Professional Documents
Culture Documents
IN Introduction 8O Restraints
5 Brakes 8R Wipers/Washers
7 Cooling 8W Wiring
8A Audio 9 Engine
8H Horn 23 Body
INTRODUCTION
TABLE OF CONTENTS
page page
DIGIT 21
Price Class
• E = Economy
• H = High Line
• L = Low Line
• M = Mid Line
• P = Premium
• S = Special/Sport
• X = Performance Image
DIGITS 22 AND 23
Fig. 2 BODY CODE PLATE LOCATION Body Type
1 - BODY COPY PLATE • 41 = Four Door Sedan
2 - BATTERY TRAY
BODY CODE PLATE LINE 1
DIGITS 20, 21, AND 22
Engine Code DIGITS 1, 2, AND 3
• EER = 2.7 L, Six Cylinder, 24 Valve, DOHC, Transaxle Codes
Gasoline, Aluminum Block (MPI) • DGX = 42LE 4-Speed Electronic Automatic
• EGG = 3.5 L, Six Cylinder, 24 Valve, SOHC, Transaxle
High Output, Gasoline, Aluminum Block (MPI)
• EGK = 3.5 L, Six Cylinder, 24 Valve, SOHC, DIGIT 4
High Output, Gasoline, Aluminum Block (MPI) Open Space
• EGJ = 3.5 L, Six Cylinder, 24 Valve, SOHC,
DIGIT 5
High Output, Gasoline, Aluminum Block
• EGC = 3.5 L, Six Cylinder, 24 Valve, SOHC, Market Code
Magnum, Gasoline, Aluminum Block • C = Canada
• B = International
DIGIT 23 • M = Mexico
Open Space • U = United States
FASTENER IDENTIFICATION
DESCRIPTION
The SAE bolt strength grades range from grade 2
to grade 8. The higher the grade number, the greater
the bolt strength. Identification is determined by the
line marks on the top of each bolt head. The actual
bolt strength grade corresponds to the number of line
marks plus 2. The most commonly used metric bolt
strength classes are 9.8 and 10.9. The metric
strength class identification number is imprinted on
the head of the bolt. The higher the class number,
the greater the bolt strength. Some metric nuts are
imprinted with a single-digit strength class on the
nut face. Refer to the Fastener Identification and
Fastener Strength Charts (Fig. 3) and (Fig. 4).
4 INTRODUCTION LH
FASTENER IDENTIFICATION (Continued)
TORQUE REFERENCES tions 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 Specifica-
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.
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.
Fig. 9 VEHICLE SAFETY CERTIFICATION LABEL - The label contains the vehicle’s emission specifica-
TYPICAL tions and vacuum hose routings. All hoses must be
connected and routed according to the label.
12 INTRODUCTION LH
MANUFACTURE 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)
LH 8W-48 REAR WINDOW DEFOGGER 8W - 48 - 1
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 (JB) . . . . . . . . . . . . . . . . . . . . . . . . . 8W-53-2 Power Distribution Center . . . . . . . . . . . 8W-53-4, 5
Fuse M (PDC) . . . . . . . . . . . . . . . . . . . . . . . 8W-53-4 Washer Fluid Level Sensor . . . . . . . . . . . . . 8W-53-3
Fuse P (PDC) . . . . . . . . . . . . . . . . . . . . . . . 8W-53-5 Wiper Switch . . . . . . . . . . . . . . . . . . . . . . . 8W-53-2
G104 . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8W-53-3, 4
LH 8W-60 POWER WINDOWS 8W - 60 - 1
C313 (LTD/CONCORDE/BUILT-UP-EXPORT) -
GRAY (BODY SIDE)
CAV CIRCUIT
1 L50 16WT/TN
2 L60 16TN
3 L95 16DG/YL (BUILT-UP-EXPORT)
4 L7 18BK/YL
5 L1 20VT/BK (BUILT-UP-EXPORT)
6 Z1 16BK
C314 (LTD/CONCORDE/BUILT-UP-EXPORT) -
GRAY (BODY SIDE)
CAV CIRCUIT
1 L50 16WT/TN
2 L61 16LG
3 L95 16DG/YL (BUILT-UP-EXPORT)
4 L7 18BK/YL
5 L1 20 VT/BK (BUILT-UP-EXPORT)
6 Z1 16BK
CLOCKSPRING C3 - 4 WAY
CAV CIRCUIT FUNCTION
1 V37 22RD/LG SPEED CONTROL SWITCH SIGNAL
2 K4 22BK/LB SENSOR GROUND
3 X920 22GY/OR RADIO CONTROL MUX RETURN
4 X20 22GY/WT RADIO CONTROL MUX
TABLE OF CONTENTS
page
CONNECTOR/GROUND/SPLICE LOCATION
DESCRIPTION . . . . . . . . . . . . . . . . . . . . . . . . . . 1
CONNECTORS
GROUNDS
SPLICES
Fig. 7 TRANSMISSION
LH 8W-91 CONNECTOR/GROUND/SPLICE LOCATION 8W - 91 - 21
CONNECTOR/GROUND/SPLICE LOCATION (Continued)
TABLE OF CONTENTS
page page
POWER DISTRIBUTION The remote rear power post is located in the right
corner of the trunk side panel.
DESCRIPTION CAUTION: DO NOT USE THE REMOTE REAR
All of the electrical current distributed throughout POWER POST AS A REMOTE JUMP POST. SERI-
this vehicle (except for police package wiring used OUS DAMAGE CAN OCCUR. REFER TO LUBRICA-
with rear fuse block) is directed through the stan- TION AND MAINTENANCE, JUMP STARTING FOR
dard equipment Power Distribution Center (PDC). PROPER JUMP STARTING PROCEDURES.
The molded plastic PDC housing is located in the left
front corner of the engine compartment, just in front The rear fuse block and the remote power post are
of the coolant reservoir bottle. The PDC housing has serviced as part of the body harness.
a molded plastic cover. The PDC cover is easily
removed for service access and has a convenient fuse OPERATION
and relay layout label affixed to the inside surface of The power distribution system for this vehicle is
the cover to ensure proper component identification. designed to provide safe, reliable, centralized and
The PDC housing is secured in the engine compart- convenient to access distribution of the electrical cur-
ment by one screw to the rear of the PDC and two rent required to operate all of the many standard
clips on the front side. A small molded plastic protec- and optional factory-installed electrical and electronic
tive cover on the front right side of the engine com- powertrain, chassis, safety, comfort and convenience
partment is unsnapped to access the battery/ systems. At the same time, these systems were
generator cable input connection studs. designed to provide centralized locations for conduct-
Included in the police package is an additional rear ing diagnosis of faulty circuits, and for sourcing the
fuse block and remote rear power post. additional current requirements of many aftermarket
The rear fuse block is located in the right corner of vehicle accessory and convenience items.
the trunk behind the trunk trim panel. The rear fuse These power distribution systems also incorporate
block houses 2 relays and three fuses. The wiring is various types of circuit control and protection fea-
routed to an area just below the instrument panel in tures, including:
a six cavity connector to provide three fused ignition • Fuses
feeds. Three fused battery feeds in the PDC also are • Fuse cartridges
provided to the center stack area of the instrument • Fusible links
panel within the same six cavity connector. • Automatic resetting circuit breakers
Only the police package has both fused ignition • Relays
and battery circuits below the instrument panel. Spe- • Flashers
cial service vehicles have only the three fused battery • Timers
circuits in the six cavity connector. • Circuit splice blocks.
8W - 97 - 2 8W-97 POWER DISTRIBUTION LH
POWER DISTRIBUTION (Continued)
The power distribution system for this vehicle con- • Move the fuse slightly right and insert it in the
sists of the following components: fuse #6 “BAT” location in the junction block.
• Power Distribution Center (PDC) • Reinstall the left instrument panel end cap.
• Junction Block (JB)
• Accessory power outlet. CAUTION:
• Many accessories that can be plugged in draw
NOTE: DO NOT ATTEMPT TO SWAP POWER DIS- power from the vehicle’s battery, even when not in
TRIBUTION CENTERS (PDC) FROM ONE VEHICLE use (i.e. cellular phones, etc.). Eventually, if plugged
TO ANOTHER. MOST OF THESE ASSEMBLIES ARE in long enough, the vehicle’s battery will discharge
VEHICLE FEATURE SPECIFIC AND THEREFORE sufficiently to degrade battery life and/or prevent
NOT INTERCHANGEABLE. ALWAYS USE THE COR- engine starting.
RECT PART NUMBERED ASSEMBLY WHEN DIAG- • Accessories that draw higher power (i.e. cool-
NOSING OR REPLACING A PDC. ers, vacuum cleaners, lights, etc.), will degrade the
battery even more quickly. Only use these intermit-
tently and with greater caution.
STANDARD PROCEDURE - CIGAR LIGHTER/ • After the use of high power draw accessories,
POWER OUTLET CUSTOMER PREFERENCE or long periods of the vehicle not being started
This vehicle was delivered with the Cigar Lighter/ (with accessories still plugged in), the vehicle must
Power Outlet activated only when the ignition is ON. be driven a sufficient length of time to allow the
To convert the lighter/outlet to operate with the igni- generator to recharge the vehicle’s battery.
tion OFF, perform the following:
• Remove the left instrument panel end cap from
the left end of the instrument panel.
• Remove fuse #6 in the upper right of the junc-
CIGAR LIGHTER/POWER
tion block (Fig. 1) from its “IGN” position. OUTLET
DESCRIPTION
The power feed to the Cigar Lighter/Power Outlet
can be HOT (12v - B+) with the ignition ON, or HOT
(12v - B+) with the ignition OFF.
OPERATION
To change the operating mode of the Cigar Lighter/
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).
(3) Using external snap ring pliers with 90 degree
tips. Insert pliers with tips against bosses and
squeeze forcing bosses out of base.
Fig. 1 Cigar Lighter/Power Outlet Customer (4) Pull out the base through mounting ring by
Preference Fuse Location gently rocking pliers. A tool can be made to do the
1 - FUSE #6 same. Refer to (Fig. 3).
(5) Disconnect the base wires.
(6) Set base aside and remove base mount ring.
LH 8W-97 POWER DISTRIBUTION 8W - 97 - 3
CIGAR LIGHTER/POWER OUTLET (Continued)
IOD FUSE
DESCRIPTION
All vehicles are equipped with an Ignition-Off
Draw (IOD) fuse that is disconnected within the
Junction Block when the vehicle is shipped from the
factory. Dealer personnel are to reconnect the IOD
fuse in the junction block as part of the preparation
procedures performed just prior to new vehicle deliv-
ery.
On left hand drive vehicles, the left end of the
instrument panel cover has a snap-fit fuse access
panel that can be removed to provide service access
to the fuses in the junction block. On right hand
drive vehicles the junction block is mounted on the
right hand side of the instrument panel. A finger
recess is molded into the access panel for easy
removal. An adhesive-backed fuse layout map is
secured to the instrument panel side of the access
panel to ensure proper fuse identification. The IOD
fuse is a 15 ampere mini blade-type fuse, located in
Fig. 2 Cigar Lighter / Power Outlet Base Removal fuse cavity # 34. The fuse is secured within a White
molded plastic fuse holder and puller unit that serves
1 - RETAINING BOSSES-ENGAGE PLIERS HERE
2 - PARTIALLY REMOVED both as a tool for disconnecting and reconnecting the
3 - EXTERNAL SNAP-RING PLIERS fuse in its junction block cavity, and as a fuse holder
4 - PULL BASE OUT-THROUGH MOUNTING RING that conveniently stores the fuse in the same junc-
tion block cavity after it has been disconnected.
REMOVAL
The Ignition-Off Draw (IOD) fuse is disconnected
from Junction Block fuse cavity # 34 when the vehi-
Fig. 4 Junction Block Location
cle is shipped from the assembly plant. Dealer per-
sonnel must reconnect the IOD fuse when the vehicle 1 - JUNCTION BLOCK/BCM
is being prepared for delivery in order to restore full
and serves in place of a bulkhead connector between
electrical system operation.
many of the engine compartment, instrument panel,
(1) Turn the ignition switch to the Off position.
and body wire harnesses.
(2) Remove the fuse access panel by unsnapping it
The JB is positioned on a mounting bracket up and
from the outboard end of the instrument panel.
under the left instrument panel. It is secured by four
(3) Grasp the outer tabs of the IOD fuse holder
screws. The JB is concealed behind the left instru-
unit in fuse cavity # 34 of the Junction Block
ment panel endcap. The left instrument panel endcap
between the thumb and forefinger and pull the unit
is a snap-fit fuse access cover that conceals the JB
firmly outward.
fuses. A fuse puller and spare fuse holders are
(4) Install the fuse access panel by snapping it
located on the back of the endcap, as well as the fuse
onto the outboard end of the instrument panel.
layout to ensure proper fuse identification. The left
instrument panel endcap must be removed to access
INSTALLATION components other than the fuses in the JB.
(1) Turn the ignition switch to the Off position.
(2) To install the IOD fuse, use a thumb to press
the IOD fuse holder unit in fuse cavity # 34 firmly
OPERATION
All of the current entering and leaving the JB does
into the junction block.
so through wire harnesses, which are connected to
(3) Install the fuse access panel by snapping it
the JB through integral connector receptacles molded
onto the left outboard end of the instrument panel.
into the JB housing. The JB houses blade-type fuses,
blade-type automatic resetting circuit breakers, full
JUNCTION BLOCK International Standards Organization (ISO) relays,
and ISO micro-relays. Internal connection of all the
DESCRIPTION JB circuits is accomplished by an intricate network of
hard wiring and bus bars. Refer to the appropriate
An electrical Junction Block (JB) is located in the
wiring information. The wiring information includes
left endcap of the instrument panel (Fig. 4). The JB
wiring diagrams, proper wire and connector repair
combines the functions previously provided by a sep-
procedures, details of wire harness routing and
arate fuseblock module and relay center. It also
retention, connector pin-out information and location
serves to simplify and centralize numerous electrical
views for the various wire harness connectors, splices
components, as well as to distribute electrical current
and grounds.
to many of the accessory systems in the vehicle. It
The fuses, circuit breakers, relays, and are avail-
eliminates the need for numerous splice connections
able for service replacement. The JB unit cannot be
LH 8W-97 POWER DISTRIBUTION 8W - 97 - 5
JUNCTION BLOCK (Continued)
repaired and is only serviced as an assembly. If any POWER DISTRIBUTION
internal circuit or the JB housing is faulty or dam-
aged, the entire Junction Block assembly must be CENTER
replaced.
DESCRIPTION
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
AND POSSIBLE PERSONAL INJURY.
ENGINE
TABLE OF CONTENTS
page page
ENGINE 2.7L
TABLE OF CONTENTS
page page
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)
2. Incorrect fuel mixture. 2. (Refer to Appropriate Diagnostic
Information)
3. Intake manifold leakage. 3. Inspect intake manifold gasket,
manifold, and vacuum hoses.
4. Faulty coil(s). 4. Test and replace as necessary.
(Refer to Appropriate Diagnostic
Information)
LH ENGINE 2.7L 9-7
ENGINE 2.7L (Continued)
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.
9-8 ENGINE 2.7L LH
ENGINE 2.7L (Continued)
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.
2. Low oil pressure. 2. Check engine oil level. Inspect oil
pump relief valve and spring.
3. Thin or diluted oil. 3. Change oil to correct viscosity.
4. Thick oil 3. (a.) Change oil and filter.
(b.) Run engine to operating
temperature.
(c.) Change oil and filter again.
5. Excessive bearing clearance. 5. Measure bearings for correct
clearance. Repair as necessary.
6. Connecting rod journal 6. Replace crankshaft or grind
out-of-round. surface.
7. Misaligned connecting rods. 7. Replace bent connecting rods.
LH ENGINE 2.7L 9-9
ENGINE 2.7L (Continued)
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.
DIAGNOSIS AND TESTING - CYLINDER (10) If one or more cylinders have abnormally low
compression pressures, repeat the compression test.
COMPRESSION PRESSURE TEST
(11) If the same cylinder or cylinders repeat an
The results of a cylinder compression pressure test
abnormally low reading on the second compression
can be utilized to diagnose several engine malfunc-
test, it could indicate the existence of a problem in
tions.
the cylinder in question. The recommended com-
Ensure the battery is completely charged and the
pression pressures are to be used only as a
engine starter motor is in good operating condition.
guide to diagnosing engine problems. An engine
Otherwise the indicated compression pressures may
should not be disassembled to determine the
not be valid for diagnosis purposes.
cause of low compression unless some malfunc-
(1) Check engine oil level and add oil if necessary.
tion is present.
(2) Drive the vehicle until engine reaches normal
operating temperature. Select a route free from traf-
fic and other forms of congestion, observe all traffic
DIAGNOSIS AND TESTING - CYLINDER
laws, and accelerate through the gears several times COMBUSTION PRESSURE LEAKAGE TEST
briskly. The combustion pressure leakage test provides an
(3) Disconnect and remove all ignition coils from accurate means for determining engine condition.
spark plugs. Combustion pressure leakage testing will detect:
(4) Remove all spark plugs from engine. As spark • Exhaust and intake valve leaks (improper seat-
plugs are being removed, check electrodes for abnor- ing).
mal firing indicators fouled, hot, oily, etc. Record cyl- • Leaks between adjacent cylinders or into water
inder number of spark plug for future reference. jacket.
(5) Be sure throttle blade is fully open during the • Any causes for combustion/compression pressure
compression check. loss.
(6) Insert compression gauge adaptor Special Tool
8116 or the equivalent, into the #1 spark plug hole in WARNING: DO NOT REMOVE THE PRESSURE CAP
cylinder head. Connect the 0–500 psi (Blue) pressure WITH THE SYSTEM HOT AND UNDER PRESSURE
transducer (Special Tool CH7059) with cable adap- BECAUSE SERIOUS BURNS FROM COOLANT CAN
tors to the DRBIIIt. For Special Tool identification, OCCUR.
(Refer to 9 - ENGINE - SPECIAL TOOLS).
Check the coolant level and fill as required. DO
(7) Crank engine until maximum pressure is
NOT install the pressure cap.
reached on gage. Record this pressure as #1 cylinder
Start and operate the engine until it attains nor-
pressure.
mal operating temperature, then turn the engine
(8) Repeat the previous step for all remaining cyl-
OFF.
inders.
Clean spark plug recesses with compressed air.
(9) Compression should not be less than 689 kPa
Remove the spark plugs.
(100 psi) and not vary more than 25 percent from cyl-
Remove the oil filler cap.
inder to cylinder.
Remove the air cleaner.
LH ENGINE 2.7L 9 - 11
ENGINE 2.7L (Continued)
Calibrate the tester according to the manufactur- will not cure if left in the uncovered tube. The
er’s instructions. The shop air source for testing anaerobic material is for use between two machined
should maintain 483 kPa (70 psi) minimum, 1,379 surfaces. Do not use on flexible metal flanges.
kPa (200 psi) maximum, with 552 kPa (80 psi) rec- MOPARt BED PLATE SEALANT is a unique
ommended. (green-in-color) anaerobic type gasket material that
Perform the test procedures on each cylinder is specially made to seal the area between the bed-
according to the tester manufacturer’s instructions. plate and cylinder block without disturbing the bear-
While testing, listen for pressurized air escaping ing clearance or alignment of these components. The
through the throttle body, tailpipe and oil filler cap material cures slowly in the absence of air when
opening. Check for bubbles in the coolant. torqued between two metallic surfaces, and will rap-
All gauge pressure indications should be equal, idly cure when heat is applied.
with no more than 25% leakage per cylinder. MOPARt GASKET SEALANT is a slow drying,
FOR EXAMPLE: At 552 kPa (80 psi) input pres- permanently soft sealer. This material is recom-
sure, a minimum of 414 kPa (60 psi) should be main- mended for sealing threaded fittings and gaskets
tained in the cylinder. against leakage of oil and coolant. Can be used on
threaded and machined parts under all tempera-
tures. This material is used on engines with multi-
STANDARD PROCEDURE layer steel (MLS) cylinder head gaskets. This
material also will prevent corrosion. Mopart Gasket
STANDARD PROCEDURE - FORM-IN-PLACE Sealant is available in a 13 oz. aerosol can or 4oz./16
GASKETS AND SEALERS oz. can w/applicator.
There are numerous places where form-in-place
gaskets are used on the engine. Care must be taken SEALER APPLICATION
when applying form-in-place gaskets to assure Mopart Gasket Maker material should be applied
obtaining the desired results. Do not use form-in- sparingly 1 mm (0.040 in.) diameter or less of sealant
place gasket material unless specified. Bead size, to one gasket surface. Be certain the material sur-
continuity, and location are of great importance. Too rounds each mounting hole. Excess material can eas-
thin a bead can result in leakage while too much can ily be wiped off. Components should be torqued in
result in spill-over which can break off and obstruct place within 15 minutes. The use of a locating dowel
fluid feed lines. A continuous bead of the proper is recommended during assembly to prevent smear-
width is essential to obtain a leak-free gasket. ing material off the location.
There are numerous types of form-in-place gasket Mopart Engine RTV GEN II or ATF RTV gasket
materials that are used in the engine area. Mopart material should be applied in a continuous bead
Engine RTV GEN II, Mopart ATF-RTV, and Mopart approximately 3 mm (0.120 in.) in diameter. All
Gasket Maker gasket materials, each have different mounting holes must be circled. For corner sealing, a
properties and can not be used in place of the other. 3.17 or 6.35 mm (1/8 or 1/4 in.) drop is placed in the
MOPARt ENGINE RTV GEN II is used to seal center of the gasket contact area. Uncured sealant
components exposed to engine oil. This material is a may be removed with a shop towel. Components
specially designed black silicone rubber RTV that should be torqued in place while the sealant is still
retains adhesion and sealing properties when exposed wet to the touch (within 10 minutes). The usage of a
to engine oil. Moisture in the air causes the material locating dowel is recommended during assembly to
to cure. This material is available in three ounce tubes prevent smearing material off the location.
and has a shelf life of one year. After one year this Mopart Gasket Sealant in an aerosol can should be
material will not properly cure. Always inspect the applied using a thin, even coat sprayed completely
package for the expiration date before use. over both surfaces to be joined, and both sides of a
MOPARt ATF RTV is a specifically designed gasket. Then proceed with assembly. Material in a
black silicone rubber RTV that retains adhesion and can w/applicator can be brushed on evenly over the
sealing properties to seal components exposed to sealing surfaces. Material in an aerosol can should be
automatic transmission fluid, engine coolants, and used on engines with multi-layer steel gaskets.
moisture. This material is available in three ounce
tubes and has a shelf life of one year. After one year STANDARD PROCEDURE - ENGINE GASKET
this material will not properly cure. Always inspect SURFACE PREPARATION
the package for the expiration date before use. To ensure engine gasket sealing, proper surface
MOPARt GASKET MAKER is an anaerobic type preparation must be performed, especially with the
gasket material. The material cures in the absence of use of aluminum engine components and multi-layer
air when squeezed between two metallic surfaces. It steel cylinder head gaskets.
9 - 12 ENGINE 2.7L LH
ENGINE 2.7L (Continued)
Never use the following to clean gasket surfaces:
• Metal scraper
• Abrasive pad or paper to clean cylinder block
and head
• High speed power tool with an abrasive pad or a
wire brush (Fig. 4)
CAUTION: Excessive pressure or high RPM (beyond Fig. 5 Core Hole Plug Removal
the recommended speed), can damage the sealing 1 - CYLINDER BLOCK
surfaces. The mild (white, 120 grit) bristle disc is 2 - REMOVE PLUG WITH PLIERS
recommended. If necessary, the medium (yellow, 80 3 - STRIKE HERE WITH HAMMER
grit) bristle disc may be used on cast iron surfaces 4 - DRIFT PUNCH
with care. 5 - CUP PLUG
(39) Attach Special Tool 8342, Engine Lifting Fix- NOTE: Do not reuse V-Band clamps.
ture to engine at the locations shown in (Fig. 9).
(40) Support transaxle with a floor jack. (22) Install new V-Band clamps at exhaust mani-
(41) Hoist engine from engine compartment. folds and tighten to 11 N·m (100 in. lbs.).
(23) Install catalytic converter down pipe front and
INSTALLATION - ENGINE ASSEMBLY rear supports.
(1) Attach Special Tool 8342, Engine Lifting Fix- (24) Install air conditioning compressor. (Refer to
ture to engine (Fig. 9). Lower engine into engine 24 - HEATING & AIR CONDITIONING/PLUMBING/
compartment. A/C COMPRESSOR - INSTALLATION)
(25) Install power steering pump. (Refer to 19 -
CAUTION: Do not tighten the transaxle case to STEERING/PUMP - INSTALLATION)
engine block bolts until all bolts have been hand (26) Install radiator. (Refer to 7 - COOLING/EN-
started, and the two mating surfaces are completely GINE/RADIATOR - INSTALLATION)
joined together, as damage to cylinder block or (27) Connect engine oil cooler lines to radiator (if
transaxle could occur. equipped).
(28) Connect transmission oil cooler lines to radia-
(2) Align engine mounts and install fasteners but tor.
do not tighten until all mounting bolts have been (29) Attach A/C condenser to radiator.
installed. (30) Install lower radiator hose.
(3) Install transaxle case to engine block bolts and (31) Install upper radiator hose.
tighten to 102 N·m (75 ft. lbs.). (32) Install accessory drive belts. (Refer to 7 -
(4) Remove 8342 Engine Lifting Fixture. COOLING/ACCESSORY DRIVE/DRIVE BELTS -
(5) Tighten left and right engine mount isolator to INSTALLATION)
engine mount bracket fasteners to 61 N·m (45 ft. (33) Install radiator fan. (Refer to 7 - COOLING/
lbs.). ENGINE/RADIATOR FAN - INSTALLATION)
(6) Raise vehicle. (34) Refill cooling system. (Refer to 7 - COOLING -
(7) Align flex plate to torque converter. Install STANDARD PROCEDURE)
mounting bolts and tighten to 75 N·m (55 ft. lbs.). (35) Fill engine with proper amount of oil.
(8) Install crankshaft position sensor. (Refer to 14 - (36) Connect hood release cable to hood latch and
FUEL SYSTEM/FUEL INJECTION/CRANKSHAFT install upper radiator crossmember. (Refer to 23 -
POSITION SENSOR - INSTALLATION) BODY/EXTERIOR/GRILLE OPENING REINFORCE-
(9) Install starter. (Refer to 8 - ELECTRICAL/ MENT - INSTALLATION)
STARTING/STARTER MOTOR - INSTALLATION) (37) Install air cleaner and air inlet hose.
(10) Install the transaxle oil cooler lines bracket to (38) Install cowl support. (Refer to 23 - BODY/EX-
engine. TERIOR/FRONT STRUT TOWER TO TOWER
(11) Install structural collar to oil pan and trans- BRACE - INSTALLATION)
axle. (Refer to 9 - ENGINE/ENGINE BLOCK/
STRUCTURAL COVER - INSTALLATION)
9 - 16 ENGINE 2.7L LH
ENGINE 2.7L (Continued)
(39) Install right and left cowl screens. (Refer to 23 (42) Connect negative cable to remote jumper ter-
- BODY/EXTERIOR/COWL GRILLE AND SCREEN - minal at right strut tower.
INSTALLATION) (43) Start engine and operate until operating tem-
(40) Install both wiper arms. (Refer to 8 - ELEC- perature is reached.
TRICAL/WIPERS/WASHERS/WIPER ARMS -
INSTALLATION)
(41) Install hood. (Refer to 23 - BODY/HOOD/
HOOD - INSTALLATION)
LH ENGINE 2.7L 9 - 17
ENGINE 2.7L (Continued)
Ft. In.
DESCRIPTION N·m
Lbs. Lbs.
Oil Pump Cover—Bolts 12 — 105
Oil Pump Pick Up 28 — 250
Tube—Bolt
PCV Valve 7 — 60
Crankshaft Rear Seal 12 — 105
Retainer—Bolts
Puller 1023
Spark Plugs 20 15 —
Starter Mounting—Bolts 41 30 —
Structural Collar (Refer to 9 - ENGINE/
ENGINE BLOCK/
STRUCTURAL COVER -
INSTALLATION)
Thermostat Housing/ 12 — 105
Water Inlet Connector—
Bolts
Throttle Body—Bolts 12 — 105 Crankshaft Damper Remover Insert 8194
Timing Chain Cover
—M6 Bolts 12 — 105
—M10 Bolts 54 40 —
Timing Chain Tensioner 54 40 —
(Primary)
Timing Chain Guide 20 15 —
Access Plug
Water Pump—Bolts 12 — 105 Crankshaft Damper Installer Screw 8179
Cooling System Bleed 12 — 105
Screw
Water Outlet Housing— 12 — 105
Bolts
SPECIAL TOOLS
Crankshaft Damper Installer 6792-1
2.7L ENGINE
Puller 5048
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. 10).
INSTALLATION
(1) If necessary, clean the inside of the air cleaner
housing.
(2) Install new filter element (Fig. 10).
(3) Place lid over air cleaner housing.
Adaptor 8116
9 - 24 ENGINE 2.7L LH
INSPECTION
(1) Before cleaning, check for leaks, damage and
cracks. Fig. 17 Check for Stretched Bolts
(2) Clean cylinder head and oil passages. 1 - STRETCHED BOLT
(3) Check cylinder head for flatness (Fig. 16). 2 - THREADS ARE NOT STRAIGHT ON LINE
(4) Cylinder head must be flat within: 3 - THREADS ARE STRAIGHT ON LINE
• Standard dimension = less than 0.05 mm (0.002 4 - UNSTRETCHED BOLT
inch.)
• Service Limit = 0.2 mm (0.008 inch.) (1) Clean sealing surfaces of cylinder head and
• Grinding Limit = Maximum of 0.2 mm (0.008 block. (Refer to 9 - ENGINE - STANDARD PROCE-
inch.) is permitted. DURE)
(2) Install new head gasket over locating dowels.
CAUTION: 0.20 mm (0.008 in.) MAX is a combined (3) Install cylinder head to block, assuring head is
total dimension of the stock removal limit from cyl- properly positioned over locating dowels.
inder head and block top surface (Deck) together. (4) Lubricate bolt threads with clean engine oil
and install bolts.
(5) Tighten bolts in sequence shown in (Fig. 18),
using the following steps and torque values:
• Step 1: Bolts 1–8 to 48 N·m (35 ft. lbs.)
• Step 2: Bolts 1–8 to 75 N·m (55 ft. lbs.)
• Step 3: Bolts 1–8 to 75 N·m (55 ft. lbs.)
• Step 4: Bolts 1–8 to +90° Turn Do not use a
torque wrench for this step.
• Step 5: Bolts 9–11 to 28 N·m (250 in. lbs.)
CAUTION: When cleaning cylinder head and cylin- Fig. 18 Cylinder Head Tightening Sequence
der block surfaces, DO NOT use a metal scraper
because the surfaces could be cut or ground. Use (6) Connect catalytic converter to exhaust manifold
ONLY a wooden or plastic scraper. with a new V-Band clamp. Tighten V-Band clamp to
10 N·m (100 in. lbs.).
9 - 28 ENGINE 2.7L LH
CYLINDER HEAD (Continued)
(7) Install all valvetrain components and cam- OPERATION
shafts. (Refer to 9 - ENGINE/CYLINDER HEAD/ The camshaft has precisely machined (egg shaped)
CAMSHAFT(S) - INSTALLATION) Tighten camshaft lobes to provide accurate valve timing and duration.
bearing caps in sequence shown in (Fig. 19) The camshaft is driven by the crankshaft via drive
sprockets and chains.
OPERATION
The intake valve allows the air/fuel mixture to
enter the combustion chamber. The exhaust valve
allows the burned air/fuel mixture to exit the com-
Fig. 26 Cylinder Head Covers bustion chamber. Also, the intake and exhaust valves
INSTALLATION seal the combustion chamber during the compression
(1) Clean cylinder head cover and both sealing sur- and power strokes.
faces. Inspect and replace gaskets as necessary (Fig.
27). STANDARD PROCEDURE - VALVE AND VALVE
(2) Install cylinder head covers and hand start all SEAT REFACING
fasteners. Verify that all double-ended studs are in The intake and exhaust valves have a 44.5 to 45
the correct locations as shown in (Fig. 26). degree face angle. The valve seats have a 45 to 45.5
(3) Tighten cylinder head cover attaching bolts and degree face angle. The valve face and valve seat
double-ended studs to 12 N·m (105 in. lbs.). angles are shown in (Fig. 28).
9 - 32 ENGINE 2.7L LH
INTAKE/EXHAUST VALVES & SEATS (Continued)
VALVES
Inspect the remaining margin after the valves are
refaced. (Refer to 9 - ENGINE - SPECIFICATIONS)
VALVE SEATS
(1) When refacing valve seats, it is important that
the correct size valve guide pilot be used for reseat-
ing stones. A true and complete surface must be
obtained.
(2) Measure the concentricity of valve seat using
dial indicator. Total runout should not exceed 0.051
mm (0.002 inch.) total indicator reading.
Fig. 28 Valve Face and Seat intake valve is greater than 47.59 (1.8737 in.) or
1 - SEAT WIDTH 49.14 (1.9347 in.) for exhaust valve, grind valve tip
2 - FACE ANGLE until within specifications. Make sure measurement
3 - SEAT ANGLE is taken from cylinder head surface to the top of
4 - SEAT CONTACT AREA valve stem.
(3) Install valve seal/spring seat assembly over
(3) Inspect the valve seat with Prussian blue to valve guides on all valve stems (Fig. 30). Ensure that
determine where the valve contacts the seat. To do the garter spring is intact around the top of the rub-
this, coat valve seat LIGHTLYwith Prussian blue ber seal.
then set valve in place. Rotate the valve with light (4) Position valve springs and retainer on spring
pressure. If the blue is transferred to the center of seat (Fig. 30).
valve face, contact is satisfactory. If the blue is trans- (5) Compress valve spring with a valve spring
ferred to top edge of valve face, then lower valve seat compressor.
with a 15 degree stone. If the blue is transferred to (6) Install retainer locks and release tool.
the bottom edge of valve face, then raise valve seat (7) If valves and/or seats are refaced, measure the
with a 65 degree stone. installed height of springs (B) (Fig. 29). Measure-
ment is taken from top of spring seat to the bottom
NOTE: Valve seats which are worn or burned can surface of spring retainer. If height is greater than
be reworked, provided that correct angle and seat 38.75 mm (1.5256 in.), install a 0.762 mm (0.030 in.)
width are maintained. Otherwise cylinder head must spacer in head counterbore under the valve spring
be replaced. seat to bring spring height back within specification.
INSPECTION
VALVES
(1) Clean and inspect valves thoroughly. Replace
burned, warped and cracked valves.
(2) Measure valve stems for wear (Fig. 31). For
valve specifications, (Refer to 9 - ENGINE - SPECI-
FICATIONS).
Fig. 32 Measuring Valve Guide Wear - Typical
NOTE: Valve stems are chrome plated and should
not be polished (Fig. 31). INSTALLATION
(1) Coat valve stems with clean engine oil and
insert them in cylinder head.
(2) If valves or seats have been reground, check
valve tip height (A) (Fig. 33). If valve tip height for
intake valve is greater than 47.59 mm (1.8737 in.) or
49.14 mm (1.9347 in.) for exhaust valve, grind valve
tip until within specifications. Make sure measure-
ment is taken from cylinder head surface to the top
of valve stem.
(3) Install valve spring. (Refer to 9 - ENGINE/
CYLINDER HEAD/VALVE SPRINGS - INSTALLA-
TION)
INSTALLATION
INSTALLATION - IN VEHICLE
(1) The valve stem seal/valve spring seat should be
pushed firmly and squarely over the valve guide
using the valve stem as guide. Do Not Force seal
against top of guide. When installing the valve
retainer locks, compress the spring only enough to
install locks
(2) Follow the same procedure on the remaining
cylinders using the firing sequence 1-2-3-4-5-6. Make
sure piston is at TDC on the cylinder that the
valve spring is to be removed.
(3) Remove spark plug adapter tool and Special
Tool MD 998772A.
(4) Install rocker arm(s).
Fig. 35 TESTING VALVE SPRING
(5) Install camshafts (Refer to 9 - ENGINE/CYL-
1 - SPECIAL TOOL C-647
INDER HEAD/CAMSHAFT(S) - INSTALLATION),
timing chain (Refer to 9 - ENGINE/VALVE TIMING/
TIMING BELT/CHAIN AND SPROCKETS -
INSTALLATION), and timing chain cover (Refer to 9
9 - 36 ENGINE 2.7L LH
VALVE SPRINGS (Continued)
- ENGINE/VALVE TIMING/TIMING BELT / CHAIN retainer. If height is greater than 38.75 mm (1.5256
COVER(S) - INSTALLATION). in.), install a 0.762 mm (0.030 in.) spacer in head
(6) Install cylinder head covers. (Refer to 9 - counterbore under the valve spring seat to bring
ENGINE/CYLINDER HEAD/CYLINDER HEAD spring height back within specification.
COVER(S) - INSTALLATION)
(7) Install upper intake manifold. (Refer to 9 -
ENGINE/MANIFOLDS/INTAKE MANIFOLD -
INSTALLATION)
(8) Install air cleaner housing and inlet hose.
(9) Connect negative cable.
REMOVAL OPERATION
(1) Remove cylinder head cover(s). (Refer to 9 - The rocker arm is the pivot point between the cam-
ENGINE/CYLINDER HEAD/CYLINDER HEAD shaft lobe and the valve.
COVER(S) - REMOVAL)
(2) Remove rocker arm(s). (Refer to 9 - ENGINE/ REMOVAL
CYLINDER HEAD/ROCKER ARMS - REMOVAL) (1) Remove cylinder head cover(s). (Refer to 9 -
ENGINE/CYLINDER HEAD/CYLINDER HEAD
CAUTION: If lash adjusters and rocker arms are to COVER(S) - REMOVAL)
be reused, always mark position for reassembly in
their original positions. CAUTION: Always rotate engine by turning the
crankshaft. Failure to do so will result in valve
(3) Remove lash adjuster(s). and/or piston damage.
INSTALLATION (2) Rotate engine until the cam lobe is on its base
(1) Install hydraulic lash adjuster making sure circle (heel), on the rocker arm being removed.
adjusters are at least partially full of oil. This can be
verified by little or no plunger travel when lash CAUTION: Depress valve spring only enough to
adjuster is depressed. remove rocker arm.
(2) Install rocker arm(s) (Refer to 9 - ENGINE/
CYLINDER HEAD/ROCKER ARMS - INSTALLA- (3) Using Special Tools 8215 and 8216 Adaptor,
TION) and cylinder head covers (Refer to 9 - depress valve spring only enough to release tension
ENGINE/CYLINDER HEAD/CYLINDER HEAD on rocker arm (Fig. 40).
COVER(S) - INSTALLATION). (4) Remove rocker arm from cylinder head.
NOTE: Inspect rocker arm for proper engagement CAUTION: Ensure all abrasives are removed from
into lash adjuster and valve tip. engine parts after honing. It is recommended that a
solution of soap and hot water be used with a
(5) Repeat procedure for each rocker arm installed. brush and the parts then thoroughly dried. The bore
(6) Install cylinder head cover(s). (Refer to 9 - can be considered clean when it can be wiped
ENGINE/CYLINDER HEAD/CYLINDER HEAD clean with a white cloth and cloth remains clean.
COVER(S) - INSTALLATION) Oil the bores after cleaning to prevent rusting.
CYLINDER BORE
NOTE: The cylinder bores should be measured at
normal room temperature, 21°C (70°F).
OPERATION
The crankshaft transfers force generated by com-
bustion within the cylinder to the flywheel or flex-
Fig. 46 Check for Stretched Bolts plate.
1 - STRETCHED BOLT
2 - THREADS ARE NOT STRAIGHT ON LINE STANDARD PROCEDURE - CRANKSHAFT END
3 - THREADS ARE STRAIGHT ON LINE
4 - UNSTRETCHED BOLT
PLAY
(1) Mount a dial indicator to a stationary point at
front of engine. Locate the probe perpendicular
CONNECTING ROD SIDE CLEARANCE against nose of crankshaft (Fig. 48).
(1) Mount a dial indicator to a stationary point on (2) Move crankshaft all the way to the rear of its
engine. Locate probe perpendicular to and resting travel.
against the connecting rod cap being checked. Move (3) Zero the dial indicator.
connecting rod all the way to rear of its travel. Zero (4) Move crankshaft all the way to the front and
the dial indicator. Move connecting rod forward to read the dial indicator. For crankshaft end play clear-
limit of travel and read the dial indicator (Fig. 47). ances (Refer to 9 - ENGINE - SPECIFICATIONS).
Compare measurement to specification listed in
engine specifications (Refer to 9 - ENGINE - SPECI-
FICATIONS). Repeat procedure for each connecting
rod. Turn crankshaft for connecting rod accessibility.
(17) Remove main bearing cap bolts and tie bolts Fig. 50 Main Bearing Cap Identification
(Fig. 50).
1 - TIE BOLTS
(18) Remove main bearing caps (Fig. 50).
2 - TIE BOLTS
FLEX PLATE
REMOVAL
(1) Remove the transaxle. (Refer to 21 - TRANS-
MISSION/TRANSAXLE/AUTOMATIC - 42LE -
REMOVAL)
(2) Remove flex plate attaching bolts.
Fig. 61 Oil Seal Retainer
(3) Remove the flex plate (Fig. 63).
1 - SCREWS (7)
2 - SEAL RETAINER
INSTALLATION
(1) Clean sealing surfaces and replace gasket as
needed.
(2) Install gasket and loose assemble seal retainer
to block.
REMOVAL
(1) Remove top ridge of cylinder bores with a reli-
able ridge reamer before removing pistons from cyl-
inder block. Be sure to keep tops of pistons
covered during this operation. Pistons and con-
necting rods must be removed from top of cyl-
inder block. When removing piston and
connecting rod assemblies from the engine,
rotate crankshaft so that each connecting rod
Fig. 64 Piston and Connecting Rod is centered in cylinder bore.
1 - “F” TOWARD FRONT OF ENGINE
2 - RING COMPRESSOR NOTE: Connecting rod bearing caps are not inter-
3 - SPECIAL TOOL 8189 changeable and should be marked before removing
4 - OIL SQUIRT HOLE to ensure correct reassembly.
LH ENGINE 2.7L 9 - 51
PISTON & CONNECTING ROD (Continued)
CAUTION: DO NOT use a number stamp or a punch INSTALLATION
to mark connecting rods. Damage to connecting (1) Install the piston rings. (Refer to 9 - ENGINE/
rod could occur. ENGINE BLOCK/PISTON RINGS - INSTALLA-
TION)
(2) Mark connecting rod and bearing cap positions (2) Before installing piston and connecting rod
using a permanent ink marker or scribe tool (Fig. assemblies into the bore, ensure that compression
66). ring gaps are staggered so that neither is in line with
oil ring rail gap.
(3) Before installing the ring compressor, make
sure the oil ring expander ends are butted and the
rail gaps located as shown in (Fig. 75).
(4) Immerse the piston head and rings in clean
engine oil, slide the ring compressor over the piston
and tighten with the special wrench. Ensure posi-
tion of rings does not change during this oper-
ation.
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)
(2) The No. 1 and No. 2 piston rings have a differ-
ent cross section. Ensure No. 2 ring is installed with
manufacturers I.D. mark (dot) facing up, towards top
of the piston (Fig. 72).
REMOVAL (9) Install upper side rail first and then the lower
(1) Remove piston and connecting rod. (Refer to 9 - side rail.
ENGINE/ENGINE BLOCK/PISTON & CONNECT- (10) Install No. 2 piston ring and then No. 1 piston
ING ROD - REMOVAL) ring (Fig. 74).
(2) Remove No. 1 and No.2 piston rings (Fig. 72) (11) Position piston ring end gaps as shown in
from piston using a ring expander tool (Fig. 74). (Fig. 75).
(3) Remove upper oil ring side rail (Fig. 72). (12) Position oil ring expander gap at least 45°
(4) Remove lower oil ring side rail (Fig. 72). from the side rail gaps but not on the piston pin cen-
(5) Remove oil ring expander (Fig. 72). ter or on the thrust direction. Staggering ring gap is
important for oil control.
9 - 54 ENGINE 2.7L LH
PISTON RINGS (Continued)
Fig. 73 SIDE RAIL - INSTALLATION Fig. 75 PISTON RING END GAP POSITION
1 - SIDE RAIL END 1 - SIDE RAIL UPPER
2 - NO. 1 RING GAP
3 - PISTON PIN
4 - SIDE RAIL LOWER
5 - NO. 2 RING GAP AND SPACER EXPANDER GAP
STRUCTURAL COLLAR /
COVER
REMOVAL
(1) Raise vehicle on hoist.
(2) Remove bolts attaching structural collar to oil
pan and transmission housing (Fig. 79).
(3) Remove collar (Fig. 79).
ENGINE MOUNTING (2) Remove the isolator attaching nuts from top of
the mounting bracket (Fig. 80).
(3) Support the engine with a jack and a block of
DESCRIPTION
wood across the full width of the oil pan.
The engine mounting system consist of three
(4) Remove the lower attaching nuts from the bot-
mounts; two hydro-type mounts are attached to the
tom of the isolator to the frame (Fig. 80).
right and left side of the engine block, and one
(5) Raise engine carefully with jack enough to
molded rubber type rear mount is attached to the
remove the isolator with heat shield from its mount.
transaxle (Fig. 80). All three mounts attach to the
suspension crossmember/engine cradle.
The engine hydro-type mounts contain a liquid
INSTALLATION
(1) Install isolator mount with heat shield onto the
that is encased in a solid rubber housing.
frame.
(2) Lower the engine onto the isolator mount.
INSPECTION
(3) Remove jack from vehicle.
Engine hydro-mounts may show surface cracks.
(4) Tighten the isolator to frame nuts to 61 N·m
This will not effect performance and mount should
(45 ft. lbs.) (Fig. 80).
not be replaced. Only replace the engine hydro-
(5) Install the upper attaching nuts to mount and
mounts when leaking fluid.
tighten to 61 N·m (45 ft. lbs.) (Fig. 80).
(6) Lower vehicle.
LEFT MOUNT
REMOVAL
(1) Raise vehicle on hoist.
REAR MOUNT (2) Remove the isolator attaching nuts from top of
the mounting bracket (Fig. 81).
(3) Support the engine with a jack and a block of
REMOVAL
wood across the full width of the oil pan.
(1) Raise vehicle on hoist.
(4) Remove the lower attaching nuts from the bot-
(2) Support transaxle with a jack.
tom of the isolator to the frame (Fig. 81).
(3) Remove isolator nuts from the mount to trans-
(5) Raise engine carefully with jack enough to
axle mount bracket (Fig. 80).
remove the isolator with heat shield from its mount.
(4) Remove rear mount isolator bolts to crossmem-
ber and remove mount (Fig. 80).
INSTALLATION
(1) Install isolator mount with heat shield onto the
INSTALLATION
frame.
(1) Position isolator onto crossmember.
(2) Lower the engine onto the isolator mount.
(2) Install bolts attaching isolator to crossmember
(3) Remove jack from vehicle.
and tighten to 33 N·m (250 in. lbs.) (Fig. 81).
(4) Tighten the isolator to frame nuts to 61 N·m
(3) Lower transaxle onto isolator.
(45 ft. lbs.) (Fig. 81).
(4) Install isolator nuts and tighten to 61 N·m (45
(5) Install the upper attaching nuts to mount and
ft. lbs.) (Fig. 81).
tighten to 61 N·m (45 ft. lbs.) (Fig. 81).
(5) Lower vehicle.
(6) Lower vehicle.
RIGHT MOUNT
REMOVAL
(1) Raise vehicle on hoist.
LUBRICATION OPERATION
Oil from the oil pan is pumped by a geroter type oil
DESCRIPTION pump directly coupled to the crankshaft (Fig. 82). Oil
The lubrication system is a full-flow filtration, pressure is controlled by a relief valve mounted
pressure feed type. The oil pump body is mounted to inside the oil pump housing. See (Fig. 82), (Fig. 83),
the engine block. The pump inner rotor is driven by and (Fig. 84) for engine oil lubrication circuits.
the crankshaft. A structural windage tray is used to
increase power by minimizing oil windage at high
engine RPM. An engine oil cooler is used on some
models.
FROM: TO:
Left Cylinder Head Oil Inlet Gallery (intake side of Oil Gallery and Accumulator – Rear of Head*
head)
Oil Gallery and Accumulator – Rear of Head* 1. Exhaust Camshaft Oil Passage
2. Intake Camshaft Oil Passage
Left Exhaust Camshaft Oil Passage 1. Left Exhaust Camshaft Journals
2. Hydraulic Valve Lash Adjusters and Rocker Arms
3. Left Camshaft (Secondary) Chain Tensioner**
Left Intake Camshaft Oil Passage 1. Left Intake Camshaft Journals
2. Hydraulic Valve Lash Adjusters and Rocker Arms
* When oil reaches the back of the cylinder head, the oil gallery feeds oil into an accumulator chamber that is
located towards center of the head. The accumulator chamber is closed off with a pressed in core plug that has a
small orifice to act as a vent. Oil then travels down at a 45 degree angle from the accumulator into two passages,
one for the intake and one for the exhaust side of the cylinder head.
** The secondary camshaft chain tensioner is the last component to receive oil on the left cylinder head.
FROM: TO:
Right Cylinder Head Oil Inlet Gallery (intake side of Oil Gallery and Accumulator – Rear of Head*
head)
Oil Gallery and Accumulator – Rear of Head* 1. Exhaust Camshaft Oil Passage
2. Intake Camshaft Oil Passage
Right Exhaust Camshaft Oil Passage 1. Right Exhaust Camshaft Journals
2. Hydraulic Valve Lash Adjusters and Rocker Arms
3. Right Camshaft (Secondary) Chain Tensioner
4. Primary Timing Chain Tensioner - Right Head**
Right Intake Camshaft Oil Passage 1. Right Intake Camshaft Journals
2. Hydraulic Valve Lash Adjusters and Rocker Arms
* When oil reaches the back of the cylinder head, the oil gallery feeds oil into an accumulator chamber that is
located towards center of the head. The accumulator chamber is closed off with a pressed in core plug that has a
small orifice to act as a vent. Oil then travels down at a 45 degree angle from the accumulator into two passages,
one for the intake and one for the exhaust side of the cylinder head.
** The timing (primary) chain tensioner is the last component to receive oil on the right cylinder head.
INSTALLATION
ENGINE OIL COOLER
(1) Install radiator assembly. (Refer to 7 - COOL-
ING/ENGINE/RADIATOR - INSTALLATION)
(2) Tighten oil cooler lines to radiator fittings to 18
N·m (160 in. lbs.).
COOLER LINES
(1) Connect cooler lines to radiator fittings and
retainer clip (Fig. 88). Tighten lines to radiator fit-
tings to 18 N·m (160 in. lbs.).
(2) Installation of NEW cooler lines:
(a) Install new line fittings to engine block and
oil pan (Fig. 89). Tighten fittings to 30 N·m (260 in.
lbs.).
(b) Position lines to fittings. Push line into fit-
ting until it locks in place. Ensure proper connec-
tion is made by pulling in-and-out on line.
(c) Connect lines to support bracket (Fig. 89).
(3) Installation of the original cooler lines:
(a) Position cooler lines to engine block and oil
pan (Fig. 89). Tighten fittings to 30 N·m (260 in. Fig. 90 ENGINE OIL FILTER
lbs.). 1 - OIL FILTER
(b) Connect lines to support bracket (Fig. 89).
Fig. 91 Structural Collar (7) Install structural collar (Fig. 91) using the fol-
1 - BOLT-HORIZONTAL
lowing tightening sequence:
2 - BOLT-VERTICAL (a) Install the vertical collar to oil pan bolts.
3 - STRUCTURAL COLLAR Torque bolts initially to 1.1 N·m (10 in. lbs.).
(b) Install the horizontal collar to transmission
bolts and torque to 55 N·m (40 ft. lbs.).
(c) Starting with the center vertical bolts and
working outward, final torque bolts to 55 N·m (40
ft. lbs.).
(8) Install oil filter and drain plug.
(9) Connect suspension stabilizer bar. (Refer to 2 -
SUSPENSION/FRONT/STABILIZER BAR - INSTAL-
LATION)
(10) Lower vehicle and install oil dipstick and
tube.
(11) Fill engine crankcase with proper oil to cor-
rect level.
gasket to crankshaft rear oil seal retainer gasket (3) Remove spring and relief valve (Fig. 93).
interface) (Fig. 92).
(3) Install oil pan gasket to block. INSPECTION
(1) Inspect oil pressure relief valve plunger for
NOTE: To prevent oil leaks at oil pan to timing scoring and free operation in its bore. Small marks
chain cover, the following tightening sequence pro- may be removed with 400-grit wet or dry sandpaper.
cedure must be performed. (2) The relief valve spring has a free length of
approximately 49.5 mm (1.95 in.) it should test
(4) Install oil pan and fasteners (Fig. 92) using the
between 101–110 N (23–25 lbs.) when compressed to
following tightening sequence:
9 - 68 ENGINE 2.7L LH
OIL PRESSURE RELIEF VALVE (Continued)
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.
(2) Position an oil collecting container under
switch location.
(3) Disconnect electrical connector.
(4) Remove switch by unscrewing from the engine
block.
INSTALLATION
(1) Apply Mopart Thread Sealant to the switch
threads.
(2) Install oil pressure switch.
(3) Connect electrical connector.
Fig. 93 Oil Pressure Relief Valve (4) Lower vehicle.
(5) Start engine and check for leaks.
1 - RELIEF VALVE
(6) Check engine oil level and adjust as neccessary.
2 - SPRING
3 - RETAINER CAP
OIL PUMP
34 mm (1.34 in.). Replace spring that fails to meet
specifications. REMOVAL
The oil pump pressure relief valve can be serviced
INSTALLATION by removing the oil pan.
(1) Lubricate relief valve with oil. (1) Remove crankshaft vibration damper. (Refer to
9 - ENGINE/ENGINE BLOCK/VIBRATION
CAUTION: The pressure relief valve must be DAMPER - REMOVAL)
installed as shown in (Fig. 93), or engine damage (2) Remove timing chain cover. (Refer to 9 -
may occur. ENGINE/VALVE TIMING/TIMING BELT / CHAIN
COVER(S) - REMOVAL)
(2) Install relief valve, spring and retainer cap
(3) Remove timing chain and sprockets. (Refer to 9
(Fig. 93). Tighten cap to 12 N·m (105 in. lbs.).
- ENGINE/VALVE TIMING/TIMING BELT/CHAIN
(3) Install the oil pan. (Refer to 9 - ENGINE/LU-
AND SPROCKETS - REMOVAL)
BRICATION/OIL PAN - INSTALLATION)
(4) Remove oil pan. (Refer to 9 - ENGINE/LUBRI-
CATION/OIL PAN - REMOVAL)
OIL PRESSURE SWITCH (5) Remove oil pick-up tube and O-ring (Fig. 95).
(6) Ensure that crankshaft position is at 60° ATDC
DESCRIPTION of No.1 cylinder, or crankshaft sprocket mark aligns
with mark on oil pump (Fig. 94). This position will
The engine oil pressure switch is located on the
properly locate oil pump upon installation.
right side of the engine block. The switch screws into
(7) Remove oil pump attaching bolts (Fig. 95).
the engine main oil gallery. The normally closed
(8) Remove oil pump.
switch provides an input through a single wire to the
low pressure indicator light on the instrument clus-
ter.
DISASSEMBLY
(1) Remove the pressure relief valve by remove the
threaded retaining cap from the oil pump housing.
LH ENGINE 2.7L 9 - 69
OIL PUMP (Continued)
(3) Remove oil pump cover screws and lift off cover
plate (Fig. 97).
(4) Remove pump rotors.
(5) Wash all parts in a suitable solvent.
(6) Inspect components carefully for damage or
wear. (Refer to 9 - ENGINE/LUBRICATION/OIL
PUMP - INSPECTION)
CLEANING
(1) Clean all parts thoroughly in a suitable sol-
vent.
INSPECTION
(1) Disassemble the oil pump. (Refer to 9 -
Fig. 95 Oil Pump and Pick-up Tube ENGINE/LUBRICATION/OIL PUMP - DISASSEM-
1 - BOLTS
BLY)
2 - O-RING (2) Clean all oil pump components. (Refer to 9 -
3 - PICK-UP TUBE ENGINE/LUBRICATION/OIL PUMP - CLEANING)
4 - BOLT (3) Inspect mating surface of the oil pump housing
5 - OIL PUMP and cover. Replace oil pump if deeply scratched or
grooved (minor surface scratches and polishing is
CAUTION: Oil pump pressure relief valve must be normal).
installed as shown in (Fig. 96) or engine damage (4) Lay a straightedge across the pump cover sur-
may occur. face (Fig. 98). If a 0.025 mm (0.001 in.) feeler gauge
can be inserted between cover and straight edge,
(2) Remove spring and relief valve. cover should be replaced.
9 - 70 ENGINE 2.7L LH
OIL PUMP (Continued)
INSTALLATION
CAUTION: Crankshaft position must be at 60° ATDC
of No.1 cylinder before installing oil pump (Fig. 94).
This position will properly locate oil pump. If not
properly located, severe damage to oil pump can
occur.
INTAKE MANIFOLD (1) File or sand the remaining port back until a
flat surface is obtained (plane normal to nipple (port)
axis).
DESCRIPTION
(2) Drill out the nipple (port) base using a 7/16”
The two piece intake manifold is made of a com-
drill bit (Fig. 104).
posite material. The intake manifold features a com-
(3) Using a 1/4”–18 NPT pipe tap, cut internal
pact, low rumble design that maximizes engine
threads (Fig. 104). Use caution to start tap in a axis
performance while minimizing induction noise.
same as original nipple.
(4) Apply Mopart Thread Sealant to threads of
OPERATION repair nipple(s).
The intake air plenum chambers absorb air pulsa- (5) Install repair nipple(s). Do not over torque
tions created during each cylinder’s intake stroke. repair nipple(s).
DIAGNOSIS AND TESTING - INTAKE
MANIFOLD LEAKS
An intake manifold air leak is characterized by
lower than normal manifold vacuum. Also, one or
more cylinders may not be functioning.
INSPECTION
Check manifold for:
• Damage and cracks
• Gasket surface damage or warpage
• Damaged or clogged EGR ports
If the manifold exihibits any damaged or warped
conditions, replace the manifold. Clean EGR ports as
neccessary.
If a vacuum port is damaged, a repair procedure
can be performed (Refer to 9 - ENGINE/MANI-
FOLDS/INTAKE MANIFOLD - STANDARD PROCE-
DURE).
INSTALLATION
(1) Clean and inspect sealing surfaces. Gaskets
can be reused, if free of cuts or tears.
INSTALLATION
(1) Inspect and clean sealing surfaces. Inspect and
replace gasket and seal as necessary.
(2) If front crankshaft seal was bench installed,
place Special Tool 6780-2, Sleeve over crankshaft
nose to guide and protect seal lip.
(3) Before installing timing cover gasket apply a
1/8 inch bead of Mopart Engine RTV GEN II to the
parting lines between the oil pan and cylinder block
(Fig. 115).
(4) Install timing cover and gasket. Tighten M10
cover bolts to 54 N·m (40 ft. lbs.) and M6 bolts to 12
N·m (105 in. lbs.) (Fig. 114).
(5) If not previously performed, install crankshaft
oil seal using Special Tool 6780-2 sleeve and 6780-2
installer.
Fig. 114 TIMING CHAIN COVER (6) Install crankshaft vibration damper. (Refer to 9
1 - GASKET
- ENGINE/ENGINE BLOCK/VIBRATION DAMPER -
2 - TIMING CHAIN COVER INSTALLATION)
3 - BOLT-M6 (7) Attach power steering pump to bracket.
4 - BOLT-M10 (8) Install A/C belt tensioner assembly to timing
cover.
(9) Install generator/power steering drive belt ten-
sioner pulley and bracket.
(10) Install radiator fan (Refer to 7 - COOLING/
ENGINE/RADIATOR FAN - INSTALLATION)
(11) Install accessory drive belts. (Refer to 7 -
COOLING/ACCESSORY DRIVE/DRIVE BELTS -
INSTALLATION)
(12) Install upper radiator crossmember. (Refer to
23 - BODY/EXTERIOR/GRILLE OPENING REIN-
FORCEMENT - INSTALLATION)
(13) Connect negative cable.
REMOVAL
REMOVAL - TIMING CHAIN
(1) Remove upper intake manifold. (Refer to 9 -
ENGINE/MANIFOLDS/INTAKE MANIFOLD -
REMOVAL)
(2) Remove cylinder head covers, crankshaft vibra-
tion damper, and timing chain cover. (Refer to 9 -
Fig. 115 TIMING CHAIN COVER SEALING ENGINE/CYLINDER HEAD/CYLINDER HEAD
1 - PLACE A 1/8 INCH BEAD OF SEALER AT PARTING LINE
COVER(S) - REMOVAL) (Refer to 9 - ENGINE/EN-
GINE BLOCK/VIBRATION DAMPER - REMOVAL)
(Refer to 9 - ENGINE/VALVE TIMING/TIMING
BELT / CHAIN COVER(S) - REMOVAL)
9 - 80 ENGINE 2.7L LH
TIMING BELT/CHAIN AND SPROCKETS (Continued)
CAUTION: When aligning timing marks, always
rotate engine by turning the crankshaft. Failure to
do so will result in valve and/or piston damage.
(16) Install the reset chain tensioner into the right (19) Turn the left side camshaft by inserting a 3/8”
cylinder head (Fig. 117). square drive extension with a breaker bar into intake
(17) Position tensioner retaining plate and tighten camshaft drive hub and rotate camshaft until the
bolts to 12 N·m (105 in. lbs.) (Fig. 117). sprocket attaching bolts can be installed. Tighten
(18) Starting at the right cylinder bank, first posi- sprocket bolts to 28 N·m (250 in. lbs.) (Fig. 118).
tion the camshaft damper (if equipped) on camshaft (20) Rotate engine slightly clockwise to remove
hub, then insert a 3/8” square drive extension with a timing chain slack, if necessary.
breaker bar into intake camshaft drive hub. Rotate (21) Activate the timing chain tensioner by using a
camshaft until the camshaft hub aligns to the cam- flat bladed pry tool to gently pry tensioner arm
shaft sprocket and damper attaching holes. Install towards the tensioner slightly (Fig. 123). Then
the sprocket attaching bolts and tighten to 28 N·m release the tensioner arm. Verify the tensioner is
(250 in. lbs.) (Fig. 118). activated (extends).
9 - 86 ENGINE 2.7L LH
TIMING BELT/CHAIN AND SPROCKETS (Continued)
ENGINE 3.5L
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).
LH ENGINE 3.5L 9 - 95
ENGINE 3.5L (Continued)
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.
9 - 96 ENGINE 3.5L LH
ENGINE 3.5L (Continued)
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
LH ENGINE 3.5L 9 - 97
ENGINE 3.5L (Continued)
specially designed black silicone rubber RTV that may be removed with a shop towel. Components
retains adhesion and sealing properties when should be torqued in place while the sealant is still
exposed to engine oil. Moisture in the air causes the wet to the touch (within 10 minutes). The usage of a
material to cure. This material is available in three locating dowel is recommended during assembly to
ounce tubes and has a shelf life of one year. After one prevent smearing material off the location.
year this material will not properly cure. Always Mopart Gasket Sealant in an aerosol can should be
inspect the package for the expiration date before applied using a thin, even coat sprayed completely
use. over both surfaces to be joined, and both sides of a
MOPARt ATF RTV is a specifically designed gasket. Then proceed with assembly. Material in a
black silicone rubber RTV that retains adhesion and can w/applicator can be brushed on evenly over the
sealing properties to seal components exposed to sealing surfaces. Material in an aerosol can should be
automatic transmission fluid, engine coolants, and used on engines with multi-layer steel gaskets.
moisture. This material is available in three ounce
tubes and has a shelf life of one year. After one year STANDARD PROCEDURE - ENGINE GASKET
this material will not properly cure. Always inspect SURFACE PREPARATION
the package for the expiration date before use. To ensure engine gasket sealing, proper surface
MOPARt GASKET MAKER is an anaerobic type preparation must be performed, especially with the
gasket material. The material cures in the absence of use of aluminum engine components and multi-layer
air when squeezed between two metallic surfaces. It steel cylinder head gaskets.
will not cure if left in the uncovered tube. The Never use the following to clean gasket surfaces:
anaerobic material is for use between two machined • Metal scraper
surfaces. Do not use on flexible metal flanges. • Abrasive pad or paper to clean cylinder block
MOPARt BED PLATE SEALANT is a unique and head
(green-in-color) anaerobic type gasket material that • High speed power tool with an abrasive pad or a
is specially made to seal the area between the bed- wire brush (Fig. 4)
plate and cylinder block without disturbing the bear-
ing clearance or alignment of these components. The NOTE: Multi-Layer Steel (MLS) head gaskets require
material cures slowly in the absence of air when a scratch free sealing surface.
torqued between two metallic surfaces, and will rap-
idly cure when heat is applied. Only use the following for cleaning gasket surfaces:
MOPARt GASKET SEALANT is a slow drying, • Solvent or a commercially available gasket
permanently soft sealer. This material is recom- remover
mended for sealing threaded fittings and gaskets • Plastic or wood scraper (Fig. 4)
against leakage of oil and coolant. Can be used on • Drill motor with 3M Roloc™ Bristle Disc (white
threaded and machined parts under all tempera- or yellow) (Fig. 4)
tures. This material is used on engines with multi-
layer steel (MLS) cylinder head gaskets. This CAUTION: Excessive pressure or high RPM (beyond
material also will prevent corrosion. Mopart Gasket the recommended speed), can damage the sealing
Sealant is available in a 13 oz. aerosol can or 4oz./16 surfaces. The mild (white, 120 grit) bristle disc is
oz. can w/applicator. recommended. If necessary, the medium (yellow, 80
grit) bristle disc may be used on cast iron surfaces
SEALER APPLICATION with care.
Mopart Gasket Maker material should be applied
sparingly 1 mm (0.040 in.) diameter or less of sealant
to one gasket surface. Be certain the material sur- STANDARD PROCEDURE - REPAIR OF
rounds each mounting hole. Excess material can eas- DAMAGED OR WORN THREADS
ily be wiped off. Components should be torqued in Damaged or worn threads (excluding spark plug
place within 15 minutes. The use of a locating dowel and camshaft bearing cap attaching threads) can be
is recommended during assembly to prevent smear- repaired. Essentially, this repair consists of drilling
ing material off the location. out worn or damaged threads, tapping the hole with
Mopart Engine RTV GEN II or ATF RTV gasket a special Heli-Coil Tap, (or equivalent) and installing
material should be applied in a continuous bead an insert into the tapped hole. This brings the hole
approximately 3 mm (0.120 in.) in diameter. All back to its original thread size.
mounting holes must be circled. For corner sealing, a
3.17 or 6.35 mm (1/8 or 1/4 in.) drop is placed in the CAUTION: Be sure that the tapped holes maintain
center of the gasket contact area. Uncured sealant the original center line.
9 - 98 ENGINE 3.5L LH
ENGINE 3.5L (Continued)
(8) Install new spark plugs.
(9) Drain engine oil and remove oil filter.
(10) Install a new oil filter.
(11) Fill engine with specified amount of approved
oil.
(12) Connect negative battery cable.
(13) Start engine and check for any leaks.
SPECIAL TOOLS
3.5L ENGINE
Adapter 8406
CYLINDER HEAD
Adaptor 8116 DESCRIPTION
The aluminum alloy cylinder heads feature cross-
flow type intake and exhaust ports. Valve guides and
seat inserts are powdered metal. Valves are arranged
in a “V”, with each camshaft on center. To improve
combustion speed the chambers are a compact spher-
ical design with a squish area of approximately 30
percent of the piston top area. The cylinder heads are
common to either cylinder bank by reversing the
Cooling System Tester 7700 direction of installation.
INSTALLATION CAMSHAFT(S)
(1) Apply light coat of engine oil to the camshaft
oil seal lip. DESCRIPTION
(2) Install the oil seal using Special Tool 6788 Seal A single overhead camshaft per cylinder head pro-
Protector Sleeve (Fig. 17) and Seal Installer 6052 vides valve actuation. The left camshaft accommo-
(Fig. 18). dates a cam sensor pick-up wheel and is therefore
(3) Install camshaft sprocket(s). (Refer to 9 - longer. Each camshaft is supported by four bearing
ENGINE/VALVE TIMING/TIMING BELT/CHAIN journals. Thrust for each camshaft is taken at a
AND SPROCKETS - INSTALLATION) thrust plate attached to the rear of each cylinder
head. Right and left camshaft driving sprockets are
not interchangeable because of the cam sensor
pick-up wheel on the left sprocket. Camshaft bearing
lubrication is provided via oil feed passage through
each rocker shaft pedestal dowel.
OPERATION
The camshaft is driven by the crankshaft via drive
sprockets and belt. The camshaft has precisely
machined lobes to provide accurate valve timing and
duration.
REMOVAL INSPECTION
Camshafts are removed from the rear of each cyl- (1) Inspect camshaft bearing journals for damage
inder head. The cylinder head must be removed. and binding (Fig. 21). If journals are binding, check
(1) Remove camshaft sprocket(s). (Refer to 9 - the cylinder head for damage. Also check cylinder
ENGINE/VALVE TIMING/TIMING BELT/CHAIN head oil holes for clogging.
AND SPROCKETS - REMOVAL) (2) Check the cam lobe and bearing surfaces for
(2) Remove cylinder head(s). (Refer to 9 - abnormal wear and damage. Replace camshaft if
ENGINE/CYLINDER HEAD - REMOVAL) defective.
(3) Mark the rocker arm and shaft assembly before
removal. Remove the rocker arm and shaft assembly NOTE: If camshaft is replaced due to lobe wear or
from the head. (Refer to 9 - ENGINE/CYLINDER damage, always replace the rocker arms.
HEAD/ROCKER ARM / ADJUSTER ASSY -
REMOVAL) (3) Measure the lobe actual wear (Fig. 21) and
(4) Remove the rear camshaft cover and O-ring replace camshaft if out of limit. Standard value is
from head. 0.0254 mm (0.001 in.), wear limit is 0.254 mm (0.010
in.).
CAUTION: Be careful not to nick or scratch the
journals when removing the camshaft.
INSTALLATION
(1) Lubricate camshaft bearing journals and cam-
Fig. 20 Cylinder Head, Camshaft, and Rocker Arms
shaft lobes with clean engine oil and install camshaft
1 - SPARK PLUG TUBE into cylinder head (Fig. 20).
2 - ROCKER ARM ASSEMBLY
(2) Install cylinder head(s). (Refer to 9 - ENGINE/
3 - CAMSHAFT
CYLINDER HEAD - INSTALLATION)
4 - SEAL
(3) Install the rocker arm assembly. (Refer to 9 -
ENGINE/CYLINDER HEAD/ROCKER ARM /
CLEANING ADJUSTER ASSY - INSTALLATION)
Clean camshaft with a suitable solvent. (4) Install camshaft sprockets and timing belt.
(Refer to 9 - ENGINE/VALVE TIMING/TIMING
BELT/CHAIN AND SPROCKETS - INSTALLATION)
LH ENGINE 3.5L 9 - 115
OPERATION
The intake valve allows the air/fuel mixture to
enter the combustion chamber. The exhaust valve
allows the burned air/fuel mixture to exit the com-
bustion chamber. Also, the intake and exhaust valves
seal the combustion chamber during the compression
and power strokes.
Fig. 26 Spark Plug Tube Seal Installation Fig. 27 Intake and Exhaust Valves
1 - SPECIAL TOOL MD-998306 1 - MARGIN
2 - SPARK PLUG TUBE SEAL 2 - FACE
3 - STEM
(5) Position wire harness on cylinder head cover 4 - VALVE SPRING RETAINER LOCK GROOVES
and install retaining nuts (Fig. 22).
(6) Install ignition coils and connect all electrical (1) Inspect the remaining margin after the valves
connectors (Fig. 23). are refaced (Fig. 27). (Refer to 9 - ENGINE - SPEC-
(7) Install upper intake manifold. (Refer to 9 - IFICATIONS)
ENGINE/MANIFOLDS/INTAKE MANIFOLD -
INSTALLATION) VALVE SEATS
(8) Install air cleaner assembly. (1) When refacing valve seats, it is important that
the correct size valve guide pilot be used for reseat-
ing stones. A true and complete surface must be
INTAKE/EXHAUST VALVES & obtained.
SEATS (2) Measure the concentricity of valve seat using
dial indicator. Total runout should not exceed 0.051
DESCRIPTION mm (0.002 inch.) total indicator reading.
Valves are made of highly heat-resistant steel and (3) Inspect the valve seat with Prussian blue to
are chrome plated to prevent stem scuffing. The determine where the valve contacts the seat. To do
intake valve is a one-piece forging, while the exhaust this, coat valve seat LIGHTLY with Prussian blue
valve has a forged head with a welded stem for lock then set valve in place. Rotate the valve with light
groove hardenability. The four valves (two intake and pressure. If the blue is transferred to the center of
two exhaust) employ a three-groove lock design to valve face, contact is satisfactory. If the blue is trans-
help facilitate valve rotation. ferred to top edge of valve face, then lower valve seat
with a 15 degree stone. If the blue is transferred to
LH ENGINE 3.5L 9 - 117
INTAKE/EXHAUST VALVES & SEATS (Continued)
the bottom edge of valve face, then raise valve seat Fig. 29 Checking Valve Tip Height and Valve Spring
with a 65 degree stone. Installed Height
1 - SPRING RETAINER
NOTE: Valve seats which are worn or burned can
2 - GARTER SPRING
be reworked, provided that correct angle and seat
3 - VALVE SPRING SEAT TOP
width are maintained. Otherwise cylinder head must 4 - CYLINDER HEAD SURFACE
be replaced.
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).
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 (e) Remove probes to allow check balls to seat.
(f) Recheck for sponginess. If the lash adjuster
ADJUSTER BLEEDING
sponginess is not completely or nearly eliminated,
Use this procedure to manually bleed aerated oil
then repeat procedure.
from the lash adjuster and remove sponginess.
(g) If the spongy condition cannot be removed,
(1) Run the engine, bringing it to operating tem-
replace effected rocker arm(s).
perature in order to freshly pressurize and warm the
(6) Install cylinder head cover(s).
valvetrain system oil supply.
(2) Remove cylinder head cover(s).
(3) Ensure the rocker arm is positioned on the
base circle of the cam (Fig. 37). Rotate engine as nec-
essary.
(4) For intake rocker arm positions:
(a) Adjust Special Tool 8351 Release Probe’s
gauge pin to extend approximately 20 mm (0.787
in.). Then, carefully insert the release probe gauge
pin into the lash adjuster service access hole (Fig.
38).
INSTALLATION
NOTE: Rocker arm and shaft assembly can be
installed either prior to or after (preferred) cylinder
head installation.
ASSEMBLY
CAUTION: New dowel pins must be installed when
reassembling.
INSTALLATION
(1) The valve stem seal/valve spring seat should be
pushed firmly and squarely over the valve guide
using the valve stem as guide. Do Not Force seal
against top of guide. When installing the valve
retainer locks, compress the spring only enough to
install the locks.
OPERATION
The valve spring returns the valve against its seat
for a positive seal of the combustion chamber.
REMOVAL
REMOVAL - CYLINDER HEAD OFF
(1) Using Special Tool C-3422–D (valve spring
compressor) with Adapter 6526 compress valve
spring and remove valve retaining locks. For Special
Tool identification, (Refer to 9 - ENGINE - SPECIAL
TOOLS).
(2) Slowly release valve spring compressor.Remove
valve spring retainer and valve spring.
(3) Remove valve stem seal assembly (Refer to 9 -
Fig. 48 Checking Valve Tip Height and Valve Spring
ENGINE/CYLINDER HEAD/VALVE STEM SEALS -
Installed Height
REMOVAL).
1 - SPRING RETAINER
2 - GARTER SPRING
3 - VALVE SPRING SEAT TOP
REMOVAL - CYLINDER HEAD ON
4 - CYLINDER HEAD SURFACE
(1) Perform fuel system pressure release procedure
before attempting any repairs. (Refer to 14 -
FUEL SYSTEM/FUEL DELIVERY - STANDARD
VALVE SPRINGS PROCEDURE)
(2) Disconnect negative cable from battery.
DESCRIPTION (3) Remove air cleaner housing and hose assembly.
The valve springs are made from chrome silicon (4) Remove upper intake manifold. (Refer to 9 -
alloy wire and incorporate a “bee-hive” design. Valve ENGINE/MANIFOLDS/INTAKE MANIFOLD -
spring retainers and locks are common from valve-to- REMOVAL)
valve. The valve spring seat is integral with the (5) Remove cylinder head covers. (Refer to 9 -
valve stem oil seal, which incorporates a garter ENGINE/CYLINDER HEAD/CYLINDER HEAD
spring to maintain consistent lubrication control to COVER(S) - REMOVAL)
the valve stem. (6) Remove rocker arm and shaft assembly. (Refer
The valve springs are unique for intake compared to 9 - ENGINE/CYLINDER HEAD/ROCKER ARM /
to exhaust. Both have different lengths and are ADJUSTER ASSY - REMOVAL)
wound in opposite directions. The valve springs are (7) Remove spark plugs. (Refer to 8 - ELECTRI-
color coded, intake spring is right hand coil direction CAL/IGNITION CONTROL/SPARK PLUG -
with orange dye on the top coils, and the exhaust REMOVAL)
spring is left hand coil direction with a yellow dye on (8) Rotate the crankshaft clockwise, until the num-
the top coils (Fig. 49). ber 1 piston is at TDC (Top Dead Center) on the com-
pression stroke.
(9) With air hose attached to spark plug adapter
installed in number 1 spark plug hole, apply 620.5 to
689 kPa (90 to 100 psi) air pressure. This is to hold
valves into place while servicing components.
(10) Using Tool MD 998772A with adapter 6527 or
equivalent, compress valve spring and remove valve
locks, retainer, and valve spring.
(11) Remove valve stem seal, if required. (Refer to
9 - ENGINE/CYLINDER HEAD/VALVE STEM
SEALS - REMOVAL)
(12) Follow the same procedure on the remaining 5
Fig. 49 Valve Spring Identification cylinders using the firing sequence 1-2-3-4-5-6. Make
1 - YELLOW DYE sure piston is at TDC in each cylinder of the
2 - ORANGE DYE valve spring that is being removed.
(13) Remove spark plug adapter tool.
9 - 126 ENGINE 3.5L LH
VALVE SPRINGS (Continued)
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
that the garter spring is intact around the top of the
rubber seal. Fig. 52 Valve, Spring, and Valve Seal
(3) Place valve spring (color-coded end facing up) 1 - VALVE
and valve retainer into position. 2 - VALVE RETAINING LOCKS
(4) Compress valve spring with valve spring com- 3 - VALVE SPRING RETAINER
4 - VALVE SPRING
pressor. Install locks and release tool. If valves
5 - VALVE SEAL AND VALVE SPRING SEAT ASSEMBLY
and/or seats are reground, measure the
installed height of springs (B) (Fig. 51), make
sure measurements are taken from top of
spring seat to the bottom surface of spring
retainer. If height is greater than 38.75 mm (1.5256
in.), install a 0.762 mm (0.030 in.) spacer in head
LH ENGINE 3.5L 9 - 127
VALVE SPRINGS (Continued)
CYLINDER BORE
NOTE: The cylinder bores should be measured at
normal room temperature, 21°C (70°F).
NOTE: The rod bearing bolts should be examined CONNECTING ROD SIDE CLEARANCE
before reuse. If the threads are necked down the (1) Mount a dial indicator to a stationary point on
bolts must be replaced (Fig. 57). engine. Locate probe perpendicular to and resting
against the connecting rod cap being checked. Move
connecting rod all the way to rear of its travel. Zero
the dial indicator. Move connecting rod forward to
limit of travel and read the dial indicator (Fig. 58).
Compare measurement to specification listed in
engine specifications (Refer to 9 - ENGINE - SPECI-
FICATIONS). Repeat procedure for each connecting
rod. Turn crankshaft for connecting rod accessibility.
CRANKSHAFT REMOVAL
(1) Remove engine from vehicle. (Refer to 9 -
DESCRIPTION ENGINE - REMOVAL)
The crankshaft (Fig. 53) is constructed of a forged (2) Remove oil pan. (Refer to 9 - ENGINE/LUBRI-
micro alloy steel. A six throw, nine counterweight CATION/OIL PAN - REMOVAL)
crankshaft is supported by four select fit main bear- (3) Remove oil pickup tube.
ings with number two serving as the thrust washer (4) Remove crankshaft vibration damper. (Refer to
location. The six separate connecting rod throws are 9 - ENGINE/ENGINE BLOCK/VIBRATION
an even-firing design which reduces torque fluctua- DAMPER - REMOVAL)
tions while a torsional vibration damper is used to (5) Remove idler pulley for accessory drive belt.
control torsion caused vibration of the crankshaft. (6) Remove front lower timing belt cover.
Rubber lipped seals are used at front and rear. The (7) Remove front main timing belt cover.
front seal is retained in the oil pump case and the (8) Remove front left side timing belt cover.
rear seal is retained in a block-mounted housing. (9) Remove timing belt tensioner and timing belt.
(10) Remove crankshaft sprocket. (Refer to 9 -
OPERATION ENGINE/VALVE TIMING/TIMING BELT/CHAIN
The crankshaft transfers force generated by com- AND SPROCKETS - REMOVAL)
bustion within the cylinder to the flywheel or flex- (11) Tap dowel pin out of crankshaft.
plate. (12) Remove oil pump assembly.
(13) Remove crankshaft rear oil seal retainer.
STANDARD PROCEDURE - CRANKSHAFT END (Refer to 9 - ENGINE/ENGINE BLOCK/CRANK-
SHAFT REAR OIL SEAL RETAINER - REMOVAL)
PLAY (14) Remove connecting rod bearing caps. Connect-
(1) Using Dial Indicator C-3339 and Mounting ing rod bearing caps are not interchangeable and
Post L-4438, attach to front of engine, locating probe should be marked before removal to insure correct
perpendicular on nose of crankshaft (Fig. 59). assembly (Fig. 60).
(2) Move crankshaft all the way to the rear of its (15) Remove main bearing caps. Main bearing caps
travel. are not interchangeable and are marked to insure
(3) Zero the dial indicator. correct assembly (Fig. 61).
(4) Move crankshaft all the way to the front and (16) Remove crankshaft from cylinder block (Fig.
read the dial indicator. Refer to Engine Specifica- 62).
tions.
NOTE: Before installing crankshaft, refer to Fitting
Main Bearings and Installation of Connecting Rod
Bearings. (Refer to 9 - ENGINE/ENGINE BLOCK/
CRANKSHAFT MAIN BEARINGS - STANDARD PRO-
CEDURE) (Refer to 9 - ENGINE/ENGINE BLOCK/
CONNECTING ROD BEARINGS - STANDARD
PROCEDURE)
INSPECTION
The crankshaft journals should be checked for
excessive wear, taper and scoring. Limits of taper or
out-of-round on any crankshaft journals should be
held to 0.015 mm (0.0006 in.). Journal grinding
should not exceed 0.305 mm (0.012 in.) under the
standard journal diameter. DO NOT grind thrust
faces of Number 2 main bearing. DO NOT nick crank
pin or bearing fillets. After grinding, remove rough
edges from crankshaft oil holes and clean out all pas-
sages.
INSTALLATION
CAUTION: Main bearings are select fit. (Refer to 9 -
ENGINE/ENGINE BLOCK/CONNECTING ROD BEAR-
INGS - STANDARD PROCEDURE)
CRANKSHAFT MAIN
BEARINGS
STANDARD PROCEDURE - CRANKSHAFT MAIN
BEARING FITTING
The main bearings are a “select fit” to achieve
proper oil clearances. For main bearing selection, the
block and crankshaft have grade identification
marks.
The marks for the cylinder block main bore grade
are located on the left side pan rail, just rear of the
left engine mount bracket (Fig. 65). These grade Fig. 65 Cylinder Block Main Bore Grade Marking
marks (1, 2, or 3) are read left to right, corresponding Location
to main bore 1, 2, 3, 4.
The grade marks for the crankshaft are located on
the rearmost crankshaft counter weight as shown in
(Fig. 66). The crankshaft journal grade marks (A, B,
or C) are read left to right, corresponding with jour-
nal number 1, 2, 3, 4.
Refer to the MAIN BEARING SELECTION
CHART—3.2/3.5L to properly select the main bear-
ings. For an example, if the main bore grade is 3 and
the journal grade is B, the proper select fit bearing
would be a (2) +0.003 mm (+0.0002 in.).
REMOVAL
Bearing caps are not interchangeable and are
marked to insure correct assembly (Fig. 68). Upper
and lower bearing halves are NOT interchangeable.
(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.
(4) Shaft seal lip surface must be free of varnish, Fig. 74 INSTALLING CRANKSHAFT OIL SEAL WITH
dirt or nicks. Polish with 400 grit paper if necessary. SPECIAL TOOL
1 - SPECIAL TOOL 6342
INSTALLATION
(1) Install crankshaft seal using Special Tool 6342
(Fig. 74).
(2) Install the dowel pin into the crankshaft to 1.2
mm (0.047 in.) protrusion (Fig. 72).
(3) Install the crankshaft sprocket. (Refer to 9 -
ENGINE/VALVE TIMING/TIMING BELT/CHAIN
AND SPROCKETS - INSTALLATION)
LH ENGINE 3.5L 9 - 137
CRANKSHAFT REAR OIL SEAL (4) While applying firm pressure to the seal
retainer against Special Tools 8225 (Fig. 78), tighten
RETAINER seal retainer screws to 12 N·m (105 in. lbs.).
REMOVAL
(1) Remove crankshaft rear oil seal. (Refer to 9 -
ENGINE/ENGINE BLOCK/CRANKSHAFT OIL
SEAL - REAR - REMOVAL)
(2) Remove oil pan. (Refer to 9 - ENGINE/LUBRI-
CATION/OIL PAN - REMOVAL)
(3) Remove seal retainer attaching screws.
(4) Remove seal retainer (Fig. 77).
INSTALLATION
(1) Install the piston rings. (Refer to 9 - ENGINE/
ENGINE BLOCK/PISTON RINGS - INSTALLA- Fig. 84 Piston Ring End Gap Position
TION) 1 - SIDE RAIL UPPER
2 - NO. 1 RING GAP
NOTE: The connecting rod bearing cap bolts must 3 - PISTON PIN
be examined before reuse. If the threads are necked 4 - SIDE RAIL LOWER
down, the bolts must be replaced. 5 - NO. 2 RING GAP AND SPACER EXPANDER GAP
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).
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).
INSTALLATION
CAUTION: The collar must be tighten using this ser-
vice procedure, as damage to collar and/or oil pan
may occur.
VIBRATION DAMPER
REMOVAL
(1) Disconnect negative cable at right strut tower.
(2) Remove upper radiator crossmember. (Refer to
23 - BODY/EXTERIOR/GRILLE OPENING REIN-
FORCEMENT - REMOVAL)
(3) Remove radiator fan. (Refer to 7 - COOLING/
ENGINE/RADIATOR FAN - REMOVAL)
(4) Remove the accessory drive belts. (Refer to 7 -
COOLING/ACCESSORY DRIVE/DRIVE BELTS -
REMOVAL)
(5) Use Special Tool 8191 to hold crankshaft
damper while removing center bolt (Fig. 95).
(6) Use Special Tool 1023 puller, and insert
C-4685-C2, remove crankshaft damper (Fig. 96).
Fig. 96 CRANKSHAFT DAMPER - REMOVAL
1 - SPECIAL TOOL
1023
2 - SPECIAL TOOL
C-4685–C2
INSERT
INSTALLATION
(1) Install crankshaft damper using Special Tools
C-4685-C1 (5.9 in.) Bolt, with Nut and Thrust Bear-
ing from 6792, and 6792-1 Installer (Fig. 97). Install
center bolt and tighten to 115 N·m (85 ft. lbs.) (Fig.
95). Fig. 97 CRANKSHAFT DAMPER - INSTALLATION
(2) Install accessory drive belts. (Refer to 7 - 1 - SPECIAL TOOL
COOLING/ACCESSORY DRIVE/DRIVE BELTS - 6792–1
INSTALLATION) 2 - SPECIAL TOOL
C-4685–C1
(3) Install radiator fan. (Refer to 7 - COOLING/
ENGINE/RADIATOR FAN - INSTALLATION)
(4) Install upper radiator crossmember. (Refer to
23 - BODY/EXTERIOR/GRILLE OPENING REIN-
FORCEMENT - INSTALLATION)
(5) Connect negative cable.
9 - 146 ENGINE 3.5L LH
ENGINE MOUNTING (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
DESCRIPTION
wood across the full width of the oil pan.
The engine mounting system consist of three
(4) Remove the lower attaching nuts from the bot-
mounts; two hydro-type mounts are attached to the
tom of the isolator to the frame (Fig. 98).
right and left side of the engine block, and one
(5) Raise engine carefully with jack enough to
molded rubber type rear mount is attached to the
remove the isolator with heat shield from its mount.
transaxle (Fig. 98). All three mounts attach to the
suspension crossmember/engine cradle.
The engine hydro-type mounts contain a liquid
INSTALLATION
(1) Install isolator mount with heat shield onto the
that is encased in a solid rubber housing.
frame.
(2) Lower the engine onto the isolator mount.
INSPECTION
(3) Remove jack from vehicle.
Engine hydro-mounts may show surface cracks.
(4) Tighten the isolator to frame nuts to 61 N·m
This will not effect performance and mount should
(45 ft. lbs.) (Fig. 98).
not be replaced. Only replace the engine hydro-
(5) Install the upper attaching nuts to mount and
mounts when leaking fluid.
tighten to 61 N·m (45 ft. lbs.) (Fig. 98).
(6) Lower vehicle.
LEFT MOUNT
REMOVAL
(1) Raise vehicle on hoist.
REAR MOUNT (2) Remove the isolator attaching nuts from top of
the mounting bracket (Fig. 99).
(3) Support the engine with a jack and a block of
REMOVAL
wood across the full width of the oil pan.
(1) Raise vehicle on hoist.
(4) Remove the lower attaching nuts from the bot-
(2) Support transaxle with a jack.
tom of the isolator to the frame (Fig. 99).
(3) Remove isolator nuts from the mount to trans-
(5) Raise engine carefully with jack enough to
axle mount bracket (Fig. 98).
remove the isolator with heat shield from its mount.
(4) Remove rear mount isolator bolts to crossmem-
ber and remove mount (Fig. 98).
INSTALLATION
(1) Install isolator mount with heat shield onto the
INSTALLATION
frame.
(1) Position isolator onto crossmember.
(2) Lower the engine onto the isolator mount.
(2) Install bolts attaching isolator to crossmember
(3) Remove jack from vehicle.
and tighten to 33 N·m (250 in. lbs.) (Fig. 99).
(4) Tighten the isolator to frame nuts to 61 N·m
(3) Lower transaxle onto isolator.
(45 ft. lbs.) (Fig. 99).
(4) Install isolator nuts and tighten to 61 N·m (45
(5) Install the upper attaching nuts to mount and
ft. lbs.) (Fig. 99).
tighten to 61 N·m (45 ft. lbs.) (Fig. 99).
(5) Lower vehicle.
(6) Lower vehicle.
RIGHT MOUNT
REMOVAL
(1) Raise vehicle on hoist.
CAUTION: Do not subject the engine assembly to (5) If the leak is not detected, very slowly turn the
more than 20.6 kpa (3 PSI) of test pressure. crankshaft and watch for leakage. If a leak is
detected between the crankshaft and seal while
• Gradually apply air pressure from 1 psi to 2.5 slowly turning the crankshaft, it is possible the
psi maximum while applying soapy water at the sus- crankshaft seal surface is damaged. The seal area on
pected source. Adjust the regulator to the suitable the crankshaft could have minor nicks or scratches
test pressure that provides the best bubbles which that can be polished out with emery cloth.
will pinpoint the leak source. If the oil leak is
detected and identified, repair per service manual CAUTION: Use extreme caution when crankshaft
procedures. polishing is necessary to remove minor nicks and
• If the leakage occurs at the crankshaft rear oil scratches. The crankshaft seal flange is especially
seal area, refer to the section, Inspection for Rear machined to complement the function of the rear oil
Seal Area Leak. seal.
(6) If no leaks are detected, turn off the air supply.
Remove the air hose, all plugs, and caps. Install the (6) For bubbles that remain steady with shaft
PCV valve and fresh air hose (make-up air). Proceed rotation, no further inspection can be done until dis-
to next step. assembled.
(7) Clean the oil off the suspect oil leak area using (7) After the oil leak root cause and appropriate
a suitable solvent. Drive the vehicle at various corrective action have been identified, replace compo-
speeds approximately 24 km (15 miles). Inspect the nent(s) as necessary.
engine for signs of an oil leak by using a black light.
DIAGNOSIS AND TESTING - CHECKING
NOTE: If oil leakage is observed at the dipstick tube ENGINE OIL PRESSURE
to block location; remove the tube, clean and reseal (1) Remove the oil pressure switch. (Refer to 9 -
using MoparT Stud & Bearing Mount (press fit tube ENGINE/LUBRICATION/OIL PRESSURE SENSOR/
applications only), and for O-ring style tubes, SWITCH - REMOVAL)
remove tube and replace the O-ring seal. (2) Install oil pressure test gauge assembly, Spe-
cial Tools C-3292 with 8406 adaptor.
(3) Start engine and monitor gauge readings.
INSPECTION FOR REAR SEAL AREA LEAKS
Since it is sometimes difficult to determine the CAUTION: If oil pressure is 0 at idle, Do Not Run
source of an oil leak in the rear seal area of the engine at 3000 RPM
engine, a more involved inspection is necessary. The
following steps should be followed to help pinpoint (4) Oil Pressure (engine at operating temperature):
the source of the leak. Curb Idle 34.5 kPa (5 psi) minimum 3000 RPM
300–724 kPa (45–105 psi).
9 - 150 ENGINE 3.5L LH
LUBRICATION (Continued)
(5) If oil pressure is 0 at idle. Shut off engine, WARNING: NEW OR USED ENGINE OIL CAN BE
check for pressure relief valve stuck open or a IRRITATING TO THE SKIN. AVOID PROLONGED OR
clogged oil pickup screen. REPEATED SKIN CONTACT WITH ENGINE OIL.
(6) Install oil pressure switch after testing is com- CONTAMINANTS IN USED ENGINE OIL, CAUSED BY
pleted. (Refer to 9 - ENGINE/LUBRICATION/OIL INTERNAL COMBUSTION, CAN BE HAZARDOUS TO
PRESSURE SENSOR/SWITCH - INSTALLATION) YOUR HEALTH. THOROUGHLY WASH EXPOSED
SKIN WITH SOAP AND WATER. DO NOT WASH
SKIN WITH GASOLINE, DIESEL FUEL, THINNER, OR
OIL SOLVENTS, HEALTH PROBLEMS CAN RESULT. DO
NOT POLLUTE, DISPOSE OF USED ENGINE OIL
DESCRIPTION PROPERLY. CONTACT YOUR DEALER OR GOVERN-
For engine oil type and capacity (Refer to LUBRI- MENT AGENCY FOR LOCATION OF COLLECTION
CATION & MAINTENANCE/FLUID TYPES - CENTER IN YOUR AREA.
DESCRIPTION - ENGINE OIL)
INSTALLATION
ENGINE OIL COOLER
(1) Install radiator assembly (Refer to 7 - COOL-
ING/ENGINE/RADIATOR - INSTALLATION).
Tighten lines to radiator fittings to 18 N·m (160 in.
lbs.) (Fig. 102).
COOLER LINES
(1) Position cooler lines and connect lines to radia-
tor fittings. Tighten lines to radiator fittings to 18
N·m (160 in. lbs.) (Fig. 102).
(2) Connect lines to pressure control valve and oil
pan fitting. Tighten lines to 30 N·m (260 in. lbs.)
(Fig. 102).
(3) Connect lines to support retainer and isolator.
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.).
Fig. 104 STRUCTURAL COLLAR (b) Install the horizontal collar to transmission
1 - BOLT-HORIZONTAL bolts and tighten to 55 N·m (40 ft. lbs.).
2 - BOLT-VERTICAL (c) Starting with center vertical bolts and work-
3 - STRUCTURAL COLLAR ing outward, final torque all bolts to 55 N·m (40 ft.
lbs.).
INSPECTION OPERATION
(1) Inspect oil pressure relief valve plunger for The oil pressure switch provides a ground for the
scoring and free operation in its bore. Small marks instrument cluster low oil pressure indicator light.
may be removed with 400-grit wet or dry sandpaper. The switch receives oil pressure input from the
(2) The relief valve spring has a free length of engine main oil gallery. When engine oil pressure is
approximately 49.5 mm (1.95 in.) it should test greater than 27.5 Kpa (4 psi), the switch contacts
between 101–110 N (23–25 lbs.) when compressed to open, providing a open circuit to the low pressure
34 mm (1.34 in.). Replace spring that fails to meet indicator light. For wiring circuits and diagnostic
specifications. information, (Refer to Appropriate Wiring/Diagnostic
Information).
INSTALLATION
(1) Lubricate relief valve with oil. REMOVAL
(1) Raise vehicle on hoist.
CAUTION: The pressure relief valve must be (2) Position an oil collecting container under
installed as shown in (Fig. 107), or engine damage switch location.
may occur. (3) Disconnect electrical connector (Fig. 108).
(4) Hold oil cooler fitting with a wrench.
LH ENGINE 3.5L 9 - 155
OIL PRESSURE SWITCH (Continued)
(5) Unscrew oil pressure switch from fitting (Fig. (4) Remove the timing belt. (Refer to 9 - ENGINE/
108). VALVE TIMING/TIMING BELT/CHAIN AND
SPROCKETS - REMOVAL)
(5) Remove the crankshaft sprocket. (Refer to 9 -
ENGINE/VALVE TIMING/TIMING BELT/CHAIN
AND SPROCKETS - REMOVAL)
(6) Remove the oil pan. (Refer to 9 - ENGINE/LU-
BRICATION/OIL PAN - REMOVAL)
(7) Remove the oil pickup tube.
(8) Remove the oil pump fasteners. Remove pump
and gasket from engine (Fig. 109).
Fig. 110 Oil Pressure Relief Valve Fig. 112 Checking Oil Pump Cover Flatness
1 - RELIEF VALVE 1 - STRAIGHT EDGE
2 - SPRING 2 - FEELER GAUGE
3 - RETAINER CAP 3 - OIL PUMP COVER
4 - COTTER PIN
Fig. 111 Oil Pump Fig. 113 Measuring Outer Rotor Thickness
1 - OIL PUMP BODY
2 - OIL PUMP OUTER ROTOR
3 - SCREWS
4 - OIL PUMP COVER
5 - OIL PUMP INNER ROTOR
Fig. 115 Measuring Outer Rotor Clearance in Fig. 117 Measuring Clearance Over Rotors
Housing 1 - STRAIGHT EDGE
1 - FEELER GAUGE 2 - FEELER GAUGES
2 - OUTER ROTOR
(9) Inspect oil pressure relief valve plunger for
scoring and free operation in its bore. Small marks
may be removed with 400-grit wet or dry sandpaper.
(10) The relief valve spring (Fig. 118) has a free
length of approximately 49.5 mm (1.95 in.) it should
test between 101–110 N (23–25 lbs.) when com-
pressed to 34 mm (1–11/32 in.). Replace spring that
fails to meet specifications.
INSPECTION
Check manifold for:
• Damage and cracks
• Gasket surface damage or warpage
Fig. 122 INTAKE MANIFOLD SUPPORT - RIGHT • Damaged or clogged EGR ports
1 - SUPPORT BRACKET If the manifold exihibits any damaged or warped
conditions, replace the manifold. Clean EGR ports as
neccessary.
LH ENGINE 3.5L 9 - 161
INTAKE MANIFOLD - UPPER (Continued)
INSTALLATION
(1) Clean all sealing surfaces.
EXHAUST MANIFOLD
DESCRIPTION
Both manifolds are a log style made of ductile cast
iron (Fig. 130). The outlets are designed for V-Band
clamp attachment of close coupled catalytic converters.
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,
Fig. 132 EXHAUST MANIFOLD hydraulic tensioner and a timing belt. The water
1 - BOLT - HEAT SHIELD
pump is driven by the back side of the timing belt.
2 - HEAT SHIELD The right and left camshaft sprockets are not inter-
3 - GASKET changeable because of the cam sensor pick-up wheel
4 - EXHAUST MANIFOLD on the left sprocket.
5 - BOLT - EXHAUST MANIFOLD
6 - HEAT SHIELD STANDARD PROCEDURE - VALVE TIMING
VERIFICATION
INSPECTION (1) Refer to Camshaft Sprocket Removal procedure
(1) Inspect exhaust manifolds for damage or for verification of valve timing (Refer to 9 - ENGINE/
cracks. VALVE TIMING/TIMING BELT/CHAIN AND
(2) Check manifold flatness. SPROCKETS - REMOVAL)
(3) Inspect the exhaust manifold gasket for obvi-
ous discoloration or distortion.
(4) Check distortion of the cylinder head mounting
surface with a straightedge and thickness gauge.
LH ENGINE 3.5L 9 - 167
VALVE TIMING (Continued)
TIMING BELT COVER(S) - (4) Remove the accessory drive belts. (Refer to 7 -
COOLING/ACCESSORY DRIVE/DRIVE BELTS -
FRONT REMOVAL)
(5) Remove crankshaft vibration damper. (Refer to
REMOVAL 9 - ENGINE/ENGINE BLOCK/VIBRATION
(1) Disconnect negative cable from remote jumper DAMPER - REMOVAL)
terminal. (6) Remove the lower belt cover located behind the
(2) Remove upper radiator crossmember. (Refer to crankshaft vibration damper (Fig. 135).
23 - BODY/EXTERIOR/GRILLE OPENING REIN- (7) Remove the A/C belt guide/lift bracket (Fig.
FORCEMENT - REMOVAL) 134).
(3) Remove the radiator fan (Refer to 7 - COOL-
ING/ENGINE/RADIATOR FAN - REMOVAL)
9 - 168 ENGINE 3.5L LH
TIMING BELT COVER(S) - FRONT (Continued)
(8) Remove the stamped steel cover (Fig. 135). Do (5) Install the crankshaft vibration damper. (Refer
not remove the sealer on the cover, it is reus- to 9 - ENGINE/ENGINE BLOCK/VIBRATION
able (Fig. 136). If some sealer is missing use DAMPER - INSTALLATION)
Mopart Engine RTV GEN II to replace the missing (6) Install the accessory drive belts. (Refer to 7 -
sealer. COOLING/ACCESSORY DRIVE/DRIVE BELTS -
(9) Remove the left cast cover (Fig. 135). INSTALLATION)
(7) Install the radiator fan. (Refer to 7 - COOL-
ING/ENGINE/RADIATOR FAN - INSTALLATION)
(8) Install upper radiator crossmember. (Refer to
23 - BODY/EXTERIOR/GRILLE OPENING REIN-
FORCEMENT - INSTALLATION)
(9) Connect negative cable to remote jumper termi-
nal.
Fig. 135 TIMING BELT COVERS NOTE: The right side rear timing belt cover has
1 - RIGHT SIDE COVER (STAMPED)
O-rings to seal the water pump passages to cylin-
2 - LEFT SIDE COVER (CAST) der block (Fig. 139). Do not reuse the O-rings.
3 - LOWER COVER
INSTALLATION
INSTALLATION (1) Inspect the rear cover foam seals for damage or
(1) Install the left cast cover (Fig. 135) and gener- wear (Fig. 138). Replace as neccessary.
ator/power steering belt tensioner pulley and bracket. (2) Clean right rear timing belt cover O-ring seal-
(2) Install the right stamped steel cover (Fig. 135). ing surfaces and grooves (Fig. 139). Lubricate new
(3) Install A/C belt guide/lift bracket (Fig. 134). O-rings with Mopart Dielectric Grease or equivalent
(4) Install the lower cover (Fig. 135). to facilitate assembly.
LH ENGINE 3.5L 9 - 169
TIMING BELT COVER(S) - REAR (Continued)
(3) Position NEW O-rings on cover (Fig. 139).
Fig. 137 Rear Timing Belt Cover Bolts (4) Install rear timing belt covers (Fig. 140) and
(Fig. 141). Tighten bolts to the following specified
1 - REAR COVER TO CYLINDER HEAD BOLTS
torque:
2 - APPLY SEALANT TO BOLT THREADS
3 - REAR COVER TO CYLINDER BLOCK BOLTS
• M10—54 N·m (40 ft. lbs.)
• M8—28 N·m (20 ft. lbs.)
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
Fig. 140 REAR COVER - RIGHT BELT AND SPROCKETS - REMOVAL - TIMING
1 - REAR COVER - RIGHT SIDE BELT)
2 - BOLT
3 - BOLT
4 - BOLT INSPECTION
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
1 - REAR COVER - RIGHT SIDE INSTALLATION - TENSIONER PULLEY
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/
VALVE TIMING/TIMING BELT AND SPROCKETS -
(5) Install camshaft sprockets and reassemble all INSTALLATION - TIMING BELT)
components. (Refer to 9 - ENGINE/VALVE TIMING/
TIMING BELT/CHAIN AND SPROCKETS -
INSTALLATION)
LH ENGINE 3.5L 9 - 171
TIMING BELT TENSIONER & PULLEY (Continued)
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).
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 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
DESCRIPTION
rear of each catalytic converter.
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
OPERATION
a V-Band clamp. The exhaust down pipes exit the The exhaust system channels the exhaust gases
converters and connect into the front resonator. The created by engine to the rear of the vehicle. The muf-
front resonator, intermediate pipe, and muffler are fler and resonator quiets the exhaust noises. The cat-
one single module. The rear resonator and tailpipe alytic converter reduces exhaust emissions.
connect to the muffler outlet. The 300M Special has
11 - 2 EXHAUST SYSTEM LH
EXHAUST SYSTEM (Continued)
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)
11 - 4 EXHAUST SYSTEM LH
EXHAUST SYSTEM (Continued)
(7) If pressure exceeds maximum limits, inspect
exhaust system for restricted component. For further
catalytic converter inspection procedures, (Refer to 11
- EXHAUST SYSTEM/CATALYTIC CONVERTER -
INSPECTION). Replace component(s) as necessary.
SPECIAL TOOLS
EXHAUST SYSTEM
INSTALLATION
RESONATOR - LEFT REAR (1) Position right rear resonator/pipe assembly into
mounting position. Loosely install attaching nuts
REMOVAL (Fig. 2).
(1) Remove the exhaust system (Refer to 11 - (2) Install the rubber isolator to the rear support
EXHAUST SYSTEM - REMOVAL). bracket on body.
(2) Loosen the clamp of the left rear resonator/pipe (3) Align right rear resonator/pipe for proper clear-
assembly (Fig. 1) or (Fig. 2). ance. Tighten nuts to 28 N·m (250 in. lbs.).
(3) Remove the left rear resonator/pipe assembly.
LH FRAME & BUMPERS 13 - 1
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.
13 - 2 FRAME & BUMPERS LH
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.
REAR BUMPER
REMOVAL
(1) Remove rear fascia.
(2) Remove attaching bolts and nuts from attach-
ing bracket to rails (Fig. 8) .
INSTALLATION - INTREPID
(1) Connect fog lamp wire connectors, if equipped. Fig. 8 REAR BUMPER REINFORCEMENT
(2) Place fascia pin position on vehicle, by fitting 1 - REAR BUMPER REINFORCEMENT
foam to bumper beam.
(3) Snap sides of fascia over drive pin fasteners on
fenders.
(4) Install fasteners to upper radiator closure.
13 - 4 FRAME & BUMPERS LH
REAR BUMPER (Continued)
REAR FASCIA
REMOVAL
REMOVAL
(1) Release deck lid latch and open deck lid.
(2) Partially remove trunk carpet to gain access to
fascia attaching nuts and remove nuts.
(3) 300M only, remove both tail lamp housings to
gain access to fascia attaching nuts and remove
attaching nuts.
(4) Remove fasteners attaching fascia to rear quar-
ter and splash shield.
(5) Remove upper push pins attaching the fascia to Fig. 10 REAR BUMPER FASCIA
the body. 1 - LOWER TRUNK OPENING
(6) Pull fascia with 30 pound force to disengage 2 - REAR FASCIA
plastic clip and grommet that attaches the fascia to
the quarter panel vertical flange one side at a time INSTALLATION
(Fig. 9). (1) Connect main wire connector to the body har-
(7) Disengage main wire connector from the body ness connector.
harness. The connector is on the left side of vehicle. (2) Place rear fascia in position on bumper rein-
(8) Remove fascia from vehicle. forcement.
(3) Align the two fascia studs to the quarter panel
vertical attachment, at the same time align the fascia
key hole slot on the horizontal flange with the drive pin.
Push fascia forward to engage the fasteners.
(4) Install push pins attaching top of fascia to
body.
(5) 300M only, install nut on fascia stud and
install tail lamp.
(6) Install trunk carpet back in position.
(7) Install fasteners attaching fascia to rear quar-
ter panel and splash shields.
INDEX
DESCRIPTION FIGURE
ENGINE COMPARTMENT TOP VIEW 11
ENGINE COMPARTMENT SIDE VIEW 12
FORWARD FRAME SECTION AND ENGINE CRADLE 13
REAR FRAME SECTION 14
13 - 6 FRAME & BUMPERS LH
FRAME (Continued)
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
REMOVAL Fig. 15 ENGINE CRADLE
CAUTION: VERIFY THAT VEHICLE IS PROPERLY 1 - FRONT FRAME RAILS
2 - TRANSAXLE CROSSMEMBER
SUPPORTED AND SECURED TO THE LIFTING
3 - CROSSMEMBER BOLTS
DEVICE. VEHICLE CENTER OF GRAVITY WILL
4 - CROSSMEMBER BOLTS
CHANGE WHEN HEAVY COMPONENTS ARE 5 - CRADLE MOUNT BOLTS
REMOVED CAUSING A HAZARDOUS CONDITION. 6 - ENGINE CRADLE
7 - ENGINE MOUNT BOLTS
(1) Release hood latch and open hood.
(2) Remove nuts holding engine mounts to cradle.
(3) Install a suitable engine support device. (1) Support cradle on wood beam and a jack.
(4) Raise and support vehicle on safety stands. (2) Position cradle under body shell.
(5) Remove bolts holding transaxle crossmember to (3) Install bolts to hold cradle to body shell.
cradle. (4) Connect lower control arms to spindles. Refer
(6) Lower vehicle and lift engine and transaxle off to Group 2, Suspension, for proper procedures.
cradle. (5) Install bolts to retain suspension lower ball
(7) Raise and support vehicle on safety stands. joints to spindles.
(8) Disconnect sway bar links. (6) Connect sway bar links.
(9) Remove bolts retaining suspension lower ball (7) Lower vehicle and lower engine and transaxle
joints to spindles. onto cradle.
(10) Separate lower control arm from spindle. (8) Raise vehicle.
Refer to Group 2, Suspension, for proper procedures. (9) Install bolts to hold transaxle crossmember to
(11) Support cradle on a 10 cm by 10 cm by 90 cm cradle.
(4 in. by 4 in. by 36 in.) wood beam and a jack. (10) Lower vehicle.
(12) Remove bolts holding cradle to body shell (11) Remove engine support device.
(Fig. 15). (12) Install nuts to hold engine mounts to cradle.
(13) Lower cradle away from body shell. (13) Align front suspension if necessary.
INSTALLATION
NOTE: If cradle replacement is required, transfer
suspension components and jounce and bounce
plates to replacement cradle.
13 - 10 FRAME & BUMPERS LH
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
Fig. 16 FRONT TOW EYE POSITION &
torque specification is required, hand tighten only
ORIENTATION
(Fig. 17).
1 - FRONT TOW EYE
(5) Reconnect the negative battery cable at the
2 - FRONT TOW EYE BRACKET
remote battery post.
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-
cation and Maintenance section of this manual, for
the required lifting procedure to be used for this
vehicle.
(3) Remove both rear wheel and tire assemblies
from the vehicle.
(4) Remove the nut and bolt attaching each of the
4 lateral links to the crossmember (Fig. 19). The
bolt for the left front lateral link may not be
removed at this time. Remove the nut only.
Once the crossmember is lowered, the bolt can
be easily removed. (Fig. 19). Notice the forward Fig. 19 LATERAL LINK ATTACHMENT TO
attaching bolts face rearward. CROSSMEMBER
1 - LATERAL LINKS
CAUTION: The bolts attaching the forward lateral 2 - LEFT FRONT LATERAL LINK BOLT
links to the crossmember must be installed with the 3 - LATERAL LINKS
bolts pointing rearward (Fig. 19) to prevent damage
to the fuel tank and or fuel tubes in case of an acci- (5) Remove the screw securing the brake tubes to
dent. The bolt attaching the left rear lateral link the left stabilizer bar isolator bushing retainer.
must be installed with the bolt pointing forward to
prevent damage to the fuel filler tube.
13 - 12 FRAME & BUMPERS LH
REAR CROSSMEMBER (Continued)
(6) Remove the 4 bolts attaching both stabilizer
bar isolator bushing retainers to the frame rails (the
2 rearward attaching bolts also attach the front cor-
ners of the rear suspension crossmember in place).
Allow the stabilizer bar to hang down.
(7) Remove the parking brake cable tensioner from
the intermediate parking brake cable. Refer to Base
Brake System in Group 5 Brakes in this manual for
the required service procedure.
(8) Remove the parking brake cable tensioner from
the left rear parking brake cable. Refer to Base
Brake System in Group 5 Brakes in this manual for
the required service procedure.
(9) Remove the right rear parking brake cable
from the intermediate parking brake cable. Refer to
Base Brake System in Group 5 Brakes in this man-
ual for the required service procedure. Fig. 21 REAR BRAKE PROPORTIONING VALVE
(10) Remove the retainer clips securing both rear 1 - CROSSMEMBER ATTACHING BOLT
parking brake cables assemblies to the rear suspen- 2 - REAR FLEX HOSE
sion crossmember (Fig. 20). 3 - BRAKE PROPORTIONING VALVE
4 - REAR CROSSMEMBER
5 - ATTACHING NUT
Fig. 20 REAR PARKING BRAKE AND RETAINER CAUTION: The bolts attaching the forward lateral
CLIP (LEFT) links to the crossmember must be installed with the
1 - INTERMEDIATE PARKING BRAKE CABLE
bolts pointing rearward (Fig. 19) to prevent damage
2 - CLIP to the fuel tank and or fuel tubes. Also, the bolt
3 - FUEL TANK attaching the left rear lateral link must be installed
4 - MUFFLER with the bolt pointing forward to prevent damage to
5 - REAR PARKING BRAKE CABLE the fuel filler tube.
FUEL SYSTEM
TABLE OF CONTENTS
page page
FUEL DELIVERY
TABLE OF CONTENTS
page page
SPECIFICATIONS
TORQUE
SPECIAL TOOLS
Fuel Pressure Test Adapter 6539
FUEL
OPERATION
Its resistance changes with the amount of fuel in
Fuel Line Adapter 1/4 the tank. The float arm attached to the sensor moves
as the fuel level changes.
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
O2S (Oxygen Sensor) Remover/Installer—C-4907 pump/level sensor connector from the bottom of the
fuel pump module electrical connector (Fig. 1).
INSTALLATION
(1) Wipe seal area of tank clean and place a new
Fig. 12 Fuel Pump Module - Typical
seal in position in the tank opening.
REMOVAL (2) Position fuel pump in the tank. Make sure the
(1) Release fuel pressure, Refer to Fuel System alignment tabs on the underside of the fuel pump
Pressure Release Procedure in the Fuel Delivery sec- module flange sits in the notches on the fuel tank
tion. (Fig. 14).
(2) Remove Fuel Tank refer to the Fuel Tank
Removal/Installation in this group.
FUEL RAIL
DESCRIPTION Fig. 15 Injector Electrical Connectors
The fuel rail supplies the necessary fuel to each 1 - FUEL INJECTOR
individual fuel injector and is mounted to the intake 2 - IGNITION COIL
manifold.
(7) Remove mounting bolts on both sides of fuel
OPERATION rail.
The fuel pressure regulator is no longer mounted (8) Lift fuel rail straight up off of cylinder head.
to the fuel rail on any engine. It is now located on (9) Remove retaining clips from fuel injectors at
the fuel tank mounted fuel pump module. Refer to fuel rail.
Fuel Filter/Fuel Pressure Regulator in the Fuel (10) Remove fuel injector from fuel rail.
Delivery System section of this group for information.
The fuel rail is not repairable.
INSTALLATION
REMOVAL - 2.7/3.5L
INSTALLATION - 2.7L
WARNING: RELEASE FUEL SYSTEM PRESSURE (1) Lightly lubricate the fuel injector O-rings with
BEFORE SERVICING FUEL RAIL. SERVICE VEHI- a couple drops of clean engine oil.
CLES IN WELL VENTILATED AREAS AND AVOID (2) Install retaining clips on fuel injectors.
IGNITION SOURCES. NEVER SMOKE WHILE SER- (3) Push injectors into fuel injector rail until clips
VICING THE VEHICLE. are in the correct position.
(4) Position fuel rail over cylinder heads, and push
(1) Release fuel system pressure. Refer to Fuel rail into place. Tighten fuel rail mounting bolts to 11
System Pressure Release Procedure in this section. N·m (100 in. lbs.) torque.
(2) Disconnect the negative battery cable. (5) Connect the fuel supply tube quick connect fit-
(3) Remove intake manifold plenum. Refer to the ting to the fuel rail. Refer to Quick Connect Fittings
Engine section for information. in the Fuel Delivery Section.
(4) Remove intake manifold plenum mounting (6) Connect the electrical connectors to the fuel
bolts. Lift Plenum up off of engine. Cover intake injectors.
LH FUEL DELIVERY 14 - 11
FUEL RAIL (Continued)
(7) Install intake manifold plenum. Refer to the are equipped with a self-diagnosing system using a
Engine section for information. Natural Vacuum Leak Detection (NVLD). Refer to
(8) Connect negative cable to battery. the Emission Control System for additional informa-
tion.
INSTALLATION - 3.5L
(1) Lightly lubricate the fuel injector O-rings with INLET CHECK VALVE
a couple drops of clean engine oil. All vehicles have an inlet check valve on the inside
(2) Install retaining clips on fuel injectors. of the fuel tank at the filler inlet
(3) Push injectors into fuel injector rail until clips The valve prevents fuel from splashing back on
are in the correct position. customer during vehicle refueling. The valve is a
(4) Position fuel rail over cylinder heads, and push non-serviceable item.
rail into place. Tighten fuel rail mounting bolts to 28
N·m (250 in. lbs.) torque. REMOVAL
(5) Connect the fuel supply tube quick connect fit- (1) Release fuel pressure, Refer to Fuel System
ting to the fuel rail. Refer to Quick Connect Fittings Pressure Release Procedure.
in the Fuel Delivery Section. (2) Disconnect battery cable (Fig. 16).
(6) Connect the electrical connectors to the fuel
injectors.
(7) Install intake manifold plenum. Refer to the
Engine section for information.
(8) Connect negative cable to battery.
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 Fig. 16 Battery Cable
without fuel leakage. To accomplish this, fuel and
1 - BATTERY CABLE
vapor flow controls are required for all fuel tank con- 2 - SERVICE VACUUM SUPPLY TEE
nections.
All models are equipped with either one or two
rollover valves mounted into the top of the fuel tank (3) Remove rear seat, refer to the Body section for
(or pump module). more information.
An evaporation control system is connected to the
rollover valve(s)/control valve(Refer to 25 - EMIS-
SIONS CONTROL/EVAPORATIVE EMISSIONS/
ORVR - OPERATION) to reduce emissions of fuel
vapors into the atmosphere, when the tank is vented
due to vapor expansion in the tank. When fuel evap-
orates from the fuel tank, vapors pass through vent
hoses or tubes to a charcoal canister where they are
temporarily held. When the engine is running, the
vapors are drawn into the intake manifold. In addi-
tion, fuel vapors produced during vehicle refueling
are allowed to pass through the vent hoses/tubes to
the charcoal canister(s) for temporary storage (prior
to being drawn into the intake manifold). All models
14 - 12 FUEL DELIVERY LH
FUEL TANK (Continued)
(4) Disconnect fuel pump electrical connector (Fig. (7) Loosen the rear stabilizer bar brackets from
17). body. Swing stabilizer bar toward rear of vehicle (Fig.
19) and (Fig. 20).
Fig. 21 Fuel and EVAP Lines (14) Remove wiring harness from body.
1 - EVAP LINES (15) Remove NVLD filter from mounting location.
2 - BRAKE LINES (16) Remove fuel tank (Fig. 24).
3 - FUEL LINE
INSTALLATION
(1) Install filler neck to filler hose.
(2) Tighten clamps.
(3) Lower vehicle.
(4) Install 3 screws to filler neck and quarter
panel.
(5) Fill tank and check for leaks.
(6) Connect negative cable from battery.
Fig. 25 INLET STRAINER
1 - INLET STRAINER
FUEL TANK VENT TUBE 2 - RETAINING CLIP
3 - FUEL LEVEL SENSOR
REMOVAL
(1) Perform fuel system pressure release. INSTALLATION
(2) Disconnect negative cable from battery. (1) Lubricate the strainer O-ring with clean engine
(3) Drain fuel tank. oil.
(4) Raise and support vehicle on host. (2) Insert strainer O-ring into outlet of strainer so
(5) Lower fuel tank, refer to Fuel Tank Removal/ that it sits evenly on the step inside the outlet.
Installation in this section. (3) Push strainer onto the inlet of the fuel pump
(6) Remove vent hose from top of tank. reservoir body. Make sure the locking tabs on the
(7) Remove vent hose from fuel filler neck. reservoir body lock over the locking tangs on the
strainer.
INSTALLATION (4) Install fuel pump module. Refer to Fuel Pump
(1) Install vent hose and tighten clamp. Module Installation in this section.
(2) Install fuel tank, refer to Fuel Tank Removal/
Installation in this section.
(3) Install vent hose to fuel filler neck and tighten
clamp.
(4) Lower vehicle.
(5) Fill fuel tank and check for leaks.
(6) Connect negative cable to battery.
LH FUEL DELIVERY 14 - 15
(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. 27 Typical Two-Tab Type Quick-Connect Fitting
windows. If they are not visible, the retainer was not 1 - TAB(S)
properly installed (Fig. 26). Do not rely upon the 2 - QUICK-CONNECT FITTING
audible click to confirm a secure connection.
(5) Connect negative cable to battery or auxiliary CAUTION: The interior components (O-rings, spac-
jumper terminal. ers) of this type of quick-connect fitting are not ser-
viced separately, but new plastic retainers are
CAUTION: When using the ASD Fuel System Test,
available. Do not attempt to repair damaged fittings
the Auto Shutdown (ASD) Relay remains energized
or fuel lines/tubes. If repair is necessary, replace
for several minutes, until the test is stopped, or
the complete fuel tube assembly.
until the ignition switch is turned to the Off posi-
tion.
(6) Use the DRB IIIt scan tool ASD Fuel System
Test to pressurize the fuel system. Check for leaks.
14 - 16 FUEL DELIVERY LH
QUICK CONNECT FITTING (Continued)
WARNING: THE FUEL SYSTEM IS UNDER A CON- PLASTIC RETAINER RING TYPE FITTING
STANT PRESSURE (EVEN WITH THE ENGINE OFF). This type of fitting can be identified by the use of a
BEFORE SERVICING ANY FUEL SYSTEM HOSES, full-round plastic retainer ring (Fig. 28) usually black
FITTINGS OR LINES, THE FUEL SYSTEM PRES- in color.
SURE MUST BE RELEASED. REFER TO THE FUEL
PRESSURE RELEASE PROCEDURE IN THIS
GROUP.
DISCONNECTION/CONNECTION
(1) Perform fuel pressure release procedure. Refer
to Fuel Pressure Release Procedure in this group.
(2) Disconnect negative battery cable from battery
or auxiliary jumper terminal.
(3) Clean fitting of any foreign material before dis-
assembly.
(4) To disconnect quick-connect fitting, squeeze
plastic retainer tabs (Fig. 27) against sides of quick-
connect fitting with your fingers. Tool use is not
required for removal and may damage plastic
retainer. Pull fitting from fuel system component
being serviced. The plastic retainer will remain on
component being serviced after fitting is discon-
nected. The O-rings and spacer will remain in quick-
connect fitting connector body.
(5) Inspect quick-connect fitting body and compo-
nent for damage. Replace as necessary.
Fig. 28 Plastic Retainer Ring Type Fitting
CAUTION: When the quick-connect fitting was dis- 1 - FUEL TUBE
connected, the plastic retainer will remain on the 2 - QUICK CONNECT FITTING
component being serviced. If this retainer must be 3 - PUSH
removed, very carefully release the retainer from 4 - PLASTIC RETAINER
the component with two small screwdrivers. After 5 - PUSH
removal, inspect the retainer for cracks or any dam- 6 - PUSH
7 - PUSH
age.
8 - PUSH
(6) Prior to connecting quick-connect fitting to
component being serviced, check condition of fitting CAUTION: The interior components (O-rings, spac-
and component. Clean parts with a lint-free cloth. ers, retainers) of this type of quick-connect fitting
Lubricate with clean engine oil. are not serviced separately. Do not attempt to repair
(7) Insert quick-connect fitting to component being damaged fittings or fuel lines/tubes. If repair is nec-
serviced and into plastic retainer. When a connection essary, replace the complete fuel tube assembly.
is made, a click will be heard.
(8) Verify a locked condition by firmly pulling on
fuel tube and fitting (15-30 lbs.). WARNING: THE FUEL SYSTEM IS UNDER A CON-
(9) Connect negative cable to battery or auxiliary STANT PRESSURE (EVEN WITH THE ENGINE OFF).
jumper terminal. BEFORE SERVICING ANY FUEL SYSTEM HOSES,
(10) Use the DRB IIIt scan tool ASD Fuel System FITTINGS OR LINES, THE FUEL SYSTEM PRES-
Test to pressurize the fuel system. Check for leaks. SURE MUST BE RELEASED. REFER TO THE FUEL
SYSTEM PRESSURE RELEASE PROCEDURE IN
THIS GROUP.
LH FUEL DELIVERY 14 - 17
QUICK CONNECT FITTING (Continued)
DISCONNECTION/CONNECTION (5) After disconnection, plastic retainer ring will
(1) Perform fuel pressure release procedure. Refer remain with quick-connect fitting connector body.
to Fuel Pressure Release Procedure in this section. (6) Inspect fitting connector body, plastic retainer
(2) Disconnect negative battery cable from battery ring and fuel system component for damage. Replace
or auxiliary jumper terminal. as necessary.
(3) Clean fitting of any foreign material before dis- (7) Prior to connecting quick-connect fitting to
assembly. component being serviced, check condition of fitting
(4) To release fuel system component from quick- and component. Clean parts with a lint-free cloth.
connect fitting, firmly push fitting towards compo- Lubricate with clean engine oil.
nent being serviced while firmly pushing plastic (8) Insert quick-connect fitting into component
retainer ring into fitting (Fig. 28). With plastic ring being serviced until a click is felt.
depressed, pull fitting from component. The plastic (9) Verify a locked condition by firmly pulling on
retainer ring must be pressed squarely into fit- fuel tube and fitting (15-30 lbs.).
ting body. If this retainer is cocked during (10) Connect negative battery cable to battery or
removal, it may be difficult to disconnect fit- auxiliary jumper terminal.
ting. Use an open-end wrench on shoulder of (11) Use the DRB IIIt scan tool ASD Fuel System
plastic retainer ring to aid in disconnection. Test to pressurize the fuel system. Check for leaks.
14 - 18 FUEL INJECTION LH
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
14 - 20 FUEL INJECTION LH
FUEL INJECTION (Continued)
1 second. Therefore, battery voltage is not supplied to • Knock sensor
the fuel pump, ignition coil, fuel injectors and heated • Throttle position
oxygen sensors. • A/C switch
• Battery voltage
ENGINE START-UP MODE • Vehicle speed
This is an OPEN LOOP mode. If the vehicle is in • Speed control
park or neutral (automatic transaxles) or the clutch • O2 sensors
pedal is depressed (manual transaxles) the ignition The PCM adjusts injector pulse width and controls
switch energizes the starter relay. The following injector synchronization by turning the individual
actions occur when the starter motor is engaged. ground paths to the injectors On and Off.
• If the PCM receives the camshaft position sensor The PCM adjusts ignition timing and engine idle
and crankshaft position sensor signals, it energizes speed. Engine idle speed is adjusted through the idle
the Auto Shutdown (ASD) relay and fuel pump relay. air control motor.
If the PCM does not receive both signals within
approximately one second, it will not energize the CRUISE OR IDLE MODE
ASD relay and fuel pump relay. The ASD and fuel When the engine is at operating temperature this
pump relays supply battery voltage to the fuel pump, is a CLOSED LOOP mode. During cruising or idle
fuel injectors, ignition coil, (EGR solenoid and PCV the following inputs are received by the PCM:
heater if equipped) and heated oxygen sensors. • Manifold absolute pressure
• The PCM energizes the injectors (on the 69° • Crankshaft position (engine speed)
degree falling edge) for a calculated pulse width until • Inlet/Intake air temperature
it determines crankshaft position from the camshaft • Engine coolant temperature
position sensor and crankshaft position sensor sig- • Camshaft position
nals. The PCM determines crankshaft position within • Knock sensor
1 engine revolution. • Throttle position
• After determining crankshaft position, the PCM • Exhaust gas oxygen content
begins energizing the injectors in sequence. It adjusts • A/C control positions
injector pulse width and controls injector synchroni- • Battery voltage
zation by turning the individual ground paths to the • Vehicle speed
injectors On and Off. The PCM adjusts injector pulse width and controls
• When the engine idles within ±64 RPM of its injector synchronization by turning the individual
target RPM, the PCM compares current MAP sensor ground paths to the injectors On and Off.
value with the atmospheric pressure value received The PCM adjusts engine idle speed and ignition
during the Ignition Switch On (zero RPM) mode. timing. The PCM adjusts the air/fuel ratio according
Once the ASD and fuel pump relays have been to the oxygen content in the exhaust gas (measured
energized, the PCM determines injector pulse width by the upstream and downstream heated oxygen sen-
based on the following: sor).
• MAP The PCM monitors for engine misfire. During
• Engine RPM active misfire and depending on the severity, the
• Battery voltage PCM either continuously illuminates or flashes the
• Engine coolant temperature malfunction indicator lamp (Check Engine light on
• Inlet/Intake air temperature (IAT) instrument panel). Also, the PCM stores an engine
• Throttle position misfire DTC in memory, if 2nd trip with fault.
• The number of engine revolutions since cranking The PCM performs several diagnostic routines.
was initiated They include:
During Start-up the PCM maintains ignition tim- • Oxygen sensor monitor
ing at 9° BTDC. • Downstream heated oxygen sensor diagnostics
during open loop operation (except for shorted)
ENGINE WARM-UP MODE • Fuel system monitor
This is an OPEN LOOP mode. The following inputs • EGR monitor (if equipped)
are received by the PCM: • Purge system monitor
• Manifold Absolute Pressure (MAP) • Catalyst efficiency monitor
• Crankshaft position (engine speed) • All inputs monitored for proper voltage range,
• Engine coolant temperature rationality.
• Inlet/Intake air temperature (IAT) • All monitored components (refer to the Emission
• Camshaft position section for On-Board Diagnostics).
LH FUEL INJECTION 14 - 21
FUEL INJECTION (Continued)
The PCM compares the upstream and downstream • Engine coolant temperature
heated oxygen sensor inputs to measure catalytic • Engine speed
convertor efficiency. If the catalyst efficiency drops • Knock sensor
below the minimum acceptable percentage, the PCM • Manifold absolute pressure
stores a diagnostic trouble code in memory, after 2 • Throttle position
trips. When the PCM senses a wide-open-throttle condi-
During certain idle conditions, the PCM may enter tion through the Throttle Position Sensor (TPS) it de-
a variable idle speed strategy. During variable idle energizes the A/C compressor clutch relay. This
speed strategy the PCM adjusts engine speed based disables the air conditioning system and disables
on the following inputs. EGR (if equipped).
• A/C sense The PCM adjusts injector pulse width to supply a
• Battery voltage predetermined amount of additional fuel, based on
• Battery temperature or Calculated Battery Tem- MAP and RPM.
perature
• Engine coolant temperature IGNITION SWITCH OFF MODE
• Engine run time When the operator turns the ignition switch to the
• Inlet/Intake air temperature OFF position, the following occurs:
• Vehicle mileage • All outputs are turned off, unless 02 Heater
Monitor test is being run. Refer to the Emission sec-
ACCELERATION MODE tion for On-Board Diagnostics.
This is a CLOSED LOOP mode. The PCM recog- • No inputs are monitored except for the heated
nizes an abrupt increase in Throttle Position sensor oxygen sensors. The PCM monitors the heating ele-
output voltage or MAP sensor output voltage as a ments in the oxygen sensors and then shuts down.
demand for increased engine output and vehicle
acceleration. The PCM increases injector pulse width FUEL CORRECTION or ADAPTIVE MEMORIES
in response to increased fuel demand.
• Wide Open Throttle-open loop DESCRIPTION
In Open Loop, the PCM changes pulse width with-
DECELERATION MODE out feedback from the O2 Sensors. Once the engine
This is a CLOSED LOOP mode. During decelera- warms up to approximately 30 to 35° F, the PCM
tion the following inputs are received by the PCM: goes into closed loop Short Term Correction and
• A/C sense utilizes feedback from the O2 Sensors. Closed loop
• Battery voltage Long Term Adaptive Memory is maintained above
• Inlet/Intake air temperature 170° to 190° F unless the PCM senses wide open
• Engine coolant temperature throttle. At that time the PCM returns to Open Loop
• Crankshaft position (engine speed) operation.
• Exhaust gas oxygen content (upstream heated
oxygen sensor) OPERATION
• Knock sensor
• Manifold absolute pressure Short Term
• Throttle position sensor The first fuel correction program that begins func-
• IAC motor (solenoid) control changes in response tioning is the short term fuel correction. This system
to MAP sensor feedback corrects fuel delivery in direct proportion to the read-
The PCM may receive a closed throttle input from ings from the Upstream O2 Sensor.
the Throttle Position Sensor (TPS) when it senses an The PCM monitors the air/fuel ratio by using the
abrupt decrease in manifold pressure. This indicates input voltage from the O2 Sensor. When the voltage
a hard deceleration (Open Loop). In response, the reaches its preset high or low limit, the PCM begins
PCM may momentarily turn off the injectors. This to add or remove fuel until the sensor reaches its
helps improve fuel economy, emissions and engine switch point. The short term corrections then begin.
braking. The PCM makes a series of quick changes in the
injector pulse-width until the O2 Sensor reaches its
WIDE-OPEN-THROTTLE MODE opposite preset limit or switch point. The process
This is an OPEN LOOP mode. During wide-open- then repeats itself in the opposite direction.
throttle operation, the following inputs are used by Short term fuel correction will keep increasing or
the PCM: decreasing injector pulse-width based upon the
• Inlet/Intake air temperature upstream O2 Sensor input. The maximum range of
14 - 22 FUEL INJECTION LH
FUEL INJECTION (Continued)
authority for short term memory is 25% (+/-) of base used. Because the goal is to keep short term at 0 (O2
pulse-width. Short term is violated and is lost when Sensor switching at 0.5 volt), long term will update
ignition is turned OFF. in the same direction as short term correction was
moving to bring the short term back to 0. Once short
Long Term term is back at 0, this long term correction factor is
The second fuel correction program is the long stored in memory.
term adaptive memory. In order to maintain correct The values stored in long term adaptive memory
emission throughout all operating ranges of the are used for all operating conditions, including open
engine, a cell structure based on engine rpm and load loop and cold starting. However, the updating of the
(MAP) is used. long term memory occurs after the engine has
Ther number of cells varies upon the driving con- exceeded approximately 170°-190° F, with fuel control
ditions. Two cells are used only during idle, based in closed loop and two minutes of engine run time.
upon TPS and Park/Neutral switch inputs. There This is done to prevent any transitional temperature
may be two other cells used for deceleration, based or start-up compensations from corrupting long term
on TPS, engine rpm, and vehicle speed. The other fuel correction.
twelve cells represent a manifold pressure and an Long term adaptive memory can change the pulse-
rpm range. Six of the cells are high rpm and the width by as much as 25%, which means it can correct
other six are low rpm. Each of these cells is a specific for all of short term. It is possible to have a problem
MAP voltage range Typical Adaptive Memory Fuel that would drive long term to 25% and short term to
Cells . another 25% for a total change of 50% away from
As the engine enters one of these cells the PCM base pulse-width calculation.
looks at the amount of short term correction being
Fuel Correction Diagnostics ground as the bus reference. The wiring is a mini-
There are two fuel correction diagnostic routines: mum 20 gage wire.
• Fuel System Rich
• Fuel System Lean OPERATION
A DTC is set and the MIL is illuminated if the Various modules exchange information through a
PCM detects either of these conditions. This is deter- communications port called the PCI Bus. The Power-
mined based on total fuel correction, short term train Control Module (PCM) transmits the Malfunc-
times long term. tion Indicator Lamp (Check Engine) On/Off signal
and engine RPM on the PCI Bus. The PCM receives
PROGRAMMABLE COMMUNICATIONS the Air Conditioning select input, transaxle gear
INTERFACE (PCI) BUS position inputs over the PCI Bus. The PCM also
receives the air conditioning evaporator temperature
DESCRIPTION signal from the PCI Bus.
The following components access or send informa-
The Programmable Communication Interface Mul-
tion on the PCI Bus.
tiplex system (PCI Bus) consist of a single wire. The
• Instrument Panel
Body Control Module (BCM) acts as a splice to con-
• Body Control Module
nect each module and the Data Link Connector
• Air Bag System Diagnostic Module
(DLC) together. Each module is wired in parallel to
• Full ATC Display Head (if equipped)
the data bus through its PCI chip set and uses its
• ABS Module
LH FUEL INJECTION 14 - 23
FUEL INJECTION (Continued)
• Transmission Control Module TROL MODULES/POWERTRAIN CONTROL MOD-
• Powertrain Control Module ULE - DESCRIPTION).
• Travel Module
• SKIM TORQUE MANAGEMENT
SYSTEM DIAGNOSIS OPERATION
The PCM receives the torque management input
OPERATION from the transmission control module. The PCM
The PCM can test many of its own input and out- receives the input when the transmission shifts
put circuits. If the PCM senses a fault in a major gears. In response, the PCM shuts off a number of
system, the PCM stores a Diagnostic Trouble Code fuel injectors when the transmission shifts gears.
(DTC) in memory.
For DTC information see On-Board Diagnostics
(Refer to 8 - ELECTRICAL/ELECTRONIC CON-
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.
(3) From the engine compartment, hold the throt- Fig. 5 CRANKSHAFT POSITION SENSOR
tle body lever in the wide open position and install 1 - CRANKSHAFT POSITION SENSOR
the throttle cable.
14 - 26 FUEL INJECTION LH
CRANKSHAFT POSITION SENSOR (Continued)
OPERATION REMOVAL
Engine speed and crankshaft position are provided The crankshaft sensor is located on the passengers
through the crankshaft position sensor. The sensor side of the transmission housing, above the differen-
generates pulses that are the input sent to the pow- tial housing. The bottom of the sensor sits above the
ertrain control module (PCM). The PCM interprets drive plate.
the sensor input to determine the crankshaft posi- (1) Disconnect electrical connector from crankshaft
tion. The PCM then uses this position, along with position sensor.
other inputs, to determine injector sequence and igni- (2) Remove sensor mounting screw. Remove sensor.
tion timing.
The crankshaft position sensor detects slots cut INSTALLATION
into the transmission driveplate extension. There are The crankshaft sensor is located on the passengers
3 sets of slots. Two sets contain 4 slots and one set side of the transmission housing, above the differen-
contains 5 slots, for a total of 13 slots (Fig. 6). Basic tial housing. The bottom of the sensor sits above the
timing is set by the position of the last slot in each drive plate.
group. Once the Powertrain Control Module (PCM) (1) Install sensor and push sensor down until con-
senses the last slot, it determines which piston will tact is made with the transmission case. While hold-
be next at TDC from the camshaft position sensor ing the sensor in this position, install and tighten the
input. It may take the PCM one engine revolution to retaining bolt to 12 N·m (105 in. lbs.) torque.
determine crankshaft position. (2) Connect electrical connector to crankshaft posi-
tion sensor.
OPERATION
The Transmission Control Module (TCM) supplies
the road speed and distance traveled inputs to the
PCM. From these inputs and the throttle position
Fig. 6 TIMING SLOTS sensor input, the PCM determines when a decelera-
1 - TORQUE CONVERTER DRIVE PLATE tion condition occurs.
2 - SLOTS
FUEL INJECTOR to flow out the orifice. Because the fuel is under high
pressure, a fine spray is developed in the shape of a
hollow cone or two streams. The spraying action
DESCRIPTION
atomizes the fuel, adding it to the air entering the
The injectors are positioned in the cylinder heads
combustion chamber. Fuel injectors are not inter-
with the nozzle ends directly above the intake valve
changeable between engines.
port (Fig. 8). The fuel injectors are electrical sole-
The PCM provides battery voltage to each injector
noids (Fig. 7).
through the ASD relay. Injector operation is con-
trolled by a ground path provided for each injector by
the PCM. Injector on-time (pulse-width) is variable,
and is determined by the PCM processing all the
data previously discussed to obtain the optimum
injector pulse width for each operating condition. The
pulse width is controlled by the duration of the
ground path provided.
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.
Fig. 8 Fuel Injector Location—Typical (4) Remove intake manifold plenum mounting
bolts. Lift Plenum up off of engine. Cover intake
1 - FUEL INJECTORS
manifold to prevent foreign material from entering
2 - IGNITION COILS
engine.
(5) Disconnect fuel supply tube quick connect fit-
OPERATION tings at the rear of intake manifold. Refer to Quick
The fuel injectors are 12 volt electrical solenoids Connect Fittings in the Fuel Delivery Section.
(Fig. 9). The injector contains a pintle that closes off (6) If the injector connectors are not tagged with
an orifice at the nozzle end. When electric current is their cylinder number, tag them to identify the cor-
supplied to the injector, the armature and needle rect cylinder
move a short distance against a spring, allowing fuel
14 - 28 FUEL INJECTION LH
FUEL INJECTOR (Continued)
(7) Remove electrical connectors from the fuel (8) Install intake manifold plenum. Refer to the
injectors. Engine section for information.
(8) Remove fuel rail mounting bolts. (9) Connect negative cable to battery.
(9) Lift fuel rail straight up off of the cylinder
head. INSTALLATION - 3.5L
(10) Remove retaining clips from fuel injectors at (1) Lightly lubricate the fuel injector O-rings with
fuel rail. a couple drops of clean engine oil.
(11) Remove fuel injectors. (2) Install retaining clips on fuel injectors.
(12) Repeat for remaining injectors. (3) Push injectors into fuel injector rail until clips
(13) Check injector O-ring for damage. If O-ring is are in the correct position.
damaged, it must be replaced. Replace the injector (4) Position fuel rail over cylinder head, and push
clip if it is damaged. rail into place. Tighten fuel rail mounting bolts to 28
N·m (250 in. lbs.) torque.
REMOVAL - 3.5L (5) Connect fuel supply tube quick connect fittings
(1) Release fuel system pressure. Refer to Fuel at the rear of the fuel rail. Refer to Quick Connect
System Pressure Release Procedure in this section. Fittings in the Fuel Delivery Section.
(2) Disconnect the negative battery cable. (6) Connect electrical connectors to fuel injectors.
(3) Remove intake manifold plenum. Refer to the (7) Install intake manifold plenum. Refer to the
Engine section for information. Engine section for information.
(4) Remove intake manifold plenum mounting (8) Connect the battery cable.
bolts. Lift Plenum up off of engine. Cover intake
manifold to prevent foreign material from entering
engine. FUEL PUMP RELAY
(5) Disconnect fuel supply tube quick connect fit-
ting at the rear of the fuel rail. Refer to Quick Con- DESCRIPTION
nect Fittings in the Fuel Delivery Section. The fuel pump relay is located in the PDC. The
(6) If the injector connectors are not tagged with inside top of the PDC cover has a label showing relay
their cylinder number, tag them to identify the cor- and fuse location.
rect cylinder.
(7) Remove electrical connectors from the fuel OPERATION
injectors. The fuel pump relay supplies battery voltage to the
(8) Remove mounting bolts on both sides of fuel fuel pump. A buss bar in the Power Distribution Cen-
rail. ter (PDC) supplies voltage to the solenoid side and
(9) Lift fuel rail straight up off of cylinder head. contact side of the relay. The fuel pump relay power
(10) Remove retaining clips from fuel injectors at circuit contains a fuse between the buss bar in the
fuel rail. PDC and the relay. The fuse is located in the PDC.
(11) Remove fuel injectors. Refer to the Wiring Diagrams for circuit information.
The PCM controls the fuel pump relay by switch-
ing the ground path for the solenoid side of the relay
INSTALLATION on and off. The PCM turns the ground path off when
the ignition switch is in the Off position. When the
INSTALLATION - 2.7L ignition switch is in the On position, the PCM ener-
(1) Lightly lubricate the fuel injector O-rings with gizes the fuel pump. If the crankshaft position sensor
a couple drops of clean engine oil. does not detect engine rotation, the PCM de-ener-
(2) Install fuel injectors. gizes the relay after approximately one second.
(3) Install retaining clips on fuel injectors.
(4) Push injectors into fuel injector rail until clips
are in the correct position.
(5) Position fuel rail over cylinder head, and push
rail into place. Tighten fuel rail mounting bolts to 11
N·m (100 in. lbs.) torque.
(6) Connect fuel supply tube quick connect fittings
at the rear of intake manifold. Refer to Quick Con-
nect Fittings in the Fuel Delivery Section.
(7) Connect electrical connectors to fuel injectors.
LH FUEL INJECTION 14 - 29
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 screws.
(5) Remove the IAC.
Fig. 10 Idle Air Control Motor
1 - THROTTLE POSITION SENSOR
2 - IDLE AIR CONTROL MOTOR
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 Fig. 11 Idle Air Control Motor
conditioning). 1 - THROTTLE POSITION SENSOR
When engine rpm is above idle speed, the IAC is 2 - IDLE AIR CONTROL MOTOR
used for the following functions:
• Off-idle dashpot
• Deceleration air flow control
INSTALLATION
• A/C compressor load control (also opens the pas-
sage slightly before the compressor is engaged so INSTALLATION - 2.7L
that the engine rpm does not dip down when the (1) Install the IAC to the throttle body.
compressor engages) (2) Tighten mounting screws to 5.5 N·m (49 in.
lbs.) torque.
(3) Attach electrical connector to the IAC.
(4) Connect the negative battery cable.
14 - 30 FUEL INJECTION LH
IDLE AIR CONTROL MOTOR (Continued)
INSTALLATION - 3.5L
(1) Install the IAC to the throttle body (Fig. 12).
(2) Tighten mounting screws to 7.3 N·m (65 in.
lbs.) torque.
(3) Attach electrical connector to the IAC.
(4) Install air plenum and tighten the clamp.
(5) Connect the negative battery cable.
INSTALLATION - 3.5L
(1) Install tuning valve. Tighten mounting screws
to 11.9 N·m (105 in. lbs.) torque.
(2) Install electrical connector.
(3) Connect negative battery cable.
Fig. 12 Idle Air Control Motor
1 - THROTTLE POSITION SENSOR
2 - IDLE AIR CONTROL MOTOR
MAP SENSOR
DESCRIPTION
INTAKE AIR TEMPERATURE The MAP sensor mounts to the driver side of the
SENSOR intake manifold plenum (Fig. 14) or (Fig. 15).
REMOVAL
(1) Remove the negative battery cable.
(2) Disconnect electrical connector from sensor.
(3) Remove sensor.
INSTALLATION
(1) Install sensor. Tighten sensor.
(2) Attach electrical connector to sensor.
(3) Install the negative battery cable.
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.
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. Fig. 18 Upstream Heated Oxygen Sensor 1/1
(2) Attach electrical connector to sensor (Fig. 16). 1 - O2 SENSOR
(3) Install the negative battery cable.
The downstream heated oxygen sensor threads into
INSTALLATION - 3.5L the outlet pipe at the rear of the catalytic convertor
(1) Bolt sensor to intake and tighten the bolts to 4 (Fig. 20).
N·m (35 in. lbs.).
(2) Attach electrical connector to sensor.
(3) Install the negative battery cable.
LH FUEL INJECTION 14 - 33
O2 SENSOR (Continued)
The PCM compares the reading from the sensors to
calculate the catalytic convertor oxygen storage
capacity and converter efficiency. Also, the PCM uses
the upstream heated oxygen sensor input when
adjusting injector pulse width.
When the catalytic converter efficiency drops below
emission standards, the PCM stores a diagnostic
trouble code and illuminates the malfunction indica-
tor lamp (MIL).
The O2 sensors produce voltages from 0 to 1 volt,
depending upon the oxygen content of the exhaust
gas. When a large amount of oxygen is present
(caused by a lean air/fuel mixture, can be caused by
misfire and exhaust leaks), the sensors produces a
low voltage. When there is a lesser amount of oxygen
present (caused by a rich air/fuel mixture, can be
caused by internal engine problems) it produces a
higher voltage. By monitoring the oxygen content
and converting it to electrical voltage, the sensors act
Fig. 19 Upstream Heated Oxygen Sensor 1/1 as a rich-lean switch.
1 - PROPORTIONAL PURGE SOLENOID The oxygen sensors are equipped with a heating
2 - O2 SENSOR element that keeps the sensors at proper operating
temperature during all operating modes. Maintaining
correct sensor temperature at all times allows the
system to enter into closed loop operation sooner.
Also, it allows the system to remain in closed loop
operation during periods of extended idle.
In Closed Loop operation the PCM monitors the O2
sensors input (along with other inputs) and adjusts
the injector pulse width accordingly. During Open
Loop operation the PCM ignores the O2 sensor input.
The PCM adjusts injector pulse width based on pre-
programmed (fixed) values and inputs from other
sensors.
The Automatic Shutdown (ASD) relay supplies bat-
tery voltage to both the upstream and downstream
heated oxygen sensors. The oxygen sensors are
equipped with a heating element. The heating ele-
ments reduce the time required for the sensors to
reach operating temperature. The PCM uses pulse
width modulation to control the ground side of the
heater to regulate the temperature on 4 cyl.
Fig. 20 Downstream Heated Oxygen Sensor 1/2, 2/1 upstream O2 heater only. All other 4 cyl. and 6 cyl.
O2 heaters do not use pulse width modulation.
1 - OXYGEN SENSORS
REMOVAL
REMOVAL - UPSTREAM 1/1, 2/1
The engines uses two heated oxygen sensors, one
in each exhaust manifold.
INSTALLATION
INSTALLATION - UPSTREAM 1/1, 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 +
6E tap. If reusing the original sensor, coat the sensor
threads with an anti-seize compound such as Loctite
771- 64 or equivalent. New sensors have compound
on the threads and do not require an additional coat-
ing. Tighten the sensor to 28 N·m (20 ft. lbs.) torque.
(2) Connect the heated oxygen sensor electrical
connector.
(3) 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-
noid energizes, allowing mechanical linkage to
redirect the intake air flow to six short runners. The
PCM looks for a current spike when actuating the Fig. 24 SHORT RUNNER VALVE (SRV)
solenoid. If the spike is not present, the PCM sets 1 - INTAKE MANIFOLD
the DTC. 2 - SRV VALVE
REMOVAL - 3.5L
(1) Remove the negative battery cable.
INSTALLATION - 3.5L
(1) Install 3 bolts and tighten to 6.7 N·m ( 60 in.
(2) Remove link.
lbs.).
(3) Remove electrical connector.
(2) Install link.
(4) Remove 3 bolts.
(3) Install electrical connector.
(5) Remove valve (Fig. 24).
(4) Install the negative battery cable.
14 - 36 FUEL INJECTION LH
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.
Fig. 25 Throttle Body 2.7L (5) Disconnect electrical connectors from throttle
1 - TPS SENSOR body.
2 - THROTTLE BODY (6) Remove the throttle body support bracket from
3 - PCV VALVE the bottom of the throttle body.
4 - EGR TUBE (7) Remove 3 throttle body bolts.
(8) Remove throttle body.
(9) Clean mating surfaces.
REMOVAL - 3.5L
(1) Disconnect negative cable from battery
(2) Remove wiper arms.
(3) Remove cowl screen.
(4) Remove cowl plenum.
(5) Disconnect air plenum from throttle body.
(6) Remove throttle cable bracket.
(7) Disconnect electrical connectors.
(8) Disconnect top vacuum hose.
(9) Remove the throttle body support bracket from
the bottom of the throttle body.
(10) Remove 3 throttle body bolts.
(11) Hold throttle lever in wide open position.
Remove throttle cable and speed control cables from
throttle arm.
(12) Clean mating surfaces.
Fig. 26 Throttle Body 3.2/3.5L
1 - THROTTLE BODY
2 - TPS
3 - IAC
LH FUEL INJECTION 14 - 37
THROTTLE BODY (Continued)
(2) Install the cable housing (throttle body end)
INSTALLATION into the cable mounting bracket on the engine.
(3) From inside the vehicle, hold up the pedal and
INSTALLATION - 2.7L install throttle cable and cable retainer in the upper
(1) Install throttle body and bolts. end of the pedal shaft (Fig. 1).
(2) Tighten bolts to 11.9 N·m (105 in. lbs.) torque. (4) At the dash panel, install the cable retainer
(3) Install the throttle body support bracket to the clip between the end of the throttle cable fitting and
bottom of the throttle body. Tighten the bolts to 27.1 grommet (Fig. 2).
N·m (20 ft. lbs.) torque. (5) From the engine compartment, rotate the
(4) Hold throttle lever in wide open throttle posi- throttle lever to wide open and install the throttle
tion. Install throttle cable and speed control cable. cable.
(5) Install throttle cable bracket and tighten bolts.
(6) Install air plenum and tighten clamp.
(7) Connect negative cable to battery. THROTTLE POSITION SENSOR
INSTALLATION - 3.5L DESCRIPTION
(1) Hold throttle lever in wide open throttle posi- The throttle position sensor mounts to the side of
tion. Install throttle cable and speed control cable. the throttle body (Fig. 27) or (Fig. 28).The sensor
(2) Install throttle body and bolts. connects to the throttle blade shaft. The TPS is a
(3) Tighten bolts to 11.9 N·m (105 in. lbs.) torque. variable resistor that provides the Powertrain Con-
(4) Install the throttle body support bracket to the trol Module (PCM) with an input signal (voltage).
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.
STEERING
TABLE OF CONTENTS
page page
Fig. 3 Pressure Hose Connection To Power Steering Fig. 5 Analyzer Connected To Power Steering Pump
Pump (2.7L Engine) (2.7L Engine)
1 - POWER STEERING FLUID PRESSURE HOSE 1 - POWER STEERING FLUID PRESSURE HOSE
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.
2. Front suspension crossmember 2. Tighten the front suspension
mounting fasteners loose at frame. crossmember mounting fasteners to the
specified torque.
3. Loose tie rod (outer or inner). 3. Check tie rod pivot points for wear.
Replace worn/loose parts as required.
4. Loose lower control arm mounting 4. Tighten control arm mounting bolts to
bolts at front suspension the specified torques.
crossmember.
5. Lower control arm pivot bushing 5. Replace lower control arm pivot
worn. bushing.
6. Lower control arm tension strut 6. Replace lower control arm tension strut
bushing worn. bushing.
7. Loose strut assembly mounting 7. Tighten strut assembly fasteners to the
fasteners at tower. specified torque.
8. Power steering fluid pressure hose 8. Adjust hose to proper position by
touching the body of the vehicle. loosening, repositioning, and tightening
fitting to specified torque. Do not bend
tubing.
9. Internal power steering gear noise. 9. Replace power steering gear.
10. Damaged front suspension 10. Replace front suspension
crossmember. crossmember.
11. Stabilizer bar link ball joints worn. 11. Replace stabilizer bar link.
LH STEERING 19 - 5
STEERING (Continued)
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 belt. drive belt to specifications. Replace belt if
PUMP) 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 flush
pump internal components. 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.
2. Missing O-Ring on power steering 2. Inspect connection and replace O-Ring
hose connection. as required.
3. Low power steering fluid level. 3. Fill power steering fluid reservoir to
proper level and check for leaks.
4. Air leak between power steering 4. Replace power steering pump (with
fluid reservoir and power steering reservoir).
pump.
SCRUBBING OR 1. Incorrect tire or wheel size. 1. Replace incorrect size tire or wheel with
KNOCKING NOISE. 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.
19 - 6 STEERING LH
STEERING (Continued)
* 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
high frequency noise similar to that experienced the development of high pressure fluid flow. Nor-
while slowly closing a water tap. The noise is mally this noise level should not be high enough to
present in every valve and results when high veloc- be objectionable.
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
DIFFICULT TO TURN.
2. Tires not inflated to specified 2. Inflate tires to the specified pressure.
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.
LH STEERING 19 - 7
STEERING (Continued)
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.
10. Excessive friction in power 10. Replace power steering gear.
steering gear.
11. Worn/binding seat and bearing in 11. Replace seat and bearing in front strut
front strut assembly. assembly.
STIFF, HARD TO TURN, 1. Tires not properly inflated. 1. Inflate tires to specified pressure.
SURGE, MOMENTARY
INCREASE IN EFFORT
WHEN TURNING.
2. Low power steering fluid level. 2. Add power steering fluid as required to
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
CENTER POSITION.
2. Improper front wheel alignment. 2. Check and adjust wheel alignment as
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.
19 - 8 STEERING LH
STEERING (Continued)
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.
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
LH COLUMN 19 - 11
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 power steering gear pinion shaft. The gear then
vehicles 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.
19 - 12 COLUMN LH
COLUMN (Continued)
WARNING: THE AIR BAG SYSTEM IS A SENSITIVE, WARNING: WHEN HANDLING AN UNDEPLOYED
COMPLEX ELECTRO-MECHANICAL UNIT. BEFORE AIRBAG MODULE DURING SERVICING OF THE
ATTEMPTING TO DIAGNOSE, REMOVE OR INSTALL STEERING COLUMN THE FOLLOWING PRECAU-
THE AIR BAG SYSTEM COMPONENTS YOU MUST TIONS SHOULD BE OBSERVED. AT NO TIME
FIRST DISCONNECT AND ISOLATE THE BATTERY SHOULD ANY SOURCE OF ELECTRICITY BE PER-
NEGATIVE (GROUND) CABLE. FAILURE TO DO SO MITTED NEAR THE INFLATOR ON THE BACK OF
COULD RESULT IN ACCIDENTAL DEPLOYMENT OF THE AIRBAG MODULE. WHEN CARRYING A LIVE
THE AIR BAG AND POSSIBLE PERSONAL INJURY. MODULE, THE TRIM COVER SHOULD BE POINTED
THE FASTENERS, SCREWS, AND BOLTS, ORIGI- AWAY FROM THE BODY TO MINIMIZE INJURY IF
NALLY USED FOR THE AIR BAG COMPONENTS, MODULE ACCIDENTLY DEPLOYS. IF AIRBAG MOD-
HAVE SPECIAL COATINGS AND ARE SPECIFI- ULE IS PLACED ON A BENCH OR OTHER SUR-
CALLY DESIGNED FOR THE AIR BAG SYSTEM. FACE, PLASTIC COVER SHOULD BE FACE UP TO
THEY MUST NEVER BE REPLACED WITH ANY SUB- MINIMIZE MOVEMENT IN CASE OF ACCIDENTAL
STITUTES. ANYTIME A NEW FASTENER IS DEPLOYMENT.
NEEDED, REPLACE WITH THE CORRECT FASTEN-
ERS PROVIDED IN THE SERVICE PACKAGE OR
FASTENERS LISTED IN THE PARTS BOOKS. WARNING: SAFETY GOGGLES SHOULD BE WORN
BEFORE SERVICING A STEERING COLUMN AT ALL TIMES WHEN WORKING ON STEERING
EQUIPPED WITH AN AIR BAG, (Refer to 8 - ELEC- COLUMNS.
TRICAL/RESTRAINTS - WARNING)
LH COLUMN 19 - 13
COLUMN (Continued)
CAUTION
CAUTIONS
CAUTION: Disconnect the negative (ground) cable
from the battery, before servicing any column com-
ponent.
Fig. 4 Lower Instrument Panel Cover Mounting Fig. 6 Park Brake Release Cable
Screws 1 - PARK BRAKE RELEASE CABLE
1 - MOUNTING SCREWS 2 - PARK BRAKE RELEASE HANDLE
2 - INSTRUMENT PANEL BRACKET 3 - LOWER INSTRUMENT PANEL COVER
3 - LOWER INSTRUMENT PANEL COVER
Fig. 21 BTSI
(26) If the vehicle is equipped with a floor 1 - SHIFT LEVER BRACKET
mounted shifter, depress the locking tab on the 2 - SOLENOID
shifter/ignition interlock cable (Fig. 20) and remove 3 - KEY CYLINDER
the cable from the key lock housing.
Fig. 23 Shift Cable Removal (31) Remove retaining pin in steering column cou-
1 - STEERING COLUMN pler pinch bolt (Fig. 26). Remove the pinch bolt from
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.
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
Fig. 33 Ignition Switch Removal/Installation
whenever any of the following conditions exist.
1 - STEERING COLUMN
• Whenever a vehicle is involved in a collision
2 - IGNITION SWITCH
which deploys the airbag, regardless of the extent of
damage done to the vehicle.
19 - 24 COLUMN LH
INTERMEDIATE SHAFT (Continued)
• If a vehicle is involved in an impact of the vehi- (3) Remove the upper and lower covers from the
cle’s front suspension or undercarriage, which results steering column.
in any type of damage to the front crossmember. (4) Turn the ignition key to the run position. When
• Under any conditions which result in the steer- ignition switch is in the run position, the lock cylin-
ing column assembly or steering column shaft receiv- der retaining tab will depress.
ing a force great enough to move the steering column (5) Depress tab and slide lock cylinder out of hous-
or shaft forward or rearward in the vehicle. ing (Fig. 36).
Inspect the intermediate shaft and integrated cou-
pler for the following conditions:
• Seized bearing
• Loose bearing stake
• Bearing not seated properly
The steering column intermediate shaft MUST be
replaced as an entire assembly if a problem condition
is found.
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 Fig. 36 Lock Cylinder Removal
detents (Fig. 35) : 1 - TAB
• Accessory 2 - KEY IN RUN POSITION
• Off (lock)
• Unlock INSTALLATION
• On/Run The lock cylinder is inserted in the end of the
• Start housing opposite the ignition switch. The ignition key
rotates the cylinder to 5 different detents:
(1) Install key in lock cylinder. Turn key to run
position (retaining tab on lock cylinder can be
depressed).
(2) The shaft at the end of the lock cylinder aligns
with the socket in the end of the housing. To align
the socket with the lock cylinder, ensure the socket is
in the Run position (Fig. 37).
(3) Align the lock cylinder with the grooves in the
housing. Slide the lock cylinder into the housing
until the tab sticks through the opening in the hous-
ing (Fig. 38).
(4) Turn key to Off position. Remove key.
(5) If the vehicle has column shift and a new lock
cylinder was used, install and adjust a new interlock
cassette. Refer to Ignition Interlock in this section. If
Fig. 35 IGNITION LOCK CYLINDER DETENTS the vehicle has a floor shift, adjust the interlock
cable when the lock cylinder is replaced. Refer to the
REMOVAL Floor Shift Interlock Adjustment procedure in the
The lock cylinder is inserted in the end of the Transmission section..
housing opposite the ignition switch. The ignition key (6) Install upper and lower cover on steering col-
rotates the cylinder to 5 different detents: umn.
(1) Disconnect negative cable from battery. (7) Install tilt lever.
(2) Remove the tilt lever attaching screw. Remove (8) Connect negative cable to battery.
lever.
LH COLUMN 19 - 25
KEY/LOCK CYLINDER (Continued)
REMOVAL
(1) Remove steering column assembly from vehicle.
Refer to the Steering Column Removal.
(2) Install Puller, Special Tool 6831-A, through
center of roll pin in flex coupler and install knurled
nut (Fig. 39).
INSTALLATION
Fig. 38 Lock Cylinder Installation (1) Start roll pin into coupler prior to installing
1 - LOCK CYLINDER HOUSING coupler on steering column shaft. Install roll pin into
2 - LOCK CYLINDER coupler just far enough to square roll pin to hole in
3 - TAB
flex coupler. If roll pin is installed too far, coupler
will not slide onto steering column shaft.
STEERING COUPLING (2) Install coupler on steering shaft until correctly
positioned to allow roll pin to be installed in coupler.
DIAGNOSIS AND TESTING - STEERING (3) Install Puller, Special Tool 6831-A, through
center of roll pin and install knurled nut (Fig. 40).
COLUMN SHAFT UPPER COUPLER (4) Using Puller, Special Tool, 6831-A, (Fig.
If the steering column shaft upper coupler is diag- 40)install roll pin into the coupler until spring pin is
nosed to be defective due to any of the following con- fully installed through both sides of the coupler.
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.
19 - 26 COLUMN LH
STEERING COUPLING (Continued)
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.
(4) Remove the tilt lever and the upper and lower Fig. 44 BTSI
steering column shrouds from steering column
1 - SHIFT LEVER BRACKET
assembly (Fig. 43). Then remove center outlet bezel. 2 - SOLENOID
(5) Remove the brake transmission shift interlock 3 - KEY CYLINDER
(BTSI) solenoid from the shift lever mechanism (Fig.
44). To do so, perform the following:
(a) Disconnect the wiring harness connector (7) Unlock shift cable adjuster.
from the solenoid. (8) Remove the 3 Torxt head screws attaching the
(b) Remove the retainer clip from the end of the shift lever assembly to the steering column tilt hous-
solenoid (Fig. 45). ing (Fig. 46), then remove shift lever assembly from
(c) Slide the solenoid straight off the shift lever tilt housing and unhook the ignition interlock cable
mounting stud. from shift lever assembly (Fig. 46).
(6) Remove the gear shift cable from the attaching (9) Remove the interlock cassette from the steering
pin on the shift lever assembly. column and discard it.
19 - 28 COLUMN LH
STEERING COLUMN GEAR SHIFT LEVER (Continued)
(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. 47)
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. 48).
(c) Install the retainer clip until it snaps into
place in the slot cut into the shift lever mounting
stud (Fig. 49).
(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.
Fig. 45 Solenoid Retainer Clip
1 - SOLENOID
2 - MOUNTING STUD
3 - RETAINER CLIP
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 Fig. 48 Guide And Flange Alignment
tilt housing. 1 - BRACKET FLANGE
(2) Install the gear shift cable onto the cable 2 - GUIDE
attaching pin on shift lever assembly.
(3) Lock the gear shift cable adjuster.
LH COLUMN 19 - 29
STEERING COLUMN GEAR SHIFT LEVER (Continued)
adjustment tab will click as it moves into position.
Ensure the tab fully depressed.
GEAR
TABLE OF CONTENTS
page page
Fig. 12 Tie Rod Attachment Bolt Retaining Tabs Fig. 14 Power Steering Hose Connections At
1 - STEERING GEAR Steering Gear
2 - TIE RODS 1 - POWER STEERING FLUID RETURN HOSE
3 - RETAINING TABS 2 - STEERING GEAR
4 - BOLTS 3 - MASTER CYLINDER FLUID RESERVIOR
5 - PLATE 4 - POWER STEERING FLUID PRESSURE HOSE
Fig. 13 Tie Rod To Steering Gear Attaching Bolts Fig. 15 Steering Gear Attachment To Crossmember
1 - TIE RODS (Left Side)
2 - BOLTS 1 - MOUNTING BOLTS
3 - MOUNTING PLATE 2 - CORSSMEMBER
4 - WASHERS 3 - STEERING GEAR
5 - STEERING GEAR
Fig. 16 Steering Gear Attachment To Crossmember Fig. 18 Steering Coupler Roll Pin
(Right Side) 1 - SPECIAL TOOL 6831–A
1 - STEERING GEAR 2 - DASH PANEL SEAL & BOOT
2 - CROSSMEMBER 3 - FLEX JOINT
3 - MOUNTING BRACKET 4 - KNURLED NUT
4 - MOUNTING BOLTS 5 - SLEEVE
6 - STEERING GEAR
7 - NUT
NOTE: If the vehicle is equipped with a 2.7 liter (b) Lift the left end of the steering gear upward ,
engine, rotate the front of the left front tire/wheel as with the steering gear positioned as shown,
far outward as possible (Fig. 21). This is necessary between the back of the engine and the front of the
to have the required clearance to allow the removal cowl (Fig. 23).
of the steering gear from a vehicle with this engine
application.
(30) Remove the steering gear from the vehicle (c) To remove the steering gear from the vehicle,
using the following steps. pull the steering gear toward the passenger side of
the vehicle out from between the cowl and the
engine.
19 - 38 GEAR LH
GEAR (Continued)
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.
LH GEAR 19 - 39
GEAR (Continued)
(8) Using roll pin Installer, Special Tool 6831A, (12) Tighten the bolts mounting the left side of the
install the roll pin in the flex joint of the intermedi- steering gear to the crossmember to a torque of 58
ate shaft (Fig. 26). Roll pin is installed in coupler N·m (43 ft. lbs.).
using the following procedure: (13) If previously loosened, tighten the bolts
(a) Remove knurled nut from small end of tool. mounting the steering gear mounting bracket to the
(b) Insert small end of removal tool through cen- right side of the steering gear (Fig. 17) to a torque of
ter of roll pin and then install and hand tighten 37 N·m (27 ft. lbs.).
knurled nut.
(c) Position sleeve of removal tool on flex joint as CAUTION: Before installing tie rods on steering
shown (Fig. 26). gear be sure the tie rod spacer block inside the
(d) While holding threaded shaft of tool from steering gear bellows (boot) (Fig. 27) is correctly
turning, tighten nut pulling roll pin into flex joint. aligned with the bolt holes in the rack of the steer-
(e) Center roll pin in flex joint. Do not over-in- ing gear and the steering gear bellows.
stall roll pin.
SPEED PROPORTIONAL
STEERING SOLENOID
Fig. 28 Tie Rod Attachment DESCRIPTION - SOLENOID CONTROL VALVE
1 - RETAINING TABS The solenoid control valve is mounted on the speed
2 - BOLTS proportional power steering gear housing (Fig. 2).
3 - RETAINING PLATE
4 - STEERING GEAR OPERATION - SOLENOID CONTROL VALVE
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.
(23) Install the wiper arms (Fig. 6) on the pivots. (3) Remove the power steering pressure hose (Fig.
Install and securely tighten the wiper arm to pivot 30)from the power steering gear.
attaching nuts. Install the caps on the wiper arms (4) Remove the power steering return hose (Fig.
covering the pivot nuts. 30)from the power steering gear.
(24) Install the intermediate shaft onto the steer- (5) Using a 1–5/16 inch crow foot (Fig. 31), loosen
ing column shaft. Install steering column coupler the solenoid control valve. Then, by hand, remove the
pinch bolt (Fig. 5) and tighten to a torque of 28 N·m solenoid control valve from the power steering gear.
(21 ft. lbs.). Install the pinch bolt nut retaining pin in
pinch bolt.
LH GEAR 19 - 41
SPEED PROPORTIONAL STEERING SOLENOID (Continued)
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 (12) Bend back the retaining tabs on the mounting
plate for the tie rod to steering gear mounting bolts
(9) Remove the nut attaching the outer tie rod end (Fig. 40).
to the steering arm on the strut (Fig. 38).
(10) Remove the tie rod end from the steering arm (13) Remove the bolt fastening the inner tie rod
of the strut using Puller, Special Tool C-3894–A (Fig. requiring service to the steering gear (Fig. 41). Be
39). careful not to loose the washer behind the tie rod.
(11) Turn the steering wheel all the way to the full (14) Loosen the bolt fastening the opposite inner
right position. tie rod to the gear, but do not fully remove it.
(15) Rotate the loose end of the mounting plate out
of the way.
19 - 44 GEAR LH
TIE ROD - INNER (Continued)
(2) Install the tie rod assembly through the tie rod
hole in the wheel opening inner fender. (4) Align the inner tie rod with the mounting hole
in the center take off on steering gear. Rotate the
mounting plate into position over the tie rod. Install
LH GEAR 19 - 45
TIE ROD - INNER (Continued)
tie rod attaching bolt through tie rod and washer (14) Install the battery ground cable onto the
into steering gear. Be sure washer is installed ground stud on the shock tower and install nut.
between tie rod and steering gear as shown (15) Adjust front toe. Refer to Wheel Alignment in
(Fig. 44). Tighten both tie rod to steering gear Suspension.
bolts to a torque of 100 N·m (74 ft. lbs.).
INSTALLATION - OUTER TIE ROD (4) Install and tighten the wheel mounting nuts in
(1) Install the outer tie rod into the adjustment proper sequence until all nuts are torqued to half
sleeve. Do not tighten the adjustment pinch bolt specification. Then repeat the tightening sequence to
at this time. the full specified torque of 135 N·m (100 ft. lbs.).
(2) Install the outer tie rod into the steering arm (5) Lower vehicle.
on front strut. Install tie rod to steering arm attach-
ing nut (Fig. 47). Tighten the attaching nut a torque
of 37 N·m (27 ft. lbs.).
(3) Install the tire and wheel assembly.
LH GEAR 19 - 47
TIE ROD - OUTER (Continued)
CAUTION: When setting the front Toe on the vehi- BUSHING - INNER TIE ROD
cle, the maximum dimension of exposed threads
allowed on the adjuster and outer tie rod cannot
REMOVAL - INNER TIE ROD BUSHING
exceed the distance shown in (Fig. 49). If the maxi-
mum distance is exceeded, inadequate retention of NOTE: When servicing inner tie rod bushings,
either the adjuster or the outer tie rod can result. replacement of both inner tie rod bushings is rec-
This condition can cause separation of the outer tie ommended.
rod end from the inner tie rod. Ensure that adjust-
ment sleeve pinch bolts are torqued to the required (1) Remove the battery ground cable from the
specification when Toe setting procedure is com- ground stud on the shock tower and isolate the
pleted. ground cable by installing the cable isolator on the
ground stud (Fig. 50).
(6) Check the front wheel toe setting on vehicle
and make required changes. When making front
wheel toe adjustments, be sure the maximum
exposed thread requirements (Fig. 49) are not
exceeded.
(7) After completion of the tie rod end installation Fig. 51 Wiper Arm Attachment To Pivot
and the toe adjustment procedure, tighten adjuster 1 - WIPER ARMS
pinch bolt (Fig. 49) to a torque of 38 N·m (28 ft. lbs.). 2 - ATTACHING NUT
Make sure the outer tie rod maintains correct per- 3 - ATTACHING NUT
pendicular orientation while tightening the adjuster
pinch bolt.
19 - 48 GEAR LH
BUSHING - INNER TIE ROD (Continued)
(3) Remove the wiper arms from the pivots. Wiper
arms are removed from the pivots by rocking them
back and force on the pivots until they can be pulled
off the pivots.
(4) Remove the wiper module cover and cowl cover
from the vehicle (Fig. 52).
Fig. 52 Wiper Module And Cowl Cover Fig. 54 In-Line Resonator And Air Inlet Hose
1 - COWL COVER 1 - AIR INLET HOSE
2 - WIPER MODULE COVER 2 - THROTTLE BODY
3 - AIR INLET HOSE
4 - AIR CLEANER HOUSING LID
(5) Remove the eight bolts attaching the cowl rein- 5 - RESONATOR
forcement to the strut towers and the one bolt 6 - IN-LINE RESONATOR
attaching the wiper module to the reinforcement
(Fig. 53). Remove the reinforcement from the vehicle.
(9) Remove the nut attaching the outer tie rod end
to the steering arm on the strut (Fig. 55).
Fig. 56 Removing Outer Tie Rod From Steering Arm Fig. 58 Tie Rod To Steering Gear Attaching Bolts
1 - TIE ROD END 1 - TIE RODS
2 - STEERING ARM 2 - BOLTS
3 - STRUT 3 - MOUNTING PLATE
4 - C-3894A 4 - WASHERS
5 - STEERING GEAR
(13) Remove the bolt fastening the inner tie rod to Fig. 59 Special Tool 8438 Set Up For Removal
the steering gear (Fig. 58). Be careful not to loose the 1 - 8438-3 (SCREW)
washer behind the tie rod. 2 - INNER TIE ROD
(14) Loosen the bolt fastening the opposite inner 3 - VISE
tie rod to the gear, but do not fully remove it. 4 - 8438-1 (RECEIVER)
(15) Rotate the loose end of the mounting plate out 5 - BUSHING
6 - 8438-4 (REMOVER/INSTALLER)
of the way.
(16) Remove the tie rod assembly from the vehicle
through the wheel opening. (18) Assemble Special Tool 8438 in the following
(17) Mount Receiver, Special tool 8438–1, in a vise manner to remove the bushing from the inner tie
as shown (Fig. 59). rod.
19 - 50 GEAR LH
BUSHING - INNER TIE ROD (Continued)
(a) Place the inner tie rod bushing end in the (a) Place the inner tie rod end in Receiver as
Receiver as shown (Fig. 59). shown (Fig. 61).
(b) Place Remover/Installer, Special Tool 8438–4, (b) Place the Sizer (with bushing) on top of the
with the small end down on top of the bushing tie rod bushing bore with the tapered end facing
(Fig. 59). downward.
(c) Insert Screw, Special Tool 8438–3, though the (c) Place Remover/Installer, Special Tool 8438–4,
Remover/Installer and tie rod bushing, until it with the small end down on top of the bushing
threads into the bottom of the Receiver. (Fig. 61).
(d) Using hand tools, tighten the Screw until it (d) Insert Screw, Special Tool 8438–3, through
bottoms out. The bushing is now removed from the the Remover/Installer, bushing (in Sizer) and tie
inner tie rod. rod, until it threads into the bottom of the
(19) Remove the Screw, then remove the Remover/ Receiver.
Installer, tie rod and bushing from the Receiver. (e) Using hand tools, tighten the Screw, pushing
the bushing out of Sizer, into the inner tie rod end.
INSTALLATION - INNER TIE ROD BUSHING Tighten the Screw until it bottoms in the tool. Do
not overtighten.
NOTE: When servicing inner tie rod bushings,
replacement of bushings on both inner tie rods is
recommended.
PUMP
TABLE OF CONTENTS
page page
PUMP REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 61
DESCRIPTION . . . . . . . . . . . . . . . . . . . . . . . . . 53 INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . 61
OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . . 54 HOSES
STANDARD PROCEDURE - POWER DESCRIPTION . . . . . . . . . . . . . . . . . . . . . . . . . 62
STEERING PUMP INITIAL OPERATION . . . . . 54 OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . . 62
REMOVAL REMOVAL - PRESSURE AND RETURN
REMOVAL - PUMP (2.7L ENGINE) . . . . . . . . . 55 HOSES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 62
REMOVAL - PUMP (3.5L ENGINE) . . . . . . . . . 56 INSTALLATION - PRESSURE AND RETURN
DISASSEMBLY - PUMP (PULLEY) .... . . . . . . 58 HOSES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 66
ASSEMBLY - PUMP (PULLEY) . . . . . . . . . . . . . 58 RESERVOIR
INSTALLATION DESCRIPTION . . . . . . . . . . . . . . . . . . . . . . . . . 67
INSTALLATION - PUMP (2.7L ENGINE) . . . . . 59 OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . . 67
INSTALLATION - PUMP (3.5L ENGINE) . . . . . 59 REMOVAL
SPECIFICATIONS REMOVAL - RESERVOIR (2.7L ENGINE) . . . . 67
POWER STEERING PUMP FLOW . . . . . . . . . 59 REMOVAL - RESERVOIR (3.5L ENGINE) . . . . 67
FLUID INSTALLATION
STANDARD PROCEDURE - POWER INSTALLATION - RESERVOIR (2.7L
STEERING FLUID LEVEL CHECKING . . . . . . 60 ENGINE) . . . . . . . . . . . . . . . . . . . . . . . . . . . . 68
FLUID COOLER INSTALLATION - RESERVOIR (3.5L
DESCRIPTION . . . . . . . . . . . . . . . . . . . . . . . . . 60 ENGINE) . . . . . . . . . . . . . . . . . . . . . . . . . . . . 69
OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . . 60
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.
No repair procedures are to be done on the internal
components of the power steering pump. Repair of a
power steering fluid leak from any area of the power
steering pump is not allowed.
19 - 54 PUMP LH
PUMP (Continued)
reduces pressure on the spring end of the flow con-
trol valve which then opens and allows the oil to
return to the intake side of the pump. This action
limits maximum pressure output of the pump to a
safe level.
Under normal power steering pump operating con-
ditions, the pressure requirements of the pump are
below maximum, causing the pressure relief valve to
remain closed.
In the event of a power steering pump drive belt
failure, manual steering control of the vehicle can
still to be maintained. However, under these condi-
tions, steering effort will significantly increase.
OPERATION
CAUTION: Use only MoparT ATF+4 Automatic Trans-
The Power steering pump operates as follows. A
mission Fluid (MS-9602). Do not overfill.
belt driven pulley turns a shaft which drives a rotor.
Rectangular pumping vanes carried by the shaft Wipe the power steering fluid reservoir and filler
driven rotor move the fluid from the intake to the cap clean. Check the level of the power steering fluid
cam ring pressure cavities. As the rotor begins to in the reservoir. The power steering fluid level should
turn, centrifugal force throws the vanes against the be between MAX. COLD and MIN. COLD when the
inside surface of the cam ring to pickup residual oil. fluid is at a normal ambient temperature of approxi-
This oil is then forced into the high pressure area. As mately 32°C to 43°C (90°F to 110°F).
more oil is picked up by the vanes, the additional oil (1) Fill the pump fluid reservoir to the proper level
is forced into the cavities of the thrust plate through and let the fluid settle for at least two (2) minutes.
two crossover holes in the cam ring and pressure (2) Start the engine and let run for a few seconds.
plate. The crossover holes empty into the high pres- Then turn the engine off.
sure area between the pressure plate and the hous- (3) Add fluid if necessary. Repeat the above proce-
ing end cover. dure until the fluid level remains constant after run-
When the high pressure area of the power steering ning the engine.
pump is filled with power steering fluid, the fluid (4) Raise the front wheels off the ground.
flows under the vanes in the rotor slots, forcing the (5) Start the engine. Slowly turn the steering
vanes to follow the inside oval surface of the cam wheel right and left, lightly contacting the wheel
ring. As the vanes reach the restricted area of the stops for less than 2 seconds at a time.
cam ring, oil is forced out from between the vanes. (6) Add power steering fluid if necessary.
When excess oil flow is generated during high-speed (7) Lower the vehicle and turn the steering wheel
operation, a regulated amount of oil returns to the slowly from lock to lock.
pump intake side through a flow control valve. The (8) Stop the engine. Check the fluid level and refill
flow control valve reduces the power required to as required.
drive the pump and holds down temperature build- (9) If the fluid is extremely foamy, allow the vehi-
up. cle to stand a few minutes and repeat the above pro-
When steering conditions exceed maximum pres- cedure.
sure requirements, such as turning the wheels (10) Lower the vehicle.
against the stops, the pressure built up in the steer-
ing gear also exerts pressure on the spring end of the
flow control valve. The end of the valve houses the
pressure relief valve. High pressure lifts the relief
valve ball from its seat and allows oil to flow through
a trigger orifice located in the outlet fitting. This
LH PUMP 19 - 55
PUMP (Continued)
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).
CAUTION: When removing the power steering fluid Fig. 5 Pressure Hose At Pump
supply hose from the nipple on the power steering 1 - POWER STEERING FLUID RESERVOIR
fluid reservoir, do not use excessive force. The will 2 - POWER STEERING FLUID PRESSURE HOSE
result in the nipple being broken off of the power
steering fluid reservoir. (8) Loosen the lock-nut (Fig. 6) on the front of the
pulley for the serpentine drive belt tensioner.
(3) Remove the power steering fluid return hose (9) Using the adjustment bolt (Fig. 6) remove the
from the power steering fluid reservoir (Fig. 4). tension from the drive belt for the power steering
(4) Let power steering fluid drain from the power pump.
steering fluid reservoir and power steering pump. (10) Remove the drive belt from the power steering
(5) Install a cap on the open nipple of the power pump pulley.
steering fluid reservoir to prevent power steering
fluid from spilling when removing the power steering NOTE: Access for the power steering pump mount-
pump. ing bolts is through the holes in the face of the
(6) Remove the power steering fluid pressure hose power steering pump pulley.
from the pressure fitting on the power steering pump
(Fig. 5). (11) Remove the 3 bolts attaching the power steer-
(7) Let remaining power steering fluid drain from ing pump to the power steering pump mounting
the power steering pump. bracket.
19 - 56 PUMP LH
PUMP (Continued)
(13) Remove the power steering pump, power
steering fluid reservoir and pulley as an assembly
from the engine. Power steering pump is removed
from the top of the engine.
(14) Transfer the required parts from the removed
power steering pump to the replacement power steer-
ing pump. See Disassembly and Assembly in this sec-
tion.
FLUID
STANDARD PROCEDURE - POWER STEERING
FLUID LEVEL CHECKING
WARNING: FLUID LEVEL SHOULD BE CHECKED
WITH ENGINE OFF TO PREVENT INJURY FROM
MOVING PARTS.
REMOVAL
(1) Using a siphon pump, remove as much power
steering fluid as possible from the power steering
fluid reservoir.
(2) Raise vehicle using a frame contact type hoist
or supported using jack stands. See Hoisting in
Lubrication And Maintenance.
(3) 300M only - The front fascia will require
removal to access the power steering cooler. See
Frames and Bumpers. Fig. 21 Air Dam Retaining Clips
(4) Remove the hose clamp from the lower hose at
1 - RETAINING CLIPS
the power steering fluid cooler (Fig. 19). Remove the 2 - AIR DAM
lower hose from the power steering fluid cooler.
Drain remaining power steering fluid from the hoses
and the power steering fluid cooler.
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
Fig. 20 Upper Hose At Power Steering Fluid Cooler (89 in. lbs.)
(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
(6) Remove the 6 clips (Fig. 21) mounting the air hose clamps are installed on hose past the
dam to the radiator lower support. upset bead on the power steering cooler.
(7) Remove the 2 nuts (Fig. 22) attaching the (5) 300M only - Reinstall front fascia.
power steering fluid cooler to the radiator lower (6) Lower the vehicle to a point where front tires
crossmember. are just off the ground.
(8) Remove the power steering fluid cooler from (7) Perform Power Steering Pump Initial Opera-
the radiator lower crossmember. tion procedure (Refer to 19 - STEERING/PUMP -
STANDARD PROCEDURE).
19 - 62 PUMP LH
(9) Using a steering wheel clamp (Fig. 28), lock the (11) Bend back the retaining tabs on the mounting
steering wheel from rotating. plate for the tie rod to steering gear mounting bolts
(Fig. 30).
CAUTION: Before removing the steering column (12) Remove the bolts, mounting plate and wash-
coupler from the intermediated steering shaft be ers attaching the tie rods to the steering gear (Fig.
sure the steering wheel is locked from rotating (Fig. 31). Lay the tie rods on top of the transaxle bell
28). If the steering wheel is allowed to rotate freely housing.
19 - 64 PUMP LH
HOSES (Continued)
Fig. 30 Tie Rod Attachment Bolt Retaining Tabs Fig. 32 Master Cylinder To Vacuum Booster
1 - STEERING GEAR Mounting
2 - TIE RODS 1 - MOUNTING NUT
3 - RETAINING TABS 2 - MASTER CYLINDER
4 - BOLTS 3 - MOUNTING NUT
5 - PLATE 4 - VACUUM BOOSTER
(19) Remove the 2 bolts attaching the steering (23) 300M only — The front fascia will require
gears right side mounting bracket to the crossmem- removal to access the power steering cooler. See
ber (Fig. 35). Frames and Bumpers.
(24) Remove the power steering fluid return hose
from the power steering fluid cooler (Fig. 37). Let the
remaining power steering fluid drain out of the
return hose and the power steering fluid cooler.
Fig. 42 Fluid Reservoir To Pump Mounting Fig. 44 Power Steering Fluid Reservoir (3.5L
1 - POWER STEERING FLUID RESERVOIR Engine)
2 - MOUNTING BOLTS 1 - SPEED CONTROL SERVO
3 - POWER STEERING PUMP 2 - POWER STEERING FLUID RESERVOIR
4 - MOUNTING BOLT
INSTALLATION - RESERVOIR (3.5L ENGINE) hose clamps, being sure they are past the hose reten-
(1) Install the power steering fluid reservoir into tion beads on reservoir nipples.
the mounting bracket. Be sure the retaining tab on (4) Lower vehicle.
the bracket is holding the reservoir in the bracket. (5) Fill the power steering pump reservoir to cor-
Fasten screw to 12 N·m (105 in. lbs.). rect fluid level. (Refer to 19 - STEERING/PUMP/
(2) Raise vehicle. FLUID - STANDARD PROCEDURE)
(3) Install the power steering return hose onto the (6) Start engine and turn steering wheel several
nipple on the side of the power steering fluid reser- times from stop to stop to bleed air from fluid in sys-
voir. Install the power steering fluid supply hose tem. Stop engine, check fluid level and inspect sys-
going to the power steering pump, on the bottom nip- tem for leaks.
ple of the power steering fluid reservoir. Install the
LH TRANSAXLE 21 - 1
TRANSAXLE
TABLE OF CONTENTS
page page
The process of elimination can be used to detect DIAGNOSIS AND TESTING - HYDRAULIC
any unit which slips and to confirm proper operation
PRESSURE TESTS
of good units. Road test analysis can diagnose slip-
Pressure testing is a very important step in the
ping units, but the cause of the malfunction cannot
diagnostic procedure. These tests usually reveal the
be determined. Practically any condition can be
cause of most transaxle problems.
caused by leaking hydraulic circuits or sticking
Before performing pressure tests, be certain that
valves.
fluid level and condition, and shift cable adjustments
have been checked and approved. Fluid must be at
operating temperature (150 to 200 degrees F.).
21 - 6 TRANSAXLE LH
42LE AUTOMATIC TRANSAXLE (Continued)
Install an engine tachometer, raise vehicle on hoist (3) Allow vehicle wheels to turn and increase
which allows front wheels to turn, and position throttle opening to achieve an indicated vehicle speed
tachometer so it can be read. of 30 mph.
Using special adapters (L-4559), attach 300 psi (4) In second gear the underdrive clutch pressure
gauge(s) (C-3293SP) to port(s) required for test being should read 110 to 145 psi.
conducted.
Test port locations are shown in (Fig. 4). TEST TWO A–SELECTOR IN OD (Fourth Gear)
NOTE: This test checks the underdrive clutch
hydraulic circuit as well as the shift schedule.
Fig. 4 Pressure Taps NOTE: This test checks the overdrive clutch
1 - TORQUE CONVERTER CLUTCH OFF
hydraulic circuit as well as the shift schedule.
2 - TURBINE SPEED SENSOR
3 - OUTPUT SPEED SENSOR
(1) Attach gauge to the overdrive clutch tap.
4 - LOW/REVERSE (2) Move selector lever to the OD position.
5 - REVERSE (3) Allow vehicle wheels to turn and increase
6 - UNDERDRIVE throttle opening to achieve an indicated vehicle speed
7 - TORQUE CONVERTER CLUTCH ON of 20 mph.
8 - OVERDRIVE (4) Overdrive clutch pressure should read 74 to 95
psi.
TEST ONE-SELECTOR IN L (1st Gear) (5) Move selector lever to the 3 position and
increase indicated vehicle speed to 30 mph.
NOTE: This test checks pump output, pressure reg- (6) The vehicle should be in second gear and over-
ulation and condition of the low/reverse clutch drive clutch pressure should be less than 5 psi.
hydraulic circuit and shift schedule.
TEST FOUR-SELECTOR IN OD (Fourth Gear)
(1) Attach pressure gauge to the low/reverse clutch
tap. NOTE: This test checks the 2/4 clutch hydraulic cir-
(2) Move selector lever to the L position. cuit.
(3) Allow vehicle wheels to turn and increase
throttle opening to achieve an indicated vehicle speed (1) Attach gauge to the 2/4 clutch tap.
to 20 mph. (2) Move selector lever to the OD position.
(4) Low/reverse clutch pressure should read 115 to (3) Allow vehicle front wheels to turn and increase
145 psi. throttle opening to achieve an indicated vehicle speed
of 30 mph. Vehicle should be in fourth gear.
TEST TWO-SELECTOR IN DRIVE (Second Gear) (4) The 2/4 clutch pressure should read 75 to 95
psi.
NOTE: This test checks the underdrive clutch
hydraulic circuit as well as the shift schedule. TEST FIVE-SELECTOR IN OVERDRIVE (Fourth
Gear, CC on)
(1) Attach gauge to the underdrive clutch tap.
(2) Move selector lever to the 3 position. NOTE: These tests check the torque converter
clutch hydraulic circuit.
LH TRANSAXLE 21 - 7
42LE AUTOMATIC TRANSAXLE (Continued)
(1) Attach gauge to the torque converter clutch off (1) Attach gauge to the reverse and low/reverse
pressure tap. clutch tap.
(2) Move selector lever to the overdrive position. (2) Move selector lever to the reverse position.
(3) Allow vehicle wheels to turn and increase (3) Read reverse clutch pressure with output sta-
throttle opening to achieve an indicated vehicle speed tionary (foot on brake) and throttle opened to achieve
of 50 mph. Vehicle should be in 4th gear, CC on. 1500 rpm.
(4) Reverse and low/reverse clutch pressure should
CAUTION: Both wheels must turn at the same read 165 to 235 psi.
speed.
TEST RESULT INDICATIONS
(4) Torque converter clutch off pressure should be (1) If proper line pressure is found in any one test,
less than 5 psi. the pump and pressure regulator are working prop-
(5) Now attach the gauge to the torque converter erly.
clutch on pressure tap. (2) Low pressure in all positions indicates a defec-
(6) Move selector to the overdrive position. tive pump, a clogged filter, or a stuck pressure regu-
(7) Allow vehicle wheels to turn and increase lator valve.
throttle opening to achieve an indicated vehicle speed (3) Clutch circuit leaks are indicated if pressures
of 50 mph. do not fall within the specified pressure range.
(8) Verify the torque converter clutch is applied (4) If the overdrive clutch pressure is greater than
mode using the RPM display of the DRB scan tool. 5 psi in Step 6 of Test Three, a worn reaction shaft
(9) Torque converter clutch on pressure should be seal ring or a defective solenoid assembly is indi-
60-90 psi. cated.
(5) If the underdrive clutch pressure is greater
TEST SIX-SELECTOR IN REVERSE than 5 psi in Step 4 of Test Two-A, a defective sole-
noid/pressure switch assembly or controller is the
NOTE: This test checks the reverse clutch hydraulic
cause.
circuit.
ALL PRESSURE SPECIFICATIONS ARE PSI (ON HOIST, WITH FRONT WHEELS FREE TO TURN)
Gear Selector Actual Gear PRESSURE TAPS
Position Under- Over- Reverse Torque Torque 2/4 Low/
drive drive Clutch Con- Con- Clutch Reverse
Clutch Clutch verter verter Clutch
Clutch Clutch
Off On
PARK * PARK 0-2 0-5 0-2 60- 45- 0-2 115-145
0 mph 110 100
REVERSE * REVERSE 0-2 0-7 165-235 50- 35-85 0-2 165-235
0 mph 100
NEUTRAL * NEUTRAL 0-2 0-5 0-2 60- 45- 0-2 115-145
0 mph 110 100
L # FIRST 110-145 0-5 0-2 60- 45- 0-2 115-145
20 mph 110 100
3 # SECOND 110-145 0-5 0-2 60- 45- 115-145 0-2
30 mph 110 100
3 # DIRECT 75-95 75-95 0-2 60-90 45-80 0-2 0-2
45 mph
OD # OVERDRIVE 0-2 75-95 0-2 60-90 45-80 75-95 0-2
30 mph
OD # OVERDRIVE 0-2 75-95 0-2 0-5 60-95 75-95 0-2
50 mph WITH TCC
* Engine Speed at 1500 rpm
# CAUTION: Both front wheels must be turning at same speed.
21 - 8 TRANSAXLE LH
42LE AUTOMATIC TRANSAXLE (Continued)
Fig. 12 Measure Input Shaft End Play Using Tool Fig. 14 Remove Transaxle Oil Pan
8266—Typical
1 - TRANSAXLE OIL PAN
1 - TOOL 8266–8
2 - TOOL 8266–2
3 - TOOL C-3339
LH TRANSAXLE 21 - 13
42LE AUTOMATIC TRANSAXLE (Continued)
(4) Remove transaxle oil filter (Fig. 15). (6) Remove valve body from transaxle (Fig. 17).
Fig. 15 Remove Transaxle Oil Filter Fig. 17 Remove Valve Body From Transaxle
1 - TRANSAXLE FILTER 1 - VALVE BODY
2 - FILTER RETAINING CLIPS
NOTE: For valve body recondition procedure, (Refer
(5) Remove seven valve body-to-case bolts (Fig. to 21 - TRANSMISSION/TRANSAXLE/AUTOMATIC -
16). 42LE/VALVE BODY - DISASSEMBLY).
Fig. 19 Remove Overdrive Accumulator and Springs Fig. 21 Remove Low/Reverse Accumulator
1 - OVERDRIVE ACCUMULATOR PISTON 1 - SNAP RING
2 - RETURN SPRINGS 2 - LOW/REVERSE ACCUMULATOR
3 - SEAL RING
4 - SEAL RING
(10) Remove the low/reverse accumulator plug
(Fig. 22).
CAUTION: Tag the springs for the Overdrive Accu-
mulator so that they are not confused with the
springs in the Low/Reverse Accumulator.
Fig. 23 Remove Low/Reverse Accumulator Piston Fig. 25 Remove Long Stub Shaft Snap Ring
1 - SEAL RINGS 1 - SNAP RING
2 - PISTON 2 - SNAP RING PLIERS
3 - PISTON 3 - LONG STUB SHAFT
4 - PETROLATUM
5 - SUITABLE TOOL
(13) Remove long stub shaft and bearing from bell-
housing using Tools 8420A and C-3752 (Fig. 26).
(15) Remove oil pump using C-3752 Pullers (Fig. (17) Remove oil pump gasket (Fig. 30).
28).
Fig. 43 Remove 2/4 Clutch Pack Fig. 45 Remove Low/Reverse Reaction Plate
1 - LOW/REVERSE REACTION PLATE (FLAT SIDE UP)
1 - CLUTCH PLATE (4)
2 - CLUTCH DISC (4)
(31) Remove one (1) low/reverse clutch disc to facil-
(29) Remove tapered snap ring (Fig. 44). itate snap ring removal (Fig. 46).
(45) Use special tool 6497 and 6498 to remove the Fig. 62 Use Arbor Press to Remove Output Shaft
transfer shaft nut or the output shaft nut (Fig. 61). from Case
(46) Remove output shaft from case using a shop
1 - OUTPUT SHAFT
press (Fig. 62).
2 - ARBOR PRESS
Use special tool 6596 with a shop press to remove 3 - TRANSAXLE CASE
front output shaft bearing cup (Fig. 63).
LH TRANSAXLE 21 - 25
42LE AUTOMATIC TRANSAXLE (Continued)
(48) Remove rear carrier front bearing cone (Fig.
65).
Fig. 68 Remove Snap Ring Fig. 70 Remove Parking Sprag Pivot Retaining
1 - SNAP RING OPENING MUST BE BETWEEN SPRING Screw
LEVERS (AS SHOWN)
1 - TRANSFER SHAFT
2 - SNAP RING PLIERS
2 - PARKING SPRAG PIVOT RETAINING SCREW
3 - SPECIAL TOOL 5059A
LH TRANSAXLE 21 - 27
42LE AUTOMATIC TRANSAXLE (Continued)
(53) Drive out anchor shaft using suitable punch
(Fig. 71).
Fig. 75 Remove Piston Retainer-to-Case Screws Fig. 77 Remove Piston Retainer Gasket
1 - LOW/REVERSE CLUTCH PISTON RETAINER 1 - GASKET HOLES MUST LINE UP
2 - SCREWDRIVER 2 - LOW/REVERSE CLUTCH PISTON RETAINER GASKET
3 - TORX-LOC SCREWS
ASSEMBLY
(57) Remove low/reverse piston retainer (Fig. 76).
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. 79 Install Piston Retainer Gasket Fig. 81 Install Retainer Attaching Screws
1 - GASKET HOLES MUST LINE UP 1 - LOW/REVERSE CLUTCH PISTON RETAINER
2 - LOW/REVERSE CLUTCH PISTON RETAINER GASKET 2 - SCREWDRIVER
3 - TORX-LOC SCREWS
Fig. 98 Properly Staked Nut CAUTION: When reinstalling drive chains, the blue
link must face outward.
1 - BOTTOMED IN SLOT
2 - CORRECTLY STAKED NUT
(15) Install output sprocket spacer (Fig. 101).
LH TRANSAXLE 21 - 35
42LE AUTOMATIC TRANSAXLE (Continued)
(17) Remove chain spreader (Fig. 103).
Fig. 127 No. 4 Thrust Plate Fig. 129 Remove Oil Pump O-Ring
1 - OVERDRIVE SHAFT ASSEMBLY 1 - OIL PUMP ASSEMBLY
2 - #4 THRUST PLATE (SELECT) 2 - O-RING
3 - PETROLATUM (FOR RETENTION)
Fig. 139 Install Low/Reverse Accumulator Plug Fig. 141 Accumulator Locations
(Cover) 1 - OVERDRIVE ACCUMULATOR LOCATION
1 - ADJUSTABLE PLIERS 2 - UNDERDRIVE ACCUMULATOR LOCATION
2 - PLUG 3 - LOW/REVERSE ACCUMULATOR
1 - SNAP RING
2 - PLUG
21 - 46 TRANSAXLE LH
42LE AUTOMATIC TRANSAXLE (Continued)
Fig. 143 Install Overdrive Accumulator and Springs Fig. 145 Install Valve Body Bolts (7)
1 - OVERDRIVE ACCUMULATOR PISTON 1 - EXTENSION
2 - RETURN SPRINGS 2 - SOCKET
3 - SEAL RING 3 - VALVE BODY
4 - SEAL RING
(1) When installing transaxle, reverse the removal (5) Check and/or adjust gearshift cable.
procedure. (6) Refill transaxle with Mopar ATF+4 (Automatic
Transmission Fluid) Type 9602.
CAUTION: To prevent damage to the structural col-
lar, hand tighten all fasteners. This will ensure that
the collar is flush against transmission and oil pan
before torquing to specifications.
21 - 48 TRANSAXLE LH
42LE AUTOMATIC TRANSAXLE (Continued)
Reverse
LH TRANSAXLE 21 - 51
42LE AUTOMATIC TRANSAXLE (Continued)
First Gear
LH TRANSAXLE 21 - 53
42LE AUTOMATIC TRANSAXLE (Continued)
Second Gear
21 - 54 TRANSAXLE LH
42LE AUTOMATIC TRANSAXLE (Continued)
Direct Gear
21 - 56 TRANSAXLE LH
42LE AUTOMATIC TRANSAXLE (Continued)
Overdrive
LH TRANSAXLE 21 - 59
42LE AUTOMATIC TRANSAXLE (Continued)
Overdrive (EMCC)
21 - 60 TRANSAXLE LH
42LE AUTOMATIC TRANSAXLE (Continued)
SPECIFICATIONS
42LE AUTOMATIC TRANSAXLE
GENERAL SPECIFICATIONS
GEAR RATIOS
CLUTCH PACK
DIFFERENTIAL
INPUT SHAFT
TRANSFER SYSTEM
TORQUE SPECIFICATIONS
SPECIAL TOOLS
42LE AUTOMATIC TRANSAXLE
Installer 6494
Wrench 6503
Remover 6495
Installer 6522
Wrench 6497
Wrench 6498
Remover 6577
Remover 6550
Installer 6558
Installer 6560
Fixture 6595
21 - 68 TRANSAXLE LH
42LE AUTOMATIC TRANSAXLE (Continued)
Remover 6596
Cooler Flusher 6906
Remover 6597
Remover 8420A
LH TRANSAXLE 21 - 69
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).
REVERSE CLUTCH
The reverse clutch is hydraulically applied in
reverse gear only by pressurized fluid against the
overdrive/reverse piston. When the reverse clutch is
applied, the front sun gear assembly is driven.
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. 154).
OPERATION
The differential assembly is driven by the transfer
shaft by way of the differential ring gear. The ring
gear drives the differential case, and the case drives
Fig. 153 Input Clutch Assembly the driveshafts through the differential gears. The
1 - INPUT SHAFT differential pinion and side gears are supported in
2 - UNDERDRIVE CLUTCH the case by thrust washers and a pinion shaft. Dif-
3 - OVERDRIVE CLUTCH ferential pinion and side gears make it possible for
4 - REVERSE CLUTCH front tires to rotate at different speeds while corner-
5 - OVERDRIVE SHAFT ing.
6 - UNDERDRIVE SHAFT
DISASSEMBLY
OPERATION The valve body and solenoid wiring connector must
The three input clutches are responsible for driving be removed from the transaxle in order to service the
different components of the planetary geartrain. 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 -
42LE/VALVE BODY - REMOVAL)
21 - 74 TRANSAXLE LH
FINAL DRIVE (Continued)
(2) Remove chain oiler (Fig. 156).
Fig. 154 Differential Assembly (3) Remove chain snubber (Fig. 157).
1 - PINION GEAR
2 - RING GEAR
3 - SHORT STUB SHAFT
4 - DIFFERENTIAL CASE ASSEMBLY
5 - TRANSFER SHAFT
Fig. 174 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
(Fig. 177) and (Fig. 178). Do not grind through the
5 - SPECIAL TOOL C-4996
transfer shaft nut into the shaft. There are two
stakes on the nut.
(14) Remove inner adjuster (Fig. 175).
If differential was not disassembled, refer to Step Fig. 203 Carrier Bearing Installation
25.
1 - ARBOR PRESS
2 - HANDLE C-4171
3 - SPECIAL TOOL C-4340
(3) Install pinion shaft roll pin (Fig. 205). CAUTION: When assembling differential halves, line
(4) Install side gear, stub shaft, and c-clip to differ- up notches on side of carrier.
ential support plate (Fig. 206).
21 - 88 TRANSAXLE LH
FINAL DRIVE (Continued)
Fig. 209 Differential Cover Installation Fig. 211 Outer Adjuster Installation
1 - O-RING
1 - SIDE COVER
2 - OUTER ADJUSTER
(33) Install transfer shaft into transaxle case (Fig. CAUTION: Bottom of support fixture must be flush
214). with face of bell housing. If the support fixture is
not flush, the seals and rear transfer shaft bearing
cup will be pressed in cocked.
Fig. 225 Staking New Nuts Fig. 227 Vent Baffle Installation
1 - ARBOR PRESS 1 - NO SEALER ON THIS EDGE
2 - STAKING TOOL (6589) 2 - APPLY SEALER
3 - VENT BAFFLE
TRANSMISSION SUMP
FLUID LEVEL CHECK
The transmission sump has a dipstick to check oil
similar to most automatic transmissions. It is located
on the left side of the engine. Be sure to wipe all dirt
Fig. 233 Dial Indicator Installation from dipstick handle before removing.
The torque converter fills in both the P Park and N
1 - DIAL INDICATOR KIT C-3339
2 - ACCESS HOLE
Neutral positions. Place the selector lever in P Park
to be sure that the fluid level check is accurate. The
engine should be running at idle speed for at
(56) If there is too much backlash, loosen the outer least one minute, with the vehicle on level
adjuster with special tool 6503. Then turn the inner ground. At normal operating temperature (approxi-
adjuster so that it moves away from the ring mately 82 C. or 180 F.), the fluid level is correct if it
gear. After adjusting the inner adjuster, retighten is in the HOT region (cross-hatched area) on the oil
the outer adjuster to the torque recorded in Step 30. level indicator (Fig. 234). The fluid level should be in
The inner adjuster should be turned in small incre- COLD region at 80° F fluid temperature. Adjust fluid
ments. level as necessary. Use only Mopart ATF+4 (Auto-
(57) If there is not enough backlash, loosen the matic Transmission Fluid—Type 9602).
outer adjuster with special tool 6503. Then turn the
inner adjuster so that it moves towards the ring FLUID LEVEL CHECK USING DRB
gear. After adjusting the inner adjuster, retighten
the outer adjuster to the torque recorded in Step 30. NOTE: Engine and Transaxle should be at normal
The inner adjuster should be turned in small incre- operating temperature before performing this proce-
ments. dure.
(58) Once backlash is with in specifications,
recheck backlash in four spots on the ring gear 90 (1) Start engine and apply parking brake.
degrees apart. All four readings should be within (2) Connect DRBIIIt scan tool and select transmis-
specifications. sion.
(59) Install inner and outer adjuster locking brack- (3) Select sensors.
ets. (4) Read the transmission temperature value.
(60) Install new inspection plug. Use a wooden (5) Compare the fluid temperature value with the
block to tap inspection plug into place. chart.
(61) Fill differential. It is easier to fill the differen- (6) Adjust transmission fluid level shown on the
tial prior to installing the transaxle back into the dipstick according to the chart (Fig. 235). Use only
vehicle. (Refer to 21 - TRANSMISSION/TRANS- Mopart ATF+4 Automatic Transmission Fluid (MS
AXLE/AUTOMATIC - 42LE/FLUID - STANDARD 9602).
PROCEDURE) (7) Check transmission for leaks.
LH TRANSAXLE 21 - 97
FLUID (Continued)
Low fluid level can cause a variety of conditions
because it allows the pump to take in air along with
the fluid. As in any hydraulic system, air bubbles
make the fluid spongy, therefore, pressures will be
low and build up slowly.
Improper filling can also raise the fluid level too
high. When the transaxle has too much fluid, the
gears churn up foam and cause the same conditions
which occur with a low fluid level.
In either case, air bubbles can cause overheating
and/or fluid oxidation, and varnishing. This can
interfere with normal valve, clutch, and accumulator
operation. Foaming can also result in fluid escaping
from the transaxle vent where it may be mistaken
for a leak.
Along with fluid level, it is important to check the
Fig. 234 Fluid Level Indicator condition of the fluid. When the fluid smells burned,
1 - FLUID LEVEL INDICATOR and is contaminated with metal or friction material
particles, a complete transaxle recondition is needed.
CAUTION: Column must be tilted fully upward to (10) Unseat the cable grommet from the firewall
remove cable retainer clip. (Fig. 246) and pull the shift cable from the interior of
the vehicle.
(9) Raise hood. From inside the engine compart- (11) Raise vehicle on hoist and unbolt fill tube
ment, remove the gear shift cable from the cable bracket. Rotate fill tube to gain access to the inte-
bracket (Fig. 244). grated shift cable clamp.
(12) Disconnect cable from routing bracket as
shown in (Fig. 245).
21 - 102 TRANSAXLE LH
GEAR SHIFT CABLE - COLUMN (Continued)
(13) Remove shift cable retaining nut and slide
cable assy. off of mounting stud (Fig. 246) .
(14) Disconnect shifter cable from shift lever
assembly at transaxle (Fig. 246) .
(15) Remove cable from vehicle.
Fig. 248 Shift Cable Adjuster Lock (3) Make sure that the transaxle shift lever (at
1 - SHIFTER PIN transaxle) is in the Park position. This is the most
2 - CABLE ADJUSTER LOCK rearward position. Verify park sprag is fully engaged.
3 - SHIFT CABLE
CAUTION: Park sprag must be engaged when
(15) Reinstall upper and lower steering column adjusting linkage. Rock vehicle back and forth to
shrouds (Fig. 240) (Fig. 242) . Then install under- ensure that park sprag is fully engaged.
panel silencer/duct.
(16) Check shifter for proper operation. It should (4) Tilt the steering column to the full down posi-
operate smoothly without binding. The engine starter tion.
should crank in park or Neutral positions only. (5) Place shifter in the park position with the key
removed.
(6) Adjust by rotating adjuster into lock position
ADJUSTMENTS (Fig. 250).
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.
• When the transaxle can be shifted without the
key in the ignition.
• If the key can be removed with the shifter in
reverse.
• When the key cannot be removed with the Fig. 250 Shift Cable Adjuster Lock
shifter in the park position. 1 - SHIFTER PIN
(1) Remove upper steering column shroud. 2 - CABLE ADJUSTER LOCK
(2) Rotate cable adjuster into unlock position. Use 3 - SHIFT CABLE
a straight blade screwdriver to unlock adjuster (Fig.
249). (7) Reinstall upper steering column shroud.
21 - 104 TRANSAXLE LH
GEAR SHIFT CABLE - COLUMN (Continued)
(8) Check shifter for proper operation. It should (5) Remove retaining clip from shift cable conduit
operate smoothly without binding. The vehicle should bracket (Fig. 253) .
crank in Park or Neutral only. (6) Disconnect shifter cable from cable attach stud
(pin) (Fig. 253) .
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
Fig. 252 Shift Cable Adjust Lever Nut
to the transaxle shift lever (Fig. 255) .
1 - CONSOLE
(3) Verify that the washer (Fig. 255) is still in
2 - ACCESS HOLE
place on the cable mounting stud. Install cable to
3 - SHIFTER HANDLE
transaxle and tighten nut to 28 N·m (250 in. lbs.).
LH TRANSAXLE 21 - 105
GEAR SHIFT CABLE - FLOOR (Continued)
ADJUSTMENT
The gearshift cable should be adjusted if any of the HOLDING CLUTCHES
following repairs or situations are encountered:
• Transaxle replacement. DESCRIPTION
• Valve body repair. Two hydraulically applied multi-disc clutches are
• Shift cable replacement. used to hold planetary geartrain components station-
• Floor shifter replacement ary while the input clutches drive others. The 2/4
• When there is no cranking in park or neutral. and Low/Reverse clutches are considered holding
If the following conditions are encountered, the clutches and are contained at the rear of the trans-
interlock cable is out of adjustment. Refer to Inter- axle case. (Fig. 259).
lock Cable Adjustment procedure.
• When the transaxle can be shifted without the OPERATION
key in the ignition.
• If the key can be removed with the shifter in NOTE: (Refer to 21 - TRANSMISSION/TRANSAXLE/
reverse. AUTOMATIC - 42LE - DIAGNOSIS AND TESTING) for
• When the key cannot be removed with the a collective view of which clutch elements are
shifter in the park position. applied at each position of the selector lever.
(1) Remove shifter handle and console bezel.
(2) Loosen nut on shifter cable adjuster (Fig. 258).
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.
LOW/REVERSE CLUTCH
The Low/Reverse clutch is hydraulically applied in
park, reverse, neutral, and first gears by pressurized
fluid against the Low/Reverse clutch piston. When
the Low/Reverse clutch is applied, the front planet
carrier/rear annulus assembly is held or grounded to
the transaxle case.
ASSEMBLY
Use petrolatum on all seals to ease assembly of
components.
(1) Using an arbor press, install input shaft to
input shaft hub (Fig. 289).
(3) Using an arbor press and Tool 6057, Install (4) Install the OD/Reverse piston assembly to the
OD/Reverse piston return spring and snap ring (Fig. input clutch retainer as shown in (Fig. 293).
291) (Fig. 292).
Fig. 306 Input Clutch Assembly on Pressure Fixture Fig. 308 Press Down on UD Clutch Pack and Zero
Tool 8391 Dial Indicator
1 - INPUT CLUTCH ASSEMBLY 1 - DIAL INDICATOR
2 - INPUT CLUTCH PRESSURE FIXTURE 8391 2 - UNDERDRIVE CLUTCH
Fig. 310 Install Waved Snap Ring Fig. 312 Install Flat Snap Ring
1 - OVERDRIVE REACTION PLATE WAVED SNAP RING 1 - ARBOR PRESS RAM
2 - SCREWDRIVER 2 - TOOL 5059A
3 - FLAT SNAP RING
Fig. 319 Press Down on Reverse Clutch and Zero Fig. 321 Install Underdrive Shaft Assembly
Indicator
1 - UNDERDRIVE SHAFT ASSEMBLY
1 - DIAL INDICATOR 2 - #2 NEEDLE BEARING
2 - REVERSE CLUTCH
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.
LH TRANSAXLE 21 - 127
SEAL - STUB SHAFT (LONG) To replace the long stub shaft bearing, install stub
shaft in soft-jawed vise. Remove the stub shaft bear-
ing C-clip (Fig. 334). Install bearing splitter onto the
REMOVAL
shaft. Install Special Tool # P-334 under the bearing.
If it has been diagnosed that the long stub shaft
Using a shop press, remove the bearing from the
seal is leaking, the following procedure can be used
stub shaft (Fig. 335).
to replace failed seal. This procedure will allow the
To install the stub shaft bearing, position new
replacement of the seals without having to set back-
bearing onto the stub shaft. Install stub shaft into
lash and measure differential bearing turning torque.
shop press. Position Special Tool # 6558 above bear-
CAUTION: The differential bearings and the differ- ing. Press bearing onto shaft (Fig. 336).
ential adjusters must be reused in order to use this
procedure. If any of the items listed above require
replacement, this procedure cannot be used. Refer
to Differential Recondition section of this manual.
INSTALLATION
(1) Lube inner adjuster threads with gear oil and
reinstall to the cross haired index marks.
(2) Install the differential carrier. Then install
stub shaft seal protector.
(3) Install the differential cover/outer adjuster
assembly with sealant applied. Install and tighten
differential cover bolts.
(4) Tighten the outer adjuster 3/4 of a turn. Seat
bearings by turning differential carrier three or four
turns in both directions. Finish tightening the
adjuster 1/4 turn to its index mark (original location).
(5) Reinstall long stub shaft, fill differential with
fluid and reinstall transaxle.
Fig. 337 Indexing Inner Adjuster (6) After installing transaxle check transmission
side fluid level.
1 - INNER ADJUSTER
2 - ADJUSTER LOCK
3 - CROSS HAIR MARKS
LH TRANSAXLE 21 - 129
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
both directions to seat differential bearings. 3 - SLIDE HAMMER C-3752
(4) Continue tightening outer adjuster until index
marks line up (original location).
(5) Install adjuster lock. (5) Index the inner differential adjuster with a
(6) Install new driveshaft retaining circlip and cross hair as shown in (Fig. 344).
O-ring on stub shaft. Then reinstall driveshaft.
(7) Check fluid level in differential and adjust as
required.
(8) Road test and recheck for leaks as required.
CAUTION: The transfer shaft rear shim, bearing Fig. 344 Indexing Inner Adjuster
cups and cones, differential bearings and the differ-
1 - INNER ADJUSTER
ential adjusters must be reused to use this proce-
2 - ADJUSTER LOCK
dure. If any of the items listed above require 3 - CROSS HAIR MARKS
replacement, refer to Differential Recondition sec-
tion of this manual.
CAUTION: If short stub shaft has corrosion, use
(1) Remove transaxle from vehicle. (Refer to 21 - caution when removing differential cover. Inspect
TRANSMISSION/TRANSAXLE/AUTOMATIC - 42LE seal and shaft for damage after removal of cover.
- REMOVAL). Replace shaft and/or seal as required.
(2) Remove valve body from transaxle (Refer to 21
- TRANSMISSION/TRANSAXLE/AUTOMATIC -
42LE/VALVE BODY - REMOVAL).
LH TRANSAXLE 21 - 131
SEAL - TRANSFER SHAFT (Continued)
(6) Index outer adjuster (Fig. 345). Remove lock (7) Tighten the outer adjuster 3/4 of a turn. Seat
bracket and back out adjuster exactly one revolution. bearings by turning differential carrier three or four
Then remove differential cover. turns in both directions. Finish tightening the
adjuster 1/4 turn to its index mark (original location).
(8) Reinstall the outer adjuster locking bracket.
INSTALLATION INSTALLATION
(1) Install transfer shaft, transfer shaft seals, oil (1) Clean and inspect oil pump seal seat. Then
baffle, rear cup, rear shim, rear cone and a new nut. install seal using special tool C-4193A (Fig. 347).
Refer to appropriate procedures within this section (2) Clean and inspect torque converter hub. If
for detailed removal and installation procedures if nicks, scratches or hub wear are found, torque con-
required. verter replacement will be required.
(2) Install a new o-ring onto the inner adjuster.
CAUTION: If the torque converter is being replaced,
(3) Lube inner adjuster threads and o-ring with
apply a light coating of grease to the crankshaft
gear oil and reinstall to the cross haired index
pilot hole. Also inspect the engine drive plate for
marks.
cracks. If any cracks are found replace the drive
(4) Reinstall the inner adjuster locking bracket.
plate. Do not attempt to repair a cracked drive plate.
(5) Install the differential carrier. Install stub
Always use new torque converter to drive plate
shaft seal protector.
bolts.
(6) Install the differential cover/outer adjuster
assembly with Mopar Silicone Sealant applied. (3) Apply a light film of transmission oil to the
Install and tighten differential cover bolts. torque converter hub and oil seal lips. Then install
21 - 132 TRANSAXLE LH
SEAL - OIL PUMP (Continued)
(2) Remove gearshift knob from shifter assy.
(3) Remove console bezel from vehicle.
(4) Remove under panel silencer/duct assembly
(Fig. 349).
(5) Remove column cover screws.
(6) Tilt column down and remove upper half of col-
umn cover.
(7) Tilt the column to the uppermost position and
remove the tilt lever (Fig. 350).
REMOVAL
NOTE: Floor Shift Models
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. Fig. 359 Latch and Shifter Gate
(1) Depress the tab on the top of the cassette. 1 - LATCH
(2) Slide the interlock cassette out of the housing. 2 - SHIFTER GATE
(3) Remove the cable from the locking arm on the 3 - CASSETTE CABLE
shifter mechanism.
(2) With the shifter in Park and the key removed,
INSTALLATION install the cable over the hook on locking arm of the
The interlock cassette slides into the housing shifter mechanism.
behind the lock cylinder (Fig. 358). The cable at the (3) Slide the cassette into the housing until it locks
rear of the cassette attaches to a locking arm on the in place.
shifter mechanism. The column shift interlock (4) To adjust the interlock system, push the adjust-
system is only adjusted after installing a new ment tab in until it stops (Fig. 360). The adjustment
cassette. It can’t be adjusted more than once. If tab will click as it moves into position. Ensure the
the system operates incorrectly, install and tab is fully depressed.
adjust a new interlock cassette.
(1) Ensure the latch rotates freely on the shifter
gate (Fig. 359).
21 - 136 TRANSAXLE LH
SHIFT INTERLOCK MECHANISM (Continued)
(6) Verify the BTSI is operating properly. With the Fig. 370 Ignition Key/Switch Positions
ignition on (engine not running) and the parking 1 - ACC
brake applied, try shifting the transmission shift 2 - LOCK
3 - OFF
lever out of the PARK position with and without the
4 - ON/RUN
brake pedal being applied. The shift lever should
5 - START
only shift out of PARK with the brake pedal being
depressed.
LH TRANSAXLE 21 - 139
SHIFT INTERLOCK SYSTEM (Continued)
COLUMN
Vehicles equipped with a column shifter utilize a
brake transmission shift interlock (BTSI) solenoid,
which prevents the transmission gear shifter from
being moved out of PARK without a driver in place
(Fig. 371).
DIAGNOSIS AND TESTING - BRAKE/ If the floor shifter cannot be moved out of the
PARK position, refer to Shifter Locked In Place
TRANSMISSION SHIFT INTERLOCK SYSTEM
below. If the shift lever can be shifted out of PARK
without the brake pedal depressed, refer to Circuit
FLOOR SHIFT MODELS
Test below.
The following chart describes the normal operation
of the Brake Transmission Shift Interlock (BTSI) sys- SHIFTER LOCKED IN PLACE
tem. If the “expected response” differs from the vehi-
(1) Remove the instrument panel cover below the
cle’s response, then system repair and/or adjustment
steering column, then remove the steering column
is necessary.
shrouds to gain access to the brake transmission
Refer to the following chart that expected shifter
shift interlock (BTSI) solenoid. The solenoid is part of
response, depending on ignition key/switch (Fig. 373)
the interlock cable assembly.
and brake pedal positions.
(2) Disconnect the wire connector from the rear of
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
interlock cable must be replaced. If the shift lever
still does not move from the park position, the prob-
Fig. 373 Ignition Key/Switch Positions lem is in the shift lever assembly or the ignition
1 - ACC interlock cassette.
2 - LOCK
3 - OFF CIRCUIT TEST
4 - ON/RUN
(1) Check the system fuse in the junction block
5 - START
(An open or blown fuse would allow the shift lever to
be moved in and out of the PARK position without
ACTION EXPECTED RESPONSE the brake pedal applied).
(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
2. Turn key to the 2. Shifter CANNOT be shift interlock (BTSI) solenoid.
9ON/RUN9 position. shifted out of park. (3) Disconnect the wire connector from the rear of
3. Turn key to the 3. Shifter CAN be shifted the BTSI solenoid.
9ON/RUN9 position and out of park. (4) Insert the ignition key and turn it to the ON
depress the brake pedal. position.
4. Leave shifter in any 4. Key cannot be (5) Back-probe the wire connector’s terminal num-
gear and try to return key returned to the 9LOCK9 or ber 2 with a test light. The test light should illumi-
to the 9LOCK9 or 9ACC9 9ACC9 position. nate. If not, there is an open or short in the ignition
position. feed circuit leading to the BTSI solenoid. Repair the
open or short.
5. Return shifter to 5. Key can be removed (6) Next, back-probe the wire connector with a test
9PARK9 and try to remove (after returning to 9LOCK9 light, placing the test light in series between the two
the key. position). wires. At this point, the test light should illuminate.
6. With the key removed, 6. Shifter cannot be If not, there is an open in the ground circuit or brake
try to shift out of 9PARK9. shifted out of 9PARK9. lamp switch. Repair the open or replace brake lamp
NOTE: Any failure to meet these expected switch as necessary.
responses requires system adjustment or repair. (7) Depress the brake pedal. The test light should
go out. If it does not, there is a short in the ground
LH TRANSAXLE 21 - 141
SHIFT INTERLOCK SYSTEM (Continued)
circuit or brake lamp switch. Repair the short or ACTION EXPECTED RESPONSE
replace brake lamp switch as necessary.
(8) Reconnect the wire connector to the solenoid. 6. With the key removed, 6. Shifter cannot be
If the circuit passes the above test and the shifter try to shift out of 9PARK9. shifted out of 9PARK9.
can still be moved freely in and out of PARK without NOTE: Any failure to meet these expected
the brake pedal depressed, replace the interlock responses requires system adjustment or repair.
cable.
If the floor shifter cannot be moved out of the
PARK position, refer to Shifter Locked In Place
COLUMN SHIFT MODELS
below. If the shift lever can be shifted out of PARK
The following chart describes the normal operation
without the brake pedal depressed, refer to Circuit
of the Brake Transmission Shift Interlock (BTSI) sys-
Test below.
tem. If the “expected response” differs from the vehi-
cle’s response, then system repair and/or adjustment SHIFT LEVER LOCKED IN PLACE
is necessary.
(1) Remove the instrument panel cover below the
Refer to the following chart that expected shifter
steering column, then remove the steering column
response, depending on ignition key/switch (Fig. 374)
shrouds to gain access to the brake transmission
and brake pedal positions.
shift interlock (BTSI) solenoid.
(2) Disconnect the wire connector from the rear of
the BTSI solenoid.
(3) Insert the ignition key and turn it to the ON
position.
(4) With the brakes applied, try shifting the trans-
mission shift lever 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
must be replaced. If the shift lever still does not
Fig. 374 Ignition Key/Switch Positions move from the park position, the problem is in the
1 - ACC shift lever assembly or the ignition interlock cassette.
2 - LOCK
3 - OFF CIRCUIT TEST
4 - ON/RUN
(1) Check the system fuse in the junction block
5 - START
(An open or blown fuse would allow the shift lever to
be moved in and out of the PARK position without
ACTION EXPECTED RESPONSE the brake pedal applied).
(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
2. Turn key to the 2. Shifter CANNOT be shift interlock (BTSI) solenoid.
9ON/RUN9 position. shifted out of park. (3) Disconnect the wire connector from the rear of
3. Turn key to the 3. Shifter CAN be shifted the BTSI solenoid.
9ON/RUN9 position and out of park. (4) Insert the ignition key and turn it to the ON
depress the brake pedal. position.
4. Leave shifter in any 4. Key cannot be (5) Back-probe the wire connector’s terminal num-
gear and try to return key returned to the 9LOCK9 or ber 2 with a test light. The test light should illumi-
to the 9LOCK9 or 9ACC9 9ACC9 position. nate. If not, there is an open or short in the ignition
position. feed circuit leading to the BTSI solenoid. Repair the
open or short.
5. Return shifter to 5. Key can be removed
(6) Next, back-probe the wire connector with a test
9PARK9 and try to remove (after returning to 9LOCK9
light, placing the test light in series between the two
the key. position).
wires. At this point, the test light should illuminate.
If not, there is an open in the ground circuit or brake
21 - 142 TRANSAXLE LH
SHIFT INTERLOCK SYSTEM (Continued)
lamp switch. Repair the open or replace brake lamp
switch as necessary.
(7) Depress the brake pedal. The test light should
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.
(8) Reconnect the wire connector to the solenoid.
If the circuit passes the above test and the shift
lever can still be moved freely in and out of PARK
without the brake pedal depressed, replace the BTSI
solenoid.
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. Fig. 376 Floor Gearshift Cable Removal/Installation
375). 1 - CUP
2 - CABLE
3 - CONDUIT BRACKET
4 - PIN
INSTALLATION
(1) Install shifter assembly (Fig. 378) .
(2) Install five shifter/cable bracket to floor pan
nuts and tighten to 31 N·m (23 ft. lbs.).
(3) Make sure shift lever and transaxle are in
“Park.”
R OP OP OP
P/N CL OP OP
1st CL OP OP
2nd OP CL OP
D OP OP CL
OD OP CL CL
OP = OPEN
CL = CLOSED Fig. 380 Solenoid Retaining Screws
A Diagnostic Trouble Code (DTC) will set if the 1 - SOLENOID/PRESSURE SWITCH ASSEMBLY
PCM senses any switch open or closed at the wrong 2 - RETAINING SCREWS
time in a given gear.
LH TRANSAXLE 21 - 145
SOLENOID/PRESSURE SWITCH ASSY (Continued)
(4) Remove Solenoid/Pressure Switch Assembly
and screen from valve body (Fig. 381).
INSTALLATION
NOTE: If the Solenoid/Pressure Switch assembly is
being replaced, the Quick Learn Procedure must be
performed. (Refer to 8 - ELECTRICAL/ELECTRONIC
CONTROL MODULES/POWERTRAIN CONTROL
MODULE - STANDARD PROCEDURE)
Fig. 384 Sensor Relation to Input Clutch Fig. 386 O-Ring Location
1 - INPUT SPEED SENSOR
1 - INPUT SPEED SENSOR
2 - TRANSAXLE CASE
2 - O-RING
3 - INPUT CLUTCH HUB
INSTALLATION
REMOVAL (1) Verify o-ring is installed into position (Fig. 386)
(1) Disconnect the input speed sensor connector
.
(Fig. 385).
(2) Install and tighten input speed sensor to 27
N·m (20 ft. lbs.) torque.
(3) Connect speed sensor connector (Fig. 385) .
(4) Connect battery negative cable.
OPERATION
Fig. 385 Speed Sensor/Connector Location The Output Speed Sensor provides information on
1 - MANUAL SHIFT LEVER how fast the output shaft is rotating. As the rear
2 - OUTPUT SPEED SENSOR planetary carrier park pawl lugs pass by the sensor
3 - LONG STUB SHAFT coil (Fig. 389), an AC voltage is generated and sent to
4 - INPUT SPEED SENSOR
the PCM. The PCM interprets this information as
output shaft rpm.
(2) Unscrew and remove the input speed sensor. The PCM compares the input and output speed
(3) Inpsect the speed sensor o-ring and replace if signals to determine the following:
necessary (Fig. 386). • Transmission gear ratio
• Speed ratio error detection
• CVI calculation
LH TRANSAXLE 21 - 147
SPEED SENSOR - OUTPUT (Continued)
REMOVAL
(1) Disconnect the output speed sensor connector
(Fig. 390) .
INSTALLATION
(1) Verify o-ring is installed into position (Fig. 391)
. Fig. 392 Torque Converter Assembly
(2) Install and tighten output speed sensor to 27 1 - TURBINE
N·m (20 ft. lbs.) torque. 2 - IMPELLER
(3) Connect speed sensor connector (Fig. 390) . 3 - HUB
4 - STATOR
(4) Connect battery negative cable.
5 - CONVERTER CLUTCH DISC
6 - DRIVE PLATE
TORQUE CONVERTER
Torque is transmitted by fluid passing through
DESCRIPTION curved vanes in both the impeller and turbine. Since
The torque converter is located in the bellhousing the coupling is produced by transmission fluid, the
area of the transaxle, between the engine and trans- turbine can slip or turn slower than the impeller.
axle. The torque converter is a fluid coupling that The stator contains a one-way overrunning clutch,
transmits torque from the engine drive plate to the which free-wheels when the impeller and turbine are
input shaft of the transaxle. The torque converter rotating at the same speed. However, the stator stops
consists of four main components (Fig. 392): when speed reduction or torque increase take place.
• Impeller When the stator stops, it changes the direction of the
• Turbine fluid leaving the turbine vanes. This directs fluid
• Stator back into the impeller with greater force, resulting in
• Converter Clutch assembly torque multiplication.
The torque converter clutch is hydraulically oper-
OPERATION ated and controlled by the TCM. It consists of a pis-
The converter impeller (driving member), which is ton and a frictional disc that form a direct
integral to the converter housing and bolted to the mechanical link between the impeller and turbine
engine drive plate, rotates at engine speed. The con- when slippage is inefficient or unnecessary.
verter turbine (driven member), which reacts from The torque converter hub drives the transmission
fluid pressure generated by the impeller, rotates and oil pump.
turns the transmission input shaft.
LH TRANSAXLE 21 - 149
TORQUE CONVERTER (Continued)
INSTALLATION
NOTE: If torque conveter 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)
CALCULATED TEMPERATURE
A failure in the temperature sensor or circuit will
result in calculated temperature being substituted for
actual temperature. Calculated temperature is a pre-
dicted fluid temperature which is calculated from a
combination of inputs:
Fig. 403 Transmission Temperature Sensor • Battery (ambient) temperature
1 - TRANSMISSION RANGE SENSOR • Engine coolant temperature
2 - TEMPERATURE SENSOR • In-gear run time since start-up
Fig. 405 Manual Shaft Retaining Screw Fig. 406 Valve Body Assembly
1 - SCREW 1 - SOLENOID/PRESSURE SWITCH ASSEMBLY
2 - TRS 2 - TRS
3 - TRANSFER PLATE
4 - SEPARATOR PLATE
(5) Slide TRS off of manual valve shaft. 5 - VALVE BODY
INSTALLATION
• Converter clutch control valve
(1) Install the TRS to the manual shaft. Make sure
• Torque converter regulator valve
TRS locating pin rests in manual valve bore slot.
• Low/Reverse switch valve
(2) Install the TRS/manual shaft retaining screw
In addition, the valve body also contains the ther-
and torque to 5 N·m (45 in. lbs.) torque (Fig. 405) .
mal valve, #2, 3, 4 & 5 check balls and the 2/4 accu-
(3) Install the manual shaft seal (Fig. 404) .
mulator assembly. (Refer to 21 - TRANSMISSION/
(4) Install valve body to transaxle. Refer to Valve
TRANSAXLE/AUTOMATIC - 42LE/VALVE BODY -
Body Removal and Installation in this group.
DISASSEMBLY).
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)
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)
(4) Verify that all retainers are installed as shown (6) Install check balls into position as shown in
in (Fig. 435). Retainers should be flush or below (Fig. 437). If necessary, secure them with petrolatum
valve body surface. or transmission assembly gel for assembly ease.
LH TRANSAXLE 21 - 165
VALVE BODY (Continued)
(7) Install thermal valve to the transfer plate (Fig. (8) Install oil screen to transfer plate (Fig. 439).
438).
Fig. 438 Install Thermal Valve to Transfer Plate Fig. 439 Install Oil Screen to Transfer Plate
1 - THERMAL VALVE 1 - OIL SCREEN
21 - 166 TRANSAXLE LH
VALVE BODY (Continued)
(9) Install separator plate to transfer plate (Fig. (11) Install the transfer plate to the valve body
440). (Fig. 442).
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
(1) Install valve body into position and start bolts.
Torque valve body to transaxle case bolts (Fig. 448)
to 12 N·m (105 in. lbs.) torque.
TIRES/WHEELS
TABLE OF CONTENTS
page page
Fig. 2 Radial Runout Measurement procedure and theory described for radial runout can
1 - MASKING TAPE
also be applied to identify and reduce lateral runout.
2 - DIAL INDICATOR (4) Wheel Runout. This runout check is per-
formed as follows:
(a) Dismount the tire from the wheel.
(2) Tire and Wheel Assembly Radial Runout. (b) Mount the wheel back on the wheel balancer.
This radial runout check is performed with the tire (c) Measure radial runout of the wheel at the
and wheel assembly off the vehicle. tire bead seat (Fig. 4). Runout should not exceed
(a) Remove tire and wheel assembly from vehicle 0.254 mm (0.010 inch) for aluminum wheels and
and install it on a suitable wheel balancer. 0.508 mm (.020 inch) for steel wheels. Replace the
(b) Check system runout using Dial Indicator wheel if it exceeds the limit.
Set, Special Tool C-3339A with 25-W wheel, or (d) Measure lateral runout of the wheel at the
equivalent. Place the end of the indicator against tire bead seat (Fig. 5). Runout should not exceed
each taped area (one at a time) (Fig. 2) and rotate 0.762 mm (0.030 inch) for all wheels. Replace the
the tire and wheel. Radial runout should not wheel if it exceeds the limit.
exceed 0.76 mm (0.030 inch) with no tread “dips” (5) Match Mounting. If the wheel runout is
or “steps.” Tread “dips” and “steps” can be identi- within specifications, tire and wheel assembly runout
fied by spikes of the dial indicator gauge. can be improved by re-indexing (match mounting)
(c) If runout exceeds limits, mark the original the tire to the wheel as described below.
location of the tire on the wheel at the valve stem (a) Remount the tire on the rim 180 degrees
(Fig. 3). Also, mark the tire and wheel to indicate from its original location (Fig. 6). Ensure the tire
the original high spot of the assembly and record bead is properly seated.
the runout measurement. (b) Re-measure the total runout. Mark the tire
(d) If runout exceeds limits, the tire will need to at the high spot and record the measurement.
be dismounted from the wheel to verify wheel vs. If runout is still excessive, perform the following:
tire contribution. Refer to Wheel Runout below. • If the new high spot is within 102 mm (4.0 inch)
(3) Lateral Runout. Lateral runout for the vehi- of the first high spot on the tire, replace the tire.
cle system as well as the tire and wheel assembly
should be less than 0.76 mm (0.030 inch). The same
22 - 4 TIRES/WHEELS LH
TIRES/WHEELS (Continued)
STANDARD PROCEDURE - TIRE AND WHEEL Fig. 11 Forward-Cross Tire Rotation Method
ROTATION DIRECTIONAL TREAD PATTERN TIRES
Some vehicles are fitted with special high-perfor-
CAUTION: If the vehicle is equipped with the Tire mance tires having a directional tread pattern. These
Pressure Monitoring (TPM) System, the TPM Sys- tires are designed to improve traction on wet pave-
tem (sensors) will need to be retrained once the tire ment. To obtain the full benefits of this design, the
and wheel rotation process is completed. Anytime tires must be installed so that they rotate in the cor-
the tire/wheel assemblies are switched, rotated or rect direction. This is indicated by arrows on the tire
replaced, the TPM System needs to be retrained. sidewalls.
(Refer to 22 - TIRES/WHEELS/TIRE PRESSURE When wheels and tires are being installed, extra
MONITORING/SENSOR - STANDARD PROCEDURE) care is needed to ensure that this direction of rota-
tion is maintained.
Refer to Owner’s Manual for rotation schedule.
22 - 8 TIRES/WHEELS LH
TIRES/WHEELS (Continued)
(1) Raise the vehicle so the tire and wheel assem- ASSEMBLY - TIRE AND WHEEL ASSEMBLY
bly clears ground level. WITH TPM
(2) Remove the 5 wheel mounting nuts from the (Refer to 22 - TIRES/WHEELS/TIRE PRESSURE
studs. MONITORING/SENSOR - INSTALLATION)
(3) Remove the tire and wheel from the hub.
OPERATION CAUTION
The Tire Pressure Monitoring (TPM) system uses
wireless technology to monitor tire air pressure lev- CAUTION:: TPM thresholds have been established
els. Sensors, mounted to each road wheel as part of for the original tire size equipped on the vehicle.
the valve stem, transmit tire pressure readings to a Use original size tires only to maintain system
receiver located in the overhead console. These trans- accuracy.
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 pro-
the Electronic Vehicle Information Center (EVIC) dis- hibited 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
LH TIRES/WHEELS 22 - 11
NOTE: There is a 60 second timer for training the CAUTION: The cap used on this valve stem con-
first sensor and a 30 second timer between training tains an O-ring seal to prevent contamination and
the remaining sensors. If either of these timers moisture from entering the valve stem. Retain this
expire, the EVIC will abort the training procedure. valve stem cap for reuse. Do not substitute a regu-
lar valve stem cap in its place.
NOTE: If at any time the EVIC display reads (TRAIN-
ING ABORTED(, move the vehicle ahead at least CAUTION: The valve stem used on this vehicle is
one foot and repeat the entire retraining procedure. made of aluminum and the core is nickel plated
brass. The original valve stem core must be rein-
(5) Press MENU button to start retraining. Dis- stalled and not substituted with a valve stem core
play will read 9TRAIN LEFT FRONT TIRE9 made of a different material. This is required to pre-
vent corrosion in the valve stem caused by the dif-
NOTE: The order for retraining all five sensors is:
ferent metals.
• Left Front
• Right Front (2) Dismount tire from wheel following tire
• Right Rear changer manufacturers instructions while paying
• Left Rear special attention to the following to avoid damaging
• Spare the pressure sensor:
(a) When breaking the tire bead loose from the
(6) Starting at left front tire, place Re-learn Mag-
wheel rim, avoid using the Bead Breaker in the
net over valve stem (Fig. 17). Within approximately 5
area of the sensor. That includes both front and
seconds, vehicle horn will chirp indicating training
rear beads of the tire.
complete for that particular sensor. Remove the mag-
(b) When preparing to dismount the tire from
net.
the wheel, carefully insert the mounting/dimount-
(7) Repeat step (6) on remaining sensors as indi-
ing tool at the valve stem ± 10° (Fig. 18), then pro-
cated by EVIC until all five TPM sensors positions
ceed to dismount the tire from the wheel. Use this
are trained.
process on both the upper an lower tire beads.
(8) Once EVIC displays 9TRAINING COMPLETE9,
(3) Using a thin wall socket, remove special nut
pressing either STEP, C/T, RESET or MENU button
retaining sensor to wheel (Fig. 19).
will exit training routine.
(4) Remove sensor from wheel (Fig. 19).
LH TIRES/WHEELS 22 - 13
SENSOR - TPM (Continued)
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.
STANDARD PROCEDURE
STANDARD PROCEDURE - TIRE INFLATION
PRESSURES
The specified tire pressures have been chosen to
provide safe operation, vehicle stability, and a smooth
ride. The proper tire pressure specification can be
found on the Tire Inflation Pressure Label provided
with the vehicle (usually on the rear face of the driv-
er’s door).
A quality air pressure gauge is recommended to
check tire air pressure. Tire pressure should be
checked cold once per month. Check tire pressure
more frequently when the weather temperature var-
ies widely. Tire pressure will decrease when the out-
door temperature drops. After checking the air Fig. 25 Under Inflation Wear
pressure, replace valve cap finger tight. 1 - THIN TIRE TREAD AREAS
Inflation pressures specified on the Tire Inflation
Pressure Label are always the cold inflation pressure
of the tire. Cold inflation pressure is obtained after
the vehicle has not been operated for at least 3
hours, or the vehicle is driven less than one mile
after being inoperative for 3 hours. Tire inflation
pressures may increase from 2 to 6 pounds per
square inch (psi) during operation. Do not reduce this
normal pressure buildup.
Improper inflation can cause:
• Uneven wear patterns
• Reduced tread life
• Reduced fuel economy
• Unsatisfactory ride
• The vehicle to drift.
Under inflation causes rapid shoulder wear, tire speed ratings, (Refer to 22 - TIRES/WHEELS/TIRES
flexing, and can result in tire failure (Fig. 25). - DESCRIPTION).
Over inflation causes rapid center wear and loss of
the tire’s ability to cushion shocks (Fig. 26). STANDARD PROCEDURE - TIRE LEAK
REPAIRING
STANDARD PROCEDURE - TIRE PRESSURE For proper repairing, a radial tire must be removed
FOR HIGH SPEED OPERATION from the wheel. Repairs should only be made if the
DaimlerChrysler Corporation advocates driving at defect, or puncture, is in the tread area (Fig. 27). The
safe speeds within posted speed limits. Speed capac- tire should be replaced if the puncture is located in
ity of a tire is a function of the tire speed rating, the sidewall.
inflation pressure and vehicle axle weight. Where Deflate tire completely before attempting to dis-
speed limits allow the vehicle to be driven at high mount the tire from the wheel. Use a lubricant
speeds, correct tire inflation pressure is very impor- such as a mild soap solution when dismounting
tant. Vehicles loaded to maximum capacity should or mounting tire. Use tools free of burrs or sharp
not be driven at continuous speeds over 120 km/h (75 edges which could damage the tire or wheel rim.
mph). Never exceed the maximum speed capacity of Before mounting tire on wheel, make sure all rust
the tire. For information on tire identification and is removed from the rim bead and repaint if neces-
sary.
22 - 18 TIRES/WHEELS LH
TIRES (Continued)
Install wheel on vehicle, and progressively tighten
the 5 wheel nuts to a torque of 135 N·m (100 ft. lbs.).
WHEELS
DIAGNOSIS AND TESTING - WHEEL
DESCRIPTION INSPECTION
Original equipment wheels are designed for proper Inspect wheels for:
operation at all loads up to the specified maximum • Excessive runout
vehicle capacity. • Dents, cracks or irregular bends
All models use steel or cast aluminum drop center • Damaged wheel stud (lug) holes
wheels. Every wheel has raised sections between the • Air Leaks
rim flanges and rim drop well called safety humps
(Fig. 28) . NOTE: Do not attempt to repair a wheel by hammer-
Initial inflation of the tires forces the bead over ing, heating or welding.
these raised sections. In case of air loss the raised
sections help hold the tire in position on the wheel If a wheel is damaged, an original equipment
until the vehicle can be brought to a safe stop. replacement wheel should be used. When obtaining
Cast aluminum wheels require special balance replacement wheels, they should be equivalent in
weights to fit on the rim flange of the wheel and spe- load carrying capacity. The diameter, width, offset,
cial wheel clamps for the alignment equipment. pilot hole and bolt circle of the wheel should be the
same as the original wheel.
LH TIRES/WHEELS 22 - 19
WHEELS (Continued)
WARNING: FAILURE TO USE EQUIVALENT WHEEL COVER
REPLACEMENT WHEELS MAY ADVERSELY
AFFECT THE SAFETY AND HANDLING OF THE
DESCRIPTION
VEHICLE.
This vehicle uses a bolt-on type wheel cover (Fig.
29).
WARNING: REPLACEMENT WITH USED WHEELS IS This bolt-on wheel cover cannot be removed from
NOT RECOMMENDED. THE SERVICE HISTORY OF the wheel until three of the five wheel mounting nuts
THE WHEEL MAY HAVE INCLUDED SEVERE TREAT- shown are removed (Fig. 29). The bolt-on wheel cover
MENT OR VERY HIGH MILEAGE. THE RIM COULD can then be removed with the remaining two wheel
FAIL WITHOUT WARNING. nuts tightened in place.
REMOVAL
CLEANING - ALUMINUM WHEEL CARE (1) Noting the location of the valve stem in rela-
Chrome plated and painted aluminum wheels tionship to the wheel mounting nuts, remove the
should be cleaned regularly using mild soap and three wheel mounting nuts securing the wheel cover
water to maintain their luster and to prevent corro- to the wheel and hub (Fig. 29).
sion.
Care must be taken in the selection of tire and
wheel cleaning chemicals and equipment to prevent
damage to the wheels. Any of the “DO NOT USE”
items listed below WILL damage chrome plated and
painted aluminum wheels.
DO NOT USE:
• any abrasive metal cleaner
• any abrasive cleaning pad or brush
• any cleaner that contains an acid (this will
immediately react with and discolor the chromium
surface)
• chrome polish (unless it is buffed off immedi-
ately after application)
• oven cleaner
• a car wash that uses carbide-tipped wheel clean-
ing brushes
Fig. 29 Wheel Mounting Nuts Securing Wheel Cover
1 - VALVE STEM
SPECIFICATIONS 2 - BOLT-ON WHEEL COVER
3 - NUTS SECURING WHEEL COVER
WHEEL
SPECIFICATIONS CAUTION: When removing the wheel cover, do not
pry the wheel cover from the wheel. This can result
DESCRIPTION SPECIFICATION in damage to the wheel cover. The wheel cover is
Wheel Mounting (Lug) removed by pulling it off the wheel by hand.
19 mm
Nut Hex Size
(2) Grasp the wheel cover at the edges in line with
Wheel Mounting Stud the remaining installed wheel nuts and pull straight
M12 x 1.5 mm
Size outward from the wheel. This will pop the wheel
cover retaining tabs over the two remaining wheel
TORQUE SPECIFICATIONS nuts, removing the wheel cover from the wheel.
(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 WHEEL MOUNTING STUDS -
the valve stem on the wheel. FRONT
(b) At the same time, align the two holes in the
wheel cover having the retaining tabs with the two REMOVAL
installed wheel nuts (Fig. 31).
(1) Raise vehicle on jackstands or centered on a
(c) Press in on center of wheel cover until wheel
frame contact type hoist. See Hoisting in the Lubri-
cover retaining tabs push past and engage rear of
cation and Maintenance section.
previously installed wheel mounting nuts (Fig. 31).
(2) Remove the 2 guide pin bolts mounting the cal-
This will hold the wheel cover in place.
iper assembly to the steering knuckle (Fig. 33).
Remove the caliper from the front steering knuckle.
Refer to Disc Brake Caliper in the Brake section for
the caliper removal procedure.
(3) Remove rotor from hub by pulling it straight
off wheel mounting studs (Fig. 34).
(4) Install a lug nut on the wheel stud to be
removed from the hub and bearing assembly (Fig. 35)
so the threads on stud are even with end of lug nut.
Install Remover, Special Tool C-4150, on hub and
bearing assembly flange and wheel stud (Fig. 35).
(5) Tighten down on special tool to push wheel
stud out of the hub and bearing assembly. When
shoulder of wheel stud is past flange, remove special
tool from hub and bearing assembly. Remove lug nut
from stud and remove wheel stud from flange.
(2) Tighten the wheel lug nut, pulling the wheel Fig. 36 Installing Wheel Stud Into Hub And Bearing
stud into the flange of the hub and bearing assembly. 1 - HUB/BEARING ASSEMBLY
When the head of the stud is fully seated against the 2 - WHEEL LUG NUT
3 - WASHERS
bearing flange, remove lug nut and washers from
wheel stud.
22 - 22 TIRES/WHEELS LH
WHEEL MOUNTING STUDS - FRONT (Continued)
(3) Install the rotor on the hub and bearing assem-
bly (Fig. 34).
(4) Install disc brake caliper back over brake rotor
and align with caliper mounting holes on steering
knuckle. Refer to the Brake section for the caliper
installation procedure. Install the caliper to steering
knuckle guide pin bolts (Fig. 33) and tighten to a
torque of 19 N·m (168 in. lbs.).
(5) Install wheel and tire assembly on vehicle.
Tighten the wheel mounting stud nuts in proper
sequence until all nuts are torqued to half specifica-
tion. Then repeat the tightening sequence to the full
specified torque of 129 N·m (95 ft. lbs.).
(6) Lower the vehicle to the ground.
BODY
TABLE OF CONTENTS
page page
BODY DECKLID . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
DESCRIPTION - VEHICLE IDENTIFICATION . . . . 1 DOOR - FRONT . . . . . . . . . . . . . . . . . . . . . . . . . 18
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 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 59
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-
Fig. 5 FIBERGLASS TAPE aged. The piece cut out can be used as a template to
shape the new patch. It is not necessary to have
VISUAL INSPECTION access to the back of the panel to install a patch.
Composite materials can mask the severity of an Bevel edges of cutout at 20 degrees to expose a larger
accident. Adhesive bond lines, interior structure of bonding area on the outer side. This will allow for an
the doors, and steel structures need to be inspected increased reinforcement areas.
carefully to get a true damage assessment. Close
inspection may require partial removal of interior PANEL PATCH FABRICATIONS
trim or inner panels. A patch can be fabricated from any rigid fiberglass
Identify the type of repair: Puncture or Crack - panel that has comparable contour with the repair
Damage that has penetrated completely through the area. Lift gates and fenders can be used to supply
panel. Damage is confined to one general area; a patch material. If existing material is not available
panel section is not required. However, a backer or compatible, a patch can be constructed with adhe-
panel, open fiberglass tape, or matted material must sive and reinforcement mesh (dry wall tape). Perform
be bonded from behind (Fig. 7) (Fig. 6). the following operation if required:
23 - 8 BODY LH
BODY (Continued)
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 component, any excess oil or grease should be
3 - PATCH removed.
4 - SPREADER
LUBRICANT APPLICATION
PATCHED PANEL SURFACING
After patch panel is installed, the patch area can DOOR LOCK CYLINDERS
be finished using the same methods as finishing (1) Apply a small amount of lubricant directly into
other types of body panels. If mesh material is the lock cylinder.
exposed in the patched area, grind surface down, and (2) Apply a small amount of lubricant to the key.
LH BODY 23 - 11
BODY (Continued)
(3) Insert key into lock cylinder and cycle the Ft. In.
mechanism from the locked to the unlocked position. DESCRIPTION N·m
Lbs. Lbs.
NOTE: Do not add more lubricant. Front seat back to seat cushion 30 22
Front seat arm rest - 60/40 12 9
(4) Cycle the lock cylinder mechanism several
times to allow the lubricant to flow throughout the Front arm rest - 50/50 split 25 18
cylinder. Front seat back recliner to seat 12 9
(5) Wipe all lubricant from exterior of lock cylinder back
and key. Front seat belt buckle anchor nut 40 29
ALL OTHER BODY MECHANISMS Front seat belt retractor bolt 38 28
(1) Clean component as described above. Front seat belt buckle anchor bolt 40 29
(2) Apply specified lubricant to all pivoting and Front door hinge to hinge pillar 28 21
sliding contact areas of component. bolt
Front door hinge to door nuts and 28 21
LUBRICANT USAGE
bolt
ENGINE OIL Front door latch striker 28 20
• Door Hinges – Hinge Pin and Pivot Contact Front seat rear outboard seat 28 20
Areas track to floor pan bolts
• Hood Hinges – Pivot Points Front strut tower to tower brace 38 28
• Liftgate Hinges bolts
MOPART SPRAY WHITE LUBE OR EQUIVALENT Decklid latch striker 22 16
• Door Check Straps Door hinge bolt and nut 28 21
• Liftgate Latches Door hinge double ended stud 14 120
• Liftgate Prop Pivots
• Ash Receiver Hood latch release cable handle 2.3 20
• Fuel Filler Door Remote Control Latch Mecha- to the cowl side to to
nism 3.4 30
• Parking Brake Mechanism Hood latch to crossmember 22.6 200
• Sliding Seat Tracks to to
• Liftgate Latch 33.9 300
Hood hinges 22.6 200
MOPART Multipurpose GREASE OR EQUIVALENT to to
• All Other Hood Mechanisms 33.9 300
MOPART LOCK CYLINDER LUBRICANT OR Rear Child Tether anchor 20 15
EQUIVALENT Rear door glass to regulator bolt 11 105
• Door Lock Cylinders Rear seat arm rest to seat back 5 46
• Liftgate Lock Cylinder with ski pass
Rear seat back and belts to floor 44 32
TORQUE SPECIFICATIONS -
Rear seat back 40 section to 60 44
collar section
Ft. In.
DESCRIPTION N·m Rear seat back 60 section 16 12
Lbs. Lbs.
Rear seat back collar assembly 60 44
Front seat track to floor pan bolts 61 45
Rear door hinge to B-pillar bolt 28 20
Front seat inboard pivot bolt 40 30
Rear door hinge to door bolt 28 20
Front seat recliner to seat cushion 12 9
frame Rear door latch striker 28 20
Front seat track to cushion frame 12 9 Sunroof module to roof panel 11 97
bolt
Front seat back 40 30
23 - 12 BODY LH
BODY (Continued)
SPECIAL TOOLS
BODY
DECKLID
TABLE OF CONTENTS
page page
COVER INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . 16
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13 LOCK CYLINDER
INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . 13 REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16
DECKLID INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . 16
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14 EMERGENCY RELEASE CABLE
INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . 14 REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16
HINGE INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . 16
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14 SLAM BUMPER
INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . 14 REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17
LATCH INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . 17
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15 SUPPORT CYLINDER
INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . 15 REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17
LATCH STRIKER INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . 17
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16
COVER
REMOVAL
(1) Release decklid latch and open decklid.
(2) Remove the grab handle, if equipped.
(3) Remove push pin fasteners attaching decklid
latch cover to decklid (Fig. 1).
(4) Remove decklid latch cover from vehicle.
INSTALLATION
(1) Place decklid latch cover in position on vehicle
(Fig. 1).
(2) Install push pin fasteners attaching decklid
cover to decklid.
(3) Install grab handle, if equipped.
DECKLID HINGE
REMOVAL REMOVAL
(1) Release decklid latch and open decklid. (1) Open decklid.
(2) Mark hinge locations on inside of decklid to aid (2) Support decklid with a suitable prop device or
installation. block.
(3) Disconnect the wire harness connector, if (3) Remove hinge bolts (Fig. 3).
equipped. (4) Remove hinge from vehicle.
(4) Remove bolts attaching top of hinge to decklid.
(5) Remove bolts attaching bottom of hinge to
decklid (Fig. 2).
(6) With aid from a helper, remove decklid from
vehicle.
INSTALLATION
(1) With aid from a helper, place decklid in posi-
tion on vehicle.
(2) Install bolts attaching bottom of hinge to deck-
lid.
(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.
LH DECKLID 23 - 15
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.
(5) Disconnect power lock connector from latch
solenoid.
(6) Disconnect decklid ajar switch connector from
latch.
(7) Remove latch from vehicle.
INSTALLATION
(1) Place latch in position on vehicle.
(2) Connect decklid ajar switch connector on latch.
Fig. 6 DECK LID LATCH - 300M
(3) Connect power lock connector on latch solenoid.
1 - LOCK CYLINDER BRACKET AND LOCK CYLINDER
(4) Place decklid latch in position on decklid.
2 - LOCK SET
(5) Install bolts to attach decklid latch to decklid.
3 - TRUNK LID LATCH
(6) Adjust decklid latch for proper decklid to quar- 4 - TRUNK LID
ter panel alignment and weatherstrip sealing.
(7) Install fasteners to attach decklid lining or
latch cover to rear of decklid.
(8) Verify decklid latch operation.
23 - 16 DECKLID LH
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.
(5) Disconnect power lock connector from latch
solenoid.
(6) Disconnect decklid ajar switch connector from
latch. Fig. 8 EMERGENCY RELEASE CABLE
(7) Remove latch from vehicle. 1 - RELEASE CABLE CLIP
(8) Remove decklid lock set. 2 - DECKLID LATCH
(9) Remove decklid lock cylinder.
INSTALLATION
(1) Clip emergency release cable onto the latch.
(2) Install the decklid cover. (Refer to 23 - BODY/
DECKLID/HATCH/LIFTGATE/TAILGATE/COVER -
INSTALLATION)
LH DECKLID 23 - 17
SLAM BUMPER
REMOVAL
(1) Open decklid.
(2) Pull slam bumper from decklid.
(3) Remove slam bumper from decklid.
INSTALLATION
(1) Place slam bumper in position on decklid.
(2) Push slam bumper into decklid.
(3) Verify decklid alignment.
SUPPORT CYLINDER
REMOVAL Fig. 9 DECKLID GAS PROP
(1) Open decklid. 1 - LOCK CAP
(2) Support decklid with a suitable prop device. 2 - DECKLID
(3) Remove gas prop lock caps on each end (Fig. 9). 3 - LOCK CAP
(4) Remove gas prop from vehicle. 4 - GAS PROP
INSTALLATION
(1) Place gas prop in position on vehicle.
(2) Install the lock caps on the gas prop.
(3) Verify decklid operation.
23 - 18 DOOR - FRONT LH
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
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.
Fig. 1 FRONT DOOR CHECK STRAP
(4) Remove bolts attaching check strap to door end
frame and body. 1 - CHECK STRAP
2 - FRONT DOOR
(5) Remove check strap from vehicle (Fig. 1).
LH DOOR - FRONT 23 - 19
CHECK STRAP (Continued)
INSTALLATION INSTALLATION
(1) Place check strap in position on vehicle. (1) Place door in position on vehicle.
(2) Install bolts attaching check strap to door end (2) Engage door onto pin on upper door hinge.
frame and body. (3) Steady door on lifting device and install bolt
(3) Install watershield. and nut attaching upper hinge to door end frame.
(4) Install door trim panel. (Refer to 23 - BODY/ Tighten the hinge bolt and nut to 28 N·m (21 ft. lbs.)
DOOR - FRONT/TRIM PANEL - INSTALLATION) torque. If the double ended stud is loosen or replaced
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.
REMOVAL (6) Connect door wire harness to instrument panel
(1) Open front door. wire harness.
(2) Mark location of hinge on door end frame. (7) Attach check strap.
(3) Disengage clips attaching wire harness connec- (8) Align door to achieve equal spacing to sur-
tor and boot to hinge pillar. rounding body panels. Panels should be flush across
(4) Remove connector from hinge pillar. all gaps. If door needs to be aligned (damages or
(5) Disengage clip attaching wire connector hinge replacement) and can not be achieved, may be
together on hinge pillar side of the connector. necessary to remove the double ended stud and
(6) Remove door wire harness from instrument replaced it with a bolt. This may allow extra move-
panel harness. ment to achieve the proper alignment.
(7) Disengage door check stop from pin on upper
door hinge.
(8) Support door on suitable lifting device. DOOR GLASS
(9) Remove bolt and nut attaching lower hinge to
door end frame (Fig. 2). REMOVAL
(10) Steady door on lifting device and remove bolt (1) Remove flag cover, door trim panel, water
and nut attaching upper hinge to door end frame. shield as necessary, and pull cup support bracket.(Re-
(11) Remove door from vehicle. fer to 23 - BODY/DOOR - FRONT/TRIM PANEL -
REMOVAL)
(2) Connect power window switch and lower win-
dow 150 mm (6 in.) from full up position.
(3) Loosen nuts attaching regulator roller channel
to glass and lift plates.
(4) Slide roller channel rearward to allow lift plate
nuts to pass through key hole slots in channel (Fig. 3).
ADJUSTMENTS
ADJUSTMENT
(1) Remove door trim panel.(Refer to 23 - BODY/
DOOR - FRONT/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. Fig. 5 OUTSIDE FRONT DOOR HANDLE
(7) Install watershield. 1 - FRONT DOOR
(8) Install door trim panel.(Refer to 23 - BODY/ 2 - DOOR HANDLE
DOOR - FRONT/TRIM PANEL - INSTALLATION)
INSTALLATION
(1) Place door handle in position on door.
(2) Install screws attaching to handle to door.
(3) Insert links into clips on latch.
(4) Engage clips attaching latch release link and
lock link to door latch.
(5) Verify door latch handle operation.
(6) Install door glass.
(7) Install water shield.
(8) Install door trim panel. (Refer to 23 - BODY/
DOOR - FRONT/TRIM PANEL - INSTALLATION)
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.
Fig. 6 FRONT DOOR HINGES (4) Verify door alignment and operation, adjust as
1 - FRONT OPENING necessary.
2 - UPPER HINGE
3 - DOOR WIRE HARNESS CONNECTOR INSTALLATION - DOOR HINGE DOUBLE ENDED
4 - LOWER HINGE
STUD
5 - CHECK STRAP
NOTE: Replacement hinge studs have thread sealer
on threads. When reusing original studs, use
MoparT Lock and Seal Adhesive or equivalent on
stud threads.
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.
Fig. 8 FRONT DOOR LATCH
1 - FRONT DOOR
2 - SCREWS
3 - DOOR LATCH
INSTALLATION
(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)
LH DOOR - FRONT 23 - 23
Fig. 10 DOOR LOCK CYLINDER Fig. 11 MIRROR FLAG COVER W/O SPEAKER
1 - CLIP
1 - FRONT DOOR COVER W/O SPEAKER
2 - LOCK CYLINDER
2 - FRONT DOOR BRACKET
3 - DOOR HANDLE
INSTALLATION
INSTALLATION (1) If previously removed, install the door bracket
(1) Push lock cylinder into socket on door handle.
and bolts.
(2) Insert link into clip on lock cylinder.
(2) Install the cover and engage the clips (Fig. 11).
(3) Engage clip to fasten lock link to lock cylinder.
(4) Verify lock operation.
(5) Install watershield.
(6) Install door trim panel. (Refer to 23 - BODY/
DOOR - FRONT/TRIM PANEL - INSTALLATION)
23 - 24 DOOR - FRONT LH
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. 12).
interface area.
(3) Remove fasteners attaching the front door flag
(8) Remove three screws in the speaker area.
enclosure plate to front door, if necessary.
NOTE: Door trim clips are reusable up to three
times, then should be replaced.
TRIM PANEL
REMOVAL
CAUTION: Do not pry on door trim panel, damage Fig. 13 FRONT DOOR TRIM PANEL - TYPICAL
to trim panel will result.
1 - REMOTE BEZEL
2 - I/P INTERFACE
(1) Remove speaker flag and housing.
3 - SCREWS
(2) Remove speaker grille by inserting trim tool at 4 - SPEAKER GRILLE
the rear of the grille and disengaging tabs holding to 5 - PULL CUP
trim panel. Remove grille (Fig. 13).
LH DOOR - FRONT 23 - 25
TRIM PANEL (Continued)
(16) Install three screws to the bottom of the door.
Tighten all screws to 1.3 to 1.9 N·m (12 to 17 in. lbs.)
torque.
(17) Place speaker grille in position on trim panel.
INSTALLATION
(1) Place door trim panel in position.
(2) Install wire harness clips into door trim panel.
(3) Connect the courtesy lamp, if equipped.
(4) Connect the radio speaker wire connector.
(5) Connect the power window switch wire connector.
(6) Connect the power door lock switch wire con- Fig. 15 WOOD TRIM CLIPS - TYPICAL
nector. 1 - RETAINER CLIPS
(7) Connect the power mirror switch wire connector. 2 - TRIM PANEL
(8) Connect the linkage to the handle assembly.
(9) Hook door trim panel over the sheet metal
flange.
INSTALLATION - WOOD TRIM
(10) Insert the forward four way alignment guide (1) Install wood trim into mounting hole of the
into position. Insert the rearward two way alignment trim panel (Fig. 16).
guide into position. (2) Install new retainer clips and seat fully (Fig. 15).
(11) Engage rear retaining clips to attach door (3) Install the door trim panel. (Refer to 23 -
trim panel to inner sheet metal panel, up to three BODY/DOOR - FRONT/TRIM PANEL - INSTALLA-
ratchet clicks. TION)
(12) Install three screws in the speaker area.
(13) Install two screws in the instrument panel
interface area.
(14) Install screw in the remote bezel, and close
trim plug.
(15) Install screw in pull cup, and close trim plug.
23 - 26 DOOR - FRONT LH
TRIM PANEL - WOOD TRIM (Continued)
fer to 23 - BODY/DOOR - FRONT/TRIM PANEL -
REMOVAL)
(2) Slide glass from regulator roller channel.
(3) Disconnect power window motor wire connector.
(4) Loosen bolt attaching regulator support brace
to door panel.
(5) Remove screw and bolt heads from keyhole
slots in door panel.
(6) Loosen bolts attaching regulator to door panel.
(7) Remove regulator from door panel.
(8) Slide regulator rearward and rotate forward
end of roller channel through access hole in door
panel (Fig. 17).
WATERDAM
REMOVAL
(1) Remove door trim panel.(Refer to 23 - BODY/
DOOR - FRONT/TRIM PANEL - REMOVAL) Fig. 17 WINDOW REGULATOR
(2) Carefully remove by pulling water dam from 1 - FRONT DOOR
door inner panel. 2 - LIFT PLATES
(3) Pull watershield around umbrella clips in sheet 3 - GLASS
metal inner panel. 4 - GLASS ROLLER CHANNEL
5 - WINDOW REGULATOR
INSTALLATION
(1) Position watershield on door inner panel. INSTALLATION
Ensure that the water dam locator holes align and (1) Insert roller channel through access hole in
watershield is over the umbrella clips. door panel.
(2) Press inward on areas with adhesive to attach (2) Insert bolt heads on regulator through key hold
dam to inner door. Ensure that the dam is sealed. slots in door panel.
(3) Install trim panel.(Refer to 23 - BODY/DOOR - (3) Tighten bolts attaching regulator to door panel.
FRONT/TRIM PANEL - INSTALLATION) (4) Tighten bolt to attach regulator support brace
to door panel.
(5) Tighten screw to attach regulator scissor chan-
WINDOW REGULATOR nel to door panel.
(6) Connect power window motor wire connector.
REMOVAL (7) Lower door glass on to regulator roller channel.
(1) Remove flag cover, door trim panel, water (8) Align glass and verify operation.
shield as necessary, and pull cup support bracket.(Re- (9) Install pull cup support bracket, water shield,
door trim panel and flag cover.
LH DOORS - REAR 23 - 27
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) Close 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).
(3) Verify check strap operation.
INSTALLATION (4) Install watershield.
(1) Place check strap in position on vehicle. (5) Install door trim panel.(Refer to 23 - BODY/
(2) Install bolt and nut attaching check strap to DOORS - REAR/TRIM PANEL - INSTALLATION)
door end and body.
23 - 28 DOORS - REAR LH
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. Fig. 5 REAR DOOR HINGE
(6) Tighten all fasteners. 1 - B-PILLAR
(7) Install watershield. 2 - DOOR WIRE HARNESS CONNECTOR
(8) Install door trim panel.(Refer to 23 - BODY/ 3 - UPPER HINGE
DOORS - REAR/TRIM PANEL - INSTALLATION) 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 bolts 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
REMOVAL
Fig. 4 REAR DOOR GLASS ADJUSTMENT (1) Close door glass.
(2) Remove door trim panel.(Refer to 23 - BODY/
1 - SCISSOR CHANNEL
DOORS - REAR/TRIM PANEL - REMOVAL)
2 - REAR DOOR
3 - DOOR GLASS ADJUSTMENT
(3) Remove rear glass channel.
(4) Disconnect lock button link from door latch.
(5) Disconnect outside door handle link from door
HINGE latch.
(6) Remove screws attaching door latch to door end
REMOVAL frame (Fig. 6).
(1) Mark outline of hinge on B-pillar and door end (7) Remove latch from door.
frame.
(2) Remove nut and bolt attaching hinge to B-pil-
lar. Refer to Rear Door Removal procedure.
(3) Remove bolts attaching hinge to door end
frame (Fig. 5).
(4) Remove hinge from door.
23 - 30 DOORS - REAR LH
LATCH (Continued)
INSTALLATION
(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 button link to door latch.
(5) Install rear glass channel.
(6) Verify door latch operation.
(7) Install door trim panel.(Refer to 23 - BODY/
DOORS - REAR/TRIM PANEL - INSTALLATION)
LATCH STRIKER
REMOVAL
(1) Open rear door.
(2) Mark location of door latch striker on C-pillar Fig. 7 REAR DOOR LATCH STRIKER
to assist installation alignment. 1 - C-PILLAR
(3) Remove bolts holding striker to C-pillar (Fig. 2 - DOOR LATCH STRIKER
7).
(4) Remove door latch striker from vehicle. (4) Verify alignment and operation of door, adjust
as necessary.
INSTALLATION
(1) Place door latch striker in position on vehicle.
(2) Install bolts attaching striker to C-pillar.
(3) Align striker to marked location on C-pillar
and tighten bolts.
LH DOORS - REAR 23 - 31
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 courtesy lamp.
(3) Connect the wiring harness clips to the trim
panel.
(4) Connect the power window switch wire harness
connector.
(5) Connect the rear door speaker wire connect.
(6) Connect the remote handle linkage.
(7) Hook the trim panel over the sheet metal Fig. 9 REAR DOOR INNER TRIM PANEL - TYPICAL
flange. 1 - REAR DOOR SPEAKER
(8) Insert the forward four way alignment guide 2 - POWER WINDOW SWITCH
3 - RETAINER CLIPS
into position. Insert the rearward two way alignment
4 - COURTESY LAMP
guide into position.
(9) Engage the three retaining clips to attach door
trim panel to door sheet metal inner panel, up to (12) Install screw in pull cup, and close the trim
three ratchet clicks. plug.
(10) 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.
(11) Install screw in the remote bezel and close the
trim plug.
23 - 32 DOORS - REAR LH
SAIL PANEL
REMOVAL
(1) Open the rear door.
Fig. 10 WOOD TRIM CLIPS - TYPICAL (2) Using a trim stick, release clip attaching sail
1 - RETAINER CLIPS panel to the door.
2 - TRIM PANEL (3) Remove sail panel.
WINDOW REGULATOR
REMOVAL
(1) Remove flag cover, door trim panel, water
shield as necessary, and pull cup support bracket.
(Refer to 23 - BODY/DOORS - REAR/TRIM PANEL -
REMOVAL)
(2) Slide glass from regulator roller channel (Fig.
12).
(3) Disconnect power window motor wire connec-
tor.
(4) Loosen screw attaching regulator scissor chan-
nel to door panel.
(5) Remove screw and bolt heads from keyhole
slots in door panel.
(6) Loosen bolt attaching regulator support brace
to door panel.
(7) Loosen bolts attaching regulator to door panel.
(8) Remove regulator from door panel. Fig. 12 REAR DOOR WINDOW REGULATOR
(9) Slide regulator rearward and rotate forward
1 - GLASS
end of roller channel through access hole in door 2 - LIFT PLATES
panel. 3 - GLASS ROLLER CHANNEL
4 - WINDOW REGULATOR
INSTALLATION 5 - REAR DOOR
(1) Insert roller channel through access hole in
door panel. (6) Connect power window motor wire connector.
(2) Insert bolt and screw heads through key hole (7) Lower door glass on to regulator roller channel.
slots in door panel. (8) Align glass and verify operation.
(3) Tighten bolts attaching regulator to door panel. (9) Install pull cup support bracket, water shield,
(4) Tighten bolt to attach regulator support brace door trim panel and flag cover.
to door panel.
(5) Tighten screw to attach regulator scissor chan-
nel to door panel.
23 - 34 EXTERIOR LH
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,
parallel to the top edge of the molding to use as a
Fig. 1 BODY SIDE MOLDING
guide, if necessary. (Fig. 1)
(4) Remove protective cover from tape on back of 1 - PROTECTIVE COVER
2 - MASKING TAPE GUIDE
molding. Apply molding to body below the masking
3 - MOLDINGS
tape guide.
LH EXTERIOR 23 - 35
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
tact
2 - COWL SCREEN RIGHT
3 - COWL SCREEN LEFT
(4) Clean away any reference points.
INSTALLATION - ADHESIVES
INSTALLATION (1) Clean panel surface with isopropy alcohol.
(1) Place cowl screen in position on vehicle. (2) Remove paper carrier and align badgeing/tape
(2) Install cowl screen screws, starting at fender to reference points or adjacent panel.
moving inboard. (3) Install and press securely, using a plastic
(3) Install wiper arms. (Refer to 8 - ELECTRICAL/ spreader to eliminate all air bubbles.
WIPERS/WASHERS/WIPER ARMS - INSTALLA- (4) Remove top protective carrier.
TION) (5) Clean away any reference points.
23 - 36 EXTERIOR LH
INSTALLATION
INSTALLATION - CONCORDE
(1) Place grille into position on vehicle.
(2) Install ten attaching grille clips.
(3) Install two screws attaching foam.
(4) Install fascia.
(5) Close hood and check alignment of the grille.
Fig. 3 COWL SUPPORT
1 - COWL SUPPORT INSTALLATION - 300 M - UPPER
2 - WINDSHIELD (1) Place grille into position on vehicle.
3 - SUPPORT FASTENERS
(2) Install six attaching grille clips.
(3) Install rivets attaching cross bracket to grille.
INSTALLATION (4) Install two screws attaching foam.
(1) Place in position the front strut tower to tower (5) Install fascia.
brace. (6) Close hood and check alignment of the grille.
(2) Install front strut tower to tower brace attach-
ing bolts. Check bolt alignment marks. INSTALLATION - 300 M - LOWER
(3) Tighten the bolts to 38 N·m (28 ft. lbs.) torque. (1) Place grille into position on vehicle.
(4) Install cowl screen. (2) Install eight attaching grille clips.
(3) Install two screws attaching foam.
(4) Install fascia.
GRILLE (5) Check alignment of the grille.
REMOVAL
REMOVAL - CONCORDE
(1) Open hood.
(2) Remove fascia.
(3) Remove two screws attaching foam.
(4) Remove ten attaching grille clips.
(5) Remove grille.
LH EXTERIOR 23 - 37
Fig. 5 FENDER
1 - FRONT FENDER
2 - TO UPPER RAIL
Fig. 4 UPPER RADIATOR CLOSURE
3 - TO RADIATOR CLOSURE PANEL
1 - ATTACHING BOLTS 4 - TO LOWER COWL
2 - JACKSCREW 5 - TO UPPER COWL
3 - FASTENERS
INSTALLATION
INSTALLATION (1) Place fender in position on vehicle.
(1) Place in position the upper radiator closure (2) From inside engine compartment, install bolts
panel. to attach fender to upper rail.
(2) Connect hood latch cable to hood latch. (3) Connect hood prop rod and support the hood
(3) Install bolts attaching upper radiator closure (4) Install fender bolts to lower radiator closure
panel. Check bolt alignment marks. panel.
(4) Install bolts attaching the forward edge of (5) Place fascia into position.
upper radiator closure panel. (6) Tighten fender bolt to the upper cowl. Use plug
(5) Install fasteners attaching upper bumper fascia. that come with fender to fill drilled hole in splash
(6) Install headlamp jackscrews both sides. shield.
(7) Check hood latch operation. (7) Install fender bolt to lower cowl.
23 - 38 EXTERIOR LH
FRONT FENDER (Continued)
(8) Install splash shield plastic rivets to sill clad- REAR WHEELHOUSE SPLASH
ding.
(9) Install splash shield plastic rivets to fascia. SHIELD
(10) Install headlamp assembly.
(11) Check fender for flush and gap. REMOVAL
(1) Hoist and support vehicle on safety stands.
(2) Remove rear wheel.
WHEELHOUSE SPLASH (3) Remove fasteners attaching splash shield. (Fig.
SHIELD 7)
(4) The shock tower area will have to be cut out of
the splash shield. This will ease the removal or
REMOVAL
Installation of the slash shield.
(1) Hoist and support vehicle on safety stands.
(5) Remove splash shield from vehicle.
(2) Remove front wheel.
(3) Remove strut assembly from vehicle.(Refer to 2
- SUSPENSION/FRONT/STRUT - REMOVAL)
(4) Remove screws attaching speed sensor bracket
(Fig. 6). Move bracket to access speed sensor wire
connector.
(5) Disconnect speed sensor wire connector.
(6) Remove fasteners attaching splash shield to
inner wheelhouse.
(7) Remove splash shield from vehicle.
INSTALLATION
(1) Place splash shield in position on vehicle with
the shock tower cut out.
(2) Install fasteners to hold splash shield place.
(3) Install rear wheel.
(4) Lower vehicle.
Fig. 6 WHEELHOUSE SPLASH SHIELD
1 - SPLASH SHIELD
2 - SPEED SENSOR BRACKET SIDE VIEW MIRROR
REMOVAL
INSTALLATION (1) Remove side view mirror cover.
(1) Place splash shield into position. (2) Remove the door trim panel.
(2) Install fasteners to attach splash shield. (3) Disconnect power window mirror motor wire
(3) Connect speed sensor wire connector. connector, if so equipped.
(4) Install screws attaching speed sensor bracket. (4) Disengage wire harness grommet from mirror
(5) Install strut assemble.(Refer to 2 - SUSPEN- flag, if so equipped.
SION/FRONT/STRUT - INSTALLATION) (5) Remove nuts attaching side view mirror to mir-
(6) Install front wheel. ror flag.
(7) Lower vehicle. (6) Remove side view mirror from vehicle.
LH EXTERIOR 23 - 39
SIDE VIEW MIRROR (Continued)
REMOVAL (3) Using one hand, firmly press the mirror glass
holder assembly into place while at the same time
WARNING: ALWAYS WEAR EYE AND HAND PRO- supporting the housing assembly from the backside
TECTION WHEN SERVICING THE MIRROR ASSEM- with the other hand.
BLY. FAILURE TO OBSERVE THESE WARNINGS
MAY RESULT IN PERSONAL INJURY FROM BRO- NOTE: Pressure must be applied equally over the
KEN GLASS. center portion of the mirror to engage the mirror
glass holder’s attaching fingers to the correspond-
(1) Carefully pull/pry the broken glass holder from ing fingers on the housing assembly. One or more
the mirror assembly. clicks may be heard when finger engagement takes
(2) Disconnect the heated mirror electrical connec- place.
tors from the terminals on the mirror glass holder, if
equipped. (4) Verify retention of the mirror glass holder
assembly by gently pulling outward on the mirror
INSTALLATION glass holder.
HOOD
TABLE OF CONTENTS
page page
HINGE INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . 41
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
bolts. The hood should be aligned to 4 mm (0.160 in.) (6) Place gas prop in position on vehicle.
gap to the front fenders and flush across the top sur- (7) Install the lock cap on the gas prop.
faces along fenders. Hinge can be adjusted up or (8) Install wiper motor assembly.(Refer to 8 -
down by hinge to body attaching bolts to achieve ELECTRICAL/WIPERS/WASHERS/FRONT WIPER
proper hood height. MOTOR - INSTALLATION)
(5) Align all marks and tighten bolts to 22.6 to (9) Remove support from under hood and verify
33.9 N·m (200 to 300 in. lbs.) torque. The hood hood operation.
should be aligned to 4 mm (0.160 in.) gap to the front
fenders and flush across the top surfaces along fend-
ers.
LH HOOD 23 - 41
INSTALLATION
(1) Place cable in position on vehicle.
(2) Push cable through access hole in dash panel.
(3) Install release cable rubber grommet into
access hole in dash panel.
(4) Install screws attaching hood latch release
cable handle to the cowl side. Tighten screws to 2.3
to 3.4 N·m (20 to 30 in. lbs.) torque.
(5) Install cable clips.
(6) Place carpet into position.
(7) Install left wheel splash shield.
(8) Install left cowl side trim panel.
(9) Connect hood release cable ferrule and cable
end to hood latch.
(10) Verify hood latch operation before closing
hood.
Fig. 8 HOOD GAS PROP
1 - LOCK CAP
SUPPORT CYLINDER 2 - GAS PROP
3 - LOCK CAP
REMOVAL
(1) Open hood. (3) Verify hood lid operation.
(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.
INSTALLATION
(1) Place gas prop in position on vehicle.
(2) Install the lock caps on the gas prop.
23 - 44 INSTRUMENT PANEL LH
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
(1) Connect headlamp switch connector. Place the
cluster bezel into position and snap it into place (2) Install the two screws over upper cluster bezel
firmly. in instrument panel brow area and all remaining
attaching screws.
LH INSTRUMENT PANEL 23 - 45
CLUSTER BEZEL (Continued)
(3) Install the items covering the bezel mounting REMOVAL), (Refer to 23 - BODY/INTERIOR/CROSS
screws. CAR BEAM - REMOVAL) and etc.
(4) Install the one screw (Concorde/300M) to clus- (2) Feed electrical wires back through the silencer
ter bezel wiring pass through holes (Fig. 2).
To service any instrument cluster component, the (3) Remove fasteners attaching silencer to the
instrument cluster must be removed from the instru- dash and side cowls.
ment panel. Use the following procedure: (4) Remove silencer from vehicle.
(5) Tilt the steering column down into the highest
position. INSTALLATION
(6) Install the steering column shroud cover. (1) Position silencer to dash panel and cowl panels
(7) Install the instrument panel left end cap. (Fig. 2).
(8) Connect the negative battery cable remote ter- (2) Push retainers over previously installed studs
minal to the remote battery post (Fig. 1). on the dash panel.
(3) Attach silencer with push pins to the side cowl
and clips to the top cowl/dash weld flange.
DASH SILENCER (4) Install all other parts removed (Refer to 23 -
BODY/INTERIOR/CROSS CAR BEAM - INSTALLA-
REMOVAL TION), (Refer to 14 - FUEL SYSTEM/FUEL INJEC-
(1) Remove all parts mounting through the dash TION/ACCELERATOR PEDAL - INSTALLATION),
silencer (Refer to 23 - BODY/INSTRUMENT PANEL/ (Refer to 5 - BRAKES/HYDRAULIC/MECHANICAL/
INSTRUMENT PANEL ASSEMBLY - REMOVAL), PEDAL - INSTALLATION), (Refer to 19 - STEER-
(Refer to 24 - HEATING & AIR CONDITIONING/ ING/COLUMN - INSTALLATION) (Refer to 24 -
DISTRIBUTION/HVAC HOUSING - REMOVAL), HEATING & AIR CONDITIONING/DISTRIBUTION/
(Refer to 19 - STEERING/COLUMN - REMOVAL), HVAC HOUSING - INSTALLATION), (Refer to 23 -
(Refer to 5 - BRAKES/HYDRAULIC/MECHANICAL/ BODY/INSTRUMENT PANEL/INSTRUMENT
PEDAL - REMOVAL), (Refer to 14 - FUEL SYSTEM/ PANEL ASSEMBLY - INSTALLATION) and etc.
FUEL INJECTION/ACCELERATOR PEDAL -
GLOVE BOX LATCH NOTE: On 300M vehicles, the center bezel must be
removed prior to the shifter bezel.
REMOVAL
(1) Remove the four screws at bottom of glove box (4) 300M, remove center bezel (Refer to 23 -
door. BODY/INSTRUMENT PANEL/INSTRUMENT
(2) Open the glove box door and slide sidewalls PANEL CENTER BEZEL - REMOVAL).
inboard to remove the door/box assembly from instru- (5) Using a trim stick (special tool #C-4755) or
ment panel. equivalent, gently pry up on shifter bezel.
(3) Place the glove box on a cloth to protect the (6) Disconnect two wire connectors, one illumina-
door surface. tion bulb socket, and remove.
(4) Remove the nine screws from backside of the (7) Remove two screws from lower instrument
door. panel cover (outside end) and disconnect deck lid
(5) Separate the inner and outer door. release switch wiring connector. Pull rearward on
(6) Remove one screw to the latch. lower instrument panel cover releasing clips. Remove
(7) Remove latch from outer door. cable to brake release handle. Pull rearward and
remove cover from vehicle.
NOTE: If the glove box door is going to be left off (8) On six passenger vehicles, remove the lower
for an extended period of time, the Ignition Off floor bin and proceed with Step 14 (Refer to 23 -
Draw (IOD) fuse should be pulled to maintain bat- BODY/INSTRUMENT PANEL/STORAGE BIN -
tery condition. REMOVAL).
(9) On five passenger vehicles, use trim stick or
equivalent to gently remove center bezel (Refer to 23
LH INSTRUMENT PANEL 23 - 47
INSTRUMENT PANEL ASSEMBLY (Continued)
- BODY/INSTRUMENT PANEL/STORAGE BIN -
REMOVAL).
(10) Disconnect wire connectors to the HVAC con-
trol and traction control switch and remove bezel
from vehicle.
(11) Remove two screws to left console side cover,
pull outboard and remove from vehicle.
(12) Lower glove box door to floor by pinching
sides together, towards each other. Remove two
screws to right console side cover, pull outboard and
remove from vehicle.
(13) Remove two front bracket screws and two
screws inside console storage bin to remove console.
(14) Remove two nuts attaching center lower
instrument panel to floor tunnel bracket (Fig. 3).
INSTALLATION and two ground eyelets left of the floor tunnel near
(1) If replacing instrument panel and pad assem- the bulkhead.
bly, transfer all parts to new assembly (Fig. 6), (Fig. (13) Install the steering column:
7), and (Fig. 8). (a) Raise steering column into position at brake
(2) With the help of an assistant, place instrument pedal support bracket.
panel into vehicle into the approximate mounting (b) Install the four column mounting bolts at
position (Fig. 5). brake pedal support bracket.
(3) Make sure that all harnesses are free and clear (c) Place the left panel A/C outlet duct into posi-
from snagging. tion and firmly snap into place.
(4) Install eight instrument panel retaining screws (d) Place the under column duct section into
to body. position and firmly snap into place.
(5) Connect the left side harness connectors to (e) Connect column wiring.
junction block and Body Control Module (BCM). (f) Connect shift interlock cable at ignition
(6) Connect the two right side harness connectors switch.
to radio antenna and amplifier DIN cable. (g) Install the steering column shrouds.
(7) Install the right side under dash silencer/pad. (14) Install one screw attaching instrument panel
(8) Place the right and left cowl side kick panels to the steering column mounting plate (Fig. 4).
into position and install the three retaining screws. (15) Place the left floor duct/silencer pad into posi-
(9) Place the right and left scuff plates into posi- tion and install the one retaining screw.
tion and firmly press them into place. Install the one (16) Connect the 16-way Diagnostic Link Connec-
screw retaining each left and right scuff plate. tor (DLC) to the steel reinforcement.
(10) Place the instrument panel top cover into (17) Install the four bolts to steel reinforcement at
position and firmly snap into place (Fig. 5). the bottom of lower instrument panel cover.
(11) Place the right and left A-pillar trim moldings (18) Install the two nuts attaching center lower
into place starting from the rear and firmly snap into instrument panel to floor tunnel bracket. On six pas-
place. senger vehicles go to Step 25 (Fig. 3).
(12) Connect the two harness connectors to the (19) Install the two front bracket screws and two
HVAC housing, the Airbag Control Module (ACM), screws inside console storage bin to console.
LH INSTRUMENT PANEL 23 - 49
INSTRUMENT PANEL ASSEMBLY (Continued)
(20) Place the right console side cover into position the left lower instrument panel cover into position
and firmly snap into place. Install the two screws to and firmly snap into place. Install the two screws to
right console side cover. the lower instrument panel cover (outside end).
(21) Raise glove box door to by pinching sides (27) Connect two wire connectors and one illumi-
together, towards each other. nation bulb socket.
(22) Place the left console side cover into position (28) Place shifter bezel into position and firmly
and firmly snap into place. Install the two screws to snap into place.
the left console side cover.
(23) Connect wire connectors to HVAC control and NOTE: On 300M vehicles, the shifter bezel must be
traction control switch. installed prior to the center bezel being installed.
(24) On five passenger vehicles, place instrument
panel center bezel into position and firmly snap into (29) Install left and right instrument panel end
place (Refer to 23 - BODY/INSTRUMENT PANEL/ covers by placing into position and firmly snapping
STORAGE BIN - INSTALLATION). into place.
(25) On six passenger vehicles, install the lower (30) Install the one Allen screw to shifter knob.
floor bin (Refer to 23 - BODY/INSTRUMENT PAN- (31) Connect the negative battery cable remote ter-
EL/STORAGE BIN - INSTALLATION). minal to the remote battery post (Fig. 1).
(26) Connect decklid release switch wiring connec-
tor, install the cable to brake release handle. Place
23 - 50 INSTRUMENT PANEL LH
INSTRUMENT PANEL ASSEMBLY (Continued)
INSTRUMENT PANEL CENTER (2) Place the instrument panel center trim bezel
into position and firmly snap into place (Fig. 9).
BEZEL (3) Install the ash receiver (if equipped).
(4) Connect the negative battery cable remote ter-
REMOVAL minal to the remote battery post (Fig. 1).
(1) Open hood and disconnect the negative battery
cable remote terminal from the remote battery post
(Fig. 1). INSTRUMENT PANEL END CAP
(2) Remove ash receiver (if applicable).
(3) Using a trim stick (special tool #C-4755) or REMOVAL
equivalent, gently pry out on center trim bezel. Dis- (1) Open the left door and pull on the access han-
connect wiring connectors to HVAC controls, cigar dle to disengage the end cap clips. Fuse diagram is
lighter/auxiliary power outlet and traction control located inside the left end cap. Fuse Access is under
switch (if equipped) (Fig. 9). the left end cap (Fig. 10).
(4) Remove instrument panel center trim bezel. (2) Open the right door and remove the right end
cover by inserting a trim stick (special tool #C-4755),
NOTE: The traction control switch, HVAC control between cap and instrument panel to disengage clips.
head and cigar lighter/auxiliary power outlet must
be transferred to new bezel if being replaced.
INSTRUMENT PANEL
SILENCER
REMOVAL
(1) Remove the retaining screw to the instrument
panel.
(2) Maneuver part and bracket off of the center
floor distribution duct.
(3) Remove the silencer/duct.
INSTALLATION
(1) Position upper right trim bezel over slots in
instrument panel and firmly snap into place. If
equipped with traction control, connect connector.
(2) Tighten the lower right edge of steering column
cover, then tighten upper right corner of steering col-
umn cover.
(3) Install the one screw in center bezel area.
(4) Install the four screws along bottom edge of
trim bezel and close glove box.
(5) Position center instrument panel bezel over
slots and firmly snap into place.
(6) Connect the negative battery cable remote ter-
minal to the remote battery post (Fig. 1). Fig. 13 CENTER FLOOR BIN
1 - INSTRUMENT PANEL
2 - INSTRUMENT PANEL FLOOR BIN
STORAGE BIN - 5 PASSENGER
VEHICLES INSTALLATION
(1) Place the instrument panel bin into position
REMOVAL and firmly snap into place.
(1) Open hood and disconnect the negative battery (2) Install one screw and one push pin to the lower
cable remote terminal from the remote battery post instrument panel.
(Fig. 1).
(2) Remove ash receiver (if applicable).
(3) Using a trim stick (special tool #C-4755), gently STEERING COLUMN COVER
pry out on center trim bezel. Disconnect wiring con-
nectors to HVAC controls, cigar lighter/auxiliary REMOVAL
power outlet and traction control switch (if (1) Remove the left end cover.
equipped). (2) Remove two screws attaching steering column
(4) Remove instrument panel center trim bezel. cover (Fig. 14).
(5) Remove two retaining screws to the storage bin (3) Pull rearward on steering column cover to
and remove. release the retaining clips on the top and right edge.
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 into position (Fig.
14).
(2) Push on steering column cover till retaining
clips lock into position.
(3) Install two attaching screws to the side of the
steering column cover.
(4) Install end cover.
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
INSTALLATION 3 - TRUNK CARPET
(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
BODY VENT locator tab is aligned.
(2) Engage the upper half of the air exhauster
REMOVAL then push the lower half in until the clips click into
(1) Open decklid. place.
(2) Move trunk carpet to access the air exhauster (3) Install trunk carpet into position.
in the right/left rear corner of the trunk (Fig. 3).
LH INTERIOR 23 - 61
INSTALLATION
(1) Slide seat belt through the B-pillar trim.
(2) Place B-pillar trim in position on vehicle.
(3) Engage clips attaching lower trim to B-pillar.
(4) Install access door above seat belt slot on B-pil-
lar trim.
(5) Install bolt attaching seat belt to floor below
B-pillar.
(6) Install upper B-pillar trim.
(7) Install seat belt height adjuster knob.
(8) Refit weatherstrip.
23 - 62 INTERIOR LH
CARPETS
REMOVAL
(1) Remove floor mats.
(2) Remove door sill trim covers.
(3) Remove cowl side trim covers.
(4) Remove front seats.
(5) Remove bolts attaching front seat belt lower
anchors to floor below B-pillar trim panels.
(6) Remove center console, if equipped.
(7) Remove rear seat cushion.
(8) Remove gas pedal bracket.
(9) Remove carpet fasteners.
(10) Remove carpet from vehicle (Fig. 6).
INSTALLATION
INSTALLATION - CONCORD
(1) Place front floor console side panel in position
on vehicle.
(2) Press on the side panel to seat clips.
(3) Install side panel(s) screws.
(4) Install floor console shift bezel.
(5) Install shift knob.
INSTALLATION
(1) Place front floor console side panel in position
on vehicle.
(2) Press on the side panel to seat clips. Fig. 13 DOOR SILL TRIM
(3) Install attaching screws. 1 - FASTENERS
(4) Install floor console shift bezel. 2 - DOOR SILL TRIM
(5) Install shift knob. 3 - DOOR OPENING SILL
INSTALLATION
(1) Place sill trim in position on vehicle.
(2) Install fasteners to attach door sill trim to sill
panel.
23 - 68 INTERIOR LH
FLOOR CONSOLE
REMOVAL
(1) Remove shift knob.
(2) Remove floor console shift bezel.
(3) Remove side panels (Fig. 14), or (Fig. 15).
(4) Disconnect the electrical connectors.
(5) Remove fasteners attaching forward bracket to
instrument panel.
(6) Remove fasteners attaching bottom of console
storage bin to rear mounting bracket (Fig. 16).
(7) Remove floor console from vehicle.
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 Fig. 15 FRONT FLOOR CONSOLE SIDE PANELS
instrument panel. 1 - INSTRUMENT PANEL
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
HEADLINER
REMOVAL
(1) Remove front passenger seat for ease of
removal of headliner.
(2) Remove right and left A-pillar trim panels.
(3) Remove right and left sun visors and retainers.
(4) Remove overhead console or front interior
lights.
(5) Disconnect wire harness along A-pillar and
wire connector to the fuse panel.
(6) Remove upper B-pillar trim panels.
(7) Remove front and rear assist handles.
(8) Remove quarter trim upper panels partial,
keeping belt attached.
(9) Fully recline seat.
(10) Disengage rear headliner locating clip, using
Headliner Clip Pliers, Special Tool C-6967.
(11) Pull headliner down, beginning from the rear.
The back side of the headliner is glue bonded to the
structural membrane and must be overcome. Fig. 18 HEADLINER
1 - REAR CLIP
NOTE: No special tools are required to release the
2 - MEMBRANE
membrane from the headliner. Pull down use hand
force only to release the membrane.
INSTALLATION
NOTE: DO NOT remove headliner membrane from
vehicle. No additional use of any additional adhe-
sives is needed.
ROOF STRUCTURAL
MEMBRANE
REMOVAL
(1) Remove headliner.
(2) Remove roof support membrane, using a Mold-
ing Removal Tool, 3-M p/n 08978.
(3) Carefully pull down corner of roof structural
membrane enough to insert molding removal tool
between roof panel and adhesive. Activate air chisel,
while keeping the blade at an angle, ensuring not to
flex the roof panel. Evenly separate the adhesive
strips from the roof panel until the structural mem-
brane is removed.
INSTALLATION
(1) Place headliner in vehicle allowing it to rest in LOWER QUARTER TRIM
a down position on the seats.
(2) Outside of the vehicle, using the adhesive sup- REMOVAL
plied, apply five 10 mm (0.39 inch) diameter beads of (1) Remove rear seat cushion and back.
adhesive within the printed black lines or at the cen- (2) Pull upper quarter trim from panel (Fig. 21).
ter of membrane strips for the length of the new (3) Remove sill trim as necessary to clear quarter
structural membrane, stopping 38 mm (1.5 inches) trim removal path.
before each end (Fig. 20). (4) Disengage clips attaching lower quarter trim to
inner quarter trim from vehicle.
NOTE: ADHESIVE MUST BE APPLIED UNIFORMLY
(5) Remove quarter trim from vehicle.
IN 10 mm (0.39 INCHES) BEADS. TOO MUCH OR
TOO LITTLE ADHESIVE WILL CAUSE ROOF PANEL
TO WARP AS ADHESIVE CURES.
INSTALLATION
INSTALLATION
(1) Position the mirror base at the bracket and
Fig. 22 PARCEL SHELF TRIM PANEL slide it downward onto the support bracket (Fig. 23).
1 - REAR SHELF TRIM (2) Tighten the setscrew 1 N·m (15 in. lbs.) torque.
2 - PUSH PIN FASTENER (3) If equipped, connect mirror harness connector.
3 - CLIP LOCATION
INSTALLATION - REARVIEW MIRROR
INSTALLATION SUPPORT BRACKET
(1) Place rear shelf trim panel in position in vehi- (1) Mark the position for the mirror bracket on the
cle. outside of the windshield glass with a wax pencil.
(2) Feed center seat belt and bezel through rear (2) Clean the bracket contact area on the glass.
trim panel. Use a mild powdered cleanser on a cloth saturated
(3) Connect CHMSL wire connector. with isopropyl (rubbing) alcohol. Finally, clean the
(4) Push parcel shelf trim rearward toward rear glass with a paper towel dampened with alcohol.
glass and engage clips. (3) Sand the surface on the support bracket with
(5) Insert push pin fasteners into position. fine grit-sandpaper. Wipe the bracket surface clean
(6) Install quarter trim lower and upper panels. with a paper towel.
LH INTERIOR 23 - 73
REAR VIEW MIRROR (Continued)
(4) Apply accelerator to the surface on the bracket (3) Pull and hold assist handle down.
according to the following instructions: (4) Remove front screw attaching assist handle to
(a) Crush the vial to saturate the felt applicator. roof (Fig. 24).
(b) Remove the paper sleeve. (5) Remove assist handle from roof.
(c) Apply accelerator to the contact surface on (6) Disengage clips attaching reading lamp socket
the bracket. to back of assist handle base.
(d) Allow the accelerator to dry for five minutes. (7) Disconnect reading lamp switch from slot on
(e) Do not touch the bracket contact surface back of assist handle base.
after the accelerator has been applied. (8) Remove assist handle from vehicle.
(5) Apply adhesive accelerator to the bracket con-
tact surface on the windshield glass. Allow the accel-
erator to dry for one minute. Do not touch the glass
contact surface after the accelerator has been
applied.
(6) Install the bracket according to the following
instructions:
(a) Apply one drop of adhesive at the center of
the bracket contact-surface on the windshield
glass.
(b) Apply an even coat of adhesive to the contact
surface on the bracket.
(c) Align the bracket with the marked position
on the windshield glass.
(d) Press and hold the bracket in place for at
least one minute.
Fig. 24 REAR ASSIST HANDLE AND READING
NOTE: Verify that the mirror support bracket is cor-
LAMP
rectly aligned, because the adhesive will cure rap-
1 - COAT HOOK
idly.
2 - ASSIST HANDLE
3 - HEADLINING
(7) Allow the adhesive to cure for 8-10 minutes.
Remove any excess adhesive with an alcohol-damp-
ened cloth. INSTALLATION
(8) Allow the adhesive to cure for an additional (1) Place assist handle in position on vehicle.
8-10 minutes before installing the mirror. (2) Connect reading lamp switch into slot on back
of assist handle base.
(3) Engage clips attaching reading lamp socket to
REAR SEAT GRAB HANDLE/ back of assist handle base.
READING LAMP (4) Place assist handle in position on roof.
(5) Pull and hold assist handle down.
REMOVAL (6) Install front screw attaching assist handle to
(1) Pull down coat hook. roof.
(2) Remove screw attaching assist handle to roof (7) Install screw behind coat hook attaching assist
from behind coat hook. handle to roof.
23 - 74 INTERIOR LH
PAINT
TABLE OF CONTENTS
page page
PAINT
SPECIFICATIONS - COLOR CODE CHARTS
EXTERIOR COLORS
DAIMLERCHRYSLER DAIMLERCHRYSLER
EXTERIOR COLOR EXTERIOR COLOR
CODE CODE
BLACK CLEARCOAT DX8 INFERNO RED TINTED WEL
PEARLCOAT
BRIGHT SILVER METALLIC WS2 LIGHT ALMOND PEARL ZKJ
CLEARCOAT METALLIC CLEARCOAT
CINNAMON GLAZE VLB ONYX GREEN PEARLCOAT YJR
METALLIC CLEARCOAT
DARK GARNET RED XRV STEEL BLUE PEARLCOAT XBQ
PEARLCOAT
DEEP SAPPHIRE BLUE YBW STONE WHITE CLEARCOAT SW1
CLEARCOAT
INTERIOR COLORS
DAIMLERCHRYSLER DAIMLERCHRYSLER
INTERIOR COLOR INTERIOR COLOR
CODE CODE
DARK SLATE GREY DV SANDSTONE T5
DARK SLATE GREY/LIGHT DV/L2 TAUPE L5
TAUPE
DARK TAUPE/ LIGHT L5/L2
TAUPE
LH PAINT 23 - 77
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 seat rear outboard seat track 28 20 —
to floor pan bolts
Front seat airbag module to seat 7 — 62
back frame
Rear seat center seat belt retractor 60 44 —
to shelf
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.
(5) Slide arm rest off of bracket (Fig. 2). Fig. 2 ARM REST BRACKET
1 - ARMREST BRACKET
INSTALLATION - 50/50 SPLIT
(1) Slide arm rest on bracket.
(2) Install arm rest nut. Tighten nut to 25 N·m (18
ft. lbs.) torque.
(3) Install access retaining nut cover.
(4) Reposition the seats.
23 - 80 SEATS LH
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). Fig. 10 REMOVE SEAT BACK
(3) Remove bolts attaching recliner to seat back 1 - RECLINER BOLT HOLE
cushion frame (Fig. 9). 2 - SEAT BACK BOLT HOLE
(4) Remove inboard and outboard pivot bolts (Fig. 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).
REMOVAL
REMOVAL
(1) Remove head restraint (Refer to 23 - BODY/
SEATS/ARMREST - FRONT - REMOVAL).
(2) Remove front seat back (Refer to 23 - BODY/
SEATS/FRONT SEAT BACK - REMOVAL).
(3) Remove lumbar support handle, if equipped.
(4) Disengage the J-strap retainer (Fig. 10).
(5) Roll cover upward to hog rings. Cut hog rings
to free cover (Fig. 14).
(6) Roll cover to top of cushion and remove head
restraint sleeve guides.
(7) Remove cover from seat back.
INSTALLATION
INSTALLATION
Fig. 16 SEAT BACK J-STRAP POSITION &
ORIENTATION NOTE: Do not reuse the recliner assembly attaching
1 - TRIM COVER J-STRAPS bolts.
2 - SEAT HEATER WIRE HARNESS
3 - SEAT AIRBAG WIRE HARNESS (1) Position cover at the top of seat back.
(2) Carefully roll cover down to the area that hog
rings are to be installed.
(3) Install hog rings.
(4) Roll cover downward.
(5) Engage the J-strap retainer
(6) Install lumbar support handle, if equipped.
(7) Install new head restraint sleeve guides.
(8) Install front seat back (Refer to 23 - BODY/
SEATS/FRONT SEAT BACK - INSTALLATION).
(9) Install head restraint (Refer to 23 - BODY/
SEATS/ARMREST - FRONT - INSTALLATION).
(10) Check seat back operation.
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-
rately. The front seat back frame will need to be
REMOVAL - AIRBAG EQUIPPED 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.
LH SEATS 23 - 91
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
INSTALLATION - 60/40
(1) Place arm rest in bracket.
(2) Install arm rest bolt. Tighten to 12 N·m (9 ft.
Fig. 31 ARM REST WITH SKI PASS lbs.) torque.
(3) Install retaining C-clip.
1 - SKI PASS
2 - DOOR
(4) Reposition the seats.
LH SEATS 23 - 93
REAR ARMREST (Continued)
(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.
REMOVAL - 40 SECTION
(1) Remove seat back collar assembly (Refer to 23 -
BODY/SEATS/REAR SEAT BACK - COLLAR
ASSEMBLY - REMOVAL). (Fig. 36)
(2) Remove bolt attaching 40 section (Fig. 37).
(3) Slide seat back 40 section off pin and remove
from the collar assembly (Fig. 38).
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).
INSTALLATION - 40 SECTION
(1) Place seat back 40 section on pin.
(2) Install bolt attaching 40 section seat back to
collar section. Tighten bolt to 16 N·m (12 ft. lbs.)
torque.
(3) Install seat back collar assembly (Refer to 23 -
BODY/SEATS/REAR SEAT BACK - COLLAR
ASSEMBLY - INSTALLATION).
INSTALLATION - 60 SECTION
(1) Install the 60 seat section on pivot bracket.
Fig. 39 REAR SEAT BACK 60 SECTION (2) Install bolt attaching 60 seat section. Tighten
bolt to 16 N·m (12 ft. lbs.) torque.
1 - ATTACHING BOLT
(3) Install the 40 seat section on pin.
(4) Install bolt attaching 40 seat section. Tighten
REMOVAL - 60/40 SEAT COLLAR ASSEMBLY bolt to 16 N·m (12 ft. lbs.) torque.
(1) Remove rear seat cushion (Refer to 23 - BODY/ (5) Install seat back collar assembly (Refer to 23 -
SEATS/SEAT CUSHION REAR - REMOVAL). BODY/SEATS/REAR SEAT BACK COLLAR ASSEM-
(2) Remove nuts attaching rear seat back collar BLY - INSTALLATION).
assembly.
(3) Remove rear seat back collar assembly.
(4) Remove the 40 seat section from the rear seat
back collar assembly.
LH SEATS 23 - 95
REAR SEAT BACK (Continued)
INSTALLATION REMOVAL
(1) Remove rear seat cushion (Refer to 23 - BODY/
(1) Position seat back cover on seat back.
SEATS/SEAT CUSHION REAR - REMOVAL).
(2) Install hog ring on right side listing pocket of
(2) Disengage the J-strap retainers (Fig. 42).
cover to foam, starting in the middle and lining up
(3) Cut hog rings to free cover (Fig. 43).
the die cuts in the listing pocket with the hog ring
(4) Remove seat cushion cover from seat cushion.
windows in the foam (three places).
(3) Repeat for the left side listing pocket of cover.
(4) Place cover seams in salvage trenches of foam.
(5) Roll corners and edges of cover over foam.
(6) Flip seat over making sure cover is pulled up
over frame on all corners. Push top, bottom, inside,
outside, corners of the foam into the cover and
engage J-strap retainers.
(7) Install rear seat back (Refer to 23 - BODY/
SEATS/REAR SEAT BACK - INSTALLATION).
INSTALLATION INSTALLATION
(1) Place rear seat cushion in position. (1) Position seat cushion cover on cushion.
(2) Engage retainer loops into cup on floor kick up. (2) Install hog rings to seat cover.
(3) Push downward at forward edge at each (3) Engage the J-strap retainers.
retainer loop of the rear seat cushion to engage (4) Steam wrinkles from seat cushion, if necessary.
retainers.
23 - 96 SEATS LH
REAR SEAT CUSHION COVER (Continued)
(2) Remove the front seat back. Refer to the proce-
dure in this group.
(3) Remove bolts attaching seat adjuster to cush-
ion pan (Fig. 44).
(4) Disconnect wire harness from cushion pan.
(5) Remove seat adjuster from seat cushion.
SEAT ADJUSTERS
REMOVAL - AIRBAG EQUIPPED Fig. 44 FRONT SEAT TRACK - TYPICAL
1 - ATTACHING BOLTS
WARNING: DISCONNECT AND ISOLATE THE NEGA-
TIVE BATTERY CABLE REMOTE TERMINAL
BEFORE BEGINNING ANY FRONT SEAT REMOVAL INSTALLATION - AIRBAG EQUIPPED
OR INSTALLATION PROCEDURE. THIS WILL DIS- (1) Place seat adjuster in position on seat cushion
ABLE THE AIRBAG SYSTEM. FAILURE TO DISCON- pan.
NECT THE BATTERY COULD RESULT IN (2) Connect wire harness to the cushion pan.
ACCIDENTAL AIRBAG DEPLOYMENT AND POSSI- (3) Install bolts attaching seat adjuster to cushion
BLE PERSONAL INJURY. pad.
(4) Install seat back. Refer to the procedure in this
group.
WARNING: ONCE THE NEGATIVE CABLE IS DIS- (5) Install bolt to attach seat back recliner to seat
CONNECTED WAIT FOR 2 MINUTES BEFORE back on each side of seat. Tighten bolt to 8 N·m (71
REMOVING ANY AIRBAG SYSTEM COMPONENTS. in. lbs.) torque.
(6) Connect the negative battery cable.
(1) Disconnect and isolate the remote negative bat-
(7) Using the DRB IIIt Scan Tool erase all DTC’s
tery cable.
and perform airbag system diagnostics.
LH STATIONARY GLASS 23 - 97
STATIONARY GLASS
TABLE OF CONTENTS
page page
STATIONARY GLASS lation (not to the glass) and wipe with clean/dry lint
free cloth until no streaks are visible.
(3) Apply Glass Primer 25 mm (1 in.) wide around
DESCRIPTION
perimeter of rear window encapsulation (not to the
Windshields and selected stationary glass are
glass). Allow at least three minutes drying time.
structural members of the vehicle. The windshield
(4) Using a razor knife, remove as much original
glass is bonded to the windshield frame with ure-
urethane as possible. Do not damage paint on rear
thane adhesive.
window fence.
(5) Apply pinch weld primer 15 mm (.75 in.) wide
BACKLITE around the rear window fence. Allow at least three
minutes drying time.
(6) Apply a 10 mm (0.4 in.) bead of urethane to the
REMOVAL
encapsulation (Fig. 1).
(1) Remove upper quarter trim panel (Refer to 23 -
(7) With the aid of a helper, position the rear win-
BODY/INTERIOR/UPPER QUARTER TRIM -
dow over the opening.
REMOVAL).
(8) Slowly lower rear window glass to the roof
(2) Disconnect the wire connectors from rear win-
fence opening and engage over the two flanges
dow defogger, and rear window mounted radio
located on the roof fence. Guide the encapsulation
antenna, if so equipped.
into proper position as necessary. Remove the back-
WARNING: WEAR EYE AND HAND PROTECTION ing paper from the tape on lower appendage and
WHEN HANDLING SAFETY GLASS. PERSONAL
INJURY CAN RESULT.
INSTALLATION
WARNING: DO NOT USE SOLVENT BASED GLASS
CLEANER TO CLEAN WINDSHIELD BEFORE
APPLYING GLASS PREP AND PRIMER. POOR
ADHESION CAN RESULT.
Fig. 1 REAR WINDOW GLASS - TYPICAL
(1) Clean inside of rear window with ammonia 1 - REAR WINDOW GLASS
based glass cleaner and lint free cloth. 2 - URETHANE
3 - CLIP
(2) Apply Glass Prep adhesion promoter 25 mm (1
4 - MOLDING
in.) wide around perimeter of rear window encapsu-
23 - 98 STATIONARY GLASS LH
BACKLITE (Continued)
push rear window inward till flush to roof line and CAUTION: Protect all painted and trimmed surfaces
C-pillars (Intrepid). from coming in contact with urethane or primers.
(9) Clean excess urethane from exterior with Be careful not to damage painted surfaces when
Mopart Super Kleen or equivalent. removing moldings or cutting urethane around
(10) Connect rear window defogger wiring connec- windshield.
tor, and rear window mounted radio antenna connec-
tor, if so equipped.
(11) Install upper quarter trim panel (Refer to 23 - OPERATION
BODY/INTERIOR/UPPER QUARTER TRIM - The windshield is attached to the window frame
INSTALLATION). with urethane adhesive. The urethane adhesive is
(12) After urethane has cured, water test rear win- applied cold and seals the surface area between the
dow to verify repair. Verify rear window defogger window opening and the glass. The primer adheres
operation, (Refer to 8 - ELECTRICAL/HEATED the urethane adhesive to the windshield.
GLASS/REAR WINDOW DEFOGGER GRID - DIAG- It is difficult to salvage a windshield during the
NOSIS AND TESTING) . removal operation. The windshield is part of the
structural support for the roof. The urethane bonding
used to secure the windshield to the fence is difficult
WINDSHIELD to cut or clean from any surface. If the moldings are
set in urethane, it would also be unlikely they could
DESCRIPTION be salvaged. Before removing the windshield, check
the availability of the windshield and moldings from
WARNING: DO NOT OPERATE THE VEHICLE the parts supplier.
WITHIN 24 HOURS OF WINDSHIELD INSTALLATION.
IT TAKES AT LEAST 24 HOURS FOR URETHANE REMOVAL
ADHESIVE TO CURE. IF IT IS NOT CURED, THE The urethane adhesive holding the windshield to
WINDSHIELD MAY NOT PERFORM PROPERLY IN the opening pinch weld (fence) can be cut using a
AN ACCIDENT. sharp cold knife from the exterior of the vehicle.
URETHANE ADHESIVES ARE APPLIED AS A SYS- Using the cold knife method is effective if the wind-
TEM. USE GLASS CLEANER, GLASS PREP SOL- shield is already broken. If the glass must be sal-
VENT, GLASS PRIMER, PVC (VINYL) PRIMER AND vaged, cutting the urethane adhesive from the
PINCH WELD (FENCE) PRIMER PROVIDED BY THE interior of the vehicle using a reciprocating or oscil-
ADHESIVE MANUFACTURER. IF NOT, STRUCTURAL lating power knife is recommended.
INTEGRITY COULD BE COMPROMISED. (1) Remove inside rear view mirror (Refer to 23 -
DAIMLERCHRYSLER DOES NOT RECOMMEND BODY/INTERIOR/REAR VIEW MIRROR - REMOV-
GLASS ADHESIVE BY BRAND. TECHNICIANS AL).
SHOULD REVIEW PRODUCT LABELS AND TECHNI- (2) Remove cowl cover (Refer to 23 - BODY/EXTE-
CAL DATA SHEETS, AND USE ONLY ADHESIVES RIOR/COWL GRILLE AND SCREEN - REMOVAL).
THAT THEIR MANUFACTURES WARRANT WILL (3) Remove drip rail weatherstrips as necessary to
RESTORE A VEHICLE TO THE REQUIREMENTS OF gain access to screws holding windshield side mold-
FMVSS 212. TECHNICIANS SHOULD ALSO INSURE ings (Fig. 2). Pull outward on molding at the bottom
THAT PRIMERS AND CLEANERS ARE COMPATIBLE of A-pillars using pliers.
WITH THE PARTICULAR ADHESIVE USED. (4) Cut urethane bonding from around windshield
BE SURE TO REFER TO THE URETHANE MANU- using a suitable sharp cold knife. A pneumatic cut-
FACTURER’S DIRECTIONS FOR CURING TIME ting device can be used if available. (Fig. 3)
SPECIFICATIONS, AND DO NOT USE ADHESIVE (5) Remove windshield from vehicle.
AFTER ITS EXPIRATION DATE.
VAPORS THAT ARE EMITTED FROM THE URE- INSTALLATION
THANE ADHESIVE OR PRIMER COULD CAUSE The urethane adhesive holding the windshield to
PERSONAL INJURY. USE THEM IN A WELL-VENTI- the opening pinch weld (fence) can be cut using a
LATED AREA. sharp cold knife from the exterior of the vehicle.
SKIN CONTACT WITH URETHANE ADHESIVE Using the cold knife method is effective if the wind-
SHOULD BE AVOIDED. PERSONAL INJURY MAY shield is already broken. If the glass must be sal-
RESULT. vaged, cutting the urethane adhesive from the
ALWAYS WEAR EYE AND HAND PROTECTION interior of the vehicle using a reciprocating or oscil-
WHEN WORKING WITH GLASS. lating power knife is recommended.
LH STATIONARY GLASS 23 - 99
WINDSHIELD (Continued)
(2) Verify the glass lays evenly against the pinch
weld fence at the sides, top and bottom of the
replacement windshield. If not, the pinch weld fence
must be formed to the shape of the new glass.
(3) Mark the glass at the support spacers with a
grease pencil or pieces of masking tape and ink pen
to use as a reference for installation (Fig. 4).
(4) Remove replacement windshield from wind-
shield opening.
(5) Position the windshield inside up on a suitable
work surface with two padded, wood 10 cm by 10 cm
by 50 cm (4 in. by 4 in. by 20 in.) blocks, placed par-
allel 75 cm (2.5 ft.) apart (Fig. 5).
SUNROOF
TABLE OF CONTENTS
page page
The sunroof features a power sliding glass panel DIAGNOSIS AND TESTING
and a sunshade which can be manually positioned Before beginning sunroof diagnostics verify that all
anywhere along its travel, rearward of glass panel other power accessories are in proper operating con-
front edge. dition. Refer to Sunroof Diagnostic Chart for possible
causes. If not, a common electrical problem may
OPERATION exist. Refer to Wiring Diagram Information, of this
The sunroof is electrically operated from a two publication for circuit, splice and component descrip-
switches located on the windshield header, rearward tions. Check the condition of the circuit protection
of the map lamp. To operate the sunroof the ignition (20 amp high current fuse (battery feed) located in
switch must be in the On/Run position. One switch the Power Distribution Center (PDC). Check the
(CLOSE) is a push button type and used too close the cover of the PDC for location of the fuse. The ten
sunroof. Pressing and holding the CLOSE button, the amp fuse (ignition feed) located in cavity 14 of the
sunroof will fully close. If the CLOSE button is Junction Block). Inspect all wiring connector pins for
released prior to the sunroof reaching the fully closed proper engagement and continuity. Check for battery
position, the sunroof will stop in that position. The voltage at battery and ignition pins of the power sun-
other switch (OPEN/VENT) is a rocker type for open- roof express module wiring connector. Refer to Wiring
ing and venting the sunroof. Pressing and releasing Diagram Information, for circuit information. The
the OPEN button once the sunroof will express open controller will not operate at less than 10 volts.
and the wind deflector will raise. If the button is Check the ground at the sunroof express module.
pressed a second time the sunroof will stop in that Before beginning diagnosis for wind noise or water
position. To open the sunroof from the vent position, leaks, verify that the problem was not caused by
push and hold the open button. The sunroof will not releasing the control switch before the was sunroof
express open until you have passed through the full fully closed. The sunroof module has a water man-
closed position. The OPEN button may be released agement system. During washing high-pressure
and the sunroof will continue to open in the express water may be forced between the glass panel seal
and the roof opening. Normally this water will drain.
23 - 102 SUNROOF LH
SUNROOF (Continued)
However, when some type of drying blower system is ing. This causes the water to blow over the edge of
used, like those found in automatic car washes, the the module and onto the headlining.
water may not have a chance to drain before the Refer to (Fig. 1) Sunroof Assembly for exploded
blower forces air between the seal and the roof open- view of the sunroof.
HOUSING ASSEMBLY (4) Connect the drain tubes to the sunroof housing.
(5) With the aid of a helper move the headliner
through the rear door into position.
REMOVAL
(6) Engage headliner rear locating clip.
(1) Remove headliner (Refer to 23 - BODY/INTE-
(7) Connect sunroof harness connector at the
RIOR/HEADLINER - REMOVAL).
C-post.
(2) Disconnect the drain tubes from sunroof hous-
(8) Connect wire harness connector along A-post to
ing (Fig. 2).
fuse panel.
(3) Loosen fasteners attaching sunroof housing
(9) Connect mirror wiring connector.
assembly.
(10) Connect wire harness connector along A-post
(4) With the aid of a helper, remove fasteners
to fuse panel.
attaching sunroof housing assembly to roof panel.
(11) Connect battery negative cable.
(12) Move both front seats into proper position.
INSTALLATION (13) Test sunroof operation, adjust as necessary.
(1) With the Glass panel in the fully closed posi-
(14) Finish installing the headliner. Ensure that
tion. door weatherstrips are in position (Refer to 23 -
(2) With the aid of a helper, raise rear end of sun-
BODY/INTERIOR/HEADLINER - INSTALLATION).
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.
INSTALLATION
Fig. 3 SUNROOF DRIVE MOTOR AND EXPRESS (1) Position glass panel, centered to opening.
MODULE (2) Start the four attaching screws.
1 - EXPRESS MODULE (3) Tighten screws.
2 - SCREW (4) Verify sunroof operation and alignment. Check
fit and adjust as necessary, refer to Sunroof Glass
(5) Remove drive motor fasteners and remove Panel Adjustment for proper procedures.
motor from the sunroof housing.
ADJUSTMENTS
INSTALLATION
(1) Ensure that the glass panel is in the fully ADJUSTMENT
closed position before mounting the motor. If motor (1) Move the sunshade rearward to the open posi-
fails with the window in the open position the sun- tion.
roof glass panel timing will have to be timed. The (2) Move the sunroof glass panel to the fully closed
new motor comes in the fully closed position and position.
with a gage for setting cable timing. Refer to Sunroof (3) Loosen the forward screws on each side enough
Glass Panel Timing. to make the front adjustment.
(2) Place drive motor into position on the sunroof
housing and install fasteners. (Fig. 3)
23 - 106 SUNROOF LH
GLASS PANEL (Continued)
(4) Adjust the front of the sunroof glass panel 1 HOUSING DRAIN HOSE
mm (1/32 inch) below the top surface of the roof
panel.
REMOVAL
(5) Tighten the front two screws.
(6) Loosen the rear screws on each side enough to
FRONT HOSES
make the rear adjustment.
(1) Move glass panel to the fully closed position.
(7) Adjust the rear of the sunroof glass panel 1 mm
(2) Disconnect the control switch and wire connec-
(1/32 inch) above the top surface of the roof panel.
tor.
(8) Tighten the rear two screws.
(3) Remove headliner as necessary (Refer to 23 -
(9) Check for proper fit. If not OK, repeat glass
BODY/INTERIOR/HEADLINER - REMOVAL).
panel adjustment.
(4) Remove side kick cowl panel.
(5) Disconnect drain hose clips from body holes
ADJUSTMENT - SUNROOF GLASS PANEL (Fig. 6)and/or (Fig. 7).
TIMING (6) Drain any liquid from hose connection, if nec-
essary.
Sunroof Drive Cable Timing (7) Remove old hoses between trim and metal and
replace with new.
NOTE: A gage comes with the new motor. (8) Work the hose back and forth to loosen.
(9) Attach the end of the old hose to the end of the
(1) If the glass panel was not in the fully closed
new hose.
position, when the sunroof drive motor was removed,
(10) Pull the old hose down and through instru-
the sunroof glass panel needs to be timed, before the
ment panel dragging new hose with it, until end of
new motor is installed.
new hose is near grommet on side cowl.
(2) Remove sunroof glass panel.
(11) Remove drain grommet from sheet metal.
(3) Set gage into the track near the rear of the
(12) Remove old hose from new hose.
opening between the move driver slide and the
bracket (Fig. 5).
(4) Move the driver slide forward or aft to get
proper setting.
(5) Repeat the operation on the other side.
(6) Install sunroof drive motor.
Fig. 6 FRONT
1 - A-PILLAR
2 - DRAIN HOSE
3 - GROMMET
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.
(3) Engage upper flair end of hose into sunroof
module drain nipple and secure with ratchet clamp.
Fig. 7 FRONT RIGHT
1 - DRAIN HOSE REAR HOUSING HOSE
2 - A-PILLAR (1) Using the proper drain hose (there is a right
3 - GROMMET and left side rear hose) attach drain hose clips to
body holes, with the flair at the top towards the sun-
REAR HOUSING HOSE roof nipple.
(1) Move glass panel to the fully closed position. (2) Connect top flair end of the drain hose to the
(2) Disconnect the control switch and wire connector. sunroof housing drain nipple with the ratchet clamp
(Fig. 8).
MODULE ASSEMBLY
REMOVAL
(1) Move the glass panel to the fully closed posi-
tion.
(2) Lower headliner as necessary to gain access to
the sunroof express module (Refer to 23 - BODY/IN-
TERIOR/HEADLINER - REMOVAL).
(3) Disconnect the express module wire harness
connectors. (Fig. 3)
(4) Remove express module screw.
(5) Remove express module from the keyway by
sliding module towards the center of the vehicle.
Fig. 9 SUNSHADE GUIDE BLOCK
INSTALLATION 1 - GUIDE BLOCK
(1) Insert sunroof express module in the keyway 2 - GUIDE BLOCK SPRING
located in the sunroof module and slide the module
outward to lock it into position.
(2) Install the sunroof express module screw. INSTALLATION
(3) Connect the wire connectors to the sunroof (1) Install the sunshade from outside of the vehicle
express module. with the sunroof 90% open.
(4) Install the headliner into position (Refer to 23 - (2) Put rear guide blocks into sunshade guide
BODY/INTERIOR/HEADLINER - INSTALLATION). track.
(5) Test sunroof operation, adjust if necessary. (3) Push sunshade back and down through the
sunroof opening.
(4) Using a flat blade tool, put front guide blocks
SUNSHADE into the sunshade track. By pushing the block
towards the center of the vehicle.
REMOVAL (5) Push sunshade back to the glass panel.
(1) Open sunroof approximately 90% of the way. (6) Push sunshade down until the sunshade clears
(2) Push sunshade down until tabs clear glass. the glass then move sunshade rearward behind the
(3) Move sunshade forward of glass panel. glass panel.
LH SUNROOF 23 - 109
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.
INSTALLATION
(1) Place wind deflector at 90% in the vertical posi-
tion to the sunroof. With the sunroof open. Fig. 10 WIND DEFLECTOR
(2) Push ends of the deflector towards the front of 1 - WIND DEFLECTOR
the vehicle to engage ends. 2 - TAB
(3) Lower wind deflector to normal position.
(4) Push one corner to the opposite side of the (6) Push the opposite corner cross vehicle until tab
vehicle until tab clears vehicle body and lower deflec- clears the body. Then lower deflector to position.
tor for that corner. (7) Test sunroof operation.
(5) Push the side that was just installed com-
pletely down.
23 - 110 WEATHERSTRIP/SEALS LH
WEATHERSTRIP/SEALS
TABLE OF CONTENTS
page page
DOOR OPENING
WEATHERSTRIP
REMOVAL
(1) Remove door opening sill plate (Refer to 23 -
BODY/INTERIOR/DOOR SILL TRIM - REMOVAL).
(2) Pull body mounted weatherstrip from fence
around door opening (Fig. 1).
INSTALLATION
(1) Position color dot on weatherstrip at the B-pil-
lar upper corner.
(2) Engage weatherstrip on the fence at upper
B-pillar and work down the B-pillar.
(3) Engage weatherstrip along the header and
down the A-pillar.
(4) Engage weatherstrip along the sill. There may
be slack material work it to the front of the opening. Fig. 1 FRONT DOOR BODY MOUNTED
(5) Verify weatherstrip sealing. WEATHERSTRIP
1 - FRONT DOOR OPENING
2 - FRONT DOOR BODY MOUNTED WEATHERSTRIP
3 - PINCH FLANGE
LH WEATHERSTRIP/SEALS 23 - 111
INSTALLATION
(1) Place drip rail weatherstrip in position on vehi-
cle.
(2) Start position clip at the fender tip.
(3) Press down till holes are align with fastener
Fig. 2 DRIP RAIL WEATHERSTRIP
holes in the body.
1 - A-PILLAR
(4) Install fasteners to attach drip rail weather-
2 - WINDSHIELD
strip to roof rail.
3 - FASTENERS
(5) Close doors and verify fit. 4 - DRIP RAIL WEATHER-STRIP
5 - FASTENERS
INSTALLATION
(1) Position color dot on weatherstrip at the B-pil-
lar upper corner.
(2) Engage weatherstrip on the fence at upper
B-pillar and work down the B-pillar.
(3) Engage weatherstrip along the header and
Fig. 4 FRONT DOOR MOUNTED WEATHERSTRIP down the C-pillar.
1 - FRONT DOOR (4) Engage weatherstrip along the sill. There may
2 - PUSH-IN FASTENERS be slack material, work the slack material to the
front of the opening.
INSTALLATION (5) Install the door opening sill plate (Refer to 23 -
(1) Place door mounted weatherstrip in position. BODY/INTERIOR/DOOR SILL TRIM - INSTALLA-
(2) Engage push pin fasteners to attach weather- TION).
strip to lower door. (6) Verify weatherstrip sealing.
(3) Verify door alignment and seal
LH WEATHERSTRIP/SEALS 23 - 113
INSTALLATION
(1) Place weatherstrip in position on vehicle.
(2) Push decklid weatherstrip onto decklid opening
fence with molded joint at striker location.
(3) Verify decklid operation and sealing.
LH BODY STRUCTURE 23 - 115
BODY STRUCTURE
TABLE OF CONTENTS
page page
SPECIFICATIONS
BODY GAP AND FLUSH MEASUREMENTS
INDEX
DESCRIPTION FIGURE
BODY GAP AND FLUSH – INTREPID 1
BODY GAP AND FLUSH – CONCORDE AND 300M 2
23 - 116 BODY STRUCTURE LH
GAP AND FLUSH (Continued)
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
LH BODY STRUCTURE 23 - 119
OPENING DIMENSIONS (Continued)
Fig. 4 REAR DOOR OPENINGS - CONCORDE/300M Fig. 5 REAR DOOR OPENINGS - INTREPID
A - Center of radius at top to door latch hole. A - Center of radius at top to door latch hole.
B - Center of radius at bottom to center of radius at top. B - Center of radius at bottom to center of radius at top.
C - Center of radius at bottom to edge of quarter panel at C-pillar. C - Center of radius at bottom to edge of quarter panel at C-pillar.
D - Upper rear door hinge rear bolt hole to door latch hole. D - Upper rear door hinge rear bolt hole to door latch hole.
LH BODY STRUCTURE 23 - 121
OPENING DIMENSIONS (Continued)
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
LH BODY STRUCTURE 23 - 125
SEALER LOCATIONS (Continued)
Fig. 20 DECKLID
LH BODY STRUCTURE 23 - 137
SEALER LOCATIONS (Continued)
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
23 - 142 BODY STRUCTURE LH
STRUCTURAL ADHESIVE LOCATIONS (Continued)
Fig. 28 DOORS
LH BODY STRUCTURE 23 - 143
STRUCTURAL ADHESIVE LOCATIONS (Continued)
Fig. 29 DECKLID
23 - 144 BODY STRUCTURE LH
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
LH BODY STRUCTURE 23 - 145
WELD LOCATIONS (Continued)
DESCRIPTION FIGURE
FLOOR PAN 65
FLOOR PAN 66
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
23 - 146 BODY STRUCTURE LH
WELD LOCATIONS (Continued)
page page
page page
HEATING & AIR distilled water. This coolant must not be mixed with
other (green in color) coolants. If this occurs, a reduc-
CONDITIONING tion in the extended service interval will result. Refer
to Lubrication and Maintenance for service sched-
DESCRIPTION - ENGINE COOLING SYSTEM ules(Refer to LUBRICATION & MAINTENANCE -
REQUIREMENTS SPECIFICATIONS).
To maintain the performance level of the HVAC
system, the engine cooling system must be properly CAUTION:
maintained. Refer to Cooling for more information- Do not add additional inhibitors, anti-rust products,
(Refer to 7 - COOLING - OPERATION). or soluble oil (sold as “water pump lubricants”).
The use of a bug screen is not recommended. Any These products may not be compatible with the
obstructions in front of the radiator or condenser can engine coolant.
reduce the performance of the A/C and/or engine cool-
Refer to Cooling for cooling system procedures(Re-
ing system.
fer to 7 - COOLING - STANDARD PROCEDURE).
WARNING:
DO NOT OPEN COOLING SYSTEM WHEN HOT AS DIAGNOSIS AND TESTING
PERSONAL INJURY OR DAMAGE TO VEHICLE MAY
RESULT.
DIAGNOSIS AND TESTING - A/C
PERFORMANCE TEST
OPERATION - ENGINE COOLING SYSTEM The air conditioning system is designed to remove
REQUIREMENTS heat and humidity from the air entering the passen-
The engine cooling system is designed to develop ger compartment. The evaporator, located in the
internal pressure of 97 to 123 kPa (14 to 18 psi). HVAC unit, is cooled to temperatures near the freez-
Wait 15 minutes (after the engine is shut off), or ing point. As warm damp air passes over the fins in
until safe temperature and pressure is attained, the evaporator, moisture in the air condenses to
before opening the cooling system. Refer to Coolin- water, dehumidifying the air. High humidity reduces
g(Refer to 7 - COOLING - OPERATION). Coolant the evaporator’s ability to cool the air. During periods
temperature can be checked using the scan tool of high heat and humidity, an air conditioning sys-
(DRBIIIt). tem will be less effective. With the a/c heater control
When additional coolant is needed, it should be set to RECIRC, only air from the passenger compart-
added to the coolant pressure bottle. Use only 50/50 ment passes through the evaporator. As the passen-
mix of Mopart Antifreeze/Coolant, 5 Year/100,000 ger compartment air dehumidifies, A/C performance
Mile Formula (orange in color), or the equivalent and levels rise.
24 - 2 HEATING & AIR CONDITIONING LH
HEATING & AIR CONDITIONING (Continued)
PERFORMANCE TEST PROCEDURE • Set temperature to the LO position
Before performing the following procedure, (Refer • Push panel mode button
to 24 - HEATING & AIR CONDITIONING/PLUMB- • Push RECIRC (Recirculation) button (A/C and
ING - WARNING). Air temperature in test room and RECIRC symbols should be lit)
in vehicle must be 21° C (70°F) minimum for this
test. NOTE: The word MANUAL should appear in the ATC
display, confirming that the system is set manually.
NOTE: When connecting the service equipment
coupling to the line fitting, verify that the valve of (3) Start engine and hold at 1000 rpm with A/C
the coupling is fully closed. This will reduce the clutch engaged.
amount of effort required to make the connection. (4) Engine should be warmed up with doors and
windows closed.
(1) Connect a tachometer and manifold gauge set (5) Insert a thermometer in the left center A/C
or an A/C Charging/Recycling Station. outlet and operate the engine for five minutes. The
(2) Set controls: A/C clutch may cycle depending on ambient condi-
tions.
MTC (Manual Temperature Control) System: (6) With the A/C clutch engaged, compare the
• A/C ON discharge air temperature to the A/C Performance
• Panel Recirculation Temperature table.
• Temperature to full cold
• High blower
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.
LH HEATING & AIR CONDITIONING 24 - 3
HEATING & AIR CONDITIONING (Continued)
TEMPERATURE REFERENCE TABLE tool or the vehicles own control head display. Refer to
the DRBIIIt menu for checking Diagnostic Trouble
Ambient Temp. Minimum Outlet Codes (DTC’s). Note that there are three DTC tables.
Floor Temp. The ATC and MTC DTC table contain faults that are
common to both the ATC and the MTC system. The
Celsius Fahrenheit Celsius Fahrenheit same diagnosis can be used for both systems. The
15.5° 60° 62.2° 144° DTC’s cover operation of the climate control unit
21.1° 70° 63.8° 147° actuators, doors, evaporator temperature sensor,
ambient temperature sensor and the A/C refrigerant
26.6° 80° 65.5° 150°
system. The MTC DTC table covers Fault Codes that
32.2° 90° 67.2° 153° are for the MTC Control Head and wiring and are
not used on an ATC system. The ATC DTC table has
If the floor outlet air temperature is insufficient, DTC’s for ATC Head Communications, In-Car Tem-
refer to Cooling for specifications(Refer to 7 - COOL- perature Sensor and Sun Sensor which are not in a
ING - DIAGNOSIS AND TESTING). Both heater MTC system.
hoses should be HOT to the touch (coolant return Some conditions of low battery voltage or
hose should be slightly cooler than the supply hose). extremely cold weather can generate a DTC for the
If coolant return hose is much cooler than the supply climate control system actuators, evaporator probe,
hose, locate and repair engine coolant flow obstruc- in-car temperature sensor (ATC), or ambient temper-
tion in heater system. ature sensor, even in a properly operating system. It
is recommended that all the DTC’s be checked as fol-
POSSIBLE LOCATIONS OR CAUSE OF lows to assure a part is faulty.
OBSTRUCTED COOLANT FLOW
(1) Pinched or kinked heater hoses. Climate Control Sensor DTC Check
(2) Improper heater hose routing. (1) Clear the DTC.
(3) Plugged heater hoses or supply and return (2) Operate the HVAC system with the engine run-
ports at cooling system connections, refer to Cooling. ning for a minimum of 30 seconds.
(4) Plugged heater core. (3) Check for DTC’s.
(5) Air locked heater core. (4) Perform diagnostics if the DTC appears again.
(6) If coolant flow is verified and outlet tempera- (Refer to Appropriate Diagnostic Information)
ture is insufficient, a mechanical problem may exist.
Climate Control Actuator Check.
POSSIBLE LOCATION OR CAUSE OF INSUFFICIENT (1) Clear the DTC.
HEAT (2) Perform HVAC system calibration. (Refer to 24
(1) Obstructed cowl air intake. - HEATING & AIR CONDITIONING - STANDARD
(2) Obstructed heater system outlets. PROCEDURE - HVAC SYSTEM CALIBRATION)
(3) Blend door not functioning properly. (3) Perform diagnostics if the DTC appears again.
(Refer to Appropriate Diagnostic Information)
TEMPERATURE CONTROL If a DTC does not appear when using the proce-
If temperature cannot be adjusted with the TEMP dures above, check the history of the vehicle for a low
knob/button on the control panel, the following could battery condition, or ambient temperatures below
require service: 40°F. Removing connections without disconnecting
(1) Blend door binding. the battery may also generate a DTC on a good part.
(2) Faulty blend door actuator. The battery should always be disconnected when ser-
(3) Improper engine coolant temperature. vicing electrical parts.
(4) Faulty A/C Heater Control. (Refer to Appropri-
ate Diagnostic Information)
Low psi Control A/C pressure Opens < 29.4 Draw 2.2 amps @ 12
transducer, line psi PCM input V ±0.5V
High psi Control mounted Opens > 431.0 Gap 0.0149 - 0.0269
psi PCM input DRB IIIT
Forced Recirc System forced BCM steps Reads TPS, RPM, A/C
Mode into Recirc at HVAC into switch test
high pressures recirc at 375 Actuators Mode doors,
psi, steps out at clutch and fan
325 psi relays
Control Head Manual type BCM
diagnostics
TORQUE SPECIFICATIONS
TORQUE SPECIFICATIONS
CONTROLS
TABLE OF CONTENTS
page page
A/C COMPRESSOR CLUTCH engage and disengage the compressor from the
engine serpentine accessory drive belt.
DESCRIPTION
The compressor clutch assembly consists of a sta-
OPERATION
When the clutch coil is energized, it magnetically
tionary electromagnetic coil, a hub bearing and pul-
draws the clutch into contact with the pulley and
ley assembly, and a clutch plate. The electromagnetic
drives the compressor shaft. When the coil is not
coil unit and the hub bearing and pulley assembly
energized, the pulley freewheels on the clutch hub
are each retained on the nose of the compressor front
bearing, which is part of the pulley. The compressor
housing with snap rings. The clutch plate is retained
clutch and coil are the only serviced parts on the
with a bolt. These components provide the means to
compressor.
LH CONTROLS 24 - 9
A/C COMPRESSOR CLUTCH (Continued)
The compressor clutch engagement is controlled by STANDARD PROCEDURE
several components: the a/c heater control head (ATC
or MTC), the evaporator temperature sensor, the a/c INSPECTION
pressure transducer, the compressor clutch relay, and Examine the friction surfaces of the clutch pulley
the Powertrain Control Module (PCM). The PCM and the front plate for wear. The pulley and front
may delay compressor clutch engagement for up to plate should be replaced if there is excessive wear or
thirty seconds. Refer to Electronic Control Modules scoring.
for more information on the PCM controls. If the friction surfaces are oily, inspect the shaft
and nose area of the compressor for oil. Remove the
DIAGNOSIS AND TESTING - COMPRESSOR felt from the front cover. If the felt is saturated with
CLUTCH COIL oil, the shaft seal is leaking and the compressor must
For circuit descriptions and diagrams, (Refer to be replaced.
Appropriate Wiring Information). The battery must Check the clutch pulley bearing for roughness or
be fully-charged before performing the following excessive leakage of grease. Replace the bearing, if
tests. Refer to Battery for more information. required.
(1) Connect an ammeter (0 to 10 ampere scale) in
series with the clutch coil terminal. Use a voltmeter STANDARD PROCEDURE - A/C COMPRESSOR
(0 to 20 volt scale) with clip-type leads for measuring CLUTCH BREAK-IN
the voltage across the battery and the compressor After new clutch installation, cycle the A/C clutch
clutch coil. 20 times (5 seconds ON and 5 seconds OFF). During
(2) In A/C, mix, defrost and the blower motor this procedure, set the system to the A/C mode,
switch in the lowest speed position, start the engine engine rpm at 1500-2000, and high blower speed.
and run it at normal idle. This procedure (burnishing) will seat the opposing
(3) The compressor clutch coil voltage should read friction surfaces and provide a higher clutch torque
within 0.2 volts of the battery voltage. If there is capability.
voltage at the clutch coil, but the reading is not
within 0.2 volts of the battery voltage, test the clutch NOTE: Excessive clutch gap will result in clutch
coil feed circuit for excessive voltage drop and repair slippage or non-engagement.
as required. If there is no voltage reading at the
clutch coil, use a DRBIIIt scan tool and (Refer to
Appropriate Diagnostic Information) for testing of the REMOVAL
compressor clutch circuit. The following components The refrigerant system can remain fully-charged
must be checked and repaired as required before you during compressor clutch, pulley, or coil replacement.
can complete testing of the clutch coil: The compressor clutch can be serviced in the vehicle.
• Fuses in the junction block and the Power Dis- (1) Disconnect and isolate the battery negative
tribution Center (PDC) cable.
• A/C heater control head (2) Remove the serpentine drive belt(Refer to 7 -
• Compressor clutch relay COOLING/ACCESSORY DRIVE/DRIVE BELTS -
• A/C pressure transducer REMOVAL) or (Refer to 7 - COOLING/ACCESSORY
• Evaporator temperature sensor DRIVE/DRIVE BELTS - REMOVAL).
• Powertrain Control Module (PCM). (3) Unplug the compressor clutch coil wire harness
(4) The compressor clutch coil is acceptable if the connector.
current draw measured at the clutch coil is approxi- (4) Remove the bolts that secure the compressor to
mately 2.2 amperes with the electrical system volt- the mounting bracket.
age at 11.5 to 12.5 volts. This should only be checked (5) Remove the compressor from the mounting
with the work area temperature at 21° C (70° F). If bracket. Support the compressor in the engine com-
system voltage is more than 12.5 volts, add electrical partment while servicing the clutch.
loads by turning on electrical accessories until the (6) Remove the compressor shaft bolt (Fig. 1). A
system voltage drops below 12.5 volts. band type oil filter removal tool can be placed around
(a) If the clutch coil current reading is four the clutch plate to aid in bolt removal.
amperes or more, the coil is shorted and should be (7) Tap the clutch plate with a plastic hammer and
replaced. remove clutch plate and shim(s) (Fig. 2).
(b) If the clutch coil current reading is zero, the
coil is open and should be replaced. CAUTION: Do not use screwdrivers between the
clutch plate assembly and pulley to remove front
plate as this may damage the front plate assembly.
24 - 10 CONTROLS LH
A/C COMPRESSOR CLUTCH (Continued)
(8) Remove pulley retaining snap ring with Snap
Ring Pliers (C-4574), and slide pulley assembly off of
compressor (Fig. 3).
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.
NOTE: The bevel side of the snap ring must be fac- (9) Install the accessory drive belts (Refer to 7 -
ing outward. COOLING/ACCESSORY DRIVE/DRIVE BELTS -
INSTALLATION) or (Refer to 7 - COOLING/ACCES-
(5) If the original front plate assembly and pulley SORY DRIVE/DRIVE BELTS - INSTALLATION).
assembly are to be reused, the old shim(s) can be
used. If not, place a trial stack of shims, 2.54 mm
(0.10 in.) thick, on the shaft against the shoulder. A/C COMPRESSOR CLUTCH
(6) Install front plate assembly onto shaft. RELAY
(7) If installing a new front plate and/or pulley
assembly, the gap between front plate and pulley face DESCRIPTION
must be checked. Use the following procedure: The compressor clutch relay is located in the Power
(a) Attach a dial indicator to front plate so that Distribution Center (PDC) in the engine compart-
movement of the plate can be measured. ment. Refer to the PDC label for relay identification
(b) With the dial indicator zeroed on the front and location.
plate, energize the clutch and record the amount of
movement. OPERATION
(c) The readings should be 0.35 to 0.65 mm The a/c compressor clutch relay is a electromechan-
(0.014 to 0.026 in.). If proper reading is not ical device that switches battery current to the a/c
obtained, add or subtract shims until desired read- compressor clutch coil when the Powertrain Control
ing is obtained. Module (PCM) grounds the coil side of the relay. The
(8) Install compressor shaft bolt. Tighten to 17.5 ± PCM responds to inputs from the a/c heater control
2 N·m (155 ± 20 in. lbs.). (Manual Temperature Control, or Automatic Temper-
ature Control) , the Body Control Module (BCM), and
NOTE: Shims may compress after tightening shaft
the a/c pressure transducer.
nut. Check air gap in four or more places to verify if
The compressor clutch relay cannot be repaired
air gap is still correct. Spin pulley for final check.
and, if faulty or damaged, it must be replaced.
24 - 12 CONTROLS LH
A/C COMPRESSOR CLUTCH RELAY (Continued)
DIAGNOSIS AND TESTING - A/C COMPRESSOR pressor clutch relay output circuit cavity of the com-
pressor clutch coil wire harness connector. If OK, go
CLUTCH RELAY
to Step 4. If not OK, repair the open circuit as
required.
RELAY TEST
(4) The relay coil battery terminal (86) is con-
The compressor clutch relay (Fig. 6) is located in
nected to the fused ignition switch output (run/start)
the Power Distribution Center (PDC). Refer to the
circuit. There should be battery voltage at the cavity
PDC label for relay identification and location.
for relay terminal 86 with the ignition switch in the
Remove the relay from the PDC to perform the fol-
On position. If OK, go to Step 5. If not OK, repair the
lowing tests:
open circuit to the fuse in the junction block as
(1) A relay in the de-energized position should
required.
have continuity between terminals 87A and 30, and
(5) The coil ground terminal cavity (85) is switched
no continuity between terminals 87 and 30. If OK, go
to ground through the Powertrain Control Module
to Step 2. If not OK, replace the faulty relay.
(PCM). There should be continuity between this cav-
(2) Resistance between terminals 85 and 86 (elec-
ity and the A/C compressor clutch relay control cir-
tromagnet) should be 75 ± 5 ohms. If OK, go to Step
cuit cavity of the PCM wire harness connector C
3. If not OK, replace the faulty relay.
(gray) at all times. If not OK, repair the open circuit
(3) Connect a battery to terminals 85 and 86.
as required.
There should now be continuity between terminals
30 and 87, and no continuity between terminals 87A
and 30. If OK, see Relay Circuit Test in the Diagno-
REMOVAL
(1) Disconnect and isolate the battery negative
sis and Testing section of this group. If not OK,
cable.
replace the faulty relay.
(2) Remove the cover from the Power Distribution
Center (PDC) (Fig. 7).
INSTALLATION
(1) Install the compressor clutch relay by aligning
the relay terminals with the cavities in the PDC and
pushing the relay firmly into place.
(2) Install the PDC cover.
(3) Connect the battery negative cable.
(4) Test the relay operation.
INSTALLATION
(1) Install the a/c pressure transducer on the dis- POWER MODULE
charge line fitting and tighten to 6 N·m (50 in. lbs.).
(2) Plug in the wire harness connector to the a/c DESCRIPTION
pressure transducer. The blower motor power module is only used in
(3) Connect the battery negative cable to the vehicles equipped with Automatic Temperature Con-
remote battery post. trol (ATC). It is located on the lower right side of the
HVAC unit housing, and is controlled by the Body
Control Module (BCM).
AMBIENT TEMP SENSOR
OPERATION
REMOVAL The power module receives pulse width modulated
The ambient air temperature sensor is located on (PWM) signals from the BCM. The power module
the inside of the right front bumper beam (Fig. 11). varies voltage to the blower motor for different
This sensor will inform the ATC system of the ambi- blower speeds based on the ATC software. There are
ent temperature outside the vehicle. This sensor is 14 selectable speeds, while the Auto mode provides
used by the ATC system to adjust blower speed, tem- 256 variations.
perature offsets, evaporator temperatures and mode
control.
(1) Remove sensor mounting screw.
(2) Disconnect sensor wiring connector.
INSTALLATION
(1) Connect the sensor wiring harness connector.
(2) Install the sensor fastener screw and tighten to
2.2 N·m (20 in. lbs.).
LH CONTROLS 24 - 15
POWER MODULE (Continued)
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 termi-
nal to the remote battery post(Refer to 8 - ELECTRI-
CAL/BATTERY SYSTEM/CABLES - INSTALLATION).
Fig. 12 EVAPORATOR TEMPERATURE SENSOR SET
EVAPORATOR TEMPERATURE POINT
EVAPORATOR TEMPERATURE SENSOR SET POINT
SENSOR AMBIENT TEMPERATURE A/C CLUTCH OFF
SENSOR READING °F (° C) EVAPORATOR TEMPERATURE
SET POINT ° F (° C)
DESCRIPTION 185 (85) 31 (-0.5)
The evaporator temperature sensor is a tempera- 100 (37.7) 31 (-0.5)
ture sensing element located at the coldest point on 77 (25) 34 (1.1)
the face of the evaporator. The evaporator tempera- 60 (15.5) 35 (1.6)
ture sensor prevents condensate water on the evapo- -70 (-56.6) 36 (2.2)
rator coil from freezing which can block airflow. The
probe is a thermistor inside a metal tube which is
wedged between the evaporator fins. The metal tube
is tightly held by the evaporator fins so that the ther-
LH CONTROLS 24 - 17
EVAPORATOR TEMPERATURE SENSOR (Continued)
INSTALLATION
The new probe must not go into the same
hole (in the evaporator coil) that the old probe
was removed. Fig. 14 ATC IN-CAR TEMPERATURE SENSOR
(1) The evaporator is manufactured with three 1 - ATC IN-CAR TEMPERATURE SENSOR
holes for probe insertion. Insert the probe in the
uppermost hole.
(2) Insert the access plate inside the HVAC hous- OPERATION
ing and orientate it so that the locking tab is one- Air drawn from the passenger compartment by the
quarter turn clockwise to where the tab snaps into in-car sensor aspirator motor assembly, and flows
the HVAC case detent. Note that the plate will be over the thermistor. The in-car sensor thermistor
flush with the outside of the HVAC housing. changes resistance with air temperature. The BCM
(3) Turn the plate one-quarter turn counter clock- measures this resistance and calculates the tempera-
wise to seat the locking tab in the HVAC case detent. ture of the air drawn into the ATC Control. The ATC
(4) Connect the wiring harness connector for the system then makes adjustments to maintain the opti-
evaporator probe. mum passenger compartment comfort. Refer to the
(5) Install the right under panel silencer. ATC In-Car Sensor Aspirator Motor Operation table
for when the ATC Sensor is operating.
24 - 18 CONTROLS LH
IN-CAR TEMPERATURE SENSOR (Continued)
REMOVAL
WARNING: ON VEHICLES EQUIPPED WITH AIR-
BAGS, DISABLE THE AIRBAG SYSTEM BEFORE
ATTEMPTING ANY STEERING WHEEL, STEERING
COLUMN, 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 AN ACCIDENTAL
Fig. 16 BLEND DOOR ACTUATOR LOCATION AIRBAG DEPLOYMENT AND POSSIBLE PERSONAL
1 - MODE DOOR ACTUATOR INJURY.
2 - RECIRCULATION DOOR ACTUATOR
3 - EVAPORATOR TEMPERATURE SENSOR (1) Open hood and disconnect the negative battery
4 - BLOWER MOTOR RESISTOR BLOCK/POWER MODULE cable remote terminal from the remote battery post
5 - BLEND DOOR ACTUATOR (Refer to 8 - ELECTRICAL/BATTERY SYSTEM/CA-
6 - HVAC PLENUM CONNECTOR BLES - REMOVAL).
(2) Remove the left and right underpanel ducts.
(4) Remove one screw from actuator on the left (3) Remove the floor console(Refer to 23 - BODY/
side. INTERIOR/FLOOR CONSOLE - REMOVAL). Refer
(5) Pull the actuator straight down from shaft and to Body for the procedures.
disconnect the electrical connection. Upon removal, (4) Remove the center floor heat adaptor duct.
note the shaft position of the actuator, because the (5) Remove the rear seat heat forward adaptor
shaft on this motor is keyed. When installing a new duct.
actuator, its shaft must be positioned in the same (6) Loosen the center support bracket and pry
location. rearward to gain access to the actuator.
(7) Remove the actuator retaining screws. Then
INSTALLATION pull the actuator straight down. Upon removal, note
(1) Connect the wire harness connector to the the shaft position of the actuator, because the shaft
blend door actuator. on this motor is keyed. When installing a new actua-
(2) Install the blend door actuator on the HVAC tor, its shaft must be positioned in the same location
housing, making sure its keyed shaft is positioned (Fig. 17).
properly. (8) Remove the electrical connection on the actua-
(3) Install the three fastener screws and tighten to tor.
2.2 N·m (20 in. lbs.).
(4) Install the left and right underpanel silencer/
ducts.
(5) Connect the negative battery cable remote termi-
nal to the remote battery post(Refer to 8 - ELECTRI-
CAL/BATTERY SYSTEM/CABLES - INSTALLATION).
24 - 20 CONTROLS LH
MODE DOOR ACTUATOR (Continued)
RECIRCULATION DOOR
ACTUATOR
REMOVAL
WARNING: ON VEHICLES EQUIPPED WITH AIR-
BAGS, DISABLE THE AIRBAG SYSTEM BEFORE
ATTEMPTING ANY STEERING WHEEL, STEERING
COLUMN, 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 AN ACCIDENTAL
AIRBAG DEPLOYMENT AND POSSIBLE PERSONAL
INJURY.
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 termi- Fig. 18 RECIRCULATION DOOR ACTUATOR
nal to the remote battery post(Refer to 8 - ELECTRI- LOCATION
CAL/BATTERY SYSTEM/CABLES - INSTALLATION). 1 - MODE DOOR ACTUATOR
2 - RECIRCULATION DOOR ACTUATOR
3 - EVAPORATOR TEMPERATURE SENSOR
4 - BLOWER MOTOR RESISTOR BLOCK/POWER MODULE
5 - BLEND DOOR ACTUATOR
6 - HVAC PLENUM CONNECTOR
REMOVAL INSTALLATION
(1) Connect the wiring harness connector to the
WARNING: ON VEHICLES EQUIPPED WITH AIR- sensor and position in the vehicle.
BAGS, DISABLE THE AIRBAG SYSTEM BEFORE (2) Install the two sensor fasteners.
ATTEMPTING ANY STEERING WHEEL, STEERING (3) Install the instrument panel top cover(Refer to
COLUMN, OR INSTRUMENT PANEL COMPONENT 23 - BODY/INSTRUMENT PANEL/INSTRUMENT
DIAGNOSIS OR SERVICE. DISCONNECT AND ISO- PANEL TOP COVER - INSTALLATION).
LATE THE BATTERY NEGATIVE (GROUND) CABLE, (4) Connect the negative battery cable remote termi-
THEN WAIT TWO MINUTES FOR THE AIRBAG SYS- nal to the remote battery post(Refer to 8 - ELECTRI-
TEM CAPACITOR TO DISCHARGE BEFORE PER- CAL/BATTERY SYSTEM/CABLES - INSTALLATION).
FORMING FURTHER DIAGNOSIS OR SERVICE. THIS
IS THE ONLY SURE WAY TO DISABLE THE AIRBAG CAUTION: The sun sensor must protrude approxi-
SYSTEM. FAILURE TO TAKE THE PROPER PRE- mately 1/4 inch above the instrument panel top
CAUTIONS COULD RESULT IN AN ACCIDENTAL cover. This will ensure proper operation.
AIRBAG DEPLOYMENT AND POSSIBLE PERSONAL
INJURY. If the sensor does not protrude 1/4 inch, perform
the following procedure:
(1) Open the hood and disconnect the negative bat- • Confirm that the top cover is properly installed
tery cable remote terminal from the remote battery • Remove the top cover
post. • Remove fasteners from sun sensor
(2) Remove the instrument panel top cover(Refer • Install one 1/4-20 nut per fastener under the sun
to 23 - BODY/INSTRUMENT PANEL/INSTRUMENT sensor so that it is shimmed higher
PANEL TOP COVER - REMOVAL). • Reinstall the sun sensor. Do not overtighten
(3) Remove the two Sun Sensor mounting screws. screw. If a longer screw is required, use 8-15x1 inch.
(4) Lift the sensor out of the instrument panel and
disconnect the wiring.
(5) Remove the sensor from the vehicle.
LH DISTRIBUTION 24 - 23
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 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 37
WARNING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 28 INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . 38
CAUTION A/C EVAPORATOR
CAUTIONS . . . . . . . . . . . . . . . . . . . . . . . . . . 28 REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 38
REFRIGERANT SYSTEM HOSES/LINES/ INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . 39
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 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40
STANDARD PROCEDURE - REFRIGERANT INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . 40
RECOVERY . . . . . . . . . . . . . . . . . . . . . . . . . . 30 HEATER CORE
STANDARD PROCEDURE - REFRIGERANT REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40
SYSTEM EVACUATE . . . . . . . . . . . . . . . . . . . 30 INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . 41
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
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)
INSTALLATION
A/C DISCHARGE LINE
WARNING: REVIEW THE WARNINGS IN THE FRONT REMOVAL
OF THIS SECTION BEFORE PERFORMING THE
WARNING: REVIEW THE WARNINGS IN THE FRONT
FOLLOWING OPERATION. (Refer to 24 - HEATING &
OF THIS SECTION BEFORE PERFORMING THE
AIR CONDITIONING/PLUMBING - WARNING)
FOLLOWING OPERATION. (Refer to 24 - HEATING &
Any kinks or sharp bends in the refrigerant plumb- AIR CONDITIONING/PLUMBING - WARNING)
ing will reduce the capacity of the entire air condi-
(1) Open the hood and disconnect the negative bat-
tioning system. Kinks and sharp bends reduce the
tery cable remote terminal from the remote battery
flow of refrigerant in the system. A good rule for the
post.
flexible hose refrigerant lines is to keep the radius of
(2) Recover the refrigerant from the system. (Refer
all bends at least ten times the diameter of the hose.
to 24 - HEATING & AIR CONDITIONING/PLUMB-
In addition, the flexible hose refrigerant lines should
ING - STANDARD PROCEDURE -REFRIGERANT
be routed so they are at least 80 millimeters (3
RECOVERY)
inches) from the exhaust manifold.
(3) Disconnect the a/c pressure transducer wire
High pressures are produced in the refrigerant sys-
harness (Fig. 7) and (Fig. 8).
tem when the air conditioning compressor is operat-
(4) Remove the a/c pressure transducer. (Refer to
ing. Extreme care must be exercised to make sure
24 - HEATING & AIR CONDITIONING/CONTROLS/
that each of the refrigerant system connections is
A/C PRESSURE TRANSDUCER - REMOVAL)
pressure-tight and leak free. It is a good practice to
(5) Disconnect the discharge line at the compressor
inspect all flexible hose refrigerant lines at least once
using an M13 Hex wrench for 2.7L, and a 6 mm
a year to make sure they are in good condition and
allen wrench for 3.2/3.5L.
properly routed.
(1) Install the auxiliary transmission cooler in the CAUTION: Cap all lines that are not being replaced
same position on the condenser with new retaining and cap the expansion valve tubes.
straps.
(2) Install the condenser in the vehicle. (6) Disconnect the discharge line at the A/C con-
(3) Install the two screws retaining the condenser denser using an M13 Hex wrench.
to the radiator. Tighten the screws to 10.5 N·m (95
in. lbs.). INSTALLATION
(4) Connect the liquid line to the condenser inlet.
Tighten the retaining nut to 23 N·m (17 ft. lbs.). WARNING: REVIEW THE WARNINGS IN THE FRONT
(5) Connect the discharge line to the condenser OF THIS SECTION BEFORE PERFORMING THE
outlet. Tighten the retaining nut to 23 N·m (17 ft. FOLLOWING OPERATION. (Refer to 24 - HEATING &
lbs.). AIR CONDITIONING/PLUMBING - WARNING)
(6) Install the retainer bracket and screw for the
auxiliary transmission cooler lines. Any kinks or sharp bends in the refrigerant plumb-
(7) Connect the auxiliary transmission cooler hose ing will reduce the capacity of the entire air condi-
fittings. tioning system. Kinks and sharp bends reduce the
flow of refrigerant in the system. A good rule for the
LH PLUMBING 24 - 35
A/C DISCHARGE LINE (Continued)
ing. Extreme care must be exercised to make sure
that each of the refrigerant system connections is
pressure-tight and leak free. It is a good practice to
inspect all flexible hose refrigerant lines at least once
a year to make sure they are in good condition and
properly routed.
(1) Connect the discharge line at the A/C con-
denser. Tighten retainer bolt to 23 N·m (17 ft. lbs.).
(2) Connect the discharge line at the compressor.
Tighten retainer bolt to 23 N·m (17 ft. lbs.).
(3) Install the a/c pressure transducer. (Refer to 24
- HEATING & AIR CONDITIONING/CONTROLS/
A/C PRESSURE TRANSDUCER - INSTALLATION)
(4) Plug the harness connector into the a/c pres-
sure transducer.
(5) Connect the negative battery cable remote ter-
minal to the remote battery post.
Fig. 7 A/C PRESSURE TRANSDUCER AND
(6) Evacuate the refrigerant system. (Refer to 24 -
DISCHARGE LINE - 3.2L/3.5L
HEATING & AIR CONDITIONING/PLUMBING -
1 - SERVICE PORTS
STANDARD PROCEDURE -REFRIGERANT SYS-
2 - SUCTION LINE
TEM EVACUATE)
3 - A/C PRESSURE TRANSDUCER AND CONNECTOR
4 - DISCHARGE LINE
(7) Charge the refrigerant system. (Refer to 24 -
5 - A/C COMPRESSOR CLUTCH ELECTRICAL CONNECTOR HEATING & AIR CONDITIONING/PLUMBING -
6 - A/C COMPRESSOR STANDARD PROCEDURE - REFRIGERANT SYS-
TEM CHARGE)
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)
INSTALLATION
WARNING: REVIEW THE WARNINGS IN THE FRONT
OF THIS SECTION BEFORE PERFORMING THE
FOLLOWING OPERATION. (Refer to 24 - HEATING &
AIR CONDITIONING/PLUMBING - WARNING)
LH PLUMBING 24 - 37
SUCTION 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)
(3) Remove the engine air inlet tube and air distri-
bution duct for access to the compressor lines. Fig. 12 SUCTION LINE 3.2L/3.5L
(4) Remove the bolt holding the line at the com-
1 - SUCTION LINE
pressor using a 6mm allen wrench (3.2/3.5L), or M10 2 - EXPANSION VALVE
Hex (2.7L) (Fig. 12) and (Fig. 13). 3 - LIQUID LINE
(5) Remove the line by pulling the rear end of the
line up out of the vehicle with the compressor end
following through the tie-rod area.
24 - 38 PLUMBING LH
SUCTION LINE (Continued)
(3) Install the engine air inlet tube and air distri-
bution duct(Refer to 9 - ENGINE/AIR INTAKE SYS-
TEM/AIR CLEANER ELEMENT - INSTALLATION).
(4) Connect the suction line to the expansion
valve. Tighten the retaining nut to 23 N·m (17 ft.
lbs.).
(5) Evacuate the refrigerant system. (Refer to 24 -
HEATING & AIR CONDITIONING/PLUMBING -
STANDARD PROCEDURE - REFRIGERANT SYS-
TEM EVACUATE)
(6) Charge the refrigerant system. (Refer to 24 -
HEATING & AIR CONDITIONING/PLUMBING -
STANDARD PROCEDURE - REFRIGERANT SYS-
TEM CHARGE)
A/C EVAPORATOR
REMOVAL
Fig. 13 SUCTION LINE 2.7L
1 - SERVICE PORT WARNING: ON VEHICLES EQUIPPED WITH AIR-
2 - SUCTION LINE BAGS, DISABLE THE AIRBAG SYSTEM BEFORE
3 - EXPANSION VALVE ATTEMPTING ANY STEERING WHEEL, STEERING
4 - LIQUID LINE COLUMN, OR INSTRUMENT PANEL COMPONENT
DIAGNOSIS OR SERVICE. DISCONNECT AND ISO-
INSTALLATION LATE THE BATTERY NEGATIVE (GROUND) CABLE,
THEN WAIT TWO MINUTES FOR THE AIRBAG SYS-
WARNING: REVIEW THE WARNINGS IN THE FRONT TEM CAPACITOR TO DISCHARGE BEFORE PER-
OF THIS SECTION BEFORE PERFORMING THE FORMING FURTHER DIAGNOSIS OR SERVICE. THIS
FOLLOWING OPERATION. (Refer to 24 - HEATING & IS THE ONLY SURE WAY TO DISABLE THE AIRBAG
AIR CONDITIONING/PLUMBING - WARNING) SYSTEM. FAILURE TO TAKE THE PROPER PRE-
CAUTIONS COULD RESULT IN AN ACCIDENTAL
Any kinks or sharp bends in the refrigerant plumb- AIRBAG DEPLOYMENT AND POSSIBLE PERSONAL
ing will reduce the capacity of the entire air condi- INJURY.
tioning system. Kinks and sharp bends reduce the
flow of refrigerant in the system. A good rule for the
flexible hose refrigerant lines is to keep the radius of WARNING: REVIEW THE WARNINGS IN THE FRONT
all bends at least ten times the diameter of the hose. OF THIS SECTION BEFORE PERFORMING THE
In addition, the flexible hose refrigerant lines should FOLLOWING OPERATION. (Refer to 24 - HEATING &
be routed so they are at least 80 millimeters (3 AIR CONDITIONING/PLUMBING - WARNING)
inches) from the exhaust manifold.
The HVAC housing must be removed from the
High pressures are produced in the refrigerant sys-
vehicle when replacing the evaporator.
tem when the air conditioning compressor is operat-
(1) Open the hood and disconnect the negative bat-
ing. Extreme care must be exercised to make sure
tery cable remote terminal from the remote battery
that each of the refrigerant system connections is
post.
pressure-tight and leak free. It is a good practice to
(2) Remove the HVAC housing from vehicle. (Refer
inspect all flexible hose refrigerant lines at least once
to 24 - HEATING & AIR CONDITIONING/DISTRI-
a year to make sure they are in good condition and
BUTION/HVAC HOUSING - REMOVAL)
properly routed.
(3) Remove the recirculation door actuator(Refer to
(1) Position the suction line in the vehicle.
24 - HEATING & AIR CONDITIONING/CONTROLS/
(2) Install the suction line fitting to the manifold
RECIRCULATION DOOR ACTUATOR - REMOVAL).
on the compressor. Tighten the mounting bolt to 23
(4) Remove the recirculation door and housing.
N·m (17 ft. lbs.). On a 2.7L, tighten the mid-line
(5) Remove the upper HVAC housing retaining
retaining nut and frame rail screw to 7 N·m (5 ft.
screws(Refer to 24 - HEATING & AIR CONDITION-
lbs.).
ING/DISTRIBUTION/HVAC HOUSING - DISAS-
SEMBLY).
LH PLUMBING 24 - 39
A/C EVAPORATOR (Continued)
(6) At the center of the HVAC housing, locate the (7) Install the recirculation door actuator. (Refer to
evaporator probe access plate. Using a flat blade pry 24 - HEATING & AIR CONDITIONING/CONTROLS/
tool, pull back on the locking tab. Twist the access RECIRCULATION DOOR ACTUATOR - INSTALLA-
plate counter clockwise one-quarter turn, and push TION)
the plate inside the HVAC housing. (8) Install the HVAC housing in the vehicle. (Refer
(7) Remove the upper half of the HVAC housing. to 24 - HEATING & AIR CONDITIONING/DISTRI-
(8) Lift the evaporator out of the lower housing. BUTION/HVAC HOUSING - INSTALLATION)
(9) Evacuate the A/C system(Refer to 24 - HEAT-
INSTALLATION ING & AIR CONDITIONING/PLUMBING - STAN-
DARD PROCEDURE).
WARNING: REVIEW THE WARNINGS IN THE FRONT (10) Charge the A/C system(Refer to 24 - HEAT-
OF THIS SECTION BEFORE PERFORMING THE ING & AIR CONDITIONING/PLUMBING - STAN-
FOLLOWING OPERATION. (Refer to 24 - HEATING & DARD PROCEDURE).
AIR CONDITIONING/PLUMBING - WARNING)
Any kinks or sharp bends in the refrigerant plumb- A/C EXPANSION VALVE
ing will reduce the capacity of the entire air condi-
tioning system. Kinks and sharp bends reduce the DESCRIPTION
flow of refrigerant in the system. A good rule for the The “H valve” type thermal expansion valve (TXV)
flexible hose refrigerant lines is to keep the radius of is located at the point where the refrigerant lines
all bends at least ten times the diameter of the hose. join the a/c evaporator on the engine compartment
In addition, the flexible hose refrigerant lines should side of the dash panel.
be routed so they are at least 80 millimeters (3 The expansion valve is a factory calibrated unit
inches) from the exhaust manifold. and cannot be adjusted or repaired. If faulty or dam-
High pressures are produced in the refrigerant sys- aged, the expansion valve must be replaced.
tem when the air conditioning compressor is operat-
ing. Extreme care must be exercised to make sure OPERATION
that each of the refrigerant system connections is High-pressure, high temperature liquid refrigerant
pressure-tight and leak free. It is a good practice to from the liquid line passes through the expansion
inspect all flexible hose refrigerant lines at least once valve orifice, converting it into a low-pressure, low-
a year to make sure they are in good condition and temperature mixture of liquid and gas before it
properly routed. enters the evaporator coil. A temperature sensor in
(1) Transfer the evaporator probe to the new evap- the expansion valve control head monitors the tem-
orator. Place the evaporator probe in the same loca- perature of the refrigerant leaving the evaporator coil
tion as on the previous evaporator(Refer to 24 - through the suction line, and adjusts the orifice size
HEATING & AIR CONDITIONING/CONTROLS/ at the liquid line to let the proper amount of refrig-
EVAPORATOR TEMPERATURE SENSOR - erant into the evaporator coil to meet the vehicle
INSTALLATION). cooling requirements. Controlling the refrigerant flow
(2) Place the evaporator in the lower HVAC hous- through the evaporator ensures that none of the
ing. refrigerant leaving the evaporator is still in a liquid
(3) Insert the acces plate inside the HVAC housing state, which could damage the compressor.
and orientate it so that the locking tab is one-quarter
turn clockwise to where the tab snaps into the HVAC DIAGNOSIS AND TESTING - A/C EXPANSION
case detent. Note that the plate will be flush with
the outside of the HVAC housing. VALVE
(4) Turn the plate one-quarter turn counter-clock- The expansion valve can fail in three different
wise to seat the locking tab in the HVAC case detent. positions (open, closed or restricted). Note, that in
(5) Place the top half of the HVAC housing on the each case, it is defective and requires replace-
lower half. Tighten fasteners to 2.2 N·m (20 in. ment.
lbs.)(Refer to 24 - HEATING & AIR CONDITION- In an Open Position: this will result in a noisy
ING/DISTRIBUTION/HVAC HOUSING - ASSEM- compressor or no cooling. The cause can be a broken
BLY). spring, broken ball or excessive moisture in the A/C
(6) Install the recirculation door and housing on system. If the spring or ball are found to be defective,
the HVAC housing and tighten the screws to 2.2 N·m replace the expansion valve. If excessive moisture is
(20 in. lbs.). found in the A/C system, recycle the refrigerant.
24 - 40 PLUMBING LH
A/C EXPANSION VALVE (Continued)
In a Closed Position: There will be low suction be routed so they are at least 80 millimeters (3
pressure and no cooling. This may be caused by a inches) from the exhaust manifold.
failed power dome or excessive moisture in the A/C High pressures are produced in the refrigerant sys-
system. If the power dome on the expansion valve is tem when the air conditioning compressor is operat-
found to be defective replace the expansion valve. If ing. Extreme care must be exercised to make sure
excessive moisture is found recycle the refrigerant. that each of the refrigerant system connections is
A Restricted Orifice: There will be low suction pressure-tight and leak free. It is a good practice to
pressure and no cooling. This may be caused by inspect all flexible hose refrigerant lines at least once
debris in the refrigerant system. If debris is believed a year to make sure they are in good condition and
to be the cause, recycle the refrigerant and replace properly routed.
the expansion valve and filter/drier. (1) Install the a/c expansion valve on the a/c evap-
orator. Tighten the fasteners to 23 N·m (17 ft. lbs.).
REMOVAL (2) Connect the lines to the expansion valve and
tighten the retaining nut to 23 N·m (17 ft. lbs.).
WARNING: REVIEW THE WARNINGS IN THE FRONT (3) Tighten the bolt at the receiver/drier to 13.6
OF THIS SECTION BEFORE PERFORMING THE N·m (10 ft. lbs.).
FOLLOWING OPERATION. (Refer to 24 - HEATING & (4) Install the engine air inlet tube and the air dis-
AIR CONDITIONING/PLUMBING - WARNING) tribution duct on vehicles equipped with 3.2/3.5 L
engine(Refer to 9 - ENGINE/AIR INTAKE SYSTEM/
(1) Recover the refrigerant from the system. (Refer AIR CLEANER ELEMENT - INSTALLATION).
to 24 - HEATING & AIR CONDITIONING/PLUMB- (5) Evacuate the refrigerant system. (Refer to 24 -
ING - STANDARD PROCEDURE -REFRIGERANT HEATING & AIR CONDITIONING/PLUMBING -
RECOVERY) STANDARD PROCEDURE - REFRIGERANT SYS-
(2) Remove the engine air inlet tube and the air TEM EVACUATE)
distribution duct on vehicles equipped with 3.2/3.5 L (6) Charge the refrigerant system. (Refer to 24 -
engine(Refer to 9 - ENGINE/AIR INTAKE SYSTEM/ HEATING & AIR CONDITIONING/PLUMBING -
AIR CLEANER ELEMENT - REMOVAL). STANDARD PROCEDURE - REFRIGERANT SYS-
(3) Remove one nut to the a/c lines at the expan- TEM CHARGE)
sion valve.
(4) Loosen the bolt at the receiver/drier to pivot
the lines away from the expansion valve. HEATER CORE
(5) Plug or cap the open end of the refrigerant
lines. REMOVAL
(6) Gently pull the a/c line out of the expansion
valve. WARNING: ON VEHICLES EQUIPPED WITH AIR-
(7) Remove two #30 torx bolts retaining the expan- BAGS, DISABLE THE AIRBAG SYSTEM BEFORE
sion valve to the a/c evaporator. ATTEMPTING ANY STEERING WHEEL, STEERING
(8) Remove the expansion valve from the vehicle. COLUMN, OR INSTRUMENT PANEL COMPONENT
DIAGNOSIS OR SERVICE. DISCONNECT AND ISO-
CAUTION: Always install new O-rings when replac- LATE THE BATTERY NEGATIVE (GROUND) CABLE,
ing the a/c expansion valve. THEN WAIT TWO MINUTES FOR THE AIRBAG SYS-
TEM CAPACITOR TO DISCHARGE BEFORE PER-
FORMING FURTHER DIAGNOSIS OR SERVICE. THIS
INSTALLATION IS THE ONLY SURE WAY TO DISABLE THE AIRBAG
SYSTEM. FAILURE TO TAKE THE PROPER PRE-
WARNING: REVIEW THE WARNINGS IN THE FRONT
CAUTIONS COULD RESULT IN AN ACCIDENTAL
OF THIS SECTION BEFORE PERFORMING THE
AIRBAG DEPLOYMENT AND POSSIBLE PERSONAL
FOLLOWING OPERATION. (Refer to 24 - HEATING &
INJURY.
AIR CONDITIONING/PLUMBING - WARNING)
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 to service the heater core.
LH PLUMBING 24 - 41
HEATER CORE (Continued)
(1) Open the hood and disconnect the negative bat- FOLLOWING OPERATION. (Refer to 24 - HEATING &
tery cable remote terminal from the remote battery AIR CONDITIONING/PLUMBING - WARNING)
post. (1) Recover the refrigerant from the system. (Refer
(2) Remove the HVAC unit housing from vehicle. to 24 - HEATING & AIR CONDITIONING/PLUMB-
(Refer to 24 - HEATING & AIR CONDITIONING/ ING - STANDARD PROCEDURE -REFRIGERANT
DISTRIBUTION/HVAC HOUSING - REMOVAL) RECOVERY)
(3) With the HVAC housing out of the vehicle, (2) Remove the engine air inlet tube and the air
remove (2) screws retaining the heater core. Then distribution duct on vehicles equipped with 3.2/3.5
pull the heater core out of the HVAC housing. liter engine(Refer to 9 - ENGINE/AIR INTAKE SYS-
TEM/AIR CLEANER ELEMENT - REMOVAL).
INSTALLATION (3) Remove one 8mm hex bolt to the receiver/drier
bracket.
WARNING: REVIEW THE WARNINGS IN THE FRONT (4) Remove the nut retaining the a/c lines to the
OF THIS SECTION BEFORE PERFORMING THE expansion valve.
FOLLOWING OPERATION. (Refer to 24 - HEATING & (5) Gently pry the receiver/drier bracket out of the
AIR CONDITIONING/PLUMBING - WARNING) strut tower.
(6) Remove one a/c line at the receiver/drier (from
(1) Install the heater core in the HVAC housing. the condenser).
Tighten the retaining screws to 2.2 N·m (20 in. lbs.). (7) Remove the receiver/drier from vehicle.
(2) Install the HVAC housing in the vehicle. (Refer (8) Remove the small line from the receiver/drier
to 24 - HEATING & AIR CONDITIONING/DISTRI- to the expansion valve to install on the new receiver/
BUTION/HVAC HOUSING - INSTALLATION) drier.
(3) Connect the negative battery cable remote ter-
minal to the remote battery post. NOTE: Always install new O-rings when replacing
filter/drier.
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
the vehicle. The receiver/drier incorporates a sight WARNING: REVIEW THE WARNINGS IN THE FRONT
glass for visual diagnosis of the refrigerant system. OF THIS SECTION BEFORE PERFORMING THE
FOLLOWING OPERATION. (Refer to 24 - HEATING &
OPERATION AIR CONDITIONING/PLUMBING - WARNING)
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.
The A/C refrigerant must be removed from the sys-
High pressures are produced in the refrigerant sys-
tem before removing the receiver/drier using a refrig-
tem when the air conditioning compressor is operat-
erant recovery machine. Replace the receiver/drier if
ing. Extreme care must be exercised to make sure
an A/C system is left open for an extended period of
that each of the refrigerant system connections is
time.
pressure-tight and leak free. It is a good practice to
The receiver/drier cannot be repaired and, if faulty,
inspect all flexible hose refrigerant lines at least once
must be replaced.
a year to make sure they are in good condition and
properly routed.
REMOVAL
NOTE: Upon installation, loosely fit all parts and
WARNING: REVIEW THE WARNINGS IN THE FRONT
lines together before individually tightening them to
OF THIS SECTION BEFORE PERFORMING THE
prevent damage.
24 - 42 PLUMBING LH
RECEIVER / DRIER (Continued)
(1) Install the small line from the receiver/drier to REFRIGERANT OIL
expansion valve on the new receiver/drier.
(2) Install the reveiver/drier in the vehicle.
DESCRIPTION
(3) Install the a/c line at the receiver/drier. Tighten
The refrigerant oil used in R-134a refrigerant sys-
the fastener to 13.6 N·m (10 ft. lbs.).
tems is a synthetic-based, PolyAlkylene Glycol (PAG),
(4) Install the receiver/drier bracket in the strut
wax-free lubricant. Mineral-based R-12 refrigerant
tower.
oils are not compatible with PAG oils, and should
(5) Install the nut retaining the a/c line to the
never be introduced to an R-134a refrigerant system.
expansion valve. Tighten to 23 N·m (17 ft. lbs.).
There are different PAG oils available, and each
(6) Install the bolt to the receiver/drier bracket.
contains a different additive package. The 10PA17
(7) Install the engine air inlet tube and the air dis-
compressor used in this vehicle is designed to use an
tribution duct on vehicles equipped with 3.2/3.5 L
ND8 PAG refrigerant oil. Use only refrigerant oil of
engine(Refer to 9 - ENGINE/AIR INTAKE SYSTEM/
this same type to service the refrigerant system.
AIR CLEANER ELEMENT - INSTALLATION).
(8) Evacuate the refrigerant system. (Refer to 24 -
HEATING & AIR CONDITIONING/PLUMBING -
OPERATION
After performing any refrigerant recovery or recy-
STANDARD PROCEDURE -REFRIGERANT SYS-
cling operation, always replenish the refrigerant sys-
TEM EVACUATE)
tem with the same amount of the recommended
(9) Charge the refrigerant system. (Refer to 24 -
refrigerant oil as was removed. Too little refrigerant
HEATING & AIR CONDITIONING/PLUMBING -
oil can cause compressor damage, and too much can
STANDARD PROCEDURE - REFRIGERANT SYS-
reduce air conditioning system performance.
TEM CHARGE)
PAG refrigerant oil is much more hygroscopic than
mineral oil, and will absorb any moisture it comes
REFRIGERANT into contact with, even moisture in the air. The PAG
oil container should always be kept tightly capped
DESCRIPTION until it is ready to be used. After use, recap the oil
The refrigerant used in this air conditioning sys- container immediately to prevent moisture contami-
tem is a HydroFluoroCarbon (HFC), type R-134a. nation.
Unlike R-12, which is a ChloroFluoroCarbon (CFC),
R-134a refrigerant does not contain ozone-depleting STANDARD PROCEDURE - REFRIGERANT OIL
chlorine. R-134a refrigerant is a non-toxic, non-flam- LEVEL
mable, clear, and colorless liquefied gas. It is important to have the correct amount of lubri-
Even though R-134a does not contain chlorine, it cant in the a/c system to ensure proper lubrication of
must be reclaimed and recycled just like CFC-type the compressor. Too little lubricant will result in
refrigerants. This is because R-134a is a greenhouse damage to the compressor. Too much lubricant will
gas and can contribute to global warming. reduce the cooling capacity of the system and conse-
quently result in higher discharge air temperatures.
OPERATION The lubricant used in the compressor is polyalka-
R-134a refrigerant is not compatible with R-12 lene glycol PAG lubricant. Only the refrigerant lubri-
refrigerant in an air conditioning system. Even a cant approved for use with this vehicle (ND8 PAG
small amount of R-12 added to an R-134a refrigerant oil) should be used to service the system. Do not use
system will cause compressor failure, refrigerant oil any other lubricant. The lubricant container should
sludge or poor air conditioning system performance. be kept tightly capped until it is ready for use.
In addition, the PolyAlkylene Glycol (PAG) synthetic Refrigerant lubricant will quickly absorb any mois-
refrigerant oils used in an R-134a refrigerant system ture it comes in contact with.
are not compatible with the mineral-based refriger- It is not necessary to check or add lubricant unless
ant oils used in an R-12 refrigerant system. it has been lost. Lubricant loss at the leak point will
R-134a refrigerant system service ports, service be evident by the presence of a wet, shiny surface
tool couplers and refrigerant dispensing bottles have around the leak.
all been designed with unique fittings to ensure that
an R-134a system is not accidentally contaminated REFRIGERANT OIL LEVEL CHECK
with the wrong refrigerant (R-12). There are also When an air conditioning system is first assem-
labels posted in the engine compartment of the vehi- bled, all components (except the compressor) are
cle and on the compressor identifying to service tech- refrigerant oil free. After the system has been
nicians that the air conditioning system is equipped charged with (R-134a) refrigerant and operated, the
with R-134a.
LH PLUMBING 24 - 43
REFRIGERANT OIL (Continued)
oil in the compressor is dispersed through the lines (4) From the suction and discharge ports on top of
and components. The evaporator, condenser, and the compressor, drain the lubricant from the com-
receiver/drier will retain a significant amount of oil. pressor.
Refer to the A/C Component Refrigerant Oil Capaci- (5) Add the system capacity minus the capacity of
ties table. When a component is replaced, the speci- the components that have not been replaced. Refer to
fied amount of refrigerant oil must be added. When the A/C Component Refrigerant Oil Capacities chart
the compressor is replaced, the amount of oil that is above. Add lubricant through the suction and dis-
retained in the rest of the system must be drained charge ports on compressor. This is not to exceed 150
from the replacement compressor. The oil capacity of ml. (5.00 oz.) in total.
the system, minus the amount of oil still in the (6) Install the compressor and connect the refriger-
remaining components (refer to the oil capacity chart ant lines. Then evacuate and charge refrigerant sys-
below) can be measured and poured into the suction tem. (Refer to 24 - HEATING & AIR
port of the compressor. When a line or component CONDITIONING/PLUMBING - STANDARD PRO-
has ruptured and oil has escaped, the receiver/drier CEDURE - REFRIGERANT SYSTEM EVACUATE)
must be replaced along with the ruptured part. (Refer to 24 - HEATING & AIR CONDITIONING/
Example: On an A/C system the evaporator retains PLUMBING - STANDARD PROCEDURE - REFRIG-
60 ml. (2 oz.). The condenser retains 30 ml. (1 oz.) of ERANT SYSTEM CHARGE)
oil, and system capacity may be 150 ml. (5.00 oz.) of (7) Most reclaim/recycling equipment will measure
oil. the lubricant being removed. This amount of lubri-
150 ml. minus 90 ml. equals 60 ml. (2.00 oz.). cant should be added back to the system. If a new
compressor is being installed, drain lubricant from
A/C COMPONENT REFRIGERANT OIL old compressor, measure the amount drained and dis-
CAPACITIES card old lubricant. Drain the lubricant from the new
compressor into a clean container. Return the
COMPONENT NAME ml. oz. amount of lubricant measured from the old compres-
Total Air Conditioning System 150 ml. 5.00 oz. sor, plus the amount reclaimed from the system back
into the new compressor.
Condenser 30 ml. 1.00 oz.
Evaporator 59 ml. 2.00 oz.
Receiver/Drier 30 ml. 1.00 oz.
SERVICE PORT VALVE CORE
Line Blown 44 ml. 1.50 oz.
REMOVAL
Compressor Drain and measure The 3.2 / 3.5L service port valve cores are located
the oil from the old on the top of the manifold (High Side) and front side
compressor. See of the manifold (Low Side) (Fig. 14). The 2.7L service
text. port valve ports are located on the A/C liquid line
(high side) and suction line (low side).
CAUTION: The refrigerant oil used in a R-134a A/C (1) Remove the valve caps. Recover the refrigerant.
system is unique. Use only oils which were (Refer to 24 - HEATING & AIR CONDITIONING/
designed to work with R-134a refrigerant. The oil PLUMBING - STANDARD PROCEDURE - REFRIG-
designated for this vehicle is ND 8 PAG (polyalka- ERANT RECOVERY)
lene glycol). (2) Using a standard valve core tool, remove the
valve core. Be careful to prevent any dirt/debris
from entering the valve core opening or getting
VERIFY REFRIGERANT ND8 LUBRICANT LEVEL on the replacement valve core.
(1) Recover the refrigerant from the system. (Refer
to 24 - HEATING & AIR CONDITIONING/PLUMB- CAUTION: A valve that is not fully seated can lead
ING - STANDARD PROCEDURE - REFRIGERANT to damage to the valve during evacuation and
RECOVERY) charge. This can result in system refrigerant dis-
(2) Disconnect the refrigerant lines from the a/c charge while uncoupling the charge adapters.
compressor. Cap the open lines to prevent moisture
from entering the system.
(3) Remove the compressor from the vehicle.
24 - 44 PLUMBING LH
SERVICE PORT VALVE CORE (Continued)
INSTALLATION
NOTE: When assembling the new valve core into
the fitting, the core should be oiled with clean ND8
PAG compressor oil.
EMISSIONS CONTROL
TABLE OF CONTENTS
page page
EVAPORATIVE EMISSIONS
TABLE OF CONTENTS
page page
OPERATION INSTALLATION
During the cold start warm-up period and the hot The solenoid attaches to a bracket near the air
start time delay, the PCM does not energize the sole- cleaner. The solenoid will not operate unless it is
noid. When de-energized, no vapors are purged. installed correctly.
The proportional purge solenoid operates at a fre- The top of the solenoid has TOP printed on it. The
quency of 200 hz and is controlled by an engine con- solenoid will not operate unless it is installed cor-
troller circuit that senses the current being applied rectly.
to the proportional purge solenoid (Fig. 2) and then (1) Install solenoid on bracket.
adjusts that current to achieve the desired purge (2) Connect vacuum tube to solenoid.
flow. The proportional purge solenoid controls the (3) Connect electrical connector to solenoid.
purge rate of fuel vapors from the vapor canister and
fuel tank to the engine intake manifold.
LH EVAPORATIVE EMISSIONS 25 - 13
EVAP/PURGE SOLENOID (Continued)
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 (Fig. 7). During refueling,
the fuel tank is vented to the vapor canister to cap-
ture escaping vapors. With air flowing into the filler
tube, there are no fuel vapors escaping to the atmo-
sphere. 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 tailpipe emissions.
As fuel starts to flow through the fill tube, it opens
the normally closed check valve and enters the fuel
tank. Vapor or air is expelled from the tank through
the control valve to the vapor canister. Vapor is
absorbed in the canister until vapor flow in the lines
Fig. 6 O-RING stops, either following shut-off or by having the fuel
(5) Install fuel tank, refer to the Fuel Delivery sec- level in the tank rise high enough to close the control
tion for Fuel Tank Installation. valve. The control valve contains a float that rises to
(6) Connect the negative battery cable. seal the large diameter vent path to the canister. At
this point in the fueling of the vehicle, the tank pres-
sure increase, the check valve closes (preventing tank
ORVR fuel from spiting back at the operator), and fuel then
rises up the filler tube to shut-off the dispensing noz-
DESCRIPTION zle.
Onboard Refueling Vapor Recovery (ORVR) System If the engine is shut-off while the On-Board diag-
Schematic and components. nostics test is running, low level tank pressure can
be trapped in the fuel tank and fuel can not be added
to the tank until the pressure is relieved. This is due
to the leak detection pump closing the vapor outlet
from the top of the tank and the one-way check valve
not allowing the tank to vent through the fill tube to
atmosphere. Therefore, when fuel is added, it will
back-up in the fill tube and shut off the dispensing
nozzle. The pressure can be eliminated in two ways:
1. Vehicle purge must be activated and for a long
enough period to eliminate the pressure. 2. Removing
the fuel cap and allowing enough time for the system
to vent thru the recirulation tube.
25 - 16 EVAPORATIVE EMISSIONS LH
ORVR (Continued)
PCV HOSE
DESCRIPTION
The PCV system has a heat exchanger in the PCV
hose that works with the cooling system of the vehi-
cle (Fig. 8) or (Fig. 9).
REMOVAL
(1) Drain the Cooling system, refer to the Cooling
system for more information.
(2) Remove hose from PCV valve.
(3) Remove hose from valve cover.
(4) Remove the 2 heater hoses from heat
exchanger in PCV hose.
INSTALLATION
(1) Install heater hoses to heat exchanger and
tighten clamps.
(2) Install hose to PCV valve. Fig. 8 PCV - 2.7L
(3) Install hose to valve cover.
LH EVAPORATIVE EMISSIONS 25 - 17
PCV HOSE (Continued)
VAPOR CANISTER
OPERATION
All vehicles use a maintenance free, evaporative
(EVAP) canister. Fuel tank vapors vent into the can-
ister. The canister temporarily holds the fuel vapors
until intake manifold vacuum draws them into the
combustion chamber. The Powertrain Control Module
Fig. 13 High Intake Manifold Vacuum Minimal Vapor (PCM) purges the canister through the proportional
Flow purge solenoid. The PCM purges the canister at pre-
determined intervals and engine conditions.
Fig. 16 EVAP CANISTER BOTTOM TABS Fig. 18 EVAP CANISTER TOP MOUNTING
(5) Swing the EVAP canister away from the lower INSTALLATION
bracket. (1) Install the EVAP canister to the upper mount-
(6) Lift the EVAP canister up and off the upper ing bracket (Fig. 17) and (Fig. 18).
mounting tab (Fig. 17) and (Fig. 18). (2) Swing EVAP canister into the lower mounting
and snap into place (Fig. 16).
(3) Install the hoses to the top of the EVAP canis-
ter (Fig. 15).
(4) Connect the electrical connector.
(5) Install the fuel tank, refer to the fuel tank
installation section
(6) Connect the negative battery cable.
TABLE OF CONTENTS
page page
EXHAUST GAS
RECIRCULATION
SPECIFICATIONS
TORQUE
DESCRIPTION N·m Ft. Lbs. In. Lbs.
EGR valve to cyl. head 31 22.8 275
EGR tube to EGR valve 11 95
EGR tube to intake manifold 11 95
EGR tube to exhaust manifold 31 22.8 275
DESCRIPTION
The EGR valve consists of three major components.
First there is the pintle, valve seat, and housing
which contains and regulates the gas flow. Second
there is the armature, return spring, and solenoid
coil to provide the operating force to regulate the
flow by changing the pintle position. The solenoid coil
assembly is in parallel with a diode and connects to
the two connectors in the connector assembly. The
third major component which senses pintle position
and is connected to the three connectors in the elec-
trical connector.
OPERATION
The exhaust gas recirculation flow is determined
by the engine controller. For a given set of conditions,
the engine controller knows the ideal exhaust gas Fig. 1 EGR tube and Valve - 3.2/3.5L
recirculation flow to optimize NOx and fuel economy
1 - EGR TUBE
as a function of the pintle position. Pintle position is 2 - EGR VALVE
obtained from the position sensor. The engine con-
troller adjusts the duty cycle of 128 Hz power sup-
plied to the solenoid coil to obtain the correct (1) Disconnect negative battery cable.
position. (2) Remove air inlet tube and resonator.
LH EXHAUST GAS RECIRCULATION 25 - 21
EGR VALVE (Continued)
(3) Disconnect electrical connector from EGR (3) Remove EGR tube mounting clips at intake
valve. manifold plenum (Fig. 3).
(4) Remove EGR tube mounting screws at EGR
valve (Fig. 1).
The EGR valve attaches to the rear of the right
cylinder head.
(5) Remove EGR valve mounting screws.
(6) Clean gasket surfaces. Discard old gasket. If
necessary, clean EGR passages.
INSTALLATION - 3.5L
INSTALLATION - 3.5L
The EGR tube attaches to the bottom of the intake
manifold plenum beside the throttle body (Fig. 4).
(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 Fig. 5 EGR tube Seal
tube to EGR valve. 1 - SILICONE SEAL
(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- (6) Install air inlet tube and resonator.
fold plenum (Fig. 5). (7) Connect negative battery cable.
(5) Install transmission to throttle body bracket.
LH ON-BOARD DIAGNOSTICS 25 - 23
ON-BOARD DIAGNOSTICS
TABLE OF CONTENTS
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