Tank Refuel Check with Problem Identified and Repaired - Take the vehicle to the gas
station and determine if it fills cleanly.
1. Fuel tank fills clean - Problem found and complete
2. Still Hard to Fill - Return above to the step below where you found an issue and continue
diagnostic.
11. EVAP System Check - Disconnect the vapor line on the fuel tank control valve (CV) Take the
vehicle to the gas station and determine if it fills cleanly.
1. Fuel tank fills clean - Replace the canister and ESIM assembly and refuel to verify
problem solved.
2. Still Hard to Fill - Move to Step 12
12. Recirculation Check - Reconnect canister at the control valve and disconnect the recirc line
at the control valve. Take the vehicle to the gas station and determine if it fills cleanly
1. Fuel tank fills clean - Replace the recirc line and the fuel filler pipe and refuel to verify
problem is solved
2. Still Hard to Fill - Replace the fuel tank and refuel to verify the problem is solved.
FUEL DELIVERY > DIAGNOSIS AND TESTING > DIESEL FUEL SYSTEM
PRELIMINARY TESTS
NOTE:
The fuel system is highly sensitive.
NOTE:
All work must be carried out with great cleanliness and care.
NOTE:
Any air in the system can damage the high pressure fuel pump. Therefore, the vehicle must
never be operated with the fuel tank empty.
CHECK TO BE MADE RESOLUTION
Drain and properly dispose of fuel tank contents and

Verify that the tank contains the right type of fuel.
clean the fuel tank.
There must be greater than 5 liters of fuel in the

Add the necessary amount of fuel.
tank.
Check for leaks in the fuel supply:

Check hoses and tubes connected to detect any
obstruction, damage, etc.;
Check that there are no points of failure /
scratches on the fuel lines or fuel injection;
Check connections of fuel lines (quick
Repair or replace components as necessary.
connectors);
Check the status of the fasteners.
Verify that the connections and seals are fitted
correctly.
Check there is no obstructions, leaks, air or water
in the fuel system.
Verify the tightening torque of the countersunk

Properly tighten the components
screws
Replace the fuel filter. Refer to FILTER, FUEL,

Check the fuel filter.
FUEL DELIVERY > STANDARD PROCEDURE > FUEL CUTOFF RESET
Resetting the of the fuel cutoff feature may be necessary following an impact of the vehicle. An event
that cuts off the fuel flow from the fuel tank is indicated by a warning indicator in the instrument cluster.
CHECK TO BE MADE RESOLUTION
Restore fuel supply

Perform the following procedure to reset the
fuel cutoff feature:
- Ignition key to "OFF" (starting condition)
- Ignition key to the "ON" position
- Activate the right turn indicator
Repair the wiring between multifunction switch and
- Turn off right turn indicator
- Activate the left turn indicator
If the wiring is OK replace multifunction switch. Refer
- Turn off left turn indicator
to SWITCH, MULTIFUNCTION, REMOVAL AND
- Activate on right turn indicator
INSTALLATION .
- Turn off right turn indicator
- Activate the left turn indicator
- Turn off left turn indicator
- Ignition key to the "OFF" position
In the presence of control units in error continue
as indicated by the diagnostic tool.
FUEL DELIVERY > SPECIAL TOOLS > SPECIAL TOOLS
Loosen / tighten the fuel

2000002100 9340
pump mounting ring
FUEL DELIVERY > FILTER, FUEL > REMOVAL AND INSTALLATION > 1.6L/2.0L >
REMOVAL
1. Open the cover of the fuse box in the engine compartment and remove the fuse F21 (15 A) of
the fuel pump.
2. Start the engine and run until the fuel in the lines is depleted.
3. Install the fuse removed earlier and close the fuse box cover.
Fig 1: Fuel Filter Couplings, Screws & Sensor
5. Disconnect the flow and return pipe quick release couplings from the fuel filter (1).
6. Disconnect the electrical connection of the temperature and the water in the fuel filter sensor
(2).
7. Remove the screws and remove the fuel filter (3).

Fig 2: Fuel Filter Support Bracket, Clip & Nuts
8. If required, loosen the nuts (1a), open the retaining clip wiring (1b) and remove the fuel filter
support bracket (1c).
FUEL DELIVERY > FILTER, FUEL > REMOVAL AND INSTALLATION > 1.6L/2.0L >
INSTALLATION
1. Install the fuel filter bracket support, close the wiring retainer clip and securely tighten the
mounting nuts.
2. Position the fuel filter into the bracket and securely tighten the mounting nuts.
3. Connect the electrical connection to the temperature and water in fuel sensor.
4. Connect the flow and return pipe quick release couplings to the fuel filter.
FUEL DELIVERY > PUMP, FUEL INJECTION > REMOVAL AND INSTALLATION >
1.6L/2.0L > REMOVAL
the fuel pump.
4. Place the vehicle on a lift.
6. Remove the belly pan. Refer to BELLY PAN, REMOVAL AND INSTALLATION or BELLY PAN,
8. Remove the air cleaner body. .
Fig 1: Injectors Fuel Return Pipe & Tank Fuel Return Pipe
10. Disconnect the quick coupling of the fuel return pipe to the tank (1).
11. Loosen the hose clamp and disconnect the fuel return pipe from the injectors (2).
Fig 2: Fuel Return Manifold & Clamp
12. Loosen the screws and move the fuel return manifold to side.
13. loosen clamp (1a) and remove the fuel return manifold (1b).
Fig 3: Timing Cover & Screws
14. Unscrew the screws (1a) and remove the timing cover (1b).
Fig 4: Fuel Pressure Regulator, Fuel Injection Pump & Coupling
15. Disconnect the electrical connection of the fuel pressure regulator (1).
16. Unscrew the fuel delivery pipe fitting from fuel injection pump (2).
17. Disconnect the quick coupling of fuel supply pipe to the pressure pump and remove it (3).
Fig 5: Fuel Manifold Delivery Pipe
18. Unscrew the fitting and remove the fuel delivery pipe from the fuel manifold (1).
Fig 6: Fuel Pipe Support Bracket & Retaining Clips
19. Open the fuel pipe retaining clips (1).
20. Unscrew the screw and remove the fuel pipe support bracket (2).
21. Unscrew the screws and remove the pressure pump protection.
Fig 7: Injection Pump Drive Pulley Screws & Nut
22. Tighten the screws of the tool (2000026900) to lock the injection pump drive pulley to its
support (1).
NOTE:
Rotate the crankshaft to align the threaded holes of the pulley with the
corresponding injection pump support and insert the calibrated screw to the position
indicated in the figure.
23. Unscrew the injection pump nut (2).

Fig 8: Water Pump Return Pipe
24. Disconnect the quick connector of the three-way union for the return pipe to the water pump
(1).
Fig 9: Injection Pump Nuts
25. Remove the nuts holding the injection pump to its support (1).
Fig 10: Injection Pump, Pulley, Extractor & Screws
26. Remove the injection pump pulley (1a) using the extractor (1b) and the screws (1c).
27. Move back, turn towards the passenger compartment and remove the injection pump (2).
28. Remove the injection pump removal tools.

FUEL DELIVERY > PUMP, FUEL INJECTION > REMOVAL AND INSTALLATION >
1.6L/2.0L > INSTALLATION
Fig 1: Special Tool & Centering Pin
1. Put in place the pressure pump, tighten the tool to rotate the pump shaft in order to align the
centering pin (a) with the Groove on the drive pulley.
Fig 2: Injection Pump Retaining Nuts
2. Tighten the injection pump retaining nuts (1) to the proper torque specification. Refer to FUEL
DELIVERY, SPECIFICATIONS .
3. Connect the quick coupling three-way fitting to the return pipe to the water pump.
4. Remove the tool used for the rotation of the pump shaft.
Fig 3: Injection Pump Drive Pulley Screws & Nut
5. Install and tighten the injection pump pulley retaining nut (1) to the proper torque specification.
Refer to FUEL DELIVERY, SPECIFICATIONS .
6. Remove the screws (2) of the tool to lock the injection pump pulley to its support.
7. Install the injection pump protection and securely tighten the screws.
8. Install the fuel pipe support bracket and securely tighten the screw.
9. Engage the fuel pipe retaining clips.

Fig 4: Fuel Manifold Delivery Pipe
10. Install the fuel delivery pipe to the fuel manifold and tighten the fitting to the proper torque
specification. Refer to FUEL DELIVERY, SPECIFICATIONS .
Fig 5: Fuel Pressure Regulator, Fuel Delivery Pipe Fitting & Coupling
11. Install the fuel supply pipe to the injection pump and connect the quick coupling (1).
12. Tighten the fuel delivery pipe fitting (2) to the proper torque specification. Refer to FUEL
DELIVERY, SPECIFICATIONS .
13. Connect the electrical connection of the fuel pressure regulator (3).
14. Install the timing cover and securely tighten the fasteners.
15. Install the fuel return manifold and tighten the screws.
16. Connect the return line from the fuel injectors to the fuel return manifold and tighten its clamp.
17. Connect the quick coupling of the fuel return pipe to the tank.
19. Install the air cleaner body. .
21. Install the belly pan. Refer to BELLY PAN, REMOVAL AND INSTALLATION or BELLY PAN,
FUEL DELIVERY > LINES, FUEL > REMOVAL AND INSTALLATION > 1.4L > REMOVAL
- FRONT FUEL DELIVERY LINE - 1.4L
2. Open the cover of the Power Distribution Center (PDC) in the engine compartment and remove
the fuel pump fuse (F21 - 15 ampere).
3. Wait for the residual pressure in the fuel distribution manifold to be relieved.
4. Reinstall the fuel pump fuse (F21 - 15 ampere) and close the PDC cover.
Fig 1: Steering Column To The Steering Gear Pinion Bolt
10. Remove the bolt (1) securing the steering column to the steering gear pinion.
Fig 2: Right And Left Lower Load Beams At The Front End
NOTE:
Right side shown in the illustration, left side similar.
11. Remove the three bolts (1) securing right and left lower load beams at the front end.
Fig 3: Front Lower Frame Strut Bolts
NOTE:
12. Remove the two bolts (1) and remove the right and left front lower frame struts for the front
end.
Fig 4: Right And Left Lower Load Beam Bottom Bolts
NOTE:
13. Remove the two bolts (1a) and remove the right and left lower load beam (1b).
Fig 5: Stabilizer Bar Nut
NOTE:
14. Remove the nut (1) from the right and left joint stabilizer bars and disconnect them from the
shock.
Fig 6: Exhaust Pipe Rear Support Bracket Bolts
15. Remove the bolts (1) from the rear bracket supporting the exhaust pipe.
Fig 7: Front Exhaust Support Bracket Bolts & Exhaust Dampening Rod Bolts
16. Remove the two bolts (1) securing the support bracket front exhaust.
17. Remove the bolt (2) from the exhaust dampening rod securing it to the crossmember.
Fig 8: Front & Rear Fuel Line Shield Bolts
18. Remove the four bolts (1) and remove the front and rear fuel line shields.
Fig 9: Fuel Delivery Line Retainer Clip & Coupling
19. Disconnect the quick coupling (1) and disengage the fuel delivery line from the rear retainer clip
(1).
Fig 10: Suspension Crossmember Rear Bolts
20. Place a suitable hydraulic lift under the suspension crossmember.
21. Remove the rear bolts (1) from the suspension crossmember that secure it to the body.
Fig 11: Suspension Crossmember Left & Right Front Siderail Bolts
22. Remove the front bolts (1) from the suspension crossmember that secure it to the left and right
siderails.
23. Lower the hydraulic lift with the suspension crossmember.
24. Remove the suspension crossmember from the lift and position it out of the way.
Fig 12: Fuel Delivery Line Coupling
25. Disconnect the front quick coupling (1) of the fuel delivery line and open the retaining clip.
Fig 13: Fuel Delivery Line & Retaining Clips
26. Disengage the fuel delivery line (1) from the front retaining clips (1) on the right side of the
engine compartment.
27. Working from the engine compartment, remove the front fuel delivery line and remove the line
from the engine compartment.
FUEL DELIVERY > LINES, FUEL > REMOVAL AND INSTALLATION > 1.4L >
INSTALLATION - FRONT FUEL DELIVERY LINE - 1.4L
Fig 1: Fuel Delivery Line & Retaining Clips
1. Working from the engine compartment, put into place the front fuel delivery line (1) and engage
the retaining clips (1).
Fig 2: Fuel Delivery Line Coupling
2. Connect the quick coupling (1) of the front fuel delivery line and close the retainer clip.
Fig 3: Suspension Crossmember Left & Right Front Siderail Bolts
3. Using a hydraulic lift, put into place the suspension crossmember. Install the front mounting
bolts (1) to the left and right side rails and tighten to the proper torque specification. Refer to
SPECIFICATIONS .
4. Install the rear bolts (1) for the suspension crossmember to the body. Tighten to the proper

Fig 4: Fuel Delivery Line Retainer Clip & Coupling
6. Connect the quick coupling (1) and insert the front fuel delivery line into the spring retainer (1).
7. Position the front and rear fuel pipe shields and install the four bolts (1).
Fig 6: Exhaust Dampening Rod & Exhaust Support Bracket Bolts
8. Position the exhaust dampening rod and install the bolt (1) securing it to the crossmember.
Tighten to the proper torque specification. Refer to SPECIFICATIONS .
9. Install the two bolts (1) securing the front exhaust support bracket. Tighten to the proper torque
Fig 7: Exhaust Pipe Rear Support Bracket Bolts
10. Install the bolts (1) for the rear bracket supporting the exhaust pipe. Tighten to the proper
Fig 8: Stabilizer Bar Nut
NOTE:
11. Connect the right and left joint stabilizer bars to the shocks and install the nuts (1). Tighten to
the proper torque specification. Refer to FRONT, SPECIFICATIONS .
Fig 9: Right And Left Lower Load Beam Bottom Bolts
NOTE:
12. Position the right and left lower load beams (1a) and install the two bolts (1b). Tighten to the
Fig 10: Front Lower Frame Strut Bolts
NOTE:
13. Position the right and left front lower frame struts for the front end and install the two bolts (1).
Tighten to the proper torque specification. Refer to SPECIFICATIONS .
Fig 11: Right And Left Lower Load Beams At The Front End
NOTE:
14. Install the three bolts (1) securing right and left lower load beams at the front end. Tighten to
15. Install a new bolt (1) securing the steering column shaft to the pinion steering gear. Tighten to
- REAR FUEL DELIVERY LINE - 1.4L
Fig 1: Fuel Pump Access Covers & Screws
4. Remove the rear seat cushion from the vehicle. Refer to SEAT CUSHION, REMOVAL AND
INSTALLATION .
5. Lift the floor covering to access and remove the screws (1) that secure the fuel pump and vent
tube access covers to the floor panel and remove the access cover.
Fig 2: Electric Fuel Pump Connector & Rear Fuel Delivery Tube Quick Coupling
6. Disconnect the wire harness connector (1) from the electric fuel pump.
7. Disconnect the rear fuel delivery tube quick coupling (2) from the electric fuel pump.
Fig 3: Rear Vent Tube Quick Coupling
8. Disconnect the rear vent tube quick coupling (1).
10. Remove the side belly pan from the underbody of the vehicle. Refer to BELLY PAN, REMOVAL
AND INSTALLATION or BELLY PAN, SIDE, REMOVAL AND INSTALLATION .
Fig 4: Fuel Tube Shield Screws
11. Remove the screws (1) that secure the fuel tube shield beneath the underbody and remove the
front and rear shields.
Fig 5: Fuel Delivery Tube Front Quick Coupling
12. Disconnect the rear fuel delivery tube front quick coupling (1).
Fig 6: Rear Fuel Delivery Tube
13. Disengage the rear fuel delivery tube (1) from the retaining clips on the underbody.
Fig 7: Fuel Tank Heat Shield Retaining Washer
14. Unscrew the serrated fuel tank heat shield retaining washer (1).
Fig 8: Front Tank Mounting Brackets & Hydraulic Lift
15. Place a suitable hydraulic lift to support the fuel tank, then remove the screws from the front
tank mounting brackets (1).
Fig 9: Rear Tank Mounting Brackets & Screws
16. Remove the screws (1) from the rear tank mounting brackets.
Fig 10: Rear Fuel Delivery Tube & Retaining Clips
17. Lower the fuel tank far enough to access and disengage the rear fuel delivery tube from the
retaining clips (1) and remove.
INSTALLATION - REAR FUEL DELIVERY LINE - 1.4L
1. Position the rear fuel delivery tube (1) to the vehicle underbody.
2. Engage the rear fuel delivery tube (1) with the retaining clips on the underbody.
3. Connect the rear fuel delivery tube front quick coupling (1).
4. Lift the fuel tank back into position then install and tighten the screws (1) for the rear tank
mounting brackets. Tighten the screws securely.
5. Install and tighten the screws that secure the front tank mounting brackets (1). Tighten the
screws securely.
6. Position the fuel tank heat shield and secure it by screwing on the serrated retainer washer
(1).
7. Position the front and rear fuel tube shields to the underbody then install and tighten the screws
(1) that secure it. Tighten the screws securely.
8. Install the side belly pan onto the underbody of the vehicle. Refer to BELLY PAN, REMOVAL
10. Lift the floor covering to access and connect the rear vent tube quick coupling (1).
Fig 9: Electric Fuel Pump Connector & Rear Fuel Delivery Tube Quick Coupling
11. Connect the rear fuel delivery tube quick coupling (2) to the electric fuel pump.
12. Connect the wire harness connector (1) to the electric fuel pump.
13. Position the fuel pump and vent tube access covers to the floor panel then install and tighten
the screws (1) to secure them. Tighten the screws securely.
14. Install the rear seat cushion into the vehicle. Refer to SEAT CUSHION, REMOVAL AND
INSTALLATION .
CAUTION:
Cleanliness cannot be overemphasized when handling or replacing diesel fuel system

components. This especially includes the fuel injectors, high-pressure fuel lines and fuel
injection pump. Very tight tolerances are used with these parts. Dirt contamination could
cause rapid part wear and possible plugging of fuel injector nozzle tip holes. This in turn
could lead to possible engine misfire. Always wash/clean any fuel system component
thoroughly before disassembly and then air dry. Cap or cover any open part after
disassembly. Before assembly, examine each part for dirt, grease or other contaminants and
clean if necessary. When installing new parts, lubricate them with clean engine oil or clean
diesel fuel only. DO NOT use any lubricating or sliding agents that contain water.
4. Remove the side belly pan. Refer to BELLY PAN, SIDE, REMOVAL AND INSTALLATION .
.
10. Remove the alternator and position it out of the way. Refer to GENERATOR, REMOVAL AND
INSTALLATION .
Fig 1: Fuel Line Shield & Bolts
11. Remove the bolts (1) and remove the fuel line shield (1).
Fig 2: Fuel Lines, Retaining Clips & Couplings
12. Disengage the fuel lines (1) from the retaining clips (1).
13. Disconnect the quick couplings (2) of the discharge and return fuel lines.
14. Disengage the fuel lines from the retaining clip (3).
Fig 3: Fuel Lines & Retaining Clip
15. Disengage the fuel lines and remove the retaining clip (1).
Fig 4: Fuel Return Pipe Coupling & Retaining Clip
16. Open the retaining clip (1) and disconnect the quick coupling (1) of the fuel return pipe.
Fig 5: A/C Suction Line Quick Coupling
17. Disconnect the quick coupling (1) of the A/C suction line from the expansion valve to the A/C
compressor flange line.
Fig 6: Retaining Clips & Nut
18. Open the retaining clips (1 and 2) and release the A/C suction and liquid lines from the clips.
19. Remove the nut (2) from the A/C line bracket and remove the bracket complete with retaining
clips (1 and 2).
Fig 7: A/C Suction Line & Retaining Clip
20. Open the retaining clip (1) for the A/C suction line and disengage the A/C suction line from the
retaining clip.
Fig 8: A/C Suction Line & Nut
21. Remove the nut (1), disconnect and remove the A/C suction line (1) from the A/C expansion
valve.
Fig 9: Fuel Pressure & Return Lines
22. Release the fuel pressure and return lines (1) from the upper and lower retaining clips.
23. Remove the front fuel delivery line from the engine compartment.
CAUTION:

1. Working from the engine compartment, put into place the front fuel delivery lines (1) and
2. Replace the O-ring on the A/C suction line at the A/C expansion valve and connect the A/C
suction line (1) to the expansion valve.
3. Install the nut (1) and torque the nut to the proper torque specification. Refer to
SPECIFICATIONS .
4. Install the A/C suction line (1) to the retaining clip and engage the retaining clip (1).
5. Position the A/C line bracket and install the nut (2) for the bracket complete with retaining clips
(1 and 2).
6. Install the A/C suction and liquid lines to the retaining clips and engage the retaining clips (1
and 2).
7. Connect the quick coupling (1) of the A/C suction line to the A/C compressor flange line.
8. Connect the quick coupling (1) for the fuel return pipe and engage the retaining clip (1).
9. Engage the fuel lines to the retaining clip (1).

10. Engage the fuel lines into the retaining clip (3).
11. Connect the quick couplings (2) for the discharge and return fuel lines.
12. Engage the fuel lines (1) into the retaining clips (1).
13. Position the fuel line shield (1) and install the bolts (1). Tighten the bolts securely.
14. Install the alternator and position it out of the way. Refer to GENERATOR, REMOVAL AND
INSTALLATION .
19. Install the side belly pan. Refer to BELLY PAN, SIDE, REMOVAL AND INSTALLATION .

- 1040B54 FUEL RETURN PIPE FRONT - 1.6L
2. Remove the front belly pan from the underside of the vehicle. Refer to BELLY PAN, REMOVAL
AND INSTALLATION .
3. Remove the side belly pan from the underbody of the vehicle. Refer to BELLY PAN, SIDE,
4. Remove the splash shield from the right front wheel house of the vehicle. Refer to SHIELD,
SPLASH, FRONT WHEELHOUSE, REMOVAL AND INSTALLATION .
5. Remove the engine cover from the vehicle. Refer to COVER, ENGINE, REMOVAL AND
INSTALLATION .
6. Remove the engine air cleaner assembly from the vehicle. .
7. Remove the fuel filter from the vehicle. Refer to FILTER, FUEL, REMOVAL AND
INSTALLATION .
8. Recover the refrigerant from the air conditioning system. Refer to PLUMBING, STANDARD
PROCEDURE .
9. Remove the mounting fasteners that secure the alternator and move the alternator aside.
Refer to GENERATOR, REMOVAL AND INSTALLATION .
shield.
11. Disengage the fuel tubes (1) from the retaining clips on the underbody.
12. Disconnect the fuel return and discharge tube quick connect fittings (2).
13. Remove the retaining clip (3).

14. Unhook the fuel lines and remove them from the retaining clip (1).
15. Open the retaining clip and disconnect the return line quick connect fitting (1).
16. Disconnect the quick connect (1) of the air conditioning expansion valve tubing, tandem tube
side.
17. Open the retaining clips and release the air conditioning tube (1).
18. Unscrew the nut and remove the complete bracket (2).
19. Open the clip and disengage the air conditioning expansion valve tandem tube (1).
20. Unscrew the nut, disconnect and remove the tube from the expansion valve to the tandem tube
on the expansion valve side (1).
21. Disengage the fuel pressure and return lines from the retaining clips (1).
22. Remove the fuel return tube front from the engine compartment.
INSTALLATION - 1040B54 FUEL RETURN PIPE FRONT - 1.6L
1. Position the front fuel return tube into the engine compartment.
2. Engage the fuel pressure and return tubes with the retaining clips (1).
3. Reconnect and install the tube from the expansion valve to the tandem tube on the expansion
valve side (1), then tighten the nut. Always be certain to use new O-ring seals on refrigerant
line fittings.
4. Engage the air conditioning expansion valve tandem tube (1) and secure the retaining clip.
5. Position the complete bracket (2) and secure it with a nut.
6. Position the air conditioning tube and engage the retaining clips (1).
7. Reconnect the quick connect (1) of the air conditioning expansion valve tubing, tandem tube
side. Always be certain to use new O-ring seals on refrigerant line fittings.
8. Reconnect the return line quick connect fitting and close the retaining clip (1).

10. Reinstall the retaining clip (3).
11. Reconnect the fuel return and discharge tube quick connect fittings (2).
12. Engage the fuel tubes (1) with the retaining clips on the underbody.
13. Position the fuel tube shield to the underbody then install and tighten the screws (1) that secure
it. Tighten the screws securely.
14. Reinstall the alternator. Refer to GENERATOR, REMOVAL AND INSTALLATION .
15. Evacuate and recharge the air conditioning system. Refer to PLUMBING, STANDARD
PROCEDURE .
16. Reinstall the fuel filter into the vehicle. Refer to FILTER, FUEL, REMOVAL AND
INSTALLATION .
17. Reinstall the engine air cleaner assembly into the vehicle. .
18. Reinstall the engine cover into the vehicle. Refer to COVER, ENGINE, REMOVAL AND
INSTALLATION .
19. Reinstall the splash shield into the right front wheel house of the vehicle. Refer to SHIELD,
20. Reinstall the side belly pan onto the underbody of the vehicle. Refer to BELLY PAN, SIDE,
21. Reinstall the front belly pan onto the underside of the vehicle. Refer to BELLY PAN, REMOVAL
CAUTION:

Fig 1: Fuel Pump Access Cover & Screws
INSTALLATION .
5. Lift the floor covering to access and remove the screws (1) that secure the fuel pump access
cover to the floor panel and remove the access cover.
Fig 2: Wire Harness Connector & Rear Fuel Delivery Tube Quick Coupling
Fig 3: Fuel Tube Shield & Screws
shield.
Fig 4: Rear Fuel Delivery Tube Front Quick Coupling
CAUTION:

3. Reconnect the rear fuel delivery tube front quick coupling (1).
screws securely.
(1).
8. Install the side belly pan onto the underbody of the vehicle. Refer to BELLY PAN, SIDE,
Fig 8: Rear Fuel Delivery Tube Quick Coupling & Wire Harness Connector
10. Lift the floor covering to access and connect the rear fuel delivery tube quick coupling (2) to
the electric fuel pump.
12. Position the fuel pump access cover to the floor panel then install and tighten the screws (1) to
secure it. Tighten the screws securely.
INSTALLATION .
- 1040B56 FUEL RETURN PIPE BACK - 1.6L
CAUTION:

INSTALLATION .
7. Disconnect the rear fuel return tube quick connect fitting (2) from the electric fuel pump.
shield.
Fig 4: Rear Fuel Return Tube Front Quick Connect Fitting
11. Disconnect the rear fuel return tube front quick connect fitting (1).
Fig 5: Rear Fuel Return Tube & Retaining Clips
12. Disengage the rear fuel return tube (1) from the retaining clips on the underbody.
16. Lower the fuel tank far enough to access and disengage the rear fuel return tube from the
INSTALLATION - 1040B56 FUEL RETURN PIPE BACK - 1.6L
CAUTION:

1. Position the rear fuel return tube (1) to the vehicle underbody.
2. Engage the rear fuel return tube (1) with the retaining clips on the underbody.
3. Reconnect the rear fuel return tube front quick connect fitting (1).
screws securely.
(1).
9. Lift the floor covering to access and reconnect the rear fuel return tube quick connect fitting (2)
to the electric fuel pump.
10. Reconnect the wire harness connector (1) to the electric fuel pump.
12. Reinstall the rear seat cushion into the vehicle. Refer to SEAT CUSHION, REMOVAL AND
INSTALLATION .
CAUTION:

.
12. Remove the air cleaner body. .

13. Remove the bolt (1) securing the steering column to the steering gear pinion.
Fig 2: Right And Left Lower Load Beams Fasteners At The Front End
NOTE:
Left side shown in the illustration, right side similar.
14. Remove the fasteners (1) securing right and left lower load beams at the front end.
Fig 3: Right And Left Front Lower Frame Struts & Bolts
NOTE:
15. Remove the two bolts (1) and remove the right and left front lower frame struts for the front
end.
Fig 4: Right And Left Lower Load Beam & Bolts
NOTE:
16. Remove the two bolts (1a) and remove the right and left lower load beam (1b).
Fig 5: Joint Stabilizer Bars & Nut
NOTE:
17. Remove the nut (1) from the right and left joint stabilizer bars and disconnect them from the
shock.
Fig 6: Collar Nut & Front Exhaust Support Bracket Bolts
18. Remove the nut (1) and loosen the collar for the exhaust connecting pipes.
19. Remove the bolts (2) securing the front exhaust support bracket.
Fig 7: Exhaust Dampening Rod Bolt
20. Remove the bolt (2) from the exhaust dampening rod securing it to the crossmember.
Fig 8: Fuel Line Shield Bolts
21. Remove the bolts (1) and remove the fuel line shield.
Fig 9: Fuel Lines, Retaining Clips & Coupling
22. Disengage the fuel lines (1) from the retaining clip (1).
23. Disconnect the quick couplings (2) of the discharge and return fuel lines.
24. Disengage the fuel lines from the retaining clip (3).
25. Open the retaining clip (1) and disconnect the quick coupling (1) of the fuel return pipe.
Fig 11: Fuel Filter Support Bracket & Nuts
26. Remove the nuts (1) and remove the fuel filter support bracket.
Fig 12: A/C Suction & Liquid Line Nuts
27. Remove the nuts (1) from the A/C suction and liquid lines and disconnect the lines from the
expansion valve. Discard the O-rings.
Fig 13: A/C Suction & Liquid Line Retaining Clips
28. Release the retaining clips (1) for the A/C suction and liquid lines.
Fig 14: A/C Suction Line, Retaining Clip & Coupling
29. Release the retaining clip (1a), disconnect quick coupling (1b) and remove the A/C suction line
(1c).
Fig 15: Retaining Bracket & Nut
30. Remove the nut (1) and remove the A/C suction and liquid lines retaining bracket (1).
Fig 16: Fuel Delivery/Return Lines & Retaining Clips
31. Disengage the fuel delivery/return lines (1) from the retaining clips (1).
32. Disengage the fuel delivery/return lines (1) from the retaining clips (1).
33. Place a suitable hydraulic lift under the suspension crossmember.
34. Remove the rear bolts (1) from the suspension crossmember that secure it to the body.
Fig 19: Suspension Crossmember Left And Right Siderail Bolts
35. Remove the front bolts (1) from the suspension crossmember that secure it to the left and right
siderails.
36. Lower the hydraulic lift with the suspension crossmember.
37. Remove the suspension crossmember from the lift and position it out of the way.
38. Working from the engine compartment, remove the front fuel delivery line and remove the line
from the engine compartment.
CAUTION:

1. Working from the engine compartment, put into place the front fuel delivery line and engage the
retaining clips.
2. Using a hydraulic lift, put into place the suspension crossmember. Install the front mounting
bolts (1) to the left and right siderails and tighten to the proper torque specification. Refer to
SPECIFICATIONS .
Fig 2: Suspension Crossmember To Body Rear Bolts
3. Install the rear bolts (1) for the suspension crossmember to the body. Tighten to the proper

5. Engage the fuel delivery/return lines (1) into the retaining clips (1).
6. Engage the fuel delivery/return lines (1) into the retaining clips (1).
7. Position the A/C suction and liquid lines retaining bracket (1) and install the nut (1). Tighten the
nut securely.
8. Engage the A/C suction line (1c) into the retaining clip (1a) and connect the quick coupling (1b).
Fig 7: A/C Suction And Liquid Line Retaining Clips
9. Engage the A/C suction and liquid lines into the retaining clips (1).
NOTE:
The O-rings must be replaced for each A/C line that was disconnected, using only
O-rings that are made for the type of refrigerant oil that is in the A/C system. Failure
to replace the O-rings may result in a refrigerant leak.
10. Install new O-rings on the A/C suction and liquid lines. Connect the lines to the expansion valve
and install the nuts (1). Torque the nuts to the proper torque specification. Refer to
SPECIFICATIONS .
11. Position the fuel filter support bracket and install the nuts (1). Tighten the nuts securely.
12. Insert the fuel return pipe into the retaining clip (1) and connect the quick coupling (1).
Fig 11: Fuel Lines, Retaining Clips & Coupling
14. Connect the quick couplings (2) for the discharge and return fuel lines.
15. Engage the fuel lines (1) into the retaining clip (1).
16. Position the fuel line shield and install the bolts (1). Tighten the bolts securely.
Fig 13: Dampening Rod To Crossmember Bolt
17. Install the bolt (1) for the dampening rod securing it to the crossmember. Tighten to the proper
Fig 14: Exhaust Dampening Rod Bolt & Collar Nut
18. Position the exhaust dampening rod and install the bolt (1) securing it to the crossmember.
Tighten to the proper torque specification. Refer to SPECIFICATIONS
19. Install the nut (2) for the collar securing the exhaust connecting pipes. Tighten to the proper
NOTE:
20. Connect the right and left joint stabilizer bars to the shocks and install the nuts (1). Tighten to
the proper torque specification. Refer to FRONT, SPECIFICATIONS .
Fig 16: Right And Left Lower Load Beams Bottom Bolts
NOTE:
21. Position the right and left lower load beams (1a) and install the two bolts (1b). Tighten to the
proper torque specifications. Refer to SPECIFICATIONS .
NOTE:
22. Position the right and left front lower frame struts for the front end and install the two bolts (1).
Tighten to the proper torque specifications. Refer to SPECIFICATIONS .
Fig 18: Right And Left Lower Load Beam Fasteners At The Front End
NOTE:
23. Install the fasteners (1) securing right and left lower load beams at the front end. Tighten to the
proper torque specifications. Refer to SPECIFICATIONS .
24. Install a new bolt (1) securing the steering column shaft to the pinion steering gear. Tighten to
- 1040B54 FUEL RETURN PIPE FRONT - 2.0L
4. Remove the engine cover from the vehicle. Refer to COVER, ENGINE, REMOVAL AND
INSTALLATION .
5. Recover the refrigerant from the air conditioning system. Refer to PLUMBING, STANDARD
PROCEDURE .
7. Remove the front belly pan from the underside of the vehicle. Refer to BELLY PAN, REMOVAL
8. Remove the front bumper fascia from the vehicle. Refer to FASCIA, FRONT, REMOVAL AND
INSTALLATION .
9. Remove the splash shield from the right front wheel house of the vehicle. Refer to SHIELD,
10. Remove the fuel filter from the vehicle. Refer to FILTER, FUEL, REMOVAL AND
INSTALLATION .
11. Remove the engine air cleaner assembly from the vehicle.
12. Remove the screw (1) that secures the steering column shaft coupling to the steering rack
pinion shaft.
Fig 2: Right And Left Lower Load Beams Fasteners At The Front End
13. Remove the screws (1) that secure the left and right brackets of the front bumper bar to the
front end structure.
14. Remove the screws and the reinforcements (1) from the left and right front end structure.
Fig 4: Right And Left Lower Load Beam & Bolts
15. Remove the screws (1) and the left and right brackets of the front bumper bar from the front
end structure.
16. Remove the lock nut and disengage the stabilizer link (1) from each of the left and right front
strut brackets.
Fig 6: Collar Nut & Front Exhaust Support Bracket Bolts
17. Remove the nut (1) and loosen the clamp connecting the return pipes.
18. Remove the screws (2) that secure the return pipe support brackets to the side of the
suspension cross member.
Fig 7: Exhaust Dampening Rod Bolt
19. Remove the screw (1) securing the rear mount to the transmission support.
shield.
21. Disengage the fuel tubes (1) from the retaining clips on the underbody.
22. Disconnect the fuel return and discharge tube quick connect fittings (2).
23. Remove the retaining clip (3).

24. Open the retaining clip and disconnect the quick connect fitting (1) on the return line side of the
return manifold.
25. Remove the nuts and the fuel filter support bracket (1).
26. Remove the nuts (1) that secure the refrigerant lines to the expansion valve.
27. Open the retaining clips (1) on the refrigerant lines.

28. Open the retaining clip (1a), disconnect the quick connect (1b) and remove the refrigerant
return line (1c).
29. Remove the nut and the refrigerant line retaining bracket (1).
30. Disengage the fuel supply and return pipes from the retaining clips (1).
31. Unhook the fuel lines and remove them from the retaining clip (1).
32. Place a suitable hydraulic lift under the rear suspension cross member.
33. Remove the screws (1) securing the rear suspension cross member to the body.
34. Remove the screws (1) securing the rear suspension cross member to the left and right side
panels.
35. Use the hydraulic lift to lower the rear suspension cross member.
37. Working from the engine compartment, remove the front fuel return pipe.
INSTALLATION - 1040B54 FUEL RETURN PIPE FRONT - 2.0L
1. Position the front fuel return tube into the engine compartment and engage with the retaining
clips.
2. Place a suitable hydraulic lift under the rear suspension cross member and raise the cross
member into place.
3. Install and tighten the screws (1) securing the rear suspension cross member to the left and
right side panels. Tighten the screws to the proper torque specification.
Fig 2: Suspension Crossmember To Body Rear Bolts
4. Install and tighten the screws (1) securing the rear suspension cross member to the body.
Tighten the screws to the proper torque specification.

6. Engage the fuel supply and return tubes with the retaining clips (1).
7. Position the refrigerant line bracket (1) and secure it with a nut.
8. Position the refrigerant return line (1c), reconnect the quick connect (1b) and close the
retaining clip (1a). Always use new o-rings on refrigerant line connections.
9. Close the retaining clips (1) on the refrigerant lines.

10. Install and tighten the nuts (1) that secure the refrigerant lines to the expansion valve. Always
use new o-rings on refrigerant line connections. Tighten the nuts securely.
11. Position the fuel filter support bracket (1), then install and tighten the nuts to secure it. Tighten
the nuts securely.
12. Reconnect the quick connect fitting (1) on the return line side of the return manifold and close
the retaining clip.
13. Install the retaining clip (3).
14. Reconnect the fuel return and discharge tube quick connect fittings (2).
15. Engage the fuel tubes (1) with the retaining clips on the underbody.
Fig 12: Dampening Rod To Crossmember Bolt
17. Install and tighten the screw (1) securing the rear mount to the transmission support. Tighten
the screw to the proper torque specification.
Fig 13: Exhaust Dampening Rod Bolt & Collar Nut
18. Install and tighten the screws (1) that secure the return pipe support brackets to the side of the
suspension cross member. Tighten the screws to the proper torque specifications.
19. Install and tighten the nut (2) for the clamp connecting the return pipes. Tighten the nut to the
proper torque specifications.
20. Engage the stabilizer links to each of the left and right front strut brackets, then install and
tighten the lock nuts (1). Tighten the nuts to the proper torque specifications.
Fig 15: Right And Left Lower Load Beams Bottom Bolts
21. Install and tighten the screws (1) that secure the left and right brackets of the front bumper bar
to the front end structure. Tighten the screws to the proper torque specifications.
22. Install and tighten the screws that secure the left and right reinforcements (1) to the front end
structure. Tighten the screws to the proper torque specifications.
Fig 17: Right And Left Lower Load Beam Fasteners At The Front End
23. Install and tighten the screws (1) that secure the left and right brackets of the front bumper bar
to the front end structure. Tighten the screws to the proper torque specifications.
24. Install and tighten the screw (1) that secures the steering column shaft coupling to the steering
rack pinion shaft. Tighten the screw to the proper torque specification.
25. Reinstall the engine air cleaner assembly into the vehicle.
26. Reinstall the fuel filter into the vehicle. Refer to FILTER, FUEL, REMOVAL AND
INSTALLATION .
27. Reinstall the splash shield into the right front wheel house of the vehicle. Refer to SHIELD,
SPLASH, FRONT WHEELHOUSE, REMOVAL AND INSTALLATION
28. Reinstall the front bumper fascia onto the vehicle. Refer to FASCIA, FRONT, REMOVAL AND
INSTALLATION .
29. Reinstall the front belly pan onto the underside of the vehicle. Refer to BELLY PAN, REMOVAL
30. Evacuate and recharge the air conditioning system. Refer to PLUMBING, STANDARD
PROCEDURE .
31. Reinstall the engine cover into the vehicle. Refer to COVER, ENGINE, REMOVAL AND
INSTALLATION .
CAUTION:

INSTALLATION .
Fig 2: Wire Harness Connector & Rear Fuel Delivery Tube Quick Coupling
shield.
CAUTION:

3. Reconnect the rear fuel delivery tube front quick coupling (1).
screws securely.
(1).
10. Lift the floor covering to access and connect the rear fuel delivery tube quick coupling (2) to
the electric fuel pump.
INSTALLATION .
- 1040B56 FUEL RETURN PIPE BACK - 2.0L
CAUTION:

INSTALLATION .
7. Disconnect the rear fuel return tube quick connect fitting (2) from the electric fuel pump.
shield.
11. Disconnect the rear fuel return tube front quick connect fitting (1).
12. Disengage the rear fuel return tube (1) from the retaining clips on the underbody.
16. Lower the fuel tank far enough to access and disengage the rear fuel return tube from the
INSTALLATION - 1040B56 FUEL RETURN PIPE BACK - 2.0L
CAUTION:

1. Position the rear fuel return tube (1) to the vehicle underbody.
2. Engage the rear fuel return tube (1) with the retaining clips on the underbody.
3. Reconnect the rear fuel return tube front quick connect fitting (1).
screws securely.
(1).
9. Lift the floor covering to access and reconnect the rear fuel return tube quick connect fitting (2)
to the electric fuel pump.
10. Reconnect the wire harness connector (1) to the electric fuel pump.
12. Reinstall the rear seat cushion into the vehicle. Refer to SEAT CUSHION, REMOVAL AND
INSTALLATION .
Fig 1: Engine Oil Vapor Hose Quick Coupling, Clean Air Hose, Clamp & Bolt
5. Remove the bolt (1) from the clean air hose which goes between the air cleaner body cover
and the throttle body.
7. Loosen the clamp (3) and disconnect the clean air hose (3) from the air cleaner body cover.
Fig 2: Clean Air Hose & Clamp
8. Disconnect the wire harness connector (1) from the inlet air temperature sensor.
9. Loosen the clamp (2) and remove the clean air hose (2).
Fig 3: Front Fuel Delivery Line Right End Quick Coupling
10. Disconnect the quick coupling (1) on the right end of the front fuel delivery line.
Fig 4: Front Fuel Delivery Line Left End Quick Coupling
11. Disconnect the quick coupling (1) on the left end of the front fuel delivery line and remove the
line from the vehicle.
Fig 1: Front Fuel Delivery Line Left End Quick Coupling
1. Position the front fuel delivery line to the engine and connect the quick coupling (1).
Fig 2: Front Fuel Delivery Line Right End Quick Coupling
2. Connect the quick coupling (1) for the right end of the front fuel delivery line.
3. Connect the clean air hose (2) to the throttle body and tighten the clamp (2) securely.
4. Connect the wire harness connector (1) to the inlet air temperature sensor.
5. Connect the clean air hose (3) to the air cleaner body cover and tighten the clamp (3) securely.
7. Install the bolt (1) for the clean air hose which goes between the air cleaner body cover and
the throttle body.
- INTERMEDIATE FUEL DELIVERY LINE - 2.4L
5. Remove the side belly pan. Refer to BELLY PAN, SIDE, REMOVAL AND INSTALLATION .
7. Remove the bolt (1) from the clean air hose which goes between the air cleaner body cover
and the throttle body.
9. Loosen the clamp (3) and disconnect the clean air hose (3) from the air cleaner body cover.
10. Disconnect the wire harness connector (1) from the inlet air temperature sensor.
11. Loosen the clamp (2) and remove the clean air hose (2).
Fig 3: A/C Suction And Liquid Line Retainers
12. Release the A/C suction and liquid lines from the retainers (1).
Fig 4: Front Fuel Delivery & Vapor Line Quick Couplings
13. Disconnect the quick couplings (1 and 2) for the right end of the front fuel delivery and vapor
lines. Release the lines from the upper and lower retaining clips.
15. Remove the four bolts (1) and remove the front and rear fuel line shields.
Fig 6: Fuel Delivery Line, Vapor Line & Quick Couplings
16. Disconnect the quick coupling (2) and disengage the intermediate fuel delivery line (2) from the
rear retaining clip.
17. Disconnect the quick coupling (1) and disengage the intermediate fuel vapor line (1) from the
rear retaining clip.
Fig 7: Intermediate Fuel Delivery And Vapor Lines
18. Disengage the intermediate fuel delivery and vapor lines (1) from the front retaining clip and
remove them from the vehicle.
INSTALLATION - INTERMEDIATE FUEL DELIVERY LINE - 2.4L
Fig 1: Intermediate Fuel Delivery And Vapor Lines
1. Position the intermediate fuel delivery and vapor lines to the vehicle and insert them into the
front retaining clip.
Fig 2: Fuel Delivery Line, Vapor Line & Quick Couplings
2. Close the front retaining clip (3) and connect the quick couplings (1) for the intermediate fuel
delivery and vapor lines.
3. Insert the intermediate fuel delivery and vapor lines (1 and 2) in the rear retaining clip.
4. Position the front and rear fuel line shields and install the bolts (1). Tighten the bolts securely.
Fig 4: Front Fuel Delivery & Vapor Line Quick Couplings
5. Connect the quick couplings (1 and 2) for the right end of the front fuel delivery and vapor lines.
Insert the lines into the upper and lower retaining clips.
Fig 5: A/C Suction And Liquid Line Retainers
6. Insert the A/C suction and liquid lines into the retainers (1).
7. Connect the clean air hose (2) to the throttle body and tighten the clamp (2) securely.
8. Connect the wire harness connector (1) to the inlet air temperature sensor.
9. Connect the clean air hose (3) to the air cleaner body cover and tighten the clamp (3) securely.
11. Install the bolt (1) for the clean air hose which goes between the air cleaner body cover and
the throttle body.
13. Install the side belly pan. Refer to BELLY PAN, SIDE, REMOVAL AND INSTALLATION .
2. Remove the fuel tank from the vehicle. Refer to TANK, FUEL, REMOVAL AND INSTALLATION .
front and rear shields.
3. Connect the rear fuel delivery tube front quick coupling (1).
4. Position the front and rear fuel tube shields to the underbody then install and tighten the screws
(1) that secure it. Tighten the screws securely.
5. Install the fuel tank into the vehicle. Refer to TANK, FUEL, REMOVAL AND INSTALLATION .
FUEL DELIVERY > MODULE, FUEL PUMP > REMOVAL AND INSTALLATION > 1.4L >
REMOVAL
the fuel pump.
Fig 1: Fuel Pipes Access Cover & Screws
5. Lift the cover, unscrew the screws and remove the cover to access the fuel pipes (1).
Fig 2: Fuel Vapor Hoses & Clamp
6. Open the clamp and release the fuel vapor hoses (1).
7. Lift the cover, unscrew the screws and remove the cover to access the fuel pump.
Fig 4: Connector, Fuel Delivery Pipe & Fuel Vapor Pipe Quick Coupling
8. Unplug the fuel pump's electrical connection (1).
9. Disconnect the fuel delivery pipe quick coupling (2).
10. Disconnect the fuel vapor pipe quick couplings (3).

Fig 5: Pump Assembly Mounting Ring Set & Special Tool
11. Mount the 2000002100 (EMEA) or (special tool #9340, SAE Fuel Pump Lock Ring Wrench)
(NAFTA) tool (1a) and remove the pump assembly mounting ring set (1b).
Fig 6: Fuel Pump Assembly
12. Remove the fuel pump assembly (1).

Fig 7: Tank Seal
13. Remove the seal on the tank (1).
INSTALLATION
Fig 1: Fuel Pump & Tank Reference Points
1. Install the fuel pump assembly, taking care to align the reference (1a) on the tank with the
appendix (1b) of the pump.
Fig 2: Fuel Pump Mounting Ring & Tank Reference Points
2. Install the fuel pump assembly mounting ring, by aligning the reference (1a) with the reference
(1b) on the tank.
(NAFTA) tool (2) and tighten the fuel pump assembly retaining nut.
4. Connect the fuel vapor quick coupling.
5. Connect the quick coupling of fuel supply hose.
6. Connect the fuel pump's electrical connection.
7. Install the access cover to the fuel pump, tighten the screws and lower the coating.
FUEL DELIVERY > MODULE, FUEL PUMP > REMOVAL AND INSTALLATION > 1.6L,
2.0L > REMOVAL
the fuel pump.
5. Lift the cover, unscrew the screws and remove the cover to access the fuel pump (1).
Fig 2: Electrical Connection, Fuel Supply & Fuel Return Pipe Quick Coupling
7. Disconnect the fuel supply pipe quick coupling (2).
8. Disconnect the fuel return pipe quick coupling (3).


Fig 5: Tank Seal
FUEL DELIVERY > MODULE, FUEL PUMP > REMOVAL AND INSTALLATION > 1.6L,
2.0L > INSTALLATION
(1b) on the tank.
4. Connect the fuel return tube quick coupling.
REMOVAL
the fuel pump.
Fig 1: Fuel Pipes Access Cover & Screws
5. Lift the cover, unscrew the screws and remove the cover to access the fuel pipes (1).
Fig 2: Fuel Vapor Hoses & Clamp
6. Open the clamp and release the fuel vapor hoses (1).
7. Lift the cover, unscrew the screws and remove the cover to access the fuel pump.
9. Disconnect the fuel delivery pipe quick coupling (2).
10. Disconnect the fuel vapor pipe quick couplings (3).

12. Disconnect the quick coupling of the fuel vapor recovery pipe.

Fig 8: Tank Seal
INSTALLATION
(1b) on the tank.
4. Connect the fuel vapor quick coupling.
FUEL DELIVERY > SENSOR, FUEL RAIL PRESSURE > REMOVAL AND
INSTALLATION > 1.6L, 2.0L > REMOVAL
Fig 1: Fuel Pressure Sensor & Connector
3. Unscrew and remove the fuel pressure sensor (2).
FUEL DELIVERY > SENSOR, FUEL RAIL PRESSURE > REMOVAL AND
INSTALLATION > 1.6L, 2.0L > INSTALLATION
Fig 1: Fuel Pressure Sensor & Connector
1. Install the fuel pressure sensor (1) and tighten to the proper torque specification. Refer to
FUEL DELIVERY, SPECIFICATIONS .
2. Connect the electrical connection of the fuel pressure sensor (2).
FUEL DELIVERY > SENDING UNIT AND SENSOR, FUEL LEVEL > DESCRIPTION AND
OPERATION > DESCRIPTION AND OPERATION
The fuel gauge sending unit (fuel level sensor) is attached to the fuel pump module (1). The sending unit
consists of a float, an arm, and a variable resistor.
The sending unit/fuel level sensor is not serviceable. If the fuel level sensor sending unit has failed, the
fuel pump module will need to be replaced. Refer to MODULE, FUEL PUMP, REMOVAL AND
INSTALLATION .
FUEL DELIVERY > TANK, FUEL > REMOVAL AND INSTALLATION > 1.4L FWD >
REMOVAL
the fuel pump.
Fig 1: Access Covers & Screws
6. Lift the cover, unscrew the screws and remove the access covers (1) to the fuel pump and the
vent pipe.
Fig 2: Fuel Delivery Pipe & Electrical Connector
7. Disconnect the electrical connection (1) of the electric pump fuel.
8. Disconnect the quick coupling of the fuel delivery pipe (2).

9. Disconnect the quick connection of the vent pipe (1).
10. Remove the right rear splash shield. Refer to SHIELD, SPLASH, REAR WHEELHOUSE,
Fig 4: Door Retention Device, Fuel Door, Clips & Screw
11. Rotate the screw (1a) 90° and remove the door retention device (1b).
12. Disengage the clips (2a) and remove the fuel door (2b).
Fig 5: Fuel Fill Tube Retaining Screw
13. Remove the fuel fill tube retaining screw (1).

Fig 6: Fuel Fill Tube Vent Pipe
14. Disconnect the quick coupling and release the vent pipe from the fuel fill tube (1).
15. Remove the muffler assembly. Refer to MUFFLER, EXHAUST, REMOVAL AND INSTALLATION
.
Fig 7: Heat Shield Toothed Washer
16. Unscrew the toothed washer (1) securing the heat shield to the body.
Fig 8: Rear Brake Lines & Retaining Clips
17. Open the retaining clips and disengage the rear brake lines (1).
Fig 9: Right Rear Brake Line & Clips
18. Open the clips and release the right rear brake line (1).
Fig 10: Hydraulic Lift & Mounting Bracket Bolts
19. Place a suitable hydraulic lift (1a) under the tank and remove the front bolts (1b) securing the
mounting brackets.
Fig 11: Rear Fuel Tank Support Bracket Bolts
20. Remove the rear fuel tank support bracket bolts (1).
21. Disconnect the quick coupling of the vapor hose from the fuel tank to the canister.
Fig 12: Fuel Delivery Pipe & Retaining Clips
22. Lower the tank and unhook the fuel delivery pipe from the retaining clips (1).
Fig 13: Fuel Tank & Support
23. Lower the support and remove the fuel tank (1).
Fig 14: Fuel Pump Assembly Lock Nut & Special Tool
24. Install the 2000002100 (EMEA) or (special tool #9340, SAE Fuel Pump Lock Ring Wrench)
(NAFTA) tool (1a) and remove the lock nut from the fuel pump assembly (1b).
25. Remove the fuel pump assembly.

Fig 15: Fuel Tank Seal Ring
26. Remove the seal ring on the tank (1).
FUEL DELIVERY > TANK, FUEL > REMOVAL AND INSTALLATION > 1.4L FWD >
INSTALLATION
1. Install a new seal on the tank.

Fig 1: Fuel Pump Assembly Reference Points
2. Install the fuel pump assembly, taking care to match the references (1a), (1b) and (1c)
3. Tighten the fuel pump assembly lock nut.
4. Using the hydraulic lift, put the fuel tank into position.
5. Engage the fuel delivery pipe with the retaining clips.
6. Connect the quick coupling of the vapor hose from the fuel tank to the canister.
Fig 2: Rear Support Bracket Bolts
7. Install the rear support bracket bolts (1) and tighten to the proper torque specification. Refer to
Fig 3: Front Support Bracket Bolts & Hydraulic Lift
8. Install the front support bracket bolts (1a) and tighten to the proper torque specification. Refer
to FUEL DELIVERY, SPECIFICATIONS .
9. Remove the hydraulic lift (1b).
10. Engage the right rear brake lines and close the retaining clips.
11. Engage the rear brake lines and close the retaining clips.
12. Install the toothed washer securing the heat shield to the body.
13. Install the muffler assembly. Refer to MUFFLER, EXHAUST, REMOVAL AND INSTALLATION .
14. Connect the quick coupling and engage the vent pipe with the spring retainer on the fuel fill
tube.
15. Install the fuel fill tube retaining screw and tighten to the proper torque specifications. Refer to
16. Install the fuel door, engaging the retaining clips.
17. Position the door retaining device and turn the screw 90°.
18. Install the right rear splash shield. Refer to SHIELD, SPLASH, REAR WHEELHOUSE,
19. Connect the quick coupling of the vent pipe.
20. Connect the quick coupling of the fuel delivery pipe.
21. Connect the electrical connection of the electric fuel pump.
22. Install the access covers for the fuel pump and the vent pipe, securely tighten the screws.
FUEL DELIVERY > TANK, FUEL > REMOVAL AND INSTALLATION > 1.4L 4X4 >
REMOVAL
the fuel pump.
.
6. Remove the propeller shaft assembly. Refer to REMOVAL AND INSTALLATION .
8. Lift the cover, unscrew the screws and remove the access cover to the fuel pump (1).
10. Disconnect the fuel vapor quick connect couplings (3).
Fig 3: Fuel Fill Tube Hose & Clamp
12. Loosen the clamp and disconnect the hose from the fuel fill tube (1).
Fig 4: Fuel Vapor Hose & Retaining Clip
13. Disengage the fuel vapor hose from the retaining clips (1).
Fig 5: Right Side Cover, Fasteners & Buttons
14. Remove buttons (1a), loosen the fasteners (1b) and remove the right side cover (1c).
mounting brackets.
Fig 14: Fuel Vapor Recovery Pipe & Quick Coupling
24. Raise the fuel pump assembly.
25. Disconnect the quick coupling of the fuel vapor recovery pipe (1).

FUEL DELIVERY > TANK, FUEL > REMOVAL AND INSTALLATION > 1.4L 4X4 >
INSTALLATION

13. Install the right side cover, tighten the hardware and install the retainer buttons.
14. Engage the fuel vapor hose with the retaining clips.
15. Connect the hose to the fuel fill tube and tighten the clamp.
16. Connect the quick coupling of the vapor pipe.
19. Install the access covers for the fuel pump and securely tighten the screws.
21. Install the propeller shaft assembly. Refer to REMOVAL AND INSTALLATION .
FUEL DELIVERY > TANK, FUEL > REMOVAL AND INSTALLATION > 1.6L > REMOVAL
the fuel pump.
5. Remove the underbody shields. Refer to (Refer to 13 - Frame and Bumpers/Under Body
Protection/SHIELD, Fuel Tank/Removal).
.

9. Disconnect the electrical connection of the electric pump fuel (1).
10. Disconnect the fuel return quick connect coupling (3).

13. Remove the right rear splash shield. Refer to SHIELD, SPLASH, FRONT WHEELHOUSE,
REMOVAL AND INSTALLATIONSHIELD, SPLASH, REAR WHEELHOUSE, REMOVAL AND
INSTALLATION .

mounting brackets.
Fig 12: Fuel Delivery & Return Pipes Retaining Clips
24. Lower the tank and unhook the fuel delivery and return pipes from the retaining clips (1).

FUEL DELIVERY > TANK, FUEL > REMOVAL AND INSTALLATION > 1.6L >
INSTALLATION

3. Securely tighten the fuel pump assembly lock nut.

tube.
13. Install the fuel fill tube retaining screw and tighten to the proper torque specification. Refer to
16. Install the right rear splash shield. Refer to SHIELD, SPLASH, FRONT WHEELHOUSE,
REMOVAL AND INSTALLATIONSHIELD, SPLASH, REAR WHEELHOUSE, REMOVAL AND
INSTALLATION .
18. Connect the quick connector of the return pipe.
the fuel pump.
5. Remove the underbody shields. Refer to UNDER BODY PROTECTION .
.
7. Remove the propeller shaft assembly. Refer to REMOVAL AND INSTALLATION .
10. Disconnect the electrical connection of the electric pump fuel (1).
11. Disconnect the fuel return quick connect coupling (3).


mounting brackets.
Fig 12: Fuel Delivery & Return Pipes Retaining Clips
25. Lower the tank and unhook the fuel delivery and return pipes from the retaining clips (1).

INSTALLATION

3. Securely tighten the fuel pump assembly lock nut.

tube.
13. Install the fuel fill tube retaining screw and tighten to the proper torque specification. Refer to

18. Connect the quick connector of the return pipe.
23. Install the propeller shaft assembly. Refer to REMOVAL AND INSTALLATION .
the fuel pump.
5. Remove the underbody shields. Refer to UNDER BODY PROTECTION .
7. Lift the cover, remove the screws and the access cover to the fuel pump (1).
9. Disconnect the fuel vapor quick connect couplings (3).
11. Loosen the clamp and disconnect the hose from the fuel fill tube (1).
Fig 4: Fuel Vapor Hose & Retaining Clip
12. Disengage the fuel vapor hose from the retaining clips (1).
mounting brackets.
Fig 8: Rear Fuel Tank Support Bracket Bolt & Retaining Clips
16. Disengage the brake line from the retaining clips (1).
17. Remove the rear fuel tank support bracket bolt (2).
Fig 9: Right Rear Fuel Tank Support Bracket Bolt & Retaining Clips
18. Disengage the brake line from the retaining clips (1).
19. Remove the right rear fuel tank support bracket bolt (2).
Fig 13: Fuel Vapor Recovery Pipe & Quick Coupling
23. Raise the fuel pump assembly.
24. Disconnect the quick coupling of the fuel vapor recovery pipe (1).

INSTALLATION

13. Install the right side cover, tighten the hardware and install the retainer buttons.
14. Engage the fuel vapor hose with the retaining clips.
15. Connect the hose to the fuel fill tube and tighten the clamp.
16. Connect the quick coupling of the vapor pipe.
19. Install the access covers for the fuel pump and securely tighten the screws.
21. Install the underbody shields. Refer to UNDER BODY PROTECTION .
FUEL DELIVERY > TUBE, FUEL TANK FILLER > REMOVAL AND INSTALLATION > 1.4
FWD, 1.6L, 2.0L > REMOVAL AND INSTALLATION
The fuel filler tube is integrated into the fuel tank (1). For removal and installation, refer to TANK, FUEL,
FUEL DELIVERY > TUBE, FUEL TANK FILLER > REMOVAL AND INSTALLATION >
1.4L 4X4 > REMOVAL
1. Place the car on a lift.
Fig 2: Fuel Filler Tube Retaining Screw
5. Remove the fuel filler tube retaining screw (1).

6. Loosen the clamp and disconnect the hose from the fuel filler tube (1).
Fig 4: Fuel Vapor Line Quick Connector, Retaining Nut & Fuel Filler Tube
7. Disconnect the fuel vapor line quick connector (1).
8. Remove the retaining nut (2), securing the fuel filler tube to the body.
9. Remove the fuel filler tube (3).

1.4L 4X4 > INSTALLATION
1. Position the fuel filler tube and install the tube to body retaining nut.
2. Connect the fuel vapor line quick connector.
3. Connect the hose to fuel filler tube and securely tighten the clamp.
4. Securely tighten the filler tube retaining screw.
6. Position the door retention device and turn the screw 90°.
8. Remove the car from the lift.
2.4L > REMOVAL
1. Place the car on a lift.
Fig 2: Fuel Filler Tube Retaining Screw
5. Remove the fuel filler tube retaining screw (1).

6. Loosen the clamp and disconnect the hose from the fuel filler tube (1).
Fig 4: Fuel Vapor Line Quick Connector, Retaining Nut & Fuel Filler Tube
7. Disconnect the fuel vapor line quick connector (1).
8. Remove the retaining nut (2), securing the fuel filler tube to the body.
9. Remove the fuel filler tube (3).

2.4L > INSTALLATION
1. Position the fuel filler tube and install the tube to body retaining nut.
2. Connect the fuel vapor line quick connector.
3. Connect the hose to fuel filler tube and securely tighten the clamp.
4. Securely tighten the filler tube retaining screw.
6. Position the door retention device and turn the screw 90°.
8. Remove the car from the lift.
FUEL DELIVERY > RECEPTACLE, FUEL FILL > REMOVAL AND INSTALLATION >
1.4L, 1.6L, 2.0L > REMOVAL
Fig 1: Fuel Fill Door, Screw, Clips & Door Retaining Device
1. Rotate the screw (1a) 90° and remove the device for retaining the door (1b).
2. Detach the clips (2a) and remove the fuel fill door (2b).
Fig 2: Retaining Clips Of Capless Fuel Fill Receptacle
3. Working with suitable screwdriver, lift the four retaining clips of the capless fuel fill receptacle
(1).
4. With the tool unseat capless fuel fill receptacle.
5. Remove the capless fuel fill receptacle to replace.
FUEL DELIVERY > RECEPTACLE, FUEL FILL > REMOVAL AND INSTALLATION >
1.4L, 1.6L, 2.0L > INSTALLATION
1. Install a new O-ring, supplied with the new capless fuel fill receptacle.
NOTE:
Make sure that the O-ring is properly positioned in the throat of the fuel fill tube.
2. Place in its seat the new capless fuel fill receptacle aligning the groove with the tooth of the
fuel fill tube.
Fig 1: Ring & Screws
3. Place the ring (1a) of the installation tool (2000039800) so that the screws (1b) coincide with
the four fastening clips of the capless fuel fill receptacle.
Fig 2: Preparing The Installation Tools
4. Prepare the installation tool (2000042900) (1a) and (1b) as shown in the illustration.
Fig 3: Positioning Special Tools
5. Position the tools (1a) and (1b) as shown in the illustration.

Fig 4: Fuel Fill Tube Ring & Collar
6. Check that the jaws have engaged the ring and the collar "a" of the fuel fill tube.
Fig 5: Capless Fuel Fill Receptacle & Screw
7. Tighten the screw (1a) to engage the capless fuel fill receptacle (1b) on the collar of the fuel fill
tube.
Fig 6: Unscrewing The Screws And Remove The Driver
8. Unscrew the screws and remove the driver shown in the figure (1).
9. Tighten the screws into the rings to crush the four fasteners.
10. Remove the tools and verify that the four pegs of the capless fuel fill receptacle are properly
installed.
11. Install the fuel fill door, engaging the retaining clips.
12. Install the fuel door retaining device and rotate the screw 90°.
FUEL DELIVERY > SENSOR, WATER IN FUEL > REMOVAL AND INSTALLATION >
1.6L, 2.0L > REMOVAL
NOTE:
The water presence sensor is integrated in the filter of the fuel filter and therefore proceed
as described below.
Fig 1: Fuel Filter Element, End Cover & Screws
2. Locate the fuel filter in a vice fitted with protective jaws.
3. Remove the screws (1a), remove the end cover (1b) complete with filter element (1c) and
store it in a suitable container.
4. Remove the filter element (1a) from the cover (1b).
FUEL DELIVERY > SENSOR, WATER IN FUEL > REMOVAL AND INSTALLATION >
1.6L, 2.0L > INSTALLATION
1. In order not to compromise the functionality of the new filter element, it is recommended that
you protect your hands with suitable gloves during all stages of assembly.
Fig 1: Filter Element, Lid, Water Drain Hose & Hole
2. Fit the new filter element (1a) in the lid (1b) engaging the water drain hose (1) into hole (1d) of
the bleed valve.
Fig 2: Water Presence Sensor & Sealing Ring
3. Check the correct position of the water presence sensor (1a) and sealing ring (1b).
Fig 3: Filter Element Cover Tooth & Base Groove
4. Install the filter element cover, taking care to bind the tooth with the groove of the base (1).
5. Securely tighten the fuel filter cover fastening screws.
6. Remove the fuel filter from the vise.
FUEL INJECTION > SPECIFICATIONS > TORQUE SPECIFICATIONS

Accelerator Pedal 6 - 53
Crankshaft Position Sensor Bolt 9 - 80
Fuel Injector Lines To Rail 19 14 -
Fuel Injector Lines To Injector 23 17 -
Injector Bracket Nuts 25 18 -

Oxygen Sensors 50 37 -
Throttle Body Bolts - Gas 8 - 71
Throttle Body Nut - Gas 8 71
Throttle Body Bolts - Diesel 25 18 -
FUEL INJECTION > INJECTOR(S), FUEL > REMOVAL AND INSTALLATION > 1.4L >
REMOVAL
the fuel pump.
Fig 1: Wire Harness Connector

Fig 2: Fuel Vapor Solenoid Retaining Bracket, Connector & Quick Connect Inlet Hose
6. Remove the fuel vapor solenoid from the retaining bracket (1).
7. Disconnect the electrical connection of the fuel vapor solenoid (2).
8. Squeeze the clamp and disconnect the quick connect inlet hose to the vapor valve solenoid.
Fig 3: Turbocharger Fuel Vapor Intake Quick Coupling
9. Squeeze the clamp and disconnect the quick coupling of the hose to the inlet of the fuel vapor
intake of the turbocharger (1).
Fig 4: Fuel Vapor Solenoid & Fuel Vapor Vacuum Hose Clamp
10. Loosen the clamp and disconnect the fuel vapor vacuum hose.
11. Remove the fuel vapor solenoid.

Fig 5: Reinforcement Bracket, Fasteners, Retaining Clips & Pipes
12. Open the retaining clips and disengage the pipes (1).
13. Unscrew the fasteners and remove the reinforcement bracket (2).
Fig 6: Electrical Connection Of The Pressure And Temperature Sensor
14. Disconnect the electrical connection of the pressure and temperature sensor and disengage
the retaining clip.
Fig 7: Fuel Rail, Screws & Fuel Injector
15. Disconnect the quick coupling of the fuel delivery pipe.
16. Remove the screws (2a) and remove the fuel rail (2b) complete with the fuel injectors.
INSTALLATION
1. Install the fuel rail complete with injectors and tighten the screws.
3. Connect the electrical connection of the pressure sensor, intake air temperature and engage
the clip retaining the wiring harness.
4. Install the reinforcement bracket and securely tighten the retainers.
5. Engage the pipes and close the retaining clips.
7. Connect the vacuum hose to the fuel vapor solenoid and secure the clamp.
8. Connect the delivery pipe quick coupling to the turbocharger.
9. Connect the quick coupling of the vapor solenoid inlet hose.
10. Connect the electrical connection of the fuel vapor solenoid.
11. Engage the fuel vapor solenoid to the retaining bracket.
12. Connect the fuel injector wiring harness.
FUEL INJECTION > INJECTOR(S), FUEL > REMOVAL AND INSTALLATION > 1.4L 4X4
> REMOVAL
the fuel pump.
Fig 1: Wire Harness Connector

Fig 2: Fuel Vapor Solenoid Retaining Bracket, Connector & Quick Connect Inlet Hose
6. Remove the fuel vapor solenoid from the retaining bracket (1).
7. Disconnect the electrical connection of the fuel vapor solenoid (2).
8. Squeeze the clamp and disconnect the quick connect inlet hose to the vapor valve solenoid.
Fig 3: Turbocharger Fuel Vapor Intake Quick Coupling
9. Squeeze the clamp and disconnect the quick coupling of the hose to the inlet of the fuel vapor
intake of the turbocharger (1).
Fig 4: Fuel Vapor Vacuum Hose & Clamp
10. Loosen the clamp and disconnect the fuel vapor vacuum hose.
Fig 5: Vapor Hose & Fuel Vapor Solenoid
11. Disconnect the vapor hose (1a).
12. Remove the fuel vapor solenoid (1b).

Fig 6: Reinforcement Bracket, Fasteners, Retaining Clips & Pipes
13. Open the retaining clips and disengage the pipes (1).
14. Unscrew the fasteners and remove the reinforcement bracket (2).
Fig 7: Electrical Connection Of The Pressure And Temperature Sensor
15. Disconnect the electrical connection of the pressure and temperature sensor and disengage
the retaining clip.
Fig 8: Fuel Rail, Screws & Fuel Injector
16. Disconnect the quick coupling of the fuel delivery pipe.
17. Remove the screws (2a) and remove the fuel rail (2b) complete with the fuel injectors.
FUEL INJECTION > INJECTOR(S), FUEL > REMOVAL AND INSTALLATION > 1.4L 4X4
> INSTALLATION
1. Install the fuel rail complete with injectors and tighten the screws.
3. Connect the electrical connection of the pressure sensor, intake air temperature and engage
the clip retaining the wiring harness.
4. Install the reinforcement bracket and securely tighten the retainers.
5. Engage the pipes and close the retaining clips.
7. Connect the vacuum hose to the fuel vapor solenoid and secure the clamp.
8. Connect the delivery pipe quick coupling.
9. Connect the quick coupling of the vapor solenoid inlet hose.
11. Engage the fuel vapor solenoid to the retaining bracket.
12. Connect the fuel injector wiring harness.
REMOVAL
Fig 1: Fuel Return Line From Injectors & Clips
2. Push the clips (1a), disconnect and remove the fuel return line from injectors (1b).
Fig 2: Fuel Pipes & Fittings
3. Unscrew the fittings (1a), (1b) and remove the pipes from the manifold to the fuel injectors (1c).
NOTE:
Use new replacement fuel injector to manifold piping.

Fig 3: Upper Turbo Heat Shield & Screws
4. Unscrew the screws and remove the upper turbo heat shield (1).
5. Unscrew the fasteners and move the heat shield to the side of the turbocharger (1).
Fig 5: Engine Wiring Duct Screws & Fuel Injector Electrical Connectors
6. Remove the screws securing the engine wiring duct (1).
7. Disconnect the electrical connections of the fuel injectors (2).

Fig 6: Oil Vapor Delivery Pipe, Quick Coupling & Screw
8. Disconnect the quick coupling (1a) and unscrew the screw fixing the oil vapor delivery pipe to
the turbocharger (1b).
Fig 7: Oil Vapor Inlet Pipe & Screws
9. Remove the screws (1a) and remove the oil vapor inlet pipe (1b).
Fig 8: Injector Bracket Retaining Nuts
10. Remove the injector bracket retaining nuts (1).

Fig 9: Extracter, Adapter & Fuel Injectors
11. Using the extractor 187073900 (1b) and the adapter 1870897300 (1a), remove the fuel
injectors (1c) complete with brackets and gaskets.
12. Start with removing the cylinder 1 injector, and continuing with 2, 3, and then 4.
INSTALLATION
1. When installing new injectors, verify the identification code printed on the upper surface is
correct.
2. Verify that the old seals from the injectors have been removed from the cylinder head.
Fig 1: Injector Nut
3. Install the injectors with new gaskets, flanges and tighten the nuts (1) to the proper torque
NOTE:
Install cylinder 4 injector first, then continue with 3, 2, then 1.
4. Install the oil vapor delivery pipe to the turbocharger and securely tighten the screws.
5. Install the oil vapor delivery pipe to the turbocharger, connect the quick connector and securely
tighten the screw.
6. Connect the electrical connections of the injectors.
7. Install and securely tighten the engine harness mounting screws.

8. Install the bottom of the turbocharger heat shield and securely tighten its hardware.
9. Install the top of the turbocharger heat shield and securely tighten the screws.
Fig 2: Fuel Injector Piping & Fittings
10. Install the new fuel injector piping (1a), tighten the fittings (1b) and (1c) to the proper torque
11. Install the return line to the fuel injectors and fasten it to the injectors until you hear the click of
REMOVAL - 2.0 L TURBO DIESEL 120 HP AND 140 HP
Fig 1: Fuel Return Line From Injectors & Clips
2. Push the clips (1a), disconnect and remove the fuel return line from injectors (1b).
Fig 2: Fuel Pipes & Fittings
3. Unscrew the fittings (1a), (1b) and remove the pipes from the manifold to the fuel injectors (1c).
NOTE:
Use new replacement fuel injector to manifold piping.

Fig 3: Upper Turbo Heat Shield & Screws
4. Unscrew the screws and remove the upper turbo heat shield (1).
5. Unscrew the fasteners and move the heat shield to the side of the turbocharger (1).
Fig 5: Engine Wiring Duct Screws & Fuel Injector Electrical Connectors
6. Remove the screws securing the engine wiring duct (1).

Fig 6: Oil Vapor Delivery Pipe, Quick Coupling & Screw
8. Disconnect the quick coupling (1a) and unscrew the screw fixing the oil vapor delivery pipe to
the turbocharger (1b).
Fig 7: Oil Vapor Inlet Pipe & Screws
9. Remove the screws (1a) and remove the oil vapor inlet pipe (1b).

Fig 9: Extracter, Adapter & Fuel Injectors
INSTALLATION - 2.0 L TURBO DIESEL 120 HP AND 140 HP
correct.
Fig 1: Injector Nut
NOTE:
5. Install the oil vapor delivery pipe to the turbocharger, connect the quick connector and securely
tighten the screw.
6. Connect the electrical connections of the injectors.
7. Install and securely tighten the engine harness mounting screws.

8. Install the bottom of the turbocharger heat shield and securely tighten its hardware.
9. Install the top of the turbocharger heat shield and securely tighten the screws.
Fig 2: Fuel Injector Piping & Fittings
10. Install the new fuel injector piping (1a), tighten the fittings (1b) and (1c) to the proper torque
REMOVAL - 2.0L TURBO DIESEL 170 HP
the fuel pump.
Fig 1: Oil Vapor Inlet Pipe & Nut
5. Loosen the screws and move the oil vapor inlet pipe to the side (1).
Fig 2: Wiring Conduit & Screws
6. Unscrew the screws securing the wiring conduit (1).

Fig 3: Fuel Return Pipe Clips
7. Disengage the clips and disconnect the fuel return pipe from injectors.
Fig 4: Fuel Injector Connectors & Fuel Pressure Line Fittings
8. Unscrew the fittings (1a), (1b) and remove the fuel pressure lines to the injectors.

Fig 5: Electrical Connection, Timing Sensor & Screw
10. Disconnect the electrical connection (1), remove the screw and remove the timing sensor.

Fig 7: Extractor, Adapter & Fuel Injectors
INSTALLATION - 2.0L TURBO DIESEL 170 HP
correct.
NOTE:
4. Install the timing sensor, tighten the fixing screw and connect the electrical connection.
Fig 2: Injector Electrical Connections & Fuel Injector Piping Fittings
5. Connect the electrical connections of the injectors (1).
6. Install the new fuel injector piping and tighten the fittings (2a) and (2b) to the proper torque
8. Install and securely tighten the wire harness duct.
REMOVAL
the fuel pump.
Fig 1: Air Hose Screw & Engine Oil Vapor Tube Quick Coupling
5. Remove the screw (1) securing the air hose from the filter to the throttle body.
6. Disconnect the engine oil vapor tube quick coupling (2).
7. Loosen the clamp and disconnect the hose from the air filter to the throttle body.
Fig 2: Air Temperature Sensor Electrical Connection & Air Filter Hose Clamp
8. Disconnect the electrical connection of the air temperature sensor (1).
9. Loosen the clamp and remove the hose from the air filter to the throttle body (2).
Fig 3: Fuel Vapor Hose Retaining Clip & Quick Coupling
10. Open the retaining clip (1a) and disconnect the quick coupling (1b) of the pipe fuel vapor hose.
Fig 4: Fuel Vapor Tube & Quick Connect
11. Disconnect the quick connect and remove the fuel vapor tube (1).
Fig 5: Acoustic Insulation Panel & Sound Absorbing Panel
12. Separate the two edges of the precut sound absorbing panel as shown in the illustration (1).
13. Remove the acoustic insulation panel (2).

Fig 6: Fuel Vapor Solenoid, Quick Connect, Electrical Connector & Fuel Vapor Discharge Tube
14. Disconnect the quick connect and move to the side (1).
15. Disconnect the electrical connection from the fuel vapor solenoid (2).
16. Disconnect the fuel vapor discharge tube (3).
17. Remove the fuel vapor solenoid (4).

Fig 7: Fuel Injector Wire Harness Connectors & Fuel Rail
19. Remove the retaining screws and remove the fuel rail, complete with injectors (2).
INSTALLATION
2. Connect the fuel injector wire harness connectors.
8. Connect the fuel vapor quick coupling hose.
9. Engage the fuel vapor tube in its retaining clip and connect the quick coupling.
10. Put in place the tubing from the air filter to the throttle body, and securely tighten the throttle
body side clamp.
11. Connect the electrical connection of the air temperature sensor.
12. Connect the air hose from the filter to the throttle body, and securely tighten the filter side
clamp.
13. Connect the engine oil vapor quick connect coupling.
14. Securely tighten the air hose retaining screw.
FUEL INJECTION > SENSOR, ACCELERATOR PEDAL POSITION > REMOVAL AND
2. Remove the left cabin air filter. Refer to FILTER, CABIN AIR, REMOVAL AND INSTALLATION .
Fig 1: Accelerator Pedal, Electrical Connection & Screw
3. Disconnect the electrical connection (1) to the accelerator pedal.
4. Remove the screw (2a), push up to release and remove the accelerator pedal (2b) from the
pedal support.
FUEL INJECTION > SENSOR, ACCELERATOR PEDAL POSITION > REMOVAL AND
1. Install the accelerator pedal and tighten the screw.
2. Connect the electrical connector to the accelerator pedal.
3. Install the left cabin air filter. Refer to FILTER, CABIN AIR, REMOVAL AND INSTALLATION .
FUEL INJECTION > SENSOR, AIR TEMPERATURE, INTAKE > REMOVAL AND
Fig 1: Intake Air Temperature Sensor & Electrical Connector
2. Disconnect the electrical connector (1) from the intake air temperature sensor (2).
3. Rotate the intake air temperature sensor 1/4 turn counter clockwise and remove the sensor
from the clean air hose.
4. The sensor O-ring seal can be reused if not damaged.

FUEL INJECTION > SENSOR, AIR TEMPERATURE, INTAKE > REMOVAL AND
1. Install the intake air temperature sensor into the clean air housing and rotate to lock into place.
FUEL INJECTION > SENSOR, CRANKSHAFT POSITION > DESCRIPTION AND

OPERATION > 1.4L MULTIAIR TURBO (EMEA)
Fig 1: Crankshaft Position Sensor
MultiAir engines are fitted with a new "Hall effect" engine rpm sensor. Besides its conventional function,
it can also store the end position of the toothed wheel in one piece with the crankshaft during the engine
stopping phase.
By remembering the last position detected during the previous engine stopping, it is possible to decrease
the starting time at the next start-up.
Fig 2: Crankshaft Position Sensor Electrical Specifications
Electrical specifications:
Power supply 5 V
Air gap 0.2 - 1.5 mm
Current 10 mA
Signal Variable frequency square wave
(frequency from 0 to =< 10 kHz, voltage from 0.4 V to < 5 V)

OPERATION > 1.4L MULTIAIR TURBO (NAFTA)
Fig 1: Crankshaft Position Sensor & Tone Wheel
The Crankshaft Position (CKP) sensor (1) is mounted into the rear crankshaft oil seal retainer. It is
positioned to read the tone wheel (2) mounted on the rear of the crankshaft. The sensor is accessed
from behind the catalytic converter and is located at the transmission and cylinder block interface.
Engine speed and crankshaft position are provided through the CKP (Crankshaft Position) sensor. The
sensor generates pulses that are the input sent to the Powertrain Control Module (PCM). The PCM
interprets the sensor input to determine the crankshaft position. The PCM then uses this position, along
with other inputs, to determine injector sequence and ignition timing.
The sensor is a hall effect device.
A tonewheel (targetwheel) is located on the rear of the crankshaft.
This tonewheel causes a pulse to be generated when passing under the sensor. The pulses are the input
to the PCM.
OPERATION > 2.0L DIESEL
Fig 1: RPM Sensor
Type
The rpm sensor is an inductive sensor, i.e. its operation is determined by magnetic field changes
generated by the teeth passing in front of the toothed wheel (60-2 teeth).
Function
The rpm sensor is used by the Powertrain Control Module to:
Determine the rotational speed of the crankshaft
Determine the angular position of the crankshaft.
Location
The rpm sensor is fitted on one side of the block and faces the toothed wheel on the crankshaft pulley.
Technical specifications
Winding resistance 790 ohm ± 20%
Winding inductance 680 mH ± 20% (f=1 kHz)
Resistance of insulation between the terminals and sensor body > 1 megohm
Operating temperature 40°C - 150°C
Air gap 0.5 - 1.5 mm
M6 fixing screw tightening torque 8 Nm ± 20%
Rpm sensor electrical specifications
Fig 2: RPM Sensor Electrical Specifications
Sensor specifications Electrical resistance equal to around 1 kilohm.
Alternating voltage with variable maximum value and frequency

Type of output signal
proportional to flywheel speed
Given the signal type, an OSCILLOSCOPE or an Examiner

equipped with an SMA module (for Examiner Smart) must be
used to display the signal.
Connect an Examiner in voltmeter mode and read the signal for
Measuring method about 2 - 5 seconds.
The graph should have the following specifications: wave
amplitude and frequency proportional to each other and to the
flywheel speed; the signal should change when the sensor reads
the missing tooth (every 58 signal peaks).
Electrical connections
Fig 3: RPM Sensor Connector Pin Out
Key:
1 - Positive (A)
2 - Earth (B)

OPERATION > 2.4L MULTIAIR
The Crankshaft Position (CKP) sensor (2) is mounted into the left side of the cylinder block at the rear of
the engine. It is positioned to read the tonewheel mounted on the crankshaft.
Engine speed and crankshaft position are provided through the CKP (Crankshaft Position) sensor. The
sensor generates pulses that are the input sent to the Powertrain Control Module (PCM). The PCM
interprets the sensor input to determine the crankshaft position. The PCM then uses this position, along
with other inputs, to determine injector sequence and ignition timing.
The sensor is a hall effect device.
A tonewheel (targetwheel) is located on the rear of the crankshaft.
This tonewheel causes a pulse to be generated when passing under the sensor. The pulses are the input
to the PCM.
FUEL INJECTION > SENSOR, CRANKSHAFT POSITION > REMOVAL AND

INSTALLATION > 1.4L - EMEA > REMOVAL
NOTE:
When replacing the sensor, connect the diagnostic tool, enter "Diagnosis active" and run the
self-learning procedure.
Fig 1: Crank Sensor Electrical Connector, Screw & Sensor
3. Disconnect crank sensor electrical connector (1).

4. Remove the screw (2a) and remove the sensor (2b).

INSTALLATION > 1.4L - EMEA > INSTALLATION
Fig 1: Crank Sensor, Electrical Connection & Screw
1. Install the crank sensor (1a) and tighten the screw (1b) to the proper torque specification.
Refer to FUEL INJECTION, SPECIFICATIONS .
2. Connect the electrical connection (2) of the crank sensor.

INSTALLATION > 1.4L - NAFTA > REMOVAL
NOTE:
.
Fig 1: Ignition Coils Heat Shield & Clamps
Fig 2: Turbocharger Support Bracket, Screws & Nut
6. Remove the screws (1a), the nut (1b) and remove the turbocharger support bracket (1c).
Fig 3: Turbocharger Heat Shield & Clamps
8. Disconnect crank sensor electrical connector (1).
9. Remove the screw (2a) and remove the sensor (2b).
10. Remove the catalytic converter. Refer to CONVERTER, CATALYTIC, REMOVAL AND
INSTALLATION .
Fig 4: Crank Sensor Electrical Connection
11. Disconnect the crank sensor electrical connection (1).

Fig 5: Heat Shield & Clamps
12. Remove the clamps (1a) and remove the heat shield (1b).
Fig 6: Spring Retainer
13. Disengage the wiring from the spring retainer (1).

Fig 7: Crank Sensor & Screw
14. Remove the screw and remove the crank sensor.

INSTALLATION > 1.4L - NAFTA > INSTALLATION
NOTE:
NOTE:
Avoid approaching the sensor to magnetic fields.
1. Install the sensor and tighten the screw to the proper torque specification. Refer to FUEL
2. Engage the wiring to the spring retainer.
3. Install the heat shield and tighten its hardware.
4. Connect the electrical connection of the sensor.
5. Install the catalytic converter. Refer to CONVERTER, CATALYTIC, REMOVAL AND

INSTALLATION .
6. Install the turbocharger heat shield and tighten its hardware.

7. Install the turbocharger support bracket (1a), tighten the new nut (1b) and screws (1c) to the
proper torque specification. Refer to FUEL INJECTION, SPECIFICATIONS .
8. Install the ignition coils heat shield and tighten its hardware.

Fig 1: Crank Sensor Electrical Connector
3. Disconnect the crank sensor electrical connector (1).

4. Remove the screw (1) and remove the crank sensor.

1. Install the crank sensor and tighten the screw (1) to the proper torque specification. Refer to
2. Connect the crank sensor electrical connection.

.
Fig 1: Crank Sensor Electrical Connector & Screw
3. Disconnect the crank sensor electrical connector (1).
4. Remove the screw (2) and remove the crank sensor.

Fig 1: Crank Sensor, Screw & Electrical Connection
1. Install the crank sensor and tighten the screw (1) to the proper torque specification. Refer to
2. Connect the crank sensor electrical connection (2).

.
Fig 1: Crank Sensor & Electrical Connection
2. Disconnect the crank sensor (1) electrical connection, loosen the screw and remove the crank
sensor.

1. Install the crankshaft position sensor and tighten the screw to the proper torque specification.
Refer to FUEL INJECTION, SPECIFICATIONS .
2. Connect and lock the wire harness connector.
FUEL INJECTION > SENSOR, MANIFOLD AIR PRESSURE (MAP) > REMOVAL AND
Fig 1: Air Pressure Sensor & Wire Harness Connection
2. Disconnect the wire harness connection (1).
3. Remove the screw and remove the air pressure sensor (2).
1. Install the air pressure sensor and securely tighten the screw.
2. Connect the wire harness connector.
Fig 1: Engine Oil Vapor Hose Quick Coupling, Air Tubing & Screw
2. Remove the screw securing the air tube to the throttle body (1).
4. Loosen the hose clamp and disconnect the air tubing (3).
Fig 2: Air Temperature Sensor Connector, Hose & Clamp
6. Loosen clamp and remove the hose from the air filter to the throttle body (2).
Fig 3: Air Pressure Sensor Electrical Connection
7. Disconnect the electrical connection air pressure sensor.

Fig 4: Air Pressure Sensor
8. Rotate 90° counter clockwise and remove the air pressure sensor (1).
1. Install the pressure sensor air and turn it 90 degrees clockwise.
2. Connect the electrical connection of the air pressure sensor.
3. Install the tubing from the air filter to the throttle body, throttle body side, and securely tighten
the clamp.
5. Connect the air hose from the filter to the throttle body, filter side, and securely tighten the
clamp.
6. Connect the engine oil vapor hose quick coupling.
7. Securely tighten the air tube to the throttle body clamp.
FUEL INJECTION > SENSOR, MASS AIRFLOW (MAF) > REMOVAL AND
INSTALLATION > 1.6L, 2.0L > REMOVAL
Fig 1: Flow Meter Electrical Connection & Air Tubing Clamps

1. Disconnect the electrical connection of the flow meter (1).
2. Loosen the clamps, disconnect and remove the mass air flow sensor from the air tubing (2).
FUEL INJECTION > SENSOR, MASS AIRFLOW (MAF) > REMOVAL AND
INSTALLATION > 1.6L, 2.0L > INSTALLATION
1. Install the mass air flow sensor, connect the air pipes and securely tighten the clamps.
Fig 1: Mass Air Flow Sensor
2. When refitting make sure that the arrow on the flow meter is facing exhaust side.
3. Connect the electrical connection of the mass air flow sensor.
FUEL INJECTION > SENSOR, OXYGEN > REMOVAL AND INSTALLATION > 1.4L 2WD
DOWNSTREAM > 1.4L 2WD REMOVAL
WARNING:
The exhaust manifold, exhaust pipes and catalytic converter(s) become very hot during
engine operation. Allow engine to cool before removing oxygen sensor. Failure to allow
engine to cool before removal may result in personal injury caused by burns.
CAUTION:
When disconnecting sensor electrical connector, do not pull directly on wires going into
oxygen sensor (O2S). Damage to the oxygen sensor may occur.
NOTE:
When replacing the oxygen sensor, connect the diagnostic tool, enter "actuators" and run

Fig 1: Downstream Oxygen Sensor Wire Harness Connector & Routing Clip

4. Open the wiring harness retainer (1).
5. Disconnect the connector (2) from the downstream oxygen sensor.

Fig 2: Oxygen Sensor
6. Unscrew and remove the oxygen sensor (1).

DOWNSTREAM > 1.4L 2WD INSTALLATION
WARNING:
CAUTION:
When Equipped: The oxygen sensor (O2S) pigtail harness must be clipped and/or bolted
back to their original positions on engine or body to prevent mechanical damage to wiring.
1. Install the front oxygen sensor (1) to the catalytic converter and tighten it to the proper torque
2. Connect the electrical connection of the front oxygen sensor at the catalytic converter.
UPSTREAM > 1.4L 2WD REMOVAL
WARNING:
CAUTION:
Fig 1: Oxygen Sensor Electrical Connection
1. Disconnect the electrical connection (1) of the front oxygen sensor at the catalytic converter.
Fig 2: Oxygen Sensor At The Catalytic Converter
2. Unscrew and remove the front oxygen sensor (1) at the catalytic converter.
UPSTREAM > 1.4L 2WD INSTALLATION
WARNING:
CAUTION:
1. Install the front oxygen sensor (1) to the catalytic converter and tighten it to the proper torque
2. Connect the electrical connection of the front oxygen sensor at the catalytic converter.
> 1.4L 4WD REMOVAL
WARNING:
CAUTION:
Fig 1: Ignition Coil Heat Shield & Clamps
Fig 2: Turbocharger Bracket Support, Screws & Nut
2. Remove the screws (1a), the nut (1b) and remove the turbocharger bracket support (1c).
Fig 3: Turbocharger Heat Shield & Clamps
Fig 4: Spring Retainer & Upstream Oxygen Sensor Electrical Connection
5. Disconnect the electrical connection (2) of the upstream oxygen sensor at the catalytic
converter.
Fig 5: Upstream Oxygen Sensor At The Catalytic Converter
6. Disengage the wiring from the upper retaining clip, unscrew and remove the upstream oxygen
sensor at the catalytic converter (1).
> 1.4L 4WD INSTALLATION
WARNING:
CAUTION:
1. Install the upstream oxygen sensor (1) to the catalytic converter and tighten it to the proper
torque specification. Refer to FUEL INJECTION, SPECIFICATIONS .
2. Connect the electrical connection of the upstream oxygen sensor at the catalytic converter.
3. Engage the wiring with the retaining clips.
4. Put into place the heat shield of the turbocharger and tighten its hardware.
Fig 2: Turbocharger Support Bracket & Nuts
5. Install the turbocharger support bracket (1a), tighten to torque the new nut (1b) and screws
(1c).
6. Install the ignition coils cover and tighten its hardware.
FUEL INJECTION > SENSOR, OXYGEN > REMOVAL AND INSTALLATION > 1.6L >
1.6L REMOVAL
WARNING:
CAUTION:
.
Fig 1: Turbocharger Top Cover & Screws
3. Remove the screws (1a) and remove the turbocharger top cover (1b).
Fig 2: Oxygen Sensor & Electrical Connection
4. Disconnect the electrical connection (1) for the oxygen sensor.
5. Open the wiring retaining clips (2).

Fig 3: Oxygen Sensor & Gasket
6. Disengage the gasket (1).
FUEL INJECTION > SENSOR, OXYGEN > REMOVAL AND INSTALLATION > 1.6L >
1.6L INSTALLATION
WARNING:
CAUTION:
Fig 1: Oxygen Sensor & Gasket
1. Put into place the oxygen sensor (1) and tighten it to the proper torque specification. Refer to
2. Engage the gasket (2).

3. Insert the wiring and close shut the retaining clips.
4. Connect the oxygen sensor electrical connection.
5. Install turbocharger cover and tighten the screws.
FUEL INJECTION > SENSOR, OXYGEN > REMOVAL AND INSTALLATION > 2.0L -
120HP / 140 HP > 2.0L REMOVAL
WARNING:
CAUTION:
.
Fig 1: Oxygen Sensor, Electrical Connector & Retaining Clip
3. Disconnect the oxygen sensor electrical connector (1).
4. Open the wiring retainer clip (2).
120HP / 140 HP > 2.0L INSTALLATION
WARNING:
CAUTION:
Fig 1: Oxygen Sensor, Electrical Connector & Retaining Clip
1. Install the oxygen sensor (1) and tighten it to the proper torque specification. Refer to FUEL
2. Connect the wiring to the wiring retainer (2).
3. Connect the oxygen sensor wiring harness (3).
170HP > 2.0L 170HP REMOVAL
WARNING:
CAUTION:
.
Fig 1: Oxygen Sensor Electrical connection
3. Disconnect the electrical connection (1) of the upstream oxygen sensor at the catalytic
converter.
Fig 2: Upstream Oxygen Sensor & Retaining Clips
4. Disengage the wiring from the spring retainer, unscrew and remove the upstream oxygen
sensor (1) at the catalytic converter.
170HP > 2.0L 170HP INSTALLATION
WARNING:
CAUTION:
Fig 1: Upstream Oxygen Sensor & Retaining Clips
1. Install the upstream oxygen sensor at the catalytic converter, tighten it to the proper torque
specification and engage the wiring in its retaining clips. Refer to FUEL INJECTION,
SPECIFICATIONS .
2. Connect the electrical connection of the upstream oxygen sensor at the catalytic converter.
FUEL INJECTION > SENSOR, OXYGEN > REMOVAL AND INSTALLATION > 2.4L
DOWNSTREAM > 2.4L REMOVAL
WARNING:
CAUTION:
Fig 1: Downstream Oxygen Sensor Electrical Connection
3. Disconnect the electrical connection (1) of the downstream oxygen sensor to catalytic
converter.
DOWNSTREAM > 2.4L INSTALLATION
WARNING:
CAUTION:
1. Install the downstream oxygen sensor at the catalytic converter (1), tighten it to the proper
torque specification. Refer to FUEL INJECTION, SPECIFICATIONS .
2. Connect the electrical connection of the downstream oxygen sensor at the catalytic converter.
UPSTREAM > 2.4L REMOVAL
WARNING:
CAUTION:
Fig 1: Upstream Oxygen Sensor To Catalytic Converter Electrical Connection
3. Disconnect the electrical connection (1) of the upstream oxygen sensor to catalytic converter.
Fig 2: Upstream Oxygen Sensor & Retaining Clip
4. Disengage the wiring from the spring retainer, unscrew and remove the upstream oxygen
sensor (1) at the catalytic converter.
UPSTREAM > 2.4L INSTALLATION
WARNING:
CAUTION:
Fig 1: Upstream Oxygen Sensor & Retaining Clip
1. Install the upstream oxygen sensor at the catalytic converter (1), tighten it to the proper torque
specification and engage the wiring in its retaining clip. Refer to FUEL INJECTION,
SPECIFICATIONS .
2. Connect the electrical connection of the upstream oxygen sensor (1) at the catalytic converter.
FUEL INJECTION > SENSOR, TMAP-INTAKE MANIFOLD > REMOVAL AND

Fig 1: Manifold Pressure/Intake Air Temperature Sensor & Electrical Connection
2. Disconnect the electrical connection of the manifold pressure and intake air temperature
sensor (1).
3. Remove the manifold pressure and intake air temperature sensor mounting fastener (2).
4. Remove the manifold pressure and intake air temperature sensor (2).
FUEL INJECTION > SENSOR, TMAP-INTAKE MANIFOLD > REMOVAL AND
1. Install the manifold pressure and intake air temperature sensor and securely tighten the
retaining screw.
2. Connect the electrical connection of the manifold pressure and temperature air sensor.
FUEL INJECTION > THROTTLE BODY > DESCRIPTION AND OPERATION > 1.4L
MULTIAIR TURBO
Fig 1: Throttle Body
The throttle body or motorized throttle, with motorized throttle control and position sensors, is used by
the Magneti Marelli 8GMK Engine Control Module with MultiAir module to adjust the quantity of air taken
in by the engine in particular conditions:
During recirculation of recovered petrol vapor
To recover the oil vapors from the blow-by

During the cut-off phase, the throttle is closed to facilitate engine slowdown
During the recovery strategy, if MultiAir module components break.
The throttle body is equipped with two built-in potentiometers, each of which controls the other. In the
event of the failure of both potentiometers or a power supply failure, the Engine Management Module
reduces the drive torque according to the position of the accelerator pedal:
Fully depressed, it cuts off the supply to one or more injectors until a maximum speed of 2500 rpm
is reached.
In intermediate positions, the supply is cut to one or more injectors, until an engine speed of less
than 1, 200 rpm is reached.
NOTE:
Replacing the throttle body or Engine Management Module requires the self-learning
procedure to be carried out
FUEL INJECTION > THROTTLE BODY > REMOVAL AND INSTALLATION > 1.4L >
REMOVAL
NOTE:
In case of replacement of the throttle body, connect the diagnosis tool, enter "actuators" and
execute the self-learning procedure.
Fig 1: Air Supply Hose & Clamps
3. Loosen the clamps and remove the air supply hose from throttle body to rigid pipe (1).
Fig 2: Throttle Body Electrical Connection, Nut & Bracket
5. Remove the nut and move the bracket to the side (2).
6. Remove the screws (1a), (1b) and remove the throttle body (1c).
Fig 4: Gasket & Centering Pins
7. Remove the gasket (1a) and verify the integrity of the centering pin (1b).
INSTALLATION
2. Install the throttle body positioning it correctly on the centering pin.
3. Install the throttle body retaining screws and tighten to the proper torque specification. Refer to
4. Install the bracket and securely tighten the nut.
5. Connect the electrical connection of the throttle body.
6. Install the air supply hose from throttle body to rigid pipe and securely tighten the clamp.
7. Install the negative battery cable.
FUEL INJECTION > THROTTLE BODY > REMOVAL AND INSTALLATION > 1.6L, 2.0L >
REMOVAL
Fig 1: Air Tube Retaining Bolt
3. Remove the air tube retaining bolt (1).

4. Open the clamp (1a) and disconnect the air hose quick coupling for the vacuum servo (1b).
Fig 3: Bolts & Air Supply Tube
5. Remove the screws (1a) and disconnect the air supply tube from the throttle body (1b)
complete with o-ring.
Fig 4: Throttle Body & Electrical Connection

Fig 5: Throttle Body, Screws & Pin Retainer Bracket
7. Remove the pin retainer bracket on the engine harness (1).
8. Remove the screws and remove the throttle body (2).

Fig 6: Intake Plenum Gasket
9. Remove the gasket from the intake plenum (1).
FUEL INJECTION > THROTTLE BODY > REMOVAL AND INSTALLATION > 1.6L, 2.0L >
INSTALLATION
1. Install a new gasket onto the intake plenum.

Fig 1: Throttle Body, Screws & Pin Retainer Bracket
2. Install the throttle body and tighten the retaining bolts to the proper torque specification. Refer
to FUEL INJECTION, SPECIFICATIONS .
3. Install and securely tighten the retaining peg (2).
5. Install the air supply tube to the throttle body, complete with o-ring and tighten the screw to the
proper torque specification. Refer to FUEL INJECTION, SPECIFICATIONS .
6. Close the clamp and connect the vacuum servo air hose quick coupling.
7. Install the air tube retaining bolt and tighten to the proper torque specification. Refer to FUEL
REMOVAL
NOTE:
In case of replacement of the throttle body, connect the diagnosis tool, enter "actuators" and
execute the self-learning procedure.

Fig 1: Engine Oil Vapor Hose Quick Coupling, Air Hose & Screw
3. Remove the screw securing the air hose from the filter to the throttle body (1).
5. Loosen the hose clamp and disconnect the air tubing from the filter to the throttle body.
Fig 2: Air Temperature Sensor Electrical Connection, Air Hose & Clamps
7. Loosen clamp and remove the hose from the air filter to the throttle body.
Fig 3: Quick Coupling, Clip & Electrical Connection Of The Throttle Body
8. Open the clip (1a), disconnect the quick coupling (1b) and move the hose for the vacuum brake
booster to the side.

Fig 4: Reinforcement Bracket At Throttle Body & Fastener
10. Remove the fastener and the reinforcement bracket from the throttle body (1).
Fig 5: Throttle Body & Fasteners
11. Remove the fasteners (1a) and remove the throttle body (1b).
Fig 6: Centering Pins & Gasket
12. Remove the gasket (1a) and verify the integrity of the centering pin (1b).
INSTALLATION
3. Install the throttle body fasteners and tighten to the proper torque specification. Refer to FUEL
4. Install the throttle body reinforcement bracket and tighten the fastener to the proper torque
6. Install the hose for the vacuum brake booster, engage it in its clip and connect the quick
coupling.
7. Install the tubing from the air filter to the throttle body, and securely tighten the clamp.

9. Connect the air hose from the filter to the throttle body, and securely tighten its strap.
10. Connect the quick coupling of engine oil vapor hose.
11. Securely tighten the air hose to the throttle body filter fastener.
Service Manual: DRIVEABILITY - GAS - NON-DTC BASED Jeep Renegade
DIAGNOSTICS - 2.4L
DIAGNOSIS AND TESTING > CHECKING THE CHARGING SYSTEM OPERATION
DIAGNOSIS AND TESTING > CHECKING THE CHARGING SYSTEM OPERATION >
THEORY OF OPERATION
Fig 1: Battery/System Circuit Diagram
The Electronic Voltage Regulation (EVR) system maintains the system voltage at a desired level by
turning the Pulse Width Modulated (PWM) Alternator Field Control circuit (A) on and off. When the
Alternator field is turned on, the system voltage increases. When the Alternator field is turned off, the
system voltage slowly drops. The rate at which this happens is dependent upon the existing electrical
loads, ambient under hood temperature, and the engine RPM. A constant system voltage (D, C, B) can
be maintained only when the Alternator field is switched on and off at a duty cycle that very accurately
emulates the existing electrical loads given the existing ambient under hood temperature and engine
RPM.
During normal operation, the voltage reading at the Alternator output stud will be very close to the
target charging voltage viewed on the scan tool. This is the system voltage and is sensed by the PCM
through the Fused B+ circuit (B). With the Alternator connector plugged in and back probing the
Alternator Sense circuit (E), the voltage reading will be approximately 3.5 volts less than the voltage at
the Alternator output stud due the resistor inside the Alternator. This is the Alternator Sense (E) input to
the PCM. These two voltage sense inputs are used and compared during the different diagnostics
performed on the EVR System by the PCM.
DIAGNOSIS AND TESTING > CHECKING THE CHARGING SYSTEM OPERATION >
DIAGNOSTIC TEST
1. CHARGING SYSTEM INSPECTION
NOTE:
This procedure is a general check of the entire charging system as a whole. It is

designed to check all phases of a malfunctioning charging system that has no
faults codes or in some cases, multiple fault codes.
1. Inspect the Battery terminals and cable ends for poor connection or corrosion.
2. Test the Battery with the Midtronics Battery Tester or equivalent for a shorted or
dead cell.
3. Inspect the Alternator drive belt and tensioner for proper alignment and adjustment.
4. Inspect the vehicle for aftermarket accessories that may exceed the Alternator
system output.
5. Inspect the fusible link in the charge wire or fuses in the PDC depending on
application. If an open fusible link or fuse is found, use the wire diagram/schematic
as a guide and inspect the wiring and connectors for damage.
Were any problems found?
Yes
1. Perform the appropriate repair.

No
1. Go To Step 2
2. CHECK FOR HIGH RESISTANCE IN THE BATTERY GROUND CABLE
1. Perform a voltage drop test on the Battery Negative (-) cable from the Battery cable
end;
1. to the engine ground eyelet.
2. to the body ground eyelet.
Is the voltage reading above 0.2 volts for either measurement?
Yes
1. Repair the Battery ground circuit for high resistance.

No
1. Go To Step 3
3. CHECK THE PCM POWER AND GROUND CIRCUITS
1. Perform the CHECKING THE PCM POWER AND GROUND CIRCUITS test
procedures. Refer to CHECKING THE PCM POWER AND GROUND CIRCUITS .
Yes
1. Repair the PCM power and ground circuit(s) as necessary.

No
1. Go To Step 4
4. CHECK THE ALTERNATOR OUTPUT AT THE ALTERNATOR OUTPUT STUD
NOTE:
Make sure all testing equipment and cables are clear of any engine parts before
starting the engine.
1. Start the engine.
WARNING:
or fatal injury.
2. Hold the engine speed above 1157 RPM.
3. With the scan tool, navigate to data display and monitor the target charging voltage.
4. Using a voltmeter, measure the voltage between ground and the Alternator Output
Stud.
Is the Alternator overcharging or undercharging as compared to the target voltage?

Alternator is overcharging
1. Go To Step 5
Alternator is undercharging
1. Go To Step 12
5. CHECK THE PCM FUSED B+ VOLTAGE
1. With the scan tool, monitor the Battery voltage reading to the PCM.
2. Compare the reading to the voltage at the Alternator Output Stud.
Is the voltage at the Alternator Output Stud equal to or above the Battery voltage
reading on the scan tool?
Above
1. Go To Step 6
Equal
1. Go To Step 8
6. CHECK FOR HIGH RESISTANCE IN THE BATTERY POSITIVE CIRCUIT
1. Perform a voltage drop test between the Battery Positive (+) Post;
1. and the Alternator Output Stud.
2. and the PDC B+ terminal.
Is the voltage reading above 0.2 volts for either measurement?
Yes
1. Repair the Battery Positive (+) circuit for high resistance.

No
1. Go To Step 7
7. CHECK THE FUSED B+ CIRCUIT FOR HIGH RESISTANCE
CAUTION:
2. Disconnect the PCM C1 harness connector and connect the (special tool #10436,
Adapter, GPEC Diagnostic) in-line with the PCM C1 harness connector.
3. Start the engine and allow it to idle.
4. Measure the voltage between ground and the Fused B+ circuit at the GPEC Adaptor.
Does the voltage read equal to the Battery voltage reading on the scan tool or equal
to the voltage reading at the Alternator Output Stud?
Voltage is equal to scan tool reading
1. Repair the Fused B+ circuit for high resistance.

Voltage is equal to the Alternator Output Stud
1. Replace and program the Powertrain Control Module in accordance with the
Service Information. Refer to MODULE, POWERTRAIN CONTROL, REMOVAL
AND INSTALLATION .

8. CHECK THE ALTERNATOR DUTY CYCLE
1. With the scan tool, check the Duty Cycle reading for the Alternator.
NOTE:
During normal operation the typical duty cycle of the field control at idle
with minimal loads is approximately 35-40%, which will equate to between
4.0 and 5.0 volts. Depending on the charging issue, the PCM can drive the
duty cycle to off (0%), which will equate to zero volts, or full field (100%),
which will equate to between 11.0 and 12.0 volts.
What is the Alternator duty cycle on the scan tool?
0%
1. Go To Step 9
100%
1. Go To Step 10
9. CHECK THE (K20) ALTERNATOR FIELD CONTROL CIRCUIT FOR A SHORT TO VOLTAGE
1. Back probe the (K20) Alternator Field Control circuit at the Alternator harness
connector.
WARNING:
or fatal injury.
2. Measure the voltage between ground and the (K20) Alternator Field Control circuit at
the Alternator harness connector.
Is there any voltage present?
Yes
1. Repair the (K20) Alternator Field Control circuit for a short to voltage.

No
1. Verify that there is good pin to terminal contact in the Alternator and Powertrain
Control Module connectors. If no problems are found, replace the Alternator.
Refer to GENERATOR, REMOVAL AND INSTALLATION .

10. CHECK THE (A804) ALTERNATOR SENSE CIRCUIT FOR AN OPEN/HIGH RESISTANCE
2. Disconnect the Alternator harness connector.
CAUTION:
5. Measure the resistance of the (A804) Alternator Sense circuit between the Alternator
harness connector and the GPEC Adaptor.
Yes
1. Go To Step 11
No
1. Repair the (A804) Alternator Sense circuit for an open or high resistance.

11. CHECK THE (A804) ALTERNATOR SENSE CIRCUIT FOR A SHORT TO GROUND
1. Check for continuity between ground and the (A804) Alternator Sense circuit at the
Alternator harness connector.
Is there continuity between ground and the (A804) Alternator Sense circuit?
Yes
1. Repair the (A804) Alternator Sense circuit for a short to ground.

No
1. Replace and program the Powertrain Control Module (PCM) in accordance with
the service information. Refer to MODULE, POWERTRAIN CONTROL,

12. CHECK THE DUTY CYCLE REQUESTED BY THE PCM
NOTE:
Before condemning an Alternator or PCM for a charging issue, it is important check

the Battery Temperature Sensor reading. A Battery Temperature Sensor that is
reading too high or too low can cause an undercharge or overcharge issue.
1. With the scan tool, check the Duty Cycle reading for the Alternator.
NOTE:
During normal operation the typical duty cycle of the field control at idle
with minimal loads is approximately 35-40%, which will equate to between
4.0 and 5.0 volts. Depending on the charging issue, the PCM can drive the
duty cycle to off (0%), which will equate to zero volts, or full field (100%),
which will equate to between 11.0 and 12.0 volts.
What is the Alternator duty cycle on the scan tool?
0%
1. Go To Step 13
Duty cycle is reading between normal and 100%
1. Go To Step 15
13. CHECK THE (A804) ALTERNATOR SENSE CIRCUIT VOLTAGE
1. Back probe and measure the voltage between ground and the (A804) Alternator
Sense circuit at the Alternator harness connector.
NOTE:
With the Alternator connector plugged in, the voltage reading on the
Alternator Sense circuit should be approximately 3.5 volts less that the
voltage at the Alternator Output Stud due to the resistor inside the
Alternator.
Is the voltage reading for the (A804) Alternator Sense circuit equal to the voltage
reading at the Alternator Output Stud?
Yes
1. Go To Step 14
No
1. Repair the (A804) Alternator Sense circuit for an open or high resistance.

14. CHECK THE (A804) ALTERNATOR SENSE CIRCUIT FOR A SHORT TO VOLTAGE
3. Measure the voltage between ground and the (A804) Alternator Sense circuit at the
Alternator harness connector.
Is the voltage reading for the (A804) Alternator Sense circuit equal to the voltage
reading at the Alternator Output Stud?
Yes
1. Repair the (A804) Alternator Sense circuit for a short to voltage.

No
1. Replace the Alternator in accordance with the Service Information. Refer to

GENERATOR, REMOVAL AND INSTALLATION .

15. CHECK DUTY CYCLE VOLTAGE AT THE ALTERNATOR
1. Back probe the (K20) Alternator Field Control circuit at the Alternator harness
connector.
2. Measure the voltage between ground and the (K20) Alternator Field Control circuit at
the Alternator harness connector.
NOTE:
Duty cycle of the field control at idle with minimal loads is approximately
35-40%, which will equate to between 4.0 and 5.0 volts, off (0%) will equate
to zero volts, and full field (100%) will equate to between 11.0 and 12.0
volts.
Does the voltage reading match up with the Alternator duty cycle on the scan tool?
Yes
1. Replace the Alternator in accordance with the Service Information. Refer to

GENERATOR, REMOVAL AND INSTALLATION .

No
1. Go To Step 16
16. CHECK THE (K20) ALTERNATOR FIELD CONTROL CIRCUIT FOR AN OPEN/HIGH
RESISTANCE
CAUTION:
5. Measure the resistance on the (K20) Alternator Field Control circuit between the
Alternator harness connector and the GPEC Adaptor.

Yes
1. Go To Step 17
No
1. Repair the (K20) Alternator Field Control circuit for an open or high resistance.
Make sure to check for a spread terminal at the PCM harness connector.

17. CHECK THE (K20) ALTERNATOR FIELD CONTROL CIRCUIT FOR A SHORT TO GROUND
1. Check for continuity between ground and the (K20) Alternator Field Control circuit at
the GPEC Adaptor.
Is there continuity between ground and the (K20) Alternator Field Control circuit?
Yes
1. Repair the (K20) Alternator Field Control circuit for a short to ground.

No
1. Go To Step 18
18. CHECK RELATED PCM AND COMPONENT CONNECTIONS
1. Perform any Service Bulletins that apply.
2. Disconnect all PCM harness connectors.
3. Disconnect all related in-line harness connections (if equipped).
4. Disconnect the related component harness connectors.
5. Inspect harness connectors, component connectors, and all male and female
terminals for the following conditions:
1. Proper connector installation.
2. Damaged connector locks.
3. Corrosion.
4. Other signs of water intrusion.
5. Weather seal damage (if equipped).
6. Bent terminals.
7. Overheating due to a poor connection (terminal may be discolored due to

excessive current draw).
8. Terminals that have been pushed back into the connector cavity.
9. Check for spread terminals and verify proper terminal tension.
Repair any conditions that are found.
6. Reconnect all PCM harness connectors. Be certain that all harness connectors are
fully seated and the connector locks are fully engaged.
7. Reconnect all in-line harness connectors (if equipped). Be certain that all connectors
are fully seated and the connector locks are fully engaged.
8. Reconnect all related component harness connectors. Be certain that all connectors
are fully seated and the connector locks are fully engaged.
9. With the scan tool, erase DTCs.
10. Test drive or operate the vehicle in accordance with the when monitored and set
conditions.
11. With the scan tool, read DTCs.
Did the DTC return?
Yes
1. Replace the Powertrain Control Module in accordance with the Service

information. (Refer to MODULE, POWERTRAIN CONTROL, REMOVAL AND
INSTALLATION ).

No

2. Test complete.
DIAGNOSIS AND TESTING > CHECKING THE ENGINE MECHANICAL SYSTEM
DIAGNOSIS AND TESTING > CHECKING THE ENGINE MECHANICAL SYSTEM >
DIAGNOSTIC TEST
CHECKING THE ENGINE MECHANICAL SYSTEM
2. Check for any of the following conditions/mechanical problems:
1. ENGINE VACUUM - must be at least 13 inches in neutral

2. ENGINE VALVE TIMING - must be within specifications
3. ENGINE COMPRESSION - must be within specifications
4. CYLINDER LEAKAGE TEST - must be within specifications
5. ENGINE EXHAUST SYSTEM - must be free of any restrictions or leaks
6. ENGINE PCV SYSTEM - must flow freely
7. TORQUE CONVERTER STALL SPEED - must be within specifications
8. POWER BRAKE BOOSTER - no internal vacuum leaks
9. FUEL - must be free of contamination
10. VALVE SPRINGS - cannot be weak or broken
11. CAM LOBES - must not be worn excessively
12. CAM SHAFTS - must not be worn or have excessive end play
Are there any engine mechanical problems?
Yes
1. Repair as necessary in accordance with the Service Information.
2. Perform the POWERTRAIN VERIFICATION TEST. Refer to the appropriate TESTING &
DIAGNOSTICS article in ENGINE PERFORMANCE .
No
1. Test Complete.
DIAGNOSIS AND TESTING > CHECKING THE EXHAUST SYSTEM FOR LEAKS >
CHECKING THE EXHAUST SYSTEM FOR LEAKS

described go to;
Channel" box.
DIAGNOSTIC TEST
CHECK THE EXHAUST SYSTEM FOR LEAKS

2. Raise and support the vehicle in accordance with the service information. Refer to HOISTING,
WARNING:
The normal operating temperature of the exhaust system is very high. Never work
around or attempt to service any part of the exhaust system until it has cooled.
Special care should be taken when working near the catalytic converter. The
temperature of the converter rises to a high level after a short period of engine
operating time.
3. Connect Exhaust Cone (special tool #8404-ECT, Exhaust Cone, Truck) to Air Pressure
Regulator (with hose) W-18-MIL-1146AS.
CAUTION:
The air pressure must not exceed 27.6 kPa (4 psi), otherwise engine damage can
occur.
4. Attach shop air to the air pressure regulator.
5. Adjust the Air Pressure Regulator to 27.6 kPa (4 psi)
6. Insert the exhaust cone into the vehicle tail pipe.
7. If the vehicle is equipped with dual exhaust, use a second Exhaust Cone (special tool
#8404-ECT, Exhaust Cone, Truck) equipped with the attached plug and plug one side of the
dual exhaust pipe. Pressurize the other as described above.
8. Apply Mopar® Air Leak Detector PN 05191804AA (or an equivalent leak finder liquid) to the
following areas:
1. All welded joints from the exhaust manifold to 45.72 cm (18 inches) behind the
downstream O2 Sensor
2. O2 Sensor seal points
3. O2 Sensor boss welds
4. Flange/joint connection(s)
5. Exhaust manifold to cylinder head connection(s)
6. EGR solenoid gasket base and tube seal points (if equipped)
9. Watch for the Mopar® Air Leak Detector PN 05191804AA (or the equivalent leak finder liquid)
to bubble.
10. Use the following definitions to help determine if system or component repair/replacement is
necessary:
1. Type 1 Leak is defined as a leak where very small foam like bubbles 1 mm (0.04 of an
inch) or less appear. Any Type 1 or greater leaks found in welded joints, O2 sensor seal
points or O2 sensor boss welds must be repaired or the component must be replaced.
2. Type 2 Leak is defined as a leak where larger bubbles pea size, 8 mm (0.3 of an inch)
or greater appear. Any Type 2 or greater leaks found in flange or joint connections,
exhaust manifold to cylinder head connections, or EGR gasket and tube seal points must
be repaired or the components must be replaced.
Repair required if results at 27.6 kPa (4 psi)

Leak Location
reveal bubble size:
Welded joints Type 1, 1 mm (0.04 of an inch) or greater
O2 Sensor seal points Type 1, 1 mm (0.04 of an inch) or greater
O2 Sensor boss welds Type 1, 1 mm (0.04 of an inch) or greater
Flange / joint connections Type 2, 8 mm (0.3 of an inch) or greater
Exhaust Manifold to cylinder head connections Type 2, 8 mm (0.3 of an inch) or greater
EGR gasket and tube seal points Type 2, 8 mm (0.3 of an inch) or greater
11. If a leak is found that matches the above definition, repair or replace the component as
necessary.
12. Once the repair is complete, repeat the procedure to verify that all leaks have been repaired.
Were any exhaust leaks found?
Yes
1. Repair or replace the leaking exhaust parts as necessary.
No
1. Test complete.
DIAGNOSIS AND TESTING > CHECKING THE FUEL DELIVERY SYSTEM (HARD
START)
START) > ?
Possible Causes
FUEL DELIVERY SYSTEM LEAKING OR DAMAGED

RESTRICTED FUEL SUPPLY LINE
FUEL PUMP INLET STRAINER PLUGGED
FUEL PUMP CONTROL OUTPUT CIRCUIT OPEN
FUEL INJECTOR(S)
FUEL PUMP MODULE
WARNING:
Follow these safety precautions to reduce the risk of fire and possible serious or fatal injury
when performing this test procedure.
Fuel or fuel vapors are highly flammable. A fire could occur if an ignition source is
present. Do not expose the fuel or the test equipment used in this procedure to open
flames or sparks.
Inhalation of fuel vapors could lead to disorientation and personal injury. Keep the
service area well ventilated, or perform this test procedure in an area where there is a
building exhaust removal system.
Relieve fuel system pressure before servicing fuel system components.
Use extreme caution when connecting and disconnecting fuel lines.
Considerable fuel leakage may occur when servicing the fuel system. Wear protective
eye wear and clothing to protect from fuel splash, and take suitable fuel containment
measures.
Wrap a shop towel around the fuel pressure gauge connection to absorb fuel leakage
that occurs when connecting the test equipment. Place the towel in an approved
container when complete.
Never store fuel in an open container due to the possibility of fire or explosion. Have a
dry chemical (Class B) fire extinguisher nearby.
START) > DIAGNOSTIC TEST
1. CHECK THE FUEL DELIVERY SYSTEM FOR LEAKS AND DAMAGE

WARNING:
The fuel system is under a constant pressure (even with the engine off). Before
testing or servicing any fuel system hose, fitting, or line, the fuel system pressure
must be released. Failure to follow these instructions can result in possible serious
or fatal injury.
1. Visually and physically inspect the fuel delivery system for external leaks and
damage.
Is the system leaking or damaged?
Yes
1. Repair or replace as necessary.
2. Perform the PCM VERIFICATION TEST. Refer to the appropriate TESTING &
No
1. Go To Step 2
2. CHECK FUEL PUMP OPERATION
2. With a scan tool, actuate the Fuel System test.
NOTE:
It may be necessary to use a mechanics stethoscope in the next step.
3. Listen for fuel pump operation at the Fuel Tank.
Does the Fuel Pump operate?
Yes
1. Go To Step 3
No
1. Check the power and ground circuits to the Fuel Pump Module assembly. If the
circuits test good, replace the Fuel Pump Module assembly.

3. INSTALL APPROPRIATE FUEL LINE ADAPTERS/FITTING FROM THE GAS AND DIESEL
FUEL PRESSURE/DECAY TESTER 8978A
Fig 1: Fuel Line Adapters/Fitting
WARNING:
The fuel system is under a constant pressure (even with the engine off).
Before testing or servicing any fuel system hose, fitting, or line, the fuel
system pressure must be released. Failure to follow these instructions can
2. Release the fuel system pressure. Refer to FUEL DELIVERY, STANDARD

PROCEDURE .
3. Disconnect the rail fuel supply line connector between the fuel supply line and the fuel
rail. (Refer to LINES, FUEL ).
4. Install the appropriate Fuel Line Adapters/Fitting from the Gas and Diesel Fuel
Pressure/Decay Tester (special tool #8978A, Decay Tool, Fuel).
Proceed
1. Go To Step 4
4. INSTALL THE FUEL PRESSURE GAUGE ASSEMBLY

Fig 2: Identifying Fuel Pressure Gauge Assembly
1. Connect the (special tool #8978A, Decay Tool, Fuel), with the Fuel Inlet Hose (1)
toward the Fuel tank side and the Fuel Outlet Hose (2) toward the fuel rail side of the
system using the Fuel Line Adapters/Fitting as needed.
2. Connect special tool Drain Extension Hose 535680 (3) to the Fuel Pressure Gauge
Assembly Drain Hose (5).
3. Connect Reservoir Assembly 534960 (4) to Drain Extension Hose 535680 (3).
WARNING:
To reduce the risk of fire and possible serious or fatal injury, place
Reservoir Assembly 534960 (4) on the floor and out of the way so that it is
not a trip hazard.
Proceed
1. Go To Step 5
5. CHECK THE FUEL PRESSURE

Fig 3: Checking Fuel Pressure
1. Perform the following procedure to purge air from the system:
1. Open the Fuel System Isolation Valve (1).

2. Close the Flow Test Valve (2).
4. With the scan tool, actuate the Fuel Pump.
5. Open the Flow Test Valve (2) for 10 seconds, then close the Valve.
6. CAUTION: Stop All Actuations.
8. Disconnect, empty and then reconnect the Reservoir Assembly.
NOTE:
On vehicles equipped with a PWM Fuel Pump, actuate the Fuel Pump at or
above 60%.
4. Read the Fuel Pressure Gauge (3) and record the reading.
NOTE:
The fuel pressure specification for all engines, including a Non SRT-4 is
407 kPa +/- 34 kPa (59 psi +/- 5 psi). SRT-4 fuel pressure specification is
552 kPa +/- 34 kPa (80 psi +/- 5 psi).
Choose a conclusion that best matches your fuel pressure reading.
Below Specification
1. Go To Step 10
Within Specification
1. Go To Step 6
Above Specification
1. Replace the fuel filter/fuel pressure regulator.

CAUTION:
Stop all actuation tests before proceeding.
6. CHECK THE FUEL DELIVERY SYSTEM OUTPUT

Fig 4: Checking Fuel Delivery System Output
WARNING:
or fatal injury.
1. With the scan tool, continue to actuate the fuel pump.
CAUTION:
4. Measure the amount of fuel in the Reservoir Assembly (2). The fuel output
specification is ml/s X 20 seconds = fuel flow in ml.
FUEL FLOW
ENGINE ml/s ml per 20 Seconds
4 Cylinder and 6 Cylinder 20.8333 417
8 Cylinder 38.88889 778
SRT-4 50 1000
10 cylinder 55.5 1110
Does the amount of fuel in the reservoir meet or exceed the specification?
Yes
1. Go To Step 7
No
1. Go To Step 8
7. CHECK THE FUEL DELIVERY SYSTEM FOR LEAK DOWN

Fig 5: Checking Fuel Delivery System For Leak Down
WARNING:
or fatal injury.
2. With the scan tool, actuate the fuel pump.
3. Close the Fuel System Isolation Valve (1).
CAUTION:
4. Turn the ignition off and then wait five minutes before proceeding.
5. Read the Fuel Inlet (2) and Fuel Outlet (3) Pressure Gauges. The pressure should
not drop more than 10 psi on either gauge.
Does the fuel pressure drop more than 10 psi?
Yes - On Fuel Inlet Gauge (2)
1. Replace the Fuel Pump Module.
Yes - On Fuel Outlet Gauge (3)
1. Replace the leaking Fuel Injector(s).
No
1. If directed here by another test, return to that test. Otherwise, test complete.
8. CHECK FOR RESTRICTED FUEL SUPPLY LINE

WARNING:
The fuel system is under a constant pressure even with the engine off. Before
testing or servicing any fuel system hose, fitting or line, the fuel system pressure
must be released.
2. Disconnect the Fuel Pressure Decay Tester.

3. Raise the vehicle on a hoist, and disconnect the fuel pressure line at the Fuel Pump
Module.
4. Install the Fuel Pressure Decay Tester between the fuel supply line and the Fuel
Pump Module.
5. Again, purge air from the system.
CAUTION:
FUEL FLOW
8 Cylinder 38.88889 778
SRT-4 50 1000
10 cylinder 55.5 1110
Yes
1. Repair/replace fuel supply line as necessary.

No
1. Go To Step 9
CAUTION:

9. CHECKING THE FUEL INLET STRAINER
WARNING:
or fatal injury.
2. Remove the Fuel Pump Module and inspect the Fuel Inlet Strainer.
Is the Fuel Inlet Strainer plugged?
Yes
1. Replace the Fuel Pump Inlet Strainer.

No


WARNING:
must be released.
2. Disconnect the Fuel Pressure Decay Tool.
3. Raise the vehicle on a hoist, and disconnect the fuel pressure line at the fuel pump
module.
4. Install the Fuel Pressure Decay Tool between the fuel supply line and the fuel pump
module.

NOTE:
above 60%.
NOTE:
552 kPa +/- 34 kPa (80 psi +/- 5 psi).
Is the fuel pressure now within specification?
Yes

No
1. Go To Step 11
CAUTION:
11. CHECKING FUEL INLET STRAINER
WARNING:
or fatal injury.
Yes

No

DIAGNOSIS AND TESTING > CHECKING THE IGNITION COIL OPERATION
DIAGNOSIS AND TESTING > CHECKING THE IGNITION COIL OPERATION >
DIAGNOSTIC TEST
1. IGNITION COIL WIRING OR CONNECTORS
NOTE:
Diagnose and repair any ignition coil, CMP sensor, or CKP sensor DTCs before
proceeding with this test.
2. Using the wiring diagram/schematic as a guide, inspect the wiring and connectors
between the Ignition Coil for the cylinder being tested and the PCM.
4. Look for broken, bent, pushed out or corroded terminals.
NOTE:
If the vehicle is not equipped with the coil on plug ignition system, check
the resistance of the ignition wire(s) before checking the cylinder with a
spark tester. The resistance should be below 10k ohms.

Yes
2. Perform the Powertrain Verification Test. Refer to the appropriate TESTING &
No
1. Go To Step 2
2. IGNITION COIL OPERATION
NOTE:
Inspect the ignition coil for damage, carbon tracking on the coil or a damaged spark
plug insulator boot. If a problem is found, replace the ignition coil.
NOTE:
Some coils must have a spark tester installed on both sides of the coil during the
following test. During the test, each side of the coil should output a crisp blue spark
that is able to jump the gap of the spark tester.
NOTE:
On some engines, it may be necessary to remove the upper intake manifold to

access the ignition coils. Once the ignition coil has been removed, the intake must
be installed in order to crank the engine. Move the ignition coil harness connector
through the slots in the upper intake and then connect the coil to the harness
connector. Secure the upper intake to the lower intake in accordance with the
Service Information.
2. If the vehicle is equipped with coil on plug ignition system, remove the ignition coil for
the cylinder being tested.
3. Disconnect the fuel injector harness connector for the cylinder being tested.
4. For coil on plug ignition systems, install a spark tester(s) on the ignition coil,
otherwise install the spark tester to the ignition wire.
5. While cranking the engine observe the spark coming from the spark tester.
NOTE:
A crisp blue spark that jumps the gap of the spark tester should be
generated.
Is good spark present?
Yes
1. Go To Step 7
No
1. Go To Step 3
3. CHECK THE ASD RELAY OUTPUT CIRCUIT FOR AN OPEN/HIGH RESISTANCE
2. Disconnect the Ignition Coil harness connector.
4. With the scan tool, actuate the ASD Relay to on.
5. Using a 12-volt test light connected to ground, check the ASD Relay output circuit at
the ignition coil harness connector.
NOTE:
The test light should be illuminated and bright. Compare the brightness to
that of a direct connection to the battery.
Is the test light illuminated and bright during the actuation?
Yes
1. Go To Step 4
No
1. Repair the ASD Relay output circuit for an open or high resistance.

4. IGNITION COIL
WARNING:
When the engine is operating, do not stand in direct line with the fan. Do not put
your hands near the pulleys, belts, or fan. Do not wear loose clothing. Failure to
follow these instructions can result in possible serious or fatal injury.
1. Using a 12-volt test light connected to 12 volts, check the Ignition Coil Control circuit
for the cylinder being tested in the Ignition Coil harness connector.
2. Crank the engine for five seconds.
NOTE:
The test light should blink each time the circuit is activated by the PCM.
Does the test light blink each time the circuit is activated by the PCM?
Yes
1. Replace the Ignition Coil in accordance with the Service Information.

No
1. Go To Step 5
5. CHECK THE IGNITION COIL CONTROL CIRCUIT FOR AN OPEN/HIGH RESISTANCE
1. Measure the resistance of the Ignition Coil control circuit for the cylinder being tested
between the Ignition Coil harness connector and the PCM harness connector.
Yes
1. Go To Step 6
No
1. Repair the Ignition Coil Control circuit for an open or high resistance.

6. POWERTRAIN CONTROL MODULE (PCM)
between the Ignition Coil for the cylinder being tested and the PCM.
4. Perform any Service Bulletins that may apply.
Yes
1. Repair as necessary.
No
1. Replace and program the Powertrain Control Module (PCM) in accordance with
the Service Information. Refer to MODULE, POWERTRAIN CONTROL,

7. SPARK PLUG(S)
2. Remove the spark plug.
3. Inspect the spark plug for any of the following conditions:
1. Cracks or damage
2. Carbon tracking
3. Foreign material
4. Gap not within specification
5. Loose or broken electrode
6. Fuel fouled
NOTE:
Lightly tap the bottom of the spark plug on a solid surface. The electrode in
the spark plug should not move.
Yes
1. Replace the spark plug.

No
1. Test Complete.
DIAGNOSIS AND TESTING > CHECKING THE MAP SENSOR OPERATION

DIAGNOSIS AND TESTING > CHECKING THE MAP SENSOR OPERATION >
DIAGNOSTIC TEST
1. MAP SENSOR WIRING OR CONNECTORS
NOTE:
Diagnose and repair any MAP Sensor circuit DTCs before proceeding with this test.
NOTE:
Diagnose and repair any sensor supply or system voltage DTCs before proceeding
with this test.
between the MAP Sensor and the PCM.
6. Monitor the scan tool data relative to the sensor and wiggle test the wiring and
connectors.
7. Look for the data to change or for a DTC to set during the wiggle test. If necessary,
check each sensor circuit for high resistance or a shorted condition.
Yes
No
1. Go To Step 2
2. MAP VACUUM/BAROMETRIC PRESSURE
1. With a scan tool, read the Barometric Pressure.

NOTE:
The Barometric Pressure should be approximately equal to the actual

barometric pressure. If necessary, compare the Barometric Pressure value
of the tested vehicle to the value of a known good vehicle of a similar make
and model.
2. Connect a vacuum gauge to a manifold vacuum source.
NOTE:
If the engine will not idle, maintain a constant RPM above idle.
WARNING:
not put your hands near the pulleys, belts, or fan. Do not wear loose
clothing. Failure to follow these instructions can result in possible serious
or fatal injury.
4. With the scan tool, read the MAP Sensor value.
NOTE:
The scan tool reading for MAP vacuum should be within 1" of the vacuum
gauge reading.
Yes
1. Go To Step 4
No
1. Go To Step 3
3. CHECK THE MAP SENSOR VOLTAGE
1. With the scan tool, monitor the MAP Sensor signal voltage.
2. With the engine idling in neutral or park, snap the throttle.

NOTE:
The MAP Sensor signal voltage should change from below 2.0 volts at idle
to above 3.5 volts at wide open throttle.
Yes
1. Go To Step 4
No
1. Test complete.
4. CHECK THE 5-VOLT SUPPLY CIRCUIT FOR HIGH RESISTANCE
2. Using a voltmeter, perform a voltage drop test on the MAP Sensor 5-Volt Supply
circuit between the MAP Sensor harness connector and the PCM harness connector.
Make sure the voltmeter leads are connected so that positive polarity is displayed on
the voltmeter.
WARNING:
or fatal injury.
Is the voltage reading below 0.1 volt?
Yes
1. Go To Step 5
No
1. Repair the 5-Volt Supply circuit for excessive resistance.

5. CHECK THE MAP SENSOR SIGNAL CIRCUIT FOR HIGH RESISTANCE
2. Using a voltmeter, perform a voltage drop test on the MAP Sensor Signal circuit
between the MAP Sensor harness connector and the PCM harness connector. Make
sure the voltmeter leads are connected so that positive polarity is displayed on the
voltmeter.
WARNING:
or fatal injury.
Yes
1. Go To Step 6
No
1. Repair the MAP Sensor Signal circuit for excessive resistance.

6. CHECK THE MAP SENSOR GROUND CIRCUIT FOR HIGH RESISTANCE
2. Using a voltmeter, perform a voltage drop test on the MAP Sensor Ground circuit
voltmeter.
WARNING:
or fatal injury.
Is the voltage below 0.1 volt?
Yes
1. Go To Step 7
No
1. Repair the MAP Sensor Ground circuit for excessive resistance.

7. MAP SENSOR
between the MAP Sensor and the Powertrain Control Module (PCM).
Yes
No
1. Replace the MAP Sensor in accordance with the Service Information. Refer to
SENSOR, MANIFOLD AIR PRESSURE (MAP), REMOVAL AND INSTALLATION
.
DIAGNOSIS AND TESTING > CHECKING THE OXYGEN SENSOR OPERATION
DIAGNOSIS AND TESTING > CHECKING THE OXYGEN SENSOR OPERATION >
THEORY OF OPERATION
The 4-Wire Oxygen Sensor is equipped with a galvanic battery that typically generates a voltage signal
between 0.0 volts and 1.0 volts. The 4-Wire O2 Sensor also includes a heating element that keeps the
sensor at proper operating temperature during all operating modes. Maintaining correct sensor
temperature at all times allows the system to enter into closed loop operation sooner. Also, it allows the
system to remain in closed loop operation during periods of extended idle.
A bias voltage in the Powertrain Control Module (PCM) shifts the signal voltage to fluctuate between 2.5
volts and 3.5 volts, depending upon the oxygen content of the exhaust gas. When a large amount of
oxygen is present (caused by a lean air/fuel mixture) the sensor produces a low voltage. When there is
a lesser amount of oxygen present (caused by a rich air/fuel mixture) it produces a higher voltage. By
monitoring the oxygen content and converting it to electrical voltage, the sensor acts as a rich-lean
switch.
In Open Loop operation the PCM ignores input from the O2 Sensors. In Closed Loop operation the PCM
monitors the O2 Sensor's input (along with other inputs) and adjusts the injector pulse width accordingly
based on pre-programmed (fixed) values and inputs from other sensors. The PCM also compares
upstream and downstream O2 Sensor inputs to calculate the catalytic convertor oxygen storage
capacity and converter efficiency.
The 4-Wire Downstream O2 Sensor serves two functions. The first function is to measure the catalyst
efficiency. If the Catalytic Converter is working properly, the oxygen content of the exhaust gases at the
converter outlet fluctuate significantly less than the converter inlet. The PCM compares the switching
rates of both Downstream and Upstream O2 Sensors under specific operating conditions to determine if
the catalyst is functioning properly. Anytime the upstream to downstream switching ratio exceeds a
calibrated value, a catalyst efficiency DTC is set.
The second function of the Downstream O2 Sensor is downstream fuel control and is active only during
downstream closed loop operation. This function trims the 4-Wire upstream O2 Sensor goal voltage
within the range of Upstream O2 Sensor operation. The Upstream O2 Sensor goal voltage is modified to
ensure long Catalytic Converter life by allowing the PCM to control the amount of oxygen that is supplied
to the catalytic converter. The downstream O2 Sensor is a good indicator of how much oxygen remains
after all of the reactions take place in the converter.
If the O2 Sensor is powered up by the PCM and operating normally, the voltage readings should be as
follows;
Key on engine off.
Measured voltage on the Signal circuit with the sensor at ambient temperature should be
near 35mv.
Measured voltage on the Return circuit with the sensor at ambient temperature should be
near 15mv.
Key on engine running.
Measured voltage on the Fused ASD Output circuit (at the PCM) should be the same as
battery voltage.
Measured voltage on the Heater Control circuit should be near 7 volts.
DIAGNOSIS AND TESTING > CHECKING THE OXYGEN SENSOR OPERATION >
DIAGNOSTIC TEST
1. TEST FOR A RICH O2 SENSOR CONDITION
2. Allow the engine to reach normal operating temperature.
3. Disconnect engine vacuum lines to create a lean running condition.
4. With the engine vacuum lines disconnected monitor the O2 Sensor graph on the
scan tool.
Did the O2 Sensor graph show a change from rich to lean?

Yes
1. Check for any of the following conditions/mechanical problems that can cause a
O2 Sensor stuck rich condition:
2. AFTERMARKET equipment or software effecting emissions.
3. AIR INDUCTION SYSTEM - must be free from blockage.
4. ENGINE VALVE TIMING - must be within specifications.
5. ENGINE COMPRESSION - must be within specifications.
6. ENGINE EXHAUST SYSTEM - must be free of any restrictions or leaks.
7. ENGINE PCV SYSTEM - must flow freely.
8. FUEL - must be free of contamination.
9. FUEL INJECTOR - plugged, stuck open or restricted injector.
No
1. Replace the Oxygen Sensor in accordance with the Service Information. Refer
to SENSOR, OXYGEN, REMOVAL AND INSTALLATION .

2. TEST FOR A LEAN O2 SENSOR CONDITION
3. Create a rich running condition.
4. With the rich running condition, monitor the O2 Sensor graph on the scan tool.
Did the O2 Sensor graph show a change from lean to rich?
Yes
2. AIR INDUCTION SYSTEM - must be free from leaks.
3. ENGINE VACUUM - must be at least 13 inches in neutral.
7. ENGINE PCV SYSTEM - must be free of leaks and flow freely.
8. POWER BRAKE BOOSTER - no internal vacuum leaks.

10. FUEL INJECTOR - plugged or restricted injector; control wire not connected to
correct injector.
No

DIAGNOSIS AND TESTING > CHECKING THE PCM POWER AND GROUND CIRCUITS
> DIAGNOSTIC TEST
1. PCM WIRING OR CONNECTORS
2. Using the wiring diagram/schematic as a guide, inspect the wiring and each
connector at the PCM.
3. Look for any chafed, pierced, pinched or partially broken wires.
Yes

No
1. Go To Step 2
2. CHECK THE PCM GROUND CIRCUITS
2. Using a 12-volt test light connected to 12 volts, probe the PCM ground circuits.
3. Wiggle test the wiring during the test to check for an intermittent open in the circuit.
NOTE:
Is the test light illuminated and bright?
Yes
1. Go To Step 3
No
1. Repair the PCM ground circuit(s) for an open or high resistance.

3. CHECK THE PCM FUSED B+ CIRCUIT
1. Using a 12-volt test light connected to ground, probe the PCM Fused B+ circuit.
NOTE:
Yes
1. Go To Step 4
No
1. Repair the PCM Fused B+ circuit for an open or high resistance.

4. CHECK THE FUSED IGNITION SWITCH CIRCUITS
2. Using a 12-volt test light connected to ground, probe the Fused Ignition Switch
circuit.
3. Check the circuit with the ignition off, ignition on/engine not running position and
during cranking.
NOTE:
The test light should be illuminated and bright with the ignition on and
during cranking. The test light should not be illuminated with the ignition off.
Compare the brightness to that of a direct connection to the battery.
Is the test light illuminated as described above?
Yes
1. Test complete.
No
1. Repair the PCM Fused Ignition Switch circuit for as necessary.

DIAGNOSIS AND TESTING > ENGINE CRANKS BUT DOES NOT START
DIAGNOSIS AND TESTING > ENGINE CRANKS BUT DOES NOT START > POSSIBLE
CAUSES
Possible Causes
5-VOLT SUPPLY CIRCUIT OPEN OR SHORTED
UNDERCHARGED BATTERY
SYSTEM DTCS PRESENT
POWERTRAIN POWER AND GROUND CIRCUIT(S) OPEN OR HIGH RESISTANCE
POWERTRAIN FUSES OPEN
FUEL DELIVERY SYSTEM
FUEL CONTAMINATION
INADEQUATE SPARK
ENGINE MECHANICAL PROBLEM
Always perform the PRE-DIAGNOSTIC TROUBLESHOOTING PROCEDURE before proceeding.

Refer to the appropriate TESTING & DIAGNOSTICS article in ENGINE PERFORMANCE .
DIAGNOSIS AND TESTING > ENGINE CRANKS BUT DOES NOT START >
DIAGNOSTIC TEST
1. UNDERCHARGED BATTERY
NOTE:
Diagnose any 5-Volt Supply DTCs before continuing
NOTE:
The Battery must be fully charged and in good condition. An undercharged Battery
may produce invalid test results.
1. Test the battery in accordance with the Service Information.
Yes
1. Charge or replace the Battery as necessary and retest.

No
1. Go To Step 2
2. OPEN FUSE(S)
1. Inspect all of the fuses in the Fuse Panel. If any open fuses are found, check the
related circuit(s) for a short to ground or high resistance.
Yes

No
1. Go To Step 3
3. SYSTEM DTCS PRESENT
1. With the scan tool, select System DTCs to read DTCs in all modules. If any DTCs
are present, perform the appropriate diagnostic procedure before continuing with this
test. If a no response condition is detected in any module, and perform the
appropriate No Response diagnostic procedure.
Yes
1. Perform the appropriate diagnostic procedure and repair as necessary. If any

pending DTCs are detected, perform the diagnostic procedure as if the DTC is
active.

No
1. Go To Step
4. PCM POWER OR GROUND CIRCUIT OPEN OR HIGH RESISTANCE
1. Perform the CHECKING THE PCM POWER AND GROUND CIRCUIT test procedure.
Refer to CHECKING THE PCM POWER AND GROUND CIRCUITS .
Yes

No
1. Go To Step
5. CHECKING THE FUEL DELIVERY SYSTEM
NOTE:
Verify that the fuel tank is not empty before continuing.
1. Perform the CHECKING THE FUEL DELIVERY SYSTEM test procedure. Refer to
CHECKING THE FUEL DELIVERY SYSTEM (HARD START) .
Yes

No
1. Go To Step 6
6. FUEL CONTAMINATION
1. Check the fuel system for contamination in accordance with the Service Information.
Was any evidence of fuel contamination found?
Yes
1. Clean and repair the fuel system as necessary in accordance with the Service
Information.

No
1. Go To Step 7
7. CHECKING THE IGNITION COIL OPERATION
1. Perform the diagnostic procedure for CHECKING THE IGNITION COIL OPERATION.
Refer to CHECKING THE IGNITION COIL OPERATION .
Yes

No
1. Go To Step 8
8. CHECKING THE ENGINE MECHANICAL SYSTEM
1. Perform the diagnostic procedure for CHECKING THE ENGINE MECHANICAL

SYSTEM. Refer to CHECKING THE ENGINE MECHANICAL SYSTEM .
Yes

No
1. Test complete. Perform any Service Bulletins that may apply.

Service Manual: DRIVEABILITY - GAS - NON-DTC BASED Jeep Renegade
DIAGNOSTICS - EXCEPT 2.4L
DIAGNOSIS AND TESTING > CHECKING THE ENGINE MECHANICAL SYSTEM
DIAGNOSIS AND TESTING > CHECKING THE ENGINE MECHANICAL SYSTEM >
DIAGNOSTIC TEST
CHECKING THE ENGINE MECHANICAL SYSTEM
2. Check for any of the following conditions/mechanical problems:
1. ENGINE VACUUM - must be at least 13 inches in neutral
2. ENGINE VALVE TIMING - must be within specifications
3. ENGINE COMPRESSION - must be within specifications
4. CYLINDER LEAKAGE TEST - must be within specifications
5. ENGINE EXHAUST SYSTEM - must be free of any restrictions or leaks
6. ENGINE PCV SYSTEM - must flow freely
7. TORQUE CONVERTER STALL SPEED - must be within specifications
8. POWER BRAKE BOOSTER - no internal vacuum leaks
9. FUEL - must be free of contamination
10. VALVE SPRINGS - cannot be weak or broken
11. CAM LOBES - must not be worn excessively
12. CAM SHAFTS - must not be worn or have excessive end play
Are there any engine mechanical problems?
Yes
No
1. Test Complete.
CHECKING THE EXHAUST SYSTEM FOR LEAKS

described go to;
Channel" box.
DIAGNOSTIC TEST
CHECK THE EXHAUST SYSTEM FOR LEAKS
2. Raise and support the vehicle in accordance with the service information. Refer to HOISTING,
WARNING:
The normal operating temperature of the exhaust system is very high. Never work
around or attempt to service any part of the exhaust system until it has cooled.
Special care should be taken when working near the catalytic converter. The
temperature of the converter rises to a high level after a short period of engine
operating time.
3. Connect Exhaust Cone (special tool #8404-ECT, Exhaust Cone, Truck) to Air Pressure
Regulator (with hose) W-18-MIL-1146AS.
CAUTION:
The air pressure must not exceed 27.6 kPa (4 psi), otherwise engine damage can
occur.
4. Attach shop air to the air pressure regulator.
5. Adjust the Air Pressure Regulator to 27.6 kPa (4 psi)
6. Insert the exhaust cone into the vehicle tail pipe.
7. If the vehicle is equipped with dual exhaust, use a second Exhaust Cone (special tool
#8404-ECT, Exhaust Cone, Truck) equipped with the attached plug and plug one side of the
dual exhaust pipe. Pressurize the other as described above.
8. Apply Mopar® Air Leak Detector PN 05191804AA (or an equivalent leak finder liquid) to the
following areas:
1. All welded joints from the exhaust manifold to 45.72 cm (18 inches) behind the
downstream O2 Sensor
2. O2 Sensor seal points
3. O2 Sensor boss welds
4. Flange/joint connection(s)
5. Exhaust manifold to cylinder head connection(s)
6. EGR solenoid gasket base and tube seal points (if equipped)
9. Watch for the Mopar® Air Leak Detector PN 05191804AA (or the equivalent leak finder liquid)
to bubble.
10. Use the following definitions to help determine if system or component repair/replacement is
necessary:
1. Type 1 Leak is defined as a leak where very small foam like bubbles 1 mm (0.04 of an
inch) or less appear. Any Type 1 or greater leaks found in welded joints, O2 sensor seal
points or O2 sensor boss welds must be repaired or the component must be replaced.
2. Type 2 Leak is defined as a leak where larger bubbles pea size, 8 mm (0.3 of an inch)
or greater appear. Any Type 2 or greater leaks found in flange or joint connections,
exhaust manifold to cylinder head connections, or EGR gasket and tube seal points must
be repaired or the components must be replaced.
Repair as required if results at 27.6 kPa (4

Leak Location
psi) reveal bubble size:
Welded joints Type 1, 1 mm (0.04 of an inch) or greater
O2 Sensor seal points Type 1, 1 mm (0.04 of an inch) or greater
O2 Sensor boss welds Type 1, 1 mm (0.04 of an inch) or greater
Flange / joint connections Type 2, 8 mm (0.3 of an inch) or greater
Exhaust Manifold to cylinder head connections Type 2, 8 mm (0.3 of an inch) or greater
EGR gasket and tube seal points Type 2, 8 mm (0.3 of an inch) or greater
11. If a leak is found that matches the above definition, repair or replace the component as
necessary.
12. Once the repair is complete, repeat the procedure to verify that all leaks have been repaired.
Were any exhaust leaks found?
Yes
1. Repair or replace the leaking exhaust parts as necessary.
No
1. Test complete.
START)
START) > POSSIBLE CAUSES
Possible Causes
FUEL DELIVERY SYSTEM LEAKING OR DAMAGED
RESTRICTED FUEL SUPPLY LINE
FUEL PUMP INLET STRAINER PLUGGED
FUEL PUMP CONTROL OUTPUT CIRCUIT OPEN
FUEL INJECTOR(S)
FUEL PUMP MODULE
WARNING:
Follow these safety precautions to reduce the risk of fire and possible serious or fatal injury
when performing this test procedure.
Fuel or fuel vapors are highly flammable. A fire could occur if an ignition source is
present. Do not expose the fuel or the test equipment used in this procedure to open
flames or sparks.
Inhalation of fuel vapors could lead to disorientation and personal injury. Keep the
service area well ventilated, or perform this test procedure in an area where there is a
building exhaust removal system.
Relieve fuel system pressure before servicing fuel system components.
Use extreme caution when connecting and disconnecting fuel lines.
Considerable fuel leakage may occur when servicing the fuel system. Wear protective
eye wear and clothing to protect from fuel splash, and take suitable fuel containment
measures.
Wrap a shop towel around the fuel pressure gauge connection to absorb fuel leakage
that occurs when connecting the test equipment. Place the towel in an approved
container when complete.
Never store fuel in an open container due to the possibility of fire or explosion. Have a
dry chemical (Class B) fire extinguisher nearby.
START) > DIAGNOSTIC TEST
1. CHECK THE FUEL DELIVERY SYSTEM FOR LEAKS AND DAMAGE
WARNING:
or fatal injury.
1. Visually and physically inspect the fuel delivery system for external leaks and
damage.
Is the system leaking or damaged?
Yes
1. Repair or replace as necessary.
No
1. Go To Step 2
2. CHECK FUEL PUMP OPERATION
2. With a scan tool, actuate the Fuel System test.
NOTE:
It may be necessary to use a mechanics stethoscope in the next step.
3. Listen for fuel pump operation at the Fuel Tank.
Does the Fuel Pump operate?
Yes
1. Go To Step 3
No
1. Check the power and ground circuits to the Fuel Pump Module assembly. If the
circuits test good, replace the Fuel Pump Module assembly.

3. INSTALL APPROPRIATE FUEL LINE ADAPTERS/FITTING FROM THE GAS AND DIESEL
FUEL PRESSURE/DECAY TESTER 8978A
Fig 1: Fuel Line Adapters/Fitting

WARNING:
The fuel system is under a constant pressure (even with the engine off).
Before testing or servicing any fuel system hose, fitting, or line, the fuel
system pressure must be released. Failure to follow these instructions can
2. Release the fuel system pressure. Refer to FUEL SYSTEM .
3. Disconnect the rail fuel supply line connector between the fuel supply line and the fuel
rail. (Refer to LINES, FUEL ).
4. Install the appropriate Fuel Line Adapters/Fitting from the Gas and Diesel Fuel
Pressure/Decay Tester (special tool #8978A, Decay Tool, Fuel).
Proceed
1. Go To Step 4
4. INSTALL THE FUEL PRESSURE GAUGE ASSEMBLY

Fig 2: Identifying Fuel Pressure Gauge Assembly
1. Connect the (special tool #8978A, Decay Tool, Fuel), with the Fuel Inlet Hose (1)
toward the Fuel tank side and the Fuel Outlet Hose (2) toward the fuel rail side of the
system using the Fuel Line Adapters/Fitting as needed.
2. Connect special tool Drain Extension Hose 535680 (3) to the Fuel Pressure Gauge
Assembly Drain Hose (5).
3. Connect Reservoir Assembly 534960 (4) to Drain Extension Hose 535680 (3).
WARNING:
To reduce the risk of fire and possible serious or fatal injury, place
Reservoir Assembly 534960 (4) on the floor and out of the way so that it is
not a trip hazard.
Proceed
1. Go To Step 5
5. CHECK THE FUEL PRESSURE

1. Perform the following procedure to purge air from the system:
1. Open the Fuel System Isolation Valve (1).

2. Close the Flow Test Valve (2).
6. CAUTION: Stop All Actuations.
8. Disconnect, empty and then reconnect the Reservoir Assembly.
NOTE:
above 60%.
NOTE:
552 kPa +/- 34 kPa (80 psi +/- 5 psi).
Choose a conclusion that best matches your fuel pressure reading.
Below Specification
1. Go To Step 10
Within Specification
1. Go To Step 6
Above Specification
1. Replace the fuel filter/fuel pressure regulator.

CAUTION:
6. CHECK THE FUEL DELIVERY SYSTEM OUTPUT

WARNING:
or fatal injury.
1. With the scan tool, continue to actuate the fuel pump.
CAUTION:
FUEL FLOW
8 Cylinder 38.88889 778
SRT-4 50 1000
10 cylinder 55.5 1110
Yes
1. Go To Step 7
No
1. Go To Step 8
7. CHECK THE FUEL DELIVERY SYSTEM FOR LEAK DOWN

Fig 5: Checking Fuel Delivery System For Leak Down
WARNING:
or fatal injury.
2. With the scan tool, actuate the fuel pump.
3. Close the Fuel System Isolation Valve (1).
CAUTION:
4. Turn the ignition off and then wait five minutes before proceeding.
5. Read the Fuel Inlet (2) and Fuel Outlet (3) Pressure Gauges. The pressure should
not drop more than 10 psi on either gauge.
Does the fuel pressure drop more than 10 psi?
Yes - On Fuel Inlet Gauge (2)
Yes - On Fuel Outlet Gauge (3)
1. Replace the leaking Fuel Injector(s).
No
1. If directed here by another test, return to that test. Otherwise, test complete.

WARNING:
must be released.
2. Disconnect the Fuel Pressure Decay Tester.

3. Raise the vehicle on a hoist, and disconnect the fuel pressure line at the Fuel Pump
Module.
4. Install the Fuel Pressure Decay Tester between the fuel supply line and the Fuel
Pump Module.
CAUTION:
FUEL FLOW
8 Cylinder 38.88889 778
SRT-4 50 1000
10 cylinder 55.5 1110
Yes

No
1. Go To Step 9
CAUTION:

9. CHECKING THE FUEL INLET STRAINER
WARNING:
or fatal injury.
Yes

No


WARNING:
must be released.
2. Disconnect the Fuel Pressure Decay Tool.
3. Raise the vehicle on a hoist, and disconnect the fuel pressure line at the fuel pump
module.
4. Install the Fuel Pressure Decay Tool between the fuel supply line and the fuel pump
module.

NOTE:
above 60%.
NOTE:
552 kPa +/- 34 kPa (80 psi +/- 5 psi).
Is the fuel pressure now within specification?
Yes

No
1. Go To Step 11
CAUTION:
11. CHECKING FUEL INLET STRAINER
WARNING:
or fatal injury.
Yes

No

DIAGNOSIS AND TESTING > CHECKING THE MAP SENSOR OPERATION
DIAGNOSIS AND TESTING > CHECKING THE MAP SENSOR OPERATION >
DIAGNOSTIC TEST
1. MAP SENSOR WIRING OR CONNECTORS
NOTE:
Diagnose and repair any MAP Sensor circuit DTCs before proceeding with this test.
NOTE:
Diagnose and repair any sensor supply or system voltage DTCs before proceeding
with this test.
between the MAP Sensor and the PCM.
6. Monitor the scan tool data relative to the sensor and wiggle test the wiring and
connectors.
7. Look for the data to change or for a DTC to set during the wiggle test. If necessary,
check each sensor circuit for high resistance or a shorted condition.
Yes
No
1. Go To Step 2
2. MAP VACUUM/BAROMETRIC PRESSURE
1. With a scan tool, read the Barometric Pressure.
NOTE:
The Barometric Pressure should be approximately equal to the actual

barometric pressure. If necessary, compare the Barometric Pressure value
of the tested vehicle to the value of a known good vehicle of a similar make
and model.
2. Connect a vacuum gauge to a manifold vacuum source.
NOTE:
If the engine will not idle, maintain a constant RPM above idle.
WARNING:
or fatal injury.
4. With the scan tool, read the MAP Sensor value.

NOTE:
The scan tool reading for MAP vacuum should be within 1" of the vacuum
gauge reading.
Yes
1. Go To Step 4
No
1. Go To Step 3
3. CHECK THE MAP SENSOR VOLTAGE
1. With the scan tool, monitor the MAP Sensor signal voltage.
2. With the engine idling in neutral or park, snap the throttle.
NOTE:
The MAP Sensor signal voltage should change from below 2.0 volts at idle
to above 3.5 volts at wide open throttle.
Yes
1. Go To Step 4
No
1. Test complete.
4. CHECK THE 5-VOLT SUPPLY CIRCUIT FOR HIGH RESISTANCE
2. Using a voltmeter, perform a voltage drop test on the MAP Sensor 5-Volt Supply
circuit between the MAP Sensor harness connector and the PCM harness connector.
Make sure the voltmeter leads are connected so that positive polarity is displayed on
the voltmeter.
WARNING:
or fatal injury.
Yes
1. Go To Step 5
No
1. Repair the 5-Volt Supply circuit for excessive resistance.

5. CHECK THE MAP SENSOR SIGNAL CIRCUIT FOR HIGH RESISTANCE
2. Using a voltmeter, perform a voltage drop test on the MAP Sensor Signal circuit
voltmeter.
WARNING:
or fatal injury.
Yes
1. Go To Step 6
No
1. Repair the MAP Sensor Signal circuit for excessive resistance.

6. CHECK THE MAP SENSOR GROUND CIRCUIT FOR HIGH RESISTANCE
2. Using a voltmeter, perform a voltage drop test on the MAP Sensor Ground circuit
voltmeter.
WARNING:
or fatal injury.
Is the voltage below 0.1 volt?
Yes
1. Go To Step 7
No
1. Repair the MAP Sensor Ground circuit for excessive resistance.
7. MAP SENSOR
between the MAP Sensor and the Powertrain Control Module (PCM).
Yes
No
1. Replace the MAP Sensor in accordance with the Service Information. Refer to
SENSOR, MANIFOLD AIR PRESSURE (MAP), REMOVAL AND INSTALLATION
.
DIAGNOSIS AND TESTING > CHECKING THE OXYGEN SENSOR OPERATION (6

WIRE)

WIRE) > THEORY OF OPERATION
The wide-band (6-Wire) O2 Sensor operates differently than the traditional 4-Wire O2 Sensor. The
wide-band O2 Sensor tip consists of two cells that provide different functions, a measurement chamber
and a detection chamber with pumping capabilities. The oxygen pumping function is the ability to pump
oxygen into or out of the measurement chamber depending on the level of oxygen in the measurement
chamber. This function provides the wide-band sensing capabilities and is critical for proper oxygen
measurement. The O2 Sensor Positive Current Control circuit provides a common bias supply to both
the O2 Sensor Signal and the O2 Sensor Pump Cell Current circuits.
During normal operation, the O2 Sensor Positive Current Control voltage and O2 Sensor Signal voltage
will be a fixed voltage value. The O2 Sensor Pump Cell Current voltage will switch from approximately
0.45 volts above and below the fixed O2 Sensor Return voltage, allowing current to flow in either
direction through the pump. This correlates with the pumping of oxygen into and out of the measurement
chamber. On a properly operating vehicle, this happens very quickly and the voltage reading will appear
as a steady 0.45 volts when taking a voltage measurement between the O2 Sensor Signal circuit and
the O2 Sensor Positive Current Control circuit of the O2 Sensor with the engine running and the O2
Sensor operating in closed loop.
When the exhaust stream has a lean air/fuel ratio (high oxygen content) the Pump Cell Current voltage
will move toward +0.45 volts pumping oxygen out of the measurement chamber. When the exhaust
stream has a rich air/fuel ratio (relatively low oxygen content) the Pump Cell Current voltage will move
toward -0.45 volts pumping oxygen into the measurement chamber.
The PCM is able to pinpoint failures to the specific O2 Sensor circuits through a series of steps which
include both "cold" and "hot" tests. To ensure that the correct malfunctioning circuit is identified, the
diagnostics are performed in three separate test conditions, a Cold test at startup, Hot test during
vehicle operation and Cold test during PCM power down .
A Cold test, performed at startup (before the O2 system enters closed loop operation), can detect a
Short Circuit to Battery. Although the diagnostics can detect the failure, it cannot identify the specific
circuit which failed and will set the generic fault code P0132.
NOTE:
The Cold test at startup cannot detect a Short Circuit to Ground or an Open Circuit failure.
When the PCM detects a circuit that falls outside the allowable range during either the cold startup test
or during O2 Sensor closed loop operation, a Hot test is initiated. The O2 Sensor is turned off and a 20
second delay timer is started. Once the timer expires, the hot test diagnostic will be performed. It takes
approximately 160 ms from the time the hot test is initiated until the fault is set. If an open circuit is
detected the specific circuit which failed can be identified during the hot test and the fault code for the
related circuit will be set. If a short to ground or short to battery is detected the diagnostics can detect
the failure, however it cannot identify the specific circuit which failed and will set the generic fault codes
P0131 for short to ground or P0132 for short to battery.
NOTE:
The hot test will be repeated every 20 seconds, as long as the circuit measurements are still
out of range. This will continue until the key is switched off or until the measurements are in
range.
The Cold test is performed at power down (ignition off) as long as the coolant temperature is at or
below 185°F (85°C). This diagnostic will run after a generic short to battery or short to ground fault is set
to identify the specific circuit which failed.
Fig 1: Wide Band O2 Sensor Monitor

If the O2 Sensor is powered up by the PCM and operating normally, the voltage readings should be as
follows;
The voltage at the (K41) O2 Sensor Signal circuit should be approximately 4.3 volts.
The voltage at the (K902) O2 Sensor Return circuit should be approximately 3.85 volts.
The voltage at the (K89) O2 Positive Current Control circuit should be switching between
approximately 3.4 volts and 4.3 volts.
The voltage between the (K89) O2 Positive Current Control circuit and the (K902) O2 Sensor
Return circuit should switch between +0.45 volts and -0.45 volts.
NOTE:
The voltage readings may vary up or down slightly depending on the age of the O2 Sensor
and operating conditions of the engine. However, if the engine and O2 Sensor are operating
normally the voltage reading between the (K89) O2 Positive Current Control circuit and the
(K902) O2 Sensor Return circuit should switch between +0.45 volts and -0.45 volts with very
little or no change.

WIRE) > DIAGNOSTIC TEST
1. VERIFY O2 SENSOR OPERATION
3. With the scan tool, select and graph the O2 Sensor suspected of not performing
correctly.
4. Review the 3 sample videos of O2 Sensor operation to determine which graph best
matches what is displayed on the scan tool for the vehicle.
5. Which video best matches the graph displayed on the scan tool?
Video 1 (Normal operation)
A multimedia supplement to the

instructions contained in this article is
available.
To view the multimedia example of the
condition described go to;
http://www.youtube.com
/user/Mitchell1Tips
then type "A00646310.vid2" into the
"Search Channel" box.
1. Perform the INTERMITTENT CONDITION diagnostic procedure. Refer to the
appropriate TESTING & DIAGNOSTICS article in ENGINE PERFORMANCE .
Video 2 (Rich operation)

available.
/user/Mitchell1Tips
1. Go To Step 2
Video 3 (Lean operation)

available.
/user/Mitchell1Tips
1. Go To Step 3
2. TESTING FOR RICH O2 SENSOR OPERATION
correctly.
3. Disconnect engine vacuum lines to create a lean running condition.
4. With the engine vacuum lines disconnected monitor the O2 Sensor graph on the
scan tool.
Did the O2 Sensor graph show a change from rich to lean?
Yes
1. Check for any of the following conditions/mechanical problems that can cause a
O2 Sensor stuck rich condition:
3. AIR INDUCTION SYSTEM - must be free from blockage.

7. ENGINE PCV SYSTEM - must flow freely.
9. FUEL INJECTOR - plugged, stuck open or restricted injector.
No

3. TESTING FOR LEAN O2 SENSOR OPERATION
correctly.
3. Create a rich running condition.
4. With the rich running condition, monitor the O2 Sensor graph on the scan tool.
Did the O2 Sensor graph show a change from lean to rich?
Yes
2. AIR INDUCTION SYSTEM - must be free from leaks.
3. ENGINE VACUUM - must be at least 13 inches in neutral.
7. ENGINE PCV SYSTEM - must be free of leaks and flow freely.
8. POWER BRAKE BOOSTER - no internal vacuum leaks.
10. FUEL INJECTOR - plugged or restricted injector; control wire not connected to
correct injector.
No
> DIAGNOSTIC TEST
1. PCM WIRING OR CONNECTORS
2. Using the wiring diagram/schematic as a guide, inspect the wiring and each
connector at the PCM.
3. Look for any chafed, pierced, pinched or partially broken wires.
Yes

No
1. Go To Step 2
2. CHECK THE PCM GROUND CIRCUITS
2. Using a 12-volt test light connected to 12 volts, probe the PCM ground circuits.
NOTE:
Yes
1. Go To Step 3
No
1. Repair the PCM ground circuit(s) for an open or high resistance.

3. CHECK THE PCM FUSED B+ CIRCUIT
1. Using a 12-volt test light connected to ground, probe the PCM Fused B+ circuit.
NOTE:
Yes
1. Go To Step 4
No
1. Repair the PCM Fused B+ circuit for an open or high resistance.

4. CHECK THE FUSED IGNITION SWITCH CIRCUITS
2. Using a 12-volt test light connected to ground, probe the Fused Ignition Switch
circuit.
3. Check the circuit with the ignition off, ignition on/engine not running position and
during cranking.
NOTE:
The test light should be illuminated and bright with the ignition on and
during cranking. The test light should not be illuminated with the ignition off.
Compare the brightness to that of a direct connection to the battery.
Is the test light illuminated as described above?

Yes
1. Test complete.
No
1. Repair the PCM Fused Ignition Switch circuit for as necessary.

DIAGNOSIS AND TESTING > ENGINE CRANKS BUT DOES NOT START
DIAGNOSIS AND TESTING > ENGINE CRANKS BUT DOES NOT START > POSSIBLE
CAUSES
Possible Causes
5-VOLT SUPPLY CIRCUIT OPEN OR SHORTED
UNDERCHARGED BATTERY
SYSTEM DTCS PRESENT
POWERTRAIN POWER AND GROUND CIRCUIT(S) OPEN OR HIGH RESISTANCE
POWERTRAIN FUSES OPEN
FUEL DELIVERY SYSTEM
FUEL CONTAMINATION
INADEQUATE SPARK
ENGINE MECHANICAL PROBLEM
Always perform the PRE-DIAGNOSTIC TROUBLESHOOTING PROCEDURE before proceeding.

Refer to the appropriate TESTING & DIAGNOSTICS article in ENGINE PERFORMANCE .
DIAGNOSIS AND TESTING > ENGINE CRANKS BUT DOES NOT START >
DIAGNOSTIC TEST
1. UNDERCHARGED BATTERY
NOTE:
Diagnose any 5-Volt Supply DTCs before continuing
NOTE:
The Battery must be fully charged and in good condition. An undercharged Battery
may produce invalid test results.
1. Test the battery in accordance with the Service Information.
Yes
1. Charge or replace the Battery as necessary and retest.

No
1. Go To Step 2
2. OPEN FUSE(S)
1. Inspect all of the fuses in the Fuse Panel. If any open fuses are found, check the
related circuit(s) for a short to ground or high resistance.
Yes

No
1. Go To Step 3
3. SYSTEM DTCS PRESENT
1. With the scan tool, select System DTCs to read DTCs in all modules. If any DTCs
are present, perform the appropriate diagnostic procedure before continuing with this
test. If a no response condition is detected in any module, and perform the
appropriate NO RESPONSE diagnostic procedure.
Yes
1. Perform the appropriate diagnostic procedure and repair as necessary. If any
pending DTCs are detected, perform the diagnostic procedure as if the DTC is
active.

No
1. Go To Step
4. PCM POWER OR GROUND CIRCUIT OPEN OR HIGH RESISTANCE
1. Perform the CHECKING THE PCM POWER AND GROUND CIRCUIT test procedure.
Refer to CHECKING THE PCM POWER AND GROUND CIRCUITS .
Yes

No
1. Go To Step
5. CHECKING THE FUEL DELIVERY SYSTEM
NOTE:
Verify that the fuel tank is not empty before continuing.
1. Perform the CHECKING THE FUEL DELIVERY SYSTEM test procedure. Refer to
CHECKING THE FUEL DELIVERY SYSTEM (HARD START) .
Yes

No
1. Go To Step 6
6. FUEL CONTAMINATION
1. Check the fuel system for contamination in accordance with the Service Information.
Was any evidence of fuel contamination found?
Yes
1. Clean and repair the fuel system as necessary in accordance with the Service
Information.

No
1. Go To Step 7
7. CHECKING THE IGNITION COIL OPERATION
1. Perform the diagnostic procedure for CHECKING THE IGNITION COIL OPERATION.
Refer to CHECKING THE IGNITION COIL OPERATION .
Yes

No
1. Go To Step 8
8. CHECKING THE ENGINE MECHANICAL SYSTEM
1. Perform the diagnostic procedure for CHECKING THE ENGINE MECHANICAL

SYSTEM. Refer to CHECKING THE ENGINE MECHANICAL SYSTEM .
Yes

No
1. Test complete. Perform any Service Bulletins that may apply.

Jeep Renegade
Service Manual: EMISSION APPLICATIONS
EMISSION APPLICATIONS
2015 Renegade
Engine & Fuel System (1) Emission Control Systems & EGR Test No.
Devices
1.4L (83") 4 Cyl. SFI Turbo PCV, EVAP, TWC, FR, SPK, ...
AFS, HO2S, CEC, MIL,
EVAP-PSOL, EVAP-VC, FP-CKV,
ORVR-FMV, SPK-CC
2.4L (144") 4-Cyl. SFI (2) CCV, EVAP, (3) TWC, FR, ...
SPK, (4) HO2S, CEC, MIL,
EVAP-LDP, EVAP-CPCS,
EVAP-ORVR, EVAP-VC
(1) Major emission control systems and devices are listed in bold type; components and other related
devices are listed in light type.
(2) System uses a vacuum controlled (PCV) valve.
(3) FWD equipped with 1 TWC. AWD equipped with 2 TWC.
(4) Equipped with 2.
Jeep Renegade
Service Manual: EMISSION CONTROL ABBREVIATIONS
"A"
A/C
Air Conditioning
A/C-ISUS
A/C Idle Speed-Up Solenoid
A/F
Air/Fuel
AAI
Air Assist Injector
ACL
Air Cleaner (Thermostatic Air Cleaner)
ACL-BMS
ACL Bimetallic Sensor
ACL-CKV
ACL Check Valve
ACL-DV
ACL Delay Valve
ACL-PVS
ACL Ported Vacuum Switch
ACL-RDV
ACL Reverse Delay Valve
ACL-RDVS
ACL Reverse Delay Valve (Single)
ACL-TCV
ACL Thermal Control Valve
ACL-TS
ACL Temperature Sensor
ACL-TSOV
ACL Temperature Sensor Override Valve
ACL-TVS
ACL Thermal Vacuum Switch
ACL-TVV
ACL Thermal Vacuum Valve
ACL-VCDV
ACL Vacuum Control Delay Valve
ACL-VCV
ACL Vacuum Control Valve
ACL-VM
ACL Vacuum Motor
ACL-WP
ACL Wax Pellet Type Motor
ADS
Anti-Dieseling Solenoid
AFR
Air/Fuel Ratio Sensor
AFS
Air/Fuel Ratio Sensor
AIH
Air Intake Heaters
AIH-TS
AIH Temperature Sensor
AIR
Air Injection System
AIS
Air Injection System
AIS-ACV
AIS Air Control Valve
AIS-AF
Air Injection System Air Filter
AIS-AMV
AIS Air Management Valve
AIS-ASV
AIS Air Switching Valve
AIS-BPV
AIS By-Pass Valve
AIS-CC
AIS Computer Controlled
AIS-CKV
AIS Check Valve
AIS-CSV
AIS Control Solenoid Valve
AIS-CV
AIS Combination Valve
AIS-DV
AIS Diverter Valve
AIS-IMCV
AIS Intake Manifold Change-Over Valve
AIS-MCV
AIS Manifold Change-Over Valve
AIS-PAF
AIS Pulse Air Feeder
AIS-PM
AIS Pump Motor
AIS-PV
AIS Pneumatic Valve
AIS-RV
AIS Relief Valve

AIS-SAV
AIS Secondary Air Valve
AIS-SOL
AIS Solenoid
AIS-SV
AIS Solenoid Valve
AIS-VCV
AIS Vacuum Control Valve
AIS-VSV
AIS Vacuum Switching Valve
AIS-VT
AIS Vacuum Tank
AIS-VCV
AIS Vacuum Control Valve
AIS-VSV
AIS Vacuum Switching Valve
AIV
Air Injection Valve
AIV-SOL
Air Injection Valve Solenoid
ALVW
Adjusted Loaded Vehicle Weight
AMV
Air Management Valve
AP
Air Pump Injection System
AP-ACV
AP Air Control Valve
AP-AMV
AP Air Management Valve

AP-ASRV
AP Air Switching Relief Valve
AP-ASS
AP Air Switching Solenoid
AP-ASV
AP Air Switching Valve
AP-BPV
AP By-Pass Valve
AP-CKV
AP Check Valve
AP-CS
AP Control Solenoid
AP-CV
AIR Cut-Off Valve
AP-DCTO
AP Dual Coolant Temperature Override
AP-DLY
AP Delay Valve
AP-DV
AP Diverter Valve
AP-EADV
AP Electric Air Control Diverter Valve
AP-EAMR
AP Electric Air Management Relay
AP-EAMS
AP Electric Air Management Solenoid
AP-EAP
AP Electric Air Pump
AP-EC
AP Electromagnetic Clutch
AP-ERLY
AP Electric Air Pump Relay
AP-RDV
AP Reed Valve
AP-RV
AP Relief Valve
AP-SOL
AP Solenoid
AP-SOV
AP Shut-Off Valve
AP-SV
AP Solenoid Valve
AP-SWV
AP Switchover Valve
AP-TV
AP Transmitting Valve
AP-VCS
AP Vacuum Control Solenoid
AP-VCSV
AP Vacuum Controlled Air Shut-Off Valve
AP-VCV
AP Vacuum Control Valve
AP-VSV
AP Vacuum Switching Valve
A/T
ATCV
Air Temperature Control Valve
"B"
BP/EGR
Backpressure EGR System
BP/EGR-BPS
BP/EGR Backpressure Sensor
BP/EGR-BPT
BP/EGR Backpressure Transducer
BP/EGR-BPV
BP/EGR Backpressure Valve
BP/EGR-BS
BP/EGR Bleed Solenoid
BP/EGR-BVSV
BP/EGR Bimetallic Vacuum Switching Valve
BP/EGR-C
BP/EGR Controller
BP/EGR-CLR
BP/EGR Cooler
BP/EGR-CS
BP/EGR Control Solenoid
BP/EGR-CTO
BP/EGR Coolant Temperature Override
BP/EGR-CV
BP/EGR Control Valve
BP/EGR-DCTO
BP/EGR Dual Coolant Temperature Override
BP/EGR-DS
BP/EGR Diagnostic Solenoid
BP/EGR-DSOL
BP/EGR Duty Solenoid
BP/EGR-DTVSW
BP/EGR Distributor Thermal Vacuum Switch

BP/EGR-DV
BP/EGR Delay Valve
BP/EGR-EET
BP/EGR Electric Transducer
BP/EGR-EPV
BP/EGR External Pressure Valve
BP/EGR-FDV
BP/EGR Forward Delay Valve
BP/EGR-LC
BP/EGR Load Control Valve
BP/EGR-PS
BP/EGR Position Sensor
BP/EGR-PT
BP/EGR Pressure Tranducer
BP/EGR-PVS
BP/EGR Ported Vacuum Switch
BP/EGR-RES
BP/EGR Reservoir
BP/EGR-RST
BP/EGR Restrictor
BP/EGR-SOL
BP/EGR Solenoid
BP/EGR-TCTVS
BP/EGR Torque Converter Thermal Vacuum Switch
BP/EGR-TCV
BP/EGR Thermal Control Valve
BP/EGR-TCVLV
BP/EGR Temperature Control Valve
BP/EGR-TS
BP/EGR Temperature Sensor

BP/EGR-TVS
BP/EGR Thermal Vacuum Switch
BP/EGR-TVV
BP/EGR Thermal Vacuum Valve
BP/EGR-VCV
BP/EGR Vacuum Control Valve
BP/EGR-VM
BP/EGR Vacuum Modulator
BP/EGR-VRV
BP/EGR Vacuum Regulator Valve
BP/EGR-VS
BP/EGR Vacuum Switch
BP/EGR-VSOL
BP/EGR Vent Solenoid
BP/EGR-VSV
BP/EGR Vacuum Switching Valve
"C"
C-4
Computer Controlled Catalytic Converter
CAC
Charge Air Cooler
CAS
Clean Air System
CB
Crankcase Breather
CB-VC
Crankcase Breather-Vapor Canister
CBPS
Coasting By-Pass System

CBVC
Crankcase Breather Vapor Canister
CCIEV
Coolant Controlled Idle Enrichment Valve
CCS
Controlled Combustion System
CCV
Closed Crankcase Ventilation
CD-REGVLV
Crankcase Depression Regulator Valve
CDRV
Crankcase Depression Relief Valve
CEAB
Cold Engine Air Bleed
CEAB-TVS
CEAB Thermal Vacuum Switch
CEAB-TVV
CEAB Thermal Vacuum Valve
CEC
Computerized Engine Controls
CESS
Cold Engine Sensor Switch
CETS
Cold Engine Temperature Switch
CFI
Continuous Fuel Injection
CMH
Cold Mixture Heater
CNG
Compressed Natural Gas

CO
Carbon Monoxide
CO2
Carbon Dioxide
CPI
Central Port Injection
CRV
Coasting Richer Valve
CSI
Central Sequential Injection
CTAVS
Cold Temperature Activated Vacuum System
CTOX
Continous Trap Oxidizer
"D"
DCLV
Deceleration Valve
DCS
Deceleration Control System
DDI
Direct Diesel Injection
DFI
Direct Diesel Injection
DI
Direct Injection
DKV
Deceleration Kick Valve
DMCV
Deceleration Mixture Control Valve

DMS
Dual Manifold System
DOC
Diesel Oxidation Catalyst
DOHC
Dual Overhead Cam
DPF
Diesel Particulate Filter
DPF/TWC
Combination Diesel Particulate Filter and Three Way Catalyst
DPFE
Differential Pressure Feedback EGR Valve
DPFEGR
Differential Pressure Feedback EGR Valve
DTM
Deceleration Throttle Modulator
"E"
EAIR
Electric Air Injection System
EAIR-DV
EAIR Diverter Valve
ECM
Electronic Control Module
ECU
Electronic Control Unit
EDC
Electronic Diesel Control
EDS
Electronic Diesel System

EEC
Electronic Engine Control
EFE
Early Fuel Evaporation
EFE-CKV
EFE Check Valve
EFE-CV
EFE Control Valve
EFE-DTVS
EFE Delay Thermal Vacuum Switch
EFE-HTR
EFE Heater
EFE-HCV
EFE Heat Control Valve
EFE-OTS
EFE Oil Temperature Switch
EFE-PTC
EFE Positive Temperature Coefficient (Intake Heater Grid)
EFE-PVS
EFE Ported Vacuum Switch
EFE-SOL
EFE Solenoid
EFE-TVS
EFE Thermal Vacuum Switch
EFE-TVV
EFE Thermal Vacuum Valve
EFE-VSV
EFE Vacuum Switching Valve
EFI
Electronic Fuel Injection

EFI-MA
EFI Mass Airflow Sensor
EFI-MAF
EFI Mass Airflow Sensor
EGR
Exhaust Gas Recirculation System
EGR-BCS
EGR Boost Check Solenoid
EGR-BPBV
EGR By-Pass Backpressure Valve
EGR-BPT
EGR Backpressure Transducer
EGR-BPV
EGR By-Pass Valve
EGR-BS
EGR Bleed Solenoid
EGR-BSSV
EGR Boost Sensor Solenoid Valve
EGR-BV
EGR Bypass Valve
EGR-BVSV
EGR Bimetallic Vacuum Switching Valve
EGR-C
EGR Controller
EGR-CC
EGR Coolant Controlled
EGR-CLR
EGR Cooler
EGR-VSOL
EGR Vacuum Solenoid

EGR-CKV
EGR Check Valve
EGR-CS
EGR Control Solenoid
EGR-CSOL
EGR Cut-Off Solenoid
EGR-CSV
EGR-CTO
EGR Coolant Temperature Override
EGR-CTS
EGR Charge Temperature Sensor
EGR-CTSW
EGR Charge Temperature Switch
EGR-CTTS
EGR Coolant Temperature Thermoswitch
EGR-CV
EGR Control Valve
EGR-CVCV
EGR Constant Vacuum Control Valve
EGR-CVS
EGR Control Vent Solenoid
EGR-DC
EGR Digital Control
EGR-DCTO
EGR Dual Coolant Temperature Override
EGR-DPFE
Differential Pressure Feedback EGR Sensor
EGR-DPFS
EGR Differential Pressure Feedback Sensor

EGR-DS
EGR Diagnostic Solenoid
EGR-DSOL
EGR Duty Solenoid
EGR-DTVS
EGR Delay Thermal Vacuum Switch
EGR-DTVSW
EGR Distributor Thermal Vacuum Switch
EGR-DV
EGR Delay Valve
EGR-EPRS
EGR Exhaust Pressure Regulator Solenoid
EGR-EPRV
EGR Exhaust Pressure Regulator Valve
EGR-EPV
EGR External Pressure Valve
EGR/EVAP-CSV
EGR/EVAP Control Solenoid Valve
EGR-EVR
EGR Vacuum Regulator
EGR-EVRV
EGR Electronic Vacuum Regulator Valve
EGR-FDV
EGR Forward Delay Valve
EGR-FJS
EGR Floor Jet System
EGR-FPS
EGR Feedback Pressure Sensor
EGR-LCV
EGR Load Control Valve

EGR-MAP
EGR Manifold Absolute Pressure Sensor
EGR-PFE
EGR-PFE Sensor
EGR-PS
EGR Position Sensor
EGR-PSW
EGR Pulse Switch
EGR-PVS
EGR Ported Vacuum Switch
EGR-REG
EGR Regulator
EGR-RES
EGR Reservoir
EGR-RST
EGR Restrictor
EGR-SC
EGR Signal Converter
EGR-SEC
EGR, Secondary
EGR-SEN
EGR Sensor
EGR-SOL
EGR Solenoid
EGR-SU
EGR Switchover Valve
EGR-SUB
Sub-EGR Valve
EGR-SVV
EGR Solenoid Vacuum Valve

EGR-T
EGR Temperature Sensor
EGR-TC
EGR Transmission Controlled
EGR-TCTVS
EGR Torque Converter Thermal Vacuum Switch
EGR-TCV
EGR Thermal Control Valve
EGR-TCVLV
EGR Temperature Control Valve
EGR-TRANS
EGR Transducer
EGR-TS
EGR Temperature Sensor
EGR-TSW
EGR Temperature Switch
EGR-TVD
EGR Throttle Valve Diaphragm
EGR-TVS
EGR Thermal Vacuum Switch
EGR-TVSOL
EGR Throttle Valve Solenoid
EGR-TVV
EGR Thermal Vacuum Valve
EGR-VA
EGR Vacuum Amplifier
EGR-VCV
EGR Vacuum Control Valve
EGR-VM
EGR Vacuum Modulator

EGR-VR
EGR Vacuum Regulator
EGR-VRS
EGR Vacuum Regulator Solenoid
EGR-VRSV
EGR Vacuum Regulator Solenoid Valve
EGR-VRV
EGR Vacuum Regulator Valve
EGR-VS
EGR Vacuum Switch
EGR-VSDV
EGR Vacuum Switch Dump Valve
EGR-VSEN
EGR Vacuum Sensor
EGR-VSOL
EGR Vent Solenoid
EGR-VSS
EGR Vacuum Switching Solenoid
EGR-VST
EGR Vacuum Surge Tank
EGR-VSV
EGR Vacuum Switching Valve
EGR-VVCS
EGR Venturi Vacuum Control System
EGRB
EGR Boost Sensor
EGRC
EGRC-BPT
EGR Control Backpressure Transducer

EGRC-SV
EGR Control Solenoid Valve
EHOC
Electronically Heated Oxidation Catalyst
EHTWC
Electronically Heated Three-Way Catalyst
EI
Electronic Ignition System
EIS
Electronic Ignition System
ELB
Electronic Lean Burn
EPR
Exhaust Pressure Regulator
EPR-SOL
EPR Solenoid
ESA
Electronic Spark Advance
ESIM
Evaporative System Integrity Monitor
EVAP
Fuel Evaporative System
EVAP-AAC
EVAP Auxiliary Air Control
EVAP-BPSV
EVAP By-Pass Solenoid Valve
EVAP-BVSV
EVAP Bimetallic Vacuum Switching Valve
EVAP-CAV
EVAP Canister Air Valve

EVAP-CCV
EVAP Control Canister Close Valve
EVAP-CCVSV
EVAP Control Canister Vent Shut Valve
EVAP-CCVVSV
EVAP Closed Canister Valve Vacuum Switching Valve
EVAP-CDCV
EVAP Canister Drain Cut Valve
EVAP-CKV
EVAP Check Valve
EVAP-CPCS
EVAP Canister Purge Control Solenoid
EVAP-CPCSV
EVAP Canister Purge Control Solenoid Valve
EVAP-CPCV
EVAP Canister Purge Control Valve
EVAP-CPRV
EVAP Canister Purge Regulator Valve
EVAP-CPSV
EVAP Canister Vent Shut Valve
EVAP-CPT
EVAP Canister Purge Timer
EVAP-CPTVS
EVAP Canister Purge Thermal Vacuum Switch
EVAP-CPV
EVAP Canister Vent Valve
EVAP-CPVCSV
EVAP Canister Purge Volume Control
EVAP-CPVCV
EVAP Canister Purge Volume Control Valve

EVAP-CPVDV
EVAP Canister Purge Vacuum Delay Valve
EVAP-CPVR
EVAP Canister Purge Valve Resonator
EVAP-CS
EVAP Control Solenoid
EVAP-CSPS
EVAP Control System Pressure Sensor
EVAP-CST
EVAP Canister Surge Tank
EVAP-CT
EVAP Catch Tank
EVAP-CVCS
EVAP Canister Vent Control Solenoid
EVAP-CVCV
EVAP Canister Vent Control Valve
EVAP-CVS
EVAP Canister Vent Solenoid
EVAP-CVSV
EVAP Carburetor Vent Switching Valve
EVAP-CVV
EVAP Canister Vent Valve
EVAP-DCTO
EVAP Dual Coolant Temperature Override
EVAP-DF
EVAP Drain Filter
EVAP-DPS
EVAP Differential Pressure Sensor
EVAP-DV
EVAP-Drain Valve
EVAP-EV
EVAP Emission Valve
EVAP-FBVV
EVAP Fuel Bowl Vent Valve
EVAP-FBVS
EVAP Fuel Bowl Vent Solenoid
EVAP-FCV
EVAP Fuel Cut Valve
EVAP-FLS
EVAP Fuel Level Sensor
EVAP-FOLV
EVAP Fuel Overflow Limiter Valve
EVAP-FS
EVAP Flow Switch
EVAP-FSV
EVAP Flow Switchover Valve<
EVAP-FTEV
EVAP Fuel Tank EVAP Valve
EVAP-FTPCSV
EVAP Fuel Tank Pressure Control Solenoid Valve
EVAP-FTPS
EVAP Fuel Tank Pressure Sensor
EVAP-FTS
EVAP Fuel Temperature Sensor
EVAP-FVCV
EVAP Fuel Vapor Control Valve
EVAP-FVS
EVAP Fuel Vapor Separator
EVAP-FVTS
EVAP Fuel Vapor Temperature Sensor

EVAP-FVV
EVAP Fuel Vent Valve
EVAP-FVVV
EVAP Fuel Vapor Vent Valve
EVAP-IVS
EVAP Inner Vent Solenoid
EVAP-LDP
EVAP Leak Detection Pump
EVAP-LDPAF
EVAP Leak Detection Pump Air Filter
EVAP-LDPF
EVAP Leak Detection Pump Filter
EVAP-LDPVV
EVAP Leak Detection Pump Vent Valve
EVAP-LSEP
EVAP Liquid Separator
EVAP-NVLD
EVAP Natural Vacuum Leak Detection
EVAP-ORVR
Evaporative On-Board Refueling Vapor Recovery System
EVAP-ORVRCV
Evaporative On-Board Refueling Vapor Recovery Check Valve
EVAP-ORVRFTVRV
EVAP-ORVR Fuel Tank Vapor Recirculation
EVAP-OVCV
EVAP Outer Vent Control Valve
EVAP-OWV
EVAP One-Way Valve
EVAP-PCDV
EVAP Purge Control Diaphram Valve

EVAP-PCSV
EVAP Purge Cut-Off Solenoid Valve
EVAP-PFS
EVAP Purge Flow Sensor
EVAP-PFSVVSV
EVAP Purge Flow Switching Valve Vacuum Switching Valve
EVAP-PRRV
EVAP Pressure Relief Rollover Valve
EVAP-PSVVSV
EVAP Pressure Switching Valve Vacuum Switching Valve
EVAP-PSOL
EVAP Purge Solenoid
EVAP-PSSV
EVAP Pressure Switching Solenoid
EVAP-PSVVSV
EVAP Pressure Switching Valve Vacuum Switching Valve
EVAP-PV
EVAP Purge (Frequency) Valve
EVAP-PVS
EVAP Ported Vacuum Switch
EVAP-RV
EVAP Rollover Valve
EVAP-RV/FTPS
EVAP Rollover Valve/Fuel Tank
EVAP-RVSV
EVAP Rollover Vapor Separator Valve
EVAP-SNR
EVAP Canister Sensor
EVAP-SOL
EVAP Solenoid
EVAP-SOV
EVAP Shutoff Valve
EVAP-SSV
EVAP Shut-Off Solenoid Valve
EVAP-SV
EVAP Solenoid Valve
EVAP-TC
EVAP Trap Canister
EVAP-TS
EVAP Temperature Switch
EVAP-TPBPV
EVAP Tank Pressure By-Pass Valve
EVAP-TPCS
EVAP Tank Pressure Control Solenoid
EVAP-TPCV
EVAP Tank Pressure Control Valve
EVAP-TRWV
EVAP Tree-Way Valve
EVAP-TV
EVAP Thermal Valve
EVAP-TVS
EVAP Thermal Vacuum Switch
EVAP-TVV
EVAP Thermal Vacuum Valve
EVAP-TWV
EVAP Two-Way Valve
EVAP-VC
EVAP Vapor Canister
EVAP-VCAT
EVAP Vapor Canister Air Tank

EVAP-VCF
EVAP Vapor Canister Filter
EVAP-VCSV
EVAP Vapor Canister Shut-off Valve
EVAP-VCTV
EVAP Vacuum Control Valve
EVAP-VCV
EVAP Vacuum Canister Valve
EVAP-VCVS
EVAP Vapor Canister Vent Solenoid
EVAP-VM
EVAP Vacuum Motor
EVAP-VPS
EVAP Vapor Pressure Sensor
EVAP-VPSVSV
EVAP Vapor Pressure Sensor Vacuum Switching Valve
EVAP-VS
EVAP Vacuum Sensor
EVAP-VSOL
EVAP Ventilation Solenoid
EVAP-VSOL/LDP
EVAP Ventilation Solenoid/Leak Detection Pump
EVAP-VST
EVAP Vacuum Surge Tank
EVAP-VSV
EVAP Vacuum Switching Valve
EVAP-VV
EVAP Ventilation Valve
EVRS
EGR Vacuum Regulator Solenoid

"F"
FBC
Feedback Carburetor
FCOV
Fuel Change Over Valve
FF
Flex Fuel
FF-CKV
Fuel Fill Check Valve
FF-FCV
Fuel Tank Fuel Cut-Off Valve
FF-FLVV
Fuel Tank Fill Limit Vent Valve
FGOV
Fuel Gravity/Overflow Valve
FGVV
Fuel Gravity Vent Valve
FI
Fuel Injected
FICD
Fast Idle Control Device
FISR
Fast Idle Solenoid Relay
FLV
Fill Limit Valve
FLVV
Fill Limiting Vent Valve
FP-CKV
Fill Pipe Check Valve

FP-RV
Fill Pipe Rollover Valve
FR
Fill Pipe Restrictor
FT-FLVV
Fuel Tank Fill Limit Vent Valve
FT-GVV
Fuel Tank Grade Vent Valve
FT-OPRV
Fuel Tank Over Pressure Vent Valve
FT-PCV
Fuel Tank Pressure Control Valve
FT-VCV
Fuel Tank Vapor Control Valve
FT-VRV
Fuel Tank Vapor Recirculation Valve
FTCV
Fuel Tank Check Valve
FTDPS
Fuel Tank Differential Pressure Sensor
FTEV
Fuel Tank EVAP Valve
FTPS
Fuel Tank Pressure Sensor
FTT
Fuel Tank Temperature Sensor
FTTS
Fuel Tank Temperature Sensor
FTV/LSV
Fuel Tank Vapor/Liquid Seperation Valve

FTVCV
Fuel Tank Vapor Control Valve
FTVPRV
Fuel Tank Ventilation Pressure Retention Valve
FVPS
Fuel Vapor Pressure Sensor
FTVV
Fuel Tank Vent Valve
FVV
Fuel Vapor Valve
"G"
GVWR
Gross Vehicle Weight Rating
"H"
HAC
High Altitude Compensator
HAFS
Heated Air Fuel Ratio Sensor
HAI
Hot Air Intake
HAS
High Altitude System
HC
Hydrocarbons
HCAC-VSV
Hydrocarbon Absorber Catalyst Vacuum Switching Valve
HDC
Heavy Duty Cooling
HDC-CTO
HDC Coolant Temperature Override
HFM-SFI
Hot Film Engine Management SFI
HIC
Hot Idle Compensator
HIM
Heated Intake Manifold
HO
High Output
HO2S
Heated Oxygen Sensor
HP
High Performance
HP
Horsepower
HPCA
Housing Pressure Cold Advance
HSC
High Swirl Combustion
"I"
IAC
Idle Air Control Valve
IACV-SW
IACV Switch
ICOM
Idle Compensator
IDI
Indirect Diesel Injection
IES
Idle Enrichment System
IMCO
Improved Combustion System
"K"
KS
Knock Sensor
"L"
LH-SFI
Hot Wire Sequential Multiport Fuel Injection
LVFD
Liquid/Vapor Fuel Discriminator
LVW
Loaded Vehicle Weight
"M"
MD-TICS
Timing & Injection rate Control System
MDP
Manifold Differential Pressure sensor
ME-SFI
Motor Electronics Sequential Fuel Injection
MFI
Multiport Fuel Injection
MFI-MAF
MFI Mass Airflow Sensor

MFLS
Main Fuel Level Sensor
MI
Mechanical Fuel Injection
MIL
Malfunction Indicator Light
M/T
Manual Transmission
"N"
NAC
Nitrogen Oxides (NOx) Adsorbing Catalyst
NLV
Non-Linear Valve
NOS
NOx Sensor
NOx
NOx Emission Control
NOxC
Nitrogen Oxide Catalyst
NOxS
Nitrogen Oxide Sensor
NOxTWC
NOx adsorptive TWC
NSC
Nitrogen Oxides (NOx) Storage Catalyst
"O"
OBD
On-Board Diagnostic System
PBD (F)/(P)
Full/Partial On-Board Diagnostic
OC
Oxidation Catalytic Converter
OHC
Overhead Cam
ORVR
On-Board Refueling Vapor Recovery
ORVR-COV
ORVR Cut-Off Valve
ORVR-CV
ORVR Control Valve
ORVR-FMV
ORVR Flow Management Valve
ORVR-FTVCV
ORVR Fuel Tank Vapor Control Valve
ORVR-FTVRV
ORVR Fuel Tank Vapor Recirculation Valve
ORVR-LV
ORVR Leveling Valve
ORVR-OCKV
ORVR Overfill Check Valve
ORVR-RCV
ORVR Refueling Control Valve
ORVR-VCV
ORVR Vapor Cut Valve
ORVR-VRV
ORVR Vapor Recirculating Valve
ORVR-VSV
ORVR Vent Shut Valve
ORVR-VV
ORVR Vent Valve
OVCV
Outer Vent Control Valve
O2S
Oxygen Sensor
"P"
PAIR
Pulsed Secondary Air Injection
PAIR-ABV
PAIR Anti-Backfire Valve
PAIR-ACOV
PAIR Air Cut-Off Valve
PAIR-ACS
PAIR Air Control Solenoid
PAIR-ACV
PAIR Air Control Valve
PAIR-AIV
PAIR Air Injection Valve
PAIR-ASCS
PAIR Air Suction Control Solenoid
PAIR-ASOV
PAIR Air Shutoff Valve
PAIR-ASS
PAIR Air Switching Solenoid
PAIR-ASV
PAIR Air Switching Valve
PAIR-ASVL
PAIR Air Suction Valve
PAIR-AVCS
PAIR Air Valve Control Solenoid
PAIR-CSV
PAIR Control Solenoid Valve
PAIR-CKV
PAIR Check Valve
PAIR-DV
PAIR Diverter Valve
PAIR-PAF
PAIR Pulse Air Feeder
PAIR-PAV
PAIR Pulse Air Valve
PAIR-RES
PAIR Resonator
PAIR-RV
PAIR Reed Valve
PAIR-SCSV
PAIR Swirl Control Solenoid Valve
PAIR-SCV
PAIR Swirl Control Valve
PAIR-SOL
PAIR Solenoid
PAIR-VSV
PAIR Vacuum Switching Valve
PCM
Powertrain Control Module
PCV
Positive Crankcase Ventilation
PCV-DOV
PCV Dual Orifice Valve
PCV-HCB
PCV Heated Crankcase Breather
PCV-HE
PCV Heating Element
PCV-PRV
PCV Pressure Regulator Valve
PCV-SOL
PCV Solenoid
PEVR
Power Enrichment Vacuum Regulator
PPM
Parts Per Million
PTOX
Periodic Trap Oxidizer
PURCV
Purge Crankcase Ventilation
PVCS
Ported Valve Control System
PVCS-A
PVCS Actuator
PVCS-CS
PVCS Control Solenoid
PVLCS
Power Valve Control System
"R"
RC
NOx Reduction Catalyst
ROV
Rollover Valve
"S"
SAI-SV
Secondary Air Injection Shutoff Valve
SAIR-CV
Secondary Air Injection Control Valve
SC
Supercharged or Super Charger
SC MFI
Supercharged Multiport Fuel Injection
SCR
Selective Catalytic Reduction
SCSV
Swirl Control Solenoid Valve
SCV
Swirl Control Valve
SCV-A
SCV Actuator
SFI
Sequential Multiport Fuel Injection
SFI-MAF
SFI Mass Airflow Sensor
SFLS
Sub-Fuel Level Sensor
SOHC
Single Overhead Cam
SPK
Spark Controls
SPK-AVM
SPK Advance Vacuum Modulator
SPK-BVSV
SPK Bimetal Vacuum Switching Valve
SPK-CC
SPK Computer Controlled
SPK-CKV
SPK Check Valve
SPK-CSSA
SPK Cold Start Spark Advance System
SPK-CSSH
SPK Cold Start Spark Hold System
SPK-CTO
SPK Coolant Temperature Override
SPK-DAVS
SPK Distributor Vacuum Advance Solenoid
SPK-DCKV
SPK Distributor Check Valve
SPK-DCTO
SPK Dual Coolant Temperature Override
SPK-DDD
SPK Dual Diaphragm Distributor
SPK-DMV
SPK Distributor Modulator Valve
SPK-DPD
SPK Dual Point Distributor
SPK-DPVS
SPK Distributor Ported Vacuum Switch
SPK-DRCV
SPK Distributor Retard Control Valve
SPK-DRS
SPK Distributor Retard Solenoid
SPK-DSVMV
SPK Distributor Spark Vacuum Modulator Valve
SPK-DTVS
SPK Distributor Thermal Vacuum Switch
SPK-DTVV
SPK Distributor Thermal Vacuum Valve
SPK-DV
SPK Delay Valve
SPK-DVA
SPK Distributor Vacuum Advance
SPK-DVAS
SPK Distributor Vacuum Advance Solenoid
SPK-DVCS
SPK Distributor Vacuum Control Solenoid
SPK-DVCSW
SPK Distributor Vacuum Controlled Switch
SPK-DVCV
SPK Distributor Vacuum Control Valve
SPK-DVDV
SPK Distributor Vacuum Delay Valve
SPK-DVRS
SPK Distributor Vacuum Retard Switch
SPK-DVRV
SPK Distributor Vacuum Regulating Valve
SPK-DVVV
SPK Distributor Vacuum Vent Valve
SPK-EAVS
SPK Electronically Actuated Vacuum Switch
SPK-EDM
SPK Electronic Distributor Modulator
SPK-EI
SPK Electronic Ignition
SPK-ESA
SPK Electronic Spark Advance
SPK-ESC
SPK Electronic Spark Control (Retard)
SPK-ESS
SPK Electronic Spark Selection
SPK-EST
SPK Electronic Spark Timing
SPK-FDV
SPK Forward Delay Valve
SPK-HPCA
SPK Housing Pressure Cold Advance
SPK-ITCS
SPK Ignition Timing Control System
SPK-ITVS
SPK Ignition Timing Vacuum Switch
SPK-NLVR
SPK Non-Linear Vacuum Regulator
SPK-OSAC
SPK Orifice Spark Advance Control
SPK-PVA
SPK Ported Vacuum Advance
SPK-PVS
SPK Ported Vacuum Switch
SPK-RDO
SPK Retard Delay Orifice
SPK-RDV
SPK Reverse Delay Valve
SPK-RDVD
SPK Reverse Delay Valve (Dual)
SPK-RDVLV
SPK Retard Delay Valve
SPK-RDVS
SPK Reverse Delay Valve (Single)
SPK-RETS
SPK Retard Switch
SPK-SC
SPK Speed Controlled
SPK-SOL
SPK Solenoid
SPK-SRRV
SPK Spark Relay Regulator Valve
SPK-TAVIA
SPK Temperature Activated Vacuum Ignition Advance
SPK-TCS
SPK Transmission Controlled Spark
SPK-TCSYS
SPK Timing Control System
SPK-TIDC
SPK Thermostatic Ignition Distributor Control
SPK-TV
SPK Thermal Valve
SPK-TVS
SPK Thermal Vacuum Switch
SPK-VACTO
SPK Vacuum Advance Coolant Temperature Override
SPK-VAS
SPK Vacuum Advance Solenoid
SPK-VAV
SPK Vacuum Advance Valve
SPK-VR
SPK Vacuum Retard
SPK-VRSW
SPK Vacuum Retard Switch
SPK-VSV
SPK Vacuum Switching Valve
SPK-VTCS
SPK Vacuum Timing Control System
SPL
Smoke Puff Limiter
SRI
Service Reminder Indicator
SSCA
Stepped Speed Control Actuator
SSCS
Stepped Speed Control Solenoid
STS
Service Throttle Soon Light
STVS
Secondary Throttle Valve System
SUB-HO2S
Sub-Heated Oxygen Sensor (after CAT)
SUB-O2S
Sub-Oxygen Sensor
SUB-TWC
Sub Three-Way Catalytic Converter

"T"
TAA
Turbo Air-To-Air
TAA
Throttle Actuator Assembly
TAB
Thermactor Air By-Pass
TAD
Thermactor Air Diverter
TAC
Thermostatic Air Cleaner
TBI
Throttle Body Injection
TBPCS
Throttle By-Pass Control System
TC
Turbo Charger
TCC
Torque Converter Clutch
TCCL
Torque Converter Control
TCD
Throttle Closing Dashpot
TC-DV
TC Delay Valve
TC-TVC
TC Thermal Vacuum Switch
TC-VS
TC Vacuum Switch
TD
Thermactor Diverter
TFT
Tank Fuel Temperature Sensor
THOS2
Third Heated Oxygen Sensor
TICV
Thermal Ignition Control Valve
TIV
Thermal Idle Valve
TK
Throttle Kicker
TLUC
Transmission Lock-Up Converter
TLUC-TVS
TLUC Thermal Vacuum Switch
TLUC-VS
TLUC Vacuum Switch
TM
Throttle Modulator
TOS
Throttle Opener System
TP
Throttle Positioner
TPI
Tuned Port Fuel Injection
TPV
Throttle Poppet Valve
TR
Thermal Reactor
TRC
Throttle Return Control
TRCS
Throttle Return Control Solenoid
TRCTL
Throttle Return Control Throttle Lever Actuator
TRSCV
Throttle Return Solenoid Control Valve
TRTVV
Temperature Regulator Thermal Vacuum Valve
TRVV
Transmission Vacuum Valve
TSOL
Throttle Solenoid
TVISD
Throttle Vacuum Idle Speed Diaphragm
TVM
Transmission Vacuum Modulator
TWC
Three-Way Catalytic Converter
TWC+OC
Three-Way + Oxidation Catalytic Converter
"V"
VA
Vacuum Advance Unit
VAC-AMP
Vacuum Amplifier
VA-CTO
VA Coolant Temperature Override

VCV
Vacuum Cut Valve
VCV-BV
VCV By-Pass Valve
VLFR
Vent Line Flow Restrictor/Anti-Trickle Fill Valve
"W"
WU
Warm-Up Catalyst
WU-OC
Warm-Up Oxidation Converter
WU-TWC
Warm-Up Three-Way Catalytic Converter

Jeep Renegade
Service Manual: EMISSIONS CONTROL
SPECIFICATIONS > EMISSION CONTROL SYSTEM
CO2 EXHAUST EMISSIONS
EMISSION CONTROL SYSTEM
CO2 emissions (according to 140 1.4L MultiAir Turbo

European directive in force (g /
km)
CO2 emissions (according to - 2.4L MultiAir

km)
CO2 emissions (according to 120 1.6L Turbo Diesel

km)
CO2 emissions (according to 134 2.0L Turbo Diesel 120/140CV

km)
CO2 emissions (according to 155 2.0L Turbo Diesel 170hp

km)

COMPONENT FASTENER Ø VALUE (daNM) VALIDITY
Retaining bolt catalytic converter Screw M6 0.7-1.0 1.4L Turbo

to the turbocharger MultiAir
Catalytic Converter Screw M8 2.3-2.7 1.4L MultiAir
Catalytic Converter Support Screw M8 2.3-2.7 1.4L MultiAir

Bracket
Oxygen Sensor M18 4.0-5.0 1.4L Turbo

MultiAir
1.6L Turbo
Diesel
2.0L Turbo
Diesel
Oxygen Sensor M18 4.1 2.4L MultiAir

EGR Complete Assembly Nut and Screw M8 2.3-2.8 1.6L Turbo
Connecting Pipes Diesel
2.0L 120 /
140HP Turbo
Diesel
EGR Cooler Screw 1.0 1.6L Turbo

Diesel
2.0L 120 /
140HP Turbo
Diesel
EGR Solenoid Screw Primary 1.6L Turbo

Reduction 0.6 Diesel
Final Tightening 2.0L 120 /
1.0 140HP Turbo
Diesel
Exhaust Temperature Sensor Junction M14 4.0-5.0 1.6L Turbo

Diesel
2.0L Turbo
Diesel
Retaining Nut - Particulate filter Nut M10 2.2-2.6 1.6L Turbo

to the turbocharger Diesel
2.0L Turbo
Diesel
Low Pressure EGR Valve Screw M6 0.8-1.0 2.0L Turbo

Support Diesel
Low Pressure EGR Valve Screw M6 0.8-1.0 2.0L Turbo

Diesel
Low Pressure EGR Valve Cooler Nut M6 0.8-1.0 2.0L Turbo

Diesel
High Pressure EGR Valve Nut M8 2.3-2.8 2.0L Turbo

Support Diesel
High Pressure EGR Solenoid Screw M8 2.3-2.8 2.0L Turbo

Diesel
High Pressure EGR Solenoid Screw - Primary 2.0L Turbo

Reduction 0.6 Diesel
Final Tightening
1.0
Duplex Pipe Screw and Nut M6 0.8-1.0 2.0L Turbo

Diesel
EVAPORATIVE EMISSIONS > DIAGNOSIS AND TESTING > EMISSIONS DIAGNOSIS >
EMISSIONS CO OR HC TOO HIGH
If the detected percentage of CO and / or HC are higher than prescribed.

0 EVERYTHING OK PROBLEMS OPERATION
ENCOUNTERED
Check the Continue to Step 1 Filter element dirty or Replace the filter
condition of the air damaged element
filter
1. CHECK FOR FAULTS IN ECU
1 CHECK WITH EVERYTHING PROBLEMS OPERATION

DIAGNOSTIC OK ENCOUNTERED
TOOL
Proceed to step 2 Presence of faults. Proceed as

Connect the indicated by the
diagnostic scan diagnostic tool.
tool
Check for the Failure to Check PCM / ECM
absence of faults communicate with for power, ground
in the engine the control unit and
control unit. communications.
Correct as needed.
2. CHECK SOLENOID VAPOR RECOVERY AND INJECTOR
2 CHECK WITH EVERYTHING OK PROBLEMS OPERATION

TOOL
Restore
connection of the
Using the injectors and
diagnostic scan solenoid valve
tool, perform the with the PCM /
Proceed to step 3 Failed test results
solenoid vapor ECM
recovery test and replace solenoid if
injector test. faulty
replace injectors if
faulty
3. CHECK UPSTREAM OXYGEN SENSOR
3 CHECK EVERYTHING OK PROBLEMS OPERATION

UPSTREAM ENCOUNTERED
OXYGEN
SENSOR
Check the
upstream oxygen Oxygen sensor Replace the
Proceed to step 4
sensor for proper defective oxygen sensor
function
4. CHECK DOWNSTREAM OXYGEN SENSOR

4 CHECK EVERYTHING PROBLEMS OPERATION
DOWNSTREAM OK ENCOUNTERED
OXYGEN
SENSOR
Check the
downstream oxygen Oxygen sensor Replace the
Proceed to step 5
function
5. CHECK AIR SUPPLY CIRCUIT
5 CHECK AIR EVERYTHING OK PROBLEMS OPERATION

SUPPLY ENCOUNTERED
CIRCUIT
Check the Replace the

Circuit components
integrity of the Proceed to step 6 affected
damaged
air supply circuit component
6. CHECK FUEL PRESSURE
6 CHECK FUEL EVERYTHING OK PROBLEMS OPERATION

PRESSURE ENCOUNTERED
Check the fuel Replace the fuel

End diagnosis Incorrect pressure.
pressure supply pump
EVAPORATIVE EMISSIONS > DIAGNOSIS AND TESTING > EMISSIONS DIAGNOSIS >
EMISSIONS CO LOW / NOX HIGH
It detects a very low percentage of CO, which corresponds to a percentage of NOX higher than
prescribed.
1. CHECK FOR FAULTS IN ECU
1 CHECK WITH EVERYTHING PROBLEMS OPERATION

DIAGNOSTIC OK ENCOUNTERED
TOOL
Proceed to step 2 Presence of faults. Proceed as

Connect the indicated by the
diagnostic scan diagnostic tool.
tool
Check for the Failure to Check PCM / ECM
absence of faults communicate with for power, ground
in the engine the control unit and
control unit. communications.
Correct as needed.
2. CHECK INJECTORS
2 CHECK WITH EVERYTHING OK PROBLEMS OPERATION
TOOL
Restore
connection of the
With the Diagnosis injectors and
equipment perform solenoid valve
Proceed to step 3 Failed test results
the diagnosis of with the PCM /
the injectors ECM
replace injectors if
faulty
3. CHECK UPSTREAM OXYGEN SENSOR

UPSTREAM ENCOUNTERED
OXYGEN
SENSOR
Check the
upstream oxygen Oxygen sensor Replace the
Proceed to step 4
function
4. CHECK DOWNSTREAM OXYGEN SENSOR
4 CHECK EVERYTHING PROBLEMS OPERATION

DOWNSTREAM OK ENCOUNTERED
OXYGEN
SENSOR
Check the
downstream oxygen Oxygen sensor Replace the
Proceed to step 5
function
5. CHECK AIR SUPPLY CIRCUIT
5 CHECK AIR EVERYTHING OK PROBLEMS OPERATION

SUPPLY ENCOUNTERED
CIRCUIT
Check the Replace the

Circuit components
integrity of the Proceed to step 6 affected
damaged
air supply circuit component
6. CHECK CIRCUIT BLOW-BY

CIRCUIT ENCOUNTERED
BLOW-BY
Check the
integrity of the
suction circuit of Restore the
gas blow-by: in Fault in the circuit functionality of the
particular verify Proceed to step 7 Fault in the circuit
the absence of separator Replace the
obstructions in separator.
the separator or
in the pipes.
7. CHECK FUEL PRESSURE
7 CHECK FUEL EVERYTHING OK PROBLEMS OPERATION

PRESSURE ENCOUNTERED
Check the fuel Replace the fuel

End diagnosis Incorrect pressure.
pressure supply pump
EVAPORATIVE EMISSIONS > DIAGNOSIS AND TESTING > CHECKING C.O. LEVEL >
1.4 TURBO MULTIAIR
1. Carry out the measurement with all the emission control devices active and at the specified
idle speed.
2. Insert the probe of an exhaust gas analyzer into the end of the exhaust pipe for at least 30 cm.
3. If the shape of the exhaust tailpipe will not allow the probe to be fully introduced, add an
extension that ensures a seal in the join area.
4. Wait for the exhaust gas analyzer indices to stabilize.
CO2 emissions (according to European Directive in force) (g / 1.4 Turbo

139
km) MultiAir
CO2 emissions (according to European Directive in force) -

1.4 Turbo
Versions with low environmental impact for specific markets 137
MultiAir
(lower emissions) (g / km)
1.4 TURBO MULTIAIR AUTOMATIC TRANSMISSION
idle speed.
2. Insert the probe of an exhaust gas analyzers into the end of the exhaust pipe for at least 30
cm.
5. With the engine idling, check that the CO2 level is within specified limits.
CO2 emissions (according to European Directive 1.4 Turbo MultiAir Automatic

157
in force) (g/km) Transmission
1.4 TURBO MULTIAIR TCT TRANSMISSION
idle speed.
1.4 Turbo MultiAir

CO2 emissions (according to European Directive in force)
133 TCT
(g/km)
Transmission
CO2 emissions (according to European Directive in force) - 1.4 Turbo MultiAir

Versions with low environmental impact for specific markets 133 TCT
(lower emissions) (g/km) Transmission
Emissioni CO2 (secondo direttiva europea vigente) - Versioni a 1.4 Turbo

basso impatto ambientale per mercati specifici (emissioni 131 MultiAir Cambio
ridotte) (g/km) TCT
1.6 E-TORQUE
idle speed.

CO2 emissions (according to European Directive in

147 1.6 E-Torque
force) (g/km)
CO2 emissions (according to European Directive in 1.6 E-Torque with

139
force) (g/km) Start/Stop
1.6 TURBO DIESEL
idle speed.
CO2 emissions (according to European Directive in force) 1.6 Turbo

109
(g/km) Diesel
CO2 emissions (according to European Directive in force) -

1.6 Turbo
Versions with low environmental impact for specific markets 107
Diesel
(lower emissions) (g/km)
2.0L TURBO DIESEL
idle speed.
CO2 emissions (according to European Directive in force) (g / 2.0 Turbo

130
km) Diesel
2.0L TURBO DIESEL AUTOMATIC TRANSMISSION
idle speed.
CO2 emissions (according to European Directive in 2.0 Turbo Diesel

144
force) (g km) Transmission 948TE
EVAPORATIVE EMISSIONS > CANISTER, VAPOR > REMOVAL AND INSTALLATION >
2. Remove the right rear wheel and splash shield. Refer to SHIELD, SPLASH, REAR
Fig 1: Fuel Vapor Quick-Connect Hose, Carbon Filter & Connector
3. Disconnect the fuel vapor quick-connect hose (1).
4. Disconnect the fuel vapor solenoid electrical connection (2).
5. Remove the nuts and remove the fuel vapor carbon filter (3).
Fig 2: Fuel Vapor Solenoid Hose
6. If needed, proceed with the removal of the fuel vapors solenoid.
7. Disconnect the hose (1) from the fuel vapors solenoid.

Fig 3: Fuel Vapor Solenoid & Clip
8. Act on the clip (1a) and twist and remove the fuel vapors solenoid (1b).
EVAPORATIVE EMISSIONS > CANISTER, VAPOR > REMOVAL AND INSTALLATION >
Fig 1: Fuel Vapor Solenoid & Clip
1. Insert the fuel vapors solenoid in its seat as shown in illustration (1).
2. Turn the fuel vapors solenoid up to engage the clip (2) into place.
3. Connect the hose to the fuel vapors solenoid.
4. Install the fuel vapors carbon filter and tighten the nuts.
5. Connect the fuel vapors solenoid electrical connection.
6. Connect the fuel vapor quick-connect hose.
7. Install the right rear wheel and splash shield. Refer to SHIELD, SPLASH, REAR
EVAPORATIVE EMISSIONS, DIESEL > TUBE, CRANKCASE BREATHER > REMOVAL

AND INSTALLATION > REMOVAL AND INSTALLATION > REMOVAL 1.6L DIESEL
1. Remove the engine cover. Refer to REMOVAL AND INSTALLATION .

Fig 1: Oil Vapor Recovery Hose & Connector - 1.6L
2. Disconnect the engine oil vapor heating resistor wire harness connector (2).
3. Detach the oil vapor heating resistor wire harness connector from the retaining bracket.
4. Disconnect the quick connect coupling and remove the oil vapor recovery hose (2).
AND INSTALLATION > REMOVAL AND INSTALLATION > INSTALLATION 1.6L DIESEL
1. Install the oil vapor recovery hose and connect the quick connect coupling (2).
2. Connect the engine oil vapor heating resistor wire harness connector (2).
3. Attach the oil vapor heating resistor wire harness connector to the retaining bracket.
4. Install the engine cover. Refer to REMOVAL AND INSTALLATION .

AND INSTALLATION > REMOVAL AND INSTALLATION > REMOVAL 2.0L DIESEL
2. Disconnect the engine oil vapor heating resistor wire harness connector (1).
3. Using the (special tool #10288, Pliers, Hose Clamp), remove the clamp and the oil vapor
recovery hose (2) from the pipe.
4. Remove the oil vapor recovery hose (2) from the turbocharger.
AND INSTALLATION > REMOVAL AND INSTALLATION > INSTALLATION 2.0L DIESEL
1. Install the oil vapor recovery hose (2) onto the turbocharger.
2. Install the oil vapor recovery hose (2) onto the pipe. Using the (special tool #10288, Pliers,
Hose Clamp), to lock the clamp.
3. Connect the engine oil vapor heating resistor wire harness connector (1).
EXHAUST GAS RECIRCULATION > COOLER, EXHAUST GAS RECIRCULATION (EGR)

> REMOVAL AND INSTALLATION > REMOVAL AND INSTALLATION > REMOVAL
2. Remove the engine beauty cover. For 1.6/2.0L, refer to COVER, ENGINE, REMOVAL AND
4. Remove the turbocharger valve control actuator solenoid. For 1.6/2.0L, refer to
TURBOCHARGER, REMOVAL AND INSTALLATION . For 1.4L, refer to TURBOCHARGER,

Fig 1: Intake Pressure Duct
7. Unscrew the fittings and remove the intake pressure duct upstream of the DPF.
Fig 2: EGR Cooler Screws
8. Unscrew the lower screws securing the EGR cooler.
9. Remove the upper screw fastening the oil dipstick tube.

Fig 3: Water Flow Actuator Control Solenoid Connector & Hose Connections
10. Disconnect the vacuum tank outlet (1) side depressor.
11. Disconnect the air hose vacuum actuator (2) for the water supply to the EGR cooler.
12. Disconnect the electrical connection (3) of the water flow actuator control solenoid to the EGR
cooler.
Fig 4: EGR Cooler & Screw
13. Remove the top screws (1a) and remove the EGR cooler (1b) complete with radiator fins.
Fig 5: EGR Cooler Gasket

Fig 6: Radiating Pack
15. Remove the radiating pack (1a) from the heat EGR system (1b).
Fig 7: Gasket
16. Remove the gasket from the radiator fins.

> REMOVAL AND INSTALLATION > REMOVAL AND INSTALLATION > INSTALLATION
1. Fit a new gasket on the radiator fins and put it in place.
2. Install a new gasket on the EGR cooler.

Fig 1: EGR Cooler & Screw
3. Position the EGR cooler (1a) complete with radiator fins and tighten the screws (1b) to the
4. Connect the electrical connection of the solenoid to the EGR cooler.
5. Connect the air hose to the water supply vacuum actuator to the EGR cooler.
6. Connect the vacuum tank depression hose, side depressor.
7. Tighten the upper screw fastening the oil dipstick tube.
8. Install the intake pressure hose upstream of the DPF and tighten their connectors.
9. Install the turbocharger valve control actuator solenoid. For 1.6/2.0L, refer to
TURBOCHARGER, REMOVAL AND INSTALLATION . For 1.4L, refer to TURBOCHARGER,
11. Install the engine beauty cover. For 1.6/2.0L, refer to COVER, ENGINE, REMOVAL AND


> REMOVAL AND INSTALLATION > VACUUM TANK
NOTE:
1.6L Turbo Diesel and 2.0L Turbo Diesel 120CV/140CV
NOTE:
The vacuum tank is integrated in the EGR heat exchanger. Refer to VALVE, EXHAUST GAS
RECIRCULATION (EGR), REMOVAL AND INSTALLATION .
EXHAUST GAS RECIRCULATION > SENSOR, EGR TEMPERATURE > REMOVAL AND
INSTALLATION > EXHAUST GAS TEMPERATURE SENSOR ON EGR SOLENOID
VALVE TO INTAKE MANIFOLD > REMOVAL
2. Remove the engine beauty cover. For 1.6/2.0L, refer to COVER, ENGINE, REMOVAL AND
Fig 1: EGR Solenoid Electrical Connector
3. Disconnect the EGR solenoid electrical connection (1).

Fig 2: Exhaust Gas Temperature Sensor & Hose
4. Remove and disengage exhaust gas temperature sensor (1a) and EGR solenoid manifold hose
(1b).
Fig 3: Temperature Sensor & Connector
5. Disconnect the temperature sensor electrical connection (1) from the EGR valve to the intake
manifold.
6. Remove the temperature sensor (2).

INSTALLATION > EXHAUST GAS TEMPERATURE SENSOR ON EGR SOLENOID
VALVE TO INTAKE MANIFOLD > INSTALLATION
1. Connect the exhaust gas temperature sensor electrical connection from the EGR valve to the
intake manifold.
2. Install the temperature sensor and tighten its connector.
3. Connect the EGR solenoid electrical connection.
4. Install the engine beauty cover. For 1.6/2.0L, refer to COVER, ENGINE, REMOVAL AND
INSTALLATION > 2.0L 120HP / 140HP EXHAUST GAS TEMPERATURE SENSOR
UPSTREAM OF CATALYST > REMOVAL
.
Fig 1: Temperature Sensor Connector & Ring
2. Disconnect the upstream exhaust gas temperature sensor electrical connector (1), disengage
the connector and the wiring from the retaining clips.
3. Remove the ring (2) and remove the sensor.
UPSTREAM OF CATALYST > INSTALLATION
1. Install the upstream exhaust gas temperature sensor and tighten its connector.
2. Engage the wiring ring connector and retaining clips.
UPSTREAM OF DPF > REMOVAL
Fig 1: Upstream Exhaust Gas Temperature Sensor & Connector
3. Disconnect the upstream exhaust gas temperature sensor electrical connection (1) at the
particulate filter (DPF).
4. Remove the connector (2) and remove the sensor.
UPSTREAM OF DPF > INSTALLATION
Fig 1: Upstream Exhaust Gas Temperature Sensor Bolt
1. Install the upstream exhaust gas temperature sensor and tighten the bolt to the proper
2. Connect the electrical connector to the sensor.
UPSTREAM OF DPF > REMOVAL
Fig 1: Downstream Exhaust Gas Temperature Sensor & Connector
2. Disconnect the downstream exhaust gas temperature sensor electrical connection (1).
3. Remove the connector (2a) and remove the sensor (2b).

UPSTREAM OF DPF > INSTALLATION
Fig 1: Downstream Exhaust Gas Temperature Sensor Bolt
1. Install the downstream exhaust gas temperature sensor and tighten the bolt (1) to the proper
specification. Refer to TORQUE SPECIFICATIONS
INSTALLATION > 2.0L 170HP EXHAUST GAS TEMPERATURE UPSTREAM OF
CATALYST > REMOVAL
.
Fig 1: Upstream Exhaust Gas Temperature Sensor Connector & Ring
2. Disconnect the upstream exhaust gas temperature sensor electrical connector (1), disengage
the connector and the wiring from the retaining clips.
3. Remove the ring (2) and remove the sensor.
INSTALLATION > 2.0L 170HP EXHAUST GAS TEMPERATURE UPSTREAM OF
CATALYST > INSTALLATION
1. Install the upstream exhaust gas temperature sensor and tighten its connector (2).
2. Engage the wiring ring connector and retaining clips (1).
Fig 1: Upstream Exhaust Gas Temperature Sensor Connector & Ring
INSTALLATION > 2.0L 170CV EXHAUST GAS TEMPERATURE SENSOR TO DPF >
REMOVAL
.
Fig 1: Upstream Oxygen Sensor Connector
4. Disconnect and upstream oxygen sensor connector (1).

Fig 2: Downstream Oxygen Sensor Connector
5. Unplug the connector from the downstream exhaust gas temperature sensor.
Fig 3: Sensor Fitting
6. Remove the wiring from the retaining clips, unscrew the fitting and remove the sensor (1).
INSTALLATION > 2.0L 170CV EXHAUST GAS TEMPERATURE SENSOR TO DPF >
INSTALLATION
Fig 1: Sensor Fitting
1. Install the downstream exhaust gas temperature sensor, engage the wiring in the retainer clips
and then tighten the sensor bolt (1b) to the proper specification. Refer to TORQUE
SPECIFICATIONS
EXHAUST GAS RECIRCULATION > SOLENOID, EXHAUST GAS RECIRCULATION

(EGR) > REMOVAL AND INSTALLATION > EGR SOLENOID
The EGR solenoid is serviced with the EGR valve. Refer to VALVE, EXHAUST GAS RECIRCULATION
EXHAUST GAS RECIRCULATION > VALVE, EXHAUST GAS RECIRCULATION (EGR) >
REMOVAL AND INSTALLATION > EGR VALVE DISASSEMBLY AND ASSEMBLY >
DISASSEMBLY
Fig 1: Tandem Pipe To EGR Cooler Retaining Screw
1. Place the EGR assembly in a vice, using the tool.
2. Remove the retaining screw (1) securing the tandem pipe to the EGR cooler.
Fig 2: Tandem Pipe Retaining Screw
3. Remove the screw (1) and remove the tandem pipe.

Fig 3: Discharge Hose Screw
4. Remove the screw (1) and remove the discharge hose to the cooler with the gasket.
Fig 4: Water Delivery Pipe To EGR Cooler Screw
5. Remove the screw (1) and remove the water delivery pipe to the EGR cooler with gasket.
Fig 5: Discharge Pipe O-Ring
6. Remove the O-ring (1) from the water discharge pipe to the EGR cooler.
Fig 6: EGR Solenoid & Screws
7. Remove the screws (1a) and remove the EGR solenoid (1b) complete with internal seal.
Fig 7: Flange & Gasket
8. Remove the screws and remove the gasket / flange.

Fig 8: Thermostat Housing & Screws
9. Remove the screws (1a) and remove the thermostat (1b) with gasket.
Fig 9: Engine Coolant Temperature Sensor
10. Unscrew and remove the engine coolant temperature sensor.

Fig 10: Vacuum Tank & Screws
11. Remove the screws (1a) and remove the vacuum tank (1b) complete with radiator fins.
Fig 11: EGR Cooler Gasket
12. Remove the gasket from the EGR cooler.

Fig 12: EGR Radiator Fins Gasket
13. Remove the gasket from the radiator fins of the exhaust gas to EGR
REMOVAL AND INSTALLATION > EGR VALVE DISASSEMBLY AND ASSEMBLY >
ASSEMBLY
Fig 1: Vacuum Tank & Screws
1. Install the cooler (1a), new gaskets and tighten the screws (1b) to the proper specification.
Fig 2: Engine Coolant Temperature Sensor
2. Install the engine coolant temperature sensor (1) and tighten it to the proper specification.
Fig 3: Thermostat Housing & Screws
3. Install the thermostat (1a) complete with new gasket and tighten the screws (1b) to the proper
Fig 4: EGR Solenoid & Screws
4. Install the gasket / flange and tighten the screws.
5. Install the EGR solenoid (1a) complete with new inner seal and tighten the screws (1b) to the
6. Install the water supply pipe to the cooler complete with new gasket and tighten the screw.
7. Install the discharge pipe to the water heater complete with new gasket and tighten the screw.
8. Install the tandem pipe complete and tighten its hardware.
9. Remove the overall EGR from the tool support.
REMOVAL AND INSTALLATION > 1.6L EGR VALVE ASSEMBLY > 1.6L REMOVAL
.

4. Remove the turbocharger valve control actuator solenoid. Refer to TURBOCHARGER,

Fig 1: Particulate Filter Differential Pressure Sensor & Connector
7. Disconnect the particulate filter differential pressure sensor electrical connector (2).
8. Loosen the nut and reposition the particulate filter differential pressure sensor.
Fig 2: EGR Solenoid Connector & Screw
10. Remove the screws (2) securing the locking hose at the EGR solenoid valve to intake manifold
EGR valve.
Fig 3: EGR Solenoid To Intake Manifold & Screw
11. Remove the screws (1a) and remove the hose from the EGR solenoid to the intake manifold
(1b).
Fig 4: O-Ring & Gasket
13. Remove the O-ring (2).

Fig 5: Tank, Hoses, Clamps & Screws
14. Loosen the clamp and disconnect the hose (1).
15. Loosen the clamp and disconnect the hose (2).
16. Remove the screws and remove the tank (3).

Fig 6: Hose, Pipe, Clamp & Fittings
17. Loosen the clamp and disconnect the intermediate pressure hose (1).
18. Remove the fittings and remove the intake pressure upstream pipeline (2).
Fig 7: Engine Oil Dipstick Tube Fastening Screw
19. Remove the engine oil dipstick tube fastening screw (1).
Fig 8: EGR Cooler Connector & Hose
20. Disconnect the water flow control actuator solenoid to the EGR cooler electrical connection
(1).
21. Disconnect the hose (2).

Fig 9: Water Supply Hose, Degassing Hose & Clamps
22. Loosen the clamp and disconnect the water supply hose (1), thermostat side.
23. Loosen the clamp and disconnect the degassing hose (2), thermostat side.
Fig 10: Engine Coolant Temperature Sensor Connector
24. Disconnect the engine coolant temperature sensor electrical connection (1).
Fig 11: Discharge Hose, Clamp & Wiring Retaining Clip
25. Loosen the clamp and disconnect the discharge (1), thermostat side.
26. Open the wiring retaining clip (2).

Fig 12: Water To Engine Cooler Hose & Quick Coupling
27. Lift the clip and disconnect the water to engine cooler hose quick coupling (1), thermostat side.
Fig 13: EGR Valve Connecting Hoses, Screws & Nuts
28. Remove the screws (1a), nuts (1b) of the complete EGR valve connecting hoses.
29. Remove the EGR valve connecting hoses with gasket.

Fig 14: EGR Valve Connecting Pipes Gasket
30. Remove the gasket from the overall EGR valve connecting pipes.
REMOVAL AND INSTALLATION > 1.6L EGR VALVE ASSEMBLY > 1.6L INSTALLATION
Fig 1: EGR Valve Connecting Hoses, Screws & Nuts
1. Position the EGR valve assembly into and connecting hoses (1a) complete with new gasket.
Tighten the screws (1b) to the proper specification. Refer to SPECIFICATIONS .
2. Screw the studs, tighten the nuts of the EGR valve assembly connecting hoses to the proper
3. Connect the quick coupling of the hose that delivers water to the engine oil cooler, thermostat
side.
4. Close the starter wiring clip retainer.
5. Connect the pressure hose to the water heater, thermostat side and tighten its strap.
6. Connect the electrical connection of the engine coolant temperature sensor.
7. Connect the degassing hose, thermostat side and tighten its strap.
8. Connect the water supply hose to the radiator, thermostat side and tighten its strap.
9. Connect the pressure take-off tube depression for vacuum tank, vacuum pump side.
10. Connect the electrical connection of the electric actuator control water flow to the EGR cooler.
11. Tighten the upper screw for the engine oil dipstick tube.
12. Put into place the intake pipeline pressure upstream of the particulate filter and tighten their
connectors.
13. Connect the intermediate pressure sampling downstream hose of the particulate filter and
tighten its strap.
14. Put into place the engine cooling power tank and tighten the screws.
15. Connect the hose of degassing tank to supply engine cooling and tighten its strap.
16. Connect the hose to the engine cooling tank plant supply and tighten its strap.
17. Put into place the hose from the EGR solenoid to the intake manifold complete with new
gaskets and tighten the screws.
18. Connect the EGR solenoid electrical connection
19. Install the differential pressure sensor and tighten the nut.
20. Connect the differential pressure sensor electrical connection.
22. Install the turbocharger valve control actuator solenoid. Refer to TURBOCHARGER,
REMOVAL AND INSTALLATION > 2.0L EGR VALVE ASSEMBLY > 2.0L REMOVAL

Fig 1: EGR Solenoid Connector & Screws
7. Remove the screws (2) securing the hose from the EGR solenoid valve, side intake manifold.
Fig 2: Temperature Exhaust Gas Sensor & Screws Securing Hose
8. Unscrew the union and disengage the temperature exhaust gas sensor (1).
9. Remove the screws securing the hose (2) from the EGR solenoid valve in the intake manifold,
EGR solenoid side.
Fig 3: Tubing, Rigid Pipe, Fittings & Clamps
10. Remove the tubing (1) from the EGR valve to the intake manifold complete with seals.
11. Remove the fittings and remove the rigid pipe (2) pressure sampling upstream of the particulate
filter.
Fig 4: Differential Pressure Sensor, Connector & Clip
12. Disconnect the DPF differential pressure sensor (1) electrical connection.
13. Open the retaining clip (2a), unscrew the nut and remove the DPF differential pressure sensor
(2b) complete with hoses.
Fig 5: Water Flow Actuator Control Solenoid Connector, Screw & Clamps
14. Remove the top fastening screw (1) securing the engine oil dipstick tube to the engine oil
dipstick.
15. Disconnect the water flow actuator control solenoid electrical connection (2).
16. Open the clamp (3) and release the oxygen sensor wiring.
17. Loosen the clamp (4) and disconnect the water supply hose to the radiator, thermostat side.
18. Loosen the clamp (5) and disconnect the degassing hose.
Fig 6: Depression Vacuum Tank Hose Outlet
19. Disconnect the hose outlet (1) for the depression vacuum tank, side depressor.
Fig 7: Engine Coolant Temperature Sensor Connector
20. Disconnect the engine coolant temperature sensor electrical connection (1).
Fig 8: EGR Solenoid Connector & Discharge Hose Clamp
21. Loosen the clamp (1) and disconnect the discharge hose to the water heater, thermostat side.

Fig 9: Water To Engine Oil Cooler Pipe & Quick Coupling
23. Lift the clip and disconnect the quick coupling (1) of the pipe that delivers water to the engine
oil cooler, thermostat side.
Fig 10: EGR Assembly And Connecting Pipes & Fasteners
24. Remove the clamps (1a) and remove the complete EGR assembly and connecting pipes (1b)
with gasket.
25. Remove the gasket from the complete EGR assembly with connecting pipes.
REMOVAL AND INSTALLATION > 2.0L EGR VALVE ASSEMBLY > 2.0L INSTALLATION
Fig 1: EGR Assembly Fasteners
1. Install the complete EGR assembly complete with new gasket and tighten the fasteners (1a) to
2. Connect the quick coupling of the hose that delivers water to the engine oil cooler, thermostat
side by engaging its peg.
4. Connect the water heater pressure hose, thermostat side and tighten its strap.
5. Connect the engine coolant temperature sensor electrical connection.
6. Connect the vacuum tank depression hose, side depressor.
7. Connect the degassing hose and tighten its strap.
8. Connect the water supply hose to the radiator, thermostat side and tighten its strap.
9. Position the oxygen sensor wiring to the wiring retainer and close the clip.
10. Connect the water flow solenoid actuator control electrical connection.
11. Tighten the upper screw fastening the engine oil dipstick tube.
12. Install the differential pressure sensor of the DPF complete with hoses, tighten the nut and
close the clip retainer.
13. Connect the differential pressure sensor electrical connection.
14. Install the pressure sampling rigid pipe upstream of the particulate filter and tighten their
connectors.
15. Install the pipe from the EGR solenoid valve in the intake manifold complete with new gaskets
and tighten the screws.
16. Install the exhaust gas temperature sensor and tighten its connector.
REMOVAL AND INSTALLATION > 2.0L HIGH PRESSURE EGR VALVE > REMOVAL
.
Fig 1: EGR High Pressure Solenoid Connector
3. Disconnect the EGR high pressure solenoid electrical connection (1).

Fig 2: EGR High Pressure Solenoid & Screws
4. Remove the screws (1a) and remove the EGR high pressure solenoid (1b).
REMOVAL AND INSTALLATION > 2.0L HIGH PRESSURE EGR VALVE >
INSTALLATION
1. Install the EGR high pressure solenoid (1a), complete with new gasket and tighten the
mounting screws (1b) to the proper specification. Refer to SPECIFICATIONS .
2. Connect the EGR high pressure solenoid electrical connection.
REMOVAL AND INSTALLATION > 2.0L HIGH PRESSURE EGR VALVE MOUNTING >
REMOVAL
.
5. Remove the thermostat. Refer to THERMOSTAT, REMOVAL AND INSTALLATION .

Fig 1: Particulate Filter Differential Pressure Sensor, Connector & Bracket
6. Unplug the particulate filter differential pressure sensor connection (1).
7. Remove the nuts and move sensor and bracket (2) to the side.
Fig 2: EGR High Pressure Solenoid Connector
8. Disconnect the EGR high pressure solenoid electrical connection (1).

Fig 3: Quick Coupling Coolant Hose
9. Lift the clip and disconnect the quick coupling (1) of the water engine oil cooler supply hose,
thermostat side.
Fig 4: DPS Hoses
10. Loosen the clamps and disconnect the particulate filter upstream and downstream exhaust gas
pressure hoses (1).
Fig 5: EGR Cooler Nuts & Bolts
11. Remove the screws (1a) and nuts (1b) securing the EGR high pressure solenoid bracket.
Fig 6: EGR Cooler & Studs
12. Using a suitable tool, unscrew the captive nuts (1) and remove the EGR high pressure
solenoid.
Fig 7: DPS Tubing, Gasket & Bolts
13. Remove the screws and remove the piping (1).
14. Remove the metal gasket (2).

Fig 8: Water Delivery Pipe & Screw
15. Remove the screw and remove the connection for the water delivery pipe (1) to the oil cooler
motor, complete with O-rings.
16. Remove the screws (1a) and remove the EGR high pressure solenoid (1b).
Fig 10: EGR Valve Gasket
17. Remove the metal gasket (1).
REMOVAL AND INSTALLATION > 2.0L HIGH PRESSURE EGR VALVE MOUNTING >
INSTALLATION
1. Install the EGR high pressure solenoid (1a), complete with new gasket and tighten the screws
(1b) to the proper specification. Refer to SPECIFICATIONS .
2. Install the water delivery pipe to oil cooler engine hose, complete with new O-ring and tighten
the screw.
3. Position and install the exhaust gas upstream and downstream outlet pressure piping of the
particulate filter and tighten the screws.
Fig 2: EGR High Pressure Solenoid Support Mounting, Screws & Nuts
4. Install the EGR high pressure solenoid support mounting complete with new gasket and tighten
the screws (1a) and nuts (1b) to the proper specification. Refer to SPECIFICATIONS .
5. Connect the exhaust gas pressure hoses upstream and downstream of the particulate filter and
tighten the clamps.
6. Connect the EGR high pressure solenoid electrical connection.
7. Install the particulate filter differential pressure sensor complete with pipes and tighten its nuts.
8. Connect the particulate filter differential pressure sensor electrical connection.
9. Install the thermostat. Refer to THERMOSTAT, REMOVAL AND INSTALLATION .
REMOVAL AND INSTALLATION > 2.0L LOW PRESSURE EGR VALVE > REMOVAL
.
4. Discharge the A/C system. Refer to PLUMBING, STANDARD PROCEDURE .
5. Remove the radiator and radiator cooling fan. Refer to RADIATOR, ENGINE COOLING,
Fig 1: Air Flow Meter Hose & Clamp
6. Loosen the hose clamp and remove the tubing from the air flow meter (1).
Fig 2: Wire Harness Connectors
7. Disconnect the low pressure EGR valve electrical connection (1).
8. Disconnect the exhaust gas temperature sensor electrical connection (2).

Fig 3: EGR Air Flow Control Valve Bolt & Clamp
9. Loosen the exhaust gas delivery clamp (1), EGR valve side of low pressure.
10. Remove the low pressure EGR valve screw (2).

Fig 4: EGR Air Flow Control Valve & Bolt
11. Remove the screws (1a) and remove the EGR low pressure valve (1b) disengaging it from the
sleeve to the turbocharger air delivery.
REMOVAL AND INSTALLATION > 2.0L LOW PRESSURE EGR VALVE >
INSTALLATION
Fig 1: Low Pressure EGR Valve & Screws
1. Install the low pressure EGR valve (1a), connect the hose to the turbocharger air delivery and
tighten the mounting screws (1b) to the proper specification. Refer to SPECIFICATIONS .
Fig 2: Exhaust Gas Delivery Pipe Clamp & Screw
2. Tighten the lower pressure EGR pipe screw to the proper specification. Refer to
SPECIFICATIONS .
3. Tighten the exhaust gas delivery pipe clamp, EGR valve side low pressure, to the proper
4. Connect the electrical connection of the exhaust gas temperature sensor.
5. Connect the electrical connection of the low pressure EGR valve.
6. Put the air flow meter hose from the air flow meter to the low pressure EGR valve in place and
tighten the clamps.
7. Install the radiator and radiator cooling fan. Refer to RADIATOR, ENGINE COOLING,
8. Recharge the A/C system. Refer to PLUMBING, STANDARD PROCEDURE .
9. Fill the engine coolant system. Refer to STANDARD PROCEDURE .
REMOVAL AND INSTALLATION > 2.0L LOW PRESSURE EGR VALVE MOUNTING >
REMOVAL
.
Fig 1: Inlet Air Hose & Clamp
8. Loosen the clamp and remove the inlet air hose to the turbocharger (1) complete with the
engine oil vapor recovery pipe.
Fig 2: Low Pressure EGR Valve Bracket & Screws
9. Remove the screws (1a) and remove support for low pressure EGR valve mounting (1b).
REMOVAL AND INSTALLATION > 2.0L LOW PRESSURE EGR VALVE MOUNTING >
INSTALLATION
Fig 1: Low Pressure EGR Valve Bracket & Screws
1. Install the low pressure EGR valve bracket (1a) and tighten the screws (1b) to the proper
2. Install the air inlet hose to the turbocharger complete with engine oil vapor recovery pipe and
tighten its strap.
8. Fill the engine coolant system. Refer to STANDARD PROCEDURE .

REMOVAL AND INSTALLATION > 2.0L LOW PRESSURE EGR VALVE SENSOR >
REMOVAL
Fig 1: EGR Temperature Sensor & Connector
4. Unscrew the ring (2) and remove the sensor.
REMOVAL AND INSTALLATION > 2.0L LOW PRESSURE EGR VALVE SENSOR >
INSTALLATION
Fig 1: EGR Temperature Sensor & Connector
1. Install the EGR temperature sensor (1) and tighten the fitting to the proper specification. Refer
to SPECIFICATIONS .
2. Connect the electrical connection of the sensor (2).
REMOVAL AND INSTALLATION > 2.0L LOW PRESSURE EXHAUST COOLER >
REMOVAL
.
Fig 1: Particulate Filter Temperature Sensor Connector
6. Disconnect the particulate filter temperature sensor electrical connection (1), upstream of the
PDF.
Fig 2: Exhaust Gas Temperature Sensor Connector

Fig 3: Air Outlet Pipe Screws & Clip
8. Open the retaining clip (1) and disengage the exhaust temperature sensor wiring.
9. Remove the air outlet pipe screw (2) from the turbocharger, the base side.
10. Remove the screws (3) and remove the outlet air rigid pipe from the turbocharger complete
with seals.
Fig 4: EGR Cooler Inlet Tube & Upper Clamp
11. Loosen the clamps and remove the pipe (1).

Fig 5: Low Pressure EGR Cooler & Nuts
12. Remove the nuts (1a) and remove the cooler housing (1b).
Fig 6: Low Pressure EGR Cooler Gasket Seals
13. Remove the gaskets (1).

Fig 7: EGR Cooler Manifold, Nuts & Bolts
14. Remove the nuts (1a), the screws (1b) and remove the cooler (1c).
REMOVAL AND INSTALLATION > 2.0L LOW PRESSURE EXHAUST COOLER >
INSTALLATION
Fig 1: Cooler & Nuts
1. Install the cooler (1a), complete with new gasket and tighten the nuts (1b) to the proper
2. Install the exhaust gas low pressure outlet pipe to its seat and tighten the relative fastening
clamps.
3. Install the air outlet pipe complete with new gasket and tighten the screw, the base side.
4. Tighten the air outlet pipe mounting screws, turbocharger side.
5. Engage the exhaust gas temperature sensors spring retainer.
6. Connect the exhaust gas temperature sensor electrical connection.
7. Connect the particulate filter temperature sensor electrical connection, upstream of the DPF.
10. Charge the A/C system. Refer to PLUMBING, STANDARD PROCEDURE .

REMOVAL AND INSTALLATION > 2.0L EGR SUPPLY AND RETURN DUPLEX PIPE >
REMOVAL
.
Fig 1: Oil Dipstick Tube & Screws
7. Remove the engine oil dipstick tube fastening screw (1).
8. Remove the lower engine oil dipstick tube screw (2) and remove the tube.
Fig 2: Output Engine Oil Pipe & Screws
9. Remove the screws securing the output engine oil pipe (1) from the turbocharger, turbocharger
side.
10. Remove the screws on the base side (2) and remove the outlet pipe complete with seals.
Fig 3: Duplex Screws & Retainer
11. Disengage the wiring spring retainer (1).
12. Remove the screws securing the thermostat duplex pipe (2).
Fig 4: Duplex Pipe & Nuts
13. Remove the nuts (1a) and remove the flow and return duplex pipe.
Fig 5: Thermostat Seals
14. Remove the seals (1) from the thermostat.

Fig 6: Heat Exchanger Seals
15. Remove the seals (1) from the heat exchanger.
REMOVAL AND INSTALLATION > 2.0L EGR SUPPLY AND RETURN DUPLEX PIPE >
INSTALLATION
Fig 1: Duplex Pipe & Nuts
1. Install the duplex pipe, heat exchanger side (1a) complete with new gaskets, and tighten the
nuts (1b) to the proper Specification. Refer to SPECIFICATIONS .
Fig 2: Duplex Screws & Retainer
2. Tighten to torque the duplex pipe mounting screws (1).
3. Engage the wiring spring retainer (2).
4. Install the turbocharger engine oil output pipe, base side and tighten the screws to the proper
5. Install the turbocharger engine oil output pipe screws, turbocharger side and tighten to the
6. Install the engine oil dipstick tube and tighten its screws.
Service Manual: IGNITION SYSTEM - SERVICE Jeep Renegade
INFORMATION
Ignition Coil Screw 9 N.m - -
Ignition coil tube - Replace

50 N.m - - *
Sleeve
Detonation sensor 24.5 N.m - - *
RPM sensor 9.0 N.m - -
Spark plugs 1.4L 18 N.m - -
Spark plugs 2.4L 27 N.m - -
COIL, IGNITION > REMOVAL AND INSTALLATION > REMOVAL AND INSTALLATION >
REMOVAL
Fig 1: Ignition Coil Electrical Connectors & Mounting Bolts
3. Unlock and disconnect the electrical connector (1) from the ignition coil.
4. Remove the ignition coil mounting bolts (2).
COIL, IGNITION > REMOVAL AND INSTALLATION > REMOVAL AND INSTALLATION >
INSTALLATION
1. Seat the ignition coils and tighten the screws to the proper torque specification. Refer to
SPECIFICATIONS .
2. Connect the electrical connectors to the ignition coils.
PLUG, GLOW > DIAGNOSIS AND TESTING > DIESEL COLD START SYSTEM
GLOW PLUG UNIT FUNCTIONALITY TEST
1 Check power unit preheating Restore the electrical continuity of the

Place the key to Run power cord
Using a multimeter to verify that Restore fuse, after identifying the cause
between pins 4 and mass is of the intervention.
present the voltage of 12 V battery Replace main contactor
Proceed to STEP 2 Replace junction unit
2 Check ground connection Restore the electrical continuity of the

Disconnect the negative battery ground wire
cable
Disconnect the wiring from the plug
control unit
Reconnect the battery
Using an ohmmeter connected
between pin 3 and ground wiring,
verify that the resistance is less
than 1 Ohm
Proceed to STEP 3
3 Check command activation unit by

preheating the engine control unit
Place the key to Run
Restore wiring between engine control
Using a multimeter:
unit and control unit plugs.
Check that between pin 2 and
If the voltage is interrupted replace the
ground is a voltage of about 0 V
engine control unit
Start the engine and check that the
voltage switch at about 10 volts
Proceed to STEP 4
4 Check power supply Restore wiring between the control unit

Check that 12 v is present on pin 5 and preheat fuses on battery
Restore power fuse after identifying the
Proceed to STEP 5
cause of the interruption.
Check power plugs Restore wiring between the control and

Start the engine and check the pre-heating glow plugs
battery voltage is properly Changes to the unit preheating
5
delivered to the individual plugs in Replace glow plug module and make sure
the preheat that the recovery process is working
The test can be closed. properly.
PLUG, GLOW > REMOVAL AND INSTALLATION > REMOVAL AND INSTALLATION >
REMOVAL
CAUTION:
The starting system is equipped with new low voltage glow plugs with a rated voltage lower
than that of the battery, it is absolutely forbidden to connect the battery voltage to the battery
post. Possible maneuvers of this type, for example testing continuity by means of a light
bulb, may be destructive for both the spark plug and for the engine.
Fig 1: Glow Plug & Special Tool
3. Disconnect the electrical connections of the glow plugs.
4. Using the special tool (2a), loosen and remove the glow plugs (2b).
PLUG, GLOW > REMOVAL AND INSTALLATION > REMOVAL AND INSTALLATION >
INSTALLATION
1. Using the tool, seat glow plug and tighten.
2. Connect the glow plug electrical connections.
ENGINE, REMOVAL AND INSTALLATION 2.4L.
SPARK PLUG > REMOVAL AND INSTALLATION > 2.4L REMOVAL AND
3. Remove the ignition coil. Refer to COIL, IGNITION, REMOVAL AND INSTALLATION .
Fig 1: Spark Plug & Appropriate Socket
NOTE:
Prior to loosening the spark plug, use compressed air to blow out any debris that
might be in the spark plug tube.
4. Using the appropriate socket (1a), unscrew and remove the spark plug (1b).
SPARK PLUG > REMOVAL AND INSTALLATION > 2.4L REMOVAL AND
CAUTION:
Handle the spark plugs with care. Do not drop or force the spark plugs into the wells,
damage to the electrodes and/or porcelain body may occur. Always start each spark plug by
hand in order to avoid cross-threading the spark plug in the cylinder head.
Always tighten spark plugs to the specified torque. Too much or not enough torque will
cause damage to the cylinder head and/or spark plug and may lead to poor engine
performance.
1. Using the appropriate socket, seat the spark plugs to the engine and tighten to the proper
2. Install the ignition coils. Refer to COIL, IGNITION, REMOVAL AND INSTALLATION .
SENSOR, CAMSHAFT POSITION > REMOVAL AND INSTALLATION > 1.4L REMOVAL
Fig 1: Hose & Nut
4. Remove the nut (1) securing the hose (2) in between the cooler and the throttle body to the
bracket on the gearbox.
5. Loosen the clamp and disconnect the hose from the air hose.
Fig 2: Screw
6. Remove the screw (1) securing the hose in between the cooler and the throttle body to the
bracket.
Fig 3: Air Pressure Sensor Electrical Connector & Hose
7. Disconnect the air pressure sensor electrical connector (1).
8. Loosen the clamp and remove the hose (2) in between the cooler and throttle body.
Fig 4: Cam Angle Sensor Electrical Connector & Screw
9. Disconnect the cam angle sensor electrical connector (1).
10. Remove the screw (2) and remove the cam angle sensor.
1. Position and install the cam angle sensor into place and tighten the screw to the proper torque
2. Connect the cam angle sensor electrical connection.
3. Position and install the hose in between the cooler and throttle body and tighten its strap.
4. Connect the air pressure sensor electrical connector.
5. Tighten the screw securing the hose in between the cooler and the throttle body to the bracket.
6. Connect the air sleeve to the hose in between the cooler and throttle body and tighten its
strap.
7. Tighten the nut securing the hose in between the cooler and the throttle body to the bracket on
the gearbox.
8. When replacing the cam angle sensor, connect the diagnostic scan tool, enter "Active
Diagnosis" and run the self-learning procedure.
2. Disconnect the cam angle sensor electrical connector (1a).
3. Remove the screw (1b) and remove the sensor.
1. Install the cam angle sensor and tighten the screw to the proper torque specification. Refer to
SPECIFICATIONS .
2. Connect the sensor electrical connection.
1.6L/2.0L Diesel,COVER, ENGINE, REMOVAL AND INSTALLATION for 1.4L or COVER,
Fig 1: Oil Vapor Pipe & Screws
3. Remove the screws and move the oil vapor pipe to the side (1).
Fig 2: Wiring Conduit & Screws
4. Remove the screws securing the wiring conduit (1).

Fig 3: Cam Angle Sensor & Screw
5. Disconnect the cam angle sensor electrical connection.
6. Remove the screw (2a) and remove the cam angle sensor (2b).
Fig 1: Cam Angle Sensor, Screw & Electrical Connection
1. Place the cam angle sensor (1a) and tighten the screw (1b) to the proper torque specification.
2. Connect the cam angle sensor electrical connection (2).
3. Tighten the screws securing the wiring conduit.
4. Place the oil vapor hose and tighten its screws.
3. Remove the nut and remove the heat shield (1).

4. Disconnect the cam angle sensor electrical connector (1).
5. Remove the screw (2) and remove the cam angle sensor.
1. Position and install the cam angle sensor into place and tighten the screw to the proper torque
2. Connect the cam angle sensor electrical connection.
3. Install the heat shield with the nut tightened to the proper torque specification. Refer to
SPECIFICATIONS .
5. Connect the negative battery cable
6. When replacing the cam angle sensor, connect the diagnostic scan tool, enter "Active
Diagnosis" and run the self-learning procedure.
SENSOR, KNOCK > REMOVAL AND INSTALLATION > 1.4L REMOVAL AND
Fig 1: Knock Sensor, Electrical Connector & Screw
4. Remove the screw and remove the knock sensor (2).
Fig 1: Bolt & Knock Sensor Electrical Connector
1. Position the knock sensor and tighten the new bolt (1) to the proper torque specification. Refer
to SPECIFICATIONS .
2. Connect the knock sensor electrical connector (2).

4. Disconnect the electrical connection (1) of the oxygen sensor upstream of the catalyst.
Fig 2: Oxygen Sensor Wiring, Clamps & Exhaust Manifold Upper Heat Shield
5. Disengage the oxygen sensor wiring (1), remove the screw and the bracket.
6. Remove the clamps (2) and remove the exhaust manifold upper heat shield (2).
Fig 3: Lower Exhaust Manifold Heat Shield & Screws
7. Remove the screws (1) and remove the heat shield (1) below the exhaust manifold.
Fig 4: Knock Sensor & Electrical Connector
1. Position the knock sensor and tighten the screw.
2. Connect the knock sensor electrical connector.
3. Position the lower heat shield of the exhaust manifold and tighten the screws.
4. Position the upper heat shield of the exhaust manifold and tighten its hardware.
5. Position the bracket wiring lambda probe upstream of the catalyst, tighten the screw and
engage the wiring in the retaining clips.
6. Connect the electrical connection of the upstream oxygen sensor.
SWITCH, IGNITION > DIAGNOSIS AND TESTING > DIAGNOSIS AND TESTING >
FAILED RECOGNITION OF THE IGNITION KEY IMMOBILIZER CODE
STEP OPERATION TO BE OK (NO FAULTS FAULT OPERATION

CARRIED OUT DETECTED) DETECTED
SECOND KEY
RECOGNITION
CHECK
Check that the

second key is
correctly The second key is
1 End of diagnosis Go to STEP 2
recognized. not recognized
If the second key

is recognize,
replace the first
key.
CHECK USING
DIAGNOSIS TOOL Replace the BCM.
Refer to MODULE,
Check that the Incorrect BCM
2 End of diagnosis BODY CONTROL,
Body Computer operation
REMOVAL AND
Module (BCM) is
INSTALLATION .
working correctly.
SWITCH, IGNITION > DIAGNOSIS AND TESTING > DIAGNOSIS AND TESTING > KEY
INSERTION IN THE IGNITION BARREL BARRED
IGNITION BARREL
CONDITION CHECK
Presence of signs
Check for the Replace the ignition
1 Go to STEP 2 of a break-in on the
presence of signs barrel
ignition barrel
of a break-in on
the ignition barrel
KEY HOUSING
CHECK
Presence of foreign
Check that there
bodies in the key Replace the ignition
2 are no foreign Go to STEP 3
housing on the barrel
bodies in the key
ignition barrel
housing on the
ignition barrel
IGNITION BARREL
OPERATION CHECK
Check that there The key still cannot

3 are no foreign End of diagnosis be inserted in the Go to STEP 4
bodies in the key ignition barrel.
housing on the
ignition barrel
IGNITION BARREL
OPERATION CHECK
Remove the
barrel from the
The key still cannot
dashboard; check
be inserted in the
the condition and
ignition barrel even Replace the ignition
4 operation of the End of diagnosis
if it has been barrel.
barrel.
removed from the
Try again to dashboard.
insert the key in
the barrel (when
removed).
ROTATION IN THE IGNITION BARREL HARDENED AT LOW TEMPERATURE

IGNITION BARREL
CONDITION CHECK
Spray a modest
quantity of grease
through the key
housing (in order
not to foul the Key rotation occurs The key still cannot
aesthetic parts). without problems. Replace the ignition
1 be rotated in the
barrel
End of diagnosis. ignition barrel.
Try again to
activate the
mechanism; do
not exceed the
torque of 2 Nm in
order not to
damage the key.
OPERATING MECHANISM BLOCKED OR HARDENED DURING USE

SECOND IGNITION
KEY OPERATION
CHECK
Check whether,
Hardened
1 with the second Go to STEP 2 Go to STEP 3
movement
ignition key, the
operating
mechanism is still
hardened
IGNITION KEY
CODING CHECK
Incorrect coding of Replace the ignition
2 Check that coding End of diagnosis
the ignition key key
of the ignition key
is correct
IGNITION BARREL
CONDITION CHECK
Presence of signs
Check for the Replace the ignition
3 Go to STEP 4 of a break-in on the
presence of signs barrel
ignition barrel
of a break-in on
the barrel
KEY HOUSING
OPERATION CHECK
Spray a modest
quantity of
grease through
the key housing End of diagnosis Hardened Replace the ignition
4
(in order not to movement barrel.
foul the aesthetic
parts).
Try again to
insert the key.
SWITCH, IGNITION > DIAGNOSIS AND TESTING > DIAGNOSIS AND TESTING > THE
IGNITION KEY COMES OUT FROM THE IGNITION BARREL AT A POSITION OTHER
THAN STOP
STEP OPERATION TO BE OK (NO FAULTS FAULT DETECTED OPERATION

CARRIED OUT DETECTED)
IGNITION BARREL
CONDITION CHECK
Check whether
The key comes out
the key comes
from the barrel at a
out from the
position other than Replace the ignition
1 barrel at a End of diagnosis
"STOP" also using barrel
position other
the second ignition
than "STOP"
key
also using the
second ignition
key
SWITCH, IGNITION > DIAGNOSIS AND TESTING > DIAGNOSIS AND TESTING > THE
STEERING LOCK DOES NOT ENGAGE WITH KEY REMOVED

IGNITION BARREL
CONDITION CHECK
Transmission shank Replace the ignition
1 With the key at End of diagnosis
broken or damaged barrel
ON, extract the
barrel from the
steering lock
device and check
the condition of the
transmission
shank.

1. Remove the steering column. Refer to COLUMN, REMOVAL AND INSTALLATION .

Fig 1: Headless Screws
2. Using a drift and a hammer, remove the headless screws (1). Work carefully to avoid
excessive vibration.
3. Remove the ignition switch with steering lock.

1. Position the ignition switch with steering lock in its housing.
2. Screw in and tighten the new special bolts until the heads shear off.
3. Place the electric steering control device in its housing and tighten the screws to the proper
4. Install the steering column. Refer to COLUMN, REMOVAL AND INSTALLATION .

Jeep Renegade
Service Manual: STATE EMISSION STANDARDS - DIESEL
ARIZONA
NOTE: Because of frequent revisions in state emission standards, the emission

standards listed in this article should only be used as a guide.
ARIZONA EMISSION STANDARDS - PHOENIX & TUCSON AREA (DIESEL OPACITY LOADED CRUISE
TEST)
Opacity (% For 10
Application Altitude (Feet) Seconds)
Light Duty Vehicles (8500 GVWR Or Less)
All Years Less Than 2000 20 Or Less
2001-4000 30 Or Less
Greater Than 4000 40 Or Less
ARIZONA EMISSION STANDARDS - PHOENIX & TUCSON AREA (DIESEL J1667 SNAP IDLE TEST)
Opacity (% For 10
Application Altitude (Feet) Seconds)
Heavy Duty Vehicles (8500 GVWR Or Greater)
1990 & Earlier All 55
1991 & Newer All 40
COLORADO
COLORADO EMISSION STANDARDS - DIESEL OPACITY
Application Opacity %
14,000 GVWR Or Less
Non-Turbo 40
Turbo 35
14,000 GVWR Or More
Non-Turbo 35
Turbo 20
CONNECTICUT
CONNECTICUT EMISSION STANDARDS - DIESEL OPACITY
10,000 GVWR Or Less
1979 & Newer 20
26,000 GVWR Or More
1974 & Earlier 70
1974-90 55
1991 & Newer 40
IDAHO
IDAHO EMISSION STANDARDS - DIESEL OPACITY
All Weight Range
1965-74 70
1975-91 55
1992 & Newer 40
KENTUCKY
KENTUCKY EMISSION STANDARDS - BOONE, CAMPBELL & KENTON COUNTIES (DIESEL
OPACITY)
Application Opacity
18,000 GVWR Or Less
All Years 10% @ Idle
MASSACHUSETTS
MASSACHUSETTS EMISSION STANDARDS - DIESEL OPACITY
Light Duty (8500 GVWR Or Less)
1984 & Newer 20
Light Duty (8501-10,000 GVWR Or Less)
1984 & Newer 40
Heavy Duty Buses (10,000 GVWR Or More)
1984-93 40
1994 & Newer 30
Heavy Duty Trucks (10,000 Or Less GVWR)
1984-90 55
1991 & Newer 40
NEW YORK
NEW YORK EMISSION STANDARDS - DIESEL OPACITY TEST
Heavy Duty Vehicles (8500 GVWR Or More)
1973 & Earlier 70
1974-90 55
1991 & Newer 40
OHIO
OHIO EMISSION STANDARDS - DIESEL OPACITY TEST
Light Duty Diesel 20
RHODE ISLAND
RHODE ISLAND EMISSION STANDARDS - DIESEL OPACITY TEST
All Model Years (8500 GVWR Or Less) 20
UTAH
UTAH EMISSION STANDARDS - DAVIS COUNTY - DIESEL OPACITY TEST
Light Duty Diesel - Turbo (16,000 GVWR Or Less) 30
Light Duty Diesel - Non-Turbo (16,000 GVWR Or Less) 35
Heavy Duty Diesel (16,000 GVWR Or More) 70
UTAH EMISSION STANDARDS - SALT LAKE COUNTY - DIESEL OPACITY TEST
All Model Years - Turbo (16,000 GVWR Or Less) 30
All Model Years - Non-Turbo (16,000 GVWR Or Less) 35
All Model Years (16,000 GVWR Or More) 70
UTAH EMISSION STANDARDS - UTAH COUNTY - DIESEL OPACITY TEST
All Model Years - Turbo (16,000 GVWR Or Less) 30
All Model Years - Non-Turbo (16,000 GVWR Or Less) 35
All Model Years (16,000 GVWR Or More) 70
WASHINGTON
WASHINGTON EMISSION STANDARDS - DIESEL OPACITY TEST
Light Duty Diesel (8500 GVWR Or Less)
All Model Years 20
Heavy Duty Diesel (8500 GVWR Or More)
1991 & Earlier 55
1992 & Newer 40

Jeep Renegade
Service Manual: STATE EMISSION STANDARDS - GAS
ALASKA
NOTE: Because of frequent revisions in state emission standards, the emission

standards listed in this article should only be used as a guide.
NOTE: As of March 1, 2012, Alaska is not testing for tailpipe emissions.
ALASKA EMISSION STANDARDS - ANCHORAGE & FAIRBANKS (2-SPEED IDLE TEST)
Application 2500 RPM HC ppm (CO

Idle HC ppm (CO %) %)
Passenger Cars (1)
1968-71 1000 (5.0) 1000 (4.0)
1972-74 1000 (4.0) 1000 (3.0)
1975-80 1000 (2.0) 1000 (2.0)
1981-83 1000 (1.0) 1000 (1.0)
1984-93 750 (1.0) 750 (1.0)
1994- 200 (0.5) 200 (0.5)
Light & Medium Duty Trucks (1)
1968-72 1000 (5.0) 1000 (4.0)
1973-78 1000 (4.0) 1000 (3.0)
1979-83 1000 (2.0) 1000 (2.0)
1984-93 750 (1.0) 750 (1.0)
1994- 220 (0.5) 220 (0.5)
Heavy Duty Vehicles (2)
1968-73 1000 (5.0) 1000 (5.0)
1974-93 1000 (4.0) 1000 (4.0)
1994- 220 (1.0) 220 (1.0)
(1) 8500 GVWR or less.

(2) 8500 GVWR or more.
ARIZONA
NOTE: Curb idle only test are for vehicles with full-time 4WD, non-defeatable traction
control and motorcycles. Curb idle and loaded cruise tests are performed on 1967-80
light-duty gasoline powered vehicles and all heavy-duty gasoline powered vehicles.
ARIZONA EMISSION STANDARDS - PHOENIX AREA (CURB IDLE & LOADED CRUISE TESTS)
(2) Loaded/Cruise HC
Application (1) Idle HC ppm (CO %) ppm (CO %)
1967-71 4-Cyl. Or Less 500 (5.50) 500 (4.20)
1967-71 More Than 4-Cyl. 450 (5.00) 450 (3.75)
1972-74 4-Cyl. Or Less 400 (5.50) 400 (4.20)
1972-74 More Than 4-Cyl. 400 (5.00) 400 (3.75)
1975-78 4-Cyl. Or Less 250 (2.20) 250 (1.65)
1975-78 More Than 4-Cyl. 250 (2.00) 250 (1.50)
1979 4-Cyl. Or Less 220 (2.20) 220 (1.65)
1979 More Than 4-Cyl. 220 (2.20) 220 (1.50)
1980 220 (1.20) 220 (1.20)
1981 & Newer 220 (1.20) .....
Light Duty Trucks (6000 GVWR Or Less)
1967-80 (3) (3)
Light Duty Trucks (6001-8500 GVWR)
1967-74 (3) (3)
1975-78 350 (4.00) 350 (3.00)
1979 4-Cyl. Or Less 220 (2.20) 220 (1.65)
1979 More Than 4-Cyl. 220 (2.00) 220 (1.50)
1980 220 (1.20) 220 (1.20)
1981 & Newer 220 (1.20) .....
Heavy Duty Trucks (Greater Than 8500 GVWR)

(3) (3)
1967-74
1975-78 350 (4.00) 350 (3.00)

1979 & Newer 300 (4.00) 300 (3.00)
Motorcycles
1967 & Newer 1800 (5.50) .....
(1) 4-stroke engines only.

(2) Except AWD, non-defeatable traction control and motorcycles.
(3) Same as light duty vehicles.
ARIZONA EMISSION STANDARDS - PHOENIX AREA (IM147 TEST)
Application HC gpm (CO gpm) NOx gpm
Light Duty Vehicles
1981-82 3.0 (25.0) 3.5
1983-85 2.4 (20.0) 3.5
1986-89 1.6 (15.0) 2.5
1990-93 1.0 (12.0) 2.5
1994 & Newer 0.8 (12.0) 2.0
Light Trucks (6000 GVWR Or Less)
1981-85 4.0 (40.0) 5.5
1986-89 3.0 (25.0) 4.5
1990-93 2.0 (20.0) 4.0
1994 & Newer 1.6 (20.0) 3.0
1981-85 4.4 (48.0) 7.0
1986-87 4.0 (40.0) 5.5
1988-89 3.0 (25.0) 5.5
1990-93 3.0 (25.0) 5.0
1994 & Newer 2.4 (25.0) 4.0
NOTE: Curb idle test only for 1967-80 light-duty gasoline vehicles, all vehicles with
full-time 4WD and/or non-defeatable traction control and motorcycles. Curb idle and loaded
cruise tests are performed on all 1981 and later vehicles except those with full-time 4WD
and/or non-defeatable traction control.
ARIZONA EMISSION STANDARDS - TUCSON AREA (CURB IDLE & LOADED CRUISE TESTS)
(2) Loaded/Cruise HC
Application (1) Idle HC ppm (CO %) ppm (CO %)
1967-71 4-Cyl. Or Less 500 (5.50) .....
1967-71 More Than 4-Cyl. 450 (5.00) .....
1972-74 4-Cyl. Or Less 400 (5.50) .....
1972-74 More Than 4-Cyl. 400 (5.00) .....
1975-78 4-Cyl. Or Less 250 (2.20) .....
1975-78 More Than 4-Cyl. 250 (2.00) .....
1979 4-Cyl. Or Less 220 (2.20) .....
1979 More Than 4-Cyl. 220 (2.20) .....
1980 220 (1.20) .....
1981 & Newer 220 (1.20) 220 (1.20)
1967-80 (3) (3)
1967-74 (3) (3)
1975-78 350 (4.00) .....
1979 4-Cyl. Or Less 220 (2.20) .....
1979 More Than 4-Cyl. 220 (2.00) .....
1980 220 (1.20) .....
1981 & Newer 220 (1.20) 220 (1.20)
Heavy Duty Trucks (Greater Than 8500 GVWR)
1967-74 (3) (3)
1975-78 350 (4.00) .....
1979-80 300 (4.00) .....
1981 & Newer 300 (4.00) 300 (3.00)
Motorcycles
1967 & Newer 1800 (5.50) .....
(1) 4-stroke engines only.

(2)
Except AWD, non-defeatable traction control and motorcycles.
(3) Same as light duty vehicles.
CALIFORNIA > CALIFORNIA EMISSION STANDARDS ASM TESTS
Specific vehicle cutpoints are available on the California BAR web site at www.bar.ca.gov under the
Industry tab, then Cutpoints Application.
Fig 1: California Emission Standards - Enhanced & Partially Enhanced Program Areas - Light & Medium
Duty Vehicles (ASM Test)
Fig 2: California Emission Standards - Enhanced & Partially Enhanced Program Areas - Heavy Duty
Vehicles (ASM Test)
CALIFORNIA > LEGEND
ESC - Emission Standard Category
GVWR - Manufacture's Gross Vehicle Weight Rating
LVW - Loaded Vehicle Weight
PC - Passenger Car
LDT1 - Light-Duty Truck up through 3750 LVW and GVWR no greater than 6000 lbs.
LDT2 - Light-Duty Truck greater than 3750 LVW and GVWR no greater than 6000 lbs.
MDV - Medium-Duty Vehicle, GVWR from 6001 to 8500 lbs.
HC - Hydrocarbon, ppm
CO - Carbon Monoxide, %
NO - Nitric Oxide, ppm
CALIFORNIA > PASS/FAIL EMISSION STANDARDS = A+B / VTW
PASS/FAIL STANDARDS - Emission standards used to determine if a vehicle passes the emission
inspection. A vehicle passes if the emission levels are equal to or less than the standards for HC, CO
and NO for ASM 5015 and ASM 2525.
GROSS POLLUTER STANDARDS - Emission standards used to designate a vehicle as a gross polluter.
A vehicle is designated as a gross polluter if the emission levels at the time of the initial inspection,
before repairs are greater than the gross polluter standards for HC, CO or NO for ASM 5015 or ASM
2525.
NOTE: If test data on emission pass/fail rates or gross polluter identification rates
indicate adjustments are required, the emission standards may be increased or decreased
by the bureau by 30% or by the following tolerances, or standards may be set for any
specific vehicle and engine configuration which the bureau determines has excessive errors
of commission of omission, whichever is necessary to comply with Section 44001.5 of the
Health and Safety Code.
COLORADO
COLORADO EMISSION STANDARDS - ENHANCED PROGRAM (IM240)
Application HC gpm CO gpm NOx gpm
Passenger Cars
1982 3.5 45 5.0
1983 3.5 30 4.5
1984 3.0 30 4.5
1985 2.5 20 4.5
1986 2.5 20 4.5
1987 2.5 20 4.0
1988 & 1989 2.0 20 4.0
1990 2.0 20 3.5
1991 1.5 20 3.5
1992 1.5 15 3.5
1993 1.5 15 3.5
1994 1.2 15 3.0
1995 1.2 15 2.5
1996 1.2 15 2.0
1997 1.2 15 2.0
1998 & Newer 1.2 15 1.5
Light Duty Vehicles
1982 6.0 65 6.0
1983 6.0 65 6.0
1984 5.0 55 6.0
1985 4.5 45 6.0
1986 4.0 40 6.0

1987 3.5 30 5.5
1988 & 1989 3.0 25 5.0
1990 3.0 25 5.0
1991 2.5 25 4.5
1992 2.5 25 4.5
1993 2.5 25 4.5
1994 2.0 20 4.0
1995 2.0 20 4.0
1996 1.2 15 3.5
1997 1.2 15 3.0
1998 1.2 15 2.0
1999 & Newer 1.2 15 2.0
COLORADO EMISSION STANDARDS - 2-SPEED IDLE TEST
Application HC ppm CO %
Passenger Cars & Light Duty Trucks
1970 & Earlier 1000 3.5
1971 1000 3.0
1972 1000 3.0
1973 1000 3.0
1974 1000 3.0
1975 600 2.0
1976 600 2.0
1977 400 1.5
1978 400 1.5
1979 400 1.5
1980 400 1.5
1981 & Newer 220 1.2
Heavy Duty Trucks (6000 GVWR Or Greater)
1967 Or Earlier 1500 7.0
1968-69 1200 6.5
1969 1200 6.5

1970 1000 5.5
1971 1000 5.5
1972 1000 5.5
1973 1000 5.5
1974 1000 5.5
1975 1000 5.5
1976 1000 5.5
1977 1000 5.5
1978 1000 5.5
Heavy Duty Trucks (8501 GVWR Or Greater)
1979 800 4.0
1980 800 3.5
1981 600 3.0
1982 600 3.0
1983 600 3.0
1984 600 3.0
1985 600 3.0
1986 & Newer 300 2.0
CONNECTICUT
CONNECTICUT EMISSION STANDARDS - IDLE TEST
Application HC ppm (CO)
10,000 GVWR Or Less
1979 250 (2.1)
1980 225 (2.0)
1981-82 200 (1.2)
1983 175 (1.0)
1984-87 150 (1.0)
1988 & Newer 125 (1.0)
DELAWARE
DELAWARE EMISSION STANDARDS - KENT, NEW CASTLE & SUSSEX COUNTIES (IDLE TEST)
Application HC ppm (CO %)
1968-70 900 (9.0)
1971-74 600 (6.0)
1975-79 400 (4.0)
1980 220 (2.0)
1981 & Newer 220 (1.2)
1970-72 900 (9.0)
1973-78 600 (6.0)
1979-83 400 (4.0)
1984 & Newer 220 (1.2)
DISTRICT OF COLUMBIA
DISTRICT OF COLUMBIA EMISSION STANDARDS - IDLE TEST
Light Duty Vehicles & Trucks (26000 GVWR Or Less)
1968-70 1250 (11.0)
1971-74 1200 (9.0)
1975-79 600 (6.5)
1980 300 (1.5)
1981 & Newer 220 (1.2)
GEORGIA
NOTE: The Georgia program incorporates original U.S. EPA recommended start-up
ASM2525 and ASM5015 standards for 1995 and older model year vehicles. Refer to
appropriate model year range in appropriate table. See U. S. EPA ASM2525 & ASM5015
START-UP EMISSION STANDARDS .
GEORGIA EMISSION STANDARDS - 2-SPEED IDLE TEST
Application (1) HC ppm (CO %)
1979 500 (5.0)
1980 350 (3.5)
1981-83 250 (1.5)
1984 & Newer 220 (1.2)
IDAHO
IDAHO EMISSION STANDARDS - 2-SPEED IDLE TEST
Light Duty Vehicles
8500 GVWR Or Less
1965-74 900 (5.0)
1975-79 700 (3.0)
1980 400 (1.5)
1981 & Newer 220 (1.2)
Heavy Duty Trucks
8501 GVWR Or More
1965-74 900 (6.0)
1975-80 700 (5.0)
1981 & Newer 500 (3.0)
ILLINOIS
ILLINOIS EMISSION STANDARDS - IM240 TEST
Application HC gpm CO gpm
1981-82 2.00 60.0

1983-87 2.00 30.0
1988-95 0.80 15.0
1996 & Newer 0.60 10.0
1981-83 7.50 100.0
1984-87 3.20 80.0
1988-95 1.60 40.0
1996 & Newer (3750 LVW Or More) (1) 0.80 13.0
1996 & Newer (3750 LVW Or Less) (1) 0.60 10.0
1981-83 7.50 100.0
1984-87 3.20 80.0
1988-95 1.60 40.0
1996 & Newer (5750 ALVW Or More) 0.80 15.0
1996 & Newer (5750 ALVW Or Less) 0.80 13.0
(1) Loaded Vehicle Weight (LVW) is vehicle curb weight plus 300 lbs.
ILLINOIS EMISSION STANDARDS - IDLE TEST
Passenger Vehicles (6000 GVWR Or Less)
1968-71 900 (9.0)
1972-74 800 (8.0)
1975-77 700 (7.0)
1978-79 600 (6.0)
1980 300 (3.0)
1981 & Newer 220 (1.2)
1968-71 900 (9.0)
1972-74 800 (8.0)
1975-78 700 (7.0)
1979-80 600 (6.0)
1981-83 300 (3.0)

1984 & Newer 220 (1.2)
1968-71 1500 (9.5)
1972-78 900 (9.0)
1979-84 700 (7.0)
1985 & Newer 300 (3.0)
INDIANA
INDIANA EMISSION STANDARDS - IM93 TEST
Application HC gpm (CO gpm) NOx (gpm)
Passenger Cars
1981-82 2.0 (60) 3.0
1983-86 2.0 (30) 3.0
1987-90 1.4 (20) 3.0
1991-95 0.8 (15) 2.5
1996 & Newer 0.6 (10) 2.5
1981-83 5.0 (80) 7.0
1984-86 3.2 (70) 7.0
1987-90 2.2 (55) 3.5
1991-95 1.6 (40) 3.0
1996 & Newer 0.8 (20) 3.0
1981-83 5.0 (80) 7.0
1984-86 3.2 (70) 7.0
1987-90 2.2 (55) 5.0
1991-96 1.6 (40) 4.5
1997 & Newer 0.8 (20) 4.5
Heavy Duty Trucks (8501-9000 GVWR)
1981-82 7.5 (100) 8.0
1983-84 6.0 (100) 8.0

1985-86 5.0 (75) 8.0
1987-90 3.0 (60) 8.0
1991-97 2.4 (40) 8.0
1998 & Newer 2.0 (30) 6.0
INDIANA EMISSION STANDARDS - IDLE TEST
Passenger Cars
1976-79 350 (3.5)
1980 250 (2.0)
1981 & Newer 220 (1.2)
1976-78 500 (5.0)
1979-83 350 (3.5)
1984 & Newer 220 (1.2)
Medium Duty Trucks (6001-8500 GVWR)
1976-78 500 (5.0)
1979-83 350 (3.5)
1984 & Newer 220 (1.2)
KENTUCKY
NOTE: Currently, there is no emission testing in Kentucky.
KENTUCKY EMISSION STANDARDS - BOONE, CAMPBELL & KENTON COUNTIES (IDLE TEST)
Application HC ppm (CO)
Passenger Cars (Automobiles)
1968 950 (8.5)
1969 900 (8.5)
1970 850 (8.1)
1972 800 (8.0)

1973 800 (7.8)
1974 800 (7.6)
1975 700 (7.5)
1976 700 (6.5)
1977 650 (6.3)
1978 600 (5.5)
1979 600 (4.5)
1980 250 (2.5)
1981 & Newer 220 (1.2)
1968 1300 (8.0)
1969 1200 (8.0)
1970-71 1100 (8.0)
1972-73 1000 (7.8)
1974 950 (7.8)
1975 900 (7.0)
1976-77 700 (7.0)
1978 700 (6.3)
1979 450 (5.5)
1980 450 (4.0)
1981 350 (1.7)
1982 & Newer 220 (1.2)
Light Duty Trucks (6001-10,000 GVWR)
1969 1500 (9.0)
1970 1100 (8.0)
1971 1000 (8.0)
1972-75 950 (7.5)
1976 900 (7.5)
1977 850 (7.5)
1978 700 (6.0)
1979 650 (5.5)
1980 550 (5.0)
1981 450 (4.0)

1982 400 (2.5)
1983 350 (2.0)
1984 220 (1.5)
1985 & Newer 220 (1.2)
Heavy Duty Trucks (10,001-18,000 GVWR)
1968 1500 (9.0)
1969-70 1300 (8.5)
1971 1200 (8.5)
1972-76 1000 (7.0)
1977-80 900 (6.5)
1982-83 400 (3.0)
1984 & Newer 250 (1.5)
MARYLAND
MARYLAND EMISSION STANDARDS - IM240 TEST
1984-87 1.80 (30.0) 2.8
1988-90 1.40 (30.0) 2.5
1991-93 1.00 (20.0) 2.2
1994-95 0.90 (20.0) 2.1
1984-87 2.80 (80.0) 5.8
1988-90 2.40 (80.0) 3.0
1991-93 2.00 (60.0) 2.7
1994-95 1.80 (60.0) 2.6
1984-87 2.90 (80.0) 6.6
1988-90 2.40 (80.0) 4.2
1991-93 2.00 (60.0) 4.0
1994-95 1.80 (60.0) 3.7

Heavy Duty Trucks (8501-9999 GVWR)
1984 5.80 (100.0) 7.7
1985-86 4.70 (80.0) 7.7
1987 3.00 (80.0) 7.7
1988-90 2.60 (80.0) 7.0
1991-97 2.50 (60.0) 5.5
1998 & Newer 2.20 (60.0) 4.0
MARYLAND EMISSION STANDARDS - IDLE TEST
1977 500 (6.0)
1978 430 (5.5)
1979 400 (4.0)
1980 220 (1.7)
1981 & Newer 220 (1.2)
1977 580 (7.0)
1978 550 (6.7)
1979 470 (5.0)
1980 350 (5.0)
1981 250 (3.0)
1982 220 (2.5)
1983 220 (1.5)
1984 & Newer 220 (1.2)
Heavy Duty Trucks (10,000-26,000 GVWR)
1977-78 650 (7.0)
1979 650 (6.5)
1980-82 500 (6.0)
1983 500 (3.5)
1984-85 440 (3.0)
1986 280 (2.5)

1987 & Newer 220 (1.2)
MASSACHUSETTS
MASSACHUSETTS EMISSION STANDARDS - MA31 TEST
Passenger Cars
1984-90 2.0 (30) 3.0
1991-95 1.2 (20) 2.5
1996 & Newer 0.8 (13) 2.0
1984-87 3.2 (80) 7.0
1988-1990 3.2 (80) 3.5
1991-95 2.4 (60) 3.0
1996 & Newer (3750 LVW (1) Or Less) 0.8 (15) 2.0
1996 & Newer (3751 LVW (1) Or Greater) 1.0 (20) 2.5
1984-87 3.2 (80) 7.0
1988-90 3.2 (80) 5.0
1991-95 2.4 (60) 4.5
1996 & Newer (5750 ALVW (2) Or Less) 1.0 (20) 2.5
1996 & Newer (5751 ALVW (2) Or Greater) 2.4 (60) 4.0
Heavy Duty Trucks (8501-10,000 Or Greater)
1984-87 3.2 (80) 7.0
1988-90 3.2 (80) 5.0
1991-95 2.4 (60) 4.5
1996 & Newer 2.4 (60) 4.0
(1) Loaded Vehicle Weight (LVW).

(2) Adjusted Loaded Vehicle Weight (ALVW).
MASSACHUSETTS EMISSION STANDARDS - 2-SPEED IDLE TEST

All Vehicles
1984-86 220 (0.80)
1987 & Newer 100 (0.60)
MISSOURI
MISSOURI EMISSION STANDARDS - JEFFERSON, ST. CHARLES & ST. LOUIS COUNTIES - IM240
TEST
1981-82 0.80 (30.0) 2.0
1983-95 0.80 (15.0) 2.0
1996 & Newer 0.60 (10.0) 1.5
1981-83 3.40 (70.0) 4.5
1984-87 1.60 (40.0) 4.5
1988-95 1.60 (40.0) 2.5
1996 & Newer (Less Than 3750 LVW) 0.80 (13.0) 1.8
1996 & Newer (3750 LVW Or Less) 0.60 (10.0) 1.5
1981-83 3.4 (70.0) 4.5
1984-87 1.6 (40.0) 4.5
1988-95 1.60 (40.0) 3.5
1996 & Newer (5750 ALVW Or Less) 0.80 (13.0) 1.8
1996 & Newer (5750 ALVW Or More) 0.80 (15.0) 2.0
MISSOURI EMISSION STANDARDS - FRANKLIN, JEFFERSON, ST. CHARLES & ST. LOUIS
COUNTIES - IDLE TEST
Application (1) HC ppm (CO %)
1971-74 700 (7.0)
1975-79 600 (6.0)

1980 300 (3.0)
1981 & Newer 220 (1.2)
MISSOURI EMISSION STANDARDS - FRANKLIN, JEFFERSON, ST. CHARLES & ST. LOUIS
COUNTIES - REMOTE SENSING CLEAN SCREEN TEST
Application (1) HC ppm (CO %) NOx ppm
All Vehicles (8500 GVWR Or Less)
1971 & Newer 200 (0.5) 2000
NEVADA
NEVADA EMISSION STANDARDS - 2-SPEED IDLE TEST
1968-69 800 (4.0)
1970-74 700 (3.5)
1975-78 500 (2.5)
1979-80 500 (2.0)
1981 & Newer 220 (1.2)
1968-69 1400 (7.0)
1970-78 1400 (6.0)
1979 1000 (5.0)
1980 1000 (4.0)
1981 & Newer 1000 (3.5)
NEW JERSEY
NOTE: The New Jersey program incorporates original U.S. EPA recommended start-up
ASM5015 standards for 1981 and newer model year vehicles. Refer to appropriate model
year range in appropriate table. See U. S. EPA ASM2525 & ASM5015 START-UP EMISSION
STANDARDS .
NEW JERSEY EMISSION STANDARDS - 2-SPEED IDLE TEST
Application Idle HC ppm (CO %) 2500 RPM HC ppm (CO %)
1967 & Earlier 1400 (8.5) .....
1968-70 700 (7.0) .....
1971-74 500 (5.0) .....
1975-80 300 (3.0) .....
1981 & Newer 220 (1.2) 100 (0.5)
Heavy Duty Vehicles (8501 GVWR Or Greater)
1967 & Earlier 1400 (8.5) .....
1968-70 1200 (8.5) .....
1971-74 700 (6.0) .....
1975-78 500 (4.0) .....
1979 & Earlier 300 (3.0) .....
NEW MEXICO
NEW MEXICO EMISSION STANDARDS - 2-SPEED IDLE TEST
Application Idle HC ppm (CO %) 2500 RPM HC ppm (CO %)
1975-78 500 (5.0) 500 (5.0)
1979-80 400 (4.0) 400 (4.0)
1981-85 220 (1.2) 220 (1.2)
1986-90 200 (1.2) 200 (1.2)
1991-95 180 (1.2) 180 (1.2)
1975-78 600 (6.0) 600 (6.0)
1979-80 600 (4.5) 600 (4.5)

1981-82 400 (2.7) 400 (3.0)
1983-88 300 (1.2) 300 (3.0)
1989-95 220 (1.2) 220 (1.2)
Medium Duty Trucks (8001-10,000 GVWR)
1975 & Newer 650 (6.5) 650 (6.5)
NEW YORK
NEW YORK EMISSION STANDARDS - IM240 TEST
HC gpm HC gpm CO gpm CO gpm NOx gpm

Application Composite Phase 2 Composite Phase 2 Both
Light Duty Vehicles
1981-82 0.80 0.50 30.0 24.0 2.0
1983-95 0.80 0.50 15.0 12.0 2.0
1996 & Newer 0.60 0.40 10.0 8.0 1.5
1981-83 3.40 2.00 70.0 56.0 4.5
1984-87 1.60 1.00 40.0 32.0 4.5
1988-95 1.60 1.00 40.0 32.0 2.5
1996 & Newer (3750 LVW 0.60 0.40 10.0 8.0 1.5
Or Less)
1996 & Newer (3751 LVW 0.80 0.50 13.0 10.0 1.8
Or More)
1981-83 3.40 2.00 70.0 56.0 4.5
1984-87 1.60 1.00 40.0 32.0 4.5
1988-95 1.60 1.00 40.0 32.0 3.5
1996 & Newer (5750 0.80 0.50 13.0 10.0 1.8

ALVW Or Less)
1996 & Newer (5751 0.80 0.50 15.0 12.0 2.0

ALVW Or More)
NEW YORK EMISSION STANDARDS - IDLE TEST

1978 300 (3.0)
1979-80 300 (2.5)
1981 & Newer 220 (1.2)
1978 600 (4.5)
1979 & Newer 300 (3.0)
NORTH CAROLINA
NORTH CAROLINA EMISSION STANDARDS - IDLE TEST
1977 450 (4.5)
1978-79 350 (3.5)
1980 250 (2.0)
1981 & Newer 250 (1.2)
Heavy Duty Trucks (8501 GVWR Or More)
1977-78 500 (5.0)
1979 & Newer 400 (4.0)
OHIO
NOTE: The Ohio program incorporates original U.S. EPA recommended start-up
ASM2525 standards for all model year vehicles. Refer to appropriate model year range in
appropriate table. See U. S. EPA ASM2525 & ASM5015 START-UP EMISSION
STANDARDS .
OHIO EMISSION STANDARDS - 2-SPEED IDLE TEST
1978 350 (4.0)
1979 275 (3.0)

1980 230 (2.0)
1981 & Newer 220 (1.2)
OREGON
OREGON EMISSION STANDARDS - METROPOLITAN PORTLAND ENHANCED AREA - BAR31
Light Duty Passenger Cars
1981-82 2.0 (64) 3.70
1983-89 2.0 (32) 3.70
1990-95 1.2 (30) 3.00
1996 & Newer OBD-II Test OBD-II Test
1981-83 8.5 (149) 8.32
1984-87 4.0 (85) 8.32
1988-89 4.0 (85) 4.62
1990-95 2.4 (80) 3.75
1981-83 8.5 (149) 8.32
1984-87 4.0 (85) 8.32
1988-89 4.0 (85) 6.47
1990-95 2.4 (80) 5.25
OREGON EMISSION STANDARDS - METROPOLITAN PORTLAND & ROGUE VALLEY AREA BASIC
TEST - 2-SPEED IDLE TEST
2500 RPM HC ppm (CO

Application Idle HC ppm (CO %) %)
Light Duty Passenger Cars (6000 GVWR Or Less)
1975-80 (No Catalyst) 300 (2.5) -
1975-80 (Catalyst) 220 (1.0) -
1981 & Newer (All) 220 (1.0) 220 (1.0)

1975 & Newer (2-Stroke) n/a (7.0) -
1975-78 (All) 350 (2.5) -
1979-80 (No Catalyst) 300 (2.5) -
1979-80 (Catalyst) 220 (1.0) -
1981 & Newer (All) 220 (1.0) 220 (1.0)
1996 & Newer (3750 LVW Or Less) 0.9 (20) 2.25
1975-78 (Carbureted) 500 (4.0) n/a (3.0)
1975-78 (Fuel Injection) 500 (4.0) -
1979-84 (Carbureted) 350 (3.0) n/a (3.0)
1979-84 (Fuel Injection) 350 (3.0) -
1985 & Newer (No Catalyst) 350 (3.0) n/a (3.0)
1985 & Newer (W/Catalyst) 220 (1.0) 220 (1.0)
OREGON EMISSION STANDARDS - METROPOLITAN PORTLAND & ROGUE VALLEY AREA BASIC
TEST - EXHAUST OPACITY TEST
Application Opacity % @ Idle Opacity % @ High Idle
1975 & Newer
2-Cycle Engines 20 .....
Gasoline Engines 0 0
PENNSYLVANIA
NOTE: The Pennsylvania (in Philadelphia area) program incorporates original U.S. EPA
recommended start-up ASM5015 standards for 1981 and newer model year vehicles. Refer
to appropriate model year range in appropriate table. See U. S. EPA ASM2525 & ASM5015
PENNSYLVANIA EMISSION STANDARDS - PITTSBURGH & OLDER PHILADELPHIA VEHICLES - IDLE

TEST
6000 GVWR Or Less

1975-79 400 (4.0)
1980 300 (3.0)
1981-92 220 (1.2)
1993 & Newer 130 (1.0)
6001-9000 GVWR
1975-78 650 (6.0)
1979 400 (4.0)
1980 300 (3.0)
1981-92 220 (1.2)
1993 & Newer 180 (1.0)
RHODE ISLAND
RHODE ISLAND EMISSION STANDARDS - RI2000 TEST
Light Duty Vehicles
1974 & Earlier 15.92 (132.44) 14.92
1975-76 6.74 (96.21) 9.92
1977-79 6.74 (96.21) 6.59
1980 2.25 (45.48) 6.59
1981-82 2.25 (45.48) 3.25
1983-95 2.25 (23.74) 3.25
1996 & Newer 1.84 (16.50) 2.42
1975 & Earlier 16.94 (175.92) 14.92
1975-78 8.78 (117.95) 9.92
1979-83 7.55 (103.45) 7.42
1984-87 3.88 (59.97) 7.42
1988-90 3.88 (59.97) 4.09
1991-95 3.88 (59.97) 4.09
1996 & Newer (3750 LVW Or Less) 1.84 (16.50) 2.42
1996 & Newer (3751 LVW Or More) 2.25 (20.84) 2.92

1974 & Earlier 16.94 (175.92) 14.92
1975-78 8.78 (117.95) 9.92
1979-83 7.55 (103.45) 7.42
1984-87 3.88 (59.97) 7.42
1989-90 3.88 (59.97) 5.75
1991-95 3.88 (59.97) 5.75
1996 & Newer (5750 LVW Or Less) 2.25 (20.84) 2.92
1996 & Newer (5751 LVW or More) 5.51 (23.74) 3.25
RHODE ISLAND EMISSION STANDARDS - 2-SPEED IDLE TEST
Application Idle (1) HC ppm (CO %)
1967 & Earlier 800 (7.0)
1968-74 700 (6.0)
1975-78 300 (3.0)
1979-80 300 (2.5)
1981 & Newer 220 (1.2)
TENNESSEE
TENNESSEE EMISSION STANDARDS - MEMPHIS - IDLE TEST
1971 & Older 900 (8.9)
1972-74 700 (8.2)
1975-79 600 (7.5)
1980 400 (4.7)
1981 & Newer 220 (1.2)
Heavy Duty Trucks (9001-25,999 GVWR)
1971 & Older 1000 (8.9)

1972-74 1000 (8.2)
1975-79 1000 (8.0)
1980 800 (6.0)
1981 & Newer 400 (4.0)
TENNESSEE EMISSION STANDARDS - DAVIDSON & NASHVILLE COUNTIES - IDLE TEST
1975-77 500 (5.0)
1978-79 400 (4.0)
1980 300 (3.0)
1981 & Newer 220 (1.2)
1975-77 750 (6.5)
1978-79 600 (6.0)
1980 400 (4.5)
1981 & Newer 400 (4.0)
TENNESSEE EMISSION STANDARDS - FOUR COUNTY AREA SURROUNDING NASHVILLE - IDLE

TEST
1975-77 500 (5.0)
1978-79 400 (4.0)
1980 300 (3.0)
1981 & Newer 220 (1.2)
1975-77 750 (6.5)
1978-79 600 (6.0)
1980 400 (4.5)
1981 & Newer 400 (4.0)

TEXAS
NOTE: The Texas program incorporates original U.S. EPA recommended start-up
ASM2525 and ASM5015 standards for 1995 and newer model year vehicles. Refer to
TEXAS EMISSION STANDARDS - 2-SPEED IDLE TEST
1979 600 (6.0)
1980 400 (4.0)
1981 & Newer 220 (1.2)
1979-81 700 (7.0)
1982-84 500 (5.0)
1985 & Newer 300 (3.0)
UTAH
UTAH EMISSION STANDARDS - DAVIS COUNTY - DC98 TEST
1989-90 2.00 (30) 3.0
1991-95 1.2 (20) 2.5
1989-90 3.2 (80) 3.5
1991-95 2.4 (60) 3.0
1989-90 3.2 (80) 5.0
1991-95 2.4 (60) 4.5
UTAH EMISSION STANDARDS - DAVIS COUNTY - 2-SPEED IDLE TEST

1968-69 800 (6.0)
1970-74 700 (5.0)
1975-76 600 (4.0)
1977-79 500 (3.0)
1980 300 (2.0)
1981-95 220 (1.2)
Light Duty Vehicles (6001-8500 GVWR)
1968-69 1500 (7.0)
1970-78 1200 (5.0)
1979 500 (3.0)
1980 300 (2.0)
1981-95 220 (1.2)
1968-69 1500 (7.0)
1970-78 1200 (5.0)
1979-80 1000 (4.0)
1981 & Newer 800 (3.5)
NOTE: The Salt Lake County program incorporates California style ASM2525 and
ASM5015 standards for 1968 and newer model year vehicles; however, actual cutpoints are
unique to this program and current information is not available at this time.
UTAH EMISSION STANDARDS - SALT LAKE COUNTY - 2-SPEED IDLE TEST
1968-69 800 (6.0)
1970-74 700 (5.0)
1975-76 600 (4.0)
1977-79 500 (3.0)
1980 300 (2.0)

1981 & Newer 220 (1.2)
1968-99 800 (6.0)
1970-74 700 (5.0)
1975-76 600 (4.0)
1977-79 500 (3.0)
1980 300 (2.0)
1981 & Newer 220 (1.2)
1968-69 1500 (7.0)
1970-78 1200 (5.0)
1979 500 (3.0)
1980 300 (2.0)
1981 & Newer 220 (1.2)
1968-69 1500 (7.0)
1970-78 1200 (5.0)
1979-80 1000 (4.0)
1981 & Newer 800 (3.5)
UTAH EMISSION STANDARDS - UTAH & WEBER COUNTIES - 2-SPEED IDLE TEST
1968-69 800 (6.0)
1970-74 700 (5.0)
1975-76 600 (4.0)
1977-79 500 (3.0)
1980 300 (2.0)
1981-95 220 (1.2)
1968-99 800 (6.0)
1970-74 700 (5.0)

1975-76 600 (4.0)
1977-79 500 (3.0)
1980 300 (2.0)
1981 & Newer 220 (1.2)
1968-69 1500 (7.0)
1970-78 1200 (5.0)
1979 500 (3.0)
1980 300 (2.0)
1981 & Newer 220 (1.2)
1968-69 1500 (7.0)
1970-78 1200 (5.0)
1979-80 1000 (4.0)
1981 & Newer 800 (3.5)
VIRGINIA
NOTE: The Virginia program incorporates original U.S. EPA recommended start-up
ASM2525 and ASM5015 standards for 1981 and newer model year vehicles. Refer to
VIRGINIA EMISSION STANDARDS - 2-SPEED IDLE TEST
8500 GVWR Or Less
1975-90 400 (4.0)
1980 220 (2.0)
1981-89 220 (1.2)
1990-95 125 (1.0)
1996 & Newer 100 (0.75)
8501-10,000 GVWR
1975-79 400 (4.0)

1980 220 (2.0)
1981-90 220 (1.2)
1991-96 150 (1.0)
1997 & Newer 125 (0.75)
WASHINGTON
WASHINGTON EMISSION STANDARDS - ASM2525 TEST
1980 & Earlier (Light-Duty Vehicles)
1750 GVWR 400 (4.2)
1875 GVWR 380 (4.0)
2000 GVWR 350 (3.8)
2125 GVWR 340 (3.6)
2250 GVWR 320 (3.4)
2375 GVWR 300 (3.2)
2500 GVWR 290 (3.0)
2625 GVWR 270 (2.9)
2750 GVWR 260 (2.8)
2875 GVWR 250 (2.7)
3000 GVWR 240 (2.6)
3125 GVWR 230 (2.5)
3250 GVWR 220 (2.4)
3375 GVWR 220 (2.3)
3500 GVWR 210 (2.2)
3625 GVWR 200 (2.1)
3750 Or Greater GVWR (Passenger Cars Only) 200 (2.1)
3750 Or Greater GVWR (Light Duty Trucks) 300 (2.5)
1981 & Newer (Light-Duty Vehicles)
1750 GVWR 250 (1.8)
1875 GVWR 240 (1.7)
2000 GVWR 220 (1.6)

2125 GVWR 210 (1.5)
2250 GVWR 200 (1.5)
2375 GVWR 190 (1.4)
2500 GVWR 180 (1.3)
2625 GVWR 180 (1.3)
2750 GVWR 171 (1.2)
2875 GVWR 160 (1.2)
3000 GVWR 160 (1.1)
3125 GVWR 150 (1.1)
3250 GVWR 150 (1.0)
3375 GVWR 150 (1.0)
3500 GVWR 150 (1.0)
3625 GVWR 150 (1.0)
3750 Or Greater GVWR (Passenger Cars Only) 150 (1.0)
3750 Or Greater GVWR (Light Duty Trucks) 300 (2.5)
WASHINGTON EMISSION STANDARDS - 2-SPEED IDLE TEST
Application Idle/2500 RPM HC ppm (CO %)
1980 & Earlier 600 (3.0)
1981 & Newer 220 (1.2)
1981 & Newer 400 (3.0)
WISCONSIN
WISCONSIN EMISSION STANDARDS - IM240 TEST
1968-72 7.0 (120) 7.0
1973-74 7.0 (120) 6.0
1975-76 3.0 (65) 6.0

1977-79 3.0 (65) 4.0
1980 2.0 (60) 4.0
1981-82 2.0 (60) 3.0
1983-86 2.0 (30) 3.0
1987-93 0.8 (15) 2.0
1991-95 0.8 (15) 2.0
1996 & Newer 0.6 (10) 1.5
1968-72 7.0 (120) 7.0
1973-74 7.0 (120) 6.0
1975-78 4.0 (80) 6.0
1979-83 3.4 (70) 4.5
1984-86 3.2 (70) 4.5
1987 1.6 (40) 4.5
1988-95 1.6 (40) 2.5
1996 & Newer (3750 LVW Or Less) 0.6 (10) 1.5
1996 & Newer (3751 LVW Or More) 0.8 (13) 1.8
1968-72 7.0 (120) 7.0
1973-74 7.0 (120) 6.0
1975-78 4.0 (80) 6.0
1979-83 3.4 (70) 4.5
1984-86 3.2 (70) 4.5
1988-96 1.6 (40) 3.5
1997 & Newer (5750 ALVW Or Less) 0.8 (13) 1.8
1997 & Newer (5751 ALVW Or More) 0.8 (15) 2.0
Heavy Duty Trucks (8501-10,000 GVWR)
1968-69 20.0 (200) 15.0
1970-73 10.0 (175) 10.0
1974-78 10.0 (150) 10.0
1979-84 7.5 (100) 8.0
1985-86 5.0 (80) 8.0
1987-90 2.0 (40) 6.0

1991-97 2.0 (40) 5.0
1998 & Newer 2.0 (30) 4.0
Heavy Duty Trucks (10,001 GVWR or More)
1968-69 24.0 (250) 30.0
1970-73 13.0 (175) 20.0
1974-78 13.0 (150) 20.0
1979-84 11.5 (150) 16.0
1985-86 10.0 (150) 16.0
1987-90 3.5 (70) 11.0
1991-97 3.5 (70) 9.0
1998 & Newer 3.5 (60) 7.0
WISCONSIN EMISSION STANDARDS - 2-SPEED IDLE TEST
Passenger Cars
1968-71 800 (8.0)
1972-74 550 (7.0)
1975-77 450 (5.5)
1978 350 (4.0)
1979 275 (3.0)
1980 230 (2.0)
1981 & Newer 220 (1.2)
1968-71 800 (8.0)
1972-74 700 (7.0)
1975-77 500 (6.0)
1978 450 (5.0)
1979 300 (3.0)
1980 275 (2.5)
1981-84 250 (2.0)
1985 & Newer 220 (1.2)

1968-69 1450 (9.0)
1970-71 800 (8.0)
1972-74 700 (7.0)
1975-77 550 (6.5)
1978 450 (5.5)
1979 300 (3.0)
1980 275 (2.5)
1981-84 250 (2.0)
1985 & Newer 220 (1.2)
1968-71 1500 (9.5)
1972-78 900 (9.0)
1979-84 700 (7.0)
1985 & Newer 300 (3.0)
U. S. EPA ASM2525 & ASM5015 START-UP EMISSION STANDARDS

U.S. EPA ASM EMISSION STANDARDS - 1968-72 LIGHT DUTY VEHICLES
Test Weight ASM5015 ASM2525
HC ppm (CO
HC ppm (CO %) NOx ppm %) NOx ppm
1750 1118 (8.02) 4990 1098 (9.90) 4990
1875 1052 (7.56) 4990 1034 (9.90) 4990
2000 992 (7.14) 4990 975 (9.90) 4990
2125 938 (6.75) 4990 921 (9.66) 4990
2250 887 (6.40) 4990 872 (9.14) 4990
2375 841 (6.07) 4990 827 (8.67) 4990
2500 800 (5.78) 4990 786 (8.25) 4990
2625 761 (5.51) 4990 748 (7.85) 4990
2750 726 (5.26) 4990 714 (7.50) 4772
2875 695 (5.03) 4892 683 (7.17) 4556
3000 666 (4.83) 4680 654 (6.87) 4359

3125 639 (4.64) 4488 628 (6.60) 4180
3250 615 (4.47) 4311 604 (6.35) 4016
3375 593 (4.31) 4150 583 (6.13) 3866
3500 573 (4.17) 4002 563 (5.92) 3728
3625 554 (4.04) 3867 544 (5.73) 3602
3750 537 (3.91) 3741 527 (5.55) 3485
3875 521 (3.80) 3625 512 (5.39) 3377
4000 506 (3.70) 3517 497 (5.24) 3276
4125 492 (3.60) 3416 484 (5.09) 3182
4250 479 (3.51) 3321 471 (4.96) 3094
4375 467 (3.42) 3230 459 (4.83) 3010
4500 455 (3.34) 3145 447 (4.71) 2930
4625 444 (3.26) 3063 436 (4.60) 2854
4750 433 (3.18) 2983 425 (4.49) 2780
4875 423 (3.11) 2907 415 (4.38) 2709
5000 412 (3.03) 2833 405 (4.28) 2540
5125 402 (2.97) 2760 395 (4.18) 2573
5250 393 (2.90) 2690 386 (4.08) 2507
5375 383 (2.83) 2621 376 (3.98) 2443
5500 374 (2.77) 2554 367 (3.89) 2381
5625 365 (2.70) 2489 359 (3.80) 2321
5750 357 (2.64) 2426 350 (3.71) 2262
5875 348 (2.59) 2366 342 (3.62) 2206
6000 341 (2.53) 2308 334 (3.54) 2152
6125 333 (2.48) 2254 327 (3.47) 2102
6250 326 (2.43) 2204 320 (3.40) 2056
6375 320 (2.39) 2159 314 (3.34) 2014
6500 315 (2.35) 2119 309 (3.28) 1977
6625 310 (2.32) 2087 304 (3.23) 1947
6750 307 (2.29) 2062 301 (3.20) 1924
6875 305 (2.28) 2046 299 (3.17) 1909
7000 304 (2.27) 2040 298 (3.17) 1904
7125 Or More 304 (2.27) 2045 298 (3.17) 1904

HC ppm (CO
1750 1118 (8.02) 4990 1098 (9.90) 4980
1875 1052 (7.56) 4990 1034 (9.90) 4906
2000 992 (7.14) 4919 975 (9.90) 4838
2125 938 (6.75) 4853 921 (9.66) 4776
2250 887 (6.40) 4792 872 (9.14) 4720
2375 841 (6.07) 4736 827 (8.67) 4668
2500 800 (5.78) 4685 786 (8.25) 4620
2625 761 (5.51) 4639 748 (7.85) 4577
2750 726 (5.26) 4596 714 (7.50) 4374
2875 695 (5.03) 4484 683 (7.17) 4176
3000 666 (4.83) 4290 654 (6.87) 3996
3125 639 (4.64) 4114 628 (6.60) 3832
3250 615 (4.47) 3952 604 (6.35) 3681
3375 593 (4.31) 3804 583 (6.13) 3544
3500 573 (4.17) 3669 563 (5.92) 3418
3625 554 (4.04) 3544 544 (5.73) 3302
3750 537 (3.91) 3429 527 (5.55) 3195
3875 521 (3.80) 3323 512 (5.39) 3096
4000 506 (3.70) 3224 497 (5.24) 3003
4125 492 (3.60) 3131 484 (5.09) 2917
4250 479 (3.51) 3044 471 (4.96) 2836
4375 467 (3.42) 2961 459 (4.83) 2759
4500 455 (3.34) 2883 447 (4.71) 2686
4625 444 (3.26) 2807 436 (4.60) 2616
4750 433 (3.18) 2735 425 (4.49) 2549
4875 423 (3.11) 2665 415 (4.38) 2483
5000 412 (3.03) 2597 405 (4.28) 2420
5125 402 (2.97) 2530 395 (4.18) 2359

5250 393 (2.90) 2466 386 (4.08) 2298
5375 383 (2.83) 2403 376 (3.98) 2240
5500 374 (2.77) 2341 367 (3.89) 2183
5625 365 (2.70) 2282 359 (3.80) 2127
5750 357 (2.64) 2224 350 (3.71) 2074
5875 348 (2.59) 2168 342 (3.62) 2022
6000 341 (2.53) 2116 334 (3.54) 1973
6125 333 (2.48) 2066 327 (3.47) 1927
6250 326 (2.43) 2020 320 (3.40) 1884
6375 320 (2.39) 1979 314 (3.34) 1846
6500 315 (2.35) 1943 309 (3.28) 1813
6625 310 (2.32) 1913 304 (3.23) 1785
6750 307 (2.29) 1890 301 (3.20) 1764
6875 305 (2.28) 1875 299 (3.17) 1750
7000 304 (2.27) 1870 298 (3.17) 1745
7125 Or More 304 (2.27) 1874 298 (3.17) 1745
HC ppm (CO %) NOx ppm HC ppm (CO %) NOx ppm
1750 774 (3.92) 4990 761 (5.45) 4980
1875 729 (3.70) 4990 717 (5.14) 4906
2000 688 (3.49) 4919 676 (4.85) 4838
2125 650 (3.31) 4853 638 (4.58) 4776
2250 615 (3.13) 4792 604 (4.34) 4720
2375 583 (2.98) 4736 573 (4.12) 4668
2500 554 (2.83) 4685 544 (3.91) 4620
2625 528 (2.70) 4639 518 (3.73) 4577
2750 503 (2.58) 4596 495 (3.56) 4374
2875 481 (2.47) 4484 473 (3.41) 4176
3000 461 (2.37) 4290 453 (3.27) 3996
3125 443 (2.28) 4114 435 (3.14) 3832

3250 426 (2.20) 3952 419 (3.02) 3681
3375 411 (2.12) 3804 404 (2.91) 3544
3500 397 (2.05) 3669 390 (2.82) 3418
3625 384 (1.99) 3544 377 (2.73) 3302
3750 372 (1.93) 3429 365 (2.64) 3195
3875 361 (1.87) 3323 355 (2.57) 3096
4000 351 (1.82) 3224 345 (2.49) 3003
4125 341 (1.77) 3131 335 (2.43) 2917
4250 332 (1.73) 3044 326 (2.36) 2836
4375 323 (1.68) 2961 318 (2.31) 2759
4500 315 (1.64) 2883 310 (2.25) 2686
4625 308 (1.61) 2807 302 (2.19) 2616
4750 300 (1.57) 2735 295 (2.14) 2549
4875 293 (1.53) 2665 288 (2.09) 2483
5000 286 (1.50) 2597 281 (2.04) 2420
5125 279 (1.46) 2530 274 (2.00) 2359
5250 272 (1.43) 2466 267 (1.95) 2298
5375 266 (1.40) 2403 261 (1.90) 2240
5500 259 (1.37) 2341 255 (1.86) 2183
5625 253 (1.34) 2282 248 (1.82) 2127
5750 247 (1.31) 2224 243 (1.78) 2074
5875 241 (1.28) 2168 237 (1.74) 2022
6000 236 (1.25) 2116 232 (1.70) 1973
6125 231 (1.23) 2066 227 (1.66) 1927
6250 226 (1.20) 2020 222 (1.63) 1884
6375 222 (1.18) 1979 218 (1.60) 1846
6500 218 (1.16) 1943 214 (1.57) 1813
6625 215 (1.15) 1913 211 (1.55) 1785
6750 213 (1.14) 1890 209 (1.54) 1764
6875 211 (1.13) 1875 207 (1.52) 1750
7000 211 (1.12) 1870 207 (1.52) 1745
7125 Or More 211 (1.12) 1874 206 (1.52) 1745

1750 774 (3.92) 4990 761 (5.45) 4950
1875 729 (3.70) 4990 717 (5.14) 4655
2000 688 (3.49) 4707 676 (4.85) 4384
2125 650 (3.31) 4441 638 (4.58) 4136
2250 615 (3.13) 4197 604 (4.34) 3909
2375 583 (2.98) 3974 573 (4.12) 3701
2500 554 (2.83) 3771 544 (3.91) 3512
2625 528 (2.70) 3585 518 (3.73) 3339
2750 503 (2.58) 3416 495 (3.56) 3181
2875 481 (2.47) 3261 473 (3.41) 3037
3000 461 (2.37) 3120 453 (3.27) 2906
3125 443 (2.28) 2992 435 (3.14) 2787
3250 426 (2.20) 2874 419 (3.02) 2677
3375 411 (2.12) 2767 404 (2.91) 2577
3500 397 (2.05) 2668 390 (2.82) 2486
3625 384 (1.99) 2578 377 (2.73) 2401
3750 372 (1.93) 2494 365 (2.64) 2323
3875 361 (1.87) 2417 355 (2.57) 2251
4000 351 (1.82) 2345 345 (2.49) 2184
4125 341 (1.77) 2277 335 (2.43) 2122
4250 332 (1.73) 2214 326 (2.36) 2063
4375 323 (1.68) 2154 318 (2.31) 2007
4500 315 (1.64) 2096 310 (2.25) 1953
4625 308 (1.61) 2042 302 (2.19) 1903
4750 300 (1.57) 1989 295 (2.14) 1854
4875 293 (1.53) 1938 288 (2.09) 1806
5000 286 (1.50) 1889 281 (2.04) 1760
5125 279 (1.46) 1840 274 (2.00) 1715
5250 272 (1.43) 1793 267 (1.95) 1672

5375 266 (1.40) 1747 261 (1.90) 1629
5500 259 (1.37) 1703 255 (1.86) 1587
5625 253 (1.34) 1659 248 (1.82) 1547
5750 247 (1.31) 1617 243 (1.78) 1508
5875 241 (1.28) 1577 237 (1.74) 1471
6000 236 (1.25) 1539 232 (1.70) 1435
6125 231 (1.23) 1503 227 (1.66) 1401
6250 226 (1.20) 1469 222 (1.63) 1371
6375 222 (1.18) 1439 218 (1.60) 1343
6500 218 (1.16) 1413 214 (1.57) 1318
6625 215 (1.15) 1391 211 (1.55) 1298
6750 213 (1.14) 1374 209 (1.54) 1283
6875 211 (1.13) 1364 207 (1.52) 1273
7000 Or More 211 (1.12) 1360 207 (1.52) 1269
U.S. EPA ASM EMISSION STANDARDS - 1980 LIGHT DUTY VEHICLES
HC ppm (CO
1750 291 (2.78) 4990 282 (3.64) 4950
1875 275 (2.63) 4990 266 (3.43) 4655
2000 260 (2.48) 4707 252 (3.24) 4384
2125 246 (2.35) 4441 239 (3.06) 4136
2250 234 (2.23) 4197 227 (2.90) 3909
2375 223 (2.12) 3974 216 (2.76) 3701
2500 212 (2.02) 3771 206 (2.62) 3512
2625 203 (1.92) 3585 197 (2.50) 3339
2750 194 (1.84) 3416 189 (2.39) 3181
2875 187 (1.76) 3261 181 (2.29) 3037
3000 180 (1.69) 3120 174 (2.19) 2906
3125 173 (1.63) 2992 168 (2.11) 2787
3250 167 (1.57) 2874 162 (2.03) 2677
3375 162 (1.52) 2767 157 (1.96) 2577

3500 157 (1.47) 2668 152 (1.89) 2486
3625 152 (1.42) 2578 148 (1.84) 2401
3750 148 (1.38) 2492 144 (1.78) 2323
3875 144 (1.34) 2417 140 (1.73) 2251
4000 140 (1.31) 2345 137 (1.68) 2184
4125 137 (1.27) 2277 133 (1.64) 2122
4250 134 (1.24) 2214 130 (1.60) 2063
4375 131 (1.21) 2154 127 (1.56) 2007
4500 128 (1.18) 2096 124 (1.52) 1953
4625 125 (1.15) 2042 122 (1.48) 1903
4750 122 (1.13) 1989 119 (1.45) 1854
4875 120 (1.10) 1938 117 (1.42) 1806
5000 117 (1.08) 1889 114 (1.38) 1760
5125 115 (1.05) 1840 112 (1.35) 1715
5250 112 (1.03) 1793 110 (1.32) 1672
5375 110 (1.01) 1747 107 (1.29) 1629
5500 108 (0.99) 1703 105 (1.26) 1587
5625 106 (0.97) 1659 103 (1.24) 1547
5750 104 (0.94) 1617 101 (1.21) 1508
5875 102 (0.92) 1577 99 (1.18) 1471
6000 100 (0.91) 1539 97 (1.16) 1435
6125 98 (0.89) 1503 95 (1.13) 1401
6250 96 (0.87) 1469 94 (1.11) 1371
6375 95 (0.86) 1439 92 (1.09) 1343
6500 93 (0.84) 1413 91 (1.08) 1318
6625 92 (0.83) 1391 90 (1.06) 1298
6750 91 (0.82) 1374 89 (1.05) 1283
6875 91 (0.82) 1364 89 (1.04) 1273
7000 91 (0.82) 1360 88 (1.04) 1269
7125 Or More 90 (0.81) 1360 88 (1.04) 1269

HC ppm (CO
1750 291 (2.78) 2272 282 (3.64) 2114
1875 275 (2.63) 2181 266 (3.43) 1991
2000 260 (2.48) 2058 252 (3.24) 1877
2125 246 (2.35) 1944 239 (3.06) 1774
2250 234 (2.23) 1839 227 (2.90) 1678
2375 223 (2.12) 1744 216 (2.76) 1592
2500 212 (2.02) 1657 206 (2.62) 1512
2625 203 (1.92) 1577 197 (2.50) 1440
2750 194 (1.84) 1504 189 (2.39) 1374
2875 187 (1.76) 1438 181 (2.29) 1313
3000 180 (1.69) 1378 174 (2.19) 1258
3125 173 (1.63) 1323 168 (2.11) 1208
3250 167 (1.57) 1273 162 (2.03) 1163
3375 162 (1.52) 1227 157 (1.96) 1121
3500 157 (1.47) 1184 152 (1.89) 1082
3625 152 (1.42) 1146 148 (1.84) 1047
3750 148 (1.38) 1110 144 (1.78) 1014
3875 144 (1.34) 1077 140 (1.73) 984
4000 140 (1.31) 1046 137 (1.68) 956
4125 137 (1.27) 1017 133 (1.64) 930
4250 134 (1.24) 990 130 (1.60) 905
4375 131 (1.21) 964 127 (1.56) 882
4500 128 (1.18) 939 124 (1.52) 859
4625 125 (1.15) 916 122 (1.48) 838
4750 122 (1.13) 893 119 (1.45) 818
4875 120 (1.10) 872 117 (1.42) 798
5000 117 (1.08) 850 114 (1.38) 778
5125 115 (1.05) 830 112 (1.35) 760
5250 112 (1.03) 810 110 (1.32) 741
5375 110 (1.01) 790 107 (1.29) 723

5500 108 (0.99) 771 105 (1.26) 706
5625 106 (0.97) 752 103 (1.24) 689
5750 104 (0.94) 734 101 (1.21) 673
5875 102 (0.92) 717 99 (1.18) 657
6000 100 (0.91) 701 97 (1.16) 642
6125 98 (0.89) 685 95 (1.13) 628
6250 96 (0.87) 671 94 (1.11) 615
6375 95 (0.86) 658 92 (1.09) 604
6500 93 (0.84) 647 91 (1.08) 593
6625 92 (0.83) 638 90 (1.06) 585
6750 91 (0.82) 631 89 (1.05) 578
6875 91 (0.82) 626 89 (1.04) 574
7000 91 (0.82) 624 88 (1.04) 573
7125 Or More 90 (0.81) 625 88 (1.04) 573
HC ppm (CO
1750 291 (1.64) 2272 282 (1.83) 2114
1875 275 (1.55) 2181 266 (1.72) 1991
2000 260 (1.47) 2058 252 (1.63) 1877
2125 246 (1.39) 1944 239 (1.54) 1774
2250 234 (1.31) 1839 227 (1.47) 1678
2375 223 (1.26) 1744 216 (1.39) 1592
2500 212 (1.20) 1657 206 (1.33) 1512
2625 203 (1.15) 1577 197 (1.27) 1440
2750 194 (1.10) 1504 189 (1.21) 1374
2875 187 (1.05) 1438 181 (1.16) 1313
3000 180 (1.01) 1378 174 (1.12) 1258
3125 173 (0.98) 1323 168 (1.08) 1208
3250 167 (0.94) 1273 162 (1.04) 1163
3375 162 (0.91) 1227 157 (1.00) 1121

3500 157 (0.88) 1184 152 (0.97) 1082
3625 152 (0.86) 1146 148 (0.94) 1047
3750 148 (0.83) 1110 144 (0.92) 1014
3875 144 (0.81) 1077 140 (0.89) 984
4000 140 (0.79) 1046 137 (0.87) 956
4125 137 (0.77) 1017 133 (0.85) 930
4250 134 (0.75) 990 130 (.83) 905
4375 131 (0.74) 964 127 (0.81) 882
4500 128 (0.72) 939 124 (0.79) 859
4625 125 (0.70) 916 122 (0.77) 838
4750 122 (0.69) 893 119 (0.76) 818
4875 120 (0.67) 872 117 (0.74) 798
5000 117 (0.66) 850 114 (0.73) 778
5125 115 (0.65) 830 112 (0.71) 760
5250 112 (0.63) 810 110 (0.70) 741
5375 110 (0.62) 790 107 (0.68) 723
5500 108 (0.61) 771 105 (0.67) 706
5625 106 (0.59) 752 103 (0.65) 689
5750 104 (0.58) 734 101 (0.64) 673
5875 102 (0.57) 717 99 (0.63) 657
6000 100 (0.56) 701 97 (0.62) 642
6125 98 (0.55) 685 95 (0.61) 628
6250 96 (0.54) 671 94 (0.60) 615
6375 95 (0.53) 658 92 (0.59) 604
6500 93 (0.52) 647 91 (0.58) 593
6625 92 (0.52) 638 90 (0.57) 585
6750 91 (0.51) 631 89 (0.57) 578
6875 91 (0.51) 626 89 (0.56) 574
7000 91 (0.51) 624 88 (0.56) 573
7125 90 (0.51) 625 88 (0.56) 573
7250 Or More 90 (0.50) 625 88 (0.56) 573

HC ppm (CO
1750 224 (1.26) 1819 216 (1.22) 1642
1875 212 (1.19) 1713 205 (1.16) 1547
2000 201 (1.13) 1616 194 (1.09) 1460
2125 191 (1.07) 1527 184 (1.04) 1380
2250 182 (1.02) 1446 175 (0.99) 1307
2375 173 (0.97) 1372 167 (0.94) 1240
2500 166 (0.93) 1304 160 (0.90) 1179
2625 159 (0.89) 1242 153 (0.86) 1123
2750 152 (0.85) 1186 147 (0.82) 1072
2875 146 (0.82) 1134 141 (0.79) 1026
3000 141 (0.79) 1088 136 (0.76) 984
3125 136 (0.76) 1045 132 (0.73) 945
3250 132 (0.73) 1006 127 (0.71) 910
3375 128 (0.71) 970 123 (0.69) 878
3500 124 (0.69) 937 120 (0.67) 848
3625 120 (0.67) 907 117 (0.65) 821
3750 117 (0.65) 879 114 (0.63) 796
3875 114 (0.63) 853 111 (0.61) 773
4000 112 (0.62) 829 108 (0.60) 751
4125 109 (0.60) 807 106 (0.58) 731
4250 107 (0.59) 786 103 (0.57) 712
4375 104 (0.58) 766 101 (0.56) 694
4500 102 (0.57) 747 99 (0.55) 677
4625 100 (0.55) 728 97 (0.54) 661
4750 98 (0.54) 711 95 (0.53) 645
4875 96 (0.53) 694 93 (0.52) 630
5000 94 (0.52) 677 92 (0.51) 615
5125 93 (0.51) 661 90 (0.50) 600
5250 91 (0.50) 646 88 (0.49) 586
5375 89 (0.49) 631 86 (0.48) 573

5500 87 (0.48) 616 85 (0.47) 559
5625 86 (0.47) 601 83 (0.46) 546
5750 84 (0.46) 587 82 (0.45) 534
5875 83 (0.45) 574 80 (0.44) 522
6000 81 (0.44) 561 79 (0.44) 510
6125 80 (0.44) 549 78 (0.43) 499
6250 79 (0.43) 538 76 (0.42) 489
6375 77 (0.42) 528 75 (0.42) 480
6500 76 (0.42) 519 74 (0.41) 473
6625 76 (0.41) 512 74 (0.41) 466
6750 75 (0.41) 507 73 (0.41) 461
6875 75 (0.40) 503 73 (0.40) 458
7000 Or More 74 (0.40) 502 72 (0.40) 457
U.S. EPA ASM EMISSION STANDARDS - 1994 & NEWER + TIER 1 LIGHT DUTY VEHICLES
1750 142 (0.80) 1212 136 (0.77) 1095
1875 134 (0.75) 1142 129 (0.73) 1031
2000 127 (0.71) 1077 123 (0.69) 973
2125 121 (0.68) 1018 116 (0.66) 920
2250 115 (0.64) 964 111 (0.62) 871
2375 109 (0.61) 915 106 (0.59) 827
2500 105 (0.59) 869 101 (0.57) 786
2625 100 (0.56) 828 97 (0.54) 749
2750 96 (0.54) 791 93 (0.52) 715
2875 92 (0.52) 756 89 (0.50) 684
3000 89 (0.50) 725 86 (0.48) 656
3125 86 (0.48) 696 83 (0.46) 630
3250 83 (0.46) 670 80 (0.45) 607
3375 81 (0.45) 647 78 (0.43) 585
3500 78 (0.44) 625 76 (0.42) 566

3625 76 (0.42) 605 74 (0.41) 547
3750 74 (0.41) 586 72 (0.40) 531
3875 72 (0.40) 569 70 (0.39) 515
4000 71 (0.39) 553 68 (0.38) 501
4125 69 (0.38) 538 67 (0.37) 487
4250 67 (0.37) 524 65 (0.36) 475
4375 66 (0.36) 510 64 (0.35) 463
4500 65 (0.36) 498 63 (0.35) 440
4625 63 (0.35) 486 61 (0.34) 440
4750 62 (0.34) 474 60 (0.33) 430
4875 61 (0.34) 463 59 (0.33) 420
5000 60 (0.33) 452 58 (0.32) 410
5125 58 (0.32) 441 57 (0.31) 400
5250 57 (0.32) 431 56 (0.31) 391
5375 56 (0.31) 420 55 (0.30) 382
5500 55 (0.30) 410 54 (0.30) 373
5625 54 (0.30) 401 53 (0.29) 364
5750 53 (0.29) 391 52 (0.29) 356
5875 52 (0.29) 383 51 (0.28) 348
6000 51 (0.28) 374 50 (0.28) 340
6125 50 (0.28) 366 49 (0.27) 333
6250 50 (0.27) 359 48 (0.27) 326
6375 49 (0.27) 352 48 (0.26) 320
6500 48 (0.26) 346 47 (0.26) 315
6625 48 (0.26) 341 46 (0.26) 311
6750 47 (0.26) 338 46 (0.26) 307
6875 47 (0.26) 335 46 (0.25) 305
7000 Or More 47 (0.25) 335 46 (0.25) 305
U.S. EPA ASM EMISSION STANDARDS - 1968-72 LIGHT DUTY TRUCKS (6000 GVWR OR LESS)
HC ppm (CO
1750 1118 (8.02) 4990 1098 (9.90) 4990
1875 1052 (7.56) 4990 1034 (9.90) 4990
2000 992 (7.14) 4990 975 (9.90) 4990
2125 938 (6.75) 4990 921 (9.66) 4990
2250 887 (6.40) 4990 872 (9.14) 4990
2375 841 (6.07) 4990 827 (8.67) 4990
2500 800 (5.78) 4990 786 (8.25) 4990
2625 761 (5.51) 4990 748 (7.85) 4990
2750 726 (5.26) 4990 714 (7.50) 4772
2875 695 (5.03) 4892 683 (7.17) 4556
3000 666 (4.83) 4680 654 (6.87) 4359
3125 639 (4.64) 4488 628 (6.60) 4180
3250 615 (4.47) 4311 604 (6.35) 4016
3375 593 (4.31) 4150 583 (6.13) 3866
3500 573 (4.17) 4002 563 (5.92) 3728
3625 554 (4.04) 3867 544 (5.73) 3602
3750 537 (3.91) 3741 527 (5.55) 3485
3875 521 (3.80) 3625 512 (5.39) 3377
4000 506 (3.70) 3517 497 (5.24) 3276
4125 492 (3.60) 3416 484 (5.09) 3182
4250 479 (3.51) 3321 471 (4.96) 3094
4375 467 (3.42) 3230 459 (4.83) 3010
4500 455 (3.34) 3145 447 (4.71) 2930
4625 444 (3.26) 3063 436 (4.60) 2854
4750 433 (3.18) 2983 425 (4.49) 2780
4875 423 (3.11) 2907 415 (4.38) 2709
5000 412 (3.03) 2833 405 (4.28) 2540
5125 402 (2.97) 2760 395 (4.18) 2573
5250 393 (2.90) 2690 386 (4.08) 2507
5375 383 (2.83) 2621 376 (3.98) 2443
5500 374 (2.77) 2554 367 (3.89) 2381
5625 365 (2.70) 2489 359 (3.80) 2321
5750 357 (2.64) 2426 350 (3.71) 2262

5875 348 (2.59) 2366 342 (3.62) 2206
6000 341 (2.53) 2308 334 (3.54) 2152
6125 333 (2.48) 2254 327 (3.47) 2102
6250 326 (2.43) 2204 320 (3.40) 2056
6375 320 (2.39) 2159 314 (3.34) 2014
6500 315 (2.35) 2119 309 (3.28) 1977
6625 310 (2.32) 2087 304 (3.23) 1947
6750 307 (2.29) 2062 301 (3.20) 1924
6875 305 (2.28) 2046 299 (3.17) 1909
7000 304 (2.27) 2040 298 (3.17) 1904
7125 Or More 304 (2.27) 2045 298 (3.17) 1904
1750 1118 (8.02) 4990 1098 (9.90) 4980
1875 1052 (7.56) 4990 1034 (9.90) 4906
2000 992 (7.14) 4919 975 (9.90) 4838
2125 938 (6.75) 4853 921 (9.66) 4776
2250 887 (6.40) 4792 872 (9.14) 4720
2375 841 (6.07) 4736 827 (8.67) 4668
2500 800 (5.78) 4685 786 (8.25) 4620
2625 761 (5.51) 4639 748 (7.85) 4577
2750 726 (5.26) 4596 714 (7.50) 4374
2875 695 (5.03) 4484 683 (7.17) 4176
3000 666 (4.83) 4290 654 (6.87) 3996
3125 639 (4.64) 4114 628 (6.60) 3832
3250 615 (4.47) 3952 604 (6.35) 3681
3375 593 (4.31) 3804 583 (6.13) 3544
3500 573 (4.17) 3669 563 (5.92) 3418
3625 554 (4.04) 3544 544 (5.73) 3302
3750 537 (3.91) 3429 527 (5.55) 3195

3875 521 (3.80) 3323 512 (5.39) 3096
4000 506 (3.70) 3224 497 (5.24) 3003
4125 492 (3.60) 3131 484 (5.09) 2917
4250 479 (3.51) 3044 471 (4.96) 2836
4375 467 (3.42) 2961 459 (4.83) 2759
4500 455 (3.34) 2883 447 (4.71) 2686
4625 444 (3.26) 2807 436 (4.60) 2616
4750 433 (3.18) 2735 425 (4.49) 2549
4875 423 (3.11) 2665 415 (4.38) 2483
5000 412 (3.03) 2597 405 (4.28) 2420
5125 402 (2.97) 2530 395 (4.18) 2359
5250 393 (2.90) 2466 386 (4.08) 2298
5375 383 (2.83) 2403 376 (3.98) 2240
5500 374 (2.77) 2341 367 (3.89) 2183
5625 365 (2.70) 2282 359 (3.80) 2127
5750 357 (2.64) 2224 350 (3.71) 2074
5875 348 (2.59) 2168 342 (3.62) 2022
6000 341 (2.53) 2116 334 (3.54) 1973
6125 333 (2.48) 2066 327 (3.47) 1927
6250 326 (2.43) 2020 320 (3.40) 1884
6375 320 (2.39) 1979 314 (3.34) 1846
6500 315 (2.35) 1943 309 (3.28) 1813
6625 310 (2.32) 1913 304 (3.23) 1785
6750 307 (2.29) 1890 301 (3.20) 1764
6875 305 (2.28) 1875 299 (3.17) 1750
7000 304 (2.27) 1870 298 (3.17) 1745
7125 Or More 304 (2.27) 1874 298 (3.17) 1745
1750 843 (5.07) 4990 828 (7.26) 4980

1875 794 (4.78) 4990 780 (6.84) 4906
2000 749 (4.51) 4919 736 (6.45) 4838
2125 707 (4.26) 4853 695 (6.10) 4776
2250 669 (4.04) 4792 658 (5.78) 4720
2375 635 (3.83) 4736 624 (5.48) 4668
2500 603 (3.65) 4685 593 (5.21) 4620
2625 574 (3.48) 4639 564 (4.96) 4577
2750 548 (3.32) 4596 539 (4.73) 4374
2875 524 (3.18) 4484 515 (4.53) 4176
3000 502 (3.05) 4290 493 (4.34) 3996
3125 482 (2.93) 4114 474 (4.17) 3832
3250 464 (2.82) 3952 456 (4.01) 3681
3375 447 (2.72) 3804 440 (3.87) 3544
3500 432 (2.63) 3669 424 (3.74) 3418
3625 418 (2.55) 3544 411 (3.62) 3302
3750 405 (2.47) 3429 398 (3.51) 3195
3875 393 (2.40) 3323 386 (3.40) 3096
4000 382 (2.33) 3224 375 (3.31) 3003
4125 371 (2.27) 3131 365 (3.22) 2917
4250 361 (2.21) 3044 355 (3.13) 2836
4375 352 (2.16) 2961 346 (3.05) 2759
4500 343 (2.11) 2883 337 (2.98) 2686
4625 335 (2.06) 2807 329 (2.90) 2616
4750 327 (2.01) 2735 321 (2.83) 2549
4875 319 (1.96) 2665 313 (2.77) 2483
5000 311 (1.92) 2597 305 (2.70) 2420
5125 304 (1.87) 2530 298 (2.64) 2359
5250 296 (1.83) 2466 291 (2.58) 2298
5375 289 (1.79) 2403 284 (2.51) 2240
5500 282 (1.75) 2341 277 (2.46) 2183
5625 276 (1.71) 2282 271 (2.40) 2127
5750 269 (1.67) 2224 264 (2.34) 2074
5875 263 (1.63) 2168 258 (2.29) 2022

6000 257 (1.60) 2116 252 (2.24) 1973
6125 251 (1.57) 2066 247 (2.19) 1927
6250 246 (1.54) 2020 242 (2.15) 1884
6375 242 (1.51) 1979 237 (2.11) 1846
6500 238 (1.48) 1943 233 (2.07) 1813
6625 234 (1.46) 1913 230 (2.04) 1785
6750 232 (1.45) 1890 227 (2.02) 1764
6875 230 (1.44) 1875 225 (2.00) 1750
7000 229 (1.43) 1870 225 (2.00) 1745
7125 Or More 229 (1.43) 1874 225 (2.00) 1745
1750 774 (4.31) 4990 761 (6.06) 4960
1875 729 (4.06) 4990 717 (5.70) 4738
2000 688 (3.83) 4778 676 (5.38) 4535
2125 650 (3.63) 4578 638 (5.09) 4349
2250 615 (3.44) 4395 604 (4.82) 4179
2375 583 (3.26) 4228 573 (4.57) 4024
2500 554 (3.10) 4076 544 (4.35) 3881
2625 528 (2.96) 3936 518 (4.14) 3752
2750 503 (2.83) 3809 495 (3.95) 3579
2875 481 (2.71) 3669 473 (3.78) 3417
3000 461 (2.60) 3510 453 (3.62) 3270
3125 443 (2.50) 3366 435 (3.48) 3135
3250 426 (2.40) 3234 419 (3.35) 3012
3375 411 (2.32) 3113 404 (3.23) 2899
3500 397 (2.24) 3002 390 (3.12) 2796
3625 384 (2.17) 2900 377 (3.02) 2701
3750 372 (2.11) 2806 365 (2.93) 2614
3875 361 (2.05) 2719 355 (2.58) 2533

4000 351 (1.99) 2638 345 (2.77) 2457
4125 341 (1.94) 2562 335 (2.69) 2387
4250 332 (1.89) 2490 326 (2.62) 2320
4375 323 (1.84) 2423 318 (2.55) 2258
4500 315 (1.80) 2359 310 (2.49) 2198
4625 308 (1.76) 2297 302 (2.43) 2140
4750 300 (1.72) 2238 295 (2.37) 2085
4875 293 (1.68) 2180 288 (2.32) 2032
5000 286 (1.64) 2125 281 (2.26) 1980
5125 279 (1.60) 2070 274 (2.21) 1930
5250 272 (1.56) 2017 267 (2.16) 1881
5375 26 (1.53) 1966 261 (2.11) 1833
5500 259 (1.49) 1916 255 (2.06) 1786
5625 253 (1.46) 1867 248 (2.01) 1740
5750 247 (1.43) 1820 243 (1.96) 1697
5875 241 (1.40) 1774 237 (1.92) 1654
6000 236 (1.37) 1731 232 (1.88) 1614
6125 231 (1.34) 1690 227 (1.84) 1577
6250 226 (1.31) 1653 222 (1.80) 1542
6375 222 (1.29) 1619 218 (1.77) 1510
6500 218 (1.27) 1590 214 (1.74) 1483
6625 215 (1.25) 1565 211 (1.72) 1460
6750 213 (1.24) 1546 209 (1.70) 1443
6875 211 (1.23) 1534 207 (1.68) 1432
7000 211 (1.23) 1530 207 (1.68) 1428
7125 Or More 211 (1.22) 1531 206 (1.68) 1428
1750 390 (3.54) 4990 381 (4.85) 4960
1875 368 (3.34) 4990 359 (4.57) 4738

2000 348 (3.16) 4778 339 (4.31) 4535
2125 329 (2.99) 4578 321 (4.08) 4349
2250 312 (2.83) 4395 305 (3.86) 4179
2375 297 (2.69) 4228 290 (3.66) 4024
2500 283 (2.56) 4076 276 (3.48) 3881
2625 270 (2.44) 3936 263 (3.32) 3752
2750 258 (2.33) 3809 252 (3.17) 3579
2875 247 (2.23) 3669 241 (3.03) 3417
3000 237 (2.14) 3510 232 (2.91) 3270
3125 228 (2.06) 3366 223 (2.79) 3135
3250 220 (1.99) 3234 215 (2.69) 3012
3375 213 (1.92) 3113 208 (2.60) 2899
3500 206 (1.86) 3002 201 (2.51) 2796
3625 200 (1.80) 2900 195 (2.43) 2701
3750 194 (1.74) 2806 189 (2.36) 2614
3875 188 (1.69) 2719 184 (2.29) 2533
4000 183 (1.65) 2638 179 (2.22) 2457
4125 179 (1.61) 2562 175 (2.16) 2387
4250 174 (1.56) 2490 170 (2.11) 2320
4375 170 (1.53) 2423 166 (2.06) 2258
4500 166 (1.49) 2359 162 (2.01) 2198
4625 162 (1.46) 2297 159 (1.96) 2140
4750 159 (1.42) 2238 155 (1.91) 2085
4875 155 (1.39) 2180 152 (1.87) 2032
5000 152 (1.36) 2125 148 (1.82) 1980
5125 148 (1.33) 2070 145 (1.78) 1930
5250 145 (1.30) 2017 142 (1.74) 1881
5375 142 (1.27) 1966 139 (1.70) 1833
5500 139 (1.24) 1916 136 (1.66) 1786
5625 136 (1.12) 1867 133 (1.62) 1740
5750 133 (1.19) 1820 130 (1.59) 1697
5875 130 (1.16) 1774 127 (1.55) 1654
6000 127 (1.14) 1731 124 (1.52) 1614

6125 125 (1.11) 1690 122 (1.49) 1577
6250 123 (1.09) 1653 120 (1.46) 1542
6375 120 (1.07) 1619 118 (1.43) 1510
6500 119 (1.06) 1590 116 (1.41) 1483
6625 117 (1.04) 1565 114 (1.39) 1460
6750 116 (1.03) 1546 113 (1.37) 1443
6875 115 (1.02) 1534 113 (1.36) 1432
7000 115 (1.02) 1530 112 (1.36) 1428
7125 Or More 115 (1.02) 1531 112 (1.36) 1428
1750 390 (3.54) 2725 381 (4.85) 2587
1875 368 (3.34) 2649 359 (4.57) 2435
2000 348 (3.16) 2499 339 (4.31) 2295
2125 329 (2.99) 2360 321 (4.08) 2167
2250 312 (2.83) 2232 305 (3.86) 2050
2375 297 (2.69) 2115 290 (3.66) 1943
2500 283 (2.56) 2009 276 (3.48) 1845
2625 270 (2.44) 1912 263 (3.32) 1756
2750 258 (2.33) 1823 252 (3.17) 1675
2875 247 (2.23) 1742 241 (3.03) 1601
3000 237 (2.14) 1668 232 (2.91) 1533
3125 228 (2.06) 1601 223 (2.79) 1471
3250 220 (1.99) 1539 215 (2.69) 1415
3375 213 (1.92) 1483 208 (2.60) 1363
3500 206 (1.86) 1432 201 (2.51) 1316
3625 200 (1.80) 1384 195 (2.43) 1273
3750 194 (1.74) 1340 189 (2.36) 1233
3875 188 (1.69) 1300 184 (2.29) 1195
4000 183 (1.65) 1262 179 (2.22) 1161

4125 179 (1.61) 1227 175 (2.16) 1126
4250 174 (1.56) 1194 170 (2.11) 1098
4375 170 (1.53) 1162 166 (2.06) 1069
4500 166 (1.49) 1132 162 (2.01) 1042
4625 162 (1.46) 1104 159 (1.96) 1015
4750 159 (1.42) 1076 155 (1.91) 990
4875 155 (1.39) 1049 152 (1.87) 966
5000 152 (1.36) 1023 148 (1.82) 942
5125 148 (1.33) 998 145 (1.78) 919
5250 145 (1.30) 974 142 (1.74) 896
5375 142 (1.27) 950 139 (1.70) 874
5500 139 (1.24) 926 136 (1.66) 853
5625 136 (1.12) 904 133 (1.62) 832
5750 133 (1.19) 882 130 (1.59) 812
5875 130 (1.16) 860 127 (1.55) 793
6000 127 (1.14) 840 124 (1.52) 774
6125 125 (1.11) 822 122 (1.49) 757
6250 123 (1.09) 804 120 (1.46) 741
6375 120 (1.07) 788 118 (1.43) 727
6500 119 (1.06) 775 116 (1.41) 714
6625 117 (1.04) 763 114 (1.39) 704
6750 116 (1.03) 755 113 (1.37) 696
6875 115 (1.02) 749 113 (1.36) 691
7000 Or More 115 (1.02) 747 112 (1.36) 689
1750 324 (2.78) 2272 315 (3.64) 2114
1875 306 (2.63) 2181 297 (3.43) 1991
2000 289 (2.48) 2058 281 (3.24) 1877
2125 274 (2.35) 1944 267 (3.06) 1774

2250 260 (2.23) 1839 253 (2.90) 1678
2375 247 (2.12) 1744 241 (2.76) 1592
2500 236 (2.02) 1657 230 (2.62) 1512
2625 225 (1.92) 1577 219 (2.50) 1440
2750 216 (1.84) 1504 210 (2.39) 1374
2875 207 (1.76) 1438 210 (2.29) 1313
3000 199 (1.69) 1378 194 (2.19) 1258
3125 191 (1.63) 1323 186 (2.11) 1208
3250 185 (1.57) 1273 180 (2.03) 1163
3375 179 (1.52) 1227 174 (1.96) 1121
3500 173 (1.47) 1184 169 (1.89) 1082
3625 168 (1.42) 1146 164 (1.84) 1047
3750 163 (1.38) 1110 159 (1.78) 1014
3875 159 (1.34) 1077 155 (1.73) 984
4000 155 (1.31) 1046 151 (1.68) 956
4125 151 (1.27) 1017 147 (1.64) 930
4250 147 (1.24) 990 143 (1.60) 905
4375 144 (1.21) 964 140 (1.56) 882
4500 141 (1.18) 939 137 (1.52) 859
4625 137 (1.15) 916 134 (1.48) 838
4750 134 (1.13) 893 131 (1.45) 818
4875 132 (1.10) 872 128 (1.42) 798
5000 129 (1.08) 850 126 (1.38) 778
5125 126 (1.05) 830 123 (1.35) 760
5250 123 (1.03) 810 120 (1.32) 741
5375 121 (1.01) 790 118 (1.29) 723
5500 118 (0.99) 771 115 (1.26) 706
5625 116 (0.97) 752 113 (1.24) 689
5750 113 (0.94) 734 111 (1.21) 673
5875 111 (0.92) 717 108 (1.18) 657
6000 109 (0.91) 701 106 (1.16) 642
6125 107 (0.89) 685 104 (1.13) 628
6250 105 (.087) 671 102 (1.11) 615

6375 103 (0.86) 658 101 (1.09) 604
6500 102 (0.84) 647 99 (1.08) 593
6625 101 (0.83) 638 98 (1.06) 585
6750 100 (0.82) 631 97 (1.05) 578
6875 99 (0.82) 626 97 (1.04) 574
7000 99 (0.82) 624 96 (1.04) 573
7125 Or More 98 (0.81) 625 96 (1.04) 573
U.S. EPA ASM EMISSION STANDARDS - 1994 + TIER 1 LIGHT DUTY TRUCKS (3750 LVW OR LESS)
1750 142 (0.80) 1212 136 (0.77) 1095
1875 134 (0.75) 1142 129 (0.73) 1031
2000 127 (0.71) 1077 123 (0.69) 973
2125 121 (0.68) 1018 116 (0.66) 920
2250 115 (0.64) 964 111 (0.62) 871
2375 109 (0.61) 915 106 (0.59) 827
2500 105 (0.59) 869 101 (0.57) 786
2625 100 (0.56) 828 97 (0.54) 749
2750 96 (0.54) 791 93 (0.52) 715
2875 92 (0.52) 756 89 (0.50) 684
3000 89 (0.50) 725 86 (0.48) 656
3125 86 (0.48) 696 83 (0.46) 630
3250 83 (0.46) 670 80 (0.45) 607
3375 81 (0.45) 647 78 (0.43) 585
3500 78 (0.44) 625 76 (0.42) 566
3625 76 (0.42) 605 74 (0.41) 547
3750 74 (0.41) 586 72 (0.40) 531
3875 72 (0.40) 569 70 (0.39) 515
4000 71 (0.39) 553 68 (0.38) 501
4125 69 (0.38) 538 67 (0.37) 487
4250 67 (0.37) 524 65 (0.36) 475

4375 66 (0.36) 510 64 (0.35) 463
4500 65 (0.36) 498 63 (0.35) 440
4625 63 (0.35) 486 61 (0.34) 440
4750 62 (0.34) 474 60 (0.33) 430
4875 61 (0.34) 463 59 (0.33) 420
5000 60 (0.33) 452 58 (0.32) 410
5125 58 (0.32) 441 57 (0.31) 400
5250 57 (0.32) 431 56 (0.31) 391
5375 56 (0.31) 420 55 (0.30) 382
5500 55 (0.30) 410 54 (0.30) 373
5625 54 (0.30) 401 53 (0.29) 364
5750 53 (0.29) 391 52 (0.29) 356
5875 52 (0.29) 383 51 (0.28) 348
6000 51 (0.28) 374 50 (0.28) 340
6125 50 (0.28) 366 49 (0.27) 333
6250 50 (0.27) 359 48 (0.27) 326
6375 49 (0.27) 352 48 (0.26) 320
6500 48 (0.26) 346 47 (0.26) 315
6625 48 (0.26) 341 46 (0.26) 311
6750 47 (0.26) 338 46 (0.26) 307
6875 47 (0.26) 335 46 (0.25) 305
7000 Or More 47 (0.25) 335 46 (0.25) 305
U.S. EPA ASM EMISSION STANDARDS - 1994 + TIER 1 LIGHT DUTY TRUCKS (3751 LVW OR MORE)
1750 224 (1.26) 1819 216 (1.22) 1642
1875 212 (1.19) 1713 205 (1.16) 1547
2000 201 (1.13) 1616 194 (1.09) 1460
2125 191 (1.07) 1527 184 (1.04) 1380
2250 182 (1.02) 1446 175 (0.99) 1307
2375 173 (0.97) 1372 167 (0.94) 1240

2500 166 (0.93) 1304 160 (0.90) 1179
2625 159 (0.89) 1242 153 (0.86) 1123
2750 152 (0.85) 1186 147 (0.82) 1072
2875 146 (0.82) 1134 141 (0.79) 1026
3000 141 (0.79) 1088 136 (0.76) 984
3125 136 (0.76) 1045 132 (0.73) 945
3250 132 (0.73) 1006 127 (0.71) 910
3375 128 (0.71) 970 123 (0.69) 878
3500 124 (0.69) 937 120 (0.67) 848
3625 120 (0.67) 907 117 (0.65) 821
3750 117 (0.65) 879 114 (0.63) 796
3875 114 (0.63) 853 111 (0.61) 773
4000 112 (0.62) 829 108 (0.60) 751
4125 109 (0.60) 807 106 (0.58) 731
4250 107 (0.59) 786 103 (0.57) 712
4375 104 (0.58) 766 101 (0.56) 694
4500 102 (0.57) 747 99 (0.55) 677
4625 100 (0.55) 728 97 (0.54) 661
4750 98 (0.54) 711 95 (0.53) 645
4875 96 (0.53) 694 93 (0.52) 630
5000 94 (0.52) 677 92 (0.51) 615
5125 93 (0.51) 661 90 (0.50) 600
5250 91 (0.50) 646 88 (0.49) 586
5375 89 (0.49) 631 86 (0.48) 573
5500 87 (0.48) 616 85 (0.47) 559
5625 86 (0.47) 601 83 (0.46) 546
5750 84 (0.46) 587 82 (0.45) 534
5875 83 (0.45) 574 80 (0.44) 522
6000 81 (0.44) 561 79 (0.44) 510
6125 80 (0.44) 549 78 (0.43) 499
6250 79 (0.43) 538 76 (0.42) 489
6375 77 (0.42) 528 75 (0.42) 480
6500 76 (0.42) 519 74 (0.41) 473

6625 76 (0.41) 512 74 (0.41) 466
6750 75 (0.41) 507 73 (0.41) 461
6875 75 (0.40) 503 73 (0.40) 458
7000 Or More 74 (0.40) 502 72 (0.40) 457
U.S. EPA ASM EMISSION STANDARDS - 1968-72 LIGHT DUTY TRUCKS (6001 GVWR OR MORE)
1750 1118 (8.02) 4990 1098 (9.90) 4990
1875 1052 (7.56) 4990 1034 (9.90) 4990
2000 992 (7.14) 4990 975 (9.90) 4990
2125 938 (6.75) 4990 921 (9.66) 4990
2250 887 (6.40) 4990 872 (9.14) 4990
2375 841 (6.07) 4990 827 (8.67) 4990
2500 800 (5.78) 4990 786 (8.25) 4990
2625 761 (5.51) 4990 748 (7.85) 4990
2750 726 (5.26) 4990 714 (7.50) 4772
2875 695 (5.03) 4892 683 (7.17) 4556
3000 666 (4.83) 4680 654 (6.87) 4359
3125 639 (4.64) 4488 628 (6.60) 4180
3250 615 (4.47) 4311 604 (6.35) 4016
3375 593 (4.31) 4150 583 (6.13) 3866
3500 573 (4.17) 4002 563 (5.92) 3728
3625 554 (4.04) 3867 544 (5.73) 3602
3750 537 (3.91) 3741 527 (5.55) 3485
3875 521 (3.80) 3625 512 (5.39) 3377
4000 506 (3.70) 3517 497 (5.24) 3276
4125 492 (3.60) 3416 484 (5.09) 3182
4250 479 (3.51) 3321 471 (4.96) 3094
4375 467 (3.42) 3230 459 (4.83) 3010
4500 455 (3.34) 3145 447 (4.71) 2930
4625 444 (3.26) 3063 436 (4.60) 2854

4750 433 (3.18) 2983 425 (4.49) 2780
4875 423 (3.11) 2907 415 (4.38) 2709
5000 412 (3.03) 2833 405 (4.28) 2640
5125 402 (2.97) 2760 395 (4.18) 2573
5250 393 (2.90) 2690 386 (4.08) 2507
5375 383 (2.83) 2621 376 (3.98) 2443
5500 374 (2.77) 2554 367 (3.89) 2381
5625 365 (2.70) 2489 359 (3.80) 2321
5750 357 (2.64) 2426 350 (3.71) 2262
5875 348 (2.59) 2366 342 (3.62) 2206
6000 341 (2.53) 2308 334 (3.54) 2152
6125 333 (2.48) 2254 327 (3.47) 2102
6250 326 (2.43) 2204 320 (3.40) 2056
6375 320 (2.39) 2159 314 (3.34) 2014
6500 315 (2.35) 2119 309 (3.28) 1977
6625 310 (2.32) 2087 304 (3.23) 1947
6750 307 (2.29) 2062 301 (3.20) 1924
6875 305 (2.28) 2046 299 (3.17) 1909
7000 304 (2.27) 2040 298 (3.17) 1904
7125 Or More 304 (2.27) 2045 298 (3.17) 1904
1750 1118 (8.02) 4990 1098 (9.90) 4980
1875 1052 (7.56) 4990 1034 (9.90) 4906
2000 992 (7.14) 4919 975 (9.90) 4838
2125 938 (6.75) 4853 921 (9.66) 4776
2250 887 (6.40) 4792 872 (9.14) 4720
2375 841 (6.07) 4736 827 (8.67) 4668
2500 800 (5.78) 4685 786 (8.25) 4620
2625 761 (5.51) 4639 748 (7.85) 4577

2750 726 (5.26) 4596 714 (7.50) 4374
2875 695 (5.03) 4484 683 (7.17) 4176
3000 666 (4.83) 4290 654 (6.87) 3996
3125 639 (4.64) 4114 628 (6.60) 3832
3250 615 (4.47) 3952 604 (6.35) 3681
3375 593 (4.31) 3804 583 (6.13) 3544
3500 573 (4.17) 3669 563 (5.92) 3418
3625 554 (4.04) 3544 544 (5.73) 3302
3750 537 (3.91) 3429 527 (5.55) 3195
3875 521 (3.80) 3323 512 (5.39) 3096
4000 506 (3.70) 3224 497 (5.24) 3003
4125 492 (3.60) 3131 484 (5.09) 2917
4250 479 (3.51) 3044 471 (4.96) 2836
4375 467 (3.42) 2961 459 (4.83) 2759
4500 455 (3.34) 2883 447 (4.71) 2686
4625 444 (3.26) 2807 436 (4.60) 2616
4750 433 (3.18) 2735 425 (4.49) 2549
4875 423 (3.11) 2665 415 (4.38) 2483
5000 412 (3.03) 2597 405 (4.28) 2420
5125 402 (2.97) 2530 395 (4.18) 2359
5250 393 (2.90) 2466 386 (4.08) 2298
5375 383 (2.83) 2403 376 (3.98) 2240
5500 374 (2.77) 2341 367 (3.89) 2183
5625 365 (2.70) 2282 359 (3.80) 2127
5750 357 (2.64) 2224 350 (3.71) 2074
5875 348 (2.59) 2168 342 (3.62) 2022
6000 341 (2.53) 2116 334 (3.54) 1973
6125 333 (2.48) 2066 327 (3.47) 1927
6250 326 (2.43) 2020 320 (3.40) 1884
6375 320 (2.39) 1979 314 (3.34) 1846
6500 315 (2.35) 1943 309 (3.28) 1813
6625 310 (2.32) 1913 304 (3.23) 1785
6750 307 (2.29) 1890 301 (3.20) 1764

6875 305 (2.28) 1875 299 (3.17) 1750
7000 304 (2.27) 1870 298 (3.17) 1745
7125 Or More 304 (2.27) 1874 298 (3.17) 1745
1750 843 (5.07) 4990 828 (7.26) 4980
1875 794 (4.78) 4990 780 (6.84) 4906
2000 749 (4.51) 4919 736 (6.45) 4838
2125 707 (4.26) 4853 695 (6.10) 4776
2250 669 (4.04) 4792 658 (5.78) 4720
2375 635 (3.83) 4736 624 (5.48) 4668
2500 603 (3.65) 4685 593 (5.21) 4620
2625 574 (3.48) 4639 564 (4.96) 4577
2750 548 (3.32) 4596 539 (4.73) 4374
2875 524 (3.18) 4484 515 (4.53) 4176
3000 502 (3.05) 4290 493 (4.34) 3996
3125 482 (2.93) 4114 474 (4.17) 3832
3250 464 (2.82) 3952 456 (4.01) 3681
3375 447 (2.72) 3804 440 (3.87) 3544
3500 432 (2.63) 3669 424 (3.74) 3418
3625 418 (2.55) 3544 411 (3.62) 3302
3750 405 (2.47) 3429 398 (3.51) 3195
3875 393 (2.40) 3323 386 (3.40) 3096
4000 382 (2.33) 3224 375 (3.31) 3003
4125 371 (2.27) 3131 365 (3.22) 2917
4250 361 (2.21) 3044 355 (3.13) 2836
4375 352 (2.16) 2961 346 (3.05) 2759
4500 343 (2.11) 2883 337 (2.98) 2686
4625 335 (2.06) 2807 329 (2.90) 2616
4750 327 (2.01) 2735 321 (2.83) 2549

4875 319 (1.96) 2665 313 (2.77) 2483
5000 311 (1.92) 2597 305 (2.70) 2420
5125 304 (1.87) 2530 298 (2.64) 2359
5250 296 (1.83) 2466 291 (2.58) 2298
5375 289 (1.79) 2403 284 (2.51) 2240
5500 282 (1.75) 2341 277 (2.46) 2183
5625 276 (1.71) 2282 271 (2.40) 2127
5750 269 (1.67) 2224 264 (2.34) 2074
5875 263 (1.63) 2168 258 (2.29) 2022
6000 257 (1.60) 2116 252 (2.24) 1973
6125 251 (1.57) 2066 247 (2.19) 1927
6250 246 (1.54) 2020 242 (2.15) 1884
6375 242 (1.51) 1979 237 (2.11) 1846
6500 238 (1.48) 1943 233 (2.07) 1813
6625 234 (1.46) 1913 230 (2.04) 1785
6750 232 (1.45) 1890 227 (2.02) 1764
6875 230 (1.44) 1875 225 (2.00) 1750
7000 229 (1.43) 1870 225 (2.00) 1745
7125 Or More 229 (1.43) 1874 225 (2.00) 1745
1750 774 (4.31) 4990 761 (6.06) 4960
1875 729 (4.06) 4990 717 (5.70) 4738
2000 688 (3.83) 4778 676 (5.38) 4535
2125 650 (3.63) 4578 638 (5.09) 4349
2250 615 (3.44) 4395 604 (4.82) 4179
2375 583 (3.26) 4228 573 (4.57) 4024
2500 554 (3.10) 4076 544 (4.35) 3881
2625 528 (2.96) 3936 518 (4.14) 3752
2750 503 (2.83) 3809 495 (3.95) 3579

2875 481 (2.71) 3669 473 (3.78) 3417
3000 461 (2.60) 3510 453 (3.62) 3270
3125 443 (2.50) 3366 435 (3.48) 3135
3250 426 (2.40) 3234 419 (3.35) 3012
3375 411 (2.32) 3113 404 (3.23) 2899
3500 397 (2.24) 3002 390 (3.12) 2796
3625 384 (2.17) 2900 377 (3.02) 2701
3750 372 (2.11) 2806 365 (2.93) 2614
3875 361 (2.05) 2719 355 (2.58) 2533
4000 351 (1.99) 2638 345 (2.77) 2457
4125 341 (1.94) 2562 335 (2.69) 2387
4250 332 (1.89) 2490 326 (2.62) 2320
4375 323 (1.84) 2423 318 (2.55) 2258
4500 315 (1.80) 2359 310 (2.49) 2198
4625 308 (1.76) 2297 302 (2.43) 2140
4750 300 (1.72) 2238 295 (2.37) 2085
4875 293 (1.68) 2180 288 (2.32) 2032
5000 286 (1.64) 2125 281 (2.26) 1980
5125 279 (1.60) 2070 274 (2.21) 1930
5250 272 (1.56) 2017 267 (2.16) 1881
5375 26 (1.53) 1966 261 (2.11) 1833
5500 259 (1.49) 1916 255 (2.06) 1786
5625 253 (1.46) 1867 248 (2.01) 1740
5750 247 (1.43) 1820 243 (1.96) 1697
5875 241 (1.40) 1774 237 (1.92) 1654
6000 236 (1.37) 1731 232 (1.88) 1614
6125 231 (1.34) 1690 227 (1.84) 1577
6250 226 (1.31) 1653 222 (1.80) 1542
6375 222 (1.29) 1619 218 (1.77) 1510
6500 218 (1.27) 1590 214 (1.74) 1483
6625 215 (1.25) 1565 211 (1.72) 1460
6750 213 (1.24) 1546 209 (1.70) 1443
6875 211 (1.23) 1534 207 (1.68) 1432

7000 211 (1.23) 1530 207 (1.68) 1428
7125 Or More 211 (1.22) 1531 206 (1.68) 1428
1750 390 (3.54) 4990 381 (4.85) 4960
1875 368 (3.34) 4990 359 (4.57) 4738
2000 348 (3.16) 4778 339 (4.31) 4535
2125 329 (2.99) 4578 321 (4.08) 4349
2250 312 (2.83) 4395 305 (3.86) 4179
2375 297 (2.69) 4228 290 (3.66) 4024
2500 283 (2.56) 4076 276 (3.48) 3881
2625 270 (2.44) 3936 263 (3.32) 3752
2750 258 (2.33) 3809 252 (3.17) 3579
2875 247 (2.23) 3669 241 (3.03) 3417
3000 237 (2.14) 3510 232 (2.91) 3270
3125 228 (2.06) 3366 223 (2.79) 3135
3250 220 (1.99) 3234 215 (2.69) 3012
3375 213 (1.92) 3113 208 (2.60) 2899
3500 206 (1.86) 3002 201 (2.51) 2796
3625 200 (1.80) 2900 195 (2.43) 2701
3750 194 (1.74) 2806 189 (2.36) 2614
3875 188 (1.69) 2719 184 (2.29) 2533
4000 183 (1.65) 2638 179 (2.22) 2457
4125 179 (1.61) 2562 175 (2.16) 2387
4250 174 (1.56) 2490 170 (2.11) 2320
4375 170 (1.53) 2423 166 (2.06) 2258
4500 166 (1.49) 2359 162 (2.01) 2198
4625 162 (1.46) 2297 159 (1.96) 2140
4750 159 (1.42) 2238 155 (1.91) 2085
4875 155 (1.39) 2180 152 (1.87) 2032

5000 152 (1.36) 2125 148 (1.82) 1980
5125 148 (1.33) 2070 145 (1.78) 1930
5250 145 (1.30) 2017 142 (1.74) 1881
5375 142 (1.27) 1966 139 (1.70) 1833
5500 139 (1.24) 1916 136 (1.66) 1786
5625 136 (1.12) 1867 133 (1.62) 1740
5750 133 (1.19) 1820 130 (1.59) 1697
5875 130 (1.16) 1774 127 (1.55) 1654
6000 127 (1.14) 1731 124 (1.52) 1614
6125 125 (1.11) 1690 122 (1.49) 1577
6250 123 (1.09) 1653 120 (1.46) 1542
6375 120 (1.07) 1619 118 (1.43) 1510
6500 119 (1.06) 1590 116 (1.41) 1483
6625 117 (1.04) 1565 114 (1.39) 1460
6750 116 (1.03) 1546 113 (1.37) 1443
6875 115 (1.02) 1534 113 (1.36) 1432
7000 115 (1.02) 1530 112 (1.36) 1428
7125 Or More 115 (1.02) 1531 112 (1.36) 1428
1750 390 (3.54) 4084 381 (4.85) 4005
1875 368 (3.34) 4054 359 (4.57) 3767
2000 348 (3.16) 3824 339 (4.31) 3548
2125 329 (2.99) 3609 321 (4.08) 3348
2250 312 (2.83) 3411 305 (3.86) 3165
2375 297 (2.69) 3231 290 (3.66) 2998
2500 283 (2.56) 3066 276 (3.48) 2845
2625 270 (2.44) 2916 263 (3.32) 2706
2750 258 (2.33) 2779 252 (3.17) 2579
2875 247 (2.23) 2654 241 (3.03) 2463

3000 237 (2.14) 2539 232 (2.91) 2357
3125 228 (2.06) 2435 223 (2.79) 2260
3250 220 (1.99) 2340 215 (2.69) 2172
3375 213 (1.92) 2253 208 (2.60) 2092
3500 206 (1.86) 2174 201 (2.51) 2018
3625 200 (1.80) 2100 195 (2.43) 1950
3750 194 (1.74) 2033 189 (2.36) 1887
3875 188 (1.69) 1970 184 (2.29) 1829
4000 183 (1.65) 1912 179 (2.22) 1775
4125 179 (1.61) 1857 175 (2.16) 1724
4250 174 (1.56) 1806 170 (2.11) 1677
4375 170 (1.53) 1757 166 (2.06) 1632
4500 166 (1.49) 1711 162 (2.01) 1589
4625 162 (1.46) 1666 159 (1.96) 1548
4750 159 (1.42) 1624 155 (1.91) 1508
4875 155 (1.39) 1583 152 (1.87) 1470
5000 152 (1.36) 1542 148 (1.82) 1433
5125 148 (1.33) 1503 145 (1.78) 1397
5250 145 (1.30) 1465 142 (1.74) 1362
5375 142 (1.27) 1428 139 (1.70) 1327
5500 139 (1.24) 1392 136 (1.66) 1294
5625 136 (1.12) 1357 133 (1.62) 1261
5750 133 (1.19) 1323 130 (1.59) 1230
5875 130 (1.16) 1290 127 (1.55) 1199
6000 127 (1.14) 1259 124 (1.52) 1171
6125 125 (1.11) 1230 122 (1.49) 1144
6250 123 (1.09) 1203 120 (1.46) 1119
6375 120 (1.07) 1179 118 (1.43) 1096
6500 119 (1.06) 1158 116 (1.41) 1077
6625 117 (1.04) 1140 114 (1.39) 1060
6750 116 (1.03) 1127 113 (1.37) 1048
6875 115 (1.02) 1118 113 (1.36) 1040
7000 Or More 115 (1.02) 1115 112 (1.36) 1037

1750 324 (2.78) 3631 315 (3.64) 3532
1875 306 (2.63) 3586 297 (3.43) 3323
2000 289 (2.48) 3383 281 (3.24) 3131
2125 274 (2.35) 3192 267 (3.06) 2955
2250 260 (2.23) 3018 253 (2.90) 2794
2375 247 (2.12) 2859 241 (2.76) 2646
2500 236 (2.02) 2714 230 (2.62) 2512
2625 225 (1.92) 2581 219 (2.50) 2389
2750 216 (1.84) 2460 210 (2.39) 2277
2875 207 (1.76) 2350 210 (2.29) 2175
3000 199 (1.69) 2249 194 (2.19) 2082
3125 191 (1.63) 2157 186 (2.11) 1997
3250 185 (1.57) 2073 180 (2.03) 1920
3375 179 (1.52) 1997 174 (1.96) 1849
3500 173 (1.47) 1926 169 (1.89) 1784
3625 168 (1.42) 1862 164 (1.84) 1724
3750 163 (1.38) 1802 159 (1.78) 1669
3875 159 (1.34) 1747 155 (1.73) 1618
4000 155 (1.31) 1695 151 (1.68) 1570
4125 151 (1.27) 1647 147 (1.64) 1526
4250 147 (1.24) 1602 143 (1.60) 1484
4375 144 (1.21) 1559 140 (1.56) 1444
4500 141 (1.18) 1518 137 (1.52) 1406
4625 137 (1.15) 1479 134 (1.48) 1370
4750 134 (1.13) 1441 131 (1.45) 1336
4875 132 (1.10) 1405 128 (1.42) 1302
5000 129 (1.08) 1369 126 (1.38) 1269
5125 126 (1.05) 1335 123 (1.35) 1237
5250 123 (1.03) 1031 120 (1.32) 1206

5375 121 (1.01) 1269 118 (1.29) 1176
5500 118 (0.99) 1237 115 (1.26) 1147
5625 116 (0.97) 1206 113 (1.24) 1118
5750 113 (0.94) 1176 111 (1.21) 1090
5875 111 (0.92) 1147 108 (1.18) 1064
6000 109 (0.91) 1120 106 (1.16) 1039
6125 107 (0.89) 1094 104 (1.13) 1015
6250 105 (.087) 1070 102 (1.11) 993
6375 103 (0.86) 1049 101 (1.09) 973
6500 102 (0.84) 1030 99 (1.08) 956
6625 101 (0.83) 1014 98 (1.06) 941
6750 100 (0.82) 1003 97 (1.05) 931
6875 99 (0.82) 995 97 (1.04) 924
7000 99 (0.82) 992 96 (1.04) 921
7125 Or More 98 (0.81) 992 96 (1.04) 921
U.S. EPA ASM EMISSION STANDARDS - 1994 + TIER 1 LIGHT DUTY TRUCKS (5750 LVW OR LESS)
1750 224 (1.26) 1819 216 (1.22) 1642
1875 212 (1.19) 1713 205 (1.16) 1547
2000 201 (1.13) 1616 194 (1.09) 1460
2125 191 (1.07) 1527 184 (1.04) 1380
2250 182 (1.02) 1446 175 (0.99) 1307
2375 173 (0.97) 1372 167 (0.94) 1240
2500 166 (0.93) 1304 160 (0.90) 1179
2625 159 (0.89) 1242 153 (0.86) 1123
2750 152 (0.85) 1186 147 (0.82) 1072
2875 146 (0.82) 1134 141 (0.79) 1026
3000 141 (0.79) 1088 136 (0.76) 984
3125 136 (0.76) 1045 132 (0.73) 945
3250 132 (0.73) 1006 127 (0.71) 910

3375 128 (0.71) 970 123 (0.69) 878
3500 124 (0.69) 937 120 (0.67) 848
3625 120 (0.67) 907 117 (0.65) 821
3750 117 (0.65) 879 114 (0.63) 796
3875 114 (0.63) 853 111 (0.61) 773
4000 112 (0.62) 829 108 (0.60) 751
4125 109 (0.60) 807 106 (0.58) 731
4250 107 (0.59) 786 103 (0.57) 712
4375 104 (0.58) 766 101 (0.56) 694
4500 102 (0.57) 747 99 (0.55) 677
4625 100 (0.55) 728 97 (0.54) 661
4750 98 (0.54) 711 95 (0.53) 645
4875 96 (0.53) 694 93 (0.52) 630
5000 94 (0.52) 677 92 (0.51) 615
5125 93 (0.51) 661 90 (0.50) 600
5250 91 (0.50) 646 88 (0.49) 586
5375 89 (0.49) 631 86 (0.48) 573
5500 87 (0.48) 616 85 (0.47) 559
5625 86 (0.47) 601 83 (0.46) 546
5750 84 (0.46) 587 82 (0.45) 534
5875 83 (0.45) 574 80 (0.44) 522
6000 81 (0.44) 561 79 (0.44) 510
6125 80 (0.44) 549 78 (0.43) 499
6250 79 (0.43) 538 76 (0.42) 489
6375 77 (0.42) 528 75 (0.42) 480
6500 76 (0.42) 519 74 (0.41) 473
6625 76 (0.41) 512 74 (0.41) 466
6750 75 (0.41) 507 73 (0.41) 461
6875 75 (0.40) 503 73 (0.40) 458
7000 Or More 74 (0.40) 502 72 (0.40) 457
U.S. EPA ASM EMISSION STANDARDS - 1994 + TIER 1 LIGHT DUTY TRUCKS (5751 LVW OR MORE)
1750 324 (2.78) 3178 315 (3.64) 3060
1875 306 (2.63) 3117 297 (3.43) 2879
2000 289 (2.48) 2941 281 (3.24) 2713
2125 274 (2.35) 2776 267 (3.06) 2561
2250 260 (2.23) 2625 253 (2.90) 2422
2375 247 (2.12) 2487 241 (2.76) 2295
2500 236 (2.02) 2361 230 (2.62) 2179
2625 225 (1.92) 2246 219 (2.50) 2073
2750 216 (1.84) 2142 210 (2.39) 1976
2875 207 (1.76) 2046 210 (2.29) 1888
3000 199 (1.69) 1959 194 (2.19) 1808
3125 191 (1.63) 1879 186 (2.11) 1734
3250 185 (1.57) 1806 180 (2.03) 1667
3375 179 (1.52) 1740 174 (1.96) 1606
3500 173 (1.47) 1679 169 (1.89) 1550
3625 168 (1.42) 1623 164 (1.84) 1498
3750 163 (1.38) 1571 159 (1.78) 1451
3875 159 (1.34) 1523 155 (1.73) 1407
4000 155 (1.31) 1479 151 (1.68) 1365
4125 151 (1.27) 1437 147 (1.64) 1327
4250 147 (1.24) 1398 143 (1.60) 1291
4375 144 (1.21) 1360 140 (1.56) 1257
4500 141 (1.18) 1325 137 (1.52) 1224
4625 137 (1.15) 1291 134 (1.48) 1193
4750 134 (1.13) 1259 131 (1.45) 1163
4875 132 (1.10) 1227 128 (1.42) 1134
5000 129 (1.08) 1196 126 (1.38) 1106
5125 126 (1.05) 1167 123 (1.35) 1078
5250 123 (1.03) 1138 120 (1.32) 1051
5375 121 (1.01) 1109 118 (1.29) 1025

5500 118 (0.99) 1082 115 (1.26) 1000
5625 116 (0.97) 1055 113 (1.24) 975
5750 113 (0.94) 1029 111 (1.21) 951
5875 111 (0.92) 1004 108 (1.18) 928
6000 109 (0.91) 980 106 (1.16) 906
6125 107 (0.89) 958 104 (1.13) 886
6250 105 (.087) 937 102 (1.11) 867
6375 103 (0.86) 919 101 (1.09) 850
6500 102 (0.84) 902 99 (1.08) 835
6625 101 (0.83) 889 98 (1.06) 823
6750 100 (0.82) 879 97 (1.05) 813
6875 99 (0.82) 872 97 (1.04) 807
7000 99 (0.82) 870 96 (1.04) 805
7125 Or More 98 (0.81) 870 96 (1.04) 805
U. S. EPA REVISED FINAL ASM EMISSION STANDARDS (ASM5015 & ASM2525)
NOTE: EPA has not published a revised final standards for High Altitude, Light Duty
Trucks 2 (6000-8500 GVWR), or vehicles older than 1980 model year. EPA guidance as of
February 2003 states that a program may choose to use combinations of the Original and
the Revised Final Standards.
U.S. EPA REVISED FINAL ASM EMISSION STANDARDS
Application ASM5015 ASM2525
Passenger Cars
1980 275 8500 500 (2.3) 4750

(1.3)
1981-82 275 3600 500 (2.3) 3500

(1.3)
1983-89 275 3600 500 (1.6) 3500

(1.1)
1990 & 275 3600 300 (1.6) 3500

Newer (1.1)
Light Duty Trucks (Less Than 6000 GVWR)
1980-83 1140 14,145 340 32,200

(9.7) (23.28)
1984-87 537 14,145 160 32,200

(5.4) (12.96)
1988-95 537 7380 160 16,800

(5.4) (12.96)
1996 & 275 6150 82 (4.40) 14,000

Newer (1.1)
U.S. EPA IM240 EMISSION STANDARDS > START-UP STANDARDS
Start-up standards should be used during the first 2 years of program operation. Tier 1 standards are
recommended for all 1996 and newer vehicles and may be used for 1994 and newer vehicles certified to
Tier 1 standards as well.
U.S. EPA IM240 HYDROCARBONS EMISSION START-UP STANDARDS
Application Hydrocarbons (Grams/Mile)
Composite Phase 2
Light Duty Vehicles
1996 & Newer 0.80 0.50
1991-95 1.20 0.75
1983-90 2.00 1.25
1980-82 2.00 1.25
1975-79 7.50 5.00
1968-74 10.0 6.00
High Altitude Light Duty Vehicles
1983-84 2.00 1.25
1982 2.00 1.25
Light Duty Trucks (0-6000 Lbs. GVWR)
1996 & Newer (Less Than 3750 LVW) 0.80 0.50
1996 & Newer (More Than 3750 LVW) 1.00 0.63
1991-95 2.40 1.50
1984-90 3.20 2.00
1979-83 7.50 5.00

1975-78 8.00 5.00
1968-74 10.0 6.00
High Altitude Light Duty Trucks (0-6000 Lbs. GVWR)
1991 & Newer 3.00 2.00
1984-90 4.00 2.50
1982-83 8.00 5.00
1996 & Newer (Less Than 5750 ALVW) 1.00 0.63
1996 & Newer (More Than 5750 ALVW) 2.40 1.50
1991-95 2.40 1.50
1984-90 3.20 2.00
1979-83 7.50 5.00
1975-78 8.00 5.00
1968-74 10.0 6.00
1991 & Newer 3.00 2.00
1984-90 4.00 2.50
1982-83 8.00 5.00
Heavy Duty Trucks (Greater Than 8500 Lbs. GVWR)
1998 & Newer 2.00 1.30
1987-97 3.00 1.90
1985-86 5.00 3.10
1979-84 6.00 3.80
1970-78 10.0 6.30
1969 & Earlier 20.0 12.50
U.S. EPA IM240 CARBON MONOXIDE EMISSION START-UP STANDARDS
Application Carbon Monoxide (Grams/Mile)
Composite Phase 2
Light Duty Vehicles
1996 & Newer 15.0 12.0
1991-95 20.0 16.0

1983-90 30.0 24.0
1980-82 60.0 48.0
1975-79 90.0 72.0
1968-74 150.0 120.0
1983-84 60.0 48.0
1982 75.0 60.0
1991-95 60.0 48.0
1984-90 80.0 64.0
1979-83 100.0 80.0
1975-78 120.0 96.0
1968-74 150.0 120.0
1991 & Newer 70.0 56.0
1984-90 90.0 72.0
1982-83 130.0 104.0
1991-95 60.0 48.0
1984-90 80.0 64.0
1979-83 100.0 80.0
1975-78 120.0 96.0
1968-74 150.0 120.0
1991 & Newer 70.0 56.0
1984-90 90.0 72.0
1982-83 130.0 104.0
1998 & Newer 30.0 24.0

1987-97 60.0 48.0
1985-86 75.0 60.0
1979-84 100.0 80.0
1974-78 150.00 120.0
1970-73 175.00 140.00
1969 & Earlier 200.0 160.0
U.S. EPA IM240 OXIDES OF NITROGEN EMISSION START-UP STANDARDS
Application Oxides Of Nitrogen (Grams/Mile)
Composite Phase 2
Light Duty Vehicles
1996 & Newer 2.0 2.0
1991-95 2.5 2.5
1981-90 3.0 3.0
1977-80 6.0 6.0
1973-76 9.0 9.0
1968-72 10.0 10.0
1982-84 3.0 3.0
1991-95 3.0 3.0
1988-90 3.5 3.5
1979-87 7.0 7.0
1973-78 9.0 9.0
1968-72 10.0 10.0
1991 & Newer 3.0 3.0
1988-90 3.5 3.5
1982-87 7.0 7.0

1991-95 4.5 4.5
1988-90 5.0 5.0
1979-87 7.0 7.0
1973-78 9.0 9.0
1968-72 10.0 10.0
1991 & Newer 4.5 4.5
1988-90 5.0 5.0
1982-87 7.0 7.0
1998 & Newer 4.0 4.0
1991-97 6.0 6.0
1979-90 8.0 8.0
1970-78 10.0 10.0
1969 & Earlier 15.0 15.0
U.S. EPA IM240 EMISSION STANDARDS > FINAL STANDARDS
Final standards are recommended for vehicles tested in calendar years 1997 and later. Tier 1 standards
are recommended for all 1996 and newer vehicles and may be used for 1994 and newer vehicles.
U.S. EPA IM240 HYDROCARBONS EMISSION FINAL STANDARDS
Application Hydrocarbons (Grams/Mile)
Composite Phase 2
Light Duty Vehicles
1996 & Newer 0.60 0.40
1980-95 0.80 0.50
1975-79 3.00 2.00
1968-74 7.00 4.50
1982-84 1.20 0.75

1984-95 1.60 1.00
1979-83 3.40 2.00
1975-78 4.00 2.50
1968-74 7.00 4.50
1988 & Newer 2.00 1.25
1984-87 2.00 1.25
1982-83 4.00 2.50
1984-95 1.60 1.00
1979-83 3.40 2.00
1975-78 4.00 2.50
1968-74 7.00 4.50
1988 & Newer 2.00 1.25
1984-87 2.00 1.25
1982-83 4.00 2.50
1998 & Newer 2.00 1.30
1987-97 2.00 1.30
1985-86 3.00 1.90
1979-84 5.00 3.10
1970-78 10.0 6.30
1969 & Earlier 20.0 12.50
U.S. EPA IM240 CARBON MONOXIDE EMISSION FINAL STANDARDS
Application Carbon Monoxide (Grams/Mile)

Composite Phase 2
Light Duty Vehicles
1996 & Newer 10.0 8.0
1983-95 15.0 12.0
1980-82 30.0 24.0
1975-79 65.0 52.0
1968-74 120.0 96.0
1983-84 30.0 24.0
1982 45.0 36.0
1984-95 40.0 32.0
1979-83 70.0 56.0
1975-78 80.0 64.0
1968-74 120.0 96.0
1988 & Newer 60.0 48.0
1984-87 60.0 48.0
1982-83 90.0 72.0
1984-95 40.0 32.0
1979-83 70.0 56.0
1975-78 80.0 64.0
1968-74 120.0 96.0
1984 & Newer 60.0 48.0
1982-83 90.0 72.0

1998 & Newer 30.0 24.0
1987-97 40.0 32.0
1985-86 50.0 40.0
1979-84 75.0 60.0
1974-78 150.0 120.0
1970-73 175.0 140.0
1969 & Earlier 200.0 160.0
U.S. EPA IM240 OXIDES OF NITROGEN EMISSION FINAL STANDARDS
Application Oxides Of Nitrogen (Grams/Mile)
Composite Phase 2
Light Duty Vehicles
1996 & Newer 1.5 1.5
1981-95 2.0 2.0
1977-80 4.0 4.0
1973-76 6.0 6.0
1968-72 7.0 7.0
1982-84 2.0 2.0
1988-95 2.5 2.5
1979-87 4.5 4.5
1973-78 6.0 6.0
1968-72 7.0 7.0
1988 & Newer 2.5 2.5
1982-87 4.5 4.5

1988-95 3.5 3.5
1979-87 4.5 4.5
1973-78 6.0 6.0
1968-72 7.0 7.0
1988 & Newer 3.5 3.5
1982-87 4.5 4.5
1998 & Newer 4.0 4.0
1991-97 5.0 5.0
1979-90 6.0 6.0
1970-78 10.0 10.0
1969 & Earlier 15.0 15.0

Service Manual: HEATING & AIR CONDITIONING - SERVICE Jeep Renegade
INFORMATION
Fig 1: Heating & Air Conditioning System
NOTE:
Only use R-1234yf refrigerant and specific refrigerant oil for the climate control system
compressor.
The vehicle is available with a manual or automatic dual zone climate control system.
With the automatic system, the operator can choose either automatic or manual operation. During
automatic operation, the operator simply sets a target temperature. The A/C and heater module, called
the Heating, Ventilation and Air Conditioning (HVAC) module, determines the best combination of A/C
compressor operation, mixing flap position, and outlet air direction and speed to control passenger
compartment humidity and reach the target temperature.
During manual operation, the operator can select A/C operation, air flow speed, air flow outlet location,
and choose either fresh or recirculated air.
The HVAC module is integrated into the A/C heater control.
Air conditioning components
The positioning of the components of the automatic climate control system is shown below.
Fig 2: Climate Control System Assembly Upper View
Climate control system assembly upper view
Solar/dusk sensor (1)
Recirculation actuator (2)
Assembly for recirculation activation (3)
Air outlet temperature sensor high right position (4)
Air outlet temperature sensor high left position (5)
In-car temperature sensor (6)

Fig 3: Climate Control System Assembly Right Side View
Right side view
Air outlet temperature sensor high right position (4)
Lower position temperature sensor (7)
Compartment for pollen filter (8)
Blower motor (9)
Right blend door actuator (10)
PTC activation relay panel (11)
PTC plate (Cabin Heater) (12)

Fig 4: Climate Control System Assembly Lower View
Lower view
Condensation drainage tube (13)
Blower motor speed regulator (14)

Fig 5: Climate Control System Assembly Front View
Front view
Expansion valve (15)
Heater core tubes (16)

Fig 6: Climate Control System Assembly Left Side View
Left side view
Left blend door actuator (17)
Heater core (18)
Rear ventilation ducts (19)
Air outlet temperature sensor low position (20)
Mode door actuator (21)
Manual Temperature Control (MTC)
The manual climate control system is used to heat up and cool down the vehicle.
This Heating, Ventilation and Air Conditioning (HVAC) system is composed of:
A blower motor
A blower motor speed regulator

Three actuators with potentiometer for position return signal (one for distribution, one for mixing,
one for recirculation)
An NTC sensor for defrosting function on the evaporator
A PTC (Cabin Heater) for additional heating
The HVAC module is connected to the Controller Area Network (CAN-B) data bus and receives the
information of the humidity sensor from the Instrument Panel Cluster (IPC) via CAN.
The A/C activation request from the user and the heated rear window activation request must be sent to
the Body Control Module (BCM) via CAN.
The A/C request status and the actuator position are stored in the HVAC.
This system manages air recirculation, distribution and temperature using the actuators with
potentiometer, for opening, closing and regulating the intermediate positions via electrical commands.
The HVAC acquires the temperature of the evaporator, via an NTC (frost) sensor, positioned in the air
flowing through the evaporator, in order to manage the valve for external control of the variable
displacement of the External Control Variable Displacement (ECVD) compressor.
This system can be updated with an additional PTC component to heat up the air more rapidly when the
engine is cold.
The HVAC manages activation of the additional PTC via two relays.
Automatic Dual Zone Temperature Control (ATC)
The automatic climate control system is used to heat up and cool down the vehicle.
This HVAC system is composed of:
A blower motor
A blower motor speed regulator
Three actuators with potentiometer for position return signal (one for distribution, one for mixing,
one for recirculation)
One actuator with potentiometer for return signal.
Four NTC air outlet sensors to measure the air temperature (two for temperature of the low
position air distribution and two for the high position air distribution)
A PTC (Cabin Heater) for additional heating
Solar radiation/dusk (Sun) sensor
An NTC sensor for defrosting function on the evaporator
A motorized sensor for the internal passenger compartment (in-car) temperature
The HVAC module is connected to the CAN-B data bus and receives the information of the humidity
sensor from the IPC via CAN.
The A/C activation request from the user and the heated rear window activation request must be sent to
the BCM via CAN.
The A/C request status and the actuator position are stored in the HVAC.
This system manages air recirculation, distribution and temperature using the actuators with
potentiometer, for opening, closing and regulating the intermediate positions via electrical commands.
The HVAC module controls the mixing temperatures through the temperature sensors located in the
climate control system.
The system manages the air temperature request by also monitoring solar radiation through a dedicated
sensor located on the dashboard.
The HVAC acquires the temperature of the evaporator, via an NTC sensor, positioned in the air flowing
through the evaporator, in order to manage the valve for external control of the variable displacement of
the ECVD compressor.
This system can be updated with an additional PTC component to heat up the air more rapidly when the
engine is cold.
The HVAC manages activation of the rear window defroster.
The HVAC manages activation of the additional PTC via two relays.
DIAGNOSIS AND TESTING > A/C BLOWER MOTOR DOES NOT WORK AT
DIFFERENT SPEEDS - ATC
CHECK BLOWER MOTOR

1 WITH A/C HEATER Result OK Result Not OK Action
CONTROL
Start the engine, set the

climate control unit in the
AUTO position, adjust the
temperature of 22° C (72°
F), and place the mode to
the vent position, external
air. Activate the fan button Diagnostic No change in air
Continue to Step 2
(upper arrow) and complete flow
progressively increase the
set speed and then
decrease the speed by
pressing the (lower arrow),
thus verifying the variation of
the air flow.
CHECK WITH DIAGNOSTIC

TOOL
Connect the diagnosis tool 1. error on blower 1. Continue to Step

and verify: motor. 4
2. short circuit 2. Continue to Step
the absence of errors Continue to Step 4
failure. 3
on the blower motor 3. error blower 3. Continue to Step
motor power module. 4
the lack of blower
motor circuit related
errors (errors of short
circuit)
CHECK ELECTRICAL
3 CONNECTIONS A/C Result OK Result Not OK Action
HEATER CONTROL
With the engine off, remove

the A/C heater control from
the instrument panel and
disconnect the wire harness
Weak or damaged Restore the
connector from the
Continue to Step 4 electrical electrical
controller. Visually check for
connections. connections.
damage on the contacts of
the connector and plug it
back in the correct way to
check for any false contacts.
CHECK ELECTRICAL
CONNECTIONS AND
BLOWER MOTOR
OPERATION
Check wiring connections

integrity.
Disconnect/reconnect the
1. electrical
connection to the blower 1. Restore correct
connections
motor. connections.
unstable
Disconnect the connector 2. Replace the
Diagnostic 2. the fan is not
and connect to a power blower motor
complete working.
supply. 3. Replace the
3. The blower motor
Under these conditions the blower motor power
power module does
blower motor should run at module
not work.
full speed, indicating that the
blower motor power module
does not work.
DIAGNOSIS AND TESTING > A/C BLOWER MOTOR DOES NOT WORK AT
DIFFERENT SPEEDS - MTC
VERIFY PROPER
1 OPERATION OF Result OK Result Not OK Action
SPEED SWITCH
Check at full speed,

the operation of the
blower motor. If it only Continue to Step 2 Weak or damaged Restore the electrical
works at full speed, electrical connections. connections.
the resistor is to be
replaced.
Check if the thermal
fuse is stopped going
to detect the electrical
continuity to the fixing
points of the thermal
fuse.
VERIFY PROPER
BLOWER MOTOR
Check for poor wiring

connection.
Disconnect /
reconnect the
connection to the
blower motor.
Verify that the blower
motor turns at all
1. Wire harness 1. Securely connect
speeds.
connections unstable or repair the wire
If it does not, check
Diagnostic complete or damaged harness connector
the blower motor fuse.
2. The blower motor 2. Replace the blower
If the issue persists,
does not work. motor
disconnect the blower
motor connector and
connect directly to the
battery.
In these conditions
the blower motor
should run at
maximum speed.
DIAGNOSIS AND TESTING > A/C BLOWS AIR IRREGULARLY - ATC
NOTE:
Blower motor airflow in the passenger compartment, through the manual control of speed, is
insufficient. Does not correspond to the speed set.
CHECK BLOWER MOTOR

1 WITH A/C HEATER Result OK Result Not OK Action
CONTROL

AUTO position, adjust the Diagnostic
No change in air flow Continue to Step 2
temperature of 22° C (72° complete
F), and place the mode to
the vent position, external
air. Activate the fan button
(upper arrow) and
progressively increase the
set speed and then
pressing the (lower arrow),
thus verifying the variation
of the air flow.
CHECK WITH DIAGNOSTIC

TOOL
Connect the diagnosis tool

and verify:
the absence of errors 1. Continue to Step

on the blower motor 1. error on blower
5
motor.
2. Continue to Step
the absence of errors 2. error blower motor
Continue to Step 5
on the mode door power module.
3 3. Continue to Step
actuator 3. errors on the mode
6
door actuator
the lack of blower 4. Continue to Step
4. short circuit failure.
motor circuit related 4
errors (errors of short
circuit)
VERIFICATION OF AIR
DUCTS AND CABIN FILTER
Check that the air ducts are 1. Restore the

intact and free of obstruction functionality of the
and that its vents are 1. Air ducts or vents air ducts and vents,
Continue to Step
positioned properly in the are obstructed. removing any
4
opening. 2. Cabin filter clogged. obstruction.
Check that the cabin filter is 2. Replace the
not clogged. cabin filter.
CHECK ELECTRICAL
HEATER CONTROL
With the engine off, remove

the A/C heater control from
the instrument panel and
disconnect the wire harness
connector from the 1. Restore the wire
Continue to Step Weak or damaged
controller. Visually check for harness
5 electrical connections.
damage on the contacts of connections.
the connector and plug it
back in the correct way to
check for any false
contacts.
CHECK ELECTRICAL
CONNECTIONS AND
BLOWER MOTOR
OPERATION
Check wiring connections

integrity.
Disconnect/reconnect the
1. Restore wire
connection to the blower 1. wire harness
harness
motor. connections unstable
connections.
Disconnect the connector 2. the blower motor is
Continue to Step 2. Replace the
and connect to a power not working.
6 blower motor
supply. 3. The blower motor
3. Replace the
Under these conditions the power module does
blower motor power
blower motor should run at not work.
module
full speed, indicating that the
blower motor power module
does not work.
CHECK PROPER
6 OPERATION OF MODE Result OK Result Not OK Action
DOOR ACTUATOR
Check wiring connection

integrity.
Disconnect visually
checking damage on the
contacts of the connector
and reconnect the
connection to the blower
motor.
1. Wire harness
If it stays, before replacing
connections bad or
the actuator, test the
damaged. 1. Restore the
functionality of the activating
2. There is no entry of electrical
in manual mode. The Diagnostic
air flow into the connections.
actuator function should complete
passenger 2. Continue to Step
work.
compartment from the 7
With the car in motion put
air vents of the
the blower motor on full
vehicle.
speed.
Place the A/C heater control
(in manual mode) so that the
mode doors are in various
positions of air distribution.
Check by placing a hand on
the outlets in the interior for
air flow.
CHECK ROTATION OF THE

MODE DOOR ACTUATOR
Remove the mode door 1. the actuator does 1. Replace the

actuator and check through Diagnostic not rotate. mode door actuator
A/C heater control command complete 2. Movement impeded 2. Replace the
that the actuator turns,
component that
checking for the presence of or broken/blocked
presents the
mechanical impediments to doors.
anomaly.
the rotation.
DIAGNOSIS AND TESTING > A/C BLOWS AIR IRREGULARLY - MTC
VERIFICATION OF AIR
1 DUCTS AND CABIN Result OK Result Not OK Action
FILTER
Check that the air ducts Restore the

are intact and free of functionality of the air
Air ducts or vents are
obstruction and that its Continue to Step 2 ducts and vents
obstructed.
vents are positioned removing any
properly in the opening. obstruction.
VERIFY PROPER
SPEED SWITCH
Check at full speed, the

operation of the blower
motor. If it only works at
full speed, the resistor
is to be replaced. Weak or damaged
Restore the wire
Check if the thermal Continue to Step 3 wire harness
harness connections.
fuse resistor is stopped connections.
going to detect the
electrical continuity to
the fixing points of the
thermal fuse.
VERIFY PROPER
BLOWER MOTOR

connection.
Disconnect / reconnect
the connection to the
blower motor.
Verify that the blower 1. Wire harness 1. Securely connect
motor turns at all connections unstable or repair the wire
speeds. Continue to Step 4 or damaged harness connector.
If it does not, check the 2. The blower motor 2. Replace the blower
blower motor fuse. does not work. motor.
If the issue persists,
disconnect the blower
motor connector and
connect directly to the
battery.
In these conditions the
blower motor should run
at maximum speed.
CHECK CORRECT
OPERATION
Research the problem

Verify that the fault is no Diagnostic
The problem persists of HVAC door/flap
longer present. complete
obstructions.
DIAGNOSIS AND TESTING > A/C DOES NOT COOL - ATC
NOTE:
The fan works properly and sends air into the passenger compartment according to
predetermined patterns, but that air remains at outside temperature and never gets cold.
NOTE:
The qualification for entering the refrigeration mode is controlled by both the A/C heater
control and the powertrain control module.
PRELIMINARY
CHECKS
Connect the vehicle to

the appropriate air
conditioning charging
1. incorrect system
equipment, and check 1. Continue to Step 1
pressure
the pressure of the Continue to Step 1 2. check the engine
2. malfunctioning
system. cooling fan circuit
engine cooling fan.
Verify the correct
cooling fan.
CHECK FOR LEAK

1 FROM THE Result OK Result Not OK Action
CONDENSER
Vehicle engine started, 1. Replace the

with the climate system condenser and
started (compressor 1. Loss of refrigerant
perform the correct
ON), check to see if the Continue to Step 2 from the condenser.
filling.
leak is in 2. pinched O-ring
2. Replace the O-rings
correspondence with seal.
and perform the
the A/C line correct filling.
connections location at
the condenser or the
location of the filter drier
or junction tubes on the
condenser.
CHECK FOR LEAK

EVAPORATOR
Vehicle engine started,

with the climate system 1. Replace the
started (compressor evaporator and
1. Loss of refrigerant
ON), using the proper perform the correct
from the evaporator.
leak detector, check to Continue to Step 3 filling.
2. pinched O-ring
see if there is a leak at 2. Replace the O-rings
seal.
the expansion valve or and perform the
at the bend of the A/C correct filling.
lines.
CHECK FOR LEAK

COMPRESSOR

with the climate system
started at maximum
speed (compressor
ON), temperature
adjusted to LO, using
leak detector, check to
see if there is a leak is
at the A/C line flange at 1. pinched O-ring 1. Replace the O-rings
the compressor. seal. and perform the
If a leak is detected, 2. Loss from the correct filling.
repeat the test to verify Continue to Step 4 compressor shaft lip 2. Replace the
the presence of a leak. seal. compressor.
With the vehicle engine 3. Loss from rear seal 3. Replace the
OFF, using leak of the compressor. compressor.
detector, check to see
if there is a leak at the
A/C compressor shaft
seal or the area at the
rear of the compressor.
If a leak is detected,
repeat the test to verify
the presence of a leak.
CHECK WITH
DIAGNOSTIC TOOL
Connect the diagnosis 1. blend door actuator 1. Continue to Step 5

tool and verify: error. 2. Continue to Step 5
Continue to Step 6
the absence of errors 2. error on air outlet 3. Continue to Step 5
on the blend door temperature sensors 4. Continue to Step 5
actuator;
the absence of errors
on the air outlet
3. ambient
temperature sensors;
temperature sensor
error
on ambient temperature
4. evaporator
sensor;
temperature sensor 5. Continue to Step 5
error 6. Continue to Step 12
on evaporator
5. interior temperature
temperature sensor;
sensor error.
6. A/C transducer
on the interior
error
temperature sensor;
on the A/C transducer.
ELECTRIC CIRCUIT
VERIFICATION
Check insulation
continuity and visually
check for any
weakness or damage
on the contacts of the
connector electrical
connection: 1. weak or damaged
1. Restore the wire
blend door actuator in wire harness
harness connections.
case of blend door Continue to Step connections.
2. Restore continuity /
actuator error; 13 2. wire harness
insulation of the wire
in case of sensor connection interrupted
harness connection.
failure of the ambient or not insulated.
temperature sensor;
of the evaporator
temperature sensor
error
A/C heater control
connector.
CHECK A/C LINE

TIGHTNESS
1. Restore the correct

Verify that the tightening of the A/C
connections of the A/C line and perform the
lines for air conditioning correct filling
1. Torque not
system are properly 2. Replace the A/C
conforming
tightened. line and perform the
2. Line damaged
Make sure that the A/C
Continue to Step 7 because the vehicle correct filling
lines are undamaged in Indicate if the A/C line
was crashed.
all their parts. The
3. The air conditioning is from accident
absence of excessive vehicle and mark it in
system obstructed.
deformations or all sections.
indentations on rubber 3. Replace the A/C
or metal parts. line and perform the
correct filling
Indicate on the
damaged A/C line the
clogged point detected
in the system.
Indicate the date of
the intervention on the
A/C lines replaced, the
mileage from the
vehicle, car dealer
name and number of
operations performed
on the defective A/C
line.
CHECK FOR
7 ABRASIONS ON Result OK Result Not OK Action
HOSES
1. Replace the A/C

line and perform the
correct filling
Check for A/C line 2. Replace the O-ring
contact with engine Refrigerant loss from and perform the
Continue to Step 8
parts (rubber part contact area. correct filling
and/or metal.) Indicate on the
defective A/C line at
the exact point of
abrasion.
CHECK FOR A/C LINE

8 CONNECTION Result OK Result Not OK Action
INTEGRITY
Vehicle engine started, 1. Replace the A/C

with the climate system line and perform the
1. Loss of refrigerant
started (compressor correct filling
from solder
ON), using a leak 2. Replace the O-rings
connection at the
detector, check to see and perform the
Continue to Step 9 flanges or rubber
if there is a leak at the correct filling
hose crimping.
A/C line flange seat Indicate on the
2. pinched O-ring
(brazing blocks and defective A/C line the
seal.
seals) or rubber hose exact point of
crimps. abrasion.
CHECK FOR LEAKS AT

9 FLEXIBLE HOSE OR Result OK Result Not OK Action
CHAFFERING
Vehicle engine started, 1. Replace the A/C

with the climate system 1. Loss of refrigerant line and perform the
started (compressor Continue to Step from the A/C line. correct filling
ON), using a leak 10 2. pinched O-ring 2. Replace the O-rings
detector, check to see seal. and perform the
if there is a leak at the correct filling
Indicate on the
A/C line rubber part or defective A/C line the
flexible hose bend. exact point of
abrasion.
CHECK WITH
DIAGNOSTIC TOOL
Connect the diagnosis

tool and verify:
1. Errors on the
powertrain control
on the powertrain
module.
control module
2. The relay is 1. Proceed as
through active
commanded on and indicated by the
diagnosis, the proper Continue to Step
the relay does not diagnostic tool
functioning of the 13
activate. 2. Go to Step 11
compressor relay
3. the relay activates 3. Go to Step 12
activation, ensuring at
but the compressor
the same time, there is
clutch does not
the activation of the
activate.
A/C clutch of the
compressor.
CHECK ELECTRIC
CIRCUIT
1. wire harness
Check continuity / connections
insulation of wire
insulation of the Continue to Step interrupted or not
harness connections
electrical circuit of the 13 insulated.
2. Replace the
compressor relay input. 2. compressor relay
compressor relay
activation malfunction.
CHECK ELECTRIC
CIRCUIT
1. wire harness
wiring insulation
insulation of the Continue to Step interrupted or not
2. Replace the
electrical power circuit 13 insulated.
compressor equipped
to the compressor. 2. Malfunctioning
with clutch.
compressor clutch.
CHECK
13 COMPRESSOR Result OK Result Not OK Action
ACTIVATION
1. Check and restore

1. wire harness
continuity / insulation
Check the correct connections
Continue to Step of the wire harness
activation of the interrupted.
14 connection.
compressor 2. A/C transducer not
2. Replace the A/C
allowing activation.
transducer.
VERIFY PROPER
14 OPERATION WITH Result OK Result Not OK Action
DIAGNOSTIC TOOL
Verify that no errors

exist: 1. Continue to Step 15
1. Error blend door
blend door actuator 2. Replace the
actuator LH.
(after teach-in ambient temperature
2. Error ambient
procedure); sensor.
Diagnostic temperature sensor.
the ambient 3. Replace the A/C
complete 3. Error interior
temperature sensor; heater control.
temperature sensor.
on the interior 4. Replace the air
4. Error on air outlet
temperature sensor; outlet temperature
temperature sensors.
on air outlet sensors.
temperature sensors.
CHECK FOR PROPER

OPERATION OF THE
BLEND DOOR
ACTUATOR
Remove the blend door

actuator and check via
1. The actuator does 1. Replace the blend
command from the
not rotate. door actuator
control unit that the Diagnostic
2. Mechanism or 2. Repair/replace the
actuator turns, checking complete
doors broken / component that is
for mechanical
blocked. causing the condition.
obstructions that
prevent its rotation.
DIAGNOSIS AND TESTING > A/C DOES NOT COOL - MTC
NOTE:
The fan works properly and sends air into the passenger compartment according to
predetermined patterns, but that air remains at outside temperature and never gets cold.
NOTE:
The qualification for entering the refrigeration mode is controlled by both the A/C heater
control and the powertrain control module.
PRELIMINARY
CHECKS
the appropriate air
equipment, and check
1. incorrect system
the pressure of the Continue to Step 1 1. Continue to Step 1
pressure
system.
Verify the correct
cooling fan.
CHECK FOR LEAK

CONDENSER

started (compressor
1. Replace the
ON), check to see if the
condenser and
leak is in
1. Loss of refrigerant perform the correct
correspondence with
Continue to Step 2 from the condenser. filling.
the A/C line connections
2. pinched O-ring seal. 2. Replace the
location at the
O-rings and perform
condenser or the
the correct filling.
location of the filter drier
or junction tubes on the
condenser.
CHECK FOR LEAK

EVAPORATOR

with the climate system 1. Replace the
started (compressor evaporator and
ON), using the proper 1. Loss of refrigerant perform the correct
leak detector, check to Continue to Step 3 from the evaporator. filling.
see if there is a leak at 2. pinched O-ring seal. 2. Replace the
the expansion valve or O-rings and perform
at the bend of the A/C the correct filling.
lines.
CHECK FOR LEAK

COMPRESSOR

started at maximum
speed (compressor
1. Replace the
ON), temperature
Continue to Step 4 1. pinched O-ring seal. O-rings and perform
adjusted to LO, using
the correct filling.
leak detector, check to
see if there is a leak is
at the A/C line flange at
the compressor.
If a leak is detected,
repeat the test to verify
the presence of a leak.
CHECK WITH
DIAGNOSTIC TOOL

tool and verify:
1. ambient
on the blend door
temperature sensor
actuator;
error 1. Continue to Step 5
the absence of errors Continue to Step 6
2. evaporator 2. Continue to Step 5
temperature sensor
sensor;
error
on evaporator
temperature sensor;
ELECTRIC CIRCUIT
VERIFICATION
Check insulation
continuity and visually
check for any weakness
or damage on the 1. Restore the wire
1. weak or damaged
contacts of the harness
wire harness
connector electrical connections.
Continue to Step connections.
connection: 2. Restore continuity
10 2. wire harness
in case of sensor failure / insulation of the
connection interrupted
of the ambient wire harness
or not insulated.
temperature sensor; connection.
of the evaporator
temperature sensor
error
CHECK WITH
DIAGNOSTIC TOOL

tool and verify:
1. Errors on the
powertrain control
on the powertrain
module.
control module
2. The relay is 1. Proceed as
through active
commanded on and indicated by the
diagnosis, the proper
Continue to Step 9 the relay does not diagnostic tool
functioning of the
activate. 2. Go to Step 7
compressor relay
3. the relay activates 3. Go to Step 8
activation, ensuring at
but the compressor
the same time, there is
clutch does not
the activation of the A/C
activate.
clutch of the
compressor.
CHECK ELECTRIC
CIRCUIT
1. wire harness
1. Restore continuity
/ insulation of wire
insulation of the interrupted or not
Continue to Step 9 harness connections
electrical circuit of the insulated.
2. Replace the
compressor relay input. 2. compressor relay
compressor relay
activation malfunction.
CHECK ELECTRIC
CIRCUIT
1. wire harness
1. Restore continuity
/ wiring insulation
insulation of the interrupted or not
Continue to Step 9 2. Replace the
electrical power circuit insulated.
compressor
to the compressor. 2. Malfunctioning
equipped with clutch.
compressor clutch.
CHECK
9 COMPRESSOR Result OK Result Not OK Action
ACTIVATION
1. Check and restore

1. wire harness
continuity / insulation
Check the correct connections
Diagnostic of the wire harness
activation of the interrupted.
complete connection.
compressor 2. A/C transducer not
2. Replace the A/C
allowing activation.
transducer.
VERIFY PROPER
DIAGNOSTIC TOOL
Verify that no errors

exist: Diagnostic Error ambient Replace the ambient
the ambient temperature complete temperature sensor. temperature sensor.
sensor;
DIAGNOSIS AND TESTING > A/C DOES NOT COOL TO DESIRED TEMPERATURE -
ATC
NOTE:
The blower motor works properly and sends air into the passenger compartment according
to predetermined patterns, but the air temperature is not the desired one.

Before you start, check the
ambient temperature of
about 20°C (68°F), the car
with the doors and windows
closed (during cooling and
the temperature detection).
The vehicle engine
powered on, at room
temperature (check with the
diagnostic tool to indicate
that the interior temperature
is about 20°C (68°F), with
the compressor switched
on, the A/C heater control
in the AUTO position, the
temperature adjusted to
maximum cold LO, the air
distribution in the front
There is no cooling
position, the speed of the
Diagnostic change to the air
blower motor to 6 bars and Continue to Step 2
complete leaving the air
the air intake on external air
vents.
intake.
After about 5 minutes under
these conditions, check
with the diagnostic tool that
the values of the
temperature of the air vents
have a decreasing trend:
starting temperature of
about 20°C (68°F) (room
temperature) to descend
progressively until the
temperature of the front
distribution air vents is
between 6-10°C
(42.8-50°F).
Verify carefully if the
outgoing air from the vents
has a variation (toward the
cold) temperature.
CHECK SYSTEM
PRESSURE
1. System pressure
Connect the unit to the is not correct. 1. Restore the correct
appropriate air conditioning 2. Low or value of pressure.
charging equipment, and excessive 2. Restore the proper
check the pressure of the Continue to Step 3 refrigerant charge. level of refrigerant.
system. 3. Improper 3. Check the cooling
Verify the correct operation operation of the fan circuit
of the engine cooling fan. electric motor
cooling.
CHECK WITH
DIAGNOSTIC TOOL

and verify: 1. blend door
the absence of errors on actuator error.
the blend door actuator; 2. air outlet
the absence of errors on temperature sensor
the air outlet temperature error
1. Continue to Step 4
sensors; 3. ambient
Continue to Step 5 3. Continue to Step 4
ambient temperature error
sensor; 4. evaporator
evaporator temperature error
sensor; 5. interior
the interior temperature error.
sensor.
CHECK ELECTRIC
CIRCUIT
With the car engine off,

remove the A/C heater
control from the instrument
panel and disconnect the
wire harness connector
from the control unit,
visually checking damage
on the contacts of the
1. Electrical
connector and reconnect it
connections
correctly to verify any poor 1. Restore the
unstable or
connections. electrical connections
damaged.
Check continuity of the Continue to Step 5 2. Restore continuity /
2. Electrical
electrical insulation of electrical
connection
connection/isolation: connection
interrupted or not
blend door actuator in case
isolated.
of a blend door actuator
error;
the sensor in the case of
ambient temperature
sensor error.
of the sensor in case of
evaporator temperature
sensor error.
5 CHECK CONDENSER Result OK Result Not OK Action
1. Condenser 1. Replace the

Verify the condenser is not
damaged. condenser.
blocked or clogged with Continue to Step 6
2. Condenser 2. Remove the dirt by
mud or damaged.
clogged. washing
VERIFY PROPER
DIAGNOSTIC TOOL
1. blend door 1. Replace the blend

Verify that no errors exist: actuator error. door actuator
blend door actuator (after 2. on air outlet 2. Replace the air
teach-in procedure); temperature sensor outlet temperature
on air outlet temperature error. sensor causing the
sensors Continue to Step 7 3. ambient anomaly.
the ambient temperature temperature sensor 3. Replace the
sensor; error. ambient temperature
on the interior temperature 4. interior sensor.
sensor. temperature sensor 4. Replace the A/C
error. heater control.
CHECK FOR PROPER

7 OPERATION OF THE Result OK Result Not OK Action
BLEND DOOR ACTUATOR
Remove the blend door

actuator and check via 1. The actuator 1. Replace the blend
command from the A/C does not rotate. door actuator
Diagnostic
heater control that the 2. Mechanism or 2. Repair/replace the
complete
actuator turns, checking for doors broken / component that is
mechanical obstructions blocked. causing the condition.
that prevent its rotation.
DIAGNOSIS AND TESTING > A/C DOES NOT COOL TO DESIRED TEMPERATURE -
MTC
NOTE:
The blower motor works properly and sends air into the passenger compartment according
to predetermined patterns, but the air temperature is not the desired one.
CHECK SYSTEM
PRESSURE
1. System
Connect the unit to the
pressure is not 1. Restore the correct
appropriate air
Continue to Step correct. value of pressure.
2 2. Low or 2. Restore the proper
equipment, and check the
excessive level of refrigerant.
pressure of the system.
refrigerant charge.
CHECK MANUAL
2 CONTROL FOR PROPER Result OK Result Not OK Action
OPERATION
Before you start, check
the following conditions:
ambient temperature of
about 20°C (68°F), the car
with the doors and
windows closed (during
cooling and the
temperature detection).
The vehicle engine
running, at room
temperature (check with
the diagnostic tool to
indicate that the interior
temperature is about 20°C
(68°F), with the
compressor switched on,
the temperature adjusted
There is no cooling
to maximum cold, the air
Continue to Step change to the air
distribution in the front Continue to Step 3
5 leaving the air
position, the speed of the
vents.
blower motor selector to 2
and the air intake on
external air intake.
After about 5 minutes
under these conditions,
check with the diagnostic
tool that the values of the
temperature of the air
vents, have a decreasing
trend: starting temperature
of about 20°C (68°F)
(room temperature) to
descend progressively
until the temperature of the
front distribution air vents
is between 6-10°C
(42.8-50°F).
CHECK WITH
DIAGNOSTIC TOOL

and verify: ambient
Continue to Step
the absence of errors on temperature Continue to Step 4
5
ambient temperature sensor error
sensor;
CHECK ELECTRIC
CIRCUIT
Check continuity of the Electrical

Restore continuity /
electrical Continue to Step connection
insulation of electrical
connection/isolation: 5 interrupted or not
connection
in case of sensor failure isolated.
sensor;
of the sensor in case of
evaporator temperature
sensor error.
CHECK A/C LINES AND

FILTER
1. obstructed
compressor 1. Replace the
Verify that the high and low discharge line to compressor discharge line
pressure A/C lines for the Continue to Step condenser. to condenser.
air conditioner are not 6 2. obstructed A/C 2. Replace the A/C liquid
obstructed. liquid line from line from condenser to
condenser to expansion valve.
expansion valve.
6 CHECK CONDENSER Result OK Result Not OK Action
1. Condenser
Verify the condenser is not 1. Replace the condenser.
Continue to Step damaged.
blocked or clogged with 2. Remove the dirt by
7 2. Condenser
mud or damaged. washing
clogged.
VERIFY PROPER
DIAGNOSTIC TOOL
Verify that no errors exist: ambient

Continue to Step Replace the ambient
the ambient temperature temperature
8 temperature sensor.
sensor; sensor error.
CHECK FOR PROPER

OPERATION
Research the problem of

Verify that the fault is no Diagnostic The anomaly mechanisms/flexible
longer present. complete persists. transmissions of the
climate group
DIAGNOSIS AND TESTING > A/C DOES NOT WORK IN ANY MODE - ATC
NOTE:
Pressing the switch-on / switch-off, the air conditioning does not work.
Check: 1. Blown fuses 1. Replace blown

Continue to Step 1 2. Relay damaged fuses
Fuses and relays of 2. Replace bad
the A/C System relay(s)
3. Incorrect
3. Find and eliminate
A/C System refrigerant pressures
leaks. Refill
refrigerant pressure 4. Improper
refrigerant to proper
operation of the
Blower motor level
blower motor
operation 4. Check the blower
motor circuit
CHECK COMPRESSOR
CLUTCH OPERATION
Check the under the

room temperature at least
5°C (41°F) and indication
of the ambient
temperature sensor 1. The LED on the
greater than 5°C (41°F). display does not turn
The engine running, with on (but the
the compressor on (check compressor is
the activation light on the engaged)
display), set the A/C 2. The LED on the
control to the AUTO display lights up (but
position, set the Diagnostic the compressor
temperature to maximum complete does not engage)
cold, LO, and distribution 3. The ambient
in the vent position. temperature input is
Using a scan tool, check incorrect
that there are no short 4. Short circuit in the
circuits to ground in the compressor circuit
compressor circuit or any 5. Errors on CAN
errors on the CAN line. line
In these conditions, verify
compressor by observing
the compressor and
clutch under the hood.
CHECK WITH
DIAGNOSTIC TOOL
scan tool to check for any
errors: 1. A/C heater control
not working properly
2. Proceed as
A/C heater control Continue to Step 3 2. Powertrain control
indicated by the
module not working
Powertrain Control diagnostic scan tool.
properly
Module
CHECKS USING
3 DIAGNOSTIC SCAN Result OK Result Not OK Action
TOOL
1. Relay not working
2. A/C pressure
transducer not
Connect a diagnostic working properly 1. Replace the relay
scan tool to check for A/C 3. Fault (short circuit 2. Check the A/C
heater control errors: or open circuit) on pressure transducer
the ambient 3. Repair the ambient
in the control relay temperature sensor temperature sensor
of the compressor circuit wiring
4. Ambient 4. Replace the
in the A/C pressure temperature sensor ambient temperature
transducer Continue to Step 5 not working properly sensor
5. Fault (short circuit 5. Check/repair the
in the ambient
or open circuit) on blower motor wire
temperature sensor
the blower motor harness and
in the blower motor circuit connections as
6. Blower motor not necessary
in the A/C working 6. Continue to Step 6
compressor wiring 7. the LED on the 7. Replace the A/C
button does not light heater control
up (but the
compressor is
engaged)
CHECK ELECTRICAL
HEATER CONTROL
With the engine off,

remove the A/C heater
control from the
instrument panel and 1. wire harness
1. Securely connect
disconnect the wire connections
or repair the
harness connector from unstable or damaged
Continue to Step 5 electrical connector
the controller. Visually 2. A/C heater control
2. Replace the A/C
verifying for possible connections are
heater control
damage on the contacts unstable
of the connector. Plug it
back in properly to check
for any poor contacts.
CHECK OPERATION OF
A/C HEATER CONTROL

AUTO position, adjust the
temperature to 22°C
(72°F), and place the Diagnostic No change in blower
Continue to Step 6
mode to the vent position, complete speed
external air.
Activate the blower motor
(upper arrow) and
progressively increase
the set speed and then
pressing the (lower
arrow), thus verifying the
variation of the air flow.
CHECK ELECTRICAL
CONNECTIONS AND
OPERATION OF THE
BLOWER MOTOR

connection.
1. Electrical
blower motor. 1. Securely connect
connections
Disconnect the blower or repair the
unstable or damaged
motor connector and electrical connector
Diagnostic 2. The blower motor
connect to a power 2. Replace the
complete does not work.
supply. blower motor
3. The A/C heater
In these conditions the 3. Replace the A/C
control does not
blower motor should run heater control
work
at maximum speed,
indicating that the A/C
heater control is not
working.
DIAGNOSIS AND TESTING > A/C DOES NOT WORK IN ANY MODE - MTC
NOTE:
Pressing the switch-on / switch-off, the air conditioning does not work.
Check: 1. Replace blown

fuses
Fuses and relays of 1. Blown fuses 2. Replace bad
the A/C System 2. Relay damaged relay(s)
Continue to Step 1
3. Incorrect 3. Find and eliminate
A/C System refrigerant pressures leaks. Refill
refrigerant pressure refrigerant to proper
level
CHECK COMPRESSOR
CLUTCH OPERATION
Check the under the 1. The LED on the 1. Replace the

Diagnostic
following conditions: display does not turn manual A/C heater
complete
room temperature at least on (but the control
5°C (41°F) and indication
of the ambient
temperature sensor
greater than 5°C (41°F).
The engine running, with
the compressor on (check
the activation light on the
display), set the
compressor is
temperature to maximum
engaged)
cold, LO, and distribution
2. The LED on the
in the vent position. 2. Continue to Step 2
display lights up (but
Using a scan tool, check
the compressor does
that there are no short
not engage)
circuits to ground in the
compressor circuit or any
errors on the CAN line.
In these conditions, verify
compressor by observing
the compressor and clutch
under the hood.
CHECK WITH
DIAGNOSTIC TOOL
scan tool to check for any
errors: Powertrain control Proceed as
Continue to Step 3 module not working indicated by the
Powertrain Control properly diagnostic scan tool.
Module
CHECKS USING
TOOL
Connect a diagnostic 1. Relay not working

scan tool to check for A/C 2. A/C pressure
1. Replace the relay
heater control errors: transducer not
2. Check the A/C
working properly
in the control relay pressure transducer
3. Fault (short circuit
of the compressor 3. Repair the
or open circuit) on
Continue to Step 5 ambient temperature
the ambient
in the A/C pressure sensor wiring
temperature sensor
transducer 4. Replace the
circuit
ambient temperature
in the ambient 4. Ambient
sensor
temperature sensor temperature sensor
not working properly
CHECK ELECTRICAL
CONNECTIONS AND
OPERATION OF THE
BLOWER MOTOR
connection.
blower motor.
Disconnect the blower 1. Electrical 1. Securely connect
motor connector and connections unstable or repair the
connect to a power Continue to Step 5 or damaged electrical connector
supply. 2. The blower motor 2. Replace the
In these conditions the does not work. blower motor
blower motor should run
at maximum speed,
indicating that the A/C
heater control is not
working.
CHECK OPERATION OF
5 THE BLOWER MOTOR Result OK Result Not OK Action
RESISTOR
Check to see if the blower

motor works at full speed.
If the blower motor works 1. Blower motor
1. Replace the
at full speed, the blower resistor does not
blower motor resistor
motor resistor needs to Diagnostic work
2. Repair the blower
be replaced. complete 2. The blower motor
motor resistor
Check to see if the circuits need to be
circuits
circuits to the blower repaired.
motor resistor are
working properly.
DIAGNOSIS AND TESTING > A/C NOISE FROM ENGINE COMPARTMENT
PRELIMINARY
CHECKS

the appropriate air
conditioning charging 1. Pressure values
equipment, and check incorrect.
the pressure of the 2. Belt alignment / 1. Continue to Step 1
system. tensioning incorrect or 2. Restore the
Check the condition of worn belt. correct belt alignment
the accessory drive belt Continue to Step 2 3. The noise comes / tension or replace
for wear, correct from other engine the belt.
alignment and belt compartment 3. Continue as
tension. components (engine indicated in the
While running the engine cooling fan motor, related diagnosis.
at idle with the a/c water pump,
system in the off alternator).
position, check if the
noise originates from
other engine
compartment
components (engine
cooling fan, water pump,
alternator). Increase the
number of engine revs
and check for the
presence of vibrations.
CHECK PRESSURE
1 VALUES OF HIGH AND Result OK Result Not OK Action
LOW PRESSURE
With the correct 1. Flush the system

charging equipment and restore the
connected, check the 1. low pressure values correct charge of oil
low and high pressure in the circuit and gas
values while the (insufficient amount of 2. Flush the system
compressor is activated refrigerant in the and restore the
and engine is running: circuit) correct charge of oil
low pressure values at 2. high pressure and gas
high and low pressure; values in the circuit 3. Replace the
Diagnostic
high pressure at high (excessive amount of compressor
complete
and low pressure; refrigerant oil in the Note: If the
Verify that the values of circuit). compressor is
pressure (high and low) 3. pressure buttons replaced because of
during operation of the values in the circuit a mechanical
compressor are not (compressor problem, remember
buttons and that the discharge valve to flush the entire
motor is switched off the always open). system and to
pressure in the circuit is change the filter
not equal slowly. drier.
CHECK A/C LINES AND

2 COMPONENT Result OK Result Not OK Action
BRACKETS
Check the correct

mounting of the
compressor, A/C lines 1. attachment 1. Restore the
and components. components tightening torque.
Verify in the following incorrectly secured. 2. Restore the proper
order: 2. Interference in the arrangement of the
attachment of the engine compartment. A/C lines
compressor to the 3. Condenser clogged 3. Clean or replace
bracket on the engine Continue to Step 3
or damaged the condenser
block; 4. Presence of cracks 4. Replace
attachment of the A/C on the hardware of the compressor or
lines (using clamps and compressor to the component that is
spacers); bracket on the engine causing the
the absence of contact block. condition.
between the A/C lines
and other components
of the engine
compartment;
cleaning or damage of
the condenser (the
presence of mud, foreign
bodies).
Also check for cracks in
the hardware of the
compressor to the
bracket on the engine
block (bolts and the
bracket).
CHECK A/C LINE

TIGHTNESS
1. Restore the
correct tightening of
the pipe and make
the correct filling
2. Replace the pipe
and perform the
correct filling.
Indicate if the line is
from accident vehicle
Check that the A/C line
and make it in all its
connections for the air
1. Torque not to parts.
conditioning system are
specification 3. Replace the pipe
properly tightened.
2. A/C line damaged and perform the
Verify that the A/C lines
Continue to Step 4 because the car was correct filling.
are intact in all their
crashed. Indicate on the
parts. Absence of
3. The air conditioning damaged line
excessive deformation
system obstructed. clogged point
or bursting of the rubber
detected in the
or metal.
system.
Indicate the date of
the intervention on
the lines replaced,
the mileage from the
car, car dealer name
and number of
operations performed
on problem line.
CHECK ABRASIONS
ON A/C LINES
1. Replace the A/C

line and perform the
Verify tubing contact correct filling
Refrigerant loss from 2. Replace the O-ring
with motor parts (rubber Continue to Step 5
contact area. and perform the
part and/or metal.)
correct filling.
Indicate on the line
on the exact point of
abrasion.
CHECK A/C LINE

CONNECTION LOSSES
With the engine started 1. Replace the line

and the climate system and perform the
engaged (compressor 1. Loss of refrigerant correct filling
ON), using the proper from solder 2. Replace the O-ring
leak a detector, check Continue to Step 6 connection flanges or and perform the
for leaks at the block rubber hose crimping. correct filling.
flanges for A/C lines in 2. pinched O-ring seal. Indicate on problem
the system (brazing line the exact point of
blocks and seals). leak.
CHECK REFRIGERANT
LEAKS FROM RUBBER
HOSE OR
CHAFFERING
1. Replace the line

With the engine started
and perform the
and the climate system
correct filling
engaged (compressor 1. Loss of refrigerant
2. Replace the O-ring
ON), using the proper from the rubber/flexible
Continue to Step 7 and perform the
leak a detector, check A/C line.
correct filling.
for leaks at the rubber 2. pinched O-ring seal.
Indicate on problem
portion or flexible part of
line the exact point of
the A/C lines.
leak.
CHECKS TO BE
CARRIED OUT WHEN
THE COMPRESSOR IS
NOT ACTIVATED
Checks to be carried out

with the engine off and
the compressor not
1. eliminate the
engaged:
contact.
disconnect the belt to 1. Presence of
2. Replace the pulley
check for the presence contact between
3. Replace the pulley
of contact between the guard and pulley.
4. replace the A/C
guard and the pulley; 2. Presence of
clutch complete with
always with belt contact between the
pulley
disconnected, check for Continue to Step 8 pulley and external
If the compressor is
contact between the elements.
replaced due to a
pulley and the external 3. Worn bearing.
mechanical problem,
elements. 4. Signs of
be certain to flush
check for wear of the overheating of the A/C
the whole system
bearing of the pulley by clutch.
and change filter
rotating the movable
dryer.
plate in both directions
of rotation.
check whether the A/C
clutch shows signs of
overheating.
CHECKS TO BE
CARRIED OUT WHEN
THE COMPRESSOR IS
ACTIVATED
After installing the belt,

check for the following
by activating the
compressor:
Visually check to see if 1. Presence of oil or 1. Clean the oil or
there is slippage of the grease on the plate. grease from the plate
A/C clutch plate due to Continue to Step 9 2. the belt slipping on and check for an oil
the presence of oil or the pulley of the leak.
grease on the plate; compressor. 2. Replace the belt.
Visually check to see if
there is slippage
between the belt and the
compressor pulley.
CHECK REFRIGERANT
9 LEAKAGE FROM Result OK Result Not OK Action
COMPRESSOR SIDE
With the engine running

activated at maximum
speed (compressor ON),
temperature setting at 1. Replace the
maximum cold, move the compressor
"nose" of the leak 2. Repair the leak
detector to analyze and 1. loss localized on
and restore the
verify any loss. If so the shaft lip seal or on
proper operation of
(loss), repeat the test to the rear head of the
the circuit.
ascertain the actual compressor.
3. Properly place the
presence of the loss. 2. Loss localized on
O-ring seals on the
With the engine off and other components of
A/C lines for the
compressor not the refrigerating
Diagnostic compressor.
activated, place the system.
complete 4. Replace the
"nose" of the leak 3. O-ring seal between
compressor
detector to the pulley the A/C lines and
If the compressor is
near the compressor compressor poorly
replaced because of
shaft lip seal and rear placed (pinched).
a mechanical
head gasket checking 4. Fastener threads
problem, be certain
for eventual loss. If so fixing the lines are
to flush the entire
(loss), repeat the test to damaged.
system and to
ascertain the actual change the filter
presence of the loss. drier.
Also, check if the leak is
localized on other
components of the
refrigerating system.
Remove the A/C lines
from the compressor
and make sure that the
O-rings are present in
the A/C lines and are
positioned correctly.
Verify the integrity on
compressor A/C line
fastener threads.
DIAGNOSIS AND TESTING > A/C RECIRCULATION DOES NOT WORK
NOTE:
When pressing the appropriate button on the A/C heater control, the recirculation function
does not work.
CHECK PROPER
1 FUNCTIONING A/C Result OK Result Not OK Action
HEATER CONTROL
The vehicle engine

running, set the climate
control unit in AUTO
position, turn the
temperature knob to
reach 22°C (71.6°F), set
the fan speed to 8 bars,
and then press the
recirculation button
(verify that the 1. The recirculation
recirculation symbol symbol does not
illuminates). appear on the
Then check for variation display.
of the air flow during the Continue to Step 2 1. Continue to Step 3
2. The recirculation
operation of opening / 2. Continue to Step 2
symbol appears on
closing door. Locate also the display (but
in the engine recirculation does
compartment, the box air not work)
intake grille and check
the air intake in the
transition from circulating
in the outdoor air intake.
"When the unit is set to
FULL AUTO function and
the outside temperature
is lower than 3°C
(37.4°F) above the air
intake door opens
automatically to prevent
discolorations at the
windshield".
CHECK WITH
DIAGNOSTIC TOOL

Errors on
tool and verify:
Continue to Step 6 recirculation Continue to Step 3
the absence of errors on
actuator
the recirculation actuator.
CHECKS USING
TOOL

tool and verify through
1. recirculation
active diagnosis:
actuator not working 1. Continue to Step 6
the proper functioning of
Continue to Step 6 2. The recirculation 2. Replace the A/C
the recirculation actuator
symbol does not heater control
correct illumination of all
illuminate.
the symbols of the LCD
graphics display.
CHECK ELECTRICAL
CONNECTIONS
Check integrity of
electrical wiring
connections.
Remove A/c heater
control from the
instrument panel,
disconnect the connector
cable from the controller,
visually inspect for
wire harness
damage to the connector, Securely connect or
connections
then reconnect it Continue to Step 5 repair the electrical
unstable or
correctly to check for connector
damaged
any false contacts.
Remove the glove box,
disconnect and visually
inspect for damage to
the recirculation actuator
connector, then
reconnect the electrical
connection to the
actuator.
VERIFY PROPER
OPERATION OF
RECIRCULATION
ACTUATOR
Proceed as follows: with
the car in motion,
manually enter the
recirculated air intake
function with the fan at
full speed. If the actuator
operates and the door is
dragged, sensitively the
kind of tone of the air
flow varies during
handling. Turn the
Incorrect operation
recirculation button off Replace the
Continue to Step 6 of the recirculation
bringing the actuator to recirculation actuator.
actuator.
the outside air position.
Locate the air intake
box, check for a change
of air intake in the
transition from external
air to recirculation air
and vice versa.
If the check is
successful, do not
replace the recirculation
actuator.
CHECK
6 RECIRCULATION DOOR Result OK Result Not OK Action
IN HVAC HOUSING
1. Clear the obstruction

1. incomplete door
from the recirculation
Visually verify that the travel.
door.
recirculation door travels Diagnostic 2. damaged
2. Replace the
the course without any complete recirculation door.
recirculation door.
impediment. 3. Mechanism / gear
3. Replace the damaged
damaged.
mechanism/gear.
DIAGNOSIS AND TESTING > ODORS FROM A/C
NOTE:
The air conditioner is operating normally, but you experience unpleasant odors in the
PRELIMINARY
CHECKS
Check with compressor
ON:
- that the condensation
drain is not clogged;
1. Condensate drain
- that condensation
clogged 1. Clean the
drains outside the
2. Condensate condensation drain
passenger
draining into car 2. Restore the correct
compartment;
3. Condensate drain functionality of the
- that the condensation
damaged condensation drain
drain is not damaged;
4. Recirculation 3. Replace the
- if the outlet air /
does not work condensation drain
recirculation is not
Continue to Step 1 5. Odors from 4. Continue as directed
working;
outside entering in Diagnostic Procedure
- that it is not
vehicle for A/C
unpleasant odors
6. Odors from RECIRCULATION DOES
coming from the
overheating of NOT WORK
outside, by operating
blower motor, 5. Continue to Step 5
the recirculation
resistor or blower 6. Replace damaged
- that it is not odors
power control component
from overheating the
module
blower motor, ceramic
resistor or blower motor
power module (vehicle
options).
1 CHECK CABIN FILTER Result OK Result Not OK Action
Check the condition of

the cabin filter
Replace the filter
The cabin filter should Continue to Step 2 clogged filter
element
be replaced at least
once a year
CHECK AIR INLET

DUCT
Check the air inlet

ducts: they should not
Continue to Step 3 Air ducts clogged Clean the ducts
be obstructed with dirty
or smelly substances
3 CHECK EVAPORATOR Result OK Result Not OK Action
With the engine started,

off (compressor OFF),
set the temperature
Continue to Step 6 Odors persist Continue to Step 4
knob on max heat,
operate the blower
motor. Verify that the
odor disappears
4 CHECK HEATER CORE Result OK Result Not OK Action

Check that the heater
core does not have the
fins blocked by dirt or
other substances.
With the car engine
running hot engine 1. dirty or clogged
1. Clean the heater core
temperature and air Diagnostic heater core
2. Replace the heater
conditioning knob complete 2. fluid leakage from
core
(temperature) in heater core
maximum heat, make
sure there is no leakage
of engine coolant inside
the car under the HVAC
housing
CHECK AIR INLET

5 HOUSING FOR Result OK Result Not OK Action
CLEANING
Verify that there are no

foreign objects inside
1. dirty or foreign
the air inlet housing. 1. clean the air inlet
object in air inlet
Check in particular the Diagnostic housing
housing
perfect tightness of the complete 2. Restore the correct
2. air inlet seal not
seal between the air positioning of the seal
sealing
inlet and engine
compartment
EVAPORATOR
REPLACEMENT
Replacing the
Ask the customer if it is
evaporator (see if you
the first time there is a
can clean it)
fault, in this case, clean
For disinfection of mold
the evaporator;
on the evaporator, we
2nd complaint by the
recommend the use of Diagnostic Evaporator covered
customer, if it has been
the Aircomatic complete with mold
more than six months,
Equipment product with
clean the evaporator
the Wynn's Airco-clean
again; if less than 6
following the
months, replace the
manufacturer's
evaporator
instructions of use.
DIAGNOSIS AND TESTING > HEATER PERFORMANCE
Before performing the following tests, see STANDARD PROCEDURE for the procedures to check the
engine coolant level and flow, engine coolant reserve/recovery system operation, accessory drive belt
condition and tension, radiator air flow and cooling fan operation. Perform the A/C System Performance
Test, which is found within the HVAC System Test. Refer to STANDARD PROCEDURE . If any
Diagnostic Trouble Codes (DTCs) are found in the A/C heater control or the Powertrain Control Module
(PCM), repair as necessary.
WARNING:
Do not remove radiator cap when engine is hot, personal injury can result.
If vehicle has been run recently, wait 15 minutes before removing the radiator cap. Place a rag over the
cap and turn it to the first safety stop. Allow pressure to escape through the overflow tube. When the
system pressure stabilizes, remove the cap completely.
DIAGNOSIS AND TESTING > HEATER PERFORMANCE > HEATER PERFORMANCE

TEST
Engine coolant is delivered to the heater core through two heater hoses. With the engine idling at normal
operating temperature, set the temperature control to the full hot position, the mode control to the floor
position, and the blower motor control to the highest speed position. Using a test thermometer, check the
temperature of the air being discharged at the HVAC housing floor outlets. Compare the test
thermometer reading to the Heater Temperature Reference chart.
HEATER TEMPERATURE REFERENCE
16° C 21° C 26° C 32° C

Ambient Air Temperature
(60° F) (70° F) (80° F) (90° F)
Minimum Heater System Air 52° C 56° C 59° C 62° C

Outlet Temperature (125° F) (133° F) (139° F) (144° F)
See ENGINE COOLING SYSTEM if the heater outlet air temperature is below the minimum specification.
Both of the heater hoses should be hot to the touch. The coolant return heater hose should be slightly
cooler than the coolant supply heater hose. If the return hose is much cooler than the supply hose,
locate and repair the engine coolant flow obstruction in the cooling system.
DIAGNOSIS AND TESTING > HEATER PERFORMANCE > OBSTRUCTED COOLANT

FLOW
Possible causes of insufficient engine coolant flow are as follows:
Improper heater hose routing.
Low engine coolant.
Pinched, kinked or plugged heater hoses.
Plugged heater core.
Plugged heater hose supply and return ports at the engine.
If proper coolant flow through the cooling system is verified, and heater outlet air temperature is still low,
a mechanical problem may exist.
STANDARD PROCEDURE > STANDARD PROCEDURE - A/C EVAPORATOR CLEANING
When equipped with A/C, some vehicle operators may experience a musty odor from the Heating,
Ventilation, and Air Conditioning (HVAC) system, primarily at start up in hot and humid climates. This odor
may be the result of microbial growth on the A/C evaporator. During normal A/C system operation,
condensation forms in and around the A/C evaporator. When airborne pollutants mix with the
condensation on The A/C evaporator, bacteria and fungi growth begins, and odor may result.
If the vehicle operator experiences a musty odor when operating the A/C system, perform the following
procedure.
WARNING:
Always use eye protection, rubber gloves and protective clothing when performing the
following procedure. Avoid continuous breathing of vapors from evaporator coil cleaning
and sealing fluids. Avoid contact with skin and eyes. Failure to follow these instruction may
1. Remove the cowl panel cover. Refer to COVER, COWL PANEL, REMOVAL AND
INSTALLATION .
2. Clean any dirt and debris that may be present at the HVAC fresh air inlet screen and at the top
of the cowl panel.
3. Install the cowl panel cover. Refer to COVER, COWL PANEL, REMOVAL AND INSTALLATION
.
5. Inspect the evaporator drain hose for foreign material that may be blocking the drain and repair
as necessary.
6. Once drain operation has been verified, temporarily pinch the drain hose closed using an
appropriate pair of heater hose pliers.
8. Place a protective cover over the driver and front passenger side floor and seating areas.
9. Remove the blower motor. (Refer to REMOVAL AND INSTALLATION ).
10. Remove and discard the cabin air filter. Refer to FILTER, CABIN AIR, REMOVAL AND
INSTALLATION .
11. Clean any dirt and debris that may be present inside the HVAC housing through all readily
accessible areas inside of the HVAC housing. If necessary, use a vacuum with a small flexible
hose, and take caution not to damage the fins of the A/C evaporator.
12. Using PSE Flex Spray Delivery Tool 534-62637 or equivalent, completely coat the entire
surface of A/C evaporator with three bottles of Mopar® Cooling Coil Cleaner through the
blower motor and filter openings. Be sure to use all of the coil cleaner in each container.
13. Allow the vehicle to sit for 30 minutes.
WARNING:
Excess cooling coil cleaner will drain from the evaporator housing when the pliers
are removed from the evaporator drain hose or tube. Always use eye protection,
rubber gloves and protective clothing. Avoid continuous breathing of vapors from
evaporator coil cleaning fluid. Avoid contact with skin and eyes. Failure to follow
these instruction may result in possible serious or fatal injury.
15. Remove the previously installed heater hose pliers and allow excess coil cleaner to drain from
the HVAC housing.
17. Refill the three empty coil cleaner bottles with clean tap water.
18. Using PSE Flex Spray Delivery Tool 534-62637 or equivalent, completely rinse the entire
surface of A/C evaporator with the three bottles of clean tap water through the blower motor
and filter openings. Be sure to use all of the water in each container.
19. Install the blower motor. (Refer to REMOVAL AND INSTALLATION ).
20. Install the cabin air filter cover, with out a filter. Refer to FILTER, CABIN AIR, REMOVAL AND
INSTALLATION .
21. Disconnect the wire harness connector from the A/C compressor to disable compressor
operation. Refer to COMPRESSOR, A/C, REMOVAL AND INSTALLATION .
22. Start the engine
23. Adjust all the windows so they are open approximately 8 mm (0.5 in.).
24. Set the A/C heater controls to the following:
1. air distribution to Panel and Recirculation mode
2. temperature to full heat
25. Allow the vehicle to run for 20 minutes.
26. Turn the engine off.
28. Inspect the evaporator drain hose for foreign material that may have blocked the drain during
evaporator coil cleaning and repair as necessary.
29. Once drain operation has been verified, temporarily pinch the drain hose closed again using an
appropriate pair of heater hose pliers.

31. Remove the blower motor. (Refer to REMOVAL AND INSTALLATION ).
32. Remove the cabin air filter cover. Refer to FILTER, CABIN AIR, REMOVAL AND
INSTALLATION .
33. Using PSE Flex Spray Delivery Tool 534-62637 or equivalent, completely coat the entire
surface of A/C evaporator with one bottle of Mopar® Cooling Coil Coating through the blower
motor and filter openings. Be sure to use all of the coil coating in the container.
NOTE:
Be sure to thoroughly clean out the spray delivery tool with warm water once coil
coating is complete to prevent damage to the tool.
34. Refill the empty bottles with clean warm tap water and completely rinse out the PSE Flex Spray
Delivery Tool 534-62637, or equivalent.
35. Allow the vehicle to sit for 30 minutes.
36. Install the blower motor. (Refer to REMOVAL AND INSTALLATION ).
37. Install a new cabin air filter and the cover. Refer to FILTER, CABIN AIR, REMOVAL AND
INSTALLATION .
WARNING:
Excess cooling coil coating will drain from the evaporator housing when the clamp,
cap or plug is removed from the evaporator drain hose or tube. Always use eye
protection, rubber gloves and protective clothing. Avoid continuous breathing of
vapors from evaporator coil sealing fluid. Avoid contact with skin and eyes. Failure
to follow these instruction may result in possible serious or fatal injury.
39. Remove the previously installed pliers from the evaporator drain hose and allow excess coil
coating to drain from the HVAC housing.
41. Start the engine
42. Adjust all the windows so they are open approximately 8 mm (0.5 in.).
43. Set the A/C heater controls to the following:
1. air distribution to Panel and Recirculation mode
2. temperature to full heat
44. Allow the vehicle to run for 20 minutes.
45. Turn vehicle off.

46. Remove the protective covers from the driver and front passenger side floor and seating
areas.
47. Connect the wire harness connector to the A/C compressor. Refer to COMPRESSOR, A/C,
48. Verify proper heating and A/C system operation.
SPECIFICATIONS > A/C SYSTEM

A/C SYSTEM SPECIFICATIONS TABLE
Type Specification - - - -
Maximum
140 cc / rev 140.6 cc / rev 140.6 cc / rev 140.6 cc / rev
Displacement
Minimum
6 cc / rev 0 cc / rev 0 cc / rev 0 cc / rev
Displacement
Number of Cylinders 6 6 6 6
Continuous RPM
8000
Maximum
Maximum speed not

continuous (max 10 8500
hours)
Maximum speed not

continuous (max 10 9200
minutes)
RPM Minimum 700

Description N.m Ft. Lbs. In. Lbs. NEW FASTENER*
A/C Compressor to
25 18 -
Engine M8 Bolts
Refrigerant Lines to
A/C Compressor M6 9 6.6 79.7
Bolt
A/C Compressor M8 20 15 177
Bolt
9 6.6 79.7
A/C Condenser
*NEW FASTENER: Do not reuse these fasteners. If removed, a new fastener must be installed
and tightened to specifications.
6801 - Terminal Probe

9764 - Pliers, A/C Snap Ring

C-4755 - Trim Stick

(Originally Shipped In Kit Number(s) 9299, 9299CC, 9299CC,
9300A-CAN.)
CONTROLS > ACTUATOR, BLEND DOOR > DESCRIPTION AND OPERATION >
The blend door actuator is a direct current motor controlled at 12 V, but usually operates between 10 V
and 16 V.
The specific feature of the potentiometer is that it is linear. The potentiometer receives a 5 V power
supply at pin 3 and receives the earth at pin 1. The signal of the potentiometer exits pin 2 and is
compared with the supply of the Heating, Ventilation, and Air Conditioning (HVAC) module. This is not an
absolute value, it is a percentage of the power supply. Therefore this measurement is not linked to the
level of the battery. The value of the potentiometer resistance must be about 4.7 kilohms.
CONTROLS > ACTUATOR, MODE DOOR > DESCRIPTION AND OPERATION >
The mode door actuator is a direct current motor controlled at 12 V, but usually operates between 10 V
and 16 V.
CONTROLS > ACTUATOR, RECIRCULATION DOOR > DESCRIPTION AND

OPERATION > DESCRIPTION AND OPERATION > DESCRIPTION
The recirculation door actuator is a direct current motor controlled at 12 V, but usually operates between
10 V and 16 V.
CONTROLS > CONTROL, A/C AND HEATER > DESCRIPTION AND OPERATION >
Fig 1: Manual Temperature Control (MTC) A/C Heater Control

Manual A/C Heater Control
The Manual Temperature Control (MTC) A/C heater control includes the following controls:
Blower motor activation/adjustment knob (1):
0 = blower motor off
blower motor speed (7 different speeds can be chosen)
Air temperature adjustment knob and MAX A/C function activation (2):
blue section = cold air
red section = hot air
Air distribution knob (3):
air from central outlets and side vents
air from central outlets, side vents and front and rear footwell vents
air outlet from the front and rear footwell vents and a light air flow also from the side vents on the
dashboard
air outlet from the front and rear footwell vents, to the windshield, the side windows and a light air
flow also at the side vents on the dashboard
air outlet to the windshield, the side windows and a light air flow also at the side vents on the
dashboard
Four further intermediate positions are also possible in the 5 main distributions described above:
Air recirculation on/off button (4)
Climate control compressor on/off button
Heated rear window on/off button
Selecting the footwell/windshield or only windshield distribution activates the climate control system
compressor (LED on A/C button on) and the air recirculation is set to "outside air" (LED on button B off).
This logic guarantees optimum visibility at the windows. The driver can always set air recirculation and
climate control system compressor.
Fig 2: Automatic Temperature Control (ATC) A/C Heater Control
Automatic A/C Heater Control
The Automatic Temperature Control (ATC) A/C heater control incorporates the following controls:
Driver side temperature display (1).
Driver side temperature adjustment knob (2).
On/off button for internal air recirculation (3).
Climate control system on/off button (4).
Air distribution selection buttons (5).
SYNC function activation button (alignment of set temperatures) driver/passenger side (6).
Passenger side temperature display (7).
AUTO function activation button (automatic operation) (8).
Passenger side temperature adjustment knob (9).
Heated rear window on/off button (10).
Blower motor speed indicator LED (11).
Button for activating the MAX DEF function (fast front window defrosting/demisting) (12).
Climate control compressor on/off button (13).

The dual zone automatic climate control system regulates the temperature in the passenger compartment
in two areas:
Driver side.
Passenger side.
The system maintains comfort inside the passenger compartment and compensates for possible
variations in outside weather conditions.
The automatically controlled parameters and functions are:
Air temperature at the driver/front passenger side vents
Air distribution at the driver/front passenger side vents
Blower motor speed (continuous variation of the air flow)
Compressor engagement (for cooling/dehumidifying the air)
Air recirculation
All these functions can be adjusted manually by operating the system and selecting one or more
functions and modifying their parameters. Manual selections always have higher priority than automatic
settings and are stored until the AUTO button is pressed, except for cases in which the system
intervenes for safety reasons.
The following operations do not deactivate the AUTO function:
Recirculation activation/deactivation
Compressor activation/deactivation
Sync function activation
Heated rear window activation/deactivation
You can adjust one function manually without affecting the automatic control of the others. The amount of
air introduced into the passenger compartment is not affected by vehicle speed; it is regulated by the
blower motor, which is electronically controlled.
The temperature of the air sent is always automatically controlled according to the temperature set on
the display (except for when the system is off or in certain conditions when the compressor is not
running).
The system allows the following to be set or adjusted manually:
Driver/passenger side air temperature
Blower motor speed (continuous variation)
Air distribution to 7 positions
Compressor engagement
Rapid defrosting/demisting function
Air recirculation
Heated rear window
System deactivation
The A/C heater control cannot be adjusted or repaired and must be replaced if inoperative or damaged.
CONTROLS > CONTROL, A/C AND HEATER > REMOVAL AND INSTALLATION >
WARNING:
NOTE:
Automatic A/C heater control shown, manual A/C heater control similar.
cable.

3. Reaching through the radio compartment to access the A/C heater control retaining clips (1a),
disengage the four retainers (1a) while pulling the A/C heater control (1b) away from the
instrument panel.
4. Disconnect the HVAC wire harness connector (2) from the A/C heater control (1b) and remove
the A/C heater control.
CONTROLS > CONTROL, A/C AND HEATER > REMOVAL AND INSTALLATION >
NOTE:
Automatic A/C heater control shown, manual A/C heater control similar.
1. Position the A/C heater control (1b) to the instrument panel and connect the HVAC wire
2. Align the four retainers (1a) of the A/C heater control (1b) with the instrument panel and press
into place. Be certain all four retainers (1a) are fully engaged with the instrument panel.

5. Initiate the Actuator Calibration function using a scan tool. Refer to STANDARD PROCEDURE
.
NOTE:
If this Electronic Control Unit (ECU) is being replaced with a new unit, a
diagnostic scan tool MUST be used to align the PROXI configuration data into
the new ECU. Follow the routine outlined in the diagnostic scan tool for
PROXI Configuration Alignment under Body Control Module (BCM)
Miscellaneous Functions menu.
CONTROLS > MODULE, POWER, BLOWER MOTOR > DESCRIPTION AND

The power blower motor module is a linear regulator. The Heating, Ventilation, and Air Conditioning
(HVAC) sends a Pulse Width Modulated (PWM) signal to control the blower motor speed. The regulator
sends its operating status to the HVAC module.
CONTROLS > SENSOR, AMBIENT TEMPERATURE > DESCRIPTION AND OPERATION

The Heating, Ventilation, and Air Conditioning (HVAC) module receives the information about outside
temperature to carry out the correct air mixing strategies from the Body Control Module (BCM) via
Controller Area Network (CAN). The ambient temperature sensor is positioned in the right door mirror
and it is managed by the BCM, which also receives the sensor's temperature information. The BCM
sends the ambient temperature value via CAN for the modules that require this information.
CONTROLS > SENSOR, EVAPORATOR TEMPERATURE > DESCRIPTION AND

The evaporator temperature sensor is used to measure the temperature of the evaporator for the
Heating, Ventilation, and Air Conditioning (HVAC) module. When the evaporator reaches a temperature
that is critical for its safety, the HVAC module disables the A/C request.
The sensor resistance is about 9.965 kilohms at 25°C (77°F) and 32.52 kilohms at 0°C (32°F).
CONTROLS > SENSOR, HUMIDITY > DESCRIPTION AND OPERATION >

CAUTION:
Use care when servicing the humidity sensor. The humidity sensor bracket cannot be
serviced separately from the windshield. If the sensor bracket becomes damaged, the
windshield will need to be replaced.
The Heating, Ventilation, and Air Conditioning (HVAC) module uses the passenger compartment humidity
value to implement the correct operating strategy to activate the compressor, set the correct amount of
recirculated air, blower motor speed and exit mode, to prevent the windshield from misting up.
The humidity sensor is managed by the Instrument Panel Cluster (IPC) module, which receives its
information and sends it via the Controller Area Network (CAN) for the modules that require it.
CONTROLS > SENSOR, HUMIDITY > REMOVAL AND INSTALLATION > REMOVAL
WARNING:
Fig 1: Remove/Install Humidity Sensor
cable.
CAUTION:
Use care when removing the humidity sensor cover. The humidity sensor bracket
cannot be serviced separately from the windshield. If the sensor bracket becomes
damaged, the windshield will need to be replaced.
2. Using trim stick C-4755 or equivalent, carefully remove the upper cover (1a).
CAUTION:
Use care when removing the humidity sensor. The humidity sensor bracket cannot
be serviced separately from the windshield. If the sensor bracket becomes
3. Using trim stick C-4755 or equivalent, carefully remove the lower cover (2a).
Fig 2: Humidity Sensor, Retaining Clip & Wire Connector

CAUTION:
Use care when removing the humidity sensor. The humidity sensor bracket cannot
4. Using a small screwdriver or similar tool, carefully disengage the metal retaining clip (2a) from
the sensor bracket and remove the humidity sensor (2b) and the clip as an assembly.
5. Disconnect the wire harness connector (1) from the humidity sensor (2b).
6. If the humidity sensor bracket is damaged and cannot be reused, replace the windshield. Refer
to WINDSHIELD, REMOVAL AND INSTALLATION .
CONTROLS > SENSOR, HUMIDITY > REMOVAL AND INSTALLATION > REMOVAL
Fig 1: Humidity Sensor, Retaining Clip & Wire Connector
1. If the humidity sensor bracket is damaged and cannot be reused, install a new windshield.
Refer to WINDSHIELD, REMOVAL AND INSTALLATION .
2. Connect the wire harness connector (1) to the humidity sensor (2b).
CAUTION:
Use care when installing the humidity sensor. The humidity sensor bracket cannot
3. Position the humidity sensor (2b) to the sensor bracket and engage the metal retaining clip
(2a) to the bracket. Be certain both sides of the retaining clip (2a) are fully engaged to the
bracket.
Fig 2: Remove/Install Humidity Sensor

CAUTION:
Use care when install the humidity sensor cover. The humidity sensor bracket
4. Carefully align the lower cover (2a) to the attachment pins (2c) on the sensor bracket.
5. Install the lower cover (2a) by pressing it into place on the attachment pins (2c). Be certain all
of the retaining tabs (2b) are fully engaged to the bracket.
CAUTION:
Use care when install the humidity sensor cover. The humidity sensor bracket
6. Position the upper cover (1a) and install it by pressing it into place. Be certain all of the
retaining tabs (1b) are fully engaged to the bracket.
CONTROLS > SENSOR, SUN > DESCRIPTION AND OPERATION > DESCRIPTION
The Heating, Ventilation, and Air Conditioning (HVAC) module uses the sun sensor to measure solar
radiation inside the passenger compartment and define the best strategy to cool down the vehicle.
Temperature sensor technical specifications:
Characteristics Value
Supply 5 V ± 0.1
Max. current uptake 10 mA
Operating range Temp. -40 to 105 °C (-40 to 221 °F)
Output current Imin = 0.25 mA & Imax = 2.18 mA
Sun sensor response time < 10 ms
CONTROLS > SENSOR, SUN > REMOVAL AND INSTALLATION > REMOVAL AND
WARNING:
Fig 1: Sun Sensor & Wire Connector
cable.
NOTE:
Take the proper precautions to protect the instrument panel from cosmetic
damage.
2. Using Trim Stick (special tool #C-4755, Trim Stick) or equivalent, remove the sun sensor (1a)
from the defroster grille.
3. Disconnect the wire harness connector (2) from the sun sensor (1a) and remove the sensor.
CONTROLS > SENSOR, SUN > REMOVAL AND INSTALLATION > REMOVAL AND
Fig 1: Sun Sensor & Wire Connector
1. Position the sun sensor (1a) to the top of the instrument panel and connect the wire harness
connector (2) to the sensor.
2. Align the tabs on the sun sensor (1b) with the slot in the opening in the defroster grille and
install the sensor into the grille. Be certain that the sensor (1a) is fully engaged to the defroster
grille.
CONTROLS > SENSOR, TEMPERATURE, AIR OUTLET > DESCRIPTION AND

Fig 1: Air Outlet Temperature Sensor
There are four temperature sensors on the HVAC unit output. Two are on the lower part and the others
are on the upper part.
These sensors are NTC type. This means that their resistance decreases when temperature increases.
The sensor resistance is about 10 kilohms at 25°C (77°F) and 32, 650 kilohms at 0°C (32°F).
The air duct temperature sensors are diagnosed using a scan tool. Refer to DIAGNOSIS AND TESTING
.
The air duct temperature sensors cannot be adjusted or repaired and must be replaced if inoperative or
damaged.
CONTROLS > SENSOR, TEMPERATURE, AIR OUTLET > REMOVAL AND

INSTALLATION > AIR OUTLET TEMPERATURE SENSOR - LOWER LEFT > REMOVAL
WARNING:
WARNING:
Disable the airbag system before attempting any steering wheel, steering column or
instrument panel component diagnosis or service. Disconnect and isolate the negative
battery (ground) cable and wait two minutes for the airbag system capacitor to discharge
before performing further diagnosis or service. This is the only sure way to disable the
airbag system. Failure to follow these instructions may result in accidental airbag
deployment and possible serious or fatal injury.
Fig 1: Remove/Install Air Outlet Temperature Sensor - Lower Left
cable.
2. Remove the steering column opening cover. Refer to COVER, STEERING COLUMN
OPENING, REMOVAL AND INSTALLATION .
3. Disconnect the HVAC wire harness (2) from the air duct temperature sensor (1a).
4. Using Trim Stick (special tool #C-4755, Trim Stick) (3) or equivalent, disengage the air duct
temperature sensor (1a) from the left side of the HVAC housing and remove the sensor.

INSTALLATION > AIR OUTLET TEMPERATURE SENSOR - LOWER LEFT >
INSTALLATION
Fig 1: Remove/Install Air Outlet Temperature Sensor - Lower Left
1. Install the air duct temperature sensor (2) into the left side of the HVAC housing. Be certain the
sensor retaining tabs (1b) are fully engaged to the housing.
2. Connect the HVAC wire harness (2) to the air duct temperature sensor (1a).

INSTALLATION > AIR OUTLET TEMPERATURE SENSOR - LOWER RIGHT >
REMOVAL
WARNING:
Fig 1: Remove/Install Air Outlet Temperature Sensor - Lower Right
cable.
2. Remove the instrument panel glovebox to gain access to the air duct temperature sensor (2a),
located on the upper right side of the HVAC housing. Refer to GLOVE BOX, INSTRUMENT
temperature sensor (2a) from the right side of the HVAC housing and remove the sensor.
INSTALLATION > AIR OUTLET TEMPERATURE SENSOR - LOWER RIGHT >
INSTALLATION
Fig 1: Remove/Install Air Outlet Temperature Sensor - Lower Right
1. Install the air duct temperature sensor (2a) into the right side of the HVAC housing. Be certain
the sensor retaining tabs (2b) are fully engaged to the housing.
3. Install the instrument panel glovebox. Refer to GLOVE BOX, INSTRUMENT PANEL, REMOVAL
AND INSTALLATION .

INSTALLATION > AIR OUTLET TEMPERATURE SENSOR - UPPER LEFT > REMOVAL
WARNING:
Fig 1: Remove/Install Steering Column Opening Cover Support Bracket
cable.
3. Disconnect the Data Link Connector (DLC) (1a) from the steering column opening cover
support bracket (1d).
4. Remove the screws (1b) and the nut (1c) for the steering column opening cover support
bracket (1d) and remove the bracket.
Fig 2: Remove/Install Air Outlet Temperature Sensor - Upper Left
5. Disconnect the wire harness connector (2) from the air duct temperature sensor (1a).
temperature sensor (1a) from the left side of the HVAC housing (2) and remove the sensor.

INSTALLATION > AIR OUTLET TEMPERATURE SENSOR - UPPER LEFT >
INSTALLATION
Fig 1: Remove/Install Air Outlet Temperature Sensor - Upper Left
1. Install the air duct temperature sensor (1a) into the left side of the HVAC housing. Be certain
Fig 2: Remove/Install Steering Column Opening Cover Support Bracket
3. Position the steering column opening cover support bracket (1d) and install the screws (1b)
and the nut (1c) for the bracket (1d). Tighten the screws and nut securely.
4. Connect the Data Link Connector (DLC) (1a) to the steering column opening cover support
bracket (1d).

INSTALLATION > AIR OUTLET TEMPERATURE SENSOR - UPPER RIGHT > REMOVAL
WARNING:
Fig 1: Remove/Install Air Outlet Temperature Sensor - Upper Right
cable.
2. Remove the instrument panel glovebox to gain access to the air duct temperature sensor (1a),
located on the upper right side of the HVAC housing. Refer to GLOVE BOX, INSTRUMENT
temperature sensor (1a) from the right side of the HVAC housing and remove the sensor.
INSTALLATION > AIR OUTLET TEMPERATURE SENSOR - UPPER RIGHT >
INSTALLATION
Fig 1: Remove/Install Air Outlet Temperature Sensor - Upper Right
1. Install the air duct temperature sensor (1a) into the right side of the HVAC housing. Be certain
3. Install the instrument panel glovebox. Refer to GLOVE BOX, INSTRUMENT PANEL, REMOVAL
AND INSTALLATION .
CONTROLS > SENSOR, TEMPERATURE, IN-CAR > DESCRIPTION AND OPERATION >
DESCRIPTION
The Heating, Ventilation, and Air Conditioning (HVAC) module uses an in-vehicle temperature sensor to
activate the correct operating strategy for the conditioning system.
Sensor specifications:
Function Unit Min. Rated Max.
Operating temperature °C (°F) -40 (-40) 23 (73.4) +85 (+185)
Operating power supply VDC 8 12 16
Operating current mA 100
CONTROLS > SENSOR, TEMPERATURE, IN-CAR > REMOVAL AND INSTALLATION >
WARNING:
NOTE:
Take the proper precautions to protect the face of the steering column opening cover
from cosmetic damage while performing this procedure.
cable.
Fig 1: Remove/Install In-Car Temperature Sensor
3. Remove the screw (1a) that secures the in-car temperature sensor (1b) to the instrument
panel and remove the sensor from the instrument panel.
Fig 2: In-Car Temperature Sensor & Wire Connector
4. Disconnect the wire harness connector (1) from the in-car temperature sensor (2) and remove
the sensor from the vehicle.
CONTROLS > SENSOR, TEMPERATURE, IN-CAR > REMOVAL AND INSTALLATION >
NOTE:
Take the proper precautions to protect the face of the steering column opening cover
from cosmetic damage while performing this procedure.
Fig 1: In-Car Temperature Sensor & Wire Connector

1. Position the in-car temperature sensor (2) to connect the wire harness connector (1) to the
sensor.
Fig 2: Remove/Install In-Car Temperature Sensor
2. Position the in-car temperature sensor (1b) to the instrument panel, guiding the aligning pin (1c)
on the sensor to the instrument panel.
3. Install the screw (1a) that secures the in-car temperature sensor (1b) to the instrument panel.
Tighten the screw securely.
DISTRIBUTION > FILTER, CABIN AIR > DESCRIPTION AND OPERATION >
Fig 1: Particulate Air Filter (Cabin Air Filter)
Some models are equipped with a cabin air filter (1) that helps purify the outside air entering the vehicle.
The cabin air filter is mounted in the HVAC housing, behind the glove box bin.
The filter should be replaced at least once a year or every 24, 000 km (15, 000 miles), and checked if
the heating and A/C system performance seems lower than expected. The cabin air filter is labeled with
an arrow (2) to indicate the direction of air flow through the filter.
DISTRIBUTION > FILTER, CABIN AIR > REMOVAL AND INSTALLATION > REMOVAL
WARNING:
cable.
2. Remove the glove box. Refer to GLOVE BOX, INSTRUMENT PANEL, REMOVAL AND
INSTALLATION .
Fig 1: Remove/Install Cabin Filter
3. Release the retainer (1a) and remove the cover (1b) for the cabin filter.
Fig 2: Cabin Filter Air Flow Direction
NOTE:
Make note of the air flow direction (1b).
4. Remove the cabin air filter (1a) from HVAC housing by pulling the filter element straight out of
the housing.
DISTRIBUTION > FILTER, CABIN AIR > REMOVAL AND INSTALLATION > REMOVAL
NOTE:
The cabin air filter is labeled with an arrow to indicate air flow direction through the filter.
Make sure to properly install the cabin air filter. Failure to properly install the filter will result
in the need to replace the filter sooner than required by design.
Fig 1: Cabin Filter Air Flow Direction
NOTE:
Make note of the air flow direction (1b).

Fig 2: Remove/Install Cabin Filter
1. Install the cabin air filter (1a) into the HVAC housing.
2. Install the cabin air filter cover (1b) onto the HVAC housing (2) and engage the retaining clip
(1a).
3. Install the glove box. Refer to GLOVE BOX, INSTRUMENT PANEL, REMOVAL AND
INSTALLATION .
DISTRIBUTION > HOUSING, HVAC > REMOVAL AND INSTALLATION >

HOUSING-HVAC > REMOVAL
WARNING:
WARNING:
Review the warnings and cautions for this system before performing the procedure. Failure
to follow these instructions may result in serious injury or death.
1. Remove the instrument panel cover. Refer to COVER, INSTRUMENT PANEL, REMOVAL AND
INSTALLATION .
2. Remove the engine cover and clean air hose. (Refer to REMOVAL AND INSTALLATION - 1.4L
or REMOVAL AND INSTALLATION - 2.4L ).
3. Partially drain the engine cooling system. Refer to STANDARD PROCEDURE .
PROCEDURE .
Fig 1: Heater Hoses, A/C Suction Lines, A/C Liquid Lines & Nuts
5. Disengage the two tabs that secure each heater hose connector (2) to the heater core tubes
and disconnect the connectors from the tubes.
6. Install plugs in, or tape over the open heater core tubes to prevent coolant spillage inside the
vehicle during HVAC housing removal.
7. Remove the two nuts (1a) that secure the A/C suction and A/C liquid lines (1b) to the A/C
expansion valve.
8. Disconnect the A/C suction and liquid lines (1) from the A/C expansion valve (2). Remove and
discard the seal washers.
9. Install plugs in, or tape over the open refrigerant line fittings and the A/C expansion valve ports.
10. Remove the instrument panel carrier. Refer to CARRIER, INSTRUMENT PANEL, REMOVAL
AND INSTALLATION .
Fig 2: Condensation Tube Clamp, Retainer, Wire Harness & Ground Wire Nut
11. Remove the condensation tube clamp (1c) and disengage the tube retainer (1b) from the HVAC
housing. Remove the condensation tube from the HVAC housing.
12. Disconnect the vehicle wire harness (2) from the HVAC wire harness.
13. Remove the nut (3) from the ground wire floor stud and disconnect the ground wire from the
vehicle.
Fig 3: HVAC Housing, Rear Air Floor Ducts & Connecting Points
14. Disconnect the rear air floor ducts (1a) from the HVAC housing at the connecting points (1b).
15. Remove the HVAC housing (2) from the vehicle.
DISTRIBUTION > HOUSING, HVAC > REMOVAL AND INSTALLATION >

HOUSING-HVAC > INSTALLATION
NOTE:
If a foam seal on the HVAC housing or air inlet housing is deformed or damaged, the seal
must be replaced.
NOTE:
Replacement of the seal washers is required anytime a refrigerant line or A/C expansion
valve is disconnected. Failure to replace the seal washers may result in a refrigerant system
leak.
Fig 1: HVAC Housing, Rear Air Floor Ducts & Connecting Points
1. Position the HVAC housing (2) to the dash panel.
2. Connect the rear air floor ducts (1a) to the HVAC housing at the connecting points (1b).
Fig 2: Condensation Tube Clamp, Retainer, Wire Harness & Ground Wire Nut
3. Attach the ground wire to the ground wire floor stud in the vehicle and install the nut (3). Tighten
the nut securely.
4. Install the condensation tube (1a) and secure the tube retainer (1b). Attach a new
condensation tube clamp (1c).
5. Connect the vehicle wire harness (2) to the HVAC wire harness.
6. Install the instrument panel carrier. Refer to CARRIER, INSTRUMENT PANEL, REMOVAL AND
INSTALLATION .
Fig 3: Heater Hoses, A/C Suction Lines, A/C Liquid Lines & Nuts
7. Remove the tape or plugs from the opened refrigerant line fittings and the expansion valve
ports.
8. Lubricate new seal washers with clean refrigerant oil and install them onto the refrigerant line
fittings. Use only the specified seals as they are made of a special material for the refrigerant
in the system. Use only refrigerant oil of the type recommended for the A/C compressor in the
vehicle.
9. Connect the A/C liquid and A/C suction lines (1b) to the A/C expansion valve.
10. Install the two nuts (1a) that secures the A/C liquid and suction lines (1) to the A/C expansion
valve. Tighten the nuts to the proper SPECIFICATIONS .
11. Remove the plugs or tape from the heater core tubes.
12. Lubricate the O-ring seals in the two heater hose connectors (2) with clean engine coolant and
connect the heater hose connectors (2) to the heater core tubes. Make sure the two retaining
tabs in each connector are fully engaged to the tubes.
13. Refill the engine cooling system. Refer to STANDARD PROCEDURE .
14. Install the instrument panel cover. Refer to COVER, INSTRUMENT PANEL, REMOVAL AND
INSTALLATION .
17. Install the engine cover and clean air hose. (Refer to REMOVAL AND INSTALLATION - 1.4L or
REMOVAL AND INSTALLATION - 2.4L ).
DISTRIBUTION > HOUSING, HVAC > DISASSEMBLY AND ASSEMBLY >

DISASSEMBLY AND ASSEMBLY - GEARS AND LEVERS > DISASSEMBLY
WARNING:
1. Remove the HVAC housing from the vehicle and place it on a workbench. Refer to HOUSING,
HVAC, REMOVAL AND INSTALLATION .
Fig 1: Mode Door Actuator, Wire Connector, Drive Gear & Screws
NOTE:
Mark the position of the gears and levers prior to disassembly to assist in the
assembly procedure.
2. Disconnect the HVAC wire harness connector (1) from the mode door actuator (3).
3. Remove the three screws (2) from mode door actuator (3).
4. Remove the mode door actuator (3), disengaging the drive gear (4). If replacing the drive gear
(4), remove it from the actuator (3).
Fig 2: Driven Gear, Transfer Lever & Fasteners
5. Remove the screw (1) from the transfer lever (2).
6. Remove the transfer lever (2).
7. Disengage the retainer (3a) and remove the driven gear (3b).
Fig 3: Gear/Lever Mechanism & Retainers
8. Release the retainers (1a) and (1b).
9. Remove the gear and lever mechanism (2).
10. Check that the various components of the gear train are not damaged.
DISTRIBUTION > HOUSING, HVAC > DISASSEMBLY AND ASSEMBLY >

DISASSEMBLY AND ASSEMBLY - GEARS AND LEVERS > ASSEMBLY
NOTE:
All of the linkage and gear to gear contact points on the HVAC housing should be
adequately lubricated, as well as the air door pivot shaft to HVAC housing contact points
using Molykote® Grease, available through Mopar. Do not get grease on the air door seals,
as this could cause unwanted flap noises and impairs the durability of the seal. Lubrication
should be performed if there is a concern or complaint of linkage chatter, grinding, or other
movement derived noises that are detectable in the cabin.
1. Check that the various components of the gear train are not worn or damaged. Replace any
gear train components that are worn or damaged.
Fig 1: Gear/Lever Mechanism & Retainers
2. Position the gear and lever mechanism (2) according to the position required for proper
alignment. Be certain the retainers are fully engaged.
Fig 2: Driven Gear, Transfer Lever & Fasteners
3. Install the driven gear (3b). Be certain the retainer (3a) is fully engaged.
4. Align the transfer lever (2) to the driven gear (3b) and install the screw (1). Tighten the screw
securely.
Fig 3: Mode Door Actuator, Wire Connector, Drive Gear & Screws
5. If removed, fit the drive gear (4) to the mode door actuator (3).
6. Align mode door drive gear (4) properly to the transfer lever and the gear and lever
mechanism.
7. Install the three screws (2) for the mode door actuator (3).
8. Connect the HVAC wire harness connector (1) to the mode door actuator (3).
9. Install the HVAC housing in the vehicle. Refer to HOUSING, HVAC, REMOVAL AND
INSTALLATION .
DISTRIBUTION > MOTOR, BLOWER > REMOVAL AND INSTALLATION > REMOVAL
WARNING: To avoid serious or fatal injury on vehicles equipped with airbags, disable
the Supplemental Restraint System (SRS) before attempting any steering wheel, steering
column, airbags, airbag curtains, knee blocker, seat belt tensioner, impact sensor or
instrument panel component diagnosis or service. Disconnect the IBS/negative battery cable
assembly from the negative battery post, then wait two minutes for the system capacitor to
discharge before performing further diagnosis or service. This is the only sure way to
disable the SRS. Failure to take the proper precautions could result in accidental airbag
deployment.
cable.
2. Remove the right front floor outlet duct (Refer to REMOVAL AND INSTALLATION ).
3. Remove the right silencer panel.
4. Working under the storage compartment, remove the screws (1a) and remove the guard (1b)
of the blower motor module.
Fig 1: Blower Motor Module Guard & Screws
5. Disconnect the electrical connection (1) for the blower motor.

Fig 2: Blower Motor, Electrical Connection & Screws
6. Remove the screws (2a) and remove the blower motor (2b).
DISTRIBUTION > MOTOR, BLOWER > REMOVAL AND INSTALLATION > REMOVAL
1. Fit the blower motor in its housing and tighten the fixing screws.
2. Connect the blower motor electrical connection.
3. Position the guard of the blower motor module and tighten the fixing screws.
4. Install the right silencer panel.
5. Install the right front floor outlet duct (Refer to REMOVAL AND INSTALLATION ).
DISTRIBUTION > OUTLET, AIR > REMOVAL AND INSTALLATION > AIR OUTLETS -
CENTER > REMOVAL
WARNING:
NOTE:
Take the proper precautions to protect the instrument panel from cosmetic damage.
Fig 1: Center Air Outlet & Fasteners
cable.
3. Working inside the radio compartment, remove the two screws (1) from the center air outlets
(2a).
4. Using trim stick C-4755 or equivalent, remove the center air outlet (2a) from the instrument
panel.
CENTER > INSTALLATION
NOTE:
Fig 1: Center Air Outlet & Fasteners
1. Position the center air outlet (2a) to the instrument panel and carefully press into place. Be
certain all retaining tabs (2b) are engaged with the instrument panel.
2. Working inside the radio compartment, install the two screws (1) to the center air outlet (2a).
DEMISTER > REMOVAL
WARNING:
NOTE:
Fig 1: Demister Air Outlet
cable.
2. Using trim stick C-4755 or equivalent, remove the demister air outlet (1) from the instrument
panel.
DEMISTER > INSTALLATION
NOTE:
Fig 1: Demister Air Outlet
1. Position the demister air outlet (1) to the instrument panel and press the outlet (1) into the
instrument panel. Be certain the retainers are fully engaged.
FRONT FLOOR > REMOVAL
WARNING:
Fig 1: Remove/Install Right Front Floor Air Outlet
cable.
2. To remove the right front floor air outlet, remove the instrument panel glovebox. Refer to
GLOVE BOX, INSTRUMENT PANEL, REMOVAL AND INSTALLATION .
3. Working in the glovebox opening, remove the retaining push pin (1) from the HVAC housing by
the blower motor.
4. Disengage the right front floor air outlet (2a and 3) from the HVAC housing (2b).
5. Remove the right front floor air outlet (2a and 3) from the vehicle.
Fig 2: Remove/Install Left Front Floor Air Outlet
6. To remove the left front floor air outlet, remove the steering column opening cover. Refer to
COVER, STEERING COLUMN OPENING, REMOVAL AND INSTALLATION .
7. Remove the retaining push pin (1a) from the instrument panel carrier (1b).
8. Disengage the left front floor air outlet (2a) from the HVAC housing (2b).
9. Remove the left front floor air outlet (2a) from the vehicle.
FRONT FLOOR > INSTALLATION
Fig 1: Remove/Install Right Front Floor Air Outlet
1. To install the right front floor air outlet, position the air outlet (2a and 3) to the HVAC housing
(2b) and push the air outlet onto the HVAC housing. Be certain the air outlet (2a) and HVAC
housing (2b) are fully engaged.
2. Insert the retaining push pin and press it into place in the HVAC housing by the blower motor.
Be certain the retaining push pin (1) is fully engaged.
3. Install the instrument panel glovebox, then go to Step 7. Refer to GLOVE BOX, INSTRUMENT
Fig 2: Remove/Install Left Front Floor Air Outlet
4. To install the left front floor air outlet, position the left front floor air outlet (2a) to the HVAC
housing and press the air outlet onto the HVAC housing. Be certain the air outlet (2a) and
HVAC housing (2b) are fully engaged.
5. Insert the retaining push pin (1a) through the left front floor air outlet and into the instrument
panel carrier (1b). Be certain the retaining push pin (1a) is fully engaged.
DISTRIBUTION > OUTLET, AIR > REMOVAL AND INSTALLATION > AIR OUTLET -
LEFT OUTER > REMOVAL
WARNING:
NOTE:
Fig 1: Air Outlet Bezel & Retaining Clips
cable.
AND INSTALLATION .
3. Using trim stick C-4755 or equivalent, remove the air outlet bezel (1a) from the instrument
cluster bezel.
Fig 2: Remove/Install Air Outlet
4. Using trim stick C-4755 or equivalent, release the retaining clips (1a) and remove the air outlet
(1b) from the instrument cluster bezel.
LEFT OUTER > INSTALLATION
NOTE:
Fig 1: Remove/Install Air Outlet
1. Position the air outlet (1b) to the instrument cluster bezel and engage the retaining clips (1a).
Be certain the retainers (1a) are fully engaged.
2. Position the air outlet bezel (1a) and press it into place in the instrument cluster bezel. Be
certain all of the retaining clips (1b) are fully engaged.
INSTALLATION .
RIGHT OUTER > REMOVAL
WARNING:
NOTE:
1.
cable.
3. Using trim stick C-4755 or equivalent, remove the air outlet bezel (1a) from the instrument
panel.
Fig 2: Remove/Install Air Outlet Bezel
4. Using trim stick C-4755 or equivalent, release the retaining clips (1b) and remove the air outlet
(1a) from the instrument panel.
RIGHT OUTER > INSTALLATION
NOTE:
Fig 1: Remove/Install Air Outlet Bezel
1. Position the air outlet (1a) to the instrument panel and engage the retaining clips (1b) to the
instrument panel. Be certain the retainers (1b) are fully engaged.
2. Position the air outlet bezel (1a) and press it into place in the instrument panel. Be certain all of
the retaining clips (1b) are fully engaged.
PLUMBING > WARNING > WARNING
WARNING:
The A/C system contains refrigerant under high pressure. Repairs should only be performed
by qualified service personnel. Serious or fatal injury may result from improper service
procedures.
WARNING:
Avoid breathing the refrigerant and refrigerant oil vapor or mist. Exposure may irritate the
eyes, nose, and/or throat. Wear eye protection when servicing the A/C refrigerant system.
Serious eye injury can result from direct contact with the refrigerant. If eye contact occurs,
seek medical attention immediately.
WARNING:
Do not expose the refrigerant to open flame. Poisonous gas is created when refrigerant is
burned. An electronic leak detector is recommended. Serious or fatal injury may result from
improper service procedures.
WARNING:
If accidental A/C system discharge occurs, ventilate the work area before resuming service.
Large amounts of refrigerant released in a closed work area will displace the oxygen and
cause suffocation and serious or fatal injury.
WARNING:
The engine cooling system is designed to develop internal pressures up to 145 kPa (21
psi). Do not remove or loosen the coolant pressure cap, cylinder block drain plugs, radiator
drain, radiator hoses, heater hoses, or hose clamps while the engine cooling system is hot
and under pressure. Allow the vehicle to cool for a minimum of 15 minutes before opening
the cooling system for service. Failure to observe this warning can result in serious burns
from the heated engine coolant.
PLUMBING > CAUTION > CAUTION

CAUTION:
Never add R-12 to a refrigerant system designed to use R-134a or R-1234yf. Never add
R-134a to a refrigerant system designed to use R-1234yf. Do not use R-12 equipment or
parts on an R-134a or R-1234yf A/C system. Do not use R-134a equipment or parts on an
R-1234yf A/C system. These refrigerants are not compatible and damage to the A/C system
will result.
CAUTION:
Never use R-12 refrigerant oil in an A/C system designed to use R-134a or R-1234yf
refrigerant oil. Never use R-134a refrigerant oil in an A/C system designed to use R-1234yf
refrigerant oil. These refrigerant oils are not compatible and damage to the A/C system will
result.
CAUTION:
The use of A/C system sealers may result in damage to A/C refrigerant recovery/evacuation
/recharging equipment and/or A/C system. Many federal, state/provincial and local
regulations prohibit the recharge of A/C systems with known leaks. Chrysler LLC
recommends the detection of A/C system leaks through the use of approved leak detectors
and fluorescent leak detection dyes. Vehicles found with A/C system sealers should be
treated as contaminated and replacement of the entire A/C refrigerant system is
recommended. A/C systems found to be contaminated with A/C system sealers, A/C
stop-leak products or seal conditioners voids the warranty for the A/C system.
CAUTION:
Recover the refrigerant before opening any fitting or connection. Open the fittings with
caution, even after the system has been discharged. Never open or loosen a connection
before recovering the refrigerant.
CAUTION:
If equipped, do not remove the secondary retention clip from any spring-lock coupler
connection while the refrigerant system is under pressure. Recover the refrigerant before
removing the secondary retention clip. Open the fittings with caution, even after the system
has been discharged. Never open or loosen a connection before recovering the refrigerant.
CAUTION:
The internal parts of the A/C system will remain stable as long as moisture-free refrigerant
and refrigerant oil is used. Abnormal amounts of dirt, moisture or air can upset the chemical
stability. This may cause operational troubles or even serious damage if present in more
than very small quantities. Before disconnecting a component, clean the outside of the
fittings thoroughly to prevent contamination from entering the refrigerant system. Keep
service tools and the work area clean. Do not open the refrigerant system or uncap a
replacement component until you are ready to service the system. Immediately after
disconnecting a component from the refrigerant system, seal the open fittings with a cap or
plug. This will prevent contamination from entering the A/C system.
CAUTION:
Refrigerant oil will absorb moisture from the atmosphere if left uncapped. Do not open a
container of refrigerant oil until you are ready to use it. Replace the cap on the oil container
immediately after using. Store refrigerant oil only in a clean, airtight, and moisture-free
container.
CAUTION:
Do not overcharge the refrigerant system. Overcharging will cause excessive compressor
head pressure and can cause compressor noise and A/C system failure.
PLUMBING > DIAGNOSIS AND TESTING > DIAGNOSIS AND TESTING -

REFRIGERANT SYSTEM LEAKS
WARNING:
Review the safety precautions and warnings in this service information before performing
this procedure. Failure to follow these instructions may result in serious injury or death.
WARNING:
Do not expose the refrigerant to open flame. Poisonous gas is created when refrigerant is
burned. An electronic leak detector is recommended. Serious or fatal injury may result from
improper service procedures.
WARNING:
Use extreme care when working around a running engine. Keep hands and fingers clear of
the radiator fan, accessory drive belt and all other moving components. Keep away when
wearing loose clothing, jewelry or long hair that is not properly secured. Underhood
components may become hot to the touch. Be careful not to come into contact with hot
engine, A/C and engine cooling system components. Failure to follow these instructions may
result in serious or fatal injury.
NOTE:
Always conduct the A/C Performance Test as outlined in this service information prior to
searching for an A/C refrigerant leak. Refer to DIAGNOSIS AND TESTING .
NOTE:
The A/C system in this vehicle comes equipped from the factory with fluorescent
refrigerant leak detection dye installed in the refrigerant system.
When searching for a refrigerant leak in the A/C system, use an Ultra Violet (UV) light and an electronic
leak detector that is designed for refrigerant used on this vehicle. It is important to use only high-quality
refrigerant leak detection equipment to properly locate refrigerant system leaks, such as the equipment
listed in the team PSE Service Equipment Catalog. When the use of additional leak detection dye is
required, use only Chrysler LLC approved refrigerant leak detection dye, available through Mopar®.

REFRIGERANT SYSTEM LEAKS > LEAK TEST
1. Begin searching for refrigerant leaks using a high quality UV light to detect the fluorescent
refrigerant leak detection dye.
1. Inspect all connections, plumbing fittings, brazed joints, hoses, hose crimps, service
ports, compressor housing, pressure relief valve and A/C condenser for dye.
2. Inspect the evaporator drain tube and condensate for presence of dye, which indicates a
leak from the A/C evaporator.
3. If equipped with rear A/C, inspect the underbody refrigerant lines, fittings, rear evaporator
drain tube and condensate for presence of dye, which indicates a leak from the rear
evaporator.
4. If no leaks are found using a UV light, proceed to Step #2 .
2. If a leak is not found with the leak detection dye, operate the heating and A/C system with the
engine at idle under the following conditions for at least 15 minutes, then proceed to Step #3 .
1. Doors or windows open
2. Transmission in Park or Neutral with the parking brake set (depending on transmission
application)
3. A/C and heater controls set to outside air, full cool, panel mode, high blower and A/C
compressor engaged (If the A/C compressor does not engage, go to LOW OR EMPTY
REFRIGERANT SYSTEM .
4. If equipped with rear A/C, set rear controls to full cool and high blower.
3. Shut the vehicle off and wait at least 5 minutes.
4. Insert a leak detector, with the proper tip attached for the refrigerant in the A/C system being
checked, into the evaporator drain tube and the instrument panel air outlets, to check for
evaporator leaks. Check the evaporator tubes at the A/C expansion valve, for leaks not visible
behind the expansion valve. Check around the front of the A/C compressor, for compressor
shaft seal leaks. Check between the A/C condenser and radiator for condenser leaks not
previously visible.
5. If equipped with rear A/C, insert the leak detector into the rear evaporator drain tube and rear
air outlets. Check the underbody A/C lines and fittings, evaporator tubes and rear A/C
expansion valve.

REFRIGERANT SYSTEM LEAKS > LOW OR EMPTY REFRIGERANT SYSTEM
NOTE:
This procedure should only be done after an A/C Performance Test has been
conducted and a refrigerant system leak has NOT been found using the factory
installed leak detection dye.
Do the following if the A/C compressor will not engage and a refrigerant leak in the A/C system is
suspected. but cannot be found using the factory installed leak detection dye.
1. Recover, evacuate and recharge the refrigerant system. Refer to PLUMBING, STANDARD
PROCEDURE .
2. Operate the heating and A/C system with the engine at idle under the following conditions for at
least 15 minutes.
1. Doors or windows open
2. Transmission in Park or Neutral with the parking brake set (depending on transmission
application)
3. A/C and heater controls set to outside air, full cool, panel mode, high blower and A/C
compressor engaged
4. If equipped with rear A/C, set rear controls to full cool and high blower
3. Shut the vehicle off and return to. Refer to LEAK TEST .
PLUMBING > STANDARD PROCEDURE > R-1234YF REFRIGERANT SYSTEM
RECOVERY
WARNING:
CAUTION:
Various aftermarket manufacturers produce A/C system sealants that are designed to stop
A/C refrigerant system leaks. The use of A/C system sealants may result in damage to A/C
refrigerant recovery/evacuation/recharging equipment and/or the vehicle A/C system and
are not recommended for use by Chrysler LLC.
Fig 1: R-1234YF Refrigerant Recovery/Recycling/Charging Station
When servicing the A/C system, an R-1234yf refrigerant recovery/recycling/charging station that meets
SAE standard J2843 must be used. Per SAE standard J2843, refrigerant recovery stations must recover
95% of the refrigerant system within 30 minutes at 21.1°C (70°F) and be able to measure the amount of
refrigerant removed from the system to an accuracy of 28 grams (1 oz.). See the operating instructions
supplied by the equipment manufacturer for proper care and use of this equipment.
NOTE:
A/C system should be tested prior to refrigerant recovery if the use of A/C system sealants
are suspected. These sealants have the potential to clog refrigerant recovery equipment
and cause vehicle A/C component damage. Various tool manufacturers make tool kits that
detect A/C system sealants. See the operating instructions supplied by the equipment
manufacturer for proper care and use of this equipment.
If sealants are detected in an A/C system, the system should be treated as contaminated and
replacement of the entire A/C refrigerant system is recommended. A/C systems found to be
contaminated with A/C system sealers, A/C stop-leak products or seal conditioners void the warranty for
the A/C system.

RECOVERY > R-1234YF RECOVERY PROCEDURE
WARNING:
CAUTION:
CAUTION:
A small amount of refrigerant oil is removed from the A/C system each time the refrigerant
system is recovered and evacuated. Before charging the A/C system, you MUST replenish
any oil lost during the recovery process. See the equipment manufacturer instructions for
more information.
1. If use of aftermarket A/C system sealant is suspected, the A/C system should be tested for
sealant prior to refrigerant system recovery. See the operating instructions supplied by the
equipment manufacturer for proper use and care of this equipment.
2. Connect an R-1234yf refrigerant recovery/recycling/charging station that meets SAE standard

J2843 to the refrigerant system.
3. Recover the A/C refrigerant system following the operating instructions supplied by the
recovery/recycling/charging station manufacturer.
4. Disconnect the refrigerant recovery/recycling/charging station from the refrigerant system

service ports.
5. Reinstall the caps onto the refrigerant system service ports.

EVACUATE
If the A/C refrigerant system has been open to the atmosphere, it must be evacuated before the A/C
system can be recharged with R-1234yf refrigerant.
NOTE:
Special effort must be used to prevent moisture from entering the A/C system oil. Moisture in
the oil is very difficult to remove and will cause a reliability problem with the A/C compressor.
Moisture and air in the A/C refrigerant system will raise the compressor head pressure above
acceptable operating levels. This will reduce the performance of the A/C system and damage the A/C
compressor. Moisture will boil at near room temperature when exposed to vacuum. Always use an
R-1234yf refrigerant recovery/recycling/charging station with a vacuum pump that meets SAE standard
J2843, or an R-1234yf compatible manifold gauge set and a stand alone vacuum pump.
If an A/C compressor is left open to the atmosphere for an extended period of time, it is recommended
that the refrigerant oil in the compressor be drained and replaced with new refrigerant oil to reduce the
possibility of contaminating the refrigerant system. Refer to OIL, REFRIGERANT, STANDARD
PROCEDURE .

EVACUATE > R-1234YF EVACUATION PROCEDURE
WARNING:
CAUTION:
more information.
1. Recover the refrigerant system. Refer to PLUMBING, STANDARD PROCEDURE .
NOTE:
When connecting service equipment couplers to refrigerant line service ports, verify
that the valve of each coupler is fully closed prior to connecting. This will reduce the
amount of effort required to make the connections.
2. Connect an R-1234yf refrigerant recovery/recycling/charging station with a vacuum pump that

meets SAE standard J2843 to the refrigerant system, or an R-1234yf compatible manifold
gauge set and a stand alone vacuum pump (depending on available equipment).
3. Open the refrigerant recovery/recycling/charging station or manifold gauge set valves and start
the vacuum pump. The vacuum pump should run a minimum of 45 minutes prior to recharge to
eliminate all moisture in system. When the low-side gauge reads to the lowest degree of
vacuum possible (approximately -88 kPa (-26 in. Hg or greater) for 30 minutes, close all valves
and turn off vacuum pump. If the refrigerant system fails to reach specified vacuum, the
refrigerant system likely has a leak that must be corrected. If the refrigerant system maintains
specified vacuum for at least 30 minutes, start the vacuum pump, open the valves and allow
the refrigerant system to evacuate an additional 10 minutes.
4. Close the refrigerant recovery/recycling/charging station or manifold gauge set valves. Turn off
and disconnect the vacuum pump.
5. Disconnect the refrigerant recovery/recycling/charging station or manifold gauge set from the
refrigerant system service ports.
6. Install the caps onto the refrigerant system service ports.

CHARGE
WARNING:
NOTE:
The Underhood HVAC Specification Label contains the refrigerant fill specification of the
vehicle being serviced.
After all refrigerant system leaks have been repaired and the refrigerant system has been evacuated, a
refrigerant charge can be injected into the system. Refer to PLUMBING, STANDARD PROCEDURE .
When charging the A/C system, use an R-1234yf refrigerant recovery/recycling/charging station that
meets SAE standard J2843. Per SAE standard J2843, refrigerant recovery stations must charge the
system to an accuracy of 14 grams (0.5 oz.). See the operating instructions supplied by the equipment

CHARGE > R-1234YF CHARGING PROCEDURE
WARNING:
CAUTION:
more information.
1. Recover and evacuate the refrigerant system. Refer to PLUMBING, STANDARD

PROCEDURE .

3. When required, adjust the refrigerant oil level. Refer to OIL, REFRIGERANT, STANDARD
PROCEDURE .
NOTE:
A/C system refrigerant capacity can be found on the HVAC Specification Label,
located in the engine compartment.
4. Open both the low and high side valves, then open the charge valve to allow the refrigerant to
flow into the refrigerant system.
5. When the transfer of refrigerant has stopped, close the valves.
WARNING:
Take care not to open the high side (high pressure) valve while performing Step 7.
6. Perform the following if all of the refrigerant charge did not transfer from the dispensing device.
1. Open all of the windows in the vehicle.
2. Set the heating and A/C system so that the A/C compressor is operating and the blower
motor is operating at its lowest speed setting.
3. Run the engine at a steady high idle (about 1400 rpm).
4. If the A/C compressor does not operate, test the compressor control circuits and repair
as required.
5. Open the low side valve and the charge valve to allow the remaining refrigerant to flow
into the refrigerant system.
6. When the transfer of refrigerant has stopped, close the valves.

service ports.
8. Install the caps onto the refrigerant system service ports.

RECOVERY - EMEA
Fig 1: R-1234YF Refrigerant System Recovery Station - EMEA
Comply with the safety standards prescribed. Refer to PLUMBING, WARNING and PLUMBING,
CAUTION .
Use the appropriate equipment to empty and refill the A/C system. When recovering the A/C refrigerant
system, use an R-1234yf refrigerant recovery/recycling/charging station (1) that meets SAE standard
J2843. Per SAE standard J2843, refrigerant recovery stations must recover 95% of the refrigerant
system within 30 minutes at 21.1°C (70°F) and be able to measure the amount of refrigerant removed
from the system to an accuracy of 28 grams (1 oz.). See the operating instructions supplied by the
equipment manufacturer for proper care and use of this equipment.
NOTE:
A/C system should be tested prior to refrigerant recovery if the use of A/C system sealants
are suspected. These sealants have the potential to clog refrigerant recovery equipment
and cause vehicle A/C component damage. Various tool manufacturers make tool kits that
detect A/C system sealants. See the operating instructions supplied by the equipment
If sealants are detected in an A/C system, the system should be treated as contaminated and
replacement of the entire A/C refrigerant system is recommended. A/C systems found to be
contaminated with A/C system sealers, A/C stop-leak products or seal conditioners void the warranty for
the A/C system.

RECOVERY - EMEA > R-1234YF RECOVERY PROCEDURE - EMEA
WARNING:
CAUTION:
CAUTION:
more information.
1. If use of aftermarket A/C system sealant is suspected, the A/C system should be tested for
sealant prior to refrigerant system recovery. See the operating instructions supplied by the
equipment manufacturer for proper use and care of this equipment.
2. Connect an R-1234yf refrigerant recovery/recycling/charging station (1) that meets SAE

standard J2843 to the refrigerant system.
3. Run the engine with air conditioner engaged for 10-15 minutes.
Fig 2: Connecting R-1234YF Refrigerant Recovery/Recycling/Charging Station
4. Depending on the type of engine in the vehicle, move or remove any parts that obstruct
connecting of the recovery, evacuation, charging station (1a), to the corresponding charging
valve (1b) and (1c) of the air conditioning.
5. Remove the caps from the service ports (1b and 1c).
6. Connect the high pressure hose (HIGH) of the equipment corresponding to the high pressure
quick coupler service port (1b).
NOTE:
To engage the fittings (3a) on the quick coupler valves, you need to pull up the
knurled fitting (3b). After connecting, tighten the locking cap (3c).
7. Connect the low pressure hose (LOW) to the low pressure quick coupler service port (1c).
NOTE:
For added security, the quick coupler fittings (3a) of the hoses connecting the
equipment are of different diameters: high pressure side is larger than the low
pressure side and low pressure side is smaller than the high pressure side.
8. Recover the A/C refrigerant system following the operating instructions supplied by the
recovery/recycling/charging station manufacturer.
Fig 3: Compressor Oil Container
9. During the emptying of the system, the compressor oil extract accumulates in an appropriate
container (1).
NOTE:
The oil is highly hygroscopic: avoid leaving open containers.
10. Refill the system with new oil in the same amount as indicated on the container.
NOTE:
In case of replacement of some components, it is necessary to add, for each of the

replaced parts, the following amounts of oil:
1. A/C Lines, 5 cm3/m
2. Evaporator, 40 cm3
3. Condenser with integrated filter, 50 cm3
In case of accidental breakage which causes "quick emptying of the system (in less than
5 minutes), it is not possible to determine the exact amount of oil loss since the high fluid
pressures can cause" entrainment ". In this case, begin with an initial amount of 50 cm3.

CHARGE - EMEA
Comply with the safety standards prescribed. Refer to PLUMBING, WARNING and PLUMBING,
CAUTION . Use the appropriate equipment to empty and refill the A/C system.
After all A/C refrigerant system repairs have been completed and the refrigerant system has been
evacuated, the A/C system can be recharged with R-1234yf refrigerant.
When charging the A/C system, use an R-1234yf refrigerant recovery/recycling/charging station (1) that
meets SAE standard J2843. Per SAE standard J2843, refrigerant recovery stations must charge the
system to an accuracy of 14 grams (0.5 oz.). See the operating instructions supplied by the equipment

CHARGE - EMEA > R-1234YF CHARGING PROCEDURE - EMEA
WARNING:
CAUTION:
more information.
1. Start the charging procedure of refrigerant according to the instructions given in the manual to
operate the equipment.
NOTE:
In case of damage to the compressor or other system components, or after

prolonged exposure of an open system to the air (over 6 hours) you must perform
the SYSTEM WASHING procedure as follows. Using filtered compressed air to
avoid introducing foreign objects into the system, clean all system components that
connect to the compressor, including the compressor.

3. Charge the A/C system with the specified amount of refrigerant using the High pressure port.
4. Recover the refrigerant from the Low pressure port using the recovery procedure.
NOTE:
A/C system refrigerant capacity can be found on the HVAC Specification Label,
located in the engine compartment.
5. Repeat the charging procedure with the specified amount of R-1234yf refrigerant.
NOTE:
In the case of SYSTEM WASHING, this procedure eliminated all oil in the system.
6. When required, adjust the refrigerant oil level with the required amount. Refer to OIL,
REFRIGERANT, STANDARD PROCEDURE .

service ports.
8. Reinstall the caps onto the refrigerant system service ports.
PLUMBING > COMPRESSOR, A/C > DESCRIPTION AND OPERATION > DESCRIPTION
AND OPERATION > A/C COMPRESSOR
Fig 1: A/C Compressor
The compressor of the air conditioning system is the variable displacement type, with electric clutch
engagement and external control of the displacement, via the External Control Variable Displacement
(ECVD) valve. The compressors are specific for engine version and market.
The Heating, Ventilation, and Air Conditioning (HVAC) module manages the ECVD valve to increase or
decrease the compressor displacement and thus the system pressure, via Pulse Width Modulation
(PWM) control. External regulation of the displacement improves comfort, operation of the air
conditioning system and saves the energy requested by the climate control system.
The external compressor controls are:
ECVD valve (1)
Electric clutch
Connector for electric clutch
CAUTION:
Be certain to adjust the refrigerant system oil level when replacing an A/C compressor.
Failure to properly adjust the refrigerant oil level can prevent the A/C system from operating
as designed and can cause serious A/C compressor damage.
PLUMBING > COMPRESSOR, A/C > REMOVAL AND INSTALLATION > A/C
COMPRESSOR - 1.4L > REMOVAL
WARNING:
Fig 1: Remove/Install A/C Suction Line
cable.
PROCEDURE .
INSTALLATION .
5. Release the quick disconnect coupling (1c) of the A/C suction line (1d) by pinching the release
tabs (1b) of the coupling together.
NOTE:
Pushing the coupling (1c) toward the metal portion of the A/C suction line (1e)
initially will make it easier to remove it when pulling it off the metal line (1e).
6. Remove the bolt (2a) that secures the metal line (1e) to the compressor (1a). Remove and
discard the seal washers.
Fig 2: Remove/Install A/C Discharge Line
7. Release the retainer (1a) for the A/C discharge line.
8. Remove the bolt (2b) that secures the A/C discharge line (1b) to the compressor (2a). Remove
and discard the seal washers.
9. Install plugs in, or tape over the opened refrigerant line fittings and compressor ports (2).
Fig 3: Remove/Install Engine Wire Harness Connector
10. Disengage the engine wire harness connector (1b) from the belt guard bracket (1c) and
disconnect the engine wire harness connector (1b).
11. Disengage the wire harness retainer (2a) from the belt guard bracket (1c) and relocate the wire
harness (2b) out of the way.
Fig 4: Belt Guard, Bracket & Bolts
12. Remove the two bolts (1a) from the belt guard (1b) and belt guard bracket (1c).
Fig 5: Wire Connectors & Compressor
13. Disconnect the wire harness connectors (1a and 1b) from the compressor (1c).
14. Remove the three bolts (1a) that secure the A/C compressor (1b) to the engine.
Fig 7: A/C Compressor
15. Remove the A/C compressor (1a) from the engine compartment.
NOTE:
If replacing the compressor, it will be necessary to adjust the oil level prior to
installation.
Refer to OIL, REFRIGERANT, STANDARD PROCEDURE .
COMPRESSOR - 1.4L > INSTALLATION
CAUTION:
If the A/C compressor is being replaced, be certain to adjust the refrigerant system oil level.
Failure to properly adjust the refrigerant oil level will prevent the A/C system from operating
CAUTION:
The A/C receiver/drier must be replaced if an internal failure of the A/C compressor has
occurred. Failure to replace the A/C receiver/drier can cause serious damage to the
replacement A/C compressor.
NOTE:
When replacing a compressor, see the Refrigerant Oil Standard Procedure to determine
how much oil should be removed from the new A/C compressor. Refer to OIL,
NOTE:
Replacement of the refrigerant line seal washer is required anytime a refrigerant line is
disconnected. Failure to replace the seal washer may result in a refrigerant system leak.
1. If the A/C compressor (1) is being replaced, the refrigerant oil in the old compressor must be
first drained and measured. Then the oil in the new A/C compressor must be drained. Finally,
the new compressor must be refilled with the same amount of new refrigerant oil that was
drained out of the old compressor. When replacing multiple A/C system components, see
REFRIGERANT OIL CAPACITIES to determine how much oil should be added to the
refrigerant system. Refer to OIL, REFRIGERANT, STANDARD PROCEDURE . Use only
refrigerant oil of the type recommended for the A/C compressor in the vehicle.
2. Position the A/C compressor (1) to the engine.
3. Install and tighten the three bolts (2) to the proper SPECIFICATIONS .
Fig 2: Wire Connectors & Compressor
4. Connect the wire harness connectors (1a and 1b) to the compressor (1c).
Fig 3: Belt Guard, Bracket & Bolts
5. Position the belt guard (1b) and belt guard bracket (1c) and install the two bolts (1a) for the
bracket (1c). Tighten the bolts securely.
Fig 4: Remove/Install Engine Wire Harness Connector
6. Position and engage the wire harness retainer (2a) with the belt guard bracket (1c).
7. Position and engage the engine wire harness connector (1b) to the belt guard bracket (1c).
Connect the engine wire harness connector (1b).
8. Remove the tape or plugs from the opened refrigerant line fittings and the compressor ports.
Fig 5: A/C Discharge Line & Fasteners
9. Lubricate new rubber seal washers with clean refrigerant oil and install them onto the
refrigerant line fittings. Use only the specified seal washers as they are made of a special
material for the system. Use only refrigerant oil of the type recommended for the A/C
compressor in the vehicle.
10. Install the A/C discharge line (1a) onto the A/C compressor.
11. Install the bolt (1b) that secures the A/C discharge line to the A/C compressor and tighten to
the proper SPECIFICATIONS .
12. Secure the A/C discharge line in the retainer (2).

Fig 6: Remove/Install A/C Discharge Line
14. Install the metal portion of the A/C suction line (1a) onto the A/C compressor.
15. Install the bolt (1b) that secures the A/C suction line to the A/C compressor and tighten to the
proper SPECIFICATIONS .
16. Connect the coupling (1c) of the A/C suction line (2b) to the metal portion of the A/C suction
line (1a). Be certain the coupling (2a) is fully engaged with the metal portion of the A/C suction
line (1a).
.
COMPRESSOR - 1.6L TURBO DIESEL > REMOVAL
WARNING:
cable.
PROCEDURE .
INSTALLATION .
Fig 1: Right Front Lower Frame Strut & Bolts
8. Remove the two bolts (1a) from the right front lower frame strut (1b).
Fig 2: Remove/Install A/C Suction & Discharge Lines
9. Disconnect the two quick disconnect fittings (1c and 2b) from the metal portion of the A/C
suction and discharge line flange (3b).
NOTE:
Pushing the coupling (1c) toward the metal portion of the A/C suction/discharge line
(1e) initially will make it easier to remove it when pulling it off the metal line (1e).
10. Remove the A/C line retaining bracket screw (3a).
11. Remove the retaining bolt (4a) and disconnect the A/C discharge and suction line flange (4b)
from the A/C compressor (1a). Remove and discard the seal washers.
Fig 3: Compressor, Hose, Retaining Clip & Coupling

12. Working in front of the compressor (1a), release the retaining clip (1b) and disconnect the
quick disconnect coupling (1c) of the hose (1d) to the internal heat exchanger (IHX).
Fig 4: Compressor, Support Bracket & Fasteners
13. Working on the left side of the compressor (1a), loosen screw (1b) and the nut (1c), then
remove the support bracket (1d).
Fig 5: Remove A/C Compressor
14. Disconnect the wire harness connectors (1a and 1b) from the A/C compressor (1c).
15. Install plugs in, or tape over all open refrigerant line fittings and compressor ports.
16. Remove the three bolts (2a) that secure the A/C compressor (1c) to the engine.
17. Remove the A/C compressor (1c) from the engine compartment.
NOTE:
installation.
COMPRESSOR - 1.6L TURBO DIESEL > INSTALLATION
CAUTION:
CAUTION:
NOTE:
When replacing the A/C compressor, see OIL, REFRIGERANT, STANDARD PROCEDURE
to determine how much oil should be removed from the new A/C compressor.
NOTE:
Replacement of the refrigerant line seal washers is required anytime a refrigerant line is
disconnected. Failure to replace the rubber seal washers may result in a refrigerant system
leak.
refrigerant system. Use only refrigerant oil of the type recommended for the A/C compressor in
the vehicle.
Fig 1: Install A/C Compressor
4. Connect the wire harness connectors (3) for the compressor (1).
Fig 2: Compressor, Support Bracket & Fasteners
5. Position the support bracket (1a) and securely tighten the bolt (1c) and nut (1b).
Fig 3: Compressor, Hose, Retaining Clip & Coupling
6. Working in front of the compressor, connect the quick disconnect coupling (1a) of the hose
(1b) to the internal heat exchanger (IHX). Be certain the hose is fully engaged and the retaining
clip (1c) is connected properly.
7. Remove the tape or plugs from the open refrigerant line fittings and the compressor ports.
9. Install the A/C discharge and suction line flange (2a) onto the A/C compressor.
10. Install the bolt (2b) that secures the A/C discharge and suction line flange (2a) to the A/C
compressor and tighten to the proper SPECIFICATIONS .
11. Position the A/C line retaining bracket and install the screw (3a). Tighten the screw securely.
12. Connect the quick disconnect couplings (4a and 5a). Be certain the couplings (4a and 5a)
have engaged the metal portion of the A/C lines (1a) completely.
13. Position the right front lower frame strut (1b) and install the two bolts (1a). Tighten the bolts to
the proper TORQUE SPECIFICATIONS .
.
COMPRESSOR - 2.0L TURBO DIESEL 120 HP/ 140 HP > REMOVAL
WARNING:
cable.
PROCEDURE .
INSTALLATION .
9. Disconnect the two quick disconnect fittings (1c and 2b) from the metal portion of the A/C
suction and discharge line flange (3b).
NOTE:
Pushing the coupling (1c) toward the metal portion of the A/C suction/discharge line
(1e) initially will make it easier to remove it when pulling it off the metal line (1e).
from the A/C compressor (1a). Remove and discard the seal washers.
Fig 3: Compressor, Support Bracket & Nuts
12. Working from the right front wheel compartment, in front of the compressor (1a), remove the
two nuts (1b) and remove the support bracket (1c).
Fig 4: Remove/Install A/C Compressor
14. Install plugs in, or tape over the open refrigerant line fittings and compressor ports.
NOTE:
installation.
COMPRESSOR - 2.0L TURBO DIESEL 120 HP/ 140 HP > INSTALLATION
CAUTION:
CAUTION:
NOTE:
When replacing the A/C compressor, see the Refrigerant Oil Standard Procedure to
determine how much oil should be removed from the new A/C compressor. Refer to OIL,
NOTE:
leak.
the vehicle.
2. Position the A/C compressor (1c) to the engine.
3. Install and tighten the three bolts (2a) to the proper SPECIFICATIONS .
4. Connect the wire harness connectors (1a and 1b) for the compressor (1c).
Fig 2: Compressor, Support Bracket & Nuts
5. Position the support bracket (1c) and securely tighten the nuts (1b).
11. Connect the quick disconnect couplings (4a and 5a). Be certain the couplings (4a and 5a)
have engaged the A/C line flange fittings (1a) completely.
.
COMPRESSOR - 2.0L TURBO DIESEL 170 HP > REMOVAL
WARNING:
cable.
PROCEDURE .
INSTALLATION .
Fig 2: Disconnecting Two Quick Disconnect Fittings
9. Disconnect the two quick disconnect fittings (1a and 2a) from the metal portion of the A/C
suction and discharge line flanges (1d and 2d).
NOTE:
Pushing the couplings (1a and 2a) toward the metal portion of the A/C
suction/discharge lines (1d and 2d) initially will make it easier to remove them when
pulling them off the metal lines.
from the A/C compressor.
12. Remove the A/C suction and discharge line flange and discard the seal washers.
Fig 3: Compressor, Retaining Clip, Coupling & Internal Heat Exchanger
13. Working below the compressor (1a), release the retaining clip (1b) and disconnect the quick
disconnect coupling (1c) of the hose (1d) to the internal heat exchanger (IHX).
Fig 4: IHX Support Bracket, Nut & Screw
14. Remove the screw (1a) and the nut (1b), then remove the IHX support bracket (1c).
Fig 5: Remove/Install A/C Compressor
NOTE:
installation.
COMPRESSOR - 2.0L TURBO DIESEL 170 HP > INSTALLATION
CAUTION:
CAUTION:
NOTE:
NOTE:
leak.
the vehicle.
4. Connect the wire harness connectors (3) for the compressor (1).
Fig 2: IHX Support Bracket, Nut & Screw
5. Position the internal heat exchanger (IHX) support bracket (1c) and install the screw (1a) and
the nut (1b). Tighten the fasteners securely.
Fig 3: Compressor, Retaining Clip, Coupling & Internal Heat Exchanger
6. Remove the tape or plugs from the open refrigerant line fittings and the compressor ports.
7. Connect coupling (1c) of the hose (1d) to the internal heat exchanger (IHX). Be certain the
coupling (1b) has engaged the IHX completely.
Fig 4: Connecting Two Quick Disconnect Fittings
12. Connect the quick disconnect couplings (4c and 5c). Be certain the couplings (4c and 5c) have
engaged the A/C line flange fittings (1a and 1b) completely.
.
COMPRESSOR - 2.4L > REMOVAL
WARNING:
cable.
PROCEDURE .
INSTALLATION .
Fig 1: A/C Discharge And Suction Lines & Retaining Bolt
8. Remove the retaining bolt (1) and disconnect the A/C discharge and suction lines from the A/C
compressor. Remove and discard the seal washers.
9. Disconnect the wire harness connectors (1a and 1b) from the A/C compressor).
11. Remove the two upper bolts (2 and 3) that secure the A/C compressor to the engine.
12. Remove the lower bolt (1) that secures the A/C compressor to the engine.
13. Remove the A/C compressor from the engine compartment.
NOTE:
installation.
COMPRESSOR - 2.4L > INSTALLATION
CAUTION:
CAUTION:
NOTE:
NOTE:
leak.
the vehicle.
2. Position the A/C compressor to the engine.
3. Install the lower compressor bolt (1). Snug the bolt up but don't tighten at this time.
4. Install the two upper compressor bolts (2 and 3). Tighten all three compressor bolts to the
proper SPECIFICATIONS .
5. Connect the wire harness connectors (1a and 1b) for the compressor.
Fig 3: A/C Discharge And Suction Lines & Retaining Bolt
8. Install the A/C discharge and suction line flange onto the A/C compressor.
9. Install the bolt (1) that secures the A/C discharge and suction line flange to the A/C compressor
and tighten to the proper SPECIFICATIONS .
.
PLUMBING > CONDENSER, A/C > DESCRIPTION AND OPERATION > DESCRIPTION
The A/C condenser is located in the front of the engine compartment behind the grille. The A/C
condenser is a heat exchanger that allows the high-pressure refrigerant gas being discharged by the A/C
compressor to give up its heat to the air passing over the condenser fins (2), which causes the
refrigerant to cool and change to a liquid state.
The A/C condenser (2) is equipped with tapping blocks for the discharge and liquid lines (1), integral
mounting brackets and a integral A/C receiver/drier (3).
Fig 1: A/C Condenser, Discharge And Liquid Lines & A/C Receiver/Drier

PLUMBING > CONDENSER, A/C > DESCRIPTION AND OPERATION > DESCRIPTION
When air passes through the fins of the A/C condenser, the high-pressure refrigerant gas within the A/C
condenser gives up its heat. The refrigerant then condenses as it leaves the A/C condenser and
becomes a high-pressure liquid. The volume of air flowing over the condenser fins is critical to the proper
cooling performance of the A/C system. Therefore, it is important that there are no objects placed in front
of the radiator grille openings at the front of the vehicle or foreign material on the condenser fins that
might obstruct proper air flow. Also, any factory-installed air seals or shrouds must be properly reinstalled
following radiator or A/C condenser service.
NOTE: Replacement of the refrigerant line O-ring seals and gaskets is required anytime
a refrigerant line is disconnected. Failure to replace the rubber O-ring seals and metal
gaskets could result in a refrigerant system leak.
The A/C condenser has no serviceable parts except for the O-ring seals and gaskets. The O-ring seals
used on the connections are made from a special type of rubber not affected by R-134a refrigerant. The
O-ring seals and gaskets must be replaced whenever a refrigerant line is disconnected from the A/C
condenser.
The A/C condenser cannot be repaired and must be replaced if leaking or damaged.
PLUMBING > CONDENSER, A/C > REMOVAL AND INSTALLATION > REMOVAL AND
cable.
2. Recover the refrigerant from the refrigerant system. (Refer to STANDARD PROCEDURE ).
3. Remove the front fascia (Refer to REMOVAL AND INSTALLATION ).

Fig 1: Lower Radiator Air Deflector & Screws
4. Remove both of the lower radiator air deflector to radiator screws (2).
5. Disengage the upper radiator air deflector to radiator clips.
6. With a suitable tool, disengage the upper air deflector panel clips (2) and remove the upper
panel (1), to aide in the removal and installation of the air deflector
NOTE: Remove the radiator air deflector through the top of the vehicle.
Fig 2: Upper Air Deflector Panel Clips & Upper Panel
7. If equipped, remove the transmission cooler enough to reposition the cooler out of the way.
(Refer to REMOVAL AND INSTALLATION ).
8. Remove the A/C discharge line to the condenser bolt (1).

Fig 3: Condenser Bolts
9. Remove the A/C liquid line to the condenser bolt (2).
10. Disconnect the A/C discharge and liquid lines from the condenser tapping blocks and remove
and discard the O-ring seals and gaskets.
11. Install plugs in, or tape over the opened refrigerant line fittings and condenser ports.
12. Disengage the two retaining tabs (1) that secure the condenser (2) to the mounting brackets
on the radiator.
Fig 4: Retaining Tabs & Condenser
13. Once the condenser is removed from the retaining clips, pull it towards the right side of the
vehicle and up to disengage the left side retaining brackets on the radiator. Lift the condenser
upward to remove the condenser (2) from the engine compartment.
PLUMBING > CONDENSER, A/C > REMOVAL AND INSTALLATION > REMOVAL AND
1. Position the A/C condenser (2) in front of the radiator so that the left side of the condenser is
between the locating brackets on the radiator and engage the left side of the condenser into
the mounting brackets on the radiator.
Fig 1: Retaining Tabs & Condenser
2. Engage the right side retaining tabs (1) that secures the condenser to the mounting brackets of
the radiator.
3. Remove the tape or plugs from the opened refrigerant line fittings and condenser ports.
4. Lubricate NEW rubber O-ring seals with clean refrigerant oil and install them and new gaskets
onto the opened refrigerant line fittings. Use only the specified O-rings as they are made of a
special material for the system. Use only refrigerant oil of the type recommended for the A/C
5. Connect the A/C liquid line to the condenser.
6. Install the A/C liquid line to the condenser bolt (2) and tighten to the proper TORQUE
SPECIFICATIONS .
Fig 2: Condenser Bolts
7. Connect the A/C discharge line to the condenser.
8. Install the A/C discharge line to the condenser bolt (1) and tighten to the proper TORQUE
SPECIFICATIONS .
9. If equipped, install the transmission cooler. (Refer to REMOVAL AND INSTALLATION ).
10. Position the radiator air deflector (1) in front of the radiator.
Fig 3: Upper Air Deflector Panel Clips & Upper Panel
11. Position the upper radiator panel (1) in place and engage the upper panel clips (2).
12. Engage the upper radiator air deflector to radiator clips.
13. Install and tighten both of the lower radiator air deflector to radiator screws (2).
Fig 4: Lower Radiator Air Deflector & Screws
14. Install the front fascia (Refer to REMOVAL AND INSTALLATION ).
16. Evacuate the refrigerant system. (Refer to STANDARD PROCEDURE ).
17. If the A/C condenser is being replaced, add 30 milliliters (1 fluid ounce) of refrigerant oil to the
refrigerant system. When replacing multiple A/C system components, see REFRIGERANT OIL
CAPACITIES to determine how much oil should be added to the refrigerant system ). Use only
refrigerant oil of the type recommended for the A/C compressor in the vehicle.
18. Charge the refrigerant system. (Refer to STANDARD PROCEDURE ).
PLUMBING > CORE, HEATER > REMOVAL AND INSTALLATION > REMOVAL AND
WARNING:
1. Comply with all prescribed safety standards. Refer to PLUMBING, WARNING and PLUMBING,
CAUTION .
2. Partially drain the engine cooling system. Refer to STANDARD PROCEDURE .
3. Remove the driver knee air bag. Refer to AIR BAG, KNEE BLOCKER, REMOVAL AND
INSTALLATION .
4. Remove the front floor console. Refer to CONSOLE, FLOOR, REMOVAL AND INSTALLATION
.
Fig 1: Remove/Install Heater Core
5. Disconnect the mode door actuator wire harness connector (1).
6. Remove the screw (2a) from the heater core retaining bracket (2b).
NOTE:
Mark the location of the retaining collars to make installation easier.
7. Unlock and disengage the heater core tube retaining collars (3a).
8. Gently disengage the heater core tubes (3b) from the heater core (5).
9. Carefully remove the heater core (5) from the HVAC housing.
NOTE:
The O-ring seals must be replaced during installation.
10. Remove and discard the O-ring seals from the heater tubes.
NOTE:
If the foam seals around the heater core are deformed or damaged, they must be
replaced.
PLUMBING > CORE, HEATER > REMOVAL AND INSTALLATION > REMOVAL AND
WARNING:
Use care when installing the heater core. Do not force the heater core into the housing. Do
not push on the heater core tubes. Apply pressure on the heater core side tank only. Failure
to follow these instructions can result in a possible engine coolant leak and serious or fatal
injury.
Fig 1: Remove/Install Heater Core
NOTE:
If the foam seals (2) around the heater core are deformed or damaged, they must be
replaced.
1. Lubricate new rubber O-ring seals with clean engine coolant and install them onto the heater
core tubes. Use only the specified O-ring as they are made of a special material for the engine
cooling system.
2. Carefully install the heater core (5) into the HVAC housing. Be certain the heater core has fully
bottomed in the HVAC housing.
3. Engage the heater core tubes (3b and 4) to the heater core (5).
4. Install the heater core tube retaining collars (3a). Be certain the collars are fully seated and
align with the marks made during the removal process.
5. Position the heater core retaining bracket (2b) and install the screw (2a). Tighten the screw
securely.
6. Connect the mode door actuator wire harness connector (1).
7. Install the driver knee air bag. Refer to AIR BAG, KNEE BLOCKER, REMOVAL AND
INSTALLATION .
8. Install the front floor console. Refer to CONSOLE, FLOOR, REMOVAL AND INSTALLATION .
9. Fill the engine cooling system. Refer to STANDARD PROCEDURE .
PLUMBING > EVAPORATOR, A/C > DESCRIPTION AND OPERATION > DESCRIPTION
The A/C evaporator for the heating-A/C system is mounted in the HVAC housing, which is located behind
the instrument panel. The A/C evaporator and its insulator are positioned within the HVAC housing so
that all air entering the housing must pass over the evaporator fins (2) before it is distributed through the
heating-A/C system ducts and outlets.
The A/C evaporator can only be serviced by removing and disassembling the HVAC housing assembly
(Refer to DISASSEMBLY AND ASSEMBLY ).
PLUMBING > EVAPORATOR, A/C > DESCRIPTION AND OPERATION > DESCRIPTION
Refrigerant enters the A/C evaporator from the A/C expansion valve as a low-temperature, low-pressure
mixture of liquid and gas. As air flows over the fins of the A/C evaporator, the humidity in the air
condenses on the fins, and the heat from the air is absorbed by the refrigerant. Heat absorption causes
the refrigerant to boil and vaporize. The refrigerant becomes a low-pressure gas when it leaves the A/C
evaporator.
gaskets could result in a refrigerant system leak.
The A/C evaporator has no serviceable parts except for the O-ring seals. The O-ring seals used on the
connections are made from a special type of rubber for the specific system.
The A/C evaporator cannot be repaired and must be replaced if leaking or damaged.
PLUMBING > LINE, A/C DISCHARGE > REMOVAL AND INSTALLATION > A/C
DISCHARGE LINE - 1.4L > REMOVAL
WARNING: Review the safety precautions and warnings in this service information
before performing this procedure. Failure to follow these instructions may result in serious
injury or death.
1. Recover the refrigerant from the refrigerant system. Refer to STANDARD PROCEDURE .
cable.
4. Remove the bolt (1b) that secures the A/C discharge line (1a) to the A/C compressor. Remove
and discard the O-ring seals .
5. Raise and support the vehicle. Refer to STANDARD PROCEDURE .
6. Remove the front passenger side splash shield. Refer to SHIELD, SPLASH, FRONT
Fig 2: A/C Discharge Line & A/C Discharge Jumper Line
7. Disconnect the quick-disconnect for the A/C discharge line (2) to the A/C discharge jumper line
(1).
8. Release the two retaining clamps (1, 3) for the A/C discharge line (2).
Fig 3: A/C Discharge Line & Retaining Clamps
9. Remove the A/C discharge line (2) from the engine compartment. Remove and discard the
O-ring seals .
10. Install plugs in, or tape over the open refrigerant line fittings, the condenser and compressor
ports.
DISCHARGE LINE - 1.4L > INSTALLATION
CAUTION: Be certain to adjust the refrigerant oil level when servicing the A/C refrigerant
system. Failure to properly adjust the refrigerant oil level will prevent the A/C system from
operating as designed and can cause serious A/C compressor damage.
NOTE: When replacing multiple A/C system components, see REFRIGERANT OIL
CAPACITIES to determine how much oil should be added to the refrigerant system ).
gaskets may result in a refrigerant system leak.
1. Position the A/C discharge line into the engine compartment.
2. Remove the tape or plugs from the opened refrigerant line fittings and the compressor and
condenser ports.
NOTE: Lubricate NEW rubber O-ring seals with clean refrigerant oil and install
them and new gaskets onto the discharge line fittings. Use only the specified
O-rings as they are made of a special material for the system. Use only refrigerant
oil of the type recommended for the A/C compressor in the vehicle.
3. Reconnect the quick-disconnect between the A/C discharge line (2) and the A/C discharge
jumper line (1).
Fig 1: A/C Discharge Line & A/C Discharge Jumper Line

4. Engage the retaining clamps (1, 3) for the A/C discharge line (2).
Fig 2: A/C Discharge Line & Retaining Clamps
5. Reinstall the front passenger side splash shield (Refer to SHIELD, SPLASH, FRONT
WHEELHOUSE, REMOVAL AND INSTALLATION ).
7. Install the bolt that secures the A/C discharge line to the A/C compressor and tighten to the
proper TORQUE SPECIFICATIONS . Install a NEW O-ring seal .
8. Install the engine cover (Refer to COVER, ENGINE, REMOVAL AND INSTALLATION ).
11. Adjust the refrigerant oil level. (Refer to STANDARD PROCEDURE ).
DISCHARGE LINE - 2.4L > REMOVAL
injury or death.
cable.

Fig 1: A/C Discharge Line Bolts
4. Remove the bolt (1) that secures the A/C discharge line to the condenser.
5. Disconnect the A/C discharge line from the A/C condenser. Remove and discard the O-ring
seal .
6. Disconnect the quick-disconnect (1) for the A/C discharge line to the A/C suction line.
Fig 2: A/C Discharge Line, Quick-Disconnect & Bolt
7. Remove the bolt (2) that secures the A/C discharge lines (3) to the A/C compressor.
8. Remove the A/C discharge line (3) from the engine compartment. Remove and discard the
O-ring seals .
ports.
DISCHARGE LINE - 2.4L > INSTALLATION
1. Position the A/C discharge line (3) into the engine compartment.
condenser ports.
3. Reconnect the quick-disconnect (1) between the A/C discharge line and the A/C suction line.
4. Install the bolt (2) that secures the A/C discharge line (3) to the A/C compressor and tighten to
the proper TORQUE SPECIFICATIONS . Install a NEW O-ring seal .
5. Connect the A/C discharge line to the condenser and install the bolt (1) that secures the A/C
discharge line to the A/C condenser and tighten to the proper TORQUE SPECIFICATIONS .
Install a NEW O-ring seal .

PLUMBING > LINE, A/C DISCHARGE JUMPER > REMOVAL AND INSTALLATION >
A/C DISCHARGE JUMPER LINE - 1.4L > REMOVAL
injury or death.
cable.
4. Raise and support the vehicle. Refer to STANDARD PROCEDURE .
5. Disconnect the quick-disconnect fitting (4) for the A/C discharge jumper line (2) to the A/C
discharge line.
Fig 1: A/C Discharge Jumper Line, Quick-Disconnect Fitting, Retaining Clamp & Nut
6. Release the retaining clamp (3) for the A/C discharge jumper line (2).
7. Remove the nut (1) that secures the A/C discharge jumper line (2) to the A/C condenser.
8. Remove the A/C discharge line from the engine compartment. Remove and discard the O-ring
seals.
ports.
PLUMBING > LINE, A/C DISCHARGE JUMPER > REMOVAL AND INSTALLATION >
A/C DISCHARGE JUMPER LINE - 1.4L > INSTALLATION
1. Position the A/C discharge line (3) into the engine compartment.
Fig 1: A/C Discharge Jumper Line, Quick-Disconnect Fitting, Retaining Clamp & Nut
condenser ports.
3. Reconnect the quick-disconnect fitting (4) between the A/C discharge jumper line (2) and the
A/C discharge line.
4. Install the nut (1) that secures the A/C discharge jumper line (2) to the A/C condenser and
tighten to the proper TORQUE SPECIFICATIONS . Install a NEW O-ring seal .
PLUMBING > LINE, A/C LIQUID > REMOVAL AND INSTALLATION > A/C LIQUID LINE
- 1.4L > REMOVAL
injury or death.
cable.
3. Remove the engine cover (Refer to COVER, ENGINE, REMOVAL AND INSTALLATION ).
4. Remove the nut (2) that secures the A/C liquid line (3) to the evaporator core.
Fig 1: A/C Liquid Line & Nuts
5. Separate the A/C liquid line (3) from the evaporator core and install plugs in, or tape over the
open refrigerant line fittings and evaporator core ports. Remove and discard the O-ring seal
.
6. Remove the air cleaner body. (Refer to REMOVAL AND INSTALLATION ).
8. Remove the nut (1) that secures the A/C liquid line to the condenser. Remove and discard the
O-ring seal.
Fig 2: A/C Liquid Line, A/C Pressure Transducer, Wire Connector & Fasteners
9. Disconnect the wire harness connector from the A/C pressure transducer (4).
10. Release the two retaining clamps (3) for the A/C liquid line (2).
11. Release the retainer for the (2) A/C liquid line service port.
Fig 3: A/C Liquid Line & Retainer
12. Release the retainer (1) for the A/C liquid line (3).
13. Remove the A/C liquid line (3) from the engine compartment.
- 1.4L > INSTALLATION
NOTE: Replacement of the refrigerant line O-ring seals is required anytime a refrigerant
line is disconnected. Failure to replace the rubber O-ring seals could result in a refrigerant
system leak.
1. Position the A/C liquid line (3) into the engine compartment.
Fig 1: A/C Liquid Line & Retainer
2. Engage the A/C liquid line (3) in the retaining clip (1).
3. Engage the clamp (2) for the A/C liquid line service port.
4. Remove the tape or plugs from the refrigerant line fittings and expansion valve ports.
NOTE: Lubricate NEW O-ring seals with clean refrigerant oil and install them
onto the refrigerant line fittings. Use only the specified O-ring seals as they are
made of a special material for the system. Use only refrigerant oil of the type
recommended for the vehicle.
5. Connect the A/C liquid line (2) to the condenser and install the bolt (1) that secures the A/C
liquid line to the condenser and tighten the nut to the proper TORQUE SPECIFICATIONS .
Fig 2: A/C Liquid Line, A/C Pressure Transducer, Wire Connector & Fasteners
6. Connect the wire harness connector to the A/C pressure transducer (4).
7. Engage both the A/C liquid line (2) retaining clip (3).
8. Engage the A/C liquid line (3) with the evaporator core. Install a NEW O-ring seal .
9. Install the nut (2) that secures the A/C liquid line (3) to the evaporator core and tighten the nut
to the proper TORQUE SPECIFICATIONS .
11. Install the air cleaner body. (Refer to REMOVAL AND INSTALLATION ).
- 2.4L > REMOVAL
injury or death.
cable.
4. Remove the air cleaner body. (Refer to REMOVAL AND INSTALLATION ).
5. Disconnect the wire harness connector (4) from the A/C pressure transducer.
6. Remove the bolt (2) that secures the A/C liquid line to the condenser. Remove and discard the
O-ring seal.
7. Install plugs in, or tape over the open refrigerant line fitting and condenser port.
8. Release the front clamp (3) for the A/C liquid line.
9. Release the front clamp (2) at the frame rail for the A/C liquid line (1).
Fig 2: A/C Liquid Line & Clamps
10. Release the rear clamp (3) for the A/C liquid line (2).
Fig 3: A/C Liquid Line & Rear Clamp
11. Release the clamp (1) for the A/C liquid line service port.
Fig 4: A/C Liquid Line Service Port Clamp
12. Remove the nut (2) that secures the A/C liquid line (3) and A/C suction line to the evaporator
core.
13. Separate the A/C liquid line (3) from the evaporator core and install plugs in, or tape over the
open refrigerant line fittings and evaporator core ports. Remove and discard the O-ring seal.
14. Remove the A/C liquid line from the engine compartment.
- 2.4L > INSTALLATION
NOTE: Replacement of the refrigerant line O-ring seals is required anytime a refrigerant
line is disconnected. Failure to replace the rubber O-ring seals could result in a refrigerant
system leak.
1. Position the A/C liquid line into the engine compartment.
2. Engage the A/C liquid line (3) with the evaporator core. Install a NEW O-ring seal .
3. Install the nut (2) that secures the A/C liquid line (3) to the evaporator core and tighten the nut
to the proper TORQUE SPECIFICATIONS .
4. Engage the A/C liquid line (2) to the rear retaining clip (3).
5. Engage the front clamp (2) at the frame rail for the A/C liquid line (1).
6. Engage the front clamp (3) for the A/C liquid line.
7. Remove the tape or plugs from the refrigerant line fittings and expansion valve ports.
NOTE: Lubricate NEW O-ring seals with clean refrigerant oil and install them
onto the refrigerant line fittings. Use only the specified O-ring seals as they are
made of a special material for the system. Use only refrigerant oil of the type
recommended for the vehicle.
8. Connect the A/C liquid line to the condenser and install the bolt (2) that secures the A/C liquid
line to the condenser and tighten the nut to the proper TORQUE SPECIFICATIONS .
9. Connect the wire harness connector (4) to the A/C pressure transducer.
10. Engage the clamp (1) for the A/C liquid line service port.
Fig 5: A/C Liquid Line Service Port Clamp
11. Install the air cleaner body. (Refer to REMOVAL AND INSTALLATION ).
PLUMBING > LINE, A/C SUCTION > REMOVAL AND INSTALLATION > A/C SUCTION
LINE - 1.4L > REMOVAL
injury or death.
cable.
3. Remove the engine cover (Refer to COVER, ENGINE, REMOVAL AND INSTALLATION ).
4. Disconnect the quick-disconnect fitting (2) between the A/C suction line and the A/C suction
line jumper.
Fig 1: Quick-Disconnect Fitting
5. Remove the retaining nut (1) that secures the A/C suction line (4) to the evaporator core.
6. Separate the A/C suction line from the evaporator core. Remove and discard the O-ring
seals .
7. Remove the A/C suction line (4) from the engine compartment.
8. Install plugs in, or tape over all the open refrigerant line fittings and expansion valve ports.
LINE - 1.4L > INSTALLATION
NOTE: Replacement of the refrigerant line seals is required anytime a refrigerant line is
disconnected. Failure to replace the rubber O-ring seals may result in a refrigerant system
leak.
1. Position the A/C suction line into the engine compartment.
NOTE: Lubricate NEW seals with clean refrigerant oil and install them onto the
open refrigerant line fittings. Use only the specified seals as they are made of a
special material for the system. Use only refrigerant oil of the type recommended for
the A/C compressor in the vehicle.
3. Engage the A/C suction line (4) into the evaporator core.
Fig 1: Quick-Disconnect Fitting
4. Install the retaining nut (1) holding the A/C suction line (4) to the evaporator core and tighten to
the proper TORQUE SPECIFICATIONS . Install NEW O-ring seal .
5. Connect the quick-disconnect fitting (2) of the A/C suction line to the A/C suction line jumper.
LINE - 2.4L > REMOVAL
injury or death.
cable.
4. Remove the air cleaner body (Refer to REMOVAL AND INSTALLATION ).
5. Disconnect the quick-disconnect fitting (1) between the flexible A/C suction line (3) and the A/C
discharge line).
6. Install plugs in, or tape over all the open refrigerant line fittings and expansion valve ports.
7. Remove the retaining nut (1) that secures the A/C suction line to the evaporator core.
8. Separate the A/C suction line (4) from the evaporator core. Remove and discard the O-ring
seals .
9. Disengage the A/C suction line (1) from the rear retaining clip (4).
10. Disengage the A/C suction line (3) from the front retaining clips (4).
11. Remove the A/C suction line (3) from the engine compartment.
LINE - 2.4L > INSTALLATION
NOTE: Replacement of the refrigerant line seals is required anytime a refrigerant line is
disconnected. Failure to replace the rubber O-ring seals may result in a refrigerant system
leak.
1. Position the A/C suction line into the engine compartment.
NOTE: Lubricate NEW seals with clean refrigerant oil and install them onto the
open refrigerant line fittings. Use only the specified seals as they are made of a
special material for the system. Use only refrigerant oil of the type recommended for
the A/C compressor in the vehicle.
3. Connect the quick-disconnect fitting (1) of the A/C suction line (3) to the A/C discharge.
4. Engage the A/C suction line (4) into the evaporator core.
5. Install the retaining nut (1) holding the A/C suction line (4) to the evaporator core and tighten to
6. Engage the A/C suction line (1) into the rear retaining clip (4).
7. Engage the A/C suction line (3) into the front retaining clip (4).

PLUMBING > LINE, A/C SUCTION JUMPER > REMOVAL AND INSTALLATION > A/C
SUCTION JUMPER LINE - 1.4L > REMOVAL
injury or death.
cable.
3. Disconnect the quick-disconnect (2a) for the A/C suction jumper line (1a) to the A/C suction
line (2b).
4. Remove the bolt (1b) that secures the A/C suction jumper line (1a) to the A/C compressor.
Remove and discard the O-ring seals.
5. Separate the A/C suction jumper line (1a) from the A/C compressor and install plugs in, or tape
over the open refrigerant line fittings and evaporator core ports. Remove and discard the
O-ring seal.
6. Remove the A/C suction jumper line from the engine compartment.
ports.
PLUMBING > LINE, A/C SUCTION JUMPER > REMOVAL AND INSTALLATION > A/C
SUCTION JUMPER LINE - 1.4L > INSTALLATION
1. Position the A/C suction jumper line (1a) into the engine compartment.
condenser ports.
3. Install the bolt (1b) that secures the A/C suction jumper line (1a) to the A/C compressor and
tighten to the proper TORQUE SPECIFICATIONS . Install a NEW O-ring seal.
4. Reconnect the quick-disconnect (2a) between the A/C suction jumper line (1a) and the A/C
suction line (2b).
PLUMBING > OIL, REFRIGERANT > STANDARD PROCEDURE > COMPRESSOR OIL
DRAIN PROCEDURE
Fig 1: Refrigerent Oil
CAUTION:
Failure to properly drain and measure the refrigerant oil from the A/C compressor can
prevent the A/C system from operating as designed and cause serious compressor
damage.
The A/C compressor is filled with refrigerant oil from the factory. Use the following procedure to drain and
measure refrigerant oil from the A/C compressor.
1. Drain all of the refrigerant oil from the old A/C compressor (A) into a clean measured container
(1).
2. Drain all of the refrigerant oil from the new A/C compressor (B) into a clean measured
container (2). The difference between amount (A) and (B) is the amount to remove (C) from (B)
before returning the refrigerant oil to the new compressor.
3. Refill the new A/C compressor with the same amount of refrigerant oil that was drained out of
the old compressor. Use only clean refrigerant oil of the type specified for the A/C compressor
in the vehicle.
4. Install the new A/C compressor onto the engine. Refer to COMPRESSOR, A/C, REMOVAL
AND INSTALLATION .
PLUMBING > OIL, REFRIGERANT > STANDARD PROCEDURE > STANDARD

PROCEDURE - REFRIGERANT OIL LEVEL
When an A/C system is assembled at the factory, all components except the A/C compressor are
refrigerant oil free. After the refrigerant system has been charged and operated, the refrigerant oil in the
A/C compressor is dispersed throughout the refrigerant system. The A/C receiver/drier, A/C evaporator,
A/C condenser and the A/C compressor will each retain a significant amount of the needed refrigerant
oil.
It is important to have the correct amount of refrigerant oil in the A/C system. This ensures proper
lubrication of the A/C compressor. Too little oil will result in damage to the A/C compressor, while too
much oil will reduce the cooling capacity of the A/C system and consequently result in higher discharge
air temperatures.
CAUTION:
Failure to properly adjust the refrigerant oil level can prevent the A/C system from operating
CAUTION:
Never use R-12 refrigerant oil in an A/C system designed to use R-134a or R-1234yf
refrigerant oil. Never use R-134a refrigerant oil in an A/C system designed to use R-1234yf
refrigerant oil. These refrigerant oils are not compatible and damage to the A/C system will
result.
NOTE:
Most reclaim/recycling equipment will measure the lubricant being removed during recovery.
This amount of lubricant should be added back into the system. See the reclaim/recycling
equipment manufacturers instructions.
It will not be necessary to check the oil level in the A/C compressor or to add oil, unless there has been
an oil loss. An oil loss may occur due to a rupture or leak from a refrigerant line, connector fitting,
component or a component seal. If a leak occurs, add 30 milliliters (1 fluid ounce) of refrigerant oil to the
refrigerant system after the repair has been made. Refrigerant oil loss will be evident at the leak point by
the presence of a wet, shiny surface around the leak.
Refrigerant oil must be added when an A/C condenser, A/C receiver/drier or A/C evaporator is replaced
(see REFRIGERANT OIL CAPACITIES ).
The refrigerant oil level in a new A/C compressor must first be adjusted prior to compressor installation.
REFRIGERANT OIL CAPACITIES
Component ml fl oz Oil Type
Total System Fill 130 4.4 -
Condenser 50 1.7 -
A/C line 5 .17 -
Evaporator 40 1.4 -
Compressor Drain and measure the oil

from the old A/C compressor.
- -
See COMPRESSOR OIL
DRAIN PROCEDURE .
1.4L MultiAir - - PAG PS-D1
1.6L E-torQ; 1.6L Turbo

Diesel; 2.0L Turbo Diesel; - - PAG ND-12
2.4L MultiAir2
PLUMBING > REFRIGERANT > SPECIFICATIONS > SPECIFICATIONS
Application Capacity
Refer to CAPACITIES AND RECOMMENDED FLUIDS,

All engines - R-1234yf
SPECIFICATIONS .
PLUMBING > TUBE, CONDENSATION DRAIN > REMOVAL AND INSTALLATION >
WARNING:
Fig 1: Right Side Center Console Closeout & Clips
cable.
2. Remove the right side center console closeout (1b) from the center console.
Fig 2: Remove/Install Condensation Drain Tube
3. Disconnect two clamps (1b and 2b) from the condensation drain tube (1a).
4. Disengage the condensation tube retainer (1c) from the HVAC housing.
5. Disengage the condensation drain tube (1a) from the floor coupling (2a) and remove the tube
from the vehicle.
PLUMBING > TUBE, CONDENSATION DRAIN > REMOVAL AND INSTALLATION >
Fig 1: Remove/Install Condensation Drain Tube
1. Connect the condensation drain tube (1a) to the floor coupling (2a) and install a new clamp
(2b).
2. Connect the condensation drain tube with clamp (1b) to the HVAC housing. Be certain the tube
is fully engaged with the HVAC housing.
Fig 2: Right Side Center Console Closeout & Clips
3. Install the right side center console closeout (1b) to the center console. Be certain all retaining
tabs (1a) are fully engaged with the console.
CABIN HEATER > UNIT, HEATER > DESCRIPTION AND OPERATION > DESCRIPTION
Fig 1: PTC Heater Unit (Cabin Heater)
On 1.4L engine equipped vehicles, the climate of the car through the heater assembly can be insufficient
due to a cold engine. As an option, an additional system of heating is offered that is activated in the first
instants of operation of the engine, according to the temperature reached by the engine coolant.
The system consists of a device for additional heating, located inside the heater assembly: in this
device are located two resistors (PTC1 - 250W, and PTC2 - 500W).
The operation of the resistors is controlled by the A/C heater control which activates one or two, thus
providing a progressive heating with a maximum power of 750 W, determined by a control logic that
depends on:
The outside temperature below 20°C (68°F)
The temperature reached by the coolant of the engine about 70°C (158°F)
The number of revolutions of the engine (which must be greater than 700 rpm)
The battery voltage (which must not fall below 12.6 V)
The power of one or two resistors is controlled through two relays placed on the HVAC housing:
Level 1: activation of the first relay (250W)
Level 2: activation of the second relay (500W)
Level 3: activation of both relays (750W)
The supply line is protected by two "MAXIFUSE", contained in the box on the positive battery terminal.
The PTC heater unit is accessed for service without removing the instrument panel.
CABIN HEATER > UNIT, HEATER > REMOVAL AND INSTALLATION > REMOVAL AND
WARNING:
WARNING:
cable.
Fig 1: Right Front Center Console Trim Panel & Clips
2. Remove the right front center console trim panel (1b) by releasing panel retaining clips (1a).
Fig 2: (PTC) Heater (Cabin Heater) Relay, Wire Connectors & Fasteners
3. Disconnect the wire harness connector (1a) from the positive temperature coefficient (PTC)
heater (cabin heater) relay assembly (1d).
4. Remove the screws (1b) from the PTC relay assembly bracket (1c) and position the relays and
connector out of the way.
5. Disconnect the PTC heater wire harness connector (2a).

Fig 3: Remove/Install PTC Heater Unit
6. Remove the screw (1) that secures the PTC heater unit (2a) to the HVAC air distribution
housing.
7. Carefully remove the PTC heater unit (2a) from the air distribution housing by pulling it straight
out of the housing, releasing it from the centering pin (2b).
CABIN HEATER > UNIT, HEATER > REMOVAL AND INSTALLATION > REMOVAL AND
Fig 1: Remove/Install PTC Heater Unit
1. Carefully install the positive temperature coefficient (PTC) heater (cabin heater) unit (2a) into
the HVAC air distribution housing. Be certain to engage the heater unit to the centering pin
(2b).
2. Install and securely tighten the screw (1) that secures the PTC heater unit to the air distribution
housing.
Fig 2: (PTC) Heater (Cabin Heater) Relay, Wire Connectors & Fasteners
3. Connect the wire harness connector (2a) to the PTC heater unit.
4. Position the PTC relay assembly bracket (1d) to the HVAC air distribution housing and install
the screws (1b) for the relay bracket (1c).
5. Connect the wire harness connector (1a) to the PTC heater relay assembly (1d).
6. Install the right front center console trim panel.
Service Manual: MAINTENANCE REMINDER LIGHT (RESET Jeep Renegade
PROCEDURES)
ENGINE OIL REPLACEMENT REMINDER
Question: RESET SERVICE LIGHT
NOTE: To determine the appropriate reset procedure, refer to ENGINE OIL

REPLACEMENT REMINDER RESET INDEX .
ENGINE OIL REPLACEMENT REMINDER RESET INDEX
Model & Year Reset Procedure
Cherokee
2014-16 Engine Oil Replacement Reminder Reset - Procedure 1
Commander
Compass
Grand Cherokee

(1)
Liberty
Patriot
Renegade
Wrangler
On some models Engine Oil Replacement Reminder Reset - Procedure 2 may also reset the
(1) Engine Oil Replacement Reminder.
ENGINE OIL REPLACEMENT REMINDER > ENGINE OIL REPLACEMENT REMINDER

RESET - PROCEDURE 1 > MANUAL RESET
NOTE: This procedure applies to all models.
1. Turn ignition on, with engine off.
NOTE: On vehicles with Keyless Enter-N-Go™, push the ENGINE

START/STOP button and cycle the ignition to the ON/ RUN position.
2. Fully depress the accelerator pedal, slowly, 3 times within 10 seconds.
3. Turn ignition switch to OFF/LOCK position.
NOTE: On vehicles with Keyless Enter-N-Go™, push the ENGINE

START/STOP button once to return the ignition to the OFF/LOCK position.
4. If indicator message illuminates when engine is started, repeat the reset procedure.

RESET - PROCEDURE 1 > ELECTRONIC VEHICLE INFORMATION CENTER (EVIC)
RESET
NOTE: This procedure applies to some models.
1. Without pushing the brake pedal, cycle the ignition to the ON/RUN position (DO NOT start the
engine).
2. Push the OK button (on the left side of steering wheel) to enter the EVIC menu screen.
3. Push and release the DOWN arrow button to access the OIL LIFE menu screen.
4. Push the LEFT or RIGHT arrow button to access the OIL LIFE submenu
5. Push the OK button to reset the "OIL LIFE" to 100%.
6. Push the UP arrow button to exit the EVIC menu screen.

RESET - PROCEDURE 2
NOTE: The manufacturer describes this procedure as a "Secondary Method For Oil
Change Reset". This method may not be appropriate for all vehicles.
1. Without pushing the brake pedal, push the engine START/STOP button and cycle the ignition to
the ON/RUN position (DO NOT START the engine).
2. Navigate to "Oil Life" submenu in "Vehicle Info" on DID.
3. Push and Hold the OK button until the gauge resets to 100%.
NOTE: If the indicator message illuminates when you start the vehicle, the oil change
indicator system did not reset. If necessary, repeat this procedure.
EMISSIONS MAINTENANCE REMINDER (EMISS MAINT)
NOTE: To determine the appropriate reset procedure, refer to EMISSIONS

MAINTENANCE REMINDER RESET INDEX .
EMISSIONS MAINTENANCE REMINDER RESET INDEX
Cherokee
1988-90 Emissions Maintenance Reminder Reset - Procedure 1
Comanche
Wagoneer
Wrangler
EMISSIONS MAINTENANCE REMINDER (EMISS MAINT) > EMISSIONS

MAINTENANCE REMINDER RESET - PROCEDURE 1
1. Vehicles are equipped with a EMISS MAINT indicator light on the instrument cluster. This light
will come on one time at 82,500 miles to alert driver that emission service is required. At this
time, oxygen sensor and PCV valve must be replaced and all other emission components
should be inspected, and serviced or replaced as necessary.
2. The Service Reminder Indicator (SRI) timer is located under dash, near accelerator pedal or to
right of steering column. Timer cannot be reset. To turn off light, timer must be replaced or
disconnected. Since timer and sensor are interdependent, if timer should fail prematurely,
oxygen sensor should be replaced at same time to preserve correct replacement interval.
3. To replace timer on Cherokee, Comanche and Wagoneer models, remove cruise control
module (if equipped). Remove timer mounting screws. Disconnect electrical connector. On
Wrangler models, remove timer mounting screws. Disconnect electrical connector. To install,
reverse removal procedure.
EMISSIONS MAINTENANCE REMINDER (MAINT REQD)
Tip: 2008 Wrangler Unlimited Rubicon
Tip: reset with OTC Genisys
NOTE: To determine the appropriate reset procedure, refer to EMISSIONS

MAINTENANCE REMINDER RESET INDEX .
EMISSIONS MAINTENANCE REMINDER RESET INDEX
Cherokee
Comanche
Grand Cherokee
1993 Emissions Maintenance Reminder Reset - Procedure 1
Wrangler
EMISSIONS MAINTENANCE REMINDER (MAINT REQD) > EMISSIONS

MAINTENANCE REMINDER RESET - PROCEDURE 1
Vehicles may be equipped with a MAINT REQD on the instrument cluster. This light will come on one time
at 82,500 miles to alert driver that emission service is required. At this time, oxygen sensor must be
replaced and all other emission components should be inspected, and serviced or replaced as
necessary. Chrysler's Diagnostic Readout Box (DRB-II) tester is required to reset the service reminder
indicator system.
Using DRB-II tester, access SELECT SYSTEMS. Select appropriate engine. Select with or without A/C.
Select FUEL & IGNITION. Select ADJUSTMENTS. Select RESET SRI LIGHT. Reset SRI light. When
DRB-II is finished resetting light, DRB-II display will read SRI LIGHT IS RESET.
MAINTENANCE SERVICE REMINDER
Tip: oil change reset - 2008 Wrangler
Tip: reset oil life - 2008 Patriot
NOTE: To determine the appropriate reset procedure, refer to MAINTENANCE SERVICE

REMINDER RESET INDEX .
MAINTENANCE SERVICE REMINDER RESET INDEX
Grand Cherokee
1994-98 Maintenance Service Reminder Reset - Procedure 1
Liberty
MAINTENANCE SERVICE REMINDER > MAINTENANCE SERVICE REMINDER RESET

- PROCEDURE 1
This vehicle may be equipped with an optional Vehicle Information Center (VIC). A PERFORM SERVICE
message is displayed when "miles/kms to service" is zero, indicating that regular service and
maintenance is due. To reset counter, turn ignition on, then press SELECT button momentarily, then
press and hold SET button for at least 2 seconds.
MAINTENANCE SERVICE REMINDER > MAINTENANCE SERVICE REMINDER RESET

- PROCEDURE 2
Tip: Simple reset - 2002 Grand Cherokee
1. The Electronic Vehicle Information Center (EVIC) displays a PERFORM SERVICE message
when distance to service interval has been reached, indicating that regular service and
maintenance is due. After performing necessary services, reset service distance by selecting
a distance to service interval.
2. To program EVIC, turn ignition switch to ON position. Depress and release MENU push button
until SERVICE INTV. = is displayed. Press and release STEP button to step through available
options. The last selected distance option displayed becomes the service interval at which the
PERFORM SERVICE message will be displayed.
3. If a new distance interval is selected, RESET SERVICE DISTANCE? with a yes or no option.
When YES is selected, the accumulated distance since the last previous PERFORM SERVICE
message will be reset to zero because the service interval has been changed. When NO is
selected, the distance until the next PERFORM SERVICE message is reduced by the
accumulated distance since the last pervious message.
4. EVIC exits programming mode and returns to its normal operation mode when the C/T button is
depressed or when the end of the programmable feature menu list is reached, whichever
occurs first.
TIRE PRESSURE MONITOR SYSTEM REMINDER
Question: low pressure tpms light stay on - 2010 Jeep Commander
NOTE: To determine the appropriate reset procedure, refer to TPMS REMINDER RESET
INDEX .
TPMS REMINDER RESET INDEX
Cherokee
2014-16 TPMS Reminder Reset - Procedure 1
Commander
Compass
Grand Cherokee
Liberty
Patriot
Renegade
Wrangler

TIRE PRESSURE MONITOR SYSTEM REMINDER > TPMS REMINDER RESET -
PROCEDURE 1
NOTE: There is no formal retraining procedure necessary. Each sensor transmits tire
pressure data approximately once every minute. Each sensor's (transmitter) broadcast is
uniquely coded so that the WCM can monitor the state of each of the sensors on the 4
rotating road wheels. The WCM automatically learns and stores the sensor's ID while driving
after a sensor has been replaced.
Once the vehicle has remained stationary for more than 20 minutes, drive vehicle for a minimum of 10
minutes while maintaining a continuous speed above 15 mph (24 km/h). During this time, the system will
learn the new sensor ID.
TIRE PRESSURE MONITOR SYSTEM REMINDER > TPMS REMINDER RESET -

PROCEDURE 2
NOTE: Use the following procedure to retrain all 4 road wheel tire pressure sensors. No
attempt should be made to retrain individual sensors.
1. Retrieve Relearn Magnet (8821).
2. Press MENU Button on EVIC until "RETRAIN TIRE SENSORS - NO" is displayed.
3. Press STEP button to select "YES".
NOTE: There is a 60-second timer for training the first sensor, and a 30-second
timer between training the remaining sensors. If either of these timers expire, the
EVIC will abort the training procedure.
NOTE: If at any time the EVIC display reads "TRAINING ABORTED", move the
vehicle ahead at least one foot and repeat the entire retraining procedure.
4. Press MENU button to start retraining. Display will read "TRAIN LEFT FRONT TIRE". The order
for retraining all 5 sensors is: Left Front, Right Front, Right Rear, Left Rear, Spare (if so
equipped).
5. Starting at left front tire, place relearn magnet over valve stem. See Fig 1. Within
approximately 5 seconds, vehicle horn will chirp indicating training complete at that particular
sensor. Remove the magnet.
6. Repeat this step on remaining sensors as indicated by EVIC until all TPM sensors positions
are trained.
7. Once EVIC displays "TRAINING COMPLETE", pressing either STEP, C/T, RESET or MENU
button will exit training routine.
Fig 1: Placing Training Magnet Around Valve Stem
Courtesy of DAIMLERCHRYSLER CORPORATION

Jeep Renegade
ENGINE
Capacities
U.S. Metric
Cooling System •
MOPAR®
Standard MS.90032.

(1.6L Engine) D3306 9.55523

(2.0L Engine) D3306 9.55523
MOPAR®
Standard MS.90032.

Engine Oil - (1.4L
Engine)



Engine)
Engine Oil Filter
(1.4L Engine)
Engine Oil Filter

(1.6L Engine)
Engine Oil Filter

(2.0L Engine)
Engine Oil Filter

(2.4L Engine)
Fuel

Engine) Ethanol

Engine)

Engine)

Engine) Ethanol

Ethanol
(E85) Models Only
CAUTION:
SPARK PLUGS
Gap
U.S. Metric

TRANSAXLE
Capacity
U.S. Metric
Automatic
Use only MOPAR® ZF

8&9 Speed
ATF™Automatic
Transmission Fluid,
performance of your
transmission.
Manual

C635 Manual
Transaxle
Transmission Fluid
CHASSIS
Capacities
U.S. Metric
Axles
Use synthetic
Rear Differential
(RDM)
75W-90 API GL5
Transfer Case
Use synthetic
Power Transfer Unit
(PTU)
75W-90 API GL5
Chassis Systems
We recommend you
use MOPAR® DOT
then DOT 3 is
acceptable.
FUSES AND RELAYS

F02 70 Amp Tan - -
Controller Power
F03 - 20 Amp Blue -
Brake Control
F04 - 30 Amp Pink -
Electronics Module
F05 70 Amp Tan - -
Steering

40 Amp Orange -
1.4 Without A/C
With A/C And All
2.4 Models
Automatic
F08 - 30 Amp Pink -
Transmission, GSM
10 Amp Red - 1.4

F11 - -
Engines
Pump Power "After

F14 - - 5 Amp Tan
Run"

Pump

Transmission
10 Amp Red - 1.4

Engines
15 Amp Blue - 2.4
Engines

Ignition Powered
Air Conditioner
Compressor
Electronic Power
F20 - - 5 Amp Tan
Four-Wheel Drive

Engine
Equipped

F24 - - 15 Amp Blue

20 Amp Yellow
Powered

Drive

F87 - - 5 Amp Tan
Transmission
IBS Sensor (Battery

F90 - - 5 Amp Tan
State Of Charge)

F31 7.5 Amp Brown

IPC

F49 7.5 Amp Brown


F53 7.5 Amp Brown

Fuse holders no. 1

F7 30 Amp Green
Passenger Side)
Fuse holders no. 2
figure.
NOTE:


STARTING
WARNING:
WARNING:
WARNING:
COLOR.
WARNING:
WARNING:
WARNING:

WARNING:
TO EXCEED 16 VOLTS.
WARNING:
CAUTION:

parts.
replaced.
CAUTION:

accessories.
CAUTION:
vehicle.
battery post.
CAUTION:

20, 40, 60, 80, 100, 120, 140, 160, 180, 200,
Kilometers:
000 000 000 000 000 000 000 000 000 000
Or Years: 1 2 3 4 5 6 7 8 9 10

• • • • • • • • • •
charge (if any).

• • • • • • • • • •
etc.).

• • • • • • • • • •
battery, etc.).


• • • • •

• • • • •

• • • • •
and adjust nozzles.

lubrication.
operation.

operation.



•
timing belt.

(1)

(2)
s. (2)

O • O • O • O • O •
(•)
60, 000 km.

NOTE:
15, 30, 45, 60, 75, 90, 105, 120, 135, 150,
Kilometers:
000 000 000 000 000 000 000 000 000 000
Or Years: 1 2 3 4 5 6 7 8 9 10

• • • • • • • • • •
(if any).


• • • • • • • • • •
etc.).


• • • • •

• • • • •

• • • • •
and adjust nozzles.
lubrication.

operation.

operation.


tensioner).

•
timing belt.

(3)
s. (3)

O • O • O • O • O •
(•)
60, 000 km.

NOTE:
procedure.

NOTE:
CAUTION:
Maintenance Chart
Mileage or time
passed 10, 20, 30, 40, 50, 60, 70, 80, 90, 100, 110, 120, 130, 140, 150,
(whichever 000 000 000 000 000 000 000 000 000 000 000 000 000 000 000
comes first)
Years 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15
16, 32, 48, 64, 80, 96, 112, 128, 144, 160, 176, 192, 208, 224, 240,
Or Kilometers
000 000 000 000 000 000 000 000 000 000 000 000 000 000 000
Check tire
condition/wear
and adjust
pressure, if
• • • • • • • • • • • • • • •
necessary,
check TIRE KIT
expiration date
(if provided).
Check operation
of lighting
system
(headlamps,
direction
indicators,
hazard warning
lights, luggage
• • • • • • • • • • • • • • •
compartment,
passenger
compartment,
glove
compartment,
instrument panel
warning lights,
etc.).
Check and, if
necessary, top
up fluid levels
(brakes/hydraulic
clutch, • • • • • • • • • • • • • • •
windshield
washer, battery,
engine coolant,
etc.).
Check engine
control system
• • • • • • • • • • • • • • •
operation (via
diagnostic tool).
Visually inspect
condition of:
exterior
bodywork,
• • • • • • •
underbody
protection, pipes
and hoses
(exhaust - fuel
system -
brakes), rubber
elements (boots,
sleeves,
bushings, etc.).
Check
windshield/rear
window wiper • • • • • • • •
blade
position/wear.
Check operation
of windshield
and adjust jets if
necessary.
Check
cleanliness of
hood and
and cleanliness
and lubrication of
linkages.
Visually check
the condition and
• • • • • • • • • • • • • • •
wear of the front
and rear brakes.
Check the front

suspension, tie
and replace if
necessary.
Visual inspect
the condition of
• • •
the accessory
drive belt.
Check the
tension of the
• • • • • • •
accessory drive
belt.
Replace the
accessory drive •
belt.
Inspect and
replace PCV
•
valve if
necessary.
Change engine
oil and replace
oil filter (*).
Inspect the PTU

• • •
fluid level.
Inspect the rear

level.
Replace spark
plugs (1.4L
• • • • •
Turbo engine).
(**)
Replace spark
plugs (2.4L •
engine). (**)
Replace engine
• • • • •
air filter. (#)
Replace brake
years.
Replace cabin
• • • • • • • • • • • • • • •
filter.
Change the
manual
transmission
fluid if using your
vehicle for any
of the following:
trailer towing,
heavy loading,
taxi, police,
delivery service
(commercial • •
service),
off-road, desert
operation or
more than 50%
of your driving is
at sustained
speeds during
hot weather,
above 90°F
(32°C).
Flush and
replace the
at 10 years or
150, 000 miles
(240, 000 km)
whichever
comes first.
Replace the
Turbo Engine).
plug replacement.
WARNING:
Brake fluid level;
Dusty roads
(if any).
etc.).
INSTALLATION .
(if any).
etc.).

NOTE:

assembly.
suitable container.


MULTIAIR)
(if any).
etc.).
NOTE:
PLUGS .



(if any).
etc.).

NOTE:

assembly.
suitable container.



MULTIAIR)
(if any).
etc.).


INSTALLATION .
(if any).
etc.).

NOTE:
PLUGS .



NOTE:
(if any).
etc.).
4x4 versions only:
NOTE:

NOTE:

assembly.
suitable container.



(if any).
etc.).

INSTALLATION .
(if any).
etc.).

NOTE:

assembly.
suitable container.


MULTIAIR)
(if any).
etc.).
NOTE:
PLUGS .




(if any).
etc.).

NOTE:

assembly.
suitable container.

NOTE:

assembly.

MULTIAIR)
(if any).
etc.).


INSTALLATION .
(if any).
etc.).

NOTE:
PLUGS .


NOTE:
(if any).
etc.).

NOTE:

assembly.
suitable container.

NOTE:

assembly.

MULTIAIR)
(if any).
etc.).

INSTALLATION .
(if any).
etc.).

4x4 versions only:

NOTE:

assembly.
suitable container.

NOTE:

assembly.

MULTIAIR)
(if any).
etc.).
NOTE:
PLUGS .




(if any).
etc.).

NOTE:

assembly.
suitable container.

NOTE:

assembly.

(if any).
etc.).

NOTE:

assembly.
suitable container.

NOTE:

assembly.

(if any).
etc.).

NOTE:

assembly.
suitable container.


Corporate name
Sincom code
Model
Version
Chassis No.
CONFORMITY
• Accessory check
VEHICLE INTERIOR
• Locks
ENGINE COMPARTMENT
CAR EXTERIOR

FINAL CHECK
• Dry vehicle
NOTE:
removed
Detected faults:
Date:
Operator's name:
VEHICLE READINESS
NOTE:
Description Action
2. Headlights Off;


seconds.
Renegade)
NOTE:


turn off.

180 Days

Process.

installed module.

shipping.


equipped)
UNDERHOOD
Description Action




All Fluid Levels

an full engagement.
ROAD TEST
Description Action

______


Keyless Go
inside vehicle.



does not drag.



Autostick
through the gears.

depressed.

depressed.




Defrost - Rear

detection zone.



disconnected.


suspension system.

flashing/chiming.

INTERIOR
Description Action
damage.

operates properly.

Rear View Mirror
operating properly.

operation.


seat system.

operating properly.




required.


Set Clock(s)




operation.



cooled cup holders.

properly.
EXTERIOR
Description Action

Preparation.


keys.

Needed
operation.

equipped)



VEHICLE STORAGE
Description Action

Description Action

Protective Covers

dings and dents.




placard

equipped)
instrument panel.


FRONT, BASE - EMEA
1.



REAR, EMEA
holder (1a).


FRONT, BASE - NAFTA



REAR, NAFTA
140CV 170CV
Maximum weight
1905 1905 2010/2080 (*) 2080
allowed (kg)
Maximum weight
axles (kg)
Maximum weight
axles (kg)
NOTE:
NOTE:
140CV 170CV
Payload including
585 kg 515 kg 580/550 kg (**) 545 kg
the driver (*)
NOTE:
NOTE:
140CV 170CV
Trailer with brakes

1000 1000 1500/1000 (*) 1500
(kg)
Trailer without
400 400 400 400
brakes (kg)
Cargo on the ball

(kg)
The maximum load

(kg) (**)
NOTE:
NOTE:
140CV 170CV

to 90% and no 1320 1390 1430/1530 (*) 1535
optional equipment)
(kg)
NOTE:

VEHICLE
FRONT
REAR
threaded pin back.
Trail Hawk Version
CAUTION:
improper towing.
CAUTION:
Warranty.
NOTE:
NOTE:
Wheels
OFF the
Ground

must be observed.
ON/RUN position.
Jeep Renegade
Service Manual: RESTRAINTS - SERVICE INFORMATION
WARNING > WARNING
WARNING:
components related to the SRS for which there is no MOPAR wiring repair kit. It is important
MOPAR wiring repair kits, please visit the MOPAR Connection Repair Kit Web Site.
Inappropriate repairs can compromise the conductivity and current carrying capacity of
those critical electrical circuits, which may cause SRS components not to deploy when
required, or to deploy when not required. Only minor cuts or abrasions of wire and terminal
insulation where the conductive material has not been damaged, or connector insulators
where the integrity of the latching and locking mechanisms have not been compromised
may be repaired using appropriate methods.
WARNING:
Chrysler Mopar® Parts Catalog. Failure to follow these instructions may result in possible
serious or fatal injury.
WARNING:
To avoid serious or fatal injury on vehicles equipped with side curtain or seat (pelvic and
thorax) airbags, disable the Supplemental Restraint System (SRS) before attempting any
Occupant Restraint Controller (ORC) diagnosis or service. The ORC contains a rollover
sensor, which enables the system to deploy the side curtains or seat airbags in the event of
a vehicle rollover event. If an ORC is accidentally rolled during service while still connected
to battery power, the side curtain and seat airbags will deploy. Disconnect and isolate the
Failure to take the proper precautions could result in accidental airbag deployment.
WARNING:
WARNING:
screens.
WARNING:
WARNING:
To avoid serious or fatal injury when handling a seat belt tensioner retractor or buckle,
proper care should be exercised to keep fingers out from under the retractor or buckle cover
and away from the seat belt webbing or cable where it exits from the retractor or buckle
cover.
WARNING:
components only with parts specified in the Chrysler Mopar® Parts Catalog. Substitute parts
may appear interchangeable, but internal differences may result in inferior occupant
protection.
WARNING:
service package or specified in the Chrysler Mopar® Parts Catalog.
WARNING:
DESCRIPTION AND OPERATION > SUPPLEMENTAL RESTRAINT SYSTEM >

DESCRIPTION - SUPPLEMENTAL RESTRAINT SYSTEM
A Supplemental Restraint System (SRS) is standard factory-installed safety equipment on this vehicle.
Available supplemental occupant restraints for this vehicle include both active and passive types. Active
restraints are those which require the vehicle occupants to take some action to employ, such as
fastening and adjusting a seat belt; while passive restraints require no action by the vehicle occupants
to be employed. Additional details of each of these subsystems of the SRS can be found elsewhere
within this service information.
In the event of a collision and the airbags are deployed, the fuel cut-off system operates, causing:
the interruption of the fuel supply, including the fuel pump and fuel injectors, with the engine
consequently cutting out
the automatic unlocking of the doors
turning on of the lights inside the vehicle
deactivation of climate control system ventilation
switching on of the hazard warning lights (to deactivate the lights press the button on the
dashboard)
On some versions, the intervention of the system is indicated by a message shown on the display. In the
same way, a dedicated message on the display warns the driver if system operation is compromised.
IMPORTANT
Carefully check the vehicle for fuel leaks, for instance in the engine compartment, under the vehicle or
near the tank area. After a collision, bring the ignition device to STOP to prevent the battery from running
down.
Fuel reactivation procedure
To restore correct operation of the vehicle, carry out the following procedure (this procedure must be
started and completed within one minute):
bring the ignition device to ON
turn on the direction indicators on the right, then on the left, then again on the right and again on
the left
now deactivate the direction indicators on the left
bring the ignition device to STOP
IMPORTANT: Multistage airbags with multiple initiators (squibs) must be checked to

determine that all squibs were used during a deployment event. Refer to STANDARD
PROCEDURE for more information regarding the squib status check and for correct airbag
disposal procedures.
DESCRIPTION AND OPERATION > SUPPLEMENTAL RESTRAINT SYSTEM >

OPERATION - SUPPLEMENTAL RESTRAINT SYSTEM
The SRS is comprised of two primary subsystems: Active Restraints and Passive Restraints. Additional
operational details on each of these subsystems of the SRS can be found elsewhere within this service
information.
DESCRIPTION AND OPERATION > ACTIVE RESTRAINTS > DESCRIPTION - ACTIVE

RESTRAINTS
The active restraints for this vehicle include:
Child Restraint Anchors - All vehicles are equipped with three, fixed-position, child seat upper
tether anchors for the rear seating. A single upper tether anchor is integral to the back of the right
seat cushion frame, and two anchors are integral to the back of the left seat cushion frame. Two
lower anchors are also provided for each outboard rear seating position. The lower anchors are
integral to the seat cushion frames. All lower anchors are accessed from the front of the rear seat
near where the seat back meets the seat cushion.
Front Seat Belts - Both front seating positions are equipped with three-point seat belt systems
employing a lower B-pillar mounted inertia latch-type emergency locking retractor, adjustable upper
B-pillar mounted turning loops, a fixed lower seat belt anchor secured to the inner sill near the base
of the B-pillar and a traveling end-release seat belt buckle secured to the inboard side of the seat
cushion frame. The driver and passenger side front seat belt buckles each include an integral seat
belt switch that detects whether the front seat belts have been fastened.
Rear Seat Belts - All three rear seating positions are equipped with three-point seat belt systems.
The outboard belts employ C-pillar mounted inertia latch-type emergency locking retractors, fixed
position upper C-pillar mounted turning loops and fixed lower seat belt anchors secured to the
quarter inner panel. The center belt employs an inertia latch-type emergency locking retractor
secured within the left seat back and a fixed lower anchor buckle secured to the floor panel
beneath the rear seat cushion. The fixed end release rear seat belt buckles are also secured to
the floor panel beneath the rear seat cushion. In vehicles manufactured for Europe-Middle
East-Africa (EMEA) markets, all three rear seat belt buckles each include an integral seat belt
switch that detects whether the rear seat belts have been fastened.
DESCRIPTION AND OPERATION > ACTIVE RESTRAINTS > OPERATION - ACTIVE

RESTRAINTS
The primary passenger restraints in this or any other vehicle are the standard equipment factory-
installed seat belts and child restraint anchors. Seat belts and child restraint anchors are referred to as
an active restraint because the vehicle occupants are required to physically fasten and properly adjust
these restraints in order to benefit from them.
DESCRIPTION AND OPERATION > PASSIVE RESTRAINTS > DESCRIPTION -

PASSIVE RESTRAINTS
Fig 1: SRS Logo
The passive restraints available for this vehicle include the following:
Active Head Restraints - Inertia-based Active Head Restraints (AHR) are standard equipment for
both front seating positions in this vehicle.
Dual Front Airbags - A Driver AirBag (DAB) and front Passenger AirBag (PAB) are standard in
this vehicle. This airbag system consists of passive, inflatable, Supplemental Restraint System
(SRS) components and vehicles with this equipment can be readily identified by the AIRBAG logo
molded into the DAB trim cover in the center of the steering wheel and also into the PAB door on
the instrument panel above the glove box. Vehicles with the airbag system can also be identified by
the airbag indicator, which will illuminate in the Instrument Panel Cluster (IPC) from four to six
seconds as a bulb test each time the status of the ignition transitions to On. Dual pyrotechnic-type
seat belt tensioners are also integral to the driver and passenger front seat belt retractors and
front seat belt anchors to work in conjunction with the dual front airbags. Vehicles manufactured for
Europe-Middle East-Africa (EMEA) markets also have pyrotechnic-type seat belt tensioners
integral to both rear outboard seat belt retractors.
Knee Blocker Airbag - In vehicles manufactured for the North American Free Trade Agreement
(NAFTA) market, the front airbag system also includes a driver knee blocker airbag (also known as
a Knee AirBag/KAB or an Inflatable Knee Blocker/IKB) that is located just below the steering
column, behind the instrument panel steering column opening cover. In vehicles manufactured for
EMEA markets the KAB is optional equipment. This airbag is also a passive, inflatable SRS
component and vehicles with this equipment can be readily identified by the AIRBAG logo molded
into the steering column opening cover on the instrument panel just beneath the steering column.
Seat Airbags - A Seat AirBag (SAB) (also known as a pelvic and thoracic airbag or a side airbag)
integrated into each front seat are standard equipment. This airbag system consists of passive,
inflatable SRS components and vehicles with this equipment can be readily identified by a sewn
tag with the AIRBAG logo located on the outboard side of the front seat back trim cover.
Side Curtain Airbags - Side curtain airbags (also known as Side AirBag Inflatable
Curtains/SABIC) are standard equipment in this vehicle. This airbag system consists of passive,
inflatable SRS components and vehicles with this equipment can be readily identified by a molded
identification AIRBAG logo located on the top of each B-pillar upper trim panel near the headliner.
The SRS includes the following major components, which are described in further detail elsewhere in this
service information:
Active Head Restraints - One Active Head Restraint (AHR) is located atop each front seat back
unit.
Airbag Indicator - The airbag indicator is integral to the IPC, which is located on the instrument
panel in front of the driver.
Clockspring - The clockspring is located near the top of the steering column, directly beneath the
steering wheel.
Driver Airbag - The Driver AirBag (DAB) is located in the center of the steering wheel, beneath
the DAB trim cover.
Driver Knee Blocker - Vehicles manufactured for EMEA markets and not equipped with an
optional driver knee airbag have a driver knee blocker. This knee blocker is a static structural
reinforcement that is integral to and concealed within the steering column opening cover of the
instrument panel.
Front Impact Sensor - Front impact sensors (also known as Early Crash Sensors/ECS) are used
on vehicles equipped with dual front airbags. In vehicles manufactured for EMEA markets a single
sensor is located on the back of the lower horizontal member of the radiator support. In vehicles
manufactured for NAFTA markets two sensors are used, one on the back of each vertical member
of the radiator support.
Knee Airbag - Vehicles manufactured for the NAFTA market have a driver Knee AirBag (KAB)
feature as standard equipment. In EMEA vehicles, the KAB is optional equipment. The KAB is
mounted to the instrument panel lower reinforcement behind the instrument panel steering column
opening cover.
Occupant Detection Sensor - All vehicles are equipped with an Occupant Detection Sensor
(ODS). The ODS is located on the top of the seat cushion foam of the passenger side front seat.
Occupant Restraint Controller - The Occupant Restraint Controller (ORC) is located on the floor
panel center tunnel near the dash panel beneath the center floor console.
Passenger Airbag - The Passenger AirBag (PAB) is located in the instrument panel, beneath the
instrument panel cover and above the glove box on the passenger side of the vehicle.
Passenger Airbag On/Off Indicator - Vehicles manufactured for EMEA markets have a
passenger airbag On/Off indicator integral to the instrument panel switch pod (also known as the
Accessory Switch Bank Module/ASBM), which is secured to the instrument panel center stack just
below the Radio Receiver Module (RRM).
Passenger Knee Blocker - The passenger knee blocker is a static structural reinforcement that
is integral to and concealed within the glove box door.
Seat Airbag - A Seat AirBag (SAB) is secured to each outboard front seat back frame, where it is
concealed beneath the seat back trim cover and foam.
Seat Belt Tensioner - A front seat belt tensioner is integral to both front seat belt retractors and
both front seat belt lower anchors. The front seat belt retractor tensioner units are secured to each
lower inner B-pillar and are concealed behind the lower B-pillar trim. The seat belt anchor tensioner
units are located on the inner sill near the base of the B-pillar and are concealed beneath the inner
sill trim. Vehicles manufactured for EMEA markets also have seat belt tensioners integral to each
rear outboard retractor. The rear seat belt retractor tensioner units are secured to each inner
C-pillar and are concealed behind the C-pillar trim.
Seat Track Position Sensor - Vehicles manufactured for NAFTA markets have a Seat Track
Position Sensor (STPS) located on the inboard side of one of the upper seat adjuster tracks on
both the driver and the passenger front seats.
Side Curtain Airbag - A standard equipment side curtain airbag is secured to each inside roof
side rail above the headliner. The side curtain airbag extends from the A-pillar to just behind the
C-pillar.
Side Impact Sensor - Four side impact sensors are used, two on each side of the vehicle. One
acceleration-type sensor is located behind the B-pillar trim of each lower inner B-pillar and one
pressure-type sensor is located behind the trim panel on the inside of each front door hardware
module carrier.
Fig 2: Six Airbags - Standard
The vehicle is equipped with six airbags as standard which make it one of the cars with the best
standard equipment of its class. It is also equipped with advanced restraint systems on the seat belts
which guarantee optimal protection of the occupants in the event of an accident.
The ORC system can be equipped with:
Driver's
Number of Driver Passenger Curtain Front Rear
knee Sidebags
charges airbag airbag airbag pretensioners pretensioners
airbag
EMEA
1 1 1 (opt) 2 2 2 2
version
NAFTA
2 3 1 2 2 2 -
version
Side Seat
Number of Side Front seat Passenger Rear seat
impact guide
sensors / ECS impact buckle presence buckle
pressure position
switches sensors switches sensor switches
sensors sensor
NAFTA
2 2 2 2 1 2 -
version
EMEA version 1 2 2 2 1 - 3
The ORC and the IPC each contain a microcontroller and programming that allow them to communicate
with each other using the Controller Area Network (CAN) data bus. This method of communication is
used by the ORC for control of the airbag indicator in the IPC. Refer to COMMUNICATION,
Hardwired circuitry connects the SRS components to each other through the electrical system of the
the vehicle electrical system, and to the SRS components through the use of a combination of soldered
splices, splice block connectors, and many different types of wire harness terminal connectors and
insulators. Refer to the appropriate SYSTEM WIRING DIAGRAMS article. The wiring information
routing and retention, as well as pin out and location views for the various wire harness connectors,
DESCRIPTION AND OPERATION > PASSIVE RESTRAINTS > OPERATION - PASSIVE

RESTRAINTS
The passive restraints are referred to as a Supplemental Restraint System (SRS) components because
they were designed and are intended to enhance the protection for the occupants of the vehicle only
when used in conjunction with the seat belts. They are referred to as passive restraints because the
vehicle occupants are not required to do anything to make them operate; however, the vehicle
occupants must be wearing their seat belts in order to obtain the maximum safety benefit from the
factory-installed SRS components. In addition, each front seat occupant must have their Active Head
Restraint (AHR) unit properly adjusted in order to obtain its maximum safety benefit.
The SRS electrical circuits are continuously monitored and controlled by a microcontroller and software
contained within the Occupant Restraint Controller (ORC). An airbag indicator in the Instrument Panel
Cluster (IPC) illuminates from four to six seconds as a bulb test each time the status of the ignition
transitions to On or Start. Following the bulb test, the airbag indicator is turned On or Off by the ORC to
indicate the status of the SRS. If the airbag indicator comes On at any time other than during the bulb
test, it indicates that there is a problem in the SRS electrical circuits. Such a problem may cause airbags
not to deploy when required, or to deploy when not required.
Vehicles manufactured for Europe-Middle East-Africa (EMEA) markets are equipped with a feature that
allows Passenger AirBag (PAB) operation to be suppressed or enabled using a setup routine in the IPC.
A passenger airbag on/off indicator is located in the instrument panel switch pod in the instrument panel
center stack. This indicator receives battery current whenever the status of the ignition is On or Start
and illuminates only when the ORC pulls the appropriate indicator control circuit to ground. The indicator
illuminates for about seven seconds as a bulb test each time the status of the ignition transitions to On
or Start. Following the bulb test, the indicator is turned On or Off by the ORC based upon the electronic
passenger airbag disable messages received from the IPC.
Deployment of the SRS components depends upon the angle and severity of an impact. Deployment is
not based upon vehicle speed; rather, deployment is based upon the rate of deceleration as measured
by the forces of gravity (G force) upon the acceleration-type impact sensors, or by a pressure wave
within a door as measured by the pressure-type impact sensor. When an impact is severe enough, the
microcontroller within the ORC signals the inflator of the appropriate airbag units to deploy their airbag
cushions.
The front seat belt retractor tensioners, front seat belt anchor tensioners, the rear outboard seat belt
retractor tensioners (if equipped) and the driver Knee AirBag (KAB) (if equipped) are provided with a
deployment signal by the ORC in conjunction with the front airbags. The side curtain airbags are
provided with a deployment signal individually by the ORC based upon a side impact sensor input for the
same side of the vehicle.
The ORC also contains a rollover sensor. Should the vehicle roll over and not cause any impact sensor
to signal the need for a deployment, the rollover sensor in the ORC will deploy the side curtain airbags
units, the SAB units and under certain conditions, will also actuate the front seat belt retractor and
anchor buckle tensioners as well as the rear outboard seat belt retractor tensioners (if equipped).
During a frontal vehicle impact, the static knee blockers work in concert with properly fastened and
adjusted seat belts to restrain the front seat occupants in the proper position for an airbag deployment.
The static knee blockers also absorb and distribute the crash energy from the front seat occupants to
the structure of the instrument panel. The seat belt tensioners remove the slack from the front seat belts
to provide further assurance that the driver and front seat passenger are properly positioned and
restrained for an airbag deployment. The load limiter integral to each seat belt retractor controls the belt
pressure applied to the chest of the wearer of that seat belt.
Typically, the vehicle occupants recall more about the events preceding and following a collision than
they do of an airbag deployment itself. This is because the airbag deployment and deflation occur very
rapidly. In a typical 48 kilometer-per-hour (30 mile-per-hour) barrier impact, from the moment of impact
until the airbags are fully inflated takes about 40 milliseconds. Within one to two seconds from the
moment of impact, the airbags are almost entirely deflated. The times cited for these events are
approximations, which apply only to a barrier impact at the given speed. Actual times will vary somewhat,
depending upon the vehicle speed, impact angle, severity of the impact, and the type of collision.
When the ORC monitors a problem in any of the SRS circuits or components, including the seat belt
tensioners, it stores a fault code or Diagnostic Trouble Code (DTC) in its memory circuit and sends an
electronic message to the IPC to turn On the airbag indicator. The hard wired circuits between
components related to the SRS may be diagnosed using conventional diagnostic tools and procedures.
Refer to the appropriate SYSTEM WIRING DIAGRAMS article. The wiring information includes wiring
diagrams, proper wire and connector repair procedures, details of wire harness routing and retention,
connector pin out information and location views for the various wire harness connectors, splices and
grounds.
However, conventional diagnostic methods will not prove conclusive in the diagnosis of the SRS or the
SRS. The most reliable, efficient and accurate means to diagnose the SRS or the electronic controls and
communication related to SRS operation, as well as the retrieval or erasure of a DTC requires the use of
a diagnostic scan tool and may also require the use of the SRS Load Tool special tool along with the
appropriate Load Tool Jumpers and Adapters. Refer to the appropriate Diagnostic & Testing article.
DIAGNOSIS AND TESTING > DIAGNOSIS AND TESTING - SUPPLEMENTAL

RESTRAINT SYSTEM
WARNING:
SENSOR DIAGNOSIS
The Occupant Restraint Controller (ORC) will set DTCs when a sensor fault is detected. The sensors
cannot be tested and are diagnosed by the process of elimination. After disconnecting the harness from
the ORC and the sensor, the sensor circuits are checked for shorts to power or earth, sensor circuits
shorted together, and wire resistance. Only after eliminating all possible circuit faults is the sensor
replaced.
SQUIB DIAGNOSIS
The ORC will set DTCs when a squib concern is detected. The squibs cannot be tested and are
diagnosed by the process of elimination. Squib circuits are tested using special SRS equipment.
The hard wired circuits between modules and components related to the Supplemental Restraint System
(SRS) may be diagnosed using conventional diagnostic tools and procedures. Refer to the appropriate
However, conventional diagnostic methods will not prove conclusive in the diagnosis of the SRS or the
SRS. The most reliable, efficient and accurate means to diagnose the SRS or the electronic controls and
communication related to SRS operation, as well as the retrieval or erasure of a DTC requires the use of
a diagnostic scan tool. Refer to the appropriate Diagnostic & Testing article.
In addition to a diagnostic scan tool that contains the latest version of the proper diagnostic software,
certain diagnostic procedures for the SRS may require the use of the SRS Load Tool special tool along
with the appropriate Load Tool Jumpers and Adapters. Refer to the appropriate Diagnostic & Testing
article.
STANDARD PROCEDURE > HANDLING NON-DEPLOYED SUPPLEMENTAL

RESTRAINTS
At no time should any source of electricity be permitted near the inflator on the back of a non-deployed
airbag or seat belt tensioner. When carrying a non-deployed airbag, the trim cover or airbag cushion
side of the unit should be pointed away from the body to minimize injury in the event of an accidental
deployment. If the airbag unit is placed on a bench or any other surface, the trim cover or airbag cushion
side of the unit should be face up to minimize movement in the event of an accidental deployment.
When handling a non-deployed seat belt tensioner, take proper care to keep fingers out from under the
retractor or buckle cover and away from the seat belt webbing or cable where it exits from the retractor
or buckle cover. In addition, the Supplemental Restraint System (SRS) should be disarmed whenever
any steering wheel, steering column, seat belt tensioner, airbag, impact sensor or instrument panel
components require diagnosis or service. Failure to observe this warning could result in accidental
airbag deployment and possible personal injury.
All damaged, ineffective or non-deployed airbags and seat belt tensioners which are replaced on
vehicles are to be handled and disposed of properly. If an airbag or seat belt tensioner unit is ineffective
or damaged and non-deployed, refer to the Hazardous Substance Control System for information
regarding the potentially hazardous properties of the subject component and the proper safe handling
procedures. Then dispose of all non-deployed and deployed airbags and seat belt tensioners in a
manner consistent with state, provincial, local and federal regulations.
STANDARD PROCEDURE > SERVICE AFTER A SUPPLEMENTAL RESTRAINT

SYSTEM DEPLOYMENT
Any vehicle which is to be returned to use following a Supplemental Restraint System (SRS) component
deployment must have the deployed restraints replaced. In addition, the following guidelines MUST be
observed.
Following ANY major vehicle impact damage in the vicinity of an impact sensor or the ORC
- It is critical that the mounting surfaces and mounting brackets for the Occupant Restraint
Controller (ORC), front impact sensors and side impact sensors located within the proximity of the
impact damage be closely inspected and restored to their original conditions. Because the ORC
and each impact sensor are used by the SRS to monitor or confirm the direction and severity of a
vehicle impact, improper orientation or insecure fastening of these components may cause airbags
not to deploy when required, or to deploy when not required.
Following ANY airbag deployment event - The Lower Anchors and Tethers for CHildren
(LATCH) provisions, the upper tether anchors and all interior trim panels must also be inspected.
If an active head restraint is deployed - An inertia-based Active Head Restraint (AHR) unit that
is undamaged following a deployment automatically resets itself. These units are designed with the
intention of reuse. (Refer to STANDARD PROCEDURE ).
If the driver airbag is deployed - If the Driver AirBag (DAB) has been deployed, the DAB, the
clockspring, the steering column assembly including the intermediate shaft and coupler, both front
seat belt anchor tensioners, both front seat belt retractor and tensioner assemblies, both rear
outboard seat belt retractor and tensioner assemblies (if equipped), any front seat belt buckle in
use and all rear seat belt retractors and buckles in use must be replaced. The front impact sensors
and the steering wheel must also be inspected.
If the knee airbag is deployed - If the driver Knee AirBag (KAB) (also known as the Inflatable
Knee Blocker/IKB) has been deployed, the KAB and the instrument panel steering column opening
cover must also be replaced. The instrument panel must also be inspected.
If the passenger airbag is deployed - If the Passenger AirBag (PAB) has been deployed, the
PAB, the PAB wire harness or connector and the instrument panel must be replaced.
If a seat airbag is deployed - If a Seat AirBag (SAB) (also known as a pelvic and thoracic airbag)
has been deployed, the SAB, the seat back frame, the seat back foam, the seat back trim cover
and the side impact sensors on the same side of the vehicle as the deployed airbag must be
replaced. Both front seat belt anchor tensioners, both front seat belt retractor and tensioner
assemblies, both rear outboard seat belt retractor and tensioner assemblies (if equipped), any
front seat belt buckle in use and all rear seat belt retractors and buckles in use must be replaced.
If a seat belt tensioner is deployed - The seat belt retractor and anchor tensioners are deployed
in conjunction with the front airbags. All seat belt tensioners must be replaced if any airbag in the
vehicle except the driver Knee AirBag (KAB) has been deployed.
If a side curtain airbag is deployed - If a side curtain airbag (also known as a Side AirBag
Inflatable Curtain/SABIC) has been deployed, the SABIC, the trim on the upper A, B and C-pillars
as well as the side impact sensors on the same side of the vehicle as the deployed airbag must be
replaced. The headliner, both front seat belt anchor tensioners, both front seat belt retractor and
tensioner assemblies, both rear outboard seat belt retractor and tensioner assemblies (if
equipped), any front seat belt buckle in use and all rear seat belt retractors and buckles in use must
be replaced. The deploy brackets on the B-pillar and C-pillar for the same side of the vehicle as the
deployed airbag must be closely inspected following a side curtain airbag deployment.
The components identified with the deployed SRS components in the preceding list are not intended for
reuse and will be damaged or weakened as a result of an airbag deployment, which may or may not be
obvious during a visual inspection. All other vehicle components should be closely inspected following
any SRS component deployment, but are to be replaced only as required by the extent of the visible
damage incurred.

SYSTEM DEPLOYMENT > AIRBAG SQUIB STATUS (NAFTA ONLY)
Vehicles manufactured for North America Free Trade Agreement (NAFTA) markets use multistage
airbags with multiple initiators (squibs) which must be checked to determine that all squibs were used
during the deployment event. The Driver AirBag (DAB) and Passenger AirBag (PAB) in these vehicles
are deployed by electrical signals generated by the Occupant Restraint Controller (ORC) through the
driver or passenger squib 1 and squib 2 circuits to the two initiators in the airbag inflators. Typically, both
initiators are used and all potentially hazardous chemicals are burned during an airbag deployment event.
However, it is possible for only one initiator to be used; therefore, it is always necessary to confirm that
both initiators have been used in order to avoid the improper handling or disposal of potentially live
pyrotechnic or hazardous materials. The following procedure should be performed using a diagnostic
scan tool to verify the status of both airbag squibs before either deployed airbag is removed from the
vehicle for disposal.
CAUTION:
Deployed front airbags having two initiators (squibs) in the airbag inflator may or may not
have live pyrotechnic material within the inflator. Do not dispose of these airbags unless you
are certain of complete deployment. Refer to the Hazardous Substance Control System for
information regarding the potentially hazardous properties of the subject component and the
proper safe handling procedures. Then dispose of all non-deployed and deployed airbags
and seat belt tensioners in a manner consistent with state, provincial, local and federal
regulations.
1. Be certain that the diagnostic scan tool contains the latest version of the proper diagnostic
software. Connect the scan tool to the 16-way Data Link Connector (DLC). The DLC is located
on the driver side lower edge of the instrument panel, outboard of the steering column.
2. Transition the ignition status to On.
3. Using the scan tool, read and record the active (current) Diagnostic Trouble Code (DTC) data.
Using the active DTC information, refer to the Airbag Squib Status table to determine the status of
both DAB squibs and both PAB squibs.
AIRBAG SQUIB STATUS
IF THE ACTIVE DTC IS: CONDITIONS SQUIB STATUS
Driver or Passenger Squib 1 AND the stored DTC minutes for both Driver Both Squib 1 and 2 were
open or Passenger squibs are within 15 minutes of used.
each other
Driver or Passenger Squib 2
open
Driver or Passenger Squib 1 AND the stored DTC minutes for Driver or Squib 1 was used; Squib 2
open Passenger Squib 2 open is GREATER than is live.
the stored DTC minutes for Driver or
Driver or Passenger Squib 2 Passenger Squib 1 by 15 minutes or more
open
Driver or Passenger Squib 1 AND the stored DTC minutes for Driver or Squib 1 is live; Squib 2 was
open Passenger Squib 1 open is GREATER than used.
the stored DTC minutes for Driver or
Driver or Passenger Squib 2 Passenger Squib 2 by 15 minutes or more
open
Driver or Passenger Squib 1 AND Driver or Passenger Squib 2 open is Squib 1 was used; Squib 2
open NOT an active code is live.
Driver or Passenger Squib 2 AND Driver or Passenger Squib 1 open is Squib 1 is live; Squib 2 was
open NOT an active code used.
NOTE:
If none of the Driver or Passenger Squib 1 or 2 open are active codes, the status of the
airbag squibs is unknown. In this case the airbag should be handled and disposed of as if
the squibs were both live.

SYSTEM DEPLOYMENT > CLEANUP PROCEDURE
Fig 1: Clean Up Safety Equipment
Following a Supplemental Restraint System (SRS) component deployment, the vehicle interior will
contain a powdery residue. This residue consists primarily of harmless particulate by-products of the
small pyrotechnic charge that initiates the propellant used to deploy a SRS component. However, this
residue may also contain traces of sodium hydroxide powder, a chemical by-product of the propellant
material that is used to generate the inert gas that inflates the airbag. Since sodium hydroxide powder
can irritate the skin, eyes, nose, or throat, be certain to wear safety glasses, rubber gloves, and a
long-sleeved shirt during cleanup.
WARNING:
To avoid serious or fatal injury, if you experience skin irritation during cleanup, run cool
water over the affected area. Also, if you experience irritation of the nose or throat, exit the
vehicle for fresh air until the irritation ceases. If irritation continues, see a physician.
Fig 2: Vacuuming Residual Powder
1. Begin the cleanup by using a vacuum cleaner to remove any residual powder from the vehicle
interior. Clean from outside the vehicle and work your way inside, so that you avoid kneeling or
sitting on a non-cleaned area.
2. Be certain to vacuum the heater and air conditioning outlets as well. Run the heater and air
conditioner blower on the lowest speed setting and vacuum any powder expelled from the
outlets.
CAUTION:
Deployed front airbags having two initiators (squibs) in the airbag inflator may or
may not have live pyrotechnic material within the inflator. Do not dispose of these
airbags unless you are certain of complete deployment. Refer to the AIRBAG
SQUIB STATUS heading within this information. All damaged, ineffective, or
non-deployed Supplemental Restraint System (SRS) components which are
replaced on vehicles are to be handled and disposed of properly. If an airbag or
seat belt tensioner unit is ineffective or damaged and non-deployed, refer to the
Hazardous Substance Control System for information regarding the potentially
hazardous properties of the subject component and the proper safe handling
procedures. Then dispose of all non-deployed and deployed airbags and seat belt
tensioners in a manner consistent with state, provincial, local and federal
regulations.
3. Next, remove the deployed SRS components from the vehicle. Refer to the appropriate service
removal procedures.
4. You may need to vacuum the interior of the vehicle a second time to recover all of the powder.

SYSTEM DEPLOYMENT > FUEL SYSTEM REACTIVATION AFTER AIRBAG
DEPLOYMENT
In the event of a collision and the airbags are deployed, the fuel cut-off system operates, causing:
the interruption of the fuel supply, including the fuel pump and fuel injectors, with the engine
consequently cutting out
the automatic unlocking of the doors
turning on of the lights inside the vehicle
deactivation of climate control system ventilation
switching on of the hazard warning lights (to deactivate the lights press the button on the
dashboard)
On some versions, the intervention of the system is indicated by a message shown on the display. In the
same way, a dedicated message on the display warns the driver if system operation is compromised.
IMPORTANT
Carefully check the vehicle for fuel leaks, for instance in the engine compartment, under the vehicle or
near the tank area. After a collision, bring the ignition device to STOP to prevent the battery from running
down.
Fuel reactivation procedure
To restore correct operation of the vehicle, carry out the following procedure (this procedure must be
started and completed within one minute):
turn on the direction indicators on the right, then on the left, then again on the right and again on
the left
now deactivate the direction indicators on the left

bring the ignition device to STOP

SYSTEM DEPLOYMENT > SQUIB CIRCUIT DAMAGE
In addition to the preceding guidelines, be aware that the heat created by the initiator during an airbag or
tensioner deployment will cause collateral damage to the connected wiring (squib circuits) and connector
insulators. There are two methods by which an airbag or seat belt tensioner may be connected to the
vehicle electrical system. The first method involves a short pigtail harness and connector insulator that
are integral to the airbag or tensioner unit and are replaced as a unit with the service replacement airbag
or seat belt tensioner. This connection method typically requires no additional wiring repair following a
deployment.
However, the second connection method involves a wire harness takeout and connector insulator that
are connected directly to the airbag or tensioner initiator or squib. These direct-connect type take outs
and connector insulators MUST be repaired following an airbag or seat belt tensioner deployment using
the approved Supplemental Restraint System Wiring Repairs procedure. Refer to STANDARD
PROCEDURE .
STANDARD PROCEDURE > SUPPLEMENTAL RESTRAINT STORAGE
Airbags and seat belt tensioners must be stored in their original, special container until they are used for
service. Also, they must be stored in a clean, dry environment away from sources of extreme heat,
sparks and high electrical energy. Always place or store any airbag on a surface with its trim cover or
airbag cushion side facing up, to minimize movement in case of an accidental deployment.
STANDARD PROCEDURE > SUPPLEMENTAL RESTRAINT SYSTEM VERIFICATION

TEST
WARNING:
NOTE:
The following procedure should be performed using a diagnostic scan tool to verify proper
Supplemental Restraint System (SRS) operation following the service or replacement of any
SRS component. Refer to the appropriate Diagnostic & Testing article.
1. During the following test, the negative cable remains disconnected and isolated from the
battery, as it was during the Supplemental Restraint System (SRS) component removal and
installation procedures.
2. Be certain that the diagnostic scan tool contains the latest version of the proper diagnostic
software. Connect the scan tool to the 16-way Data Link Connector (DLC). The DLC is located
on the driver side lower edge of the instrument panel, near the steering column opening cover
and outboard of the steering column.
3. Transition the status of the ignition switch to On and exit the vehicle with the scan tool.
4. Check to be certain that nobody is in the vehicle, then reconnect the negative cable to the
battery. If equipped with an Intelligent Battery Sensor (IBS), reconnect the IBS connector.
5. Using the scan tool, read and record the active (current) Diagnostic Trouble Code (DTC) data.
6. Next, use the scan tool to read and record any stored (historical) DTC data.
7. If any DTC is found in Step 5 or Step 6, Refer to the appropriate Diagnostic & Testing article.
8. Use the scan tool to erase the stored DTC data. If any problems remain, the stored DTC data
will not erase. Refer to the appropriate Diagnostic & Testing article to diagnose any stored
DTC that will not erase. If the stored DTC information is successfully erased, go to Step 9.
9. Transition the status of the ignition switch to Off for about 15 seconds, and then back to On.
Observe the airbag indicator in the instrument cluster. It should light from four to six seconds,
and then go out. This indicates that the SRS is functioning normally and that the repairs are
complete. If the airbag indicator fails to light, or lights and stays On, there is still an active SRS
fault or malfunction. Refer to the appropriate Diagnostic & Testing article to diagnose the
problem.
STANDARD PROCEDURE > SUPPLEMENTAL RESTRAINT SYSTEM WIRING REPAIRS
It is important when repairing any Supplemental Restraint System (SRS) electrical circuits to use the
recommended splicing kit and procedure. For applicable and available MOPAR wiring repair kits, please
visit the MOPAR Connection Repair Kit Web Site.
This recommended procedure involves crimping the wires together with a splice band, soldering the
crimped connection and, finally, sealing and protecting the repair. The crimp and solder ensure a strong
mechanical bond that will always pass a pull test while also maintaining the conductivity and current
carrying capacity of the circuit. The adhesive sealant and heat shrink tubing ensures the splice repair will
perform as well or better than the original wire and be safe from potential corrosion or short circuits.
There is no limit to the number of splice repairs that can be made in one harness using this procedure.
However, as has been past practice, multiple adjacent splices should be offset from each other. This
wiring splice repair procedure is approved for harness side repairs only. Repairs and splices to pigtail
wires on SRS components such as airbag units, seat belt tensioner units or clocksprings are not
approved or recommended.
STANDARD PROCEDURE > SUPPLEMENTAL RESTRAINT SYSTEM WIRING REPAIRS
> REPAIR PROCEDURE
CAUTION:
If additional wire is needed when making a splice repair to any wire, it is important that the
same or next larger size wire gauge be used. Refer to the appropriate wiring diagram for the
original wire gauge size.
1. Remove 13 millimeters (0.50 inch) of insulation from each wire that needs to be spliced.
Fig 1: Splice Band
2. Place a piece of adhesive sealant-lined heat shrink tubing (Part Number 04778570 or
equivalent) over the wire on one side of the splice. Be certain the length of tubing will be
sufficient to cover and seal the entire repair area.
3. Place the strands of the wires being spliced so that they are overlapping each other within the
splice band (1).
Fig 2: Crimping Tool
4. Using a crimping tool (1) (MOPAR Part Number 05019912AA, Miller Special Tool Number
(special tool #10042, Crimper, Wire/Terminal) or equivalent) crimp the splice band and wires
together securely.
Fig 3: Solder Splice
CAUTION:
Never use acid core solder for electrical wiring repairs.
5. Using rosin core type solder (1) only and a suitable soldering iron (3), solder the wire and
splice band connection (2) together.
Fig 4: Heat Shrink Tube
6. Center the heat shrink tubing (2) over the splice joint repair and heat using a suitable heat gun.
Heat the joint until the tubing is tightly sealed and sealant (1) begins to ooze out of both ends of
the tubing.

Seat Belt Turning Loop Height

40 30 -
Adjuster Mounting Screw
Seat Belt Turning Loop To Height

40 30 -
Adjuster Screw
Front Seat Belt Buckle Mounting

40 30 -
Screw
Rear Seat Belt Buckle Mounting

40 30 -
Screw
Front Seat Belt Anchor Tensioner

40 30 -
Mounting Screw
Rear Outboard Seat Belt

40 30 -
Retractor Mounting Screw
Rear Outboard Seat Belt Lower

Anchor To C-Pillar Mounting 40 30 -
Screw
Front Seat Belt Retractor To
40 30 -
B-Pillar Mounting Screw
Rear Center Seat Belt Retractor

40 30 -
Mounting Screw
Rear Outboard Seat Belt Turning

40 30 -
Loop To C-Pillar Mounting Screw
Passenger Airbag Mounting

20 15 -
Screw
10042 - Crimper, Wire/Terminal

ADJUSTER, SEAT BELT TURNING LOOP > REMOVAL AND INSTALLATION >
WARNING:
Fig 1: Remove/Install B-Pillar Trim
1. Adjust the front seat to its most forward position for easiest access to the front seat belt and
the B-pillar trim.
2. Firmly grasp the top of the trim cover (2a) for the front seat belt turning loop height adjuster on
the inside of the upper B-pillar and pull it away from the height adjuster far enough to unsnap it,
then disengage the lower snap features of the trim cover from the adjuster.
3. Remove the screw (2b) that secures the front seat belt turning loop to the height adjuster on
the inside of the upper B-pillar.
4. Remove the seat belt turning loop from the height adjuster.
5. Remove the upper trim from the inside of the B-pillar. Refer to PANEL, B-PILLAR TRIM,
LOWER, REMOVAL AND INSTALLATION and PANEL, B-PILLAR TRIM, UPPER, REMOVAL
AND INSTALLATION .
6. Remove the two screws that secure the height adjuster to the inside of the upper B-pillar.
7. Lift the height adjuster upward on the B-pillar far enough to disengage the hooks on the back of
the adjuster from the B-pillar.
8. Remove the height adjuster from the B-pillar.
ADJUSTER, SEAT BELT TURNING LOOP > REMOVAL AND INSTALLATION >
WARNING:
Fig 1: Remove/Install B-Pillar Trim
1. Position the front seat belt turning loop height adjuster to the inside of the upper B-pillar.
2. Lift the height adjuster upward on the B-pillar far enough to engage the hooks on the back of
the adjuster into the B-pillar clearance holes.
3. Install and tighten the two screws that secure the height adjuster to the inside of the upper
B-pillar. Tighten the screws securely.
4. Install the upper trim (3b) onto the inside of the B-pillar. Refer to PANEL, B-PILLAR TRIM,
AND INSTALLATION .
5. Position the front seat belt turning loop onto the height adjuster on the inside of the upper
B-pillar.
6. Install and tighten the screw (2b) that secures the turning loop to the height adjuster. Tighten
the screw to the proper SPECIFICATIONS .
7. Engage the lower snap features of the trim cover under the height adjuster, then use hand
pressure to press the top of the trim cover firmly and evenly over the height adjuster until it
snaps into place.
AIR BAG, DRIVER > DESCRIPTION AND OPERATION > DESCRIPTION AND
Fig 1: Driver Airbag (DAB)
Depending on the market, the Driver Airbag (DAB) can be single-stage (EMEA) or multi-stage (NAFTA).
The Occupant Restraint Controller (ORC) module will operate the single or the double charge.
Only the single charge is available in the EMEA market.
The DAB cannot be repaired, and must be replaced if deployed, ineffective or in any way damaged. The
DAB trim cover and the floating horn switch are serviced only as a unit with the DAB.
AIR BAG, DRIVER > DESCRIPTION AND OPERATION > DESCRIPTION AND
The Driver AirBag (DAB) is deployed by electrical signals generated by the Occupant Restraint
Controller (ORC) through the DAB squib circuits to the initiator in the airbag inflator. In vehicles
manufactured for North America Free Trade Agreement (NAFTA) markets having two initiators, the airbag
can be deployed at multiple levels of force. The force level is controlled by the ORC to suit the monitored
impact conditions by providing one of several delay intervals between the electrical signals provided to
the two initiators. The longer the delay between these signals, the less forcefully the airbag will deploy.
When the ORC sends the proper electrical signal to the initiator, the electrical energy generates enough
heat to initiate a small pyrotechnic charge, which in turn ignites chemical pellets within the inflator. Once
ignited, these chemical pellets burn rapidly and produce a large quantity of inert gas. The inflator is
sealed to the back of the DAB housing and a diffuser in the inflator directs all of the inert gas into the
airbag cushion, causing the cushion to inflate. As the cushion inflates, the DAB trim cover will split at
predetermined breakout lines, then fold back out of the way. Following a deployment, the airbag cushion
quickly deflates by venting the inert gas towards the instrument panel through vent holes within the fabric
used to construct the back (steering wheel side) panel of the airbag cushion.
Some of the chemicals used to create the inert gas may be considered hazardous while in their solid
state before they are burned, but they are securely sealed within the airbag inflator. In NAFTA vehicles
with multistage airbags only, typically both initiators are used and all potentially hazardous chemicals are
burned during an airbag deployment event. However, it is possible for only one initiator to be used during
a deployment due to a Supplemental Restraint System (SRS) fault; therefore, it is necessary to always
confirm that both initiators have been used in order to avoid the improper disposal of potentially live
pyrotechnic or hazardous materials. Refer to STANDARD PROCEDURE .
The inert gas that is produced when the chemicals are burned during a deployment is harmless.
However, a small amount of residue from the burned chemicals may cause some temporary discomfort if
it contacts the skin, eyes, or breathing passages. If skin or eye irritation is noted, rinse the affected area
with plenty of cool, clean water. If breathing passages are irritated, move to another area where there is
plenty of clean, fresh air to breath. If the irritation is not alleviated by these actions, contact a physician.
The ORC monitors the condition of the DAB through circuit resistance. If any fault is detected the ORC
will illuminate the airbag indicator in the instrument cluster and store a Diagnostic Trouble Code (DTC).
Proper diagnosis of the DAB initiator and squib circuits requires the use of a diagnostic scan tool and
may also require the use of the SRS Load Tool special tool along with the appropriate Load Tool
Jumpers and Adapters. Refer to the appropriate Diagnostic & Testing article.
AIR BAG, DRIVER > REMOVAL AND INSTALLATION > REMOVAL AND
WARNING:
WARNING:
cushion and other interior surfaces. In large doses, these deposits may cause irritation to
the skin and eyes.
Fig 1: Access Holes, Latches & Screwdriver

NOTE:
The following procedure is for replacement of an ineffective or damaged Driver AirBag

(DAB). If the airbag is ineffective or damaged, but not deployed, review the recommended
procedures for Handling Non-Deployed Supplemental Restraints. Refer to STANDARD
PROCEDURE . If the DAB has been deployed, review the recommended procedures for
Service After A Supplemental Restraint Deployment before removing the airbag from the
vehicle. Refer to STANDARD PROCEDURE .
from the battery. Wait two minutes for the system capacitor to discharge before further
service.
2. Locate the access holes (1b) in the lower surface of the steering wheel hub rear trim cover
near each of the two horizontal spokes.
3. Insert an appropriately sized straight-bladed screwdriver through one of the steering wheel
access holes far enough to engage the blade of the screwdriver between the latch feature (1c)
of the DAB and the hook of the steering wheel armature.
4. While pulling the DAB lightly upward, rotate the screwdriver handle (1a) to disengage the DAB
latch feature from the hook of the steering wheel armature.
5. Insert a trim stick or another long and thin obstacle between the released side of the DAB and
the steering wheel. This will help to prevent the released side of the DAB from becoming
accidentally engaged again, while the latch feature on the opposite side is being released.
6. Repeat Steps 3 and 4 for the opposite side of the DAB.

Fig 2: Clockspring Pigtail & Steering Wheel Wire Harness
7. Pull the DAB away from the steering wheel far enough to access the clockspring pigtail (2) and
steering wheel wire harness (1) connections to the horn switch and the DAB inflator initiators.
8. Disconnect the steering wheel wire harness connector (1) from the floating horn switch plate
connector on the back of the switch plate.
CAUTION:
Do not pull on the clockspring pigtail wires or pry on the connector insulators to
disengage them from the Driver AirBag (DAB) inflator initiator connector
receptacles. Improper removal of these pigtail wires and their connector insulators
can result in damage to the airbag circuits or the connector insulators.
Fig 3: Clockspring DAB Pigtail Wire Connector Insulators, Latches & Connector Position
Assurance (CPA) Lock
9. The clockspring DAB pigtail wire connector insulator (1) is secured by integral latches (3) and a
Connector Position Assurance (CPA) lock (2) to the airbag inflator connector receptacle, which
is located on the back of the floating horn switch plate and the DAB housing. Pull the lock
straight out from the connector insulator, then pull the insulator straight out from the connector
receptacle to disengage and disconnect it.
10. Remove the DAB and floating horn switch plate from the steering wheel as a unit.
11. If the DAB has been deployed, the clockspring and stalk unit as well as the steering column
must be replaced. Refer to CLOCKSPRING, REMOVAL AND INSTALLATION and COLUMN,
AIR BAG, DRIVER > REMOVAL AND INSTALLATION > REMOVAL AND
WARNING:
WARNING:
entering the Driver AirBag (DAB), or becoming entrapped between the DAB cushion and the
DAB trim cover. Failure to observe this warning could result in occupant injuries upon airbag
deployment.
WARNING:
To avoid serious or fatal injury, the driver airbag trim cover must never be painted.
Replacement airbags are serviced with trim covers in the original colors. Paint may change
the way in which the material of the trim cover responds to an airbag deployment. Failure to
observe this warning could result in occupant injuries upon airbag deployment.
Fig 1: Clockspring Pigtail & Steering Wheel Wire Harness
NOTE:
The following procedure is for replacement of an ineffective or damaged Driver AirBag

(DAB). If the airbag is ineffective or damaged, but not deployed, review the recommended
PROCEDURE . If the DAB has been deployed, review the recommended procedures for
1. Position the Driver AirBag (DAB) and floating horn switch unit close enough to the steering
wheel to access the clockspring pigtail (2) and steering wheel wire harness (1) connections to
the horn switch and the DAB inflator initiator.
2. Connect the steering wheel wire harness connector to the floating horn switch connector on
the back of the mounting and horn switch plate.
3. Connect the clockspring pigtail wire connector to the airbag inflator initiator connector
receptacle by pressing straight in on the connector insulator. Be certain to engage each keyed
and color-coded connector to the matching connector receptacle. Be certain that each
connector is fully engaged in its receptacle, then push the connector lock straight into the
connector to lock it into place.
4. Carefully position the DAB and floating horn switch unit into the steering wheel hub cavity while
tugging lightly upward on the clockspring pigtail wires for the airbag and tucking the wires into
the upper hub cavity of the steering wheel. Be certain that none of the steering wheel wiring is
pinched between the airbag housing or the horn switch and the steering wheel armature.
5. Using both hands, push firmly and evenly on both sides of the DAB trim cover until both latch
features have snapped into place under the hooks within the hub cavity of the steering wheel.
6. Do not connect the negative cable to the battery at this time. The Supplemental Restraint
component. Refer to STANDARD PROCEDURE .
AIR BAG, KNEE BLOCKER > DESCRIPTION AND OPERATION > DESCRIPTION AND
Fig 1: Knee Airbag (KAB)
The Knee Airbag (KAB), also known as Inflatable Knee Blocker (IKB), can help prevent leg injuries during
an impact event. A molded thermoplastic KAB deployment door, located below the dashboard, is the
most visible part of the KAB. The housing contains the airbag inflator. The airbag inflator is a single-
initiator and the two units are sealed within the KAB housing. Europe-Middle East-Africa (EMEA)
vehicles can be equipped optionally with driver knee bags. North America Free Trade Agreement
(NAFTA) vehicles are always equipped with driver knee airbags.
When the Occupant Restraint Controller (ORC) sends the proper electrical signals to the initiator, the
electrical energy generates enough heat to initiate a small pyrotechnic charge, which in turn ignites
chemical pellets within the inflator. Once ignited, these chemical pellets burn rapidly and produce a large
quantity of inert gas. The inflator is sealed to the airbag cushion and a diffuser in the inflator directs all of
the inert gas into the airbag cushion, causing the cushion to inflate.
As the cushion inflates, the KAB deployment door will split at predetermined tear seam lines concealed
on the underside of the door, then the door will fold open and out of the way. The cushion protects the
lower extremities of the vehicle driver and helps to keep the seat occupant properly positioned for the
driver airbag deployment during a frontal impact collision. Following an airbag deployment, the KAB
cushion quickly deflates by expelling the inert gas through the loose weave of the fabric.
The KAB cannot be repaired, and must be replaced if deployed, ineffective, or in any way damaged.
Following a KAB deployment, the KAB and the steering column opening cover must be replaced.
AIR BAG, KNEE BLOCKER > DESCRIPTION AND OPERATION > DESCRIPTION AND
The KAB is deployed by an electrical signal generated by the ORC through the KAB squib circuits to the
initiator in the airbag inflator. When the ORC sends the proper electrical signal to the initiator, the
electrical energy generates enough heat to initiate a small pyrotechnic charge which, in turn ignites
chemical pellets within the inflator.
Once ignited, these chemical pellets burn rapidly and produce a large quantity of inert gas. The inflator is
sealed to the back of the airbag housing and a diffuser in the inflator directs all of the inert gas into the
airbag cushion, causing the cushion to inflate. As the cushion inflates, the KAB cover will split at
predetermined breakout lines, then fold down out of the way. Following an airbag deployment, the airbag
cushion quickly deflates by venting the inert gas towards the instrument panel through vent holes within
the fabric used to construct the back panel of the airbag cushion.
Some of the chemicals used to create the inert gas may be considered hazardous while in their solid
state before they are burned, but they are securely sealed within the airbag inflator. Typically, all
potentially live pyrotechnic or hazardous chemicals are burned during an airbag deployment event.
The inert gas that is produced when the chemicals are burned is harmless. However, a small amount of
residue from the burned chemicals may cause some temporary discomfort if it contacts the skin, eyes,
or breathing passages. If skin or eye irritation is noted, rinse the affected area with plenty of cool, clean
water. If breathing passages are irritated, move to another area where there is plenty of clean, fresh air
to breath. If the irritation is not alleviated by these actions, contact a physician.
The ORC monitors the condition of the knee airbag through circuit resistance. If any fault is detected the
ORC will illuminate the airbag indicator in the instrument cluster and store a Diagnostic Trouble Code
(DTC). Proper diagnosis of the KAB initiator and squib circuit requires the use of a diagnostic scan tool
and may also require the use of the SRS Load Tool special tool along with the appropriate Load Tool
AIR BAG, KNEE BLOCKER > REMOVAL AND INSTALLATION > REMOVAL AND
WARNING:
WARNING:
cushion and other interior surfaces. In large doses, these deposits may cause irritation to
the skin and eyes.
Fig 1: KAB Unit & Screws

NOTE:
The following procedure is for replacement of an ineffective or damaged Knee AirBag

(KAB). If the airbag is ineffective or damaged, but not deployed, review the recommended
PROCEDURE . If the KAB has been deployed, review the recommended procedures for
cable Wait two minutes for the system capacitor to discharge before further service.
2. Remove the steering column opening cover from the instrument panel. Refer to COVER,
STEERING COLUMN OPENING, REMOVAL AND INSTALLATION .
3. From below the instrument panel, remove the four screws (1a) that secure the KAB unit (1b) to
the lower instrument panel support structure.
Fig 2: KAB Unit & Electrical Connection
4. Pull the KAB (2) down and back from the instrument panel far enough to access the electrical
connection (1) to the KAB inflator initiator connector receptacle on the inboard end of the KAB
housing.
5. Pull the connector insulator straight out from the inflator initiator to disconnect it from the
connector receptacle.
6. Remove the KAB from the vehicle.
AIR BAG, KNEE BLOCKER > REMOVAL AND INSTALLATION > REMOVAL AND
WARNING:
WARNING:
entering the Inflatable Knee Blocker (IKB) airbag, or becoming entrapped between the IKB
airbag cushion and the IKB cover. Failure to observe this warning could result in occupant
injuries upon airbag deployment.
Fig 1: KAB Unit & Electrical Connection
NOTE:
The following procedure is for replacement of an ineffective or damaged Knee AirBag

(KAB). If the airbag is ineffective or damaged, but not deployed, review the recommended
PROCEDURE . If the KAB has been deployed, review the recommended procedures for
1. Position the KAB unit (2) below the instrument panel in a vertical orientation with the KAB
inflator initiator connector (1) receptacle facing upward.
2. Connect the connector insulator of the instrument panel wire harness take out for the KAB to
the inflator initiator connector receptacle by pressing straight in on the connector. You can be
certain that the connector is fully engaged in its receptacle by listening carefully for a distinct,
audible click as the connector latches snap into place.
Fig 2: KAB Unit & Screws
3. Carefully position the KAB and cover (1b) onto the lower instrument panel support structure.
4. Install the four screws (1a) that secure the KAB and cover to the instrument panel support
structure. Tighten the screws securely.
5. Install the steering column opening cover onto the instrument panel. Refer to COVER,
STEERING COLUMN OPENING, REMOVAL AND INSTALLATION .
AIR BAG, PASSENGER > DESCRIPTION AND OPERATION > DESCRIPTION AND
Fig 1: Passenger Airbag (PAB)
The Passenger Airbag (PAB) is integral to the top of the dashboard and bolts to the frame. The PAB
contains an active vent.
In NAFTA versions, the PAB is a multistage, adaptive-deployment airbag. The airbag contains three
squib circuits. Two squibs inflate the airbag, the third squib activates the last charge which allows the
cushion to follow a curve of deflation appropriate to impact severity.
Only the single charge is available in the EMEA market.
The PAB cannot be repaired, and must be replaced if deployed, ineffective or in any way damaged. The
PAB door and retainer are serviced only as a unit with the instrument panel cover. If the PAB is
deployed, the PAB mounting bracket and the instrument panel must also be replaced.
AIR BAG, PASSENGER > DESCRIPTION AND OPERATION > DESCRIPTION AND
The Passenger AirBag (PAB) is deployed by electrical signals generated by the Occupant Restraint
Controller (ORC) through the PAB squib circuits to the initiator in the airbag inflator and, in vehicles so
equipped, to the initiator of the Micro Gas Generator (MGG) for the adaptive vent (North America Free
Trade Agreement/NAFTA market vehicles only).
In NAFTA market vehicles, using two initiators and an adaptive vent, the PAB can be deployed at multiple
levels of force. The force level is controlled by the ORC to suit the monitored impact conditions by
providing one of multiple delay intervals between the electrical signals provided to the two initiators and
the MGG. The longer the delay between the initiator signals and the sooner the adaptive vent is opened,
the less forcefully the PAB will deploy.
When the ORC sends the proper electrical signals to the initiator, the electrical energy generates
enough heat to initiate a small pyrotechnic charge which, in turn ignites chemical pellets within the
inflator. Once ignited, these chemical pellets burn rapidly and produce a large quantity of inert gas. The
inflator is sealed to the airbag cushion and a diffuser in the inflator directs all of the inert gas into the
airbag cushion, causing the cushion to inflate. As the cushion inflates, the PAB door area of the
instrument panel cover will split at predetermined breakout lines, then fold back out of the way. Following
an airbag deployment, the airbag cushion quickly deflates by venting the inert gas through a discrete
vent hole in each fabric side panel of the airbag cushion.
In NAFTA market vehicles the MGG inflates a small cushion within the primary cushion to control the
adaptive vent. The ORC monitors a seat track position sensor on the passenger front seat. If the seat is
in the full forward position when an airbag deployment occurs, the ORC keeps the adaptive vent open.
With the adaptive vent open the airbag deployment is less forceful, which reduces the possibility of an
airbag-induced injury when the passenger is seated close to the deploying airbag. If the passenger front
seat is not in the full forward position, the adaptive vent is closed during airbag deployment.
Typically in multistage airbags (NAFTA market only) all initiators are used during a PAB deployment
event. However, it is possible for only one initiator to be used during a deployment due to a
Supplemental Restraint System (SRS) fault; therefore, it is necessary to always confirm that all initiators
have been used in order to avoid the improper disposal of potentially live pyrotechnic materials. See the
Service After A Supplemental Restraint Deployment STANDARD PROCEDURE for additional
information.
The inert gas that is produced when the chemicals are burned during a deployment is harmless.
However, a small amount of residue from the burned chemicals may cause some temporary discomfort if
it contacts the skin, eyes, or breathing passages. If skin or eye irritation is noted, rinse the affected area
with plenty of cool, clean water. If breathing passages are irritated, move to another area where there is
plenty of clean, fresh air to breath. If the irritation is not alleviated by these actions, contact a physician.
The ORC monitors the condition of the passenger airbag through circuit resistance. If any fault is
detected the ORC will illuminate the airbag indicator in the instrument cluster and store a Diagnostic
Trouble Code (DTC). Proper diagnosis of the PAB inflator, the adaptive vent MGG and the squib circuits
requires the use of a diagnostic scan tool and may also require the use of the SRS Load Tool special
tool along with the appropriate Load Tool Jumpers and Adapters. Refer to the appropriate Diagnostic &
Testing article.
AIR BAG, PASSENGER > REMOVAL AND INSTALLATION > REMOVAL AND
WARNING:
WARNING:
skin and eyes.
Fig 1: Remove/Install Passenger AirBag (PAB)
NOTE:
The following procedure is for replacement of an ineffective or damaged Passenger AirBag

(PAB). If the airbag is ineffective or damaged, but not deployed, review the recommended
PROCEDURE . If the PAB has been deployed, review the recommended procedures for
service.
2. Remove the glove box from the instrument panel. Refer to GLOVE BOX, INSTRUMENT
3. Reach through the instrument panel glove box opening to access and remove the two screws
(3a) that secure the Passenger AirBag (PAB) lower mounting bracket (3b) to the instrument
panel carrier.
4. Reach through the instrument panel glove box opening to access and disconnect the
instrument panel wire harness connector (2) from the PAB jumper wire harness connector.
Fig 2: Instrument Panel Cover
5. Remove the PAB and instrument panel cover (1a) as a unit from the instrument panel carrier.
Refer to COVER, INSTRUMENT PANEL, REMOVAL AND INSTALLATION .
6. Place the instrument panel cover on a suitable work surface with the top facing down. If the
cover will be reused, be certain to take the proper precautions to prevent the cover from
receiving cosmetic damage during the following procedures.
Fig 3: PAB Housing, Retainer/Chute & Hooks
7. Disengage each of the hooks (2c) on the rear side of the PAB housing (1a) from the windows
in the rearward vertical wall of the PAB retainer or chute (1b) on the underside of the top cover.
To disengage the hooks, use a suitable prying tool to pull the upper edge of the receptacle wall
outward far enough to disengage the hooks on the adjacent edge of the PAB housing.
8. With all of the hooks on the rear side of the PAB housing disengaged from the retainer, rotate
that side of the housing upward far enough to disengage the hooks (2b) on the forward side of
the housing from the rearward vertical wall of the retainer (2a).
9. With all of the hooks disengaged, lift the PAB housing, inflator and cushion as a unit from the
receptacle of the PAB retainer or chute on the underside of the instrument panel top cover.
AIR BAG, PASSENGER > REMOVAL AND INSTALLATION > REMOVAL AND
WARNING:
WARNING:
skin and eyes.
WARNING:
entering the passenger airbag, or from becoming entrapped between the airbag cushion and
the deployment door. Failure to observe this warning could result in occupant injuries upon
airbag deployment.
WARNING:
To avoid serious or fatal injury, the instrument panel cover must never be painted.
Replacement covers are serviced in the original colors. Paint may change the way in which
the material of the cover responds to an airbag deployment. Failure to observe this warning
could result in occupant injuries upon airbag deployment.
Fig 1: PAB Housing, Retainer/Chute & Hooks
NOTE:
The following procedure is for replacement of an ineffective or damaged Passenger AirBag

(PAB). If the airbag is ineffective or damaged, but not deployed, review the recommended
PROCEDURE . If the PAB has been deployed, review the recommended procedures for
1. Place the instrument panel trim cover on a suitable work surface with the Passenger AirBag
(PAB) retainer or chute receptacle facing up. Be certain to take the proper precautions to
prevent the instrument panel cover from receiving cosmetic damage during the following
procedures.
2. Carefully position the PAB housing (1a) to the PAB retainer or chute receptacle. The side of
the PAB housing with 5 hooks faces rearward in the vehicle.
3. Engage all of the hooks (2b) on the forward side of the PAB housing through the windows in the
vertical wall on the forward side of the PAB retainer or chute (2a), then rotate the rearward
side of the PAB housing downward into the receptacle.
4. Inspect around the perimeter of the PAB making certain each of the hooks (2b and 2c) on the
PAB housing is fully engaged through the windows in the forward (2a) and rearward (1b)
vertical walls of the PAB retainer or chute receptacle.
5. Install the PAB and the instrument panel cover onto the instrument panel carrier as a unit.
Refer to COVER, INSTRUMENT PANEL, REMOVAL AND INSTALLATION .
Fig 2: Remove/Install Passenger AirBag (PAB)
6. Reach through the instrument panel cover glove box opening to access and reconnect the
instrument panel wire harness connector (2) to the PAB jumper wire harness connector. Be
certain the connectors are fully engaged and locked.
7. Reach through the instrument panel glove box opening to install and tighten the two screws
(3a) that secure the PAB lower mounting bracket (3b) to the instrument panel carrier. Tighten
the screws to the proper SPECIFICATIONS .
8. Install the glove box into the instrument panel. Refer to GLOVE BOX, INSTRUMENT PANEL,
AIR BAG, SEAT > DESCRIPTION AND OPERATION > DESCRIPTION AND OPERATION
> DESCRIPTION
Fig 1: Seat AirBags (SAB)
The vehicle includes seat-mounted (thorax) airbags for front external positions in NAFTA / EMEA
vehicles.
The Seat AirBags (SAB) are standard equipment on this vehicle. These airbags are completely
concealed beneath the seat back trim cover on the upper outboard sides of both front seat backs. These
airbags are secured to the seat back frame by nuts on two studs (3). The two studs are integral to the
airbag inflator. The airbag cushion is constructed of a white coated nylon fabric.
The airbag inflator is a self-contained, single-initiator, non-azide, pyrotechnic-type unit that is secured to
the seat back frame and sealed to the airbag cushion. The SAB is connected to the vehicle electrical
system through a dedicated take out of the seat wire harness with a connector insulator that connects
directly to the inflator initiator. The connector insulators are uniquely keyed and color-coded to ensure
they can only be connected to the airbag initiator.
The SAB cannot be repaired, and must be replaced if deployed, ineffective, or in any way damaged. If
the SAB is deployed, the seat back frame, the seat back foam, the seat back trim cover and the seat
airbag wire harness must also be replaced.
AIR BAG, SEAT > DESCRIPTION AND OPERATION > DESCRIPTION AND OPERATION
> OPERATION
Each SAB is deployed individually by an electrical signal generated by the Occupant Restraint Controller
(ORC) to which it is connected through left or right SAB line 1 and line 2 (or squib) circuits. When the
ORC sends the proper electrical signal to the pyrotechnic-type Micro Gas Generator (MGG) inflator, the
electrical energy generates enough heat to initiate a small pyrotechnic charge which ignites chemical
pellets within the inflator.
Once ignited, these chemical pellets burn rapidly and produce a large quantity of inert gas. The inflator is
sealed to the SAB cushion and a diffuser in the inflator directs all of the inert gas into the folded SAB
cushion, causing the cushion to inflate. As the cushion inflates it will split the outboard side of the seat
back trim cover. The cushion expands into the area between the outboard side of the front seat and the
front door, protecting the front seat occupant during a side impact collision.
Following the airbag deployment, the SAB cushion rapidly deflates by venting the inert gas through a
vent hole of the cushion fabric, and the deflated cushion hangs down loosely from the outboard side of
the front seat back.
The ORC monitors the condition of the seat airbags through circuit resistance. If any fault is detected
the ORC will illuminate the airbag indicator in the instrument cluster and store a Diagnostic Trouble Code
(DTC). Proper diagnosis of the SAB inflator and squib circuits requires the use of a diagnostic scan tool
and may also require the use of the SRS Load Tool special tool along with the appropriate Load Tool
AIR BAG, SEAT > REMOVAL AND INSTALLATION > REMOVAL AND INSTALLATION >
REMOVAL
WARNING:
WARNING:
skin and eyes.
Fig 1: Remove/Install Seat AirBag (SAB)
NOTE:
The following procedure is for replacement of an ineffective or damaged Seat AirBag (SAB).
If the airbag is ineffective or damaged, but not deployed, review the recommended
PROCEDURE . If the SAB has been deployed, review the recommended procedures for
service.
2. Working from behind the front seat, fold the seat back fully forward to access and disengage
the J-channel (1) that secures the front of the seat back trim cover to the back.
3. Unzip (2) the outboard side of the seat back trim cover to access the seat back frame.
4. Disengage the cord (3a) that secures the seat back pad from the button (3b) on the outboard
side of the seat back frame.
Fig 2: Seat Back Padding, Nuts & Ground Wire
5. Move the seat back padding (1) aside far enough to access the Seat AirBag (SAB) mounting
provisions on the inside of the outboard seat back frame.
6. Remove the two nuts (2) that secure the studs of the SAB to the inside of the seat back frame.
7. Remove the ground wire (3) eyelet terminal from the upper SAB stud.
Fig 3: Seat AirBag (SAB) & Wire Connector
8. Rotate the SAB (1a) out from the outboard side of the seat back frame far enough to access
the electrical connection.
CAUTION:
Do not pull on the seat wire harness take out or pry on the connector insulator to
disengage the connector from the seat airbag inflator connector receptacle.
Improper removal of this take out and its connector insulator can result in damage
to the airbag circuits or the connector insulator.
9. Disconnect the seat wire harness connector (1b) from the SAB inflator.
10. Remove the SAB from the seat back.
AIR BAG, SEAT > REMOVAL AND INSTALLATION > REMOVAL AND INSTALLATION >
INSTALLATION
WARNING:
Fig 1: Seat AirBag (SAB) & Wire Connector
NOTE:
The following procedure is for replacement of an ineffective or damaged Seat AirBag (SAB).
If the airbag is ineffective or damaged, but not deployed, review the recommended
PROCEDURE . If the SAB has been deployed, review the recommended procedures for
1. Position the Seat AirBag (SAB) unit (1a) close enough to the outboard side of the seat back
frame to connect the seat wire harness connector (1b) to the SAB inflator. Be certain that the
connector latches and lock are fully engaged.
2. Position the SAB unit to the outboard side of the seat back frame and insert the studs through
the mounting holes in the frame.
Fig 2: Seat Back Padding, Nuts & Ground Wire
3. Move aside the seat back padding (1) far enough to access and install the ground wire (3)
eyelet terminal over the upper SAB stud on the inside of the seat back frame.
4. Install and tighten the two nuts (2) that secure the SAB to the inside of the seat back frame.
Tighten the nuts securely.
Fig 3: Remove/Install Seat AirBag (SAB)
5. Engage the cord (3a) that secures the seat back pad to the button (3b) on the outboard side of
the seat back frame.
6. Zip up (2) the outboard side of the seat back trim cover.
7. Engage the J-channel (1) that secures the front of the seat back trim cover to the back.
AIR BAG, SIDE CURTAIN > DESCRIPTION AND OPERATION > DESCRIPTION AND
Fig 1: Side Curtain Airbag
Side curtain airbags are used in markets where they are required equipment. Vehicles with side curtain
airbags can be identified by a molded trim button with the Supplemental Restraint System (SRS) logo
located at the top of each B- and C-pillar trim.
The side curtains use a hybrid inflator. To deploy the airbag, the Occupant Restraint Controller (ORC)
sends a current to the airbag inflator which ignites the chemical pellets. When the chemical pellets ignite,
the pressure of the expanding gases produces enough pressure to break a containment cap of a cylinder
of inert gas. The gas is directed into the side curtain airbag. The side current airbags will stay inflated for
approximately five seconds to help protect passengers in the event of a rollover event. The deflation
rate of the airbags is controlled by the tightness of the airbag fabric mesh.
The side curtain airbag units cannot be adjusted or repaired and must be replaced if deployed,
ineffective, or in any way damaged. Once a side curtain airbag has been deployed, the complete side
curtain airbag unit, the headliner, the upper A, B and C-pillar trim, the B and C-pillar deploy brackets as
well as all other visibly damaged components must be replaced.
AIR BAG, SIDE CURTAIN > DESCRIPTION AND OPERATION > DESCRIPTION AND
Each side curtain airbag (also known as Side AirBag Inflatable Curtain/SABIC) is deployed individually
by an electrical signal generated by the ORC to which it is connected through the left or right SABIC line
1 and line 2 (or squib) circuits. The hybrid-type inflator assembly for each airbag contains a small
canister of highly compressed inert gas. When the ORC sends the proper electrical signal to the airbag
inflator, the electrical energy creates enough heat to ignite chemical pellets within the inflator.
Once ignited, these chemicals burn rapidly and produce the pressure necessary to rupture a
containment disk in the inert gas canister. The inflator and inert gas canister are sealed and connected
to a tubular manifold so that all of the released gas is directed into the folded airbag cushion, causing the
cushion to inflate. As the cushion inflates it will drop down from the roof rail between the edge of the
headliner and the side glass/body pillars to form a curtain-like cushion to protect the vehicle occupants
during a side impact collision incident. The cushion features large chambers that inflate adjacent to the
head of each front and rear seat occupant.
The front and rear tethers keep the side curtain airbag cushion taut to the side of the vehicle. In addition,
ramps integral to the side trim of the interior, integral to the side curtain airbag modules themselves and
deploy brackets at the tops of the B and C-pillars guide the cushion into the proper deployment position.
Following the deployment, the cushion slowly deflates by venting the inert gas through the loose weave
of the cushion fabric and the deflated cushion hangs down loosely from the roof rail.
The ORC monitors the condition of the side curtain airbags through circuit resistance. If any fault is
detected the ORC will illuminate the airbag indicator in the instrument cluster and store a Diagnostic
Trouble Code (DTC). Proper diagnosis of the side curtain airbag inflator and squib circuits requires the
use of a diagnostic scan tool and may also require the use of the SRS Load Tool special tool along with
the appropriate Load Tool Jumpers and Adapters. Refer to the appropriate Diagnostic & Testing article.
AIR BAG, SIDE CURTAIN > REMOVAL AND INSTALLATION > REMOVAL AND
INSTALLATION > REMOVAL - AIRBAG
WARNING:
WARNING:
skin and eyes.
WARNING:
entering the side curtain airbag, or becoming entrapped between the side curtain airbag
cushion and the headliner. Failure to observe this warning could result in occupant injuries
upon airbag deployment.
Fig 1: Remove/Install Side Curtain Airbag
NOTE:
The following procedure is for replacement of an ineffective or damaged side curtain airbag
(also known as Side AirBag Inflatable Curtain/SABIC). If the airbag is ineffective or
damaged, but not deployed, review the recommended procedures for Handling
Non-Deployed Supplemental Restraints. Refer to STANDARD PROCEDURE . If the side
curtain airbag has been deployed, review the recommended procedures for Service After A
Supplemental Restraint Deployment before removing the airbag from the vehicle. Refer to
service.
2. Fully recline both front seat backs.
NOTE:
Use the headliner removal procedure to lower the headliner from the inner roof
panel. The headliner will NOT be removed from the vehicle interior.
3. Lower the headliner from the inner roof panel and allow it to rest within the vehicle interior.
Refer to HEADLINER, REMOVAL AND INSTALLATION .
4. Remove the screws (1a) that secure the Side AirBag Inflatable Curtain (SABIC) (1b) to the
inner A-pillar and front inner roof rail.
5. Disengage the front tether (2a) from the retaining clip (2b) on the inner A-pillar.
Fig 2: SABIC, Wire Connector & Screws
6. Disconnect the body wire harness connector (1a) for the SABIC (1b) from the connector
receptacle of the inflator above the front door opening.
7. Remove the screws (2a) that secure the SABIC to the inner roof rail above the front and rear
door openings.
Fig 3: SABIC & Screws
8. Remove the screws (1a) that secure the SABIC to the rear of the inner roof rail.
9. Remove the SABIC (1b) from the vehicle as a unit.
NOTE:
If the SABIC has been deployed, the B-pillar and C-pillar deploy brackets must also
be inspected. Refer to REMOVAL - DEPLOY BRACKET - B-PILLAR or REMOVAL -
DEPLOY BRACKET - C-PILLAR .
INSTALLATION > REMOVAL - DEPLOY BRACKET - B-PILLAR
Fig 1: Deploy Bracket B-Pillar
NOTE:
If a side curtain airbag has been deployed, the B-pillar and C-pillar deploy brackets for the
same side of the vehicle will be deformed or weakened and must be replaced with new
units.
1. Remove the side curtain airbag (also known as Side AirBag Inflatable Curtain/SABIC) from the
vehicle. Refer to AIR BAG, SIDE CURTAIN, REMOVAL AND INSTALLATION .
2. Using a drill motor and an appropriate bit, carefully drill out the blind rivets that secure the
deploy bracket to the inner B-pillar.
3. Disengage the deploy bracket tabs from the slotted holes in the inner B-pillar and remove the
bracket from the vehicle.
INSTALLATION > REMOVAL - DEPLOY BRACKET - C-PILLAR
Fig 1: Deploy Bracket C-Pillar
NOTE:
units.
1. Remove the side curtain airbag (also known as Side AirBag Inflatable Curtain/SABIC) from the
2. Using a drill motor and an appropriate bit, carefully drill out the blind rivets that secure the
deploy bracket to the inside of the C-pillar.
3. Disengage the deploy bracket tabs from the slotted holes in the inner C-pillar and remove the
bracket from the vehicle.
INSTALLATION > INSTALLATION - AIRBAG
WARNING:
WARNING:
skin and eyes.
WARNING:
entering the side curtain airbag, or becoming entrapped between the side curtain airbag
cushion and the headliner. Failure to observe this warning could result in occupant injuries
upon airbag deployment.
Fig 1: SABIC, Wire Connector & Screws
NOTE:
The following procedure is for replacement of an ineffective or damaged side curtain airbag
(also known as Side AirBag Inflatable Curtain/SABIC). If the airbag is ineffective or
damaged, but not deployed, review the recommended procedures for Handling
Non-Deployed Supplemental Restraints. Refer to STANDARD PROCEDURE . If the side
curtain airbag has been deployed, review the recommended procedures for Service After A
Supplemental Restraint Deployment before removing the airbag from the vehicle. Refer to
1. Position the Side AirBag Inflatable Curtain (SABIC) (1b) into the vehicle as a unit. Be certain
that the SABIC is not twisted.
2. Install and tighten the screws (2a) that secure the SABIC to the inner roof rail above the front
and rear door openings. Tighten the screws securely.
3. Connect the body wire harness connector (1a) for the SABIC to the connector receptacle of
the inflator above the front door opening.
Fig 2: SABIC & Screws
4. Install and tighten the screws (1a) that secure the SABIC and the rear tether to the rear of the
inner roof rail. Tighten the screws securely.
Fig 3: Remove/Install Side Curtain Airbag
5. Install and tighten the screws (1a) that secure the SABIC (1b) and the front tether (2a) to the
inner A-pillar and front inner roof rail. Tighten the screws securely.
6. Engage the front tether with the retaining clip (2b) on the inner A-pillar.
7. Install the headliner into the vehicle. Refer to HEADLINER, REMOVAL AND INSTALLATION .
INSTALLATION > INSTALLATION - DEPLOY BRACKET - B-PILLAR
Fig 1: Deploy Bracket B-Pillar
NOTE:
units.
1. Position the deploy bracket near the top of the inner B-pillar with the locating tabs engaged in
the slotted holes of the B-pillar.
2. Secure the deploy bracket to the inner B-pillar using a blind rivet installation tool and new blind
rivets.
3. Reinstall the side curtain airbag (also known as Side AirBag Inflatable Curtain/SABIC) into the
INSTALLATION > INSTALLATION - DEPLOY BRACKET - C-PILLAR
Fig 1: Deploy Bracket C-Pillar
NOTE:
units.
1. Position the deploy bracket near the top of the inner C-pillar with the locating tabs engaged in
the slotted holes of the C-pillar.
2. Secure the deploy bracket to the inner C-pillar using a blind rivet installation tool and new blind
rivets.
3. Reinstall the side curtain airbag (also known as Side AirBag Inflatable Curtain/SABIC) into the
ANCHOR, CHILD SEAT > DESCRIPTION AND OPERATION > DESCRIPTION AND
Fig 1: LATCH System
The rear (also known as second row) seat for this vehicle is equipped with a Lower Anchors and Tether
for CHildren (LATCH) child restraint anchorage system for North America Free Trade Agreement (NAFTA)
markets. The LATCH system provides for the installation of suitable child restraints in certain seating
positions without using the standard equipment seat belt provided for that seating position.
The rear seats in these vehicles are equipped with a fixed-position child restraint upper tether anchor (4)
for all three rear seating positions. The three upper tether anchors are integral to the rear seat back
frames. These anchors are each constructed from heavy-gauge steel wire loops that are securely
welded onto the backs of each seat back frame, two for the left (1) rear seat back frame and one for the
right (3) rear seat back frame. A label (2) imprinted with an icon representing a child restraint upper
tether anchor is located on the seat back panels adjacent to each anchor location. The child restraint
upper tether anchors cannot be adjusted or repaired and, if ineffective or damaged, they must be
replaced as a unit with their respective rear seat back frame.
Fig 2: Child Restraint Lower Anchors
Child restraint lower anchors (also known as ISOFIX anchors) are also provided for both outboard rear
seating positions. A label (2) on each rear seat cover (1) clearly identifies the anchor locations. The
lower anchors are integral to the rear seat cushion frames. These anchors are each constructed from a
heavy-gauge steel wire loop that is securely welded to each seat cushion frame, four on each frame.
The anchor loops are accessed from the front of their respective seats, near where the rear seat back
meets the rear seat cushion (3). These lower anchors cannot be adjusted or repaired and, if ineffective
or damaged, they must be replaced as a unit with the rear seat cushion frame.
Vehicles manufactured for Europe-Middle East-Africa (EMEA) markets are not equipped with the upper
tether anchors, but do have the ISOFIX lower anchors.
WARNING:
Chrysler Mopar® Parts Catalog.
ANCHOR, CHILD SEAT > DESCRIPTION AND OPERATION > DESCRIPTION AND
All vehicles manufactured for sale in North America Free Trade Agreement (NAFTA) markets are required
to be equipped with a Lower Anchors and Tether for CHildren, or LATCH child restraint anchorage
system. The rear seats in this vehicle have two pairs of anchor provisions for installing a LATCH-
compatible child seat. A single seat may be mounted in the center seating position, or one in each
outboard seating position.
With LATCH, child seats are secured by direct attachment to the vehicle structure, rather than by the
seat belts. With LATCH-compatible child seats, lower (also known as ISOFIX) anchors attach to the seat
structure through heavy-gauge wire loops located near the intersection between the seat cushion and
the seat back surfaces.
Three upper tether anchors are integral to the rear seat back frames to secure the top tether strap of
child seats equipped with this feature. These upper tether anchors work with both LATCH-compatible and
other child seats equipped with a top tether strap. Vehicles manufactured for Europe-Middle East-Africa
(EMEA) markets are equipped with only the ISOFIX lower anchors and have no upper tether anchor
provisions.
The owner's information packet in the vehicle glove box contains details and suggestions on the proper
use of all of the factory-installed child restraint anchors.
BUCKLE, SEAT BELT > STANDARD PROCEDURE > STANDARD PROCEDURE - REAR
CENTER SEAT BELT LOWER ANCHOR BUCKLE RELEASE
WARNING:
Fig 1: Seat Belt Latch Plate, Notch, Buckle & Anchor Latch Plate
Insert the tip of a seat belt latch plate (1) or a small screwdriver into the notch (4) of the rear center seat
belt anchor buckle (3) to release the anchor latch plate (2) from the anchor buckle.
BUCKLE, SEAT BELT > REMOVAL AND INSTALLATION > SEAT BELT BUCKLE,
FRONT > REMOVAL - FRONT SEAT
WARNING:
Fig 1: Remove/Install Front Seat Belt Buckle
service.
2. Remove the appropriate left or right front seat from the vehicle. Refer to SEAT, FRONT,
3. Remove the screw (1a) that secures the buckle (1b) lower anchor to the bracket on the
inboard rear corner of the seat cushion frame.
4. Note or mark the routing of the seat belt switch pigtail wire (2) to ease reinstallation.
5. Release the seat belt switch pigtail wire from the retainers on the underside of the front seat
cushion.
6. Disconnect the seat belt switch pigtail connector (3) from the seat wire harness.
7. Remove the seat belt buckle from the front seat.
BUCKLE, SEAT BELT > REMOVAL AND INSTALLATION > SEAT BELT BUCKLE,
FRONT > INSTALLATION - FRONT SEAT
WARNING:
Fig 1: Remove/Install Front Seat Belt Buckle
1. Position the seat belt buckle (1b) lower anchor to the bracket on the inboard rear corner of the
front seat.
2. Route the seat belt switch pigtail wire (2) beneath the seat and engage it with the retainers on
the underside of the front seat cushion.
3. Connect the seat belt switch pigtail wire connector (3) to the seat wire harness.
4. Install and tighten the screw (1a) that secures the buckle lower anchor to the seat bracket.
Tighten the screw to the proper SPECIFICATIONS .
5. Install the left or right front seat into the vehicle. Refer to SEAT, FRONT, REMOVAL AND
INSTALLATION .
BUCKLE, SEAT BELT > REMOVAL AND INSTALLATION > REMOVAL AND
INSTALLATION - REAR SEAT BELT BUCKLE > REMOVAL - REAR SEAT
WARNING:
Fig 1: Rear Right & Rear Center Seat Belt Buckles, Lower Anchor & Rear Left Buckles
NOTE:
The rear right (1) and rear center (2) seat belt buckles are serviced individually; however,
the rear center lower anchor (3) and rear left (4) buckles are serviced only as a unit. In
vehicles manufactured for Europe-Middle East-Africa (EMEA) markets, each of the rear
buckles (except the center lower anchor buckle) also includes a seat belt switch and pigtail
wire harness. Seat belt switches are not used in the rear buckles of vehicles manufactured
for North America Free Trade Agreement (NAFTA) markets.
service.
2. Release the rear center seat belt lower anchor from the lower anchor buckle. Refer to
BUCKLE, SEAT BELT, STANDARD PROCEDURE .
INSTALLATION .
4. If equipped, disconnect the seat belt switch pigtail wire connector for the buckle being serviced
from the body wire harness.
5. Remove the screw or screws that secure the rear seat belt buckle anchor to the rear floor
panel.
6. Remove the buckle unit from the rear floor panel.
BUCKLE, SEAT BELT > REMOVAL AND INSTALLATION > REMOVAL AND
INSTALLATION - REAR SEAT BELT BUCKLE > INSTALLATION - REAR SEAT
WARNING:
Fig 1: Rear Right & Rear Center Seat Belt Buckles, Lower Anchor & Rear Left Buckles
NOTE:
The rear right (1) and rear center (2) seat belt buckles are serviced individually; however,
the rear center lower anchor (3) and rear left (4) buckles are serviced only as a unit. In
vehicles manufactured for Europe-Middle East-Africa (EMEA) markets, each of the rear
buckles (except the center lower anchor buckle) also includes a seat belt switch and pigtail
wire harness. Seat belt switches are not used in the rear buckles of vehicles manufactured
for North America Free Trade Agreement (NAFTA) markets.
1. Position the rear seat belt buckle unit onto the rear floor panel.
2. Install and tighten the screw or screws that secure the rear seat belt buckle anchor to the rear
floor panel. Tighten the screws to the proper SPECIFICATIONS .
3. If equipped, connect the seat belt switch pigtail wire connector for the buckle being serviced to
the body wire harness.
4. Install the rear seat cushion into the vehicle. (Refer to REMOVAL AND INSTALLATION ).
component. (Refer to STANDARD PROCEDURE ).
CLOCKSPRING > DESCRIPTION AND OPERATION > DESCRIPTION AND OPERATION

> DESCRIPTION
Fig 1: Right/Left Multifunction Switch & Clockspring
The clockspring (3) for this vehicle is secured to the stalk unit near the top of the steering column below
the steering wheel. The clockspring also includes an integral, internal turn signal cancel cam that is
serviced as a unit with the clockspring. The stalk unit also supports the left (lighting) multifunction switch
(1) and the right (wiper) multifunction switch (2). Each of these switches and the wiring between the
switches and the clockspring can not be separated and are serviced only as a complete assembly with
the clockspring. The stalk unit case includes integral tabs on the back for mounting the unit with a band
clamp to the steering column support tube. The multifunction switches and the clockspring are each
integral to the stalk unit. The clockspring and the multifunction switches are each constructed of molded
plastic.
The stalk unit case includes one connector receptacle on the back of the unit facing toward the
instrument panel which contains the circuits for the multifunction switches. The connectors near the
bottom of the unit contain the circuits for the clockspring. Within the plastic clockspring case is a
spool-like molded plastic rotor with a large exposed hub. The upper surface of the rotor hub has a large
center hole and a short pigtail wire or wires with a connector or connectors. The pigtail connectors
contain the circuits for the Driver AirBag (DAB). Connector receptacles on the rotor hub contain the
circuits for the other switches mounted on the steering wheel.
Wound around the rotor spool within the clockspring case is a long ribbon-like tape that consists of
several thin copper wire leads sandwiched between two thin plastic membranes. The outer end of the
tape terminates at the connector receptacle on the top of the stalk unit case, while the inner end of the
tape terminates at the pigtail wires and connector receptacles on the hub of the clockspring rotor that
face the steering wheel. The outer surface of the rotor hub rim within the clockspring case also has the
integral lobes of the turn signal cancel cam.
The service replacement clockspring is shipped pre-centered and has a spring actuated molded plastic
automatic locking ring installed. The automatic locking ring secures the centered clockspring rotor to the
clockspring case during shipment and handling, and automatically releases the rotor when the steering
wheel is installed. However, it is recommended that an additional strap be installed through the two
retainer loops integral to the outer circumference of the clockspring rotor and the stalk unit case to
secure the rotor to the case while the clockspring is removed from the steering column to prevent
accidental loss of clockspring centering.
The clockspring cannot be repaired. If the clockspring is ineffective, damaged, or if the DAB has been
deployed, the clockspring, turn signal cancel cam and stalk unit must be replaced.
CLOCKSPRING > DESCRIPTION AND OPERATION > DESCRIPTION AND OPERATION

> OPERATION
The clockspring is a mechanical electrical circuit component that is used to provide continuous electrical
continuity between the fixed instrument panel wire harness and certain electrical components mounted
on or in the rotating steering wheel. On this vehicle the rotating electrical components include the DAB,
the Electronic Vehicle Information Center (EVIC) switches, the horn switch, the remote radio switches,
the speed control switches and the hands-free communication switches, if the vehicle is so equipped.
The clockspring is positioned and secured near the top of the steering column. The fixed connector
receptacles on the back of the fixed clockspring case connect the clockspring to the vehicle electrical
system through take outs and connectors from the instrument panel wire harness.
The turn signal cancel cam is integral to the rim of the clockspring rotor hub within the clockspring case
so it also moves with the rotation of the steering wheel. Short pigtail wires on the upper surface of the
clockspring rotor connect the clockspring to the DAB and a wire harness connected to the EVIC
switches, the horn switch, the speed control switch and, if the vehicle is so equipped, the optional
remote radio and hands-free communication switches on the steering wheel.
Like the clockspring in a timepiece, the clockspring tape has travel limits and can be damaged by being
wound too tightly during full stop-to-stop steering wheel rotation. To prevent this from occurring, the
clockspring is centered when it is installed on the steering column. Centering the clockspring indexes the
clockspring tape to the movable steering components so that the tape can operate within its designed
travel limits. If the steering wheel is removed from the steering column or if the clockspring is removed
from the steering column, a spring-actuated automatic locking ring pops up from the face of the
clockspring rotor to lock the rotor from rotation. However, if the locking ring is manually compressed or if
the steering shaft is disconnected from the steering gear with the steering wheel installed, the
clockspring spool can change position relative to the other steering components. Loss of clockspring
centering will result in damage to the clockspring tape.
Service replacement clocksprings are shipped pre-centered and with a plastic locking pin installed. This
locking pin should not be removed until the clockspring has been installed on the steering column. If the
locking pin is removed before the clockspring is installed on a steering column, clockspring centering
may be compromised.
The hard wired clockspring circuits may be diagnosed using conventional diagnostic tools and
diagnostic methods will not prove conclusive in the diagnosis of the clockspring squib circuits for the
Supplemental Restraint System (SRS). The most reliable, efficient and accurate means to diagnose the
circuits related to SRS operation requires the use of a diagnostic scan tool and may also require the use
of the SRS Load Tool special tool along with the appropriate Load Tool Jumpers and Adapters. Refer to
the appropriate Diagnostic & Testing article.
CLOCKSPRING > STANDARD PROCEDURE > STANDARD PROCEDURE -

CLOCKSPRING CENTERING
WARNING:
CAUTION:
Always turn the steering wheel until the front wheels are in the straight-ahead position. Then,
prior to disconnecting the steering column from the steering gear, lock the steering wheel to
the steering column. If clockspring centering has been compromised for ANY reason, the
entire Steering Column Control Module (SCCM) and clockspring unit MUST be replaced with
a new unit.
Fig 1: Clockspring, Red Plastic Locking Pin & Spring Activated Locking Ring
Like the clockspring in a timepiece, the clockspring tape has travel limits and can be damaged by being
wound too tightly during full stop-to-stop steering wheel rotation. To prevent this from occurring, the
clockspring is centered when it is installed on the steering column. Centering the clockspring indexes the
clockspring tape to the movable steering components so that the tape can operate within its designed
travel limits. However, if the steering shaft is disconnected from the steering gear, the clockspring rotor
spool can change position relative to the fixed steering components. This clockspring has no
provisions for re-centering.
The service replacement stalk unit is shipped with the clockspring (1) pre-centered and with a red plastic
locking pin (2) installed. This locking pin should not be removed until the stalk unit has been properly
installed on the steering column. If the locking pin is removed before the stalk unit is installed on a
steering column, clockspring centering may become compromised. The locking pin is removed by rotating
it in a clockwise direction, breaking it off in the stalk unit housing. Do not bend the locking pin to break it
off as this may damage the stalk unit housing.
In addition, this clockspring is equipped with a spring activated locking ring (3) that automatically extends
to lock the clockspring rotor spool to the stalk unit housing as soon as the steering wheel is removed.
However, if the locking ring is manually compressed while the clockspring is removed from the steering
column, clockspring centering may be compromised. When the steering wheel is properly installed onto
the steering column, the locking ring is automatically compressed to unlock the clockspring rotor spool.
CLOCKSPRING > REMOVAL AND INSTALLATION > REMOVAL AND INSTALLATION >
REMOVAL
WARNING:
CAUTION:
a new unit.
Fig 1: Remove/Install Steering Column Control Module (SCCM)
1. Place the front wheels in the straight ahead position and inhibit the steering column shaft from
rotation.
service.
3. Remove the steering wheel from the upper steering column shaft. Refer to WHEEL,
STEERING, REMOVAL AND INSTALLATION .
4. If the removed clockspring and stalk unit is to be reused, be certain that the spring-activated
clockspring locking ring has extended upward following steering wheel removal to lock the
clockspring rotor to the stalk unit case and maintain clockspring centering until the steering
wheel is reinstalled on the steering column. Do not manually compress the clockspring
locking ring while the stalk unit is removed from the steering column as this may result
in the loss of clockspring centering. If clockspring centering is not maintained, the entire
clockspring and stalk unit must be replaced with a new unit before the steering wheel is
reinstalled.
5. Move the steering column to the fully lowered (down) position.
6. Remove the upper and lower shrouds from the steering column. Refer to SHROUD, STEERING
7. Disconnect the instrument panel wire harness connectors (2) from the connector receptacles
near the top and the bottom on the back of the clockspring.
8. Remove the clockspring and stalk unit from the steering column.
CLOCKSPRING > REMOVAL AND INSTALLATION > REMOVAL AND INSTALLATION >
INSTALLATION
WARNING:
CAUTION:
a new unit.
Fig 1: Remove/Install Steering Column Control Module (SCCM)

NOTE:
A service replacement clockspring and stalk unit is shipped with the clockspring
pre-centered and with a molded plastic locking pin installed. This locking pin should not be
removed until the clockspring and stalk unit has been installed on the steering column.
1. Position the clockspring and stalk unit (3) onto the top of the steering column jacket.
2. Tighten the screw (1) that tensions the band clamp that secures the stalk unit to the top of the
steering column jacket. Tighten the screw securely.
3. Connect the instrument panel wire harness connectors (2) to the connector receptacles on the
back of the stalk unit housing near the top and the bottom.
4. Install the upper and lower shrouds onto the steering column. Refer to SHROUD, STEERING
5. Move the steering column to the fully raised (up) position.

Fig 2: Clockspring, Red Plastic Locking Pin & Spring Activated Locking Ring

CAUTION:
The clockspring locking pin is removed by rotating it in a clockwise direction,

breaking it off in the SCCM housing. Do not bend the locking pin to break it off as
this may damage the SCCM housing.
6. If a new clockspring and stalk unit is being used, break off the plastic locking pin (2) that
secures the clockspring rotor (1) to the stalk unit housing to maintain clockspring centering.
Rotate the pin in a clockwise direction to break it off in the stalk unit housing.
7. Install the steering wheel onto the steering column. Refer to WHEEL, STEERING, REMOVAL
AND INSTALLATION .
INDICATOR, PASSENGER AIR BAG > DESCRIPTION AND OPERATION >

Fig 1: Instrument Panel Switch Pod & Passenger AirBag (PAB) On/Off Indicator
Vehicles manufactured for Europe-Middle East-Africa (EMEA) markets are equipped with a Passenger
AirBag (PAB) on/off indicator (2). This indicator is integral to the instrument panel switch pod (1), which
is secured to the instrument panel center stack just below the Radio Receiver Module (RRM). Refer to
POD, SWITCH, DESCRIPTION AND OPERATION .
The text PASSENGER AIRBAG appears on a lens just to the right of the hazard warning switch in the
instrument panel switch pod. The text ON and OFF , each below an International Control and Display
Symbol icon, are stencil-like cutouts in the opaque overlay within the indicator. The dark outer lens
prevents the text and icon of the indicator from being clearly visible when it is not illuminated. Dedicated
LED units behind the lens and each overlay causes the text and icon to appear in amber through the
translucent lens when the indicator is illuminated from behind by the LED.
The PAB on/off indicator cannot be repaired or adjusted and, if ineffective or damaged the instrument
panel switch pod must be replaced.
INDICATOR, PASSENGER AIR BAG > DESCRIPTION AND OPERATION >

The Passenger AirBag (PAB) on/off indicator (also known as the Passenger Airbag Disable Lamp/PADL)
gives an indication when the passenger seat is occupied and the PAB and seat belt tensioner
deployment circuits are enabled or disabled by the Occupant Restraint Controller (ORC). This indicator
is controlled by a transistor within the ORC through hard wired outputs based upon electronic
passenger airbag status request messages received by the ORC from the Instrument Panel Cluster
(IPC) over the Controller Area Network (CAN) data bus. The IPC messages to the ORC are based upon
the status of a setup routine performed through the IPC by the vehicle operator.
The PAB on/off indicator Light Emitting Diode (LED) units are completely controlled by the ORC. The
LED units receive a battery current input on a fused ignition output (run) circuit. Therefore, the LED units
will always be Off when the status of the ignition is anything except On. The LED units only illuminate
when they are provided a path to ground by the ORC transistor. The IPC will request the ORC to turn On
the PAB on/off indicators for the following reasons:
Bulb Test - Each time the status of the ignition transitions to On the PAB on/off indicators are
illuminated for about eight seconds.
Passenger AirBag Disabled - Each time the ORC receives an electronic message from the IPC
indicating the setup routine has requested the Passenger AirBag (PAB) be disabled, the PAB and
seat belt tensioner deployment circuits are deactivated and the PAB OFF indicator will be
illuminated. The indicator remains illuminated until the ORC receives an electronic message from
the IC indicating the setup routine has requested the PAB be enabled, or until the status of the
ignition transitions to Off, whichever occurs first.
Passenger AirBag Enabled - Each time the ORC receives an electronic message from the IPC
indicating the setup routine has requested the Passenger AirBag (PAB) be enabled, the PAB and
seat belt tensioner deployment circuits are activated and the PAB ON indicator will be illuminated.
The indicator remains illuminated until the ORC receives an electronic message from the IC
indicating the setup routine has requested the PAB be disabled, or until the status of the ignition
transitions to Off, whichever occurs first.
Communication Error - If the ORC receives invalid messages or no messages from the IPC the
PAB on/off indicator status remains as it was when the last valid message was received. The ORC
will also maintain the PAB deployment status as it was when the last valid message was received.
The ORC and IPC will set a Diagnostic Trouble Code (DTC) and will illuminate the airbag indicator
in the IPC when a communication error has been detected. The PAB indicator remains illuminated
in the current status until the ORC receives a valid message from the IPC, or until the status of the
ignition transitions to Off, whichever occurs first.
The ORC continually monitors the messages from the IPC to decide whether the PAB and seat belt
tensioner deployment circuits should be activated or deactivated. The IPC provides the proper
messages to the ORC, and the ORC provides the proper control output to turn the appropriate PAB
on/off indicator On.
The hard wired circuits between the PAB on/off indicator and the ORC may be diagnosed using
article. However, conventional diagnostic methods will not prove conclusive in the diagnosis of the PAB
on/off indicator or the electronic controls and communication between other modules and devices that
provide the features of this indicator. The most reliable, efficient and accurate means to diagnose the
PAB on/off indicator or the electronic controls and communication related to PAB on/off indicator
article.
INDICATOR, SEAT BELT REMINDER (SBR) > DESCRIPTION AND OPERATION >
Fig 1: Seat Belt Reminder (SBR) Indicator
7" DID/EVIC (1)
3.5" TFT EVIC (2)
rear left seat belt (A)
rear central seat belt (B)
rear right seat belt (C)
The Seat Belt Reminder (SBR) system warns the passengers of the front and rear seats if their seat belt
is not fastened.
The system signals unfastened seat belts with visual warnings (warning lights on in the Instrument Panel
Cluster (IPC) and icons on the Electronic Vehicle Information Center/EVIC display) and an acoustic
signal.
The Occupant Restraint Controller (ORC) will send the buckle condition messages to the IPC via the
CAN network for the activation of the indications.
MODULE, OCCUPANT RESTRAINT CONTROLLER > DESCRIPTION AND OPERATION
Fig 1: Occupant Restraint Controller (ORC) Module
The Occupant Restraint Controller (ORC) module, located on the floor tunnel under the instrument panel
center console, monitors the impact and occupant sensors and activates restraint system devices in the
event of an impact. The ORC also contains impact sensors that are used to determine the level of
deployment and to verify the information received from the remote sensors.
An arrow printed on the ORC label indicates the installation orientation. The arrow must point toward the
front of the vehicle. The ORC must be installed correctly for correct restraint system operation.
The ORC module will set a specific DTC which cannot be deleted, not even using the diagnostic tool.
This will happen when you reach:
3 activations of the pretensioners, EMEA only
2 activations of the pretensioners, NAFTA only
3 activations of the side airbags, EMEA only
2 activations of the side airbags, NAFTA only
1 activation of the pretensioners plus the front airbags; all versions
Any other combination of the above mentioned cases until one of the limits is reached
When one of the above mentioned limits is reached, the ORC module will have to be replaced.
In EMEA versions the front passenger airbag can be deactivated via the vehicle menu. A dedicated LED
indicates its deactivation.
Fig 2: Airbag Deactivation LED (EMEA) & (NAFTA)
The yaw or lateral acceleration sensor is installed inside the ORC module and is used for the correct
operation of the vehicle dynamic stability functions.
The impact sensor and safing sensor internal to the ORC are calibrated for the specific vehicle, and are
only serviced as a unit with the ORC. In addition, there are unique versions of the ORC for vehicles with
or without certain optional Supplemental Restraint System (SRS) components. The ORC cannot be
repaired or adjusted and, if damaged or ineffective, it must be replaced.
MODULE, OCCUPANT RESTRAINT CONTROLLER > DESCRIPTION AND OPERATION

> DESCRIPTION AND OPERATION > OPERATION
The microcontroller within the ORC contains the SRS logic circuits and controls all of the SRS
components. The ORC uses On-Board Diagnostics (OBD) and can communicate with other electronic
modules in the vehicle as well as with the diagnostic scan tool using the Controller Area Network (CAN)
data bus. This method of communication is used for control of the airbag indicator in the Instrument
Panel Cluster (IPC) and for SRS diagnosis and testing through the 16-way data link connector located
on the driver side lower edge of the instrument panel.
The ORC microcontroller continuously monitors all of the SRS electrical circuits to determine the system
readiness. If the ORC detects a monitored system fault, it sets an active and stored Diagnostic Trouble
Code (DTC) and sends electronic messages to the IPC over the CAN data bus to turn On the airbag
indicator. An active fault only remains for the duration of the fault, or in some cases for the duration of
the current ignition cycle, while a stored fault causes a DTC to be stored in memory by the ORC. For
some DTCs, if a fault does not recur for a number of ignition cycles, the ORC will automatically erase the
stored DTC. For other internal faults, the stored DTC is latched forever.
The ORC receives battery current through two circuits; a fused ignition output (run) circuit through a fuse
in the Body Control Module (BCM) and a fused ignition output (run-start) circuit through a second fuse in
the BCM. The ORC receives ground through a ground circuit and take out of the instrument panel wire
harness that is secured by a nut to a weld stud on the floor panel transmission tunnel. These
connections allow the ORC to be operational whenever the status of the ignition is Start or On.
The ORC also contains an energy-storage capacitor. When the status of the ignition is Start or On this
capacitor is continually being charged with enough electrical energy to deploy the SRS components for
up to one second following a battery disconnect or failure. The purpose of the capacitor is to provide
backup SRS protection in case there is a loss of battery current supply to the ORC during an impact.
Various sensors within the ORC are continuously monitored by the ORC logic. These internal sensors,
along with several external impact sensor inputs allow the ORC to determine both the severity of an
impact and to verify the necessity for deployment of any SRS components. In vehicles manufactured for
Europe-Middle East-Africa (EMEA) markets, a remote front impact sensor (also known as an Early
Crash Sensor/ECS) is located on the back of the lower horizontal member of the radiator support near
the center. In vehicles manufactured for North America Free Trade Agreement (NAFTA) markets, remote
front impact sensors are located on the back of the right and left vertical members of the radiator support
inboard of the headlamps. The electronic impact sensors are accelerometers that sense the rate of
vehicle deceleration, which provides verification of the direction and severity of an impact.
The ORC also monitors inputs from the seat track position sensors (NAFTA market only), the front seat
belt switches, the rear seat belt switches (EMEA markets only), an internal rollover sensor and four
additional remote side impact sensors located on the left and right front door hardware module carriers
and on the right and left lower B-pillars to control deployment of the side curtain airbag units and, if
equipped, the front seat airbags (also known as pelvic and thoracic airbags). The ORC uses the seat
belt switch inputs along with inputs from the Occupant Detection Sensor (ODS) in the passenger front
seat cushion to support the seat belt alert feature, and will send electronic messages to the IPC to
illuminate the seat belt indicator when appropriate.
The impact sensors within the ORC are electronic accelerometer sensors that provide an additional
logic input to the ORC microcontroller. These sensors are used to verify the need for a SRS component
deployment by detecting impact energy of a lesser magnitude than that of the primary electronic impact
sensors, and must exceed a safing threshold in order for the SRS components to deploy. A separate
impact sensor within the ORC provides confirmation to the ORC microcontroller of side impact forces.
This separate sensor is a bi-directional unit that detects impact forces from either side of the vehicle.
Pre-programmed decision algorithms in the ORC microcontroller determine when the deceleration rate
as signaled by the impact sensors indicate an impact that is severe enough to require SRS protection. In
NAFTA market vehicles, based upon the severity of the monitored impact, the ORC also determines the
level of front airbag deployment force required for each front seating position. When the programmed
conditions are met, the ORC sends the proper electrical signals to deploy the front airbags, the front
seat belt tensioners and either side curtain and, if equipped, seat airbag unit.
The BCM stores and compares vehicle configuration data with the ORC as well as with other Electronic
Control Units (ECU) in the vehicle. This process is referred to as PRogramming Of Configuration of
Systems Integrated (PROCSI) (also known as PROXI). If a configuration mismatch is detected, the BCM
sets a DTC. A configuration mismatch DTC will require the performance of a Restore BCM PROXI
Configuration routine, or a PROXI Configuration Alignment routine using a diagnostic scan tool.
The hard wired inputs and outputs for the ORC may be diagnosed using conventional diagnostic tools
and procedures. Refer to the appropriate SYSTEM WIRING DIAGRAMS article. However, conventional
diagnostic methods will not prove conclusive in the diagnosis of the ORC or the electronic controls and
communication between other modules and devices that provide some features of the SRS. The most
reliable, efficient and accurate means to diagnose the ORC or the electronic controls and
communication related to SRS operation requires the use of a diagnostic scan tool and may also require
the use of the SRS Load Tool special tool along with the appropriate Load Tool Jumpers and Adapters.
Refer to the appropriate Diagnostic & Testing article.
MODULE, OCCUPANT RESTRAINT CONTROLLER > REMOVAL AND INSTALLATION >

WARNING:
Supplemental Restraint System (SRS) before attempting any Occupant Restraint Controller
(ORC) diagnosis or service. The ORC may contain a rollover sensor, which enables the
system to deploy the side SRS components in the event of a vehicle rollover event. If an
ORC containing a rollover sensor is accidentally rolled during service while still connected
to battery power, the side SRS components will deploy. Disconnect and isolate the battery
negative (ground) cable, then wait two minutes for the system capacitor to discharge before
WARNING:
WARNING:
To avoid serious or fatal injury, never strike or drop the Occupant Restraint Controller (ORC),
as it can damage the impact sensor or affect its calibration. The ORC contains the impact
sensor, which enables the system to deploy the SRS components. If an ORC is accidentally
dropped during service, the module must be scrapped and replaced with a new unit. Failure
to observe this warning could result in accidental, incomplete, or improper SRS component
deployment.
Fig 1: Front Side Panel

service.
2. Remove the front side panel (1b) from the right side of the center floor console on the floor
panel center tunnel. Refer to CONSOLE, FLOOR, REMOVAL AND INSTALLATION .
Fig 2: Occupant Restraint Controller (ORC), Wire Connector & Nuts

3. Disconnect the wire harness connectors (1) from the rearward-facing end of the Occupant
Restraint Controller (ORC) (2b). To disconnect the wire harness connector from the ORC,
depress the release tab and lift the lever arm on the connector.
4. Remove the three nuts (2a) that secure the ORC to the weld studs on the floor panel center
tunnel.
5. Lift the ORC off of the weld studs and remove it from the vehicle.
MODULE, OCCUPANT RESTRAINT CONTROLLER > REMOVAL AND INSTALLATION >

WARNING:
Supplemental Restraint System (SRS) before attempting any Occupant Restraint Controller
(ORC) diagnosis or service. The ORC may contain a rollover sensor, which enables the
system to deploy the side SRS components in the event of a vehicle rollover event. If an
ORC containing a rollover sensor is accidentally rolled during service while still connected
to battery power, the side SRS components will deploy. Disconnect and isolate the battery
negative (ground) cable, then wait two minutes for the system capacitor to discharge before
WARNING:
WARNING:
To avoid serious or fatal injury, never strike or drop the Occupant Restraint Controller (ORC),
as it can damage the impact sensor or affect its calibration. The ORC contains the impact
sensor, which enables the system to deploy the SRS components. If an ORC is accidentally
dropped during service, the module must be scrapped and replaced with a new unit. Failure
to observe this warning could result in accidental, incomplete, or improper SRS component
deployment.
Fig 1: Occupant Restraint Controller (ORC), Wire Connector & Nuts
1. Carefully position the Occupant Restraint Controller (ORC) (2b) onto the weld studs on the top
of the floor panel center tunnel. When the ORC is correctly positioned, the bottom of the
housing will fit flush with the top of the floor panel center tunnel and the orientation arrow on the
label on top of the housing will be pointed forward in the vehicle.
2. Install and tighten the three nuts (2a) that secure the ORC to the weld studs on the top of the
floor panel center tunnel. Tighten the nuts securely.
3. Connect both wire harness connectors (1) to the rearward-facing end of the ORC. Be certain
that the latch on each connector is fully engaged.
Fig 2: Front Side Panel
4. Align the snap clips (1a) of the front side panel with the right side of the center floor console
and snap it into place. Refer to CONSOLE, FLOOR, REMOVAL AND INSTALLATION .
5. If this Electronic Control Unit (ECU) is being replaced with a new unit, a diagnostic scan tool
MUST be used to align the PROXI configuration data into the new ECU. Follow the routine
outlined in the diagnostic scan tool for PROXI Configuration Alignment under Body Control
Module (BCM) Miscellaneous Functions menu.
6. If this Electronic Control Unit (ECU) is being replaced with a new unit, the Initialize ORC
Miscellaneous Function must be run using a diagnostic scan tool.
RESTRAINT, ACTIVE HEAD > DESCRIPTION AND OPERATION > DESCRIPTION AND
Fig 1: Active Head Restraint (AHR) Units & Mechanical Components
Active Head Restraint (AHR) units (1) are standard equipment for both front seating positions in this
vehicle. One inertia-activated AHR unit is located atop each front seat back. Outwardly, an inertia-
activated AHR appears the same as a non-active head restraint. The mechanical components (2) that
articulate the inertia-activated AHR headrest pad are all concealed within the front seat back frame
assembly.
At the top of the seat back frame are two stamped steel headrest guide tubes. The guide tubes are each
inserted through a molded plastic fulcrum bushing installed in the upper seat back frame member and are
permanently fixed to a movable stamped steel armature bracket located just below the upper frame
member near the top of the seat back. The armature bracket is secured to a stamped steel pivot link at
each side that pivots on a screw threaded into a mounting bracket welded to each side member of the
seat back frame.
The pivot links each have a spring attached to a lever opposite the armature bracket attachment that is
anchored to the seat back frame side member below, which provides the spring-loaded return action of
the inertia mechanism. The upper end of the static lumbar assembly is secured at each side to the base
of the armature bracket. Each side of the lower end of the lumbar assembly is engaged in a ramp bracket
riveted to the lower seat back frame member.
The inertia-activated AHR linkage cannot be repaired. If damaged or ineffective, it must be replaced as a
unit with a new seat back frame unit.
RESTRAINT, ACTIVE HEAD > DESCRIPTION AND OPERATION > DESCRIPTION AND
The inertia-activated Active Head Restraint (AHR) units are deployed automatically by the mechanism
contained within each front seat back assembly. During a rear impact, inertia drives the seat occupant
rearward into the seat back, loading the seat lumbar assembly. The ramp brackets at the base of the
lumbar assembly translate this rearward travel into a vertical motion. The vertical motion of the lumbar
assembly is then transmitted to the armature bracket.
Through the rotation of the pivot links at each side of the armature bracket, the vertical motion of the
lumbar assembly is converted to a slightly forward and upward arc of the armature bracket, headrest
guide tubes and headrest that is designed to reduce the space between the back of the head of the seat
occupant and the head restraint pad. Closing this space catches the head of the seat occupant during a
low speed rear impact collision event and is important in reducing or eliminating potentially debilitating
cervical (also known as whiplash) injuries.
Unless damaged, following the rear impact, the inertia-activated AHR can be reset by simply pushing the
front seat headrests rearward to their normal positions.
RESTRAINT, ACTIVE HEAD > STANDARD PROCEDURE > STANDARD PROCEDURE -

ACTIVE HEAD RESTRAINT RESET
If the Active Head Restraint (AHR) units have been deployed, both the driver and passenger side units
must be reset. You can recognize that an AHR has been deployed by the forward position of the head
restraint cushion. If deployed, the AHR units can be manually reset by pressing the head restraint
rearward.
RETRACTOR, SEAT BELT > DESCRIPTION AND OPERATION > DESCRIPTION AND
The seat belt retractors used in all seating positions include an inertia-type, emergency locking
mechanism as standard equipment. Both front seat belt retractors also include a retractor tensioner, an
anchor tensioner unit and load limiting features as standard equipment. The outboard rear seat belt
retractors in vehicles manufactured for Europe-Middle East-Africa (EMEA) markets include a retractor
tensioner and the load limiting feature. The center rear seat retractor for all markets and the outboard
rear seat belt retractors for North America Free Trade Agreement (NAFTA) markets include only the load
limiting feature. Refer to TENSIONER, SEAT BELT, DESCRIPTION AND OPERATION .
The emergency locking mechanism, the retractor tensioner mechanism and the load limiting feature are
each integral to the retractor unit and are concealed beneath molded plastic covers located on each side
of the retractor spool. These features cannot be adjusted or repaired and if ineffective, damaged or
deployed, the entire seat belt and retractor unit must be replaced.
RETRACTOR, SEAT BELT > DESCRIPTION AND OPERATION > DESCRIPTION AND
The standard inertia-type emergency locking retractor will allow the seat belt webbing to unwind from and
wind onto the retractor spool freely unless and until a predetermined inertia load is sensed. The retractor
has an internal inertia latch mechanism that will lock the retractor spool once the predetermined inertia
load is sensed. Locking the retractor spool prevents the seat belt webbing from being extracted from the
retractor and firmly restrains the occupant wearing the seat belt. The retractor spool is automatically
unlatched once the loading of the retractor inertia mechanism and the seat belt are relieved.
RETRACTOR, SEAT BELT > REMOVAL AND INSTALLATION > REMOVAL AND
INSTALLATION > REMOVAL - FRONT
WARNING:
WARNING:
Fig 1: Remove/Install B-Pillar
NOTE:
The following procedure is for replacement of an ineffective or damaged seat belt and
retractor unit. The front retractors also include a retractor seat belt tensioner and a lower
anchor seat belt tensioner. If the front seat belt, retractor or either tensioner is ineffective or
damaged, but either seat belt tensioner is not deployed, review the recommended
PROCEDURE . If the seat belt tensioners have been deployed, review the recommended
procedures for Service After A Supplemental Restraint Deployment before removing the unit
from the vehicle. Refer to STANDARD PROCEDURE .
service.
2. Adjust the front seat to its most forward position for easiest access to the front seat belt,
retractor, lower anchor and the B-pillar trim.
3. Firmly grasp the top of the trim cover (2a) for the front seat belt turning loop height adjuster on
the inside of the upper B-pillar and pull it away from the height adjuster far enough to unsnap it,
then disengage the lower snap features of the trim cover from the adjuster.
4. Remove the screw (2b) that secures the front seat belt turning loop to the height adjuster on
the inside of the upper B-pillar.
5. Remove the seat belt turning loop from the height adjuster.
6. Remove the trim (3b) from the inside of the B-pillar. Refer to PANEL, B-PILLAR TRIM,
AND INSTALLATION .
7. Remove the trim from the inner sill. Refer to PLATE, SCUFF, LIFTGATE SILL, REMOVAL AND
INSTALLATION .
Fig 2: Seat Belt Web Guide & Retainers
8. Disengage the retainers (1a) that secure the seat belt web guide (1b) to the inner B-pillar.
Fig 3: Remove/Install Retractor Tensioner
9. Disconnect the body wire harness connector (1) from the initiator for the retractor tensioner.
10. Remove the screw (2) that secures the retractor bracket to the base of the inner B-pillar.
11. Lift the retractor (3a) upward far enough to disengage the T-tab (3b) on the retractor bracket
from the notch in the inner B-pillar.
Fig 4: Remove/Install Retractor & Anchor Tensioner
12. Disengage the anchor tensioner pigtail wire (1a) from the retainer and disconnect it from the
body wire harness connector (1b) for the tensioner.
13. Pull the carpet away from the inner sill far enough to access and remove the screw (2) that
secures the anchor tensioner to the inner sill.
14. Pull the anchor tensioner (3a) away from the inner sill far enough to disengage locating tab (3b)
from the sill.
15. Remove the front seat belt, retractor and anchor tensioner (4) from the vehicle as a unit.
INSTALLATION > REMOVAL - REAR SEAT CENTER
WARNING:
Fig 1: Remove/Install Rear Seat Back
1. Remove the left rear seat back from the vehicle. Refer to SEAT BACK, REAR, REMOVAL AND
INSTALLATION .
2. Remove the screws (1a) that secure the center rear seat belt flange (1b) to the top of the seat
back.
3. Disengage the seat belt flange from the belt webbing through the slit (1c) in the flange.
4. Remove the trim cover and foam from the left rear seat back. Refer to COVER, SEAT BACK,
FRONT, REMOVAL AND INSTALLATION .
Fig 2: Remove/Install Rear Center Seat Belt & Retractor
5. Working through the access hole in the seat back panel, remove the screw (1a) that secures
the retractor to the seat back frame.
6. Working from the front of the seat back frame, disengage the T-tab of the retractor bracket
from the keyed hole (2b) in the seat back frame.
7. Disengage the seat belt webbing and latch plates (3a) from the guide (3b) at the top of the seat
back frame.
8. Remove the rear center seat belt and retractor from the seat back frame as a unit.
INSTALLATION > REMOVAL - REAR OUTBOARD
WARNING:
WARNING:
Fig 1: Rear Outboard Seat Belt & Screw
NOTE:
retractor unit. In vehicles manufactured for Europe-Middle East-Africa (EMEA) markets the
rear outboard retractors also include a retractor seat belt tensioner. If the rear outboard seat
belt, retractor or tensioner is ineffective or damaged, but the seat belt tensioner is not
deployed, review the recommended procedures for Handling Non-Deployed Supplemental
Restraints. Refer to STANDARD PROCEDURE . If the seat belt tensioner has been
deployed, review the recommended procedures for Service After A Supplemental Restraint
Deployment before removing the unit from the vehicle. Refer to STANDARD PROCEDURE .
service.
2. Remove the screw (1a) that secures the rear outboard seat belt (1b) lower anchor near the
base of the C-pillar.
3. Remove the trim from the quarter inner panel. Refer to PANEL, QUARTER TRIM, REMOVAL
AND INSTALLATION .
Fig 2: Remove/Install Rear Outboard Seat Belt & Retractor
4. Remove the screw (1) that secures the rear outboard seat belt turning loop near the top of the
C-pillar.
5. Remove the seat belt turning loop from the upper C-pillar.
6. If equipped, disconnect the body wire harness connector (2) for the retractor tensioner from
the initiator.
7. Remove the screw (3a) that secures the retractor (3b) to the quarter inner panel.
8. Remove the rear outboard seat belt and retractor from the quarter inner panel as a unit.
INSTALLATION > INSTALLATION - FRONT SEAT
WARNING:
WARNING:
Fig 1: Remove/Install Retractor & Anchor Tensioner
NOTE:
retractor unit. The front retractor also includes a seat belt tensioner. If the front seat belt or
retractor is ineffective or damaged, but the seat belt tensioner is not deployed, review the
recommended procedures for Handling Non-Deployed Supplemental Restraints. Refer to
STANDARD PROCEDURE . If the seat belt tensioner has been deployed, review the
recommended procedures for Service After A Supplemental Restraint Deployment before
removing the unit from the vehicle. Refer to STANDARD PROCEDURE .
1. Position the front seat belt, retractor and anchor tensioner (4) into the vehicle as a unit.
2. Engage the locating tab (3b) of the anchor tensioner (3a) with the inner sill.
3. Install and tighten the screw (2) that secures the anchor tensioner to the inner sill. Tighten the
screw to the proper SPECIFICATIONS .
4. Connect the body wire harness connector (1b) to the anchor tensioner pigtail wire then engage
the wire with the retainer (1a).
Fig 2: Remove/Install Retractor Tensioner
5. Position the seat belt retractor unit (3a) to the B-pillar by engaging the T-tab (3b) on the
retractor bracket into the notch in the inner B-pillar.
6. Install and tighten the screw (2) that secures the retractor bracket to the base of the inner
B-pillar. Tighten the screw to the proper SPECIFICATIONS .
7. Connect the body wire harness connector (1) to the initiator for the retractor tensioner.
Fig 3: Seat Belt Web Guide & Retainers
8. Engage the retainers (1a) that secure the seat belt web guide (1b) to the inner B-pillar. Be
certain that the seat belt webbing between the retractor and the web guide is not twisted.
Fig 4: Remove/Install B-Pillar
9. Install the trim onto the inner sill. Refer to PLATE, SCUFF, LIFTGATE SILL, REMOVAL AND
INSTALLATION .
10. Install the trim onto the inside of the B-pillar. Refer to PANEL, B-PILLAR TRIM, LOWER,
REMOVAL AND INSTALLATION and PANEL, B-PILLAR TRIM, UPPER, REMOVAL AND
INSTALLATION .
11. Position the front seat belt turning loop onto the height adjuster. Be certain that the seat belt
webbing between the web guide and the turning loop is not twisted.
12. Install and tighten the screw (2b) that secures the turning loop to the height adjuster. Tighten
13. Install the trim cover (2a) over the top of the seat belt turning loop height adjuster.
14. Be certain that the seat belt webbing between the turning loop and the lower anchor buckle is
not twisted.
INSTALLATION > INSTALLATION - REAR SEAT CENTER
WARNING:
Fig 1: Remove/Install Rear Center Seat Belt & Retractor
1. Position the rear center seat belt and retractor (1b) to the bracket from the front of the left rear
seat back frame as a unit.
2. Engage the T-tab (2a) of the retractor bracket with the keyed hole (2b) in the seat back
bracket.
3. Route the seat belt webbing and latch plates (3a) through the guide (3b) at the top of the seat
back frame. Be certain the seat belt webbing is not twisted between the retractor and the top
of the seat back.
4. Working through the access hole on the back of the seat back, install and tighten the screw
(1a) that secures the retractor to the frame. Tighten the screw to the proper
SPECIFICATIONS .
5. Reinstall the trim cover and foam onto the left rear seat back frame. Refer to COVER, SEAT
BACK, FRONT, REMOVAL AND INSTALLATION .
Fig 2: Remove/Install Rear Seat Back
6. Reinstall the flange (1b) by inserting the seat belt webbing through the slit (1c) of the flange.
7. Position the flange onto the seat back. Be certain the seat belt webbing is not twisted.
8. Install and tighten the two screws (1a) that secure the flange to the seat back frame. Tighten
the screws securely.
9. Reinstall the left rear seat back into the vehicle. Refer to SEAT BACK, FRONT, REMOVAL
AND INSTALLATION and SEAT BACK, REAR, REMOVAL AND INSTALLATION .
INSTALLATION > INSTALLATION - REAR OUTBOARD
WARNING:
WARNING:
Fig 1: Remove/Install Rear Outboard Seat Belt & Retractor
NOTE:
retractor unit. In vehicles manufactured for Europe-Middle East-Africa (EMEA) markets the
rear outboard retractors also include a retractor seat belt tensioner. If the rear outboard seat
belt, retractor or tensioner is ineffective or damaged, but the seat belt tensioner is not
deployed, review the recommended procedures for Handling Non-Deployed Supplemental
Restraints. Refer to STANDARD PROCEDURE . If the seat belt tensioner has been
deployed, review the recommended procedures for Service After A Supplemental Restraint
Deployment before removing the unit from the vehicle. Refer to STANDARD PROCEDURE .
1. Position the rear outboard seat belt and retractor (3b) to the quarter inner panel as a unit.
2. Install and tighten the screw (3a) that secures the retractor to the quarter inner panel. Tighten
3. If equipped, connect the body wire harness connector (2) for the retractor tensioner to the
initiator.
4. Position the seat belt turning loop to the upper C-pillar. Be certain the seat belt webbing
between the retractor and the turning loop is not twisted.
5. Install and tighten the screw (1) that secures the turning loop to the upper C-pillar. Tighten the
screw to the proper SPECIFICATIONS .
6. Install the trim onto the quarter inner panel. Refer to PANEL, QUARTER TRIM, REMOVAL AND
INSTALLATION .
Fig 2: Rear Outboard Seat Belt & Screw
7. Position the rear seat belt (1b) lower anchor near the base of the C-pillar. Be certain the seat
belt webbing between the turning loop and the lower anchor is not twisted.
8. Install and tighten the screw (1a) that secures the lower anchor near the base of the C-pillar.
Tighten the screw to the proper SPECIFICATIONS .
SENSOR, IMPACT > DESCRIPTION AND OPERATION > DESCRIPTION AND

OPERATION > IMPACT SENSORS
Remote or satellite impact sensors are mounted in various strategic locations of the vehicle. These
sensors are mounted remotely from the impact sensor that is internal to the Occupant Restraint
Controller (ORC). Sensors at the front of the vehicle provide an additional logic input for use by the ORC
to control the front airbags, the seat belt pretensioners and, if equipped, the driver Knee AirBag (KAB).
Sensors on each side of the vehicle provide an additional logic input for use by the ORC to control the
side curtain airbags, seat airbags and the seat belt pretensioners. Two types of sensors are used in this
vehicle. They are the acceleration-type and the pressure-type, which are described elsewhere within
this service information.
Market-specific impact sensors:
EMEA version
4 impact sensors (2 accelerometer sensors, 2 pressure sensors)
1 front impact sensor ECS (Early Crash Sensor)
NAFTA version
4 impact sensors (2 accelerometer sensors, 2 pressure sensors)
2 front impact sensors ECS (Early Crash Sensor)

Fig 1: Front Impact Sensor
Front impact sensor
The front impact sensors detect frontal impacts and support the driver/passenger airbags and
pretensioners. The sensors contain accelerometers that measure the rate of vehicle deceleration in the
event of an impact. The sensors are located inside the front crossmember.
In head-on collisions, the impact sensor in the ORC acts as the primary sensor and the front sensors
provide confirmation of the event. In angled or offset front impacts, the front sensors act as the primary
sensors and the ORC sensors provide confirmation of the event.
Fig 2: Side Pressure & Impact Sensors

Side pressure and impact sensors
One pressure sensor is located in each of the front doors to protect front row passengers in the event of
side crashes.
The pressure sensors can detect a sudden change in air pressure within the door which is consistent
with a direct impact to the door. The sensor signal alone cannot command the explosion of the airbag.
The ORC or a second sensor must detect a crash event simultaneously to deploy the side airbags.
Fig 3: B-pillar Side Impact Sensor
B-pillar side impact sensor
Two accelerometric impact sensors are used on each side of the vehicle to detect a side impact and
support the side curtain airbags, the seat-mounted thorax airbags, and the seat belt pretensioners.
An accelerometer crash sensor for each side is located behind the cover at the bottom of the B-pillar. All
sensors in the passive restraints system relay information to the ORC using the Peripheral Sensor
Interface 5 (PSI5) network architecture.
During side impacts, the first sensor detects the impact and the other sensors confirm the event.

OPERATION > IMPACT SENSORS > ACCELERATION TYPE
Fig 1: Remote Or Satellite Acceleration-Type Impact Sensors
Remote or satellite acceleration-type impact sensors (1) are mounted in various locations in the vehicle.
These sensors are mounted remotely from the impact sensor that is internal to the ORC. Sensors at the
front of the vehicle provide an additional logic input for use by the ORC to control the front airbags, the
seat belt pretensioners and, if equipped, the driver Knee AirBag (KAB). Sensors on each side of the
vehicle provide an additional logic input for use by the ORC to control the side curtain airbags, the seat
belt tensioners and the seat (also known as pelvic and thoracic) airbags.
Although the front and side acceleration-type impact sensors are similar in appearance and construction,
they may not be interchangeable. The front impact sensors may monitor acceleration forces on a
different axis than those monitored by the side impact sensors. Each sensor is secured with a single nut
to a weld stud in its mounting location.
In vehicles manufactured for Europe-Middle East-Africa (EMEA) markets a front sensor is located on the
back of the lower horizontal member of the radiator support near the vehicle center line. In vehicles
manufactured for North America Free Trade Agreement (NAFTA) markets a front sensor is located on the
back of each vertical member of the radiator support below the inboard side of the headlamp housing.
Vehicles for all markets have a side acceleration-type sensor located near the base of each inner
B-pillar, concealed behind the interior trim.
Each sensor housing has an integral connector receptacle (3), an integral locator and anti-rotation pin
(4) and an integral mounting hole with a metal sleeve (2) to provide crush protection. A cavity in the
center of the molded plastic impact sensor housing contains the electronic circuitry of the sensor which
includes an electronic communication chip and an electronic acceleration sensor. Potting material fills
the cavity and a translucent molded cover is laser welded over the cavity to seal and protect the internal
electronic circuitry and components.
The front impact sensors are each connected to the vehicle electrical system through dedicated take
outs and connectors of the headlamp and dash wire harness, while the side impact sensors are
connected through dedicated take outs and connectors of the body wire harness.
The acceleration-type impact sensors cannot be repaired or adjusted and, if damaged or ineffective,
they must be replaced.

OPERATION > IMPACT SENSORS > PRESSURE TYPE
Fig 1: Pressure-Type Front Door Side Impact Sensors

Two pressure-type front door side impact sensors (1) are used on this vehicle, one each for the left and
right sides of the vehicle. These sensors are mounted remotely from the impact sensor that is internal to
the ORC. Each side sensor is secured with two screws and is sealed by a resilient gasket to a front
door hardware module carrier. The sensors are concealed behind the front door trim panel within the
The right and left front door side impact sensors are identical in construction and calibration. The impact
sensor housing has an integral connector receptacle (3), two integral mounting tabs (4) and an integral
hood-like water shield (2). The water shield extends through a hole in the hardware module carrier into
the interior of the door cavity and protects the sensor orifice from contamination. A cavity in the center
of the molded plastic impact sensor housing contains the electronic circuitry of the sensor, which
includes an electronic communication chip and the pressure sensor.
The housing cavity is filled with a potting material to seal and protect the internal electronic circuitry and
components. The pressure-type side impact sensors are each connected to the vehicle electrical
system through a dedicated take out and connector of the door wire harness.
These pressure-type door side impact sensors cannot be adjusted or repaired and, if damaged or
ineffective, they must be replaced.

OPERATION > IMPACT SENSORS
Two types of impact sensors are used in this vehicle. They are the acceleration-type and the
pressure-type. Additional operational details of each of these sensor types is described in further detail
below.

OPERATION > IMPACT SENSORS > ACCELERATION-TYPE
The acceleration-type impact sensors are electronic accelerometers that sense the rate of vehicle
deceleration, which provides verification of the direction and severity of an impact. Each sensor also
contains an electronic communication chip that allows the unit to communicate the sensor status as well
as sensor fault information to the microcontroller within the ORC.
The ORC microcontroller continuously monitors all of the passive restraint system electrical circuits to
determine the system readiness. If the ORC detects a monitored system fault, it sets a Diagnostic
Trouble Code (DTC) and controls the airbag indicator operation accordingly. The acceleration-type and
pressure-type side impact sensors for each side of the vehicle are connected in series (daisy-chained)
to the ORC. The impact sensors on each side of the vehicle receive battery current and ground through
dedicated left and right sensor plus and minus circuits from the ORC. The impact sensors and the ORC
communicate by modulating the voltage in the sensor plus circuit.
The hard wired circuits between the impact sensors and the ORC may be diagnosed using conventional
However, conventional diagnostic methods will not prove conclusive in the diagnosis of the impact
sensors or the electronic controls and communication between other modules and devices that provide
some features of the Supplemental Restraint System (SRS). The most reliable, efficient and accurate
means to diagnose the acceleration-type impact sensors or the electronic controls and communication
related to impact sensor operation requires the use of a diagnostic scan tool. Refer to the appropriate

OPERATION > IMPACT SENSORS > PRESSURE-TYPE
The pressure-type door side impact sensors recognize a side impact in the door area by monitoring
changes in pressure within the door cavity. A sudden pressure wave is created as the door collapses
during an impact event. Each sensor also contains an electronic communication chip that allows the unit
to communicate the sensor status as well as sensor fault information to the microcontroller within the
ORC.
The ORC microcontroller continuously monitors all of the passive restraint system electrical circuits to
determine the system readiness. If the ORC detects a monitored system fault, it sets a DTC and
controls the airbag indicator operation accordingly. The pressure-type and acceleration-type side impact
sensors for each side of the vehicle are connected in series (daisy-chained) to the ORC. The impact
sensors each receive battery current and ground through dedicated left and right sensor plus and minus
circuits from the ORC. The impact sensors and the ORC communicate by modulating the current in the
sensor plus circuit.
The hard wired circuits between the pressure-type door side impact sensors and the ORC may be
diagnosed using conventional diagnostic tools and procedures. Refer to the appropriate SYSTEM
WIRING DIAGRAMS article. However, conventional diagnostic methods will not prove conclusive in the
diagnosis of the impact sensors or the electronic controls and communication between other modules
and devices that provide features of the Supplemental Restraint System (SRS). The most reliable,
efficient and accurate means to diagnose the pressure-type impact sensors or the electronic controls
and communication related to impact sensor operation requires the use of a diagnostic scan tool. Refer
SENSOR, IMPACT > REMOVAL AND INSTALLATION > IMPACT SENSOR, FRONT >
REMOVAL - FRONT - EMEA MARKETS
WARNING:
WARNING:
To avoid serious or fatal injury, never strike or drop the front impact sensor, as it can
damage the impact sensor or affect its calibration. The front impact sensor enables the
system to deploy the front supplemental restraints. If an impact sensor is accidentally
dropped during service, the sensor must be scrapped and replaced with a new unit. Failure
to observe this warning could result in accidental, incomplete, or improper front
supplemental restraint deployment.
Fig 1: Remove/Install Front Impact Sensor (EMEA Markets)
NOTE:
The following procedure applies only to vehicles manufactured for the Europe-Middle
East-Africa (EMEA) markets.
service.
2. Reach below and behind the center of the lower horizontal member of the radiator support to
access and disconnect the headlamp and dash wire harness (2b) connector from the front
impact sensor (1b) connector receptacle.
3. Remove the nut (1a) that secures the front impact sensor to the stud on the back of the
radiator support.
4. Disengage the locating and anti-rotation pin of the sensor from the clearance hole in the
radiator support.
5. Remove the front impact sensor from the vehicle.
REMOVAL - FRONT - NAFTA MARKETS
WARNING:
WARNING:
system to deploy the front supplemental restraints. If an impact sensor is accidentally
dropped during service, the sensor must be scrapped and replaced with a new unit. Failure
to observe this warning could result in accidental, incomplete, or improper front
supplemental restraint deployment.
Fig 1: Remove/Install Front Impact Sensor (NAFTA Markets)
NOTE:
The following procedure applies only to vehicles manufactured for the North America Free
Trade Agreement (NAFTA) markets.
service.
2. Reach behind and below the inboard side of the right or left headlamp on the vertical member
of the radiator support to access and disconnect the headlamp and dash wire harness (2)
connector from the front impact sensor (1b) connector receptacle.
3. Remove the nut that secures the front impact sensor to the stud (1a) on the back of the
radiator support.
4. Disengage the locating and anti-rotation pin of the sensor from the clearance hole in the
radiator support.
5. Remove the front impact sensor from the vehicle.
INSTALLATION - FRONT - EMEA MARKETS
WARNING:
WARNING:
system to deploy the front Supplemental Restraint System (SRS) components. If an impact
sensor is accidentally dropped during service, the sensor must be scrapped and replaced
with a new unit. Failure to observe this warning could result in accidental, incomplete, or
improper front SRS component deployment.
Fig 1: Remove/Install Front Impact Sensor (EMEA Markets)
NOTE:
The following procedure applies only to vehicles manufactured for the Europe-Middle
East-Africa (EMEA) markets.
1. Reach below and behind the center of the lower horizontal member of the radiator support to
position the front impact sensor (1b) onto the stud on the back of the support member. Be
certain that the locating and anti-rotation pin on the back of the sensor is engaged in the
clearance hole of the support member.
2. Install and tighten the nut (1a) that secures the sensor to the radiator support. Tighten the nut
securely.
3. Connect the headlamp and dash wire harness (2b) connector to the sensor connector
receptacle.
INSTALLATION - FRONT - NAFTA MARKETS
WARNING:
WARNING:
system to deploy the front Supplemental Restraint System (SRS) components. If an impact
improper front SRS component deployment.
Fig 1: Remove/Install Front Impact Sensor (NAFTA Markets)
NOTE:
1. Reach behind and below the inboard side of the right or left headlamp on the vertical member
of the radiator support to position the front impact sensor (1b) onto the stud on the back of the
support member. Be certain that the locating and anti-rotation pin on the back of the sensor is
engaged in the clearance hole of the support member.
2. Install and tighten the nut that secures the front impact sensor to the stud (1a) on the back of
the radiator support. Tighten the nut securely.
3. Connect the headlamp and dash wire harness (2) connector to the sensor connector
receptacle.
SENSOR, IMPACT > REMOVAL AND INSTALLATION > REMOVAL AND

INSTALLATION - SIDE IMPACT SENSOR > REMOVAL - SIDE - B-PILLAR
WARNING:
WARNING:
To avoid serious or fatal injury, never strike or drop the side impact sensor, as it can
damage the impact sensor or affect its calibration. The side impact sensor enables the
system to deploy the side Supplemental Restraint System (SRS) components. If an impact
improper side SRS component deployment.
Fig 1: Remove/Install B-Pillar Side Impact Sensor
1. Adjust the driver or passenger side front seat to its most forward position for easiest access to
the B-pillar.
service.
3. Remove the trim from the inside of the lower right or left B-pillar. Refer to PANEL, B-PILLAR
TRIM, LOWER, REMOVAL AND INSTALLATION and PANEL, B-PILLAR TRIM, UPPER,
4. Remove the trim from the inside of the lower right or left rear sill. Refer to PLATE, SCUFF,
LIFTGATE SILL, REMOVAL AND INSTALLATION .
5. Remove the nut (1a) that secures the side impact sensor (1b) to the weld stud on the lower
B-pillar.
6. Disconnect the body wire harness connector (2a) from the sensor connector receptacle.
7. Disengage the locating and anti-rotation pin of the sensor from the clearance hole in the inner
B-pillar.
8. Remove the sensor from the weld stud on the B-pillar.

INSTALLATION - SIDE IMPACT SENSOR > REMOVAL - SIDE - FRONT DOOR
WARNING:
WARNING:
Fig 1: Remove/Install Front Door Side Impact Sensor
service.
2. Remove the trim panel from the inside of the front door. Refer to PANEL, DOOR TRIM,
3. Disconnect the door wire harness connector (1) from the sensor connector receptacle.
4. Remove the two screws (2a) that secure the impact sensor (2b) to the door hardware module
carrier.
5. Remove the sensor from the door hardware module carrier.

INSTALLATION - SIDE IMPACT SENSOR > INSTALLATION - SIDE - B-PILLAR
WARNING:
WARNING:
Fig 1: Remove/Install B-Pillar Side Impact Sensor

1. Position the side impact sensor (1b) onto the weld stud on the inner B-pillar. Be certain that the
locating and anti-rotation pin on the back of the sensor is engaged in the clearance hole of the
B-pillar.
2. Connect the body wire harness connector (2a) to the side impact sensor connector
receptacle.
3. Install and tighten the nut (1a) that secures the sensor to the stud on the inner B-pillar. Tighten
the nut securely.
4. Install the trim onto the inside of the lower right or left sill. Refer to PLATE, SCUFF, LIFTGATE
SILL, REMOVAL AND INSTALLATION .
5. Install the trim onto the inside of the B-pillar. Refer to PANEL, B-PILLAR TRIM, LOWER,
REMOVAL AND INSTALLATION and PANEL, B-PILLAR TRIM, UPPER, REMOVAL AND
INSTALLATION .

INSTALLATION - SIDE IMPACT SENSOR > INSTALLATION - SIDE - FRONT DOOR
WARNING:
WARNING:
Fig 1: Remove/Install Front Door Side Impact Sensor
1. Position the impact sensor (2b) to the front door hardware module carrier.
2. Install and tighten the two screws (2a) that secure the impact sensor to the carrier. Tighten the
screws securely.
3. Connect the door wire harness connector (1) to the impact sensor connector receptacle.
4. Install the trim panel onto the inside of the front door. Refer to PANEL, DOOR TRIM, REMOVAL
AND INSTALLATION .
SENSOR, OCCUPANT DETECTION > DESCRIPTION AND OPERATION >

Fig 1: Occupant Detection Sensor (ODS) Seat
The Occupant Detection Sensor (ODS) is a resistive pressure switch. The ODS closes when a
pre-programmed load is placed on the seat. The ODS is used to trigger a seat belt reminder if a
passenger is detected on the seat. The ODS does not affect the level of airbag deployment.
Fig 2: Occupant Detection Sensor (ODS)
The ODS cannot be adjusted or repaired, and must be replaced if damaged or ineffective.
SENSOR, OCCUPANT DETECTION > DESCRIPTION AND OPERATION >

The ODS acts as a simple switch to detect loads placed upon the passenger side front seat cushion.
The sensor circuits are connected to and monitored by the Occupant Restraint Controller (ORC)
whenever the status of the ignition is On. The ORC uses an algorithm logic in monitoring the changing
states of the sensor input to determine whether the seat cushion load is static or dynamic.
The ORC microcontroller continuously monitors all of the Supplemental Restraint System (SRS)
electrical circuits to determine the system status and readiness. If the ORC detects a monitored system
fault, it sets a Diagnostic Trouble Code (DTC). However, because the ODS input is only used for control
of the passenger belt alert feature, which has no effect on SRS component features or functions, the
airbag indicator is NOT illuminated in response to a detected ODS circuit fault.
The ODS receives source current and a clean ground through dedicated sensor plus and minus circuits
from the ORC. The ORC then sends the appropriate sensor status information over the Controller Area
Network (CAN) data bus to the Instrument Panel Cluster (IPC), which uses this information as an
additional logic input used for control of the seat belt indicator and the passenger belt alert feature.
The hard wired circuits between the ODS and the ORC may be diagnosed using conventional diagnostic
tools and procedures. Refer to the appropriate SYSTEM WIRING DIAGRAMS article. However,
conventional diagnostic methods will not prove conclusive in the diagnosis of the ODS or the electronic
controls and communication between other modules and devices that provide some features of the
passenger belt alert feature. The most reliable, efficient and accurate means to diagnose the ODS or the
electronic controls and communication related to the passenger belt alert feature operation requires the
use of a diagnostic scan tool. Refer to the appropriate Diagnostic & Testing article.
SENSOR, OCCUPANT DETECTION > REMOVAL AND INSTALLATION > REMOVAL

WARNING:
Fig 1: Seat Track Position Sensor, ODS, Wire Connectors & Retainers
1. Position the passenger side front seat to its most forward position for easiest access to the
front seat mounting hardware.
cable Wait two minutes for the system capacitor to discharge before further service.
3. Remove the passenger side front seat from the vehicle. Refer to SEAT, FRONT, REMOVAL
AND INSTALLATION .
4. Disengage the seat wire harness retainers (1a, 1b and 1c).
5. Disconnect the seat wire harness connections under the seat cushion for the seat track
position sensor (2a) and the Occupant Detection Sensor (ODS) (2b).
6. Remove the seat back from the seat cushion. Refer to SEAT BACK, FRONT, REMOVAL AND
INSTALLATION .
7. Remove the trim from the front seat cushion foam and frame. Refer to COVER, SEAT
CUSHION, FRONT, REMOVAL AND INSTALLATION .
8. If equipped remove the heater mat from the front seat cushion foam.
9. Reach under the back of the front seat cushion frame to access and disengage the Occupant
Detection Sensor (ODS) pigtail wire harness from the retainers.
10. Carefully disengage the adhesive patch of the ODS from the top surface of the seat cushion
foam.
NOTE:
Care must be taken not to pull off any of the seat cushion foam along with the ODS
mat. If part of the seat cushion foam is removed with the mat, the entire seat cushion
foam should be replaced.
11. Extract the tail of the ODS and the sensor pigtail wire harness through the clearance hole in
the seat cushion foam.
SENSOR, OCCUPANT DETECTION > REMOVAL AND INSTALLATION > REMOVAL

WARNING:
CAUTION:
When handling a new Occupant Detection Sensor (ODS), it should never be bent, creased,
torn, cut or abraded. The ODS should not be handled with or come into contact with hard or
sharp-edged tools or objects. Do not allow the ODS to drop more than 2 meters (6.5 feet).
Prior to installation, do not sit on, stand on or place boxes, tools or any other foreign object
on the ODS. If the ODS adhesive patches become inadvertently adhered to any seat
materials or foreign objects prior to proper positioning on the seat cushion, the ODS must be
scrapped and replaced with a new unit. Do not modify the seat foam or trim materials of a
seat that contains an ODS. Failure to observe these cautions may result in an inoperative
ODS, or an ODS that provides inaccurate inputs to the Occupant Restraint Controller (ORC).
CAUTION:
The adhesive used to secure the ODS to the seat is heat activated and requires that both
the adhesive and the material it is applied to be ideally between 21° and 38° C (between 70°
and 100° F). Application of the ODS to surfaces below 10° C (50° F) is not recommended as
the adhesive becomes too firm to readily adhere. Do not touch or allow the adhesive
patches to contact any foreign materials with the release paper removed. Do not attempt to
add adhesive materials to the ODS.
1. Carefully inspect the Occupant Detection Sensor (ODS) to be certain that it is in good
condition.
2. If the removed ODS sensor is being reused, apply a spray adhesive for plastics to the
adhesive area after providing suitable protection from overspray to the remaining portions of
the sensor mat.
3. If a new ODS is being used, remove the release paper from the adhesive patch of the ODS
mat.
NOTE:
The release paper should not be removed from the adhesive patch of a new ODS
mat until just prior to application to the seat cushion foam.
4. If the seat cushion foam is being reused, apply a spray adhesive for plastics to the adhesive
area after providing suitable protection from overspray to the remaining portions of the seat
cushion foam.
5. If a new seat cushion foam is being used, remove the release paper from the adhesive area of
the seat cushion foam.
NOTE:
The release paper should not be removed from the adhesive area of a new seat
cushion foam until just prior to application of the ODS mat.
6. Insert the ODS pigtail wire harness and the tail of the ODS through the clearance hole in the
seat cushion foam.
7. Carefully position and center the ODS mat onto the seat cushion foam with the adhesive patch
of the mat centered over the adhesive area of the seat cushion foam.
8. Apply hand pressure (0.8 bar or 12 psi) over the adhesive patch of the ODS for at least four
seconds to activate and adhere the adhesive to the seat cushion foam.
9. Reach under the back of the front seat cushion frame to access and route the ODS pigtail wire
and connector.
10. Install the seat back onto the seat cushion. Refer to SEAT BACK, FRONT, REMOVAL AND
INSTALLATION .
11. Install the trim onto the front seat cushion foam and frame. Refer to COVER, SEAT CUSHION,
FRONT, REMOVAL AND INSTALLATION .
12. Connect the seat wire harness connections under the seat cushion for the seat track position
sensor (2a) and the Occupant Detection Sensor (ODS) (2b).
13. Engage the seat wire harness retainers (1a, 1b and 1c).
14. Install the passenger side front seat into the vehicle. Refer to SEAT, FRONT, REMOVAL AND
INSTALLATION .
SENSOR, SEAT TRACK POSITION > DESCRIPTION AND OPERATION >
Fig 1: Seat Track Position Sensor
Vehicles manufactured for the North America Free Trade Agreement (NAFTA) market are equipped with a
Seat Track Position Sensor (STPS) for each front seat. The STPS is a Hall-effect sensor designed to
provide seat position data to the ORC indicating whether the driver or passenger side front seat is in a
full forward or a not full forward position. The Occupant Restraint Controller (ORC) uses the seat guide
input as a factor in determining the appropriate force to be used when deploying the multistage driver or
passenger airbag.
The seat guide position sensor receives a 5 V signal from the ORC. The sensor communicates the seat
position by modulating the voltage returned to the ORC. The ORC monitors the current produced by the
modulating voltage. The ORC also monitors the condition of the sensor circuits and will store a DTC for
any detected fault and make a request to the Body Control Module (BCM) over CAN-C to switch on the
airbag warning light in the instrument panel.
The STPS cannot be adjusted or repaired and, if ineffective or damaged, the entire STPS unit must be
replaced.
SENSOR, SEAT TRACK POSITION > DESCRIPTION AND OPERATION >
The STPS is designed to provide a seat position data input to the ORC indicating whether the driver or
passenger front seat is in a full forward or a not full forward position. The ORC uses this data as an
additional logic input for use in determining the appropriate deployment force to be used when deploying
the multistage Driver AirBag (DAB) and Passenger AirBag (PAB).
The STPS receives a nominal five volt supply from the ORC. The STPS communicates the seat position
by modulating the voltage returned to the ORC on a sensor data circuit. The ORC also monitors the
condition of the STPS circuits and will store a DTC for any fault that is detected. The ORC then sends
messages over the CAN data bus to control the illumination of the airbag indicator in the Instrument
Panel Cluster (IPC).
The hard wired circuits between the STPS and the ORC may be diagnosed using conventional
However, conventional diagnostic methods will not prove conclusive in the diagnosis of the STPS or the
Supplemental Restraint System (SRS). The most reliable, efficient and accurate means to diagnose the
STPS or the electronic controls and communication related to STPS operation requires the use of a
SENSOR, SEAT TRACK POSITION > REMOVAL AND INSTALLATION > REMOVAL
WARNING:
NOTE:
service.
2. Reach under the rear edge of the front seat cushion to access the Seat Track Position Sensor
(STPS) on a bracket located on the inboard side near the rear of one of the upper seat tracks.
3. Using a small screwdriver, hold the latch feature depressed while sliding the connector end of
the STPS off of the bracket.
4. Disconnect the seat wire harness connector (2a) from the STPS connector receptacle.
5. Remove the STPS from under the front seat.
SENSOR, SEAT TRACK POSITION > REMOVAL AND INSTALLATION > REMOVAL
WARNING:
NOTE:
1. Reach under the rear edge of the front seat cushion to connect the seat wire harness
connector (2a) to the Seat Track Position Sensor (STPS) connector receptacle. Be certain
that the latch on the connector is fully engaged.
2. Align the open end of the STPS mounting slot to the blade of the STPS bracket located on the
inboard side near the rear of one of the upper seat tracks.
3. Push the STPS firmly onto the bracket until the latch feature snaps into place with an audible
click.
SWITCH, SEAT BELT > DESCRIPTION AND OPERATION > DESCRIPTION AND
Fig 1: Seat Belt Switch
The buckles of driver and front and rear passenger seats are equipped with a sensor that checks the
fastening and differ depending on the market:
EMEA version
Driver side Hall-effect sensor
Resistive sensors on anchorage of front and rear passenger buckles
NAFTA version
Driver and front passenger side Hall-effect sensor
The resistive and Hall-effect sensors are hardwired to, and monitored by the Occupant Restraint
Controller (ORC). When the latch plate is inserted into the buckle it pushes on the spring device and the
window of the slide aligns between the Hall-effect sensor and the permanent magnet. When the sensor
and the magnet align, the Hall-effect sensor changes state indicating that the seat belt is fastened.
A 1 kilohm diagnostic resistor is connected in parallel with the Hall-effect sensor where the two pigtail
wire leads connect to the Hall-effect sensor pins. The resistor allows a small amount of current to flow
through the circuit continuously. The ORC monitors the current in the circuit. When 5-8 mA are present,
the seat belt is unbuckled. When 12-17 mA are present, the seat belt is buckled. If the harness is
disconnected, the current flow is interrupted and a seat belt switch DTC is set.
The resistive sensor is based on the current flowing through a normally closed contact.
The rated current is about 10mA while the operating current will be approximately between 10mA and
400mA.
The seat belt switches cannot be adjusted or repaired and, if ineffective or damaged, the entire front or
rear seat belt buckle-half unit must be replaced.
SWITCH, SEAT BELT > DESCRIPTION AND OPERATION > DESCRIPTION AND
The front and rear (if equipped) seat belt switches are designed to control a hard wired sense input to
the ORC. A spring-loaded slide with a small window-like opening is integral to the buckle latch
mechanism. When a seat belt tip-half is inserted and latched into the seat belt buckle, the slide is pushed
downward and the window of the slide exposes the Hall Effect Integrated Circuit chip within the buckle.
The field of the permanent magnet induces a current within the chip. The chip provides this induced
current as an output to the ORC. When the seat belt is unbuckled, the spring-loaded slide moves upward
and shields the Integrated Circuit from the field of the permanent magnet, causing the output current from
the seat belt switch to be reduced.
The seat belt switches receive a supply of current from the ORC, and the ORC senses the status of the
seat belt switches through its connection to each switch. The ORC provides electronic seat belt switch
status messages to the Instrument Panel Cluster (IPC) over the Controller Area Network (CAN) data
bus. The IPC uses these messages as an additional logic input for control of the seat belt indicator. The
ORC monitors the condition of the seat belt switch circuits and will store a Diagnostic Trouble Code
(DTC) for any fault that is detected.
The hard wired circuits between the seat belt switches and the ORC may be diagnosed using
article. However, conventional diagnostic methods will not prove conclusive in the diagnosis of the
switches or the electronic controls and communication between other modules and devices that provide
some features of the seat belt reminder system. The most reliable, efficient and accurate means to
diagnose the seat belt switches or the electronic controls and communication related to seat belt switch
article.
TENSIONER, SEAT BELT > DESCRIPTION AND OPERATION > DESCRIPTION AND
OPERATION > DESCRIPTION - SEAT BELT TENSIONERS
Fig 1: Seat Belt Tensioners
Two seat belt tensioners, one on the seat belt anchor (1) and the other in the front and rear seat belt
retractors (2) (rear retractors in Europe-Middle East-Africa/EMEA) are deployed by the Occupant
Restraint Controller (ORC) in conjunction with the dual front airbags. When the ORC sends the proper
electrical signal to the tensioners, the electrical energy generates enough heat to initiate a small
pyrotechnic gas generator.
On the retractor tensioner, a gas generator is installed in one end of a steel tube that contains numerous
steel balls. As the gas expands, it pushes the steel balls through the tube into a cast metal housing,
where a ball guide directs the balls into engagement with the teeth of a sprocket that is geared to one
end of the retractor spool. As the balls drive past the sprocket, the sprocket turns and drives the seat
belt retractor spool causing the slack to be removed from the front seat belts. The ball trap captures the
balls as they leave the sprocket and are expelled from the housing.
On the anchor tensioner, the gas generator is installed in one end of the tubular metal piston housing,
which contains a piston secured to one end of a cable. The cable is routed around an integral guide to
the buckle anchor, which is secured to the opposite end of the cable. As the gas expands, it pushes the
piston and the cable through the tube and pulls the buckle anchor downward, removing the slack from the
front seat belt.
The seat belts for both front seats in this vehicle incorporate dual tensioners. One tensioner is integral to
the seat belt retractor (2), and one tensioner is integral to the seat belt lower anchor (1). In vehicles
manufactured for EMEA markets a single tensioner is also integral to each rear outboard retractor. Each
of these tensioner types along with the load limiter are described in further detail elsewhere within this
service information.
OPERATION > DESCRIPTION - SEAT BELT TENSIONERS > LOAD LIMITER
A load-limiting device is integral to the front seat belt retractors to supplement the dual lower anchor and
retractor tensioners. The load limiter is also used on the outboard rear seat belt retractors to supplement
the retractor tensioners in vehicles manufactured for EMEA markets. The load limiter decreases the
force transmitted by the seat belt to the chest of the occupant being restrained. The force level at which
the limiters act is sufficient to considerably reduce the risk of skeletal fractures, even in individuals who
might suffer from brittle bones.
A load limiter cannot be adjusted or repaired and, if ineffective or damaged, the entire front or rear
outboard seat belt and retractor unit must be replaced. If the front airbags have been deployed, the
retractor and anchor tensioners have also been deployed. The retractor and anchor tensioners are not
intended for reuse and must be replaced following any front airbag deployment. Refer to RETRACTOR,
SEAT BELT, REMOVAL AND INSTALLATION .
OPERATION > DESCRIPTION - SEAT BELT TENSIONERS > LOWER ANCHOR
TENSIONER
Fig 1: Lower Anchor Tensioner
A seat belt lower anchor tensioner supplements the dual front airbag system for all versions of this
vehicle. These tensioners are integral to the front seat belt and retractor units, and are secured by a
screw (4) to the inner sill panel near the base of the B-pillar outboard of each front seat. The lower
anchor tensioner consists of an eyelet (1) through which the seat belt webbing (2) is secured, a rod (5),
a small pyrotechnically activated gas generator and an initiator connected through a pigtail wire (3) to
the electrical system of the vehicle. The lower anchor tensioners are controlled by the ORC.
The lower anchor tensioners cannot be repaired and, if ineffective or damaged, the entire seat belt and
retractor with the lower anchor tensioner unit must be replaced. If the front airbags have been deployed,
the lower anchor tensioners have also been deployed. The lower anchor tensioners are not intended for
reuse and must be replaced following any front airbag deployment. Refer to RETRACTOR, SEAT BELT,
OPERATION > DESCRIPTION - SEAT BELT TENSIONERS > RETRACTOR TENSIONER
Fig 1: Retractor Tensioner
Seat belt retractor tensioners supplement the dual front airbag system for all versions of this vehicle.
These tensioners are integral to the front seat belt and retractor units (3), which are secured to the inner
B-pillar on the right and left sides of the vehicle. Retractor tensioners are also used in the rear outboard
seating positions of vehicles manufactured for EMEA markets. The retractor is concealed beneath the
molded plastic inner B-pillar lower trim or C-pillar upper trim. The retractor tensioners are controlled by
the ORC. Each retractor tensioner has a Micro Gas Generator (MGG) (1) controlled by an initiator (2)
connected to the vehicle electrical system through a dedicated take out of the body wire harness by a
keyed and latching yellow molded plastic connector insulator to ensure a secure connection.
The retractor tensioners cannot be repaired and, if ineffective or damaged, the entire front or rear
outboard seat belt and retractor unit must be replaced. If the front airbags have been deployed, the
retractor tensioners have also been deployed. The retractor tensioners are not intended for reuse and
must be replaced following any front airbag deployment. A growling or grinding sound while attempting to
operate the seat belt retractor is a sure indication that the retractor tensioner has been deployed and
requires replacement. Refer to RETRACTOR, SEAT BELT, REMOVAL AND INSTALLATION .
The seat belt tensioners are deployed in conjunction with the dual front airbags by signals generated by
the ORC through the individual retractor (or sill end), pretensioner (or anchor) line 1 and line 2 (or squib)
circuits. When the ORC sends the proper electrical signal to the tensioner initiators, the electrical
energy generates enough heat to initiate a small pyrotechnic Micro Gas Generator (MGG).
In sequence, the ORC activates the retractor tensioner, followed by the lower anchor tensioner. The
retractor tensioner MGG drives the seat belt retractor spool causing slack to be removed from the seat
belt. The lower anchor tensioner gas generator pulls the front seat belt webbing downward, causing the
slack to be removed from the front seat belt.
Removing excess slack from the seat belts not only keeps the occupants properly positioned for an
airbag deployment following a frontal impact of the vehicle, but also helps to reduce injuries that the
occupants might experience in these situations as a result of harmful contact with the steering wheel,
steering column, instrument panel, windshield or other interior objects. The seat belt retractors also have
a mechanical-type load limiter consisting of a torsion bar mechanism that is designed to deform in order
to reduce the force of the tightened seat belt on the chest of the seat occupant during a frontal impact,
further reducing the potential for injuries.
The ORC monitors the condition of the seat belt tensioners through circuit resistance. If any fault is
detected, the ORC will illuminate the airbag indicator in the instrument cluster and store a Diagnostic
Trouble Code (DTC). Proper diagnosis of the seat belt tensioner initiators and squib circuits requires the
use of a diagnostic scan tool and may also require the use of the SRS Load Tool special tool along with
the appropriate Load Tool Jumpers and Adapters. Refer to the appropriate Diagnostic & Testing article.
Jeep Renegade
Service Manual: STEERING SYSTEM
This vehicle comes with Electric Power Steering (EPS) as standard equipment and it is the only steering
system available. The power steering system consists of these major components:
Rack and Pinion Steering Gear
Power Steering Column with EPS assist
Inner and Outer Tie Rod Ends
Turning of the steering wheel is converted into linear (side-to-side) travel through the meshing of the
helical pinion teeth with the rack teeth within the steering gear. The lateral travel pushes and pulls the tie
rods to change the direction of the vehicle's front wheels.
Power assist steering is provided by an electric motor connected to the steering column. The Electric
Power Steering (EPS) system provides variable assist for steering maneuvers based on several inputs,
including Vehicle Speed, Steering Angle Sensor (SAS), and Vehicle Voltage.
The EPS system communicates over the CAN C network. The steering angle sensor is internal to the
EPS column and outputs the SAS position to other modules. The steering column is designed to be
serviced only as a complete assembly if an internal component is found to be defective.
Manual steering control of the vehicle can be maintained if power steering assist is lost. However, under
this condition, steering effort is significantly increased.
DIAGNOSIS AND TESTING > STEERING SYSTEM DIAGNOSIS CHARTS
NOTE:
There are three diagnosis charts following that cover NOISE, VIBRATION AND HARSHNESS
(NVH) ISSUES, PERFORMANCE ISSUES, and FLUID ISSUES.
DIAGNOSIS AND TESTING > STEERING SYSTEM DIAGNOSIS CHARTS >

PERFORMANCE ISSUES
CONDITION POSSIBLE CAUSES EVALUATION/CORRECTION
STEERING WHEEL IS 1. Perform wheel alignment Make sure to

1. Front toe is out of adjustment. perform the Clear Steering Pull
OFF CENTER
Compensation and Vehicle Trim
procedures with the steering wheel lock
still on the steering wheel. Refer to
WHEEL ALIGNMENT, STANDARD
PROCEDURE .
1. Steering wheel lock was 1. With the steering wheel straight ahead
taken off before the Clear and locked in position, perform the Clear
Steering Pull Compensation Steering Pull Compensation and Vehicle
procedure was performed during Trim procedures. Refer to STANDARD
an alignment. PROCEDURE .
2. With the steering wheel straight ahead

2. The Electric Power Steering and locked in position, perform the Clear
(EPS) module has the incorrect Steering Pull Compensation and Vehicle
VEHICLE PULLS LEFT center position. Trim procedures Refer to STANDARD
OR RIGHT PROCEDURE .
3. Perform wheel alignment. Make sure to

3. The center position of the perform the Clear Steering Pull
column does not match the Compensation and Vehicle Trim
center position of the vehicle procedures. Refer to WHEEL
alignment. ALIGNMENT, STANDARD PROCEDURE
and STANDARD PROCEDURE .
4. Suspension components are 4. Inspect suspension components for

bent and/or damaged. damage.
STEERING WHEEL OR 1. Loose coupling pinch bolt at 1. Check pinch bolt torque. Replace pinch
COLUMN HAS gear input shaft. bolt with thread locker patch and tighten to
FREE-PLAY/LASH specifications.
/LOOSENESS
(CLUNKING OR
RATTLING)
2. Steering gear loose on 2. Inspect gear mounting bolts. Replace if

cradle/crossmember. necessary and tighten to specifications.
3. Excessive free-play or noise 3. Replace steering column.

from steering column bearings.
4. Excessive intermediate 4. Rotate steering wheel back-and-forth

(steering) shaft coupling U-joint while watching coupling. Observe for
free-play. free-play.
5. For evaluation and correction, refer to

5. Loose or worn outer tie rod.
GEAR .
6. Lubricate ball joint if equipped with a

zerk fitting and check for function. If not
6. Lack of lubrication in lower
equipped with a zerk fitting, test and
ball joint or ball joint is damaged.
replace ball joint/lower control arm as
necessary.
7. Excessive lash inside 7. Disconnect intermediate shaft and turn

steering gear. steering gear input shaft. Observe for any
movement without a corresponding tire
movement. Replace steering gear as
necessary.
STEERING WHEEL HAS 1. Steering wheel retaining bolt 1. Check steering wheel retaining bolt
FORE AND AFT loose. torque and tighten to specifications as
LOOSENESS necessary.
2. Loose steering column to 2. Check steering column to instrument

instrument panel fasteners. panel fastener torque and tighten to
specifications as necessary.
STEERING WHEEL, 1. Tire(s) not properly inflated. 1. Check and inflate tires to the specified
DASH OR VEHICLE pressure.
VIBRATES DURING
STEERING MANEUVERS
(ESPECIALLY AT LOW
SPEED OR STANDSTILL)
2. Excessive engine vibration. 2. Ensure that the engine is tuned

properly.
3. Loose tie rod end jam nut. 3. Check torque and tighten the inner to
outer tie rod jam nut to specifications.
4. Grounded, damaged or loose 4. Visually inspect for damaged or

engine mount. misaligned mounts. Check fastener
torque. Replace or realign as necessary.

5. Loose or worn outer tie rod.
GEAR .
6. Steering gear noisy. 6. During a parking event at 0 mph, verify

there is vibration only with steering. Steer
in both directions and verify that the noise
follows the steering input. Check TSBs for
any known issues. Replace steering gear
as necessary.
CAUTION:
Do not turn past two revolutions.

Damage to the clockspring may
occur. Always rotate steering column
back to initial position. Steering
column is equipped with an absolute
STEERING IS DIFFICULT 1. Steering column internal
position sensor that has a unique
IN BOTH DIRECTIONS issue.
zero position.
1. Disconnect the intermediate shaft and

rotate steering column. If condition is still
present, replace steering column. Refer to
COLUMN, REMOVAL AND
INSTALLATION .
STEERING CATCHES, 1. Tire(s) not properly inflated. 1. Check and inflate tires to the specified
SURGES OR STICKS IN pressure.
CERTAIN POSITIONS OR
IS DIFFICULT TO TURN
2. Lack of lubrication in lower 2. Lubricate ball joint if equipped with a

ball joint or ball joint is damaged. zerk fitting and check for function. If not
necessary.
3. Lack of lubrication in steering 3. For evaluation and correction, refer to

gear outer tie rod end(s). GEAR .
4. Excessive friction in 4. Disconnect intermediate shaft/coupler

intermediate shaft/coupler joint. at steering gear and check joint for
smooth operation in all directions.
5. Excessive friction in steering

column.
CAUTION:
Do not turn past two revolutions.

Damage to the clockspring may
occur. Always rotate steering column
back to initial position. Steering
column is equipped with an absolute
position sensor that has a unique
zero position.
5. Disconnect intermediate shaft/coupler

at steering gear. Turn steering wheel two
revolutions in either direction from on
center and check for smooth operation.
Replace steering column as necessary.
6. Worn or binding seat and 6. Disconnect outer tie rod ends from
bearing in front strut assembly. knuckles, then turn tire and wheel
assembly checking for smooth operation.
Replace front strut assembly seat and
bearing.
7. With vehicle on hoist, tires unsupported

and engine off, steer gear throughout
travel and check for smooth operation.
7. Faulty steering gear.
Replace steering gear (only after all
previous components have been
checked).
STEERING WHEEL 1. Tire(s) not properly inflated. 1. Check and inflate tires to the specified
DOES NOT RETURN TO pressure.
CENTER POSITION
2. Improper front wheel 2. Check and adjust wheel alignment as

alignment. necessary.
3. Lack of lubrication in lower 3. Lubricate ball joint if equipped with a
ball joint or ball joint is damaged. zerk fitting and check for function. If not
necessary.
4. Excessive friction in 4. Disconnect intermediate shaft/coupler

intermediate shaft/coupler joint. at steering gear and check joint for
smooth operation in all directions.
Replace steering column.
5. Excessive friction in steering 5. Disconnect intermediate shaft/coupler

column. at steering gear. Turn steering wheel two
revolutions in either direction from on
center and check for smooth operation.
DO NOT turn past two revolutions.
Damage to the clockspring may occur.
Replace steering column as necessary.
6. Worn or binding seat and 6. Disconnect steering gear outer tie rod
bearing in front strut assembly. ends at knuckles, then turn tire and wheel
assembly in and out checking for smooth
operation. Replace seat and bearing as
necessary.
7. Excessive friction in steering 7. With vehicle on hoist, tires unsupported

gear. and engine off, steer gear throughout
travel and check for smooth operation.
Replace steering gear (only after all
previous components have been
checked).
8. If all previous steps did not fix the

8. EPS system issue.
issue, the EPS must be replaced.
EXCESSIVE STEERING 1. Steering gear loose on 1. Inspect gear mounting bolts. Replace if
WHEEL KICKBACK cradle/crossmember. necessary and tighten to specifications.
FROM ROAD INPUTS
2. Steering column, coupling or 2. Rotate steering wheel back-and-forth

intermediate shaft worn or while inspecting intermediate shaft going
loose. into steering gear. Look for excessive
free-play. Retighten if loose bolt is found.
Replace steering column, coupling. Refer
to COLUMN, REMOVAL AND
INSTALLATION .
DIAGNOSIS AND TESTING > STEERING SYSTEM DIAGNOSIS CHARTS > NOISE,
VIBRATION AND HARSHNESS (NVH) ISSUES
CONDITION POSSIBLE CAUSES EVALUATION/CORRECTION
OBJECTIONABLE 1. Electric Power Steering (EPS) 1. Replace the steering column, which
ELECTRICAL BUZZING* System issue. includes the EPS system. Refer to
OR STRONG VIBRATIONS COLUMN, REMOVAL AND
WHILE TURNING INSTALLATION .
STEERING WHEEL
WHEN STATIONARY OR
MOVING SLOWLY
1. Verify column fasteners are tightened

NOISE FROM THE
1. EPS column fasteners are to correct specifications.
ELECTRIC POWER
loose. 2. Verify intermediate shaft pinch bolt is
STEERING (EPS)
2. Intermediate shaft is loose. tightened to the correct specification.
SYSTEM WHILE VEHICLE
3. Tire pressure is incorrect. 3. Check and inflate tires to the specified
IS MOVING
pressure.
RATTLE OR EXCESSIVE 1. Steering gear loose on engine 1. Check fastener torque and tighten to
CLUNK* cradle/crossmember. specifications. Replace as necessary.
Check steering wheel center following
repair.
2. Loose strut assembly 2. Check fastener torque and tighten to

mounting fasteners at tower or specifications.
knuckle.
3. Excessive play in outer tie 3. For evaluation and correction, refer to

rod. GEAR .
4. Engine cradle/crossmember 4. Check fastener torque and tighten to

mounting fasteners loose at specifications. Inspect bushings and
frame or bushings worn. repair as necessary.
5. Wheel mounting (lug) bolts 5. Inspect wheel mounting (Lug) bolts and
loose. repair as necessary. Tighten bolts to
specifications.
6. Stabilizer bar link joints worn 6. At park, jounce only one side of
(occurs with steering input only vehicle front to exercise stabilizer bar.
when moving, not stationary). Replace stabilizer bar link.
7. Loose lower control arm 7. Check control arm mounting bolts and
mounting bolts at engine cradle, tighten to specified torque.
frame or crossmember (occurs
with steering input only when
moving, not stationary).
8. Rotate intermediate (steering) shaft in

8. Loose intermediate shaft or relationship to gear, checking for
column. free-play. Check column fasteners and
tighten to specifications as necessary.
9. Lower control arm pivot 9. Inspect bushings for wear and replace
bushing worn (occurs with lower control arm as necessary.
steering input only when moving,
not stationary).
10. Internal steering gear noise. 10. Drive vehicle on rough road, then
steer rapidly back and forth when
stopped. Replace steering gear as
necessary.
11. Loose inner tie rod. 11. For evaluation and correction, refer
to GEAR .
12. Damaged engine 12. Inspect the cradle/crossmember for

cradle/crossmember. cracks or other damage. Replace as
necessary.
POPPING NOISE 1. Loose steering gear mounting 1. Check fasteners for proper torque and
fasteners. retighten as necessary.
2. Loose outer tie rod mounting 2. Check fastener torque. Replace nuts
nut or jam nut. as necessary and tighten to
specifications.
3. Loose intermediate (steering) 3. Make sure coupling is fully seated on

shaft coupling at gear input gear input shaft. Retighten or re-seat as
shaft. necessary.

4. Worn tie rod (outer or inner).
GEAR .
5. Worn axle half-shaft. 5. For evaluation and correction. Refer to

SQUEAKING OR 1. Steering column shroud or 1. While turning the steering wheel, listen
RUBBING SOUND shaft rubbing. down column to locate. Check
interference between moving
components. Move or realign shrouds or
shaft as necessary. Replace components
if this does not correct problem.
2. Clockspring inside steering 2. Remove clockspring and reinstall

column noisy. steering wheel for testing. If noise is
gone, replace clockspring.
3. Boot/dash seal lubrication 3. Remove boot seal and recheck for

inadequate. noise. Lubricate seal as necessary.
4. Steering gear outer tie rod 4. While a helper turns the steering
noisy. wheel, use an electronic listening tool to
determine if noise is coming from either
outer tie rod. Replace outer tie rods as
necessary.
5. Steering gear internally noisy. 5. Remove dash seal boot, then exercise
the steering wheel. If noise is still present
at gear, replace steering gear.
SCRUBBING OR 1. Incorrect tire or wheel size. 1. Replace incorrect size tire or wheel
KNOCKING SOUND with original equipment size.
2. Drive vehicle, moving accelerator

2. Worn motor or transmission pedal rapidly up and down attempting to
mount. locate noise. Try in both forward and
reverse. Replace mounts as necessary.
3. Make sure wheel house is properly
positioned. If not, reposition as
necessary. If steering wheel is properly
centered, check steering gear travel left
3. Tires contacting wheel well.
to right by rotating the steering wheel to
each stop. Steering wheel should rotate
the same amount in both directions from
center. If not, replace steering gear.
4. Interference between moving 4. Check for bent or misaligned

steering components and other components. Correct or replace as
components. necessary.
NOTE:
* Slight noise is normal in the EPS system. There is only a problem if the noise is very
intense or there are strong vibrations in the steering wheel that cannot be attributed to other
steering components.
NOTE:
** A light clunk may be felt or heard during steering wheel reversal while vehicle is
stationary. This results from internal steering gear rack movement at the bushings and in no
way affects the performance of the steering system. This movement may be felt in the
steering components during steering wheel reversal.
Steering rod from

1871000700 C-4150A Extractor
knuckle extractor
Type Energy absorbing coupled steering column. Electric power steering rack.
Turning radius (m) 11.07/10.76 (*)
NOTE:
(*) Trailhawk versions

STEERING SYSTEM TORQUE SPECIFICATIONS
NEW
DESCRIPTION N.m Ft. Lbs. In. Lbs.
FASTENER*
Intermediate Shaft to Steering Gear Bolt 60 44 - X
Outer Tie Rod End to Steering Knuckle Nut 40 30 - X
Steering Column to Dash Frame Bolts 20 15 -
Steering Column to Dash Frame Nuts 20 15 - X
Steering Gear to Crossmember 110 81 -
Steering Wheel to Column Nut 50 37 -
Tie Rod Jam Nut 56 41 -
* NEW FASTENER: Do not reuse these fasteners. If removed, a new fastener must be installed and
COLUMN > DESCRIPTION AND OPERATION > DESCRIPTION AND OPERATION
Electric Power Steering (EPS)

Fig 1: Steering Column, Locking/Unlocking Lever & Actuator
1. Steering column
2. Steering wheel adjustment locking/unlocking lever
3. Steering column
4. Power assistance actuator
The vehicle features Electric Power Steering (EPS) produced by TRW. Since the steering system is fully
electric, all power assistance is provided by an electric motor system. The motor:
Improves fuel economy as there is no power uptake from a power steering pump.
Reduces steering system-generated noise, and allows optimal tuning of feedback to the driver.
The speed-sensitive, variable power assistance responds to sensors monitoring steering torque,
steering wheel speed and angle, and vehicle speed. The steering system is fully integrated with the
electronic stability control system and helps compensate in situations where the wheels have different
grip.
Operation
The EPS system is a power steering system designed to reduce the force necessary for maneuvering
the vehicle at low speed, without rendering steering too light at higher speeds. EPS provides:
A lighter and less complex system with fewer components.
Less noise and improved driving comfort.
Power assistance is relative to vehicle speed.
The EPS system operates according to the operating information received by the CAN, such as:
Vehicle speed
Engine speed
Ignition status
The EPS assembly includes two built-in sensors that provide:
Steering angle
Steering wheel torque (driver input)
The system will turn off power assistance if the following criteria are met:
Engine speed is less than 600 RPM
Ignition is in the OFF position
This allows the system to continue providing assistance in the event of a stall, or a condition where
ignition input is lost due to an electrical fault.
Fig 2: EPS Module & Mounts
1. EPS module
2. Upper electric steering mounts
3. Lower electric steering mounts
COLUMN > REMOVAL AND INSTALLATION > REMOVAL AND INSTALLATION >
REMOVAL
WARNING:
When an undeployed airbag module is to be removed from the vehicle, first disconnect the
battery ground cable and isolate it. Allow the system capacitor to discharge for a minimum of
two minutes before starting any removal.
NOTE:
Before proceeding, refer to WARNING .
NOTE:
In case of replacing steering column, connect the diagnostic tool to calibrate the "sensor".
NOTE:
Position the front wheels straight, enter the first block steering to the right and remove the
ignition key.
NOTE:
Keep closed the adjustment lever steering column during all phases of removal / installation.
2. Remove the steering wheel. Refer to WHEEL, STEERING, REMOVAL AND INSTALLATION .
3. Remove the clockspring. Refer to CLOCKSPRING, REMOVAL AND INSTALLATION .
4. Remove the sentry key antenna. Refer to ANTENNA, SENTRY KEY, REMOVAL AND
INSTALLATION .
5. Remove the driver knee airbag. Refer to AIR BAG, KNEE BLOCKER, REMOVAL AND
INSTALLATION .
Fig 1: Intermediate Shaft & Pinch Bolt
6. Remove the intermediate shaft pinch bolt (1a), and remove the intermediate shaft (1b) from the
steering gear.
Fig 2: Steering Column Support Bolts, Data Link Connector, Nut, Screws & Connectors
7. Remove the Data Link Connector (DLC) (1a) from the dash frame.
8. Remove the screws (1b), and the nut (1c) then remove the airbag support frame.
9. Remove the front two steering column support bolts (3).

Fig 3: Steering Column & Column To Dash Frame Bolts
10. Remove the steering column to dash frame bolts (1a), and remove the steering column (1b).
COLUMN > REMOVAL AND INSTALLATION > REMOVAL AND INSTALLATION >
INSTALLATION
1. Position the steering column in the vehicle. Install the four steering column to dash frame bolts,
and tighten to the proper specification. Refer to SPECIFICATIONS .
Fig 1: Steering Column Support Bolts, Data Link Connector, Nut, Screws & Connectors
2. Install and tighten the screws (1b), and the nut (1c) for the airbag support frame.
3. Install the Data Link Connector (DLC) into the dash frame.
Fig 2: Intermediate Shaft & Pinch Bolt
4. Install the intermediate shaft (1b) to the steering gear. Tighten the intermediate shaft pinch bolt
(1a) to the proper specification. Refer to SPECIFICATIONS .
5. Install the driver knee airbag. Refer to AIR BAG, KNEE BLOCKER, REMOVAL AND
INSTALLATION .
6. Install the sentry key antenna. Refer to ANTENNA, SENTRY KEY, REMOVAL AND
INSTALLATION .
7. Install the clockspring. Refer to CLOCKSPRING, REMOVAL AND INSTALLATION .
8. Install the steering wheel. Refer to WHEEL, STEERING, REMOVAL AND INSTALLATION .

COLUMN > SHROUD, STEERING COLUMN > REMOVAL AND INSTALLATION >
AND INSTALLATION .
Fig 1: Bottom Cover, Tilt Lever, Screws & Retainers
2. Lower the tilt lever (1).

3. Remove the screws (2a) securing the bottom cover (2b) to the steering column.
4. Remove the bottom cover (3a) by disengaging the inside retainers (3b).
Fig 2: Top Shroud & Screws
5. Remove the screws (1a) securing the top shroud (1b).

Fig 3: Top Shroud, Closeout Flange, Tabs & Clips
6. Remove the small closeout flange (1a) by releasing the inside tabs (1b)
7. Remove the top shroud (2a) by releasing the inside clips (2b).
COLUMN > SHROUD, STEERING COLUMN > REMOVAL AND INSTALLATION >
1. Position the top steering column shroud by engaging the inside clips.
2. Tighten the screws that secure the top shroud to the steering column.
3. Install the small closeout flange by engaging the inside retainers.
4. Position the lower steering column shroud by engaging the inside clips.
5. Tighten the screws that secure the lower shroud to the steering column.
INSTALLATION .
COLUMN > WHEEL, STEERING > REMOVAL AND INSTALLATION > REMOVAL AND
WARNING:
Do not place a non-deployed airbag face down on a hard surface. The airbag will
propel into the air if accidentally deployed. Failure to follow this instruction may result
in possible serious or fatal injury.
Disconnect and isolate the battery negative (ground) cable before beginning steering
wheel removal or installation. This will disable the airbag system. Failure to follow this
instruction may result in accidental airbag deployment and possible serious or fatal
injury.
Allow the airbag system capacitor to discharge for two minutes before removing the
steering wheel or any airbag system component. Failure to follow this instruction may
result in accidental airbag deployment and possible serious or fatal injury.
2. Remove drivers airbag. Refer to AIR BAG, DRIVER, REMOVAL AND INSTALLATION .
NOTE:
Straighten the front wheels, engage the first steering lock and remove the ignition
key.
Fig 1: Steering Wheel Nut & Cover
3. Remove the steering wheel nut cover (1).
4. Remove the steering wheel to column nut (2).

Fig 2: Steering Wheel Electrical Connector
5. Partially remove the steering wheel and disconnect the steering wheel electrical connector (1).
6. Remove the steering wheel from the vehicle, transfer the switches if necessary.
COLUMN > WHEEL, STEERING > REMOVAL AND INSTALLATION > REMOVAL AND
Fig 1: Steering Wheel Electrical Connector
1. If removed, install the steering wheel switches.
2. Position the steering wheel on the shaft, aligning the references on the steering wheel and on
the steering column.
3. Connect the steering wheel electrical connector (1).

Fig 2: Steering Wheel Nut & Cover
4. Install the steering wheel nut (2), and tighten to the proper specification. Refer to
SPECIFICATIONS .
5. Install the steering wheel nut cover (1).
6. Install drivers airbag. Refer to AIR BAG, DRIVER, REMOVAL AND INSTALLATION .

GEAR > REMOVAL AND INSTALLATION > REMOVAL AND INSTALLATION >
REMOVAL
1. For the removal of the steering gear. Refer to CROSSMEMBER, FRONT SUSPENSION,
GEAR > REMOVAL AND INSTALLATION > REMOVAL AND INSTALLATION >
INSTALLATION
1. For the installation of the steering gear. Refer to CROSSMEMBER, FRONT SUSPENSION,
Jeep Renegade
Service Manual: STEERING WHEEL
Fig 1: Switch Unit
The car can be equipped with heated front seats and heated steering wheel. Both can be activated or
deactivated through dedicated keys of the switch unit on the center console.
The driver and front passenger seats have two heating setting levels while the steering wheel has only
one level.
On models equipped with Remote Start, the heated steering wheel and the heated seats will activate
automatically during the remote start at temperatures below 40°F (4.4°C).
When the occupants of the front seats request the activation of the heated seats (two heating levels) or
the steering wheel through the central control panel, the command is sent via LIN line to the BCM. The
BCM translates the command received and sends it via BH CAN to the seats/steering wheel heating
control unit (CSWM). The CSWM will supply the heater pads placed on the front seat backrests and
cushions and will receive the signal directly from the two temperature sensors (one per seat) in the
cushions, to learn the temperature of the seats and implement the correct strategies for supplying the
heater pads. The heater pads in the steering wheel cover are supplied directly by the CSWM, while the
temperature signal is received by the SWS (steering wheel switch unit) and sent via LIN to the BCM
which will put it on the CAN network.
The CSWM monitors the operation of the system and will generate the appropriate DTCs in the event of
failure.
When operating the heated seat switch, one of three switch positions can be selected: OFF, LOW, or
HIGH. The CSWM can provide three levels of power to the heating elements for the HIGH setting. These
power levels are changed by modulating the pulse width of the positive side of the circuit. The strategy
used by the CSWM is to operate the heating element at the highest pulse-width until the target time or
temperature for the pulse width is met. The CSWM then reduces the pulse width and repeats this
process until the system times out. When the LOW setting is selected, the pulse width remains at 25%
until the target temperature or time is reached (205 minutes for leather and 115 minutes for fabric). The
following table provides an overview of the adjustment strategy used to control the amount of current
provided to the seat heating elements:
Parameter name Definition Unit Leather Fabric

Temp_OFF Maximum temperature for heating program °C 67 55
DH_S3 PWM for heating - high level 3 s 100% 100%
T1S First timing program for seat heating min. 25 20
T2S Second timing program for seat heating min. 85 35
T3S Third timing program for seat heating min. 145 95
DL_S1 PWM for heating level Low s 25% 25%
TempSL1 Maximum temperature for heating program Low °C 65 48
T4S Fourth timing program for seat heating min. 205 115
Fig 1: Heated Systems Circuit Diagram
1. CSWM
2. Cushion heater
3. Backrest heater
4. BCM
5. SWS (steering wheel switch unit)
6. Steering wheel heater
7. CSS (central control panel)
8. Cushion heater
9. Backrest heater
10. Clock spring junction
Power supply of the seat heating control unit reaches from relay switch located in the luggage
compartment fuse box, through a line protected by a fuse.
Relay switch receives an ignition-operated power supply (INT) from the line protected by a fuse.
The control unit then connects via CAN to the other network nodes.
The BCM receives a direct power supply from the battery through the line protected by a maxi fuse
located in the engine compartment junction unit.
The BCM receives an ignition-operated power supply (INT). This signal is used, amongst other things, to
"wake up the network".
The coil activation signal reaches the BCM via the LIN line.
Controls for the steering wheel coil are sent through coil spring, whose control thermostat is located in
the steering wheel controls.
Service Manual: FRONT SUSPENSION & WHEEL Jeep Renegade
ALIGNMENT
Loosen / tighten nut drive

1870815000 * Anti-torque
shaft to the wheel hub
1874555001 * Strut Machine Disassembly of Strut
2016900020 10287 Hub Nut Actuator Crimp Hub Nut
DIAGNOSIS AND TESTING > DIAGNOSIS AND TESTING
ROAD TEST TO EVALUATE THE COMFORT
Carry out on roads open to traffic in safety, while respecting the rules of the road.
Before the test check the tire pressure of the two cars, bringing them back to the correct values if you
encounter incorrect values.
Carry out the test on irregular bottom at a speed of 40 km / h, to test the ability of the suspension of
absorb small bumps and absorb stress (damping suspension) with consequent impact noise inside the
car.
Check the ability of the suspension to absorb bumps on the net, which influences the solicitations
induced noise inside the vehicle: test at a speed of 40 km / h on a course that presents a series of
drains.
Check the fast damping of any pitch caused by uneven road profile, performing the test at a speed of 50
km / h on a straight road with the presence of bumps / dips properly separated. This type of test should
always be carried out by comparison with respect to a new vehicle or a reference to the same set-up
and engine, available in the shop at the time of the test in question.
Presenting at the end of the test in question a judgment / vote on the ride comfort of the vehicle in
accordance with the attached tables
SENSE Score
Poor 3
Average 4
At the limit of acceptability 5, 5
Acceptable 6
Good 7
NOTE:
"The referenced vehicle has a default vote of 7 on ride quality".
ROAD TEST TO EVALUATE THE ROLLING / PITCH
Carry out on roads open to traffic in safety, while respecting the rules of the road.
Before the test check the tire pressure of the two cars, bringing them back to the correct values if you
encounter incorrect values.
Carry out the test on a route where there are curves to the right / left of different radius, considering the
loading speed of the car on corners, trying to trace the curve at a constant speed, avoiding
pulling/releasing maneuvers.
To assess the stability of the car simulate a lane change/overtake and check that during the manoeuvre,
you do not experience the onset of a violent reaction of car inducing uncertainty in the guide.
Carry out a road test then disconnected (rails transverse, block paving, cobbles) with the presence of
various radius curves to the right / left to assess the trends in the loss of adhesion of the rear of the
vehicle (for drift).
This type of test should always be compared to than a new vehicle or reference hand in setting up and
engine, available in the shop at the time of the test in question.
Presenting at the end of the test object in a judgment / vote on the behavior of the vehicle to roll / pitch
according to the attached table.
SENSE Score
Poor 3
Average 4
At the limit of acceptability 5, 5
Acceptable 6
Good 7
NOTE:
"The vehicle has as reference the default behavior vote to roll / pitch of 7".
FRONT > WARNING > WARNING
WARNING:
FCA US LLC does not manufacture any vehicles or replacement parts that contain asbestos.
packaging for product information.
Whether the product contains asbestos or not, dust and dirt can accumulate on brake parts
during normal use. Follow practices prescribed by appropriate regulations for the handling,
processing and disposing of dust and debris.
WARNING:
Do not remove the strut rod nut while strut assembly is installed in vehicle, or before the coil
spring is compressed with a compression tool. The spring is held under high pressure.
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. It may come into
contact with the strut or coil spring.
CAUTION:
Wheel bearing damage will result if after loosening the axle hub nut, the vehicle is rolled on
the ground or the weight of the vehicle is allowed to be supported by the tires for any length
of time.
FRONT > DESCRIPTION > DESCRIPTION
The front suspension is MacPherson type. The MacPherson layout is renowned for its characteristics of
compact dimensions and low weight. The geometry and elastokinematic characteristics have been
optimized to improve the loss of camber somewhat in order to achieve enhanced steering response and
handling.
Fig 1: Front Suspension Components
The front suspension consists of:
1. A flat high-strength-steel crossmember which increases the vehicle's rigidity and features
attachment housings for the third load line which are sufficiently strong to absorb the loads in
the event of impact.
2. High-strength-steel lower wishbones for longer life. On front-wheel drive vehicles they are
made of a single sheet of high-strength steel (HSS). On 4 X 4 vehicles they are made with
double sheets of HSS. The production process permits optimal weight to be achieved,
contributing to efficiency in terms of fuel consumption.
3. The anti-roll bar connecting rods are made of composite material - an innovative and rare
application (they are more commonly made of steel) - which optimizes the exchange of forces
between the suspension and chassis and efficiently filters out vibrations, further improving ride
quality.
4. Aluminum stub axles (available later with regard to the commercial launch; at launch they are
made of cast iron) are fitted on 4 X 4 models for the reduced weight and greater agility, and
they improve noise/vibration levels.
5. Coil springs which optimize the thrust axis and contain transverse loads on the shock absorber
to improve comfort. The adoption of high-strength-steel springs also permitted minimal weight.
FRONT > SPECIFICATIONS > TECHNICAL SPECIFICATIONS
COIL SPRINGS
12.80 ± 0.05
12.60 ± 0.05
Wire diameter (mm) 13.00 ± 0.05 (*) 12.80 ± 0.05 13.00 ± 0.05
12.80 ± 0.05 (*)
12.80 ± 0.05 (***)
4.50
4.52 4.64
The number of coils 4.64 (*) 4.50
4.82 (*) 4.92 (*) (***)
4.92 (***)
Number useful sense of

Right-handed
Helix winding
380 375
Height uncompressed 415
420 (*) 415 (*) 375
spring (mm) 460 (*) (***)
410 (*) (**) 440 (***)
86
Compressed spring 85 89
89 (*) 86
height (mm 90 (*) 93 (*) (***)
91 (***)
358 ± 3% 382 ± 3%
Load (daN) for 208 mm 492 ± 3%
458 ± 3% (*) 492 ± 3% (*) 382 ± 3%
resultant length 528 ± 3% (*) (***)
437 ± 3% (*) (**) 499 ± 3% (***)
Color Orange
Color Orange
2003 + Orange
2003 + Silver Color White 9010
2003
9007 Color Orange + Silver 9007
Color Brown 8011
Color mark Color White 9010 2003 + Silver Color Pink 3015 +
+ Pink 3015 (*)
+ Silver 9007 (*) 9007 White 9010 (*)
Color Green 6010
Color Blue 5012 + (***)
+ Green 6010 (*)
Blue 5012 (***)
(**)
NOTE:
(*) For 4x4 versions
NOTE:
(**) For automatic transmission

NOTE:
(***) For Trailhawk versions
SHOCKS
Type MacPherson
Overall length 571 ± 3

(Extended length) (mm) 581 ± 3 (*)
Compressed Length 403 ± 3

(flush) (mm) 413 ± 3 (*)
Stroke (mm) 168
Shaft Diameter (mm) 22
NOTE:
STABILIZER BAR
Outer diameter
25 ± 0.2
(mm)
Color mark Red
FRONT > SPECIFICATIONS > TORQUE SPECIFICATIONS

FRONT SUSPENSION TORQUE SPECIFICATIONS
Front Stabilizer Bar

Bracket to Crossmember 45 33 -
Bolt
Hub Nut 71 + 63° 52 + 63° +/- 2° -
Hub and Bearing to

105 77 -
Knuckle Bolts
Lower Ball Joint to
60 44 -
Knuckle Bolt
Lower Control Arm to rear

125 92 -
crossmember Bolt
Lower Control Arm to

Crossmember Vertical 130 + 90° 96 + 90° -
Bolt
Lower Control Arm to

Crossmember Horizontal 130 + 90° 96 + 90° -
Bolt
Stabilizer Bar Link to

80 59 -
Stabilizer Bar Nut
Stabilizer Bar Link to Strut

80 59 -
Nut
Strut to Body Nuts 60 44 -
Strut to Knuckle Bolts 100 + 90° 74 + 90° -
Strut Rod to Strut Mount

70 52 -
Nut
FRONT > ARM, LOWER CONTROL > DIAGNOSIS AND TESTING > DIAGNOSIS AND
TESTING - LOWER CONTROL ARM
Inspect the lower control arm for signs of damage from contact with the ground or road debris. If the
lower control arm shows any sign of damage, look for distortion. Do not attempt to repair or straighten a
broken or bent lower control arm. If damaged, the lower control arm is serviced only as a complete
component.
Inspect both lower control arm isolator bushings for severe deterioration and replace the lower control
arm as required.
FRONT > ARM, LOWER CONTROL > REMOVAL AND INSTALLATION > REMOVAL
3. Remove the lower load beam. Refer to FRAME .
4. Remove the front stabilizer bar links. Refer to LINK, STABILIZER BAR, REMOVAL AND
INSTALLATION .
5. Remove the front hub nut. Refer to HUB AND BEARING, REMOVAL AND INSTALLATION .
6. Remove the outer tie rod end from the knuckle. Refer to GEAR .
Fig 1: Lower Control Arm To Knuckle Bolt
7. Remove the lower control arm to knuckle bolt (1), and remove the knuckle from the lower
control arm.
8. Remove the halfshaft from the hub and bearing.
NOTE:
Properly support halfshaft.

Fig 2: Lower Control Arm To Cradle Rear Bolt
9. Remove the lower control arm to cradle rear bolt (1).

Fig 3: Lower Control Arm & Cradle Front Bolt
10. Remove the lower control arm to cradle front bolt (1a), and remove the lower control arm (1b)
from the vehicle.
FRONT > ARM, LOWER CONTROL > REMOVAL AND INSTALLATION > REMOVAL
Fig 1: Installing Lower Control Arm & Cradle Front Bolt
1. Position the lower control arm (1) in the vehicle, and hold into position with hydraulic jack.
2. Install the lower control arm to cradle front bolt (2), and tighten to the proper specification.
Fig 2: Lower Control Arm To Cradle Rear Bolt
3. Install the lower control arm to cradle rear bolt (1), and tighten to the proper specification.
4. Check the integrity of the lower ball joint boot ring (1).
5. Install the lower control arm to knuckle bolt (1), and tighten to the proper specification. Refer to
6. Install the outer tie rod end to the knuckle. Refer to GEAR, REMOVAL AND INSTALLATION .
7. Install the front hub nut. Refer to HUB AND BEARING, REMOVAL AND INSTALLATION .
8. Install the front stabilizer bar links. Refer to LINK, STABILIZER BAR, REMOVAL AND
INSTALLATION .
9. Install the lower load beam. Refer to FRAME .
11. If necessary, perform a wheel alignment. Refer to WHEEL ALIGNMENT, STANDARD

PROCEDURE .
12. Install the under body splash shield. Refer to BELLY PAN, REMOVAL AND INSTALLATION .
FRONT > HUB AND BEARING > DIAGNOSIS AND TESTING > DIAGNOSIS AND
TESTING - HUB BEARING - NOISE
NOTE:
The wheel bearing is designed to last for the life of the vehicle and requires no type of
periodic maintenance. If it becomes necessary to replace a faulty bearing, do not replace in
pairs unless the Service Information specifically states to do so.
Bearings will produce noise if worn or damaged. The noise will generally change when the bearings are
loaded. A road test of the vehicle is normally required to determine if there is a bearing noise, or if it is
some other component. To assist in finding the location, the following procedure, together with the
DIAGNOSTIC TABLE , should help determine if a bearing is causing the noise, and if so which one.
Keep in mind that bearing noises are not typically intermittent. If a particular vehicle road test maneuver
results in noise only part of the time, it is not likely a faulty bearing.
NOTE:
Damaged bearing seals and the resulting excessive grease loss may also require bearing
replacement. Moderate grease seepage from the bearing is considered normal and should
not require replacement of the wheel bearing. To diagnose the hub, measure hub runout.
FRONT > HUB AND BEARING > DIAGNOSTIC PROCEDURE
1. Perform a drive evaluation. Find a smooth level road surface void of traffic or obstructions.
Turn off any accessories which may cause background noise. Evaluate for noise at 50 km/h
(30 mph) and 100 km/h (60 mph) and with vehicle in neutral to eliminate potential drivetrain
noises. With vehicle at a constant speed, steer back and forth to left and right. This will load
and unload the bearings and may change the noise level. When bearing damage is slight, the
noise is sometimes noticeable at lower speeds and at other times is more noticeable at higher
speeds.
2. Drive evaluation results: Did the noise increase when turning right which may indicate a
problem with the left bearing? Did the noise increase when turning left which may indicate a
problem with the right bearing?
3. Put vehicle up on hoist. Grab the tire by pushing in on the top center and pulling out on the
bottom center to check for excessive movement in the bearing.
4. Check for potential rubbing on rotating components, such as rotor splash shields, heat shields
touching propshaft or halfshaft, wheel well liners contacting tire, wheel cover on wheel, etc.
Any cyclic noise (once per wheel revolution for example) is not a wheel bearing fault.
5. Remove the wheel and tire assembly, disc brake caliper and brake rotor. Refer to ROTOR,
BRAKE, REMOVAL AND INSTALLATION .
6. Rotate the wheel hub, checking for resistance or roughness.
7. Any roughness or resistance to rotation may indicate dirt intrusion or a failed hub bearing. If
the bearing exhibits any of these conditions, the hub & bearing will require replacement. Do not
attempt to disassemble the bearing for repair.
8. Rotate the wheel hub, utilize Chassis Ears (or stethoscope) to check for noise.
9. If none of the above checks indicate a bearing failure, refer to the DIAGNOSTIC TABLE for
other possible causes.
DIAGNOSTIC TABLE - HUB BEARING
CONDITION POSSIBLE CAUSES POTENTIAL CORRECTIONS
1. Fill power steering fluid

1. Low Power Steering Fluid reservoir to proper level, check
Level (if applicable) for leaks (make sure all air is
bled from system fluid)
FRONT END WHINE ON TURNS 2. Worn Tires and/or Incorrect 2. Replace Tires, Check And
Wheel Alignment Reset Wheel Alignment
3. Defective Wheel Bearing 3. Replace Wheel Bearing
4. Wrong Power Steering Fluid 4. Replace With Correct Power

(if applicable) Steering Fluid
1. Loose Wheel Lug Nuts 1. Verify Wheel Lug Nut Torque
2. Engine Mount Grounding 2. Check For Engine Mount

Against Frame Or Body Of Hitting Frame Rail And
Vehicle Reposition Engine As Required
3. Worn Tires and/or Incorrect 3. Replace Tires, Check and

FRONT END GROWL OR Wheel Alignment Reset Wheel Alignment
GRINDING ON TURNS
5. Worn or Broken C/V Joint 5. Replace C/V Joint
6. Engine Not Centered,

Causing Axle Half Shaft to 6. Center the Engine
Bottom Out
1. Insufficient Hub Nut Torque 1. Torque Hub Nut to Spec
POPPING/CLICKING/SNAPPING 2. Separate Half Shaft From Hub

DURING ACCELERATION AFTER 2. Insufficient Grease on and Bearing and Wipe Mating
DRIVE-TO-REVERSE SHIFT, Mating Surface of Axle Half Surfaces Clean. Apply Light
REVERSE-TO-DRIVE SHIFT OR Shaft Outer C/V Joint to Wheel Coating of Wheel Bearing
WHILE TURNING Hub/Bearing, or Worn/Damaged Grease to C/V Joint Surface and
Gasket Reassemble, or Replace Gasket.
Torque Hub Nut to Spec
WHINE/HUM/ROAR WITH VEHICLE 1. Worn Tires and/or Incorrect 1. Replace Tires and Reset
GOING STRAIGHT AT A CONSTANT Wheel Alignment Wheel Alignment
SPEED 2. Defective Wheel Bearing 2. Replace Wheel Bearing
GROWL OR GRINDING WITH 1. Engine Mount Grinding 1. Check and Reposition Engine
VEHICLE GOING STRAIGHT AT A Against Frame or Body as Required
CONSTANT SPEED 2. Defective Wheel Bearing 2. Replace Wheel Bearing
FRONT > HUB AND BEARING > REMOVAL AND INSTALLATION > REMOVAL AND
3. Remove the front brake rotor. Refer to ROTOR, BRAKE, REMOVAL AND INSTALLATION .
Fig 1: Unstaking Hub Nut
4. With the appropriate tool, unstake the hub nut (1).

Fig 2: Hub Nut & Special Tool
5. Install the special tool 1870815000 (1a), and remove the hub nut (1b).
Fig 3: Removing Outer Tie Rod From Knuckle
6. Remove the outer tie rod end (1b) from the knuckle. Refer to GEAR .
7. Remove the wheel speed sensor to knuckle bolt (2), and remove the wheel speed sensor head
from the knuckle.
Fig 4: Hub And Bearing Bolts
8. Remove the hub and bearing bolts (1).

Fig 5: Hub And Bearing
9. Remove the hub and bearing (1) from the knuckle.
10. Check that the internal surfaces of the front steering knuckle for wear or damage. Check the
front steering knuckle arms for wear or damage. Install a new front steering knuckle, as
necessary.
FRONT > HUB AND BEARING > REMOVAL AND INSTALLATION > REMOVAL AND
1. Position the hub and bearing into the knuckle.
2. Tighten the hub and bearing bolts (1) to the proper specification. Refer to FRONT,
SPECIFICATIONS .
3. Install the wheel speed sensor head into the knuckle, and tighten the wheel speed sensor to
knuckle bolt to the proper specification. Refer to TORQUE SPECIFICATIONS .
4. Install the outer tie rod end into the knuckle. Refer to GEAR .
5. Install the special tool 1870815000 (1a), and install the NEW hub nut (1b) to the proper
6. Stake the hub nut as shown in illustration with special tool (special tool #10287-1, Tool,
Staking).
7. Install the front brake rotor. Refer to ROTOR, BRAKE, REMOVAL AND INSTALLATION .
FRONT > KNUCKLE, STEERING > DIAGNOSIS AND TESTING > DIAGNOSIS AND
TESTING - KNUCKLE
The front suspension knuckle is not a repairable component of the front suspension. It must be replaced
if found to be damaged in any way. If it is determined that the knuckle is bent when servicing the vehicle,
no attempt is to be made to straighten the knuckle.
FRONT > KNUCKLE, STEERING > REMOVAL AND INSTALLATION > REMOVAL AND
3. Remove the front brake rotor. Refer to ROTOR, BRAKE, REMOVAL AND INSTALLATION .
4. Remove the hub nut. Refer to HUB AND BEARING, REMOVAL AND INSTALLATION .
Fig 1: Removing Outer Tie Rod From Knuckle
5. Remove the outer tie rod end (1b) from the steering knuckle. Refer to GEAR .
6. Remove the wheel speed sensor to knuckle bolt (2), and remove the wheel speed sensor.
7. Remove the lower control arm to knuckle bolt (1).

Fig 3: Steering Knuckle & Strut Bolts
8. Remove the strut to knuckle bolts (1a).
9. Remove the steering knuckle (1b) from the vehicle.
10. If necessary, transfer the remaining parts.

FRONT > KNUCKLE, STEERING > REMOVAL AND INSTALLATION > REMOVAL AND
Fig 1: Steering Knuckle & Strut Bolts
1. Position the steering knuckle (1a) assembly in the vehicle.
2. Align the steering knuckle to the front strut and install the strut to knuckle bolts (1b). Tighten the
bolts to the proper specification. Refer to FRONT, SPECIFICATIONS .
3. Check the integrity of the lower ball joint boot closure ring (1).
4. Install the lower control arm to the knuckle, and tighten the lower control arm to knuckle nut (1)
to the proper specification. Refer to FRONT, SPECIFICATIONS .
5. Install the wheel speed sensor head into the knuckle. Tighten the wheel speed sensor to
knuckle bolt to the proper specification. Refer to FRONT, SPECIFICATIONS .
6. Install the outer tie rod end to the knuckle. Refer to GEAR .
7. Install the hub nut. Refer to HUB AND BEARING, REMOVAL AND INSTALLATION .
8. Install the brake rotor. Refer to ROTOR, BRAKE, REMOVAL AND INSTALLATION .
FRONT > LINK, STABILIZER BAR > REMOVAL AND INSTALLATION > REMOVAL AND
3. Remove the stabilizer bar link nut at the stabilizer bar. Separate the stabilizer bar link from the
stabilizer bar.
4. Remove the stabilizer bar link nut at the front strut. Separate the stabilizer bar link from the
front strut.
5. Remove the stabilizer bar link.
FRONT > LINK, STABILIZER BAR > REMOVAL AND INSTALLATION > REMOVAL AND
1. Install the stabilizer bar link to the stabilizer bar and install the stabilizer bar link nut.
2. Install the stabilizer bar link to the front strut and install the stabilizer bar link nut.
FRONT > STABILIZER BAR, FRONT > REMOVAL AND INSTALLATION > REMOVAL
For the removal of the front stabilizer bar. Refer to CROSSMEMBER, FRONT SUSPENSION, REMOVAL
AND INSTALLATION .
FRONT > STABILIZER BAR, FRONT > REMOVAL AND INSTALLATION > REMOVAL
For the installation of the front stabilizer bar. Refer to CROSSMEMBER, FRONT SUSPENSION,
FRONT > STRUT, SUSPENSION, ASSEMBLY > DIAGNOSIS AND TESTING >
DIAGNOSIS AND TESTING - STRUT ASSEMBLY
Inspect the strut assembly for the following conditions:
Inspect for a damaged or broken coil spring.
Inspect for a torn or damaged dust shield.
Lift the dust shield and inspect the strut assembly for evidence of fluid running from the upper end
of the strut fluid reservoir. Must change jounce bumper if a leaky strut is found. (Actual leakage will
be a stream of fluid running down the side and dripping off lower end of unit). A slight amount of
seepage between the strut shaft and strut shaft seal is not unusual and does not affect
performance of the strut assembly.
Inspect the jounce bumper for signs of damage or deterioration.
Inspect the clearance between the shock tower and the coil spring. Make sure no fasteners are
protruding through the shock tower possibly contacting the coil spring and strut. Because of the
minimum clearance in this area, installation of metal fasteners could damage the coil spring coating
and lead to a corrosion failure of the spring.
FRONT > STRUT, SUSPENSION, ASSEMBLY > REMOVAL AND INSTALLATION >
3. Remove the front wiper cowl. Refer to COVER, COWL PANEL, REMOVAL AND
INSTALLATION .
Fig 1: Sway Bar Link To Strut Nut
4. While holding the stem with the appropriate tool, remove the sway bar link to strut nut (1a).
Fig 2: Brake Hose Retaining Clip, Wheel Speed Sensor Wiring & Strut To Knuckle Bolts
5. Remove the retaining clip and remove the brake hose from the strut (1).
6. Remove the wheel speed sensor (2) from the strut.
7. Remove the two strut to knuckle bolts (3).

Fig 3: Strut To Body Nuts
9. Remove the three strut to body nuts (1).

Fig 4: Strut
10. Remove the strut (1) from the vehicle.

Fig 5: Strut Rod To Strut Mount Nut
11. Position the strut assembly into the strut compressor and compressor the spring.
12. Remove the strut rod to strut mount nut (1a).

Fig 6: Removing Strut From Spring Assembly
13. Remove the strut (1) from the spring assembly.

Fig 7: Jounce Bumper
14. Lower the boot and remove the jounce bumper (1).
Fig 8: Strut Boot
15. Remove the boot (1) from the strut.

Fig 9: Lower Spring Isolator
16. Remove the lower spring isolator (1).

Fig 10: Upper Spring Isolator
17. Remove the upper spring isolator (1).

Fig 11: Spring
18. If necessary, decompress spring and remove the spring (1) from the strut compressor.
FRONT > STRUT, SUSPENSION, ASSEMBLY > REMOVAL AND INSTALLATION >
1. If removed, install and compress the strut spring in the compressor.
2. Assemble the strut with the upper and lower spring isolators, boot, and the jounce bumper.
Fig 1: Upper Strut Mount & Nut
3. Position the upper strut mount (1a) onto the spring, install and tighten the strut rod to strut
mount nut (1b) to the proper specification. Refer to FRONT, SPECIFICATIONS .

Fig 2: Strut To Body Nuts
5. Position the strut into the vehicle and install and tighten the strut to body nuts (1) to the proper
Fig 3: Brake Hose Retaining Clip, Wheel Speed Sensor Wiring & Strut To Knuckle Bolts
6. Install the strut to knuckle bolts (1), and tighten the bolts to the proper specification. Refer to
7. Install the wheel speed sensor (2) to the strut.
8. Install the brake hose to the strut and install the retaining clip (3).
Fig 4: Sway Bar Link To Strut Nut
9. Install the stem into the strut, and tighten the sway bar link to strut nut (1b) to the proper
10. Install the front wiper cowl. Refer to COVER, COWL PANEL, REMOVAL AND INSTALLATION .
13. Perform a front end alignment. Refer to WHEEL ALIGNMENT, STANDARD PROCEDURE .
WHEEL ALIGNMENT > STANDARD PROCEDURE > WHEEL ALIGNMENT > FRONT
WHEEL ALIGNMENT
This control operation must always be performed after each intervention on the mechanical front
suspension components with the function to define the position of the wheels relative to the frame (e.g.:
control arms, struts, shock absorbers, springs, etc.).
General Information
OPERATING CYCLE
Buoyancy checks/wheel angles must be carried out, with special optical equipment, after checking and
adjusting the tire inflation pressure to prescribed values and making sure the car meets the following load
condition:
"Standard 0"-exhaust vehicle including spare wheel, tools, accessories, supply with 5 liters of fuel.
"Standard"-exhaust vehicle including spare wheel, tools, accessories, supply (full of fuel).
ATTITUDE CONTROL
Check that the front wheel falls within the prescribed values; the set-up is measured by checking the
share from the ground to the point of maximum curvature of the front mudguard.
PARTIAL TOE-IN CONTROL
4x2
4x4
In case of partial toe front wheels does not fall into the prescribed values, proceed to registration
as described below.
Straighten the steering wheel and secure it with a suitable tool.
Loosen the lock nuts on the left and right of the steering gear.
Tighten or loosen the Steering box braces until the partial toe-in prescribed, keeping the front
wheels aligned.
After recording the number of free threads on the tie rod right steering should be equal to the number of
free threads on the tie rod left.
Tighten to torque the tie rod nuts left and right steering box.
Remove the tool for locking of the steering wheel.
CAMBER CONTROL
The front wheel camber is not adjustable. If the value is not within the prescribed limits control the lower
control arm and the body.
4x2
4x4
Check that the front wheel camber falls within the values specified.
IMPACT CONTROL
The caster of the front wheels is not adjustable. If the value is not within the prescribed limits control the
lower control arm and the body.
4x2
4x4
Check that the front wheels incidence falls within the values specified.
NOTE:
Connect the diagnosis tool to perform the calibration of the steering position sensor.
WHEEL ALIGNMENT > STANDARD PROCEDURE > WHEEL ALIGNMENT > REAR
WHEEL ALIGNMENT
This control operation must always be performed after each intervention on the mechanical front
suspension components with the function to define the position of the wheels relative to the frame (e.g.:
control arms, struts, shock absorbers, springs, etc.).
General Information
OPERATING CYCLE
Buoyancy checks/wheel angles must be carried out, with special optical equipment, after checking and
adjusting the tire inflation pressure to prescribed values and making sure the car meets the following load
condition:
"Standard 0"-exhaust vehicle including spare wheel, tools, accessories, supply with 5 liters of fuel.
"Standard"-exhaust vehicle including spare wheel, tools, accessories, supply (full of fuel).
PARTIAL TOE-IN CONTROL
4x2
4x4
Check that the partial toe-in of the rear wheels falls within the values specified.
To adjust the partial toe-in rear wheels adjust screws fastening cam rear swinging arms to the
cross of the rear suspension.
As A result of this adjustment, tighten screws to specified torque.
After recording the number of free threads on the tie rod right steering should be equal to the number of
free threads on the tie rod left.
CAMBER CONTROL
The values of rear wheel camber are not adjustable.
4x2
4x4
WHEEL ALIGNMENT > SPECIFICATIONS > SPECIFICATIONS

NOTE:
This check procedure must be carried out after each operation on the mechanical
components of the front suspension since it defines the position of the wheels in relation to
the body (e.g.: control arms, struts, shock absorbers, springs etc.).
The wheel geometry/angle checks must be carried out using appropriate optical equipment after
checking and adjusting tire inflation pressure to the prescribed values and ensuring that the car complies
with one of the following load conditions:
Standard 0 - vehicle unladen including spare wheel, tools, accessories and consumables with 5
liters of fuel.
"Standard A" - vehicle unladen including spare wheel, tools, accessories and consumables (full
tank of fuel).
Front Wheel Alignment - 4x2
Measure Value Validity
-.08° +/-.07° (Standard 0 e

Single Toe front wheels 1.4L - 2.4L - 1.6L
Standard A)
Camber front wheels -.62° +/-.50° (Standard 0) 1.4L - 2.4L - 1.6L
Camber front wheels -.63° +/-.50° (Standard A) 1.4L - 2.4L - 1.6L
Caster front wheels 5.22° +/-.50° (Standard 0) 1.4L - 2.4L - 1.6L
Caster front wheels 5.27° +/-.50° (Standard A) 1.4L - 2.4L - 1.6L
Front Wheel Alignment - 4x4
-.10° +/-.07° (Standard 0 e

Single Toe front wheels 1.4L EMEA - 2.0L EMEA
Standard A)
-.07° +/-.07° (Standard 0 e

Single Toe front wheels 1.4L NAFTA - 2.4L NAFTA
Standard A)
Camber front wheels -.78° +/-.50° (Standard 0) 1.4L EMEA - 2.0L EMEA
Camber front wheels -.82° +/-.50° (Standard A) 1.4L EMEA - 2.0L EMEA
Camber front wheels -.63° +/-.50° (Standard 0) 1.4L NAFTA - 2.4L NAFTA
Camber front wheels -.67° +/-.50° (Standard A) 1.4L NAFTA - 2.4L NAFTA
Caster front wheels 5.05° +/-.50° (Standard 0) 1.4L EMEA - 2.0L EMEA
Caster front wheels 5.07° +/-.50° (Standard A) 1.4L EMEA - 2.0L EMEA
Caster front wheels 4.95° +/-.50° (Standard 0) 1.4L NAFTA - 2.4L NAFTA
Caster front wheels 4.95° +/-.50° (Standard 0) 1.4L NAFTA- 2.4L NAFTA
Front Wheel Alignment - TrailHawk
-.05° +/-.07° (Standard 0 e 2.4L NAFTA Base - 2.0L

Single Toe front wheels
Standard A) 170CV
-.08° +/-.07° (Standard 0 e

Single Toe front wheels 2.4L NAFTA - 2.4L JAPAN
Standard A)
2.4L NAFTA Base - 2.0L

Camber front wheels -.55° +/-.50° (Standard 0)
170CV
2.4L NAFTA Base - 2.0L 170

Camber front wheels -.58° +/-.50° (Standard A)
CV
Camber front wheels -.72° +/-.50° (Standard 0) 2.4L NAFTA - 2.4L JAPAN
Camber front wheels -.75° +/-.50° (Standard A) 2.4L NAFTA - 2.4L JAPAN

Caster front wheels 4.90° +/-.50° (Standard 0)
170CV

Caster front wheels 4.93° +/-.50° (Standard A)
170CV
Caster front wheels 4.75° +/-.50° (Standard 0) 2.4L NAFTA - 2.4L JAPAN
Caster front wheels 4.78° +/-.50° (Standard A) 2.4L NAFTA - 2.4L JAPAN
Rear Wheel Alignment - 4x2
Single Toe front wheels .15° +/-.07° (Standard 0) 1.4L - 2.4L - 1.6L
Single Toe front wheels .17° +/-.07° (Standard A) 1.4L - 2.4L - 1.6L
Camber front wheels -1.07° +/-.50° (Standard 0) 1.4L - 2.4L - 1.6L
Camber front wheels -1.17° +/-.50° (Standard A) 1.4L - 2.4L - 1.6L
Rear Wheel Alignment - 4x4
Single Toe front wheels .12+/-.07° (Standard 0) 1.4L EMEA - 2.0L EMEA
Single Toe front wheels .15° +/-.07° (Standard A) 1.4L EMEA - 2.0L EMEA
Single Toe front wheels .08° +/-.07° (Standard 0) 1.4L NAFTA- 2.4L NAFTA
Single Toe front wheels .10° +/-.07° (Standard A) 1.4L NAFTA- 2.4L NAFTA
Camber front wheels -1.18° +/-.50° (Standard 0) 1.4L EMEA - 2.0L EMEA
Camber front wheels -1.30° +/-.50° (Standard A) 1.4L EMEA - 2.0L EMEA
Camber front wheels -1.02 +/-.50° (Standard 0) 1.4L NAFTA- 2.4L NAFTA
Camber front wheels -1.13° +/-.50° (Standard A) 1.4L NAFTA- 2.4L NAFTA
Rear Wheel Alignment - TrailHawk

Single Toe front wheels .07° +/-.07° (Standard 0)
170CV

Single Toe front wheels .08° +/-.07° (Standard A)
170CV
.05° +/-.07° (Standard 0 e

Single Toe front wheels 2.4L NAFTA - 2.4L JAPAN
Standard A)

Camber front wheels -.95° +/-.50° (Standard 0)
170CV

Camber front wheels -1.05° +/-.50° (Standard A)
170CV
Camber front wheels -.92° +/-.50° (Standard 0) 2.4L NAFTA - 2.4L JAPAN
Camber front wheels -1.03° +/-.50° (Standard A) 2.4L NAFTA - 2.4L JAPAN
Jeep Renegade
Service Manual: REAR SUSPENSION
WARNING > WARNING
WARNING:
FCA US LLC does not manufacture any vehicles or replacement parts that contain asbestos.
packaging for product information. Whether the product contains asbestos or not, dust and
dirt can accumulate on brake parts during normal use. Follow practices prescribed by
appropriate regulations for the handling, processing and disposing of dust and debris.
CAUTION:
Only frame contact or wheel lift hoisting equipment can be used on this vehicle. It cannot be
hoisted using equipment designed to lift a vehicle by the rear axle. If this type of hoisting
equipment is used, damage to rear suspension components will occur.
NOTE:
If a rear suspension component becomes bent, damaged or fails, no attempt should be

made to straighten or repair it. Always replace it with a new component.
As on the front, there is an independent wheel MacPherson suspension layout at the back of the vehicle.
Fig 1: Rear Suspension Components
The rear suspension consists of the following main components:
1. Rear suspension support produced with optimized weight/rigidity ratio (the FWD version has
greater optimization of the ratio to achieve more efficient consumption).
2. Coil springs optimized along the thrust axis and able to contain side loads. The springs are
made of high-strength-steel in order to minimize the weight with consequent benefits in terms of
consumption.
3. Spring isolators between the springs and their base mountings in order to reduce noise.
4. Telescopic shock absorbers with high lateral rigidity which enhances ride quality.
5. Anti-roll bar connecting rod.
Loosen / tighten nut

1870815000 * Anti-torque drive shaft to the wheel
hub
COIL SPRINGS 4X2
11.32 ± 0.05
Wire diameter (mm)
11.50 ± 0.05 (*)
3.09
The number of coils
3.27 (*)
Number useful sense of

Right-handed
Helix winding
Height uncompressed 320

spring (mm) 335 (*)
Compressed spring 60
height (mm) 63 (*)
Load (daN) for 208 mm 247 ± 3%

resultant length 257 ± 3% (*)
Color Orange 2003 + Orange 2003

Color mark
Color scale White 9010 + Blue 5012 (*)
NOTE:
(*) For models with sun-roof
COIL SPRINGS 4X4
1.4 MultiAir Turbo 2.4 MultiAir 2.0 16V Multijet
11.80 ± 0.05 11.80 ± 0.05

Wire diameter (mm) 12.30 ± 0.05
12.05 ± 0.05 (*) 12.30 ± 0.05 (**)
3.30 3.30
The number of coils 4.02
3.57 (*) 4.02 (**)
Number useful sense of Helix

Right-handed
winding
Height uncompressed spring 340

340 370
(mm) 350 (**)
Compressed spring height 52 52
63
(mm) 56 (*) 63 (**)
Compress (load) to resulting 336 ± 3% 336 ± 3%

389 ± 3%
length 193 mm 359 ± 3% (*) 354 ± 3% (**)
2 color Silver 9007 2 color Silver 9007

Color White 9010 +
Color mark Color Brown 8011 + Color Pink 3015 +
Color Orange 2003
Color Orange 2003 (*) Color Orange 2003 (*)
NOTE:
(*) For models with sun-roof
NOTE:
(**) For Trailhawk models
SHOCKS
Type MacPherson
Overall Length 599 ± 3

(starting buffer) (mm) 624 ± 3 (*)
Compressed Length 408 ± 3

(flush) (mm) 421 ± 3 (*)
191
Stroke (mm)
203 (*)
Shaft Diameter (mm) 22
NOTE:

REAR SUSPENSION TORQUE SPECIFICATIONS

FASTENER*
Front Lower Control Arm to Crossmember

125 92 -
Bolt
Front Lower Control Arm to Knuckle Bolt 100 + 90° 74 + 90° -
52 + 63° +/-
Hub Nut 71 + 63° -
2°
Hub and Bearing to Knuckle Bolts 105 77 -
Rear Lower Control Arm to Crossmember

125 92 -
Bolt
Rear Lower Control Arm to Knuckle Bolt 100 + 90° 74 + 90° -
Rear Wheel Speed Sensor to Knuckle Bolt 7 - 62
Stabilizer Bar to Crossmember Bolts 25 18 -
Stabilizer Bar Link to Stabilizer Bar Nut 80 59 - X
Stabilizer Bar Link to Strut Nut 80 59 - X
Strut to Body Bolts 50 37 - X
Strut to Knuckle Bolts 100 + 90° 74 + 90° -
Strut Rod to Upper Mount Nut 70 52 -
Trailing Arm to Knuckle Bolt 100 + 90° 74 + 90° -
Trailing Arm to Body Bracket Bolt 100 + 90° 74 + 90° -
ARM, LOWER CONTROL > REMOVAL AND INSTALLATION > FRONT > REMOVAL
Fig 1: Lower Control Arm Bolts
3. Remove the front lower control arm to knuckle bolt (1).
4. Remove the front lower control arm to crossmember bolt (2), and remove the front lower
control arm.
ARM, LOWER CONTROL > REMOVAL AND INSTALLATION > FRONT >
INSTALLATION
Fig 1: Raising Rear Suspension
1. With a suitable jack raise the rear suspension to the proper specification. Refer to WHEEL
ALIGNMENT, SPECIFICATIONS .
Fig 2: Lower Control Arm Bolts
2. Position the front lower control arm into the vehicle and install the bolts.
3. Tighten the front lower control arm to crossmember bolt (1) to the proper specification. Refer to
SPECIFICATIONS .
4. Tighten the front lower control arm to knuckle bolt (2) to the proper specification. Refer to
SPECIFICATIONS .
7. Perform a wheel alignment. Refer to WHEEL ALIGNMENT, STANDARD PROCEDURE .
ARM, LOWER CONTROL > REMOVAL AND INSTALLATION > REAR > REMOVAL
Fig 1: Rear Lower Control Arm To Knuckle Bolt
3. Remove the rear lower control arm to knuckle bolt (1).

Fig 2: Rear Lower Control Arm To Crossmember Bolt
4. Remove the rear lower control arm to crossmember bolt (1), and remove the rear lower control
arm.
ARM, LOWER CONTROL > REMOVAL AND INSTALLATION > REAR > INSTALLATION
Fig 2: Rear Lower Control Arm To Crossmember Bolt
2. Position the rear lower control arm into the vehicle and install the bolts.
3. Tighten the rear lower control arm to crossmember bolt (1) to the proper specification. Refer to
SPECIFICATIONS .
Fig 3: Rear Lower Control Arm To Knuckle Bolt
4. Tighten the rear lower control arm to knuckle bolt (2) to the proper specification. Refer to
SPECIFICATIONS .
7. Perform a wheel alignment. Refer to WHEEL ALIGNMENT, STANDARD PROCEDURE .
HUB AND BEARING > DIAGNOSIS AND TESTING > DIAGNOSIS AND TESTING - HUB
BEARING - NOISE
NOTE:
The wheel bearing is designed to last for the life of the vehicle and requires no type of
periodic maintenance. If it becomes necessary to replace a faulty bearing, do not replace in
pairs unless the Service Information specifically states to do so.
Bearings will produce noise if worn or damaged. The noise will generally change when the bearings are
loaded. A road test of the vehicle is normally required to determine if there is a bearing noise, or if it is
some other component. To assist in finding the location, the following procedure, together with the
DIAGNOSTIC TABLE , should help determine if a bearing is causing the noise, and if so which one.
Keep in mind that bearing noises are not typically intermittent. If a particular vehicle road test maneuver
results in noise only part of the time, it is not likely a faulty bearing.
NOTE:
Damaged bearing seals and the resulting excessive grease loss may also require bearing
replacement. Moderate grease seepage from the bearing is considered normal and should
not require replacement of the wheel bearing. To diagnose the hub, measure hub runout.
DIAGNOSTIC PROCEDURE:
1. Perform a drive evaluation. Find a smooth level road surface void of traffic or obstructions.
Turn off any accessories which may cause background noise. Evaluate for noise at 50 km/h
(30 mph) and 100 km/h (60 mph) and with vehicle in neutral to eliminate potential drivetrain
noises. With vehicle at a constant speed, steer back and forth to left and right. This will load
and unload the bearings and may change the noise level. When bearing damage is slight, the
noise is sometimes noticeable at lower speeds and at other times is more noticeable at higher
speeds.
2. Drive evaluation results: Did the noise increase when turning right which may indicate a
problem with the left bearing? Did the noise increase when turning left which may indicate a
problem with the right bearing?
3. Put vehicle up on hoist. Grab the tire by pushing in on the top center and pulling out on the
bottom center to check for excessive movement in the bearing.
4. Check for potential rubbing on rotating components, such as rotor splash shields, heat shields
touching propshaft or halfshaft, wheel well liners contacting tire, wheel cover on wheel, etc.
Any cyclic noise (once per wheel revolution for example) is not a wheel bearing fault.
5. Remove the wheel and tire assembly, disc brake caliper and brake rotor. Refer to ROTOR,
BRAKE, REMOVAL AND INSTALLATION .
6. Rotate the wheel hub, checking for resistance or roughness.
7. Any roughness or resistance to rotation may indicate dirt intrusion or a failed hub bearing. If
the bearing exhibits any of these conditions, the hub & bearing will require replacement. Do not
attempt to disassemble the bearing for repair.
8. Rotate the wheel hub, utilize Chassis Ears (or stethoscope) to check for noise.
9. If none of the above checks indicate a bearing failure, refer to the DIAGNOSTIC TABLE for
other possible causes.
DIAGNOSTIC TABLE - HUB BEARING
CONDITION POSSIBLE CAUSES POTENTIAL CORRECTIONS
FRONT END WHINE ON TURNS 1. Low Power Steering Fluid 1. Fill power steering fluid
reservoir to proper level, check
Level (if applicable) for leaks (make sure all air is bled
from system fluid)
2. Worn Tires and/or Incorrect 2. Replace Tires, Check And

Wheel Alignment Reset Wheel Alignment
4. Wrong Power Steering Fluid 4. Replace With Correct Power

(if applicable) Steering Fluid
1. Loose Wheel Lug Nuts 1. Verify Wheel Lug Nut Torque
2. Engine Mount Grounding 2. Check For Engine Mount

Against Frame Or Body Of Hitting Frame Rail And
Vehicle Reposition Engine As Required
3. Worn Tires and/or Incorrect 3. Replace Tires, Check and

FRONT END GROWL OR Wheel Alignment Reset Wheel Alignment
GRINDING ON TURNS
6. Engine Not Centered,

Causing Axle Half Shaft to 6. Center the Engine
Bottom Out
1. Insufficient Hub Nut Torque 1. Torque Hub Nut to Spec
POPPING/CLICKING/SNAPPING 2. Separate Half Shaft From Hub

DURING ACCELERATION AFTER 2. Insufficient Grease on and Bearing and Wipe Mating
DRIVE-TO-REVERSE SHIFT, Mating Surface of Axle Half Surfaces Clean. Apply Light
REVERSE-TO-DRIVE SHIFT OR Shaft Outer C/V Joint to Wheel Coating of Wheel Bearing
WHILE TURNING Hub/Bearing, or Worn/Damaged Grease to C/V Joint Surface and
Gasket Reassemble, or Replace Gasket.
Torque Hub Nut to Spec
WHINE/HUM/ROAR WITH VEHICLE 1. Worn Tires and/or Incorrect 1. Replace Tires and Reset
GOING STRAIGHT AT A CONSTANT Wheel Alignment Wheel Alignment
SPEED 2. Defective Wheel Bearing 2. Replace Wheel Bearing
1. Engine Mount Grinding 1. Check and Reposition Engine

GROWL OR GRINDING WITH Against Frame or Body as Required
VEHICLE GOING STRAIGHT AT A
CONSTANT SPEED
HUB AND BEARING > REMOVAL AND INSTALLATION > 4X2 > REMOVAL - 4X2
3. Remove the rear brake rotor. Refer to ROTOR, BRAKE, REMOVAL AND INSTALLATION .
4. Remove the wheel speed sensor to knuckle bolt (1), and remove the wheel speed sensor
head.
5. Remove the hub and bearing to knuckle bolts (1a), and remove the closeout flange (1b).
Fig 3: Hub And Bearing Assembly
6. Remove the hub and bearing from the vehicle (1).
HUB AND BEARING > REMOVAL AND INSTALLATION > 4X2 > INSTALLATION - 4X2
Fig 1: Hub And Bearing, Closeout Flange & Bolts
1. Position the hub and bearing (1a) into the knuckle.
2. Install the closeout flange (1b) and the hub and bearing bolts (1c). Tighten the hub and bearing
to knuckle bolts to the proper specification. Refer to SPECIFICATIONS .
3. Install the wheel speed sensor head in to the knuckle. Install and tighten the wheel speed
sensor to knuckle nut to the proper specification. Refer to SPECIFICATIONS .
4. Install the rear brake rotor. Refer to ROTOR, BRAKE, REMOVAL AND INSTALLATION .
HUB AND BEARING > REMOVAL AND INSTALLATION > 4X4 > REMOVAL - 4X4
Fig 1: Unstaking Hub Nut
4. With the appropriate tool, unstake the hub nut (1).

5. Install the special tool 1870815000 (1a), and remove the hub nut (1b).
head.
7. Remove the hub and bearing to knuckle bolts (1).

Fig 5: Hub And Bearing Assembly
8. Remove the hub and bearing from the vehicle (1).
HUB AND BEARING > REMOVAL AND INSTALLATION > 4X4 > INSTALLATION - 4X4
Fig 1: Dust Cover
1. Make sure the dust cover (1) is mounted correctly to the CV joint.
2. Position the hub and bearing into the knuckle.
3. Install the hub and bearing bolts (1). Tighten the hub and bearing to knuckle bolts to the proper
4. Install the wheel speed sensor head in to the knuckle. Install and tighten the wheel speed
sensor to knuckle bolt (1) to the proper specification. Refer to SPECIFICATIONS .
5. Install the special tool 1870815000 (1a), and install the NEW hub nut (1b) to the proper
KNUCKLE, REAR > REMOVAL AND INSTALLATION > 4X2 > REMOVAL
3. Remove the hub and bearing assembly. Refer to HUB AND BEARING, REMOVAL AND
INSTALLATION .
Fig 1: Rear Lower Control Arm, Front Lower Control Arm & Trailing Link Bolts
4. Remove the trailing link to knuckle bolt (1).

Fig 2: Strut Bolts
7. Remove the strut to knuckle bolts (1), and remove the knuckle.
KNUCKLE, REAR > REMOVAL AND INSTALLATION > 4X2 > INSTALLATION
Fig 1: Both Lower Control Arms & Trailing Link Bolts
1. Position the knuckle to both lower control arms and the trailing link, install the bolts but DO NOT
TIGHTEN AT THIS TIME.
2. Place a jack under the knuckle.

3. Lift the knuckle assembly (1) up to specification. Refer to WHEEL ALIGNMENT,

SPECIFICATIONS .
SPECIFICATIONS .
SPECIFICATIONS .
6. Tighten the trailing link to knuckle bolt (3) to the proper specification. Refer to
SPECIFICATIONS .
Fig 4: Strut & Knuckle
7. Lower the jack until the knuckle and the strut (1) line up, and install the strut to knuckle bolts.
Fig 5: Strut Bolts
8. Tighten the strut to knuckle bolts (1) to the proper specification. Refer to SPECIFICATIONS .
9. Install the hub and bearing assembly. Refer to HUB AND BEARING, REMOVAL AND
INSTALLATION .
12. Perform an alignment. Refer to WHEEL ALIGNMENT, STANDARD PROCEDURE .
KNUCKLE, REAR > REMOVAL AND INSTALLATION > 4X4 > REMOVAL
4. Remove the rear hub nut. Refer to HUB AND BEARING, REMOVAL AND INSTALLATION .
head.
6. Remove the trailing link to knuckle bolt (1).

Fig 3: Strut Bolts
9. Remove the strut to knuckle bolts (1).

Fig 4: Knuckle Assembly
10. Remove the knuckle assembly (1) from the vehicle.
KNUCKLE, REAR > REMOVAL AND INSTALLATION > 4X4 > INSTALLATION
1. Position the knuckle to both lower control arms and the trailing link, install the bolts but DO NOT
2. Place a jack under the knuckle.

3. Lift the knuckle assembly (1) up to specification. Refer to WHEEL ALIGNMENT,

SPECIFICATIONS .
Fig 3: Rear Lower Control Arm, Front Lower Control Arm & Trailing Link Bolts In Position
SPECIFICATIONS .
SPECIFICATIONS .
SPECIFICATIONS .
Fig 4: Strut & Knuckle
7. Lower the jack until the knuckle and the strut (1) line up, and install the strut to knuckle bolts.
Fig 5: Strut Bolts
8. Tighten the strut to knuckle bolts (1) to the proper specification. Refer to SPECIFICATIONS .
9. Install the wheel speed senor into the knuckle, install and tighten the wheel speed sensor to
knuckle bolt to the proper specification. Refer to SPECIFICATIONS .
10. Install the rear hub nut. Refer to HUB AND BEARING, REMOVAL AND INSTALLATION .
14. Perform an alignment. Refer to WHEEL ALIGNMENT, STANDARD PROCEDURE .
LINK, TRAILING, REAR > REMOVAL AND INSTALLATION > REMOVAL AND
Fig 1: Trailing Link To Body Bracket Bolt
3. Remove the trailing link to body bracket bolt (1).

Fig 2: Trailing Link To Knuckle Bolt
4. Remove the trailing link to knuckle bolt (1), and remove the trailing link from the vehicle.
LINK, TRAILING, REAR > REMOVAL AND INSTALLATION > REMOVAL AND
Fig 1: Trailing Link To Body Bracket Bolt
1. Install the trailing link to the body bracket and install the trailing link to body bracket bolt. DO
NOT TIGHTEN AT THIS TIME.
Fig 2: Trailing Link To Knuckle Bolt
2. Install the trailing link to the knuckle and install the trailing link to knuckle bolt (1). DO NOT
Fig 4: Trailing Link To Body Bracket Bolt In Position
4. Tighten the trailing link to body bracket bolt (1) to the proper specification. Refer to
SPECIFICATIONS .
Fig 5: Trailing Link To Knuckle Bolt In Position
SPECIFICATIONS .
STABILIZER BAR, REAR SUSPENSION > REMOVAL AND INSTALLATION > REMOVAL
Fig 1: Sway Bar Link To Stabilizer Bar Nut
3. While holding the stem with the appropriate tool, remove the sway bar link to stabilizer bar nut
(1a).
NOTE:
Perform the same procedure on the opposite side.

Fig 2: Stabilizer Bar & Bracket Bolts
4. Remove the stabilizer bar bracket bolts (1a).
5. Remove the stabilizer bar (1b).
STABILIZER BAR, REAR SUSPENSION > REMOVAL AND INSTALLATION > REMOVAL
1. Position the rear stabilizer bar (1a) in the vehicle.

Fig 1: Stabilizer Bar & Bracket Bolts
2. Install the stabilizer bar bracket bolts (1b) and tighten the stabilizer bar bracket bolts to the
Fig 2: Sway Bar Link To Stabilizer Bar Nut
3. Install the stem into the stabilizer bar, and tighten the sway bar link to stabilizer bar nut (1b) to
NOTE:
Perform the same procedure on the opposite side.
STRUT, REAR > REMOVAL AND INSTALLATION > REMOVAL AND INSTALLATION >
REMOVAL
3. If necessary, remove the vapor canister. Refer to CANISTER, VAPOR, REMOVAL AND
INSTALLATION .
Fig 1: Wheel Speed Sensor Harness, Electric Park Brake Harness & Brake Hose Retainer Clip
4. Remove the brake hose retainer clip (1), and remove the brake hose from the strut.
5. Remove the wheel speed sensor harness (2) from the strut.
6. Remove the Electric Park Brake (EPB) harness (3) from the strut.
Fig 2: Strut Bolts & Sway Bar Link Nut
7. While properly holding the stem, remove the sway bar link to strut nut (1).
8. Remove the strut to knuckle bolts (2).

Fig 3: Upper Strut Bolts
9. Remove the upper strut to body bolts (1a). Remove the strut (1b) from the vehicle.
Fig 4: Strut Rod Mount Nut
10. Position the strut on the strut compressor.
11. Compress the strut, remove the strut rod to strut mount nut (1a).
Fig 5: Jounce Bumper & Boot
12. Remove the jounce bumper (1a) and boot (1b) from the strut.
Fig 6: Strut Rod & Spring Assembly
13. Remove the strut from the spring assembly (1).
14. If necessary, decompress the spring and remove the spring from the compressor.
STRUT, REAR > REMOVAL AND INSTALLATION > REMOVAL AND INSTALLATION >
INSTALLATION
1. If removed, install and compress the strut spring in the compressor.
2. Assemble the strut with the boot and jounce bumper.

Fig 1: Strut Rod Mount Nut
3. Install the upper strut mount (1a), and tighten the strut rod to strut mount nut (1b) to the proper
4. Remove the strut from the compressor.

Fig 2: Upper Strut Bolts
5. Position the strut into the vehicle (1a).
6. Install and tighten the strut to body bolts to the proper specification. Refer to
SPECIFICATIONS .
Fig 3: Strut Bolts & Sway Bar Link Nut
7. Install and tighten the strut to knuckle bolts (1) to the proper specification. Refer to
SPECIFICATIONS .
8. Install the stem into the strut, and tighten the sway bar link to strut nut (2) to the proper
9. Install the Electric Park Brake (EPB) harness to the strut.

10. Install the wheel speed sensor harness to the strut.
11. Install the brake hose to the strut and install the retainer clip.
12. If removed, install the vapor canister. Refer to CANISTER, VAPOR, REMOVAL AND
INSTALLATION .
15. Perform vehicle alignment. Refer to WHEEL ALIGNMENT, STANDARD PROCEDURE .

Service Manual: TIRES & WHEELS - SERVICE Jeep Renegade
INFORMATION
DIAGNOSIS AND TESTING > DIAGNOSIS AND TESTING - TIRE AND WHEEL
VIBRATION
Tire and wheel imbalance, runout and tire road force variation can cause vehicles to exhibit steering
wheel vibration and/or seat vibration.
VEHICLES WITH A VIBRATION OR SHAKE
The following procedure is to identify, prevent and correct tire flat spotting.
Description
Immediately following delivery, some vehicles may exhibit a vibration or shake due to temporary tire
flat-spotting. The vibration may be felt in the steering wheel or seat and will be most noticeable at
highway speeds 96 kph (60 mph). This could be misinterpreted as an out of balance tire. Flat Spotting
can occur if the vehicle has not been moved for a few days or for a longer period of time. In most cases
it is temporary condition. In extreme cases it can be permanent.
Tire pressure is often inflated to the maximum sidewall pressure at the vehicle assembly plant to prevent
"flat spots" on tires during new vehicle shipping and vehicle storage. Inflating tires to the maximum
sidewall tire pressure helps to preserve the integrity of the tire and reduces potential technical issues.
It is important to remove temporary flat spotting before performing tire balance, tire run-out or tire road
force checks. If the flat spotting is not removed it can result in incorrect measurements.
Flat Spotting Removal
NOTE:
If the vehicle has been sitting for an extended period of time it is recommended to drive the
vehicle to warm the tires. This process could eliminate flat spots that can cause vibration.
1. Drive the vehicle at highway speeds until the vibration (flat spotting) is eliminated.
NOTE:
In most cases, flat spot vibrations will be eliminated within 20 minutes (about 20
miles) of driving at highway speeds. If the vehicle has been stored without moving
for an extended time, it may be necessary to drive the vehicle longer at highway
speeds. If the vibration is not completely eliminated during the test drive, proceed to
Step 2.
2. Within 10 minutes after driving the vehicle, raise the vehicle so there is no load on the tires.
3. Check the tire and wheel assemblies for balance, run-out, and road force variation. Refer to
4. Only install new tires after the vehicle has been driven as directed and all appropriate wheel
and tire diagnostics have been completed.
VIBRATION > VISUAL INSPECTION
Visual inspection of the vehicle is recommended prior to road testing or performing any other procedure.
Raise and support the vehicle. Refer to HOISTING, STANDARD PROCEDURE .
Inspect for the following:
Verify correct (OEM) wheel and tire, as well as presence of wheel weights.
Inspect tires and wheels for damage, mud packing and unusual wear; correct as necessary.
Check and adjust tire air pressure to the pressure listed on the label attached to the driver's door
opening.
VIBRATION > ROAD TEST
NOTE:
If a Noise & Vibration Analyzer is available, use it to diagnosis the issue during the road test.
NOTE:
If the vehicle has been sitting for an extended period of time it is recommended to drive to
warm the tires. This process could eliminate flat spots that can cause vibration.
Road test vehicle on a smooth road at and near the designated speed where legal speed limits allow.
Lightly place hands on steering wheel at the 10:00 and 2:00 positions and observe for:
Steering wheel oscillation: clockwise/counterclockwise
Steering wheel high frequency movement: rapid vibration up and down
Seat high frequency movement: rapid vibration up and down
To rule out vibrations due to brakes or powertrain:
Lightly apply brakes at the designated speed; if vibration occurs or is enhanced, vibration is likely
due to a brake concern.
Shift transmission into neutral while vibration is occurring; if vibration is eliminated, vibration is
likely due to a powertrain (differential or driveline) concern.
VIBRATION > TIRE/WHEEL BALANCE AND ROAD FORCE VARIATION
NOTE:
If wheel balance equipment is capable of testing tire road force variation and the tire/wheel
assemblies are within specification, place the tires with the greater road force variation on
the rear of the vehicle.
Balance the tire and wheel assemblies as necessary, and if wheel balance equipment is capable, also
test for tire and wheel runout and road force variation following the wheel balancer manufacturer's
instructions and using the information listed in Tire And Wheel Balance. Refer to STANDARD
PROCEDURE . Repeat the road test above to verify the vibration is repaired.
STANDARD PROCEDURE > TIRE AND WHEEL BALANCE
BACK CONE MOUNTING

described go to;
Channel" box.
FLANGE PLATE MOUNTING

described go to;
Channel" box.
CHROME/PLASTIC CLAD WHEEL SERVICE

described go to;
Channel" box.
FORCE MATCHING

described go to;
Channel" box.
NOTE:
Always verify the wheel and tire balance before removing any wheel weights. If assembly is
within specification and weights are not corroded or loose, do not remove weights. The
process of removing and adding weight could damage wheel protective coating.
NOTE:
Balance and road force variation equipment must be calibrated and maintained per
equipment manufacturer's specifications.
NOTE:
If a tire sealant & inflator kit was used to temporarily repair small punctures then the tire must
be removed from wheel and all the sealant must be removed with a water damped cloth
before repairing & balancing the assembly.
NOTE:
Some wheels may not have an outer flange. Apply adhesive weights on midplane surface to
balance.
Fig 1: Balancing Wheels Using Cone/Collet
NOTE:
Use of the proper collet will prevent potential damage to the Chrome Clad wheels.
NOTE:
Balance equipment could read an incorrect balance result when measuring Chrome Clad
wheels. This is caused by the equipments mounting cone/collet contacting the cladding or
the cone/collet is not balanced. A dual-taper collet (1) type wheel centering tool is
recommended as opposed to a high-taper cone (2) type wheel centering tool. Always use
the manufacturer's recommended balance equipment.
Dual-taper collet type (1)
High-taper cone type (2)

Possible obstruction (3)
May not seat properly (4)
No obstruction (5)
Properly seated (6)
NOTE:
If wheel balance equipment is capable of testing tire road force variation and the tire/wheel
assemblies are within specification, place the tires with the greater road force variation on
the rear of the vehicle.
Fig 2: Dynamic Balancing
For dynamic balancing (recommended ), the balance equipment is designed to indicate the location
and amount of weight to be applied to both the inner and outer rim flanges (2).
Fig 3: Static Balancing
For static balancing (not recommended ), find the location of the heavy spot causing the imbalance
(1). Counter balance the wheel directly opposite the heavy spot. Determine weight required to
counterbalance the area of imbalance. Place half of this weight on the inner rim flange and the other
half on the outer rim flange (3) at the predetermined spots.
Aluminum wheels use a different type whe

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Jeep Renegade

Service Manual: VEHICLE DATA

Fig 1: Information Symbols

Courtesy of CHRYSLER GROUP, LLC

INTERNATIONAL INFORMATION SYMBOL IDENTIFICATION

SYMBOL DESCRIPTION SYMBOL DESCRIPTION

1 115-Volt Power Inverter 11 Side Airbag

2 USB Connector 12 Seat Belt

4 Fuel Fill Side 14 Supplemental Restraint System

6 Fuse 16 See Owner's Manual

See Appropriate Service

8 Warning 18 Emergency Release Handle

9 Child Seat Tether Anchor 19 Jack/Jack Tools Location

Lower Anchors and Tether for

Courtesy of CHRYSLER GROUP, LLC

INTERNATIONAL INDICATOR SYMBOL IDENTIFICATION

SYMBOL DESCRIPTION SYMBOL DESCRIPTION

1 Electronic Speed Control 30 Door Ajar

Brake System Warning Parking

5 Security Indicator 34 Four Wheel Drive

6 Turn Signals 35 Four Wheel Drive Low

7 Water In Fuel 36 Tow/Haul

8 Low Fuel 37 Service Four Wheel Drive

9 Side Airbag 38 Service Four Wheel Drive

10 Seat Belt Reminder 39 Cruise Indicator

Brake System Warning Parking

12 Passenger Airbag Off 41 Tire Pressure Monitor

Failure Of Anti-Lock Braking

HEV Brake Regenerative

15 Electronic Throttle Control 44 Rear Axle Lock

16 HEV Service Light 45 Park Asist Indicator

17 Engine Oil 46 Park Brake Indicator

Electronic Stability Control/Traction

19 Glow Plug/Intake Air Heated 48 Trailer Brake System Off

20 Power Steering Fluid 49 Diesel Exhaust Fluid

21 Engine Coolant Temperature 50 Coolant Level

22 Malfunction Indicator Light 51 Fuel Cap

24 Diesel Exhaust Brake 53 Icy Road Condition

25 High Beam 54 Electric Vehicle Plug In State

26 Front Fog Light 55 Vehicle Theft Alarm

27 Rear Fog Light 56 Stored Warnings

28 Cargo Lamp 57 Service ETC

29 Exterior Bulb Failure 58 Electric Vehicle System Service

Courtesy of CHRYSLER GROUP, LLC

INTERNATIONAL CONTROL SYMBOL IDENTIFICATION

SYMBOL DESCRIPTION SYMBOL DESCRIPTION SYMBOL DESCRIPTION

Rear Window Convertible Top

7 Adjustable Pedals 34 Low Beam 61 Power Rear Window

10 Windshield Washer 37 Cargo Lamp 64 SwayBar Disconnect

Windshield 115-Volt Power

Key Activate (Power

Windshield Wiper Four Wheel Drive

Master Lighting Four Wheel Drive

Four Wheel Drive

17 Upper Air Outlet 44 Park Lights 71 Front Axle Lock

Upper And Lower Instrument Panel

Defrost And Lower Diesel Exhaust

21 Heated Seat Low 48 Overdrive Off 75 Step

22 Heated Seat High 49 Hood Release 76 Reset

24 Recirculation 51 Door Ajar 78 Traction Control Off

Heated Steering Electronic Stability

Passenger Air Bag

VEHICLE INFORMATION > INTERNATIONAL VEHICLE CONTROL AND DISPLAY

Fig 1: International Symbols