Professional Documents
Culture Documents
2004
300M, CONCORDE
AND INTREPID
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Proper service and repair is important to the safe, reliable, operation of all motor vehi-
cles. The service procedures recommended and described in this publication were
developed for professional service personnel and are effective methods for perform-
ing vehicle repair. Following these procedures will help assure efficient economical
vehicle performance and service reliability. Some of these service procedures require
the use of special tools designed for specific procedures. These special tools should
be used when recommended throughout this publication.
Special attention should be exercised when working with spring or tension loaded fas-
teners and devices such as E-Clips, Circlips, Snap rings, etc., as careless removal may
cause personal injury. Always wear safety goggles whenever working on vehicles or vehi-
cle components.
It is important to note that this publication contains various Cautions and Warnings.
These should be carefully read in order to minimize the risk of personal injury, or the
possibility that improper service methods may damage the vehicle or render it unsafe.
It is important to note that these Cautions and Warnings cover only the situations and
procedures DaimlerChrysler Corporation has encountered and recommended.
DaimlerChrysler Corporation could not possibly know, evaluate, and advise the
service trade of all conceivable ways that service may be performed, or of the possi-
ble hazards of each. Consequently, DaimlerChrysler Corporation has not undertaken
any such broad service review. Accordingly, anyone who uses a service procedure, or
tool, that is not recommended in this publication must assure oneself thoroughly that
neither personal safety, nor vehicle safety, be jeopardized by the service methods they
select.
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The special service tools referred to herein are required for certain service oper-
ations. These special service tools or their equivalent, if not obtainable through a
local source, are available through the following outlet.
INTERNATIONAL
The special service tools referred to herein are required for certain service oper-
ations. These special service tools or their equivalent, if not obtainable through a
local source, are available through the following outlet.
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The information contained in this service manual has been prepared for the professional automotive tech-
nician involved in daily repair operations. Information describing the operation and use of standard and
optional equipment is included in the Owner’s Manual provided with the vehicle.
Information in this manual is divided into groups. These groups contain description, operation, diagnosis,
testing, adjustments, removal, installation, disassembly, and assembly procedures for the systems and compo-
nents. To assist in locating a group title page, use the Group Tab Locator on the following page. The solid bar
after the group title is aligned to a solid tab on the first page of each group. The first page of the group has
a contents section that lists major topics within the group. If you are not sure which Group contains the infor-
mation you need, look up the Component/System in the alphabetical index located in the rear of this manual.
A Service Manual Comment form is included at the rear of this manual. Use the form to provide
DaimlerChrysler Corporation with your comments and suggestions.
Tightening torques are provided as a specific value throughout this manual. This value represents the
midpoint of the acceptable engineering torque range for a given fastener application. These torque values are
intended for use in service assembly and installation procedures using the correct OEM fasteners. When
replacing fasteners, always use the same type (part number) fastener as removed.
DaimlerChrysler Corporation reserves the right to change testing procedures, specifications, diagnosis,
repair methods, or vehicle wiring at any time without prior notice or incurring obligation.
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Introduction
2 Suspension
3 Driveline
5 Brakes
7 Cooling
8A Audio/Video
8B Chime/Buzzer
8C Clock
8F Engine Systems
8G Heated Systems
8H Horn
8I Ignition Control
8J Instrument Cluster
8L Lamps
8M Message Systems
8N Power Systems
8O Restraints
8P Speed Control
8R Wipers/Washers
8W Wiring
9 Engine
11 Exhaust System
14 Fuel System
19 Steering
21 Transaxle
22 Tires/Wheels
23 Body
25 Emissions Control
INTRODUCTION
TABLE OF CONTENTS
page page
DIGIT 4
Open Space
DIGIT 5
Market Code
• C = Canada
Fig. 2 BODY CODE PLATE LOCATION • B = International
1 - BODY COPY PLATE • M = Mexico
2 - BATTERY TRAY
• U = United States
• EGJ = 3.5 L, Six Cylinder, 24 Valve, SOHC, DIGIT 6
High Output, Gasoline, Aluminum Block
Open Space
• EGC = 3.5 L, Six Cylinder, 24 Valve, SOHC,
Magnum, Gasoline, Aluminum Block DIGITS 7 THROUGH 23
DIGIT 23 Vehicle Identification Number
• (Refer to VEHICLE DATA/VEHICLE INFOR-
Open Space
MATION/VEHICLE IDENTIFICATION NUMBER -
DESCRIPTION) for proper breakdown of VIN code.
BODY CODE PLATE – LINE 2
DIGITS 1 THROUGH 12 IF TWO BODY CODE PLATES ARE REQUIRED
Vehicle Order Number The last code shown on either plate will be fol-
DIGITS 13, THROUGH 15 lowed by END. When two plates are required, the
Vinyl Roof Code last code space on the first plate will indicate (CTD)
When a second plate is required, the first four
DIGITS 16 AND 17 spaces of each line will not be used due to overlap of
Open space the plates.
DIGITS 18 AND 19
Vehicle Shell Line
• LH
FASTENER IDENTIFICATION
DIGITS 20 DESCRIPTION
Carline The SAE bolt strength grades range from grade 2
• C = Chrysler to grade 8. The higher the grade number, the greater
• D = Dodge the bolt strength. Identification is determined by the
• Y = Chrysler line marks on the top of each bolt head. The actual
DIGIT 21 bolt strength grade corresponds to the number of line
Price Class marks plus 2. The most commonly used metric bolt
• E = Economy strength classes are 9.8 and 10.9. The metric
• H = High Line strength class identification number is imprinted on
• L = Low Line the head of the bolt. The higher the class number,
• M = Mid Line the greater the bolt strength. Some metric nuts are
• P = Premium imprinted with a single-digit strength class on the
• S = Special/Sport nut face. Refer to the Fastener Identification and
• X = Performance Image Fastener Strength Charts (Fig. 3) and (Fig. 4).
TORQUE REFERENCES Chart for torque references not listed in the individual
torque charts (Fig. 7).
DESCRIPTION
Individual Torque Charts appear within many or the
Groups. Refer to the Standard Torque Specifications
VEHICLE IDENTIFICATION
NUMBER
DESCRIPTION
The Vehicle Identification Number (VIN) is located
on the upper left corner of the upper plenum, near
the left windshield pillar (Fig. 8). The VIN consists of
17 characters in a combination of letters and num-
bers that provide specific information about the vehi-
cle. Refer to VIN Code Breakdown table for decoding
information.
4 = High Line
5 = Premium
6 = Sport
7 = Special
Transmission Table For Bux B = 4 Speed Automatic
W/DGL, DGX
7 Body Style 6 = 4 Door Sedan
8 Engine G = 3.5L V6 Cyl 24 Valve SOHC (MPI)
K = 3.5L V6 Cyl 24 valve (MPI)
M = 3.5L V6 Cyl 24 valve SOHC
R = 2.7L V6 Cyl 24 Valve DOHC (MPI)
V = 3.5L V6 Cyl 24 Valve SOHC
9 Check Digit See explanation in this section.
10 Model Year 4 = 2004
11 Assembly Plant H = Bramalea Assembly
12 through 17 Sequence Number Six digit number assigned by assembly plant
VECI LABEL
DESCRIPTION
All models have a Vehicle Emission Control Infor-
mation (VECI) Label. Chrysler 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 specifica-
Fig. 9 VEHICLE SAFETY CERTIFICATION LABEL - tions and vacuum hose routings. All hoses must be
TYPICAL connected and routed according to the label.
MANUFACTURER PLATE
DESCRIPTION
The Manufacturer Plate (Fig. 11) is located in the
engine compartment on the passenger side rear cor-
ner of the hood. The plate contains five lines of infor-
mation:
1. Vehicle Identification Number (VIN)
2. Gross Vehicle Mass (GVM)
3. Gross Train Mass (GTM)
Fig. 11 MANUFACTURER PLATE
4. Gross Front Axle Rating (GFAR)
5. Gross Rear Axle Rating (GRAR)
page page
SAE VISCOSITY
An SAE viscosity grade is used to specify the vis-
cosity of engine oil. Use only engine oils with multi-
ple viscosities such as 5W-30 or 10W-30. These are
specified with a dual SAE viscosity grade which indi-
cates the cold-to-hot temperature viscosity range. Fig. 3 API SYMBOL
Select an engine oil that is best suited to your par- ENGINE OIL ADDITIVES/SUPPLEMENTS
ticular temperature range and variation (Fig. 2). The manufacturer does not recommend the addi-
tion of any engine oil additives/supplements to the
specified engine oil. Engine oil additives/supplements
should not be used to enhance engine oil perfor-
mance. Engine oil additives/supplements should not
be used to extend engine oil change intervals. No
additive is known to be safe for engine durability and
can degrade emission components. Additives can con-
tain undesirable materials that harm the long term
durability of engines by:
• Doubling the level of Phosphorus in the engine
oil. The ILSAC (International Lubricant Standard
Approval Committee) GF-2 and GF-3 standards
require that engine oil contain no more than 0.10%
Fig. 2 TEMPERATURE/ENGINE OIL VISCOSITY Phosphorus to protect the vehicles emissions perfor-
mance. Addition of engine oil additives/supplements
ENERGY CONSERVING OIL can poison, from the added sulfur and phosphorus,
An Energy Conserving type oil is recommended for catalysts and hinder efforts to guarantee emissions
gasoline engines. The designation of ENERGY CON- performance to 80,000 miles.
SERVING is located on the label of an engine oil con- • Altering the viscosity characteristics of the
tainer. engine oil so that it no longer meets the require-
ments of the specified viscosity grade.
CONTAINER IDENTIFICATION • Creating potential for an undesirable additive
Standard engine oil identification notations have compatibility interaction in the engine crankcase.
been adopted to aid in the proper selection of engine Generally it is not desirable to mix additive packages
oil. The identifying notations are located on the front from different suppliers in the crankcase; there have
label of engine oil plastic bottles and the top of been reports of low temperature engine failures
engine oil cans (Fig. 3). caused by additive package incompatibility with such
This symbol means that the oil has been certified mixtures.
by the American Petroleum Institute (API). Diamler-
Chrysler only recommend API Certified (GF-3) GEAR LUBRICANTS
engine oils that meet the requirements of Material SAE ratings also apply to multigrade gear lubri-
Standard MS-6395. Use Mopart or an equivalent oil cants. In addition, API classification defines the
meeting the specification MS-6395. lubricants usage. Such as API GL-5 and SAE 75W-
90.
SYNTHETIC ENGINE OILS
There are a number of engine oils being promoted LUBRICANTS AND GREASES
as either synthetic or semi-synthetic. If you chose to Lubricating grease is rated for quality and usage
use such a product, use only those oils that meet the by the NLGI. All approved products have the NLGI
American Petroleum Institute (API) and SAE viscos- symbol (Fig. 4) on the label. At the bottom NLGI
ity standard. Follow the service schedule that symbol is the usage and quality identification letters.
describes your driving type. Wheel bearing lubricant is identified by the letter
“G”. Chassis lubricant is identified by the latter “L”.
The letter following the usage letter indicates the
DESCRIPTION
The fluid check/fill point locations are located in CAUTION: Failure to perform the required mainte-
each applicable service manual section. nance items may result in damage to the vehicle.
* This maintenance is recommended by the manu- Inspection and service should also be performed
facture to the owner but is not required to maintain anytime a malfunction is observed or suspected.
the emissions warranty. Retain all receipts.
‡ This maintenance is not required if previously
replaced.
* This maintenance is recommended by the manu- months, whichever comes first and follow schedule
facture to the owner but is not required to maintain “B” of the (Maintenance Schedules( section of this
the emissions warranty. manual.
‡ This maintenance is not required if previously
replaced. NOTE: Most vehicles are operated under the condi-
Inspection and service should also be performed tions listed for Schedule (B(.
anytime a malfunction is observed or suspected.
Retain all receipts. Use the schedule that best describes your driving
conditions. Where time and mileage are listed, follow
WARNING: You can be badly injured working on or the interval that occurs first.
around a motor vehicle. Do only that service work
for which you have the knowledge and the right NOTE: Under no circumstances should oil change
equipment. If you have any doubt about your ability intervals exceed 6000 miles (10 000 km) or 6
to perform a service job, take your vehicle to a months whichever comes first.
competent mechanic.
CAUTION: Failure to perform the required mainte-
nance items may result in damage to the vehicle.
DESCRIPTION - EXPORT
There are two maintenance schedules that show
the required service for your vehicle. At Each Stop for Fuel
First is Schedule “A”. It is for vehicles that are not • Check the engine oil level about 5 minutes after a
operated under any of the conditions listed under fully warmed engine is shut off. Checking the oil level
Schedule “B”. while the vehicle is on level ground will improve the
Second is Schedule (B(. It is for vehicles that are accuracy of the oil level reading. Add oil only when the
operated under the conditions that are listed below level is at or below the ADD or MIN mark.
and at the beginning of the schedule. • Check the windshield washer solvent and add if
• Day or night temperatures are below 32° F (0° C). required.
• Stop and go driving.
• Extensive engine idling. Once a Month
• Driving in dusty conditions. • Check tire pressure and look for unusual wear
• Short trips of less than 10 miles (16 km). or damage.
• More than 50% of your driving is at sustained high • Inspect the battery and clean and tighten the
speeds during hot weather, above 90° F (32° C).L terminals as required.
• Trailer towing.L • Check the fluid levels of coolant bottle, brake
• Taxi, police, or delivery service (commercial ser- master cylinder and transmission, add as needed.
vice).L • Check all lights and all other electrical items for
• Off-road or desert operation. correct operation.
• If equipped for and operating with E-85 • Check rubber seals on each side of the radiator
(ethanol) fuel. for proper fit.
SCHEDULE “A”
* This maintenance is recommended by the manu- Inspection and service should also be performed
facture to the owner but is not required to maintain anytime a malfunction is observed or suspected.
the emissions warranty. Retain all receipts.
‡ This maintenance is not required if previously
replaced.
* This maintenance is recommended by the manu- WARNING: You can be badly injured working on or
facture to the owner but is not required to maintain around a motor vehicle. Do only that service work
the emissions warranty. for which you have the knowledge and the right
‡ This maintenance is not required if previously equipment. If you have any doubt about your ability
replaced. to perform a service job, take your vehicle to a
Inspection and service should also be performed competent mechanic.
anytime a malfunction is observed or suspected.
Retain all receipts.
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.
If the vehicle has a discharged battery, booster
cables may be used to obtain a start from another
vehicle. This type of start can be dangerous if done
improperly, so follow the procedure carefully.
NOTE:
The battery is stored in a compartment in front of
the tire in the right front fender and is accessible
through the engine compartment.
Fig. 9 TOWING
Use a flat bed towing device when wheel lift tow-
ing device is not available.
SUSPENSION
TABLE OF CONTENTS
page page
FRONT SUSPENSION
TABLE OF CONTENTS
page page
CAUTION SPECIFICATIONS
CAUTION: Only frame contact hoisting equipment FRONT SUSPENSION FASTENER TORQUE
can be used on this vehicle. All vehicles have a
fully independent rear suspension. The vehicles
cannot be hoisted using equipment designed to lift Ft. In.
DESCRIPTION N·m
a vehicle by the rear axle. If this type of hoisting Lbs. Lbs.
equipment is used, damage to rear suspension Ball Joint Pinch Bolt Nut 55 40 —
components will occur. Hub And Bearing Mounting
110 81 —
Bolts
CAUTION: If the vehicle is equipped with the Tire Hub And Bearing Axle Hub
142 105 —
Pressure Monitoring (TPM) System, the tire/wheel Nut
assembly needs to be reinstalled in the same loca- Lower Control Arm Pivot
142 105 —
tion it is removed from or the TPM System (sen- Bolt
sors) will need to be retrained. Mark each tire/wheel Stabilizer Bar Bushing
assembly indicating location, prior to its removal. If 61 45 —
Retainer Bolts
the tire/wheel assemblies are switched, rotated or
replaced, the TPM System needs to be retrained. Stabilizer Bar Link Lower
88 65 —
(Refer to 22 - TIRES/WHEELS/TIRE PRESSURE Nut
MONITORING/SENSOR - STANDARD PROCEDURE) Stabilizer Bar Link Upper
95 70 —
Nut
Strut Body Tower Mounting
CAUTION: At no time when servicing a vehicle, can 37 28 —
Nuts
a sheet metal screw, bolt or other metal fastener be
installed in the shock tower to take the place of an Strut Clevis-to-Knuckle Nuts 203 150 —
original plastic clip. Also, NO holes can be drilled Strut Shaft Nut 95 70 —
into the front shock tower in the area shown (Fig.
Tie Rod Adjuster Pinch Bolt 38 28 —
2), for the installation of any metal fasteners into
the shock tower. Because of the minimum clear- Tie Rod Steering Arm Nut 37 27 —
ance in this area, installation of metal fasteners Tension Strut Mounting Nut 130 95 —
could damage the coil spring coating and lead to a Wheel Mounting (Lug) Nuts 135 100 —
corrosion failure of the spring.
SPECIAL TOOLS
FRONT SUSPENSION
HUB / BEARING
DESCRIPTION
The front wheel bearing and front wheel hub of
this vehicle are a hub and bearing unit type assem-
bly. This unit combines the front wheel mounting
hub (flange) and the front wheel bearing into a
sealed one piece unit. The hub and bearing is
mounted to the center of the steering knuckle and is
retained by three mounting bolts accessible from the
Socket/Wrench Front Strut Nut 6864 rear of the steering knuckle. The hub flange has five
wheel mounting studs.
The wheel mounting studs used to mount the tire
and wheel to the vehicle are the only replaceable
components of the hub and bearing assembly. Other-
wise, the hub and bearing is serviced only as a com-
plete assembly.
OPERATION
The hub and bearing has internal bearings that
Puller C-3894A
allow the hub to rotate with the driveshaft and tire
and wheel. The five wheel mounting studs mount the
tire and wheel, and brake rotor to the vehicle.
KNUCKLE
DESCRIPTION - STEERING KNUCKLE
The steering knuckle is a single casting with legs
machined for attachment to the front strut assembly Fig. 11 Steering Knuckle
and lower control arm ball joint (Fig. 1). The steering 1 - STRUT ASSEMBLY
2 - STUB AXLE
knuckle also has machined abutments on the casting 3 - BRAKE CALIPER MOUNTING BOSSES
to support and align the front brake caliper. The 4 - HUB/BEARING ASSEMBLY
knuckle also holds the hub and bearing, and supports 5 - HUB/BEARING ATTACHING BOLTS
6 - LOWER CONTROL ARM
the driveshaft. The hub and bearing is positioned 7 - FRONT KNUCKLE ASSEMBLY
through the center of the knuckle. The driveshaft
Fig. 29 Lower Control Arm And Tension Strut Fig. 30 Lower Control Arm Pivot Bushing
1 - BALL JOINT STUD 1 - ARBOR PRESS RAM
2 - BALL JOINT SEAL 2 - SPECIAL TOOL 6644-2
3 - LOWER CONTROL ARM TENSION STRUT BUSHING 3 - SPECIAL TOOL MB990799
4 - NUT 4 - PIVOT BUSHING
5 - TENSION STRUT 5 - LOWER CONTROL ARM
6 - TENSION STRUT TO CRADLE ISOLATOR BUSHING
7 - LOWER CONTROL ARM
8 - LOWER CONTROL ARM PIVOT BUSHING
9 - WORD 9FRONT9 STAMPED IN CONTROL ARM HERE
DISASSEMBLY
DISASSEMBLY - LOWER CONTROL ARM
(PIVOT BUSHING)
(1) Remove lower control arm and tension strut as
an assembly from the vehicle.
(2) Separate the tension strut from the lower con-
trol arm assembly.
(3) Position lower control arm in arbor press with
large end of pivot bushing inside Receiver, Special
Tool MB-990799, as shown (Fig. 30). Position
Remover, Special Tool 6644-2, on top of pivot bushing
(Fig. 30). Fig. 31 Removing Lower Control Arm Tension Strut
(4) Using the arbor press, press the lower control Bushing
arm pivot bushing out of lower control arm. 1 - ARBOR PRESS RAM
2 - SPECIAL TOOL 6644-4
(5) Remove the pressed out lower control arm 3 - SPECIAL TOOL MB990799
pivot bushing from the Receiver and discard. 4 - TENSION STRUT BUSHING
5 - LOWER CONTROL ARM
DISASSEMBLY - LOWER CONTROL ARM
(4) Lower the arbor press ram, pressing Remover,
(TENSION STRUT BUSHING) Special Tool 6644-4, down through the tension strut
(1) Remove lower control arm and tension strut as bushing until the arbor press can push it no farther.
an assembly from the vehicle. See Lower Control This action will cut the bushing into two pieces.
Arm/Removal in this section. (5) Remove lower control arm from arbor press.
(2) Separate the tension strut from the lower con- Remove pieces of tension strut and Remover, Special
trol arm assembly. Tool 6644-4, from lower control arm.
(3) Position lower control arm in arbor press with
tension strut bushing inside Receiver, Special Tool
MB-990799, as shown (Fig. 31). Position Remover,
Special Tool 6644-4, on top of tension strut bushing
(Fig. 31).
ASSEMBLY
ASSEMBLY - LOWER CONTROL ARM (PIVOT
BUSHING)
(1) Position the lower control arm so it is sup-
ported by Receiver, Special Tool MB-990799, as
shown (Fig. 32).
(2) Place new pivot bushing in lower control arm
so it is square with the bushing hole. Position
Installer, Special Tool 6644-1, on top of pivot bushing,
with pivot bushing setting in recessed area of
Installer (Fig. 32).
OPERATION
Jounce and rebound movements affecting one
wheel are partially transmitted to the opposite wheel
of the vehicle through the stabilizer bar. This helps
to minimize the body roll of the vehicle during sus-
pension movement.
Fig. 36 Stabilizer
1 - STABILIZER BAR
2 - SLIT
3 - FRONT OF CAR Fig. 38 Stabilizer Bar Link At Strut
4 - SLIT 1 - NUT
5 - ISOLATOR BUSHINGS 2 - OUTER TIE ROD
6 - RETAINERS 3 - NUT
4 - STEERING ARM
REMOVAL - STABILIZER BAR (FRONT) 5 - STRUT ASSEMBLY
(1) Remove the 4 strut assembly upper mount to
(5) Remove the left stablizer bar link nut at the
strut tower mounting nut and washer assemblies
stabilizer bar (Fig. 39). Remove the link from the sta-
securing the right front strut in place (Fig. 37).
bilizer bar.
(2) Raise vehicle on jack stands or centered on a
(6) Loosen, but do not remove, the right outer tie
frame contact hoist. See Hoisting in Lubrication and
rod end to strut arm attaching nut. Release right
Maintenance.
outer tie rod end from right strut steering arm using
(3) Remove right front wheel and tire assembly
Puller, Special Tool C-3894A (Fig. 40), then remove
from the vehicle.
nut and tie rod from the steering arm.
Fig. 39 Stabilizer Bar At Left Link Fig. 41 Speed Sensor Cable Routing Bracket
1 - LINK 1 - STRUT ASSEMBLY
2 - STABILIZER BAR 2 - ROUTING BRACKET
3 - LOWER ARM 3 - SCREW
4 - NUT 4 - SPEED SENSOR CABLE
5 - KNUCKLE
(8) Remove the 2 strut assembly to steering
knuckle attaching bolts (Fig. 42).
STRUT
DESCRIPTION - STRUT ASSEMBLY (FRONT) Fig. 52 Strut Assembly Components
The front strut and suspension of the vehicle is 1 - SEAT AND BEARING
supported by coil springs positioned around the 2 - DUST SHIELD
3 - CUP
struts (Fig. 1). The springs are contained between an 4 - LOWER SPRING ISOLATOR
upper seat, located just below the upper strut mount 5 - STRUT
and a lower spring seat on the strut housing. A steer- 6 - JOUNCE BUMPER
7 - COIL SPRING
ing arm is permanently attached to each strut mak- 8 - UPPER SPRING ISOLATOR
ing it side specific. 9 - UPPER MOUNT
The top of each strut assembly is bolted to the
upper fender reinforcement (strut tower) through a OPERATION - STRUT ASSEMBLY (FRONT)
rubber isolated mount. The strut assembly cushions the ride of the vehicle,
The bottom of the strut assembly attaches to the controlling vibration, jounce and rebound of the sus-
top of the steering knuckle with two serrated pension.
through-bolts and prevailing torque nuts. The coil spring controls ride quality and maintains
Coil springs are rated separately for each corner or proper ride height.
side of the vehicle depending on optional equipment The spring isolators isolate the coil spring at the
and type of vehicle service. top and bottom from coming into metal-to-metal con-
The components of the strut assembly listed below tact with the upper mounting seat and the strut.
are serviceable if found to be defective (Fig. 52): The jounce bumper limits suspension travel and
• Strut shaft retainer nut metal-to-metal contact under full jounce condition.
• Upper mount The strut dampens jounce and rebound motions of
• Seat and bearing the coil spring and suspension.
• Dust shield
Fig. 55 Stabilizer Bar Link At Strut Fig. 57 Speed Sensor Cable Routing Bracket
1 - OUTER TIE ROD 1 - STRUT ASSEMBLY
2 - NUT 2 - ROUTING BRACKET
3 - STABILIZER BAR ATTACHING LINK 3 - SCREW
4 - STRUT ASSEMBLY 4 - SPEED SENSOR CABLE
5 - STEERING ARM
6 - NUT
(6) Remove the 2 guide pin bolts mounting the cal-
iper assembly to the steering knuckle (Fig. 58).
Fig. 64 Strut Assembly Components NOTE: If the coil spring has been removed from the
spring compressor, proceed with the next step, oth-
1 - SEAT AND BEARING
2 - DUST SHIELD erwise, proceed with step 5.
3 - CUP
4 - LOWER SPRING ISOLATOR (1) Place the coil spring in the compressor follow-
5 - STRUT
6 - JOUNCE BUMPER
ing the manufacturers instructions (Fig. 62). Before
7 - COIL SPRING compressing the spring, rotate the spring to the posi-
8 - UPPER SPRING ISOLATOR tion noted in the note between steps 7 and 8.
9 - UPPER MOUNT
(2) If disassembled, reinstall the upper spring iso-
lator and dust shield on seat and bearing. Match the
(10) Remove the lower spring isolator from the
step in the isolator with the step in the seat and
lower spring seat on the strut (Fig. 65).
bearing.
(11) Inspect the strut assembly components for the
(3) Install the seat and bearing (with dust shield
following and replace as necessary:
attached) on top of the coil spring. Position the step
• Inspect the strut for any condition of shaft bind-
ing over the full stroke of the shaft.
TENSION STRUT
DESCRIPTION
This vehicle uses a steel tension strut on each side
of the vehicle’s front suspension, between the lower
control arm and front suspension cradle/crossmember
(Fig. 1). The strut has rubber isolator bushings,
Fig. 68 Bushing Installed On Tension Strut
retainer washers and nuts at each end where it
mounts. 1 - TENSION STRUT TO CRADLE BUSHING
2 - RETAINING WASHER
3 - LOWER CONTROL ARM
OPERATION 4 - TENSION STRUT
5 - RETAINING WASHERS
The tension strut controls longitudinal (fore-and- 6 - TENSION STRUT TO LOWER CONTROL ARM BUSHING
aft) movement of each front wheel and the front sus- 7 - NUT
pension. Controlling the longitudinal movement helps
reduce harshness when the wheel hits sudden irreg-
ularities in the road surface.
The tension strut’s rubber isolator bushings isolate
suspension noise from the body of the vehicle.
REAR SUSPENSION
TABLE OF CONTENTS
page page
CAUTION: If the vehicle is equipped with the Tire CAUTION: If a rear suspension component
Pressure Monitoring (TPM) System, the tire/wheel becomes bent, damaged or fails, no attempt should
assembly needs to be reinstalled in the same loca- be made to straighten or repair it. Always replace
tion it is removed from or the TPM System (sen- with a new component.
sors) will need to be retrained. Mark each tire/wheel
assembly indicating location, prior to its removal. If
the tire/wheel assemblies are switched, rotated or
replaced, the TPM System needs to be retrained.
(Refer to 22 - TIRES/WHEELS/TIRE PRESSURE
MONITORING/SENSOR - STANDARD PROCEDURE)
LATERAL LINK
DESCRIPTION
Fig. 2 Storing Caliper There are two tubular lateral links on each side of
1 - FLEX HOSE
the rear suspension (Fig. 1). The lateral links have
2 - STRUT rubber isolator bushings at each end. They are
3 - WIRE HANGER attached to the rear suspension crossmember, and
4 - CALIPER ASSEMBLY
the spindle using a bolt and nut assembly at each
end. The rear lateral link incorporates a threaded
(5) Remove rear hub and bearing assembly cotter
wheel alignment toe adjustment sleeve.
pin and nut retainer (Fig. 3). Remove the hub and
bearing retaining nut and washer from the spindle
(Fig. 3). Remove hub and bearing assembly from
OPERATION
spindle. The lateral movement of the rear spindle is con-
trolled by the lateral links connecting the front and
rear centerline of the spindle to the rear suspension
crossmember. The threaded adjustment sleeve of the
rear link allows for setting rear wheel alignment toe
adjustment.
SPINDLE
DESCRIPTION
A forged rear spindle is mounted to each side of
the rear suspension (Fig. 1). The top attaches to the
rear strut assembly. Two lateral links leading from
the rear suspension crossmember are mounted to the
forward and rearward ends of the spindle centerline.
A trailing arm leading from the frame rail connects
to the bottom of the spindle.
OPERATION
The spindle moves up and down with the tire and
wheel under jounce and rebound conditions. The lat-
eral links control lateral movement of the spindle
while the trailing arm controls fore-and-aft move-
ment. Fig. 6 Storing Caliper
The spindle acts as a mount for the rear hub and
1 - FLEX HOSE
bearing, tire and wheel, and rear brakes. 2 - STRUT
3 - WIRE HANGER
DIAGNOSIS AND TESTING - SPINDLE 4 - CALIPER ASSEMBLY
The rear suspension spindle is not a repairable
(5) Remove rear hub and bearing assembly cotter
component of the rear suspension, If it is determined
pin and nut retainer (Fig. 7). Remove the hub and
that the spindle is broken or bent when servicing the
bearing retaining nut and washer from the spindle
vehicle, no attempt is to be made to repair or to
(Fig. 7). Then remove hub and bearing assembly from
straighten the spindle.THE SPINDLE MUST BE
spindle.
REPLACED IF FOUND TO BE DAMAGED IN
ANY WAY.
REMOVAL - SPINDLE
(1) Raise vehicle on jackstands or centered on a
frame contact type hoist. See Hoisting in Lubrication
and Maintenance.
(2) Remove the rear wheel and tire assembly from
the vehicle.
(3) Remove the rear caliper assembly from the
adapter. Refer to Brakes/Disc Brake Caliper. After
removing caliper assembly store caliper by hanging it
from frame of vehicle (Fig. 6). Do not let weight of
rear caliper assembly hang from flexible brake hose.
If vehicle is equipped with rear drum brakes, remove
the brake flex hose bracket from the support plate
and wheel cylinder.
(4) Remove rear braking disc from hub. Fig. 7 Hub And Bearing Retaining Nut and Washer
1 - HUB RETAINING NUT
2 - NUT RETAINER
3 - COTTER PIN
4 - SPINDLE
STABILIZER BAR
DESCRIPTION
The stabilizer bar interconnects both rear strut
assemblies and is attached to the rear frame rails of
the vehicle (Fig. 1).
Attachment of the stabilizer bar to the rear frame
rails of the vehicle is through 2 rubber-isolator bush-
ings and bushing retainers. Stabilizer bar to strut
assembly attachment is done utilizing a rubber-iso-
lated stabilizer bar attaching link. All parts of the
stabilizer bar are replaceable as individual compo- Fig. 15 Link Attachment To Stabilizer Bar
nents. 1 - STABILIZER BAR ATTACHING LINK
The stabilizer bar to frame rail bushings are slit 2 - LINK STUD
for easy removal and installation. The slit must be 3 - STABILIZER BAR
4 - WRENCHES
positioned toward the front of the vehicle when the 5 - BRAKE CALIPER
stabilizer bar is installed. 6 - STRUT ASSEMBLY
STRUT
DESCRIPTION - STRUT ASSEMBLY (REAR)
The rear strut assemblies support the weight of
the vehicle using coil springs positioned around the
struts (Fig. 1). The coil springs are contained
between the upper mount of the strut assembly and
a lower spring seat on the body of the strut assembly.
The top of each strut assembly is bolted to the top
of the inner fender through the rubber isolated upper
mount.
The bottom of the strut assembly attaches to the
spindle. Strut attachment to the spindle is accom-
plished using a split collar on the rear spindle. The
collar uses a pinch bolt to retain the spindle to the
Fig. 19 Strut Assembly
strut.
The rear coil springs are rated separately for each 1 - UPPER STRUT MOUNT
2 - UPPER SPRING ISOLATOR
corner or side of the vehicle depending on optional 3 - DUST BOOT
equipment and type of vehicle service. Coil springs 4 - LOWER SPRING ISOLATOR
come in a various rates; be sure the correct spring is 5 - STRUT ASSEMBLY
6 - COIL SPRING
in use.
The components of the strut assembly listed below (2) Inspect for torn or damaged strut assembly
are serviceable if found to be defective (Fig. 19). dust boots (Fig. 19).
• Strut shaft retainer nut (3) Inspect for damaged upper and lower spring
• Upper mount isolators (Fig. 19).
• Dust shield (4) Lift dust boot and inspect strut assembly for
• Jounce bumper evidence of fluid running from the upper end of fluid
• Coil spring reservoir. (Actual leakage will be a stream of fluid
• Upper spring isolator running down the side and dripping off lower end of
• Lower spring isolator unit). A slight amount of seepage between the strut
• Strut (damper) rod and strut shaft seal is not unusual and does not
affect performance of the strut assembly. Also inspect
OPERATION - STRUT ASSEMBLY (REAR) jounce bumpers inside dust boot for signs of damage
The rear strut assemblies support the weight of or deterioration.
the vehicle. They cushion the ride of the vehicle, con- (5) Verify correct struts and coil springs are
trolling vibration, jounce and rebound of the suspen- installed on vehicle.
sion. Coil springs are rated separately for each side of
The coil spring controls ride quality and maintains vehicle depending on optional equipment and type of
ride height. service.
The jounce bumper limits suspension travel and
metal-to-metal contact under full jounce. NOTE: If the coils springs require replacement, be
The strut dampens jounce and rebound motions of sure that the springs being replaced, are replaced
the coil spring and suspension. with springs meeting the correct load and spring
rate for the vehicle.
DIAGNOSIS AND TESTING - STRUT ASSEMBLY
(REAR) Replacement of the coil spring requires removal
and disassembly of the strut assembly. (Refer to 2 -
(1) Inspect for damaged or broken coil springs
SUSPENSION/REAR/STRUT - REMOVAL)
(Fig. 19).
(18) Lower vehicle enough to access rear passenger CAUTION: When installing the spring compressor’s
compartment. hooks on the coil spring, do not position the hooks
of the spring compressor on the sleeve of the coil
NOTE: When removing rear strut assembly from
spring. Positioning the spring compressor on the
vehicle, access to the 3 rear strut assembly-to-strut
sleeve could cause the sleeve to dislodge from the
tower attaching nuts is through the passenger com-
coil spring when it is compressed. This would
partment of the vehicle.
result in the required replacement of the coil spring.
(19) Mark the location of the 3 strut assembly-to-
(2) Position the strut assembly in the strut coil
rear strut tower attaching nuts (Fig. 27).
spring compressor following the manufacturers
(20) Remove the 3 strut assembly-to-rear strut
instructions. Position the strut assembly so the out-
tower attaching nuts (Fig. 27), then remove strut
board side of the strut is outward away from the
assembly from vehicle.
compressor. Grasp the upper and lower coils of the
spring with the upper and lower hooks of the com-
pressor. Place a clamp on the lower end of the coil
spring, so the strut is held in place once the strut
shaft nut is removed. Compress the coil spring until
all load is removed from the upper strut mount.
(3) Install Strut Shaft Socket, Special Tool 6864,
on the strut shaft nut. Use a deep well socket
inserted into the opening of tool 6864 to keep strut
shaft from turning. With the spring compressed,
remove the nut from the strut shaft.
(4) Remove the strut upper mount assembly, upper
spring isolator, dust shield, and jounce bumper. The
jounce bumper should come off with the dust shield.
The dust shield and upper spring isolator can be
removed from the upper mount if necessary.
(5) Remove the clamp and remove the strut out
Fig. 27 Strut Assembly Attaching Nuts from the bottom of the coil spring.
1 - FRONT OF CAR (6) Remove the lower spring isolator from the strut
2 - ATTACHING NUTS coil spring seat.
3 - MOUNTING STUDS
4 - STRUT ASSEMBLY (7) Inspect the strut assembly components for the
5 - SPEAKER OPENING following and replace as necessary:
TRAILING ARM/LINK
DESCRIPTION - TRAILING ARM
There is one trailing arm on each side of the vehi-
cle (Fig. 1). It spans from the spindle forward to the
frame rail and rear torque box. The trailing arm
Fig. 29 Spindle Attachment To Strut
attaches to the rear spindle through a bracket which
1 - STRUT ASSEMBLY
2 - SPINDLE
is bolted to the bottom of the spindle. The trailing
3 - PINCH BOLT arm attaches to the body using a bracket attached to
4 - LOCATING TAB the frame rail and rear torque box. The trailing arm
5 - NOTCH
has rubber isolator bushings at each end to isolate
suspension noise from the body of the vehicle.
(5) Install the lateral links on the spindle (Fig. 22).
Install, but DO NOT fully tighten lateral links to
spindle attaching bolt at this time.
OPERATION - TRAILING ARM
The purpose of the trailing arm is to control the
CAUTION: Tightening lateral link attaching bolt to fore-and-aft movement of the spindle.
spindle at this time will contort the bushing at curb
height and lead to bushing failure. This bolt is to be DIAGNOSIS AND TESTING - TRAILING ARM
tightened only when the vehicle is at curb riding Inspect the trailing arm and trailing arm bushings
height. for signs of deterioration and or damage. If the trail-
ing arm bushings are deteriorated or the trailing arm
(6) Install stabilizer bar link onto stabilizer bar is damaged in any way, replacement of the trailing
(Fig. 23). Install stabilizer link to stabilizer bar arm will be required.
WHEEL ALIGNMENT
TABLE OF CONTENTS
page page
CAMBER
Camber is the inward or outward tilt of the top of
the tire and wheel assembly (Fig. 1). Camber is mea- Fig. 1 Camber
sured in degrees of angle relative to a true vertical 1 - WHEELS TILTED OUT AT TOP
2 - WHEELS TILTED IN AT TOP
line. Camber is a tire wearing angle.
Fig. 2 Caster
Fig. 3 Toe
CROSS CASTER 1 - TOE-IN
Cross caster is the difference between left and 2 - TOE-OUT
right caster.
Front End Whine On Turns 1. Defective wheel bearing 1. Replace wheel bearing
2. Incorrect wheel alignment 2. Check and reset wheel alignment
3. Worn tires 3. Replace tires
Front End Clunk Or Snap 1. Loose lug nuts 1. Verify wheel lug nut torque
On Turns
2. Worn or broken C/V joint 2. Replace C/V joint
3. Worn or loose tie rod 3. Tighten or replace tie rod end
4. Worn or loose ball joint 4. Tighten or replace ball joint
5. Worn/loose control arm bushing 5. Replace control arm bushing
6. Loose stabilizer bar. 6. Tighten stabilizer bar to specified
torque
7. Loose strut mount to body 7. Tighten strut attachment to specified
attachment torque
8. Loose crossmember bolts 8. Tighten crossmember bolts to
specified torque
Front End Whine With 1. Defective wheel bearing 1. Replace wheel bearing
Vehicle Going Straight At A
Constant Speed
2. Incorrect wheel alignment 2. Check and reset wheel alignment
3. Worn tires 3. Replace tires
4. Worn or defective transaxle gears or 4. Replace transaxle gears or bearings
bearings
Front End Whine When 1. Worn or defective transaxle gears or 1. Replace transaxle gears or bearings
Accelerating Or bearings
Decelerating
Front End Clunk When 1. Worn or broken engine mount 1. Replace engine mount
Accelerating Or
Decelerating
2. Worn or defective transaxle gears or 2. Replace transaxle gears or bearings
bearings
3. Loose lug nuts 3. Verify wheel lug nut torque
4. Worn or broken C/V joint 4. Replace C/V joint
5. Worn or loose ball joint 5. Tighten or replace ball joint
6. Worn or loose control arm bushing 6. Replace control arm bushing
7. Loose crossmember bolts 7. Tighten crossmember bolts to
specified torque
8. Worn tie rod end 8. Replace tie rod end
Excessive Steering Free 1. Worn or loose tie rod ends 1. Replace or tighten tie rod ends
Play
2. Loose steering gear mounting bolts 2. Tighten steering gear bolts to specified
torque
3. Worn steering gear 3. Replace Steering Gear
4. Loose or worn steering shaft coupler 4. Replace steering shaft coupler
Excessive Steering Effort 1. Low tire pressure 1. Inflate all tires to recommended
pressure
2. Low power steering fluid level 2. Fill power steering fluid reservoir to
correct level
3. Loose power steering pump drive 3. Correctly adjust power steering pump
belt drive belt
4. Lack of lubricant in ball joints 4. Lubricate or replace ball joints
5. Steering gear malfunction 5. Replace steering gear
6. Lack of lubricant in steering coupler 6. Replace steering coupler
DIAGNOSIS AND TESTING - VEHICLE Proceed with the Caster Bias procedure before
attempting the Camber Bias procedure.
LEAD/PULL
To assure correct diagnosis, it is important to fol-
CASTER BIAS
low the steps outlined below in the order shown.
On a vehicle that leads left, create more caster on
Road test the vehicle before and after each step to
the left than on the right. On a right lead vehicle,
verify that the lead condition has been corrected.
the procedure is opposite. Try to get at least 0.8
When evaluating a vehicle, always drive the same
degree of cross caster, but do not exceed the maxi-
road in both directions to get a feel for the effect of
mum specification of 1.0 degree.
road crown and cross wind. A neutral vehicle will
(1) Loosen the four engine cradle to frame bolts.
exhibit a small amount of drift on both right and left
Rotate the cradle forward on the side that you need
crowned roads (normal crown sensitivity). A vehicle
to increase the caster.
with pronounced lead/pull may have one or more of
(2) Tighten the engine cradle to frame bolts to 163
the following conditions:
N·m (120 ft. lbs.).
(1) UNEQUAL TIRE PRESSURE. Adjust tire pres-
(3) Center the steering wheel and set toe (toe must
sure to the pressure stated on door placard. Make
be reset before doing another caster sweep to ensure
sure the tire pressure is equal on all four tires and
accuracy).
evaluate the car. Also verify that the tire size and
(4) Verify that the lead is corrected. If vehicle still
type are correct and match each other. If the car still
leads, continue with the Camber Bias procedure.
has a lead condition go to step (2).
(2) TIRE CONICITY. Excessive tire conicity is one
CAMBER BIAS
of the more frequent causes of vehicle lead. Cross-
On a vehicle that leads left, create either more
switch the front tires and evaluate the car. If the car
negative camber on the left or more positive camber
still leads in the same direction or gets worse, return
on the right. On a right lead vehicle, the procedure is
the front tires to their original position, then go to
opposite. To minimize uneven tire wear, try to
step (3).
achieve the same amount of camber bias on each
(3) SUSPENSION ALIGNMENT. Check and record
side. For example, if the car leads left, compensate
the wheel alignment settings including caster. Non-
by setting the front left camber to -0.3 degrees and
symmetrical front caster or camber can sometimes
front right camber to +0.3 degrees. Do not exceed
cause a lead condition or can be used to fix a lead
cross camber maximum specification of 0.7 degree, or
condition. To bias the front suspension caster and
individual camber specification of -0.6 to +0.6
camber alignment settings to correct or minimize a
degrees.
lead condition, perform the Vehicle Lead/Pull Align-
(1) Raise the front of the vehicle until the front
ment Bias repair procedure (Refer to 2 - SUSPEN-
suspension is not supporting the weight of the vehi-
SION/WHEEL ALIGNMENT - STANDARD
cle and tires are clearing the floor. Remove the pre-
PROCEDURE). If the car still leads after the align-
ferred wheel and tire assembly.
ment bias procedure, go to step (4) or (5) accordingly.
(2) Remove one of the strut clevis to knuckle bolts
(4) STEERING GEAR VALVE IMBALANCE.
and loosely assemble a reduced shank bolt and nut
Steering gear valve imbalance can sometimes cause a
(Available through the Mopart Parts system) in its
vehicle lead. Although there is no quick test or mea-
place. Loosen the other strut clevis to knuckle bolt to
surement that can be performed to verify a good or
provide for adjustment. In severe cases where a wide
bad steering gear valve, generally the steering efforts
range of adjustment is required, two reduced shank
will feel much lighter in the lead direction and
bolts should be used per knuckle. Repeat the proce-
heavier in the opposite direction with an unbalanced
dure to the other side strut clevis as necessary.
valve. Replace the steering gear only as a 9last
(3) Install the wheel and tire assembly. Lower the
resort9 to solve the problem. To replace the steering
vehicle until the full weight of the vehicle is resting
gear, (Refer to 19 - STEERING/GEAR - REMOVAL).
on the suspension.
(4) Adjust the front camber to the preferred set-
STANDARD PROCEDURE ting by physically pushing in or pulling out the top of
the wheel and tire assembly as required. When the
STANDARD PROCEDURE - VEHICLE camber is correct, tighten both strut clevis to knuckle
bolts to 203 N·m (150 ft. lbs.). Set front toe to speci-
LEAD/PULL ALIGNMENT BIAS fications.
This procedure is designed to be used in conjunc-
tion with Diagnosis And Testing - Vehicle Lead/Pull
(Refer to 2 - SUSPENSION/WHEEL ALIGNMENT -
DIAGNOSIS AND TESTING).
SPECIFICATIONS
WHEEL ALIGNMENT
NOTE: All specifications are given in degrees.
DRIVELINE
HALFSHAFT
TABLE OF CONTENTS
page page
HALFSHAFT OPERATION
Halfshaft assemblies are designed to transmit
DESCRIPTION power from the transaxle to the front wheels, while
The front halfshaft assemblies are flexible assem- allowing for powertrain and suspension flex.
blies consisting of an inner and outer flexible joint
connected by an solid shaft (Fig. 1) (Fig. 2). Trans- DIAGNOSIS AND TESTING - DRIVELINE
axle packaging and location requires the use of
unequal length halfshafts, with the left shaft being HALFSHAFT VISUAL INSPECTION
longer than the right. (1) Check for grease in the vicinity of the inboard
The inner joints are of a tripod design (Fig. 2), and tripod joint and outboard C/V joint; this is a sign of
allow for axial and angular movement to accommo- inner or outer joint seal boot or seal boot clamp dam-
date for shifting of powertrain and suspension com- age.
ponents. The inner joints incorporate a female spline (2) A light film of grease may appear on the inner
which install over the transaxle stub shafts. tripod joint seal boot; this is considered normal and
The outer joints are of a Rzeppa design (Fig. 2), should not require replacement of the seal boot. All
and only offer angular flexibility. The outer joints inner tripod joint seal boots are made of silicone rub-
incorporate a male spline, which connect to the wheel ber; which will allow the weeping (sweating) of the
hub/bearing. The outer joint is fastened to the hub to joint lubricant to pass through it while in operation.
ensure that there is no axial movement (end-play).
Both inner and outer joints utilize flexible “boots”
(Fig. 1) (Fig. 2) which maintain grease within the
joints, protect the joints from the environment/ele-
ments, and facilitate the axial and angular move-
ment of the joints. The inner joint boots are
constructed of silicone rubber. The outer boots are
made of Hytrel plastic.
REMOVAL
(1) Raise vehicle on jackstands or centered on a
frame contact type hoist.
(2) Remove the front wheel and tire assembly from
the vehicle.
(3) Remove the front caliper assembly from the
front steering knuckle assembly (Fig. 3).
Fig. 6 Hub And Bearing To Stub Axle Retaining Nut Fig. 8 Strut Assembly To Steering Knuckle
1 - HUB/BEARING ASSEMBLY Attaching Bolts
2 - NUT
1 - STRUT ASSEMBLY
2 - NUTS
3 - STRUT ASSEMBLY TO STEERING KNUCKLE ATTACHING
BOLTS
4 - STEERING KNUCKLE
SPECIFICATIONS
TORQUE
TORQUE SPECIFICATIONS
SPECIAL TOOLS
DRIVELINE
INSTALLATION
(1) Slide a new seal boot to interconnecting shaft
retaining clamp, onto the interconnecting shaft. Then
slide the replacement outer C/V joint assembly seal-
ing boot onto the interconnecting shaft.
(2) Install outer C/V joint assembly onto intercon-
necting shaft. Joint is installed on interconnecting
shaft, by pushing interconnecting shaft into outer
C/V joint, until retaining snap ring is seated in
groove on interconnecting shaft (Fig. 32). Verify the
snap ring is fully seated into groove on interconnect-
ing shaft.
Fig. 35 Sealing Boot Retaining Clamp Installed Fig. 37 Sealing Boot Retaining Clamp Installed
1 - SEALING BOOT 1 - BOOT CLAMP
2 - SPECIAL TOOL C-4975 2 - SPECIAL TOOL C-4975
3 - CLAMP BRIDGE 3 - SEALING BOOT
4 - OUTER C/V JOINT
(7) Clamp sealing boot onto outer C/V joint hous-
ing using Crimper, Special Tool C-4975 and the fol- (8) Install the driveshaft requiring boot replace-
lowing procedure. Place crimping tool C-4975 over ment back on the vehicle. (Refer to 3 - DIFFEREN-
bridge of clamp (Fig. 36). Tighten nut on crimping TIAL & DRIVELINE/HALF SHAFT -
tool C-4975 until jaws on tool are closed completely INSTALLATION)
together, face to face (Fig. 37).
BRAKES
TABLE OF CONTENTS
page page
TABLE OF CONTENTS
page page
BRAKES - BASE BRAKE lever pulls on cables that actuate parking brake
shoes at each rear wheel.
SYSTEM For more information on the operation of any indi-
vidual base brake component, refer to that compo-
DESCRIPTION - BASE BRAKES nent elsewhere in this section.
The base brake system consists of the following
components: WARNING
• Brake pedal
• Master cylinder WARNING: DUST AND DIRT ACCUMULATING ON
• Power brake booster BRAKE PARTS DURING NORMAL USE MAY CON-
• Brake tubes and hoses TAIN ASBESTOS FIBERS FROM PRODUCTION OR
• Proportioning valves (2) AFTERMARKET BRAKE LININGS. BREATHING
• Disc brakes (front and rear) EXCESSIVE CONCENTRATIONS OF ASBESTOS
• Brake lamp switch FIBERS CAN CAUSE SERIOUS BODILY HARM.
• Brake fluid level switch EXERCISE CARE WHEN SERVICING BRAKE
• Parking brake PARTS. DO NOT SAND OR GRIND BRAKE LINING
All brakes are power assist type through the use of UNLESS EQUIPMENT USED IS DESIGNED TO CON-
a vacuum operated power brake booster. TAIN THE DUST RESIDUE. DO NOT CLEAN BRAKE
The hydraulic brake system is diagonally split on PARTS WITH COMPRESSED AIR OR BY DRY
both the non-antilock and antilock braking systems. BRUSHING. CLEANING SHOULD BE DONE BY
This means the left front and right rear brakes are DAMPENING THE BRAKE COMPONENTS WITH A
on one hydraulic circuit from the master cylinder and FINE MIST OF WATER, THEN WIPING THE BRAKE
the right front and left rear are on the other. COMPONENTS CLEAN WITH A DAMPENED CLOTH.
Front disc brakes control the braking of the front DISPOSE OF CLOTH AND ALL RESIDUE CONTAIN-
wheels; rear braking is controlled by rear disc ING ASBESTOS FIBERS IN AN IMPERMEABLE
brakes. CONTAINER WITH THE APPROPRIATE LABEL. FOL-
Vehicles equipped with the optional antilock brake LOW PRACTICES PRESCRIBED BY THE OCCUPA-
system (ABS) (with and without traction control) use TIONAL SAFETY AND HEALTH ADMINISTRATION
a system designated Mark 20i. This system shares (OSHA) AND THE ENVIRONMENTAL PROTECTION
most base brake hardware used on vehicles without AGENCY (EPA) FOR THE HANDLING, PROCESSING,
ABS. All components differing from the base brake AND DISPOSING OF DUST OR DEBRIS THAT MAY
hardware are described in detail in the Antilock CONTAIN ASBESTOS FIBERS.
Brake System section.
The parking brake on this vehicle is pedal-oper-
ated. CAUTION
For more information on the description of any
individual base brake component, refer to that com- CAUTION: Use only MoparT brake fluid or an equiv-
ponent elsewhere in this section. For information on alent from a tightly sealed container. Brake fluid
the brake lamp switch, (Refer to 8 - ELECTRICAL/ must conform to DOT 3 specifications. Do not use
LAMPS/LIGHTING - EXTERIOR/BRAKE LAMP petroleum-based fluid because seal damage in the
SWITCH - DESCRIPTION) brake system will result.
OPERATION - BASE BRAKES CAUTION: Brake fluid will damage painted surfaces.
When a vehicle needs to be stopped, the driver If brake fluid is spilled on any painted surfaces,
applies the brake pedal. The brake pedal pushes the wash it off immediately with water.
input rod of the power brake booster into the booster.
The booster uses vacuum to ease pedal effort as force
is transferred through the booster to the master cyl- CAUTION: Never use gasoline, kerosene, alcohol,
inder. The booster’s output rod pushes in the master motor oil, transmission fluid, or any fluid containing
cylinder’s primary and secondary pistons applying mineral oil to clean system components. These flu-
hydraulic pressure through the chassis brake tubes, ids damage rubber cups and seals.
junction block, and proportioning valves to the
brakes at each tire and wheel assembly.
The pedal-operated parking brake operates in the CAUTION: During service procedures, grease or
following manner. When applied, the parking brake any other foreign material must be kept off the cal-
iper assembly, brake linings, brake rotor and exter-
nal surfaces of the hub.
SPECIAL TOOLS
BASE BRAKE SYSTEM
DESCRIPTION - REAR DISC BRAKES The adapter and disc shield are mounted to the
The rear disc brakes are similar to front disc rear suspension knuckles of vehicle. The adapter is
brakes, however, there are several distinctive fea- used to mount the brake shoes and actuating cables
tures that require different service procedures. This for the parking brake system. The adapter also
single piston, floating caliper rear disc brake assem- mounts the rear caliper assembly to the vehicle. The
bly includes (Fig. 8): adapter has two machined abutments which are used
• Disc brake caliper to position and align the caliper and brake shoes for
• Brake shoes (pads/linings) movement inboard and outboard.
• Brake rotor This vehicle uses a 14 inch solid non-vented rear
• Disc brake caliper adapter disc brake rotor (Fig. 8). It is a drum-in-hat style. It
This vehicle is equipped with a caliper assembly serves a dual purpose. The braking disc area of the
that has a 36 mm (1.42 in.) piston. rotor functions as a normal brake rotor for disc
The caliper assembly on all applications floats on brakes. The center section of the rotor has a built-in
rubber bushings using internal metal sleeves which brake drum that is used by the parking brakes. Refer
are attached to the adapter using threaded guide pin to Parking Brake for more information.
bolts (Fig. 8).
OPERATION
OPERATION - FRONT DISC BRAKES
Two machined abutments on the steering knuckle
(Fig. 6) position and align the caliper fore-and-aft.
The guide pin bolts, sleeves, and bushings control the
side-to-side movement of the caliper.
Although there are different disc brake systems
available, they operate and are serviced in the same
manner.
A square-cut rubber piston seal is located in a
machined groove in the cylinder bore. This provides a
hydraulic seal between the piston and the cylinder Fig. 9 Piston Seal Function for Automatic
wall (Fig. 9). The piston seal is designed to pull the Adjustment Of Front Brakes
piston back into the bore of the caliper when the 1 - PISTON
brake pedal is released. This, along with the brake 2 - CYLINDER BORE
3 - PISTON SEAL BRAKE PRESSURE OFF
shoe retractor clips, maintains the proper brake shoe 4 - CALIPER HOUSING
to rotor clearance. 5 - DUST BOOT
A molded rubber dust boot is installed in a groove 6 - PISTON SEAL BRAKE PRESSURE ON
in the cylinder bore and the piston, keeping contam-
ination from the cylinder wall and the piston (Fig. 9). OPERATION - REAR DISC BRAKES
The brake shoe lining material rides against the Rear disc brakes operate similarly to front disc
brake rotors braking surface. When the brakes are brakes. Refer to Front Disc Brakes for additional
applied, the shoes apply pressure against the rotor, information.
thus slowing the vehicle.
As brake shoe linings wear, master cylinder reser- DIAGNOSIS AND TESTING - BASE BRAKE
voir brake fluid level will go down. If brake fluid has SYSTEM
been added to the reservoir, overflow may occur if the
piston is pushed back into the recessed position. NOTE: There are three diagnosis charts following
An audible wear indicator (Fig. 5) is mounted on that cover the RED BRAKE WARNING LAMP,
the outboard pad of the front disc brake assemblies. BRAKE NOISE and OTHER BRAKE CONDITIONS.
Upon contact with the brake rotor, this indicator
emits a sound, signaling that brake shoes may need
inspection or replacement.
RED BRAKE WARNING 1. Parking brake lever not fully 1. Release parking brake lever.
LAMP ON released.
2. Parking brake warning lamp 2. Inspect and replace switch as necessary.
switch on parking brake lever.
3. Brake fluid level low in reservoir. 3. Fill reservoir. Check entire system for
leaks. Repair or replace as required.
4. Brake fluid level switch. 4. Disconnect switch wiring connector. If
lamp goes out, replace switch.
5. Mechanical instrument cluster 5. Refer to Chassis Diagnostic Procedures
(MIC) problem. manual.
BRAKES CHATTER 1. Disc brake rotor has excessive 1. Isolate condition as rear or front. Reface
thickness variation. or replace brake rotors as necessary.
BRAKES DRAG (FRONT OR 1. Contaminated brake fluid. 1. Check for swollen seals. Replace all
ALL) system components containing rubber.
2. Binding caliper pins or bushings. 2. Replace pins and bushings
3. Binding master cylinder. 3. Replace master cylinder.
4. Binding brake pedal. 4. Replace brake pedal.
BRAKES DRAG (REAR 1. Parking brake cables binding or froze 1. Check cable routing. Replace cables as
ONLY) up. necessary.
2. Parking brake cable return spring not 2. Replace cables as necessary.
returning shoes.
3. Obstruction inside the center console 3. Remove console and remove
preventing full return of the parking obstruction.
brake cables.
BRAKES GRAB 1. Contaminated brake shoe linings. 1. Inspect and clean, or replace shoes.
Repair source of contamination.
2. Improper power brake booster assist. 2. Refer to Power Brake Booster in the
diagnosis and testing section.
EXCESSIVE PEDAL TRAVEL 1. Power brake booster runout (vacuum 1. Check booster vacuum hose and
(PEDAL GOES TO FLOOR - assist). engine tune for adequate vacuum supply.
CAN’T SKID WHEELS) Refer to power brake booster in the
diagnosis and testing section.
EXCESSIVE PEDAL TRAVEL 1. One of the two hydraulic circuits to 1. Inspect system for leaks. Check master
(ONE FRONT WHEEL the front brakes is malfunctioning. cylinder for internal malfunction.
LOCKS UP DURING HARD
BRAKING)
PEDAL PULSATES/SURGES 1. Disc brake rotor has excessive 1. Isolate condition as rear or front. Reface
DURING BRAKING thickness variation. or replace brake rotors as necessary.
PREMATURE REAR WHEEL 1. Contaminated brake shoe linings. 1. Inspect and clean, or replace shoes.
LOCKUP Repair source of contamination.
2. Inoperative proportioning valve. 2. Test proportioning valves folowing
procedure listed in diagnosis and testing
section. Replace valves as necessary.
3. Improper power brake booster assist. 3. Refer to power brake booster in the
diagnosis and testing section.
STOP LAMPS STAY ON 1. Brake lamp switch out of adjustment. 1. Adjust brake lamp switch.
2. Brake pedal binding. 2. Inspect and replace as necessary.
3. Obstruction in pedal linkage. 3. Remove obstruction.
4. Power Brake Booster not allowing 4. Replace power brake booster.
pedal to return completely.
VEHICLE PULLS TO RIGHT 1. Frozen brake caliper piston. 1. Replace frozen piston or caliper. Bleed
OR LEFT ON BRAKING brakes.
2. Contaminated brake shoe lining. 2. Inspect and clean, or replace shoes.
Repair source of contamination.
3. Pinched brake lines. 3. Replace pinched line.
4. Leaking piston seal. 4. Replace piston seal or brake caliper.
5. Suspension problem. 5. Refer to the Suspension group.
PARKING BRAKE - 1. Rear parking brake shoes out of 1. Adjust rear parking brake shoes.
EXCESSIVE LEVER TRAVEL adjustment.
REMOVAL
REMOVAL - FRONT DISC BRAKE SHOES
(1) Raise vehicle. (Refer to LUBRICATION &
MAINTENANCE/HOISTING - STANDARD PROCE-
DURE)
(2) Remove front wheel and tire assemblies from
vehicle.
(3) Remove the two caliper guide pin bolts (Fig.
11).
INSTALLATION
INSTALLATION - FRONT DISC BRAKE SHOES
(1) Completely retract caliper piston back into pis-
ton bore of caliper assembly.
(2) Lubricate both steering knuckle abutments
with a liberal amount of Mopart Brake Grease For
Caliper Slides Lubricant, or equivalent.
Fig. 17 Installing Outboard Brake Shoe Assembly
(3) Remove the protective paper from the noise
suppression gasket on both the inner and outer brake 1 - BRAKE SHOE ASSEMBLY
2 - BRAKE CALIPER
shoe assemblies (if equipped).
sure the alignment tabs on the shims are positioned
NOTE: The inboard and outboard brake shoes are toward the abutments.
not common, refer to (Fig. 16) for inboard and out- (7) Carefully position caliper and brake shoes over
board brake shoe assembly identification. rotor by reversing the removal procedure (Fig. 12).
REMOVAL
REMOVAL - FRONT CALIPER
(1) Using a brake pedal holding tool, depress brake
pedal past its first 1 inch of travel and secure in this
position. This will isolate the master cylinder reser-
voir from the brake hydraulic system, not allowing
the brake fluid to drain out of the reservoir.
(2) Raise vehicle on jackstands or centered on a
hoist. See Hoisting in Lubrication and Maintenance.
(3) Remove front wheel and tire assembly from
vehicle.
(4) Remove the banjo bolt connecting the brake
flex hose to the caliper. There will be two washers
(one on each side of the flex hose fitting) that will
come off at the same time.
NOTE: Note the positioning of the two rail shims Fig. 25 Caliper Removal/Installation
between the knuckle’s machined abutments and the
1 - BRAKE SHOES
brake shoes. 2 - STEERING KNUCKLE
3 - BRAKING DISC
(5) Remove the two caliper guide pin bolts (Fig. 4 - CALIPER ASSEMBLY
5 - MACHINED ABUTMENT
24).
(6) Remove caliper assembly from steering
knuckle. Proceed by first rotating top of caliper away
from steering knuckle, then lifting caliper off bottom
machined abutment on steering knuckle (Fig. 25).
Take care not to lose the two rail shims.
INSPECTION - CALIPER
Inspect the disc brake caliper for the following:
Fig. 31 Honing Brake Caliper Piston Bore
• Brake fluid leaks in and around boot area and
1 - CALIPER
2 - CALIPER BORE
inboard lining
3 - SPECIAL TOOL C-4095 • Ruptures, brittleness or damage to the piston
dust boot
NOTE: During the honing procedure, coat the • Damaged, dry or brittle guide pin dust boots
stones and bore with brake fluid. After honing the If caliper fails inspection, disassemble and recondi-
bore, carefully clean the seal and boot grooves with tion caliper, replacing the seals and dust boots.
a stiff non-metallic rotary brush. Use extreme care
in cleaning the caliper after honing. Remove all dirt
and grit by flushing the caliper bore with fresh
clean brake fluid; wipe it dry with a clean, lint free
cloth and then clean it a second time.
(5) Position the dust boot into the counterbore of (5) Carefully position caliper and brake shoes over
the caliper assembly piston bore. rotor by reversing removal procedure (Fig. 25).
(6) Using a hammer and Installer, Special Tool
C-4689 or C-4842 (depending on piston size), and CAUTION: When being installed, extreme caution
Handle, Special Tool C-4171, drive the boot into the should be taken not to crossthread the caliper
counterbore of the caliper as necessary (Fig. 39). guide pin bolts.
(7) Reinstall the caliper on the vehicle and bleed
the brakes as necessary. Refer to Installation in this (6) Install the caliper guide pin bolts. Tighten
section. guide pin bolts to a torque of 22 N·m (192 in. lbs.).
(7) Install the banjo bolt connecting the flex hose
to the caliper. One washer should be installed on
INSTALLATION each side of the flex hose fitting before installing the
banjo bolt. Tighten banjo bolt to a torque of 48 N·m
INSTALLATION - FRONT CALIPER (35 ft. lbs.).
(8) Install the wheel and tire assembly.
CAUTION: Use care when installing the caliper (9) Tighten the wheel mounting stud nuts in
assembly on the steering knuckle, so seals on cal- proper sequence until all nuts are torqued to half
iper guide pin bushings do not get damaged by the specification. Then repeat the tightening sequence to
steering knuckle bosses. the full specified torque of 135 N·m (100 ft. lbs.).
(10) Lower vehicle.
(1) Completely retract the caliper piston back into
the piston bore of the caliper. CAUTION: After performing any service to the vehi-
(2) If removed, install brake rotor on hub (Fig. 26). cle brake system, be sure to obtain a firm brake
(3) Lubricate both machined knuckle abutments pedal before moving vehicle.
with a liberal amount of Mopart Brake Grease For
Caliper Slides Lubricant, or equivalent. (11) Remove the brake pedal holding tool.
(4) Install one rail shim on each machined abut- (12) Bleed the base brakes. (Refer to 5 - BRAKES -
ment where it will contact the brake shoes. Make BASE - STANDARD PROCEDURE)
sure the alignment tabs on the shims are positioned
toward the abutments.
DISASSEMBLY
DISASSEMBLY - CALIPER GUIDE PIN
BUSHINGS
Before disassembling the brake caliper, clean and
inspect it. Refer to CLEANING or INSPECTION in
this section.
(1) With one hand, push the guide pin bushing
sleeve towards the back of the caliper, and at the
same time, pull the sleeve out the back of the caliper
and bushing (Fig. 44).
(2) Insert the folded bushing into the caliper Fig. 51 Bushing Correctly Installed In Caliper
mounting boss using your fingers (Fig. 50). 1 - BUSHING
2 - CALIPER
3 - BE SURE BOTH BUSHING FLANGES ARE FULLY SEATED
AROUND CALIPER BUSHING BORES.
(5) Position the dust boot into the counterbore of (4) Carefully lower caliper and brake shoes over
the caliper assembly piston bore. rotor and onto the adapter using the reverse proce-
(6) Using a hammer and Installer, Special Tool dure for removal (Fig. 41).
C-4689 or C-4842 (depending on piston size), and
Handle, Special Tool C-4171, drive the boot into the CAUTION: When installing guide pin bolts extreme
counterbore of the caliper as necessary (Fig. 56). caution should be taken not to crossthread the cal-
(7) Reinstall the caliper on the vehicle and bleed iper guide pin bolts.
the brakes as necessary. Refer to Installation in this
section. (5) Install the caliper guide pin bolts. Tighten the
guide pin bolts to a torque of 22 N·m (192 in. lbs.).
INSTALLATION- REAR CALIPER (6) Install the wheel and tire assembly.
(7) Tighten the wheel mounting stud nuts in
NOTE: Step 1 below is only required when installing proper sequence until all nuts are torqued to half
the disc brake caliper after new brake shoes have specification. Then repeat the tightening sequence to
been installed. the full specified torque of 135 N·m (100 ft. lbs.).
(8) Remove jackstands or lower hoist.
(1) Completely retract caliper piston back into pis-
ton bore of caliper assembly. CAUTION: Before moving vehicle, pump the brake
(2) Lubricate both adapter abutments with a lib- pedal several times to insure the vehicle has a firm
eral amount of Mopart Multipurpose Lubricant, or brake pedal to adequately stop vehicle.
equivalent.
(3) Install the rear rotor on the hub, making sure (9) Road test the vehicle and make several stops to
it is squarely seated on the face of the hub (Fig. 43). wear off any foreign material on the brakes and to
seat the brake shoe linings.
CAUTION: Use care when installing the caliper
assembly onto the adapter, so the caliper guide pin
bushings do not get damaged by the mounting
bosses.
FLUID
DIAGNOSIS AND TESTING - BRAKE FLUID
CONTAMINATION
Indications of fluid contamination are swollen or
deteriorated rubber parts.
Swollen rubber parts indicate 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 fluid sepa-
rates into layers, there is mineral oil or other fluid
contamination of the brake fluid.
If brake fluid is contaminated, drain and thor-
oughly flush system. Replace master cylinder, propor-
tioning valve, caliper seals, wheel cylinder seals,
Antilock Brakes hydraulic unit and all hydraulic
fluid hoses. Fig. 57 Master Cylinder Fluid Level
1 - BOOSTER
2 - MASTER CYLINDER
STANDARD PROCEDURE - BRAKE FLUID 3 - MASTER CYLINDER FLUID RESERVOIR
LEVEL CHECK 4 - FLUID LEVEL FULL MARK
5 - FLUID LEVEL SWITCH
Check master cylinder reservoir brake fluid level a
minimum of twice a year. only Mopart brake fluid or an equivalent from a
Master cylinder fluid reservoirs for both standard tightly sealed container.
and antilock brake systems are marked with a FULL
fill line indicating the reservoirs proper fluid level CAUTION: Never use reclaimed brake fluid or fluid
(Fig. 57). from a container which has been left open. An open
container will absorb moisture from the air and con-
NOTE: When filling brake fluid reservoir, use only taminate the fluid.
MoparT brake fluid or an equivalent stored in a
tightly sealed container. Brake fluid must conform
to DOT 3 specifications. Do not use brake fluid with CAUTION: Never use any type of petroleum-based
a lower boiling point than DOT 3, as brake failure fluid in the brake hydraulic system. Use of such
could result during prolonged hard braking. Do not type fluids will result in seal damage of the vehicle
use petroleum-based fluid because seal damage in brake hydraulic system causing a failure of the
the brake system will result. vehicle brake system. Petroleum based fluids
include items such as engine oil, transmission fluid,
If necessary, add brake fluid to reservoir, bringing power steering fluid, etc.
brake fluid level to the FULL fill line shown on fluid
reservoir (Fig. 57).
The master cylinder brake fluid reservoir used on
this vehicle includes a brake fluid level switch. The BRAKE JUNCTION BLOCK
brake fluid level sensor location is in the body of the
brake fluid reservoir (Fig. 57). In the event of low DESCRIPTION
brake fluid level in the brake fluid reservoir, the A junction block is used on vehicles that are not
RED brake warning indicator lamp in the instrument equipped with antilock brakes (ABS). The junction
cluster will turn on. block is located in front of the driver’s side front tire
behind the front fascia (Fig. 63). The junction block
mounts in the same location as the ABS integrated
SPECIFICATIONS control unit (ICU) does on vehicles with ABS.
It has six threaded ports to which the brake tubes
BRAKE FLUID connect. Two are for the brake tubes coming from the
The brake fluid used in this vehicle must conform master cylinder. The remaining four ports are for the
to DOT 3 specifications and SAE J1703 standards. brake tubes going to each brake assembly. The valve
No other type of brake fluid is recommended or is permanently mounted to a bracket which fastens
approved for usage in the vehicle brake system. Use to the engine cradle crossmember.
OPERATION
The junction block distributes the brake fluid com-
ing from the master cylinder primary and secondary
ports to the four brake tubes leading to the brakes.
Since the junction block mounts in the same location
as the ABS integrated control unit (ICU), it allows
for the common use of brake tubes on the vehicle
whether it is equipped with or without ABS.
Later applications of the junction block include two
proportioning valves. Placed in the fluid flow pas-
sages leading to the rear brake tube ports, they bal-
ance front-to-rear braking. (Refer to 5 - BRAKES -
BASE/HYDRAULIC/MECHANICAL/PROPORTION-
ING VALVE - OPERATION)
Fig. 60 Servo And Filler Tube Fasteners
REMOVAL 1 - SPEED CONTROL SERVO
(1) Disconnect and isolate the negative battery 2 - WINDSHIED WASHER FILLER TUBE
connection at the right front strut tower. 3 - SCREW
(2) Using a brake pedal holding tool such as shown 4 - SCREW
(Fig. 59), depress brake pedal past its first 1 inch of
travel and secure in this position. This will isolate
the master cylinder reservoir from the brake hydrau-
lic system, not allowing the brake fluid to drain out
of the reservoir.
NOTE: Make sure open ends of bleeder tubes stay (4) Slide master cylinder straight out from the
below surface of brake fluid once reservoir is filled booster.
to proper level to avoid ingesting air while bleeding.
DISASSEMBLY
(1) Remove the master cylinder from the power
brake booster. (Refer to 5 - BRAKES/HYDRAULIC/
MECHANICAL/MASTER CYLINDER - REMOVAL)
(2) Using an appropriate cleaner such as Mopart
Brake Parts Cleaner, clean the master cylinder hous-
ing and brake fluid reservoir.
(3) Remove the filler cap and empty all brake fluid
from reservoir.
(4) Clamp the master cylinder in vise.
(5) Remove the 2 fluid reservoir to master cylinder
retaining pins (Fig. 67).
PEDAL
DESCRIPTION
A suspended type brake pedal is used on this vehi-
cle (Fig. 70). The pedal pivots on a shaft mounted in
the pedal support bracket under the instrument
panel. The pedal also connects to the power brake Fig. 70 Brake Pedal
booster input rod. The pedal ratio is 3.44:1. 1 - BUSHINGS
2 - BRAKE PEDAL
3 - BRAKE LAMP SWITCH
OPERATION 4 - PIVOT SHAFT
When the brake pedal is depressed, it pushes in on
the power brake booster input rod applying the
brakes. At the same time, it allows the brake lamp
switch’s plunger to extend, thus applying the brake
lamps.
REMOVAL
(1) Disconnect and isolate the remote ground bat-
tery cable from the ground stud on the right strut
tower.
(2) Remove the brake lamp switch from its bracket
(Fig. 70). The brake lamp switch is removed by
depressing and holding the brake pedal while rotat-
ing brake lamp switch in a counterclockwise direction
approximately 30 degrees. Pull the switch rearward
and remove it from its mounting bracket.
(3) Remove the retaining clip from the brake pedal
pin securing the power brake booster to the pedal Fig. 71 Brake Pedal Retaining Clip
using following procedure (Fig. 71). Position a small 1 - BRAKE PEDAL
screwdriver between the center tang on the retaining 2 - INPUT ROD
clip and the brake pedal pin. Rotate blade of screw- 3 - SCREWDRIVER
4 - RETAINING CLIP
driver enough so center tang on retaining clip can 5 - BRAKE PEDAL PIN
pass over end of brake pedal pin, then pull retaining
clip off brake pedal pin. INSTALLATION
(4) Remove the booster input rod from the brake (1) Make sure the pedal has a properly installed
pedal pin. bushing on each side of the pedal (Fig. 70).
(5) Remove the nut from the brake pedal pivot (2) Lubricate the brake pedal pivot shaft and
shaft (Fig. 70). The pivot shaft has a flat on it to hold brake pedal bushings using Mopar Lubriplate or an
while the nut is removed. equivalent.
(6) Remove the brake pedal pivot shaft from the (3) Install the brake pedal in the pedal bracket
brake pedal and pedal mounting bracket. (Fig. 70). Align the hole in brake pedal with the pivot
(7) Remove the brake pedal with bushings from shaft holes in the pedal bracket.
mounting bracket (Fig. 70). (4) Install the brake pedal shaft (Fig. 70).
NOTE: The bushings can be easily removed from
the pedal by pulling them straight out each side.
(2) Remove caps from both wiper arms at the Fig. 77 Reinforcement Attachment To Vehicle
attachment to the pivots to expose the wiper arm 1 - RIGHT STRUT TOWER
attaching nut. Remove the nut attaching each wiper 2 - WIPER MODULE
3 - LEFT STRUT TOWER
arm to its pivot (Fig. 75). 4 - ATTACHING BOLTS
(3) Remove the wiper arms from the pivots. Wiper 5 - ATTACHING BOLT
arms are removed from the pivots by rocking them 6 - REINFORCEMENT
7 - ATTACHING BOLTS
back and force on the pivots until they can be pulled
off the pivots.
(9) Disconnect vacuum hose from power brake NOTE: Before installing master cylinder, reposition
booster check valve. DO NOT REMOVE CHECK under hood wiring harness above master cylinder
VALVE FROM POWER BRAKE BOOSTER. mounting studs, in front of booster (Fig. 79).
(10) From under instrument panel, position a
(5) Carefully position master cylinder on booster.
small screwdriver between the center tang on the
Position wire harness routing bracket onto right mas-
power brake booster input rod to brake pedal pin
ter cylinder mounting stud.
retaining clip.
OPERATION
Proportioning valves balance front to rear braking
by controlling (at a given ratio) brake hydraulic pres-
sure to the rear brakes above a preset level (split
point). On light pedal applications equal brake pres-
sure is transmitted to both the front and rear brakes.
On heavier pedal applications, through the use of
proportioning valves, the pressure transmitted to the
rear will be lower than the front brakes. This pre-
vents premature rear wheel skid.
If hydraulic pressure is lost in one-half of the diag-
onally split brake hydraulic system, the operation of
the proportioning valve in the remaining half is not Fig. 81 Servo And Filler Tube Fasteners
affected.
1 - SPEED CONTROL SERVO
2 - WINDSHIED WASHER FILLER TUBE
3 - SCREW
4 - SCREW
Sales Code Brake System Type Split Point Slope Identification Inlet Pressure Outlet Pressure
All All Disc/Disc 400 psi 0.34 Bar Code Label 1000 psi 525-625 psi
ROTOR RUNOUT
On-vehicle rotor runout is the combination of the
individual runout of the hub face and the runout of
the rotor. (The hub and rotor runouts are separable).
To measure rotor runout on the vehicle, first remove
the tire and wheel assembly. Reinstall the wheel
mounting nuts on the studs, tightening the rotor to
the hub. Mount the Dial Indicator, Special Tool
C-3339, with Mounting Adaptor, Special Tool SP-
1910 on steering arm. The dial indicator plunger
should contact braking surface of rotor approximately
25 mm (one inch) from outer edge of rotor (Fig. 86).
Check lateral runout on both sides of the rotor, Fig. 87 Marking Rotor and Wheel Stud
marking the low and high spots on both. Runout lim- 1 - CHALK MARK
its can be found in the table at the end of this brake
rotor information. Remove the rotor from the hub.
CAUTION: Do not machine the rotor if it will cause Fig. 92 Rear Rotor Thickness Markings
the rotor to fall below minimum thickness. 1 - BRAKING DISC MINIMUM THICKNESS MARKING
2 - PARK BRAKE DRUM MAXIMUM DIAMETER MARKING
Before installation, verify the brake rotor face and
the hub adapters are free of any chips, rust, or con- Machine both sides of the brake rotor at the same
tamination. time. Cutting both sides at the same time minimizes
When mounting and using the brake lathe, strict the possibility of a tapered or uneven cut.
attention to the brake lathe manufacturer’s operating When refacing a rotor, the required TIR (Total
instructions is required. Indicator Reading) and thickness variation limits
MUST BE MAINTAINED. Extreme care in the oper-
ation of rotor turning equipment is required.
INSTALLATION
INSTALLATION - BRAKE ROTOR (FRONT)
(1) Install brake rotor over the wheel mounting
studs onto hub (Fig. 93).
(2) Install disc brake caliper and shoes following
the procedure found in Brake Pads/Shoes. (Refer to 5
- BRAKES - BASE/HYDRAULIC/MECHANICAL/
BRAKE PADS/SHOES - INSTALLATION)
(3) Pump the brake pedal several times to ensure
the vehicle has a firm brake pedal to adequately stop
vehicle.
(4) Check and adjust brake fluid level as neces-
sary.
INSTALLATION
(1) Mark tensioner rod 6.35 mm (1/4 in.) from edge
of tensioner bracket (Fig. 98).
(9) Lower vehicle until rear wheels are 15-20 cm Fig. 99 Cable At Torque Box
(6-8 in.) off shop floor. 1 - INTERMEDIATE PARK BRAKE CABLE
2 - LEFT FRAME RAIL
(10) Release park brake foot pedal and verify that 3 - TORQUE BOX
rear wheels rotate freely without drag. Verify pedal 4 - CABLE RETAINER
returns to the fully released position. 5 - LEFT REAR TRAILING ARM
(11) Lower vehicle to the ground.
(7) Remove the intermediate cable from the ten-
sioner bracket using the box end of a 1/2 inch
PARKING BRAKE CABLE - wrench.
(8) Release the latch on the routing clip for the
FRONT intermediate cable, mounted above the left rear cable
retainer clip, on rear suspension crossmember.
REMOVAL - FRONT CABLE (9) Remove the intermediate park brake cable.
The front parking brake cable is serviced with the
parking brake lever. (Refer to 5 - BRAKES - BASE/ INSTALLATION - INTERMEDIATE CABLE
PARKING BRAKE/LEVER - REMOVAL) (1) Install the intermediate park brake cable.
INSTALLATION - FRONT CABLE NOTE: When guiding the cable towards the front of
The front parking brake cable is serviced with the the rear crossmember from the left side, make sure
parking brake lever. (Refer to 5 - BRAKES - BASE/ the cable is routed between the rear suspension
PARKING BRAKE/LEVER - INSTALLATION) crossmember and the frame rail crossing below the
rear park brake cable. It should also be routed
below the brake tubes at this point.
PARKING BRAKE CABLE -
INTERMEDIATE (2) Install the intermediate cable to the tensioner
bracket by snapping it into place.
(3) Reinstall retainer clip on top of left side of
REMOVAL - INTERMEDIATE CABLE crossmember, around intermediate cable and into
(1) Raise the vehicle using a frame contact type
place.
hoist or correctly supported on jackstands. See Hoist-
(4) Connect the intermediate cable to the right
ing in Lubrication and Maintenance.
rear cable connector.
(2) Loosen the park brake cable tensioner adjuster
(5) Install the intermediate cable through the hole
nut until tension is removed from cables.
in the body torque box (Fig. 99). Install the bolt
(3) Disconnect the cable connector between the
attaching the intermediate cable retainer to the body
front and intermediate cable.
torque box.
(4) Remove the bolt attaching the intermediate
(6) Connect the intermediate cable to the front
cable retainer to the body torque box (Fig. 99).
cable connector.
(5) Remove the intermediate cable from the body
(7) Adjust parking brake. (Refer to 5 - BRAKES -
torque box (Fig. 99).
BASE/PARKING BRAKE - ADJUSTMENTS)
(6) Remove the connector from the intermediate
(8) Lower the vehicle.
cable at the right rear park brake cable.
PARKING BRAKE CABLE - (11) Remove the park brake actuator lever from
the rear park brake cable.
REAR (12) Using a screwdriver, carefully compress the
retainer tabs securing the rear park brake cable to
REMOVAL - REAR CABLE the disc brake adapter.
(13) Remove the rear parking brake cable from the
NOTE: This procedure can be used to remove either disc brake adapter and vehicle.
rear parking brake cable.
INSTALLATION - REAR CABLE
(1) Raise vehicle using a frame contact type hoist
or correctly jack and support the vehicle using jack NOTE: This procedure can be used to install either
stands. See Hoisting in Lubrication And Mainte- rear parking brake cable.
nance.
(2) Loose the park brake cable tensioner nut until (1) Install the rear parking brake cable by routing
tension is removed from cables. the leading end above the intermediate cable, then,
(3) Left rear cable only - Remove the rear cable between the frame, crossmember, and stabilizer bar.
from the connector at the park brake cable tensioner. (2) Install the other end of the cable into the disc
(4) Right rear cable only - Remove the rear brake adapter, allowing the retainer tabs to lock into
cable from the connector at the intermediate cable. place in the adapter.
(5) Remove the retainer clip securing the preferred (3) Install the park brake actuator lever onto the
rear park brake cable to the crossmember (Fig. 100). end of the rear park brake cable behind the spring.
(4) Install the parking brake shoes. (Refer to 5 -
BRAKES - BASE/PARKING BRAKE/SHOES -
INSTALLATION)
(5) Install the rear disc brake rotor on the hub/
bearing.
(6) Install the brake caliper on the rotor and
adapter. (Refer to 5 - BRAKES - BASE/HYDRAULIC/
MECHANICAL/DISC BRAKE CALIPERS - INSTAL-
LATION)
(7) Install the caliper guide pin bolts and tighten
to 41 N·m (30 ft. lbs.).
(8) Install the tire and wheel assembly. Tighten
wheel mounting nuts to 135 N·m (100 ft. lbs.).
(9) Raise the vehicle back up.
(10) Install the rear park brake cable into the rear
suspension crossmember mounting hole.
Fig. 100 Left Rear Parking Brake (11) Install a new retainer clip, on the end of the
1 - INTERMEDIATE PARKING BRAKE CABLE cable housing, to secure it in place.
2 - CLIP (12) Left rear cable only - Connect the left rear
3 - FUEL TANK
4 - MUFFLER
park brake cable to the connector on the park brake
5 - REAR PARKING BRAKE CABLE cable tensioner.
(13) Right rear cable only - Connect the right
(6) Lower the vehicle enough to have rear brakes rear park brake cable to the connector on the inter-
at good working height. mediate park brake cable.
(7) Remove the rear wheel and tire assembly from (14) When repairs are complete, adjust parking
the side of the vehicle requiring service to the park brake shoes, then adjust parking brake tensioner.
brake cable. (Refer to 5 - BRAKES - BASE/PARKING BRAKE -
(8) Remove the rear disc brake caliper from the ADJUSTMENTS)
adapter and rotor. (Refer to 5 - BRAKES - BASE/HY-
DRAULIC/MECHANICAL/DISC BRAKE CALIPERS
- REMOVAL)
(9) Remove the rear brake rotor from the rear hub/
bearing assembly.
(10) Remove the parking brake shoes from the disc
brake adapter. (Refer to 5 - BRAKES - BASE/PARK-
ING BRAKE/SHOES - REMOVAL)
Fig. 108 Front Park Brake Cable At Rear Floor Pan (2) Guiding the lever assembly up past the fuse junc-
1 - REAR SEAT CUSHION tion block, position the park brake release cable into
2 - B-PILLAR
3 - ROUTING BRACKET SCREW place. Also, reinstall the brake warning lamp wire,
4 - FRONT PARK BRAKE CABLE through access hole in lever assembly, onto switch.
5 - FLOOR PLAN (3) Position the lever assembly in its mounting
6 - RETAINER BRACKET SCREWS
place. Install the rear mounting bolt and tighten it to
(24) Remove 2 routing bracket screws securing a torque of 27 N·m (19 ft. lbs.). Tighten the 2 mount-
front park brake cable to left side of the passenger ing nuts to a torque of 27 N·m (19 ft. lbs.).
compartment floor. One screw is at the base of the (4) Ensure that the park brake cable is properly
B-pillar by the seat belt anchor bolt (Fig. 108), and routed and install the two routing bracket screws.
the other is below the park brake lever assembly on (5) Install the 2 screws securing the front park
the floor pan (Fig. 109). brake cable retainer bracket to the rear floor pan.
(25) Remove the rear bolt, and loosen the 2 front (6) Install the foot rest, securing it in place with
nuts on studs, securing the parking brake lever its one mounting screw.
assembly in place. (7) Reposition the carpeting in place.
(26) Lower the parking brake lever assembly (8) Reinstall the front seat belt anchor bolt at the
enough to gain access to the warning lamp ground base of the B-pillar.
wire connector. Remove the brake warning light (9) Reinstall the rear door opening sill cover.
ground wire from the switch on the park brake lever (10) Reposition the fuse junction block in place,
assembly. and install the two lower, then, the two upper mount-
(27) Continue to move parking brake lever, with ing screws.
front park brake cable attached, downward, and (11) Reinstall the lower A/C duct in place.
remove both from vehicle together. (12) Install the diagnostic connector to the instru-
ment panel steel reinforcement. Reinstall the steel
INSTALLATION - PARKING BRAKE LEVER AND reinforcement to the instrument panel.
(13) Connect the park brake release cable to the
CABLE release handle.
(1) Install the parking brake lever, with front (14) Reconnect the trunk release harness connec-
cable, back in vehicle by first running the front cable, tor to the release switch.
starting from front to the rear, along the left side of (15) Reinstall the lower instrument panel cover
passenger compartment. Guide it into the hole at the below the steering column. Reinstall the 2 screws
rear of the floor pan. securing the lower instrument panel cover behind the
fuse panel cover.
TABLE OF CONTENTS
page page
BRAKES - ANTILOCK BRAKE allows the driver to retain greater control of the vehi-
cle during braking.
SYSTEM This system features ABS Plus and Electronic Vari-
able Brake Proportioning (EVBP). (Refer to 5 -
BRAKES - ABS - ABS PLUS - DESCRIPTION)(Refer
DESCRIPTION to 5 - BRAKES - ABS - ELECTRONIC VARIABLE
BRAKE PROPORTIONING - DESCRIPTION)
DESCRIPTION - ANTILOCK BRAKES For information on traction control equipped vehi-
This section covers the physical and operational cles, (Refer to 5 - BRAKES - ABS - TRACTION CON-
descriptions and the on-car service procedures for TROL - DESCRIPTION).
vehicles equipped with the Mark 20e Antilock Brake
System and the Mark 20e Antilock Brake System DESCRIPTION - ABS PLUS
with traction control. There is an ABS Plus function built into the ABS
The purpose of this four-channel design antilock CAB. ABS Plus is a brake-on stability enhancement.
brake system is to prevent wheel lockup under brak- It is designed to help maintain the directional stabil-
ing conditions on virtually any type of road surface. ity of the vehicle during braking. There are no addi-
Antilock braking is desirable because a vehicle that tional external components required for this function.
is stopped without locking the wheels retains direc-
tional stability and some steering capability. This
DESCRIPTION - ELECTRONIC VARIABLE rear wheels are controlled together for better vehicle
stability.
BRAKE PROPORTIONING
The system can build and release pressure at each
Vehicles equipped with ABS use electronic variable
wheel, depending on signals generated by the wheel
brake proportioning (EVBP) to balance front-to-rear
speed sensors (WSS) at each wheel and received at
braking. The EVBP is used in place of a rear propor-
the controller antilock brake (CAB).
tioning valve. The EVBP system uses the ABS sys-
tem to control the slip of the rear wheels in partial
NOISE AND BRAKE PEDAL FEEL
braking range. The braking force of the rear wheels
During ABS braking, some brake pedal movement
is controlled electronically by using the inlet and out-
may be felt. In addition, ABS braking will create
let valves located in the integrated control unit
ticking, popping, or groaning noises heard by the
(ICU).
driver. This is normal and is due to pressurized fluid
EVBP activation is invisible to the customer since
being transferred between the master cylinder and
there is no pump motor noise or brake pedal feed-
the brakes. If ABS operation occurs during hard
back.
braking, some pulsation may be felt in the vehicle
body due to fore and aft movement of the suspension
DESCRIPTION - TRACTION CONTROL as brake pressures are modulated.
Traction control reduces wheel slip and maintains
At the end of an ABS stop, ABS is turned off when
traction at the driving wheels at speeds below 56
the vehicle is slowed to a speed of 5–7 km/h (3–4
km/h (35 mph) when road surfaces are wet or snow
mph). There may be a slight brake pedal drop any-
covered. The traction control system reduces wheel
time that the ABS is deactivated, such as at the end
slip by braking the wheel that is losing traction.
of the stop when the vehicle speed is less than 5
km/h (3 mph) or during an ABS stop where ABS is
OPERATION no longer required. These conditions exist when a
vehicle is being stopped on a road surface with
OPERATION - ANTILOCK BRAKES patches of ice, loose gravel, or sand on it. Also, stop-
There are a few performance characteristics of the ping a vehicle on a bumpy road surface activates
Mark 20e Antilock Brake System that may at first ABS because of the wheel hop caused by the bumps.
seem abnormal, but in fact are normal. These char-
acteristics are described below.
TIRE NOISE AND MARKS
Although the ABS system prevents complete wheel
NORMAL BRAKING lockup, some wheel slip is desired in order to achieve
Under normal braking conditions, the ABS func- optimum braking performance. Wheel slip is defined
tions the same as a standard base brake system with as follows: 0 percent slip means the wheel is rolling
a diagonally split master cylinder and conventional freely and 100 percent slip means the wheel is fully
vacuum assist. locked. During brake pressure modulation, wheel slip
is allowed to reach up to 25–30 percent. This means
ABS BRAKING that the wheel rolling velocity is 25–30 percent less
ABS operation is available at all vehicle speeds than that of a free rolling wheel at a given vehicle
above 5–8 km/h (3–5 mph). If a wheel locking ten- speed. This slip may result in some tire chirping,
dency is detected during a brake application, the depending on the road surface. This sound should not
brake system enters the ABS mode. During ABS be interpreted as total wheel lockup.
braking, hydraulic pressure in the four wheel circuits Complete wheel lockup normally leaves black tire
is modulated to prevent any wheel from locking. marks on dry pavement. The ABS will not leave dark
Each wheel circuit is designed with a set of electric black tire marks since the wheel never reaches a
solenoids to allow modulation and each wheel fully locked condition. However, tire marks may be
receives its own separate electrical signal. Wheel noticeable as light patched marks.
lockup may be perceived at the very end of an ABS
stop and is considered normal.
START-UP CYCLE
When the ignition is turned on, a popping sound
During an ABS stop, the brakes hydraulic system
and a slight brake pedal movement may be noticed.
is still diagonally split. However, the brake system
The ABS warning indicator lamp will also be on for
pressure is further split into four control channels.
up to 5 seconds after the ignition is turned on. These
During antilock operation of the vehicle’s brake sys-
conditions occur as part of ABS self-diagnosis check.
tem, the front wheels are controlled independently
The popping sound is a result of brief activation of
and are on two separate control channels, and the
the solenoids in the integrated control unit.
CAUTION: The CAB 24-way connector should never DIAGNOSIS AND TESTING - INSPECTION AND
be connected or disconnected with the ignition ROAD TEST
switch in the ON position. (1) Visually inspect the ABS for damaged or dis-
connected components and connectors.
(2) Verify the brake lamps are operational. If they
CAUTION: This vehicle utilizes active wheel speed are not, repair them prior to continuing.
sensors. Do not apply voltage to wheel speed sen- (3) Connect the DRBIIIt scan tool to the Data
sors at any time. Link Connector located under the instrument panel
to the left of the steering column (Fig. 1). If the
CAUTION: Use only factory wiring harnesses. Do DRBIIIt does not power-up, check the power and
not cut or splice wiring to the brake circuits. The ground supplies to the connector.
addition of aftermarket electrical equipment (car (4) Turn the ignition key to the ON position. Select
phone, radar detector, citizen band radio, trailer ANTILOCK BRAKES.
lighting, trailer brakes, etc.) on a vehicle equipped (5) Read and record any Diagnostic Trouble Codes
with antilock brakes may affect the function of the (DTCs). If any DTCs are present, refer to the appro-
antilock brake system. priate chassis diagnostic information.
SPECIFICATIONS
ABS FASTENER TORQUE
Ft. In.
DESCRIPTION N·m
Lbs. Lbs.
Brake Tubes 17 12 145
CAB To HCU Mounting
2 — 17
Screws
ICU Mounting Screws 11 — 97
Wheel Speed Sensor Head
7 — 60
Mounting Bolt Fig. 2 Front Wheel Speed Sensor
1 - WHEEL SPEED SENSOR
TONE WHEEL RUNOUT 2
3
-
-
CV BOOT
TONE WHEEL
4 - ROTOR
DESCRIPTION SPECIFICATION
Front Tone Wheel OPERATION
0.15 mm (0.006 in.) The CAB sends 12 volts to power an Integrated
Maximum Runout
Circuit (IC) in the sensor. The IC supplies a constant
Rear Tone Wheel 7 mA power supply to the CAB. The relationship of
0.15 mm (0.006 in.)
Maximum Runout the tooth on the tone wheel to the permanent magnet
in the sensor, signals the IC to enable a second 7 mA
WHEEL SPEED SENSOR AIR GAP power supply. The output of the sensor, sent to the
CAB, is a DC voltage signal with changing voltage
DESCRIPTION SPECIFICATION and current levels. The ground for the IC and the
current sense circuit is provided by the CAB.
0.42 – 1.71 mm
Front Sensor When a valley of the tone wheel is aligned with the
0.017 – 0.067 in.
sensor, the voltage signal is approximately 0.8 volts
0.38 – 1.31 mm and a constant 7 mA current is sent to the CAB. As
Rear Sensor
0.015 – 0.052 in. the tone wheel rotates, the tooth shifts the magnetic
field and the IC enables a second 7 mA current
source. The CAB senses a voltage signal of approxi-
mately 1.6 volts and 14 mA. The CAB measures the
amperage of the digital signal for each wheel. The
resulting signal is interpreted by the ABS CAB as
the wheel speed.
REMOVAL
(1) Raise vehicle. (Refer to LUBRICATION &
MAINTENANCE/HOISTING - STANDARD PROCE-
DURE)
(2) Remove the tire and wheel assembly from the
vehicle.
(3) Remove bolt securing the speed sensor cable
routing bracket (Fig. 3) to the strut assembly.
OPERATION
The CAB sends 12 volts to power an Integrated
Circuit (IC) in the sensor. The IC supplies a constant
7 mA power supply to the CAB. The relationship of
the tooth on the tone wheel to the permanent magnet
in the sensor, signals the IC to enable a second 7 mA Fig. 6 Wheel Speed Sensor At Adapter
power supply. The output of the sensor, sent to the
1 - STABILIZER BAR LINK
CAB, is a DC voltage signal with changing voltage 2 - STABILIZER BAR
and current levels. The ground for the IC and the 3 - LATERAL LINK
current sense circuit is provided by the CAB. 4 - BOLT
5 - WHEEL SPEED SENSOR
When a valley of the tone wheel is aligned with the 6 - STRUT ASSEMBLY
sensor, the voltage signal is approximately 0.8 volts 7 - NUT
and a constant 7 mA current is sent to the CAB. As
the tone wheel rotates, the tooth shifts the magnetic INSTALLATION
field and the IC enables a second 7 mA current (1) Install rear wheel speed sensor and routing
source. The CAB senses a voltage signal of approxi- bracket into brake caliper adapter. Install head
mately 1.6 volts and 14 mA. The CAB measures the attaching bolt (Fig. 6) and tighten to 7 N·m (60 in.
amperage of the digital signal for each wheel. The lbs.).
resulting signal is interpreted by the ABS CAB as (2) Install the sensor cable to the routing bracket
the wheel speed. attached to the strut tower flange.
TONE WHEEL
TRACTION CONTROL SWITCH
DESCRIPTION
The tone wheel is used in conjunction with the REMOVAL
wheel speed sensors. (Refer to 5 - BRAKES - ABS/ The traction control switch in located in the upper
ELECTRICAL/FRONT WHEEL SPEED SENSOR - right trim bezel on the instrument panel. The upper
DESCRIPTION) or (Refer to 5 - BRAKES - ABS/ right trim bezel must be removed to service the
ELECTRICAL/REAR WHEEL SPEED SENSOR - switch. Refer to Upper Right Trim Bezel Removal
DESCRIPTION) and Installation.
(1) With the bezel removed, press the tabs in at
OPERATION both sides of the switch and remove the switch from
The tone wheel is used in conjunction with the the bezel.
wheel speed sensors. (Refer to 5 - BRAKES - ABS/
ELECTRICAL/FRONT WHEEL SPEED SENSOR - INSTALLATION
OPERATION) or (Refer to 5 - BRAKES - ABS/ELEC- (1) Position the switch over the hole in the upper
TRICAL/REAR WHEEL SPEED SENSOR - OPERA- right bezel, push through hole and firmly snap into
TION) place.
(2) Install the upper right trim bezel. Refer to
INSPECTION Body, Instrument Panel, Upper Right Trim Bezel,
Tone wheels can cause erratic wheel speed sensor Installation.
signals. Inspect tone wheels for the following possible
causes.
• missing, chipped, or broken teeth HYDRAULIC/MECHANICAL
• contact with the wheel speed sensor
• wheel speed sensor to tone wheel alignment OPERATION - HYDRAULIC CIRCUITS AND
• wheel speed sensor to tone wheel clearance VALVES
• excessive tone wheel runout The hydraulic fluid control valves within the HCU
• tone wheel loose on its mounting surface control the flow of pressurized brake fluid to the
If a front tone wheel is found to need replacement, wheel brakes during the different modes of ABS
the drive shaft must be replaced. No attempt should braking. The following paragraphs explain how this
be made to replace just the tone wheel. Refer to DIF- works. For purposes of explanation only, it is
FERENTIAL AND DRIVELINE for removal and assumed that only the right front wheel is experienc-
installation. ing antilock braking; the following diagrams show
If a rear tone wheel is found to need replacement, only the right front wheel in an antilock braking
the rear hub and bearing must be replaced. No operation.
attempt should be made to replace just the tone
wheel. Refer to SUSPENSION for removal and
installation.
If wheel speed sensor to tone wheel contact is evi-
dent, determine the cause and correct it before
replacing the wheel speed sensor or tone wheel.
OPERATION
For information of the ICU, refer to these individ-
Fig. 12 Integrated Control Unit (ICU) ual components of the ICU:
1 - PUMP/MOTOR • CONTROLLER ANTILOCK BRAKE (CAB)
2 - HCU (Refer to 8 - ELECTRICAL/ELECTRONIC CON-
3 - PUMP/MOTOR WIRING CONNECTOR TROL MODULES/CONTROLLER ANTILOCK
4 - CAB
BRAKE - OPERATION)
Two different ICU’s (HCU and CAB) are used on • HYDRAULIC CONTROL UNIT (HCU) (Refer to
this vehicle depending on whether or not the vehicle 5 - BRAKES - ABS/HYDRAULIC/MECHANICAL/
is equipped with traction control. The HCU on a HCU (HYDRAULIC CONTROL UNIT) - OPERA-
vehicle equipped with traction control has a valve TION)
block that is approximately one inch longer than a For information on the ICU’s hydraulic circuits,
HCU on a vehicle that is equipped with ABS only. refer to HYDRAULIC CIRCUITS AND VALVE
The ABS-only ICU consists of the following compo- OPERATION. (Refer to 5 - BRAKES - ABS/HY-
nents: the CAB, eight (build/decay) solenoid valves DRAULIC/MECHANICAL - OPERATION)
(four inlet valves and four outlet valves), valve block,
fluid accumulators, a pump, and an electric motor.
The ABS-with traction control ICU consists of the
following components: the CAB, eight (build/decay)
solenoid valves (four inlet valves and four outlet
valves), two traction control (ASR) valves, two
hydraulic shuttle valves, valve block, fluid accumula-
tors, a pump, and an electric motor.
The replaceable components of the ICU are the
HCU and the CAB. No attempt should be made to
service any individual components of the HCU or
CAB.
REMOVAL - ICU
(1) Remove the remote ground cable from the
ground stud on the right strut tower.
(2) Correctly isolate remote ground cable when ser-
vicing vehicle by installing the ground cable insulator
on the strut tower ground stud as shown in (Fig. 14)
and installing the nut on the stud. This will pre-
vent accidental grounding of the remote
ground cable.
INSTALLATION - ICU
(1) Install the ICU back in the vehicle and attach
it to its mounting bracket. Tighten the 3 ICU mount-
ing bolts to 11 N·m (97 in. lbs.).
(2) Reinstall the inner fender splash shield.
(3) Reinstall the tire and wheel assembly. (Refer to
22 - TIRES/WHEELS - INSTALLATION)
(4) Lower the vehicle.
COOLING
TABLE OF CONTENTS
page page
PRESSURE CAP IS BLOWING 1. Pressure relief valve in radiator 1. Check condition of radiator cap and
OFF STEAM AND/OR cap is defective, or was not cap seal. Refer to Pressure Cap in this
COOLANT. TEMPERATURE properly seated. group. Replace cap as necessary.
GAUGE READING MAY BE
ABOVE NORMAL BUT NOT 2. Incorrect cap was installed. 2. Replace cap as necessary.
HIGH. COOLANT LEVEL MAY
3. Incorrect coolant mixture. 3. Make sure a 50% by volume mixture
BE HIGH IN COOLANT
of coolant is used.
RESERVE/OVERFLOW TANK.
4. System overfilled. 4. Ensure cold coolant level is between
MIN and MAX marks on coolant bottle.
COOLANT LOSS TO THE 1. Coolant leaks in radiator, cooling 1. Pressure test and repair as
GROUND WITHOUT system hoses, water pump or necessary. (Refer to 7 - COOLING -
PRESSURE CAP BLOWOFF. engine. DIAGNOSIS AND TESTING -
GAUGE IS READING HIGH OR COOLING SYSTEM LEAK TESTING)
HOT.
HOSE(S) COLLAPSE AS 1. Vacuum created in cooling 1. (a) Pressure cap relief valve stuck.
ENGINE COOLS DOWN. system on engine cool-down is not (Refer to 7 - COOLING/ENGINE/
being relieved through coolant RADIATOR PRESSURE CAP -
bottle system. INSPECTION) Replace as necessary.
(b) Hose between the pressure and
overflow container is plugged. Clean
vent and repair as necessary.
(c) Vent at coolant reserve/overflow
container is plugged. Clean vent and
repair as necessary.
(d) Reserve/overflow container is
internally blocked. Clean and repair as
necessary
ELECTRIC RADIATOR FAN 1. Fan relay, Powertrain Control 1. (Refer to Appropriate Diagnostic
RUNS ALL THE TIME. Module (PCM) or engine coolant Information) Repair as necessary.
temperature sensor possibly
defective.
2. Check for low coolant level. 2. Repair as necessary.
3. A/C pressure transducer 3. (Refer to Appropriate Diagnostic
defective. Information) Repair as necessary.
NOISY RADIATOR FAN. 1. Fan blade loose. 1. Replace radiator fan assembly.
(Refer to 7 - COOLING/ENGINE/
RADIATOR FAN - REMOVAL)
2. Fan blade striking a surrounding 2. Locate point of fan blade contact and
object. repair/replace as necessary.
3. Air obstructions at radiator or A/C 3. Remove obstructions and/or clean
condenser. debris.
4. Electric fan motor defective. 4. Replace radiator fan assembly.
(Refer to 7 - COOLING/ENGINE/
RADIATOR FAN - REMOVAL)
INADEQUATE AIR 1. Radiator and/or A/C condenser is 1. Remove restriction and/or clean as
CONDITIONER restricted, obstructed or dirty necessary.
PERFORMANCE (COOLING (insects, leaves, etc.).
SYSTEM SUSPECTED).
2. Electrical radiator fan not 2. (Refer to Appropriate Diagnostic
operating when A/C is operated. Information) Repair as necessary.
3. Engine is overheating (heat may 3. Correct overheating condition.
be transferred from radiator to A/C
condenser. High underhood
temperatures due to engine
overheating may also transfer heat
to A/C components.
4. All models are equipped with air 4. Check for missing or damaged air
seals at the radiator and/or A/C seals and repair as necessary.
condenser. If these seals are
missing or damaged, not enough
air flow will be pulled through the
radiator and A/C condenser.
HEAT ODOR 1. Various heat shields are used at 1. Locate missing shields and replace
certain driveline components. One or repair as necessary.
or more of these shields may be
missing.
2. Is the temperature gauge reading 2. Refer to Temperature Gauge Reads
above the normal range? High in these Diagnosis Charts.
STEAM IS COMING FROM 1. During wet weather, moisture 1. Occasional steam emitting from this
FRONT OF VEHICLE NEAR (snow, ice, rain, or condensation) area is normal. No repair is necessary.
GRILL AREA WHEN WEATHER on the radiator will evaporate when
IS WET, ENGINE WARMED UP the thermostat opens. The
AND RUNNING WITH VEHICLE thermostat opening allows heated
STATIONARY, OR JUST SHUT coolant into the radiator. When the
OFF. TEMPERATURE GAUGE moisture contacts the hot radiator,
IS NORMAL. steam may be emitted. this usually
occurs in cold weather with no fan
or air flow to blow it away.
COOLANT COLOR 1. Coolant color is not necessarily 1. Check the freeze point of the
an indication of adequate corrosion coolant. (Refer to 7 - COOLING/
or temperature protection. Do not ENGINE/COOLANT - DIAGNOSIS AND
rely on coolant color for determining TESTING) Adjust the ethylene
condition of coolant. glycol-to-water ratio as necessary and
service according to maintenance
schedule. (Refer to LUBRICATION &
MAINTENANCE/MAINTENANCE
SCHEDULES - DESCRIPTION)
DIAGNOSIS AND TESTING - COOLING SYSTEM All hoses, radiator and heater, should be moved
while at 15 psi since some leaks occur while driving
LEAK
due to engine rock, etc.
With engine not running, wipe the coolant bottle
If the cooling system will not pressurize easily and
neck sealing seat clean.
there is no coolant leaks, the cooling system is only
Attach a radiator pressure tester to the coolant
partially filled. (Refer to 7 - COOLING - STANDARD
bottle, as shown in (Fig. 2) and apply 104 kPa (15
PROCEDURE - COOLING SYSTEM FILL)
psi) pressure. If the pressure drops more than 2 psi
If there are no external leaks after the gauge dial
in 2 minutes inspect all points for external leaks.
shows a drop in pressure, detach the tester. Start
engine and run the engine to normal operating tem-
If the needle on the dial does not fluctuate, race The coolant bottle provides a quick visual method
the engine a few times. If an abnormal amount of for determining the coolant level without removing
coolant or steam is emitted from the tail pipe, it may the pressure cap. With the engine cold, the level of
indicate a faulty head gasket, cracked engine block or the coolant in the coolant bottle (Fig. 3) should be
cylinder head. between the MIN and MAX lines on the bottle.
There may be internal leaks which can be deter-
mined by removing the oil dipstick. If water globules
appear intermixed with the oil it will indicate an
internal leak in the engine. If there is an internal
leak, the engine must be disassembled for repair.
SPECIAL TOOLS
COOLING
ACCESSORY DRIVE
TABLE OF CONTENTS
page page
ACCESSORY DRIVE belt drives the generator and power steering pump
on all engines.
DESCRIPTION
The accessory drive system on 2.7L and 3.5L
OPERATION
engines utilizes two different belts. A conventional The accessory drive belts provide the link between
V-belt drives the air conditioning compressor on 3.5L the engine crankshaft and the engine driven accesso-
engines, a Poly-V belt on the 2.7L engine. A Poly-V ries.
CLEANING
Clean all foreign debris from belt pulley grooves.
The belt pulleys must be free of oil, grease, and cool-
ants before installing the drive belt.
INSTALLATION
AIR CONDITIONING BELT - NEW
WARNING: DO NOT REMOVE A/C BELT TENSIONER
LOCKING BOLT WITHOUT FIRST HOLDING THE
TENSIONER WITH A 1/2” DRIVE BREAKER BAR, AS
PERSONAL INJURY COULD RESULT.
Fig. 4 Air Conditioning Belt Tensioner Spring
NOTE: Verify that torsion spring position is in the Position
new belt position before installing a NEW belt (Fig. 1 - TENSIONER
4). If torsion spring is not in the new belt position, 2 - TORSION SPRING
3 - NEW BELT POSITION
follow steps 1–7 to change the tensioner spring 4 - USED BELT POSITION
from the USED belt position to the NEW belt posi-
tion. AIR CONDITIONING BELT - USED
(1) Insert a 1/2” drive breaker bar into the square NOTE: A “used belt” is considered having more
opening on the tensioner. Hold counterclockwise pres- than 500 miles of service use.
sure on tensioner while removing the locking bolt
(Fig. 2).
(2) Carefully release spring load of the torsion NOTE: Perform steps 1–7 to change the tensioner
spring on the tensioner. spring from the NEW belt position, to the USED belt
(3) Remove pivot bolt, tensioner, and spring from position.
front timing cover.
(4) Insert spring arm into the NEW belt position (1) Insert a 1/2” drive breaker bar into the square
on the tensioner (Fig. 4). opening on tensioner. Hold counterclockwise pressure
(5) Install torsion spring, tensioner, and pivot bolt. on tensioner, while removing tensioner locking bolt
(6) Install pivot bolt. Tighten only finger tight, at (Fig. 2).
this time. (2) Carefully release the tension of spring on ten-
(7) Using a 1/2” drive breaker bar, apply counter- sioner.
clockwise pressure until locking bolt can be installed.
INSTALLATION
NOTE: Use Special Tool 7198, Belt Tension Gauge
to obtain proper tension on accessory drive belts.
For Special Tool identification, (Refer to 7 - COOL-
ING - SPECIAL TOOLS). For accessory drive belt
tension specifications, (Refer to 7 - COOLING/AC-
CESSORY DRIVE/DRIVE BELTS - ADJUSTMENTS).
ENGINE
TABLE OF CONTENTS
page page
ENGINE INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . 25
CLEANING . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18 HEATER SUPPLY TUBE - 3.5L
INSPECTION ........................ . . 19 REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25
COOLANT INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . 26
DESCRIPTION - ENGINE COOLANT . . . . . . . . . 19 HOSE CLAMPS
DIAGNOSIS AND TESTING - COOLANT DESCRIPTION . . . . . . . . . . . . . . . . . . . . . . . . . 26
CONCENTRATION TESTING . . . . . . . . . . . . . 19 OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . . 26
STANDARD PROCEDURE - COOLANT RADIATOR
SERVICE . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19 REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27
COOLANT OUTLET CONNECTOR - 2.7L CLEANING . . . . . . . . . . . . . . . . . . . . . . . . . . . . 28
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20 INSPECTION ....................... . . . 28
INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . 20 INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . 28
COOLANT RECOVERY PRESSURE RADIATOR DRAINCOCK
CONTAINER REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 28
DESCRIPTION . . . . . . . . . . . . . . . . . . . . . . . . . 20 INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . 28
OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . . 20 PRESSURE CAP
ENGINE BLOCK HEATER DESCRIPTION . . . . . . . . . . . . . . . . . . . . . . . . . 29
DESCRIPTION . . . . . . . . . . . . . . . . . . . . . . . . . 21 OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . . 29
OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . . 21 INSPECTION ....................... . . . 29
DIAGNOSIS AND TESTING - ENGINE BLOCK RADIATOR FAN
HEATER .......................... . . 21 DESCRIPTION . . . . . . . . . . . . . . . . . . . . . . . . . 30
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21 OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . . 30
INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . 21 DIAGNOSIS AND TESTING - RADIATOR FAN
ENGINE COOLANT TEMPERATURE SENSOR CONTROL . . . . . . . . . . . . . . . . . . . . . . . . . . . 30
DESCRIPTION . . . . . . . . . . . . . . . . . . . . . . . . . 21 REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 32
OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . . 22 INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . 32
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22 RADIATOR FAN RELAY
INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . 22 DESCRIPTION . . . . . . . . . . . . . . . . . . . . . . . . . 32
ENGINE COOLANT THERMOSTAT OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . . 33
DESCRIPTION . . . . . . . . . . . . . . . . . . . . . . . . . 22 WATER PUMP
OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . . 22 DIAGNOSIS AND TESTING - WATER PUMP . . . 33
DIAGNOSIS AND TESTING - ENGINE WATER PUMP - 2.7L
COOLANT THERMOSTAT . . . . . . . . . . . . . . . 23 DESCRIPTION . . . . . . . . . . . . . . . . . . . . . . . . . 33
ENGINE COOLANT THERMOSTAT - 2.7L REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 33
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23 INSPECTION - 2.7L .................. . . . 34
INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . 24 INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . 35
ENGINE COOLANT THERMOSTAT - 3.5L WATER PUMP - 3.5L
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24 DESCRIPTION . . . . . . . . . . . . . . . . . . . . . . . . . 36
INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . 24 REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 36
HEATER SUPPLY TUBE - 2.7L INSPECTION ....................... . . . 36
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25 INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . 37
ENGINE tor hose is hot. Stop engine and drain water from
system. If water is dirty; fill, run, and drain system
again, until water runs clear. Refill cooling system
CLEANING
with a 50/50 mixture of the recommended ethylene
Drain cooling system and refill with clean water.
glycol and distilled water (Refer to LUBRICATION &
Refer to drain and fill procedures in this section. Run
MAINTENANCE/FLUID TYPES - DESCRIPTION).
engine with radiator cap installed until upper radia-
COOLANT OUTLET (4) Lubricate O-ring and insert heater tube assem-
bly into outlet connector. Tighten screws to 3 N·m (30
CONNECTOR - 2.7L in. lbs.).
(5) Install upper intake manifold (Refer to 9 -
REMOVAL ENGINE/MANIFOLDS/INTAKE MANIFOLD -
INSTALLATION).
WARNING: DO NOT REMOVE PRESSURE CAP (6) Fill cooling system (Refer to 7 - COOLING -
WITH THE SYSTEM HOT AND UNDER PRESSURE STANDARD PROCEDURE).
BECAUSE SERIOUS BURNS FROM COOLANT CAN
OCCUR.
COOLANT RECOVERY
(1) Drain cooling system (Refer to 7 - COOLING -
STANDARD PROCEDURE). PRESSURE CONTAINER
(2) Remove upper intake manifold (Refer to 9 -
ENGINE/MANIFOLDS/INTAKE MANIFOLD - DESCRIPTION
REMOVAL). The coolant bottle consists of a pressure chamber
(3) Remove screws attaching heater tube to outlet and a overflow chamber (Fig. 2) that is mounted in
connector. the engine compartment (Fig. 3). The overflow hose
(4) Disengage tube from outlet connector only connects the pressure chamber to the overflow cham-
enough for connector removal. ber.
(5) Remove bolts attaching water outlet connector
(Fig. 1). NOTE: Coolant will normally be in the pressure
(6) Remove outlet connector. chamber side of the coolant bottle. The overflow
chamber should normally be empty
ENGINE BLOCK HEATER CAUTION: To prevent damage, the power cord must
be secured in its retainer clips, and not positioned
DESCRIPTION so it could contact linkages or exhaust manifolds.
The engine block heater is mounted in the cylinder (5) Lower vehicle.
block, near the right rear corner (Fig. 4). The block
heater is a dry cylinder type design and is powered
by 110 volt AC. The power cord must be secured ENGINE COOLANT
in its retainer clips, and not positioned so it
could contact linkages or exhaust manifolds TEMPERATURE SENSOR
and become damaged.
DESCRIPTION
OPERATION The engine coolant temperature sensor threads
When power is applied (110 volt AC) to the block into the coolant system (Fig. 5) or (Fig. 6).
heater, the heating element transfers heat through
the aluminum engine block and into the coolant
without directly penetrating the cooling system.
REMOVAL
(1) Raise vehicle on hoist.
(2) Detach power cord plug from heater (Fig. 4).
(3) Remove block heater attaching screw located
below heater terminals.
(4) Remove block heater from cylinder block.
ENGINE COOLANT
THERMOSTAT
DESCRIPTION
The thermostat on the 2.7L and 3.5L engines are
located on the lower left side of engine, near the
front (Fig. 7) and (Fig. 8). The thermostat on both
engines are on the inlet side of the water pump. The
thermostats have an air bleed located in the thermo-
stat flange. The air bleed allows internal trapped air
during cooling system filling to be released.
OPERATION
The sensor provides an input to the Powertrain
Control Module (PCM). As coolant temperature var-
ies, the sensor resistance changes, resulting in a dif-
ferent input voltage to the PCM.
When the engine is cold, the PCM will demand
slightly richer air-fuel mixtures and higher idle
speeds until normal operating temperatures are Fig. 7 THERMOSTAT AND HOUSING - 2.7L
reached. 1 - THERMOSTAT AND GASKET
The engine coolant sensor input also determines 2 - THERMOSTAT HOUSING/COOLANT INLET
operation of the low and high speed cooling fans.
OPERATION
REMOVAL The engine cooling thermostat is a wax pellet
(1) Disconnect negative cable from remote jumper driven, reverse poppet type. The thermostat is
terminal. located in the inlet side of the engine to provide fast
(2) With the engine cold, disconnect coolant sensor warm up and to optimize a consistent temperature in
electrical connector (Fig. 5) or (Fig. 6). the engine. The thermostat is designed to prevent
(3) Remove sensor. leakage through it and to guarantee a minimum
engine operating temperature of 82°C (180°F). They
INSTALLATION also automatically reach wide open at a temperature
(1) Install engine coolant temperature sensor (Fig. of approximately 95°C (203°F) so they do not restrict
5) or (Fig. 6). Tighten sensor to 28 N·m (20 ft. lbs.) flow to the radiator as temperature of the coolant
torque. rises in hot weather to around 104°C (220°F). Above
(2) Attach electrical connector to sensor. 102°C (215°F) the coolant temperature is controlled
(3) Connect negative cable to remote jumper termi- by the radiator, fan, and ambient temperature, not
nal. the thermostat.
ENGINE COOLANT
THERMOSTAT - 2.7L
REMOVAL
(1) Disconnect negative cable from remote jumper
terminal.
INSTALLATION
(1) Inspect heater tube O-ring. Replace as neces-
sary.
(2) Lubricate O-ring with a silicone type grease
such as Mopart Dielectric Grease. Fig. 11 Heater Supply Tube - Removal/Installation
(3) Install the heater tube by inserting tube in-be- 1 - OUTLET CONNECTOR
2 - SCREW (2)
tween cylinder heads. Insert tube into water outlet 3 - HEATER TUBE
housing (Fig. 11). 4 - O-RING
(4) Attach heater tube to the retaining clip at rear
of engine. HEATER SUPPLY TUBE - 3.5L
(5) Install attaching screws and tighten to 3 N·m
(30 in. lbs.). REMOVAL
(6) Install radiator upper and heater hoses to
heater tube. WARNING: DO NOT REMOVE PRESSURE CAP
(7) Connect electrical connector to coolant temper- WITH SYSTEM HOT AND UNDER PRESSURE
ature sensor. BECAUSE SERIOUS BURNS FROM COOLANT CAN
(8) Install radiator upper crossmember. (Refer to OCCUR.
23 - BODY/EXTERIOR/GRILLE OPENING REIN-
FORCEMENT - INSTALLATION) (1) Drain cooling system. (Refer to 7 - COOLING -
(9) Fill cooling system. (Refer to 7 - COOLING - STANDARD PROCEDURE)
STANDARD PROCEDURE) (2) Remove upper and lower intake manifold.
(Refer to 9 - ENGINE/MANIFOLDS/INTAKE MANI-
FOLD - REMOVAL)
(3) Position lower intake manifold upside down on
bench and remove the tube retaining bolt (Fig. 12).
(4) Remove tube from manifold and discard O-ring.
HOSE CLAMPS
DESCRIPTION
The cooling system utilizes both worm drive and
spring type hose clamps. If a spring type clamp
replacement is necessary, replace with the original
Mopart equipment spring type clamp. To identify
size of spring hose clamps, the size in millimeters
has been stamped on each clamp (Fig. 13). Refer to
HOSE CLAMP USAGE CHART for proper size and
Fig. 14 HOSE CLAMP TOOL
location of hose clamps. 1 - HOSE CLAMP TOOL 6094
2 - HOSE CLAMP
RADIATOR
REMOVAL
NOTE: It is not necessary to discharge air condi-
tioning system when removing the radiator.
Fig. 15 RADIATOR
1 - ENGINE OIL COOLER FITTINGS (IF EQUIPPED)
2 - DRAINCOCK
3 - LOWER MOUNTING ISOLATORS
4 - TRANSMISSION COOLER LINE NIPPLES
INSTALLATION INSTALLATION
(1) Position radiator into engine compartment. (1) Inspect the draincock body and O-ring for dam-
Seat the radiator assembly lower rubber isolators age. Replace as necessary.
into the mounting holes in radiator lower support
(Fig. 15).
INTAKE (CHARGE)
ENGINE COOLANT TEMPERATURE
TEMPERATURE
Engine @ Idle < 13
Vehicle Speed < 45
A/C Off A/C On Km/h (8 MPH)
Km/h (28 MPH)**
Vehicle Speed
Fan Speed Low High Low High Low High Low High
Fan On: 106°C 110°C 105°C 110°C 104°C 110°C 65°C (149°F) After
(223°F) (230°F) (221°F) (230°F) (219°F) - (230°F) if Low Fan
After 1st coolant<93°C On for 8
Fan Cycle (199°F) minutes.
61°C (142°F)
if coolant
>105°C
(221°F)
Fan Off: 102°C 107°C 102°C 106°C Fan on 105°C 64°C (147°F) Fan on
(216°F) (225°F) (216°F) (223°F) time = 4 (221°F) if time = 4
minutes* coolant<92°C minutes*
(197°F
60°C (140°F)
if
coolant>104°C
(219°F
*Minimum fan on time = 90 seconds
**Note: If low fan is on for 8 minutes, fan turns on high speed for 4 minutes, then goes back to low speed.
A/C PRESSURE TRANSMISSION OIL TEMPERATURE
Fan Speed Low High Low High
Fan On: 1,448 Kpa (210 psi) 1,717 Kpa (249 psi) 109°C (228°F) 111°C (232°F)
Fan Off: 1,207 Kpa (175 psi) 1,503 Kpa (218 psi) 104°C (220°F) 109°C (228°F)
REMOVAL
(1) Remove radiator upper crossmember (Refer to
23 - BODY/EXTERIOR/GRILLE OPENING REIN-
FORCEMENT - REMOVAL).
(2) Disconnect radiator fan motor electrical connec-
tor.
(3) Partially drain cooling system below the level
of the upper radiator hose.
(4) Disconnect upper radiator hose from radiator.
(5) Remove radiator fan attaching fasteners and
upper clip (Fig. 23).
(6) Remove radiator fan by lifting upward to clear
radiator.
INSTALLATION
(1) Install radiator fan.
(2) Install upper clip and fasteners (Fig. 23). Fig. 23 RADIATOR FAN
(3) Connect upper radiator hose to radiator. 1 - ELECTRICAL CONNECTOR
2 - FASTENERS
(4) Connect fan motor electrical connector (Fig. 3 - CLIPS
23).
(5) Install radiator upper crossmember (Refer to
23 - BODY/EXTERIOR/GRILLE OPENING REIN-
RADIATOR FAN RELAY
FORCEMENT - INSTALLATION).
(6) Fill cooling system (Refer to 7 - COOLING - DESCRIPTION
STANDARD PROCEDURE - COOLING SYSTEM The HI/LO and HI radiator fan relays are located
FILLING). in the Power Distribution Center (PDC) near the
coolant recovery pressure container (Fig. 24). A decal
on the inside of the PDC covers shows the location of
each relay and fuse contained in the PDC. It is an
ISO relay.
OPERATION
2.7L BASE
The cooling system uses two fans. Both fans oper-
ate at two different speeds, low and high. Depending
on engine coolant temperature and A/C system high
side pressure, the fans operate at either low or high
speed. The PCM controls radiator fan speed by
grounding the coil side of either the HI/LO fan relay
or the HI fan relay. The ignition switch supplies volt-
age to the coil sides of the relay. When the PCM
grounds the coil side of the relay, the contacts close
and the battery supplies power to the fans. Refer to
WIRING DIAGRAMS.
WATER PUMP
DIAGNOSIS AND TESTING - WATER PUMP
A quick test to determine water pump operation is
to check for proper heater system performance (Refer
to 24 - HEATING & AIR CONDITIONING - DIAG-
NOSIS AND TESTING). A defective pump will not
circulate heated coolant through the heater hoses.
For additional diagnosis, (Refer to 7 - COOLING -
DIAGNOSIS AND TESTING). For water pump
inspection, (Refer to 7 - COOLING/ENGINE/WATER
PUMP - INSPECTION).
INSTALLATION
(1) Clean all sealing surfaces.
(2) Install water pump and gasket. Tighten mount- Fig. 30 Secondary Water Pump Weep Passage -
ing bolts to 12 N·m (105 in. lbs.). 2.7L
(3) Install timing chain guides and timing chain 1 - WEEP PASSAGE TO VALLEY OF BLOCK
(Refer to 9 - ENGINE/VALVE TIMING/TIMING 2 - HOLE IN REAR OF BLOCK
BELT/CHAIN AND SPROCKETS - INSTALLA-
TION). (7) Install the radiator fan (Refer to 7 - COOLING/
(4) Install the timing chain cover (Refer to 9 - ENGINE/RADIATOR FAN - INSTALLATION) and
ENGINE/VALVE TIMING/TIMING BELT / CHAIN (8) Install the radiator upper crossmember (Refer
COVER(S) - INSTALLATION). to 23 - BODY/EXTERIOR/GRILLE OPENING REIN-
(5) Install the crankshaft damper (Refer to 9 - FORCEMENT - INSTALLATION).
ENGINE/ENGINE BLOCK/VIBRATION DAMPER - (9) Fill cooling system. (Refer to 7 - COOLING -
INSTALLATION). STANDARD PROCEDURE)
(6) Install the accessory drive belts. (Refer to 7 -
COOLING/ACCESSORY DRIVE/DRIVE BELTS -
INSTALLATION)
REMOVAL
The water pump on all models can be replaced
without discharging the air conditioning system.
INSTALLATION
(1) Clean all O-ring surfaces on pump and cover.
(2) Apply Mopart Dielectric Grease or the equiva-
lent silicone grease to the O-ring to facilitate assem-
bly. Install new O-ring on water pump (Fig. 32).
TRANSMISSION
TABLE OF CONTENTS
page page
REMOVAL CLEANING
The in-tank transmission oil cooler is serviced with Check the external cooler for debris on the cooling
the radiator (Refer to 7 - COOLING/ENGINE/RADI- fin surfaces. Clean as necessary.
ATOR - REMOVAL).
For removal of external trans cooler perform the INSPECTION
following procedures: Inspect all hoses, tubes, clamps and connections for
(1) Disconnect negative cable from remote jumper leaks, cracks, or damage. Replace as necessary. Use
terminal. only approved transmission oil cooler hoses that are
(2) Remove the radiator upper support (Refer to 23 molded to fit the space available.
- BODY/EXTERIOR/GRILLE OPENING REIN- Inspect external coolers for leaks, loose mounts, or
FORCEMENT - REMOVAL). damage. Replace as necessary.
(3) Raise vehicle on hoist.
(4) Remove right and left front wheels. INSTALLATION
(5) Remove front fascia (Refer to 13 - FRAMES & For in-tank transmission oil cooler installation
BUMPERS/BUMPERS/FRONT FASCIA - REMOV- (Refer to 7 - COOLING/ENGINE/RADIATOR -
AL). INSTALLATION).
(6) Disconnect the hoses connecting to the external For external trans oil cooler installation, perform
cooler. the following procedures:
(7) Remove the radiator side air shields. (1) Remove the bolts attaching the A/C condenser
(8) Remove the screw attaching the cooler line to the radiator (Fig. 3).
support bracket and remove the bracket. (2) Lift A/C condenser up to disengage from upper
(9) Cut-off the cooler to condenser attaching straps retainers on radiator.
(Fig. 2).
(10) Remove the transmission oil cooler and lines
(Fig. 2).
INSPECTION
Inspect all cooler lines and clamps. Replace as nec-
essary.
AUDIO/VIDEO
TABLE OF CONTENTS
page page
AMPLIFIER
DESCRIPTION
MIDLINE AND INFINITY l SYSTEM
The amplifier is located in the right front cowl
panel.
INFINITY ll SYSTEM
The amplifier is located beneath the trunk liner
covering the right quarter inner panel.
OPERATION
For specific operation of each individual system,
refer to the vehicles owners manual, Audio System
Operation Manual.
When the radio system is ON, and all or some
speakers are not operating or have a noise distortion
refer to the diagnostic tests. Refer to the appropriate
wiring information. The wiring information includes Fig. 1 Midline/Infinity Remote Amplifier Location
wiring diagrams, proper wire and connector repair 1 - HVAC UNIT
2 - REMOTE AMPLIFIER
procedures, details of wire harness routing and 3 - RECIRCULATION AIR MOTOR
retention, connector pin-out information and location
views for the various wire harness connectors, splices (3) Remove three retaining screws (Fig. 2).
and grounds. (4) Disconnect two wire connectors.
(5) Remove remote amplifier from vehicle.
REMOVAL
INSTALLATION
MIDLINE/INFINITY l SYSTEM
(1) Disconnect and isolate the negative battery MIDLINE/INFINITY l SYSTEM
cable. (1) Install the remote amplifier into vehicle.
(2) Remove right under panel silencer/duct. (2) Connect two wiring connectors.
(3) Remove mounting fastener to remote amplifier (3) Push the amplifier upward and then outboard
(Fig. 1). to install into upper retaining clips.
(4) Pull amplifier inboard and then pull downward (4) Install mounting fastener to remote amplifier.
to remove from upper retaining clips. (5) Install right under panel silencer/duct.
(5) Disconnect two wiring connectors. (6) Connect the negative battery cable.
(6) Remove remote amplifier from vehicle.
INFINITY II SYSTEM
INFINITY ll SYSTEM (1) Install remote amplifier into vehicle.
(1) Disconnect and isolate the negative battery (2) Connect two wire connectors.
cable. (3) Install three retaining screws.
(2) Inside trunk, pull the trunk liner aside (right (4) Install the trunk liner (right quarter panel pas-
quarter panel passenger side). senger side).
OPERATION
The satellite radio antenna receives signals from
orbiting satellites and sends these signals to the sat-
ellite receiver module. The satellite radio antenna
must have open space in which to operate. Items car-
ried on the roof, parking inside etc. can have an
effect on the antenna’s ability to receive signals.
REMOVAL
(1) Disconnect and isolate the battery negative
cable.
(2) Lower the rear portion of the headliner as nec-
Fig. 2 Infinity ll Remote Amplifier Location essary to access underside of antenna (Refer to 23 -
1 - RIGHT DECKLID SUPPORT
BODY/INTERIOR/HEADLINER - REMOVAL).
2 - RETAINING SCREWS (3) A adhesive removal tool can be created by
3 - RIGHT INNER FENDER WELL using a 18 to 24 inch piece of nylon cord wrapped
around two handles. (Fig. 3). Using the removal tool,
(5) Connect the negative battery cable. guide the nylon cord under the dust seal on the for-
ward side of the antenna. Grab the handles and work
the cord through the adhesive. Continue this for 360°
ANTENNA BODY & CABLE around the antenna.
REMOVAL
(1) Disconnect and isolate the battery negative
cable.
(2) Inside trunk, pull passenger side trunk liner
aside.
(3) Unplug antenna lead from base of antenna
mast.
(4) Remove antenna mast by unscrewing mast
from antenna body.
(5) Remove screw from mounting bracket.
(6) Pull antenna body down through the rubber
grommet.
INSTALLATION
(1) Push antenna body up through the rubber
grommet in the quarter panel.
(2) Install the screw to the mounting bracket. Fig. 3 ANTENNA REMOVAL
(3) Install antenna mast. Tighten to 2 N·m (15 in. 1 - SATELLITE ANTENNA
2 - NYLON CORD
lbs.). Ensure that the antenna mast is fully 3 - WOODEN DOWEL ROD
seated on antenna base and that there is no gap
between the mast and base. (4) Disconnect the wire harness connectors from
(4) Plug antenna lead into the antenna base. the antenna.
ANTENNA - NAVIGATION
RADIO
REMOVAL
(1) Disconnect and isolate the battery negative
cable.
(2) Remove the radio (Refer to 8 - ELECTRICAL/
AUDIO/RADIO - REMOVAL).
(3) Disconnect antenna from radio. Remove tape
securing antenna to air duct, and remove antenna. Fig. 4 ANTENNA CABLE - SATELLITE RADIO
1 - SATELLITE RECEIVER MODULE
INSTALLATION 2 - SATELLITE RADIO ANTENNA CABLE
(1) Secure antenna to air duct.
(2) Connect antenna to radio. INSTALLATION
(3) Install radio (Refer to 8 - ELECTRICAL/AU- (1) Secure the antenna cable to the body harness.
DIO/RADIO - INSTALLATION). Connect the wire harness connectors at each end of
(4) Connect battery negative cable. the antenna cable.
(2) Install the front and rear door sill trim (Refer
to 23 - BODY/INTERIOR/DOOR SILL TRIM -
ANTENNA CABLE - SATELLITE INSTALLATION).
RADIO (3) Install the lower quarter trim (Refer to 23 -
BODY/INTERIOR/LOWER QUARTER TRIM -
DESCRIPTION INSTALLATION).
The satellite radio antenna connects the roof (4) Install the headliner (Refer to 23 - BODY/IN-
mounted antenna to the satellite receiver module. It TERIOR/HEADLINER - INSTALLATION).
has two connectors at each end and is routed above (5) Connect the battery negative cable.
the headliner, then down the right side of the vehicle
floor below the carpet.
CD CHANGER (5) Place center trim bezel into position and snap
into place.
(6) Install ash receiver (if applicable).
DESCRIPTION
(7) Connect the negative battery cable remote ter-
The 6 Disc In-Dash CD Changer (if equipped) is
minal to the remote battery post.
located in the existing cubby bin. It is a cartridge-
less changer controlled by the radio and allows the
occupants to load up to six discs, one at a time. MULTIPLEXER
OPERATION REMOVAL
Due to its compact design, the CD changer can
(1) Disconnect and isolate the battery negative
only carry out one operation at a time. For example,
cable.
you can not load a new disc while playing another at
(2) Remove the radio (Refer to 8 - ELECTRICAL/
the same time. Each operation happens sequentially.
AUDIO/RADIO - REMOVAL).
The radio unit provides control over all features of
(3) Remove mounting fasteners (Fig. 5).
the CD changer with the exception of the CD load
and eject functions, which are controlled by buttons
located on the front of the CD changer. All features
you would expect, such as Disc Up/Down, Track
Up/Down, Random and Scan are controlled by the
radio, which also displays all relevant CD changer
information on the radio display.
The CD changer contains a Load/Eject button and
an indicator light for each of the six disc positions.
The individual light indicates whether a CD is cur-
rently loaded in that particular chamber of the CD
changer. Pressing the individual Load/Eject button
for a particular chamber will eject a disc currently
present in that chamber. If the chamber is currently
empty, actuating the Load/Eject button will position
that chamber to receive and load a new disc in that
chamber.
Fig. 5 MULTIPLEXER
REMOVAL 1 - RADIO
2 - MULTIPLEXER
(1) Open hood and disconnect the negative battery 3 - CD CHANGER
cable remote terminal from the remote battery post.
(2) Remove ash receiver (if applicable). (4) Disconnect wire harness connectors and remove
(3) Using a trim stick (special tool #C-4755), gently multiplexer.
pry out on center trim bezel. Disconnect wiring con-
nectors to HVAC controls, cigar lighter/auxiliary INSTALLATION
power outlet and traction control switch. (1) Connect wire harness connectors and place
(4) Remove instrument panel center trim bezel. multiplexer into position.
(5) Remove two retaining screws to in-dash CD (2) Install mounting fasteners.
changer. (3) Install radio (Refer to 8 - ELECTRICAL/AU-
(6) Pull CD changer out of instrument panel, dis- DIO/RADIO - INSTALLATION).
connect wiring and remove from vehicle. (4) Connect battery negative cable.
INSTALLATION
(1) Connect wiring and install CD changer into RADIO
instrument panel. Make sure the rubber bumper
engages into the instrument panel. DESCRIPTION
(2) Install two retaining screws to in-dash CD Available factory-installed radio receivers for this
changer. model include:
(3) Install instrument panel center trim bezel. • AM/FM/cassette/CD (RAZ sales code)
(4) Connect wiring connectors to HVAC controls, • AM/FM/cassette with CD changer control fea-
cigar lighter/auxiliary power outlet and traction con- ture (RBB sales code)
trol switch.
INSTALLATION
(1) Place radio near instrument panel opening.
(2) Connect wiring and antenna lead to radio and
slide into place.
(3) Install four radio mounting screws.
REMOVAL
(1) Open hood and disconnect the negative battery
cable remote terminal from the remote battery post.
(2) Remove right upper quarter trim panel. (Refer
to 23 - BODY/INTERIOR/UPPER QUARTER TRIM -
REMOVAL).
(3) Remove the attaching screw from module.
(4) Disconnect wire connectors and radio antenna
coaxial cable (Fig. 8).
(5) Remove module from vehicle.
INSTALLATION
(1) Install module from vehicle.
(2) Connect wire connectors and radio antenna
coaxial cable (Fig. 8).
(3) Install the attaching screw to module.
(4) Install right upper quarter trim panel. (Refer
to 23 - BODY/INTERIOR/UPPER QUARTER TRIM -
Fig. 10 REMOTE RADIO SWITCHES
INSTALLATION).
1 - PRESET ADVANCE
(5) Connect the negative battery cable remote ter- 2 - SEEK
minal to the remote battery post. 3 - MODE ADVANCE
4 - VOLUME
REMOTE SWITCHES BCM sends a five volt reference signal to both switch
units on one circuit, and senses the status of all of
DESCRIPTION the switches by reading the voltage drop on a second
Remote radio control switches are rocker-type circuit.
switch units (Fig. 10) are mounted in the upper When the BCM senses an input (voltage drop) from
spoke covers of the rear (instrument panel side) any one of the remote radio switches, it sends the
steering wheel trim cover. The switch unit on the left proper switch status messages on the Programmable
side is the seek switch and has seek up, seek down, Communication Interface (PCI) data bus network to
and preset station advance switch functions. The the radio receiver. The electronic circuitry within the
switch unit on the right side is the volume control radio receiver is programmed to respond to these
switch and has volume up, volume down, and mode remote radio switch status messages by adjusting the
advance switch functions. radio settings as requested. For diagnosis of the
The two remote radio switch units are each BCM or the PCI data bus, the use of a DRB III scan
retained in a mounting hole located on opposite sides tool and the proper Body Diagnostic Procedures man-
of the rear steering wheel trim cover by four integral ual are recommended.
snap features. A plastic bracket on the back of each For more information on the features and control
switch unit provides additional support for the unit functions for each of the remote radio switches, see
by extending towards the center of the steering the owner’s manual in the vehicle glove box.
wheel where it is clamped between the steering
wheel armature and the steering wheel rear trim DIAGNOSIS AND TESTING - REMOTE
cover mounting boss by the trim cover mounting SWITCHES
screw. Any diagnosis of the Audio system should
The two remote radio switch units share a common begin with the use of the DRB IIIt diagnostic
steering wheel wire harness with the vehicle speed tool. For information on the use of the DRB
control switches. The steering wheel wire harness is IIIt, refer to the appropriate Diagnostic Service
connected to the instrument panel wire harness Manual.
through the clockspring. Refer to the appropriate wiring information. The
wiring information includes wiring diagrams, proper
OPERATION wire and connector repair procedures, details of wire
The six switches in the two remote radio switch harness routing and retention, connector pin-out
units are normally open, resistor multiplexed information and location views for the various wire
momentary switches that are hard wired to the Body harness connectors, splices and grounds.
Control Module (BCM) through the clockspring. The
INFINITY l SYSTEM
The Infinity l System includes:
• A 240 watt Infinity power amplifier with six out-
put channels
• One 2.5 inch, round single-cone, spatial imaging
speaker in the center of the instrument panel.
• Two 2.5 inch round, single cone, spatial imaging
speakers in the lower corners of the front door win-
dows.
• Two 6.5 inch, round single-cone speakers in the
Fig. 13 SATELLITE RECEIVER MODULE front doors.
1 - SATELLITE RECEIVER MODULE • Two 6 x 9-inch, single-cone speakers mounted in
2 - FRONT PASSENGER DOOR
the rear shelf panel.
(4) Pull satellite receiver module inboard, and then
downward to remove from upper retaining clips. INFINITY ll SYSTEM
(5) Disconnect wiring harness connectors. The Infinity ll System includes:
(6) Remove satellite receiver module from vehicle. • A 360 watt power amplifier with nine output
channels, one for each speaker location.
INSTALLATION • One 2.5 inch, round single-cone, spatial imaging
speaker in the center of the instrument panel.
(1) Install the satellite receiver module to the vehi-
• Two 2.5 inch round, single cone, spatial imaging
cle.
speakers in the lower corners of the front door win-
(2) Connect the wire harness connectors.
dows.
(3) Push the module upward, and then outboard to
• Two 6.5 inch, round single-cone speakers in the
install into upper retaining clips.
front doors.
(4) Install mounting fasteners.
• Two 6 x 9-inch, single-cone speakers mounted in
(5) Install instrument panel silencer (Refer to 23 -
the rear shelf panel.
BODY/INSTRUMENT PANEL/INSTRUMENT
• Two 2.5 inch, round speakers mounted in the
PANEL TOP COVER - INSTALLATION).
rear doors.
(6) Connect the battery negative cable.
OPERATION
SPEAKER Two wires connected to each speaker, one feed cir-
cuit (+) and one return circuit (–), allow the audio
DESCRIPTION output signal electrical current to flow through the
There are four different system combinations avail- voice coil. For complete circuit diagrams, refer to the
able on the LH models. They are a Base, Midline, appropriate wiring information. The wiring informa-
Infinity l, and Infinity ll system. tion includes wiring diagrams, proper wire and con-
nector repair procedures, details of wire harness
BASE SYSTEM routing and retention, connector pin-out information
The Base System includes: and location views for the various wire harness con-
• Two 6.5 inch round, full-range speakers in the nectors, splices and grounds.
front doors.
DIAGNOSIS AND TESTING - SPEAKER Step 6. If not OK, repair the shorted speaker feed (+)
Any diagnosis of the Audio system should and/or return (-) circuits(s) to the speaker as
begin with the use of the DRB IIIt diagnostic required.
tool. For information on the use of the DRB (6) Disconnect wire harness connector at the inop-
IIIt, refer to the appropriate Diagnostic Service erative speaker. Check for continuity between the
Manual. speaker feed (+) circuit cavities of the radio receiver
Refer to the appropriate wiring information. The wire harness connector or if equipped, the amplifier
wiring information includes wiring diagrams, proper wire harness connector and the speaker wire harness
wire and connector repair procedures, details of wire connector. Repeat the check between the speaker
harness routing and retention, connector pin-out return (-) circuit cavities of the radio receiver wire
information and location views for the various wire harness connector and the speaker wire harness con-
harness connectors, splices and grounds. nector. In each case, there should be continuity. If
OK, replace the faulty speaker. If not OK, repair the
WARNING: DISABLE THE AIRBAG SYSTEM open speaker feed (+) and/or return (-) circuits(s) as
BEFORE ATTEMPTING ANY STEERING WHEEL, required.
STEERING COLUMN, SEAT BELT TENSIONER, SIDE
AIRBAG, OR INSTRUMENT PANEL COMPONENT REMOVAL
DIAGNOSIS OR SERVICE. DISCONNECT AND ISO-
LATE THE BATTERY NEGATIVE (GROUND) CABLE, FRONT DOOR - LOWER
THEN WAIT TWO MINUTES FOR THE AIRBAG SYS- (1) Disconnect and isolate the battery negative
TEM CAPACITOR TO DISCHARGE BEFORE PER- cable.
FORMING FURTHER DIAGNOSIS OR SERVICE. THIS (2) Open drivers door.
IS THE ONLY SURE WAY TO DISABLE THE AIRBAG (3) Using a trim stick (special tool #C-4755), care-
SYSTEM. FAILURE TO TAKE THE PROPER PRE- fully pry speaker grille away from door trim panel
CAUTIONS COULD RESULT IN ACCIDENTAL AIR- (Fig. 14).
BAG DEPLOYMENT AND POSSIBLE PERSONAL (4) Remove three speaker retaining screws.
INJURY. (5) Pull speaker away from door and disconnect
wiring.
INSTRUMENT PANEL
(1) Place speaker into position on instrument
panel.
(2) connect wiring connector, install two retaining
screws to center speaker.
(3) Install instrument panel top cover.
(4) Connect battery negative cable.
REAR DOOR
(1) Connect wiring and place speaker in door
speaker opening.
(2) Install two speaker retaining screws.
(3) Place speaker grille into place and firmly snap
into place on the door trim panel.
(4) Connect battery negative cable.
Fig. 15 Rear Door Speaker
1 - DOOR SPEAKER REAR SHELF
(1) Connect wire connector and place speaker into
(4) Remove two speaker retaining screws. speaker opening.
(5) Pull speaker away from door and disconnect
wiring. CAUTION: Be sure that the wiring connectors are
facing forward when installed.
REAR SHELF
(1) Disconnect and isolate the battery negative (2) Install the four retaining screws.
cable. (3) Install the rear shelf trim panel.
(2) Remove the rear shelf trim panel. (Refer to 23 - (4) Connect battery negative cable.
BODY/INTERIOR/REAR SHELF TRIM PANEL -
REMOVAL).
CHIME/BUZZER
TABLE OF CONTENTS
page page
CLOCK
TABLE OF CONTENTS
page page
page page
CLUTCH VOLUMES
When Updated Proper Clutch
Clutch
Shift Sequence Oil Temperature Throttle Angle Volume
2-1 or 3-1 coast
L/R > 70° < 5° 35 to 83
downshift
2/4 1-2 shift 20 to 77
5 - 54°
OD 2-3 shift > 110° 48 to 150
UD 4-3 or 4-2 shift > 5° 24 to 70
ENGINE SYSTEMS
TABLE OF CONTENTS
page page
BATTERY SYSTEM
TABLE OF CONTENTS
page page
THE BATTERY SEEMS 1. The electrical system 1. Refer to the IGNITION-OFF DRAW TEST
WEAK OR DEAD WHEN ignition-off draw is excessive. Standard Procedure for the proper test
ATTEMPTING TO START procedures. Repair the excessive ignition-off
THE ENGINE. draw, as required.
2. The charging system is 2. Determine if the charging system is performing
faulty. to specifications. Refer to Charging System for
additional charging system diagnosis and testing
procedures. Repair the faulty charging system, as
required.
3. The battery is discharged. 3. Determine the battery state-of-charge using the
Micro 420 battery tester. Refer to the Standard
Procedures in this section for additional test
procedures. Charge the faulty battery, as
required.
4. The battery terminal 4. Refer to Battery Cables for the proper battery
connections are loose or cable diagnosis and testing procedures. Clean
corroded. and tighten the battery terminal connections, as
required.
5. The battery has an 5. Refer to Battery System Specifications for the
incorrect size or rating for proper size and rating. Replace an incorrect
this vehicle. battery, as required.
6. The battery is faulty. 6. Determine the battery cranking capacity using
the Micro 420 battery tester. Refer to the
Standard Procedures in this section for additional
test procedures. Replace the faulty battery, as
required.
7. The starting system is 7. Determine if the starting system is performing
faulty. to specifications. Refer to Starting System for the
proper starting system diagnosis and testing
procedures. Repair the faulty starting system, as
required.
8. The battery is physically 8. Inspect the battery for loose terminal posts or a
damaged. cracked and leaking case. Replace the damaged
battery, as required.
THE BATTERY STATE OF 1. The battery has an 1. Refer to Battery System Specifications for the
CHARGE CANNOT BE incorrect size or rating for proper specifications. Replace an incorrect
MAINTAINED. this vehicle. battery, as required.
2. The battery terminal 2. Refer to Battery Cable for the proper cable
connections are loose or diagnosis and testing procedures. Clean and
corroded. tighten the battery terminal connections, as
required.
3. The electrical system 3. Refer to the IGNITION-OFF DRAW TEST
ignition-off draw is excessive. Standard Procedure for the proper test
procedures. Repair the faulty electrical system, as
required.
4. The battery is faulty. 4. Test the battery using the Micro 420 battery
tester. Refer to Standard Procedures for
additional test procedures. Replace the faulty
battery, as required.
5. The starting system is 5. Determine if the starting system is performing
faulty. to specifications. Refer to Starting System for the
proper starting system diagnosis and testing
procedures. Repair the faulty starting system, as
required.
6. The charging system is 6. Determine if the charging system is performing
faulty. to specifications. Refer to Charging System for
additional charging system diagnosis and testing
procedures. Repair the faulty charging system, as
required.
7. Electrical loads exceed the 7. Inspect the vehicle for aftermarket electrical
output of the charging equipment which might cause excessive electrical
system. loads.
8. Slow driving or prolonged 8. Advise the vehicle operator, as required.
idling with high-amperage
draw systems in use.
THE BATTERY WILL NOT 1. The battery is faulty. 1. Test the battery using the Micro 420 battery
ACCEPT A CHARGE. tester.. Charge or replace the faulty battery, as
required.
SPECIFICATIONS
The battery Group Size number, the Cold Cranking
Amperage (CCA) rating, and the Reserve Capacity
(RC) rating or Ampere-Hours (AH) rating can be
found on the original equipment battery label. Be
certain that a replacement battery has the correct
Group Size number, as well as CCA, and RC or AH
ratings that equal or exceed the original equipment
specification for the vehicle being serviced. Battery
sizes and ratings are discussed in more detail below.
Fig. 1 Battery Cleaning - Typical • Group Size - The outside dimensions and ter-
minal placement of the battery conform to standards
1 - CLEANING BRUSH
2 - WARM WATER AND BAKING SODA SOLUTION established by the Battery Council International
3 - BATTERY (BCI). Each battery is assigned a BCI Group Size
number to help identify a correctly-sized replace-
(4) If equipped, clean the battery heater blanket ment.
with a sodium bicarbonate (baking soda) and warm • Cold Cranking Amperage - The Cold Crank-
ing Amperage (CCA) rating specifies how much cur-
(2) Determine that the underhood lamp is operat- battery negative cable terminal clamp and the bat-
ing properly, then disconnect the lamp wire harness tery negative terminal post. If continuity between the
connector or remove the lamp bulb. battery negative terminal post and the negative cable
(3) Disconnect the battery negative cable. terminal clamp is lost during any part of the IOD
(4) Set an electronic digital multi-meter to its test, the electronic timer function will be activated
highest amperage scale. Connect the multi-meter and all of the tests will have to be repeated.
between the disconnected battery negative cable ter- (5) After about three minutes, the high-amperage
minal clamp and the battery negative terminal post. IOD reading on the multi-meter should become very
Make sure that the doors remain closed so that the low or nonexistent, depending upon the electrical
illuminated entry system is not activated. The multi- equipment in the vehicle. If the amperage reading
meter amperage reading may remain high for up to remains high, remove and replace each fuse or circuit
three minutes, or may not give any reading at all breaker in the Power Distribution Center (PDC) and
while set in the highest amperage scale, depending then in the Junction Block (JB), one at a time until
upon the electrical equipment in the vehicle. The the amperage reading becomes very low, or nonexist-
multi-meter leads must be securely clamped to the ent. Refer to the appropriate wiring information in
(2) Connect the positive lead of the voltmeter to Fig. 8 Test Battery Positive Cable Resistance -
the battery positive terminal post. Connect the nega- Typical
tive lead of the voltmeter to the battery positive cable 1 - BATTERY
terminal clamp (Fig. 7). Rotate and hold the ignition 2 - VOLTMETER
switch in the Start position. Observe the voltmeter. If 3 - STARTER MOTOR
voltage is detected, correct the poor connection
OPERATION
The battery tray provides a secure mounting loca-
tion and supports the battery. On some vehicles, the
battery tray also provides the anchor point/s for the
battery holddown hardware. The battery tray and
the battery holddown hardware combine to secure
and stabilize the battery in the engine compartment,
which prevents battery movement during vehicle
operation. Unrestrained battery movement during
vehicle operation could result in damage to the vehi-
cle, the battery, or both.
REMOVAL
(1) Turn the ignition switch to the Off position. Be
certain that all electrical accessories are turned off.
(2) Disconnect and isolate the remote battery neg-
ative cable terminal.
(3) Remove the battery from the vehicle. Refer to
the procedure in this group.
(4) One at a time, trace the battery cable retaining
pushpins, fasteners and routing clips until the cables
are free from the vehicle.
(5) Remove the battery cables from the engine
compartment.
INSTALLATION
(1) Position the battery cables in the engine com-
partment.
(2) One at a time, install the battery cable retain-
ing pushpins, fasteners and routing clips until the
cables are installed exactly where they were in the
vehicle.
(3) Install the battery in the vehicle. Refer to the
procedure in this group. Fig. 10 LH Heater Blanket
(4) Connect the remote battery negative cable ter- A heater blanket (Fig. 10) is used to improve the
minal. battery cold-start ability. This blanket operates on
110 volt AC current and is used with Alaska and
Canada cold weather packages.
CHARGING
TABLE OF CONTENTS
page page
CHARGING OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . . 19
DESCRIPTION - CHARGING SYSTEM . . . . . . . 17 REMOVAL
OPERATION - CHARGING SYSTEM . . . . . . . . . 17 REMOVAL - 2.7L . . . . . . . . . . . . . . . . . . . . . . 20
DIAGNOSIS AND TESTING - ON-BOARD REMOVAL - 3.5L . . . . . . . . . . . . . . . . . . . . . . 20
DIAGNOSTIC SYSTEM . . . . . . . . . . . . . . . . . 18 INSTALLATION
SPECIFICATIONS INSTALLATION - 2.7L . . . . . . . . . . . . . . . . . . 21
GENERATOR .................. . . . . . . 19 INSTALLATION - 3.5L . . . . . . . . . . . . . . . . . . 21
SPECIFICATIONS - TORQUE ...... . . . . . . 19 VOLTAGE REGULATOR
GENERATOR DESCRIPTION . . . . . . . . . . . . . . . . . . . . . . . . . 21
DESCRIPTION . . . . . . . . . . . . . . . . . . . . . . . . . 19 OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . . 21
SPECIFICATIONS
GENERATOR
SPECIFICATIONS - TORQUE
TORQUE SPECIFICATIONS
STARTING
TABLE OF CONTENTS
page page
STARTER 1. BROKEN TEETH ON 1. REMOVE STARTER. INSPECT RING GEAR AND REPLACE
ENGAGES, STARTER RING GEAR. IF NECESSARY.
SPINS OUT
BEFORE
ENGINE
STARTS.
2. STARTER ASSEMBLY 2. IF ALL OTHER STARTING SYSTEM COMPONENTS AND
FAULTY. CIRCUITS CHECK OK, REPLACE STARTER ASSEMBLY.
SPECIFICATIONS - TORQUE
STARTER MOTOR
DESCRIPTION
DESCRIPTION - 2.7L
The Melco is a permanent magnet starter motor.
DESCRIPTION - 3.5L
The Nippondenso is a reduction gear-field coil
starter motor.
OPERATION
OPERATION - 2.7L
A planetary gear train transmits power between
starter motor and pinion shaft. The fields have per-
manent magnets.
INSTALLATION
(1) Connect battery positive feed wire to starter.
(2) Connect posi-lock starter solenoid connector.
(3) Jack engine up slightly to give more room to
maneuver starter assembly.
(4) Install the starter.
(5) Install three bolts attaching starter to engine
Fig. 1 NEGATIVE BATTERY CABLE (Fig. 2). Tighten all fasteners to the proper torque.
1 - RIGHT STRUT TOWER Refer to the Torque Specifications chart in this section.
2 - AIR CLEANER INLET TUBE (6) Install three left engine mount mounting bolts
3 - REMOTE TERMINAL
to engine block.
(2) Raise vehicle. (7) Install starter solenoid assembly from trans-
(3) Remove three bolts attaching starter to engine mission housing. Position the starter to gain access
(Fig. 2). to the Connector Positive Assurance (CPA) wiring
(4) Remove battery positive feed wire from starter. connector.
(5) Remove starter solenoid assembly from trans- (8) Lower vehicle.
mission housing. Position the starter to gain access (9) Connect the battery negative cable (Fig. 1).
DESCRIPTION
The Starter Relay is a micro relay located in the
Power Distribution Center (PDC), positioned in the
left front corner of the engine compartment.
OPERATION
As battery power is applied to the relay from the
ignition switch, battery power is applied to the
starter motor through the relay to the starter sole-
noid.
DIAGNOSIS AND TESTING - STARTER RELAY gized position. This terminal supplies battery voltage
to the starter solenoid field coils. There should be
WARNING: CHECK TO ENSURE THAT THE TRANS- continuity between the cavity for relay terminal 87
MISSION IS IN THE PARK POSITION/NEUTRAL and the starter solenoid terminal at all times. If OK,
WITH THE PARKING BRAKE APPLIED go to Step 4. If not OK, repair the open circuit to the
starter solenoid as required.
The starter relay is located in the Power Distribu- (4) The coil battery terminal (86) is connected to
tion Center (PDC) in the engine compartment. Refer the electromagnet in the relay. It is energized when
to the PDC label for relay identification and location. the ignition switch is held in the Start position.
Remove the starter relay from the PDC as Check for battery voltage at the cavity for relay ter-
described in this group to perform the following tests. minal 86 with the ignition switch in the Start posi-
Refer to Starter Relay Chart for terminal numbers tion, and no voltage when the ignition switch is
and locations. released to the On position. If OK, go to Step 5. If
(1) A relay in the de-energized position should not OK, check for an open or short circuit to the igni-
have continuity between terminals 87A and 30, and tion switch and repair, if required. If the circuit to
no continuity between terminals 87 and 30. If OK, go the ignition switch is OK, refer to the Ignition Switch
to Step 2. If not OK, replace the faulty relay. Test procedure in this group.
(2) Resistance between terminals 85 and 86 (elec- (5) The coil ground terminal (85) is connected to
tromagnet) should be 75 ±5 ohms. If OK, go to Step the electromagnet in the relay. The relay is grounded
3. If not OK, replace the faulty relay. through Pin 8 of the PCM, when the gear selector
(3) Connect a battery B+ lead to terminals 86 and lever is in the Park or Neutral position. Check for
a ground lead to terminal 85 to energize the relay. continuity to ground at the cavity for relay terminal
The relay should click. Also test for continuity 85, when the gear selector lever is in the Park or
between terminals 30 and 87, and no continuity Neutral position. If not OK, check for an open circuit
between terminals 87A and 30. If OK, refer to to Pin 8 of the PCM and from Pin 76 of the PCM to
Starter Relay Circuit Test procedure. If not OK, transmission range sensor. Repair as necessary. If
replace the faulty relay. both circuits are OK, refer to the Transmission
Range Sensor Test in Transaxle. If the Transmission
STARTER RELAY CIRCUIT TEST Range Sensor test OK, and all other tests are OK,
(1) The relay common feed terminal cavity (30) is replace the PCM.
connected to battery voltage and should be hot at all
times. If OK, go to Step 2. If not OK, repair the open REMOVAL
circuit to the PDC fuse as required. The relay is located in the Power Distribution Cen-
(2) The relay normally closed terminal (87A) is ter (PDC). Refer to the PDC cover for relay location.
connected to terminal 30 in the de-energized position,
but is not used for this application. Go to Step 3.
(3) The relay normally open terminal (87) is con-
nected to the common feed terminal (30) in the ener-
HEATED SYSTEMS
TABLE OF CONTENTS
page page
HEATED GLASS
TABLE OF CONTENTS
page page
REAR WINDOW DEFOGGER relay contact is held against one of the fixed contacts
(normally closed) by spring pressure. When the elec-
RELAY tromagnetic coil is energized, it draws the movable
contact away from the normally closed fixed contact,
DESCRIPTION and holds it against the other (normally open) fixed
The rear window defogger relay is an electrome- contact.
chanical device that switches fused battery current to When the electromagnetic coil is de-energized,
the rear glass heating grid and the Light-Emitting spring pressure returns the movable contact to the
Diode (LED) indicator of the rear window defogger normally closed position. The resistor or diode is con-
switch, when the Body Control Module (BCM) rear nected in parallel with the electromagnetic coil in the
window defogger timer and logic circuitry grounds relay, and helps to dissipate voltage spikes that are
the relay coil. The rear window defogger relay is produced when the coil is de-energized.
located in the right rear trunk area behind the car-
peting. DIAGNOSIS AND TESTING - REAR WINDOW
The rear window defogger relay is a International DEFOGGER RELAY
Standards Organization (ISO) relay. Relays conform-
(1) Stop the engine. Connect the negative lead of a
ing to the ISO specifications have common physical
0-15 volt range voltmeter to a known good vehicle
dimensions, current capacities, terminal patterns,
electrical ground.
and terminal functions.
(2) Reconnect rear window grid connections if dis-
The rear window defogger relay cannot be repaired
connected for the Fuse and Electrical Short Test.
or adjusted and, if faulty or damaged, it must be
Start the engine check the voltages present at the
replaced.
rear window defogger relay and rear window defog-
ger grid (Fig. 3). Refer to the Rear Window Defogger
OPERATION Relay Test table for diagnosis.
The ISO relay consists of an electromagnetic coil, a
resistor or diode, and three (two fixed and one mov-
able) electrical contacts. The movable (common feed)
VOLTAGE AT
SYSTEM REAR WINDOW
VOLTAGE AT REAR WINDOW
ON OR OFF DEFOGGER
DEFOGGER RELAY POINT TO
POTENTIAL PROBLEM WITH GRID TO GOOD
GOOD VEHICLE GROUND
ENGINE VEHICLE
RUNNING GROUND
1 2 3 4 A B
NO PROBLEM. VOLTAGES AS MORE MORE MORE
EXPECTED WITH THE SYSTEM OFF THAN THAN 0 THAN 0 0
OFF. 11 11 11
NO PROBLEM. VOLTAGES AS MORE MORE MORE LESS MORE LESS
EXPECTED WITH THE SYSTEM ON THAN THAN THAN THAN THAN THAN
ON. 11 11 11 1.0 11 1.0
MORE MORE LESS
RELAY CONTACTS NOT CLOSING.
ON THAN THAN 0 THAN 0 0
REPLACE RELAY.
11 11 1.0
WIRING OPEN BETWEEN BODY
CONTROL MODULE AND REAR MORE MORE MORE
WINDOW DEFOGGER RELAY, OR, ON THAN THAN 0 THAN 0 0
DEFECTIVE BODY CONTROL 11 11 11
MODULE.
VOLTAGE AT
SYSTEM REAR WINDOW
VOLTAGE AT REAR WINDOW
ON OR OFF DEFOGGER
DEFOGGER RELAY POINT TO
POTENTIAL PROBLEM WITH GRID TO GOOD
GOOD VEHICLE GROUND
ENGINE VEHICLE
RUNNING GROUND
1 2 3 4 A B
POOR CONNECTION BETWEEN
MORE MORE MORE LESS
PIN 3 OF RELAY AND POSITIVE
ON THAN THAN THAN THAN 0 0
CONNECTION ON REAR WINDOW
11 11 11 1.0
DEFOGGER GRID CIRCUIT.
POOR CONNECTION TO GROUND MORE MORE MORE LESS MORE MORE
ON NEGATIVE SIDE OF REAR ON THAN THAN THAN THAN THAN THAN
WINDOW DEFOGGER GRID. 11 11 11 1.0 11 11
POOR WIRING CONNECTION
MORE
BETWEEN PINS 1 TO 2 OF THE
ON THAN 0 0 0 0 0
REAR WINDOW DEFOGGER
11
RELAY.
OPEN FUSE OR OPEN WIRING
CONNECTION TO PIN 1 OF REAR ON 0 0 0 0 0 0
WINDOW DEFOGGER RELAY.
RELAY CONTACTS SHORTED. MORE MORE MORE MORE MORE
REPLACE RELAY. REAR WINDOW OFF THAN THAN THAN THAN THAN 0
DEFOGGER WILL NOT TURN OFF. 11 11 11 11 11
INSTALLATION
(1) Plug the relay into the wire harness connector.
(2) Install the relay fastener screw.
(3) Place the carpet back into position and install
the fasteners.
(4) Connect the negative battery cable to the
remote ground post.
(5) Test the rear window defogger system for
proper operation.
HEATED MIRRORS
TABLE OF CONTENTS
page page
TABLE OF CONTENTS
page page
HEATED SEAT SYSTEM mounted under the drivers front seat cushion. Refer
to the Electronic Control Modules section for addi-
tional memory heated seat/mirror module informa-
DESCRIPTION
tion.
Individually controlled, electrically heated front
• Heated Seat Sensors - Two heated seat sen-
seats are available as a factory-installed option on
sors are used per vehicle, one for each front seat
some LH models. Vehicles with this option can be
cushion. The sensors are integral to the individual
visually identified by the leather trim seats and the
front seat cushion heating elements and cannot be
two separate heated seat switches mounted in the
removed once installed at the factory. Refer to heated
seat cushion side shields. The heated seat system
seat sensor later in this section for additional infor-
allows the front seat driver and passenger to select
mation.
from two different levels of electrical seat heating, or
• Heated Seat Switches - Two heated seat
no seat heating to suit their individual comfort
switches are used per vehicle. One switch is mounted
requirements. The heated seat system for this vehicle
in each of the front seat cushion side shields. Each
includes the following major components, which are
switch includes two Light-Emitting Diode (LED)
described in further detail later in this section:
HI/LO indicator lamps and an incandescent back
• Heated Seat Elements - Four heated seat ele-
lighting bulb. Refer to the appropriate heated seat
ments are used per vehicle, one for each front seat
switch later in this section for additional information.
back and one for each front seat cushion. The heating
elements are integral to the individual front seat and WARNING: SOME VEHICLES ARE EQUIPPED WITH
seat back trim covers and cannot be removed once SEATBACK MOUNTED AIRBAGS. BEFORE
installed at the factory. On some models, replacement ATTEMPTING TO DIAGNOSE OR SERVICE ANY
seat heating elements/sensor are available, without SEAT OR POWER SEAT SYSTEM COMPONENT
having to replace the entire seat cushion or trim YOU MUST FIRST DISCONNECT AND ISOLATE THE
cover. Refer to heated seat element later in this sec- BATTERY NEGATIVE CABLE. THEN WAIT TWO MIN-
tion for additional information. UTES FOR THE SYSTEM CAPACITOR TO DIS-
• Memory Heated Seat/Mirror Module - also CHARGE BEFORE FURTHER SYSTEM SERVICE.
referred to as the MHSMM, this module contains the THIS IS THE ONLY SURE WAY TO DISABLE THE
solid state electronic control and diagnostic logic cir- AIRBAG SYSTEM. FAILURE TO DO SO COULD
cuitry for the heated seat and memory seat/mirror RESULT IN ACCIDENTAL AIRBAG DEPLOYMENT
systems. One module is used per vehicle and is AND POSSIBLE PERSONAL INJURY.
PRELIMINARY TEST
Before testing the individual components in the
heated seat system, check the following:
• Using the DRB IIIt scan tool, check the memory
heated seat/mirror module (MHSMM) for any stored
fault codes. Record these codes on paper for reference
and resolve using the appropriate Body Diagnostic
Procedures Manual.
• Check the vehicles battery open-circuit voltage
and charging system performance. If the vehicles
electrical system is defective or weak it may not be
suppling sufficient energy to operate the heated seat
system. Fig. 1 Heated Seat Switch
• If the heated seat switch backlighting does not
1 - HEATED SEAT SWITCH HOUSING
light with the ignition switch in the On position, 2 - LIGHT EMITTING DIODE (LED) INDICATOR LAMPS
check the fused ignition switch fuse in the junction
block and the G300 ground splice. If OK, refer to signal to the Memory Heated Seat/Mirror Module
Heated Seat Switch Diagnosis and Testing in (MHSMM) via a hard-wired mux circuit. Each switch
this section. If not OK, repair the shorted circuit or has a center neutral position and momentary Low
component as required and replace the faulty fuse or and High positions so that both the driver and the
repair the open ground circuit as required. front seat passenger can select a preferred level of
• If the heated seat switch HI/LO LED indicators seat heating. Each heated seat switch contains two
do not light with the ignition switch in the On posi- Light-Emitting Diode (LED) indicator lamps, which
tion and the heated seat switch in the Low or High indicate the selected mode of the seat heater (HI/LO).
position, check the fused ignition switch fuse in the Each switch also contains a incandescent bulb, which
junction block. If OK, refer to Heated Seat Switch provides dimmer controlled back lighting of the
Diagnosis and Testing in this section. If not OK, switch when the headlamps or park lamps are on.
repair the shorted circuit or component as required The two LED indicator lamps and the incandescent
and replace the faulty fuse. bulb in each heated seat switch cannot be repaired or
• If the heated seat switch HI/LO LED indicators replaced. If the LED indicator lamps or back lighting
light, but the heating elements do not heat, check cir- bulb are faulty or damaged, the complete heated seat
cuit breaker #2 in the junction block. If OK, refer to switch must be replaced.
Heated Seat Element Diagnosis and Testing in
this section. If not OK, replace the faulty circuit OPERATION
breaker. The heated seat switches receive battery current
through a fused ignition switch output (run) circuit
when the ignition switch is in the On position.
DRIVER HEATED SEAT Depressing the heated seat switch rocker to its
SWITCH momentary High or Low position provides a hard-
wired resistance signal to the Memory Heated Seat/
DESCRIPTION Mirror Module (MHSMM). This signal tells the
The heated seat switches are located on the out- module to energize the heated seat element of the
board seat cushion side shield of the driver and pas- selected seat and maintain the requested tempera-
senger front seats. ture setting. If the heated seat switch is depressed to
The momentary, bidirectional rocker-type heated a different position (LO or HI) than the currently
seat switch (Fig. 1) provides a resistor-multiplexed selected state, the module will change states to sup-
DIAGNOSIS AND TESTING - DRIVER HEATED Fig. 2 Heated Seat Switch (Rear View)
SEAT SWITCH
HEATED SEAT SWITCH PIN IDENTIFICATION
Inspect the Heated Seat Switch for apparent dam-
age or sticking/binding condition, replace if necessary.
Refer to Heated Seat Switch Removal and Installa- PIN FUNCTION
tion. For circuit description and diagrams, refer to 1 LO LED
Wiring.
2 OPEN
(1) Remove the heated seat switch from its mount-
ing location. Refer to Heated Seat Switch Removal 3 GROUND
and Installation. 4 IGNITION FEED
(2) Using an ohm meter, check the ground circuit 5 HI LED
cavity of the heated seat switch electrical connector
for a good continuity to ground. If OK, go to Step 3. 6 REQUEST LINE
If not OK, repair the open ground circuit as required.
(3) Turn the ignition switch to the RUN position. HEATED SEAT SWITCH TESTING
Using an volt meter, check the 12v (B+) circuit cavity
of the heated seat switch electrical connector for 12v. CONTINUITY SWITCH READING
If OK, go to Step 4. If not OK, repair the open or BETWEEN POSITION
shorted 12v B+ circuit as required. PIN 4 AND 6 OFF 2200 OHMS
(4) Turn the ignition switch OFF. Using an ohm
meter, check the continuity between pin 4 and pin 6 PIN 4 AND 6 LO 415 OHMS
of the heated seat switch, while in its neutral, LO PIN 4 AND 6 HI 33 OHMS
and HI positions. Measure the resistance between
the two pins and compare with the chart below (Fig. REMOVAL
2). If the readings do not correspond to those in the (1) Disconnect and isolate the negative battery
Heated Seat Switch Continuity table, replace the cable remote terminal from the remote battery post.
heated seat switch. (2) Remove the appropriate seat cushion side
shield (Fig. 3). Refer to the Body section of this man-
ual for the procedure.
INSTALLATION
(1) Connect the heated seat switch electrical con-
nector
Fig. 5 Heated Seat Switch (Rear View)
(2) Push the heated seat switch into its mounting
location.
(3) Install the appropriate seat cushion side shield.
Refer to the Body section of this manual for the pro-
cedure.
(4) Connect the remote negative battery cable.
HORN
TABLE OF CONTENTS
page page
DIAGNOSIS AND TESTING - HORN SYSTEM Check fuse 18 in the Junction Block and fuse L in
the Power Distribution Center. Refer to Horn System
WARNING: DISABLE THE AIRBAG SYSTEM Test table.
BEFORE ATTEMPTING ANY STEERING WHEEL,
STEERING COLUMN, SEAT BELT TENSIONER, SIDE
HORN INSTALLATION
(1) Position both horns and the mounting bracket
DIAGNOSIS AND TESTING - HORN onto the vehicle as a unit.
(1) Disconnect wire connector at each horn. (2) Install and tighten the screw that secures the
(2) Using a voltmeter, connect one lead to body horn mounting bracket to vehicle. Tighten the screw
ground and the other lead to the horn relay output to 11.3 N·m (100 in. lbs.).
pin of the horn connector (Fig. 1). (3) Connect the wire connector.
(4) Connect the battery negative cable.
HORN CONNECTOR PIN CALL-OUT
HORN RELAY
PIN # CIRCUIT NAME
1 GROUND DIAGNOSIS AND TESTING - HORN RELAY
2 HORN RELAY OUTPUT (1) Remove horn relay.
(2) Using ohmmeter, test between relay connector
terminals 85 to 86 for 75 ± 8 ohms resistance. If
resistance not OK, replace relay (Fig. 2).
HORN SWITCH
DIAGNOSIS AND TESTING - HORN SWITCH
WARNING: DISABLE THE AIRBAG SYSTEM
BEFORE ATTEMPTING ANY STEERING WHEEL,
STEERING COLUMN, SEAT BELT TENSIONER, SIDE
AIRBAG, OR INSTRUMENT PANEL COMPONENT
DIAGNOSIS OR SERVICE. DISCONNECT AND ISO-
LATE THE BATTERY NEGATIVE (GROUND) CABLE,
THEN WAIT TWO MINUTES FOR THE AIRBAG SYS-
TEM CAPACITOR TO DISCHARGE BEFORE PER-
FORMING FURTHER DIAGNOSIS OR SERVICE. THIS
IS THE ONLY SURE WAY TO DISABLE THE AIRBAG
SYSTEM. FAILURE TO TAKE THE PROPER PRE-
CAUTIONS COULD RESULT IN ACCIDENTAL AIR-
BAG DEPLOYMENT AND POSSIBLE PERSONAL
INJURY.
Fig. 3 Horn Relay Location (1) Using ohmmeter, connect one lead to ground
1 - HORN RELAY wire and the other lead to the positive wire (Fig. 4).
(2) Depress horn switch, continuity should be
present. Repeat for other switch. If no continuity,
replace switches.
IGNITION CONTROL
TABLE OF CONTENTS
page page
SPECIFICATIONS
TORQUE
SPARK PLUGS
AUTO SHUT DOWN RELAY For both SBEC and NGC vehicles, the ASD relay
also provides a sense circuit to the PCM for diagnos-
tic purposes. If the PCM does not receive 12 volts
DESCRIPTION
from this input after grounding the control side of
The relay is located in the Power Distribution Cen-
the ASD relay, it sets a Diagnostic Trouble Code
ter (PDC) (Fig. 1). For the location of the relay
(DTC). The PCM energizes the ASD any time there is
within the PDC, refer to the PDC cover for location.
an engine speed that exceeds a predetermined value
Check electrical terminals for corrosion and repair as
(typically about 50 rpm). The ASD relay can also be
necessary.
energized after the engine has been turned off to per-
form an O2 sensor heater test, if vehicle is equipped
with OBD II diagnostics.
As mentioned earlier, the PCM energizes the ASD
relay during an O2 sensor heater test. This test is
performed only after the engine has been shut off for
SBEC vehicles. On NGC vehicles it checks the O2
heater upon vehicle start. The PCM still operates
internally to perform several checks, including moni-
toring the O2 sensor heaters.
CAMSHAFT POSITION
SENSOR
DESCRIPTION
The camshaft position sensor is mounted in the
front of the head on 2.7L (Fig. 2) or belt cover on the
3.5L (Fig. 3). It is a hall effect device.
Fig. 1 Power Distribution Center (PDC)
1 - PDC COVER
2 - PDC
OPERATION
The ASD sense circuit (SBEC vehicles) or the
engine switched battery (NGC vehicles) informs the
PCM when the ASD relay energizes. A 12 volt signal
at this input indicates to the PCM that the ASD has
been activated. This input is also used to power cer-
tain drivers on NGC vehicles.
When energized, the ASD relay on SBEC vehicles
supplies battery voltage to the fuel injectors, ignition
coils and the heating element in each oxygen sensor.
When energized, the ASD relay on NGC vehicles
provides power to operate the injectors, ignition coil,
generator field, O2 sensor heaters (both upstream
and downstream), evaporative purge solenoid, EGR
solenoid (if equipped) wastegate solenoid (if
equipped), and NVLD solenoid (if equipped). Fig. 2 Camshaft Position Sensor - 2.7L
1 - ENGINE COOLANT TEMPERATURE SENSOR
2 - CAMSHAFT POSITION SENSOR
OPERATION
The camshaft position sensor contains a hall effect
device that provide cylinder identification to the Pow-
ertrain Control Module (PCM) (Fig. 4) or (Fig. 5).
The sensor generates pulses as groups of notches on
the camshaft sprocket pass underneath it. The PCM
keeps track of crankshaft rotation and identifies each
cylinder by the pulses generated by the notches on
the camshaft sprocket.
When metal aligns with the sensor, voltage goes
low (less than 0.3 volts). When a notch aligns with
the sensor, voltage spikes high (5.0 volts). As a group
of notches pass under the sensor, the voltage
switches from low (metal) to high (notch) then back
to low. The number of notches determine the amount
of pulses. If available, an oscilloscope or DRBIIIt Fig. 5 Camshaft Position Sensor 3.5L
PEP Module can display the square wave patterns of (1) Disconnect the negative battery cable.
each timing event. (2) Loosen the upper intake plenum, refer to the
Intake System section.
(3) Disconnect electrical connector from sensor.
REMOVAL (4) Remove camshaft position sensor screw.
(5) Pull sensor up out of the timing belt housing
REMOVAL - 2.7L cover.
The camshaft position sensor is mounted in the
front of the head.
(1) Disconnect electrical connector from sensor. INSTALLATION
(2) Remove camshaft position sensor screw.
(3) Without pulling on the connector, pull the sen- INSTALLATION - 2.7L
sor out of the chain case cover. The camshaft position sensor is mounted in the
front of the head.
REMOVAL - 3.5L (1) Install sensor in the chain case cover and push
The camshaft position sensor is installed in the sensor in until contact is made with the boss on the
timing belt housing cover above the left camshaft head. While holding the sensor in this position,
sprocket.
INSTALLATION - 3.5L
The camshaft position sensor is installed in the
timing belt housing cover above the left camshaft
sprocket.
If the removed sensor is reinstalled, com-
pletely remove the old spacer from the sensor
face. Attach a NEW SPACER to the face of the
sensor before installation. If installing a new sen-
sor, confirm that the paper spacer is attached to the
face (Fig. 6).
INSTALLATION
(1) Install ignition coil assembly for spark plug.
(2) Install coil screws and tighten: 2.7L engine to
6.2 N·m (55 in. lbs.), 3.5L engines to 6.7 N·m (60 in.
lbs.).
(3) Connect the electrical connector.
INSTALLATION REMOVAL
(1) Install capacitor and tighten nut. The sensors screws into the cylinder block, directly
(2) Attach electrical connector to capacitor. below the intake manifold.
(3) Install the negative battery cable. (1) Remove intake manifold plenum refer to the
Engine section.
(2) 2.7L Remove the passenger side cylinder head,
KNOCK SENSOR refer to the Engine section.
(3) Disconnect electrical connector from knock sen-
DESCRIPTION sor (Fig. 12) or (Fig. 13).
The knock sensor threads into the cylinder block.
The knock sensor is designed to detect engine vibra-
tion that is caused by detonation.
OPERATION
When the knock sensor detects a knock in one of
the cylinders, it sends an input signal to the PCM. In
response, the PCM retards ignition timing for all cyl-
inders by a scheduled amount.
Knock sensors contain a piezoelectric material
which constantly vibrates and sends an input voltage
(signal) to the PCM while the engine operates. As the
intensity of the crystal’s vibration increases, the
knock sensor output voltage also increases.
The voltage signal produced by the knock sensor
increases with the amplitude of vibration. The PCM
receives as an input the knock sensor voltage signal.
If the signal rises above a predetermined level, the
PCM will store that value in memory and retard
ignition timing to reduce engine knock. If the knock Fig. 12 KNOCK SENSOR 2.7 L
sensor voltage exceeds a preset value, the PCM 1 - KNOCK SENSOR
retards ignition timing for all cylinders. It is not a
selective cylinder retard.
The PCM ignores knock sensor input during engine
idle conditions. Once the engine speed exceeds a
specified value, knock retard is allowed.
Knock retard uses its own short term and long
term memory program.
Long term memory stores previous detonation
information in its battery-backed RAM. The maxi-
mum authority that long term memory has over tim-
ing retard can be calibrated.
Short term memory is allowed to retard timing up
to a preset amount under all operating conditions (as
long as rpm is above the minimum rpm) except WOT.
The PCM, using short term memory, can respond
quickly to retard timing when engine knock is
detected. Short term memory is lost any time the
ignition key is turned off.
SPARK PLUG
DESCRIPTION - PLATINUM PLUGS
The V6 engines use platinum resistor spark plugs.
They have resistance values of 6,000 to 20,000 ohms
when checked with at least a 1000 volt tester. For
spark plug identification and specifications, Refer to
the Specifications section.
Do not use an ohm meter to check the resis-
Fig. 15 Setting Spark Plug Electrode Gap
tance of the spark plugs. This will give an inac-
curate reading. 1 - TAPER GAUGE
When the spark plugs use a single or double plat-
inum tips and they have a recommended service life REMOVAL
of 100,000 miles for normal driving conditions per Always remove the ignition coil assembly by grasp-
schedule A in this manual. The spark plugs have a ing at the spark plug boot, turning the assembly 1/2
recommended service life of 75,000 miles for severe turn and pulling straight back in a steady motion.
driving conditions per schedule B in this manual. A (1) Prior to removing the spark plug, spray com-
thin platinum pad is welded to both or just the cen- pressed air around the coil area and spark plug.
ter electrode end(s) as shown in (Fig. 14). Extreme (2) Remove electrical connector from ignition coil.
care must be used to prevent spark plug cross On 3.5L engines, it is necessary to loosen the
threading, mis-gapping (Fig. 15) and ceramic insula- screws by alternating back and forth. Do not lose the
tor damage during plug removal and installation. spacers under the coil when loosening the screws.
(3) Remove 2 fasteners from ignition coil.
(4) Remove ignition coil assembly.
(5) Remove the spark plug using a quality socket
with a rubber or foam insert.
(6) Inspect the spark plug condition.
INSTALLATION
Always remove the ignition coil assembly by grasp-
ing at the spark plug boot, turning the assembly 1/2
turn and pulling straight back in a steady motion.
(1) To avoid cross threading, start the spark plug
into the cylinder head by hand.
(2) 3.5L engines tighten spark plugs to 28 N·m (20
ft. lbs.) torque, 2.7L engine tighten spark plugs to
17.6 N·m (13 ft. lbs.).
(3) Install ignition coil assembly onto spark plug.
(4) Install coil screws and tighten: 2.7L engine to 6.2
Fig. 14 Platinum Pads
N·m (55 in. lbs.), 3.5L engines to 6.7 N·m (60 in. lbs.).
1 - APPLY ANTI-SEIZE COMPOUND HERE ONLY
2 - PLATINUM SPARK SURFACE
(5) Connect the electrical connector.
INSTRUMENT CLUSTER
TABLE OF CONTENTS
page page
INSTRUMENT CLUSTER
DESCRIPTION
The mechanical instrument cluster is an electro-
mechanical module which receives most of its infor-
mation via the Programmable Communication
Interface (PCI) bus.
There are three types of clusters (Fig. 1) and (Fig.
2).
Fig. 2 CLUSTER - 300M
• Electronic transmission range
The warning and information indicators include
the following:
• Check Engine
• Airbag
• Charging system
• Low oil pressure
• High temperature
• Low fuel
Fig. 1 CLUSTER - INTREPID/CONCORDE • Seat belt
The Instrument Cluster for the Intrepid and Con- • Cruise
corde (Fig. 1) are almost identical. The gauge and • Brake/park brake
warning lamp location and functionality are identi- • High beam
cal. The difference being, the Intrepid has white • Turn signals
gauges with black numbers, and the Concorde has • Door Ajar
black gauges with white numbers and chrome rings • Decklid Ajar
around the gauges. • ABS (optional)
• Speedometer • Traction Control Active (if equipped)
• Tachometer • Traction Control Off (if equipped)
• Odometer/trip odometer • Low Washer Fluid
• Fuel gauge
• Temperature gauge
ANTI-LOCK BRAKE SYSTEM NOTE: Tilt steering wheel down to gain access for
instrument cluster removal.
INDICATOR
(10) Remove the instrument cluster from panel.
DESCRIPTION The instrument panel wiring harness connectors are
The amber Anti-Lock Brake System (ABS) warning self-aligning, mounted directly to the rear panel. A
indicator lamp is located on the instrument panel in force of approximately 9 kilograms (30 lbs.) will be
the instrument cluster. required to disengage the cluster from the connectors
and upper clips.
OPERATION (11) Remove two screws to mask/lens (Fig. 3).
When the ignition key is turned to the ON posi-
tion, the amber ABS warning indicator lamp is lit
until the Controller Anti-Lock Brakes (CAB) com-
pletes it’s self-tests and turns off the indicator lamp
(approximately 4 seconds). The amber ABS warning
indicator lamp will illuminate when the CAB detects
a condition that results in the shutdown of ABS func-
tion or when the instrument cluster does not receive
messages from the CAB. The CAB sends a message
across the PCI bus circuit that informs the instru-
ment cluster to turn on the amber ABS warning indi-
cator lamp.
ODOMETER
TACHOMETER
REMOVAL
The instrument cluster must be removed for Odom- DESCRIPTION
eter service. Refer to Instrument Cluster Removal Refer to Electrical, Instrument Cluster, Description
and Installation. for more information.
On Intrepid, Concorde, and 300M models, the
odometer and PRNDL are one assembly retained by OPERATION
three screws. The tachometer receives its information across the
(1) Open hood and disconnect the negative battery PCI Bus from the Body Control Module (BCM). Infor-
cable remote terminal from the remote battery post. mation on engine RPM is transmitted from the Pow-
(2) Remove instrument cluster from vehicle. Refer ertrain Control Module (PCM) across the PCI Bus to
to Instrument Cluster Removal and Installation. the BCM. The BCM calculates the position of the
(3) Remove five cluster back cover retaining tachometer pointer based on the input from the PCM
screws and remove the cover. and adjusts the position of the gauge pointer to the
(4) Unplug connectors from printed circuit board. necessary position. This signal is sent over the PCI
Bus to the instrument cluster.
LAMPS
TABLE OF CONTENTS
page page
LAMPS/LIGHTING - EXTERIOR
TABLE OF CONTENTS
page page
BACK UP LAMP
REMOVAL
(1) Disconnect and isolate the battery negative
cable.
(2) Remove screws holding back up lamp unit to
bumper.
(3) Separate back up lamp unit from bumper.
(4) Rotate lamp socket counterclockwise one quar-
ter turn.
(5) Pull lamp socket from back of lamp unit.
(6) Pull lamp from lamp socket.
INSTALLATION
Fig. 1 BRAKE LAMP SWITCH
(1) Push lamp into lamp socket.
(2) Push lamp socket into back of lamp unit. 1 - STEERING COLUMN COUPLER
2 - BRAKE PEDAL
(3) Rotate lamp socket clockwise one quarter turn 3 - SWITCH
until it stops.
(4) Position back up lamp unit into opening on OPERATION
bumper. The brake lamp switch has three internal switches
(5) Install screws to hold back up lamp unit to used for various functions. Among these are:
bumper. • Brake lamp actuation
(6) Connect the battery negative cable.
INSTALLATION
NOTE: Prior to installing the brake lamp switch into
it’s bracket, the plunger must be moved to its fully
extended position using the procedure in Step 1.
ADJUSTMENTS
ADJUSTMENT - BRAKE LAMP SWITCH
(1) Depress and hold the brake pedal.
(2) Remove the brake switch from it’s bracket (Fig.
4). To do so, rotate the brake lamp switch in a coun- Fig. 5 CHMSL - REAR SHELF
terclockwise direction approximately 30 degrees from 1 - CHMSL HOUSING
its proper mounting position. Pull the switch rear-
ward and remove it from it’s mounting bracket. INTREPID
(3) Hold the brake lamp switch firmly in one hand. (1) Open hood, disconnect and isolate the battery
Using your other hand, pull outward on the plunger negative cable.
of the switch until it has ratcheted out to its fully (2) Release decklid latch and open decklid.
extended position. (3) Remove decklid cover.
INTREPID
(1) Install bulb into socket.
(2) Install socket into housing.
(3) Connect negative battery cable and close hood.
(4) Verify CHMSL operation.
(5) Install decklid cover.
300M
(1) Install bulb(s) in socket(s).
(2) Install socket(s) into housing.
Fig. 6 CHMSL - INTREPID (3) Connect battery negative cable and close hood.
1 - TRUNK LID APPLIQUE AND CHMSL
(4) Verify CHMSL operation.
2 - BODY WIRING AND LAMPS (5) Install decklid cover.
3 - PLASTIC HEX NUT
INTREPID
(1) Release decklid latch and open decklid.
(2) Remove decklid cover.
(3) Disconnect CHMSL wire connector from body
harness (Fig. 6).
(4) Remove fasteners attaching CHMSL and appli-
que to the decklid.
(5) Remove CHMSL from decklid.
300M
(1) Release decklid latch and open decklid.
Fig. 7 CHMSL - 300M (2) Remove decklid cover.
1 - CHMSL LAMP (3) Disconnect CHMSL wire connector from body
2 - TRUNK LID LOWER EDGE harness (Fig. 7).
(4) Remove fasteners attaching CHMSL to the
decklid.
COMBINATION FLASHER
DESCRIPTION
The Combination Flasher, also refered to as the
combo-flasher, is mounted to the in-line bracket
which is located to the right of the Junction Block.
The flasher can be removed by pulling in a rearward
direction. The left under panel silencer duct must be
removed to access the flasher. The combo-flasher is
black in color for ease of identification.
OPERATION
The Turn Signal and Hazard Warning Flasher is
combined into one unit called a Combination Flasher
(Combo-Flasher). The combo-flasher controls the
Fig. 8 CHMSL - REAR SHELF - CONCORDE flashing of the hazard warning system and the turn
1 - REAR SHELF TRIM PANEL signal system. An inoperative bulb or incomplete
2 - ATTACHING SCREWS turn signal circuit will result in an increase in
flasher speed.
(5) Remove CHMSL from decklid.
DIAGNOSIS AND TESTING - COMBINATION
INSTALLATION
FLASHER
CONCORDE (Refer to 8 - ELECTRICAL/LAMPS/LIGHTING -
(1) Place CHMSL in position on rear shelf upper EXTERIOR/MULTI-FUNCTION SWITCH - DIAG-
panel. NOSIS AND TESTING) and the COMBINATION
(2) Install fasteners to attach CHMSL to rear shelf FLASHER DIAGNOSIS table.
upper panel.
(3) Install rear shelf upper panel. REMOVAL
(4) Connect CHMSL wire connector to body har- (1) Open hood and disconnect the negative battery
ness. cable remote terminal from the remote battery post
(5) Connect the battery negative cable and close (Fig. 9).
hood.
(6) Verify CHMSL operation.
INTREPID
(1) Place CHMSL in position on decklid.
(2) Install fasteners attaching CHMSL and appli-
que to decklid.
(3) Connect CHMSL wire connector to body har-
ness.
(4) Verify CHMSL operation.
(5) Install decklid cover.
300M
(1) Place CHMSL in position on decklid.
(2) Install fasteners attaching CHMSL to decklid.
(3) Connect CHMSL wire connector to body har-
ness.
(4) Verify CHMSL operation.
(5) Install decklid cover. Fig. 9 BATTERY NEGATIVE CABLE REMOVE/
INSTALL
1 - RIGHT STRUT TOWER
2 - AIR CLEANER INLET TUBE
3 - REMOTE TERMINAL
OPERATION
The DRL allows the high beam headlamps to illu-
minate at reduced power when the ignition switch is Fig. 10 Trunk Lamp Bulb
in the RUN position with the high and low beam 1 - BULB
headlamp switches in the OFF position. The Park 2 - TRUNK LAMP SOCKET
Brake must be released and the Brake Fluid Level 3 - REAR SHELF
4 - LENS
switch must be in the OPEN position to allow the
headlamps to operate in DRL mode. The daytime
running lamps will go out when the headlamp switch
INSTALLATION
is turned ON. The passing light feature will flash (1) Insert bulb into socket.
bright high beams while the daytime running lamps (2) Install lamp lens.
are activated. (3) Connect the battery negative cable and close
hood.
DIAGNOSIS AND TESTING - DAYTIME
RUNNING LAMP MODULE FOG LAMP
The Daytime Running Lamp Module (DRL Module)
is controlled by inputs received from the ignition DIAGNOSIS AND TESTING - FOG LAMP
switch and High or Low Beam Headlamp relays, When a vehicle experiences problems with the fog
Park Brake switch, and the Brake Fluid Level lamp system, verify the condition of:
switch. Refer to Wiring Diagrams, for component • Battery connections
location and circuit information and the proper Body • Charging system
Diagnostic Procedures manual. • Fog lamp bulbs
• Headlamp switch
• Body Control Module
• Wire connectors
Refer to Wiring Diagrams, for component locations
and circuit information.
FOG LAMPS ARE DIM 1. Loose or corroded battery cables. 1. Clean and secure battery cable clamps
WITH ENGINE IDLING OR and posts.
IGNITION TURNED OFF.
2. Loose or worn generator drive 2. Adjust or replace generator drive belt.
belt.
3. Charging system output too low. 3. Test and repair charging system, refer
to Electrical, Battery.
4. Battery has insufficient charge. 4. Test battery state-of-charge, refer to
Electrical, Battery.
5. Battery is sulfated or shorted. 5. Load test battery, refer to Electrical,
Battery.
6. Poor lighting circuit Z1 ground. 6. Test for voltage drop across Z1 ground
locations, refer to Wiring Diagrams.
7. Both fog lamps are defective. 7. Replace both fog lamp bulbs.
FOG LAMP BULBS BURN 1. Charging system output too high. 1. Test and repair charging system, refer
OUT FREQUENTLY to Electrical, Battery.
FOG LAMPS ARE DIM 1. Charging system output too low. 1. Test and repair charging system, refer
WITH ENGINE RUNNING to Electrical, Battery.
ABOVE IDLE
2. Poor lighting circuit Z1 ground. 2. Test for voltage drop across Z1 ground
locations, refer to Wiring Diagrams.
3. High resistance in fog lamp circuit. 3. Test amperage draw of fog lamp circuit.
4. Both fog lamp bulbs defective. 4. Replace both fog lamp bulbs.
FOG LAMPS FLASH 1. Poor lighting circuit Z1-ground. 1. Test for voltage drop across Z1-ground
RANDOMLY locations, refer to Wiring Diagrams.
2. High resistance in fog lamp circuit. 2. Test amperage draw of fog lamp circuit.
3. Faulty fog lamp switch. 3. Replace headlamp switch.
4. Loose or corroded terminals or 4. Inspect and repair all connectors and
splices in circuit. splices, refer to Wiring Diagrams.
5. Bad connection between 5. Test and diagnose circuit between
headlamp switch and BCM headlamp switch and BCM.
6. Loose relay. 6. Inspect and reset fog lamp relay.
7. Faulty Body Control Module. 7. Replace Body Control Module.
FOG LAMPS DO NOT 1. Blown fuse for fog lamps. 1. Replace fuse, refer to Wiring Diagrams.
ILLUMINATE 2. No Z1-ground at fog lamps. 2. Repair circuit ground, refer to Wiring
Diagrams.
3. Faulty fog lamp switch. 3. Replace headlamp switch.
4. Broken connector terminal or wire 4. Repair connector terminal or wire splice.
splice in fog lamp circuit.
5. Broken connection between BCM 5. Test relay connectors in the Junction
and fog lamp relay. Block and the circuit to BCM. Repair as
necessary.
6. Faulty fog lamp relay. 6. Replace relay.
7. Faulty Body Control Module. 7. Replace Body Control Module.
REMOVAL
INTREPID/300M
(1) Remove fog lamp housing screw in front fascia
and pull lamp housing from the fascia.
(2) Remove rear cover from fog lamp housing.
(3) Disengage wire clip holding bulb in fog lamp.
(4) Hinge wire clip out of bulb removal path.
(5) Pull bulb from lamp housing (Fig. 11) or (Fig.
12).
(6) Disengage wire connector from fog lamp wire
harness.
CONCORDE
(1) Remove fog lamp housing screw in front fascia
and pull lamp housing from the front fascia.
(2) Disconnect wire connector from fog lamp socket Fig. 13 FOG LAMP BULB - CONCORDE
(Fig. 13). 1 - FOG LAMP BULB/SOCKET
(3) Rotate socket and pull bulb/socket from lamp 2 - FOG LAMP
housing.
CONCORDE
CAUTION: Do not touch the glass of halogen bulbs
with fingers or other possibly oily surface, reduced
bulb life will result.
REMOVAL
(1) Open hood, disconnect and isolate the battery
negative cable.
(2) Remove screw(s) attaching fog lamp to fascia
(Fig. 18), (Fig. 19), and (Fig. 20).
(3) Pull fog lamp forward from opening in front
bumper fascia.
(4) Disconnect fog lamp wire connector from front
lighting wire harness.
(5) Remove fog lamp from vehicle.
REMOVAL
(1) Remove the headlamp module from the vehicle
(Refer to 8 - ELECTRICAL/LAMPS/LIGHTING -
EXTERIOR/HEADLAMP UNIT - REMOVAL).
Fig. 21 FRONT POSITION LAMP - EXPORT
(2) Twist and remove the front position lamp
1 - FRONT POSITION LAMP SOCKET socket from the headlamp module.
2 - HEADLAMP MODULE
(3) Pull the front position lamp bulb straight from
All vehicles are equipped with front position lamps. its socket (Fig. 22).
One front position lamp is incorporated into each of
the headlamp modules (Fig. 21). These lamps utilize INSTALLATION
a clear lens and clear bulb and function in the same (1) Install the front position lamp bulb in lamp
way that Parking Lamps do on other market built socket.
vehicles (U.S., Canada). The front position lamp is (2) Verify lamp operation.
built in to the headlamp and therefore doesn’t (3) Install front position lamp socket in the head-
require its own lamp housing. lamp module.
(4) Install the headlamp module in the vehicle
OPERATION (Refer to 8 - ELECTRICAL/LAMPS/LIGHTING -
The front position lamps are turned on or off with EXTERIOR/HEADLAMP UNIT - INSTALLATION).
the headlamp switch. These lamps function in the
same way that the parking lamps do on other market
built vehicles. (U.S., Canada). Refer to the appropri-
ate 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 connec-
tors, splices and grounds.
LAMP SYSTEMS
Vehicles use lighting on the interior and exterior of
the vehicle for illuminating and indicating purposes.
Lighting circuits are protected by fuses or circuit
breakers. Lighting circuits require an overload pro-
tected power source, on/off device, lamps and body
ground to operate properly. Plastic lamp sockets
require a wire in the harness to supply body ground
to the lamp socket. Lamp sockets that are exposed to
moisture should be coated with Mopart Multi pur-
pose Grease or equivalent to avoid corrosion. If a
socket has become corroded, clean socket and bulb
base with abrasive fiber sanding pad or metallic bris-
tle brush. Replace sockets and bulbs that are
Fig. 22 FRONT POSITION LAMP BULB deformed from corrosion that could prevent a contin-
1 - FRONT POSITION LAMP BULB uous body ground.
2 - FRONT POSITION LAMP SOCKET Wire connectors can make intermittent contact or
become corroded. Before coupling wire connectors,
HEADLAMP inspect the terminals inside the connector. Male ter-
minals should not be bent or disengaged from the
DESCRIPTION insulator. Female terminals should not be sprung
open or disengaged from the insulator. Bent and
HEADLAMP SYSTEM sprung terminals can be repaired using needle nose
The headlamp system is controlled completely by pliers and pick tool. Corroded terminals appear
the Body Control Module (BCM). The BCM controls chalky or green. Corroded terminals should be
the Park lamps, Headlamps, and Front Fog Lamps replaced to avoid recurrence of the problem symp-
using relays located in the Junction Block. Three toms. Wire connector terminals should be coated with
wires are connected between the headlamp switch Mopart Multi purpose Grease or equivalent to avoid
and the BCM. The first wire contains information corrosion.
regarding the position of the headlamp switch (Off, Begin electrical system failure diagnosis by testing
Automatic Headlamps, Automatic Headlamp switch related fuses and circuit breakers in the fuse block
fog, Park with Fog, Head, or Head with Fog Lamps). and engine compartment. Verify that bulbs are in
The second wire contains information regarding the good condition and test continuity of the circuit
position of the dimmer switch (Dome Lamp, Daytime ground. Refer to Wiring Diagrams, for component
Brightness, or Dimming Level). The third wire is a location and circuit information.
dedicated signal return (ground) wire.
HIGH INTENSITY DISCHARGE HEADLAMPS - 300M
AUTO HEADLAMP SYSTEM SPECIAL
The Automatic Headlamp system turns the instru- This vehicle is equipped with High Intensity Dis-
mentation and exterior illumination lamps ON when charge Headlamps (HID). The HID type lamp is
the ambient light levels are low and OFF when light used in place of the conventional halogen low beam
levels are high. lamp. High beam lamps remain the same halogen
type.
HEADLAMPS ON WITH WIPERS There are three components in the HID system
For vehicles equipped with the Automatic Head- (Fig. 23), the ballast module (attached to the bottom
lamp System, the instrumentation and exterior illu- of the headlamp unit), the igniter (plugs into the bal-
mination lamps will be turned ON when the last module), and the lamp itself (part of the igniter
headlamp switch is in the AUTO position and the assembly and only replaceable with the igniter).
HEADLAMPS ARE DIM 1. Loose or corroded battery cables. 1. Clean and secure battery cable clamps
WITH ENGINE IDLING OR and posts.
IGNITION TURNED OFF
2. Loose or worn generator drive 2. Adjust or replace generator drive belt.
belt.
3. Charging system output too low. 3. Test and repair charging system, refer
to Electrical, Battery
4. Battery has insufficient charge. 4. Test battery state-of-charge, refer to
Electrical, Battery.
5. Battery is sulfated or shorted. 5. Load test battery, refer to Electrical,
Battery.
6. Poor lighting circuit Z1 ground. 6. Test for voltage drop across Z1 ground
locations, refer to Wiring Diagrams.
7. Both headlamp bulbs defective. 7. Replace both headlamp bulbs.
HEADLAMP BULBS BURN 1. Charging system output too high. 1. Test and repair charging system, refer
OUT FREQUENTLY to Electrical, Battery.
HEADLAMPS ARE DIM 1. Charging system output too low. 1. Test and repair charging system, refer
WITH ENGINE RUNNING to Electrical, Battery.
ABOVE IDLE
2. Poor lighting circuit Z1 ground. 2. Test for voltage drop across Z1 ground
locations, refer to Wiring Diagrams.
3. High resistance in headlamp 3. Test amperage draw of headlamp
circuit. circuit.
4. Both headlamp bulbs defective. 4. Replace both headlamp bulbs.
HEADLAMPS FLASH 1. Poor lighting circuit Z1-ground. 1. Test for voltage drop across Z1-ground
RANDOMLY locations, refer to Wiring Diagrams.
2. High resistance in headlamp 2. Test amperage draw of headlamp
circuit. circuit.
3. Faulty headlamps switch circuit 3. Replace headlamp switch.
breaker.
4. Loose or corroded terminals or 4. Inspect and repair all connectors and
splices in circuit. splices, refer to Wiring Diagrams.
5. Loose relay 5. Inspect and reset headlamp and
parking lamp relays.
6. Faulty Body Control Module 6. Replace Body Control Module
INSTRUMENT PANEL 1. No voltage to dimmer switch. 1. Check fuse. If good repair open
LAMPS DO NOT DIM OR headlamp circuit, refer to Wiring
ILLUMINATE Diagrams.
2. No Z1-ground at headlamps. 2. Repair circuit ground, refer to Wiring
Diagrams.
3. Faulty dimmer switch. 3. Replace dimmer switch.
DIAGNOSIS AND TESTING - HIGH INTENSITY (1) Inspect lamp/igniter assembly for a burned out
lamp. If lamp is burned out it will appear black or
DISCHARGE HEADLAMPS - 300M SPECIAL
smoky, similar to a normal halogen bulb. If lamp
The High Intensity Discharge (HID) headlamps are
looks OK, go to Step 2.
supplied B+ voltage and ground by the same connec-
(2) Check for B+ battery voltage at the two pin
tor used to power the normal halogen low beam
connector going into the ballast module. Refer to Wir-
lamp. The low beam system is different from there
ing Diagrams for connector location. If battery volt-
forward. The ballast module is mounted to the bot-
age and a good ground are present, go to Step 3. If
tom of the headlamp unit (Fig. 23). The ballast mod-
B+ voltage and a good ground are not present, refer
ule has internal circuit protection to prevent module
to Wiring Diagrams for circuit and connector loca-
damage in case of an open or shorted circuit. If the
tions to find short or open circuit.
module senses a short or open circuit condition, it
(3) Plug in a known good ballast module and check
will not operate the lamp/igniter.
for lamp operation. If lamp lights, replace ballast
The headlamp unit assembly must be removed to
module. If lamp still fails to light, replace lamp/ig-
perform the following tests (Refer to 8 - ELECTRI-
niter assembly.
CAL/LAMPS/LIGHTING - EXTERIOR/HEADLAMP
UNIT - REMOVAL).
REMOVAL
CONCORDE/300M
NOTE: Headlamp lens fogging is a normal condition
and does not require service unless excessive or
continual. Moisture will vent from tubes or vents
located on the back of the lamp.
BALLAST MODULE
Fig. 26 HEADLAMP REMOVAL (1) Remove headlamp unit (Refer to 8 - ELECTRI-
CAL/LAMPS/LIGHTING - EXTERIOR/HEADLAMP
1 - RETAINING RING
2 - WIRE CONNECTOR UNIT - REMOVAL).
3 - BULB (2) Disconnect the igniter/lamp assembly connector
4 - LAMP SOCKET from ballast module (Fig. 28).
(3) Remove the three retaining screws to the bal-
HIGH INTENSITY DISCHARGE HEADLAMPS - 300M last module (Fig. 28).
SPECIAL
INTREPID
IGNITER/LAMP ASSEMBLY
(1) Remove headlamp unit (Refer to 8 - ELECTRI- NOTE: Headlamp lens fogging is a normal condition
CAL/LAMPS/LIGHTING - EXTERIOR/HEADLAMP and does not require service unless excessive or
UNIT - REMOVAL). continual. Moisture will vent from tubes or vents
(2) Disconnect the igniter assembly connector from located on the back of the lamp.
the ballast module (Fig. 23).
(3) Remove three screws to the rubber shield (1) Release hood latch and open hood.
retaining ring (Fig. 27). (2) Disconnect and isolate the battery negative
(4) Pull up on rubber water shield and pull back cable.
over igniter wire (Fig. 27). (3) Remove jackscrews attaching headlamp unit to
crossmember and remove to access the lamp(s).
INSTALLATION
CONCORDE/300M
CAUTION: Do not touch the glass of halogen bulbs
with fingers or other possibly oily surface, reduced
bulb life will result.
BALLAST MODULE
(1) Install the three retaining screws to the ballast
module.
(2) Connect the igniter/lamp connector to the bal-
last module.
(3) Install the headlamp unit (Refer to 8 - ELEC-
TRICAL/LAMPS/LIGHTING - EXTERIOR/HEAD-
LAMP UNIT - INSTALLATION).
INTREPID
CAUTION: Do not touch the glass of halogen bulbs
with fingers or other possibly oily surface, reduced
Fig. 29 HEADLAMP - INTREPID bulb life will result.
1 - LOW BEAM
2 - PARKING AND TURN SIGNAL (1) Rotate bulb (High beam or Low beam) and
3 - HIGH BEAM
push into headlamp unit.
(2) Connect wire connector to the back of lamp
socket (Fig. 29).
ONE MOTOR DOES NOT 1. Poor electrical connection at 1. Check for proper electrical connection at
OPERATE. motor. motor.
2. No voltage at motor. 2. Repair no voltage condition. Refer to
Wiring Diagrams.
3. No ground at motor. 3. Repair no ground condition. Refer to
Wiring Diagrams.
4. Defective motor. 4. Replace leveling motor.
BOTH MOTORS DO NOT 1. No voltage at or from headlamp 1. Repair no voltage condition. Check for
OPERATE. leveling switch. proper headlamp leveling switch operation.
2. No voltage at leveling motors. 2. Repair no voltage condition. Refer to
Wiring Diagrams.
3. No ground at leveling motors. 3. Repair no ground condition. Refer to
Wiring Diagrams.
4. Both motors defective. 4. Replace both motors.
RESISTANCE
SWITCH POSITION
BETWEEN PINS 1&2
0 0.752V
1 0.564V
2 348.8V
REMOVAL
The headlamp leveling switch is integrated into
the headlamp switch. If the headlamp leveling switch
proves faulty the entire headlamp switch must be
replaced. (Refer to 8 - ELECTRICAL/LAMPS/LIGHT-
ING - EXTERIOR/HEADLAMP SWITCH - REMOV-
AL).
INSTALLATION
The headlamp leveling switch is integrated into
the headlamp switch. If the headlamp leveling switch
proves faulty the entire headlamp switch must be
replaced. (Refer to 8 - ELECTRICAL/LAMPS/LIGHT-
ING - EXTERIOR/HEADLAMP SWITCH - INSTAL- Fig. 31 HEADLAMP SWITCH - POLICE
LATION) 1 - APPROACH MODE (APPREHEND MODE - PULLED OUT)
2 - OFF
3 - HEADLAMPS
4 - PARKING LAMPS
HEADLAMP SWITCH
DIAGNOSIS AND TESTING - HEADLAMP
DESCRIPTION - POLICE SWITCH
This vehicle is equipped with a stealth mode. Dur-
Using an ohmmeter, test for resistance values
ing periods of surveillance, the headlamp switch may
between the terminals of the switch as shown in the
be placed in the “A” position or Approach mode (Fig.
HEADLAMP SWITCH RESISTANCE table and (Fig.
31). In this position, all exterior lighting (Daytime
32).
Running Lamps - if equipped) will be cancelled.
HEADLAMP SWITCH RESISTANCE
NOTE: On Canadian vehicles, the Daytime Running
Lamps will not be disabled. These must stay oper- POSITION TERMINALS RESISTANCE
able due to Canadian federal regulations. OFF 6 & 12 3600 V - 5400
V
By pulling out on the switch (toward the driver)
the lamps will be in Apprehend mode (Fig. 31). In PARK LAMP ON 6 & 12 44.65 V - 49.35
this mode, all M2 circuit interior illumination, except V
for PRNDL, odometer, cluster back lighting, and PARK LAMP 6 & 12 115 V ± 5%
vehicle critical warning indicators will be cancelled. W/FRONT FOG
The cluster back lighting, PRNDL, and odometer will HEADLAMP ON 6 & 12 209.2 V - 231
go to a minimum dimming level. V
The Body Control Module (BCM) must be flashed
HEADLAMP 6 & 12 690 V ± 5%
with a special police package for the stealth mode to
W/FRONT FOG
work. A security provision may require the unique
engine controller to broadcast a code to allow the AUTO 6 & 12 370.5 V - 409.5
BCM to be flashed with the police package program. V
AUTO W/FRONT 6 & 12 1390 V ± 5%
OPERATION - POLICE FOG
RHEOSTAT 6&3 180 V - 1870 V
APPROACH MODE (THUMBWHEEL) (POT)
To place the vehicle’s lighting system into DIM POSITION
Approach mode, turn the switch counterclockwise to
the A on the headlamp switch (Fig. 31). RHEOSTAT 6&3 2280 V - 2520
(THUMBWHEEL) V
APPREHEND MODE BRIGHT
To place the vehicle’s lighting system into Appre- POSITION
hend mode, turn the switch counterclockwise to the A (FUNERAL
on the headlamp switch and pull out (toward the MODE)
driver) on the selector knob (Fig. 31). DOME LAMP 6&3 3230 V - 3570
V
HEADLAMP UNIT ADJUSTMENT NOT cover the headlamp(s) for extended periods, as
The low beam hot spot cut off should be within 2 the heat may damage them. To adjust headlamp
inches above/below the horizontal center line, and to alignment, rotate the alignment screws to achieve
the right of the vertical center line (Fig. 33). This the specified pattern.
puts the low beam hot spot in the lower right quad-
rant of the aiming screen. Occasional stray filament
images should be disregarded while verifying aim.
Verify the vertical adjustment by checking the high
beams to ensure they are centered within ± 2 inches
relative to the horizontal center line. The low beams
should be shielded when checking high beams. Do
ALIGNMENT SCREEN PREPARATION FOR To adjust headlamp unit alignment, rotate align-
HEADLAMP UNIT ALIGNMENT ment screws to achieve the specified low beam hot
(1) Position vehicle on a level surface perpendicu- spot pattern (Fig. 34).
lar to a flat wall 10 meters (32.8 ft) away from front
of headlamp lens. REMOVAL
(2) If necessary, tape a line on the floor 10 meters
NOTE: Some moisture accumulation inside a vented
(32.8 ft) away from and parallel to the wall.
headlamp unit is normal. Moisture will vent from
(3) Place 75 kg in the drivers seat to simulate the
tubes or vents located on the back of the unit. This
ride height of the vehicle when driven.
normal condition will appear as a fogging on the
(4) Measure from the floor up 1.27 meters (5 ft)
inside of the headlamp lens (similar to the fog that
and tape a line on the wall at the centerline of the
sometimes appears on the inside of the wind-
vehicle (Fig. 34). Sight along the centerline of the
shield). This moisture may be removed by activat-
vehicle (from rear of vehicle forward) to verify accu-
ing the headlamps on high beam for 15 minutes.
racy of the line placement.
If water droplets larger than 1 mm in size have
(5) Rock vehicle side-to-side three times to allow
accumulated on the inside of the headlamp lens,
suspension to stabilize.
the headlamp unit should be replaced.
(6) Jounce front suspension three times by pushing
downward on front bumper and releasing.
(7) Measure the distance from the center of head- CONCORDE/300M
lamp lens to the floor. Transfer measurement to the (1) Release hood latch and open hood.
alignment screen (with tape). Use this line for (2) Disconnect and isolate the battery negative
up/down adjustment reference (this should be 623 remote cable.
mm (24.5 in.). (3) Remove the one bolt retaining the washer bot-
(8) Place a tape line 100 mm (4 in.) below and par- tle filler neck and move aside.
allel to the center of headlamp line (Fig. 34). (4) Remove the two bolts retaining the speed con-
(9) Measure distance from the centerline of the trol servo and move aside.
vehicle to the center of each headlamp unit being (5) Remove fasteners to upper radiator crossmem-
aligned. Transfer measurements to screen (with tape) ber:
to each side of vehicle centerline. Use these lines for • Two jack screws on each side.
left/right adjustment reference (this should be 1338.5 • Three crossmember retaining bolts on each side.
mm (52.7 in.) ). • Three push pin fasteners across top of grille.
INTREPID
(1) Release hood latch and open hood.
(2) Disconnect and isolate the battery negative Fig. 35 HEADLAMP UNIT - INTREPID
cable.
1 - JACKSCREW
(3) Remove jackscrews attaching headlamp to body 2 - HEADLAMP HOUSING
(Fig. 35). 3 - BODY WIRE CONNECTOR
(4) Remove headlamp from body.
(5) Disconnect wire connector from headlamp and
parking, side marker, and turn signal lamps.
(6) Remove headlamp housing from vehicle.
INTREPID INSTALLATION
(1) Push bulb into socket.
NOTE: Headlamp lens fogging is a normal condition (2) Install socket into lamp.
and does not require service unless excessive or (3) Place license plate lamp in position on rear
continual. Moisture will vent from tubes or vents bumper fascia.
located on the back of the lamp. (4) Install screws to attach license plate lamp to
rear bumper fascia.
(1) Place headlamp unit in position on vehicle.
(2) Connect wire connectors to headlamp, parking,
side marker, and turn signal lamps. LICENSE PLATE LAMP UNIT
(3) Place headlamp unit in position on body.
(4) Install screws to attach headlamp unit to body. REMOVAL
(1) Remove screws holding license plate lamp to
fascia (Fig. 37).
(2) Remove license plate lamp from vehicle.
SWITCH POSITION
TURN HAZARD CONTINUITY
SIGNAL WARNING
NEUTRAL OFF 1 AND 2
LEFT OFF 7 AND 6
RIGHT OFF 7 AND 8
NEUTRAL ON 2 AND 3
7 AND 8
7 AND 6
4 AND 5 Fig. 41 BEAM SELECT SWITCH CONNECTOR PIN
CALL OUT
REMOVAL
(1) Open hood and disconnect the negative battery
cable remote terminal from the remote battery post.
(2) Remove tilt lever.
(3) Remove both upper and lower steering column
shrouds. Refer to Body, Instrument Panel, Steering
Column Shrouds, Removal.
(4) Remove multi-function switch mounting screws
and connectors (Fig. 42).
INSTALLATION
(1) Install the multi-function switch connectors
and mounting screws (Fig. 42).
(2) Tighten multi-function switch retaining screws
to 17 in. lbs. (2 N·m) torque.
(3) Install both upper and lower steering column
shrouds. Refer to Body, Instrument Panel, Steering
Column Shrouds, Installation.
DESCRIPTION (1) Remove the rear fog lamp bulb and check for
burned out condition, replace bulb if necessary.
(2) If bulb appears OK, reinstall the bulb in its
socket and turn fog lamps ON and check for proper
operation. If lamp is still inoperative proceed to Step
3.
(3) Remove lamp bulb and check for proper power
(12v) and ground connections in lamp socket. If
power and/or ground connections are not present,
trace wire until open or short is found.
REMOVAL
(1) Remove the tail lamp from the vehicle.
(2) Rotate the rear fog lamp socket one-third turn
and pull from lamp housing (Fig. 45).
(3) Pull the rear fog lamp bulb straight from its
socket.
INSTALLATION
(1) Install the rear fog lamp bulb and socket in the
lamp housing (Fig. 45).
(2) Verify lamp operation.
Fig. 45 TAIL LAMP BULBS (3) Install the tail lamp assembly in the vehicle.
1 - REAR TURN SIGNAL LAMP
2 - REAR TAIL LAMP
3 - REAR STOP LAMP REAR FOG LAMP SWITCH -
4 - REAR FOG LAMP
5 - BACK-UP LAMP EXPORT
6 - TAIL LAMP ASSEMBLY
DESCRIPTION
Some vehicles are equipped with rear fog lamps Vehicles equipped with rear fog lamps utilize a
(Fig. 45). The rear fog lamp is integrated into the tail rear fog lamp switch. This switch is located next to
lamp assembly. If the rear fog lamp proves faulty the the headlamp switch on (Fig. 46). The rear fog lamp
entire tail lamp must be replaced. Rear fog lamps switch is the primary controller of the rear fog
utilize a red lens and clear bulb. lamps.
REMOVAL
(1) Open front door.
INSTALLATION
(1) Install the side repeater lamp bulb in the
socket.
(2) Verify lamp operation.
(3) Install the side repeater lamp socket into the
lamp unit.
(4) Install the side repeater lamp in the front
fender. Be certain lamp unit is secure in fender.
DESCRIPTION
This vehicle may be equipped with up to two spot
lamp assemblies, attached to the A-Pillars (Fig. 50).
The spot lamp assembly switch is located on the han-
dle (Fig. 51), just above the rotating handle grip.
REMOVAL
CAUTION: Make sure that fuse F (master spot lamp
feed) or either fuse X or Y (left or right spot lamp
feed) are removed from the Power Distribution Cen-
ter (PDC) before performing service on the spot
lamps.
INSTALLATION
(1) Place lamp unit in position on fascia.
(2) Install lamp unit fastener.
(3) Install bulb socket in lamp unit.
(4) Connect the battery negative cable.
(5) Verify lamp operation.
(6) Install headlamp unit.
(7) Close hood.
Fig. 61 TAIL LAMP - CONCORDE
1 - PLASTIC HEX NUT (4)
2 - TAIL LAMP UNIT
INSTALLATION
(1) Position the underhood lamp unit on the hood
inner panel.
(2) Install the push-pin fastener attaching the
lamp unit base to the inner hood panel.
(3) Install the lamp unit and press into place.
(4) Connect the wire harness connector.
(5) Connect the battery negative remote cable or
reinsert fuse Y in the PDC.
(6) Verify system and vehicle operation.
(7) Close hood.
LAMPS/LIGHTING - INTERIOR
TABLE OF CONTENTS
page page
SPECIFICATIONS
INDICATOR LAMP APPLICATION TABLE
INTERIOR LAMPS
INDICATOR BULB
DIMMER CONTROLLED INTERIOR LAMPS AIR BAG LED
Service procedures for most of the lamps in the
ANTI-LOCK BRAKE LED
instrument panel, Instrument cluster and switches
are located in Electrical, Instrument Cluster. Some BRAKE WARNING LED
components have lamps that can only be serviced by CHARGING SYSTEM LED
an Authorized Service Center (ASC) after the compo- CHECK ENGINE LED
nent is removed from the vehicle. Contact local
dealer for location of nearest ASC. CRUISE 74
DOOR OPEN LED
DIMMER CONTROLLED LAMP APPLICATION ENGINE OIL PRESSURE LED
TABLE
ENGINE
LED
TEMPERATURE
LAMP BULB
HIGH BEAM 74
A/C HEATER CONTROL 330
LOW FUEL LED
INSTRUMENT CLUSTER PC194
LOW WASHER FLUID LED
RADIO ASC
SEAT BELT LED
ANALOG CLOCK A9625
DECK LID OPEN LED
INDICATOR LAMPS TURN SIGNAL PC194
Service procedures for most of the lamps in the TRAC ON 74
instrument cluster are located in Electrical, Instru- TRAC OFF LED
ment Cluster.
CLUSTER LAMPS
REMOVAL Fig. 1 CLUSTER LAMPS - INTREPID
To service instrument cluster lamps, the cluster
must be removed from the instrument panel (Refer to
8 - ELECTRICAL/INSTRUMENT CLUSTER -
REMOVAL).
Refer to (Fig. 1), (Fig. 2), and (Fig. 3) for cluster
lamp locations.
The illumination/indicator lamps that ARE replace-
able are called out on the back cover of the instru-
ment cluster. All other indicators are Light Emitting
Diodes (LED’s), and are serviced with the cluster Fig. 2 CLUSTER LAMPS - CONCORDE
assembly. If a LED is non-functional, the entire
instrument cluster must be replaced. Refer to the
INDICATORS - BULBS table for applications.
INDICATORS - BULBS
COURTESY LAMP
DESCRIPTION
The Body Control Module (BCM) illuminates the
courtesy lamps whenever a door is opened. When the
last door is closed, the BCM “fades-to-OFF” the cour-
tesy lamps in five seconds if not in illuminated entry
mode. If a door is left ajar, the courtesy lamps
remain on for a maximum of 15 minutes when the
ignition switch is OFF. After 15 minutes, the BCM
“fades-to-OFF” the courtesy lamps.
MESSAGE SYSTEMS
TABLE OF CONTENTS
page page
COMPASS DISPLAY
To display the vehicle direction, the Compass Mini-
Trip Computer processes information from a sensor
internal to the module. The Compass Mini-Trip Com-
puter is self- calibrating and requires only variance
adjustments dependent upon location. The Compass
Mini-Trip Computer displays the label CAL whenever
the compass is in the fast calibration mode.
If all three of the following conditions listed below
occur, the vehicle must be demagnetized.
• Compass portion of the display is blank
• Temperature portion of the display is OK
• The label CAL is illuminated
If demagnetizing the vehicle is needed, refer to the
demagnetizing procedure in this section. After
demagnetizing, to calibrate the compass refer to Cal-
ibration Procedure and to set the variance refer to
Variance Procedure, both within this section. If the Fig. 7 Compass Mini-Trip Computer Retaining
compass portion of the display is still blank, replace Screws
the Compass Mini-Trip Computer. 1 - ILLUMINATION LAMPS
2 - CMTC RETAINING SCREWS
COMPASS MINI-TRIP COMPUTER - SELF
DIAGNOSTIC TEST (3) Remove the Compass Mini-Trip Computer from
(1) With the ignition switch in the OFF position overhead console.
simultaneously press the C/T and STEP buttons and
hold. INSTALLATION
(2) Turn ignition switch ON, then release C/T and (1) Position the Compass Mini-Trip Computer and
STEP buttons. install the retaining screws.
(3) Compass Mini-Trip Computer lights all seg- (2) Connect the Compass Mini-Trip Computer elec-
ments on the VFD for 2-4 seconds. Check for seg- trical connector. Make sure the wire that was clipped
ments that are not illuminated. into the module housing is properly clipped into the
(4) If Compass Mini-Trip Computer displays PASS, new module before the overhead console is placed
the module is OK. back into the headliner.
(5) If Compass Mini-Trip Computer displays FAIL, (3) Install the overhead console (Refer to 8 -
replace the module. ELECTRICAL/OVERHEAD CONSOLE - INSTALLA-
TION).
UNIVERSAL TRANSMITTER
DESCRIPTION
On some LH models a Universal Transmitter is
standard factory-installed equipment. The universal
transmitter transceiver is integral to the Electronic
Vehicle Information Center (EVIC), which is located
in the overhead console. The only visible component
Fig. 8 Electronic Vehicle Information Center (EVIC) of the universal transmitter are the three transmit-
Module ter push buttons centered between the four EVIC
1 - OVERHEAD CONSOLE HOUSING push buttons located just rearward of the EVIC dis-
2 - EVIC MODULE
3 - VFD ILLUMINATION LAMPS
play screen in the overhead console. The three uni-
4 - SCREWS versal transmitter push buttons are identified with
one, two or three light indicators so that they be eas-
(4) Remove the EVIC module from the overhead ily identified by sight.
console housing. Each of the three universal transmitter push but-
tons controls an independent radio transmitter chan-
NOTE: If the EVIC module is being replaced, the tire nel. Each of these three channels can be trained to
pressure monitoring system must be programmed. transmit a different radio frequency signal for the
Refer to the tires/wheels section of this manual for remote operation of garage door openers, motorized
detailed instructions. gate openers, home or office lighting, security sys-
tems or just about any other device that can be
equipped with a radio receiver in the 288 to 410
INSTALLATION MegaHertz (MHz) frequency range for remote opera-
(1) Position the EVIC module onto the overhead tion. The universal transmitter is capable of operat-
console housing. ing systems using either rolling code or non-rolling
(2) Install and tighten the four screws that secure code technology.
the EVIC module to the overhead console housing.
Tighten the screws to 0.9 N·m (8 in. lbs.).
OPERATION
The universal transmitter operates on a non-
switched source of battery current so the unit will
remain functional, regardless of the ignition switch Fig. 9 Radio Frequency Detector
position. For more information on the features, pro-
1 - SIGNAL DETECTION LED’S
gramming procedures and operation of the universal 2 - POWER LED
transmitter, see the owner’s manual in the vehicle 3 - ON/OFF SWITCH
glove box. 4 - 9V BATTERY
OPERATION
The ambient temperature sensor is a variable
resistor that operates on a five-volt reference signal Fig. 11 Negative Battery Cable Remote Terminal
sent to it by the Powertrain Control Module (PCM). 1 - RIGHT STRUT TOWER
The resistance in the sensor changes as temperature 2 - AIR CLEANER INLET TUBE
3 - REMOTE TERMINAL
changes, changing the temperature sensor signal cir-
cuit voltage to the PCM. Based upon the resistance (2) Raise and support the vehicle on safety stands.
in the sensor, the PCM senses a specific voltage on (3) From behind front bumper fascia, remove the
the temperature sensor signal circuit, which it is pro- screw attaching the ambient temperature sensor to
grammed to correspond to a specific temperature. radiator closure panel.
POWER SYSTEMS
TABLE OF CONTENTS
page page
POWER LOCKS
TABLE OF CONTENTS
page page
INSTALLATION
(1) Install the two mounting motor screws and
remote key cable retainers and motor.
(2) Install the cover and latch cover attaching
screws.
(3) Connect and isolate the negative battery cable
remote terminal onto the remote battery post.
(4) Close the deck lid.
KEYLESS ENTRY
TRANSMITTER
DIAGNOSIS AND TESTING - KEYLESS ENTRY
TRANSMITTER
Using special tool 9001, first test to ensure that the
transmitter is functioning. Typical testing distance is
2.5 centimeters (1 inch) for Asian transmitters and
30.5 centimeters (12 inches) for all others. To test,
position the transmitter as shown (Fig. 4). Press any
transmitter button, then test each button individually.
The tool will beep if a radio signal strength that lights
five or more LED’s is detected. Repeat this test three
times. If transmitter fails any of the test, refer to the
Diagnostic Procedures manual.
SPECIFICATIONS INSTALLATION
(1) Place module into position on BCM and snap
TRANSMITTER the RKE Module into place.
(2) Attach the junction block/BCM and install the
BATTERY four retaining screws.
The transmitter has two 3 volt batteries, which can (3) Connect battery negative cable.
be removed and replaced without special tools. Insert Install the BCM. Refer to Electrical, Electronic
a dime in the side slot of the transmitter and twist. Control Modules, Body Control Module, Installation.
the halves should separate and the batteries are
stacked on top of each other. The batteries are avail- NOTE: The RKE transmitters must be repro-
able at local retail stores. Recommended batteries are grammed to the new RKE module.
Panasonic CR 2016 or equivalent. Battery life is
about two years (Fig. 1).
RANGE
Operation range is within 12 meters (40 ft.) of the
module/receiver.
POWER MIRRORS
TABLE OF CONTENTS
page page
AUTOMATIC DAY / NIGHT block. If OK, go to Step 3. If not OK, repair the open
circuit to the ignition switch as required.
MIRROR (3) Turn the ignition switch to the Off position.
Disconnect and isolate the battery negative cable.
DESCRIPTION Unplug the wire harness connector from the auto-
The automatic day/night mirror uses a thin layer matic day/night mirror. Connect the battery negative
of electrochromic material between two pieces of con- cable. Turn the ignition switch to the On position.
ductive glass to make up the face of the mirror. Check for battery voltage at the fused ignition switch
When the mirror switch is in the On position, two output (run/start) circuit cavity of the automatic day/
photocell sensors are used by the mirror circuitry to night mirror wire harness connector. If OK, go to
monitor external light levels and adjust the reflec- Step 4. If not OK, repair the open circuit to the junc-
tance of the mirror. tion block as required.
(4) Turn the ignition switch to the Off position.
OPERATION Disconnect and isolate the battery negative cable.
The ambient photocell sensor is located on the for- Check for continuity between the ground circuit cav-
ward-facing (windshield side) of the rear view mirror ity of the automatic day/night mirror wire harness
housing, and detects the ambient light levels outside connector and a good ground. There should be conti-
of the vehicle. The headlamp photocell sensor is nuity. If OK, go to Step 5. If not OK, repair the cir-
located inside the rear view mirror housing behind cuit to ground as required.
the mirror glass and faces rearward, to detect the (5) Connect the battery negative cable. Turn the
level of the light being received at the rear window ignition switch to the On position. Set the parking
side of the mirror. When the circuitry of the auto- brake. Place the transmission gear selector lever in
matic day/night mirror detects that the difference the Reverse position. Check for battery voltage at the
between the two light levels is too great (the light backup lamp switch output circuit cavity of the auto-
level received at the rear of the mirror is much matic day/night mirror wire harness connector. If
higher than that at the front of the mirror), it begins OK, go to Step 6. If not OK, repair the open circuit
to darken the mirror. as required.
The automatic day/night mirror circuitry also mon- (6) Turn the ignition switch to the Off position.
itors the transmission using an input from the Disconnect the battery negative cable. Plug in the
backup lamp circuit. The mirror circuitry is pro- automatic day/night mirror wire harness connector.
grammed to automatically disable its self-dimming Connect the battery negative cable. Turn the ignition
feature whenever it senses that the transmission switch to the On position. Place the transmission
backup lamp circuit is energized. gear selector lever in the Neutral position. Place the
The automatic day/night mirror is a completely mirror switch in the On (the LED in the mirror
self-contained unit and cannot be repaired. If faulty switch is lighted) position. Cover the forward facing
or damaged, the entire mirror assembly must be ambient photocell sensor to keep out any ambient
replaced. light.
DIAGNOSIS AND TESTING - AUTOMATIC NOTE: The ambient photocell sensor must be cov-
ered completely, so that no light reaches the sen-
DAY/NIGHT INSIDE MIRROR
sor. Use a finger pressed tightly against the sensor,
For complete circuit diagrams, refer to the appro-
or cover the sensor completely with electrical tape.
priate wiring information. The wiring information
includes wiring diagrams, proper wire and connector (7) Shine a light into the rearward facing head-
repair procedures, details of wire harness routing lamp photocell sensor. The mirror glass should
and retention, connector pin-out information and darken. If OK, go to Step 8. If not OK, replace the
location views for the various wire harness connec- faulty automatic day/night mirror unit.
tors, splices and grounds. (8) With the mirror glass darkened, place the
(1) Check the fuse in the junction block. If OK, go transmission gear selector lever in the Reverse posi-
to Step 2. If not OK, repair the shorted circuit or tion. The mirror should return to its normal reflec-
component as required and replace the faulty fuse. tance. If not OK, replace the faulty automatic day/
(2) Turn the ignition switch to the On position. night mirror unit.
Check for battery voltage at the fuse in the junction
REMOVAL
(1) Disconnect and isolate the battery negative
cable.
(2) Using a trim stick, remove power mirror switch
from mounting position.
(3) Disconnect wire connector.
(4) Remove switch.
INSTALLATION
(1) Connect the wire connector to the switch.
Fig. 2 Mirror Switch Connector Pin Call-Out (2) Insert power mirror switch to the mounting
position.
(3) Connect battery negative cable.
SIDEVIEW MIRROR
REMOVAL
For removal procedure, (Refer to 23 - BODY/EXTE-
RIOR/SIDE VIEW MIRROR - REMOVAL)
POWER SEATS
TABLE OF CONTENTS
page page
REMOVAL
(1) Open hood, disconnect and isolate the negative
battery cable remote terminal from the remote bat-
tery post.
OPERATION
When a power seat switch control knob or knobs
are actuated, a battery feed and a ground path are
applied through the switch contacts to the power seat
track or recliner adjuster motor. The selected
adjuster motor operates to move the seat track or
recliner through its drive unit in the selected direc-
tion until the switch is released, or until the travel
limit of the adjuster is reached. When the switch is
moved in the opposite direction, the battery feed and
ground path to the motor are reversed through the
switch contacts. This causes the adjuster motor to
run in the opposite direction.
No power seat switch should be held applied in any
direction after the adjuster has reached its travel
limit. The power seat adjuster motors each contain a
self-resetting circuit breaker to protect them from
overload. However, consecutive or frequent resetting
of the circuit breaker must not be allowed to con-
tinue, or the motor may be damaged. See the owner’s
manual in the vehicle glove box for more information
Fig. 5 Removing Switch Control Knobs - Typical on the power seat switch functions and the seat
adjusting procedures.
(5) Remove switch attaching screws.
(6) Remove switch from cushion side shield
DIAGNOSIS AND TESTING - PASSENGER
INSTALLATION POWER SEAT SWITCH
(1) Position the switch and install the switch (1) Remove the power seat switch, refer to the
attaching screws. Switch Removal and Installation procedures in this
(2) Install the knobs on the switch. section.
(3) Connect wiring electrical connector on switch. (2) Using an ohmmeter, check pin #1 of the power
(4) Install the seat cushion side shield. Refer to seat switch connector for continuity to ground. It
the Body section for the procedure. should be present, If OK go to Step 3 , If NOT OK
(5) Connect the negative battery cable remote ter- repair the open ground circuit as required.
minal on the remote battery post. (3) Using an voltmeter, check pin #5 of the power
seat switch connector for approx. 12v. It should be
REMOVAL
WARNING: SOME VEHICLES ARE EQUIPPED WITH
SEATBACK MOUNTED AIRBAGS. BEFORE
ATTEMPTING TO DIAGNOSE OR SERVICE ANY
SEAT OR POWER SEAT SYSTEM COMPONENT
YOU MUST FIRST DISCONNECT AND ISOLATE THE
BATTERY NEGATIVE CABLE. THEN WAIT TWO MIN- Fig. 10 Seat Track Removal
UTES FOR THE SYSTEM CAPACITOR TO DIS- 1 - TRACK TO SEAT CUSHION BOLTS
2 - FRONT
CHARGE BEFORE FURTHER SYSTEM SERVICE. 3 - SEAT BACK RECLINER BOLTS
THIS IS THE ONLY SURE WAY TO DISABLE THE 4 - VIEWED FROM TOP OF TRACK
AIRBAG SYSTEM. FAILURE TO DO SO COULD
RESULT IN ACCIDENTAL AIRBAG DEPLOYMENT INSTALLATION
AND POSSIBLE PERSONAL INJURY. (1) Position the seat track and install the retaining
bolts in the seat cushion pan. Torque the bolts to
(1) Remove the appropriate front seat from the 45-60 N·m.
vehicle. Refer to the Body section for the procedure. (2) Install the two seat back mounting bolts.
(2) Remove two seat back mounting bolts and also Torque the bolts to 45-60 N·m.
remove two seat back recliner bolts (Fig. 10). (3) Install the two seat back recliner bolts. Torque
(3) Remove four seat track mounting bolts from the bolts to 45-60 N·m.
cushion pan. (4) Install the seat in the vehicle. Refer to the
(4) Remove the seat track from seat. Body section of the service manual for the procedure.
POWER WINDOWS
TABLE OF CONTENTS
page page
WINDOW SWITCH
DIAGNOSIS AND TESTING - WINDOW SWITCH
For switch testing, remove the switch from its
mounting, refer to Switch Removal. Using an ohm-
meter, refer to Window Switch Continuity Charts to
determine if continuity is correct (Fig. 2) and (Fig. 3).
If the results are not obtained, replace the switch.
The master window switch has an Auto-Down fea-
ture. Actuation of the master switch to the second
down detent position will move the drivers side win-
dow completely down. The electronic switch will
automatically disconnect the motor approximately 1
second after the window bottoms out. Failure of the
electronic switch to detect stall current, will cause
the switch to disconnect after approximately 15 sec- Fig. 3 Passenger Window Switch
onds of operation. The auto down function can be OFF8 PIN 2 to 5
canceled by any movement of the switch. PIN 6 to 3
UP PIN 6 to 3
PIN 4 to 5
DOWN PIN 2 to 5
PIN 4 to 3
REMOVAL
MASTER SWITCH
Fig. 2 Master Window Switch INTREPID AND CONCORDE
PIN 8 to 10 (1) Open hood and disconnect the negative battery
PIN 8 to 11
PIN 8 to 7
cable remote terminal from the remote battery post.
PIN 8 to 6 (2) Remove driver’s door trim panel. (Refer to 23 -
OFF
PIN 8 to 3 BODY/DOOR - FRONT/TRIM PANEL - REMOVAL).
PIN 8 to 4
PIN 8 to 9
(3) Remove three mounting screws.
PIN 8 to 2 (4) Remove switch and disconnect wire connector.
UP DRIVER’S PIN 8 to 10
LHS and 300M
PIN 5 to 11
UP RIGHT PIN 8 to 7 (1) Open hood and disconnect the negative battery
cable remote terminal from the remote battery post.
FRONT PIN 5 to 6 (2) Using a trim stick (special tool #C-4755) or
UP LEFT PIN 8 to 3 equivalent, gently pry up on switch trim bezel and
REAR PIN 5 to 4
UP RIGHT PIN 8 to 9 lift up and out of trim panel.
(3) Disconnect wire connector from rear of switch
REAR PIN 5 to 2 and remove switch from vehicle.
DOWN DRIVER’S PIN 8 to 11
PASSENGER SWITCH
PIN 5 to 10
DOWN RIGHT PIN 8 to 6 (1) Open hood and disconnect the negative battery
cable remote terminal from the remote battery post.
FRONT PIN 5 to 7 (2) Remove passenger door trim panel. (Refer to 23
DOWN LEFT PIN 8 to 4 - BODY/DOOR - FRONT/TRIM PANEL - REMOV-
REAR PIN 5 to 3
DOWN RIGHT PIN 8 to 2 AL).
REAR PIN 5 to 9 (3) Disconnect switch wire connector.
WINDOW LOCK PIN 5 to 1
(4) Remove switch from bezel and vehicle.
RESTRAINTS
TABLE OF CONTENTS
page page
RESTRAINTS OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . . 15
DESCRIPTION - SIDE IMPACT AIRBAG OCCUPANT RESTRAINT CONTROLLER
SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2 DESCRIPTION . . . . . . . . . . . . . . . . . . . . . . . . . 15
OPERATION - SIDE IMPACT AIRBAG SYSTEM .2 OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . . 15
WARNING OCCUPANT RESTRAINT CONTROLLER - 5
WARNING . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2 PASSENGER VEHICLES
WARNING - AIRBAG DEPLOYMENT ZONES REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15
- POLICE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4 INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . 16
DIAGNOSIS AND TESTING - AIRBAG SYSTEM . 5 OCCUPANT RESTRAINT CONTROLLER - 6
STANDARD PROCEDURE PASSENGER VEHICLES
STANDARD PROCEDURE - HANDLING REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16
AIRBAGS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6 INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . 17
STANDARD PROCEDURE - SERVICE PASSENGER AIRBAG
AFTER AN AIRBAG DEPLOYMENT . . . . . . . . . 6 DESCRIPTION . . . . . . . . . . . . . . . . . . . . . . . . . 17
CHILD RESTRAINT ANCHOR OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . . 17
DESCRIPTION . . . . . . . . . . . . . . . . . . . . . . . . . . 7 REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18
OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7 INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . 19
REMOVAL .............................7 REAR SEAT BELT & RETRACTOR
INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . 8 REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20
CHILD TETHER CUP INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . 20
REMOVAL .............................8 REAR SEAT BELT & RETRACTOR - CENTER
INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . 8 REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21
CHILD TETHER CUP COVER INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . 21
REMOVAL .............................8 SEAT AIRBAG
INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . 8 DESCRIPTION . . . . . . . . . . . . . . . . . . . . . . . . . 22
CLOCK SPRING OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . . 22
DESCRIPTION . . . . . . . . . . . . . . . . . . . . . . . . . . 8 REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22
OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8 INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . 23
STANDARD PROCEDURE - CLOCK SPRING SEAT AIRBAG WIRING HARNESS
CENTERING . . . . . . . . . . . . . . . . . . . . . . . . . . 8 REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23
REMOVAL .............................9 INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . 24
INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . 10 SEAT BELT BUCKLE - REAR SEAT
DRIVER AIRBAG REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25
DESCRIPTION . . . . . . . . . . . . . . . . . . . . . . . . . 10 INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . 25
OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . . 10 SEAT BELT BUCKLE - FRONT SEAT CENTER
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11 OCCUPIED - CONCORDE/INTREPID
INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . 11 REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25
DRIVER AIRBAG TRIM COVER INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . 25
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11 SIDE IMPACT AIRBAG CONTROL MODULE
INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . 11 DESCRIPTION . . . . . . . . . . . . . . . . . . . . . . . . . 26
FRONT SEAT BELT & RETRACTOR OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . . 26
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14 REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26
INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . 15 INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . 27
IMPACT SENSOR
DESCRIPTION . . . . . . . . . . . . . . . . . . . . . . . . . 15
1 - SEATING REFERENCE
2 - DRIVER AIRBAG CUSHION LATERAL DEPLOYMENT ZONE DIAGNOSIS AND TESTING - AIRBAG SYSTEM
(1) With the battery negative remote cable discon-
nected, connect the DRB IIIt scan tool to the Data
Link connector.
(2) Turn the ignition key to the ON position. Exit
vehicle with the scan tool.
(3) After checking that no one is inside the vehicle,
connect the battery negative remote terminal.
(4) Read and record the ACTIVE Diagnostic Trou-
ble Code (DTC) data.
(5) Read and record any STORED DTC’s.
(6) Refer to the proper Body Diagnostic Procedures
manual if any DTC’s are found in Step 4 and Step 5.
(7) If the airbag warning lamp either fails to light,
or goes ON and stays ON, there is a system malfunc-
tion. To test the airbag warning lamp (bulb) opera-
tion in the cluster, refer to Electrical, Instrument
Cluster, Diagnosis and Testing - Instrument Cluster.
Refer to the proper Body Diagnostic Procedures man-
ual for any other system problems.
UNDEPLOYED AIRBAG
The airbags must be stored in its original special
container until used for service. At no time should a
source of electricity be permitted near the inflator on
the back of an airbag module. When carrying or han-
dling an undeployed airbag module, the trim side of
the airbag should be pointing away from the body to
minimize possibility of injury if accidental deploy-
ment occurs. Do not place undeployed airbag face
down on a solid surface, the airbag will propel into
the air if accidental deployment occurs.
REMOVAL
WARNING: DURING, AND FOLLOWING, ANY CHILD
Fig. 7 VACUUM HEATER AND A/C OUTLETS -
RESTRAINT ANCHOR SERVICE, DUE TO IMPACT
TYPICAL
EVENT OR VEHICLE REPAIR, CAREFULLY INSPECT
CHILD RESTRAINT ANCHOR ALL MOUNTING HARDWARE, TETHER STRAPS
AND ANCHORS FOR PROPER INSTALLATION,
DESCRIPTION OPERATION, OR DAMAGE. IF A CHILD RESTRAINT
Vehicles manufactured for sale in the North Amer- ANCHOR IS FOUND DAMAGED IN ANY WAY, THE
ican market are equipped with a Lower Anchors and ANCHOR MUST BE REPLACED.
Tether for CHildren, or LATCH child restraint
(1) Remove the lower seat cushion (Refer to 23 -
anchorage system. The LATCH system provides for
BODY/SEATS/SEAT CUSHION - REMOVAL).
the installation of suitable child restraints in certain
(2) Remove two nuts to LATCH bracket.
seating positions without using the standard equip-
(3) Remove bracket from vehicle.
ment seat belt provided for that seating position. The
rear seat in these models are equipped with a fixed-
position child restraint upper tether anchor and child
restraint lower anchors for the two outboard seating
positions only. Vehicles manufactured for sale outside
of North America are equipped with a fixed-position
child restraint upper tether anchor for both the cen-
REMOVAL
(1) Place the front road wheels in the straight
ahead position then:
• Rotate the steering wheel half turn (180 Fig. 10 TILT LEVER - REMOVE/INSTALL
degrees) to the right (clockwise). 1 - TILT LEVER
• Lock column with ignition lock cylinder. 2 - LOWER SHROUD
(2) Open hood and disconnect the negative battery
cable remote terminal from the remote battery post. (9) Remove the steering column upper shroud from
(3) Wait two minutes for the system reserve capac- the steering column using the following procedure.
itor to discharge before servicing any airbag compo- First, on the right seam between the upper and lower
nents. shrouds, push in on seam at the forward end. When
(4) Remove speed control switch mounting screws, the upper shroud unsnaps, pull the upper shroud
from the back of the steering wheel, and disconnect upward away from the lower. Repeat this procedure
the wire connectors. If equipped with remote radio on the opposite side of the column to release the
switches, the speed control switches can remain upper shroud from the lower. Remove the upper
attached to the wire connectors. shroud from the steering column.
(5) Remove the Driver Airbag attaching bolts. (10) Remove the two screws attaching the lower
(6) Lift airbag out of steering wheel and disconnect shroud to the steering column (Fig. 11). Remove the
the airbag and horn wire connectors. If equipped lower shroud from the steering column.
with remote radio switches, disconnect the 4-way
connector between the clock spring and the steering
wheel wiring harness.
(7) Remove the steering wheel (Refer to 19 -
STEERING/COLUMN/STEERING WHEEL -
REMOVAL).
(8) Remove the tilt lever (Fig. 10) from the steer-
ing column (if equipped).
OCCUPANT RESTRAINT
IMPACT SENSOR CONTROLLER - 5 PASSENGER
DESCRIPTION VEHICLES
The Airbag System is a supplemental safety device
designed to help protect the driver and passenger REMOVAL
from serious injury, caused by a frontal impact of the (1) Open hood and disconnect the negative battery
vehicle. cable remote terminal from the remote battery post.
The Occupant Restraint Controller’s (ORC) inter- (2) Wait two minutes for the system reserve capac-
nal impact sensor provides verification of the direc- itor to discharge before servicing any airbag compo-
tion and severity of an impact. The sensor is nents.
mounted within the ORC.
NOTE: If working on a Concorde, the Instrument
OPERATION Panel must be removed. Refer to Body, Instrument
The Occupant Restraint Controller (ORC) uses Panel for Removal and Installation. Then go to Step
data collected from it’s internal accelerometers to dis- 11.
criminate the direction and severity of an impact.
(3) Remove one screw to shift knob.
The ORC will activate power stages internal to the
(4) Remove two screws to shifter bezel.
module in order to deploy the driver and passenger
(5) Disconnect power outlet connector and remove
side airbags once a predetermined threshold has
bezel from vehicle.
been exceeded. The ORC is calibrated for a particular
(6) Remove left instrument panel end cap covering
vehicle family and uses an advanced software algo-
the junction block.
rithm to discriminate the severity and direction of
(7) Remove two screws to steering column cover
any vehicle event.
then pull toward rear of vehicle to disengage clips.
(8) Open glove box door. Continue to pull down on
the door until the glove box drops and you see the
screws in the upper and lower left corner or the glove
box bin.
(9) Pull the right console side panel off.
(10) Remove two screws to left console side panel
and pull off.
(1) Position the ORC (arrow pointing forward in NOTE: If working on a Concorde, the Instrument
vehicle) on the ORC mounting bracket. The mounting Panel must be removed. Refer to Body, Instrument
bosses on the controller will correctly position the Panel, for Removal. Then go to Step 11.
ORC on the bracket. Attach the ORC to the bracket
with the three screws supplied and torque to 88 to (4) Remove the left endcap at the junction block.
124 in. lbs. (10 to 14 N·m). (5) Remove two screws to steering column cover
then pull toward rear of vehicle to disengage clips.
CAUTION: USE SUPPLIED SCREWS ONLY. (6) Open glove box door. Continue to pull down on
the door until the glove box drops and you see the
(2) Tighten the top screw on the drivers side. screws in the upper and lower left corner or the glove
(3) Install the two side ORC mounting screws on box bin.
the drivers side. (7) Remove the instrument panel center bezel. The
(4) Connect ORC 23-way connector and slide the temperature control module, power outlet and trac-
red Connector Position Assurance (CPA) tab in. tion control switch will pop out with the center bezel.
(8) Disconnect the connectors at center bezel.
NOTE: If working on a Concorde, the Instrument (9) Remove four screws to Chin bezel. Two on the
Panel must be installed. Refer to Body, Instrument right side and two on the left side of vehicle.
Panel for Installation and then go to Electrical,
(10) Remove one screw and one push fastener
Restraints, Diagnosis and Testing - Airbag System. retaining floor bin.
(11) With the ORC now exposed, slide the red Con-
(5) Install left console side panel and two retaining
nector Position Assurance (CPA) tab out. Press down
screws.
on the locking latch and disconnect the ORC 23-way
(6) Install the right console side panel.
connector.
(7) Install the screws in the upper and lower left
(12) Remove the two side module mounting screws
corner or the glove box bin.
on the drivers side.
(8) Close the glove box door.
(13) Loosen the top screw on the drivers side.
(9) Install the steering wheel cover and the two
(14) Lift up the module and slide out the ORC.
screws to steering column cover.
(10) Install the left instrument panel end cover
NOTE: If the ORC cannot be lifted out, the passen-
covering the junction block.
ger side screw needs some additional loosening.
(11) Connect power outlet connector and install the
center bezel into vehicle. (15) Remove the ORC from vehicle.
(12) Install the two screws to shifter bezel.
(13) Install the one screw to shift knob.
INSTALLATION
WARNING: THE ORC IS A SAFETY MODULE. FAIL-
URE TO INSTALL AND SECURE IT PROPERLY
COULD CAUSE THE MODULE TO MALFUNCTION
AND CAUSE PERSONAL INJURY.
(2) Tighten the top screw on the drivers side. Fig. 19 AIRBAG COMPONENT LOCATION
(3) Install the two side module mounting screws
1 - DRIVER AIRBAG
on the drivers side. 2 - PASSENGER AIRBAG
(4) Connect the ORC 23-way connector. Slide the 3 - OCCUPANT RESTRAINT CONTROLLER (ORC)
red Connector Position Assurance (CPA) tab in. 4 - KNEE BLOCKER
NOTE: If working on a Concorde, the Instrument The instrument panel top cover/pad is the most
Panel must be installed. Refer to Body, Instrument visible part of the passenger airbag system. Located
Panel, for Installation and then go to Electrical, under the instrument panel top pad are the airbag
Restraints, Diagnosis and Testing - Airbag System. door, the passenger airbag cushion and the airbag
cushion supporting components.
(5) Install the one screw and one push fastener The passenger airbag includes an extruded housing
retaining the floor bin. within which the cushion and inflator are mounted
(6) Install the four screws to Chin bezel. Two on and sealed. Two stamped metal brackets, one on each
the right side and two on the left side of vehicle. end of the housing, enclose the cushion and inflator
(7) Connect the connectors at center bezel. and also serve as the mounting brackets for the air-
(8) Install the instrument panel center bezel. bag.
(9) Install the screws in the upper and lower left Following a passenger airbag deployment, the pas-
corner or the glove box bin. Close the glove box door. senger airbag and instrument panel must be
(10) Install the two screws to steering column replaced. The passenger airbag cannot be repaired,
cover. and must be replaced if deployed or in any way dam-
(11) Install the left end cover at the junction block. aged.
WARNING: DO NOT CONNECT THE BATTERY NEG- (1) Remove the seat cushion and back.
ATIVE CABLE REMOTE TERMINAL. REFER TO (2) Remove the upper quarter trim panel.
ELECTRICAL, RESTRAINTS, DIAGNOSIS AND TEST- (3) Remove the lower quarter trim panel.
ING - AIRBAG SYSTEM FIRST. (4) Remove the nut attaching the lower seat belt
anchor to the floor.
(5) Remove the turning loop bolt.
DEPLOYED AIRBAG (6) Remove the bolt attaching the seat belt retrac-
(1) Transfer all instrument panel components tor to the quarter panel. (Fig. 23).
which are not damaged to NEW instrument panel (7) Remove the seat belt retractor from the vehicle.
and pad assembly. Tighten screws to 2.3 N·m (20 in.
lbs.) torque. INSTALLATION
(2) Install the four screws to the airbag reinforce-
ment brace on the airbag. Torque screws to 2 N·m WARNING: INSPECT THE CONDITION OF THE
(20 in. lbs.) (Fig. 22). SHOULDER/LAP BELT. REPLACE THE RETRACTOR
(3) Install the airbag assembly into the instrument IF THE BELT IS CUT, FRAYED, TORN, OR DAM-
panel retainer. AGED IN ANY WAY.
OPERATION
Only the Side Impact Airbag Control Module
(SIACM) can deploy the side airbags. When supplied
with the proper electrical signal the seat airbag infla-
tor will produce a gas and discharge the bag directly
between the occupant and the side of the vehicle,
protecting the occupant. Upon deployment, the seat
back trim cover will tear open and allow the side air-
bag to fully inflate and quickly deflate.
REMOVAL
WARNING: DO NOT REPLACE A DEPLOYED AIR-
BAG. IF SEAT AIRBAG HAS BEEN DEPLOYED, THE
ENTIRE SEAT BACK AND ALL DAMAGED PARTS
MUST BE REPLACED.
DISCONNECT AND ISOLATE THE NEGATIVE BAT-
TERY CABLE REMOTE TERMINAL BEFORE BEGIN-
NING ANY FRONT SEAT REMOVAL OR
INSTALLATION PROCEDURE. THIS WILL DISABLE
THE AIRBAG SYSTEM. FAILURE TO DISCONNECT
Fig. 25 REAR SEAT BACK RETAINING NUTS
THE BATTERY COULD RESULT IN ACCIDENTAL
1 - ELASTIC STRAPS AIRBAG DEPLOYMENT AND POSSIBLE PERSONAL
INJURY.
SEAT AIRBAG ONCE THE BATTERY NEGATIVE CABLE IS DISCON-
NECTED, WAIT 2 MINUTES BEFORE REMOVING
DESCRIPTION ANY AIRBAG SYSTEM COMPONENT.
REMOVAL
(1) Disconnect and isolate the battery negative
cable remote terminal.
(2) Wait two minutes for the system reserve capac-
itor to discharge before servicing any airbag compo-
nents.
(3) Remove the lower B-pillar trim from the appro-
priate side of the vehicle. Refer to Body, Interior,
B-Pillar Lower Trim, Removal.
(4) Disconnect the side impact airbag control mod-
ule electrical connector (Fig. 32).
(5) Remove the SIACM retaining screws and
remove the module from the vehicle (Fig. 32).
SPEED CONTROL
TABLE OF CONTENTS
page page
DIAGNOSIS AND TESTING - ROAD TEST CAUTION: When test probing for voltage or conti-
Perform a vehicle road test to verify reports of nuity at electrical connectors, care must be taken
speed control system malfunction. The road test not to damage connector, terminals or seals. If
should include attention to the speedometer. Speed- these components are damaged, intermittent or
ometer operation should be smooth and without flut- complete system failure may occur.
ter at all speeds.
Flutter in the speedometer indicates a problem
which might cause surging in the speed control sys-
SPECIFICATIONS - TORQUE
REMOVAL - 2.7L
(1) Disconnect the negative battery cable.
(2) Remove speed control cable from throttle cam
by sliding clasp out hole used for throttle cable.
(3) Compress the retaining tabs on the cable and
slide cable out of bracket.
(4) Remove 2 nuts and 1 bolt from servo bracket.
(5) Disconnect electrical connectors and vacuum
hose.
(6) Remove two nuts attaching speed control cable
and mounting bracket to servo.
(7) Pull cable away from servo to expose retaining
clip and remove clip attaching cable to servo.
(8) Remove servo mounting bracket.
SERVO INSTALLATION
(1) With throttle in full open position align hole in
DESCRIPTION speed control cable sleeve with hole in servo pin and
The servo unit consists of a solenoid valve body, install retaining clip.
and a vacuum chamber. The solenoid valve body con- (2) Connect vacuum hose to servo.
tains three solenoids: (3) Connect electrical connector.
• Vacuum (4) Insert servo studs through holes in speed con-
• Vent trol cable and mounting bracket.
• Dump (5) Install nuts, tighten to 6.7 N·m (60 in. lbs.).
The vacuum chamber contains a diaphragm with a (6) Install servo and bracket and tighten bolt and
cable attached to control the throttle linkage. nuts.
(7) Connect negative battery cable.
OPERATION
The PCM controls the solenoid valve body. The
solenoid valve body controls the application and
SWITCH
release of vacuum to the diaphragm of the vacuum
servo. The servo unit cannot be repaired and is ser- DESCRIPTION
viced only as a complete assembly. There are two separate switch pods that operate
Power is supplied to the servo by the PCM through the speed control system and are located on the
the brake switch. The PCM controls the ground path steering wheel.
for the vacuum and vent solenoids.
The dump solenoid is energized anytime it receives OPERATION
power. If power to the dump solenoid is interrupted, The speed control system has five separate resis-
the solenoid dumps vacuum in the servo. This pro- tive switches that provide a single multiplexed
vides a safety backup to the vent and vacuum sole- (MUX) voltage inputs to the PCM.The switch names
noids. are: ON, OFF, SET, COAST, RESUME, ACCEL, TAP-
The vacuum and vent solenoids must be grounded UP, COAST, and CANCEL. Based on conditions when
by the PCM to operate. When the PCM grounds the the buttons are pushed (and released), the five volt-
vacuum servo solenoid, the solenoid allows vacuum ages ranges provided to the PCM result in the follow-
to enter the servo and pull open the throttle plate ing functions: ON, OFF, SET, COAST, RESUME,
using the cable. When the PCM breaks the ground, ACCEL, TAP-UP, TAP-DOWN, COAST, and CAN-
the solenoid closes and no more vacuum is allowed to CEL. Refer to the Speed Control Section for more
enter the servo. The PCM also operates the vent sole- information
noid via ground. The vent solenoid opens and closes a Also the PCM receives an input from the brake
passage to bleed or hold vacuum in the servo as switch to sense whether the brake pedal has been
required. depressed. When the PCM receives the brake
The PCM cycles the vacuum and vent solenoids to depressed input, it turns off power to the speed con-
maintain the set speed, or to accelerate and deceler- trol servo and disengages speed control. Also the
ate the vehicle. To increase throttle opening, the power to the servo is supplied through the brake
PCM grounds the vacuum and vent solenoids. To switch, which opens the circuit when the brake pedal
decrease throttle opening, the PCM removes the is depressed.
grounds from the vacuum and vent solenoids. The individual switches cannot be repaired. If one
switch fails, the entire switch module must be
REMOVAL replaced.
(1) Disconnect the negative battery cable.
(2) Remove three bolts from servo bracket. REMOVAL
(3) Disconnect electrical connectors and vacuum The speed control switch is mounted in the steer-
hose. ing wheel and wired through the clock spring device
(4) Remove two nuts attaching speed control cable under the airbag module.
and mounting bracket to servo.
WARNING: IF REMOVAL OF AIRBAG MODULE IS
(5) Remove servo mounting bracket.
NECESSARY, REFER TO THE RESTRAINT SYS-
(6) Pull cable away from servo to expose retaining
TEMS SECTION FOR MORE INFORMATION.
clip and remove clip attaching cable to servo.
(1) Remove the negative battery cable.
(2) Turn off ignition.
DESCRIPTION INSTALLATION
The vacuum reservoir is located in the engine com- (1) Connect vacuum hose.
partment. It is made of plastic. (2) Install vacuum reservoir and tighten fasteners.
(3) Install PDC and bracket and tighten fasteners.
OPERATION (4) Install coolant reservoir.
The reservoir stores engine vacuum. Manifold vac- (5) Install PCM refer to the Fuel Injection System
uum is supplied from the brake booster check valve. section.
The speed control vacuum supply hose has a check (6) Connect the negative battery cable.
valve at the source (brake booster) to maintain the
page page
OPERATION (2) Insert one of the two valid Sentry Key tran-
Each Sentry Key transponder has a unique tran- sponders into the ignition switch and turn the igni-
sponder identification code programmed into it by the tion switch to the ON position.
manufacturer. The Sentry Key Immobilizer Module (3) After the ignition switch has been in the ON
(SKIM) has a unique “Secret Key” code programmed position for about three seconds, but no more than
into it by the manufacturer. When a Sentry Key fifteen seconds, cycle the ignition switch back to the
transponder is programmed into the memory of the OFF position. Replace the first valid Sentry Key in
SKIM, the SKIM learns the transponder identifica- the ignition lock cylinder with the second valid Sen-
tion code from the transponder, and the transponder try Key and turn the ignition switch back to the ON
learns the “Secret Key” code from the SKIM. Each of position. Both operations must be performed within
these codes is stored within the transponder and in 15 seconds.
the nonvolatile memory of the SKIM. Therefore, (4) About ten seconds after the completion of Step
blank keys for the SKIS must be programmed by and 3, the VTSS indicator LED will start to flash and a
into the SKIM, in addition to being cut to match the single audible chime tone will sound to indicate that
mechanical coding of the ignition lock cylinder. See the system has entered the “Customer Learn” pro-
Sentry Key Immobilizer System Transponder Pro- gramming mode.
gramming in this section for more information. (5) Within about fifty seconds of entering the “Cus-
The Sentry Key transponder is within the range of tomer Learn” programming mode, turn the ignition
the SKIM transceiver antenna ring when it is switch to the OFF position, replace the valid Sentry
inserted in the ignition lock cylinder. When the igni- Key with a blank Sentry Key transponder, and turn
tion switch is turned to the START or ON positions, the ignition switch back to the ON position.
the SKIM transceiver issues a Radio Frequency (RF) (6) About ten seconds after the completion of Step
signal that excites the transponder chip. The tran- 5, a single audible chime tone will sound and the
sponder chip responds by issuing an RF signal con- VTSS indicator LED will stop flashing and stay on
taining its transponder identification code and the solid for about three seconds to indicate that the
“Secret Key” code. The SKIM transceiver compares blank Sentry Key transponder has been successfully
the transponder codes with the codes stored in its programmed. The SKIS will immediately return to
memory to determine whether a valid key is in the normal system operation following exit from the
ignition lock cylinder. “Customer Learn” programming mode.
The Sentry Key transponder cannot be repaired (7) Go back to Step 2 and repeat this process for
and, if faulty or damaged, it must be replaced. each additional Sentry Key transponder blank to be
programmed.
STANDARD PROCEDURE - TRANSPONDER If any of the above steps is not completed in the
proper sequence, or within the allotted time, the
PROGRAMMING SKIS will automatically exit the “Customer Learn”
Two programmed sentry key transponders are programming mode. The SKIS will also automatically
included with the Sentry Key Immobilizer System exit the “Customer Learn” programming mode if it
(SKIS) when it is shipped from the factory. The Sen- sees a non-blank Sentry Key transponder when it
try Key Immobilizer Module (SKIM) can be pro- should see a blank, if it has already programmed
grammed to recognize up to six additional eight valid Sentry Keys, or if the ignition switch is
transponders, for a total of eight Sentry Keys. The turned to the OFF position for more than about fifty
following “Customer Learn” programming procedure seconds.
for the programming of additional transponders
requires access to at least two of the valid Sentry
Keys. If two valid Sentry Keys are not available, Sen- VTSS INDICATOR
try Key programming will require the use of a DRB
IIIt scan tool and the proper Body Diagnostic Proce- DESCRIPTION
dures Manual. The Sentry Key Immobilizer System (SKIS) uses
the Vehicle Theft Security System (VTSS) indicator
CUSTOMER LEARN LED to give an indication when the SKIS is faulty or
(1) Obtain the additional Sentry Key transponder
when the vehicle has been immobilized due to the
blank(s) that are to be programmed for the vehicle.
use of an invalid ignition key. The LED is controlled
Cut the additional Sentry Key transponder blanks to
by the BCM based upon messages received from the
match the ignition lock cylinder mechanical key
Sentry Key Immobilizer Module (SKIM). The VTSS/
codes.
SKIS indicator LED is hard wired directly to the
BCM.
WIPERS/WASHERS
TABLE OF CONTENTS
page page
WIPERS/WASHERS INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . 16
DESCRIPTION . . . . . . . . . . . . . . . . . . . . . . . . . . 2 WASHER PUMP MOTOR - INTREPID
OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2 REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16
DIAGNOSIS AND TESTING INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . 16
DIAGNOSIS AND TESTING - WASHER RESERVOIR
INTERMITTENT WIPERS . . . . . . . . . . . . . . . . . 2 REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17
DIAGNOSIS AND TESTING - WINDSHIELD INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . 17
WASHERS . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 WASHER RESERVOIR - INTREPID
DIAGNOSIS AND TESTING - WIPER REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18
SYSTEM CONDITIONS . . . . . . . . . . . . . . . . . . 6 INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . 18
HEADLAMP WASHERS - EXPORT WASHER RESERVOIR FILLER TUBE
DESCRIPTION . . . . . . . . . . . . . . . . . . . . . . . . . . 8 REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18
OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9 INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . 18
DIAGNOSIS AND TESTING - HEADLAMP WIPER ARMS
WASHER - EXPORT . . . . . . . . . . . . . . . . . . . . 9 STANDARD PROCEDURE - WIPER ARM
STANDARD PROCEDURE - HEADLAMP ALIGNMENT . . . . . . . . . . . . . . . . . . . . . . . . . 19
WASHER SYSTEM PRIMING - EXPORT . . . . 13 REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19
HEADLAMP WASHER HOSES - EXPORT INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . 19
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13 WIPER BLADES
INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . 13 DESCRIPTION . . . . . . . . . . . . . . . . . . . . . . . . . 19
HEADLAMP WASHER NOZZLE - EXPORT OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . . 19
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14 REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19
INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . 14 INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . 19
HEADLAMP WASHER PUMP - EXPORT WIPER BLADE ELEMENT
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14 REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20
INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . 15 INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . 20
WASHER FLUID LEVEL SWITCH WIPER LINKAGE
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15 REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20
INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . 15 INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . 20
WASHER FLUID LEVEL SWITCH - INTREPID WIPER MODULE
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15 REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21
INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . 15 INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . 21
WASHER HOSES WIPER MOTOR
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15 DIAGNOSIS AND TESTING - WIPER MOTOR . . 22
INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . 16 REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26
WASHER NOZZLE INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . 26
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16 WIPER SWITCH
INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . 16 DIAGNOSIS AND TESTING -
WASHER PUMP MOTOR WIPER SWITCH ................... . . . 27
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16
WASHER SYSTEM
The wash function can be accessed in the OFF
position of the wiper control switch. Wash switch
must be pressed for at least 0.5 second to get the
wipe after wash. Holding the wash button depressed
Fig. 1 WIPER/WASHER SWITCH when the switch is in the OFF position will operate
1 - WINDSHIELD WASHER BUTTON the wipers and washer motor pump continuously
2 - CONTROL STALK (BEAM SELECT) until the washer button is released. Releasing the
3 - HAZARD WARNING BUTTON button will stop the washer pump but the wipers will
4 - MULTI-FUNCTION SWITCH
5 - WINDSHIELD WIPER CONTROL complete the current wipe cycle, followed by an aver-
age of two more wipe cycles (±1) before the wipers
The windshield wiper system is controlled by a park and the module turns off. If the wash switch is
switch located on the multi-function switch stalk pressed momentarily with the wipers in the OFF or
(Fig. 1). The multi-function switch is located on the INTERMITTENT position, a pulse wipe cycle consist-
steering column behind the steering wheel. ing of two wipes will occur.
Fluid is gravity fed from the reservoir to the motor.
WASHER SYSTEM The fluid is forced by the pump through rubber hoses
All models are equipped with electric operated to the hood mounted nozzles which direct the fluid
windshield washer pumps. The electric pump assem- streams to the windshield. The one way flow check
bly is mounted with a grommet directly to the reser- valves are located in each hood nozzle. The purpose
voir. of the check valves is to improve fluid flow response
The windshield washer system is controlled by a time and to prevent excessive washer fluid staining
switch located on the multi-function switch stalk the surface of the hood. The hood mounted nozzles
(Fig. 1). The multi-function switch is located on the distribute washer fluid on the surface of the wind-
steering column behind the steering wheel. shield. The pump and reservoir are serviced as sepa-
rate assemblies.
OPERATION
WIPER SYSTEM DIAGNOSIS AND TESTING
The windshield wipers will operate when the igni-
tion switch is in the ACCESSORY or IGNITION ON DIAGNOSIS AND TESTING - INTERMITTENT
position. The windshield wipers will return to the WIPERS
parked position when the ignition switch is turned to The intermittent wiper function is controlled by
the OFF position. Fuses, located in the Junction the Body Control Module (BCM), located in the left
Block and Power Distribution Center protects the cir- side of the instrument panel, attached to the Junc-
cuitry of the wiper system and the vehicle. tion Block (Fig. 2). If the Body Control Module is
The wiper motor has permanent magnet fields. The determined to be the problem, refer to Electrical,
speeds are determined by current flow to the appro- Electronic Control Modules, Body Control Module,
priate set of brushes. Removal.
WASHER POWER FEED 1. JUNCTION BLOCK FUSE 1. CHECK FUSE #5. REPLACE IF NOT OK.
FUSE OPEN. #5 BLOWN.
HOOD NOZZLE WILL NOT 1. FROZEN NOZZLE. 1. DE-ICE NOZZLE BY ALLOWING TIME FOR
FLOW. UNDERHOOD ENGINE HEAT TO THAW
NOZZLE. IF NOT OK, MOVE VEHICLE INTO
HEATED AREA. ASSURE WASHER FLUID IS
PROPERLY BLENDED FOR AMBIENT OUTSIDE
TEMPERATURES.
WASHER FLUID OUTPUT IS 1. PARTIALLY PINCHED 1. ASSURE WASHER HOSE IS NOT PARTIALLY
LOW. HOSE. PINCHED. IF NOT OK, PROPERLY ROUTE
HOSE.
HOOD NOZZLE STREAM 1. NOZZLE NOT SEATED IN 1. ASSURE NOZZLE IS SNAPPED IN PLACE.
OVERSHOOTS HOOD.
WINDSHIELD.
WIPER WILL NOT CYCLE 1. OPEN OR DEFECTIVE 1. OPEN OR DEFECTIVE CIRCUIT BETWEEN
WHEN WASHER SWITCH IS WASHER SYSTEM WIPER/WASHER SWITCH CONNECTOR
DEPRESSED. CONTROL CIRCUIT. TERMINAL #2 AND BCM #C2 BLACK
CONNECTOR TERMINAL #7. IF NOT OK
REPAIR CIRCUIT.
WASHER FLUID LEVEL 1. LOOSE FLUID LEVEL 1. PROPERLY SEAT CONNECTOR TO SWITCH.
INDICATOR INOPERATIVE. SENSOR CONNECTOR.
LEAKING WASHER FLUID. 1. FILLER TUBE LEAKING. 1. ASSURE FILLER TUBE IS NOT LOOSE OR
DISCONNECTED. IF NOT OK, PROPERLY
SEAT FILLER TUBE.
2. FILLER TUBE OUT OR 2. REPLACE FILLER TUBE.
DAMAGED.
3. PUMP OR SENSOR 3. REPLACE PUMP OR SENSOR GROMMET.
GROMMET DEFECTIVE.
4. LEAKING OR DEFECTIVE 4. REPLACE RESERVOIR BODY.
RESERVOIR BODY.
DIAGNOSIS AND TESTING - WIPER SYSTEM (c) If motor is still inoperative and the fuse does
not blow, go to Step 2.
CONDITIONS
(d) If replacement fuse blows, go to Step 11.
The following is a list of general wiper motor sys-
(2) Disconnect motor wire harness connector.
tem problems and tests that are to be performed to
(3) Check the wiper motor low speed. Using two
locate the faulty part, and the corrective action to be
jumper wires, connect one jumper wire between the
taken. When installing harness connector to motor
battery positive jump start terminal and Pin 2 on the
connector on vehicle, assure motor terminals are not
wiper motor connector. Connect the other jumper
bent causing an open circuit to motor.
wire to ground and Pin 5 on the wiper motor connec-
tor. Check the wiper motor high speed, connect the
MOTOR WILL NOT RUN IN ANY SWITCH
positive jumper wire to Pin 1 on the wiper motor con-
POSITION nector. Connect the negative jumper wire to Pin 5 on
(1) Check fuse 5, in the Junction Block and fuse M the wiper motor connector.
in the Power Distribution Center and. Refer to Wir- (a) If motor runs, go to Step 4.
ing Diagrams for pin call outs. (b) If motor does not run, high or low speed
(a) If fuse(s) are good, go to Step 2. replace the wiper motor.
(b) If fuse(s) are defective replace, and check (4) Using an ohmmeter, check for good ground at
motor operation in all switch positions. Pin 5 of the wiper motor wire harness connector. If
not OK, repair the ground circuit as necessary. If OK,
go to Step 5.
MOTOR WILL KEEP RUNNING WITH SWITCH IN WIPERS DO NOT RUN WHEN WASHER MOTOR IS
OFF POSITION. ENGAGED
(1) Check wiper motor wiring harness for shorts (1) Disconnect the C2 black 24-way connector from
between the low speed motor feed terminal 2 or high the BCM.
speed motor feed terminal 1 and battery or ignition. (2) Using a voltmeter, connect positive lead to ter-
(2) Check for faulty wiper ON/OFF or HI/LO relay. minal 7 of the C2 black 24-way connector and the
(3) Check circuit from ON/OFF relay terminal C to negative lead to ground.
HI/LO relay terminal B for short to battery or igni- (3) Engage the washer switch so that the washer
tion. motor runs continuously.
(4) Disconnect the C3 bone 12-way connector from (a) If the voltage is zero, check the wiring
the BCM. Check circuit from terminal 4 of C3 bone between the washer switch terminal 2 and the
12-way connector to terminal C of the ON/OFF wiper BCM and repair as necessary.
relay for short to ground. (b) If the battery voltage is shown, replace the
(5) Check circuit from terminal 3 of C2 bone BCM.
24–way connector to Pin 4 of the wiper motor har-
ness connector for an open. If open circuit, repair as
necessary.
HEADLAMP WASHERS -
(6) Using a voltmeter, connect positive lead to ter- EXPORT
minal 8 of the C2 black 24-way connector. Connect
negative lead to ground. If voltmeter reads greater DESCRIPTION
than 0 volts, check wiper switch and wiring. Headlamp washers are available as a factory-in-
(7) Using a voltmeter, connect positive lead to ter- stalled option on this model. The headlamp washers
minal 8 of the C3 black 12-way connector. on this vehicle work in conjunction with the wind-
(a) If voltmeter reads 10 to 15 volts, check the shield washers. The headlamp washers are enabled
circuit for short to battery or ignition. with the headlamps “ON” and the windshield wash-
(b) If the voltmeter reads 0 volts, replace the ers activated. With the windshield washers activated
BCM. the headlamp washers will spray for a preset amount
of time controlled by a relay.
WASHER POWER FEED 1. JUNCTION BLOCK FUSE 1. CHECK FUSE #5. REPLACE IF NOT OK.
FUSE OPEN. #5 BLOWN.
WASHER SYSTEM WILL 1. JUNCTION BLOCK FUSE 1. SHORT CIRCUIT BETWEEN JUNCTION
NOT FLOW WASHER #5 BLOWN. BLOCK FUSE #5 AND WIPER SWITCH
FLUID. TERMINAL #1. SHORT IN WIPER SWITCH. IF
NOT OK, REPAIR CIRCUIT OR REFER TO
WIPER/WASHER SWITCH DIAGNOSTIC
PROCEDURES.
HOOD NOZZLE WILL NOT 1. PINCHED NOZZLE 1. ASSURE NOZZLE HOSE IS NOT PINCHED,
FLOW. HOSE. LOOSE, BROKEN, OR DISCONNECTED. IF
NOT OK, PROPERLY ROUTE OR REPAIR
NOZZLE HOSE.
WIPER WILL NOT CYCLE 1. OPEN OR DEFECTIVE 1. OPEN OR DEFECTIVE CIRCUIT BETWEEN
WHEN WASHER SWITCH IS WASHER SYSTEM WIPER/WASHER SWITCH CONNECTOR
DEPRESSED. CONTROL CIRCUIT. TERMINAL #2 AND BCM #C2 BLACK
CONNECTOR TERMINAL #7. IF NOT OK
REPAIR CIRCUIT.
WASHER FLUID LEVEL 1. LOOSE FLUID LEVEL 1. PROPERLY SEAT CONNECTOR TO SWITCH.
INDICATOR INOPERATIVE. SENSOR CONNECTOR.
2. FLUID LEVEL SENSOR 2. ASSURE SENSOR FLOAT SWITCH IS
SWITCH OPEN OR CLOSED (DOWN POSITION). APPLY
DEFECTIVE. OHMMETER TO SWITCH TO CHECK FOR
COMPLETE CIRCUIT. IF NOT OK, REPLACE
SWITCH.
INSTALLATION
(1) Install the headlamp washer hoses to the radi-
ator closure panel.
(2) Connect the headlamp washer hoses quick dis-
connect connectors (Fig. 3) and (Fig. 4).
(3) Reinstall the front fascia. Refer to Body for
Installation procedures.
(4) Lower vehicle from hoist.
(5) Refill the washer fluid. Fig. 4 RIGHT SIDE HEADLAMP WASHER HOSE
(6) Reconnect the negative battery cable remote 1 - HEADLAMP WASHER NOZZLE
terminal. 2 - HEADLAMP WASHER HOSE QUICK DISCONNECT
INSTALLATION
(1) Place the headlamp washer nozzle in position
on the headlamp assembly.
(2) Install the headlamp washer nozzle retaining
screws. Torque to 0.7 to 1.3 N·m.
(3) Reinstall the headlamp assembly. Electrical,
Lamps/Lighting - Exterior, Headlamp Unit, Installa- Fig. 6 HEADLAMP WASHER PUMP
tion.
1 - WINDSHIELD/HEADLAMP WASHER RESERVOIR
(4) Reinstall the front fascia as necessary. Refer to 2 - HEADLAMP WASHER PUMP
Body for Installation procedures.
(5) Lower vehicle from hoist. (7) Disconnect the headlamp washer pump electri-
(6) Refill the washer fluid. cal connector and the headlamp washer pump hose.
(7) Prime the headlamp washer system. Refer to (8) Pull the headlamp washer pump from the res-
the Electrical, Wipers/Washerr, Headlamp Washers, ervoir.
INSTALLATION INSTALLATION
(1) Route washer hose up through engine compart- (1) Install new rubber grommet in reservoir.
ment. (2) Carefully install pump motot into reservoir.
(2) Connect washer hose to top of reservoir and to Care must be taken not to puncture reservoir (Fig.
washer pump discharge port. 8).
(3) Connect hose clips to hood, tower to tower (3) Connect the wire connectors to the reservoir
beam, and fender beam. pump.
(4) Connect right and left hood nozzle hoses at “Y” (4) Install the front fascia as necessary (left side
connector. only and use a 2x4 to prop left edge of fascia away
(5) Connect “Y” connector to hood. from body). Refer to Body for Installation.
(6) install the underhood silencer pad clips along (5) Lower vehicle from hoist.
left rear of hood. (6) Connect the negative battery cable remote ter-
(7) Install the left headlamp unit. Refer to Electri- minal to the remote battery post.
cal, Lamps/Lighting - Exterior, Headlamp Unit,
Installation.
Be sure to test and check system for leaks and WASHER PUMP MOTOR -
pinched or kinked hoses. INTREPID
WASHER RESERVOIR
REMOVAL
(1) Open hood and disconnect the negative battery
cable remote terminal from the remote battery post.
(2) Hoist vehicle.
(3) Remove front fascia as necessary (left side only
and use a 2x4 to prop left edge of fascia away from
body). Refer to Body for Removal.
(4) Disconnect the wire connectors from the reser-
voir pump and float sensor.
(5) Disconnect the washer hose and block the liq-
uid outlet to prevent the liquid from running out of
the reservoir.
(6) Reach up behind the washer reservoir and pull
the filler tube off the rear of the reservoir.
(7) Remove four mounting bolts to washer reser- Fig. 8 WASHER RESERVOIR
voir (Fig. 7). 1 - RETAINING BOLTS
2 - WASHER RESERVOIR
3 - FLUID LEVEL SENSOR
4 - WASHER FLUID PUMP
INSTALLATION
(1) Transfer fluid level sensor, pump, and washer
fluid to new reservoir (Fig. 8).
(2) Place washer reservoir into vehicle into the
mounting position.
(3) Install the four mounting bolts to the washer
reservoir (Fig. 7).
(4) Reach up behind the washer reservoir and
place the filler tube onto the rear of the reservoir.
(5) Connect the washer hose to the washer pump
outlet.
(6) Connect the wire connectors to the reservoir
pump and float sensor.
(7) Install the front fascia as necessary (left side
only and use a 2x4 to prop left edge of fascia away
from body). Refer to Body for Installation.
(8) Lower vehicle from hoist.
(9) Connect the negative battery cable remote ter-
Fig. 7 WASHER RESERVOIR REMOVAL minal to the remote battery post.
1 - WASHER RESERVOIR FILLER TUBE
2 - WASHER RESERVOIR
INSTALLATION
NOTE: When transferring pump and sensor, make
sure to use a new grommet for proper sealing and
to avoid leaks.
REMOVAL
(1) Cycle the wiper arm/blades into PARK position
and turn ignition OFF.
(2) Using a trim stick (special tool #C-4755) or
equivalent, gently pry up on the wiper arm retaining
nut cap and remove.
(3) Remove the retaining nut from the wiper arm
pivot. Fig. 10 WIPER BLADE AND ELEMENT
(4) Lift wiper arm to raise blade off glass and 1 - ARM RELEASE TAB
remove the arm from the pivot using a rocking 2 - VERTABRA
motion and remove from vehicle. 3 - RUBBER ELEMENT
INSTALLATION INSTALLATION
(1) Place the wiper arm on wiper pivot. (1) LIft wiper arm tip off glass and snap blade and
(2) Install the retaining nut to the wiper arm element onto wiper arm (Fig. 11). The vertebra is
pivot. curved on the right blade only. Install with the curve
(3) Install the wiper arm retaining nut cap. matching the shape of the windshield.
(4) Cycle the wiper arm/blades to make sure the (2) Lower wiper arm to glass.
arms are positions correctly.
Refer to Electrical, Wipers and Washers, Wiper
Arms, Standard Procedures for adjustments if neces-
sary.
WIPER LINKAGE
REMOVAL
There a two serviceable link assemblies in the
wiper module (Fig. 13). The Master Link connects
the motor output crank to the drivers side pivot. The
Slave link connects the driver side pivot to the pas-
senger side pivot. To service these links, remove the
wiper module from the vehicle.
The wiper module mounting grommets can be ser-
viced anytime the module is removed from the vehi-
Fig. 11 REMOVE BLADE FROM ARM cle. Replace module mounting grommets if they are
1 - RELEASE TAB broken, cracked, deteriorated, or defective.
WIPER MODULE
REMOVAL
(1) Open hood and disconnect the negative battery
cable remote terminal from the remote battery post.
(2) Remove driver and passenger side wiper arms.
Refer to Electrical, Wipers and Washers, Wiper Arm
Removal.
(3) Remove nine screws to cowl screen panel. Refer
to Body for Removal. Fig. 16 WIPER FRAME GROMMETS
(4) Remove wiper module mounting bolt located on 1 - GROMMETS
top of the tower to tower beam.
(5) Remove eight bolts to Tower to Tower (crosscar) (11) Remove one nut to crank arm and remove
support (Fig. 14). Refer to Body for Removal. from motor (Fig. 17).
(12) Remove three retaining bolts from wiper
motor (Fig. 17).
(13) Remove wiper motor from wiper module
assembly. Install onto new wiper module assembly.
Refer to Electrical, Wipers and Washers, Wiper
Motor, Removal.
INSTALLATION
(1) Install the wiper motor onto the wiper module
assembly. Refer to Electrical, Wipers and Washers,
Wiper Motor, Removal.
(2) Install the three retaining bolts to the wiper
motor (Fig. 17).
(3) Install the crank arm and install the one nut to
Fig. 14 TOWER TO TOWER SUPPORT REMOVAL crank arm (Fig. 17).
1 - TOWER TO TOWER SUPPORT
2 - RETAINING BOLTS NOTE: If replacing module, transfer wiper module
grommets to new module assembly (Fig. 16).
(6) Remove three retaining bolts to windshield
wiper module (Fig. 15). (4) Install the windshield wiper module into vehi-
(7) Lift wiper module away from vehicle body. cle.
(8) Disconnect one wire connector.
(9) Remove windshield wiper module from vehicle.
WIPER OPERATES IN LOW 1. HI/LO RELAY 1. CHECK HI/LO RELAY WITH KNOWN GOOD
SPEED OR INTERMITTENT DEFECTIVE. RELAY. IF NOT OK, REPLACE HI/LO RELAY.
ONLY.
2. OPEN OR DEFECTIVE 2. OPEN OR DEFECTIVE CIRCUIT BETWEEN
CONTROL CIRCUIT IN HI/LO RELAY CAVITY 9C9 AND BCM
BCM. CONNECTOR TERMINAL #12C. DEFECTIVE
BCM. IF NOT OK, REPAIR CIRCUIT OR REFER
TO BCM DIAGNOSTIC PROCEDURES.
3. DEFECTIVE WIPER 3. REFER TO WIPER SWITCH DIAGNOSTIC
SWITCH. PROCEDURES.
4. OPEN HIGH SPEED 4. OPEN OR DEFECTIVE CIRCUIT BETWEEN
CIRCUIT. HI/LO RELAY CAVITY 9D9 AND WIPER MOTOR
CONNECTOR TERMINAL #1. IF NOT OK,
REPAIR CIRCUIT.
5. DEFECTIVE MOTOR. 5. APPLY BATTERY JUMPER OVER TO WIPER
TERMINAL #1 AND GROUND TERMINAL #5. IF
NOT OK, REPLACE MOTOR.
WIPER OPERATES IN HIGH 1. DEFECTIVE HI/LO 1. CHECK WIPER HI/LO RELAY WITH KNOWN
SPEED ONLY. RELAY. GOOD RELAY. REPLACE IF NOT OK.
WIPER WILL NOT PARK. 1. OPEN WIPER MOTOR 1. OPEN OR DEFECTIVE CIRCUIT BETWEEN
PARK CIRCUIT. WIPER MOTOR CONNECTOR TERMINAL #4
AND BCM TERMINAL #3C. IF NOT OK, REPAIR
CIRCUIT.
WIPER RUNS THRU PARK 1. DEFECTIVE ON/OFF 1. CHECK WIPER ON/OFF RELAY WITH
POSITION ON RELAY. KNOWN GOOD RELAY. IF NOT OK, REPLACE
WINDSHIELD. RELAY.
2. OPEN ON/OFF RELAY 2. OPEN OR DEFECTIVE CIRCUIT BETWEEN
GROUND CIRCUIT. ON/OFF RELAY CAVITY 9E9 AND LEFT
HEADLAMP GROUND #5 OR ENGINE
GROUND #1 OR 2.
WIPER MOTOR POWER 1. POWER DISTRIBUTION 1. CHECK FUSE 9M9. IF NOT OK, REPLACE
FEED FUSE OPEN. CENTER (PDC) FUSE 9M9 FUSE.
DEFECTIVE.
WIPER SWITCH POWER 1. JUNCTION BLOCK FUSE 1. CHECK FUSE #5. IF NOT OK, REPLACE
FEED FUSE OPEN. #5 DEFECTIVE. FUSE.
WIPER SYSTEM WILL NOT 1. PDC FUSE 9M9 BLOWN. 1. SHORT CIRCUIT BETWEEN PDC FUSE 9M9
RUN. AND ON/OFF RELAY CAVITY 9A9 OR 9D9 OR
HI/LO RELAY CAVITY 9A9. SHORT CIRCUIT IN
ON/OFF RELAY OR HI/LO RELAY. SHORT
CIRCUIT BETWEEN ON/OFF RELAY CAVITY
9B9 AND HI/LO RELAY CAVITY 9B9. IF NOT OK,
REPLACE ON/OFF RELAY OR REPAIR
CIRCUIT(S).
WIPER SYSTEM MAKES 1. LOOSE ARM TO BLADE 1. INSPECT CONNECTION FOR DAMAGE,
REVERSAL NOISE. CONNECTION. BENDING, EXCESSIVE WARE. REPLACE ARM
OR BLADE IF NOT OK.
DRIVER AND/OR 1. ARM(S) OUT OF 1. REMOVE ARM OFF PIVOT SHAFT, CYCLE
PASSENGER ARM OR POSITION. MODULE TO PARK. REPOSITION ARM/BLADE
BLADE HITS COWL TO LOCATION MARKS ON WINDSHIELD.
SCREEN OR WINDSHIELD SECURE ARM TO PIVOT SHAFT AND TORQUE
MOLDINGS. TO SPECIFICATION.
WIPER BLADE(S) STREAK. 1. CONTAMINATION ON 1. CLEAN BLADE ELEMENT EDGE WITH MILD
BLADE ELEMENT OR SOAP OR ALCOHOL AND WATER. CLEAN
WINDSHIELD. WINDSHIELD WITH MILD SOAP OR NON-
ABRASIVE CLEANSER AND WATER. CHECK
FOR PROPER WIPE QUALITY. IF NOT OK,
REPLACE BLADE ELEMENT.
REMOVAL INSTALLATION
The Wiper Module Assembly must be removed to (1) Place wiper motor in position onto wiper mod-
service the wiper motor. ule.
(1) Open hood and disconnect the negative battery (2) Install the three retaining bolts to the wiper
cable remote terminal from the remote battery post. motor (Fig. 17).
(2) Remove wiper module. Refer to Electrical, Wip- (3) Connect the wiper module master link to the
ers and Washers, Wiper Module Removal. motor crank by carefully snapping together. Do not
(3) Disconnect wiper module master link from damage ball and socket or seal.
motor crank by carefully using a ball and socket (4) Install the wiper module. Refer to Electrical,
wedge. Do not damage ball and socket or seal when Wipers and Washers, Wiper Module Installation.
using wedge. (5) Connect the negative battery cable remote ter-
(4) Remove three retaining bolts from the wiper minal to the remote battery post.
motor (Fig. 17).
(5) Remove wiper motor from wiper module.
WIPER SWITCH
DIAGNOSIS AND TESTING - WIPER SWITCH
To test the multi-function/wiper switch, first dis-
connect the switch wires from the body wiring in the
steering column (Fig. 18). Using an ohmmeter, test
for continuity between the terminals of the switch, as
indicated in the following continuity table. The iden-
tity of each terminal is shown in (Fig. 19).
For test purposes, the first position is the OFF
position, the next six positions are for the DELAY
wipe. LOW is the next detent position and HIGH is Fig. 19 MULTI-FUNCTION/WIPER SWITCH PIN CALL
the full counterclockwise detent position. OUT
In any wiper switch position, if the control stalk
end cap is depressed, the washer circuit will be com-
pleted.
WIRING
TABLE OF CONTENTS
page page
TABLE OF CONTENTS
page page
DESCRIPTION - CONNECTOR, GROUND AND WARNING: BE SURE THAT THE IGNITION SWITCH
ALWAYS IS IN THE OFF POSITION, UNLESS THE
SPLICE INFORMATION
PROCEDURE REQUIRES IT TO BE ON.
CAUTION: Not all connectors are serviced. Some
connectors are serviced only with a harness. A typ- WARNING: SET THE PARKING BRAKE WHEN
ical example might be the Supplemental Restraint WORKING ON ANY VEHICLE. AN AUTOMATIC
System connectors. Always check parts availability TRANSMISSION SHOULD BE IN PARK. A MANUAL
before attempting a repair. TRANSMISSION SHOULD BE IN NEUTRAL.
STANDARD PROCEDURE
STANDARD PROCEDURE - ELECTROSTATIC
DISCHARGE (ESD) SENSITIVE DEVICES
All ESD sensitive components are solid state and a
symbol (Fig. 6) is used to indicate this. When han-
dling any component with this symbol, comply with
the following procedures to reduce the possibility of
Fig. 5 PROBING TOOL electrostatic charge build up on the body and inad-
vertent discharge into the component. If it is not
1 - SPECIAL TOOL 6801
2 - PROBING END known whether the part is ESD sensitive, assume
that it is.
INTERMITTENT AND POOR CONNECTIONS (1) Always touch a known good ground before han-
Most intermittent electrical problems are caused dling the part. This should be repeated while han-
by faulty electrical connections or wiring. It is also dling the part and more frequently after sliding
possible for a sticking component or relay to cause a across a seat, sitting down from a standing position,
problem. Before condemning a component or wiring or walking a distance.
assembly, check the following items. (2) Avoid touching electrical terminals of the part,
• Connectors are fully seated unless instructed to do so by a written procedure.
• Spread terminals, or terminal push out (3) When using a voltmeter, be sure to connect the
• Terminals in the wiring assembly are fully ground lead first.
seated into the connector/component and locked into (4) Do not remove the part form it’s protective
position packing until it is time to install the part.
• Dirt or corrosion on the terminals. Any amount of (5) Before removing the part from it’s pakage,
corrosion or dirt could cause an intermittent problem ground the pakage to a known good ground on the
• Damaged connector/component casing exposing vehicle.
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
• Wiring broken inside of the insulation
Fig. 9 TESTING FOR VOLTAGE DROP TERMINAL REMOVING TOOLS 6932 AND 8638
CONNECTOR INSTALLATION
(1) Insert the removed terminal in the same cavity
REMOVAL on the repair connector.
(1) Disconnect battery. (2) Repeat steps for each terminal in the connec-
(2) Release Connector Lock (Fig. 10). tor, being sure that all wires are inserted into the
(3) Disconnect the connector being repaired from proper cavities. For additional connector pin-out
its mating half/component. identification, refer to the wiring diagrams.
(4) Remove the dress cover (if applicable) (Fig. 10). (3) When the connector is re-assembled, the sec-
ondary terminal lock must be placed in the locked
position to prevent terminal push out.
(4) Replace dress cover (if applicable).
(5) Connect connector to its mating half/compo-
nent.
(6) Connect battery and test all affected systems.
DIODE TERMINAL
REMOVAL REMOVAL
(1) Disconnect the battery. (1) Follow steps for removing terminals described
(2) Locate the diode in the harness, and remove in the connector removal section.
the protective covering. (2) Cut the wire 6 inches from the back of the con-
(3) Remove the diode from the harness, pay atten- nector.
tion to the current flow direction (Fig. 13).
INSTALLATION
(1) Select a wire from the terminal repair kit that
best matches the color and gage 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).
(4) Insert the repaired wire into the connector.
(5) Install the connector locking wedge, if required,
and reconnect the connector to its mating half/compo-
nent.
(6) Re-tape the wire harness starting at 1–1/2
inches behind the connector and 2 inches past the
repair.
Fig. 13 DIODE IDENTIFICATION (7) Connect battery and test all affected systems.
1 - CURRENT FLOW
2 - BAND AROUND DIODE INDICATES CURRENT FLOW
3 - DIODE AS SHOWN IN THE DIAGRAMS
INSTALLATION
(1) Remove the insulation from the wires in the
harness. Only remove enough insulation to solder in
the new diode.
(2) Install the new diode in the harness, making
sure current flow is correct. If necessary, refer to the
appropriate wiring diagram for current flow (Fig. 13).
(3) Solder the connection together using rosin core
type solder only. Do not use acid core solder.
(4) Tape the diode to the harness using electrical
tape. Make sure the diode is completely sealed from
the elements.
(5) Re-connect the battery and test affected sys-
tems.
8W-53 WIPERS
Component Page Component Page
Body Control Module . . . . . . . . . . . . . 8W-53-2, 4, 5 G106 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8W-53-5
Front Washer Pump Motor . . . . . . . . . . . . . 8W-53-3 Headlamp Washer Pump Motor . . . . . . . . . 8W-53-5
Front Wiper High/Low Relay . . . . . . . . . . . 8W-53-4 Headlamp Washer Relay . . . . . . . . . . . . . . 8W-53-5
Front Wiper Motor . . . . . . . . . . . . . . . . . . . 8W-53-4 Instrument Cluster . . . . . . . . . . . . . . . . . . . 8W-53-3
Front Wiper On/Off Relay . . . . . . . . . . . . . 8W-53-4 Junction Block . . . . . . . . . . . . . . . . . . . . . . 8W-53-2
Fuse 5 . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8W-53-2 Power Distribution Center . . . . . . . . . . . 8W-53-4, 5
Fuse M . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8W-53-4 Washer Fluid Level Sensor . . . . . . . . . . . . . 8W-53-3
Fuse P . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8W-53-5 Wiper Switch . . . . . . . . . . . . . . . . . . . . . . . 8W-53-2
G104 . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8W-53-3, 4
CLOCKSPRING C3 - 4 WAY
CAV CIRCUIT FUNCTION
1 V37 22RD/LG S/C SWITCH SIGNAL
2 K4 22BK/LB SENSOR GROUND
3 X920 22GY/OR RADIO CONTROL MUX RETURN
4 X20 22GY/WT RADIO CONTROL MUX
DRIVER POWER SEAT REAR RISER MOTOR SENSOR (MEMORY) - NATURAL 3 WAY
CAV CIRCUIT FUNCTION
1 P29 20BR/WT SEAT SENSOR 5 VOLT SUPPLY
2 P27 20LB/RD REAR RISER POSITION SIGNAL
3 P28 20BR/RD SEAT POSITION SENSOR GROUND
TABLE OF CONTENTS
page
CONNECTOR/GROUND/SPLICE LOCATION
DESCRIPTION . . . . . . . . . . . . . . . . . . . . . . . . . . 1
CONNECTORS
SPLICES
Fig. 10 TRANSMISSION
TABLE OF CONTENTS
page page
CIGAR LIGHTER/POWER
STANDARD PROCEDURE - CIGAR LIGHTER/ OUTLET
POWER OUTLET CUSTOMER PREFERENCE
This vehicle was delivered with the Cigar Lighter/ DESCRIPTION
Power Outlet activated only when the ignition is ON. The power feed to the Cigar Lighter/Power Outlet
To convert the lighter/outlet to operate with the igni- can be HOT (12v - B+) with the ignition ON, or HOT
tion OFF, perform the following: (12v - B+) with the ignition OFF.
• Remove the left instrument panel end cap from
the left end of the instrument panel.
OPERATION
• Remove fuse #6 in the upper right of the junc-
To change the operating mode of the Cigar Lighter/
tion block (Fig. 1) from its “IGN” position.
Power Outlet, (Refer to 8 - ELECTRICAL/POWER
DISTRIBUTION - STANDARD PROCEDURE).
REMOVAL
(1) Open hood and disconnect the negative battery
cable remote terminal from the remote battery post.
(2) Look inside and note position of the retaining
bosses (Fig. 2).
CAUTION:
• Many accessories that can be plugged in draw
power from the vehicle’s battery, even when not in
use (i.e. cellular phones, etc.). Eventually, if plugged Fig. 2 Cigar Lighter / Power Outlet Base Removal
in long enough, the vehicle’s battery will discharge 1 - RETAINING BOSSES-ENGAGE PLIERS HERE
2 - PARTIALLY REMOVED
sufficiently to degrade battery life and/or prevent 3 - EXTERNAL SNAP-RING PLIERS
engine starting. 4 - PULL BASE OUT-THROUGH MOUNTING RING
OPERATION
The term ignition-off draw identifies a normal con-
dition where power is being drained from the battery
with the ignition switch in the Off position. The IOD
fuse feeds the memory and sleep mode functions for
some of the electronic modules in the vehicle as well
as various other accessories that require battery cur-
rent when the ignition switch is in the Off position.
Fig. 3 Tool For Cigar Lighter / Power Outlet The only reason the IOD fuse is disconnected is to
Removal reduce the normal IOD of the vehicle electrical sys-
1 - 2.5MM (3/32 INS.) tem during new vehicle transportation and pre-deliv-
2 - WELD ery storage to reduce battery depletion, while still
3 - 100MM (4 INS.) allowing vehicle operation so that the vehicle can be
4 - 22.25 TO 22.45MM (7/8 TO 57/64 INS.)
loaded, unloaded and moved as needed by both vehi-
(5) Disconnect the base wires. cle transportation company and dealer personnel.
(6) Set base aside and remove base mount ring. The IOD fuse is disconnected from JB fuse cavity
#19 when the vehicle is shipped from the assembly
INSTALLATION plant. Dealer personnel must reconnect the IOD fuse
when the vehicle is being prepared for delivery in
(1) Install base mount ring.
order to restore full electrical system operation. Once
(2) Connect the base wires.
the vehicle is prepared for delivery, the IOD function
(3) Firmly snap base into position inside of instru-
of this fuse becomes transparent and the fuse that
ment panel.
has been assigned the IOD designation becomes only
(4) Connect the negative battery cable remote ter-
another Fused B(+) circuit fuse.
minal to the remote battery post.
The IOD fuse can be used by the vehicle owner as
a convenient means of reducing battery depletion
IOD FUSE when a vehicle is to be stored for periods not to
exceed about thirty days. However, it must be
DESCRIPTION remembered that disconnecting the IOD fuse will not
eliminate IOD, but only reduce this normal condition.
All vehicles are equipped with an Ignition-Off
If a vehicle will be stored for more than about thirty
Draw (IOD) fuse that is disconnected within the
days, the battery negative cable should be discon-
Junction Block when the vehicle is shipped from the
nected to eliminate normal IOD; and, the battery
factory. Dealer personnel are to reconnect the IOD
should be tested and recharged at regular intervals
fuse in the junction block as part of the preparation
during the vehicle storage period to prevent the bat-
procedures performed just prior to new vehicle deliv-
tery from becoming discharged or damaged.
ery.
The left end of the instrument panel cover has a
snap-fit fuse access panel that can be removed to pro-
REMOVAL
vide service access to the fuses in the junction block. The Ignition-Off Draw (IOD) fuse is disconnected
An adhesive-backed fuse layout map is secured to the from Junction Block fuse cavity # 19 when the vehi-
instrument panel side of the access panel to ensure cle is shipped from the assembly plant. Dealer per-
proper fuse identification. The IOD fuse is a 15 sonnel must reconnect the IOD fuse when the vehicle
ampere mini blade-type fuse, located in fuse cavity # is being prepared for delivery in order to restore full
19. electrical system operation.
(1) Turn the ignition switch to the Off position.
REMOVAL
WARNING: ON VEHICLES EQUIPPED WITH AIR-
BAGS, 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
Fig. 4 Junction Block Location AND POSSIBLE PERSONAL INJURY.
1 - JUNCTION BLOCK/BCM
The Junction Block and Body Control Module
An electrical Junction Block (JB) is located in the (BCM) are attached to each other. After removal,
left endcap of the instrument panel (Fig. 4). The JB they can be separated. The Junction Block/BCM
combines the functions previously provided by a sep- assemblies are located on the driver’s side of the
arate fuseblock module and relay center. It also vehicle.
serves to simplify and centralize numerous electrical (1) Open hood and disconnect the negative battery
components, as well as to distribute electrical current cable remote terminal from the remote battery post.
to many of the accessory systems in the vehicle. It (2) Open the front driver’s door and remove left
eliminates the need for numerous splice connections end cap.
and serves in place of a bulkhead connector between (3) Remove two screws from lower instrument
many of the engine compartment, instrument panel, panel cover (outside end). Pull rearward on lower
and body wire harnesses. instrument panel cover releasing clips. Disconnect
decklid release switch wiring, cable to hood release,
and remove cover from vehicle.
INSTALLATION
(1) Install Junction Block/BCM to vehicle.
(2) Connect BCM wire connectors and RKE
antenna connector.
(3) Install Junction Block/BCM.
(4) Install wire harness connectors to Junction
Block/BCM.
(5) Install four mounting screws.
(6) Install under column ducts. Fig. 5 Power Distribution Center Location
(7) Install left knee blocker. 1 - POWER DISTRIBUTION CENTER
(8) Connect cable to hood release, decklid release 2 - LEFT FRONT FENDER
3 - LEFT FRONT HEADLAMP
switch wiring, and install two screws to lower instru-
ment panel.
just inside the left end of the PDC housing. The PDC
(9) Install left end cap.
houses up to fourteen maxi-fuse cartridges, which
(10) Connect the negative battery cable remote ter-
replace all in-line fusible links. The PDC also houses
minal to the remote battery post.
up to six blade-type fuses, up to four full Interna-
tional Standards Organization (ISO) relays, and up
POWER DISTRIBUTION to seven ISO micro-relays. Internal connection of all
the PDC circuits is accomplished by an intricate net-
CENTER work of hard wiring and bus bars. Refer to the appro-
priate wiring information. The wiring information
DESCRIPTION includes wiring diagrams, proper wire and connector
All of the electrical current distributed throughout repair procedures, details of wire harness routing
this vehicle is directed through the standard equip- and retention, connector pin-out information and
ment Power Distribution Center (PDC) (Fig. 5). The location views for the various wire harness connec-
molded plastic PDC housing is located in the left tors, splices and grounds.
front corner of the engine compartment, just in front The fusible link, fuse cartridges, fuses and relays
of the coolant reservoir bottle. The PDC housing has are available for service replacement. The PDC unit
a molded plastic cover. The PDC cover is easily cannot be repaired and is only serviced as a unit
removed for service access and has a convenient fuse with the engine compartment wire harness. If the
and relay layout label affixed to the inside surface of PDC is faulty or damaged, the engine compartment
the cover to ensure proper component identification. wire harness assembly must be replaced.
The PDC housing is secured in the engine compart-
ment by one screw to the rear of the PDC and two REMOVAL
clips on the front side. A small molded plastic protec- The Power Distribution Center (PDC) is serviced
tive cover on the front right side of the engine com- as a unit with the engine compartment wire harness.
partment is unsnapped to access the battery/ If any internal circuit of the PDC or the PDC hous-
generator cable input connection studs. ing is faulty or damaged, the entire PDC and engine
compartment wire harness unit must be replaced.
OPERATION (1) Disconnect and isolate the battery negative
All of the PDC outputs are through the integral remote cable.
engine compartment wire harness, which exits from (2) Disconnect each of the engine compartment
the front of the PDC housing. wire harness connectors. (Refer to 8 - ELECTRICAL/
All of the current from the battery/generator cable WIRING DIAGRAM INFORMATION - DIAGNOSIS
connection enters the PDC that is secured with nuts
ENGINE
TABLE OF CONTENTS
page page
NOISY VALVES 1. High or low oil level in 1. Check and correct engine oil
crankcase. level.
CONNECTING ROD NOISE 1. Insufficient oil supply. 1. Check engine oil level.
MAIN BEARING NOISE 1. Insufficient oil supply. 1. Check engine oil level.
OIL PRESSURE DROP 1. Low oil level. 1. Check engine oil level.
OIL CONSUMPTION OR SPARK 1. PCV system malfunction. 1. Check system and repair as
PLUGS FOULED necessary. (Refer to Appropriate
Diagnostic Manual)
2. Worn, scuffed or broken rings. 2. Hone cylinder bores. Install new
rings.
3. Carbon in oil ring slots. 3. Clean pistons and install new
rings.
4. Rings fitted too tightly in grooves. 4. Remove rings and check
grooves. If groove is not proper
width, replace piston.
5. Worn valve guide(s). 5. Replace cylinder head(s).
6. Valve stem seal(s) worn or 6. Replace seal(s).
damaged.
ENGINE WILL NOT START 1. Weak battery. 1. Test battery. Charge or replace
as necessary. (Refer to 8 -
ELECTRICAL/BATTERY SYSTEM/
BATTERY - DESCRIPTION)
2. Corroded or loose battery 2. Clean and tighten battery
connections. connections. Apply a coat of light
mineral grease to terminals.
3. Faulty starter. 3. Test starting system. (Refer to 8 -
ELECTRICAL/STARTING -
DIAGNOSIS AND TESTING)
4. Faulty coil(s) or control unit. 4. Test and replace as needed.
(Refer to Appropriate Diagnostic
Information)
5. Incorrect spark plug gap. 5. Check and adjust gap as needed.
6. Contamination in fuel system. 6. Clean system and replace fuel
filter.
7. Faulty fuel pump. 7. Test fuel pump and replace as
needed. (Refer to Appropriate
Diagnostic Information)
8. Incorrect engine timing. 8. Check for a skipped timing
belt/chain or a loose camshaft
sprocket (3.2/3.5L).
ENGINE STALLS OR IDLES 1. Idle speed too low. 1. Test minimum air flow. (Refer to
ROUGH Appropriate Diagnostic Information)
ENGINE LOSS OF POWER 1. Dirty or incorrectly gapped plugs. 1. Set gap as needed or replace
plug(s).
ENGINE MISSES ON 1. Dirty or incorrectly gapped spark 1. Set gap as needed or replace
ACCELERATION plugs. plug(s).
ENGINE MISSES AT HIGH SPEED 1. Dirty or incorrect spark plug gap. 1. Set gap as needed or replace
plug(s).
2. Faulty coil(s). 2. Test and replace as necessary.
(Refer to Appropriate Diagnostic
Information)
3. Dirty fuel injector(s). Test and replace as necessary.
(Refer to Appropriate Diagnostic
Information)
4. Contamination in fuel system. 4. Clean system and replace fuel
filter.
DIAGNOSIS AND TESTING - CYLINDER • Leaks between adjacent cylinders or into water
jacket.
COMPRESSION PRESSURE TEST
• Any causes for combustion/compression pressure
The results of a cylinder compression pressure test
loss.
can be utilized to diagnose several engine malfunc-
tions. WARNING: DO NOT REMOVE THE PRESSURE CAP
Ensure the battery is completely charged and the WITH THE SYSTEM HOT AND UNDER PRESSURE
engine starter motor is in good operating condition. BECAUSE SERIOUS BURNS FROM COOLANT CAN
Otherwise the indicated compression pressures may OCCUR.
not be valid for diagnosis purposes.
(1) Check engine oil level and add oil if necessary. Check the coolant level and fill as required. DO
(2) Drive the vehicle until engine reaches normal NOT install the pressure cap.
operating temperature. Select a route free from traf- Start and operate the engine until it attains nor-
fic and other forms of congestion, observe all traffic mal operating temperature, then turn the engine
laws, and accelerate through the gears several times OFF.
briskly. Clean spark plug recesses with compressed air.
(3) Disconnect and remove all ignition coils from Remove the spark plugs.
spark plugs. Remove the oil filler cap.
(4) Remove all spark plugs from engine. As spark Remove the air cleaner.
plugs are being removed, check electrodes for abnor- Calibrate the tester according to the manufactur-
mal firing indicators fouled, hot, oily, etc. Record cyl- er’s instructions. The shop air source for testing
inder number of spark plug for future reference. should maintain 483 kPa (70 psi) minimum, 1,379
(5) Be sure throttle blade is fully open during the kPa (200 psi) maximum, with 552 kPa (80 psi) rec-
compression check. ommended.
(6) Insert compression gauge adaptor Special Tool Perform the test procedures on each cylinder
8116 or the equivalent, into the #1 spark plug hole in according to the tester manufacturer’s instructions.
cylinder head. Connect the 0–500 psi (Blue) pressure While testing, listen for pressurized air escaping
transducer (Special Tool CH7059) with cable adap- through the throttle body, tailpipe and oil filler cap
tors to the DRBIIIt. For Special Tool identification, opening. Check for bubbles in the coolant.
(Refer to 9 - ENGINE - SPECIAL TOOLS). All gauge pressure indications should be equal,
(7) Crank engine until maximum pressure is with no more than 25% leakage per cylinder.
reached on gage. Record this pressure as #1 cylinder FOR EXAMPLE: At 552 kPa (80 psi) input pres-
pressure. sure, a minimum of 414 kPa (60 psi) should be main-
(8) Repeat the previous step for all remaining cyl- tained in the cylinder.
inders.
(9) Compression should not be less than 689 kPa
(100 psi) and not vary more than 25 percent from cyl- STANDARD PROCEDURE
inder to cylinder.
(10) If one or more cylinders have abnormally low STANDARD PROCEDURE - FORM-IN-PLACE
compression pressures, repeat the compression test. GASKETS AND SEALERS
(11) If the same cylinder or cylinders repeat an There are numerous places where form-in-place
abnormally low reading on the second compression gaskets are used on the engine. Care must be taken
test, it could indicate the existence of a problem in when applying form-in-place gaskets to assure
the cylinder in question. The recommended com- obtaining the desired results. Do not use form-in-
pression pressures are to be used only as a place gasket material unless specified. Bead size,
guide to diagnosing engine problems. An engine continuity, and location are of great importance. Too
should not be disassembled to determine the thin a bead can result in leakage while too much can
cause of low compression unless some malfunc- result in spill-over which can break off and obstruct
tion is present. fluid feed lines. A continuous bead of the proper
width is essential to obtain a leak-free gasket.
DIAGNOSIS AND TESTING - CYLINDER There are numerous types of form-in-place gasket
COMBUSTION PRESSURE LEAKAGE TEST materials that are used in the engine area. Mopart
The combustion pressure leakage test provides an Engine RTV GEN II, Mopart ATF-RTV, and Mopart
accurate means for determining engine condition. Gasket Maker gasket materials, each have different
Combustion pressure leakage testing will detect: properties and can not be used in place of the other.
• Exhaust and intake valve leaks (improper seat- MOPARt ENGINE RTV GEN II is used to seal
ing). components exposed to engine oil. This material is a
Fig. 6 Plastigage Placed in Lower Shell—Typical (3) Mark hood position at hinges and remove hood.
1 - PLASTIGAGE (Refer to 23 - BODY/HOOD/HOOD - REMOVAL)
(4) Remove both wiper arms. (Refer to 8 - ELEC-
(3) Remove the bearing cap and compare the
TRICAL/WIPERS/WASHERS/WIPER ARMS -
width of the flattened Plastigage with the metric
REMOVAL)
scale provided on the package. Locate the band clos-
(5) Remove both right and left cowl screens. (Refer
est to the same width. This band shows the amount
to 23 - BODY/EXTERIOR/COWL GRILLE AND
of clearance in thousandths of a millimeter. Differ-
SCREEN - REMOVAL)
ences in readings between the ends indicate the
(6) Remove strut tower brace.(Refer to 23 - BODY/
amount of taper present. Record all readings taken.
EXTERIOR/FRONT STRUT TOWER TO TOWER
Compare clearance measurements to specs found in
BRACE - REMOVAL)
engine specifications (Refer to 9 - ENGINE - SPECI-
(7) Remove air cleaner assembly with air inlet
FICATIONS). Plastigage generally is accompa-
hose (Fig. 8).
nied by two scales. One scale is in inches, the
(8) Remove upper radiator crossmember. (Refer to
other is a metric scale.
23 - BODY/EXTERIOR/GRILLE OPENING REIN-
NOTE: Plastigage is available in a variety of clear- FORCEMENT - REMOVAL)
ance ranges. Use the most appropriate range for (9) Disconnect hood release cable from hood latch.
the specifications you are checking. (10) Drain cooling system. (Refer to 7 - COOLING
- STANDARD PROCEDURE)
(4) Install the proper crankshaft bearings to (11) Remove radiator fan. (Refer to 7 - COOLING/
achieve the specified bearing clearances. ENGINE/RADIATOR FAN - REMOVAL)
(12) Remove accessory drive belts. (Refer to 7 -
COOLING/ACCESSORY DRIVE/DRIVE BELTS -
REMOVAL)
SPECIAL TOOLS
3.5L ENGINE
Adapter 8406
Combustion Leak Tester C-3685-A
AIR CLEANER ELEMENT
REMOVAL
(1) Remove air cleaner lid. Lift lid off of air cleaner
housing.
(2) Remove filter element (Fig. 9).
INSTALLATION
(1) If necessary, clean the inside of the air cleaner
housing.
(2) Install new filter element (Fig. 9).
(3) Place lid over air cleaner housing.
Adaptor 8116
INSPECTION
(1) Before cleaning, check for leaks, damage and
cracks.
(2) Clean cylinder head and oil passages.
(3) Check cylinder head for flatness (Fig. 12).
(4) Cylinder head must be flat within:
• Standard dimension = less than 0.05 mm (0.002
inch.)
• Service Limit = 0.2 mm (0.008 inch.)
• Grinding Limit = Maximum of 0.2 mm (0.008
inch.) is permitted.
INSTALLATION
(1) Apply light coat of engine oil to the camshaft
oil seal lip.
(2) Install the oil seal using Special Tool 6788 Seal
Protector Sleeve (Fig. 17) and Seal Installer 6052 Fig. 18 Camshaft Oil Seal - Installation
(Fig. 18). 1 - SPECIAL TOOL 6052
(3) Install camshaft sprocket(s). (Refer to 9 -
ENGINE/VALVE TIMING/TIMING BELT/CHAIN OPERATION
AND SPROCKETS - INSTALLATION) The camshaft is driven by the crankshaft via drive
sprockets and belt. The camshaft has precisely
machined lobes to provide accurate valve timing and
CAMSHAFT(S) duration.
DESCRIPTION STANDARD PROCEDURE - MEASURING
A single overhead camshaft per cylinder head pro-
vides valve actuation. The left camshaft accommo- CAMSHAFT END PLAY
dates a cam sensor pick-up wheel and is therefore (1) Oil camshaft journals and install camshaft
longer. Each camshaft is supported by four bearing WITHOUT rocker arms. Install rear cam caps and
journals. Thrust for each camshaft is taken at a tighten screws to specified torque.
thrust plate attached to the rear of each cylinder (2) Using a suitable tool, move camshaft as far
head. Right and left camshaft driving sprockets are rearward as it will go.
not interchangeable because of the cam sensor (3) Zero dial indicator (Fig. 19).
pick-up wheel on the left sprocket. Camshaft bearing (4) Move camshaft as far forward as it will go.
lubrication is provided via oil feed passage through (5) Record reading on dial indicator. For end play
each rocker shaft pedestal dowel. specification, (Refer to 9 - ENGINE - SPECIFICA-
TIONS).
CLEANING
Clean camshaft with a suitable solvent.
INSPECTION
(1) Inspect camshaft bearing journals for damage
Fig. 21 Camshaft Inspection
and binding (Fig. 21). If journals are binding, check
1 - ACTUAL WEAR
the cylinder head for damage. Also check cylinder 2 - LEFT CAMSHAFT
head oil holes for clogging. 3 - RIGHT CAMSHAFT
(2) Check the cam lobe and bearing surfaces for 4 - BEARING JOURNAL
5 - LOBE
abnormal wear and damage. Replace camshaft if
defective.
INSTALLATION
NOTE: If camshaft is replaced due to lobe wear or (1) Lubricate camshaft bearing journals and cam-
damage, always replace the rocker arms. shaft lobes with clean engine oil and install camshaft
into cylinder head (Fig. 20).
INSTALLATION
Fig. 22 WIRE HARNESS RETAINING NUTS (1) Clean cylinder head and cover mating surfaces.
1 - NUTS Inspect and replace gasket and seals as necessary
2 - WIRE HARNESS (Fig. 25).
(2) To replace spark plug tube seals:
(6) For right cylinder head cover removal perform (a) Using a suitable pry tool, carefully remove
the following: tube seals.
(a) Remove A/C compressor belt. (Refer to 7 - (b) Position new seal with the part number on
COOLING/ACCESSORY DRIVE/DRIVE BELTS - seal facing cylinder head cover.
REMOVAL) (c) Install seals using Special Tool MD-998306
(b) Remove A/C compressor mounting bolts. (Fig. 26).
(c) Move compressor aside for cylinder head (3) Install cylinder head cover bolts and tighten to
cover clearance. 12 N·m (105 in. lbs.) (Fig. 24).
VALVES
CLEANING
(1) Clean all valves thoroughly and discard
burned, warped and cracked valves.
INSPECTION
INSPECTION - VALVES
(1) Measure valve stems for wear (Fig. 32) approx-
imately 60 mm (2.36 in.) below the valve lock
grooves.
(2) Compare measurement to specifications, (Refer
to 9 - ENGINE - SPECIFICATIONS).
NOTE: Valve stems are chrome plated and should Fig. 33 Measuring Valve Guide Wear
not be polished (Fig. 32).
INSTALLATION
(1) Coat valve stems with clean engine oil and
INSPECTION - VALVE GUIDES insert them in cylinder head.
(1) Measure valve stem-to-guide clearance as fol- (2) If valves or seats have been reground, check
lows: valve tip height (A) (Fig. 34). If valve tip height is
(2) Install valve into cylinder head so it is 15 mm greater than 43.65 mm (1.7185 in.) intake or 45.98
(0.590 inch.) off the valve seat. A small piece of hose mm (1.8102 in.) exhaust, grind valve tip until within
may be used to hold valve in place. specifications. Make sure measurement is taken from
(3) Attach dial indicator Tool C-3339 to cylinder cylinder head surface to the top of valve stem.
head and set it at right angle of valve stem being (3) Install valve stem seals and valve springs.
measured (Fig. 33). (Refer to 9 - ENGINE/CYLINDER HEAD/VALVE
(4) Move valve to and from the indicator. STEM SEALS - INSTALLATION) (Refer to 9 -
(5) Note dial indicator reading and compare to ENGINE/CYLINDER HEAD/VALVE SPRINGS -
engine specifications. (Refer to 9 - ENGINE - SPEC- INSTALLATION)
IFICATIONS)
DESCRIPTION
DESCRIPTION - ROCKER ARM
Rocker arms are made of light weight permanent
mold aluminum alloy with a roller type follower oper-
ating against the camshaft (Fig. 35). The valve actu-
ating end of the rocker arms are machined to retain
hydraulic lash adjusters, eliminating the need for
manual valve lash adjustment.
STANDARD PROCEDURE - HYDRAULIC LASH (b) Gently unseat BOTH lash adjuster’s internal
check ball at the same time.
ADJUSTER BLEEDING
(c) While the internal check ball is held
Use this procedure to manually bleed aerated oil
unseated, press the rocker arm into the valve tip,
from the lash adjuster and remove sponginess.
allowing the lash adjuster to fully collapse. Hold
(1) Run the engine, bringing it to operating tem-
this fully collapsed position for about one second,
perature in order to freshly pressurize and warm the
or longer.
valvetrain system oil supply.
(d) Slowly release the rocker arm, thereby allow-
(2) Remove cylinder head cover(s).
ing the lash adjuster to extend, which in turn
(3) Ensure the rocker arm is positioned on the
refills the high pressure chamber with non-aerated
base circle of the cam (Fig. 37). Rotate engine as nec-
oil.
essary.
(e) Remove probes to allow check balls to seat.
(4) For intake rocker arm positions:
(f) Recheck for sponginess. If the lash adjuster
(a) Adjust Special Tool 8351 Release Probe’s
sponginess is not completely or nearly eliminated,
gauge pin to extend approximately 20 mm (0.787
then repeat procedure.
in.). Then, carefully insert the release probe gauge
(g) If the spongy condition cannot be removed,
pin into the lash adjuster service access hole (Fig.
replace effected rocker arm(s).
38).
(6) Install cylinder head cover(s).
CAUTION: If probe tip breaks off within the lash
adjuster, replace the affected rocker arm.
DISASSEMBLY
(1) Remove rocker arm and shafts. (Refer to 9 -
ENGINE/CYLINDER HEAD/ROCKER ARM /
ADJUSTER ASSY - REMOVAL)
(2) Remove dowel pin using a 4 mm screw, nut,
spacer, and washer installed into the pin (Fig. 40).
Thread the screw into the pin, then loosen the nut on
the screw. This will pull the dowel out of the shaft
support. Do not reuse dowel pins. Remove the rocker
arms and pedestals in order.
NOTE: To prevent air ingestion into lash adjusters, (3) Check the rocker arm mounting portion of the
avoid turning rocker arm assembly upside down. shafts for wear or damage. Replace if damaged or
heavily worn.
(4) Check shaft oil holes for clogging with small
CAUTION: Do not allow rocker arm assembly to rest wire, clean as required.
on lash adjusters, as damage may occur to lash
adjusters and/or plastic retainers. INSPECTION
The rocker arm shafts are hollow and are used as
lubrication oil ducts. The rocker arm and shaft
assembly on the right side of the engine has an oil
passage hole from the cylinder head located at the
third rocker shaft support pedestal. The rocker arm
and shaft assembly on the left side of the engine has
an oil passage hole from the cylinder head located at
the second rocker shaft support pedestal.
ASSEMBLY
CAUTION: New dowel pins must be installed when
reassembling.
INSTALLATION
NOTE: Rocker arm and shaft assembly can be
installed either prior to or after (preferred) cylinder
head installation.
Fig. 44 Camshaft Sprockets Neutral Position Fig. 46 Servicing Spark Plug Tubes
1 - SPARK PLUG TUBE
2 - LOCKING PLIERS
INSTALLATION
(1) Apply Mopart Stud and Bearing Mount to a Fig. 47 Valve Stem Seal - Removal
new tube approximately 1 mm (0.039 in.) from the 1 - VALVE SEAL TOOL
end of tube, in a 3 mm (0.118 in.) wide area. 2 - VALVE STEM
(2) Install sealer end of tube into the cylinder
head. Then carefully install the tube using a hard- INSTALLATION
wood block and mallet. Install the tube until it is (1) The valve stem seal/valve spring seat should be
seated into the bottom of the bore. pushed firmly and squarely over the valve guide
(3) For spark plug tube seal replacement, (Refer to using the valve stem as guide. Do Not Force seal
9 - ENGINE/CYLINDER HEAD/CYLINDER HEAD against top of guide. When installing the valve
COVER(S) - REMOVAL). retainer locks, compress the spring only enough to
install the locks.
INSTALLATION
INSTALLATION - CYLINDER HEAD OFF
(1) Install valves if removed.
(2) Install valve stem seal/spring seat assembly
over valve guides on all valve stems (Fig. 52). Ensure Fig. 52 Valve, Spring, and Valve Seal
that the garter spring is intact around the top of the
1 - VALVE
rubber seal. 2 - VALVE RETAINING LOCKS
(3) Place valve spring (color-coded end facing up) 3 - VALVE SPRING RETAINER
and valve retainer into position. 4 - VALVE SPRING
5 - VALVE SEAL AND VALVE SPRING SEAT ASSEMBLY
(4) Compress valve spring with valve spring com-
pressor. Install locks and release tool. If valves
and/or seats are reground, measure the
installed height of springs (B) (Fig. 51), make
sure measurements are taken from top of
CYLINDER BORE
NOTE: The cylinder bores should be measured at
normal room temperature, 21°C (70°F).
CRANKSHAFT
DESCRIPTION
The crankshaft (Fig. 53) is constructed of a forged
micro alloy steel. A six throw, nine counterweight
crankshaft is supported by four select fit main bear-
ings with number two serving as the thrust washer
location. The six separate connecting rod throws are
an even-firing design which reduces torque fluctua-
tions while a torsional vibration damper is used to
control torsion caused vibration of the crankshaft.
Fig. 56 CHECKING CONNECTING ROD BEARING Rubber lipped seals are used at front and rear. The
front seal is retained in the oil pump case and the
rear seal is retained in a block-mounted housing.
INSTALLATION
CAUTION: Main bearings are select fit. (Refer to 9 -
ENGINE/ENGINE BLOCK/CONNECTING ROD BEAR-
INGS - STANDARD PROCEDURE)
REMOVAL INSTALLATION
Bearing caps are not interchangeable and are Bearing caps are not interchangeable and are
marked to insure correct assembly (Fig. 68). Upper marked to insure correct assembly. Upper and lower
and lower bearing halves are NOT interchangeable. bearing halves are NOT interchangeable (Fig. 70).
(1) Remove oil pan. (Refer to 9 - ENGINE/LUBRI-
CATION/OIL PAN - REMOVAL)
(2) Remove oil pick-up tube and windage tray.
(3) Identify bearing caps before removal (Fig. 68).
(4) Remove bearing caps one at a time. Remove
upper half of bearing by inserting Special Main Bear-
ing Tool C-3059 (Fig. 69) into the oil hole of crank-
shaft.
(5) Slowly rotate crankshaft clockwise, forcing out
upper half of bearing shell.
The main bearing cap bolts must be tightened in (3) Remove crankshaft seal using Special Tool
the proper sequence. First the inner main cap bolts, 6341A (Fig. 73).
secondly the windage tray bolts, lastly the main cap
tie (horizontal) bolts. CAUTION: Do not nick shaft seal surface or seal
(6) Install each main bearing cap and tighten bore.
inner bolts finger tight.
(7) Tighten inner main bearing cap bolts to 20 N·m
+ 1/4 turn (15 ft. lbs. + 1/4 turn).
INSTALLATION
(1) Install crankshaft seal using Special Tool 6342
(Fig. 74).
INSTALLATION
(1) Clean all sealing surfaces. Replace retainer
assembly if gasket is torn or damaged.
(2) Install seal retainer to block, but do not tighten
attaching screws at this time.
Fig. 78 Rear Crankshaft Seal Retainer Alignment The pistons are made of a high strength aluminum
1 - SEAL RETAINER alloy. Top land height has been decreased to reduce
2 - SPECIAL TOOLS 8225 emissions. Piston skirts are coated with a solid lubri-
cant for scuff resistance. Connecting rod is forged
FLEX PLATE steel with a squirt hole and attaches to the piston
with a full floating pin retained by lock rings.
REMOVAL
(1) Remove the transaxle. (Refer to 21 - TRANS- STANDARD PROCEDURE - FITTING PISTONS
MISSION/TRANSAXLE/AUTOMATIC - 42LE - The pistons are machined to two different weight
REMOVAL) specifications and matched to rods based on weight.
(2) Remove flex plate attaching bolts. All piston and rod assemblies weigh the same to
(3) Remove the flex plate (Fig. 79). maintain engine balance.
Piston and cylinder wall must be clean and dry.
INSTALLATION Piston diameter should be measured 90 degrees to
(1) Position flex plate with backing plate on the piston pin at size location shown in (Fig. 80). Cylin-
crankshaft (Fig. 79). der bores should be measured halfway down the cyl-
(2) Apply Mopart Lock & Seal Adhesive to the flex inder bore and transverse to the engine crankshaft
plate bolts. center line (Refer to 9 - ENGINE - SPECIFICA-
(3) Install flex plate bolts (Fig. 79). Tighten bolts TIONS). Pistons and cylinder bores should be
to 95 N·m (70 ft. lbs.). measured at normal room temperature, 70°F
(4) Install the transaxle. (Refer to 21 - TRANS- (21°C).
MISSION/TRANSAXLE/AUTOMATIC - 42LE -
INSTALLATION) REMOVAL
(1) Remove the cylinder heads (Refer to 9 -
ENGINE/CYLINDER HEAD - REMOVAL)
PISTON RINGS
STANDARD PROCEDURE - PISTON RING
FITTING
(1) Wipe cylinder bore clean. Insert ring and push
down with piston to ensure it is square in bore. The
ring gap measurement must be made with the ring
positioning at least 12 mm (0.50 in.) from bottom of
cylinder bore. Check gap with feeler gauge (Fig. 88).
For clearance specifications, (Refer to 9 - ENGINE -
SPECIFICATIONS).
(2) Check piston ring to groove clearance: (Fig. 89).
For clearance specifications, (Refer to 9 - ENGINE -
SPECIFICATIONS).
REMOVAL
(1) Remove piston and connecting rod. (Refer to 9 -
ENGINE/ENGINE BLOCK/PISTON & CONNECT-
ING ROD - REMOVAL)
(2) Remove No. 1 and No.2 piston rings from pis-
ton using a ring expander tool (Fig. 92). Fig. 90 PISTON RING - INSTALLATION
(3) Remove upper oil ring side rail (Fig. 90). 1 - SIDE RAIL
2 - SPACER EXPANDER
(4) Remove lower oil ring side rail (Fig. 90).
(5) Remove oil ring expander (Fig. 90).
INSTALLATION
(1) Measure clearance of piston rings to the cylin-
der bore and piston. (Refer to 9 - ENGINE/ENGINE
BLOCK/PISTON RINGS - STANDARD PROCE-
DURE)
The No. 1 and No. 2 piston rings have a different
cross section. Insure that the No. 2 ring is installed
with manufacturers I.D. mark (dot) facing up,
towards top of the piston (Fig. 90).
STRUCTURAL COLLAR /
COVER
REMOVAL
(1) Raise vehicle on hoist.
(2) Remove bolts attaching structural collar to oil
pan and transmission housing (Fig. 94).
(3) Remove collar (Fig. 94).
ENGINE MOUNTING
DESCRIPTION
The engine mounting system consist of three
Fig. 96 CRANKSHAFT DAMPER - REMOVAL
mounts; two hydro-type mounts are attached to the
1 - SPECIAL TOOL right and left side of the engine block, and one
1023
2 - SPECIAL TOOL molded rubber type rear mount is attached to the
C-4685–C2 transaxle (Fig. 99). All three mounts attach to the
INSERT
suspension crossmember/engine cradle.
The engine hydro-type mounts contain a liquid
INSTALLATION that is encased in a solid rubber housing.
(1) Install crankshaft damper using Special Tools
C-4685-C1 (5.9 in.) Bolt, with Nut and Thrust Bear-
INSPECTION INSTALLATION
Engine hydro-mounts may show surface cracks. (1) Install isolator mount with heat shield onto the
This will not effect performance and mount should frame.
not be replaced. Only replace the engine hydro- (2) Lower the engine onto the isolator mount.
mounts when leaking fluid. (3) Remove jack from vehicle.
(4) Tighten the isolator to frame nuts to 61 N·m
(45 ft. lbs.) (Fig. 98).
LEFT MOUNT (5) Install the upper attaching nuts to mount and
tighten to 61 N·m (45 ft. lbs.) (Fig. 98).
REMOVAL (6) Lower vehicle.
(1) Raise vehicle on hoist.
(2) Remove the isolator attaching nuts from top of
the mounting bracket (Fig. 98).
(3) Support the engine with a jack and a block of
wood across the full width of the oil pan.
(4) Remove the lower attaching nuts from the bot-
tom of the isolator to the frame (Fig. 98).
(5) Raise engine carefully with jack enough to
remove the isolator with heat shield from its mount.
INSTALLATION
(1) Apply a 1/8 inch bead of Mopart Engine RTV
GEN II at the parting line of the oil pump housing
and the rear seal retainer (Fig. 106).
(2) Install oil pan gasket to the engine block.
(3) Install pan and attaching fasteners (Fig. 105).
(4) Install the structural collar (Fig. 104), using
the follow procedure:
(a) Install the vertical collar to oil pan bolts.
Pre-torque bolts to 1.1 N·m (10 in. lbs.).
(b) Install the horizontal collar to transmission
bolts and tighten to 55 N·m (40 ft. lbs.).
(c) Starting with center vertical bolts and work-
ing outward, final torque all bolts to 55 N·m (40 ft.
lbs.).
(5) Lower vehicle and install dipstick and tube.
(6) Fill engine crankcase with proper oil to correct Fig. 106 OIL PAN SEALING
level.
(7) Connect negative cable.
OIL PRESSURE RELIEF VALVE (2) Install valve, spring and retainer cap (Fig.
107).
(3) Install new cotter pin.
REMOVAL
(4) Install the oil pan. (Refer to 9 - ENGINE/LU-
(1) Remove the oil pan. (Refer to 9 - ENGINE/LU-
BRICATION/OIL PAN - INSTALLATION)
BRICATION/OIL PAN - REMOVAL)
(2) To remove the relief valve, proceed as follows:
(a) Remove the cotter pin that retains the OIL PRESSURE SWITCH
retainer cap.
(b) Drill a 3.175 mm (1/8 inch.) hole into the
DESCRIPTION
relief valve retainer cap
The engine oil pressure switch is located on the
(c) Insert a self-threading sheet metal screw into
lower left front side of the engine (Fig. 108). It
cap.
screws into the engine oil cooler adapter fitting that
(d) Using a suitable slide hammer tool, remove
is installed into the engine main oil gallery. The nor-
retainer cap. Discard retainer cap
mally closed switch provides an input through a sin-
(e) Remove spring and relief valve (Fig. 107).
gle wire to the low pressure indicator light on the
instrument cluster.
OPERATION
The oil pressure switch provides a ground for the
instrument cluster low oil pressure indicator light.
The switch receives oil pressure input from the
engine main oil gallery. When engine oil pressure is
greater than 27.5 Kpa (4 psi), the switch contacts
open, providing a open circuit to the low pressure
indicator light. For wiring circuits and diagnostic
information, (Refer to Appropriate Wiring/Diagnostic
Information).
REMOVAL
(1) Raise vehicle on hoist.
Fig. 107 Oil Pressure Relief Valve (2) Position an oil collecting container under
1 - RELIEF VALVE switch location.
2 - SPRING (3) Disconnect electrical connector (Fig. 108).
3 - RETAINER CAP (4) Hold oil cooler fitting with a wrench.
4 - COTTER PIN
(5) Unscrew oil pressure switch from fitting (Fig.
108).
INSPECTION
(1) Inspect oil pressure relief valve plunger for
scoring and free operation in its bore. Small marks
INSTALLATION
(1) Apply Mopart Thread Sealant to the switch
may be removed with 400-grit wet or dry sandpaper.
threads.
(2) The relief valve spring has a free length of
(2) Install oil pressure switch to fitting (Fig. 108).
approximately 49.5 mm (1.95 in.) it should test
(3) Hold oil cooler fitting with a wrench and
between 101–110 N (23–25 lbs.) when compressed to
tighten oil pressure switch.
34 mm (1.34 in.). Replace spring that fails to meet
(4) Connect electrical connector (Fig. 108).
specifications.
(5) Lower vehicle.
(6) Start engine and check for leaks.
INSTALLATION (7) Check engine oil level and adjust as neccessary.
(1) Lubricate relief valve with oil.
DISASSEMBLY
(1) To remove the relief valve, proceed as follows:
(2) Remove cotter pin. Drill a 3.175 mm (1/8 inch.)
Fig. 108 OIL PRESSURE SWITCH hole into the relief valve retainer cap and insert a
1 - OIL PRESSURE SWITCH self-threading sheet metal screw into cap.
2 - OIL COOLER FITTING (3) Clamp screw into a vise and while supporting
3 - ELECTRICAL CONNECTOR
oil pump body, remove cap by tapping oil pump body
using a soft hammer. Discard retainer cap and
OIL PUMP remove spring and relief valve (Fig. 110).
REMOVAL
It is necessary to remove the oil pump body to ser-
vice the oil pump rotors.
The oil pump pressure relief valve can be serviced
by removing the oil pan. (Refer to 9 - ENGINE/LU-
BRICATION/OIL PRESSURE RELIEF VALVE -
REMOVAL)
(1) Drain the cooling system. (Refer to 7 - COOL-
ING - STANDARD PROCEDURE)
(2) Remove the radiator fan. (Refer to 7 - COOL-
ING/ENGINE/RADIATOR FAN - REMOVAL)
(3) Remove the accessory drive belts. (Refer to 7 -
COOLING/ACCESSORY DRIVE/DRIVE BELTS -
REMOVAL)
(4) Remove the timing belt. (Refer to 9 - ENGINE/
VALVE TIMING/TIMING BELT/CHAIN AND Fig. 110 Oil Pressure Relief Valve
SPROCKETS - REMOVAL) 1 - RELIEF VALVE
(5) Remove the crankshaft sprocket. (Refer to 9 - 2 - SPRING
3 - RETAINER CAP
ENGINE/VALVE TIMING/TIMING BELT/CHAIN 4 - COTTER PIN
AND SPROCKETS - REMOVAL)
(6) Remove the oil pan. (Refer to 9 - ENGINE/LU- (4) Remove oil pump cover screws, and lift off
BRICATION/OIL PAN - REMOVAL) cover.
(7) Remove the oil pickup tube. (5) Remove pump rotors.
(8) Remove the oil pump fasteners. Remove pump (6) Wash all parts in a suitable solvent and inspect
and gasket from engine (Fig. 109). carefully for damage or wear (Fig. 111).
INSPECTION
(1) Disassemble oil pump. (Refer to 9 - ENGINE/
LUBRICATION/OIL PUMP - DISASSEMBLY)
(2) Clean all parts thoroughly. Mating surface of
the oil pump housing should be smooth. Replace
pump cover if scratched or grooved.
(3) Lay a straightedge across the pump cover sur-
face (Fig. 112). If a 0.025 mm (0.001 in.) feeler gauge
can be inserted between cover and straight edge,
cover should be replaced.
Fig. 115 Measuring Outer Rotor Clearance in Fig. 117 Measuring Clearance Over Rotors
Housing 1 - STRAIGHT EDGE
2 - FEELER GAUGES
1 - FEELER GAUGE
2 - OUTER ROTOR
VALVE TIMING
DESCRIPTION
The timing drive system (Fig. 133) has been
designed to provide quiet performance and reliability
to support a NON free-wheeling engine.
The timing drive components include a crankshaft
sprocket, camshaft sprockets, tensioner pulley,
hydraulic tensioner and a timing belt. The water
pump is driven by the back side of the timing belt.
The right and left camshaft sprockets are not inter-
changeable because of the cam sensor pick-up wheel
on the left sprocket.
REMOVAL
REMOVAL - TENSIONER PULLEY ASSEMBLY
(1) Remove the timing belt. (Refer to 9 - ENGINE/
VALVE TIMING/TIMING BELT AND SPROCKETS -
REMOVAL - TIMING BELT)
(2) Remove the timing belt tensioner pulley and
bracket assembly by unscrewing the pivot bolt from
the oil pump housing (Fig. 142).
REMOVAL - TENSIONER
(1) For timing belt tensioner removal procedure
(Refer to 9 - ENGINE/VALVE TIMING/TIMING
BELT AND SPROCKETS - REMOVAL - TIMING
Fig. 140 REAR COVER - RIGHT BELT)
1 - REAR COVER - RIGHT SIDE
2 - BOLT
3 - BOLT INSPECTION
4 - BOLT
INSPECTION - TENSIONER PULLEY ASSEMBLY
NOTE: The tensioner pulley, bracket, and pivot bolt
is serviced as an assembly.
INSPECTION - TENSIONER
(1) Inspect hydraulic tensioner for fluid loss
around the plunger seal (Fig. 143). Replace tensioner
if leaking.
INSTALLATION
Fig. 141 REAR COVER - LEFT
INSTALLATION - TENSIONER PULLEY
1 - REAR COVER - RIGHT SIDE
2 - BOLT ASSEMBLY
3 - REAR COVER - LEFT SIDE (1) Install the timing belt tensioner pulley assem-
4 - BOLT
5 - BOLT bly (Fig. 142). Tighten the pivot bolt to 61 N·m (45 ft.
6 - BOLT lbs.).
(2) Install the timing belt. (Refer to 9 - ENGINE/
(5) Install camshaft sprockets and reassemble all VALVE TIMING/TIMING BELT AND SPROCKETS -
components. (Refer to 9 - ENGINE/VALVE TIMING/ INSTALLATION - TIMING BELT)
INSTALLATION - TENSIONER
(1) For timing belt tensioner installation procedure
(Refer to 9 - ENGINE/VALVE TIMING/TIMING
BELT AND SPROCKETS - INSTALLATION - TIM-
ING BELT).
REMOVAL
REMOVAL - TIMING BELT
CAUTION: The following procedure can only be
used when the camshaft sprockets HAVE NOT
BEEN LOOSENED or removed from the camshafts.
Once the camshaft sprockets are loosened, an
Fig. 142 TENSIONER PULLEY ASSEMBLY engine timing procedure is required. This procedure
1 - TENSIONER PULLEY is detailed in the Camshaft Removal and Installation
2 - PIVOT BOLT procedures (Refer to 9 - ENGINE/VALVE TIMING/
3 - TENSIONER BRACKET
TIMING BELT AND SPROCKETS - REMOVAL).
Fig. 143 TIMING BELT TENSIONER CAUTION: When aligning timing marks, always
rotate engine by turning the crankshaft. Failure to
1 - PLUNGER (EXTENDED POSITION)
2 - TENSIONER HOUSING do so will result in valve and/or piston damage.
NOTE: Each sprocket has a “D” shaped hole that NOTE: If belt requires replacing, ensure the proper
allows it to rotate several degrees in each direction length belt is used.
on its shaft. This design requires the crankshaft-to-
camshaft to be properly timed to ensure proper
engine performance.
EXHAUST SYSTEM
TABLE OF CONTENTS
page page
EXHAUST SYSTEM
DESCRIPTION
The exhaust system (Fig. 1) or (Fig. 2) consists of
two front close coupled catalytic converters. Both con-
verters attach directly to the exhaust manifold using
a V-Band clamp. The exhaust down pipes exit the
converters and connect into the front resonator. The
front resonator, intermediate pipe, and muffler are
one single module. The rear resonator and tailpipe
connect to the muffler outlet. The 300M Special has
both a left and right rear resonator. The upstream
oxygen sensors are located in each exhaust manifold.
The downstream oxygen sensors are located at the
rear of each catalytic converter.
EXCESSIVE EXHAUST NOISE 1. Leak at exhaust pipe joints. 1. Tighten clamps at leaking joints.
2. Burned or rusted out muffler 2. Replace exhaust module, rear
assembly or exhaust pipe. resonator/tailpipe assembly or
exhaust pipe with catalytic converter
assembly.
3. Burned or rusted out 3. Replace resonator assembly.
resonator(s).
4. Restriction in exhaust system. 4. Remove restriction if possible, or
replace components as necessary.
5. Converter material in muffler or 5. Replace muffler, resonators and
resonators. converter assemblies. Check fuel
injection and ignition systems for
proper operation.
DIAGNOSIS AND TESTING - EXHAUST SYSTEM (2) Install the Exhaust Back Pressure Fitting
Adaptor CH8519.
RESTRICTION CHECK
(3) Connect the Low Pressure Sensor (15 psi)
Exhaust system restriction can be checked by mea-
CH7063 to the back pressure fitting.
suring back pressure using the DRB IIIt and PEP
(4) Following the PEP module instruction manual,
module pressure tester.
connect all required cables to the DRB IIIt and PEP
WARNING: THE NORMAL OPERATING TEMPERA- module. Select the available menu options on the
TURE OF THE EXHAUST SYSTEM IS VERY HIGH. DRBIIIt display screen for using the digital pressure
THEREFORE, NEVER WORK AROUND OR ATTEMPT gauge function.
TO SERVICE ANY PART OF THE EXHAUST SYSTEM (5) Apply the park brake and start the engine.
UNTIL IT IS COOLED. SPECIAL CARE SHOULD BE (6) With transmission in Park or Neutral, raise
TAKEN WHEN WORKING NEAR THE CATALYTIC engine speed to 2000 RPM. Monitor the pressure
CONVERTER. THE TEMPERATURE OF THE CON- readings on the DRBIIIt. Back pressure should not
VERTER RISES TO A HIGH LEVEL AFTER A SHORT exceed specified limit. Refer to specification in table
PERIOD OF ENGINE OPERATION TIME. below EXHAUST BACK PRESSURE LIMITS.
(1) Disconnect and remove the upstream (before NOTE: For applications with dual catalytic convert-
catalytic converter) oxygen sensor. (Refer to 14 - ers, repeat test on opposite converter using the
FUEL SYSTEM/FUEL INJECTION/O2 SENSOR - previous steps.
REMOVAL)
It is easier to service the exhaust system module • To ensure proper alignment with other parts in
components (Fig. 1) or (Fig. 2), when system is the system.
removed from the vehicle. • Provide acceptable exhaust noise levels and does
(1) Raise vehicle on hoist. not change exhaust system back pressure that could
(2) Apply penetrating oil and loosen band clamps affect emissions and performance.
at resonator connector.
(3) Remove screw attaching exhaust system INSPECTION
ground strap to left rear resonator. Inspect the exhaust pipes, catalytic converters,
(4) Separate exhaust module at front resonator muffler, and resonators for cracked joints, broken
from the converter downpipes. welds and corrosion damage that would result in a
leaking exhaust system. Inspect the clamps, support
CAUTION: At this time, the exhaust system is held
brackets, and insulators for cracks and corrosion
by only isolators. Support the exhaust system
damage.
underneath the front resonator and the muffler
while the isolators are being removed. Do not use NOTE: Slip joint band clamps are spot welded to
any tools to remove the isolators, remove by hand exhaust system. If a band clamp must be replaced,
only. Soapy water or silicone-based spray may be the spot weld must be ground off.
used to assist removal. Do Not use a petroleum-
based lubricant on the isolators. This will damage
the rubber material. INSTALLATION - EXHAUST SYSTEM
(1) Install and loose assemble the front resonator
(5) Support exhaust system with jack stand.
to the converter pipes.
(6) Remove the rubber isolators from the rear sus-
(2) Place the exhaust system on two supports (one
pension crossmember and support brackets on body
on side of muffler, one behind the resonator). Connect
(Fig. 3) and (Fig. 4).
the system to the converter pipes.
(7) Lower exhaust system and lay on the ground.
(3) Install the system’s rubber isolators onto the
NOTE: When replacement is required on any com- support brackets (Fig. 3) and (Fig. 4).
ponent of the exhaust system, it is most important (4) Install exhaust system ground strap.
that original equipment parts be used for the follow- (5) Visually inspect the isolators. They should be
ing reasons: straight when viewing from front to back of the vehi-
cle. Working from the front of system, align each
component to maintain position and proper clearance (3) Tighten all clamps and brackets once align-
with underbody parts. ment and clearances are achieved.
(6) Tighten band clamps to 61 N·m (45 ft. lbs.).
(7) Lower the vehicle.
(8) Start the engine and inspect for exhaust leaks. SPECIFICATIONS
Repair exhaust leaks as necessary.
(9) Check the exhaust system for contact with the TORQUE
body panels. Make the necessary adjustments, if
needed. DESCRIPTION N·m Ft. In.
Lbs. Lbs.
ADJUSTMENTS Band Clamp 61 45 —
A misaligned exhaust system is usually indicated
by a vibration, rattling noise, or binding of exhaust Catalytic Converter Pipe to Support 47 35 —
system components. These noises are sometimes hard Bracket - Nut
to distinguish from other chassis noises. Inspect V-Band Clamp - Exhaust Manifold to 11 — 100
exhaust system for broken or loose clamps, heat Catalytic Converter
shields, isolators, and brackets. Replace or tighten as Exhaust Support to Body Bracket - 25 — 215
necessary. It is important that exhaust system clear- Fasteners
ances and alignment be maintained.
Exhaust Support Bracket to 47 35 —
Perform the following procedures to align the
Transmission - Fasteners
exhaust system:
(1) Loosen clamps and support brackets. Right Rear Resonator (300M 28 — 250
(2) Align the exhaust system starting at the front, Special) - Nuts
working rearward.
SPECIAL TOOLS
EXHAUST SYSTEM
CAUTION: Due to exterior physical similarities of (1) Disconnect negative battery cable at remote
some catalytic converters with pipe assemblies, jumper terminal located at right strut tower.
extreme care should be taken with replacement (2) Raise vehicle on hoist.
parts. There are internal converter differences (3) Remove exhaust system (Refer to 11 -
required in some parts of the country (particularly EXHAUST SYSTEM - REMOVAL).
vehicles built for States with strict emission (4) Lower vehicle.
requirements). (5) Disconnect Inlet Air Temperature (IAT) Sensor
connector.
(6) Loosen hose clamp for throttle body air inlet
INSPECTION hose.
(7) Disconnect make up air hose from right cylin-
WARNING: THE NORMAL OPERATING TEMPERA- der head cover.
TURE OF THE EXHAUST SYSTEM IS VERY HIGH. (8) Remove air cleaner assembly with air inlet
THEREFORE, NEVER ATTEMPT TO SERVICE ANY hose (Fig. 6).
PART OF THE EXHAUST SYSTEM UNTIL IT IS
COOLED. SPECIAL CARE SHOULD BE TAKEN
WHEN WORKING NEAR THE CATALYTIC CON-
VERTER. THE TEMPERATURE OF THE CONVERTER
RISES TO A HIGH LEVEL AFTER A SHORT PERIOD
OF ENGINE OPERATION TIME.
page page
FRONT BUMPER
REINFORCEMENT
REMOVAL
(1) Remove front fascia.
(2) Remove end plugs in ends of bumper after
removing screws in front of bumper.
(3) Remove attaching bolts from bumper reinforce-
ment to adapter plate through ends of the bumper.
(Fig. 1).
(4) If beam is damaged, the adapter plate to rail
welds will have to be cut off
INSTALLATION
(1) Place reinforcement in position on front of vehi- Fig. 1 FRONT BUMPER REINFORCEMENT
cle.
1-END CAP
(2) Install attaching bolts to inside of bumper rein- 2-FRONT BUMPER REINFORCEMENT
forcement to adapter plates. 3-END CAP
(3) Install end plugs in ends of bumper, using
screws in front of the bumper.
(4) Install front fascia.
FRONT FASCIA
REMOVAL
REMOVAL
(1) Release hood latch and open hood.
(2) Remove large rubber grommet (70 mm x 168
mm) from splash shield to gain access to fascia fas-
teners (Fig. 2).
(3) Remove fasteners attaching fascia to the front
fender and splash shield.
(4) Remove the nuts on the fascia studs through
the splash shield access holes on each side (Fig. 3).
(5) Remove the fasteners attaching the fascia to
the lower crossmember (Fig. 4). Fig. 3 FASTENER LOCATIONS
(6) Remove the fasteners attaching the fascia to
1 - THROUGH ACCESS REMOVE FASTENER
the upper radiator closure panel (Fig. 4). 2 - FASTENERS
(7) Disconnect wire connectors (fog lamps, parking/
turn signal, side marker), if equipped (Fig. 5).
(8) Remove fascia from vehicle.
REMOVAL - INTREPID
(1) Release hood latch and open hood.
(2) Remove push pin fasteners attaching bottom of
fascia (air dam) to lower crossmember (Fig. 6).
(3) Remove fasteners attaching fascia to splash
shields (Fig. 7).
(4) Remove push pin fasteners attaching the fascia
to upper radiator closure panel.
(5) Pull the sides of the fascia outwards to disen- Fig. 5 FRONT BUMPER FASCIA
gage fascia from drive pins then pull fascia forward.
1 - BODY & FASCIA WIRE CONNECTORS
(6) Disconnect fog lamp wire connectors, if 2 - FRONT FASCIA
equipped.
(7) Remove fascia from vehicle.
INSTALLATION - INTREPID
(1) Connect fog lamp wire connectors, if equipped.
(2) Place fascia pin position on vehicle, by fitting
foam to bumper beam.
(3) Snap sides of fascia over drive pin fasteners on
fenders.
(4) Install fasteners to upper radiator closure.
(5) Install fasteners attaching fascia to splash
Fig. 6 AIR DAM shields.
(6) Install fasteners attaching bottom of fascia to
1 - AIR DAM
2 - LOWER CROSSMEMBER lower crossmember.
REAR BUMPER
REMOVAL
(1) Remove rear fascia.
(2) Remove attaching bolts and nuts from attach-
ing bracket to rails (Fig. 8).
INSTALLATION
INSTALLATION Fig. 8 REAR BUMPER REINFORCEMENT
(1) Connect wire connectors. 1 - REAR BUMPER REINFORCEMENT
(2) Place fascia in position on vehicle, by fitting
foam to bumper reinforcement. Use care not to INSTALLATION
scratch fender. Tape may be put on fender for protec- (1) Place reinforcement in position on rear of vehicle.
tion. (2) Install bracket to rails attaching bolts and
(3) Install the top center fasteners, to upper radi- nuts.
ator closure panel.
(4) Align fascia to bumper reinforcement.
(5) Align the two fascia studs to the fender vertical REAR FASCIA
attachments, at the same time align the fascia groove
on the horizontal flange with the fender fasteners. REMOVAL
Push fascia rearward to engage the fasteners. (1) Release deck lid latch and open deck lid.
INSTALLATION - INTREPID
(1) Connect the license plate lamp wire connector
Fig. 9 REAR BUMPER FASCIA
to the body harness.
INSTALLATION (2) Place rear fascia in position on vehicle, by fit-
(1) Connect main wire connector to the body har- ting foam to bumper beam.
ness connector. (3) Install center fastener to lower trunk panel.
(2) Place rear fascia in position on bumper rein- (4) Snap sides of fascia between quarter panel and
forcement. bracket.
(3) Align the two fascia studs to the quarter panel (5) Install fasteners attaching fascia to rear quar-
vertical attachment, at the same time align the fas- ter panel and splash shields.
cia key hole slot on the horizontal flange with the (6) Install the remaining fasteners to lower trunk
drive pin. Push fascia forward to engage the fasten- panel.
ers.
(4) Install push pins attaching top of fascia to
body. FRAME
(5) 300M only, install nut on fascia stud and
install tail lamp and fasteners under tail lamp.
(6) Install trunk carpet back in position.
SPECIFICATIONS
(7) Install fasteners attaching fascia to rear quar-
ter panel and splash shields. FRAME DIMENSIONS
Frame dimensions are listed in metric scale then
converted to inch scale listed in parenthesis. All
REAR FASCIA - INTREPID dimensions are from center to center of Principal
Locating Point (PLP), or from center to center of PLP
REMOVAL - INTREPID and fastener location. Vertical dimensions can be taken
(1) Open deck lid. from the work surface to the locations indicated.
DESCRIPTION FIGURE
ENGINE COMPARTMENT TOP VIEW 11
ENGINE COMPARTMENT SIDE VIEW 12
FORWARD FRAME SECTION AND ENGINE CRADLE 13
REAR FRAME SECTION 14
SPECIFICATIONS - TORQUE
TORQUE SPECIFICATIONS
Ft. In.
DESCRIPTION N·m
Lbs. Lbs.
Rear bumber reinforcement 28 21 —
attaching nut
Front suspension crossmember 109 80 —
front attaching bolt
Front suspension crossmember 102 75 —
rear attaching bolt
Radiator support crossmember 51 45 —
attaching bolts
ENGINE CRADLE
CROSSMEMBER
Fig. 15 ENGINE CRADLE
REMOVAL
1 - FRONT FRAME RAILS
2 - TRANSAXLE CROSSMEMBER
CAUTION: VERIFY THAT VEHICLE IS PROPERLY 3 - CROSSMEMBER BOLTS
SUPPORTED AND SECURED TO THE LIFTING 4 - CROSSMEMBER BOLTS
DEVICE. VEHICLE CENTER OF GRAVITY WILL 5 - CRADLE MOUNT BOLTS
6 - ENGINE CRADLE
CHANGE WHEN HEAVY COMPONENTS ARE 7 - ENGINE MOUNT BOLTS
REMOVED CAUSING A HAZARDOUS CONDITION.
(3) Install bolts to hold cradle to body shell.
(1) Release hood latch and open hood. (4) Connect lower control arms to spindles. Refer
(2) Remove nuts holding engine mounts to cradle. to Group 2, Suspension, for proper procedures.
(3) Install a suitable engine support device. (5) Install bolts to retain suspension lower ball
(4) Raise and support vehicle on safety stands. joints to spindles.
(5) Remove bolts holding transaxle crossmember to (6) Connect sway bar links.
cradle. (7) Lower vehicle and lower engine and transaxle
(6) Lower vehicle and lift engine and transaxle off onto cradle.
cradle. (8) Raise vehicle.
(7) Raise and support vehicle on safety stands. (9) Install bolts to hold transaxle crossmember to
(8) Disconnect sway bar links. cradle.
(9) Remove bolts retaining suspension lower ball (10) Lower vehicle.
joints to spindles. (11) Remove engine support device.
(10) Separate lower control arm from spindle. (12) Install nuts to hold engine mounts to cradle.
Refer to Group 2, Suspension, for proper procedures. (13) Align front suspension if necessary.
(11) Support cradle on a 10 cm by 10 cm by 90 cm
(4 in. by 4 in. by 36 in.) wood beam and a jack.
(12) Remove bolts holding cradle to body shell FRONT TOW EYE
(Fig. 15).
(13) Lower cradle away from body shell. REMOVAL
(1) Unthread the front tow eye from the tow eye
INSTALLATION bracket (Fig. 16).
(2) Remove the front tow eye.
NOTE: If cradle replacement is required, transfer
suspension components and jounce and bounce
plates to replacement cradle.
INSTALLATION
(1) Install the front tow eye bracket and fasteners.
Torque bolts to 23 to 34 N·m (Fig. 16).
(2) Reinstall the front fascia as necessary. Refer to
Body for procedure.
(3) Lower vehicle from the hoist.
(4) Install the tow eye into the tow eye bracket. No
torque specification is required, hand tighten only
(Fig. 17).
(5) Reconnect the negative battery cable at the
remote battery post.
OPERATION
The purpose of the rear suspension crossmember is
to support the lower end of the rear suspension
through the use of four lateral links. Two lateral
links are mounted on each end of the crossmember
(Fig. 18).
REMOVAL
(1) Open the fuel filler door. Remove the 3 fuel
filler neck attaching screws. Remove the fuel filler
cap.
(2) Raise vehicle on jackstands or centered on a
frame contact type hoist. See Hoisting in the Lubri-
Fig. 17 FRONT TOW EYE INSTALLATION cation and Maintenance section of this manual, for
the required lifting procedure to be used for this
1 - NO SPACE
2 - TOW EYE vehicle.
(3) Remove both rear wheel and tire assemblies
from the vehicle.
FRONT TOW HOOK BRACKET (4) Remove the nut and bolt attaching each of the
4 lateral links to the crossmember (Fig. 19). The
REMOVAL bolt for the left front lateral link may not be
(1) Unthread the front tow eye from the tow eye removed at this time. Remove the nut only.
bracket (Fig. 16). Once the crossmember is lowered, the bolt can
Fig. 20 REAR PARKING BRAKE AND RETAINER (20) Remove the link attaching bolt and link from
CLIP (LEFT) the left front corner of the crossmember.
1 - INTERMEDIATE PARKING BRAKE CABLE (21) Remove the rear suspension crossmember
2 - CLIP from the vehicle.
3 - FUEL TANK
4 - MUFFLER
5 - REAR PARKING BRAKE CABLE DISASSEMBLY
(1) Lay the crossmember right-side-up on a bench
with the bushing to be removed hanging over the
edge of the bench.
(2) Install cup, Special Tool 8173–1, in well of
press, Special Tool C-4212F.
(3) Install Remover/Installer, Special Tool 8173–2,
on end of the threaded push rod on Special Tool
C-4212F.
(4) Install Special tool C-4212F with Special Tools
8173–1, and 8173–2, on bushing (Fig. 22).
(5) Turn the threaded rod, pushing bushing down
through crossmember and into cup 8173–1.
(6) Remove special tools, and bushing
ASSEMBLY
(1) Clean bore in crossmember where bushing
mounts.
Fig. 21 REAR BRAKE PROPORTIONING VALVE (2) Thoroughly coat new bushing and crossmember
1 - CROSSMEMBER ATTACHING BOLT bore with Mopart Rubber Bushing Installation Lube.
2 - REAR FLEX HOSE (3) Place Installer, Special Tool C-8173–3, on top of
3 - BRAKE PROPORTIONING VALVE
4 - REAR CROSSMEMBER crossmember bushing bore with inside taper end fac-
5 - ATTACHING NUT ing up. Locater lip on bottom of tool should align the
tool with bushing bore.
(13) Position a transmission jack under the muf- (4) Coat the tapered bore of Special Tool C-8173–3
fler. with Mopart Rubber Bushing Installation Lube, then
(14) Disconnect the hanger securing the exhaust place the bushing in its tapered bore (Fig. 24).
resonator to the rear frame rail. (5) Install Special Tool 8173–4 in the cup, Special
(15) Disconnect the hangers securing the exhaust Tool 8173–1 (Fig. 23). Install cup, Special Tool
muffler to the rear suspension crossmember. There is 8173–1 into well of press, Special Tool C–4212F (Fig.
one hanger on each side of the muffler. 23).
(16) Lower the transmission jack and muffler (6) Install Remover/Installer, Special Tool 8173–2,
enough to allow for better access to the rear cross- on end of the threaded push rod on Special Tool
member. C-4212F.
(17) Remove the screw securing the fuel filler neck (7) Place special tools on crossmember and bush-
to the left frame rail. ing (Fig. 24).
Fig. 24 BUSHING INSTALLATION CAUTION: Tightening the lateral link attaching bolts
1 - SPECIAL TOOL C-4212F at this time will cause the bushings contort at curb
2 - SPECIAL TOOL 8173–2 riding height, leading to premature failure of the
3 - BUSHING bushings. Tighten bolts only when vehicle is at
4 - SPECIAL TOOL 8173–3
5 - SPECIAL TOOL 8173–1 curb riding height.
(10) Install the retainer clips securing both rear (19) Install wheel and tire assemblies on vehicle.
parking brake cables assemblies to the rear suspen- (20) Tighten the wheel mounting stud nuts in
sion crossmember (Fig. 20). proper sequence until all nuts are torqued to half
(11) Reconnect the right rear parking brake cable specification. Then repeat the tightening sequence to
to the intermediate parking brake cable. the full specified torque of 129 N·m (95 ft. lbs.).
(12) Install the parking brake cable tensioner to (21) Lower vehicle to the ground.
the left rear parking brake cable. (22) Install the 3 fuel filler neck attaching screws.
(13) Install the parking brake cable tensioner to Reinstall the fuel filler cap.
the intermediate parking brake cable. Refer to Base (23) Tighten all 4 lateral arm to crossmember
Brake System in Group 5 Brakes in this manual for attaching bolt and nut assemblies to 95 N·m (70 ft.
the required service procedure to install and properly lbs.).
adjust the parking brakes. (24) Check and reset rear wheel TOE to specifica-
(14) Install the 4 bolts attaching both stabilizer tions if required.
bar isolator bushing retainers to the frame rails (the
INSTALLATION
(1) Position rear tow eye bracket on vehicle.
(2) Install bolts to hold rear tow eye bracket to
rear frame rail. Torque bolts to 48 N·m.
(3) Lower vehicle.
FUEL SYSTEM
TABLE OF CONTENTS
page page
FUEL DELIVERY
TABLE OF CONTENTS
page page
SPECIFICATIONS
TORQUE
SPECIAL TOOLS
FUEL
OPERATION
Its resistance changes with the amount of fuel in
the tank. The float arm attached to the sensor moves
as the fuel level changes.
Fuel Line Adapter 1/4
The fuel level input is used as an input for OBD II.
If the fuel level is below 15% or above 85% of total
tank capacity several monitors are disabled. There
are diagnostics for the level circuit open and shorted.
REMOVAL
Remove fuel pump module. Refer to Fuel Pump
Module in this section.
(1) Depress the retaining tab and remove the fuel
pump/level sensor connector from the bottom of the
fuel pump module electrical connector (Fig. 1).
INSTALLATION
(1) Insert level sensor wires in bottom of stand-
pipe.
FUEL LINES
DESCRIPTION - FUEL LINES/HOSES AND
CLAMPS
Also refer to Quick-Connect Fittings.
DESCRIPTION OPERATION
A combination fuel filter and fuel pressure regula- The pump draws fuel through a strainer and
tor is used on all gas powered engines. It is located pushes it through the motor to the outlet. The pump
on the side of the fuel pump module (Fig. 8) in the contains a check valve. The valve, in the pump out-
fuel tank. let, maintains pump pressure during engine off con-
It contains a diaphragm, calibrated springs and a ditions, for a short while. It is normal for fuel
fuel return valve. pressure to drop to zero after cooldown. The fuel
pump relay provides voltage to the fuel pump. The
OPERATION fuel pump has a maximum deadheaded pressure out-
Fuel Pressure Regulator Operation: The pres- put of approximately 880 kPa (130 psi). The regula-
sure regulator is a mechanical device that is cali- tor adjusts fuel system pressure to approximately
brated to maintain fuel system operating pressure of 400 kpa ±34 kpa (58 psi ± 5 psi).
approximately 400 kPa (58 psi) at the fuel injectors.
NOTE: Checkvalve maintains volume of fuel in the
Fuel is supplied to the regulator by the electric fuel
rail and lines, not pressure.
pump through an opening tube at the bottom of reg-
ulator.
The fuel pump module contains a check valve to
maintain some fuel pressure when the engine is not
operating. This will help to start the engine (Fig. 8).
If fuel pressure at the pressure regulator exceeds
approximately 58 psi, an internal diaphragm closes
and excess fuel pressure is routed back into the tank
FUEL PUMP MODULE (6) Use Special Tool #6856 to remove fuel pump
module locknut (Fig. 9).
(7) Remove fuel pump and O-ring seal from tank.
DESCRIPTION
Discard old seal.
The fuel pump module contains the fuel pump, fuel
reservoir, level sensor, inlet strainer, and fuel pres-
sure regulator.
OPERATION
The Chrysler fuel pump modul is an in-tank unit
with an integral fuel level sensor and pressure regu-
lator. The pump is driven by a 12 volt DC motor any
time the fuel pump relay is energized. Serviceable
components on the module include:
• Inlet strainer
• Fuel level sensor
• Pressure regulator
The pump draws fuel through a strainer and
pushes it through the motor to the outlet. The pump
contains two check valves. One valve relieves inter-
nal fuel pump pressure and regulates maximum
pump output. The second valve, in the pump outlet,
maintains pump pressure during engine off condi-
tions. Fig. 9 FUEL TANK LOCKNUT
The fuel systems use either a positive displace- 1 - SPECIAL TOOL #6856
ment, gerotor, with a permanent magnet electric 2 - LOCKING RING
motor. This fuel system does not contain the tradi- 3 - FUEL PUMP MODULE
tional fuel return lines. The regulator contains a cal-
ibrated spring which forces a diaphragm against the INSTALLATION
fuel filter return port. When pressure exceeds the (1) Wipe seal area of tank clean and place a new
calibrated amount, the diaphragm retracts, allowing seal in position in the tank opening.
excess pressure and fuel to vent into the tank. (2) Position fuel pump in the tank. Make sure the
The maximum deadhead pressure is approximately alignment tabs on the underside of the fuel pump
880 kPa (130 psi). The regulator adjusts fuel system module flange (Fig. 10) sits in the notches on the fuel
pressure to approximately 400 ±34 kPa (58 ± 5 psi). tank (Fig. 11).
REMOVAL
(1) Release fuel pressure, Refer to Fuel System
Pressure Release Procedure in the Fuel Delivery sec-
tion.
(2) Remove Fuel Tank refer to the Fuel Tank
Removal/Installation in this group.
REMOVAL - 2.7/3.5L
WARNING: RELEASE FUEL SYSTEM PRESSURE
BEFORE SERVICING FUEL RAIL. SERVICE VEHI-
CLES IN WELL VENTILATED AREAS AND AVOID
IGNITION SOURCES. NEVER SMOKE WHILE SER-
VICING THE VEHICLE.
FUEL RAIL
Fig. 12 Injector Electrical Connectors
DESCRIPTION 1 - FUEL INJECTOR
The fuel rail supplies the necessary fuel to each 2 - IGNITION COIL
individual fuel injector and is mounted to the intake
(7) Remove mounting bolts on both sides of fuel
manifold.
rail.
(8) Lift fuel rail straight up off of cylinder head.
OPERATION
(9) Remove retaining clips from fuel injectors at
The fuel pressure regulator is no longer mounted
fuel rail.
to the fuel rail on any engine. It is now located on
(10) Remove fuel injector from fuel rail.
FUEL TANK
DESCRIPTION
The fuel tank is constructed of a plastic material.
Its main functions are for fuel storage and for place-
ment of the fuel pump module. The tank is made
from High density Polyethylene (HDPE) material.If
equipped with ORVR (Onboard Refueling Vapor
Recovery) it has been added to the fuel tank to con-
trol refueling vapor emissions.
OPERATION
All models pass a full 360 degree rollover test
without fuel leakage. To accomplish this, fuel and Fig. 13 Battery Cable
vapor flow controls are required for all fuel tank con- 1 - BATTERY CABLE
nections. 2 - SERVICE VACUUM SUPPLY TEE
INSTALLATION
(1) Install filler neck to filler hose.
(2) Tighten clamps.
(3) Lower vehicle.
(4) Install 3 screws to filler neck and quarter Fig. 22 INLET STRAINER
panel. 1 - INLET STRAINER
(5) Fill tank and check for leaks. 2 - RETAINING CLIP
(6) Connect negative cable from battery. 3 - FUEL LEVEL SENSOR
INSTALLATION
FUEL TANK VENT TUBE (1) Lubricate the strainer O-ring with clean engine
oil.
REMOVAL (2) Insert strainer O-ring into outlet of strainer so
(1) Perform fuel system pressure release. that it sits evenly on the step inside the outlet.
(2) Disconnect negative cable from battery. (3) Push strainer onto the inlet of the fuel pump
(3) Drain fuel tank. reservoir body. Make sure the locking tabs on the
(4) Raise and support vehicle on host. reservoir body lock over the locking tangs on the
(5) Lower fuel tank, refer to Fuel Tank Removal/ strainer.
Installation in this section. (4) Install fuel pump module. Refer to Fuel Pump
(6) Remove vent hose from top of tank. Module Installation in this section.
(7) Remove vent hose from fuel filler neck.
(1) Using a clean lint free cloth, clean the fuel tube
nipple and retainer.
(2) Prior to connecting the fitting to the fuel tube,
coat the fuel tube nipple with clean engine oil.
(3) Push the quick-connect fitting over the fuel
tube until the retainer seats and a click is heard.
(4) The plastic quick-connect fitting has windows
in the sides of the casing. When the fitting com-
pletely attaches to the fuel tube, the retainer locking
ears and the fuel tube shoulder are visible in the Fig. 24 Typical Two-Tab Type Quick-Connect Fitting
windows. If they are not visible, the retainer was not
1 - TAB(S)
properly installed (Fig. 23). Do not rely upon the 2 - QUICK-CONNECT FITTING
audible click to confirm a secure connection.
CAUTION: The interior components (O-rings, spac-
ers) of this type of quick-connect fitting are not ser-
viced separately, but new plastic retainers are
available. Do not attempt to repair damaged fittings
or fuel lines/tubes. If repair is necessary, replace
the complete fuel tube assembly.
FUEL INJECTION
TABLE OF CONTENTS
page page
FUEL INJECTION sensor diagnostics (they are checked for shorted con-
ditions at all times).
During CLOSED LOOP modes the PCM monitors
OPERATION the inputs from the upstream and downstream
heated oxygen sensors. The upstream heated oxygen
OPERATION - INJECTION SYSTEM sensor input tells the PCM if the calculated injector
All engines used in this section have a sequential pulse width resulted in the ideal air-fuel ratio of 14.7
Multi-Port Electronic Fuel Injection system. The MPI to one. By monitoring the exhaust oxygen content
system is computer regulated and provides precise through the upstream heated oxygen sensor, the
air/fuel ratios for all driving conditions. The Power- PCM can fine tune injector pulse width. Fine tuning
train Control Module (PCM) operates the fuel injec- injector pulse width allows the PCM to achieve opti-
tion system. mum fuel economy combined with low emissions.
The PCM regulates: For the PCM to enter CLOSED LOOP operation,
• Ignition timing the following must occur:
• Air/fuel ratio (1) Engine coolant temperature must be over 35°F.
• Emission control devices • If the coolant is over 35°F the PCM will wait 38
• Cooling fan seconds.
• Charging system • If the coolant is over 50°F the PCM will wait 15
• Idle speed seconds.
• Vehicle speed control • If the coolant is over 167°F the PCM will wait 3
Various sensors provide the inputs necessary for seconds.
the PCM to correctly operate these systems. In addi- (2) For other temperatures the PCM will interpo-
tion to the sensors, various switches also provide late the correct waiting time.
inputs to the PCM. (3) O2 sensor must read either greater than 0.745
The PCM can adapt its programming to meet volts or less than 0.29 volt.
changing operating conditions. (4) The multi-port fuel injection systems has the
Fuel is injected into the intake port above the following modes of operation:
intake valve in precise metered amounts through • Ignition switch ON (Zero RPM)
electrically operated injectors. The PCM fires the • Engine start-up
injectors in a specific sequence. Under most operat- • Engine warm-up
ing conditions, the PCM maintains an air fuel ratio • Cruise
of 14.7 parts air to 1 part fuel by constantly adjust- • Idle
ing injector pulse width. Injector pulse width is the • Acceleration
length of time the injector is open. • Deceleration
The PCM adjusts injector pulse width by opening • Wide Open Throttle
and closing the ground path to the injector. Engine • Ignition switch OFF
RPM (speed) and manifold absolute pressure (air (5) The engine start-up (crank), engine warm-up,
density) are the primary inputs that determine deceleration with fuel shutoff and wide open throttle
injector pulse width. modes are OPEN LOOP modes. Under most operat-
ing conditions, the acceleration, deceleration (with
OPERATION - MODES OF OPERATION A/C on), idle and cruise modes, with the engine at
As input signals to the PCM change, the PCM operating temperature are CLOSED LOOP modes.
adjusts its response to output devices. For example,
the PCM must calculate a different injector pulse IGNITION SWITCH ON (ZERO RPM) MODE
width and ignition timing for idle than it does for When the ignition switch activates the fuel injec-
Wide Open Throttle (WOT). There are several differ- tion system, the following actions occur:
ent modes of operation that determine how the PCM • The PCM monitors the engine coolant tempera-
responds to the various input signals. ture sensor and throttle position sensor input. The
There are two different areas of operation, OPEN PCM determines basic fuel injector pulse width from
LOOP and CLOSED LOOP. this input.
During OPEN LOOP modes the PCM receives • The PCM determines atmospheric air pressure
input signals and responds according to preset PCM from the MAP sensor input to modify injector pulse
programming. Inputs from the upstream and down- width.
stream heated oxygen sensors are not monitored dur- When the key is in the ON position and the engine
ing OPEN LOOP modes, except for heated oxygen is not running (zero rpm), the Auto Shutdown (ASD)
and fuel pump relays de-energize after approximately
SPECIFICATIONS
TORQUE
SPECIAL TOOLS
FUEL
INSTALLATION
(1) Position accelerator pedal assembly over studs
onto dash panel. Ensure carpet and insulation are
trapped between the lip of the pedal base and the
floor plan (Fig. 4). Install mounting nuts and tighten
to 12 N·m (105 in. lbs.) torque.
(2) From inside the vehicle, hold up the pedal and
install the throttle cable and cable retainer in the
upper end of the pedal shaft. Fig. 5 CRANKSHAFT POSITION SENSOR
(3) From the engine compartment, hold the throt-
1 - CRANKSHAFT POSITION SENSOR
tle body lever in the wide open position and install
the throttle cable.
OPERATION tial housing. The bottom of the sensor sits above the
Engine speed and crankshaft position are provided drive plate.
through the crankshaft position sensor. The sensor (1) Disconnect electrical connector from crankshaft
generates pulses that are the input sent to the pow- position sensor.
ertrain control module (PCM). The PCM interprets (2) Remove sensor mounting screw. Remove sensor.
the sensor input to determine the crankshaft posi-
tion. The PCM then uses this position, along with INSTALLATION
other inputs, to determine injector sequence and igni- The crankshaft sensor is located on the passengers
tion timing. side of the transmission housing, above the differen-
The crankshaft position sensor detects slots cut tial housing. The bottom of the sensor sits above the
into the transmission driveplate extension. There are drive plate.
3 sets of slots. Two sets contain 4 slots and one set (1) Install sensor and push sensor down until con-
contains 5 slots, for a total of 13 slots (Fig. 6). Basic tact is made with the transmission case. While hold-
timing is set by the position of the last slot in each ing the sensor in this position, install and tighten the
group. Once the Powertrain Control Module (PCM) retaining bolt to 12 N·m (105 in. lbs.) torque.
senses the last slot, it determines which piston will (2) Connect electrical connector to crankshaft posi-
be next at TDC from the camshaft position sensor tion sensor.
input. It may take the PCM one engine revolution to
determine crankshaft position.
ENGINE SPEED SENSOR
DESCRIPTION
The PCM receives a signal from the TCM and the
transaxle output speed sensor over the bus communi-
cation line to indicate vehicle speed on automatic
transmission cars. On Manual transmission cars (if
equipped) vehicle, a dedicated vehicle speed sensor is
connected to the PCM.
OPERATION
The Transmission Control Module (TCM) supplies
the road speed and distance traveled inputs to the
PCM. From these inputs and the throttle position
sensor input, the PCM determines when a decelera-
tion condition occurs.
REMOVAL
REMOVAL - 2.7L
(1) Release fuel system pressure. Refer to Fuel
System Pressure Release Procedure in this section.
(2) Disconnect negative cable to battery.
(3) Remove intake manifold plenum. Refer to the
Engine section for information.
(4) Remove intake manifold plenum mounting
bolts. Lift Plenum up off of engine. Cover intake
manifold to prevent foreign material from entering
engine.
(5) Disconnect fuel supply tube quick connect fit-
tings at the rear of intake manifold. Refer to Quick
Connect Fittings in the Fuel Delivery Section.
(6) If the injector connectors are not tagged with
their cylinder number, tag them to identify the cor-
Fig. 8 Fuel Injector Location—Typical rect cylinder
1 - FUEL INJECTORS (7) Remove electrical connectors from the fuel
2 - IGNITION COILS
injectors.
(8) Remove fuel rail mounting bolts.
combustion chamber. Fuel injectors are not inter-
(9) Lift fuel rail straight up off of the cylinder
changeable between engines.
head.
The PCM provides battery voltage to each injector
(10) Remove retaining clips from fuel injectors at
through the ASD relay. Injector operation is con-
fuel rail.
trolled by a ground path provided for each injector by
(11) Remove fuel injectors.
the PCM. Injector on-time (pulse-width) is variable,
(12) Repeat for remaining injectors.
and is determined by the PCM processing all the
(13) Check injector O-ring for damage. If O-ring is
data previously discussed to obtain the optimum
damaged, it must be replaced. Replace the injector
injector pulse width for each operating condition. The
clip if it is damaged.
pulse width is controlled by the duration of the
ground path provided.
REMOVAL - 3.5L
(1) Release fuel system pressure. Refer to Fuel
System Pressure Release Procedure in this section.
(2) Disconnect the negative battery cable.
INSTALLATION - 3.5L
(1) Lightly lubricate the fuel injector O-rings with
a couple drops of clean engine oil.
(2) Install retaining clips on fuel injectors.
(3) Push injectors into fuel injector rail until clips
are in the correct position.
(4) Position fuel rail over cylinder head, and push
rail into place. Tighten fuel rail mounting bolts to 28
N·m (250 in. lbs.) torque.
(5) Connect fuel supply tube quick connect fittings
at the rear of the fuel rail. Refer to Quick Connect
Fittings in the Fuel Delivery Section. Fig. 10 TPS & IDLE AIR CONTROL VALVE
(6) Connect electrical connectors to fuel injectors.
1 - TPS
2 - IAC
OPERATION
The PCM adjusts engine idle speed through the
idle air control motor to compensate for engine load,
coolant temperature or barometric pressure changes.
The throttle body has an air bypass passage that
provides air for the engine during closed throttle idle.
The idle air control motor pintle protrudes into the
air bypass passage and regulates air flow through it.
The PCM adjusts engine idle speed by moving the
IAC motor pintle in and out of the bypass passage.
The adjustments are based on inputs the PCM
receives. The inputs are from the throttle position
sensor, crankshaft position sensor, coolant tempera-
ture sensor, MAP sensor, vehicle speed sensor and
various switch operations (brake, park/neutral, air
conditioning).
When engine rpm is above idle speed, the IAC is
used for the following functions:
• Off-idle dashpot
• Deceleration air flow control Fig. 11 Idle Air Control Motor
• A/C compressor load control (also opens the pas- 1 - TPS
sage slightly before the compressor is engaged so 2 - IAC
that the engine rpm does not dip down when the
(2) Tighten mounting screws to 5.5 N·m (49 in.
compressor engages)
lbs.) torque.
(3) Attach electrical connector to the IAC.
Target Idle
(4) Connect the negative battery cable.
Target idle is determined by the following inputs:
• Gear position
• ECT Sensor
INSTALLATION - 3.5L
• Battery voltage (1) Install the IAC to the throttle body (Fig. 12).
• Ambient/Battery Temperature Sensor (2) Tighten mounting screw to 7.3 N·m (65 in. lbs.)
• VSS torque.
• TPS (3) Attach electrical connector to the IAC.
• MAP Sensor (4) Install air plenum and tighten the clamp.
(5) Connect the negative battery cable.
REMOVAL
REMOVAL - 2.7L
(1) Disconnect the negative battery cable.
(2) Disconnect the IAC electrical connector.
(3) Remove the IAC mounting screws.
(4) Remove the IAC.
REMOVAL - 3.5L
(1) Disconnect the negative battery cable.
(2) Disconnect the air plenum.
(3) Disconnect the electrical connector (Fig. 11).
(4) Remove the mounting screw.
(5) Remove the IAC.
INSTALLATION
Fig. 12 Idle Air Control Motor
INSTALLATION - 2.7L 1 - TPS
(1) Install the IAC to the throttle body. 2 - IAC
MAP SENSOR
DESCRIPTION
The MAP sensor mounts to the driver side of the
intake manifold plenum (Fig. 14) or (Fig. 15).
OPERATION
The MAP serves as a PCM input, using a silicon
based sensing unit, to provide data on the manifold
vacuum that draws the air/fuel mixture into the com-
bustion chamber. The PCM requires this information
to determine injector pulse width and spark advance.
INLET TEMPERATURE SENSOR - 3.5L When MAP equals Barometric pressure, the pulse
width will be at maximum.
INSTALLATION Also like the cam and crank sensors, a 5 volt ref-
(1) Install sensor into clean air hose to throttle erence is supplied from the PCM and returns a volt-
body. age signal to the PCM that reflects manifold
(2) Attach electrical connector to sensor. pressure. The zero pressure reading is 0.5V and full
(3) Install the negative battery cable. scale is 4.5V. For a pressure swing of 0 — 15 psi the
voltage changes 4.0V. The sensor is supplied a regu-
REMOVAL
REMOVAL - 2.7L
(1) Remove the negative battery cable.
(2) Disconnect the electrical connector from the
MAP sensor (Fig. 16).
(3) Remove bolt from sensor.
O2 SENSOR
DESCRIPTION
The upstream oxygen sensor threads into the out-
let flange of the exhaust manifold (Fig. 18) or (Fig.
19).
REMOVAL - 3.5L
(1) Remove the negative battery cable.
(2) Disconnect the electrical connector from the
MAP sensor.
(3) Remove bolts from sensor.
(4) Remove sensor.
INSTALLATION
INSTALLATION - 2.7L
(1) The sensor mounts onto intake manifold ple-
num (Fig. 17). Tighten screws to 4.5 N·m (40 in. lbs.)
torque.
(2) Attach electrical connector to sensor (Fig. 16).
Fig. 18 Upstream Heated Oxygen Sensor 1/2
(3) Install the negative battery cable.
1 - O2 SENSOR
REMOVAL
REMOVAL - UPSTREAM 1/1 or 2/1
The engines uses two heated oxygen sensors, one
in each exhaust manifold.
CAUTION: When disconnecting the sensor electrical Fig. 22 Downstream Heated Oxygen Sensors—1/2
connector, do not pull directly on wire going into (R) 2/2 (L)
sensor. 1 - OXYGEN SENSORS
(1) Remove the negative battery cable. WARNING: THE EXHAUST MANIFOLD, EXHAUST
(2) Disconnect the heated oxygen sensor electrical PIPES AND CATALYTIC CONVERTER BECOME
connector. VERY HOT DURING ENGINE OPERATION. ALLOW
(3) Use a socket such as Snap-On YA8875 or a ENGINE TO COOL BEFORE REMOVING OXYGEN
crow foot wrench to remove oxygen sensor (Fig. 21). SENSOR.
INSTALLATION
INSTALLATION - UPSTREAM 1/1 or 2/1
The engines uses two heated oxygen sensors, one
in each exhaust manifold.
(1) After removing the sensor, the exhaust mani-
fold threads must be cleaned with an 18 mm X 1.5 +
Fig. 23 Short Runner Valve (SRV)
6E tap. If reusing the original sensor, coat the sensor
threads with an anti-seize compound such as Loctite 1 - INTAKE MANIFOLD
2 - SRV VALVE
771- 64 or equivalent. New sensors have compound
on the threads and do not require an additional coat- solenoid. If the spike is not present, the PCM sets
ing. Tighten the sensor to 28 N·m (20 ft. lbs.) torque. the DTC.
(2) Connect the heated oxygen sensor electrical
connector. REMOVAL - 3.5L
(3) Install the negative battery cable. (1) Remove the negative battery cable.
(2) Remove link.
INSTALLATION - DOWNSTREAM 1/2, 2/2 (3) Remove electrical connector.
The O2 sensor are located at the outlet ends of the (4) Remove 3 bolts.
catalytic converter. (5) Remove valve (Fig. 24).
Threads of new oxygen sensors are factory coated
with anti-seize compound to aid in removal. DO
NOT add any additional anti-seize compound to
the threads of a new oxygen sensor.
(1) Install the O2 sensor. Tighten to 28 N·m (20 ft.
lbs.) torque.
(2) Connect the O2 sensor wire connector.
(3) Lower the vehicle.
(4) Install the negative battery cable.
OPERATION
The SRV (Fig. 23) system operates under WOT
conditions above 5000 rpm to maximize engine per-
formance. When actuated by the PCM, the SRV sole- Fig. 24 SHORT RUNNER VALVE (SRV)
noid energizes, allowing mechanical linkage to 1 - INTAKE MANIFOLD
2 - SRV VALVE
redirect the intake air flow to six short runners. The
PCM looks for a current spike when actuating the
INSTALLATION - 3.5L
(1) Install 3 bolts and tighten to 6.7 N·m ( 60 in.
lbs.).
(2) Install link.
(3) Install electrical connector.
(4) Install the negative battery cable.
THROTTLE BODY
DESCRIPTION
The throttle body is located on the intake manifold
(Fig. 25) or (Fig. 26). Fuel does not enter the intake
manifold through the throttle body. Fuel is sprayed
into the manifold by the fuel injectors.
REMOVAL
REMOVAL - 2.7L
(1) Disconnect negative cable from battery
(2) Disconnect air plenum from throttle body.
(3) Hold throttle lever in wide open position.
Remove throttle cable and speed control cables from
throttle arm.
(4) Remove throttle cable bracket.
(5) Disconnect electrical connectors from throttle
body.
(6) Remove the throttle body support bracket from
Fig. 25 Throttle Body 2.7L
the bottom of the throttle body.
1 - TPS SENSOR (7) Remove 3 throttle body bolts.
2 - THROTTLE BODY
3 - PCV VALVE (8) Remove throttle body.
4 - EGR TUBE (9) Clean mating surfaces.
INSTALLATION (3) From inside the vehicle, hold up the pedal and
install throttle cable and cable retainer in the upper
INSTALLATION - 2.7L end of the pedal shaft (Fig. 1).
(1) Install throttle body and bolts. (4) At the dash panel, install the cable retainer
(2) Tighten bolts to 11.9 N·m (105 in. lbs.) torque. clip between the end of the throttle cable fitting and
(3) Install the throttle body support bracket to the grommet (Fig. 2).
bottom of the throttle body. Tighten the bolts to 27.1 (5) From the engine compartment, rotate the
N·m (20 ft. lbs.) torque. throttle lever to wide open and install the throttle
(4) Hold throttle lever in wide open throttle posi- cable.
tion. Install throttle cable and speed control cable.
(5) Install throttle cable bracket and tighten bolts.
(6) Install air plenum and tighten clamp.
THROTTLE POSITION SENSOR
(7) Connect negative cable to battery.
DESCRIPTION
INSTALLATION - 3.5L The throttle position sensor mounts to the side of
(1) Hold throttle lever in wide open throttle posi- the throttle body (Fig. 27) or (Fig. 28).The sensor
tion. Install throttle cable and speed control cable. connects to the throttle blade shaft. The TPS is a
(2) Install throttle body and bolts. variable resistor that provides the Powertrain Con-
(3) Tighten bolts to 11.9 N·m (105 in. lbs.) torque. trol Module (PCM) with an input signal (voltage).
(4) Install the throttle body support bracket to the
bottom of the throttle body. Tighten the bolts to 27.1
N·m (20 ft. lbs.) torque.
(5) Install vacuum hose.
(6) Install throttle cable bracket and tighten bolts.
(7) Install air plenum and tighten clamp.
(8) Install cowl plenum.
(9) Install cowl screen.
(10) Install wiper arms.
(11) Connect negative cable to battery.
Fig. 28 THROTTLE POSITION SENSOR 3.2/3.5L Fig. 29 Throttle Position Sensor—2.7L Engine
ENGINE 1 - TPS SENSOR
1 - TPS 2 - THROTTLE BODY
2 - IAC 3 - PCV VALVE
4 - EGR TUBE
STEERING
TABLE OF CONTENTS
page page
RATTLE OR CLUNK 1. Power steering gear loose on front 1. Inspect power steering gear mounting
suspension crossmember. bolts. Replace as necessary. Tighten to
the specified torque.
POPPING NOISE 1. Worn outer tie rod. 1. Replace outer tie rod.
CHIRP OR SQUEAL 1. Loose power steering pump drive 1. Check and adjust power steering pump
(POWER STEERING PUMP) belt. drive belt to specifications. Replace belt if
worn or glazed.
WHINE OR GROWL 1. Low fluid level. 1. Fill power steering fluid reservoir to
(POWER STEERING proper level and check for leaks (make
PUMP)** sure all air is bled from the system fluid).
2. Power steering hose touching 2. Adjust hose to proper position by
vehicle body or frame. loosening, repositioning, and tightening
fitting to specified torque. Do not bend
tubing. Replace hose if damaged.
3. Extreme wear of power steering 3. Replace power steering pump and
pump internal components. flush system as necessary.
4. Loose power steering pump drive 4. Check and adjust power steering pump
belt. drive belt to specifications. Replace belt if
worn or glazed.
5. Extremely cold temperatures below 5. Noise is typical when starting vehicle in
-18°C (0°F). extremely cold temperature. Normal
duration of noise at start-up is less than
one minute. If noise persists for extended
time, verify proper fluid level. If fluid is
low, inspect for leaks.
SUCKING AIR SOUND 1. Loose clamp on power steering fluid 1. Tighten or replace hose clamp.
return hose.
SCRUBBING OR 1. Incorrect tire or wheel size. 1. Replace incorrect size tire or wheel
KNOCKING NOISE. with size used as original equipment.
2. Interference between steering gear 2. Check for bent or misaligned
and other vehicle components. components and correct as necessary.
3. Steering gear internal stops worn 3. Replace steering gear.
excessively allowing tires to be steered
excessively far.
* NOTE: There is some noise in all power steering ity fluid passes valve orifice edges. There is no
systems. One of the most common is a hissing relationship between this noise and the perfor-
sound evident when turning the steering wheel mance of the steering system.
when at a standstill or when parking and the steer-
ing wheel is at the end of its travel. Hiss is a very ** NOTE: Power steering pump growl results from the
high frequency noise similar to that experienced development of high pressure fluid flow. Normally this
while slowly closing a water tap. The noise is noise level should not be high enough to be objection-
present in every valve and results when high veloc- able.
STEERING WHEEL/ 1. Loose steering coupling pinch 1. Replace pinch bolt and torque to
COLUMN CLICKING, bolt. specifications.
CLUNKING OR RATTLING.
2. Steering column bearings. 2. Replace steering column.
STEERING WHEEL HAS 1. Steering wheel retaining nut not 1. Tighten the steering wheel retaining nut
FORE AND AFT properly tightened and torqued. to its specified torque.
LOOSENESS.
2. Steering column lower bearing 2. Replace steering column.
spring retainer slipped on steering
column shaft.
STEERING WHEEL OR 1. Air in the fluid of the power 1. Bleed air from system following the
DASH VIBRATES DURING steering system. power steering pump initial operation
LOW SPEED OR service procedure.*
STANDSTILL STEERING
MANEUVERS. 2. Tires not properly inflated. 2. Inflate tires to the specified pressure.
3. Excessive engine vibration. 3. Ensure that the engine is running
properly.
4. Loose tie rod end jam nut. 4. Tighten the inner to outer tie rod jam nut
to the specified torque.
5.Overcharged air conditioning 5.Check air conditioning pump head
system. pressure and correct as necessary.
STEERING CATCHES, 1. Low power steering fluid level. 1. Fill power steering fluid reservoir to
STICKS IN CERTAIN specified level and check for leaks.
POSITIONS OR IS 2. Tires not inflated to specified 2. Inflate tires to the specified pressure.
DIFFICULT TO TURN. pressure.
3. Lack of lubrication in front 3. Lubricate ball joints if ball joints are not a
suspension control arm ball joints. lubricated-for-life type ball joint. If ball joint
is a lubricated-for-life ball joint, replace ball
joint or control arm.
4. Worn lower control arm ball joint. 4. Replace lower control arm.
5. Lack of lubrication in steering gear 5. Lubricate tie rod ends if they are not a
outer tie rod ends. lubricated-for-life type. If tie rod end is a
lubricated-for-life type, replace tie rod end.
6. Loose power steering pump drive 6. Tighten the power steering pump drive
belt. belt to specifications. If drive belt is worn or
glazed, replace belt.
7. Faulty power steering pump flow 7. Replace power steering pump.
control (Follow Power Steering
System Flow and Pressure Test
procedure).
8. Excessive friction in steering 8. Isolate and correct condition.
column or intermediate shaft/coupler.
9. Binding lower control arm ball 9. Replace the lower control arm.
joint.
STIFF, HARD TO TURN, 1. Tires not properly inflated. 1. Inflate tires to specified pressure.
SURGE, MOMENTARY
INCREASE IN EFFORT 2. Low power steering fluid level. 2. Add power steering fluid as required to
WHEN TURNING. power steering fluid reservoir to obtain
proper level. Check for leaks.
3. Loose power steering pump drive 3. Tighten the power steering pump drive
belt. belt to specifications. If drive belt is worn or
glazed, replace belt.
4. Lack of lubrication in lower control 4. Lubricate ball joints if ball joints are not a
arm ball joints. lubricated-for-life type ball joint. If ball joint
is a lubricated-for-life ball joint, replace
lower control arm.
5. Low power steering pump 5. Replace the power steering pump as
pressure (Follow Power Steering necessary.
System Flow and Pressure Test
procedure).
6. High internal leak in power 6. Replace power steering gear.
steering gear (Follow Power Steering
System Flow and Pressure Test
procedure).
STEERING WHEEL DOES 1. Tires not inflated properly. 1. Inflate tires to specified pressure.
NOT RETURN TO 2. Improper front wheel alignment. 2. Check and adjust wheel alignment as
CENTER POSITION. necessary.
3. Lack of lubrication/binding in front 3. Lubricate ball joints if ball joints are not a
lower control arm ball joints. lubricated for life type of ball joint, then
inspect ball joint for wear, replace lower
control arm as necessary. If ball joint is a
lubricated for life ball joint, replace lower
control arm.
4. Steering column coupling joints 4. Realign steering column coupling joints.
misaligned.
5. Steering wheel rubbing.** 5. Adjust steering column shrouds to
eliminate rubbing condition.
6. Damaged, mis-positioned or 6. Replace, reposition, or lubricate dash
un-lubricated steering column seal.
coupler to dash seal.**
7. Binding seat and bearing in front 7. Replace seat and bearing in front strut
strut assembly. assembly.
8. Tight shaft bearing in steering 8. Replace the steering column.
column.
9. Excessive friction in steering 9. Replace steering column coupling.
column coupling.
10. Excessive friction in power 10. Replace power steering gear.
steering gear.
EXCESSIVE STEERING 1. Air in the fluid of the power 1. Bleed air from system following the the
WHEEL KICKBACK OR steering system. power steering pump initial operation
TOO MUCH STEERING service procedure.*
WHEEL FREE PLAY. 2. Power steering gear loose on 2. Inspect power steering gear mounting
crossmember. bolts. Replace as necessary. Tighten to the
specified torque.
3. Power steering gear housing 3. Replace power steering gear housing
isolator bushings worn. isolator bushings.
4. Steering column coupling or 4. Replace steering column coupling or
intermediate shaft worn, broken or intermediate shaft.
loose.
5. Free play in steering column. 5. Check all components of the steering
column and repair or replace as required.
6. Worn lower control arm ball joints. 6. Replace lower control arm as required.
7. Loose steering knuckle-to-ball joint 7. Inspect pinch bolt, replace as necessary,
stud pinch bolt. and tighten to specified torque.
8. Front wheel bearing loose or 8. Replace hub and bearing or knuckle as
worn. necessary.
9. Loose outer tie rod end. 9. Replace outer tie rod end that has
excessive free play.
10. Worn inner tie rod bushing. 10. Replace inner tie rod.
11. Defective steering gear rotary 11. Replace power steering gear.
valve.
* NOTE: Steering shudder can be expected in new ** NOTE: To evaluate this condition, it may be nec-
vehicles and vehicles with recent steering system essary to disconnect the coupling at the base of the
repairs. Shudder should dissipate after the vehicle steering column. Turn the steering wheel and feel or
has been driven several weeks. listen for internal rubbing in steering column. To
avoid damaging the column clockspring, note the
following. Before disconnecting coupling, place
tires in the straight-ahead position and center steer-
ing wheel. Once disconnected, DO NOT rotate
steering wheel more than one revolution in either
direction and place steering wheel in original loca-
tion before reconnecting coupling. If this position is
lost, the steering column clockspring must be
recentered following the procedure found within the
procedure for steering column installation in the
steering column section.
LOW FLUID LEVEL WITH 1. Loose power steering hose 1. Tighten the fitting to its specified torque.
VISIBLE LEAK. fittings.
AERATED FLUID. 1. Low fluid level.* 1. Fill power steering fluid reservoir to
proper level.
2. Air leak between power steering 2. Inspect for proper sealing. Replace the
fluid reservoir and pump. power steering pump (with reservoir).
3. Cracked power steering pump 3. Replace the power steering pump.
housing.
RESERVOIR FLUID 1. Water contamination. 1. Drain the power steering fluid from the
OVERFLOW AND FLUID system. Flush the system with fresh clean
THAT IS MILKY IN COLOR power steering fluid, drain, then refill to the
proper level.
Ft. In.
DESCRIPTION N·m
Lbs. Lbs.
Airbag Module Mounting
8 — 75
Bolts
Speed Control Switch
1.5 — 13
Screws
Puller C-4333
Steering Column Coupler
27 20 240
Pinch Bolt
Steering Column Mounting
12 — 105
Bolts
Steering Column Mounting
12 — 105
Nuts
Steering Wheel Retaining
61 45 —
Nut
Puller C-3894-A
SPECIAL TOOLS
POWER STEERING
Installer C-4063B
COLUMN
TABLE OF CONTENTS
page page
COLUMN OPERATION
Turning of the steering wheel mounted to the col-
DESCRIPTION umn shaft, is transferred down the shaft, through
This vehicle uses a tilt-type steering column (Fig. the upper coupler and intermediate shaft to the
1). Two styles are available, one is for floor shift vehi- power steering gear pinion shaft. The gear then
cles and the other is for column shift vehicles. moves the front strut assemblies steering the vehicle.
The steering column used on this vehicle (Fig. 1),
has been designed to be serviced as an assembly; less WARNING
wiring, switches, clockspring, gear shift lever, shift
ignition interlock, brake interlock solenoid (column WARNING: BEFORE BEGINNING ANY SERVICE
shift only), shrouds and steering wheel. These compo- PROCEDURES THAT INVOLVES REMOVING THE
nents can be serviced without removing the steering AIR BAG. REMOVE AND ISOLATE THE NEGATIVE
column from the vehicle. (-) BATTERY CABLE (GROUND) FROM THE VEHI-
CLE BATTERY. THIS IS THE ONLY SURE WAY TO
BRAKE TRANSMISSION SHIFT INTERLOCK DISABLE THE AIR BAG SYSTEM. FAILURE TO DO
THIS COULD RESULT IN ACCIDENTAL AIR BAG
SOLENOID
DEPLOYMENT AND POSSIBLE PERSONAL INJURY.
Column shift vehicles have a brake transmission
shift interlock (BTSI) solenoid mounted on the steer-
ing column. The BTSI solenoid works in conjunction WARNING: WHEN AN UNDEPLOYED AIRBAG MOD-
with the brake lamp switch and will not allow the ULE IS TO BE REMOVED FROM THE STEERING
steering column shift lever to be moved out of the WHEEL, DISCONNECT BATTERY GROUND CABLE
PARK position without the brake pedal being AND ISOLATE. ALLOW SYSTEM CAPACITOR TO
applied. For Description And Operation, Diagnosis DISCHARGE FOR A MINIMUM OF TWO MINUTES,
And Testing, and Removal And Installation informa- THEN BEGIN AIRBAG REMOVAL.
tion, refer to the Transaxle section in this service
manual.
(21) Remove the wiring harness connectors from (23) If the vehicle is equipped, disconnect the wire
the clockspring (Fig. 16). harness connector at the SKIM module. Remove the
mounting screw and unclip the module from the key
cylinder halo bezel.
(24) Remove the wiring harness from the routing
clip on the top of the multi-function switch. Remove
the 2 screws (Fig. 18) mounting the multi-function
switch to the steering column. Remove the multi-
function switch, with the wiring harness attached,
from the steering column.
Fig. 23 Shift Cable Removal (31) Remove retaining pin in steering column cou-
pler pinch bolt (Fig. 26). Remove the pinch bolt from
1 - STEERING COLUMN
2 - SCREWDRIVER the steering column coupler. The pinch bolt nut is
3 - PIN caged to coupler and is not removable. Separate the
4 - SHIFT CABLE
5 - SHIFTER MECHANISM
steering column flex coupler from steering intermedi-
ate shaft.
(29) Remove the shift cable mounting bracket (Fig.
24) from the steering column. The shift cable mount-
ing bracket is mounted to the steering column by the
2 mounting screws (Fig. 24).
INSTALLATION
The ignition switch attaches to the lock cylinder
housing on the end opposite the lock cylinder. For Fig. 34 Ignition Switch Alignment
ignition switch terminal and circuit identification, 1 - IGNITION SWITCH
refer to the Wiring Diagrams section. 2 - TAB
3 - NOTCH
(1) A tab on the ignition switch indexes to a notch 4 - SHAFT
in the lock cylinder housing (Fig. 34). Also, a slot in
the end of the ignition switch fits over the shaft in
INTERMEDIATE SHAFT
DIAGNOSIS AND TESTING - STEERING
COLUMN INTERMEDIATE SHAFT
The steering column (to steering gear) intermedi-
ate shaft has an integrated lower coupler with uni-
versal joint. The entire assembly MUST be replaced
whenever any of the following conditions exist.
• Whenever a vehicle is involved in a collision
which deploys the airbag, regardless of the extent of
damage done to the vehicle.
• If a vehicle is involved in an impact of the vehi-
cle’s front suspension or undercarriage, which results
in any type of damage to the front crossmember.
• Under any conditions which result in the steer-
ing column assembly or steering column shaft receiv- Fig. 35 IGNITION LOCK CYLINDER DETENTS
ing a force great enough to move the steering column
or shaft forward or rearward in the vehicle. (2) Remove the tilt lever attaching screw. Remove
Inspect the intermediate shaft and integrated cou- lever.
pler for the following conditions: (3) Remove the upper and lower covers from the
• Seized bearing steering column.
• Loose bearing stake (4) Turn the ignition key to the run position. When
• Bearing not seated properly ignition switch is in the run position, the lock cylin-
The steering column intermediate shaft MUST be der retaining tab will depress.
replaced as an entire assembly if a problem condition (5) Depress tab and slide lock cylinder out of hous-
is found. ing (Fig. 36).
KEY/LOCK CYLINDER
DESCRIPTION
The lock cylinder is inserted in the end of the
housing opposite the ignition switch.
OPERATION
The ignition key rotates the cylinder to 5 different
detents (Fig. 35) :
• Accessory
• Off (lock)
• Unlock
• On/Run
• Start
Fig. 36 Lock Cylinder Removal
REMOVAL 1 - TAB
The lock cylinder is inserted in the end of the 2 - KEY IN RUN POSITION
housing opposite the ignition switch. The ignition key
rotates the cylinder to 5 different detents:
(1) Disconnect negative cable from battery.
SHROUD - LOWER (4) Remove the wiring harness connector from the
trunk release switch in the lower instrument panel
cover (Fig. 44).
REMOVAL
(1) Remove the fuse panel cover from the left end
of the instrument panel (Fig. 42).
SHROUD - UPPER
REMOVAL
CAUTION: The upper shroud is retained to the
steering column by a snap fit to the lower shroud.
When removing the upper shroud from the lower
shroud, DO NOT use a hard or sharp tool. This will
damage the shrouds. If a tool must be used, use a
soft tool such as a trim stick.
STEERING COUPLING
DIAGNOSIS AND TESTING - STEERING
COLUMN SHAFT UPPER COUPLER
If the steering column shaft upper coupler is diag-
nosed to be defective due to any of the following con-
ditions: seized bearing, loose bearing stake or a
bearing not fully seated in the yoke of the coupler
assembly, the coupler can be serviced as a separate
component of the steering column assembly.
REMOVAL
(1) Remove steering column assembly from vehicle.
Refer to the Steering Column Removal.
(2) Install Puller, Special Tool 6831-A, through Fig. 48 Tool Set-Up For Installing Roll Pin
center of roll pin in flex coupler and install knurled 1 - SPECIAL TOOL 6831–A
nut (Fig. 47). 2 - ROLL PIN
3 - KNURLED NUT
4 - FLEX COUPLER
STEERING WHEEL
REMOVAL
(1) Place the front road wheels in the straight-
ahead position, then:
(a) Rotate the steering wheel one-half turn (180
degrees) to the right (clockwise).
(b) Lock column in place with the ignition cylin-
der lock.
Fig. 47 Removing Roll Pin NOTE: The steering column on vehicles with an
1 - ROLL PIN automatic transmission may not be equipped with
2 - KNURLED NUT
3 - FLEX COUPLER an internal locking shaft that allows the ignition key
4 - SPECIAL TOOL 6831–A cylinder to be locked with the key. Alternative meth-
5 - STEERING COLUMN ods of locking the steering wheel for service will
have to be used.
(3) While holding hex on end threaded rod, tighten
the nut on threaded rod of Puller, Special Tool (2) Open hood and disconnect the negative battery
6831-A. This will pull the roll pin out of the coupler. cable remote terminal from the remote battery post.
(4) Remove the coupler from the steering column (3) Wait two minutes for the reserve capacitor to
shaft discharge before removing non-deployed airbag.
INSTALLATION
(1) Confirm that:
• The steering wheel position is a half turn (180
degrees) to the right (clockwise).
• The column is locked with the ignition cylinder lock.
• Check that the turn signal stalk is in the neu-
tral position.
WARNING: DO NOT CONNECT THE BATTERY NEG- (3) Remove the lower instrument panel cover. The
ATIVE CABLE REMOTE TERMINAL AT THIS TIME. lower instrument panel cover is attached by retain-
REFER TO ELECTRICAL, RESTRAINTS, AIRBAG ing clips along the top and right edge.
SYSTEM TEST FOR PROCEDURE.
INSTALLATION
(1) Install new shift lever assembly on tilt housing
of steering column. Install and securely tighten the 3
Torxt head screws attaching shift lever assembly to
tilt housing.
(2) Install the gear shift cable onto the cable
attaching pin on shift lever assembly.
(3) Lock the gear shift cable adjuster.
(4) Install the brake transmission interlock sole-
noid on the shift lever mechanism. To do so, perform
the following:
(a) Align the flat inside the solenoid (Fig. 55)
with the flat on the shift lever mounting stud.
(b) Slide the solenoid completely onto the shift
lever mounting stud aligning the plastic guide
formed into the solenoid housing with the flange on
the shift lever mechanism bracket (Fig. 56). Fig. 56 Guide And Flange Alignment
(c) Install the retainer clip until it snaps into 1 - BRACKET FLANGE
place in the slot cut into the shift lever mounting 2 - GUIDE
stud (Fig. 57).
(d) Verify the solenoid is locked in place and will
not slide off the mounting stud.
(e) Connect the wiring harness connector to the
solenoid.
GEAR
TABLE OF CONTENTS
page page
Fig. 10 Wiring Harness Fig. 12 Tie Rod Attachment Bolt Retaining Tabs
1 - SPEED PROPORTIONAL STEERING SOLENOID CONNECTOR 1 - STEERING GEAR
2 - MASTER CYLINDER RESERVOIR 2 - TIE RODS
3 - RETAINING TABS
(12) Remove the two nuts mounting the master 4 - BOLTS
5 - PLATE
cylinder to the vacuum booster (Fig. 11).
Fig. 21 Required Tire Position (c) To remove the steering gear from the vehicle,
1 - LEFT FRONT TIRE pull the steering gear toward the passenger side of
the vehicle out from between the cowl and the
(30) Remove the steering gear from the vehicle engine.
using the following steps.
(a) Slide the end of the steering gear through
the tie rod hole in the right side inner fender (Fig.
22). Steering gear needs to be slid through tie rod
hole until about half of the steering gear is through
the hole (Fig. 22).
DISASSEMBLY - POWER STEERING GEAR toms in the recessed area of the steering gear hous-
ing.
(HOUSING BUSHINGS)
The power steering gear must be removed from the
vehicle for the bushings to be serviced. Refer to
REMOVAL in this section.
(1) Install the Receiver, Special Tool 8523-2, into
the cup of the Ball Joint Press, Special Tool C-4212F,
and tighten the set screw. Install the Driver, Special
Tool 8523-1, on the tip of the Ball Joint Press screw
drive.
(2) Place the power steering gear housing against
the Receiver (Fig. 24). Tighten the screw drive until
the Driver contacts the outer circumference of the
bushing evenly (Fig. 24). Continue to tighten the
screw drive until the bushing is pressed completely
out of the steering gear housing.
(3) Back off the Ball Joint Press screw drive and
remove the power steering gear from the press.
(4) Repeat the above procedure on the other power
steering gear housing bushing.
ASSEMBLY- POWER STEERING GEAR (2) Install the right tie rod through the tie rod hole
in the inner fender.
(HOUSING BUSHINGS) (3) Install the outer tie rod on the steering arm of
(1) Install the Receiver, Special Tool 8523-2, into the right strut. Install the tie rod to steering arm
the cup of the Ball Joint Press, Special Tool C-4212F, attaching nut (Fig. 19). Tighten the attaching nut to
and tighten the set screw. Install the Driver, Special a torque of 37 N·m (27 ft. lbs.).
Tool 8523-1, on the tip of the Ball Joint Press screw (4) Install the right side tire/wheel.
drive. (5) Install and tighten wheel mounting stud nuts
(2) Place the steering gear housing against the in proper sequence until all nuts are torqued to half
Receiver in a way that the Receiver does not come in specification. Then repeat the tightening sequence to
contact with the support ribs on the gear housing the full specified torque of 135 N·m (100 ft. lbs.).
(Fig. 25). Start the bushing in the bottom of the (6) Lower the vehicle until the front tires are just
housing and tighten the screw drive until the Driver clear of the floor.
contacts the bushing retainer washer (Fig. 25). (7) Install the intermediate steering shaft on the
Slowly tighten the screw drive until the bushing bot- steering gear.
SPEED PROPORTIONAL
STEERING SOLENOID
DESCRIPTION - SOLENOID CONTROL VALVE
Fig. 28 Tie Rod Attachment The solenoid control valve is mounted on the speed
proportional power steering gear housing (Fig. 2).
1 - RETAINING TABS
2 - BOLTS
3 - RETAINING PLATE OPERATION - SOLENOID CONTROL VALVE
4 - STEERING GEAR
5 - WASHER
Variable-effort power steering is provided by con-
6 - TIE RODS trolling power steering fluid pressure at the power
7 - WASHER steering gear. A solenoid control valve located on the
steering gear (Fig. 2) is used to control power steer-
(17) Install the vacuum hose for the power brake ing gear return fluid pressure. The pressure is con-
booster on intake manifold vacuum port. Install hose trolled by varying the size of an orifice.
clamp on vacuum hose. The variable-assist speed-proportional solenoid con-
(18) Install the master cylinder on the power trol valve is controlled by the Body Control Module
brake vacuum booster. Install the two nuts attaching (BCM). The BCM receives the vehicle speed signal
the master cylinder to the booster. Tighten the mas- sent from the Powertrain Control Module (PCM).
ter cylinder mounting nuts to a torque of 28 N·m Upon receiving the vehicle speed signal from the
(250 in. lbs.). PCM, the BCM converts that speed signal into an
(19) Connect wire connector to the brake fluid electrical current usable by the solenoid control valve
level switch on the side of the master cylinder fluid for controlling the variable effort of the power steer-
reservoir. ing system.
(20) Install the in-line resonator and inlet hose The solenoid control valve is a serviceable compo-
(Fig. 9) on the throttle body and air inlet hose com- nent of the variable-effort, speed-proportional power
ing from the lid of the air cleaner housing. steering gear assembly.
(21) Install the cowl reinforcement on the vehicle
(Fig. 8). Install the eight bolts attaching the rein- REMOVAL - SOLENOID CONTROL VALVE
forcement to the strut towers. Install the bolt attach- (1) Disconnect the solenoid control valve electrical
ing the wiper module to the reinforcement. connector from the wiring harness at the power
(22) Install the covers (Fig. 7) over the wiper mod- steering gear end cap below the brake master cylin-
ule and the cowl. Install and securely tighten the der (Fig. 29).
attaching screws. (2) Unclip the connector from the gear end cap.
Fig. 37 In-Line Resonator And Air Inlet Hose Fig. 39 Removing Outer Tie Rod From Steering Arm
1 - AIR INLET HOSE 1 - TIE ROD END
2 - THROTTLE BODY 2 - STEERING ARM
3 - AIR INLET HOSE 3 - STRUT
4 - AIR CLEANER HOUSING LID 4 - C-3894A
5 - RESONATOR
6 - IN-LINE RESONATOR (11) Turn the steering wheel all the way to the full
right position.
(7) Raise the vehicle on a frame contact hoist until (12) Bend back the retaining tabs on the mounting
the front tires of the vehicle are just off the floor. See plate for the tie rod to steering gear mounting bolts
Hoisting in Lubrication And Maintenance. (Fig. 40).
(8) Remove front wheel and tire assembly from
side requiring repair.
(9) Remove the nut attaching the outer tie rod end
to the steering arm on the strut (Fig. 38).
1 - TIE RODS
2 - BOLTS (2) Install the tie rod assembly through the tie rod
3 - MOUNTING PLATE hole in the wheel opening inner fender.
4 - WASHERS (3) Install the outer tie rod on the steering arm of
5 - STEERING GEAR
the strut. Install the tie rod steering arm nut (Fig.
(15) Rotate the loose end of the mounting plate out 38). Do not tighten the nut at this time.
of the way.
CAUTION: Before installing tie rod on steering gear
(16) Remove the tie rod assembly from the vehicle
be sure the tie rod spacer block inside the steering
through the wheel opening.
gear bellows (boot) is correctly aligned with the bolt
(17) Loosen the pinch bolt at the outer to inner tie
holes in the rack of the steering gear and the steer-
rod adjustment sleeve.
ing gear bellows (Fig. 43).
(18) Remove outer tie rod from adjustment sleeve
and inner tie rod.
Fig. 49 Tie Rod Thread Engagement Requirements Fig. 50 Correctly Isolated Remote Ground Cable
1 - OUTER TIE ROD 1 - CABLE ISOLATOR
2 - ADJUSTER 2 - GROUND STUD
3 - PINCH BOLT 3 - GROUND CABLE
4 - INNER TIE ROD
5 - ALLOWABLE THREADS EXPOSED ON OUTER TIE ROD AND (2) Remove caps from both wiper arms at the
ADJUSTER IS A MAXIMUM OF 20 MILLIMETERS. REFER TO
AREA INDICATED ABOVE ON THE OUTER TIE ROD AND attachment to the pivots to expose the wiper arm
ADJUSTER. attaching nut. Remove the nut attaching each wiper
arm to its pivot (Fig. 51).
CAUTION: When torquing the adjuster pinch bolt,
the following procedure must be followed to ensure
adequate retention of the adjuster is obtained. Not
following this procedure, could result in the Toe
Setting Adjustment changing and/or the separation
of the outer tie rod from the inner tie rod.
(5) Remove the eight bolts attaching the cowl rein- Fig. 54 In-Line Resonator And Air Inlet Hose
forcement to the strut towers and the one bolt 1 - AIR INLET HOSE
attaching the wiper module to the reinforcement 2 - THROTTLE BODY
(Fig. 53). Remove the reinforcement from the vehicle. 3 - AIR INLET HOSE
4 - AIR CLEANER HOUSING LID
5 - RESONATOR
6 - IN-LINE RESONATOR
(11) Turn the steering wheel all the way to the (15) Rotate the loose end of the mounting plate out
full-right position. of the way.
(12) Bend back the retaining tabs on the mounting (16) Remove the tie rod assembly from the vehicle
plate for the tie rod to steering gear mounting bolts through the wheel opening.
(Fig. 57). (17) Mount Receiver, Special tool 8438–1, in a vise
as shown (Fig. 59).
(18) Assemble Special Tool 8438 in the following
manner to remove the bushing from the inner tie
rod.
(a) Place the inner tie rod bushing end in the
Receiver as shown (Fig. 59).
(b) Place Remover/Installer, Special Tool 8438–4,
with the small end down on top of the bushing
(Fig. 59).
(c) Insert Screw, Special Tool 8438–3, though the
Remover/Installer and tie rod bushing, until it
threads into the bottom of the Receiver.
(d) Using hand tools, tighten the Screw until it
bottoms out. The bushing is now removed from the
inner tie rod.
(19) Remove the Screw, then remove the Remover/
Installer, tie rod and bushing from the Receiver.
Fig. 57 Tie Rod Attachment Bolt Retaining Tabs
1
2
-
-
STEERING GEAR
TIE RODS
INSTALLATION - INNER TIE ROD BUSHING
3 - RETAINING TABS
4 - BOLTS NOTE: When servicing inner tie rod bushings,
5 - PLATE replacement of bushings on both inner tie rods is
recommended.
(13) Remove the bolt fastening the inner tie rod to
the steering gear (Fig. 58). Be careful not to loose the (1) Using Mopart Silicone Spray Lubricant, spray
washer behind the tie rod. bushing, inner tie rod end, and inside of Sizer, Spe-
cial Tool 8438–2.
(6) Install the tie rod assembly through the tie rod
hole in the wheel opening inner fender.
(7) Install the outer tie rod on the steering arm of
the strut. Install the tie rod steering arm nut (Fig.
55). Do not tighten the nut at this time. Fig. 64 Tie Rod Attachment
CAUTION: Before installing tie rod on steering gear 1 - RETAINING TABS
2 - BOLTS
be sure the tie rod spacer block inside the steering 3 - RETAINING PLATE
gear bellows (boot) is correctly aligned with the bolt 4 - STEERING GEAR
holes in the rack of the steering gear and the steer- 5 - WASHER
6 - TIE RODS
ing gear bellows (Fig. 63). 7 - WASHER
(8) Align the inner tie rod with the mounting hole in
the center take off on steering gear. Rotate the mount-
ing plate into position over the tie rod. Install tie rod
attaching bolt through tie rod and washer into steering
gear. Be sure washer is installed between tie rod
and steering gear as shown (Fig. 64).
PUMP
TABLE OF CONTENTS
page page
PUMP REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 66
DESCRIPTION . . . . . . . . . . . . . . . . . . . . . . . . . 58 INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . 66
OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . . 59 HOSES
STANDARD PROCEDURE - POWER DESCRIPTION . . . . . . . . . . . . . . . . . . . . . . . . . 67
STEERING PUMP INITIAL OPERATION . . . . . 59 OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . . 67
REMOVAL REMOVAL - PRESSURE AND RETURN
REMOVAL - PUMP (2.7L ENGINE) . . . . . . . . . 60 HOSES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 67
REMOVAL - PUMP (3.5L ENGINE) . . . . . . . . . 61 INSTALLATION - PRESSURE AND RETURN
DISASSEMBLY - PUMP (PULLEY) .... . . . . . . 63 HOSES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 71
ASSEMBLY - PUMP (PULLEY) . . . . . . . . . . . . . 63 RESERVOIR
INSTALLATION DESCRIPTION . . . . . . . . . . . . . . . . . . . . . . . . . 72
INSTALLATION - PUMP (2.7L ENGINE) . . . . . 64 OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . . 72
INSTALLATION - PUMP (3.5L ENGINE) . . . . . 64 REMOVAL
SPECIFICATIONS REMOVAL - RESERVOIR (2.7L ENGINE) . . . . 73
POWER STEERING PUMP FLOW . . . . . . . . . 65 REMOVAL - RESERVOIR (3.5L ENGINE) . . . . 73
FLUID INSTALLATION
STANDARD PROCEDURE - POWER INSTALLATION - RESERVOIR (2.7L
STEERING FLUID LEVEL CHECKING . . . . . . 65 ENGINE) . . . . . . . . . . . . . . . . . . . . . . . . . . . . 74
FLUID COOLER INSTALLATION - RESERVOIR (3.5L
DESCRIPTION . . . . . . . . . . . . . . . . . . . . . . . . . 65 ENGINE) . . . . . . . . . . . . . . . . . . . . . . . . . . . . 74
OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . . 65
PUMP
DESCRIPTION
Hydraulic pressure for the operation of the power
steering system is provided by a belt driven rotary
power steering pump. The power steering pump is a
constant flow rate and displacement vane type pump.
Vehicles equipped with the 2.7 liter engine use a
power steering pump that has an integral reservoir
for the power steering fluid (Fig. 1). Vehicles
equipped with the 3.5 liter engine use a power steer-
ing pump (Fig. 2) that has a remotely mounted res-
ervoir for the power steering fluid.
Both power steering pumps mount to the front of
the engine on the driver’s side.
The service procedures for the power steering Fig. 1 Power Steering Pump (2.7L Engine)
pump are limited to the areas and components listed 1 - POWER STEERING FLUID RESERVOIR
below. 2 - POWER STEERING PUMP PRESSURE FITTING
• Power steering fluid reservoirs, related compo- 3 - POWER STEERING PUMP
nents and attaching hardware.
• Power steering pump pulley. power steering fluid leak from any area of the power
No repair procedures are to be done on the internal steering pump is not allowed.
components of the power steering pump. Repair of a
Fig. 2 Power Steering Pump (3.5L Engine) STANDARD PROCEDURE - POWER STEERING
1 - POWER STEERING PUMP
2 - PUMP PRESSURE FITTING
PUMP INITIAL OPERATION
3 - FLUID SUPPLY FITTING
WARNING: THE FLUID LEVEL SHOULD BE
OPERATION CHECKED WITH ENGINE OFF TO PREVENT INJURY
The Power steering pump operates as follows. A FROM MOVING COMPONENTS.
belt driven pulley turns a shaft which drives a rotor.
Rectangular pumping vanes carried by the shaft CAUTION: Use only MoparT ATF+4 Automatic Trans-
driven rotor move the fluid from the intake to the mission Fluid (MS-9602). Do not overfill.
cam ring pressure cavities. As the rotor begins to
turn, centrifugal force throws the vanes against the Wipe the power steering fluid reservoir and filler
inside surface of the cam ring to pickup residual oil. cap clean. Check the level of the power steering fluid
This oil is then forced into the high pressure area. As in the reservoir. The power steering fluid level should
more oil is picked up by the vanes, the additional oil be between MAX. COLD and MIN. COLD when the
is forced into the cavities of the thrust plate through fluid is at a normal ambient temperature of approxi-
two crossover holes in the cam ring and pressure mately 32°C to 43°C (90°F to 110°F).
plate. The crossover holes empty into the high pres- (1) Fill the pump fluid reservoir to the proper level
sure area between the pressure plate and the hous- and let the fluid settle for at least two (2) minutes.
ing end cover. (2) Start the engine and let run for a few seconds.
When the high pressure area of the power steering Then turn the engine off.
pump is filled with power steering fluid, the fluid (3) Add fluid if necessary. Repeat the above proce-
flows under the vanes in the rotor slots, forcing the dure until the fluid level remains constant after run-
vanes to follow the inside oval surface of the cam ning the engine.
ring. As the vanes reach the restricted area of the (4) Raise the front wheels off the ground.
cam ring, oil is forced out from between the vanes. (5) Start the engine. Slowly turn the steering
When excess oil flow is generated during high-speed wheel right and left, lightly contacting the wheel
operation, a regulated amount of oil returns to the stops for less than 2 seconds at a time.
pump intake side through a flow control valve. The (6) Add power steering fluid if necessary.
flow control valve reduces the power required to (7) Lower the vehicle and turn the steering wheel
drive the pump and holds down temperature build- slowly from lock to lock.
up. (8) Stop the engine. Check the fluid level and refill
When steering conditions exceed maximum pres- as required.
sure requirements, such as turning the wheels (9) If the fluid is extremely foamy, allow the vehi-
against the stops, the pressure built up in the steer- cle to stand a few minutes and repeat the above pro-
ing gear also exerts pressure on the spring end of the cedure.
flow control valve. The end of the valve houses the (10) Lower the vehicle.
pressure relief valve. High pressure lifts the relief
REMOVAL
REMOVAL - PUMP (2.7L ENGINE)
(1) Remove the battery ground cable from the
ground stud on the shock tower and isolate the
ground cable by installing the cable isolator on the
ground stud (Fig. 3).
(1) Place the power steering pump pulley on the (3) Insert the Pulley Installer, Special Tool C-4063,
end of the power steering pump shaft. Make sure the (without adapters) through hole in spacer. Thread
pulley is installed squarely on the end of the shaft.
SPECIFICATIONS
POWER STEERING PUMP FLOW
SPECIFICATIONS
DESCRIPTION SPECIFICATION
Flow At 1500 RPM And 8.0 – 9.5 Liters/Min.
Minimum Pressure 2.1 – 2.5 GPM
Control Valve Relief 8618 – 9308 kPa
Pressure 1250 – 1350 psi
FLUID
STANDARD PROCEDURE - POWER STEERING
Fig. 17 Fluid Reservoir (3.5L Engine)
FLUID LEVEL CHECKING
1 - POWER STEERING FLUID RESERVOIR
2 - MIN. COLD LEVEL
WARNING: FLUID LEVEL SHOULD BE CHECKED 3 - MAX. COLD LEVEL
WITH ENGINE OFF TO PREVENT INJURY FROM 4 - MAX. HOT LEVEL
MOVING PARTS.
FLUID COOLER
Wipe off the power steering fluid reservoir so that
it is free of dirt (Fig. 16) (Fig. 17). Check the fill level
DESCRIPTION
of the fluid in the reservoir according to the mark-
All models of this vehicle are equipped with a
ings on the side of the reservoir. Measure the MAX.
cooler for the power steering system fluid (Fig. 18).
COLD/MIN. COLD fluid levels when the fluid is at
The power steering fluid cooler is located at the front
normal ambient temperature, approximately 32°C to
of the vehicle. It is mounted to the radiator lower
43°C (90°F to 110°F). Add fluid as necessary and do
support just forward of the air-conditioning con-
not overfill.Use only Mopart ATF+4 Automatic
denser and just rearward of the front fascia (Fig. 18).
Transmission Fluid in this power steering sys-
The cooler is positioned so it is in the air flow
tem.
through the front fascia of the vehicle.
OPERATION
Fig. 16 Fluid Reservoir (2.7L ENGINE) The purpose of the power steering fluid cooler is to
1 - POWER STEERING FLUID RESERVOIR keep the temperature of the power steering system
2 - MAX. COLD LEVEL fluid from rising to a level that would affect the per-
3 - MIN. COLD LEVEL
4 - MAX. HOT LEVEL formance of the power steering system.
The cooler used on this vehicle is referred to as a
fluid-to-air type cooler. This means that the air flow
across the tubes of the cooler is used to extract the
REMOVAL
(1) Using a siphon pump, remove as much power
steering fluid as possible from the power steering
fluid reservoir. Fig. 21 Air Dam Retaining Clips
(2) Raise vehicle using a frame contact type hoist
1 - RETAINING CLIPS
or supported using jack stands. See Hoisting in 2 - AIR DAM
Lubrication And Maintenance.
(3) 300M only - The front fascia will require (7) Remove the 2 nuts (Fig. 22) attaching the
removal to access the power steering cooler. See power steering fluid cooler to the radiator lower
Frames and Bumpers. crossmember.
(4) Remove the hose clamp from the lower hose at
the power steering fluid cooler (Fig. 19). Remove the
lower hose from the power steering fluid cooler.
Drain remaining power steering fluid from the hoses
and the power steering fluid cooler.
Fig. 19 Lower Hose At Power Steering Fluid Cooler Fig. 22 Cooler Attachment
1 - POWER STEERING FLUID COOLER 1 - POWER STEERING FLUID COOLER
2 - HOSE CLAMP 2 - FASCIA
3 - LOWER HOSE 3 - NUT
4 - RADIATOR LOWER SUPPORT
(5) Remove the hose clamp and upper hose (Fig. 5 - NUT
6 - AIR DAM
20) from the power steering fluid cooler.
(8) Remove the power steering fluid cooler from
the radiator lower crossmember.
INSTALLATION
(1) Install the power steering fluid cooler on the
radiator lower crossmember.
(2) Install the 2 nuts (Fig. 22) attaching the power
steering fluid cooler to the radiator lower crossmem-
ber. Tighten the attaching nuts to a torque of 10 N·m
(89 in. lbs.)
Fig. 20 Upper Hose At Power Steering Fluid Cooler
(3) Install the air dam on the radiator lower sup-
1 - HOSE CLAMP
2 - UPPER HOSE
port. Attach the air dam to the radiator lower sup-
3 - POWER STEERING FLUID COOLER port using new retaining clips.
(4) Install power steering fluid hoses (Fig. 20) and
(Fig. 19) on the power steering fluid cooler. Be sure
HOSES
DESCRIPTION
The power steering fluid hoses connect the compo-
nents of the power steering system.
The power steering fluid supply hose (3.5L engine
only) is a special rubber hose that connects the power Fig. 23 Correctly Isolated Remote Ground Cable
steering fluid reservoir to the power steering pump. 1 - CABLE ISOLATOR
The hose is secured at each end using a standard 2 - GROUND STUD
adjustable clamp. 3 - GROUND CABLE
The power steering fluid pressure hose is a high
pressure hose that connects the power steering pump
to the gear. At both ends of the flexible hose portion
are steel fittings. A tube nut fitting with an O-ring is
used at each end to connect it to either the power
steering pump or the gear.
The power steering fluid return hose is a special
rubber hose that connects the power steering gear
and the power steering fluid cooler, back to the fluid
reservoir. A standard tube nut fitting with an O-ring
is used to connect it to the power steering gear. The
Fig. 24 Wiper Arm Attachment To Pivot
hose is secured to the cooler and reservoir using
1 - WIPER ARMS
standard adjustable clamps. 2 - ATTACHING NUT
3 - ATTACHING NUT
OPERATION
The power steering fluid hoses transfer fluid from (5) Remove the wiper arms from the pivots. Wiper
one power steering system component to the next. arms are removed from the pivots by rocking them
back and force on the pivots until they can be pulled
REMOVAL - PRESSURE AND RETURN HOSES off the pivots.
(1) Remove the battery ground cable from the (6) Remove the wiper module cover and cowl cover
ground stud on the shock tower and isolate the (Fig. 25).
ground cable by installing the cable isolator on the
ground stud (Fig. 23).
(2) Position the front tires of the vehicle so that
they are facing straight-ahead.
(3) Raise the vehicle on a frame contact type hoist
until the front tires of the vehicle are just off the
floor. See Hoisting in the Lubrication and Mainte-
nance section of this manual for the required lifting
procedure to be used for this vehicle.
(4) Remove caps from both wiper arms at the
attachment to the pivots to expose the wiper arm Fig. 25 Wiper Module And Cowl Cover
attaching nuts. Remove the nut (Fig. 24)attaching 1 - COWL COVER
each wiper arm to its pivot 2 - WIPER MODULE COVER
NOTE: The following step should be done to pre- Fig. 33 Power Steering Hose Connections
vent excessive spilling of power steering fluid when At Steering Gear
the power steering fluid lines are removed from the 1 - POWER STEERING FLUID RETURN HOSE
steering gear. 2 - STEERING GEAR
3 - MASTER CYLINDER FLUID RESERVIOR
4 - POWER STEERING FLUID PRESSURE HOSE
RESERVOIR
DESCRIPTION
Vehicles equipped with the 2.7 liter engine use a
power steering pump that has an integral reservoir
(Fig. 1). Vehicles equipped with the 3.5 liter engine
use a power steering pump that has a remotely
mounted reservoir (Fig. 41).
REMOVAL
REMOVAL - RESERVOIR (2.7L ENGINE)
The 2.7 liter engine uses a power steering fluid
reservoir that is integral to the power steering pump.
To replace the power steering fluid reservoir used on
this power steering pump the power steering pump
will need to be removed from the engine.
(1) Remove the power steering pump from the
engine. (Refer to 19 - STEERING/PUMP -
REMOVAL)
(2) Remove the 3 bolts (Fig. 42) mounting the
power steering fluid reservoir to the power steering
pump.
TRANSAXLE
TABLE OF CONTENTS
page page
The process of elimination can be used to detect be determined. Practically any condition can be
any unit which slips and to confirm proper operation caused by leaking hydraulic circuits or sticking
of good units. Road test analysis can diagnose slip- valves.
ping units, but the cause of the malfunction cannot
Fig. 4 Pressure Taps (1) Attach gauge to the overdrive clutch tap.
1 - TORQUE CONVERTER CLUTCH OFF (2) Move selector lever to the OD position.
2 - TURBINE SPEED SENSOR (3) Allow vehicle wheels to turn and increase
3 - OUTPUT SPEED SENSOR throttle opening to achieve an indicated vehicle speed
4 - LOW/REVERSE
5 - REVERSE of 20 mph.
6 - UNDERDRIVE (4) Overdrive clutch pressure should read 74 to 95
7 - TORQUE CONVERTER CLUTCH ON
8 - OVERDRIVE
psi.
(5) Move selector lever to the 3 position and
TEST ONE-SELECTOR IN L (1st Gear) increase indicated vehicle speed to 30 mph.
(6) The vehicle should be in second gear and over-
NOTE: This test checks pump output, pressure reg- drive clutch pressure should be less than 5 psi.
ulation and condition of the low/reverse clutch
hydraulic circuit and shift schedule. TEST FOUR-SELECTOR IN OD (Fourth Gear)
(1) Attach pressure gauge to the low/reverse clutch NOTE: This test checks the 2/4 clutch hydraulic cir-
tap. cuit.
(2) Move selector lever to the L position.
(3) Allow vehicle wheels to turn and increase (1) Attach gauge to the 2/4 clutch tap.
throttle opening to achieve an indicated vehicle speed (2) Move selector lever to the OD position.
to 20 mph. (3) Allow vehicle front wheels to turn and increase
(4) Low/reverse clutch pressure should read 115 to throttle opening to achieve an indicated vehicle speed
145 psi. of 30 mph. Vehicle should be in fourth gear.
(4) The 2/4 clutch pressure should read 75 to 95
psi.
ALL PRESSURE SPECIFICATIONS ARE PSI (ON HOIST, WITH FRONT WHEELS FREE TO TURN)
DIAGNOSIS AND TESTING - CLUTCH AIR to the low/reverse or the 2/4 clutches. This locks the
output shaft. Use a piece of rubber hose wrapped
PRESSURE TESTS
around the input shaft and a pair of clamp-on pliers
Inoperative clutches can be located by substituting
to turn the input shaft. Next apply air pressure to
air pressure for fluid pressure. The clutches may be
the underdrive clutch (Fig. 6). The input shaft should
tested by applying air pressure to their respective
not rotate with hand torque. Release the air pressure
passages after the valve body has been removed. Use
and confirm that the input shaft will rotate.
Special Tool 6599-1 and 6599-2 to perform test (Fig.
5).
REVERSE CLUTCH
Apply air pressure to the reverse clutch apply pas-
sage and watch for the push/pull piston to move rear-
Fig. 5 Air Pressure Test Plate ward. The piston should return to its starting
1 - AIR PRESSURE TEST PLATES position when the air pressure is removed.
2 - 2/4 CLUTCH RETAINER HOLE
2/4 CLUTCH
To make air pressure tests, proceed as follows: Apply air pressure to the feed hole located on the
2/4 clutch retainer. Look in the area where the 2/4
NOTE: The compressed air supply must be free of piston contacts the first separator plate and watch
all dirt and moisture. Use a pressure of 30 psi. carefully for the 2/4 piston to move rearward. The
piston should return to its original position after the
Remove oil pan and valve body. See Valve body
air pressure is removed.
recondition.
Apply air pressure to the holes in the special tool,
LOW/REVERSE CLUTCH
one at a time.
Apply air pressure to the low/reverse clutch feed
Listen for the clutch to apply. It will give a slight
hole passage. Look in the area where the low/reverse
thud sound. If a large amount of air is heard escap-
piston contacts the first separator plate. Watch care-
ing, the transaxle must be removed from vehicle, dis-
fully for the piston to move forward. The piston
assembled and all seals inspected.
should return to its original position after the air
pressure is removed.
OVERDRIVE CLUTCH
Apply air pressure to the overdrive clutch apply
passage and watch for the push/pull piston to move
DIAGNOSIS AND TESTING - FLUID LEAKAGE
The 42LE is a dual sump transaxle. The transaxle
forward. The piston should return to its starting
uses both automatic transaxle fluid (ATF) for the
position when the air pressure is removed.
main sump and hypoid gear lube for the differential
UNDERDRIVE CLUTCH sump. When diagnosing a leak, it is important to dis-
tinguish which type of fluid is leaking. Factory fill
Because this clutch piston cannot be seen, its oper-
ation is checked by function. Air pressure is applied
REMOVAL
NOTE:
When a transaxle failure has contaminated the fluid,
the oil cooler(s) must be flushed (Refer to 7 -
COOLING/TRANSMISSION - STANDARD PROCE-
DURE). The cooler bypass valve in the transaxle
must be inspected and/or replaced also. The torque
converter must also be replaced with an exchange
unit. This will ensure that metal particles or sludged Fig. 10 Crankshaft Position Sensor Location
oil are not later transferred back into the recondi- 1 - CRANKSHAFT POSITION SENSOR
tioned (or replaced) transaxle. 2 - DIFFERENTIAL COVER
DISASSEMBLY
NOTE: If the transaxle is being reconditioned
(clutch/seal replacement) or replaced, it is neces-
Fig. 11 Half Shaft Removal
sary to perform the Quick Learn Procedure using
1 - TRANSAXLE DIFFERENTIAL
2 - DRIVE SHAFT
the DRBIIIT Scan Tool (Refer to 8 - ELECTRICAL/
3 - PRY BAR ELECTRONIC CONTROL MODULES/TRANSMISSION
CONTROL MODULE - STANDARD PROCEDURE).
(23) Pull bottom of knuckles and drive shafts out-
ward to allow clearance during transaxle removal. Before disassembling transaxle, move the shift
The drive shafts do not have to be completely lever clockwise as far as it will go and then remove
removed from the vehicle. Do not allow the inner the shift lever.
tripod joints to hang unsupported or joint dam-
age may occur. NOTE: Tag all clutch pack assemblies, as they are
(24) Disconnect O2 sensor wiring and remove left removed, for reassembly identification.
catalytic converter pipe.
(25) Unbolt starter assembly. Do not disconnect
CAUTION: Do not intermix clutch discs or plates as
wiring or completely remove the starter from the
the unit might then fail.
vehicle. Allow the starter to sit between the engine
and the frame. (1) Measure input shaft end play using Tool 8266.
(26) Remove engine oil pan collar. Set up Tool 8266 and a dial indicator as shown in
(27) Remove torque converter bolts. The torque (Fig. 12). Move input shaft in and out to obtain end
converter is indexed to the flex plate. Mark the play reading. End play specifications are 0.13 to 0.64
mm (0.005 to 0.025 inch). Record indicator reading
(20) Remove input clutch assembly (Fig. 33). (22) Remove front sun gear assembly and #4
thrust washer (if still in place) (Fig. 35).
Fig. 40 Remove 2/4 Clutch Retainer Fig. 42 Remove 2/4 Clutch Return Spring
1 - 2/4 CLUTCH RETAINER 1 - 24 CLUTCH RETURN SPRING
(34) Remove chain cover (Fig. 49). CAUTION: Be sure to reinstall the chain snubber
and chain oiler when reassembling.
Fig. 52 Remove Output Shaft Sprocket Snap Ring Fig. 54 Install Chain Spreader
and Wave Washer 1 - OUTPUT SPROCKET
1 - WAVE WASHER 2 - SPECIAL TOOL 6550
2 - SNAP RING 3 - TRANSFER SPROCKET
Fig. 60 Opening Nut Stakes Fig. 62 Use Arbor Press to Remove Output Shaft
1 - CHISEL from Case
2 - NUT STAKE
1 - OUTPUT SHAFT
2 - ARBOR PRESS
(45) Use special tool 6497 and 6498 to remove the 3 - TRANSAXLE CASE
transfer shaft nut or the output shaft nut (Fig. 61).
Use special tool 6596 with a shop press to remove
front output shaft bearing cup (Fig. 63).
ASSEMBLY
NOTE: If the transaxle assembly is being recondi-
tioned (clutch/seal replacement) or replaced, it is
necessary to perform the Quick Learn Procedure
using the DRBIIIT Scan Tool (Refer to 8 - ELECTRI-
CAL/ELECTRONIC CONTROL MODULES/TRANS-
MISSION CONTROL MODULE - STANDARD
PROCEDURE).
Fig. 80 Install Piston Retainer
1 - LOW/REVERSE CLUTCH PISTON RETAINER
2 - GASKET
Fig. 109 Install Low/Reverse Clutch Pack (26) Install low/reverse reaction plate with flat
1 - CLUTCH PLATES (5) side up (Fig. 112).
2 - CLUTCH DISCS (5)
Fig. 113 Tapered Snap Ring Instructions (29) Select the proper low/reverse reaction plate to
achieve specifications:
LOW/REVERSE REACTION PLATE CHART
Fig. 116 Install 2/4 Clutch Pack Fig. 118 Install 2/4 Clutch Return Spring
1 - CLUTCH PLATE (4) 1 - 24 CLUTCH RETURN SPRING
2 - CLUTCH DISC (4)
(33) Set up Tool 5058 as shown in (Fig. 121). Com- (35) Install the #7 needle bearing to the rear sun
press 2/4 clutch just enough to facilitate snap ring gear (Fig. 123). The number 7 needle bearing has
installation. three antireversal tabs and is common with the
number 5 and number 2 position. The orienta-
tion should allow the bearing to seat flat
against the rear sun gear. A small amount of
petrolatum can be used to hold the bearing to
the rear sun gear.
Fig. 128 View Through Turbine Speed Sensor Hole 4446670AB 2.67mm (0.105 in.)
Fig. 131 Install Input Clutch Assembly NOTE: To align oil pump, gasket, and case during
1 - INPUT CLUTCH ASSEMBLY installation, use threaded dowels or phillips screw-
drivers.
(41) Install #1 caged needle bearing (Fig. 132).
(43) Install oil pump gasket (Fig. 134).
(51) Install valve body into place as shown in (Fig. (53) Install transaxle oil filter (Fig. 146).
144).
Reverse
First Gear
Second Gear
Direct Gear
Overdrive
Overdrive (EMCC)
SPECIFICATIONS
42LE AUTOMATIC TRANSAXLE
GENERAL SPECIFICATIONS
GEAR RATIOS
CLUTCH PACK
DIFFERENTIAL
INPUT SHAFT
TRANSFER SYSTEM
SPECIAL TOOLS
42LE AUTOMATIC TRANSAXLE
Installer C-4340
Installer 5050A
Adapter C-4996
Compressor 5058A
Remover 6310
Disk 6057
Installer 6494
Remover 6495
Installer 6522
Wrench 6497
Puller Jaws 6545
Wrench 6498
Turning Fork 6548
Remover 6550
Wrench 6503
Remover 6577
Remover 6596
Remover 8420A
ACCUMULATOR
DESCRIPTION
The 42LE underdrive, overdrive, low/reverse, and
2/4 clutch hydraulic circuits each contain an accumu-
lator. An accumulator assembly typically consists of a
piston, seals, return spring(s), and a cover or plug
(Fig. 150).
FINAL DRIVE
DESCRIPTION
The 42LE differential is a conventional open
design. It consists of a hypoid type ring and pinion
set, and a differential case. The differential case con-
sists of pinion and side gears, and a pinion shaft. The
differential case is supported in the transaxle by
tapered roller bearings (Fig. 155).
OPERATION
The three input clutches are responsible for driving
different components of the planetary geartrain.
Fig. 155 Differential Assembly
NOTE: (Refer to 21 - TRANSMISSION/TRANSAXLE/
1 - PINION GEAR
AUTOMATIC - 42LE - DIAGNOSIS AND TESTING) for 2 - RING GEAR
a collective view of which clutch elements are 3 - SHORT STUB SHAFT
applied at each position of the selector lever. 4 - DIFFERENTIAL CASE ASSEMBLY
5 - TRANSFER SHAFT
DISASSEMBLY
The valve body and solenoid wiring connector must
be removed from the transaxle in order to service the
transaxle differential. The transfer shaft cannot be
removed with the valve body in place. Remove the
valve body assembly from the transaxle. (Refer to 21
- TRANSMISSION/TRANSAXLE/AUTOMATIC - Fig. 157 Remove Chain Oiler
42LE/VALVE BODY - REMOVAL) 1 - CHAIN SNUBBER
(1) Remove transfer chain cover (Fig. 156). 2 - CHAIN OILER
Fig. 159 Remove Output Shaft Sprocket Snap Ring Fig. 161 Install Chain Spreader
and Wave Washer 1 - OUTPUT SPROCKET
1 - WAVE WASHER 2 - SPECIAL TOOL 6550
2 - SNAP RING 3 - TRANSFER SPROCKET
(5) Remove transfer shaft sprocket snap ring and (7) Remove chains and sprockets as an assembly
wave washer (Fig. 160). (Fig. 162).
Fig. 160 Remove Transfer Shaft Sprocket Snap Ring Fig. 162 Remove Chains and Sprockets as an
and Wave Washer Assembly
1 - TRANSFER SHAFT 1 - CHAINS
2 - WAVE WASHER
3 - SNAP RING CAUTION: To ensure proper gear ratio, verify that
4 - SNAP RING
5 - WAVE WASHER the correct chain and sprocket ratio is selected.
Fig. 163 Remove Long Stub Shaft Snap Ring Fig. 165 Remove Inner Differential Adjuster Lock
1 - SNAP RING 1 - INNER DIFFERENTIAL ADJUSTER LOCK
2 - SNAP RING PLIERS 2 - INNER DIFFERENTIAL ADJUSTER
3 - LONG STUB SHAFT
(11) Remove differential outer adjuster lock (Fig.
(9) Using slide hammer C-3752 and remover 166).
8420A, remove long stub shaft from transaxle (Fig.
164).
Fig. 175 Carrier Bearing Removal WARNING: WEAR SAFETY GOGGLES WHILE
1 - SPECIAL TOOL C-293 PA
GRINDING STAKE NUTS.
2 - WRENCH
3 - DIFFERENTIAL CARRIER (16) Using a die grinder or equivalent, grind the
4 - SPECIAL TOOL JAWS (4) stakes in the shoulder of the shaft nut as shown in
C-293–48
5 - SPECIAL TOOL C-4996 (Fig. 178) and (Fig. 179). Do not grind through the
transfer shaft nut into the shaft. There are two
(14) Remove inner adjuster (Fig. 176). stakes on the nut.
Fig. 176 Remove Inner Adjuster By Turning Fig. 178 Grinding Stakes
Clockwise 1 - TRANSFER SHAFT
1 - SPECIAL TOOL 6502–B 2 - GRIND HERE
2 - INNER DIFFERENTIAL ADJUSTER 3 - GRIND HERE
4 - NUT STAKE
Fig. 183 Preload Shim Removal Fig. 185 Transfer Shaft Seal Remover
1 - TRANSFER SHAFT PRELOAD SHIM 1 - SPECIAL TOOL 6310
2 - TRANSFER SHAFT
(23) Remove the front transfer shaft bearing cup
(21) Remove transfer shaft assembly from case using special tool 6495 and handle C-4171 (Fig. 186).
(Fig. 184). Use a press with special tools to remove cup.
Fig. 184 Remove Transfer Shaft Assembly From Fig. 186 Front Transfer Shaft Cup Removal
Case 1 - SPECIAL TOOL C-4171
1 - TRANSFER SHAFT 2 - SPECIAL TOOL 6495
(9) Before making a pinion depth measurement Fig. 197 Mounting Dial Indicator to Centering Block
the dial indicator must be zeroed. This is done by 1 - CENTERING BLOCK
placing the dial indicator in the zeroing fixture (spe- 2 - GAUGE DISC
cial tool 6549-6). Then place the zeroing fixture on a 3 - DIAL INDICATOR
flat surface. Adjust the dial face so the pointer on the
dial indicator lines up with the zero (Fig. 196). (11) Pivot dial indicator back and forth (Fig.
198)on centering pin to obtain the shortest distance
measurement. This will be the lowest number
reading on dial indicator. Record the number
obtained. Now rotate the gauge disc clockwise 1/3 of
a turn and recheck readings. Record number
obtained. Rotate the gauge disc another 1/3 of a turn
clockwise and take another reading. Average the
three readings. Record this pinion depth measure-
ment. If the readings differ by more than two thou-
sandths recheck gauge disc installation, it may have
been installed slightly cocked.
DIFFERENTIAL ASSEMBLY (3) Install pinion shaft roll pin (Fig. 206).
(1) Install differential carrier bearings using an
arbor press, driver handle C-4171, and Tool C-4340
(Fig. 204).
Fig. 225 Checking Turning Torque Fig. 227 Correctly Staked Nut
1 - SOCKET (6498) 1 - BOTTOMED IN SLOT
2 - TRANSFER SHAFT NUT 2 - CORRECTLY STAKED NUT
3 - IN. LBS. TORQUE WRENCH
FILL
(1) Install drain plug into differential housing.
Tighten drain plug to 7 N·m (60 in. lbs.)
(2) Fill differential with Mopart Fuel Saving
75W-90 petroleum based hypoid gear lubricant. The
fluid should be level with the bottom of the fill hole.
The differential capacity is 0.95 liters (32 ounces).
(3) Install differential fill plug. Tighten fill plug to Fig. 239 Panel Removal/Installation
47 N·m (35 ft. lbs.).
1 - SILENCER/DUCT ASSEMBLY
Fig. 243 Lower Column Cover Removal/Installation Fig. 245 Throttle/Gearshift Cable Bracket
1 - LOWER COLUMN COVER 1 - CABLE BRACKET
2 - GEARSHIFT CABLE
3 - THROTTLE CABLE
(7) Remove cable from shift pin (Fig. 244).
(8) Remove cable retainer clip from shift cable con-
duit bracket (Fig. 244).
INSTALLATION
(1) Make sure transaxle shift lever is in “park.” This
is the most rearward position. Verify park sprag is fully
engaged by rotating either a tire or an axle shaft.
(2) Position cable in vehicle and connect cable end
to the transaxle shift lever (Fig. 247).
(3) Verify that the washer (Fig. 247) is still in
place on the cable mounting stud. Install cable to
transaxle and tighten nut to 28 N·m (250 in. lbs.).
(4) Rotate fill tube to original location. Install and
tighten fill tube bracket bolt.
(5) Install cable “push pin” into bracket as shown
in (Fig. 246).
(6) Route transaxle shift cable through hole in
dash panel (Fig. 247) (Fig. 248).
(7) Lubricate cable grommet with a synthetic
lubricant (or equivalent) and secure to hole. Verify
that it is seated by pulling outward on cable.
(8) Install cable into throttle/gearshift cable Fig. 248 Shift Cable Routing
bracket (Fig. 245). 1 - LH A/C DUCT OUTLET
(9) Inside the vehicle, route the gearshift between 2 - LH LOWER HEAT DUCT
the left a/c duct and the left lower heat duct (Fig. 3 - GEARSHIFT CABLE
248) and up to the steering column.
(10) Tilt steering column all the way up and make (11) Connect transaxle shift cable to shift cable
sure shift lever is still in “park.” conduit bracket and secure with new clip (Fig. 244).
(15) Reinstall upper and lower steering column (4) Tilt the steering column to the full down position.
shrouds (Fig. 241) (Fig. 243). Then install underpanel (5) Place shifter in the park position with the key
silencer/duct. removed.
(16) Check shifter for proper operation. It should (6) Adjust by rotating adjuster into lock position
operate smoothly without binding. The engine starter (Fig. 251).
should crank in park or Neutral positions only.
ADJUSTMENTS
ADJUSTMENT
The gearshift cable should be adjusted if any of the
following repairs or situations are encountered:
• Transaxle replacement.
• Valve body repair.
• Shift cable replacement.
• Column shifter replacement.
• When there is no cranking in Park or Neutral.
If the following conditions are encountered, the
interlock cable is out of adjustment. Refer to Inter-
lock Cable Adjustment procedure. Fig. 251 Shift Cable Adjuster Lock
• When the transaxle can be shifted without the 1 - SHIFTER PIN
key in the ignition. 2 - CABLE ADJUSTER LOCK
• If the key can be removed with the shifter in 3 - SHIFT CABLE
reverse.
• When the key cannot be removed with the (7) Reinstall upper steering column shroud.
shifter in the park position. (8) Check shifter for proper operation. It should
(1) Remove upper steering column shroud. operate smoothly without binding. The vehicle should
(2) Rotate cable adjuster into unlock position. Use a crank in Park or Neutral only.
straight blade screwdriver to unlock adjuster (Fig. 250).
GEAR SHIFT CABLE - FLOOR (5) Remove retaining clip from shift cable conduit
bracket (Fig. 254).
(6) Disconnect shifter cable from cable attach stud
REMOVAL
(pin) (Fig. 254).
(1) Using suitable size allen wrench, remove the
shift handle retaining screw (Fig. 252).
INSTALLATION
(1) Make sure transaxle shift lever is in “Park.”
This is the most rearward position. Verify park sprag
is fully engaged by rotating either a tire or an axle
shaft.
(2) Position cable in vehicle and connect cable end
to the transaxle shift lever (Fig. 256).
(3) Verify that the washer (Fig. 256) is still in
place on the cable mounting stud. Install cable to
transaxle and tighten nut to 28 N·m (250 in. lbs.).
(4) Rotate fill tube to original location. Install and
tighten fill tube bracket bolt.
(5) Install cable “push pin” into bracket as shown
in (Fig. 255).
(6) Route transaxle shift cable through hole in
dash panel (Fig. 256) (Fig. 258).
(7) Lubricate cable grommet with a synthetic
lubricant (or equivalent) and secure to hole. Verify
that it is seated by gently pulling outward on cable.
(8) Install cable into throttle/gearshift cable
bracket (Fig. 255).
Fig. 256 Gearshift Cable Removal (9) Inside the vehicle, route the gearshift cable
1 - CABLE between the left a/c duct and the left lower heat duct
2 - FIREWALL (Fig. 258) and towards the gearshift mechanism.
3 - WASHER
4 - SHIFT LEVER
5 - NUT
6 - STUD
Fig. 257 Cable Routing Bracket (10) Route cable through hole in shifter conduit
1 - BRACKET
bracket and attach to cable attaching shift pin by
2 - CABLE snapping into place (Fig. 254).
OPERATION
NOTE: (Refer to 21 - TRANSMISSION/TRANSAXLE/
AUTOMATIC - 42LE - DIAGNOSIS AND TESTING) for
a collective view of which clutch elements are
applied at each position of the selector lever.
2/4 CLUTCH
The 2/4 clutch is hydraulically applied in second
and fourth gears by pressurized fluid against the 2/4
clutch piston. When the 2/4 clutch is applied, the
front sun gear assembly is held or grounded to the
transaxle case.
(3) Remove reverse clutch snap ring (Fig. 262). Fig. 264 Reverse Clutch Reaction Plate
(4) Pry up and remove reverse clutch reaction
1 - REVERSE CLUTCH REACTION PLATE (INSTALL FLAT SIDE DOWN)
plate (Fig. 263) (Fig. 264).
Fig. 265 Reverse Clutch Pack (8) Remove OD/Reverse reaction plate wave snap
ring (Fig. 268).
1 - REVERSE CLUTCH PLATE
2 - REVERSE CLUTCH DISC
Fig. 294 Install OD/Reverse Piston Fig. 296 Install Input Hub Tapered Snap Ring
1 - PUSH DOWN TO INSTALL OVERDRIVE/REVERSE PISTON 1 - INPUT SHAFT
2 - INPUT CLUTCHES RETAINER 2 - INPUT HUB SNAP RING (TAPERED SIDE UP WITH TABS IN
CAVITY)
(5) Install the input hub/shaft assembly to the 3 - SNAP RING PLIERS
OD/Reverse piston/clutch retainer assembly (Fig.
(7) Install UD clutch piston (Fig. 297).
295).
(9) Using Tool 5059A and an arbor press, install (10) Install the UD clutch pack (four fibers/four
the UD spring retainer and snap ring. (Fig. 299), steels) (Fig. 301). Leave the top disc out until after
(Fig. 300) Compress just enough to install snap ring. the snap ring is installed.
Fig. 306 Seating Tapered Snap Ring Fig. 308 Set Up Dial Indicator to Measure UD Clutch
1 - OVERDRIVE/UNDERDRIVE CLUTCHES REACTION PLATE Clearance
TAPERED SNAP RING
2 - SCREWDRIVER 1 - DIAL INDICATOR
2 - UNDERDRIVE CLUTCH
(15) Install input clutch assembly to the Input
Clutch Pressure Fixture - Tool 8391 (Fig. 307). (17) Using moderate pressure, press down and
hold (near indicator) the UD clutch pack with screw-
driver or suitable tool and zero dial indicator (Fig.
309). When releasing pressure on clutch pack, indica-
tor reading should advance 0.005–0.010.
Fig. 309 Press Down on UD Clutch Pack and Zero (23) Install the OD/Reverse reaction plate with
Dial Indicator large step down (towards OD clutch pack) (Fig. 312).
1 - DIAL INDICATOR
2 - UNDERDRIVE CLUTCH
(32) Set up a dial indicator on the reverse clutch Fig. 320 Press Down on Reverse Clutch and Zero
pack as shown in (Fig. 319). Indicator
(33) Using moderate pressure, press down and 1 - DIAL INDICATOR
hold (near indicator) reverse clutch disc with screw- 2 - REVERSE CLUTCH
driver or suitable tool and zero dial indicator (Fig.
320). When releasing pressure, indicator should (34) Apply 30 psi (206 kPa) air pressure to the
advance 0.005-0.010. as clutch pack relaxes. reverse clutch hose on Tool 8391. Measure and record
reverse clutch pack measurement in four (4) places,
90° apart.
OPERATION
As the torque converter rotates, the converter hub
rotates the inner and outer gears. As the gears
rotate, the clearance between the gear teeth
increases in the crescent area, and creates a suction
Fig. 326 Input Clutch Assembly at the inlet side of the pump. This suction draws
1 - INPUT CLUTCH ASSEMBLY fluid through the pump inlet from the oil pan. As the
2 - OVERDRIVE SHAFT ASSEMBLY clearance between the gear teeth in the crescent area
decreases, it forces pressurized fluid into the pump
outlet and to the valve body.
1 - PUMP HOUSING
2 - REACTION SHAFT SUPPORT
(6) Measure clearance between outer gear and
3 - PUMP GEARS crescent. Clearance should be 0.060-0.298 mm
(0.0023-0.0117 in.).
(3) Remove the pump gears (Fig. 329) and check (7) Measure clearance between inner gear and
for wear and damage on pump housing and gears. crescent. Clearance should be 0.093-0.385 mm
(0.0036-0.0151 in.).
(8) Position an appropriate piece of Plastigage
across both pump gears.
(9) Align the Plastigage to a flat area on the reac-
tion shaft support housing.
(10) Install the reaction shaft to the pump hous-
ing. Tighten the bolts to 27 N·m (20 ft. lbs.).
(11) Remove bolts and carefully separate the hous-
ings. Measure the Plastigage following the instruc-
tions supplied.
(12) Clearance between outer gear side and the
reaction shaft support should be 0.020-0.046 mm
(0.0008-0.0018 in.). Clearance between inner gear
side and the reaction shaft support should be 0.020-
0.046 mm (0.0008-0.0018 in.).
ASSEMBLY
(1) Assemble oil pump as shown in (Fig. 331)
(2) Install and torque reaction shaft support-to-oil
pump housing bolts to 28 N·m (20 ft. lbs.) torque.
OPERATION
The planetary geartrain utilizes two planetary gear
sets that connect the transmission input shaft to the
output shaft. Input and holding clutches drive or lock
different planetary members to change output ratio
or direction.
Fig. 334 Stub Shaft Bearing C-clip Fig. 336 Install Bearing Onto Shaft
1 - C-CLIP 1 - TOOL 6558
2 - LONG STUB SHAFT 2 - STUB SHAFT BEARING
3 - STUB SHAFT BEARING 3 - STUB SHAFT
Fig. 335 Remove Stub Shaft Bearing C-clip Fig. 337 Indexing Inner Adjuster
1 - BEARING SPLITTER 1 - INNER ADJUSTER
2 - STUB SHAFT BEARING 2 - ADJUSTER LOCK
3 - CROSS HAIR MARKS
(3) Index the inner differential adjuster with a
cross hair as shown in (Fig. 337).
INSTALLATION
(1) Lube O-ring, threads on adjuster, seal protector
and seal lips with gear oil before installing.
(2) Install outer adjuster into transaxle case and
tighten adjuster within 10 ft. lbs. of the torque read- Fig. 343 Long Stub Shaft Removal
ing recorded in step five. 1 - LONG STUB SHAFT
(3) Rotate ring gear three or four revolutions in 2 - SPECIAL TOOL 8420A
3 - SLIDE HAMMER C-3752
both directions to seat differential bearings.
(4) Continue tightening outer adjuster until index
marks line up (original location).
SEAL - OIL PUMP (2) Clean and inspect torque converter hub. If
nicks, scratches or hub wear are found, torque con-
verter replacement will be required.
REMOVAL
The transaxle must be removed from the vehicle to CAUTION: If the torque converter is being replaced,
replace this oil seal. apply a light coating of grease to the crankshaft
(1) Remove the transaxle from the vehicle (Refer pilot hole. Also inspect the engine drive plate for
to 21 - TRANSMISSION/TRANSAXLE/AUTOMATIC cracks. If any cracks are found replace the drive
- 42LE - REMOVAL). plate. Do not attempt to repair a cracked drive plate.
(2) Remove the torque converter from the trans- Always use new torque converter to drive plate
axle bellhousing. bolts.
(3) Use special tool C-3981B to remove oil pump
seal (Fig. 346). (3) Apply a light film of transmission oil to the
torque converter hub and oil seal lips. Then install
torque converter into transaxle. Be sure that the hub
lugs mesh with the front pump lugs when installing.
(4) Reinstall the transaxle into the vehicle.
INSTALLATION
(1) Clean and inspect oil pump seal seat. Then
install seal using special tool C-4193A (Fig. 347).
Fig. 353 Interlock Cable Locking Tab Fig. 355 Ignition Key/Switch Positions
1 - TAB 1 - ACC
2 - INTERLOCK CABLE 2 - LOCK
3 - LOCK CYLINDER HOUSING 3 - OFF
4 - ON/RUN
5 - START
ADJUSTMENTS
ADJUSTMENT - INTERLOCK CABLE
(1) Remove the shifter handle.
(2) Remove the console bezel.
(3) Move the gear shifter to PARK and the ignition
key to the LOCK position (Fig. 356).
(4) If the interlock cable is being replaced, remove
the pin to allow cable to “self adjust.” Press locking
clip (Fig. 357)by hand to secure adjustment.
(5) If the interlock cable is not being replaced, the
pin will not exist. Loosen the locking clip (Fig. 357) on
the interlock cable to allow cable to “self adjust.” Press
locking clip (Fig. 357) by hand to secure adjustment.
SHIFT INTERLOCK
MECHANISM
REMOVAL
The interlock cassette slides into the housing
behind the lock cylinder (Fig. 358). The cable at the
rear of the cassette attaches to a locking arm on the
shifter mechanism. The column shift interlock
system is only adjusted after installing a new
cassette. It can’t be adjusted more than once. If
the system operates incorrectly, install and
adjust a new interlock cassette.
(1) Depress the tab on the top of the cassette.
(2) Slide the interlock cassette out of the housing.
(3) Remove the cable from the locking arm on the
shifter mechanism. Fig. 359 Latch and Shifter Gate
1 - LATCH
2 - SHIFTER GATE
3 - CASSETTE CABLE
INSTALLATION
The interlock cassette slides into the housing
behind the lock cylinder (Fig. 358). The cable at the
rear of the cassette attaches to a locking arm on the
shifter mechanism. The column shift interlock
system is only adjusted after installing a new
cassette. It can’t be adjusted more than once. If Fig. 360 Ignition Interlock Adjustment Tab
the system operates incorrectly, install and 1 - LOCK CYLINDER HOUSING
adjust a new interlock cassette. 2 - INTERLOCK CASSETTE
(1) Ensure the latch rotates freely on the shifter 3 - ADJUSTMENT TAB
gate (Fig. 359).
SHIFT INTERLOCK SOLENOID (3) Remove the lower instrument panel cover. The
lower instrument panel cover is attached by retain-
ing clips along the top and right edge.
REMOVAL
(1) Remove the fuse panel cover from the left end NOTE: The upper shroud on this steering column is
of the instrument panel (Fig. 361). retained to the steering column by a snap fit to the
lower shroud. When removing the upper shroud
from the steering column lower shroud, DO NOT
use a hard or sharp tool. This will damage the
shrouds. If a tool must be used, use a soft tool
such as a trim stick.
DIAGNOSIS AND TESTING - BRAKE/ If the floor shifter cannot be moved out of the PARK
position, refer to Shifter Locked In Place below. If the
TRANSMISSION SHIFT INTERLOCK SYSTEM
shift lever can be shifted out of PARK without the brake
pedal depressed, refer to Circuit Test below.
FLOOR SHIFT MODELS
The following chart describes the normal operation SHIFTER LOCKED IN PLACE
of the Brake Transmission Shift Interlock (BTSI) sys-
(1) Remove the instrument panel cover below the
tem. If the “expected response” differs from the vehi-
steering column, then remove the steering column
cle’s response, then system repair and/or adjustment
shrouds to gain access to the brake transmission
is necessary.
shift interlock (BTSI) solenoid. The solenoid is part of
Refer to the following chart that expected shifter
the interlock cable assembly.
response, depending on ignition key/switch (Fig. 373)
(2) Disconnect the wire connector from the rear of
and brake pedal positions.
the BTSI solenoid.
(3) Insert the ignition key and turn it to the ON
position.
(4) With the brakes applied, try moving the shifter
out of the PARK position.
• If the lever now moves freely in and out of
PARK, perform the Circuit Test below.
• If the shift lever still does not move from the
PARK position, remove the BTSI solenoid from the
shift lever assembly.
If the shift lever now moves freely in and out of the
park position, the BTSI solenoid is faulty and the inter-
lock cable must be replaced. If the shift lever still does
not move from the park position, the problem is in the
shift lever assembly or the ignition interlock cassette.
Fig. 373 Ignition Key/Switch Positions
1 - ACC CIRCUIT TEST
2 - LOCK
3 - OFF
(1) Check the system fuse in the junction block
4 - ON/RUN (An open or blown fuse would allow the shift lever to
5 - START be moved in and out of the PARK position without
the brake pedal applied).
ACTION EXPECTED RESPONSE (2) Remove the instrument panel cover below the
1. Turn key to the 9OFF9 1. Shifter CAN be shifted steering column, then remove the steering column
position. out of park. shrouds to gain access to the brake transmission
shift interlock (BTSI) solenoid.
2. Turn key to the 2. Shifter CANNOT be
(3) Disconnect the wire connector from the rear of
9ON/RUN9 position. shifted out of park.
the BTSI solenoid.
3. Turn key to the 3. Shifter CAN be shifted (4) Insert the ignition key and turn it to the ON
9ON/RUN9 position and out of park. position.
depress the brake pedal. (5) Back-probe the wire connector’s terminal num-
4. Leave shifter in any 4. Key cannot be ber 2 with a test light. The test light should illumi-
gear and try to return key returned to the 9LOCK9 or nate. If not, there is an open or short in the ignition
to the 9LOCK9 or 9ACC9 9ACC9 position. feed circuit leading to the BTSI solenoid. Repair the
position. open or short.
(6) Next, back-probe the wire connector with a test
5. Return shifter to 5. Key can be removed
light, placing the test light in series between the two
9PARK9 and try to remove (after returning to 9LOCK9
wires. At this point, the test light should illuminate.
the key. position).
If not, there is an open in the ground circuit or brake
6. With the key removed, 6. Shifter cannot be lamp switch. Repair the open or replace brake lamp
try to shift out of 9PARK9. shifted out of 9PARK9. switch as necessary.
NOTE: Any failure to meet these expected (7) Depress the brake pedal. The test light should
responses requires system adjustment or repair. go out. If it does not, there is a short in the ground
circuit or brake lamp switch. Repair the short or
replace brake lamp switch as necessary.
CIRCUIT TEST
Fig. 374 Ignition Key/Switch Positions (1) Check the system fuse in the junction block
1 - ACC
(An open or blown fuse would allow the shift lever to
2 - LOCK be moved in and out of the PARK position without
3 - OFF the brake pedal applied).
4 - ON/RUN
5 - START
(2) Remove the instrument panel cover below the
steering column, then remove the steering column
shrouds to gain access to the brake transmission
ACTION EXPECTED RESPONSE
shift interlock (BTSI) solenoid.
1. Turn key to the 9OFF9 1. Shifter CAN be shifted (3) Disconnect the wire connector from the rear of
position. out of park. the BTSI solenoid.
2. Turn key to the 2. Shifter CANNOT be (4) Insert the ignition key and turn it to the ON
9ON/RUN9 position. shifted out of park. position.
3. Turn key to the 3. Shifter CAN be shifted (5) Back-probe the wire connector’s terminal number
9ON/RUN9 position and out of park. 2 with a test light. The test light should illuminate. If
depress the brake pedal. not, there is an open or short in the ignition feed circuit
leading to the BTSI solenoid. Repair the open or short.
4. Leave shifter in any 4. Key cannot be (6) Next, back-probe the wire connector with a test
gear and try to return key returned to the 9LOCK9 or light, placing the test light in series between the two
to the 9LOCK9 or 9ACC9 9ACC9 position. wires. At this point, the test light should illuminate.
position. If not, there is an open in the ground circuit or brake
5. Return shifter to 5. Key can be removed lamp switch. Repair the open or replace brake lamp
9PARK9 and try to remove (after returning to 9LOCK9 switch as necessary.
the key. position). (7) Depress the brake pedal. The test light should
6. With the key removed, 6. Shifter cannot be go out. If it does not, there is a short in the ground
try to shift out of 9PARK9. shifted out of 9PARK9. circuit or brake lamp switch. Repair the short or
replace brake lamp switch as necessary.
NOTE: Any failure to meet these expected
(8) Reconnect the wire connector to the solenoid.
responses requires system adjustment or repair.
SHIFT MECHANISM
REMOVAL
(1) Remove shifter handle and console bezel.
(2) If equipped with Autostick, disconnect the
Autostick switch connector.
(3) Loosen adjuster nut on shifter adjuster (Fig.
375).
R OP OP OP
P/N CL OP OP
1st CL OP OP Fig. 380 Solenoid Retaining Screws
1 - SOLENOID/PRESSURE SWITCH ASSEMBLY
2nd OP CL OP 2 - RETAINING SCREWS
D OP OP CL
OD OP CL CL
OP = OPEN
CL = CLOSED
OPERATION
The Output Speed Sensor provides information on
how fast the output shaft is rotating. As the rear
planetary carrier park pawl lugs pass by the sensor
coil (Fig. 389), an AC voltage is generated and sent to
the PCM. The PCM interprets this information as
output shaft rpm.
REMOVAL
NOTE: If torque conveter assembly is being
replaced, it is necessary to restart the TCC Break-In
Strategy. (Refer to 8 - ELECTRICAL/ELECTRONIC
CONTROL MODULES/TRANSMISSION CONTROL
MODULE - STANDARD PROCEDURE)
ADJUSTMENTS
DRIVE SPROCKET HEIGHT ADJUSTMENT
Fig. 396 Screwdriver Placement PROCEDURE
1 - PRY TOOL A spacer beneath the output sprocket is used to
2 - CHAINS position the output sprocket in line with the transfer
sprocket. The sprocket must be within 0.0159 of each
(5) Pry the chains up at the center of the chain.
other. In order to do this operation, install original
(6) Butt a scale against the snubber and place a
spacer over the output shaft. If original spacer is not
second mark on the scale at the bottom of the chains
available, use the thickest available shim as a start-
(Fig. 397).
ing point. Refer to Output Sprocket Spacer Chart for
available sizes. Then install the two sprockets with-
out the chain.
OUTPUT SPROCKET SPACER CHART
OPERATION
The relay is supplied fused B+ voltage, energized
by the PCM, and is used to supply power to the sole-
noid pack when the transmission is in normal oper-
ating mode. When the relay is “off”, no power is
supplied to the solenoid pack and the transmission is
in “limp-in” mode. After a controller reset (ignition
key turned to the “run” position or after cranking
engine), the PCM energizes the relay. Prior to this,
the PCM verifies that the contacts are open by check-
ing for no voltage at the switched battery terminals.
After this is verified, the voltage at the solenoid pack
pressure switches is checked. After the relay is ener-
Fig. 400 Checking Sprocket Height gized, the PCM monitors the terminals to verify that
1 - STRAIGHT EDGE the voltage is greater than 3 volts.
2 - FEELER GAUGE
TRANSMISSION RANGE
SENSOR
DESCRIPTION
The Transmission Range Sensor (TRS) is mounted
to the top of the valve body inside the transaxle and
can only be serviced by removing the valve body
assembly. The electrical connector extends through
the transaxle case (Fig. 402).
REMOVAL
(1) Disconnect the TRS connector.
(2) Remove valve body assembly from vehicle. Refer
to Valve Body removal and Installation in this group.
(3) Remove the manual shaft seal (Fig. 404).
INSTALLATION
(1) Install the TRS to the manual shaft. Make sure
TRS locating pin rests in manual valve bore slot.
(2) Install the TRS/manual shaft retaining screw
and torque to 5 N·m (45 in. lbs.) torque (Fig. 405).
(3) Install the manual shaft seal (Fig. 404).
(4) Install valve body to transaxle. Refer to Valve
Body Removal and Installation in this group.
REMOVAL
NOTE: If valve body is being reconditioned or
replaced, it is necessary to perform the Quick Learn
Procedure. (Refer to 8 - ELECTRICAL/ELECTRONIC
CONTROL MODULES/POWERTRAIN CONTROL
MODULE - STANDARD PROCEDURE)
Fig. 410 Transaxle Oil Filter Fig. 412 Valve Body From Transaxle
1 - TRANSAXLE FILTER 1 - VALVE BODY
2 - FILTER RETAINING CLIPS
CAUTION: The overdrive and underdrive accumula-
CAUTION: The 42LE transaxle oil filter is not inter- tors and springs may fall out when removing the
changeable with the 41TE transaxle filter. Installa- valve body (Fig. 413) (Fig. 414) (Fig. 415).
tion of a 41TE oil filter in a 42LE may cause
transaxle damage.
(5) Remove valve body stiffener plate (Fig. 419). Fig. 420 Remove Transfer Plate-to-Valve Body
Screws
1 - SCREW (24)
2 - TRANSFER PLATE
Fig. 422 Remove Separator Plate-to-Transfer Plate Fig. 424 Remove Oil Screen to Transfer Plate
Screws 1 - OIL SCREEN
1 - SEPARATOR PLATE
2 - SCREW (2) (11) Remove thermal valve (Fig. 425) from transfer
3 - TRANSFER PLATE plate.
(9) Remove separator plate from transfer plate
(Fig. 423).
ASSEMBLY
NOTE: If the valve body assembly is being recondi-
tioned or replaced, it is necessary to perform the
Quick Learn Procedure using the DRBIIIT Scan
Tool. (Refer to 8 - ELECTRICAL/ELECTRONIC CON-
TROL MODULES/POWERTRAIN CONTROL MODULE
- STANDARD PROCEDURE)
Fig. 433 Install Regulator Valve Spring Retainer Fig. 434 Install Dual Retainer Plate using Tool 6301
using Tool 6302 1 - TOOL 6301
2 - RETAINER
1 - TOOL 6302
2 - RETAINER
Fig. 440 Install Separator Plate to Transfer Plate Fig. 442 Install Transfer Plate to Valve Body
1 - SEPARATOR PLATE 1 - TRANSFER PLATE
2 - TRANSFER PLATE 2 - VALVE BODY
(10) Install the two separator plate-to-transfer (12) Install the transfer plate-to-valve body screws
plate screws (Fig. 441). (Fig. 443)and torque to 5 N·m (45 in. lbs.).
INSTALLATION (3) Make sure oil pan and case rail are clean and
(1) Install valve body into position and start bolts. dry. Install an 1/8” bead of RTV to the transaxle oil
Torque valve body to transaxle case bolts (Fig. 448) pan and install to case. Tighten bolts (Fig. 450) to 23
to 12 N·m (105 in. lbs.) torque. N·m (17 ft. lbs.).
Fig. 448 Valve Body Bolts Fig. 450 Transaxle Oil Pan Bolts
1 - EXTENSION 1 - EXTENSION
2 - SOCKET 2 - TRANSAXLE OIL PAN
3 - VALVE BODY 3 - SOCKET
(2) Install transaxle oil filter (Fig. 449). (4) Lower vehicle and connect the TRS connector.
(5) Connect solenoid/pressure switch assembly con-
nector.
(6) Lower vehicle.
(7) Fill transaxle with ATF+4 (Automatic Trans-
mission Fluid-Type MS-9602). Verify proper fluid
level. (Refer to 21 - TRANSMISSION/TRANSAXLE/
AUTOMATIC - 42LE/FLUID - STANDARD PROCE-
DURE)
TIRES/WHEELS
TABLE OF CONTENTS
page page
OPERATION CAUTION
The Tire Pressure Monitoring (TPM) system uses CAUTION: TPM thresholds have been established
wireless technology to monitor tire air pressure lev- for the original tire size equipped on the vehicle.
els. Sensors, mounted to each road wheel as part of Use original size tires only to maintain system
the valve stem, transmit tire pressure readings to a accuracy.
receiver located in the overhead console. These trans-
missions occur once every minute at speeds over 20
mph (32 km/h). The tire pressure status is shown on CAUTION: The use of tire sealants is strictly prohib-
the Electronic Vehicle Information Center (EVIC) dis- ited for vehicles equipped with the Tire Pressure
play upon demand. The Tire Pressure Monitoring Monitoring system. Tire sealants can clog tire pres-
system remains active even if it is not displayed in sure sensors.
the EVIC.
If any road tire pressure has exceeded the low or
high pressure threshold (refer to chart below), the
TPM system will display a message on the EVIC and
sound a chime. It will then go into the tire pressure
display screen and flash the pressure value of the
tire that is low or high. This will be displayed for the
INSTALLATION
NOTE: Before reinstalling a tire pressure sensor,
replace sealing grommet at base of valve stem.
TIRES
DESCRIPTION
DESCRIPTION - TIRE
Tires are designed and engineered for each specific
vehicle. They provide the best overall performance
for normal operation. The ride and handling charac-
teristics match the vehicle’s requirements. With
proper care they will give excellent reliability, trac-
tion, skid resistance, and tread life.
Driving habits have more effect on tire life than
any other factor. Careful drivers will obtain, in most
cases, much greater mileage than severe use or care-
less drivers. A few of the driving habits which will
shorten the life of any tire are:
• Rapid acceleration
• Severe application of brakes
• High-speed driving
• Taking turns at excessive speeds
• Striking curbs and other obstacles
Fig. 20 Mounting Tire Using Rotating Wheel • Operating vehicle with over or under inflated
Machine tire pressures
1 - HEAD OF CHANGER LOCATED HERE Radial ply tires are more prone to irregular tread
2 - VALVE STEM wear. It is important to follow the tire rotation inter-
val shown in the section on Tire Rotation. This will
help to achieve a greater tread-life potential.
TIRE IDENTIFICATION
Tire type, size, load index and speed rating are
encoded in the letters and numbers imprinted on the
side wall of the tire. Refer to the Tire Identification
chart to decipher the code. For example purposes, the
tire size P225/60 R 16 97 T is used in the chart. An
All Season type tire will also have either M + S, M &
S or M - S (indicating mud and snow traction)
imprinted on the side wall. An Extra or Light Load
marking “XL” or “LL” may also be listed on the side-
wall. The absence of an “XL” or “LL” marking infers
a standard load tire.
* NOTE: Consult the tire manufacturer regarding WARNING:: IN ORDER TO MAINTAIN THE SPEED
any questions on tire specifications or capabilities. CAPABILITY OF THE VEHICLE, REPLACEMENT
TIRES MUST HAVE SPEED RATINGS EQUAL TO OR
HIGHER THAN THOSE FITTED TO THE VEHICLE AS
ORIGINAL EQUIPMENT. IF TIRES WITH LOWER
SPEED RATINGS ARE FITTED, THE VEHICLE’S
HANDLING MAY BE AFFECTED AND THE SPEED
CAPABILITY OF THE VEHICLE MAY BE LOWERED
TO THE MAXIMUM SPEED CAPABILITY OF THE
REPLACEMENT TIRES. TO AVOID AN ACCIDENT
RESULTING IN SEVERE OR FATAL INJURY, CON-
SULT THE TIRE MANUFACTURER IN REGARDS TO
MAXIMUM SPEED RATINGS.
(1) Place the wheel cover on the wheel in the fol- Fig. 32 Tightening Sequence
lowing fashion:
(a) Align the valve notch in the wheel cover with
the valve stem on the wheel.
(b) At the same time, align the two holes in the
wheel cover having the retaining tabs with the two
installed wheel nuts (Fig. 31).
INSTALLATION
CAUTION: DO NOT hammer studs into the hub
flange. If a stud is installed in such a manner, dam-
age to the hub and bearing assembly may occur
leading to premature bearing failure.
BODY
TABLE OF CONTENTS
page page
BODY DECKLID . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
DESCRIPTION - VEHICLE IDENTIFICATION . . . . 1 DOOR - FRONT . . . . . . . . . . . . . . . . . . . . . . . . . 17
WARNING DOORS - REAR . . . . . . . . . . . . . . . . . . . . . . . . . 27
SAFETY PRECAUTIONS AND WARNINGS . . . 1 EXTERIOR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 34
DIAGNOSIS AND TESTING HOOD . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40
DIAGNOSIS AND TESTING - WATER LEAKS .1 INSTRUMENT PANEL . . . . . . . . . . . . . . . . . . . . . 44
DIAGNOSIS AND TESTING - WIND NOISE . . . 2 INTERIOR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60
STANDARD PROCEDURE PAINT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 76
STANDARD PROCEDURE - PLASTIC BODY SEATS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 78
PANEL REPAIR . . . . . . . . . . . . . . . . . . . . . . . . 3 STATIONARY GLASS . . . . . . . . . . . . . . . . . . . . . 97
STANDARD PROCEDURE - HEAT STAKING . 10 SUNROOF . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 101
SPECIFICATIONS WEATHERSTRIP/SEALS . . . . . . . . . . . . . . . . . . 110
BODY LUBRICATION . . . . . . . . . . . . . . . . . . . 10 BODY STRUCTURE . . . . . . . . . . . . . . . . . . . . . 115
TORQUE SPECIFICATIONS . . . . . . . . . . . . . . 11
SPECIAL TOOLS
BODY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
PATCHING PANELS
An panel that has extensive puncture type damage
can be repaired by cutting out the damaged material
(Fig. 7). Use a suitable reciprocating saw or cut off
wheel to remove the section of the panel that is dam-
aged. 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
Fig. 5 FIBERGLASS TAPE of cutout at 20 degrees to expose a larger bonding area
VISUAL INSPECTION on the outer side. This will allow for an increased rein-
Composite materials can mask the severity of an forcement areas.
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 (Fig. 7) (Fig. 6).
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 lubri-
cated. During the winter season, external door lock
cylinders should be lubricated to assure proper oper-
ation when exposed to water and ice.
Prior to the application of any lubricant, the parts
concerned should be wiped clean to remove dust and
Fig. 15 COVER MESH WITH ADHESIVE grit. If necessary, a suitable solvent can be used to
1 - ADHESIVE clean the item to be lubricated. After lubricating a
2 - MESH
3 - PATCH component, any excess oil or grease should be
4 - SPREADER removed.
SPECIAL TOOLS
BODY
DECKLID
TABLE OF CONTENTS
page page
COVER INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . 15
REMOVAL - INTREPID, CONCORDE .. . . . . . . 13 LOCK CYLINDER
INSTALLATION - INTREPID, CONCORDE . . . . . 13 REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15
DECKLID INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . 15
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13 EMERGENCY RELEASE CABLE
INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . 13 REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16
HINGE INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . 16
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14 SLAM BUMPER
INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . 14 REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16
LATCH INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . 16
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14 SUPPORT CYLINDER
INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . 15 REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16
LATCH STRIKER INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . 16
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15
INSTALLATION
(1) With aid from a helper, place decklid in posi-
tion on vehicle.
(2) Install bolts attaching bottom of hinge to deck-
lid.
INSTALLATION
(1) Place hinge in position on vehicle.
(2) Install hinge bolts.
(3) Verify decklid operation and alignment.
LATCH
REMOVAL
(1) Open decklid.
(2) Remove fasteners attaching decklid lining or
latch cover to rear of decklid as necessary.
(3) Remove bolts attaching decklid latch to decklid
(Fig. 4), (Fig. 5) or (Fig. 6).
(4) Remove decklid latch from decklid.
Fig. 2 DECKLID (5) Disconnect power lock connector from latch
solenoid.
1 - REMOVE BOLTS
2 - DECKLID (6) Disconnect decklid ajar switch connector from
3 - WIRE HARNESS latch.
(7) Remove latch from vehicle.
(3) Install bolts to attach top of hinge to decklid.
(4) Connect wire harness connector.
(5) Align decklid to achieve equal spacing on all
sides and flush across gaps.
(6) Verify decklid operation and sealing.
HINGE
REMOVAL
(1) Open decklid.
(2) Support decklid with a suitable prop device or
block.
(3) Remove hinge bolts (Fig. 3).
(4) Remove hinge from vehicle.
LATCH STRIKER
REMOVAL
(1) Open decklid.
(2) Remove trunk liner as necessary.
(3) Remove bolts attaching latch striker (Fig. 7).
(4) Remove latch striker from vehicle.
INSTALLATION
(1) Place latch striker in position.
(2) Install bolts attaching latch striker.
(3) Verify decklid operation and alignment.
(4) Place decklid liner in position.
LOCK CYLINDER
REMOVAL
(1) Open decklid.
(2) Remove fasteners attaching decklid lining to
rear of decklid.
(3) Remove bolts attaching decklid latch to decklid
(Fig. 4) , (Fig. 5) or (Fig. 6).
(4) Remove decklid latch from decklid.
Fig. 6 DECK LID LATCH - 300M
(5) Disconnect power lock connector from latch
1 - LOCK CYLINDER BRACKET AND LOCK CYLINDER
2 - LOCK SET
solenoid.
3 - TRUNK LID LATCH (6) Disconnect decklid ajar switch connector from
4 - TRUNK LID latch.
(7) Remove latch from vehicle.
INSTALLATION (8) Remove decklid lock set.
(1) Place latch in position on vehicle. (9) Remove decklid lock cylinder.
(2) Connect decklid ajar switch connector on latch.
(3) Connect power lock connector on latch solenoid. INSTALLATION
(4) Place decklid latch in position on decklid. (1) Install decklid lock cylinder.
(5) Install bolts to attach decklid latch to decklid. (2) Install decklid lock set.
(6) Adjust decklid latch for proper decklid to quar- (3) Place latch in position on vehicle.
ter panel alignment and weatherstrip sealing. (4) Connect decklid ajar switch connector on latch.
(7) Install fasteners to attach decklid lining or (5) Connect power lock connector on latch solenoid.
latch cover to rear of decklid. (6) Place decklid latch in position on decklid.
(8) Verify decklid latch operation. (7) Install bolts to attach decklid latch to decklid.
DOOR - FRONT
TABLE OF CONTENTS
page page
DOOR - FRONT
DESCRIPTION
The front and rear door on all LH models require
the same basic service procedures regardless of door
trim configuration. The art used in this section is
typical and features only one of the current produc-
tion models.
CHECK STRAP (10) Steady door on lifting device and remove bolt
and nut attaching upper hinge to door end frame.
(11) Remove door from vehicle.
REMOVAL
(1) Place door glass in the full up position.
(2) Remove door trim panel.(Refer to 23 - BODY/
DOOR - FRONT/TRIM PANEL - REMOVAL)
(3) Remove watershield as necessary.
(4) Remove bolts attaching check strap to door end
frame and body.
(5) Remove check strap from vehicle (Fig. 1).
INSTALLATION INSTALLATION
(1) Place door in position on vehicle.
(1) Place check strap in position on vehicle.
(2) Engage door onto stud on upper door hinge.
(2) Install bolts attaching check strap to door end
(3) Steady door on lifting device and install bolt
frame and body.
and nut attaching upper hinge to door end frame.
(3) Install watershield.
Tighten the hinge bolt and nut to 28 N·m (21 ft. lbs.)
(4) Install door trim panel. (Refer to 23 - BODY/
torque. If the double ended stud is loosen or replaced
DOOR - FRONT/TRIM PANEL - INSTALLATION)
tighten the stud to 14 N·m (10 ft. lbs.) torque.
(4) Install bolt and nut attaching lower hinge to
DOOR door end frame.
(5) Verify door alignment and operation.
(6) Connect door wire harness to instrument panel
REMOVAL
wire harness.
(1) Open front door.
(7) Attach check strap.
(2) Mark location of hinge on door end frame.
(8) Align door to achieve equal spacing to sur-
(3) Disengage clips attaching wire harness connec-
rounding body panels. Panels should be flush across
tor and boot to hinge pillar.
all gaps. If door needs to be aligned (damages or
(4) Remove connector from hinge pillar.
hinge replacement) and can not be achieved, may be
(5) Disengage clip attaching wire connector
necessary to remove the double ended stud and
together on hinge pillar side of the connector.
replaced it with a bolt. This may allow extra move-
(6) Remove door wire harness from instrument
ment to achieve the proper alignment.
panel harness.
(7) Remove bolts attaching check strap to body.
(8) Support door on suitable lifting device.
(9) Remove bolt and nut attaching lower hinge to
door end frame (Fig. 2).
REMOVAL ADJUSTMENT
(1) Remove flag cover, door trim panel, water (1) Remove door trim panel.(Refer to 23 - BODY/
shield as necessary, and pull cup support bracket.(Re- DOOR - FRONT/TRIM PANEL - REMOVAL)
fer to 23 - BODY/DOOR - FRONT/TRIM PANEL - (2) Remove watershield as necessary.
REMOVAL) (3) Loosen fastener attaching scissor channel to
(2) Connect power window switch and lower win- door panel at rear of access hole (Fig. 4).
dow 150 mm (6 in.) from full up position. (4) Position glass in run weatherstrips to achieve
(3) Loosen nuts attaching regulator roller channel smooth operation and proper fit.
to glass and lift plates. (5) Push glass aft and apply slight downward pres-
(4) Slide roller channel rearward to allow lift plate sure on scissor channel and tighten screw.
nuts to pass through key hole slots in channel (Fig. (6) Tighten all fasteners.
3). (7) Install watershield.
(5) Remove glass from roller channel. (8) Install door trim panel.(Refer to 23 - BODY/
(6) Raise glass upward and out of the opening at DOOR - FRONT/TRIM PANEL - INSTALLATION)
top of door.
INSTALLATION
(1) Lower glass into opening at top of door.
(2) Place glass in position against roller channel.
(3) Insert lift plate nuts into key hole slots in
roller channel and slide channel forward to locked
position.
(4) Tighten nuts to attach regulator roller channel
to glass and lift plates.
(5) Install pull cup support bracket, water shield ,
door trim panel, and flag cover. (Refer to 23 - BODY/
DOOR - FRONT/TRIM PANEL - INSTALLATION)
HINGE
REMOVAL
Fig. 7 DOOR HINGE DOUBLE ENDED STUD
1 - DOUBLE ENDED STUD
REMOVAL 2 - NUT
(1) Mark location of hinge on hinge pillar.
(2) Remove bolt and nut attaching hinge to front
door.
INSTALLATION
INSTALLATION
(1) Place hinge in position on vehicle.
(2) Install bolt and nut attaching hinge to hinge
pillar. Tighten the hinge bolt to 28 N·m (250 in lbs.)
torque.
(3) Install bolt and nut attaching hinge to front
door. Tighten the hinge bolt and nut to 28 N·m (250
in lbs.) torque. If the double ended stub is removed
or replaced tighten the stud to 14 N·m (120 in. lbs.)
torque.
(4) Verify door alignment and operation, adjust as
necessary.
(1) Install double ended stud into the door frame. (6) Install the door trim panel (Refer to 23 -
Tighten the double ended stud to 14 N·m (120 in. BODY/DOOR - FRONT/TRIM PANEL - INSTALLA-
lbs.) torque. TION).
(2) Install hinge. Tighten the hinge bolt and nut to
28 N·m (250 in lbs.) torque.
(3) Verify door alignment and operation, adjust as
necessary.
INSTALLATION
(1) Clean the back of trim panel of plastic fillings
Fig. 9 INSTALL PUSH NUTS
(2) Seat the new handle bezel into position.
(3) Place the push nuts onto the handle bezel posts 1 - 10 mm SOCKET
2 - DOOR HANDLE BEZEL
(Fig. 9). 3 - PUSH NUT(S)
(4) Use a 10 mm socket to install the push nuts
onto the posts. Wiggling side to side motion may be
helpful. Ensure that push nuts all the way down to
secure the handle bezel to the door trim panel.
(5) Install the lock switch from the original handle
bezel to the new door handle bezel.
INSTALLATION
(1) Place door latch striker in position on vehicle.
(2) Install bolts attaching striker to B-pillar.
(3) Verify alignment and operation of door, adjust
as necessary.
LOCK CYLINDER
REMOVAL
(1) Remove door trim panel. (Refer to 23 - BODY/
DOOR - FRONT/TRIM PANEL - REMOVAL)
(2) Remove water shield, as necessary
Fig. 10 FRONT DOOR LATCH (3) Raise door glass.
1 - FRONT DOOR (4) Disengage clip holding lock link to lock cylinder.
2 - SCREWS (5) Disconnect link from lock cylinder.
3 - DOOR LATCH (6) Disconnect clip attaching lock cylinder to door
handle.
INSTALLATION (7) Pull lock cylinder from door handle (Fig. 12).
(1) Place latch in position in door.
(2) Install screws attaching door latch to door end
frame.
(3) Connect outside door handle link to door latch.
(4) Connect lock cylinder link to door latch.
(5) Connect door lock button link to door latch.
(6) Install rear glass channel.
(7) Verify latch operation.
(8) Install watershield.
(9) Install door trim panel. (Refer to 23 - BODY/
DOOR - FRONT/TRIM PANEL - INSTALLATION)
LATCH STRIKER
REMOVAL Fig. 12 DOOR LOCK CYLINDER
(1) Open front door. 1 - CLIP
2 - LOCK CYLINDER
(2) Mark location of door latch striker on B-pillar 3 - DOOR HANDLE
to assist installation alignment.
TRIM PANEL
Fig. 13 MIRROR FLAG COVER W/O SPEAKER
1 - FRONT DOOR COVER W/O SPEAKER
REMOVAL
2 - FRONT DOOR BRACKET
CAUTION: Do not pry on door trim panel, damage
INSTALLATION to trim panel will result.
(1) If previously removed, install the door bracket
(1) Remove speaker flag and housing.
and bolts.
(2) Remove speaker grille by inserting trim tool at
(2) Install the cover and engage the clips (Fig. 13).
the rear of the grille and disengaging tabs holding to
trim panel. Remove grille (Fig. 15).
SIDE VIEW MIRROR FLAG (3) Open trim plug from the pull cup and remote
bezel by inserting a small flat blade tool into the
notch and lifting up.
REMOVAL - WITH SPEAKER (4) Remove three screws from bottom of door.
(1) Open the front door. (5) Remove screw in pull cup.
(2) Remove fasteners attaching the front door flag (6) Remove screw in remote bezel.
enclosure cover to the door. Remove speaker from (7) Remove two screws in the instrument panel
cover, if necessary (Fig. 14). interface area.
WATERDAM
REMOVAL
(1) Remove door trim panel.(Refer to 23 - BODY/
DOOR - FRONT/TRIM PANEL - REMOVAL)
Fig. 17 WOOD TRIM CLIPS - TYPICAL (2) Carefully remove by pulling water dam from
1 - RETAINER CLIPS door inner panel.
2 - TRIM PANEL
(3) Pull watershield around umbrella clips in sheet
metal inner panel.
INSTALLATION - WOOD TRIM
(1) Install wood trim into mounting hole of the INSTALLATION
trim panel (Fig. 18).
(1) Position watershield on door inner panel.
(2) Install new retainer clips and seat fully (Fig.
Ensure that the water dam locator holes align and
17).
watershield is over the umbrella clips.
(3) Install the door trim panel. (Refer to 23 -
(2) Press inward on areas with adhesive to attach
BODY/DOOR - FRONT/TRIM PANEL - INSTALLA-
dam to inner door. Ensure that the dam is sealed.
TION)
(3) Install trim panel.(Refer to 23 - BODY/DOOR -
FRONT/TRIM PANEL - INSTALLATION)
DOORS - REAR
TABLE OF CONTENTS
page page
DOORS - REAR
DESCRIPTION
The front and rear door on all LH models require
the same basic service procedures regardless of door
trim configuration. The art used in this section is
typical and features only one of the current produc-
tion models.
CHECK STRAP
REMOVAL
(1) Raise door glass.
(2) Remove door trim panel. (Refer to 23 - BODY/
DOORS - REAR/TRIM PANEL - REMOVAL)
Fig. 1 REAR DOOR CHECK STRAP
(3) Remove watershield as necessary.
(4) Remove bolt and nut attaching check strap to 1 - CHECK STRAP
2 - REAR DOOR
door end and body.
(5) Remove check strap from vehicle (Fig. 1). (5) Install door trim panel.(Refer to 23 - BODY/
DOORS - REAR/TRIM PANEL - INSTALLATION)
INSTALLATION
(1) Place check strap in position on vehicle.
(2) Install bolt and nut attaching check strap to
door end and body.
(3) Verify check strap operation.
(4) Install watershield.
ADJUSTMENTS
ADJUSTMENT
(1) Remove door trim panel. (Refer to 23 - BODY/
DOORS - REAR/TRIM PANEL - REMOVAL)
(2) Remove watershield as necessary.
(3) Loosen fastener attaching scissor channel to
door panel at rear of access hole (Fig. 4).
(4) Position glass in run weatherstrips to achieve
smooth operation and proper fit.
(5) Push glass aft and apply slight downward pres-
sure on scissor channel and tighten screw.
(6) Tighten all fasteners.
(7) Install watershield. Fig. 5 REAR DOOR HINGE
(8) Install door trim panel.(Refer to 23 - BODY/ 1 - B-PILLAR
DOORS - REAR/TRIM PANEL - INSTALLATION) 2 - DOOR WIRE HARNESS CONNECTOR
3 - UPPER HINGE
4 - LOWER HINGE
5 - CHECK STRAP
INSTALLATION
(1) Align hinge to marks on door end frame.
(2) Place hinge in position on door.
(3) Install nut and bolt attaching hinge to door end
frame.
(4) Align hinge to marks on B-pillar.
(5) Install nut and bolt attaching hinge to B-pillar.
(6) Verify door alignment and operation, adjust as
necessary.
LATCH
Fig. 4 REAR DOOR GLASS ADJUSTMENT REMOVAL
1 - SCISSOR CHANNEL (1) Close door glass.
2 - REAR DOOR
3 - DOOR GLASS ADJUSTMENT (2) Remove door trim panel.(Refer to 23 - BODY/
DOORS - REAR/TRIM PANEL - REMOVAL)
HINGE (3) Remove rear glass channel.
(4) Disconnect lock button link from door latch.
(5) Disconnect outside door handle link from door
REMOVAL
latch.
(1) Mark outline of hinge on B-pillar and door end
(6) Remove screws attaching door latch to door end
frame.
frame (Fig. 6).
(2) Remove nut and bolt attaching hinge to B-pil-
(7) Remove latch from door.
lar. Refer to Rear Door Removal procedure.
(3) Remove nut and bolt attaching hinge to door
end frame (Fig. 5).
INSTALLATION
(1) Place latch in position in door.
(4) Remove hinge from door.
(2) Install screws attaching door latch to door end
frame.
(3) Connect outside door handle link to door latch.
(4) Connect lock button link to door latch.
LATCH STRIKER
REMOVAL
(1) Open rear door.
(2) Mark location of door latch striker on C-pillar
to assist installation alignment.
(3) Remove bolts holding striker to C-pillar (Fig.
7).
(4) Remove door latch striker from vehicle.
TRIM PANEL
REMOVAL
CAUTION: Do not pry on door trim panel, damage
to trim panel will result.
(1) Open trim plug from the pull cup and remote
bezel by inserting a small flat blade tool into the
notch and lifting up.
(2) Remove screw in the pull cup.
(3) Remove screw in remote bezel.
(4) Remove three screws from the bottom edge of
door (Fig. 8).
INSTALLATION
(1) Place trim panel in position on door.
(2) Connect the wiring harness clips to the trim
panel.
(3) Connect the power window switch wire harness Fig. 9 REAR DOOR INNER TRIM PANEL - TYPICAL
connector. 1 - REAR DOOR SPEAKER
(4) Connect the rear door speaker wire connect. 2 - POWER WINDOW SWITCH
(5) Connect the remote handle linkage. 3 - RETAINER CLIPS
4 - REFLECTOR
(6) Hook the trim panel over the sheet metal
flange. (10) Install screw in the remote bezel and close the
(7) Insert the forward four way alignment guide trim plug.
into position. Insert the rearward two way alignment (11) Install screw in pull cup, and close the trim
guide into position. plug.
(8) Engage the three retaining clips to attach door
trim panel to door sheet metal inner panel, up to
three ratchet clicks.
(9) Install three screws to the bottom of the door.
Tighten all screws 1.3 to 1.9 N·m (12 to 17 in. lbs.)
torque.
SAIL PANEL
REMOVAL
(1) Open the rear door.
(2) Using a trim stick, release clip attaching sail
Fig. 10 WOOD TRIM CLIPS - TYPICAL panel to the door.
1 - RETAINER CLIPS (3) Remove sail panel.
2 - TRIM PANEL
INSTALLATION
(1) Install the cable into the door and through the
hole in the door shut face.
(2) Install and tighten the cable nut.
(3) Install the knob lock nut and the actuator
knob.
(4) Tighten the lock nut.
(5) Attach the cable to the latch and engage the
clip.
(6) Install the support bracket screws and verify
correct actuator operation.
(7) Loosen the support bracket screws and adjust
the cable if necessary.
(8) Replace any support tie straps, if equipped.
(9) Install the watershield and the trim panel.
(Refer to 23 - BODY/DOORS - REAR/TRIM PANEL -
Fig. 12 REAR DOOR WINDOW REGULATOR INSTALLATION)
1 - GLASS
2 - LIFT PLATES
3 - GLASS ROLLER CHANNEL
4 - WINDOW REGULATOR
5 - REAR DOOR
INSTALLATION
(1) Insert roller channel through access hole in
door panel.
(2) Insert bolt and screw heads through key hole
slots in door panel.
(3) Tighten bolts attaching regulator to door panel.
(4) Tighten bolt to attach regulator support brace
to door panel.
EXTERIOR
TABLE OF CONTENTS
page page
BODY SIDE MOLDINGS (5) Remove masking tape guide and heat body and
molding, see step one. Firmly press molding to body
surface to assure adhesion.
REMOVAL
(1) Warm the effected stick on molding and body
metal to approximately 38° C (100° F) using a suit-
able heat lamp or heat gun.
(2) Pull stick on molding from painted surface.
(3) Remove adhesive tape residue from painted
surface of vehicle.
INSTALLATION
(1) If molding is to be reused, remove tape residue
from molding. Clean back of molding with Mopart
Super Kleen solvent or equivalent. Wipe molding dry
with lint free cloth. Apply new body side molding
(two sided adhesive) tape to back of molding.
(2) Clean body surface with Mopart Super Kleen sol-
vent or equivalent. Wipe surface dry with lint free cloth.
(3) Apply a length of masking tape on the body,
Fig. 1 BODY SIDE MOLDING
parallel to the top edge of the molding to use as a
guide, if necessary. (Fig. 1) 1 - PROTECTIVE COVER
2 - MASKING TAPE GUIDE
(4) Remove protective cover from tape on back of 3 - MOLDINGS
molding. Apply molding to body below the masking
tape guide.
REMOVAL - ADHESIVES
(1) Mark reference points before removing.
(2) Using a heat gun gently apply heat in a circu-
lar motion to loosen the adhesive bond.
(3) With your fingernail lift up and peel away
badgeing/tape from panel, using a heat gun as you
go.
(4) Clean off all traces of adhesive from the pan-
el(s) with a general purpose adhesive remover.
INSTALLATION
INSTALLATION - DOUBLE SIDED TAPE
(1) Clean panel surface with isopropy alcohol.
Fig. 2 COWL SCREEN (2) Align badgeing to reference points.
(3) Install and press securely to full adhesive con-
1 - PLENUM COWL SCREEN
2 - COWL SCREEN RIGHT tact
3 - COWL SCREEN LEFT (4) Clean away any reference points.
(1) Carefully pull/pry the broken glass holder from (4) Verify retention of the mirror glass holder
the mirror assembly. assembly by gently pulling outward on the mirror
(2) Disconnect the heated mirror electrical connec- glass holder.
tors from the terminals on the mirror glass holder, if
equipped.
HOOD
TABLE OF CONTENTS
page page
HINGE INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . 42
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40 LATCH RELEASE CABLE
INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . 40 REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 42
HOOD INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . 43
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 41 SUPPORT CYLINDER
INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . 41 REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 43
LATCH INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . 43
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 41
HINGE
REMOVAL
(1) Support hood on the side that requires hinge
replacement.
(2) Mark all bolt and hinge attachment locations
with a grease pencil or other suitable device to pro-
vide reference marks for installation.
(3) Remove the gas prop lock caps on the hinge
side.
(4) Remove the gas prop from the hinge.
(5) Remove bolts attaching hood to hinge.
(6) Remove bolts attaching hood hinge to vertical
wall of load beam and remove hinge from vehicle
(Fig. 1). To gain access to the lower left hood hinge
the wiper motor assembly will have to be removed.
(Refer to 8 - ELECTRICAL/WIPERS/WASHERS/
FRONT WIPER MOTOR - REMOVAL)
INSTALLATION
(1) If necessary, paint new hinge before installa-
tion. Fig. 1 HOOD HINGE
(2) Place hinge in position on vehicle.
1 - HOOD
(3) Install bolts attaching hood hinge to vertical 2 - HOOD HINGE
wall of load beam. 3 - GAS PROP
(4) Install bolts attaching hood to hinge. When
installing hood hinge, align all marks and secure (8) Install wiper motor assembly.(Refer to 8 -
bolts. The hood should be aligned to 4 mm (0.160 in.) ELECTRICAL/WIPERS/WASHERS/FRONT WIPER
gap to the front fenders and flush across the top sur- MOTOR - INSTALLATION)
faces along fenders. Hinge can be adjusted up or (9) Remove support from under hood and verify
down by hinge to body attaching bolts to achieve hood operation.
proper hood height.
(5) Align all marks and tighten bolts to 22.6 to
33.9 N·m (200 to 300 in. lbs.) torque. The hood
should be aligned to 4 mm (0.160 in.) gap to the front
fenders and flush across the top surfaces along fend-
ers.
(6) Place gas prop in position on vehicle.
(7) Install the lock cap on the gas prop.
INSTALLATION
(1) Place hood in position on vehicle. With assis-
tance from a helper at the opposite side of the vehicle
to support the hood, install bottom bolts attaching
hood to hinge finger tight.
(2) Install top bolts to attach hood to hinge finger
tight. When installing hood, align all marks and
secure bolts. The hood should be aligned to 4 mm
(0.160 in.) gap to the front fenders and flush across
the top surfaces along fenders.
INSTALLATION
(1) Connect hood release cable to hood latch.
(2) Place hood latch in position on crossmember.
(3) Install nuts attaching hood latch to crossmem-
ber. Tighten nuts to 22.6 to 33.9 N·m (200 to 300 in.
lbs.) torque.
(4) Verify hood latch operation before closing hood.
SUPPORT CYLINDER
REMOVAL
(1) Open hood.
(2) Support hood with a suitable prop device.
(3) Remove gas prop lock caps on each end (Fig. 8).
(4) Remove gas prop from vehicle.
INSTRUMENT PANEL
TABLE OF CONTENTS
page page
CLUSTER BEZEL
REMOVAL
(1) Open hood and disconnect the negative battery
cable remote terminal from the remote battery post
(Fig. 1).
(2) Remove the instrument panel left end cap.
(3) Remove steering column shroud cover.
(4) Tilt the steering column down into the lowest
position.
(5) Remove one screw (Concorde/300M) to cluster
bezel
(6) Remove the items to expose bezel mounting
screws. Items vary depending on model.
(7) Remove two screws over upper cluster bezel in
instrument panel brow area and all remaining
attaching screws.
(8) Using a trim stick (special tool #C-4755), gently Fig. 1 NEGATIVE BATTERY CABLE REMOTE
pry out on the instrument panel cluster bezel, discon- TERMINAL
nect headlamp switch connector, and remove. 1 - RIGHT STRUT TOWER
2 - AIR CLEANER INLET TUBE
INSTALLATION 3 - REMOTE TERMINAL
NOTE: If the glove box door is going to be left off NOTE: If the glove box door is going to be left off
for an extended period of time, the Ignition Off for an extended period of time, the Ignition Off
Draw (IOD) fuse should be pulled to maintain bat- Draw (IOD) fuse should be pulled to maintain bat-
tery condition. tery condition.
INSTALLATION INSTALLATION
(1) Install latch from outer door. (1) Install latch from outer door.
(2) Install one screw to the latch. (2) Install one screw to the latch.
(3) Place teh the inner and outer door together. (3) Place teh the inner and outer door together.
(4) Install the nine screws to the backside of the (4) Install the nine screws to the backside of the
door. door.
(5) Slide sidewalls inboard to install the door/box (5) Slide sidewalls inboard to install the door/box
assembly into instrument panel. assembly into instrument panel.
(6) Install the four screws at bottom of glove box (6) Install the four screws at bottom of glove box
door to instrument panel. door to instrument panel.
INSTRUMENT PANEL CENTER located inside the left end cap. Fuse Access is under
the left end cap (Fig. 10).
BEZEL (2) Open the right door and remove the right end
cover by inserting a trim stick (special tool #C-4755),
REMOVAL between cap and instrument panel to disengage clips.
(1) Open hood and disconnect the negative battery
cable remote terminal from the remote battery post
(Fig. 1).
(2) Remove ash receiver (if applicable).
(3) Using a trim stick (special tool #C-4755) or
equivalent, gently pry out on center trim bezel. Dis-
connect wiring connectors to HVAC controls, cigar
lighter/auxiliary power outlet and traction control
switch (if equipped) (Fig. 9).
(4) Remove instrument panel center trim bezel.
INSTALLATION
(1) Pull body mounted weatherstrip form fence
along the side of the instrument panel.
(2) Align the end cap with the retaining slots in
instrument panel and firmly snap into place (Fig.
10).
(3) Engage weatherstrip along the header and
down the A-pillar.
(4) Verify weatherstrip sealing.
(5) Close door.
Fig. 9 INSTRUMENT PANEL CENTER UPPER BEZEL
1 - INSTRUMENT PANEL
2
3
-
-
INSTRUMENT PANEL BEZEL
CONSOLE
INSTRUMENT PANEL
4 - CONSOLE SIDE PANEL SILENCER
INSTALLATION REMOVAL
(1) Connect wiring connectors to HVAC controls, (1) Remove the retaining screw to the instrument
cigar lighter/auxiliary power outlet and traction con- panel.
trol switch (if equipped). (2) Maneuver part and bracket off of the center
(2) Place the instrument panel center trim bezel floor distribution duct.
into position and firmly snap into place (Fig. 9). (3) Remove the silencer/duct.
(3) Install the ash receiver (if equipped).
(4) Connect the negative battery cable remote ter- INSTALLATION
minal to the remote battery post (Fig. 1). (1) Install the silencer/duct.
(2) Maneuver part and bracket on to the center
floor distribution duct.
INSTRUMENT PANEL END CAP (3) Install the retaining screw to the instrument
panel.
REMOVAL
(1) Open the left door and pull on the access han-
dle to disengage the end cap clips. Fuse diagram is
INSTALLATION
(1) Install the two retaining screws to the storage
bin.
(2) Install the instrument panel center trim bezel.
(3) Connect wiring connectors to HVAC controls,
cigar lighter/auxiliary power outlet and traction con-
trol switch (if equipped).
(4) Firmly snap the center trim bezel into place.
(5) Install the ash receiver (if applicable).
(6) Connect the negative battery cable remote ter-
minal to the remote battery post (Fig. 1).
INSTALLATION
(1) Place steering column cover reinforcement in
position.
(2) Connect diagnostic connector to the steering
column cover reinforcement. Fig. 15 STEERING COLUMN COVER
(3) Install the four bolts attaching steering column REINFORCEMENT
cover reinforcement (Fig. 15). 1 - INSTRUMENT PANEL
(4) Install steering column cover (Refer to 23 - 2 - STEERING COLUMN BRACKET
BODY/INSTRUMENT PANEL/STEERING COLUMN 3 - CROSS CAR BEAM
4 - STEERING COLUMN COVER REINFORCEMENT
OPENING COVER - INSTALLATION).
INTERIOR
TABLE OF CONTENTS
page page
A-PILLAR TRIM
REMOVAL
(1) Remove instrument panel end cap.
(2) Disengage clips attaching trim to A-pillar by
pulling on trim (Fig. 1).
(3) Slide A-pillar trim rearward, to disengaging
from instrument panel top cover.
(4) Remove A-pillar trim from vehicle.
INSTALLATION
(1) Slide A-pillar trim forward ensuring that the
trim engages with the instrument panel top cover.
(2) Engage clips to attach trim to A-pillar.
(3) Install instrument panel end cap.
ASSIST HANDLE
REMOVAL
(1) Pull and hold assist handle down.
(2) Remove screws attaching assist handle to roof
(Fig. 2). Fig. 3 AIR EXHAUSTER
(3) Remove assist handle from vehicle. 1 - AIR EXHAUSTER
2 - REAR TRUNK FENCE
3 - TRUNK CARPET
INSTALLATION
(1) Place assist handle in position on vehicle.
(2) Install screws to attach assist handle to roof.
INSTALLATION
(1) Place air exhauster in position. Ensure that the
locator tab is aligned.
BODY VENT (2) Engage the upper half of the air exhauster
then push the lower half in until the clips click into
REMOVAL place.
(1) Open decklid. (3) Install trunk carpet into position.
(2) Move trunk carpet to access the air exhauster
in the right/left rear corner of the trunk (Fig. 3).
CENTER CONSOLE ARMREST (3) Loosen set screw attaching gear shift knob to
gear shift.
LID ASSEMBLY (4) Remove gear shift knob from gear shift.
(5) Disengage clips attaching bezel to floor console
REMOVAL (Fig. 7), or (Fig. 8).
(1) Open armrest lid. (6) Disconnect the power outlet, if equipped.
(2) Remove lid attaching screws. (7) Disconnect the transmission range indicator
(3) Remove lid from console. illumination connector.
(8) Remove bezel from vehicle.
INSTALLATION
(1) Place lid in position. INSTALLATION
(2) Install screws attaching lid to console. (1) Connect the transmission range indicator illu-
(3) Check operation of lid. mination connector.
(2) Connect power outlet, if equipped.
(3) Place bezel in position on vehicle.
CENTER CONSOLE BEZEL (4) Engage clips attaching bezel to floor console.
(5) Install instrument panel center bezel. (Refer to
REMOVAL 23 - BODY/INSTRUMENT PANEL/INSTRUMENT
PANEL CENTER BEZEL - INSTALLATION)
NOTE: The Transmission Range Indicator Lamp (6) Push gear shift knob onto gear shift.
(electroluminescent) is not serviceable. Replace (7) Tighten set screw attaching gear shift knob to
Floor Console Panel for replacement of the lamp. gear shift.
(1) Set park brake and place gear selector in neu-
tral.
(2) Remove instrument panel center bezel. (Refer
to 23 - BODY/INSTRUMENT PANEL/INSTRUMENT
PANEL CENTER BEZEL - REMOVAL)
Fig. 8 FRONT FLOOR CONSOLE SIDE PANELS - Fig. 9 CONSOLE BEZEL WOOD TRIM
INTREPID SHOWN - 300M SIMILAR 1 - CENTER CONSOL BEZEL
2 - NUTS
1 - INSTRUMENT PANEL
3 - LOCKING TAB
2 - FLOOR CONSOLE BEZEL
3 - POWER OUTLET/CIGAR LIGHTER CONNECTORS
4 - TRANSMISSION RANGE INDICATOR ILLUMINATION
CONNECTORS
5 - REAR END CAP
6 - FLOOR CONSOLE
7 - FRONT FLOOR CONSOLE PANEL
INSTALLATION
(1) Place cup attaching into floor console and align
screw holes.
(2) Install upper and lower screws.
(3) Lower console armrest lid.
(4) Install floor console shift bezel.
(5) Install shift knob. Fig. 12 FLOOR CONSOLE END CAP
1 - FASTENERS
2 - LOCATOR PINS
3 - TABS
INSTALLATION
(1) Align rear end cap in position on console.
(2) Install rear end cap attaching screws.
(3) Push forward at the bottom to lock tabs in
position.
REMOVAL
(1) Remove shift knob.
(2) Remove console shift bezel (Fig. 8).
(3) To remove right side panel, open glove box and
remove side panel attaching screws.
(4) To remove left side panel, remove steering col-
umn cover and remove side panel attaching screws.
(5) Disengage clips from center console.
(6) Remove floor console side panel. Fig. 13 DOOR SILL TRIM
1 - FASTENERS
2 - DOOR SILL TRIM
INSTALLATION 3 - DOOR OPENING SILL
INSTALLATION
(1) If power tap wire harness was removed reat-
tach the harness with tape, along the indicated
markings.
(2) If previously removed, install the power outlet
tap. (Refer to 8 - ELECTRICAL/POWER DISTRIBU-
TION/CIGAR LIGHTER OUTLET - INSTALLA-
TION)
(3) Place center console in position on vehicle.
(4) Install fasteners attaching forward bracket to
instrument panel.
(5) Install fasteners attaching bottom of console
storage bin to rear mounting bracket.
(6) Connect the electrical connectors.
(7) Install side panels.
(8) Install center console shift bezel.
(9) Install shift knob.
INSTALLATION
(1) Place molding in position on door.
(2) Install screws attaching molding to window
frame.
(3) Install door glass run weatherstrip.
(4) Install the mirror, water shield, door trim
panel, speaker and flag trim. Fig. 17 FRONT DOOR FRAME WINDOW
1 - REMOVE SCREWS
2 - LOOSEN HALFWAY
HEADLINER
(5) Disconnect wire harness along A-pillar and
wire connector to the fuse panel.
REMOVAL
(6) Remove upper B-pillar trim panels.
(1) Remove front passenger seat for ease of
(7) Remove front and rear assist handles (if
removal of headliner.
equipped).
(2) Remove right and left A-pillar trim panels.
(8) Remove quarter trim upper panels partial,
(3) Remove right and left sun visors. Do not
keeping belt attached.
remove sun visor retainers at this time.
(9) Fully recline front seat.
(4) Remove overhead console or front interior
(10) Remove right and left sun visor retainers.
lights.
ROOF STRUCTURAL
MEMBRANE
REMOVAL
Fig. 18 HEADLINER (1) Remove headliner.
1 - REAR CLIP (2) Remove roof support membrane, using a Mold-
2 - MEMBRANE
ing Removal Tool, 3-M p/n 08978.
(3) Carefully pull down corner of roof structural
INSTALLATION membrane enough to insert molding removal tool
between roof panel and adhesive. Activate air chisel,
NOTE: DO NOT remove headliner membrane from
while keeping the blade at an angle, ensuring not to
vehicle. No additional use of any additional adhe-
flex the roof panel. Evenly separate the adhesive
sives is needed.
strips from the roof panel until the structural mem-
(1) Place headliner in proper position in vehicle. brane is removed.
(2) Engage the locator flexible clip to attach head-
NOTE: USE EXTREME CARE WHEN PULLING ON
liner to roof above rear window and press on the
THE STRUCTURAL MEMBRANE, THE ROOF PANEL
membrane to ensure contact.
WILL DENT/DING/CREASE/FLEX AND CAUSE PER-
(3) Install upper right and left quarter trim pan-
MANENT DAMAGE.
els.
(4) Install front and rear assist handles (if (4) Using a razor blade scraper tool, scrape off
equipped). remaining adhesive residue.
(5) Install right and left sun visors and retainers.
INSTALLATION
(1) Place quarter trim in position on vehicle.
(2) Engage clips attaching lower quarter trim to
inner quarter panel.
(3) Install upper quarter trim.
(4) Install sill trim.
(5) Install rear seat cushion and back.
INSTALLATION
All vehicles with driver and passenger side airbags
Fig. 24 REAR ASSIST HANDLE AND READING must have a colored coded five bullet point airbag
LAMP warning label applied to the sun visor, verify label
1 - COAT HOOK availability and ensure the label is installed.
2 - ASSIST HANDLE (1) Engage visor vanity lamp wire connector, if
3 - HEADLINING
equipped.
(2) Place visor in position on header.
INSTALLATION (3) Install screws attaching outboard visor pivot
(1) Place assist handle in position on vehicle.
base to over head.
(2) Connect reading lamp switch into slot on back
(4) Install screw attaching inboard visor retainer
of assist handle base.
to over head.
INSTALLATION
(1) Fold carpet and load into position in the trunk.
(2) Install fasteners at back and sides panel.
(3) Install spare tire board, jack, and tire.
(4) Install fasteners at forward edge along wheel-
housing
(5) Install rear seat back and cushion.
INSTALLATION
(1) Slide belt through trim panel.
(2) Place upper quarter trim in position on vehicle.
(3) Engage clips attaching upper quarter trim to
inner quarter panel.
PAINT
TABLE OF CONTENTS
page page
PAINT
SPECIFICATIONS - COLOR CODE CHARTS
EXTERIOR COLORS
DAIMLERCHRYSLER DAIMLERCHRYSLER
EXTERIOR COLOR EXTERIOR COLOR
CODE CODE
BRIGHT SILVER METALLIC WS2 INFERNO RED TINTED WEL
CLEARCOAT PEARLCOAT
BRILLIANT BLACK AXR LIGHT ALMOND PEARL ZKJ
PEARLCOAT METALLIC CLEARCOAT
BUTANE BLUE METALLIC ABE MIDNIGHT BLUE BB8
CLEARCOAT PEARLCOAT
DEEP LAVA RED ZMQ ONYX GREEN PEARLCOAT YJR
PEARLCOAT
GRAPHITE METALLIC ZDP STONE WHITE CLEARCOAT SW1
CLEARCOAT
INTERIOR COLORS
DAIMLERCHRYSLER DAIMLERCHRYSLER
INTERIOR COLOR INTERIOR COLOR
CODE CODE
DARK SLATE GREY DV SANDSTONE T5
DARK SLATE GREY DV TAUPE L5
SEATS
TABLE OF CONTENTS
page page
SEATS
SPECIFICATIONS - TORQUE
TORQUE SPECIFICATIONS
Ft. In.
DESCRIPTION N·m
Lbs. Lbs.
Front seat track to floor pan bolts 61 45 —
Front seat inboard and outboard 30 23 —
pivot bolts
Front seat recliner to seat cushion 12 9 —
frame
Front seat track to cushion frame 12 9 —
bolt
Front seat back 40 30 — Fig. 1 ARM REST ACCESS HOLE
Front seat back to seat cushion 30 22 — 1 - REMOVE ACCESS HOLE
2 - NUT
Front seat back recliner to seat 8 — 71 3 - ARM REST
back 4 - COVER
FRONT ARMREST
REMOVAL - 50/50 SPLIT
(1) Move the driver seat full forward and the pas-
senger seat full rearward.
(2) Open arm rest lid (Fig. 1).
(3) Remove access retaining nut cover.
(4) Remove arm rest retaining nut. Fig. 2 ARM REST BRACKET
(5) Slide arm rest off of bracket (Fig. 2).
1 - ARMREST BRACKET
INSTALLATION
Fig. 3 HEAD RESTRAINT REMOVAL
1 - SLEEVE GUIDE
2 - BUTTON
INSTALLATION
3 - STIFF WIRE (1) Place head restraint in position.
(2) Push head restraint down into the lock posi-
REMOVAL - AIRBAG EQUIPPED tion.
(3) Raise head restraint to ensure it locks at the
WARNING: DISCONNECT AND ISOLATE THE NEGA- last stop.
TIVE BATTERY CABLE REMOTE TERMINAL
BEFORE BEGINNING ANY FRONT SEAT REMOVAL INSTALLATION - AIRBAG EQUIPPED
OR INSTALLATION PROCEDURE. THIS WILL DIS- (1) Place head restraint in position.
ABLE THE AIRBAG SYSTEM. FAILURE TO DISCON- (2) Push head restraint down into the lock posi-
NECT THE BATTERY COULD RESULT IN tion.
ACCIDENTAL AIRBAG DEPLOYMENT AND POSSI- (3) Raise head restraint to ensure it locks at the
BLE PERSONAL INJURY. last stop.
(4) Connect the remote negative battery cable.
WARNING: ONCE THE NEGATIVE CABLE IS DIS-
CONNECTED WAIT FOR 2 MINUTES BEFORE
REMOVING ANY AIRBAG SYSTEM COMPONENTS.
REMOVAL
REMOVAL
(1) Remove front seat from vehicle (Refer to 23 -
BODY/SEATS/FRONT SEAT - REMOVAL).
(2) Remove front seat cushion side shields (Refer
to 23 - BODY/SEATS/SEAT SIDE SHIELD -
REMOVAL).
(3) Remove bolts attaching recliner to seat back Fig. 10 REMOVE SEAT BACK
cushion frame (Fig. 9). 1 - RECLINER BOLT HOLE
(4) Remove inboard and outboard pivot bolts (Fig. 2 - SEAT BACK BOLT HOLE
3 - J-STRAP RETAINER
10).
(5) Disconnect any electrical connectors to the seat
WARNING: ONCE THE NEGATIVE CABLE IS DIS-
back, if equipped.
CONNECTED WAIT FOR 2 MINUTES BEFORE
(6) Remove seat back from seat cushion.
REMOVING ANY AIRBAG SYSTEM COMPONENTS.
FRONT SEAT BACK COVER (1) Disconnect and isolate the negative battery
cable (Fig. 15).
(2) Remove the front seat from the vehicle. Refer
REMOVAL to the procedure in this group.
(3) Remove the front seat head restraint. Refer to
REMOVAL the procedure in this group.
(1) Remove head restraint (Refer to 23 - BODY/ (4) Remove the front seat back panel. Refer to the
SEATS/ARMREST - FRONT - REMOVAL). procedure in this group.
(2) Remove front seat back (Refer to 23 - BODY/ (5) Remove the head restraint guide sleeves from
SEATS/FRONT SEAT BACK - REMOVAL). the seat back. Refer to the procedure in this group.
(3) Remove lumbar support handle, if equipped. (6) Remove the front seat cushion side shield.
(4) Disengage the J-strap retainer (Fig. 10). Refer to the procedure in this group.
(5) Roll cover upward to hog rings. Cut hog rings (7) Release all J-strap retaining clips (Fig. 16).
to free cover (Fig. 14). (8) Remove the outboard recliner attaching bolt
(6) Roll cover to top of cushion and remove head (Fig. 17). This will allow access to the seat back heat-
restraint sleeve guides. ing element wire harness.
(7) Remove cover from seat back. (9) Disconnect heating element wire connector.
(10) Disconnect seat airbag module electrical con-
nector at the module. Slide the yellow locking tab
down to release lock function. Then depress the two
retaining tangs (located on the sides of the connector
) and pull straight out (Fig. 18).
(11) Remove the seat airbag module retaining nuts
and plastic shield, if equipped. Carefully slide module
from nylon sleeve (Fig. 18).
REMOVAL - NON AIRBAG (1) Disconnect and isolate the remote negative bat-
tery cable.
(1) Remove front seat from vehicle (Refer to 23 -
(2) Remove seat from vehicle. Refer to the proce-
BODY/SEATS/FRONT SEAT - REMOVAL).
dure in this group.
(2) Remove screws attaching seat cushion side
(3) Remove screws attaching seat cushion side
shield to the bottom and side of seat cushion (Fig. 26)
shield to the bottom and side of seat cushion (Fig. 26)
and (Fig. 27).
and (Fig. 27).
(3) Remove shield from seat
(4) Remove shield from seat
(4) Disconnect switch wire connectors, if equipped.
(5) Disconnect switch wire connectors, if equipped.
(5) Remove seat switches, if equipped.
(6) Remove seat switches, if equipped.
INSTALLATION
INSTALLATION - NON AIRBAG
(1) Transfer seat switches, if equipped.
(2) Connect switch wire connectors to cushion side
shield, if equipped.
(3) Place shield in position on seat cushion.
(4) Install screws attaching seat cushion side
shield. Tighten screws in sequence, refer to (Fig. 26).
(5) Install front seat (Refer to 23 - BODY/SEATS/
FRONT SEAT - INSTALLATION).
Fig. 26 BOTTOM VIEW OF SIDE SHIELD AND
TIGHTENING SEQUENCE INSTALLATION - AIRBAG EQUIPPED
(1) Transfer seat switches, if equipped.
(2) Connect switch wire connectors to cushion side
shield, if equipped.
(3) Place shield in position on seat cushion.
(4) Install screws attaching seat cushion side
shield. Tighten screws in sequence, refer to (Fig. 26).
(5) Install seat. Tighten front screws to 61 N·m (45
ft. lbs.) and the rear screws to 61 N·m (45 ft. lbs.)
torque.
(6) Connect the remote negative battery cable.
LUMBAR SUPPORT
Fig. 27 SIDE VIEW OF SIDE SHIELD
1 - SIDESHIELD FASTENERS REMOVAL
The front seat lumbar support is not service sepa-
REMOVAL - AIRBAG EQUIPPED rately. The front seat back frame will need to be
replaced.
WARNING: DISCONNECT AND ISOLATE THE NEGA-
TIVE BATTERY CABLE REMOTE TERMINAL
BEFORE BEGINNING ANY FRONT SEAT REMOVAL
OR INSTALLATION PROCEDURE. THIS WILL DIS-
ABLE THE AIRBAG SYSTEM. FAILURE TO DISCON-
NECT THE BATTERY COULD RESULT IN
ACCIDENTAL AIRBAG DEPLOYMENT AND POSSI-
BLE PERSONAL INJURY.
(1) Remove seat cushion side shield (Refer to 23 - (5) Install bolt attaching seat back recliner to seat
BODY/SEATS/SEAT SIDE SHIELD - REMOVAL). back on each side of seat. Tighten bolt to 8 N·m (71
(2) Remove bolts attaching seat back recliner to in. lbs.) torque.
seat back frame on each side of seat (Fig. 28). (6) Install the seat cushion side shields (Refer to
(3) Remove bolts attaching seat adjuster to cush- 23 - BODY/SEATS/SEAT SIDE SHIELD - INSTAL-
ion pan (Fig. 29). LATION).
(4) Disconnect wire harness fasteners from cushion
pan.
(5) Remove seat adjuster from seat cushion.
REAR ARMREST
REMOVAL
REMOVAL - 60/40
(1) Fold down 40 side rear seat back.
(2) Remove arm rest bolt (Fig. 30).
(3) Remove retaining C-clip.
(4) Remove arm rest.
INSTALLATION
(1) Place seat adjuster in position on seat cushion
pan.
(2) Connect wire harness fasteners to the cushion
pan.
(3) Install bolts attaching seat adjuster to cushion Fig. 30 REAR SEAT ARM REST - 60/40
pad. 1 - BOLT
(4) Install seat back. 2 - RETAINING C-CLIP
REMOVAL
REMOVAL
(1) Remove rear seat cushion (Refer to 23 - BODY/
SEATS/SEAT CUSHION - REAR - REMOVAL).
(2) Remove inboard nuts attaching rear seat back
and belts to floor and outboard bolts attaching seat
back to floor (Fig. 35).
(3) Pull bottom of seat back out to slide rear seat
back mounts off studs. Push rear seat back upward
to disengage hooks at top of seat back.
(4) Remove rear seat back from vehicle.
Fig. 36 Collar Assembly
1 - 40 SECTION
2 - 60 SECTION
INSTALLATION - 60 SECTION
(1) Install the 60 seat section on pivot bracket.
(2) Install bolt attaching 60 seat section. Tighten
bolt to 16 N·m (12 ft. lbs.) torque.
(3) Install the 40 seat section on pin.
(4) Install bolt attaching 40 seat section. Tighten
bolt to 16 N·m (12 ft. lbs.) torque.
(5) Install seat back collar assembly (Refer to 23 -
BODY/SEATS/REAR SEAT BACK COLLAR ASSEM-
BLY - INSTALLATION).
INSTALLATION
Fig. 41 REAR SEAT CUSHION (1) Position seat cushion cover on cushion.
1 - RETAINER LOOP (2) Install hog rings to seat cover.
2 - REAR SEAT BACK (3) Engage the J-strap retainers.
3 - REAR SEAT CUSHION
4 - CUPS (4) Steam wrinkles from seat cushion, if necessary.
(5) Install seat cushion (Refer to 23 - BODY/
SEATS/SEAT CUSHION REAR - INSTALLATION).
STATIONARY GLASS
TABLE OF CONTENTS
page page
OPERATION
The windshield is attached to the window frame
with urethane adhesive. The urethane adhesive is
applied cold and seals the surface area between the
window opening and the glass. The primer adheres
the urethane adhesive to the windshield.
Fig. 1 REAR WINDOW GLASS - TYPICAL It is difficult to salvage a windshield during the
removal operation. The windshield is part of the
1 - REAR WINDOW GLASS
2 - MOLDING structural support for the roof. The urethane bonding
3 - URETHANE used to secure the windshield to the fence is difficult
to cut or clean from any surface. If the moldings are
WINDSHIELD set in urethane, it would also be unlikely they could
be salvaged. Before removing the windshield, check
DESCRIPTION the availability of the windshield and moldings from
the parts supplier.
WARNING: DO NOT OPERATE THE VEHICLE
WITHIN 24 HOURS OF WINDSHIELD INSTALLATION. REMOVAL
IT TAKES AT LEAST 24 HOURS FOR URETHANE The urethane adhesive holding the windshield to
ADHESIVE TO CURE. IF IT IS NOT CURED, THE the opening pinch weld (fence) can be cut using a
WINDSHIELD MAY NOT PERFORM PROPERLY IN sharp cold knife from the exterior of the vehicle.
AN ACCIDENT. Using the cold knife method is effective if the wind-
URETHANE ADHESIVES ARE APPLIED AS A SYS- shield is already broken. If the glass must be sal-
TEM. USE GLASS CLEANER, GLASS PREP SOL- vaged, cutting the urethane adhesive from the
VENT, GLASS PRIMER, PVC (VINYL) PRIMER AND interior of the vehicle using a reciprocating or oscil-
PINCH WELD (FENCE) PRIMER PROVIDED BY THE lating power knife is recommended.
ADHESIVE MANUFACTURER. IF NOT, STRUCTURAL (1) Remove inside rear view mirror (Refer to 23 -
INTEGRITY COULD BE COMPROMISED. BODY/INTERIOR/REAR VIEW MIRROR - REMOV-
DAIMLERCHRYSLER DOES NOT RECOMMEND AL).
GLASS ADHESIVE BY BRAND. TECHNICIANS (2) Remove cowl cover (Refer to 23 - BODY/EXTE-
SHOULD REVIEW PRODUCT LABELS AND TECHNI- RIOR/COWL GRILLE AND SCREEN - REMOVAL).
CAL DATA SHEETS, AND USE ONLY ADHESIVES (3) Remove drip rail weatherstrips as necessary to
THAT THEIR MANUFACTURES WARRANT WILL gain access to screws holding windshield side mold-
RESTORE A VEHICLE TO THE REQUIREMENTS OF ings (Fig. 2). Pull outward on molding at the bottom
FMVSS 212. TECHNICIANS SHOULD ALSO INSURE of A-pillars using pliers.
THAT PRIMERS AND CLEANERS ARE COMPATIBLE (4) Cut urethane bonding from around windshield
WITH THE PARTICULAR ADHESIVE USED. using a suitable sharp cold knife. A pneumatic cut-
BE SURE TO REFER TO THE URETHANE MANU- ting device can be used if available. (Fig. 3)
FACTURER’S DIRECTIONS FOR CURING TIME (5) Remove windshield from vehicle.
SPECIFICATIONS, AND DO NOT USE ADHESIVE
AFTER ITS EXPIRATION DATE.
VAPORS THAT ARE EMITTED FROM THE URE-
Fig. 4 Center Windshield and Mark at Support Fig. 6 Lower Windshield Into Position
Spacers 1 - FENCE
2 - WINDSHIELD WITH URETHANE APPLIED
1 - A-PILLAR 3 - REFERENCE MARKS
2 - WINDSHIELD
3 - MARKS
4 - FOAM BLOCK (3)
5 - COWL
SUNROOF
TABLE OF CONTENTS
page page
SUNROOF express open until you have passed through the full
closed position. The OPEN button may be released
and the sunroof will continue to open in the express
DESCRIPTION
open feature. If the VENT button is pressed and held
WARNING: Keep fingers and other body parts out while the sunroof is in the open position, the sunroof
of sunroof opening at all times. will travel to the close position and then to the vent
position. Releasing the button at anytime during the
The sunroof features a power sliding glass panel travel will cause the sunroof to stop at that current
and a sunshade which can be manually positioned position.
anywhere along its travel, rearward of glass panel
front edge. DIAGNOSIS AND TESTING
Before beginning sunroof diagnostics verify that all
OPERATION other power accessories are in proper operating con-
The sunroof is electrically operated from a two dition. Refer to Sunroof Diagnostic Chart for possible
switches located on the windshield header, rearward causes. If not, a common electrical problem may
of the map lamp. To operate the sunroof the ignition exist. Refer to Wiring Diagram Information, of this
switch must be in the On/Run position. One switch publication for circuit, splice and component descrip-
(CLOSE) is a push button type and used too close the tions. Check the condition of the circuit protection
sunroof. Pressing and holding the CLOSE button, the (20 amp high current fuse (battery feed) located in
sunroof will fully close. If the CLOSE button is the Power Distribution Center (PDC). Check the
released prior to the sunroof reaching the fully closed cover of the PDC for location of the fuse. The ten
position, the sunroof will stop in that position. The amp fuse (ignition feed) located in cavity 14 of the
other switch (OPEN/VENT) is a rocker type for open- Junction Block). Inspect all wiring connector pins for
ing and venting the sunroof. Pressing and releasing proper engagement and continuity. Check for battery
the OPEN button once the sunroof will express open voltage at battery and ignition pins of the power sun-
and the wind deflector will raise. If the button is roof express module wiring connector. Refer to Wiring
pressed a second time the sunroof will stop in that Diagram Information, for circuit information. The
position. To open the sunroof from the vent position, controller will not operate at less than 10 volts.
push and hold the open button. The sunroof will not Check the ground at the sunroof express module.
HOUSING ASSEMBLY (1) Move glass panel to the fully closed position.
(2) Disconnect the control switch wire connector.
(3) Remove headliner as necessary to gain access
REMOVAL
to sunroof drive motor (Refer to 23 - BODY/INTERI-
(1) Remove headliner (Refer to 23 - BODY/INTE-
OR/HEADLINER - REMOVAL).
RIOR/HEADLINER - REMOVAL).
(4) Disconnect the drive motor wire harness con-
(2) Disconnect the drain tubes from sunroof hous-
nectors (Fig. 3).
ing (Fig. 2).
(3) Loosen fasteners attaching sunroof housing
assembly.
(4) With the aid of a helper, remove fasteners
attaching sunroof housing assembly to roof panel.
INSTALLATION
(1) With the Glass panel in the fully closed posi-
tion.
(2) With the aid of a helper, raise rear end of sun-
roof housing assembly and guide into position and
start fasteners.
(3) Tighten the fasteners attaching the sunroof
module to roof panel. Tighten the fasteners to 8.5 to
9 N·m (75 to 80 in. lbs.) torque. Fig. 3 SUNROOF DRIVE MOTOR AND EXPRESS
(4) Connect the drain tubes to the sunroof housing. MODULE
(5) With the aid of a helper move the headliner 1 - EXPRESS MODULE
through the rear door into position. 2 - SCREW
(6) Engage headliner rear locating clip.
(7) Connect sunroof harness connector at the (5) Remove drive motor fasteners and remove
C-post. motor from the sunroof housing.
(8) Connect wire harness connector along A-post to
fuse panel. INSTALLATION
(9) Connect mirror wiring connector. (1) Ensure that the glass panel is in the fully
(10) Connect wire harness connector along A-post closed position before mounting the motor. If motor
to fuse panel. fails with the window in the open position the sun-
(11) Connect battery negative cable. roof glass panel timing will have to be timed. The
(12) Move both front seats into proper position. new motor comes in the fully closed position and
(13) Test sunroof operation, adjust as necessary. with a gage for setting cable timing. Refer to Sunroof
(14) Finish installing the headliner. Ensure that Glass Panel Timing.
door weatherstrips are in position (Refer to 23 - (2) Place drive motor into position on the sunroof
BODY/INTERIOR/HEADLINER - INSTALLATION). housing and install fasteners. (Fig. 3)
(3) Set headliner into position.
(4) Connect express module, drive motor, and con-
DRIVE MOTOR trol switch wire connectors.
(5) Test sunroof operation, adjust as necessary.
REMOVAL (6) Finish installing the headliner (Refer to 23 -
BODY/INTERIOR/HEADLINER - INSTALLATION).
NOTE: (7) Connect the control switch wire connector.
The sunroof system is timed from the factory so
that the motor shuts off automatically when the
sunroof window reaches a certain position. Extreme
care must be taken when removing the motor, tim-
ing may be thrown off causing possible damage to
the sunroof system. Anytime the motor is removed
from the sunroof assembly the sunroof glass panel
must be in the FULLY CLOSED POSITION or the
unit will be out of time. The drive motor cannot be
reset to the park position after being removed.
Refer to sunroof timing.
GLASS PANEL (6) Loosen the rear screws on each side enough to
make the rear adjustment.
(7) Adjust the rear of the sunroof glass panel 1
REMOVAL
mm (1/32 inch) above the top surface of the roof
(1) Slide sunshade rearward to the open position.
panel.
(2) Move the glass panel to the fully closed posi-
(8) Tighten the rear two screws.
tion.
(9) Check for proper fit. If not OK, repeat glass
(3) Remove the four attaching screws (Fig. 4).
panel adjustment.
(4) Lift off glass panel and remove from vehicle.
ADJUSTMENT - SUNROOF GLASS PANEL
TIMING
Sunroof Drive Cable Timing
NOTE: A gage comes with the new motor.
ADJUSTMENTS
ADJUSTMENT
(1) Move the sunshade rearward to the open posi-
tion.
(2) Move the sunroof glass panel to the fully closed
position.
(3) Loosen the forward screws on each side enough
to make the front adjustment.
(4) Adjust the front of the sunroof glass panel 1
mm (1/32 inch) below the top surface of the roof
panel.
(5) Tighten the front two screws.
Fig. 5 SUNROOF DRIVE CABLE TIMING
1 - MOVE DRIVER SLIDE FORWARD/AFT
2 - GAGE
INSTALLATION
FRONT HOSES
(1) Insert end of new hose into drain grommet and
replace grommet into sheet metal (Fig. 6) and/or (Fig.
7).
(2) Attach hose upper clips into holes in sheet
metal.
Fig. 6 FRONT
(3) Engage upper flair end of hose into sunroof
1 - A-PILLAR module drain nipple and secure with ratchet clamp.
2 - DRAIN HOSE
3 - GROMMET
REAR HOUSING HOSE
REAR HOUSING HOSE (1) Using the proper drain hose (there is a right
(1) Move glass panel to the fully closed position. and left side rear hose) attach drain hose clips to
(2) Disconnect the control switch and wire connec- body holes, with the flair at the top towards the sun-
tor. roof nipple.
(2) Connect top flair end of the drain hose to the INSTALLATION
sunroof housing drain nipple with the ratchet clamp (1) Insert sunroof express module in the keyway
(Fig. 8). located in the sunroof module and slide the module
(3) Connect the lower end of the drain tube to the outward to lock it into position.
rubber grommet near the rear window of the vehicle. (2) Install the sunroof express module screw.
(4) Connect the drain hose to the sunroof housing (3) Connect the wire connectors to the sunroof
and test drainage. express module.
(5) Install shelf panel, ensure not to pinch the rub- (4) Install the headliner into position (Refer to 23 -
ber grommets (Refer to 23 - BODY/INTERIOR/REAR BODY/INTERIOR/HEADLINER - INSTALLATION).
SHELF TRIM PANEL - INSTALLATION). (5) Test sunroof operation, adjust if necessary.
(6) Install headliner (Refer to 23 - BODY/INTERI-
OR/HEADLINER - INSTALLATION).
(7) Connect the control switch wire connector. SUNSHADE
Install control switch.
(8) Test for proper operation of the sunroof. REMOVAL
(1) Open sunroof approximately 90% of the way.
(2) Push sunshade down until tabs clear glass.
MODULE ASSEMBLY (3) Move sunshade forward of glass panel.
(4) Using a flat blade tool, remove front guide
REMOVAL blocks from track. By pushing block toward the cen-
(1) Move the glass panel to the fully closed posi- ter of the vehicle (Fig. 9).
tion. (5) Slide the sunshade forward while lifting the
(2) Lower headliner as necessary to gain access to front through the opening until the rear guide blocks
the sunroof express module (Refer to 23 - BODY/IN- are accessible.
TERIOR/HEADLINER - REMOVAL).
(3) Disconnect the express module wire harness CAUTION: Use care not to crease the sunshade
connectors. (Fig. 3) when removing or installing.
(4) Remove express module screw.
(5) Remove express module from the keyway by (6) Disengage rear guide blocks from track.
sliding module towards the center of the vehicle.
INSTALLATION INSTALLATION
(1) Install the sunshade from outside of the vehicle (1) Place wind deflector at 90% in the vertical posi-
with the sunroof 90% open. tion to the sunroof. With the sunroof open.
(2) Put rear guide blocks into sunshade guide (2) Push ends of the deflector towards the front of
track. the vehicle to engage ends.
(3) Push sunshade back and down through the (3) Lower wind deflector to normal position.
sunroof opening. (4) Push one corner to the opposite side of the
(4) Using a flat blade tool, put front guide blocks vehicle until tab clears vehicle body and lower deflec-
into the sunshade track. By pushing the block tor for that corner.
towards the center of the vehicle. (5) Push the side that was just installed com-
(5) Push sunshade back to the glass panel. pletely down.
(6) Push sunshade down until the sunshade clears (6) Push the opposite corner cross vehicle until tab
the glass then move sunshade rearward behind the clears the body. Then lower deflector to position.
glass panel. (7) Test sunroof operation.
WIND DEFLECTOR
REMOVAL
(1) Open sunroof glass panel.
(2) Push down one corner of the wind deflector and
let the other corner rise up (Fig. 10).
(3) Push the low corner towards the opposite side
of the vehicle until tab on sunshade clears the body.
Then raise the corner up.
(4) Repeat the procedure to the other corner.
(5) Lift wind deflector to 90% of the way.
(6) Push the attaching ends of the deflector to the
rear of the vehicle to disengage the deflector.
WEATHERSTRIP/SEALS
TABLE OF CONTENTS
page page
INSTALLATION
(1) Place door mount weatherstrip in position on
door with the paint dot in the upper corner of the
B-pillar.
(2) Install push pin fasteners to attach door
mounted weatherstrip to lower door.
(3) Verify door alignment and seal.
BODY STRUCTURE
TABLE OF CONTENTS
page page
DESCRIPTION FIGURE
BODY GAP AND FLUSH – INTREPID 1
BODY GAP AND FLUSH – CONCORDE AND 300M 2
OPENING DIMENSIONS
SPECIFICATIONS - BODY OPENING DIMENSION
INDEX
DESCRIPTION FIGURE
WINDSHIELD AND FRONT DOOR OPENINGS 3
REAR DOOR OPENINGS - CONCORDE/300M 4
REAR DOOR OPENINGS - INTREPID 5
REAR WINDOW AND TRUNK OPENING - CONCORDE 6
REAR WINDOW AND TRUNK OPENINGS - INTREPID 7
REAR WINDOW AND TRUNK OPENINGS - 300M 8
SEALER LOCATIONS
SPECIFICATIONS - SEALER LOCATIONS
INDEX
DESCRIPTION FIGURE
METHODS OF APPLYING AUTO BODY SEALANT 9
STRUT TOWER AND COWL AREA 10
LOAD BEAM AND COWL AREA 11
BODY SIDE APERTURE 12
FLOOR PAN 13
FLOOR PAN 14
FLOOR PAN 15
FLOOR PAN 16
REAR TRUNK AREA 17
INNER WHEELHOUSE 18
REAR QUARTER PANE 19
DECKLID 20
FRONT DOORS 21
REAR DOORS 22
Fig. 20 DECKLID
STRUCTURAL ADHESIVE
LOCATIONS
SPECIFICATIONS - STRUCTURAL ADHESIVE
LOCATIONS
INDEX
DESCRIPTION FIGURE
HOOD - CONCORDE AND 300M 23
HOOD - INTREPID 24
FRONT FENDER 25
ROOF 26
SUNROOF 27
DOORS 28
DECKLID 29
Fig. 26 ROOF
Fig. 27 SUNROOF
Fig. 28 DOORS
Fig. 29 DECKLID
WELD LOCATIONS
SPECIFICATIONS - WELD LOCATIONS
INDEX
DESCRIPTION FIGURE
ENGINE COMPARTMENT 30
ENGINE COMPARTMENT 31
ENGINE COMPARTMENT 32
ENGINE COMPARTMENT 33
ENGINE COMPARTMENT 34
ENGINE COMPARTMENT 35
ENGINE COMPARTMENT 36
ENGINE COMPARTMENT 37
ENGINE COMPARTMENT 38
ENGINE COMPARTMENT 39
ENGINE COMPARTMENT 40
DASH AND COWL 41
DASH AND COWL 42
DASH AND COWL 43
DASH AND COWL 44
DASH AND COWL 45
DASH AND COWL 46
ROOF PANEL AND ROOF BOWS 47
ROOF PANEL AND ROOF BOWS 48
ROOF PANEL AND ROOF BOWS 49
ROOF PANEL AND ROOF BOWS 50
BODY SIDE APERTURE 51
BODY SIDE APERTURE 52
BODY SIDE APERTURE 53
BODY SIDE APERTURE 54
BODY SIDE APERTURE 55
BODY SIDE APERTURE 56
BODY SIDE APERTURE 57
BODY SIDE APERTURE 58
BODY SIDE APERTURE 59
BODY SIDE APERTURE 60
BODY SIDE APERTURE 61
BODY SIDE APERTURE 62
BODY SIDE APERTURE 63
FLOOR PAN 64
FLOOR PAN 65
FLOOR PAN 66
DESCRIPTION FIGURE
FLOOR PAN 67
FLOOR PAN 68
FLOOR PAN 69
FLOOR PAN 70
FLOOR PAN 71
FLOOR PAN 72
FLOOR PAN 73
FLOOR PAN 74
FLOOR PAN 75
FLOOR PAN 76
FLOOR PAN 77
FLOOR PAN 78
FLOOR PAN 79
FLOOR PAN 80
REAR SHELF 81
REAR SHELF 82
REAR SHELF 83
page page
HEATING & AIR other (green in color) coolants. If this occurs, a reduc-
tion in the extended service interval will result. Refer
CONDITIONING to Lubrication and Maintenance for service sched-
ules(Refer to LUBRICATION & MAINTENANCE -
DESCRIPTION - ENGINE COOLING SYSTEM SPECIFICATIONS).
REQUIREMENTS
To maintain the performance level of the HVAC CAUTION: Do not add additional inhibitors, anti-rust
system, the engine cooling system must be properly products, or soluble oil (sold as “water pump lubri-
maintained. Refer to Cooling for more information- cants”). These products may not be compatible
(Refer to 7 - COOLING - OPERATION). with the engine coolant.
The use of a bug screen is not recommended. Any
Refer to Cooling for cooling system procedures(Re-
obstructions in front of the radiator or condenser can
fer to 7 - COOLING - STANDARD PROCEDURE).
reduce the performance of the A/C and/or engine cool-
ing system.
DIAGNOSIS AND TESTING
WARNING: DO NOT OPEN COOLING SYSTEM
WHEN HOT AS PERSONAL INJURY OR DAMAGE
DIAGNOSIS AND TESTING - A/C
TO VEHICLE MAY RESULT.
PERFORMANCE TEST
The air conditioning system is designed to remove
OPERATION - ENGINE COOLING SYSTEM heat and humidity from the air entering the passen-
REQUIREMENTS ger compartment. The evaporator, located in the
HVAC unit, is cooled to temperatures near the freez-
The engine cooling system is designed to develop
ing point. As warm damp air passes over the fins in
internal pressure of 97 to 123 kPa (14 to 18 psi).
the evaporator, moisture in the air condenses to
Wait 15 minutes (after the engine is shut off), or
water, dehumidifying the air. High humidity reduces
until safe temperature and pressure is attained,
the evaporator’s ability to cool the air. During periods
before opening the cooling system. Refer to Coolin-
of high heat and humidity, an air conditioning sys-
g(Refer to 7 - COOLING - OPERATION). Coolant
tem will be less effective. With the a/c heater control
temperature can be checked using the scan tool
set to RECIRC, only air from the passenger compart-
(DRBIIIt).
ment passes through the evaporator. As the passen-
When additional coolant is needed, it should be
ger compartment air dehumidifies, A/C performance
added to the coolant pressure bottle. Use only 50/50
levels rise.
mix of Mopart Antifreeze/Coolant, 5 Year/100,000
Mile Formula (orange in color), or the equivalent and
distilled water. This coolant must not be mixed with
DIAGNOSIS AND TESTING - HEATER hose to check temperature, and for pressure in the
system. If the hose is very firm, allow time to cool
PERFORMANCE TEST
down. Place a rag over the cap and turn it to the first
safety stop. Allow pressure to escape through the
PRE-DIAGNOSTIC PREPARATIONS
overflow tube. When the system stabilizes, remove
Check the coolant level, drive belt tension, vacuum
the cap completely.
line connections, electrical connections, radiator air
flow and fan operation. Start engine and allow to
MAXIMUM HEATER OUTPUT: TEST AND ACTION
warm up to normal temperature.
Engine coolant is provided to the heater system by
WARNING: DO NOT REMOVE RADIATOR CAP two 19 mm (3/4 inch inside diameter) heater hoses.
WHEN ENGINE IS HOT, SEVERE PERSONAL With engine idling at normal running temperature,
INJURY CAN RESULT. set the control to maximum heat, floor, and high
blower setting. Using a test thermometer, check the
If vehicle has been run recently, wait until engine air temperature coming from the floor outlets. Refer
is cool before removing cap. Squeeze the radiator to Temperature Reference Table.
TORQUE SPECIFICATIONS
TORQUE SPECIFICATIONS
CONTROLS
TABLE OF CONTENTS
page page
(9) Remove coil wire bracket/ground clip screw and Fig. 4 CLUTCH COIL SNAP RING
wire harness. 1 - SNAP RING PLIERS
2 - CLUTCH COIL
3 - SNAP RING
4 - COMPRESSOR
INSTALLATION
(1) Align pin in back of field coil with hole in com-
pressor end housing, and position field coil into place.
Make sure that lead wires are properly routed, and
fasten the diode and coil wire bracket with retaining
screw.
(2) Install field coil retaining snap ring with Snap
Ring Pliers (C- 4574). Press snap ring to make sure
it is properly seated in the groove.
DIAGNOSIS AND TESTING - A/C COMPRESSOR clutch coil wire harness connector. If OK, go to Step 4.
If not OK, repair the open circuit as required.
CLUTCH RELAY
(4) The relay coil battery terminal (86) is connected
to the fused ignition switch output (run/start) circuit.
RELAY TEST
There should be battery voltage at the cavity for relay
The compressor clutch relay (Fig. 6) is located in
terminal 86 with the ignition switch in the On posi-
the Power Distribution Center (PDC). Refer to the
tion. If OK, go to Step 5. If not OK, repair the open
PDC label for relay identification and location.
circuit to the fuse in the junction block as required.
Remove the relay from the PDC to perform the fol-
(5) The coil ground terminal cavity (85) is switched
lowing tests:
to ground through the Powertrain Control Module
(1) A relay in the de-energized position should
(PCM). There should be continuity between this cav-
have continuity between terminals 87A and 30, and
ity and the A/C compressor clutch relay control cir-
no continuity between terminals 87 and 30. If OK, go
cuit cavity of the PCM wire harness connector C
to Step 2. If not OK, replace the faulty relay.
(gray) at all times. If not OK, repair the open circuit
(2) Resistance between terminals 85 and 86 (elec-
as required.
tromagnet) should be 75 ± 5 ohms. If OK, go to Step
3. If not OK, replace the faulty relay.
(3) Connect a battery to terminals 85 and 86.
REMOVAL
(1) Disconnect and isolate the battery negative
There should now be continuity between terminals
cable.
30 and 87, and no continuity between terminals 87A
(2) Remove the cover from the Power Distribution
and 30. If OK, see Relay Circuit Test in the Diagno-
Center (PDC) (Fig. 7).
sis and Testing section of this group. If not OK,
replace the faulty relay.
INSTALLATION
(1) Install the blower motor resistor in the HVAC
housing.
(2) Install the two screws that secure the blower
motor resistor to the HVAC housing and tighten to
2.2 N·m (20 in. lbs.).
(3) Plug in the harness connector to the blower
motor resistor.
(4) Install the lower right underpanel silencer/
duct.
(5) Connect the negative battery cable remote ter-
minal to the remote battery post(Refer to 8 - ELEC-
TRICAL/BATTERY SYSTEM/CABLES -
INSTALLATION).
Fig. 12 EVAPORATOR TEMPERATURE SENSOR SET
POINT
EVAPORATOR TEMPERATURE EVAPORATOR TEMPERATURE SENSOR SET POINT
SENSOR AMBIENT TEMPERATURE
SENSOR READING °F (° C)
A/C CLUTCH OFF
EVAPORATOR TEMPERATURE
SET POINT ° F (° C)
185 (85) 31 (-0.5)
DESCRIPTION 100 (37.7) 31 (-0.5)
The evaporator temperature sensor is a tempera- 77 (25) 34 (1.1)
ture sensing element located at the coldest point on 60 (15.5) 35 (1.6)
-70 (-56.6) 36 (2.2)
the face of the evaporator. The evaporator tempera-
ture sensor prevents condensate water on the evapo-
rator coil from freezing which can block airflow. The
REMOVAL
(1) Open the hood and disconnect the negative bat-
probe is a thermistor inside a metal tube which is
tery cable remote terminal from the remote battery
wedged between the evaporator fins. The metal tube
post (Refer to 8 - ELECTRICAL/BATTERY SYSTEM/
is tightly held by the evaporator fins so that the ther-
CABLES - REMOVAL).
mistor in the tube will detect the temperature of the
(2) Remove the right under panel silencer.
evaporator. The thermistor will change resistance as
(3) Disconnect the wiring connector for the evapo-
the temperature changes.
rator probe.
(4) At the center of the HVAC housing, locate the
OPERATION
evaporator probe access plate. Using a flat blade pry
The Body Control Module (BCM) will send a Pro-
tool, pull back on the locking tab. Twist the access
grammable Communications Interface (PCI) bus mes-
plate counter clockwise one-quarter turn, and push
sage to the Powertrain Control Module (PCM), which
the plate inside the HVAC housing (Fig. 13).
will check engine, coolant temperature, and refriger-
(5) Orient the plate in such a way that allows it to
ant pressure temperature before turning ON the A/C
be pulled through the mounting hole, and remove it.
Compressor Clutch. Turning ON the A/C Compressor
(6) Pull the evaporator probe out of evaporator
Clutch will allow the system to cool the evaporator.
core.
The BCM will send a message to the PCM when the
evaporator temperature becomes too cold. The PCM
will then turn OFF the A/C Compressor Clutch,
INSTALLATION
The new probe must not go into the same
before evaporator freeze up occurs. The DRBIIIt scan
hole (in the evaporator coil) that the old probe
tool can be used to monitor this operation. The tem-
was removed.
perature set point at which the clutch is turned OFF
(1) The evaporator is manufactured with three
varies with the outside ambient temperature. The
holes for probe insertion. Insert the probe in the
temperature at which the clutch is turned ON is pre-
uppermost hole.
set to 2° F above the OFF setpoint mentioned above.
(2) Insert the access plate inside the HVAC hous-
Refer to Evaporator Temperature Sensor Set point
ing and orientate it so that the locking tab is one-
table and (Fig. 12) for the correct setpoint.
INSTALLATION
(1) Connect the wire harness connector to the
mode door actuator.
(2) Install the mode door actuator on the HVAC
housing, making sure its keyed shaft is positioned
properly.
(3) Install the three fastener screws and tighten to
2.2 N·m (20 in. lbs.).
(4) Reposition the center support bracket and
install fastener. Refer to Body for the procedures.
(5) Install the rear seat heat forward adaptor duct.
(6) Install the center floor heat adaptor duct.
(7) Install the floor console(Refer to 23 - BODY/IN-
TERIOR/FLOOR CONSOLE - INSTALLATION).
(8) Install the left and right underpanel ducts.
(9) Connect the negative battery cable remote ter-
minal to the remote battery post(Refer to 8 - ELEC-
TRICAL/BATTERY SYSTEM/CABLES -
INSTALLATION).
SUN SENSOR The sun sensor is located so the sun hits the sen-
sor in the same way that it hits the driver and the
passenger. It is important that the area in front of
DESCRIPTION
the sensor be unobstructed. Check that the following
The sun sensor is only used on vehicles equipped
items are not in the way of the sun sensor.
with Automatic Temperature Control (ATC). The sen-
• Windshield wipers that are adjusted too high.
sor is mounted on the top of the instrument panel
• Stickers on the windshield that are directly in
below the instrument panel top cover (Fig. 19).
front of the sensor.
• Top cover which is not properly installed. The
sun sensor should be 1/4 inch. above the top cover.
• Caps or papers which might cover the sensor.
Some ATC equipped vehicles may exhibit a lack of
passenger comfort in sunny weather such as in the
early afternoon. Verify that the ATC system is func-
tioning properly. Inspect the location of the sun sen-
sor. The sun sensor must protrude approximately 1/4
inch above the instrument panel top cover to insure
proper operation. If the sensor does not protrude 1/4
inch, perform the following procedure:
• Confirm that the top cover is properly installed
• Remove the top cover
• Remove fasteners from sun sensor
• Install one 1/4-20 nut per fastener under the sun
sensor so that it is shimmed higher
Fig. 19 ATC SUN SENSOR • Reinstall the sun sensor. Do not overtighten
screw. If a longer screw is required, use 8-15x1 inch.
OPERATION Refer to the proper Diagnostic Information for the
The sun sensor is not a thermistor type sensor but electrical test.
rather a photo diode. For this reason the sun sensor
responds to sun light intensity rather than tempera- REMOVAL
ture. It is used to aid in determining proper mode
door position, temperature door position and blower WARNING: ON VEHICLES EQUIPPED WITH AIR-
speed. The sun sensor is also used to sense day/night BAGS, DISABLE THE AIRBAG SYSTEM BEFORE
conditions for automatic headlight control if so ATTEMPTING ANY STEERING WHEEL, STEERING
equipped, and has an LED indicator for the vehicle COLUMN, OR INSTRUMENT PANEL COMPONENT
security system. DIAGNOSIS OR SERVICE. DISCONNECT AND ISO-
The sun sensor is not serviceable and must be LATE THE BATTERY NEGATIVE (GROUND) CABLE,
replaced if found to be defective. THEN WAIT TWO MINUTES FOR THE AIRBAG SYS-
TEM CAPACITOR TO DISCHARGE BEFORE PER-
DIAGNOSIS AND TESTING - SUN SENSOR FORMING FURTHER DIAGNOSIS OR SERVICE. THIS
IS THE ONLY SURE WAY TO DISABLE THE AIRBAG
WARNING: ON VEHICLES EQUIPPED WITH AIR- SYSTEM. FAILURE TO TAKE THE PROPER PRE-
BAGS, DISABLE THE AIRBAG SYSTEM BEFORE CAUTIONS COULD RESULT IN AN ACCIDENTAL
ATTEMPTING ANY STEERING WHEEL, STEERING AIRBAG DEPLOYMENT AND POSSIBLE PERSONAL
COLUMN, OR INSTRUMENT PANEL COMPONENT INJURY.
DIAGNOSIS OR SERVICE. DISCONNECT AND ISO-
LATE THE BATTERY NEGATIVE (GROUND) CABLE, (1) Open the hood and disconnect the negative bat-
THEN WAIT TWO MINUTES FOR THE AIRBAG SYS- tery cable remote terminal from the remote battery
TEM CAPACITOR TO DISCHARGE BEFORE PER- post.
FORMING FURTHER DIAGNOSIS OR SERVICE. THIS (2) Remove the instrument panel top cover(Refer
IS THE ONLY SURE WAY TO DISABLE THE AIRBAG to 23 - BODY/INSTRUMENT PANEL/INSTRUMENT
SYSTEM. FAILURE TO TAKE THE PROPER PRE- PANEL TOP COVER - REMOVAL).
CAUTIONS COULD RESULT IN AN ACCIDENTAL (3) Remove the two Sun Sensor mounting screws.
AIRBAG DEPLOYMENT AND POSSIBLE PERSONAL (4) Lift the sensor out of the instrument panel and
INJURY. disconnect the wiring.
(5) Remove the sensor from the vehicle.
INSTALLATION
(1) Connect the wiring harness connector to the
sensor and position in the vehicle.
(2) Install the two sensor fasteners.
(3) Install the instrument panel top cover(Refer to
23 - BODY/INSTRUMENT PANEL/INSTRUMENT
PANEL TOP COVER - INSTALLATION).
(4) Connect the negative battery cable remote ter-
minal to the remote battery post(Refer to 8 - ELEC-
TRICAL/BATTERY SYSTEM/CABLES -
INSTALLATION).
DISTRIBUTION
TABLE OF CONTENTS
page page
DISTRIBUTION INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . 24
DESCRIPTION HVAC HOUSING
DESCRIPTION - HVAC SYSTEM AIRFLOW . . 23 REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24
DESCRIPTION - HVAC FORCED DISASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . 25
RECIRCULATION . . . . . . . . . . . . . . . . . . . . . . 23 ASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25
OPERATION - HVAC SYSTEM AIRFLOW . . . . . 23 INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . 26
BLOWER MOTOR INSTRUMENT PANEL DEMISTER DUCTS
DESCRIPTION . . . . . . . . . . . . . . . . . . . . . . . . . 23 DESCRIPTION . . . . . . . . . . . . . . . . . . . . . . . . . 26
OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . . 23 OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . . 26
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24
PLUMBING
TABLE OF CONTENTS
page page
PLUMBING INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . 36
DESCRIPTION - REFRIGERANT LINE . . . . . . . 27 SUCTION LINE
OPERATION - REFRIGERANT LINE . . . . . . . . . 28 REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 36
WARNING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 28 INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . 38
CAUTION A/C EVAPORATOR
REFRIGERANT SYSTEM PRECAUTIONS . . . 28 REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 38
REFRIGERANT SYSTEM HOSES/LINES/ INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . 38
TUBES/PRECAUTIONS . . . . . . . . . . . . . . . . . 28 A/C EXPANSION VALVE
DIAGNOSIS AND TESTING - REFRIGERANT DESCRIPTION . . . . . . . . . . . . . . . . . . . . . . . . . 39
SYSTEM LEAKS . . . . . . . . . . . . . . . . . . . . . . 29 OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . . 39
STANDARD PROCEDURE DIAGNOSIS AND TESTING - A/C EXPANSION
STANDARD PROCEDURE - REFRIGERANT VALVE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 39
SYSTEM SERVICE EQUIPMENT . . . . . . . . . . 29 REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 39
STANDARD PROCEDURE - REFRIGERANT INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . 40
RECOVERY . . . . . . . . . . . . . . . . . . . . . . . . . . 30 HEATER CORE
STANDARD PROCEDURE - REFRIGERANT REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40
SYSTEM EVACUATE . . . . . . . . . . . . . . . . . . . 30 INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . 40
STANDARD PROCEDURE - REFRIGERANT RECEIVER / DRIER
SYSTEM CHARGE . . . . . . . . . . . . . . . . . . . . . 31 DESCRIPTION . . . . . . . . . . . . . . . . . . . . . . . . . 41
SPECIFICATIONS OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . . 41
CHARGE CAPACITY . . . . . . . . . . . . . . . . . . . 31 REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 41
A/C COMPRESSOR INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . 41
DESCRIPTION . . . . . . . . . . . . . . . . . . . . . . . . . 31 REFRIGERANT
OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . . 31 DESCRIPTION . . . . . . . . . . . . . . . . . . . . . . . . . 42
DIAGNOSIS AND TESTING - COMPRESSOR OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . . 42
NOISE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 31 REFRIGERANT OIL
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 32 DESCRIPTION . . . . . . . . . . . . . . . . . . . . . . . . . 42
INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . 32 OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . . 42
A/C CONDENSER STANDARD PROCEDURE - REFRIGERANT
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 33 OIL LEVEL . . . . . . . . . . . . . . . . . . . . . . . . . . . 42
INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . 34 SERVICE PORT VALVE CORE
A/C DISCHARGE LINE REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 43
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 34 INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . 44
INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . 34
LIQUID LINE
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35
A/C COMPRESSOR
DESCRIPTION
The air conditioning system uses a Nippondenso
10PA17 ten cylinder, double-acting swash plate-type
compressor on all models. This compressor has a
fixed displacement of 170 cubic centimeters (10.374
cubic inches), and has both the suction and discharge
ports located on the cylinder head. A label identifying
the use of R-134a refrigerant is located on the com-
pressor. This compressor uses an aluminum swash
plate, teflon coated pistons and aluminum cylinder
walls. One-way check valves are used to regulate
refrigerant flow through the compressor.
REMOVAL
The A/C compressor may be unbolted and reposi-
tioned without discharging the refrigerant system.
Discharging is not necessary if removing the com-
pressor clutch/coil assembly, engine, cylinder head, or
alternator.
A/C CONDENSER
REMOVAL
WARNING: REVIEW THE WARNINGS IN THE FRONT
OF THIS SECTION BEFORE PERFORMING THE
FOLLOWING OPERATION. (Refer to 24 - HEATING &
AIR CONDITIONING/PLUMBING - WARNING)
LIQUID LINE
REMOVAL
WARNING: REVIEW THE WARNINGS IN THE FRONT
OF THIS SECTION BEFORE PERFORMING THE
FOLLOWING OPERATION. (Refer to 24 - HEATING &
AIR CONDITIONING/PLUMBING - WARNING)
Fig. 8 A/C PRESSURE TRANSDUCER AND
DISCHARGE LINE - 2.7L (1) Recover the refrigerant from the system. (Refer
1 - A/C COMPRESSOR CLUTCH ELECTRICAL CONNECTOR to 24 - HEATING & AIR CONDITIONING/PLUMB-
2 - DISCHARGE LINE ING - STANDARD PROCEDURE - REFRIGERANT
3 - A/C PRESSURE TRANSDUCER AND CONNECTOR
4 - SUCTION LINE
RECOVERY)
5 - A/C COMPRESSOR (2) Remove the engine air inlet tube and the air
distribution duct on vehicles equipped with 3.2/3.5 L
Any kinks or sharp bends in the refrigerant plumb- engines.
ing will reduce the capacity of the entire air condition- (3) Remove the a/c line to the expansion valve fas-
ing system. Kinks and sharp bends reduce the flow of tener using a M10 Hex wrench. Remove the suction
refrigerant in the system. A good rule for the flexible line block from the expansion valve, cap the line and
hose refrigerant lines is to keep the radius of all bends swing it out of the way.
at least ten times the diameter of the hose. In addi-
tion, the flexible hose refrigerant lines should be CAUTION: Cap off all lines that are not being
routed so they are at least 80 millimeters (3 inches) replaced. Cap/plug the expansion valve and con-
from the exhaust manifold (Whenever possible). denser fittings.
(3) Remove the engine air inlet tube and air distri-
bution duct for access to the compressor lines.
(4) Remove the bolt holding the line at the com-
pressor using a 6mm allen wrench (3.2/3.5L), or M10
Hex (2.7L) (Fig. 12) and (Fig. 13).
Any kinks or sharp bends in the refrigerant plumb- WARNING: REVIEW THE WARNINGS IN THE FRONT
ing will reduce the capacity of the entire air condi- OF THIS SECTION BEFORE PERFORMING THE
tioning system. Kinks and sharp bends reduce the FOLLOWING OPERATION. (Refer to 24 - HEATING &
flow of refrigerant in the system. A good rule for the AIR CONDITIONING/PLUMBING - WARNING)
flexible hose refrigerant lines is to keep the radius of
all bends at least ten times the diameter of the hose. The HVAC housing must be removed from the
In addition, the flexible hose refrigerant lines should vehicle when replacing the evaporator.
be routed so they are at least 80 millimeters (3 (1) Open the hood and disconnect the negative bat-
inches) from the exhaust manifold. tery cable remote terminal from the remote battery
High pressures are produced in the refrigerant sys- post.
tem when the air conditioning compressor is operat- (2) Remove the HVAC housing from vehicle. (Refer
ing. Extreme care must be exercised to make sure to 24 - HEATING & AIR CONDITIONING/DISTRI-
that each of the refrigerant system connections is BUTION/HVAC HOUSING - REMOVAL)
pressure-tight and leak free. It is a good practice to (3) Remove the recirculation door actuator(Refer to
inspect all flexible hose refrigerant lines at least once 24 - HEATING & AIR CONDITIONING/CONTROLS/
a year to make sure they are in good condition and RECIRCULATION DOOR ACTUATOR - REMOVAL).
properly routed. (4) Remove the recirculation door and housing.
(1) Position the suction line in the vehicle. (5) Remove the upper HVAC housing retaining
(2) Install the suction line fitting to the manifold screws(Refer to 24 - HEATING & AIR CONDITION-
on the compressor. Tighten the mounting bolt to 23 ING/DISTRIBUTION/HVAC HOUSING - DISAS-
N·m (17 ft. lbs.). On a 2.7L, tighten the mid-line SEMBLY).
retaining nut and frame rail screw to 7 N·m (5 ft. (6) At the center of the HVAC housing, locate the
lbs.). evaporator probe access plate. Using a flat blade pry
(3) Install the engine air inlet tube and air distri- tool, pull back on the locking tab. Twist the access
bution duct(Refer to 9 - ENGINE/AIR INTAKE SYS- plate counter clockwise one-quarter turn, and push
TEM/AIR CLEANER ELEMENT - INSTALLATION). the plate inside the HVAC housing.
(4) Connect the suction line to the expansion (7) Remove the upper half of the HVAC housing.
valve. Tighten the retaining nut to 8 N·m (6 ft. lbs.). (8) Lift the evaporator out of the lower housing.
(5) Evacuate the refrigerant system. (Refer to 24 -
HEATING & AIR CONDITIONING/PLUMBING - INSTALLATION
STANDARD PROCEDURE - REFRIGERANT SYS-
TEM EVACUATE) WARNING: REVIEW THE WARNINGS IN THE FRONT
(6) Charge the refrigerant system. (Refer to 24 - OF THIS SECTION BEFORE PERFORMING THE
HEATING & AIR CONDITIONING/PLUMBING - FOLLOWING OPERATION. (Refer to 24 - HEATING &
STANDARD PROCEDURE - REFRIGERANT SYS- AIR CONDITIONING/PLUMBING - WARNING)
TEM CHARGE)
Any kinks or sharp bends in the refrigerant plumb-
ing will reduce the capacity of the entire air condi-
A/C EVAPORATOR tioning system. Kinks and sharp bends reduce the
flow of refrigerant in the system. A good rule for the
REMOVAL flexible hose refrigerant lines is to keep the radius of
all bends at least ten times the diameter of the hose.
WARNING: ON VEHICLES EQUIPPED WITH AIR- In addition, the flexible hose refrigerant lines should
BAGS, DISABLE THE AIRBAG SYSTEM BEFORE be routed so they are at least 80 millimeters (3
ATTEMPTING ANY STEERING WHEEL, STEERING inches) from the exhaust manifold.
COLUMN, OR INSTRUMENT PANEL COMPONENT
RECEIVER / DRIER (9) Plug or cap liquid line fittings while system is
open to prevent moisture intrusion.
DESCRIPTION
The receiver/drier is located in the engine compart- INSTALLATION
ment near the dash panel on the passenger side of
WARNING: REVIEW THE WARNINGS IN THE FRONT
the vehicle. The receiver/drier incorporates a sight
OF THIS SECTION BEFORE PERFORMING THE
glass for visual diagnosis of the refrigerant system.
FOLLOWING OPERATION. (Refer to 24 - HEATING &
AIR CONDITIONING/PLUMBING - WARNING)
OPERATION
High-pressure liquid refrigerant from the con- Any kinks or sharp bends in the refrigerant plumb-
denser flows into the receiver/drier. A drying agent, ing will reduce the capacity of the entire air condi-
called a desiccant, is used to remove any traces of tioning system. Kinks and sharp bends reduce the
moisture from the refrigerant system. The receiver/ flow of refrigerant in the system. A good rule for the
drier also performs a filtering action to prevent for- flexible hose refrigerant lines is to keep the radius of
eign material in the refrigerant from contaminating all bends at least ten times the diameter of the hose.
the expansion valve. In addition, during periods of In addition, the flexible hose refrigerant lines should
high demand air conditioner operation, the receiver/ be routed so they are at least 80 millimeters (3
drier acts as a reservoir to store surplus refrigerant. inches) from the exhaust manifold (whenever possi-
The A/C refrigerant must be removed from the sys- ble).
tem before removing the receiver/drier using a refrig- High pressures are produced in the refrigerant sys-
erant recovery machine. Replace the receiver/drier if tem when the air conditioning compressor is operat-
an A/C system is left open for an extended period of ing. Extreme care must be exercised to make sure
time. that each of the refrigerant system connections is
The receiver/drier cannot be repaired and, if faulty, pressure-tight and leak free. It is a good practice to
must be replaced. inspect all flexible hose refrigerant lines at least once
a year to make sure they are in good condition and
REMOVAL properly routed.
WARNING: REVIEW THE WARNINGS IN THE FRONT NOTE: Upon installation, loosely fit all parts and
OF THIS SECTION BEFORE PERFORMING THE lines together before individually tightening them to
FOLLOWING OPERATION. (Refer to 24 - HEATING & prevent damage.
AIR CONDITIONING/PLUMBING - WARNING)
(1) Recover the refrigerant from the system. (Refer NOTE: Always install new O-rings and lubricate with
to 24 - HEATING & AIR CONDITIONING/PLUMB- the proper refrigerant before installation.
ING - STANDARD PROCEDURE -REFRIGERANT
RECOVERY) (1) Install the small line from the receiver/drier to
(2) Remove the engine air inlet tube and the air expansion valve on the new receiver/drier.
distribution duct on vehicles equipped with 3.2/3.5 (2) Install the receiver/drier in the vehicle.
liter engine(Refer to 9 - ENGINE/AIR INTAKE SYS- (3) Install the a/c line at the receiver/drier. Tighten
TEM/AIR CLEANER ELEMENT - REMOVAL). the fastener to 13.6 N·m (10 ft. lbs.).
(3) Remove one 8mm hex bolt to the receiver/drier (4) Install the receiver/drier bracket in the strut
bracket. tower.
(4) Remove the nut retaining the a/c lines to the (5) Install the nut retaining the a/c line to the
expansion valve. expansion valve. Tighten to 8 N·m (6 ft. lbs.).
(5) Gently pry the receiver/drier bracket out of the (6) Install the bolt to the receiver/drier bracket.
strut tower. (7) Install the engine air inlet tube and the air dis-
(6) Remove one a/c line at the receiver/drier (from tribution duct on vehicles equipped with 3.2/3.5 L
the condenser). engine(Refer to 9 - ENGINE/AIR INTAKE SYSTEM/
(7) Remove the receiver/drier from vehicle. AIR CLEANER ELEMENT - INSTALLATION).
EMISSIONS CONTROL
TABLE OF CONTENTS
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DESCRIPTION - HIGH AND LOW LIMITS Technicians can display stored DTC’s. Refer to
Diagnostic Trouble Codes (Refer to 8 - ELECTRICAL/
The PCM compares input signal voltages from each
ELECTRONIC CONTROL MODULES/POWER-
input device with established high and low limits for
TRAIN CONTROL MODULE - DESCRIPTION). For
the device. If the input voltage is not within limits
obtaining the DTC information, use the Data Link
and other criteria are met, the PCM stores a diagnos-
Connector with the DRBIIIt scan tool (Fig. 1).
tic trouble code in memory. Other diagnostic trouble
code criteria might include engine RPM limits or
input voltages from other sensors or switches that
must be present before verifying a diagnostic trouble
code condition.
OPERATION
OPERATION - SYSTEM
The Powertrain Control Module (PCM) monitors
many different circuits in the fuel injection, ignition,
emission and engine systems. If the PCM senses a
problem with a monitored circuit often enough to
indicate an actual problem, it stores a Diagnostic
Trouble Code (DTC) in the PCM’s memory. If the
code applies to a non-emissions related component or
system, and the problem is repaired or ceases to
exist, the PCM cancels the code after 40 warmup
cycles. Diagnostic trouble codes that affect vehicle
emissions illuminate the Malfunction Indicator Lamp Fig. 1 Data Link Connector
(MIL). Refer to Malfunction Indicator Lamp in this
section.
DRB IIIT STATE DISPLAY TEST MODE an open circuit, a short circuit, or a defective switch.
If the State Display screen shows the change from
OPERATION HIGH to LOW or LOW to HIGH, assume the entire
The switch inputs to the Powertrain Control Mod- switch circuit to the PCM functions properly. From
ule (PCM) have two recognized states; HIGH and the state display screen, access either State Display
LOW. For this reason, the PCM cannot recognize the Inputs and Outputs or State Display Sensors.
difference between a selected switch position versus
EVAPORATIVE EMISSIONS
TABLE OF CONTENTS
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OPERATION
The emission control principle used in the ORVR
system is that the fuel flowing into the filler tube
(approx. 1” I.D.) creates an aspiration effect which
draws air into the fill tube. During refueling, the fuel
tank is vented to the vapor canister to capture escap-
ing vapors. With air flowing into the filler tube, there
are no fuel vapors escaping to the atmosphere. Once
the refueling vapors are captured by the canister, the
vehicle’s computer controlled purge system draws
vapor out of the canister for the engine to burn. The
vapors flow is metered by the purge solenoid so that
there is no or minimal impact on driveability or
Fig. 5 ASSEMBLY REMOVED tailpipe emissions.
INSTALLATION As fuel starts to flow through the fill tube, it opens
(1) Install O-ring to EVAP canister (Fig. 6). the normally closed check valve and enters the fuel
(2) Install NVLD assembly (Fig. 4) and twist the tank. Vapor or air is expelled from the tank through
assembly clockwise to lock assembly in the EVAP the control valve to the vapor canister. Vapor is
canister (Fig. 5). absorbed in the canister until vapor flow in the lines
(3) Connect the hoses to the NVLD assembly. stops, either following shut-off or by having the fuel
(4) Connect the electrical connector to the NVLD level in the tank rise high enough to close the control
assembly. valve. The control valve contains a float that rises to
(5) Install fuel tank, refer to the Fuel Delivery sec- seal the large diameter vent path to the canister. At
tion for Fuel Tank Installation. this point in the fueling of the vehicle, the tank pres-
(6) Connect the negative battery cable. sure increase, the check valve closes (preventing tank
fuel from spiting back at the operator), and fuel then
rises up the filler tube to shut-off the dispensing noz-
zle.
PCV VALVE
DESCRIPTION
The PCV valve contains a spring loaded plunger.
The plunger meters the amount of crankcase vapors
routed into the combustion chamber based on intake
manifold vacuum (Fig. 10) or (Fig. 11).
OPERATION (1) With engine idling, remove the hose from the
When the engine is not operating or during an PCV valve. If the valve is not plugged, a hissing
engine backfire, the spring forces the plunger back noise will be heard as air passes through the valve. A
against the seat. This prevents vapors from flowing strong vacuum should also be felt when a finger is
through the valve (Fig. 12). placed over the valve inlet.
(2) Install hose on PCV valve. Remove the
make-up air hose from the air plenum at the rear of
the engine. Hold a piece of stiff paper (parts tag)
loosely over the end of the make-up air hose.
(3) After allowing approximately one minute for
crankcase pressure to reduce, the paper should draw
up against the hose with noticeable force. If the
engine does not draw the paper against the grommet
after installing a new valve, replace the PCV valve
Fig. 12 Engine Off or Engine Backfire No Vapor hose.
Flow (4) Turn the engine off. Remove the PCV valve
from intake manifold. The valve should rattle when
When the engine is at idle or cruising, high mani- shaken.
fold vacuum is present. At these times manifold vac- (5) Replace the PCV valve and retest the system if
uum is able to completely compress the spring and it does not operate as described in the preceding
pull the plunger to the top of the valve (Fig. 13). In tests. Do not attempt to clean the old PCV valve.
this position there is minimal vapor flow through the If the valve rattles, apply a light coating of Loctitet
valve. Pipe Sealant With Teflon to the threads. Thread the
PCV valve into the manifold plenum and tighten to 7
N·m (60 in. lbs.) torque.
VAPOR CANISTER
OPERATION
All vehicles use a maintenance free, evaporative
(EVAP) canister. Fuel tank vapors vent into the can-
Fig. 13 High Intake Manifold Vacuum Minimal Vapor ister. The canister temporarily holds the fuel vapors
Flow until intake manifold vacuum draws them into the
During periods of moderate intake manifold vac- combustion chamber. The Powertrain Control Module
uum the plunger is only pulled part way back from (PCM) purges the canister through the proportional
the inlet. This results in maximum vapor flow purge solenoid. The PCM purges the canister at pre-
through the valve (Fig. 14). determined intervals and engine conditions.
REMOVAL
(1) Disconnect the negative battery cable.
(2) Remove the fuel tank, refer to the fuel tank
removal in this section
(3) Disconnect the EVAP hoses from the EVAP can-
ister and the electrical connector (Fig. 15).
TABLE OF CONTENTS
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EXHAUST GAS
RECIRCULATION
SPECIFICATIONS
TORQUE
INSTALLATION - 3.5L
(1) Disconnect negative battery cable. Fig. 2 EGR tube and Valve
(2) Remove air inlet tube and resonator. 1 - EGR TUBE
(3) Disconnect electrical connector from EGR 2 - EGR VALVE
valve.
(4) Remove EGR tube mounting screws at EGR (1) Loosely install EGR valve and new gasket on
valve (Fig. 1). cylinder head (Fig. 2).
The EGR valve attaches to the rear of the right (2) Using a new gasket, loosely install the EGR
cylinder head. tube and mounting screws.
(5) Remove EGR valve mounting screws. (3) Tighten EGR valve to cylinder head screws to
(6) Clean gasket surfaces. Discard old gasket. If 31 N·m (275 in. lbs.) torque.
necessary, clean EGR passages. (4) Tighten the EGR tube to EGR valve screws to
11 N·m (95 in. lbs.) torque.
(5) Attach electrical connector to solenoid.
INSTALLATION (6) Install air inlet tube and resonator.
(7) Connect negative battery cable.
INSTALLATION - 2.7L
(1) Loosely install EGR valve and lower tube, use
a new gasket between tube and EGR valve.
(2) Install EGR valve to rear of Cylinder head, do
not tighten screws.
EGR TUBE - 2.7L (5) Remove EGR tube mounting screws at EGR
valve.
(6) Remove EGR upper tube.
REMOVAL (7) When removing EGR upper tube assembly
being careful not to drop the silicone rubber seals in
REMOVAL - 2.7L UPPER TUBE the intake manifold. Clean gasket surfaces on the
EGR valve. Note that any loose dirt can lodge
between the pintle and the seat and cause valve
leakage that will give a rough idle and depressed
manifold vacuum.
INSTALLATION
INSTALLATION - 2.7L UPPER TUBE
The EGR tube attaches to the intake manifold ple-
num on both sides of the throttle body and the EGR
Fig. 4 PCV Valve—2.7L Engine valve (Fig. 6).
1 - PCV VALVE (1) inspect rubber silicone seals on intake manifold
2 - THROTTLE BODY end of EGR tube.
3 - EGR TUBE
INSTALLATION - 3.5L
The EGR tube attaches to the bottom of the intake
manifold plenum beside the throttle body (Fig. 8).
(1) Install rubber silicone seals on intake manifold
end of EGR tube, being careful to be sure silicone
rubber seals is correctly installed and undamaged.
(2) Using a new gasket, loosely install the EGR
tube into the intake manifold and loosely install EGR
tube to EGR valve.
(3) Tighten the EGR tube to EGR valve screws to
11 N·m (95 in. lbs.) torque.
(4) Install clips for the EGR tube to intake mani-
fold plenum (Fig. 9).
(5) Install transmission to throttle body bracket.
(6) Install air inlet tube and resonator.
(7) Connect negative battery cable.
ON-BOARD DIAGNOSTICS
TABLE OF CONTENTS
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Diagnostic Trouble Codes (DTCs) DTCs can be erased anytime with a DRBIIIt.
Erasing the DTC with the DRBIIIt erases all OBD II
With OBD II, different DTC faults have different
information. The DRBIIIt automatically displays a
priorities according to regulations. As a result, the
warning that erasing the DTC will also erase all
priorities determine MIL illumination and DTC era-
OBD II monitor data. This includes all counter infor-
sure. DTCs are entered according to individual prior-
mation for warm-up cycles, trips and Freeze Frame.
ity. DTCs with a higher priority overwrite lower
priority DTCs. Trip Indicator
Priorities The Trip is essential for running monitors and
extinguishing the MIL. In OBD II terms, a trip is a
• Priority 0 —Non-emissions related trouble codes.
set of vehicle operating conditions that must be met
• Priority 1 — One trip failure of a two trip fault
for a specific monitor to run. All trips begin with a
for non-fuel system and non-misfire. (MIL Off)
key cycle.
• Priority 2 — One trip failure of a two trip fault
Good Trip
for fuel system (rich/lean) or misfire. (MIL Off)
The Good Trip counters are as follows:
• Priority 3 — Two trip failure for a non-fuel sys-
• Global Good Trip
tem and non-misfire or matured one trip comprehen-
• Fuel System Good Trip
sive component fault. (MIL On)
• Misfire Good Trip
• Priority 4 — Two trip failure or matured fault
• Alternate Good Trip (appears as a Global Good
for fuel system (rich/lean) and misfire or one trip cat-
Trip on DRBIIIt)
alyst damaging misfire. Catalyst damage misfire is a
• Comprehensive Components
2 trip MIL. The MIL flashes on the first trip when
• Major Monitor
catalyst damage misfire levels are present. (MIL On)
• Warm-Up Cycles
Non-emissions related failures have no priority.
Global Good Trip
One trip failures of two trip faults have low priority.
To increment a Global Good Trip, the Oxygen sen-
Two trip failures or matured faults have higher pri-
sor and Catalyst efficiency monitors must have run
ority. One and two trip failures of fuel system and
and passed, and 2 minutes of engine run time.
misfire monitor take precedence over non-fuel system
Fuel System Good Trip
and non-misfire failures.
To count a good trip (three required) and turn off
DTC Self Erasure the MIL, the following conditions must occur:
With one trip components or systems, the MIL is • Engine in closed loop
illuminated upon test failure and DTCs are stored. • Operating in Similar Conditions Window
Two trip monitors are components requiring failure • Short Term multiplied by Long Term less than
in two consecutive trips for MIL illumination. Upon threshold
failure of the first test, the Task Manager enters a • Less than threshold for a predetermined time
maturing code. If the component fails the test for a If all of the previous criteria are met, the PCM will
second time the code matures and a DTC is set. count a good trip (three required) and turn off the
After three good trips the MIL is extinguished and MIL.
the Task Manager automatically switches the trip