CHRYSLER

MOTORS
SERVICE MANUAL

1991 FRONT WHEEL DRIVE

ALL WHEEL DRIVE
VAN/WAGON

To order the special service tools used and

illustrated, please refer to the instructions on
inside back cover.

CHRYSLER
W MOTORS

NO PART OF THIS PUBLICATION MAY BE

REPRODUCED, STORED IN A RETRIEVAL
SYSTEM, OR TRANSMITTED, IN ANY FORM
OR BY ANY MEANS, ELECTRONIC, ME­
CHANICAL, PHOTOCOPYING, RECORDING,
OR OTHERWISE, WITHOUT THE PRIOR
WRITTEN PERMISSION OF CHRYSLER
MOTORS.

Chrysler Motors reserves the right to make changes in design or to make

additions to or improvements in its products without imposing any obliga­
tions upon itself to install them on its products previously manufactured.

Litho in U.S.A. Copyright © 1990 Chrysler Motors 20M890

 FOREWORD
The information contained in this service manual has been prepared for the profes­
sional automotive technician involved in daily repair operations. This manual does not
cover theory of operation, which is addressed in service training material.
Information in this manual is divided into groups. These groups contain general
information, diagnosis, testing, adjustments, removal, installation, disassembly, and
assembly procedures for the components.
The Component and System Index in the front of the manual identifies the correct
group for the component or system to be serviced.
To assist in locating a group title page, use the Group Tab Locator on the following
page. The solid bar after the group title is aligned to a solid tab on the first page of
each group. The first page of the group has a contents section that lists major topics
within the group.
Chrysler Motors reserves the right to change testing procedures, specifications,
diagnosis, repair methods, or vehicle wiring at any time without prior notice or
incurring obligation.
Information describing the operation and use of standard and optional equipment is
included in the Owner’s Manual provided with the vehicle.
GROUP TAB LOCATOR

Introduction ^ m ^ jjjjj

0 Lubrication and Maintenance

2 Suspension

5 Brakes 1 I

1 ■
7 Cooling System 1 ■

8 Electrical 1 I

9 Engine 1 I

11 Exhaust System/Intake 1 I
Manifc

13 Frame 1 I

14 Fuel System s 1_______ I

19 Steering

21 Transaxle 1 I

22 Wheels/Tires 1 ■

23 Body I ■

24 Heating/Air Conditioning 1 1

25 Emission Control S ystem s 1 I

 COMPONENT AND SYSTEM INDEX
NAME GROUP-PAGE
B R A K E S ............................................... ................................. 5-1
Anti-Lock Brake System Bendix Anti-Lock 10
As Body F W D /A W D ................................................... 5-49
Brake Disc (Rotor) ......................................................... 5-36
Disc Brakes ....................................... ............................ 5-27
Drum Brakes ................................................................... 5-14
General Information ......................................................... 5-1
Hydraulic System Control Valves ................................ 5-22
Kelsey Hayes Double Pin Family Caliper ............ . 5-30
Master C ylinder............................................................... 5-44
Parking Brakes ............................................................ . 5-40
Power Brakes ................................................................. 5-46
Service Adjustments ....................................................... 5-3
Service Procedures ....................................................... 5-25
Wheel Bearings ............................................................. 5-47
Wheel Cylinders ............................................................. 5-20
COOLING SYSTEM ............................................................. 7-1
Accessory Drive Belts ................................................... 7-24
Engine Block Heater ..................................................... 7-29
General Information ......................................................... 7-1
Service Procedures ....................................................... 7-10
Specifications ................................................................. 7-31
ELECTRICAL ..................................................................... 8A-1
Alternator Service ......................................................... 8C-1
Battery/Starter Service ................................................. 8B-1
Battery/Starting/Charging Systems Diagnostics ........ 8A-1
Horns .......... ........ ............................................... 8G-1
Ignition S y s te m ............................................................... 8D-1
Instrument Panel and G a u g e s ..................................... 8E-1
L a m p s ................................................................................ 8L-1
Power Locks ................................................................... 8P-1
Power Mirrors ................................................................. 8T-1
Power Seats ................................................................... 8R-1
Power Windows ..................................... ....................... 8S-1
Radio, Antenna and S peakers..................................... 8F-1
Rear Window Defogger ............................................... 8N-1
Restraint System ........................................................... 8M-1
Speed Control ............................................... ............... 8H-1
Turn Signal and Flashers ............................................. 8J-1
Windshield Wipers and Washers ............................... 8K-1
'Wiring Diagrams ............................. ............................. 8W-1
EMISSIO N CONTR O L SYSTEMS ................................. 25-1
Evaporative Emission Controls ................................... 25-1
Exhaust Emission Controls........................................... 25-5
ENGINE ............................................. .................................. 9-1
2.5L Engine ....................................................................... 9-8
3.0L Engine ............................................. ................... . 9-51
3.3L Engine ..................................................................... 9-88
Standard Service Procedures......................................... 9-1
EXHAUST SYSTEM AND INTAKE MANIFOLD .............. 11-1
Exhaust System Diagnosis ....................................... ... 11-3
General Information ....................................................... 11-1
Service Procedures ....................................................... 11-4
Torque Specification ............................................. . 11 -20
FRAME ................................................................................. 13-1
All Wheel Drive Van/Wagon Crossmember................ 13-5
Frame Dimensions ......................................................... 13-1
Front Wheel Drive Van/Wagon Crossmember .......... 13-5
General Information ....................................................... 13-1
FUEL S Y S T E M ................................................................... 14-1
Accelerator Pedal and Throttle Cable ...................... 14-27
Component Identification— 2.5L TBI Engines .......... 14-29
Component Identification— 3.0L E ngines.................. 14-62
Component Identification— 3.3L E ngines.................. 14-93
Fuel Delivery System— All Wheel D riv e .................... 14-10
Fuel Delivery System— Front Wheel Drive ................ 14-3
Fuel Tank— All Wheel Drive ....................................... 14-22
Fuel Tank— Front Wheel Drive ............................. 14-16
General Diagnosis— 2.5L TBI Engines...................... 14-40
General Diagnosis— 3.0L Engines ............................ 14-71
General Diagnosis—3.3L Engines .......................... 14-103
General Information .......... ............................................ 14-1
NAME GROUP-PAGE
Multi-Point Fuel Injection— 3.0L Engines .................. 14-62
Multi-Point Fuel Injection— 3.3L Engines .................. 14-93
Service Procedures— 2.5L TBI E ngines.................... 14-53
Service Procedures— 3.0L Engines .......................... 14-85
Service Procedures 3.3L E ngines............................ 14-117
Single Point Fuel Injection— 2.5L TBI E ng ines........ 14-29
HEATING AND AIR C O N D ITIO N IN G .............................. 24-1
Auxiliary Rear Heating or
Heating-Air/Conditioning .......................................... 24-61
Component Removal/Installation and Overhaul . . . . 24-31
Diagnostic Servicing Procedures.................................. 24-4
General Information ....................................................... 24-1
Refrigerant..................................................................... 24-25
INTRODUCTION ................................................................. 1-1
Body Code Plate Location and
Decoding Information .................................................... 1-3
International Symbols ..................................................... 1-5
Metric System ................................................................... 1-6
Metric Thread and Grade Identification ........................ 1-4
Torque References........................................................... 1-4
Vehicle Family Identification ............................................ 1-1
Vehicle Identification N um ber.......................................... 1-1
Vehicle Safety Certification Label .................................. 1-1
LUBRICATION AND MAINTENANCE .............................. 0-1
Chassis and Body ......................................................... 0-16
Drivetrain ......................................................................... 0-13
E ngine................................................................................. 0-6
General Information ......................................................... 0-1
REAR SUSPENSION AND DRIVELINE .......................... 3-1
All Wheel Drive Rear Suspension .................................. 3-3
Rear Drive Line Module Assembly
(All Wheel D riv e )........................................................... 3-6
Rear Drive Line Module Assembly
Service Procedures ..................................................... 3-8
Rear Drive Line Module Vacuum Shift
Motor Diagnosis ......................................................... 3-36
Specifications ................................................................. 3-41
Two Wheel Drive Rear Suspension .............................. 3-1
STEERING ......................................................................... 19-1
Acustar Standard and Tilt Steering Wheel .............. 19-20
Gear and Pump ............................................................. 19-1
General Information ........................................................ 19-1
Specifications and Tightening Reference ................ 19-26
SUSPENSION ....................................................................... 2-1
Driveshafts....................................................................... 2-17
Front Suspension ............................................................. 2-1
Front Suspension Service Procedures .......................... 2-5
General Information ......................................................... 2-1
Intermediate Shaft ......................................................... 2-36
Rear Suspension ............................................................ 2-40
TRANSAXLE ....................................................................... 21-1
A-413 and A-670 Three Speed Torqueflite
Automatic Transaxle .................................................. 21-1
A-413 and A-670 Torqueflite Diagnosis and Tests .. 21-3
A-604 Ultradrive 4-Speed Electronic
Automatic Transaxle ................................................ 21-63
A-604 Ultradrive Diagnosis and Tests ...................... 21-66
All Wheel Drive Power Transfer Unit (P.T.U.) ___ 21-135
Bearing Adjustment Procedure (A-604) .................. 21-132
Bearing Adjustment Procedures (A-413/A-670) ___ 21-60
Maintenance and Adjustments (A-604) .................... 21-89
Maintenance and Adjustments (A-413/A-670) ........ 21-21
Power Transfer Unit Service Procedures .............. 21-136
Service In Vehicle (A-413/A-670) .............................. 21-24
Service Out of Vehicle (A413/A-670) ........................ 21-25
Service In Vehicle (A-604) .......................................... 21-90
Service Out of Vehicle (A-604) .................................. 21-91
Specifications ............................................................. 21-153
WHEELS TIRES ................................................................. 22-1
Service Procedures ....................................................... 22-2
Tires ................................................................................. 22-1
Wheels ............................................................................. 22-6
 INTRODUCTION
CONTENTS
Page Page
BODY CODE PLATE LOCATION AND TORQUE REFERENCES ............ ........ ......... 4
DECODING INFORMATION 3 VEHICLE FAMILY IDENTIFICATION ................ 1
INTERNATIONAL SYMBOLS 5 VEHICLE IDENTIFICATION NUMBER .............. 1
METRIC SYSTEM . 6 VEHICLE SAFETY CERTIFICATION LABEL....... 1
METRIC THREAD AND GRADE
IDENTIFICATION 4
VEHICLE FAMILY IDENTIFICATION
Throughout this service manual references are made V.I.N.
to Vehicle Family, Body Codes. The letters AS is a PLATE
body code that is assigned to a individual vehicle
family (Fig. 1). Also digit boxes 16 and 17 on the Body DASH
PANEL
Code Plate indicate the Vehicle family.

VEHICLE CAI V1M1CL1 BODY

UNI NAME S fY U
Y T ow n 4 Country-AW D 53
K Caravan-FW D 12
K C aravan-FW D 13
K G ra n d Caravan-FW D 52

AS K G r a n d Caravan-FW D 53. 90IN -2

ICiOY D Caravan-A W D '12
Fig. 2 Vehicle Identification Number (VIN Plate)
D Caravan-A W D 13
D G ra n d Caravan-A W D 52 VEHICLE SAFETY CERTIFICATION LABEL
D G ra n d Caravan-A W D 53
H V oyager-FW D 12
A vehicle safety certification label (Fig. 3) is at­
tached to the rear facing of the driver’s door. This
H V oyager-FW D 13
label indicates date of manufacture (month and year),
H G ra n d V oyager-FW D 52 Gross Vehicle Weight Rating (GVWR), Gross Axle
H G ra n d V oyager-FW D 53 Weight Rating (GAWR) front, Gross Axle Weight Rat­
P Voyager-A W D 52
ing (GAWR) rear and the Vehicle Identification Num­
ber (VIN). The Month, Day and Hour of manufacture
P G r a n d V oyager-A W D 53 is also included.
12 = V an Short W h eel B ase Y = AWD C h ry sle r All communications or inquiries regarding the vehi­
13 = V an Long W h eel B ase K = PWD Dod§® cle should include the Month-Day-Hour and Vehicle
52 = W ag o n Short W h eel B ase D = AWD D o dg e
Identification Number.
53 = W ag o n Long W h eel B ase H = PWD P lym outh
PWD = Front W h eel Drive P = AW D P lym o u th
AWD = All W h eel Drive
91 IN -7

Fig. 1 Vehicle Family Identification

VEHICLE IDENTIFICATION NUMBER

The Vehicle Identification Number (VIN) is located
on the upper left corner of the instrument panel, near
the left windshield pillar. The VIN consists of 17 char­
acters in a combination of letters and numbers that
provide specific information about the vehicle (Fig. 2).
Refer to Vehicle Identification Number Decoding Chart.
 (UNITED STATES) (CANADA)
(CANADA
TjJ CHHYSLf
• M OATIOF SALES
IM M NIM 6nM I
ONLY)
CHHYS t l n
I
M T IO F
MMWMCnME

CAUTION-DO NOT USE WEMHT RATING DATA PROVIDEO ABOVE FOR DETERMINING MAXI­
MUM VEWGtl PASSENGER ANO/OR CARGO LOAO CAPACITY. FOR DETERMINING MAXIMUM
PASSENGER AND/OB CARGO LOAO CAPACITY. USE THE VALUES PROVIDED ON THE TIRE
PRESSURE PLACARD AFFIXED ELSEWHERE ON THIS VEHICLE.
MAOE IN i.S it. S»ftS8
J RN882
CAUTION— DO NOT USE WEIGHT RATIN6 DATA PR0VI0E0 ABOVE FOR 0ETERMININ6 MAXI­
MUM VEHICLE PASSENGER AND/OR CARGO LOAD CAPACITY. FOR DETERMINING MAXIMUM
PASSENGER AND/OR CARSO LOAD CAPACITY. USE THE VALUES PROVIDED ON THE TIRE
PRESSURE PiACARO AFFIXED ELSEWHERE ON THIS VEHICLE.
MM MADE IN CANADA 3759157

Fig. 3 Vehicle Safety Certification label

VEHICLE IDENTIFICATION NUMBER DECODING CHART

P O S IT IO N INTERPRET A ? iO M C O D E O P T IO N S

1 Country of Origin 1 = United States 2 = Canada 3 = Mexico

Mai B = Dodge C = Chrysler P = Plymouth

3 Type of Vehicle 3 = Multipurpose Passenger Vehicle

4 Gross Vehicle Weight
D = 0-1360 kg (1-3000 lbs.)
E = 1361-1814 kg (3001 -4000 lbs.)
F = 1815-2267 kg (4001-5000 lbs.)
G = 2268-2721 kg (5001-6000 lbs.)
H = 2722-3175 kg (6001-7000 lbs.)
J =3176-3628 kg (7001-8000 lbs.)
K = 3629-4082 kg (8001-9000 lbs.)
L = 4083-4535 kg (9001-10000 lbs.)
M = 4536-6350 kg (10001-14000 lbs.)
W = Busses/Incomplete Vehicles with Hydraulic Brakes

5 Line K= Dodge-Caravan/Grand Caravan/Caravan C /V 4x2

D= Dodge-Caravan/Grand Caravan 4x4
H= Plymouth-Voyager/Grand Voyager 4x2
P= Plymouth-Voyager/Grand Voyager 4x4
Y= Chrysler-Town and Country 4x4

6 Series 1 = Economy Line 2 = Low Line 3 = Medium Line

4 = High Line 5 = Premium Line 6 = Sport
7 = Special 8 = Miscellaneous
7 Body Style 1 = Van 4 = Extended W agon/Van
5 = Wagon
Engine K = 2.5L EFI R = 3.3L EFI
9 M odel Year M = 19

■ 10 Assembly Plant R = Windsor X = St. Louis II

12 through 17 = Vehicle Build Sequence

91 IN -11
 BODY CODE PLATE

X X X X X X X X X

BLANK LINE

5. X X X X X X X X X X X X

4. X X X X X X X X X X X X X X X X X X

3.
000000000000 000 000000
2. 000 [25] [2*] [27] [2s] [29] [30 ]00 0000 [37] [3s] [39]

1. 40 41 42 43 44 45 46 47 48 49 50 51 52 53 54 55 56 57 58 59 60

91 I N -4

BODY CODE PLATE LOCATION AND • P = Premium

DECODING INFORMATION • S = Special/Sport
• X = Performance Image
The Body Code Plate is attached to the top of the
radiator closure panel in the engine compartment. DIGIT BOXES 20 AND 21—Body Type
There are seven lines of information on the body code • 12 = Van Short Wheel Base
plate. Lines 4, 5, 6, and 7 are not used to define
• 13 = Van Long Wheel Base
service information. Information reads from left to
right, starting with line 3 in the center of the plate to • 52 = Wagon Short Wheel Base
line 1 at the bottom of the plate. • 53 = Wagon Long Wheel Base

BODY CODE PLATE LINE 3 BODY CODE PLATE LINE 2

DIGIT BOXES 1 THROUGH 12—Vehicle Order Number DIGIT BOXES 22,23, AND 24—Paint Procedure
DIGIT BOXES 13,14, AND 15—Vinyl Roof Code DIGIT BOXES 25 THROUGH 28—Primary Paint
See Group 23, Body for color codes
DIGIT BOXES 16, 17, AND 18—Vehicle Shell Car Line
• ASY = 4x4-Town & Country DIGIT BOXES 29 THROUGH 32—Secondary Paint
• ASK = 2x4-Caravan CV, Caravan, Caravan SE,
Grand Caravan SE, Caravan LE, Grand Car­ DIGIT BOXES 33 THROUGH 36—Interior Trim Code
avan LE DIGIT BOXES 37, 38, AND 39—Engine Code
• ASD = 4x4-Caravan CV, Caravan SE, Grand Cara­ • EDM = 2.5 L, 4 cylinder EFI Gas—Automatic or
van SE, Caravan LE, Grand Caravan LE Manual Transaxle
• ASH = 2x4-Voyager, Voyager SE, Grand Voyager • EFA = 3.0 L, V6 Gas (EFI)—Automatic or Manual
SE, Voyager LE, Grand Voyager LE Transaxle
• ASP = 4x4-Voyager SE, Grand Voyager SE, Voy­ • EGA = 3.3 L, V6 Gas (EFI)—Automatic
ager LE, Grand Voyager LE
BODY CODE PLATE LINE 1
DIGIT BOX 19—Price Class
DIGIT BOXES 40, 41, AND 42—Transaxle Codes
• E = Economy
• DGM = A670 3-speed Automatic Transaxle
• H = High Line • DGC = A413 3-speed Automatic Transaxle
• L = Low Line
• DGL = A604 4-speed Electronic Automatic Transaxle
• M = Maximum
 STANDARD BODY DIMENSIONS

IJfllliSCill DIMENSIONS
WHEELBASE HACK OVERALL
WIW1CIE mow FRONT REAR length WSIITM ] IIISIIIII
FAMILY STYLE m m /ln , m m /I n . m m /In . mmi In. m m /I n . f m m /In .
AS K-12 2846/112.0 1578/62.1 4468/176.9 1764/69.4 1698/66.9
AS K-13 3024/119.1 1623/60.0 1578/62.1 4838/190.5 1764/69.4 1714/67
AS HK-52 2846/112.0 1522/59.9 1578/62.1 4516/177.8 1764/69.4 1672/65,
AS . HK-53 3025/1 I f . 1 1521/59.9 1578/62.1 4888/192.4 1764/69.4 161
11
VBHICLE mow MEAD ROOM UOROOM SHOULDER ROOM mm m om
FAMILY STYLE FiO N f REAR FRONT REAR FRONT REAR vm m v REAR
970 mm 1484 mm 1344 mm
AS K-12/13 39.0 in. | 38.2 in. 58.4 in. 52.9 in.
jjjaaMp >a^ ^ >ai
970 mm 959 mm 1484 mm 1557 mm 1344 mm 1#2§ mm
AS HK-52/S3 39.0 in. j 38.2 in. 38.2 in. 37.8 in. 58.4 in. 61.3 in. 51.9 in. 63.8 in.
91 IN-8

DIGIT BOX 43—Market Code

BOLT TORQUE
• U = United States
GRAM 5 till AO! S
• C = Canada BOLT
SiZl N*m ''' ft-lbs N*m ft-lbs
• B = International (In-lbs) (in-lbs)
• M = Mexico
1/4-20 TT (95) 14 (125)
DIGIT BOXES 44 THROUGH 60— 1/4-28 11 (95) 17 (150)
Vehicle Identification Number (VIN) 5/ 16-18 23 (200) 31 (270)
Refer to Vehicle Identification Number (VIN) para­ 5/ 16-24 27 20 ' 34- 25
graph for proper breakdown of VIN code. 3/ 8-16 41 30 54 40
3/ 8-24 48 35 61 45 ‘
7/ 16-14 68 50 88 65
IF TWO BODY CODE PLATES ARE REQUIRED 7/ 16-20 75 55 95 70
The last code shown on either plate will be followed 1/ 2-13 ■ 102 75 136 100
by END. When two plates are required, the last code 1/2-20 ■’ 115 ■ 85 149 110
space on the first plate will show CTD (for continued). 9/ 16-12 142 105 183 135
When a second plate is required, the first four spaces 9/ 16-18 156 115 203 . 150
of each line will not be used due to overlap of the 5/ 8-11 203 150 • 264 195
plates. 5/ 8-18 217 160 285 210
3/ 4-16 237 175 305 225
TORQUE REFERENCES
J89IN-9
Individual Torque Charts appear at the end of many
Groups. Refer to the Standard Torque Specifications Fig. 4 Grade 5 and 8 Standard Torque Specifications
and Bolt Identification Chart in this Group for tor­
ques not listed in the individual torque charts (Fig. 4). Torque specifications on the Bolt Torque chart are
based on the use of clean and dry threads. Reduce the
torque by 10% when the threads are lubricated with
engine oil and by 20% if new plated bolts are used.
Various sizes of Torx head fasteners are used to
secure numerous components to assemblies. Due to
ever changing usage of fasteners, Torx head fasten­
ers may not be identified In art or text.

METRIC THREAD AND GRADE IDENTIFICATION

Metric and SAE thread notations differ slightly.
The difference is illustrated in Figure 5.
 SAE CLASSIFICATION
INCH METRIC
GRADE 5 GRADE 8
5/16-18 M8 X 1.25

THREAD NUMBER THREAD DISTANCE

MAJOR Of MAJOR BETWEEN MARKINGS FO UND f < T >
DIAMETER THiEADS DIAMETER IN THREADS IN O N TOP O f BOLT
IN INCHES PER INCH MILLIMETERS MILLIMETERS HEAD INDICATE
GRADE

120° 60°
PR606B

Fig. 5 Thread Notation (Metric and SAE)

Common metric fastener strength classes are 9.8

and 12.9, with the class identification embossed on the
head of each bolt (Fig. 8). Some metric nuts will be
d
marked with a single digit strength number on the
nut face. (SAE) BOLTS—IDENTIFICATION MARKS CORRESPOND
TO BOLT STRENGTH— INCREASING NUMBERS
REPRESENT INCiEASING STRENGTH.
J89IN-11

Fig. 7 SAE Bolt Identification

'METRIC BOLTS— IDENTIFICATION CLASS NUMBERS
CORRESPOND TO BOLT STRENGTH— INCREASING NUMBERS
REPRESENT INCREASING STRENGTH. J89IN-10
Fig. § Metric Bolt Identification
INTERNATIONAL SYMBOLS
Some International Symbols are used to identify
controls and displays in this vehicle. These symbols
are. applicable to those controls which are displayed
on the instrument panel or in the immediate vicinity
of the driver (Fig. 8).

SAE strength classes range from grade 2 to 8 with

lime identification embossed on each bolt head. Mark­
ings corresponding to two lines less than the actual
grade (Fig. 7). For Example: Grade 7 bolt will exhibit
5 embossed lines on the bolt head.
 INTERNATIONAL SYMBOLS

i i »

ID D A V
WINDHiELD WINDSHIELD
UPPER BEAM LOWER BEAM TURN SIGNAL HAZAtD WAttMING
WIPER WASHER ■<

I i i
P; x
WINDSHIELD WIPEI REAR HOOD CHOKE (COLD
AND WASHER VENTILATING FAN PARKING LIGHTS FRONT HOOD (TRUNK) . STARTING AID)

- +
» K
ENGINE COOLANT BATTERY CHAIGING
HORN FUEL ENGINE OIL SEAT BELT
TEMPERATURE CONDITION

□I (© )
WINDSCREEN
REAR WINDOW REAR WINDOW PARKING BRAKE ■ BRAKE FAILURE DEMISTING
LIGHTER
W iPEi WASHER
AND DEFROSTING
RK230

Fig. 8 International Symbols

METRIC SYSTEM
Figure art, specifications, and tightening references
in this Service Manual are identified in the metric
system and in the SAE system. . Mega (M) Million Deci .(D) Tenth
During any maintenance or repair procedures, it is
important to salvage metric fasteners (nuts, bolts, etc.) Kilo' (K) Thousand ’ Cent! ’ - (C) Hundreth
for reassembly. If the fastener is not salvageable, a
fastener of equivalent specification should be used. Midi - (m) Thousandth

WARNING: USE OF AN INCORRECT FASTENER MAY

J901N-2
RESULT IN COMPONENT DAMAGE OR PERSONAL
INJURY. Fig. 9 Metric Prefixes
The metric system is based on quantities of one, ten,
The following Tables will assist you in conversion
one hundred, one thousand, and one million (Fig. 9).
procedures.
 CONVERSION TABLES

in-lbs to N *m N«m to in-lbs

in- lb N*m in-lb N«m in-lb N*m in-lb N*m in-lb N*m N#nn in-lb N*m in-lb N*m in-lb N*m in-lb N#m in-lb

2 .2260 42 4.7453 82 9.2646 122 13.7839 162 18.3032 .2 1.7702 4.2 37.1747 8.2 72.5792 12.2 107.9837 16.2 143.3882
4 .4519 44 4.9713 84 9.49m 124 14.0099 164 18.5292 .4 3.5404 4.4 38.9449 8.4 74.3494 12.4 109.7539 16.4 145.1584
6 .6779 46 5.1972 86 9.7165 126 14.2359 166 18.7552 .6 5.3107 4.6 40.7152 8.6 76.1197 12.6 111.5242 16.6 146.9287
8 .9039 48 5.4232 88 9.9425 128 14.4618 168 18.9811 .8 7.0809 4.8 42.4854 8.8 77.8899 12.8 113.2944 16.8 148.6989
10 1.1298 50 5.6492 90 10.1685 130 14.6878 170 19.2071 1 8.8511 5 44.2556 9 79.6601 13 115.0646 17 150.4691
12 1.3558 52 5.8751 92 10.3944 132 14.9138 172 19.4331 1.2 10.6213 5.2 46.0258 9.2 81.4303 13.2 116.8348 17.2 152.2393
14 1.5818 54 6.1011 94 10.6204 134 15.1397 174 19.6590 1.4 12.3916 5.4 ' 47.7961 9.4 83.2006 13.4 118.6051 17.4 154.0096
16 1.8077 56 6.3270 96 10.8464 136 15.3657 176 19.8850 1.6 14.1618 5.6 49.5663 9.6 84.9708 13.6 120.3753 17.6 155.7798
18 2.033? 58 6.5530 98 11.0723 138 15.5917 178 20.1110 1.8 15.9320 5.8 51.3365 9.8 86.7410 13.8 122.1455 17.8 ■ 157.5600
20 2.2597 60 6.7790 100 11.2983 140 15.8176 180 20.3369 2 17.7022 6 53.1067 10 88.5112 14 123.9157 18 159.3202
22 2.4856 62 7.0049 102 11.5243 142 16.0436 182 20.5629 2.2 19.4725 6.2 54.8770 10.2 90.2815 14.2 125.6860 18.5 163.7458
24 2.7116 64 7.2309 104 11.7502 144 16.2696 184 20.7889 2.4 21.2427 6.4 56.6472 10.4 92.0517 14.4 127.4562 19 168.1714
26 2.9376 66 7.4569 106 11.9762 146 16.4955 186 21.0148' 2.6 23.0129 6.6 58.4174 10.6 93.8219 14.6 129.2264 19.5 172.5970
28 3.1635 m 7.6828 108 12.2022 148 16.7215 188 21.2408 2.8 24.7831 6.8 60.1876 10.8 95.5921 14.8 130.9966 20 177.0225
30 3.3895 70 7.9088 110 12.4281 150 16.9475 190 21.4668 3 26.5534 7 61.9579 11 97.3624 15 132.7669 20.5 181.4480
32 3.6155 72 8.1348 112 12.6541 152 17.1734 192 21.6927 3.2 28.3236 7.2 63.7281 11.2 99.1326 15.2 134.5371 21 185.87%
34 3.8414 74 8.3607 114 12.8801 154 17.3994 194 21.9187 3.4 30.0938 7.4 65.4983 11.4 100.9028 15.4 136.3073 22 194.7247
36 4.0674 76 8.5867 116 13.1060 156 17.6253 196 22.1447 3.6 31.8640 7.6 67.2685 11.6 102.6730 15.6 • 138.0775 23 203.5759
38 4.2934 78 8.8127 118 13.3320 158 17.8513 198 22.3706 3.8 33.6342 7.8 69.0388 11.8 104.4433 15.8 139.8478 24 212.4270
40 4.5193 80 9.0386 120 13.5580 160 18.0773 200 22.5966 4 35.4045 8 70.8090 12 106.2135 16 141.6180 25 221.2781

f t - lb s t o N # nr1 NJ * m t o f t - l t 5S

Mb N*m ft-lb N*m ft-lb N*m ft-lb N#m ft-lb N*m N«m m t N*m ft-lb N*m ft-lb N«m ft-lb N«m mb

1 1.3558 21 28.4722 41 55.5885 61 82.7049 81 109.8212 1 .7376 21 15.9888 41 30.2400 61 44.9913 81 59.7425
2 2.7116 22 29.8280 42 56.9444 62 84.0607 82 111.1770 2 1.4751 22 16.2264 42 30.9776 62 45.7289 82 60.4801
3 4.0675 23 31.1838 43 58.3002 63 85.4165 83 112.5328 3 2.2127 23 16.9639 43 31.7152 63 46.4664 83 61.2177
' 4 5.4233 24 32.5396 44 59.6560 64 86.7723 84 113.8888 4 2.9502 24 17.7015 44 32.4527 64 47.2040 84 61.9552
5 6.7791 25 33.8954 45 61.0118 65 88.1281 85 115.2446 5 3.6878 25 18.4391 45 33.1903 65 47.9415 85 62.6928
6 8.1349 26 35.2513 46 62.3676 66 89.4840 86 116.6004 6 4.4254 26 19.1766 46 33.9279 66 48.6791 86 63.4303
7 9.4907 27 36,6071 47 63.7234 67 90.8398 87 117.9562 7 5.1629 27 19.9142 47 34.6654 67 49.4167 87 64.1679
8 10.8465 28 37.9629 48 65.0793 68 92.1956 88 119.3120 8 5.9005 28 20.6517 48 35.4030 68 » .1 542 88 64.9545
9 12.2024 29 39.3187 49 66.4351 69 93.5514 89 120.6678 9 6.6381 29 21.3893 49 36.1405 69 50.8918 89 65.6430
10 13.5582 30 40.6745 50 67.7909 70 94.9073 90 122.0236 10 7.3756 30 22.1269 50 36.8781 70 51.6293 90 66.3806
.11 14.9140 31 42.0304 51 69.1467 71 96.2631 91 123.3794 11 8.1132 31 22.8644 51 37.6157 71 52.3669 91 67.1181
12 16.2698 32 43.3862 52 70.5025 72 97.6189 92 124.7352 12 8.8507 32 23.6020 52 38.3532 72 53.1045 92 67.8557
13 17.6256 33 44.7420 53 71.8583 73 98.9747 93 126.0910 .13 9.5883 33 24.3395 53 39.0908 73 53.8420 93 68.5933
14 18.9815 34 46.0978 54 73.2142 74 100.3316 94 127.4468 14 10.3259 34 25.0771 54 39.8284 74 54.5720 94 69.3308
15 20.3373 35 47.4536 55 74.5700 75 101.6862 95 128.8026 15 11.0634 35 25.8147 55 40.5659 75 55.3172 95 70.0684
16 21.6931 36 48.8094 56 75.92® 76 103.0422 96 130.1586 16 11.8010 36 26.5522 56 41.3035 76 56.0547 96 70.8060
17 23.0489 37 » . l 653 57 77.2816 77 104,3980 97 131.5144 17 12.5386 37 27.2898 57 42.0410 77 56.7923 97 71.5435
18 24.4047 38 51.5211 58 78.6374 78 105.7538 98 132.8702 18 13.2761 38 28.0274 58 42.7786 78 5 7 .5 m 98 72.2811
19 25.7605 39 52.8769 59 79.9933 79 107.1196 99 134.2260 19 14.0137 39 28.7649 59 43.5162 79 58.2674 99 73.0187
20 27.1164 40 54.2327 60 81.3491 80 108.4654 100 135.5820 20 14.7512 40 29.5025 60 44.2537 80 59.0050 100 73.7562

in . t o m m m m t o in .

in. mm in. mm in. mm in. mm in. mm mm in. mm in. mm in. mm in. mm in.

.01 .254 .21 5.334 .41 10.414 .61 15.494 .81 20.574 .01 .00039 .21 .00827 .41 .01614 .61 .02402 .81 .03189
.02 .508 .22 5.588 .42 10.668 .62 15.748 .82 20.828 .02 .00079 .22 .00866 .42 .01654 .62 .02441 .82 .03228
.03 .762 .23 5.842 .43 10.922 .63 16.002 .83 21.082 .03 .00118 .23 .00906 .43 .01693 .63 .02480 .83 .03268
.04 1.016 .24 6.096 .44 11.176 .64 16.256 .84 21,336 .04 .00157 .24 .00945 .44 .01732 .64 .02520 .84 .03307
.05 1.270 .25 6.350 .45 11.430 .65 16.510 .85 21.590 .05 .00197 .25 .00984 .45 .01772 .65 .02559 .85 .03346
.06 1.524 .26 6.604 .46 11.684 .66 16.764 .86 21.844 .06 .00236 .26 .01024 .46 .01811 .66 .025% .86 .0 3 m
.07 1.778 .27 6.858 .47 11.938 .67 17.018 .87 22.098 .07 .00276 .27 .01063 .47 .01850 .67 .02638 .87 .03425
.08 2.032 .28 7.112 .48 12.192 .68 17.272 .88 22.352 .08 .00315 .28 .01102 .48 .01890 .68 .02677 .88 .03465
.09 2.286 .29 7.366 .49 12.446 .69 17.526 .89 22.606 .09 .00354 .29 .01142 .49 .01929 .69 .02717 .89 .03504
JO 2.540 .30 7.6® .50 12.700 .70 17.780 .90 22.860 .10 .00394 .30 .01181 .50 .01969 .70 .02756 .90 .03543
J1 2.794 .31 7.874 .51 12.954 .71 18.034 .91 23.114 .11 .0)433 .31 .01220 .51 .02008 .71 .02795 .91 .03583
.12 3.048 .32 8.128 .52 13.208 .72 18.288 .92 23.368 .12 .00472 .32 .01260 .52 .02047 .72 .02835 .92 .03622
.13 3.302 .33 8.382 .53 13.462 .73 18.542 .93 23.622 .13 .00512 .33 .01299 .53 .02087 .73 .02874 .93 .03661
.14 3.556 .34 8.636 .54 13.716 .74 18.796 .94 23.876 .14 .00551 .34 .01339 .54 .02126 .74 .02913 .94 .03701
.15 3.810 .35 8.890 .55 13.970 .75 19.050 .95 24.130 .15 .00591 .35 .01378 .55 .02165 .75 .02953 .95 .03740
.16 4.064 .36 9.144 .56 14.224 .76 19.304 .96 24.384 .16 .00630 .36 .01417 .56 .02205 .76 ,02992 .96 .03780
.17 3.318 .37 9.398 .57 14.478 .77 19.558 .97 24.638 .17 '.00669 .37 .01457 .57 .02244 .77 .03032 .97 .03819
.18 4.572 .38 9.652 .58 14.732 .78 19.812 .98 24.892 .18 .00709 .38 .01496 .58 .02283 .78 • .03071 .98 .03858
.19 4.826 .39 9.906 .59 14.986 .79 20.066 .99 25.146 .19 .00748 .39 .01535 .59 .02323 .79 .03110 .99 .03898
.20 5.080 .40 10.160 .60 15.240 .80 20.320 1.00 25.400 .20 .00787 .40 .01575 .60 .02362 .80 .03150 1.0) .03937
 CONVERSION TABLES

H v ftlp ly By fs» «!•!? M tfM p ly By I # iiiit

in.-lbs. x 0.11298 = New ton-M etres (N*tn) (N m ) x 8.851 = in.-lbs.
ft.-fbs. x 1.3558 = New ton-M etres (N*m) (N ut) x 0.7376 ft.-lbs.

Inches Hg. (60°F) x 3.377 = Kilopascals (kPa) (kfo) x 0.2961 = Inches Hg.
Pounds/Sq. In. x 6.895 = Kilopascals (kPa) (kPc) x 0.145 = Pounds/Sq. In.

Inches . x 25.4 = Millimetres (mm) (mm) x 0.03937 =Inches

Feet x 0.3048 = M etres (M) (M) i 3.281 = Feet
Yards x 0.9144 = M etres (M) (M) x 1.0936 = Yards
Miles x 1.6093 = Kilometres (Km) (Km) x 0.6214 = Miles

M iles/Hr. x 1.6093 = Kilometres/Hr. (Km/h) (Km/h) x 0.6214 = Miles/Hr.

feet/S ec. x 0.3048 = M etres/Sec. (M/S) ' (M/S) x 3.281 = Feet/Sec.
Kilometres/Hr. x 0.27778 = M etres/Sec. (M/S) (M/S) x 3.600 = Kilometres/Hr.
M iles/Hr. x 0.4470 = M etres/Sec. (M/S) (M/S) x 2.237 = M iles/Hr.

COMMON METRIC EQUIVALENTS

1 Inch = 25 Millimeters 1 Cubic Inch = 16 Cubic Centimeters

1 fo o t = 0.3 M eter 1 Cubic fo o t = 0.03 Cubic M eter
1 Yard = 0.9 M eter 1 Cubic Yard = 0.8 Cubic M eter
1 Mile = 1 .6 Kilometers

J901N -11
 LUBRICATION AND MAINTENANCE
CONTENTS
Page Page
CHASSIS AND BODY ..................... . 16 ENGINE....................... 6
DRIVETRAIN............................................. 13 GENERAL INFORMATION 1
GENERAL INFORMATION
INDEX
Page Page
Classification of Lubricants . . , ............................................ Parts and Lubricant Recommendations ....................... 1
Fuel Usage .......... ...................... ...................................... Parts Requiring No Lubrication ...................................... 1
Hoisting Recommendations ........................................... Severe Service .................................................................. 1
Introduction ........................................................... .......... 1 Towing Recommendations ............................................. 4
Jump Starting Procedure .................. .................. .......... 3

INTRODUCTION organizations standards should be used to service a

Chrysler Motors vehicle.
Chrysler Motors has compiled recommended lubri­
• Society of Automotive Engineers (SAE)
cation and maintenance schedules and procedures to
help reduce premature wear or failure over a broad • American Petroleum Institute (API)
range of operating conditions. When selecting the • National Lubricating Grease Institute (NLGI)
proper maintenance schedule, the climate and operat­
ENGINE OIL
ing conditions must be considered. A vehicle subjected
to severe usage requires service more frequently than SAE GRADE RATING INDICATES ENGINE OIL VISCOSITY
a vehicle used for general transportation. • SAE 30 = single grade engine oil.
• SAE 5W-30 = multiple grade engine oil.
PARTS AND LUBRICANT RECOMMENDATIONS
API QUALITY CLASSIFICATION.
When service is required, Chrysler Motors recom­ • SG service engine oil is a high quality crankcase
mends that only Mopar® brand parts, lubricants and lubricant designed for use in all naturally aspirated
chemicals be used. Mopar® provides the best engineered engines.
products for servicing Chrysler Motors vehicles. • SG/CD service engine oil is a high quality crankcase
lubricant designed for use in most naturally aspirated
SEVERE SERVICE and turbocharged gasoline or diesel engines.
If a vehicle is operated under any of the following GEAR LUBRICANTS
conditions, it is considered severe service. SAE ratings also apply to multiple grade gear lubri­
• Extremely dusty areas. cants. In addition, API classification defines the lubri­
• 50% or more of vehicle operation in 32°C (90°F) or cants usage.
higher temperatures.
• Prolonged idling ( such as, vehicle operation in stop LUBRICANTS AND GREASES
and go traffic). Semisolid lubricants are rated by the NLGI and are
• Frequent short running periods. Not allowing en­ classified as grades 0,1,2,3,....
gine to warm to operating temperatures.
PARTS REQUIRING NO LUBRICATION
• Police or taxi usage.
Many components on a Chrysler Motors vehicle re­
FUEL USAGE quire no periodic maintenance. Some components are
sealed and permanently lubricated. Rubber bushings
All Chrysler Motors engines require the use of un­
can deteriorate or limit damping ability if lubricated.
leaded fuel to reduce exhaust emissions. Use fuel with
The following list of components require no lubrication:
a minimum octane rating of 87,(R + M)/2. See Engine
• Air Pump
section of this group for Fuel Recommendations.
• Alternator Bushings
CLASSIFICATION OF LUBRICANTS • Drive Belts
• Drive Belt Idler/Tensioner Pulley
Only lubricants that are endorsed by the following
(continued on page 3)
 LUBRICATION AND MAINTENANCE SCHEDULES
SCHEDULED MAINTENANCE FOR EMISSION CONTROL A N D PROPER VEH ICLE PERFORMANCE
Inspection and Service should also be performed any time a malfunctio n is observed or = Except California Vehicles
COMPONENT SBtWICt M IUAOf IN THOUSANDS 7.S IS 22.S m 973 m 5 2 .5 m ♦7 .5 75 • 2 .5 §© f 7 .5 105 112.5 1M
H iTM V A i KILOMETERS IN THOUSANDS 12 24 3* m m 72 m m 104 120 132 144 194 144 140 its
CHANGE ENGINE OIL EVERY 6 MONTHS OR X X X X X X o o o O O O O O O o
CHANGE ENGINE OIL FILTER EVERY SECOND OIL CHANGE (1) OR X X X o O o O o
INSPECT DRIVE BELTS POLY-V REPLACE AS NECESSARY AT o X o o O o o o
REPLACE SPARK PLUGS AT X o o o
REPLACE ENGINE AIR FILTER AND PCV FILTER AT X o o o
REPLACE OXYGEN SENSOR AT O*
REPLACE EGR VALVE & TUBE & CLEAN PASSENGES AT ©• O*
REPLACE DISTRIBUTOR CAP & ROTOR AT o* o
-REPLACE PCV V AT o* o#
REPLACE VACUUM OPERATED EMISSION COMPONENTS AT o o
INSPECT TIMING BELT 3.01 ONLY AT o o
ADJUST IGNITION TIMING IF NOT TO SPECIFICATIONS AT o o
REPLACE IGNITION CABLES, DISTRIBUTOR CAP 4 ROTOR AT o o
FLUSH &REPLACE ENGINE COOLANT AT 36 MONTHS OR o
& 24 MONTHS OR 30,000 MILES (48 000 Km) THEREAFTER
REPLACE DRIVE BELT AT o o
CHECK ENGINE COOLANT CONDITION, COOLANT HOSES & CLAMPS AT X X X X X o o 0 O O o o o O o
INSPECT EXHAUST SYSTEM AT X X X X X X o ...s u ,O .
...a ... J S U J B U o
(1) Note: If mileage is less than 7,500 miles (12,000 km) each 12 month#, replace oil filter of each oil change.
‘Service when Emissions Maintenance Lamp remains on continuously with key ON.
G ENERA L M A IN T E N A N C E SEiVlCES FOR PROPER VEHICLE PE1PORMANCE
. . . . , Mllaag^ i n Thousando 7.5 IS 22.5 i# S7.S 45
G eneral M aintenance
K ilom eters In Ihouoando 12 24 m 4S 60 72
Check & Service As Required Every 12 Months
Cooling System Drain, Flush, and Refill At 36 Months Or 52,500 Miles (84 000 Kilometers) And Every 24 Months Or 30,000 Miles
(48 000 Kilometers) Thereafter
Brake Hoses Inspect For Deterioration And Leaks Whenever Brake System is Serviced And Every 7,500 Miles (12 000 km) Or
12 Months, Whichever Occurs First, For Non-turbocharged Vehicles and 7,500 Miles (12 000 km) or 6 Months,
Whichever Occurs First, For Turbocharged Vehicles, Replace if Necessary.
Brake Linings—Front ’ At X X
Brake Linings—Rear ' At X X
Rear W heel Bearings inspect At X X
Tie Rod Ends and
Steering Linkage Lubricate Every 3 Years If Equipped With Fittings Or X
CV Joint Boots Inspect For Deterioration And Leaks Every Oil Change.
Replace if Necessary. Or X X X X X X
S iV I I I SERVICE MAINTENANCE*
- _ « _ M ileag e in Thousands 3 6 9 It IS IS 11 M 27 SO 33 iift i f 42 m 4S
K ilom eters in Thousands 4 .8 9 .6 14 I f 2 4 I t 3 4 i l l 4 3 *11 53 SS 62 6 7 72 7 7
Brake Linings (Front & Rear)
and Rear W heel Bearings Inspect X X X X X
Constant V elocity
Universal Joints Inspect at every oil change
Engine O il Refer to Frequency of Engine Oil and F ilter Changes
Engine O il F ilte r Paragraph in Engine Section of this Group
Front Suspension
Ball Joints Inspect at every oil change
Transmission Fluid and Change at (adjust bands at time of
FI Ite r—A utom atic fluid and filter change) X X X
Steering Linkage Lubricate every 18 months
Tie Rod Ends If Equipped With Fittings or X X X
Engine A ir F ilte r nspect and replace if required X X X
Power Transfer U nit Change Lubricant at X X X X
O verrunning Clutch Change Fluid at X X
D rive Line M odule Change Lubricant at X X

* Driving under any of the following operating conditions: Stop and go driving in dusty conditions, extensive idling, frequent short trips, operating at
sustained high speeds during hot weather (above + 30°C, + 90°F)
(continued from page 1)
• Front Wheel Bearings • Throttle Control Cable -
• Rubber Bushings • Throttle Linkage ■ '
• Starter Bearings/Bushings • Water Pump Bearings
• Suspension Strut Bearings

. FLUID CAPACITIES . \
in f In® Cooling System ' Liters U.S. Qts.
2 . 5 1 . .............. .. . ... . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9 .0 ' - 9.5 ■•
3.0L or 3.3L . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9.5 ’ 10.0 '' ' '
T hese, c a p a c itie s include .47 Liter (1 pint) fo r re co v e ry ta n k . ADD 0.95 Liters (1 qt.)
w h e n e q u ip p e d w ith r e a r h e a te r. .
Engine Crankcase* ; Liters . U.S. Of*.— ••
2.5L . . . . . . .v. . . . v . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4.3 ■■ '' 4.5 ■' • ■ .
3.01 . . . . . . . . . . . . v . 4. 3 > ,4.5
3.3L- . . . . . . _ . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4.3 ' , " 4.5
^Includes 0.4 liters (0.5 q ts.) fo r filter c h a n g e ’ .- .
Automatic Transaxle . . Llferf. ' • U.S. Of*.
Service Fill E stim ated C apacity
AH ... 3.8 ' ' 4 .0 .
O v e rh a u l Fill C apacity w ith c o n v e rte r e m p ty : . , .
A413 f l e e t 8. 7 . '9.2 ,. .
A413 o r A670 Lock-up .......................................... .................................................................................. 8 .0 8 .5
A604 U ltradrive ................................... .......................................................................................... 8 .6 9.1
Power Transfer Unit ’ - Liters ' •' . FI. Oss. ••
Fill to b o tto m of fill h o le. :'
All . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ..................................... i .. US ' ■ ' ' 3 8 .8 ^v
Overrunning Clutch ‘ . Liters FI. Ozs.
Fill to b o tto m of fill h o le. ' .■ '■ '
All . L.". . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ■ 0.37, 12.4 ■
Drive Line Module ^ Liters FI. Ozs.
Fill to b o tto m of fill h ole.
All . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ■ 1.9' 6 ■ • 64.2 .... , ■ ■’ ■
Power Steering 9 • ■ Liters , ' • U.S. Pints ■
All . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0.81 •■ 1.7
Fuel Tank ■■ / , ' ■ Litmm . ■ U.S. Gal. 9 .
S ta n d a rd . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 56.8 . . . . 15.0 ■ . ,
O p tio n a l . . 75.7 ' ' ' 20.0 9100-14

JUMP STARTING PROCEDURE TO JUMP START A DISABLED VEHICLES

WARNING: REVIEW ALL SAFETY PRECAUTIONS AND (1), hood vehicle and visually in-
WARNINGS IN GROUP 8A, BATTERY/STARTING/ spect engine compartment for.
CHARGING SYSTEMS DIAGNOSTICS. * Battery Cable damp C0ndltl0n>clean lf necessary-
DO NOT JUMP START A FROZEN BATTERY, PER- • Frozen battery
SONAL INJURY CAN RESULT. • Yellow or bright color test indicator, if equipped
DO NOT JUMP START WHEN BATTERY INDICA- • Low battery fluid level.
TOR DOT IS YELLOW OR BRIGHT COLOR. • Alternator drive belt condition and tension.
DO NOT ALLOW JUMPER CABLE CLAMPS TO # FUel fumes or leakage, correct if necessary.
TOUCH EACH OTHER WHEN CONNECTED TO A
BOOSTER SOURCE. CAUTION: If the cause of starting problem on disa-
DO NOT USE OPEN FLAME NEAR BATTERY. bled vehicle Is severe, damage to booster vehicle
REMOVE METALLIC JEWELRY WORN ON HANDS charging system can result.
OR WRISTS TO AVOID INJURY BY ACCIDENTAL When using another vehicle as a booster source,
ARCHING OF BATTERY CURRENT. turn off all accessories, place gear selector in park or
WHEN USING A HIGH OUTPUT BOOSTING DEVICE, neutralj set park bra^ or equivalent and operate
DO NOT ALLOW BATTERY VOLTAGE TO EXCEED en^ ne at 120o rpm.
16 VOLTS. REFER TO INSTRUCTIONS PROVIDED ^ vehicle, place gear selector in park
WITH DEVICE BEING USED. or neutral and set park brake or equivalent. Turn off
CAUTION: When using another vehicle as a booster, all accessories.
do not allow vehicles to touch. Electrical systems (4) Connect jumper cables to booster battery. RED
can be damaged on either vehicle. clamp to positive terminal (+). BLACK clamp to neg-
ative terminal (-). DO NOT allow clamps at opposite no. 2
end of cables to touch, electrical arc will result (Fig.
1). Review all warnings in this procedure.
(5) On disabled vehicle, connect RED jumper cable
clamp to positive (+ ) terminal. Connect BLACK jumper
cable clamp to engine ground as close to the ground
cable attaching point as possible (Fig. 1).
BOOSTER NEGATIVE JUMPER
BATTERY CABLE

POSITIVE JUMPER
CABLE
R :2 3 -l/2 " R :1 8 -l/2 "

DISCHARGED
BATTERY

BATTERY NEGATIVE
CABLE

DO NOT ALLOW VEHICLES TO TOUCH 9100-3

Fig. 1 Jumper Cable Clamp Connections

CAUTION: Do not crank starter motor on disabled

vehicle for more than 15 seconds, starter will over­
heat and could fail.
(6) Allow battery in disabled vehicle to charge to at
least 12.4 volts (75% charge) before attempting to
start engine. If engine does not start within 15 sec­
onds, stop cranking engine and allow starter to cool
(15 min.), before cranking again.
DISCONNECT CABLE CLAMPS AS FOLLOWS:
• Disconnect BLACK cable clamp from engine ground
on disabled vehicle.
• When using a Booster vehicle, disconnect BLACK
cable clamp from battery negative terminal. Discon­
nect RED cable clamp from battery positive terminal.
• Disconnect RED cable clamp from battery positive
terminal on disabled vehicle.
I DRIVE-ON HOIST I TWIN POST HOIST
I FRAME CONTACT HOIST FLOOR JACK
9100-18
Fig. 2 Hoisting and Jacking Points
TOWING RECOMMENDATIONS
RECOMMENDED TOWING EQUIPMENT
To avoid damage to bumper fascia and air dams use
of a wheel lift or flat bed towing device (Fig. 3) is
recommended. When using a wheel lift towing device,
be sure the unlifted end of disabled vehicle has at
least 100 mm (4 in.) ground clearance. If minimum
ground clearance cannot be reached, use a towing
dolly. If a flat bed device is used, the approach angle
should not exceed 15 degrees.

HOISTING RECOMMENDATIONS
Refer to Owner’s Manual provided with vehicle for
proper emergency jacking procedures.
WHEEL LIFT
WARNING: THE HOISTING AND JACK LIFTING POINTS
PROVIDED ARE FOR A COMPLETE VEHICLE. WHEN
THE ENGINE OR REAR SUSPENSION IS REMOVED
FROM A VEHICLE, THE CENTER OF GRAVITY IS
ALTERED MAKING SOME HOISTING CONDITIONS
FUT BED 9100-17
UNSTABLE. PROPERLY SUPPORT OR SECURE VE­
HICLE TO HOISTING DEVICE WHEN THESE CONDI­
Fig. 3 Recommended Towing Devices
TIONS EXIST.
GROUND CLEARANCE CAUTION: Do not damage brake lines, exhaust sys­
CAUTION: If vehicle is towed with wheels removed, tem, shock absorbers, sway bars, or any other under
install lug nuts to retain brake drums or rotors. vehicle components when attaching towing device
to vehicle.
A towed vehicle should be raised until lifted wheels
Remove or secure loose or protruding objects from
are a minimum 100 mm (4 in) from the ground. Be
a damaged vehicle before towing.
sure there is adequate ground clearance at the oppo­
Refer to state and local rules and regulations be­
site end of the vehicle, especially when towing over
fore towing a vehicle.
rough terrain or steep rises in the road. If necessary,
Do not allow weight of towed vehicle to bear on
remove the wheels from the lifted end of the vehicle
lower fascia, air dams, or spoilers.
and lower the vehicle closer to the ground, to increase
the ground clearance at the opposite end of the vehi­
TOWING—FRONT WHEEL LIFT
cle. Install lug nuts on wheel attaching studs to retain
Chrysler Motors recommends that a vehicle be towed
brake drums or rotors.
with the front end lifted, whenever possible.
LOCKED VEHICLE TOWING
TOWING—REAR WHEEL LIFT
When a locked vehicle must be towed with the front
If a front wheel drive vehicle cannot be towed with
wheels on the ground, use a towing dolly or flat bed
the front wheels lifted, the rear wheels can be lifted
hauler.
provided the following guide lines are observed.
FLAT TOWING WITH TOW BAR CAUTION: Do not use steering column lock to se­
• Ultradrive 4-speed automatic transaxle vehicles can cure steering wheel during towing operation.
be flat towed at speeds not to exceed 72 km/h (44 mph)
• Unlock steering column and secure steering wheel
for not more than 160 km (100 miles). The steering
in straight ahead position with a clamp device de­
column must be unlocked and gear selector in neutral.
signed for towing.
• 3-speed automatic transaxle vehicles can be flat towed
• Verify that front drive line and steering components
at speeds not to exceed 40 km/h (25 mph) for not more
are in good condition.
than 25 km (15 miles). The steering column must be
unlocked and gear selector in neutral. • Ultradrive 4-speed automatic transaxle vehicles can
be towed at speeds not to exceed 72 km/h (44 mph) for
WARNING: DO NOT ALLOW TOWING ATTACHMENT not more than 160 km (100 miles). The gear selector
DEVICES TO CONTACT THE FUEL TANK OR LINES, must be in neutral position.
FUEL LEAK CAN RESULT. • 3-speed automatic transaxle vehicles can be towed
DO NOT LIFT OR TOW VEHICLE BY FRONT OR at speeds not to exceed 40 km/h (25 mph) for not more
REAR BUMPER, OR BUMPER ENERGY ABSORBER than 25 km (15 miles). The gear selector must be in
UNITS. neutral position.
DO NOT VENTURE UNDER A LIFTED VEHICLE IF
NOT SUPPORTED PROPERLY ON SAFETY STANDS.
DO NOT ALLOW PASSENGERS TO RIDE IN A
TOWED VEHICLE.
USE A SAFETY CHAIN THAT IS INDEPENDENT
FROM THE TOWING ATTACHMENT DEVICE.
 ENGINE
INDEX

Page Page
Battery ................................................................. .......... 13 Engine Oil Filter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
Crankcase Ventilation System . . . . . ...... .................... 11 Frequency of Engine Oil and Filter Changes . . . . . . . 6
Drive Belts ......................................... ........................... 12 Fuel Filter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
Emission Control System ................................. ............ 12 Fuel Recommendations . . . . . . . . . . . . . . . . . . . . . . . . 12
Engine Air Cleaner ............................................. .. 9 Ignition Cables, Distributor Capf and Rotor . . . . . . . 12
Engine Cooling System .................................................. 8 Rubber and Plastic Component Inspection . . . . . . . . 13
Engine Oil ...................................................................... 6 Spark Plugs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12

FREQUENCY OF ENGINE OIL AND FILTER CHANGES OIL PROPERLY. CONTACT YOUR DEALER OR GOV­
ERNMENT AGENCY FOR LOCATION OF COLLEC­
ENGINE OIL TION CENTER IN YOUR AREA..
Road conditions as vsrell- as;"your "Mud of driving
affect the interval at which -your oil should be"changed. BREAK-IN PERIOD
Check the following to determine i f any apply to you: CAUTION; Wide open throttle operation in low gears,
• Frequent short trip driving less than 8 kilometers (5 before engine break-in period is complete, can dam­
miles) age engine.
• Frequent driving in dusty conditions... f. On a Chrysler Motors vehicle an extended break-in
• Frequent trailer towing period is not required. Driving speeds of 'not over
• Extensive idling (such as vehicle operation in stop 80-90 km/h (50-55 mph) for the first 100 km (60
and go traffic) miles) is recommended. 'Hard acceleration and high
• More than 50% of your driving is at sustained high engine rpm in lower gears should be avoided.
speeds during hot weather, above 32°C (90°F )
If any of these apply to you then change your en­ SELECTING ENGINE OIL
gine oil every 4 800 kilometers (3,000 miles) or 3 CAUTION: Do not yse non-detergent or straight min­
months, whichever comes first. eral oil when adding or changing crankcase lubri­
If none of these apply to you then change your oil cant. "Engine or Turbocharger failure can result. :
every 12. 000 kilometers (7,500 miles) or 8 months, The factory fill engine oil is a high quality, energy
whichever comes first. conserving, crankcase lubricant. The Recommended
If none of these apply and'the vehicle is in commer­ SAE Viscosity Grades chart defines the viscosity
cial type service such as,'Police, Taxi or Limousine grades that must be used based on temperature in the
used for highway driving of 40 kilometers (25 miles) region where vehicle is operated (Fig. 1) and optional
or more between stations, the engine oil should be equipment. ■ . ■ ■,
changed every 8 000 kilometers (5,000 miles) or 6 Chrysler Motors recommends that Mopar® motor oil,
months. or equivalent, be used when adding or changing crank­
case lubricant. The API symbol (Fig. 2) on the con­
OIL FILTER tainer indicates the viscosity grade, quality and fuel
The engine oil filter should be replaced with a new economy ratings of the lubricant it contains. Use EN­
filter at every second oil change. ERGY CONSERVING 11 motor oil with API SER­
VICE SG or SG/CD classification.
ENGINE OIL • SG service engine oil is a high quality crankcase
lubricant designed for use in all naturally aspirated
WARNING: NEW OR USED ENGINE OIL CAN BE IR­ engines.
RITATING TO THE SKIN. AVOID PROLONGED OR • SG/CD service engine oil is a high quality crankcase
REPEATED SKIN CONTACT WITH ENGINE OIL CON­ lubricant designed for use in most naturally aspirated
TAMINANTS IN USED ENGINE OIL, CAUSED BY IN- and turbocharged gasoline or diesel engines.
IERNAL COMBUSTION, CAN BE HAZARDOUS TO
• SAE 5W-30 engine oil is recommended for use in
YOUR HEALTH. THOROUGHLY 'WASH EXPOSED
3.0L and 3.3L engines in temperatures below 38°C
SKIN WITH SOAP AND WATER.
(100°F) to reduce low temperature cranking effort.
DO NOT WASH SKIN WITH GASOLINE, DIESEL
SAE 5W-30 engine oil is not recommended for use in
FUEL, THINNER, OR SOLVENTS, HEALTH PROBLEMS
2.5L engine in temperatures above 0°C (32°F).
CAN RESULT.
DO NOT POLLUTE, DISPOSE OF USED ENGINE • SAE 10W-30 engine oil is recommended for use in
2.5L engine in temperatures above -18°C (0°F).
 Recommended Viscosity Grades ENGINE OIL ADDITIVES
Chrysler Motors recommends that Mopar® Engine
I— .....i . i : i i i Oil Supplement or equivalent be used when friction
_____________ 10W-30______________ > and corrosion reducing materials added to the crank­
5W -30 EXCEPT 2.5 L ENG INE case lubricant is desired.
5W -30 2.5 L ENGINE
CRANKCASE OIL LEVEL INSPECTION
CAUTION: Do not overfill crankcase with engine oil,
F-20 0 10 20 32 60 80 100
C-29 -18 -12 -7 0 16 27 38
oil foaming and oil pressure loss can result.
TEMPERATURE RANGE ANTIC IPATED BEFO RE NEXT OIL Inspect engine oil level approximately every 800
CHANGE.
kilometers (5 0 0 miles). Position vehicle on level sur­
9100-19 face. With engine OFF, allow enough time for oil to
settle to bottom of crankcase, remove engine oil level
indicator (dipstick) and wipe clean. Install dipstick
and verify it is seated in the tube. Remove dipstick,
with handle above tip, take oil level reading (Fig. 3).
Add oil only if level is below MIN or ADD mark on
dipstick.

Fig. 3 Oil Level Indicator Dipstick—Typical

ENGINE OIL CHANGE

Change engine oil at mileage and time intervals
described in Lubrication and Maintenance Schedules.

TO CHANGE ENGINE OIL:

Fig. 1 Shaded Areas Cover Regions Where
Minimum Temperatures Can Be Consistently Below
-12°C (10°F) During Winter Seasons
(1) OIL QUALITY
(2) SAE GRADE
(3) FUEL ECONOMY BENEFIT
(1) Position the vehicle on a level surface.
(2) Hoist and support vehicle on safety stands. Refer
to Hoisting and Jacking Recommendations in this
group.
(3) Place a suitable 3.8 liter (4 qt.) drain pan under
crankcase drain.
(4) Remove drain plug from crankcase and allow oil
to drain into pan. Inspect drain plug threads for stretch­
ing or other damage. Replace drain plug and gasket if
damaged.
(5) Install drain plug in crankcase.
(6) Lower vehicle and fill crankcase with specified
type and amount of engine oil described in this section.
(7) Start engine and inspect for leaks.
(8) Stop engine and inspect oil level.

Fig. 2 API Symbol

ENGINE OIL FILTER
SELECTING OIL FILTER
Chrysler Motors recommends a Mopar® or equivalent
oil filter be used when replacement is required. A
replacement filter must be designed to withstand 1756
kPa (256 psi) of internal pressure.
OIL FILTER REMOVAL:
(1) Position a drain pan under the oil filter.
(2) Using a suitable oil filter wrench (Fig. 4) loosen
filter.
(3) When filter separates from adapter nipple, tip
gasket end upward to minimize oil spill. Remove filter
from vehicle.
(4) With a wiping cloth, clean the gasket sealing
surface (Fig. 5) of oil and grime. Wipe off oil residue
from below oil filter adapter.
OIL FILTER INSTALLATION:
(1) Lightly lubricate oil filter gasket with engine oil
or chassis grease.
(2) Thread filter onto adapter nipple. When gasket
makes contact with sealing surface, tighten filter one
full turn. If necessary use a filter wrench, do not over
tighten.
(3) Add oil, verify crankcase oil level and start en­
gine. Inspect for oil leaks.
Fig. 4 Remove Oil Filter
Fig. 5 Install Oil Filter
ENGINE COOLING SYSTEM
WARNINGS AND PRECAUTIONS
WARNING: ANTIFREEZE IS AN ETHYLENE GLYCOL
BASE COOLANT AND IS HARMFUL IF SWALLOWED
OR INHALED. IF SWALLOWED, DRINK TWO GLASSES
OF WATER AND INDUCE VOMITING. IF INHALED,
MOVE TO FRESH AIR AREA. SEEK MEDICAL AT­
TENTION IMMEDIATELY. DO NOT STORE IN OPEN
OR UNMARKED CONTAINERS. WASH SKIN AND
CLOTHING THOROUGHLY AFTER COMING IN CON­
TACT WITH ETHYLENE GLYCOL. KEEP OUT OF
REACH OF CHILDREN.
DISPOSE OF GLYCOL BASE COOLANT PROPERLY,
CONTACT YOUR DEALER OR GOVERNMENT AGEN­
CY FOR LOCATION OF COLLECTION CENTER IN
YOUR AREA.
DO NOT OPEN A COOLING SYSTEM WHEN THE
ENGINE IS AT RUNNING TEMPERATURE, PERSONAL
INJURY CAN RESULT.
AVOID RADIATOR COOLING FAN WHEN ENGINE
COMPARTMENT RELATED SERVICE IS PERFORMED,
PERSONAL INJURY CAN RESULT.
CAUTION: Do not use straight antifreeze as engine
coolant, inadequate engine running temperatures can
result.
Do not operate vehicle without proper concentra­
tion of recommended ethylene glycol coolant, high
running temperatures and cooling system corrosion
can result.
The engine cooling system will develop internal pres­
sure of 97 to 123 kPa (14 to 18 psi) at normal operat­
ing temperature. Allow the vehicle approximately one
half hour to cool off before opening the cooling system.
As an indicator of pressure, squeeze the upper radia­
tor hose between index finger and thumb. If it col­
lapses with little effort the system would have low
internal pressure and should be safe to open to the
first safety notch of the radiator cap. Refer to Group 7,
Cooling System.
COOLING SYSTEM INSPECTION
Coolant level (Fig. 6) should be inspected when other
engine compartment service is performed or when cool­
ant leak is suspected. Coolant recovery tank level
should read between the MIN and MAX marks, lo­
cated on the side of recovery tank, when the engine is
at normal operating temperature. Normal coolant level
maintenance does not require the removal of radiator
cap. Cooling system freeze protection should be tested
at the onset of the winter season or every 12 months.
Service is required if coolant is low, contaminated,
rusty or freeze protection is inadequate. To properly
test cooling system, see Group 7, Cooling System.

Fig. 6 Coolant Recovery Tank—Typical
The cooling system factory fill is a mixture of 50%
Glycol based antifreeze and 50% water. Using a suit­
able hydrometer, measure antifreeze concentration in
the radiator when the engine is cool. If the cooling
system has recently been serviced, allow coolant to
circulate for at least 20 minutes before taking hy­
drometer reading. Properly mixed coolant will protect
the cooling system to -37°C (-35°F). If the freeze pro­
tection is above -28°C (-20°F), drain enough coolant
from the cooling system to allow room to add anti­
freeze to achieve adequate protection. A mix table on
the coolant container indicates the amount of anti­
freeze required to winterize the cooling system based
on the capacity, see Capacity Chart in General Infor­
mation section of this group.
SELECTING ANTIFREEZE
Chrysler Motors recommends Mopar® Antifreeze/
Summer Coolant, or equivalent be used to winterize
and protect cooling system.
RADIATOR CAP
The radiator cap must be secure to provide proper
pressure release and coolant recovery. Inspect and
test radiator cap when cooling system service is per­
formed or when problem is suspected.
COOLING SYSTEM SERVICE
The cooling system should be drained, flushed and
filled with the proper coolant mixture at the intervals
described in the Lubrication and Maintenance Sched­
ules. Refer to General Information section of this group.
For proper service instructions see Group 7, Cooling
System.
ENGINE AIR CLEANER
The engine air cleaner should be serviced at the
intervals described in the Lubrication and Mainte­
nance Schedules. Refer to General Information section
of this group. Additional information can be found in
Group 14, Fuel System and Group 25, Emission Sys­
tem. Inspect all air cleaner hoses or tubes for damage
or leaks when other engine compartment service is
performed. Replace faulty components.
AIR CLEANER SERVICE
CAUTION: The air cleaner cover must be installed
properly for the emissions system and engine con­
troller to function correctly.
Do not immerse paper air filter element or temper­
ature sensor In cleaning solvents, damage can result.
TO SERVICE AIR CLEANER ASSEMBLY:
(1) Raise hood of vehicle and inspect all air cleaner
components for damage or improper attachment.
(2) Remove air cleaner cover (Figs. 7, 8 or 9).
(3) Remove paper air filter element from air cleaner
body. Hold a shop light on throttle body side of ele­
ment. Inspect air intake side of element. If light is
visible through element, blow dust from element (Fig.
10) and reuse. If element is saturated with oil or light
is not visible, replace filter. If element is saturated
with oil, perform crankcase ventilation system tests.
(4) Remove fiber crankcase filter (Figs. 7, 8 or 9)
and clean with solvent, squeeze filter dry and apply
small amount of engine oil. If a metallic mesh is used
to retain fiber filter, clean mesh with solvent and
reuse.
(5) Clean inside of air cleaner cover and body with
vacuum or compressed air. If oily, wash with solvent.
To Install, reverse the preceding operation.
Fig. 7 Air Cleaner Assembly—3.0L Engine
 FI BER CRANKCASE -^-1 A I R CLEANER COVER
FILTER (CLEAN AND OIL LI GHTLY)

COVER HOLD-
DOWN BAILS (4)

PAPER AIR FILTER'

ELEMENT RROODl

Fig. 8 Air Cleaner Assembly—2.5L EFI Engine

9000-10

Fig. 9 Air Cleaner Assembly—3.3L Engine

 CtANKtASE'VENI INTAKE MANIFOLD
HOSE VACUUM HOSE

rn m m m m 9000-12

Pig. 12 PCW System—3.3L Engine

CRANKCASE VENTILATION SYSTEM ' ' CYLINDER

HEAD COVER
Engine crankcase pressure and emissions are vented
into combustion chambers" through the positive crank­
case ventilation (PCV) system. The PCV-system-con­
sists of' a crankcase filter (Figs. 7, 8 or 9), PCV valve
(Figs. 11, 12 or 13) and hoses to complete a vacuum
circuit. The PCV system should have enough volume
to overcome crankcase pressure created by piston back­
wash. If a PCV system becomes plugged, the crank­
case pressure will increase and force engine oil past
the piston rings creating oil consumption. Blockage of
PCV system can occur at the vacuum source coupling,
PCV valve, crankcase filter or a collapsed hose, AIR CLEANER
Chrysler Motors recommends that a PCV valve not RR00D5 ASSEMBLY
be cleaned. A new Mopar® or equivalent PCV valve
should be installed when servicing is required. Over a , ■ FI®. 13 PCW System ..iu ii EFI Engine
period of time, depending on the environment where
PCV S Y S T E M T E S T
vehicle is used, deposits build up in the PCV vacuum
(1) Verify'-that fiber crankcase filter is clean-and
circuit. PCV system should be inspected at every oil
properly installed in the air cleaner assembly.
change. Service PCV system if engine oil is discharged
(2) With the engine running at idle, remove crank­
into air cleaner. '
case inlet hose from the inlet filter nipple. Position a
SO mm (2 in.) square paper card over end of inlet hose.
M B P CYLINDER HEAD
COVER
The'"card should be drawn to the end of the inlet hose
within 15 seconds. If not, a leak or restriction exists in
the PCV vacuum circuit.
' (3)' If card does not hold to end of inlet hose, discon­
nect PCV valve from cylinder head cover or adapter.
Vacuum hissing sound should be heard and engine
should run steady. Place a finger over end of PCV
valve' (Fig. 14). The check valve in the PCV valve
should click and rattle when PCV valve is shaken.
(4) Remove PCV valve from vacuum source ‘hose.
The engine should run very erratically or stall. If not,
a vacuum restriction or blockage exists at the vacuum
source.

Fig. 11 PCW System—3.0L Engine


9025-47
Fig. 14 PCV Valve Test
FUEL RECOMMENDATIONS
Chrysler Motors recommends that only fuel pur­
chased from a reputable retailer be used. Use high
quality, unleaded gasoline to provide satisfactory
driveability and highest fuel economy. Gasoline con­
taining detergent and corrosion control additives are
desireable. If the engine develops spark knock (audi­
ble ping), poor performance, hard starting or stalling,
purchase fuel from another source. Engine performance
can vary when using different brands of gasoline with
the same octane rating. Occasional light engine spark
knock under heavy acceleration, at low speed or when
vehicle is heavily loaded is not harmful. Extended
periods of spark knock under moderate acceleration or
at cruising speed can damage the engine. The cause of
excessive spark knock condition must be diagnosed
and corrected. For diagnostic procedures refer to Group
14, Fuel System and Powertrain Diagnostic Proce­
dures manual.
SELECTING GASOLINE
CAUTION:Do not use fuel containing METHANOL
(methyl or wood alcohol), damage to fuel system will
result.
Do not use leaded gasoline, damage to catalytic
converter will result and vehicle will not conform to
emission control standards.
NON-BLENDED GASOLINE
Use regular unleaded gasoline having a minimum
octane rating of 87 (R + M)/2. Higher octane premium
unleaded gasoline can be used if desired.
ETHANOL OR MTBE BLENDS
All Chrysler Motors vehicles are designed to use
unleaded gasoline ONLY. Gasohol blends, containing
10% Ethanol (ethyl or grain alcohol) 90% unleaded
gasoline can be used provided it has adequate octane
rating. Fuel blends containing up to 15% MTBE
(Methyl Tertiary Butyl Ether) and 85% unleaded gas­
oline can also be used.
METHANOL BLENDS
Using gasoline blended with methanol can result in
starting and driveability problems. Deterioration of
fuel system components will result. Methanol induced
problems are not the responsibility of Chrysler Motors
and may not be covered by the vehicle warranty.
FUEL FILTER
The fuel filter requires service only when a fuel
contamination problem is suspected. For proper diag­
nostic and service procedures refer to Group 14, Fuel
System,
IGNITION CABLES, DISTRIBUTOR CAP, AND ROTOR
Inspect and test ignition cables, distributor cap and
rotor when the spark plugs are replaced, oil and grime
should be cleaned from the ignition cables and distrib­
utor cap to avoid possible spark plug fouling. Mopar®,
Foamy Engine Degreaser, or equivalent is recom­
mended for cleaning the engine compartment. For
proper service and diagnostic procedures refer to Group
8D, Ignition System.
SPARKPLUGS
Ignition spark plugs should be replaced at the mile­
age interval described in the Lubrication and Mainte­
nance Schedules. Refer to the General Information
section of this group. For proper service procedures
refer to Group 8D, Ignition Systems.
DRIVE BELTS
Inspect and adjust drive belts at the interval de­
scribed in the Lubrication and Maintenance Sched­
ules. Refer to General Information section of this group.
For proper inspection and adjustment procedures, see
Group 7, Cooling System.
EMISSION CONTROL SYSTEM
Inspect all emission control components and hoses
when other under hood service is performed. Refer to
emission system Vacuum Hose Label located on the
inside of the hood in the engine compartment and
Group 25, Emission Control Systems for proper ser­
vice procedures.
BATTERY
Inspect battery tray, hold down and terminal con­
nections when other under hood service is performed.
For proper diagnostic procedures refer to Group 8A,
Battery/Starting/Charging System Diagnostics. For ser­
vice and cleaning procedures refer to Group 8B, Battery/
Starter Service.
RUBBER AND PLASTIC COMPONENT INSPECTION
CAUTION: Plastic hoses or wire harness covers will
melt or deform when exposed to heat from exhaust
system or engine manifolds.
Position plastic or rubber components away from
moving parts in engine compartment or under vehi­
cle, or damage will result.
Do not allow rubber engine mounts or other com­
ponents to become oil contaminated, repair cause of
oil contamination and clean area.
DRIVETRAIN
INDEX
Page
Automatic Transaxle ..................................... ................ 13
Automatic Transaxle Shift Mechanism .....................13
Drive Line M o d u le .......................................................... 15
Drive Shaft CV and Tripod Joint Boots .....................15
Front Wheel Bearings (Rear Wheel Bearings
on all Wheel Drive M o d e ls .......... ............................ 15
AUTOMATIC TRANSAXLE SHIFT MECHANISM
If the automatic transaxle shift mechanism becomes
difficult to operate or starts to make objectionable
noise, the mechanism should be lubricated before other
service repair is performed. Apply a film of Mopar®
Multipurpose Grease or equivalent, to slide surfaces
and pawl spring. For additional information, refer to
Group 21, Transaxle.
AUTOMATIC TRANSAXLE
The automatic transaxle should be inspected for
fluid leaks and proper fluid level when other under
hood service is performed.
CAUTION: To minimize fluid contamination, verify
that dipstick is seated in the fill hole or tube after
fluid level reading is taken.
TO INSPECT THE TRANSAXLE FLUID LEVEL:
(1) Position the vehicle on a level surface.
(2) Start engine and allow to idle in PARK for at
least 60 seconds. The warmer the transaxle fluid, the
more accurate the reading.
All rubber and plastic components should be in­
spected when engine compartment or under vehicle
service is performed. When evidence of deterioration
exists, replacement is required. To reduce deteriora­
tion of rubber components, Chrysler Motors recom­
mends Mopar® Foamy Engine Degreaser or equivalent
be used to clean engine compartment of oil and road
grime.
EXHAUST SYSTEM ISOLATOR AND HANGER
The exhaust system should be inspected when un­
der vehicle service is performed. The exhaust system
should not make contact with under body, brake ca­
bles, brake/fuel lines, fuel tank or suspension compo­
nents. Slight cracking in rubber isolator or hanger is
acceptable. Severely cracked or broken rubber compo­
nents must be replaced. For proper service procedures
see Group 11, Exhaust System and Intake Manifold.
Page
Overrunning Clutch.................................................. 15
Power Transfer Unit .................................................14
Tires ........................ ...............................................16
(3) While sitting in driver seat, apply brakes and
place gear selector in each position. Return gear selec­
tor to park.
(4) Raise hood and remove transaxle fluid level in­
dicator (dipstick) and wipe clean with a suitable cloth.
(5) Install dipstick and verify it is seated in fill hole
or tube (Fig. 1 or 2).
CAUTION: Do not overfill automatic transaxle, leak­
age or damage can result.
(6) Remove dipstick, with handle above tip, take
fluid level reading (Fig. 3). If the vehicle has been
driven for at least 15 minutes before inspecting fluid
level, transaxle can be considered hot and reading
should be above the WARM mark. If vehicle has run
for less than 15 minutes and more than 60 seconds
transaxle can be considered warm and reading should
be above ADD mark. Add fluid only if level is below
ADD mark on dipstick when transaxle is warm.
The automatic transaxle does not require periodic
maintenance when used for general transportation. If
the vehicle is subjected to severe service conditions,
the automatic transaxle will require fluid/filter change
and band adjustments every 24 §00 km (15 000 miles).
For additional information, refer to Severe' Service
paragraph and Lubrication and Maintenance Sched­ AUTOMATIC TRANSAXLE
ules in General Information section of this group. The FlUID-LEVEL INDICATOR
fluid and' filter should be changed when water'con­ • : (DIPSTICK)
tamination is suspected. If fluid has foamy or milky
appearance, it is probably contaminated. If the fluid ..SEE SELECTION OF LUBRICANT
appears brown or dark and a foul odor is apparent, the FOR RECOMMENDED FLUID TYPE
fluid is burned, transaxle requires maintenance or
8900-4
service. A circular magnet located in the transaxle
pan, collects metallic particles circulating in the oil.
For proper diagnostic and service procedures, refer to Fig. 3 Automatic Transaxle Dipstick—Typical
Group 21,. Automatic Transaxle.
POWER TRANSFER UNIT
SELECTING AU TO M ATIC T M N S A X I E FLUID
The All Wheel Drive (AWD) power transfer unit
Chrysler Motors recommends Mopar® ATF Plus (au­
should be inspected for oil leaks and proper oil level
tomatic transmission fluid type 7178) be used to add
when other under vehicle .service is performed. To
to or replace automatic transaxle fluid. If ATF Plus is
inspect the power transfer unit oil level, position the
not available use Mopar® Dexron 11®Automatic Trans­
vehicle on a level surface and remove fill plug (Fig. 4)
mission Fluid or equivalent.
from the unit. The oil level should be at the bottom
edge of oil fill opening.
The power transfer unit does not require periodic
maintenance when subjected to normal driving condi­
tions. The oil should be changed when water contami­
nation is suspected. If oil has foamy or milky appearance
it probably is contaminate^- If the vehicle is subjected
to severe driving conditions, the power -transfer unit
would require periodic maintenance every 29 000 km
(12,000 miles). Refer to Severe Service paragraph in
General Information of this ’group for definition of
severe service, A magnet located in the unit, to collect
metallic particles circulating in the oil. For proper
diagnostic and service procedures, refer to Group 21,
Transaxle/Power Transfer Unit.

SELECTING L U B R IC A N T '' : ‘
Fig. I Automatic Transaxle Fill liole . Chrysler Motors recommends Mopar® Gear Lube, SAE
85W-90, or equivalent, be used to fill the power trans­
fer unit.

Fig. 2 Ultradrive Automatic Transaxle Fill tube

Fig. 4 Power Transfer Unit Fill Plug

OVERRUNNING CLUTCH severe driving conditions, the drive line module would
require periodic maintenance every 36 000 km (22,500
The All Wheel Drive (AWD) overrunning clutch miles). Refer to Severe Service paragraph in General
should be inspected for oil leaks and proper oil level Information of this group for definition of severe ser­
when other under vehicle service is performed. To vice. For proper diagnostic and service procedures,
inspect the overrunning clutch oil level, position the refer to Group 3, Rear Suspension and Driveline.
vehicle on a level surface and remove fill plug (Fig. 5)
from the unit. The oil level should be at the bottom SELECTING LUBRICANT
edge of oil fill opening. Chrysler Motors recommends Mopar® Gear Lube, SAE
The overrunning clutch does not require periodic 85W-90, or equivalent, be used to fill the drive line
maintenance when subjected to normal driving condi­ module.
tions. The oil should be changed when water contami­
nation is suspected. If oil has foamy or milky appearance
it probably is contaminated. If the vehicle is subjected
to severe driving conditions the overrunning clutch
would require periodic maintenance every 36 000 km
(22,500 miles). Refer to Severe Service paragraph in
General Information of this group for definition of severe
service. For proper diagnostic and service procedures,
refer to Group 3, Rear Suspension and Driveline.

SELECTING LUBRICANT
Chrysler Motors recommends Mopar® ATF Plus (au­
tomatic transmission fluid type 7176) or equivalent, Fig. 6 Drive Line Module Fill Plug
be used to add to or replace overrunning clutch fluid.
DRIVE SHAFT CV AND TRIPOD JOINT BOOTS
The front drive shaft constant velocity and tripod
joint boots (Fig. 7) should be inspected when other
under vehicle service is performed. Inspect boots for
cracking, tears, leaks or other defects. If service repair
is required, refer to Group 2, Suspension.

Fig. 5 Overrunning Clutch Fill Plug

DRIVE LINE MODULE

The drive line module should be inspected for oil
leaks and proper oil level when other under vehicle
service is performed. To inspect the power transfer
unit oil level, position the vehicle on a level surface Fig. 7 Drive Shaft Boots
and remove fill plug (Fig. 6) from the module. The oil
level should be at the bottom edge of oil fill opening. FRONT WHEEL BEARINGS (REAR WHEEL BEARINGS
The drive line module does not require periodic main­ ON ALL WHEEL DRIVE MODELS)
tenance when subjected to normal driving conditions.
The oil should be changed when water contamination The front wheel bearings are permanently sealed,
is suspected. If oil has foamy or milky appearance it requiring no lubrication. For proper diagnostic and
probably is contaminated. If the vehicle is subjected to service procedures refer to Group 2, Suspension.
TIRES inflation specifications refer to the Owner’s Manual.
A Tire Inflation sticker is located in the driver door
The tires should be inspected at every engine oil opening. For proper diagnostic procedures, see Group
change for proper inflation and condition. For tire 22, Wheels and Tires.

CHASSIS AND BODY

INDEX
Page
Body Lubrication___ 19 Power Steering .............................................................. 17
B rakes......................... 19 Rear Wheel Bearings (Front
Headlamps ................. 19 Wheel Drive Only) ......................................................
Lower Ball J o in ts ___ 16 Steering Linkage ............................................................

STEERING LINKAGE
INSPECTION
The steering linkage and steering gear should be
inspected for wear, leaks or damage when other under
vehicle service is performed. The rack and pinion steer­
ing gear end boots should not have excess oil or grease
residue on the outside surfaces or surrounding areas
(Fig.l). If boot is leaking, it should be repaired. For
proper service procedures, see Group 19, Steering.
The tie rod end seal should fit securely between the
steering knuckle and tie rod end (Fig.2). The steering
linkage should be lubricated at the time and distance
intervals described in the Lubrication and Mainte­
nance Schedules. Refer to General Information section
of this group.

TIE ROD END LUBRICATION

Lubricate the steering linkage with Mopar®, Multi­
mileage Lube or equivalent. Using a wiping cloth,
clean grease and dirt from around grease fitting and
joint seal. Using a grease gun, fill tie rod end until
lubricant leaks from around the tie rod end side of the
seal (Fig.2). When lube operation is complete, wipe off
excess grease.
LOWER BALL JOINTS
INSPECTION
The front suspension lower ball joints should be
inspected for wear, leaks or damage when other under
vehicle service is performed. The ball joint seal should
fit securely between the steering knuckle and lower
control arm (Fig. 3). The ball joints should be lubri­
cated at the time and distance intervals described in
the Lubrication and Maintenance Schedules. Refer to
the General Information section of this group.

BALL JOINT LUBRICATION

Fig. 1 Inspect Steering Linkage
CAUTION: Do not over fill ball joint with grease,
damage to seal can result.
Lubricate the ball joints with Mopar®, Multi-mileage
Lube or equivalent. Using a wiping cloth, clean grease
and dirt from around grease fitting and joint seal.
Using a grease gun, fill ball joint until seal starts to
swell (Fig. 3). When lube operation is complete, wipe
off excess grease.
(4) Remove reservoir cap or dipstick and wipe off
fluid.
(5) Install cap or dipstick.
(6) Remove cap or dipstick. Holding handle or cap
above tip of dipstick, read fluid level (Fig. 4, 5, or 6).
Add fluid if reading is below cold level mark on dipstick.

Fig. 3 Ball Joint Lubrication

POWER STEERING
The power steering fluid level should be inspected
when other under hood service is performed. If the
fluid level is low and system is not leaking, use Mopar®,
Power Steering Fluid or equivalent. The power steer­
ing system should be inspected for leaks when other
under vehicle service is performed. For proper service
procedures, refer to Group 19, Steering.
The power steering pump drive belt should be in­
spected at the time and distance interval described in
the Lubrication and Maintenance Schedules. Refer to
the General Information section of this group.

POWER STEERING FLUID INSPECTION

WARNING: ENGINE MUST NOT BE RUNNING WHEN
INSPECTING POWER STEERING FLUID LEVEL, PER­
SONAL INJURY CAN RESULT.
CAUTION: Do not over fill power steering reservoir
when adding fluid, seal damage and leakage can
result.

TO INSPECT FLUID LEVEL:

(1) Position vehicle on a level surface with engine at
normal running temperature.
(2) Turn OFF engine and remove ignition key.
(3) Using a wiping cloth, clean oil and dirt residue
from around power steering reservoir cap.

POWER STEERING-
X FLUID LEVEL'
9000-13
Fig. 6 Power Steering Reservoir Dipstick—
3.31 Engine
REAR WHEEL BEARINGS
(FRONT WHEEL DRIVE ONLY)
INSPECTION
The rear wheel bearings should be packed with new
lubricant at the distance interval described in the
Lubrication and Maintenance Schedules. Refer to the
General Information section of this group. The bear­
ings should be inspected for contamination and wear
before they are cleaned. Slight discoloration of bear­
ing rollers and race cup is normal. If metal flakes are
visible in the used lubricant or the bearing rollers and
race cup is discolored, the bearing and race cup should
be replaced. For proper service procedures, see Group
5, Brakes. Replace the inner seal whenever the wheel
bearings are serviced.
remove inner grease seal (Fig. 7). For proper service
procedure, see Group 5, Brakes.
(5) Inspect bearings, refer to Inspection paragraph
of this procedure. Wash used lubricant from bearings
with solvent and blot or blow dry.
(6) Using a bearing packing device, lubricate the
bearings with Mopar®, Wheel'-Bearing Grease or
equivalent.
(7) With a wiping cloth, clean used lubricant form
wheel hub assembly and axle spindle.
(§5 Install inner wheel bearing in the hub assembly,
small end of bearing toward hub. With a finger, smooth
out grease around the outside of bearing.
(9) Using a seal driver, install new inner hub seal.
(10) Install wheel hub (drum) assembly on axle
spindle.
(11) Install outer wheel bearing over the spindle
end, small end of bearing toward hub. With a finger,
smooth out grease around the outside of bearing. '
(12) Install washer and spindle nut. While rotating
hub, tighten spindle nut to 27 to 34 N*m (240 to 300
in. lbs.) torque. Loosen spindle nut one quarter turn.
Hand tighten spindle nut.
(13) Install spindle nut lock cover, cotter pin and
grease cap.
(14) Install disc brake caliper on vehicles with disc
brakes.
CAUTION: Pump brake pedal several times before
driving vehicle to verify brai© operation.
(15) Install wheel and lower vehicle.

r e a r w h e e l b e a r in g l u b r ic a t io n
CAUTION: Combining two types of lubricant can cause
bearing failure. Wash ysed or new bearings with a
suitable solwent and blot dry with a lint free ctoth
before packing with new lubricant
WARNING: DO NOT ALLOW BEARING TO SPIN AT
HIGH RPM WHEN USING COMPRESSED AIR TO
BLOW CLEANING SOLVENT FROM BEARING. BEAR­
ING CAGE CAN EXPLODE, CAUSING PERSONAL
INJURY.

TO LUBRICATE REAR WHEEL BEARINGS:

(1) Hoist rear wheels off the ground and support
vehicle on safety stands. Refer to Hoisting Recommen­
dations in- the General Information section of this
group.
(2) Remove rear wheels.
(3) Remove brake caliper on vehicles with rear disc
brakes. For proper procedure, see Group 5, Brakes.
(4) Remove rear wheel hub (drum) assembly aid
 •UIBNGAfKIN- AND: iA H T IIA iC E 1-18

BRAKES ■■ ■
m m n e p a d jimp l i n i n g i n s p e c t i o n
The brake pads and linings should be inspected, at
distance intervals described in the Lubrication and
Maintenance Schedules. Refer to the General Infor­
mation section of this group. If brake pads or linings
appear excessively worn, the brakes would require
service. For' proper service procedures, refer to Group
5, Brakes.

BRAKE HOSE INSPECTION

WARNING: IF FRONT WHEEL, REAR AXLE, OR
ANTI-LOCK UNIT BRAKE HOSE OUTER COVER IS
CRACKED, CHAFED, OR BULGED, REPLACE HOSE
IMMEDIATELY. BRAKE FAILURE CAN RESULT.
The front wheel, rear axle and anti-lock unit (if
equipped) brake hoses should be inspected at time and
distance intervals described in the Lubrication and
Maintenance Schedules. Refer to the General Infor­
mation section of this group. A hose must be replaced
if it has signs of cracking, chafing, fatigue or bulging.
For proper service procedures, refer to Group 5, Brakes.

BRAKE LINE INSPECTION

The metal brake lines should be inspected when
other under vehicle service is preformed. If a line is
pinched, kinked, or corroded, it should be repaired.
For proper service procedures, refer to Group 5, Brakes.

mm'kKE r e s e r v o i r l e v e l i n s p e c t i o n
WARNING; DO NOT ALLOW PETROLEUM OR WA­
TER BASE LIQUIDS TO CONTAMINATE BRAKE FLUID,
SEAL DAMAGE AND BRAKE FAILURE CAN RESULT.
RELIEVE PRESSURE IN ANTI-LOCK BRAKE SYS­
TEM BEFORE ADDING BRAKE FLUID TO RESER­
VOIR. IF NOT, BRAKE FLUID COULD DISCHARGED
FROM THE RESERVOIR POSSIBLY CAUSING PER­
SONAL INJURY.
The brake reservoir level should be inspected when
other under hood service is performed. It is normal for
the reservoir level to drop as disc brake pads wear.
When fluid must be added, use Mopar®, Brake Fluid or
equivalent. Use only brake fluid conforming to DOT
3, Federal, Department of Transportation specifica­
tion. To avoid brake fluid contamination, use fluid
from a properly sealed container.
On vehicles with anti-lock brakes, depressurize the
system before inspecting fluid level. Turn OFF the
ignition and remove the key. Pump the brake pedal at
least 50 times to relieve the pressure in the system.
On all vehicles, if fluid should become low after
several thousand kilometers (miles), fill the reservoir
to level marks on the side of the-reservoir (Fig. 8 or 9).
HEADLAMPS
The headlamps should be inspected for intensity
and aim whenever a problem is suspected. When lug­
gage compartment is heavily loaded, the headlamp
aim should be adjusted to compensate for vehicle height
change. For proper service procedures, refer to Group
8L, Lamps. _ --
BODY LUBRICATION
"Body mechanisms and linkages should be inspected,
cleaned and lubricated as required to maintain ease of
operation and to prevent corrosion and wear.
Before a component is Imbricated, oil, grease and
dirt should be wiped off. If necessary, use solvent to
clean component to be ..lubricated. After lubrication is
complete, wipe off excess grease or oil.
During winter season, external lock cylinders should
be lubricated with Mopar®, Lock Lubricant or equiva­
lent to assure proper operation when exposed to water USE 10P1R® LUBRIPLATE OR EQUIVALENT ON
and ice. • Door check straps.
' To assure proper hood latching component opera­ • Liftgate latches.
tion, use engine oil to lubricate the latch, safety catch • Liftgate prop rod pivots.
and hood hinges when other under hood service is • Ash tray slides.
performed. Mopar®, Multi-purpose Grease or equiva­
• Fuel Fill Door latch mechanism.
lent should be applied sparingly to all pivot and slide
contact areas. • Park brake mechanism.
• Front seat tracks.
USE ENGINE OIL 01 • Sliding door rear latch striker.
• Door hinges—Hinge pin and pivot points, • sliding door closure wedges
• Hood hinges—Pivot points.
• Litigate hinges—Pivot points. USE iO P li® MULTI-PURPOSE GREASE
• Sliding door center hinge pivot. OR EQUIVALENT ON
• Sliding door center track.
• Sliding door upper track.
• Sliding door open position striker spring.
 SUSPENSION
CONTENTS

DRIVESHAFTS ...................................... .. 17 GENERAL INFORMATION .......................... 1

FRONT SUSPENSION.................................
FRONT SUSPENSION SERVICE
PROCEDURES ......................................
GENERAL INFORMATION
Throughout this group, references may be made to a
particular vehicle by letter or number designation. A
chart showing the breakdown of these designations is
included in the Introduction section at the front of
this Service Manual.
An independent MacPherson Type front suspension
is used on these vehicles. Vertical shock absorbing
struts attach to the upper fender reinforcement and
1 INTERMEDIATE SHAFT .............. ............ 36
REAR SUSPENSION .......... ..................... 40
5
the steering knuckle to provide upper steering knuckle
position. Lower control arms are attached inboard to a
crossmember and outboard to the steering knuckle
through a ball joint to provide lower steering knuckle
position. During steering maneuvers, the strut (through
a pivot bearing in the upper retainer) and the steering
knuckle turn as an assembly (Fig.l).

FRONT SUSPENSION
1. FRONT SUSPENSION CROSSMEMBER
2. FRONT PIVOT BOLT
3. LOWER CONTROL ARM
4. SWAY ELIMINATOR SHAFT ASSEMBLY
5. LOWER ARM BALL JO INT ASSEMBLY
6. STEERING GEAR
7. TIE ROD ASSEMBLY
8. DRIVESHAFT
9. STEERING KNUCKLE
10. STRUT DAMPER ASSEMBLY
11. COI L SPRING
12. UPPER SPRING SEAT
13. REBOUND STOP
14. UPPER MOUNT ASSEMBLY
15. JOUNCE BUMPER
16. DUST SHIELD

Fig.l Front Suspension (Typical)

FRONT SUSPENSION MAJOR COMPONENTS
(FIG 1 and 2)
s tr u t su ppo rt
The system is supported by coil springs positioned
offset around the struts. The springs are contained
between an upper seat at the bottom of the strut
mount and a lower spring seat, on the strut lower
housing.
The top of each stm t assembly is bolted to the upper
fender reinforcement through rubber isolated mounts.
The bottom attaches to the top of the steering knuckle
with two through bolts. One bolt is formed to retain
an eccentric cam, for camber adjustment. Caster is
fixed.
ST E E R IN G KN U C K LE
The steering knuckle is a single casting, with legs
machined for attachment to the strut damper, steer­
ing linkage, brake adaptor, and lower control arm ball
joint. The knuckle also holds the front drive hub bear­
ing and hub positioned through the bearing and
knuckle. The constant velocity stub shaft is splined
through the hub.
LO W ER C O NTRO L ARM
The lower control arm is a casting with 2 large
spool type rubber pivot bushings. The lower control
arm is bolted to the crossmember through the rubber
pivot bushings.
The ball joint is pressed into the control arm, and
has a non-tapered stud with a notch 'for clamp bolt
clearance. The stud is damped..and: locked.into,, the
steering knuckle leg with a clamp bolt. ■ ■ ; ■,
The lower control arms are inter-connected'through
.a rubber, isolated sway bar.
D R IV E SH A P T S
Driveshafts are attached inboard to the transaxle
differential' side gears, and outboard to the driven
wheel hub.'
To deliver driving force from the transaxle to the
front wheels during turning maneuvers and suspen­
sion movement, both shafts are constructed with con­
stant velocity universal joints at both ends.
Both shafts have a' Tripod (sliding) joint at the
transaxle ..end and Rzeppa joints (with splined stub
shafts) on the hub ends. Due to the transaxle location
the connecting shafts between the C/V joints are of
different length and construction.' The right shaft is
longer and of tubular construction. The left shaft is
solid.
 NUT WOT

KNUCKLE
ASSEMBLY

aou SPACER
(AS REQUIRED)

COIL
SPRING

KNUCKLE BOLT

CONTROL
ASSEMBLY

C AM SO U

KNUCKLE ASSEMBLY

SUSPENSION
BOLT 9102-54

2-3
Fig.2 Front Suspension (Typical)
 SUSPENS/ON/STEERINQ/DRNE DIAGNOSIS FRONT WHEEL DRIVE

■XClfifWI IXCKSflWB
PItOMT IND if lllllllll i f i lllilll
NMM P i l l Plklll mom
ic u ill l i f l lilill l

T
ON TURNS INCORRECT UNEQUAL INCORRECT STEERING LOW THE
TIRE PRESSURE THE GEAR ADJUSTMENT PRESSURE
WHEEL BEARINGS PRESSURE

ACCELERATING
OR DECELERATING INCOilECT FRONT - RADIAL TIRE LEAD '
WORN OR LOOSE LACK OF LUIRICANT
■ OR REAR
FRONT-WHEEL-BEARING SEE'TIRE SERVICE ' TIE ROD ENDS IN STEERING GEAI
WHEEL TOE
OR TRANSAXLE

CLONK-ON-ACCIEIERAI-
fNGOR-DECELERATlON LOOSE STEERING LOW FLUID LEVEL
LOOSE OR WORN INCORRECT FRONT
GEAR MOUNTING LOOSE PUMP BELT
T O ^ ^ i« A is WHEEL BEARINGS WHEEL CAMBER IOLTS (POWER STEERING)
OR BEARINGS

CLICKING NOISE ON
TURNS LOOSE OR WORN POWER STEERING LOOSE OR WORN LACK OF LUIRICANT
CONTROL ARM GEAR VALVE STEERING SHAFT ; IN STEERING
. WORN OR BROKEN BUSHINGS 1NIALANCE COUPLING IALL JOINTS
C.V. JOINT

LOOSE OR W O IN WHEEL BRAKING

■ EXCESSIVE FRICTION STEERING GEAR
CONTROL ARM IN STEERING GEAR MALFUNCTION
BUSHINGS SEE IRAKI SERVICE

LOOSE O t WORN ■ EXCESSIVE FRICTION LACK OF LUBRICANT

SWAYIAR IN STEERING SHAFT IN STEERING SHAFT
ATTACHMENTS COUPLING COUPLING

W O IN OR LOOSE EXCESSIVE FRICTION

FRONT STRUT IN STRUT UPPER
UPPER MOUNT BEARING
9102-3
 FRONT SUSPENSION SERVICE PROCEDURES
INDEX
Page Page
Hub and Bearing Assembly 12 Strut Damper Assembly 7
Knuckle (Front Suspension) 11 Suspension Coil Springs 9
Lower Control Arm Assembly 10 Sway Bar 10
Shock Absorbers (Strut Damper) ................................. 10 Wheel A lignm ent............................................................ 5

WHEEL ALIGNMENT depending on the type of equipment being used. The

Front wheel alignment is the proper adjustment of
all the interrelated suspension angles affecting the
running and steering of the front wheels of the vehicle.
The method of checking front alignment will vary
instructions furnished by the manufacturer of the equip­
ment should always be followed. With the exception
that the specifications recommended by Chrysler Cor­
poration should always be used.
 2-6
SUSPENSION
TIGHTEN
NUTS TO
lOON-m
(76 FT. LBS.)
PLUS 1 /4 TURN

0°

TOE OUT-
CAMIER
TOE
9102-4

fff.f Alignment Csmber/Tm

 There are six basic factors which are the foundation TOE ADJUSTMENT
to front wheel alignment, height, caster, camber, toe-in, (1) Prepare vehicle as described in Pre-Alignment.
steering axis inclination and toe-out on turns. Of the (2) Center steering w h eel'and hold with steering
six basic factors only camber and toe are mechanically wheel clamp.
adjustable (Fig.l). 1 (8) Loosen Me rod locknuts (Fig.l). Rotate rods to
Do not attempt to modify any suspension or steer­ align toe to specifications. -
ing components by heating or bending. .:
CAUTION: Do not twist tie rod to-steering^ gear rub­
Adjustments and checks should be made in the fol­
ber boots during adjustment.
lowing sequence. ■
(a) Camber (4) Tighten tie rod locknuts -to 75 N-m (58 ft.lbs.)
(b) Toe torque. ■*
Camber is the number of degrees the top of the (5) Adjust steering gear to tie rod boots at tie rod.
wheel is tilted inward or outward from a true vertical. (6) Remove steering wheel clamp. ■'
Inward tilt is negative camber. Outward tilt Is posi­
tive camber. STRUT DAMPER ASSEMBLY -
Excessive camber is a tire wear factor: negative
REMOVAL ' ■ .
camber causes -wear on the inside of the tire, while
(1) Loosen wheel nuts.
positive camber causes wear to the outside.
(2) Raise vehicle, see Hoisting in Lubrication and
Toe is measured in degrees or inches and is the
Maintenance, Group O.
distance the front edges of the tires are closer (or
(3) Remove wheel and tire assembly.
farther apart) than the rear edges. See front wheel
Where service procedyre includes assembly of origi­
drive Specifications for Toe.
nal strut (shock absorber) to original knuckle, mark
cam adjusting boil (Flg.3).
PRE-ALIGNMENT . ■ ' •
(4) Remove cam bolt, knuckle bolt and brake hose to
Before any attempt is made to change or correct the
damper bracket retaining screw (Fig.l).
wheel alignment factors, the following inspection and
(5) Remove strut damper to shock tower mounting
necessary corrections must be made on those parts
nut and washer assemblies (Fig.l)
which influence the steering of the vehicle.
(1) Check and inflate tires .to recommended pres­
sure. All tires should be the same size and in good
condition and have approximately the same wear. Note
type of tread wear which will aid in diagnosing, see
Wheels and Tires, Group 22.
(2) Check front wheel and tire assembly for radial
runout.
,. (3) Inspect lower ball joints and all steering linkage
for looseness.
(4) Check for broken or sagged front and rear springs.
• Front Suspension must only be checked after'vehicle
has the recommended tire pressures, full tank of fuel,
no passenger or luggage compartment load and is on a
level floor or alignment rack.
Just prior to each alignment reading the vehicle
should be bounced (rear first, then front) by grasping
bumper at center and jouncing each end an equal
number of times, always release bumpers at bottom of
down cycle.

CAUBEM A D JU ST M E N T MARK CAM LOCAT ION

(1) Prepare vehicle as described in Pre-Alignment.
(2) Loosen cam and through bolts each side (See
Fig.l).
(3) Rotate cam bolt to move top of wheel in or out to
specified camber.
(4) Tighten bolts to 1§0 N*m (75 ft. lbs.) torque plus
1/4 turn beyond specified torque.
BEFORE REMOVING BOLTS RH1158
f ff .f Strut Damper Removal
SMOCK A B S O R B E R IN S P E C T
Inspect for evidence of fluid running from the upper
end of the reservoir. (Actual leakage will be a stream
of fluid running down the side and dripping off lower
end of unit. A slight amount of seepage is not unusual
and does not affect performance).
tmSTALLMTIOM
(1) Install unit into shock tower and install retain­
ing nut and washer assemblies. Tighten nut to 27 N*m
(20 ft. lbs.) torque.
(2) Position knuckle neck into strut, position- washer
plate and install cam and knuckle bolts.
(3) Attach brake hose retainer to damper, tighten
screw to 13 N*m (10 ft. lbs.) torque.
(4) Index cam bolt to original mark (Fig.2).
(5) Place a 4 inch (or larger) C clamp on the strut
and knuckle (Fig.2). Tighten the clamp just enough to
eliminate any looseness between the knuckle and the
strut. Check alignment of the index marks and tighten
the bolts to 100 N-m (75 ft. lbs.) torque plus 1/4 turn
beyond specified torque. Remove C clamp.
(8) Install wheel and tire assembly. Tighten wheel 9102-6
nuts to 108 N*m (80 ft. Ibs.) torque. Fig.4 Compressing Coil Spring

Fig.5 Loosening Stmt Rod Nut

(4) Remove coil spring. Mark spring for Installation

on same side of wehicie.
CAUTION; see Suspension Coll Springs btfore re­
leasing coll from Tool C-4S38,
Fig.2 Stmt Damper Installation

D IS A S S E M B L Y (S T K V T DAMPBR)
(1) Compress Coil with Spring Compressor, Special
Tool C-4838 (Fig. 4).
(2) Hold strut rod while loosening strut rod nut.
Remove nut (Fig. 5).
(3) Remove mount assembly (strut damper).
 fUSPINSiO N 2-1

REBOUND RETAINER

MOUNT
'ASSEMBLY
STANDARD
SPRING
SEAT

JOUNCE BUMPER

C
DUST SHIELD
STRUT ROD
(SHOCK ABSORBER)
STRUT TUBE
(SHOCK ABSORBER) (3) Using Socket Holder, Special Tool L-4558 (Fig.8)
tighten rod nut to 81 N-m (60 ft. lbs.) torque. It is
9102-7 important that this step be done before Spring Com­
pressor Tool C-4838 is released.
Fig.6 Mount Assembly (4) Release Spring Compressor Tool C-4838.

(5) Inspect strut damper, mount assembly (Fig.6) for:
(a) Severe deterioration of rubber isolator; retain­
ers for cracks and distortion and bond failure of re­
tainers and rubber isolators.
(b) Bearings for binding.
(c) Shock Absorber for flat spots over full stroke
also see, Shock Absorbers, (strut damper).
ASSEMBLE (STRUT DAMPER)
(1) Install:
(a) Dust shield, jounce bumper, spacer (as required),
and spring seat to top of spring (Fig.6).
(b) Mount assembly to rod, check for presence of
lower washer.
(c) Rebound retainer and rod nut.
(2) Position spring seat tab alignment correctly with
respect to bottom bracket (Fig.7).
SUSPENSION COIL SPRINGS
Springs are rated separately for each side of vehicle
depending on optional equipment and type of service.
During service procedures where both springs are re­
moved, mark springs (Chalk, Tape, etc.) to ensure
installation in original position.
During service procedures requiring the removal
or installation of a coil spring with Spring Compres­
sor, Special Tool C-4838, it is required that five coils
be captured within the Jaws of the tool (Fig.1).
NOTE POSITION

PARALLEL

Flg.1 Identifying Coil Springs

SPRING RETAINER UPPER

Ensure that upper spring retainer is positioned prop­
ISO-STRUT MOUNT 9102-8 erly, see; step (2), Assemble (Strut Damper).
Flg.7 Spring Seat Alignment Notch Position to Bracket
SPRING SEAT LOWER CiOSSMEMBIR PIVOT BOLT PIVOT BOLT
During assembly of spring to strut damper ensure
that lower coil end is seated in strut damper spring
seat recess refer to (Fig.7) in assemble (Strut Damper)
section.

SHOCK ABSORBERS (Strut Damper)

INSPECTION
Inspect for evidence of fluid running from the upper
end of the reservoir. (Actual leakage will be a stream
of fluid running down the side and dripping off lower
end of unit. A slight amount of seepage is not unusual
and does not affect performance).

LOWER CONTROL ARM ASSEMBLY

The lower control arms are serviced only as a
complete assembly. The pivot bushings and ball joints
are not serviceable as separate components of the
lower control arms. ■ •■ - . . . ?
To check for wear on the Ball Joint refer to Ball
Joint Inspection, (on vehicle) BEFORE lower control
arm assembly removal.

REHMOVAL
(1) Raise vehicle. See Hoisting in Lubrication,
Group 0.
(2) Remove (Fig.l): • Fig. f Lower Control Arm Remove/Install
(a) Front inner pivot through bolt.
(b) Rear stub strut nut, retainer and bushing. SWAY BAR
(c) Ball joint to steering knuckle clamp bolt.
(8) Separate ball joint stud from steering knuckle. The sway bar interconnects the lower control ^arftis
and attaches to the crossmember (Fig.l).
CAUTION: Pulling steering knuckle out from vehicle
Jounce and rebound movements affecting one wheel
after releasing from ball pint can separate inner C/Y
are partially transmitted to the opposite wheel to sta­
joint. See Driweshafts.
bilize body roll. •'
(4) Remove sway bar to control arm end bushing Attachment to the crossmember, and lower control
retainer nuts and rotate control arm over sway bar. arms is through rubber-isolated bushings. All parts
Remove stub strut retainer. are serviceable, and the,;crossmember bushings ■ are
Inspect lowir control arm for distortion. Check bush­ split for easy removal and installation. The split in
ings for severe deterioration. the bushing should be positioned forward on the vehicle.

INSTALLATION
(1) Position Lower Control Arm over sway bar and
install pivot bolts and loosely assemble nuts (Fig.l).
(2) Install Ball Joint Stud into Steering Knuckle
and install clamp bolt. Tighten clamp bolt to 145 N*m
(105 ft. lbs.)
(3) Position sway bar end bushing retainer to con­
trol arm (Fig.l). Install retainer bolts and tighten to
70 N m (50 ft. lbs.)
(4) Lower the vehicle so it is on the ground fully
supported by the suspension at curb height. Tighten
the lower control pivot bolts to 169 N-m (125 ft.lbs.)
(F ig .l)/
TORQUE 7C N*m (50 FT. LBS.)
Flg.1 Front Sway Bar
REMOVAL
(1) Raise and support the vehicle. See Hoisting in
Lubrication and Maintenance, Group 0.
(2) Remove nuts, bolts, and retainers at the control
arms (Fig.l).
(3) Remove bolts at crossmember clamps, and re­
move clamps and sway bar from vehicle (Fig.l).
INSPECTION
Inspect for broken or distorted clamps, retainers,
and bushings. If bushing replacement is required, the
inner bushing can be removed by opening the split;
the outer bushing must be cut or hammered off the
bar. If replaced, the outer bushings should be forced
on so that approximately 1/2 inch of the bar pro­
trudes. Note that the control arm retainers are sym­
metric and bend slightly upon installation.
INSTALLATION
(1) Position the crossmember bushings on the bar
with the external rib up and the split to the front of
RUBBER ISOLATOR
STRAP
9102-56
the vehicle. Lift the bar assembly into the crossmember,
and install the lower clamps and bolts. The center
offset in the sway bar should be oriented toward the
front of the vehicle (Fig.l)
(2) Position retainers at control arms, insert bolts,
and install nuts. The bolts should be installed so that
the threaded portion of the bolt is up, with the nut
against the lower control arm (Fig.l).
(3) With lower control arms raised to design height,
tighten bolts to 70 N-m (50 ft. lbs.) torque.
(4) Lower vehicle.
KNUCKLE (FRONT SUSPENSION)
The front suspension knuckle (Fig.l) provides for
steering, braking and alignment. It also supports the
front (driving) hub (and axle) assembly.
Service repair or replacement of front drive bearing,
hub, or knuckle can be completed on the vehicle.
 CAM BOLT NUT STRUT DAMPER
' IREFEIENCE)
ADAPTOR SCREW AND WASHER

HAKE CALIPER 'DRIVE SHAFT

STEERING UNKAGI

COTTER
PIN

LOWER CONTROL ARM

NUT LOCK HUB NUT WHEEL BOLT ■ ■ (REFERENCE} 9102-12

Fig.l Knuckle Asmmim Tfplml

HUB AND BEARING ASSEMBLY (2) Loosen hub nut while the vehicle is on the floor
with the brakes applied (Fig.3). The hub and driveshaft
The Unit III Front Hub bearing is used on all Cara­ are splined together through the knuckle (bearing)
van, Voyager and Mini Ram Vans. and retained by the hub nut.
This unit is serviced as a complete assembly. It is
attached to the steering knuckle by four mounting
bolts that are removed from the rear of the knuckle.

REMOVAL
(1) Remove cotter pin, nut lock, and spring washer
(Fig.2).

Flg.3 Loosen Hub Nut

Flg.2 Remove Cotter Pin, Nut Lock, & Spring Washer
 (3) Raise vehicle, see Hoisting Recommendations in
Group 0 of this service manual.
(4) Remove hub nut, washer, and wheel and tire
assembly.
(5) Disconnect tie rod end from steering arm with
Puller Special, Tool C-3894-A (Fig.4).

8902-3

Flg.5 Remove Clamp Bolt and Caliper Guide Pins

Fig.4 Disconnect Tie Rod End
(7) Remove caliper guide pins and separate caliper
(6) Remove clamp bolt securing ball joint stud into assembly from braking disc. Support caliper with wire
steering knuckle (Fig.5).
hook and not by hydraulic hose. (Fig.6) Remove brak­
ing disc (Fig.7).

PR1479A
‘P \

Flg.6 Supporting Brake Caliper

 Fig.7 Remove or Install Braking Disc

(8) Separate ball joint stud from knuckle assembly.

Pull knuckle assembly out and away from driveshaft
(Fig.8).

Fig.9 Remove Hub and Bearing Assembly from Knuckle

INSTALLATION
(1) Install new hub and bearing assembly and tighten
bolts in a criss-cross pattern to 65 N-m (45 ft. lbs.)
torque.
CAUTION: Knuckle and bearing mounting surfaces
must be smooth and completely free of foreign ma­
terial or nicks.
(2) Position new seal in recess and assemble In­
staller Special Tool C-4698. (Tool is provided with a
SPECIAL TOOL C-4689

Care must be taken not to separate the inner C/V

joint during this operation. Do not allow driveshaft to
hang by inner C/V joint, driveshaft must be supported.
(9) Remove the four hub and bearing assembly
mounting bolts from rear of steering knuckle.
(10) Remove hub and bearing assembly (Fig.9). Re­
placement of the grease seal is recommended when­
ever this service is performed.

Fig.10 Tool Set-Up for Seal Installation

handle and dual purpose drive head for installing seal
into knuckle and (head reversed) for installing wear
sleeve into C/V joint housing). Also see Driveshafts.
(3) See (Fig. 10), assemble tool and install seal.
CAUTION: During any service procedures where
knuckle and driveshaft are separated, thoroughly
clean seal and wear sleeve and lubricate BOTH
components.
(4) Lubricate the FULL circumference of the seal
(and wear sleeve) with MOPAR Multi-Purpose Lubri­
cant, or equivalent (Fig. 11).
LUBRICANT

9102-17

Flg.12 Installing Knuckle Assembly

(6) Install original (or equivalent) ball joint to knuckle

clamp bolt (Fig.13), tighten to 145 N-m (105 ft. lbs.)
C /V JOINT torque.
HOUSING

Fig.11 Seal and Wear Sleeve Lubrication

(5) Install driveshaft through hub, then install steer­

ing knuckle assembly on lower control arm ball joint
stud (Fig. 12).

^LOWER CONTROL ARM KNUCKLE 9102-18

Fig.13 Tighten Clamp Bolt

 (7) Install tie rod end into steering arm (Fig.14),
tighten nut to 47 N-m (35 ft. lbs.) torque and install
cotter key.

Fig.16 Install Washer and Hub Nut

(11) With brakes applied, tighten nut to (244 N*m)

180 ft. lbs. torque (Fig.17).

(8) Install braking disc (Fig.7).

(9) Carefully lower caliper over braking disc.(Fig.l5).

PR2419

Fig.17 Tighten Hub Nut

(12) Install spring washer, nut lock, and new cotter

pin. Wrap cotter pin prongs tightly around nut lock
(Fig.18).
Install wheel and tire assembly. Tighten wheel nuts
to (115 N-m) 85 ft.lbs. torque.

Fig.15 Installing Family Caliper

Install caliper assembly guide pin bolts. Tighten to

25-35 N*m (18-26 ft. lbs.) torque. When installing guide
pins, use extreme caution not to cross the threads.
(10) Install washer and hub nut after cleaning for­
eign matter from threads (Fig. 16).
 COTTER PIN

"PUll" THROUGH
\ / AND "WRAP" TIGHT
\ RP1052 m m m F \ m r L 9CKi
Fig.18 Install Spring Washer, Nut Lock, & Cotter Pin

DRIVESHAFTS
INDEX
Page Page
C/V Joint Boots .............................................................. 30 General Information ...................................................... 17
Damper Weights ............................................................ 34 Inner C/V J o in t.......... ............ ......................................... 24
Driveshaft Positioning Specifications......................... 35 Outer C/V Joint .............................................................. 26
Driveshaft Recondition ............................................... .. 23 Service Procedures ........................................................ 18
Driveshafts ...................................................................... 19

GENERAL INFORMATION
Chrysler front wheel drive vans and wagons use
two different driveshaft systems. Some turbocharged
wagons use an equal length system while others use
an unequal length system (Fig. 1).
 3AN JOINT BEARING AND BRACKET ASSEMBLY

RUBBER WASHER SEAL

M M H P
TRANSAXLE
LEFT DRIVESHAFT
EQUAL LENGTH SYSTEM (TYPICAL) RIGHT DRIVESHAFT

- TRIPOD JOINT

TRANSAXLE INTERCONNECTING SHAFT

LEFT DRIVESHAFT
RIGHT DRIVESHAFT
HH7371

Fig. f Front-Wheel-Drlva Driveshaft Systems

The equal length system has short solid intercon­ SERVICE PROCEDURES
necting shafts of equal length on the left and right
sides. The unequal length system has a short sold Procedures for the removal and installation of the
interconnecting shaft on the left side with a longer driveshafts are essentially the same for all front wheel
tubular interconnecting shaft on the right. drive vehicles. Each driveshaft has a spring within
The driveshaft assemblies can be serviced in the the inboard tripod C/V joint that maintains constant
same manner for both systems with the exception of a engagement with the transaxle, which allows it to be
rubber washer seal attached to the right inner C/V removed without dismantling part of the transaxle.
(constant Telocity) joint, on an equal length installa­
CAUTION: Boot sealing is vital to retain special lu­
tion. The equal length system also has an intermedi­
bricants and to prevent foreign contaminanta from
ate shaft attached to a cardan joint (U~joint). With a
entering the C/V joint. Mishandling, stjch as allowing
stub shaft splined into the right side of the transaxle
the assemblies to dangi© unsupported, pulling or
with a bearing and bracket assembly fastened to the
pushing the ends can cut boots or damage C/V Joints.
right rear of the engine block.
During removal and installation procedures always
The driveshaft assemblies are three piece units. Each
support both ends of the driveshaft to prevent
driveshaft has a tripod joint, an interconnecting shaft
damage.
and a Rzeppa joint. The Tripod joint is splined into the
transaxle side gear and the Rzeppa joint has a stub
shaft that is splined into the wheel hub.
DRIVESHAFTS
HUB NUT ASSEMBLIES REMOVE
Hub nut removal and installation is the same for all
front wheel drive vehicles. For installation see HUB
NUT ASSEMBLIES INSTALL.

Fig.3 Remove Hub Nut & Washer Loosen Shaft

(4) Remove hub nut, washer and wheel and tire

assembly (Fig.3).

Fig. 7 Remove Cotter Pin, Nut Lock, & Spring Washer
(1) Remove cotter pin, lock and spring washer (Fig.l).
DRIVESHAFT ASSEMBLIES
REMOVE
Inboard C/V joints have stub shafts splined into the
differential side gears, or splined into the intermedi­
ate shaft on the right side as an equal length system.
Driveshafts are retained in the side gears by a con­
stant force provided by a spring contained within the
inboard C/V joints.

Fig.2 Loosen Hub Nut & Wheel Nuts

(2) Loosen hub nut and wheel nuts while vehicles is

on floor and brakes applied (Fig.2).
(3) Raise vehicle, see Hoisting in Lubrication and
Maintenance, Group 0.
(1) For removal of right driveshaft, the speedometer
pinion must be removed BEFORE shaft removal (Fig.4).
 CLAMP BOLT

MOVE KNUCKLE ASSEMBLY TO

REMOVE OR INSTALL SHAFT
PR2400B

Fig.5 Remove Ball Joint to Steering Knuckle Flg.7 Separate Outer C/V Joint Shaft from Hub
Clamp Bolt
(4) Separate outer C/V joint splined shaft from hub
(2) Remove clamp bolt securing ball joint stud into by holding C/V housing while moving knuckle (hub)
steering knuckle (Fig.5). assembly away (Fig.7).
CAUTION: Do not pry on or otherwise damage wear
sleeve on outer C/V joint.

PRY BAR PR2161A

Flg.6 Separate Ball Joint from Knuckle

(3) Separate ball joint stud from steering knuckle

by prying against knuckle leg and control arm (Fig.6). Flg.8 Removing Driveshaft Assembly Unequal Length
CAUTION: Do not damage ball Joint or C/V joint boots (5) Support assembly at C/V joint housings. Remove
(Fig.6). by pulling outward on the inner joint housing. DO
NOT PULL ON SHAFT (Figs.8 and 9).
 The driveshaft, when installed, acts as a bolt and
secures the hub/bearing assembly. If the vehicle is
to be supported or moved on its wheels. Install a
bolt through the hub to ensure that the hub bearing
assembly cannot loosen.
INSTALL
(1) Hold inner joint assembly at housing (Figs.8 and
10) while aligning and guiding the inner joint spline
into the transaxle or intermediate shaft assembly. On
vehicles using the equal length drive shaft system, be
sure that the rubber washer seal is in place on the
inner C/V Joint. (See F ig.l at the beginning of this
section).
Fig.10 Installing Inner Shaft Into Transaxle
Fig.11 Seal & Wear Sleeve Lubrication
CAUTION: Seal/Wear Sleeve Lubrication During any
service procedures where knuckle and driveshaft are
separated, thoroughly clean seal and wear sleeve
with suitable solvent (solvent must not touch boot)
and lubricate both components prior to installing
driveshaft. Lubricate wear sleeve and seal with
MOPAR Multi-Purpose Lubricant, or equivalent.
Apply on the full circumference of the Wear Sleeve
a bead of lubricant that is 6 mm (1/4 in.) wide to seal
contact area (Fig. 11). Fill lip to housing cavity on
Seal, complete circumference, and wet seal lip with
lubricant (F ig.ll).
(2) Push knuckle (hub) assembly out and install
splined outer C/V joint shaft in hub (Fig. 12).
 r-m (105 ft.

9102-17 (5) Install speedometer pinion (Fig. 15).

Fig.13 Install Knuckle Assembly on Ball Joint Stud (6) Fill differential with proper lubricant (see Lubri­
cation and Maintenance Group 0).
(3) Install knuckle assembly on ball joint stud (7) Install hub nut assembly.
(Fig.13). (8) If after installing the driveshaft assembly, the
Inboard boot appears collapsed or deformed, vent the
CAUTION: Steering knuckle clamp bolt shown in
inner boot by inserting, a round tipped small diameter
Figs.13 and 14 is prevailing torque type, original or
rod between the boot and shaft. If necessary, massage
equivalent bolt must be installed during assembly.
the boot to remove all puckers being careful ribt to
allow dirt to enter or grease to leave the boot cavity. If
the boot is clamped to the shaft with a rubber garter
clamp, it need not be removed to perform this venting
operation. If the boot is clamped to the shaft using a
metal clamp, the clamp must be removed and dis­
carded before the rod can be inserted. After venting,
install a new Service Clamp, or equivalent using spe­
cial Tool C-4653 (see Boots Install section at the end
of this group for details).
HUB NUT ASSEMBLIES INSTALL
The front wheel hub nuts use a lock and cotter pin
to maintain proper wheel bearing preload and prevent
the nut from backing off. Install the assembly as
follows.
HUB NUT
RP1050
Fig.l6 Install Washer and Hub Nut
(1) Install washer and hub nut after cleaning for­
eign matter from threads (Fig. 16).
PR2419
Fig.17 Tighten Hub Nut
(2) With brakes applied, tighten hub nut to 245 N-m
(180 ft. lbs.) torque (Fig.17).
COTTER PIN
"PULL" THROUGH
AND "WRAP" TIGHT
„RP1052
Fig.18 Install Spring Washer, Nut Lock,
and New Cotter Pin
(3) Install nut lock, spring washer and new cotter
pin. Wrap cotter pin prongs tightly around nut lock
(Fig. 18).
Fig.19 Install Wheel & Tire Assembly
(4) Install wheel and tire assembly. Tighten wheel
nuts to 129 N-m (95 ft. Ibs;) torque (Fig.19).
DRIVESHAFT RECONDITION
Driveshaft reconditioning and/or boot replacement
for all front wheel drive vehicles is essentially the
same per C/V Joint.
Note that lubricant requirements and quantities are
different for inner joints than for outer joints, and type
being serviced. Use only the recommended lubricants.
Complete driveshaft components are shown in Fig.
1.
Driveshaft requirements are different for various
vehicle models, engines, and transaxles, and often
change from one model year to the next.
 Fig. 1 Driveshaft Components

Driveshaft parts will be different to accommodate

this. Therefore, when replacing parts, be sure to use
only those specified in the service parts catalog for
the exact model year, model, engine, transaxle, and
type being serviced.

INNER C/V JOINT

DISASSEMBLE
(1) Remove the boot clamps and pull back the boot
to gain access to the tripod retention system, which
prevents accidental separation from the C/V joint
housing.

(2) The retaining tabs on this assembly are an inte­

gral part of the housing cover (can). Hold the housing
as shown (Fig. 2) and lightly compress the C/V joint
retention spring while bending the tabs back with a
pair of pliers. Support the housing as the retention
spring pushes it from the tripod. This will prevent the
housing from becoming over angulated and keep the
tripod rollers from being pulled from the tripod studs.
 CHAMFERED END
CAUTION: When removing the housing from the tri­
pod, hold the rollers in place on the trunnion studs
to prevent the rollers and needle bearings from fall­
ing away. After the tripod is out of the housing se­
cure the rollers in place with tape (Fig. 3).
(3) Remove the snap ring from the shaft end groove. NON-CHAMFERED
Remove the tripod by hand or by tapping the body END
with a brass punch (Fig. 3).
TRIPOD RETAINING
RING GROOVE

G.K.N. RH1193

Flg.4 Tripod Installation

(3) Install the snap ring into the groove on the

interconnecting shaft to lock the tripod in position
(Fig.5).

SNAP RING
Flg.3 Remove Snap Ring then Tripod

INSPECTION
Remove as much grease as possible from assembly
and inspect joint housing ball raceway and tripod com­
ponents for EXCESSIVE wear and replace, if necessary.
CAUTION: Mineral spirits or solvents should not be SNAP RING GROOVE
used to clean the inner C/V Joint housing. Solvents
will destroy the rubber seals that are hidden in these
housings and allow leakage of the grease.
RH707
Inspect the spring, spring cup, and the spherical SNAP RING PLIERS
end of the connecting shaft for EXCESSIVE wear or
damage and replace, if necessary. Fig.5 Tripod Snap Ring Installation

(4) Distribute two of the three packets of grease into

ASSEMBLE
the boot and the remaining packet in the housing.
(1) Fasten the (new) boot to interconnecting shaft.
(5) Position the spring in the housing spring pocket
See Boots Install.
with the spring cup attached to the exposed end of the
(2) Install the tripod on the interconnecting shaft as
spring (Fig.6). Place a small amount of grease on the
follows:
concave surface of the spring cup.
Slide the tripod on the shaft with the non-chamfered
end facing the tripod retainer ring groove (Fig.4).
 SOFT HAMMER
(TAP HOUSING)
SPRING CUP

IRCLIP (OUTER END OF SHAFT) 8902-14

Fig.6 Spring and Cup Installation Fig.8 Remove Joint from Shaft (Past Circlip)

(6) Slip the tripod into the housing and bend the (3) Support shaft in vise (with soft jaws). Support
retaining tabs down to their original position. Check outer joint, using a soft hammer, give a sharp tap to
for the ability of the retaining tabs to hold tripod in top of joint body to dislodge joint from internal circlip.
housing. Installed in a groove at the outer end of the shaft
(Fig.8).
CAUTION: Care must be taken to ensure proper spring
positioning. The spring must remain centered in the
housing spring pocket when the tripod is installed
and seated in the spring cup (Fig.6).
(7) Position the boot over the boot retaining groove in
the housing and clamp in place. See Boots Installation.

OUTER C/V JOINT

DISASSEMBLE
Figs. 7 through 21 show service procedures typi­
cally for either manual or automatic outer C/V joints.
(1) Remove boot clamps on boot and discard (Fig.7).
(2) Wipe away grease to expose joint.

CAGE
CROSS (DRIVER) Fig.9 Remove Circlip
CLAMP
WEAR SLEEVE
HOUSING (OUTER)
A wear sleeve installed on the outer C/V joint hous­
WEAR SLEEVE ing (Fig.8) provides a wipe surface for the hub bearing
seal (installed in the steering knuckle).
COTTER PIN
(4) If bent or damaged, carefully pry wear sleeve
BALLS (6)
from C/V joint machined ledge.
(5) Remove circlip from shaft groove and discard
'CIRCLIP (OUTER) (Fig.9). A replacement boot package will include this
■ WASHER circlip.
■HUB NUT (6) With joint separated proceed as follows:
•NUT LOCK RR02E26 (a) If outer C/V joint was operating satisfactorily
and grease does not appear to be contaminated. Just
Fig.7 Outer C/V Joint Components replace boot, bypass the following disassembly See
Boots Installation.
 (b) If outer joint is noisy or badly worn, replace (8) Hold joint vertically in vise by clamping on splined
entire unit. It is also recommended that the boot be shaft, using soft jaws to prevent damage.
replaced. The Boot Package includes the boot, clamps, (9) Press down on one side of inner race to tilt cage
retaining ring (circlip). and remove ball from opposite side (Figs. 10 and 11).
If joint is tight, use a hammer and brass drift to tap
inner race. Do not hit the cage. Repeat this step until
all 6 balls are removed. A screwdriver may be used to
pry balls loose.

CAGE— ROTATE
90°, POSITION
LONG OPENINGS
BETWEEN BALL
RACES— LIFT OUT

BALL RACE

Fig.10 Rotate Cage and Cross to Remove Balls CAGE

WINDOW
(7) Wipe off surplus grease and mark relative posi­ PR2433 A
tion of inner cross, cage and housing with dab of paint
(Fig.10). Fig.12 Removing Cage and Cross Assembly
from Housing
(10) Tilt the cage and inner race assembly vertically
and position two opposing cage windows in area be-

CROSS (DRIVER)-UP

TURN CROSS 90°

POSITION LAND
THROUGH CAGE
W IN D O W -
ROTATE
OUT

Fig.11 Ball Released

PR2434
Fig.13 Removing Cross from Cage
tween the ball grooves. Remove the cage and inner ASSEMBLE
race assembly by pulling upward away from the hous­ (1) Position new wear sleeve on joint housing ma­
ing (Fig. 12). chined ledge (Fig. 14). Assemble Installer, Special Tool
(11) Turn inner cross (driver) 90° to cage and align C-4698 (Tool is provided with handle and dual pur­
one of the race spherical lands with cage window. pose drive head) for installing wear sleeve onto C/V
Raise land into cage window and remove inner race joint housing and (head reversed) seal into knuckle).
by swinging out (Fig. 13). See KNUCKLE BEARING SEAL.
(2) See Fig. 14. Assemble tool and install wear sleeve.
INSPECTION (3) Lightly oil all components before assembling
Check grease for contamination and all parts for outer joint.
defects as follows: (4) Align parts according to paint markings.
(1) Wash all parts in suitable solvent and dry, pref­
erably with compressed air.
(2) Inspect housing ball races for excessive wear
and scouring.
(3) Check splined shaft and nut threads for damage.
(4) Inspect all 6 balls for pitting, cracks, scouring
and wear. Dulling of surface is normal.
(5) Inspect cage for excessive wear on inside and
outside spherical surfaces, surface ripples on cage win­
dow, cracks, and chipping.
(6) Inspect inner race (cross) for excessive wear or
scouring of ball races.
Any of the above defects will warrant replacing the
C/V assembly as a unit.
Polished areas in races (cross and housing) and
on cage spheres are normal and do not indicate
need for joint replacement unless they are suspected
FEED CROSS
of causing noise and vibration. LAND THROUGH
CAGE WINDOW—
POSITION INSIDE
THEN TURN 90°
PR2435

Fig.15 Installing Cross into Cage

(5) Insert one of the inner race (cross) lands into

cage window (Fig. 15) and feed race into cage. Pivot
cross 90° to complete cage assembly (Fig. 16).
(6) Align opposing cage windows with housing land
and feed cage assembly into housing (Fig.17). Pivot
cage 90° to complete installation.
 JOINT HOUSING

COUNTERBORE SHOULDER
INWARD RH1195

Fig. 16 Cage and Cross Assembled Fig. 18 Cage and Cross Installed In Housing

Fig.17 Installing Cage (and Cross) into Housing Flg.19 Inserting Balls Into Raceway

When properly assembled the cross counterbore (8) Insert balls into raceway by tilting cage and
should be facing outward from the joint (Figs. 16 and inner race assembly (Fig. 19).
18). (9) Fasten boot to shaft. See Boots Installation.
(7) Apply lubricant to ball races from packet pro­ (10) Insert new circlip, provided with kit in shaft
vided in boot kit and distribute equally between all groove. Do not over expand or twist circlip during
sides of ball grooves. One packet is sufficient to lubri­ assembly (Fig.20).
cate the joint. (11) Position outer joint on splined end with hub
nut on stub shaft. Engage splines, and tap sharply
with mallet (Fig.21).
 (12) Check that circlip is properly seated by at­ BOOTS INSPECTION
tempting to pull joint from the shaft. Noticeable amounts of grease on areas adjacent and
(18) Locate large end of boot over joint housing on the exterior of the C/V joint boot is the first indica­
checking that boot is not twisted. tion that a boot is punctured, tom or that a clamp has
(14) Fasten boot to housing. See Boots Installation. loosened. When a C/V joint is removed for service, the
boot should be properly cleaned and inspected for
CIRCLIP ■ INSTALL CIRCLIP
EVENLY — DO NOT cracks, tears and scuffed areas on interior surfaces. If
GROOVE
TWIST any of these conditions exist, boot replacement is
recommended.

BOOTS INSTALLATION
i i i l i C/V JOINT BOOTS ONLY
Boots must be serviced with the strap and buckle
clamp, using the Clamp Installer, Special Tool C-4653.
Proceed with the boot installation as follows:
(1) Slide the small end of the boot over the shaft.
Position the boot into the groove on the shaft, (Fig.l).

VENT. SLEEVE (CITROEN) 8902*16

.Fig.20 installing,New Clrdlp

MALLET*

WEAR SLEEVE FlgJ CIV Joint Boot Positioning

(2) Install the C/V joint. See Inner or Outer C/V
OUTER JOINT Joint Assemble.
HOUSING 8 9 0 2 -1 7 (3) Slide the large diameter of the boot into the
locating groove on the housing of the inner C/V joint.
FigM Position Joint onto Shaft Splines (4) Wrap binding strap around boot twice, PLUS 83
mm (2-1/2 inches) (Fig. 2).
C/V JOINT BOOTS
BOOTS HANDLING AND CLEANING |^2v&'vj
It’ is vitally important during arty service proce­ SPECIAL TOOL
dures requiring boot handling. That care be taken not C-4653.
to puncture, tear or pinch the boot. (By over tighten­
ing clamps or misuse of tools). Pinching can occur by
rotating the C/V joints (especially the tripod) beyond
normal working angles.
The rubber material in driveshaft boots is not com­
patible with oil, gasoline, or cleaning solvents. Care
must be taken that boots never come in contact with
any of these. The only acceptable cleaning agent for
driweshaft boots is soap and water. After washing,
boot must be thoroughly rinsed and 'dried before
9102-28
reusing.
Fig.2 Measure and Cut Binding Strap
 (3) Pass the strap through the buckle and fold it
back about 29 mm (1-1/8 inches) on the inside of the
buckle (Fig.3).

RB158

Fig.5 Fold Strap Lightly to Keep Position

(5) Fold the strap back slightly to prevent it from

slipping backwards (Fig.5).
Fig.3 Install Buckle on Strap

(4) Put the strap around the boot with the eye of the
buckle toward you (Fig.4). Wrap the strap around the
boot once and pass it through the buckle, then wrap it
around a second time also passing it through the buckle.

Fig.6 Open Tool, Position Strap in

Narrow Slot 1/2 Inch from Buckle

(6) Open the tool all the way and place strap in
narrow slot approximately 13 mm (1/2 inch) from buckle
(Fig.6).

Fig.4 Wrap Strap (through Buckle Eye) Twice

 Fig.7 Push Tool Forward and Fit Into Buckle Eye Fig.9 Retighten Strap (if Required)

(7) Hold the binding strap with the left hand. Push (9) If the strap is not tight enough, re-engage the
the Tool forward and slightly upward. Then fit the tool a second or even a third time, always about 13
hook of the Tool into the eye of the buckle (Fig.7). mm (1/2 inch) from the buckle (Fig. 9). When tighten­
ing always be careful to see that the strap slides in a
straight line and without resistance in the buckle,
that is without making a fold. An effective grip will
be obtained only by following the above instructions.

Fig.8 Tighten Strap

(8) Tighten the strap as shown in (Fig.8) by closing

the tool handles. Then rotate the tool (handles) down­
ward while slowly releasing the pressure on the tool
handles. Allow the tool (handles) to open progres­
sively. Then open the tool entirely and remove them
sideways.
Fig.10 What Not to Do
(10) Fig.10 shows WHAT NOT TO DO, NEVER fold
the strap back or bring the tool down while tighten­
ing, this action would cause the strap to be broken.
 RB166A
Pig.13 Correctly Installed Clamp

Seal: Fill lip to housing cavity (full circumference)

and wet seal lip with lubricant.

OUTER C/V JOINT ONLY

(1) Slide the small diameter boot clamp on the shaft.
This, must be ion# b#for© boot Is Instilled on shaft.
(2) Position the small end of the of the boot over the
end ofthe shaft. Slide the boot down the shaft, until it
is evenly seated in the boot groove on the shaft. See
Ftg.11 Correct lightening Procedure (Fig.l) in this section.
(3) Position clamp evenly in the clamp groove on
(11) F ig .ll shows how to pull the tool down while the end of the boot (Fig. 14),
releasing the pressure on the tool handle.

RBM5A SOOT
CLAMP
FlgJ2 Cut Strep 1/8 Inch from Buckle

(12) If the strap is tight enough. Remove the tool OUTEi C /V JOINT
o u t e r c/v HOUSING
sideways and cut off the strap 8 mm (1/8 inch), so that
JOINT BOOT 9102*58
it does not overlap the edge of the buckle. Complete
job by folding the strip back neatly (Fig. 12).
f f f .f 4 Clamp Installed on Boot
(18) Fig.13 shows the finished binding strap type
clamp in position, correctly fitted and unable to come (4) Using Clamp Installer, Special Tool C-4975
lo o se , (Fig.15). Open the jaws of the tool until the tabs of the
(14) After attaching the boot to the shaft, install the clamp are between the jaws.
inner or outer C/V joint following procedures under
Inner C/V Joint Assemble or Outer C/V Joint Assemble.
(15) Slip the large end of the boot on the housing
and align it in the boot groove.
(18) Repeat steps 2—13 for boot clamping.
 OUTER C/V
JOINT BOOT

BOOT CLAMP

BE SURE TOP TAB

OUTER C /V JOINT IS FULLY SEATED
HOUSING 9102-59 AGAINST TAB ON
LOWER BAND OF CLAMP 9102-60

Fig.15 Interlocking Boot Clamp Fig. 16 Boot Clamp Installed

(5) Tighten the bolt on the Clamp Installer tool, (6) Install the large end boot clamp using the same
until the tabs on the boot clamp interlock with each tools and procedure as above. Following the installa­
other as illustrated in (Fig. 16). Then loosen and re­ tion of the of the Outer C/V joint.
move tool from the clamp.
DAMPER WEIGHTS

TWO PIECE
S plit
DAMPER WEIGHT

DAMPER WEIGHT
FASTENERS (2)
DAMPER WEIGHT
RH744 LOCATING SHOULDERS

Flg.1 Left Driveshaft with Damper Weight

Damper weights are used on the left driveshaft as­

semblies of all front wheel drive vehicles (Fig.l). These
weights are attached to the interconnecting shaft and
are available as a separate service part. They should
be removed from the driveshaft assembly during
driveshaft positioning specification procedures. When
the weights are attached between the locating shoul­
ders, tighten the fasteners to 28 N-m (21 ft. lbs.) torque.
DRIVESHAFT POSITIONING SPECIFICATIONS (3) If the lengths of both shafts are within the range
specified, on the chart below, no further action is
Front wheel drive vehicles have engine mounts with required.
slotted holes allowing for side to side positioning of If either the left or right shaft length is not within
the engine. If the vertical bolts on the right or left the specified range, refer to Engine, Group 09, Engine
upper engine mount have been loosened (e.g., engine Removal and Installation to properly position the en­
removal and installation) for any reason, or if the gine according to the driveshaft lengths specified.
vehicle has experienced front structural damage, (4) If proper driveshaft lengths cannot be achieved
driveshaft lengths must be checked and corrected, if within the travel limits available in the slotted en­
required. A shorter than required driveshaft length gine mounts, check for any condition that could effect
can result in objectionable noise. A longer than re­ the side to side position of the measurement locations
quired driveshaft length may result in potential (e.g., engine support brackets, siderail alignment, etc.).
damage. (5) After ensuring proper driveshaft lengths the trans­
Use of the following procedure will ensure satisfac­ mission shift linkage must be adjusted to ensure proper
tory driveshaft engagement under all normal vehicle operation. Refer to Transaxle, Group 21.
operating conditions.
(1) The vehicle must be completely assembled. Front
wheels must be properly aligned and in the straight
ahead position. The vehicle must be in a position so
that the full weight of the body is distributed to all
four tires. A platform hoist, or front end alignment
rack, is recommended.
(2) Using a tape measure or other suitable measur­
ing device, measure the direct distance from the inner
edge of the outboard boot to the inner edge of the
inboard boot on both driveshafts. This measurement 9102-61
must be taken at the bottom (six o’clock position) of
the driveshafts (Fig.l). Flg.1 Driveshaft Positioning
Note that the required dimensions vary with drive­
shaft manufacturer.

DRIVESHAFT DIMENSIONS INSTALLED

DMVSSHAFT IDKNimCATION “A" DIMENSION

ENGINE
Jypm ' %Mm | mm in c h

2.51/3 .0 1 /3 .3 1 520-530 20.5-20.9

GKN
4x2«AUIO Left 228-238 9.0- 9.4

3 .3 4 GKN Right 292-302 11.5-11.9

4 m4-AUTO G Left 228-238 9.0- 9.4

9102-62
 INTERMEDIATE SHAFT
INDEX
Page Page
Assembly Recondition 36 Intermediate Shaft Assembly Installation 38
Bracket, Bearing, and Slinger Assembly . . . . . . . . . . 37 Universal Joint and Roller ....... .............. 37

ASSEMBLY RECONDITION
BUSHING AND ROLLERS

SEAL

BUSHING
RETAINER

SEAL
RETAINER

BUSHII' BUSHING BEARING

RETAINER AND ROLLERS ASSEMBLY
9002-13
Flg.1 Intermediate Shaft Assembly

Reconditioning of the Intermediate Shaft Assembly

is the same for the manual and automatic transaxles
(Fig.l).

INTERMEDIATE SHAFT ASSEMBLY REMOVAL

(1) Remove right driveshaft. See Driveshaft Assem­
blies Removal.
(2) Remove speedometer pinion from the extension
housing (Fig.2).

PR2416

Fig.2 Remove Speedometer Pinion

 (3) Remove the two screws from the bearing assem­
bly bracket to the engine block.
(4) Remove assembly from transaxle extension by
pulling outward on the yoke (Fig.3).

Fig.3 Removing Intermediate Shaft Assembly

UNIVERSAL JOINT AND ROLLER Fig.5 Assemble Universal Joint

(3) Striking socket with hammer will cause yoke to

DISASSEMBLE
move down and bushing to move up out of yoke into
(1) Mark relationship of shaft to shaft to ensure
socket.
proper alignment at assembly. Apply penetrating oil
(4) After removing one bushing, turn parts in vise
to bushings and remove snap rings.
and remove other bushing in same manner.
(2) Support yoke in vise and place a socket large
enough to receive bushing on top of yoke. A 1-1/8 inch
ASSEMBLE
socket is suitable (Fig.4).
(1) Hold cross in position between yoke ears with
one hand and start one bushing assembly into yoke
with other hand (Fig.5).
(2) Continue to hold cross in position, then hammer
bushing assembly into yoke and install snap ring.
(3) Install opposite bushing and snap ring in same
manner.
(4) Repeat process for stub shaft yoke after aligning
marks on yoke and shaft.

BRACKET, BEARING, AND SLINGER ASSEMBLY

DISASSEMBLE
(1) Remove the two screws that hold the bearing
assembly to the support bracket.
(2) Press the intermediate shaft out of the bearing
assembly and outer slinger. Do not dent or damage
the inner slinger. Also avoid damaging the end of the
stub shaft, the rubber seal on the right driveshaft
mates with this surface. Excessive wear to the rubber
seal would result and allow moisture to enter, corrod­
ing the internal splines.
(3) If either slinger is damaged, it should be re­
placed. Carefully press the shaft through the slinger,
discard the slinger.
The bearing assembly is not serviceable and must
be replaced as an assembly.
 HAMMER

Flg.7 Installing Intermediate Shaft Assembly

(3) Swing the bracket into position on the engine

and loosely install the screws through the slotted holes.
(4) Push the intermediate shaft assembly into the
transaxle as far as it can travel. Hold the assembly in
Fig.6 Slinger Installation Intermediate Shaft this position and tighten the screws (bracket to engine
block) to 54 N-m (40 ft. lbs.) torque. This will ensure
ASSEMBLE full seal engagement between the journal on the inter­
(1) Place new slinger on stub shaft and drive it on mediate shaft and the seal in the transaxle extension.
until it bottoms out on the shoulder of the shaft (Fig.6). (5) Distribute a liberal amount of grease in side spline
A tool for this purpose can be fabricated from a piece and pilot bore on bearing end of intermediate shaft.
of pipe that has the dimensions noted in (Fig.6). Use MOPAR Multi-Purpose Lubricant, or equivalent.
(6) Install speedometer pinion (Fig.8).
CAUTION: Do not dent or bend the slinger during
(7) Install right driveshaft. See Driveshaft Assem­
this installation, since it could prevent the bearing
blies Installation.
assembly from seating properly.
(2) Press bearing assembly into position on the shaft,
there should be a minimum of 1 mm (1/32 inch) clear­
ance between slinger and bearing assembly when prop­
erly installed.
CAUTION: Apply pressure only to the inner race of
the bearing during this procedure or damage may
result which could cause premature bearing failure.
(3) Press the outer slinger into place with the same
tool used for bearing installation. The slinger must
bottom out on the shoulder of the shaft.

INTERMEDIATE SHAFT ASSEMBLY INSTALLATION

(1) Securely fasten bracket to bearing assembly and
tighten to 28 N*m (21 ft. lbs.) torque (Figs.9 and 10).
(2) Hold the stub yoke while aligning and guiding
the splined end into the transaxle (Fig.7).
(ENGINE)
BRACKET

TO TO
TRANSMISSION WHEEL

BEARING
BRACKET
INSTALL BEARING
BRACKET ON THIS'
FACE 9002-14

F/g.9 3.3L Intermediate Drlwesh&tt Bearing Plg.10 2.5L Turbochargedi-Engine Design

Brackets) Pm ltlm
 REAR SUSPENSION
INDEX
Page Page
General Information ......................................... . .......... 40 Rear Springs (Front Wheel Drive) ............................... 41
Jounce Bumper .............................................................. 42 Specifications ................................................................ 44
Rear Springs (All Wheel Drive) ................................... 41 Sway Bar ......................................................................... 43

GENERAL INFORMATION design provides greater stability in addition to con­

trolling ride motion.
The rear suspension on these vehicles include leaf
CAUTION: The Installation of aftermarket load level­
springs, sway bar shock absorbers and a tube and cast­
ing devices is prohibited on these models. Adjusta­
ing axle, designed to handle various load requirements.
ble air shocks or helper springs. Will cause the rear
Shackle angles have been selected to provide in­
brake height sensing proportioning valve to sense a
creasing suspension rates as the vehicle is loaded.
light load condition. That is actually a loaded condi­
This provides a comfortable unloaded ride and also
tion supported by add-on devices. (See Brakes Group
ample suspension travel when the vehicle is loaded.
5 of this manual for detailed information on the rear
The rear shock absorbers are mounted at an angle,
brake height sensing proportioning valve).
parallel to the springs and forward at the top. This
TORQUE BUMPER REAR
35 FT. LBS. 47 N*ro ASSEMBLY HANGER
f
# 105 FT. LBS. 142 N*m
80 FT. LBS. 108 N*m
65 FT. LBS. 88 N*m
€> 45 FT. LBS. 61 N*m
85 FT. LBS. 115 N*m
290 IN. LBS. 33 N*m

FRONT
SPRING
HANGER

9102-63

Fig. 1 Rear Suspension Front Wheel Drive

REAR SPRINGS (FRONT WHEEL DRIVE)
REMOVAL (FIG.1)
(1) Raise vehicle on frame contact hoist to a com­
fortable working position.
(2) Using floor stands under the axle assembly, raise
axle assembly to relieve weight on rear springs.
(3) Disconnect the actuator assembly for height sens­
ing proportioning valve. Disconnect lower ends of rear
shock absorbers at axle brackets.
(4) Loosen and remove U-bolt nuts and washers,
remove U-bolts.
(5) Lower rear axle assembly, permitting rear springs
to hang free.
(6) Loosen and remove four bolts from front spring
hanger.
(7) Loosen and remove rear spring shackle nuts and
plate, remove shackle from spring.
(8) Loosen and remove front pivot bolt from front
spring hanger.
INSTALLATION (FIG. 1)
(1) Assemble shackle, bushings and plate on rear of
spring and rear spring hanger, start shackle bolt nuts.
Do not tighten.
(2) Assemble front spring hanger to front of spring
eye and install pivot bolt and nut. Do not tighten.
CAUTION: Pivot bolt must face Inboard to prevent
structural damage during installation of spring.
(3) Raise front of spring and install four hanger
bolts, tighten to 61 N*m (45 ft. lbs.) torque. Connect
actuator assembly for height sensing proportioning
valve.
(4) Raise axle assembly into correct position with
axle centered under spring center bolt.
(5) Install U-bolts, nuts and washers. Tighten U-bolt
nuts to 81 N-m (60 ft. lbs.) torque.
(6) Install shock absorbers and start bolts.
(7) Lower vehicle to floor and with full weight of
vehicle on wheels, tighten component fasteners as
follows:
• Front pivot bolt — 142 N*m (105 ft. lbs.)
• Shackle nuts — 47 N-m (35 ft. lbs.)
• Shock absorber bolts:
• Upper — 115 N-m (85 ft. lbs.)
• Lower — 108 N-m (80 ft. lbs.)
(8) Raise vehicle and connect rear brake proportion­
ing valve spring and adjust (see Adjusting Procedure
in Brake Section of this manual).
REAR SPRINGS (ALL WHEEL DRIVE)
REMOVAL (FIG.2)
(1) Raise vehicle on frame contact hoist to a com­
fortable working position.
(2) Using floor stands under the axle assembly, raise
axle assembly to relieve weight on rear springs.
(3) Disconnect the actuator assembly for height sens­
ing proportioning valve. Disconnect lower ends of rear
shock absorbers at axle brackets.
(4) Loosen and remove U-bolt nuts and washers,
remove U-bolts.
(5) Lower rear axle assembly, permitting rear springs
to hang free.
(6) Loosen and remove four bolts from front spring
hanger.
(7) Loosen and remove the rear spring, shackle and
pin assembly through bolt nuts.
(8) Loosen and remove the 2 shackle and pin assem­
bly retaining bolts.
(9) Separate the rear shackle plate, from the shackle
and pin assembly. Remove the shackle and pin assem­
bly from the spring.
(10) Loosen and remove front pivot bolt from front
spring hanger.
FRAME 4x4 BUSHING
RAIL TAB SCREW

REAR HANGER

ACTUATOR BRACKET
FRONT SPRING ASSEMBLY (BRAKE
HANGER PROPORTIONING VALVE)

BUSHING 9102-64

Fig.2 Rear Suspension All Wheel Drive

INSTALLATION (FIG.2) CAUTION:The following sequence must be followed

(1) Assemble shackle and pin assembly, bushings
and shackle plate on rear of spring and rear spring
hanger. Start shackle and pin assembly through bolt
nuts. Do not tighten.
(2) Assemble front spring hanger to front of spring
eye and install pivot bolt and nut. Do not tighten.
CAUTION: Pivot bolt must face inboard to prevent
structural damage during installation of spring.
(3) Raise front of spring and install four hanger
bolts, tighten to 61 N-m (45 ft. lbs.) torque. Connect
actuator assembly for height sensing proportioning
valve.
(4) Raise axle assembly into correct position with
axle centered under spring center bolt.
(5) Install U-bolts, nuts and washers. Tighten U-bolt
nuts to 88 N-m (65 ft. lbs.) torque.
(6) Install shock absorbers and start bolts.
(7) Lower vehicle to floor and with full weight of
vehicle on wheels, tighten component fasteners as
follows:
• Front pivot bolt — 142 N-m (105 ft. lbs.)
when tightening the rear shackle pin assembly and
nut. First, the shackle and pin assembly through
bolts must be torqued to the specification listed be­
low. Second, torque the shackle and pin assembly
retaining bolts to the torque listed below. This se­
quence must be followed to properly seat the bush­
ings into the springs and avoid bending the shackle
assembly.
• Shackle and pin assembly through bolt nuts — 47
N-m (35 ft. lbs.)
• Shackle and pin assembly retaining bolts — 47 N-m
(35 ft. lbs.)
• Shock absorber bolts:
• Upper — 115 N-m (85 ft. lbs.)
• Lower — 108 N-m (80 ft. lbs.)
(8) Raise vehicle and connect rear brake proportion­
ing valve spring and adjust (see Adjusting Procedure
in Brake Section of this manual).
JOUNCE BUMPER
If the jounce bumper is removed from the vehicle for
service or replacement it must be replaced in the
correct location on the frame rail. This location is
important so that the bumper will contact the axle
 Flg.1 Rear Sway Bar
correctly and not interfere with the rear drive shaft
on the All Wheel Drive applications.
The frame rail has 4 holes in the area where the
jounce bumper mounts. Two of the holes are threaded
and 2 are not. Refer to (Fig.2) for the tab and screw
location for the Front Wheel Drive and All Wheel
Drive mounting of the jounce bumper to the frame
rail.
SWAY BAR
The sway bar interconnects both sides of the rear
axle and attaches to the rear frame rails using 2
rubber isolated link arms (Fig.l).
Jounce and rebound movements affecting one wheel
are partially transmitted to the opposite wheel to re­
duce body roll.
Attachment to the rear axle tube, and rear frame
rails is through rubber-isolated bushings. All parts
are serviceable, and the sway bar to axle bushings are
split for easy removal and installation. The split in
the bushing should be positioned up when installed on
the vehicle.
The 2 rubber isolated link arms are connected to
the rear frame rails by brackets which are bolted to
the bottom of the frame rails (Fig.l).
REMOVE
(1) Raise and support the vehicle. See Hoisting in
Lubrication and Maintenance, group 0.
(2) Remove the 2 lower bolts which hold the sway
bar to the link arm on each side of the vehicle (Fig.2)
(3) Loosen but do not fully remove the 4 bolts. That
attach the sway bar bushing retainers to the rear axle
tube brackets (Fig.2).
(4) While holding the sway bar in place. Fully re­
move the 4 bolts holding the bushing retainers and
bushings to the axle brackets. Remove sway bar from
vehicle (Fig.2).
(5) If the link arms need to be serviced. Remove the
upper link arm to bracket bolt, and remove link arm
from frame rail attaching bracket (Fig.2).
INSPECTION
Inspect for broken or distorted clamps, retainers,
and bushings. If bushing replacement is required the
sway bar to axle bushing can be removed by opening
the split.
 INSTALL
(1) Install the link arms onto the frame rail brack­
ets (Fig.2). DO NOT TIGHTEN.
(2) Position the axle to sway bar bushings on the
sway bar. With the slit in the bushing facing up in the
installed position (Fig.2)
(3) Lift the bar assembly onto the rear axle and
install the retainers and 4 bolts (Fig.2). DO NOT
TIGHTEN.
(4) Install the 2 lower link arm bolts to the sway
bar (Fig.2). DO NOT TIGHTEN.
(5) Lower the vehicle so the weight is on all 4 tires
and vehicle is at curb height. Tighten all the attach­
ing bolts to there proper torques listed below.
• Bushing to Axle Bracket Bolt - 61 N-m (45 ft. lbs.)
• Link Arm To Frame Rail Bracket - 61 N-m (45 ft.
lbs.)
• Sway Bar To Link Arm - 61 N- (45 ft. lbs.)
• Link Arm Bracket to Frame Rail - 33 N-m (290
in. lbs)
RETAINER 9102-66 For the fastener locations referring to the torques
listed above see (Fig.l & 2).
Flg.2 Rear Sway Bar Remove and Replace
SPECIFICATIONS
ALIGNMENT SPECIFICATIONS AT CURB HEIGHT

FRONT WHEEL ALIGNMENT

ACCEPTABLE ALIGNMENT RANGE PREFERRED
; ;AT CURB HEIGHT SiTfMG

CAMBER...All M o d e ls —0,2® to + .80 ( 1 /4 " to 3 /4 " ) + 0 .3 ° ( + 5,

TOE...All M odels . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Specified in Inches . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. 7 /3 2 " In to 1/8 " O u t 1 /1 6 " In i t / 1 # 1
S pecifie d in D e g r e e s . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4® In- to . 2° Out 0.1 ° 1

CASTER* REFERENCE ANGLE '' ''

All M odels Van/W agon 1.7®

*Side To Side C a s te r Should N o t E xceed 1,5 D e g re e s .

REAR WHEEL ALIGNMENT ACCEPTABLE ALIGNMENT RANGE PREFERRED

AT CURB HEIGHT .. SETTING

CAMBER...All M o d e ls ................................ - . 8 ° to + . 4 ° ( - 1 to + 1 / 2 ) —0.2 _ (1/4)

TOE*...All M odels
S pecified in Inches .. .3 " Out to .3 " In 0.0"
S pecified in D e g re e s . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6® O u t to .6® In ■ 0.0 °

T hrust A n g l e . . . . . . . . . . . . . . . . . • . . . . . . . . . . . . . . . . . . . . . . . ! - .40° to + .40® ■ ■ ~ .40° to + .40®

*TOE OUT W h en l a c k e d O n A lig n m e n t Rack Is TOE IN

W h en Driving.

9102-67
 TORQUE SPECIFICATIONS

suspension COMPONENT m in is f CllOf P iC llllillf

Leaf Spring to H a n g e r M ounting N u t 142 105

Shock A b s o rb e r M ou n tin g Bolts U pper IIS •5

L ow er iCil Ǥ

B ra k e A sse m b ly a n d S pindle M o u n ti ng Bolts 108 so

R e ar S pring U-Bolts as m
S pring S h a c k le N uts 4? 35
W h ee l Lug N u ts 129 95

S trut D a m p e r to K nuckle Leg *10© *78

L ow er C ontrol A rm P iv o t Bolts lit 125

S w ay B ar C ushion (A ttac h m en t) Bolts 70 50

S w ay Bar End Bushing B ra ck e t Bolts 70 50

Bali Jo in t Stud to S te e rin g K nuckle 145 105

PLUS 1/4 (90°) TURN

9102-68
 REAR SUSPENSION AND DRIVELINE
CONTENTS
Page Page
ALL WHEEL DRIVE REAR SUSPENSION 3 REAR DRIVE LINE MODULE VACUUM
REAR DRIVE LINE MO DULE ASSEMBLY SHIFT MOTOR DIAGNOSIS .. . . . . 36
(ALL WHEEL DRIVE SPECIFICATIONS ................................ 41
REAR DRIVE LINE MO )ULE ASSEMBLY TWO WHEEL DRIVE REAR SUSPENSION 1
SERVICE PROCEDURES 8
TWO WHEEL DRIVE REAR SUSPENSION
INDEX
Page Page
General Information ........................................................ 1 Rear Springs .. 1
Rear Shock Absorbers...................................................... 2

GENERAL INFORMATION brake height sensing proportioning valve to sense a

The rear suspension on these vehicles include leaf
springs and a "tube and casting axle”, designed to
handle various load requirements.
Shackle angles have been selected to provide in­
creasing suspension rates as the vehicle is loaded.
This provides a comfortable unloaded ride and also
ample suspension travel when the vehicle is loaded.
The rear shock absorbers are mounted at an angle,
parallel to the springs and forward at the top. This
design provides greater stability in addition to con­
trolling ride motion.
CAUTION: The installation of aftermarket load level­
ing devices is prohibited on these models. Adjusta­
ble air shocks or helper springs will cause the rear
light load condition that is actually a loaded condi­
tion supported by add-on devices. See “Brakes”
Group 5 of this manual for detailed information on
the rear brake height sensing proportioning valve.
REAR SPRINGS
REMOVAL
(1) Raise vehicle on frame contact hoist to a com­
fortable working position.
(2) Using floor stands under the axle assembly, raise
axle assembly to relieve weight on rear springs.
(3) Disconnect the actuator assembly for height sens­
ing proportioning valve (Fig. 1). Disconnect lower ends
of rear shock absorbers at axle brackets.
LET TORQUE REAR
HANGER
35 FT. LiS. 47 N«m

Z
•
< l> 105 FT. LiS., 142

E
INSERT
< l> so FT. LiS. 108 N

65 FT. LBS. §8 N»m '

BUSHINGS
<E> 45 FT. LIS. #1 N*m

< f> 85 FT. LBS. 115 N

SHACKLE

FRONT
SPRING
HANGER

ACTUATOR BRACKET SEAL

SPINDLE
ASSEMBLY (BRAKE
'PROPORTIONING VALVE) 9002-65

Fig. 1 Rear Suspension

(4) Loosen and remove "U” bolt nuts and washers,
remove "U” bolts.
(5) Lower rear axle assembly, permitting rear springs
to hang free.
(6) Loosen and remove four bolts from front spring
hanger.
(7) Loosen and remove rear spring shackle nuts and
plate, remove shackle from spring.
(8) Loosen and remove front pivot bolt from front
spring hanger.
INSTALLATION
(1) Assemble shackle, bushings and plate on rear of
spring and rear spring hanger, start shackle bolt nuts.
Do not tighten.
(2) Assemble front spring hanger to front of spring
eye and install pivot bolt and nut. Do not tighten.
CAUTION: Pivot bolt must face inboard to prevent
structural damage during installation of spring.
(3) Raise front of spring and install four hanger
bolts, tighten to 61 N-m (45 ft. lbs.) torque. Connect
actuator assembly for height sensing proportioning
valve.
(4) Raise axle assembly into correct position with
axle centered under spring center bolt.
(5) Install "U” bolts, nuts and washers. Tighten "U”
bolt nuts to 81 N-m (60 ft. lbs.) torque.
(6) Install shock absorbers and start bolts.
(7) Lower vehicle to floor and with full weight of
vehicle on wheels, tighten component fasteners as
follows:
• Front pivot bolt — 142 N-m (105 ft. lbs.)
• Shackle nuts — 47 N-m (35 ft. lbs.)
• Shock absorber bolts:
Upper — 115 N-m (85 ft. lbs.)
Lower — 108 N-m (80 ft. lbs.)
(8) Raise vehicle and connect rear brake proportion­
ing valve spring and adjust (see Adjusting Procedure
in Brake Section of this manual).
REAR SHOCK ABSORBERS
REMOVAL AND INSTALLATION
(1) Lift vehicle on a frame contact hoist.
(2) Support axle with a jack stand.
(3) Remove lower shock bolt.
(4) While holding shock, remove upper shock bolt.
(5) To Install, Reverse Removal Procedure.
 ALL WHEEL DRIVE REAR SUSPENSION
INDEX
Page Page
General Information ........................................................ 3 Rear Springs...................................................................... 5
Rear Shock Absorbers...................................................... 5 Rear Wheel Bearings...... .................... ............................. 3

GENERAL INFORMATION TOSIS AND/OR CANCER. EXTREME CARE SHOULD

BE TAKEN WHILE SERVICING BRAKE ASSEMBLIES
The rear suspension on these vehicles include leaf OR COMPONENTS.
springs and a "tube and casting axle”, designed to
(3) Remove brake drum (Fig. 1).
handle various load requirements.
Shackle angles have been selected to provide in­
creasing suspension rates as the vehicle is loaded.
This provides a comfortable unloaded ride and also
ample suspension travel when the vehicle is loaded.
The rear shock absorbers are mounted at an angle,
parallel to the springs and forward at the top. This
design provides greater stability in addition to con­
trolling ride motion.
CAUTION: The installation of aftermarket load level­
ing devices is prohibited on these models. Adjusta­
ble air shocks or helper springs will cause the rear
brake height sensing proportioning valve to sense a
light load condition that is actually a loaded condi­
tion supported by add-on devices. See “Brakes”
Group 5 of this manual for detailed information on
the rear brake height sensing proportioning valve.

REAR WHEEL BEARINGS

The rear wheel bearings used in the All Wheel
Drive system are similar to the bearings used in the 9103-33
front wheels. The bearings are permanently sealed
and require no maintenance. The bearing, hub and Fig. 1 Remove Rear Drum
retainer are serviced as an assembly.
(4) Remove cotter pin, nut lock, spring washer and
Defective or damaged rear wheel bearings produce
hub nut (Fig. 2).
a vibration or "growl” noise that will continue after
the transmission is shifted to "NEUTRAL” and the
vehicle is coasting.
In order to tell the difference between rear wheel NUT LOCK
bearing noise and differential gear noise, road test the
vehicle on a smooth road (black top) at medium to low
speed. With traffic permitting, "swerve” the vehicle
sharply right-to-left. If the noise is caused by a rear
wheel bearing, it will usually increase in loudness
when the vehicle is "swerved”.

REMOVAL
(1) Raise vehicle on hoist.
COTTER PIN
(2) Remove wheel and tire assembly.
WARNING: DUST INSIDE OF BRAKE DRUM MAY CON­ RP1086
TAIN ASBESTOS FIBERS. BREATHING EXCESSIVE
CONCENTRATIONS OF ASBESTOS FIBERS CAN
CAUSE SERIOUS BODILY HARM, SUCH AS ASBES- Fig. 2 Hub Nut Assembly
 (5) Remove half shaft flange retaining bolts (Fig. 3).

(6) The half shaft is spring loaded. Compress inner

half shaft joint slightly and pull downward to clear
rear carrier output shaft. Then pull half shaft assem­
bly inboard to remove (Fig. 4).
(8) Remove wheel bearing and hub assembly (Fig
6).

CAUTION: The half shaft, when Installed, acts as a

bolt and secures the hub/bearing assembly. If the
vehicle is to be supported or moved on its wheels,
install and torque a bolt through the hub to Insure
that the hub/bearing assembly cannot loosen.
9103-37
(7) Remove wheel bearing mounting bolts (Fig 5).
Fig. 6 Pull Wheel Bearing Assembly from Housing

(9) Replacement of the grease seal is recommended

whenever this service is performed.

INSTALLATION
(1) Install new hub and bearing assembly and tighten
screws in a cris-cross pattern to 130 N-m (96 ft. lbs.).
 HEAR SUSPENSION-.AND DRIVELINE l-S

CAUTION; Knuckle and bearing mounting surfaces- CAUTION: Pivot bolt must fa©*! inboard to prevent
must be smooth and completely free of foreign ma­ structural damage during installation of spring.
terial or nick*.
(3) Raise front of spring and install four hanger
(2) U se sp ecial tool No. 6586-A To in s ta ll sea l if sea l bolts, tighten to 61 N*m (45 ft. lbs.) torque* Connect
re p la c e m e n t is re q u ire d , actuator assembly for height sensing proportioning
valve.
CAUTION: Dyrlng any serwice procedures where
(4) Raise axle assembly into correct position with
knuckle and half shaft are separated, thoroughly clean
axle centered under spring center bolt. ^
seal and wear sleeve and lubricate BOTH components.
(5) Install mUn bolts, nuts and washers. Tighten mW f
(3) L u b ric a te th e F U L L circumference of th e seal bolt nuts to 81 N*m (60 ft. lbs.) torque.
(and w e a r sleeve) w ith M O PA R M u lti-P u rp o se L u b ri­ (6) Install shock absorbers, and start bolts.
c a n t, P a r t No. 4818088, o r e q u iv a le n t. (7) Lower vehicle to floor and with full weight of
(4) In s ta ll w a sh e r a n d h u b n u t a fte r c le a n in g for­ vehicle on wheels, tighten component fasteners as
e ig n m a tte r from th re a d s . follows:
(5) W ith b ra k e s ap p lied , tig h te n n u t to 244 N-m (180 • Front pivot bolt — 142 N*m (105 ft. lbs.)
ft. lbs.). • Shackle nuts — 47 N*m (35 ft. lbs.)
(6) In s ta ll s p rin g w a sh e r, n u t lock a n d n ew c o tte r • Shock absorber bolts:
pin. W rap c o tte r p in p ro n g s tig h tly a ro u n d n u t lock.
Upper — 115 N*m (85 ft. lbs.)
(?) in s ta ll w h eel a n d tir e assem b ly . T ig h te n w h eel
Lower — 108 N-m (80 ft, lbs.)
n u ts to 115 N-m (85 ft. lbs.).
(8) Raise vehicle and connect rear brake proportion­
ing valve spring and acfjtist (see Adjusting Procedure
REAR SPRINGS in Brake Section of this manual).
REMOVAL
(1) R aise vehicle on fra m e c o n ta c t hoist to a com ­
REAR SH 0C I ABSORBERS ' '
fo rta b le w o rk in g p osition.
m M O V A L AN D IN ST A L L A T IO N
(2) U sin g floor s ta n d s u n d e r th e ax le assem b ly , ra is e
(1) Lift vehicle on a frame contact hoist.
ax le a sse m b ly to re lie v e w e ig h t on r e a r sp rin g s.
(2) Support axle with a jack stand.
(8) D isconnect th e a c tu a to r a ssem b ly for h e ig h t se n s­
(3) Remove lower shock bolt.
in g p ro p o rtio n in g v alv e. D isconnect low er en d s of r e a r
(4) While holding shock, remove upper shock bolt.
shock a b so rb e rs a t ax le b ra c k e ts.
(5) To Install, Reverse Removal Procedure.
(4) L oosen a n d rem ove "U ” b o lt n u ts a n d w a sh e rs,
rem ove "U ” b olts.
(8) Low er r e a r axle assem bly, p e rm ittin g r e a r sp rin g s
to h a n g free.
(6) Loosen a n d rem o v e fo u r b o lts from fro n t sp rin g
h a n g e r.
(7) Loosen a n d rem ove r e a r s p rin g sh a c k le n u ts a n d
p la te , rem o v e sh a c k le from sp rin g .
(8) Loosen a n d rem ove fro n t p iv o t b o lt from fro n t
sp rin g h a n g e r.

INSTALLATION
(1) Assemble sh a ck le , bushings a n d p la te on r e a r of
sp rin g a n d r e a r sp rin g h a n g e r, s ta r t sh a c k le b o lt n u ts.
Do n o t tig h te n .
(2) A ssem b le fro n t sp rin g h a n g e r to fro n t of sp rin g
eye a n d in s ta ll p iv o t b o lt a n d n u t. Do n o t tig h te n .
 REAR DRIVE LINE MODULE ASSEMBLY (ALL WHEEL DRIVE)
INDEX
Page
Fluid Leak Diagnosis........................................................ 7
General Information ........................................................ 6
GENERAL INFORMATION
The All Wheel Drive (AWD) system is available on
all Caravan/Voyager models equipped with 3.3 Liter
V-6 engine and Ultradrive transaxle.
The primary benefit of All Wheel Drive is:
• Superior straight line acceleration, and cornering
on all surfaces
• Better traction and handling under adverse condi­
tions, resulting in improved hill climbing ability and
safer driving.
The heart of the system is an inter-axle viscous
coupling. The Vehicle retains predominantly front-wheel
drive characteristics, but the All Wheel Drive capabil­
ity takes effect when the front wheels start to slip.
Under normal level road, straight line driving, 90% of
the torque is allocated to the front wheels. The viscous
coupling allows more torque to the rear wheels in
accordance with the amount of the slippage at the
front wheels. The variable torque distribution is auto­
matic with no driver inputs required.
The rear drive line module assembly consists of five
main parts: the rear carrier, torque tube, overrunning
clutch assembly, a vacuum operated dog clutch, and a
viscous coupling.
The rear carrier contains a conventional open dif­
ferential with hypoid ring gear and pinion gear set.
The hypoid gears are lubricated by SAE 85W-90 gear
lubricant.
The torque tube assembly attaches to the overrun­
ning clutch case. The front torque shaft bearing is
located in the torque tube. The front torque shaft
bearing is permanently sealed and does not require
maintenance. The torque shaft is located within the
torque tube assembly. The vacuum reservoir and sole­
noid assembly are attached to the top of the torque
tube.
The overrunning clutch allows the rear wheels to
overrun the front wheels during a rapid front wheel
lock braking maneuver. The overrunning action pre­
vents any feed-back of front wheel braking torque to
the rear wheels and allows the braking system to
control the braking behavior as a two wheel drive
(2WD) vehicle.
The overrunning clutch has a separate oil sump and
is filled independently from the differential. The fill
plug is located on the side of the overrunning clutch
case. When filling the overrunning clutch with lubri-
Page
Rear Drive Line Noise Diagnosis ................................... 6
cant use Mopar Type 7176 Automatic Transmission
fluid or equivalent.
The dog-clutch provides All Wheel Drive in reverse
by bridging and locking out the overrunning clutch.
The dog-clutch is operated by a double-acting servo
using intake manifold vacuum as its power source.
Two vacuum solenoids, controlled by the back up light
switch, engage and disengage the dog-clutch. A spring
in the vacuum servo disengages the dog clutch if vac­
uum is lost.
Located in front of the torque tube is the viscous
coupling. The viscous coupling controls and distrib­
utes torque/power to the rear wheels. The coupling is
similar to a multi-plate clutch and consists of a series
of closely spaced discs, alternately connected to the
front and rear drive units, which operate in silicone
fluid. The unit is totally sealed and partially filled
with silicone fluid. There is no adjustment, mainte­
nance or fluid checks required during the life of the
unit.
REAR DRIVE LINE NOISE DIAGNOSIS
Different sources can be the cause of noise that the
rear drive line module assembly is suspected of mak­
ing. Refer to the following causes for noise diagnosis.
REAR CARRIER ASSEMBLY NOISE
The most important part of rear carrier service is
correctly identifying the cause of failures and noise
complaints. The cause of most rear carrier failures is
relatively easy to identify, but the cause of rear car­
rier noise is more difficult to identify.
If vehicle noise becomes objectionable, or if it occurs
at all vehicle speeds, an effort should be made to
isolate the noise to one particular area of the vehicle.
Many noises that are reported as coming from the
rear carrier may actually originate at other sources.
For example tires, road surfaces, wheel bearings, en­
gine, transmission, exhaust, propeller shaft (vibration),
or vehicle body ("drumming”). Rear carrier noises are
normally divided into two categories: gear noise or
bearing noise. A thorough and careful inspection should
be completed to determine the actual source of the
noise before replacing the rear carrier.
The rear carrier assembly rubber mounting bush­
ings help to "dampen-out” rear carrier noise when
correctly installed. Inspect to confirm that no metal
contact exists between the rear carrier case and the
body. Metal-to-metal contact can result in a noise that BEARING NOISE (DRIVE PINION
would not normally be objectionable if the components AND DIFFERENTIAL)
were correctly installed and tightened. The complete Defective or damaged bearings will normally pro­
isolation of noise to any one area requires consider­ duce a rough "growl” that is constant in pitch and
able expertise and experience. Identifying certain types varies with the speed of the vehicle. Being aware of
of vehicle noise baffles even the most experienced this will enable a technician to separate bearing noise
technicians. Often such practices as: from gear noise.
• increase tire inflation pressure to eliminate tire noise. Drive pinion bearing noise that results from defec­
• listen for noise at varying speeds with different drive- tive or damaged bearings can usually be identified by
line load conditions (e.g., "drive”, "float” and "coast”) its constant, rough sound. Drive pinion front bearing
• "swerving” the vehicle from left to right to detect is usually more pronounced during a "coast” condi­
wheel bearing noise. tion, where as drive pinion rear bearing noise is more
pronounced during a "drive” condition. The drive pin­
All rear carrier assemblies produce noise to a cer­
ion bearings are rotating at a higher rate of speed
tain extent. Slight carrier noise that is noticeable only
than either the differential side bearings or the axle
at certain speeds or isolated situations should be con­
shaft bearing.
sidered normal. Carrier noise tends to "peak” at a
Differential side bearing noise will usually produce
variety of vehicle speeds and noise is NOT ALWAYS
a constant, rough sound that is much lower in fre­
an indication of a problem within the carrier.
quency than the noise caused by drive pinion bearings.
Bearing noise can best be detected by road testing
TIRE NOISE the vehicle on a smooth road (black top). However, it
Tire noise is often mistaken for rear carrier noise.
is easy to mistake tire noise for bearing noise. If a
Tires that are unbalanced, worn unevenly or are worn
doubt exists, the tire treads should be examined for
in a "saw-tooth” manner are usually noisy and often
irregularities that often causes a noise that resembles
produce a noise that appears to originate in the rear
bearing noise.
carrier.
Tire noise changes with different road surfaces, but
ENGINE AND TRANSMISSION NOISE
rear carrier noise does not. Inflate all four tires with
Occasionally noise that appears to originate in the
approximately 20 psi (138 kPa) more than the recom­
rear carrier assembly is actually caused by the engine
mended inflation pressure (for test purposes only).
or the transmission. To identify the true source of the
This will alter noise caused by tires, but will not
noise, note the approximate vehicle speed and/or RPM
affect noise caused by the differential. Rear axle noise
when the noise is most noticeable. Stop the vehicle
usually ceases when coasting at speeds less than 30
next it brick or cement wall (this will help
mph (48 km/h); however, tire noise continues, but at a
reflect the sound). With the transmission in "NEU­
lower frequency, as the speed is reduced.
TRAL”, accelerate the engine slowly up through and
After test has been completed lower tire pressure
then decelerate down through the engine speed that
back to recommended pressure.
approximately corresponds to the vehicle speed and/or
RPM noted when the noise occurred. If a similar noise
GEAR NOISE (DRIVE PINION AND RING GEAR) is produced by this method, it usually indicates that
Abnormal gear noise is rare and, if it exists, is
the noise is being caused by the engine or the transaxle,
usually caused by "scoring” on the ring gear and drive
not the differential assembly.
pinion as a result of insufficient or incorrect lubricant
in the carrier housing.
Abnormal gear noise can be recognized easily be­
FLUID LEAK DIAGNOSIS
cause it produces a "cycling” tone that will be very
When diagnosing fluid leaks on the rear drive line
pronounced within a given speed range. The noise can
module assembly two weep holes are provided to diag­
occur during one or more of the following drive
nose certain seal leaks. These holes are located on the
conditions:
bottom side of the assembly (Fig. 1).
• "drive”
• "road load”
• "float”
• "coast”
Abnormal gear noise usually tends to peak within a
narrow vehicle speed range or ranges. It is usually
more pronounced between 30 to 40 mph (48 to 64
km/h) and 50 to 60 mph (80 to 96 km/h). When objec­
tionable gear noise occurs, note the driving conditions
and the speed range.
 REAR CARRIER CASE
If fluid leak is detected from either weep hole, seal
TORQUE TUBE
replacement is necessary. Do not attempt to rfepair
the leak by sealing weep holes, they must be kept
clear of sealants for proper seal operation.
If fluid is leaking from weep hole "A” (Fig. 1) and it
is identified to be Automatic Transmission Fluid by
its red color, this indicates that the front overrunning
clutch seal is leaking. For replacement of this seal
refer to Rear Drive Line Assembly Service Procedures.
If fluid is leaking from weep hole "B” (Fig. 1) the
type of fluid leaking will determine which seal is
leaking. If the fluid leaking is red in color (transmis­
sion fluid) this indicates that the rear overrunn; “
clutch seal should be replaced. If the fluid leaking is
WEEP HOLE
"A" 9103-105 light brown (hypoid gear lube) this indicates that the
input pinion seal should be replaced. For replacement
Fig. 1 Weep Hole Locations of these seals refer to Rear Drive Line Assembly Ser­
vice Procedures.

REAR DRIVE LINE MODULE ASSEMBLY SERVICE PROCEDURES

INDEX
Page Page
Case Cover Service ........................................................ 21 Propeller Shaft S ervice.................................................. 33
Drive Pinion Bearing Shim Selection ......................... 19 Rear Carrier Output Shaft Seals ................................. 10
Drive Pinion Seal And/Or Rear Rear Carrier U n i t ............................................................ 10
Overrunning Clutch Seal ......................................... 15 Rear Drive Line Module Assembly ............................. 8
Front Overrunning Clutch Seal ................................... 12 Rear Driveline Module Differential Side Gears 20
Half Shaft S ervice......................................... ................ 33 Torque T u b e .................................................................... 24
Overrunning Clutch ........................................................ 26

REAR DRIVE LINE MODULE ASSEMBLY (3) Support inner side of half shaft with mechanics
wire or equivalent (Fig.2). Do not allow half shafts to
REMOVAL AND INSTALLATION hang freely.
(1) Raise vehicle on hoist.
(2) Remove right and left inner half shaft joint mount­ N DRIVE SHAFT
LY
ing bolts (Fig. 1).

9103-38

Fig. 2 Support Half Shafts

(4) Remove mounting bolts from the rear side of

propeller shaft (Fig. 3).
 Fig. 3 Remove Mounting Bolts

CAUTION :Do not allow propeller shaft to hang freely

(10) Remove rear drive line module assembly front
(5) Support propeller shaft with mechanics wire mounting bolts (Fig. 6).
and/or jack stand
(6) Remove viscous coupling retaining nut and slide
viscous coupling off of rear drive line module assem­
bly (Fig. 4).

(7) Disconnect main vacuum line for rear drive line

module assembly. Also disconnect electrical connec­
tions at the front of the module.
(8) Support rear drive line module assembly with
transmission jack or equivalent.
WARNING: BE SURE TO CHAIN REAR DRIVE LINE
MODULE ASSEMBLY SECURELY TO THE JACK TO
PREVENT IT FROM FALLING.
(9) Remove rear drive line module assembly rear
mounting bolts (Fig. 5).
(11) Partially lower rear drive line module assem­
bly and disconnect remote solenoid vent and remote
carrier vent.
(12) Remove rear drive line module assembly.
(13) To Install, Reverse Removal Procedure. Refer
to TORQUE SPECIFICATION in the rear of this sec­
tion for tightening specifications.
REAR CARRIER UNIT
REMOVAL AMD INSTALLATION
(1) Remove rear drive line module assembly from
vehicle.
(2) Drain oil from overrunning clutch case.
(3) Remove overrunning clutch case to rear carrier
case bolts (Fig.8).

Fig. 9 Separate Rear Carrier Case from

Overrunning Clutch Case

(4) Separate rear carrier case from overrunning clutch

case (Fig.9).
(5) For Installation, Reverse Removal Procedure.
CLUTCH CASE
9103-259 REAR CARRIER OUTPUT SHAFT SEALS
Fig. 8 Overrunning Clutch Case to The rear drive line module assembly does not have
Rear Carrier Case Bolts to be removed from vehicle to service the carrier out­
put shaft seals.
The output shaft seals are located on the rear car­
rier unit (Fig. 1).
 DRIVE PINION OUTPUT SHAFT SEAL

REMOVAL
(1) Remove inner half shaft retaining bolts (Fig. 2).

9103-38

Fig. 3 Support Half Shafts

9103-34

(3) Using two prybars and wooden support blocks,

Fig. 2 Inner Half Shaft Bolts pop out output shaft (Fig. 4).
CAUTION :Do not allow half shafts to hang freely
(2) Support inner side of half shaft with mechanics
wire or equivalent (Fig. 3).
 PRYBAR REAR CARRIER HAMMER
CASE

SPECIAL TOOL
MD998334 9103-82

Fig. 6 Installing Oil Seal

(3) Install output shaft (Fig. 7). Lightly tap shaft to

seat retainer ring into differential side gear.
REAR CARRIER
CASE

Fig. 4 Output Flange Removal

(4) Using a prybar, pry out oil seal (Fig.5), being

careful not to damage race.

REAR CARRIER
CASE

REAR CARRIER 9103-83

Fig. 7 Installing Output Shaft

(4) Check differential fluid level, fill as required.

OUTPUT
SHAFT
9103-81
FRONT OVERRUNNING CLUTCH SEAL
SEAL

Fig. 5 Seal Removal
INSTALLATION
(1) Clean and inspect shaft and seal area.
(2) Install oil seal with special tool MD998334 (Fig.6).
The rear drive line module must be removed to
service this seal.
The front overrunning clutch seal is located in the
overrunning clutch case (Fig.l).
REMOVAL (7) Remove overrunning clutch inner race snap ring
(1) Remove rear drive line module assembly from (Fig. 10).
vehicle.
(2) Remove viscous coupling unit.
(3) Remove overrunning clutch cover assembly.
(4) Drain fluid from overrunning clutch case.
(5) Remove overrunning clutch case to rear carrier
bolts (Fig. 8).

(8) Slide overrunning clutch inner race off of shaft

(Fig. 11).

OVERRUNNING
CLUTCH CASE 9103-78

Fig. 8 Overrunning Clutch Case to Rear Carrier Bolts

(6) Separate overrunning clutch case from rear car­

rier case (Fig.9).

Fig. 11 Remove Overrunning Clutch Inner Race

(9) Remove shaft snap ring and slide dog clutch off
of the shaft (Fig. 12).

Fig. 9 Separate Housings

 SNAP RING

OVERRUNNING
CLUTCH CASE

DOG C
LUTCH 9103-113

Fig. 12 Remove Snap Ring

(10) Remove torque shaft snap ring (Fig. 13) and

torque tube bearing shield.
TORQU1

Fig. 14 Torque Tube Bolts

BEARING
SHIELD (12) Remove inner torque shaft bearing snap ring.
(13) Separate overrunning clutch case from torque
tube.
(14) Remove rear torque shaft bearing retaining
outer snap ring in overrunning clutch case (Fig. 15).

OVERRUNNING
CLUTCH CASE

SNAP RING 9103-87

Fig. 13 Remove Torque Shaft Snap Ring and

Torque Tube Bearing Shield

(11) Remove torque tube retaining bolts (Fig. 14).

TORQUE SHAFT
REAR BEARI NG 9103-86

Fig. 15 Torque Shaft Rear Bearing Snap Ring

 (15) Remove rear torque shaft bearing.
(18) Drive out seal with special tool 0-498? (Fig. 18)

Fig. 17 Installing New,. Sml ,

(9) Apply Mopar Gasket" Maker P/N 4318083, Loctite

Gasket Eliminator No. 518 or equivalent and reinstall
overrunning clutch cover. When installing cover'be
INSTALLATION
sure that the overrunning clutch fork engages into
(1) Clean and inspect shaft sealing surface and case
the overrunning clutch dog.
for nicks or grooves. Replace as required.
(10) Install rear drive line module assembly into
(2) Install new seal with special tool MD998384.
vehicle.
Seal should be flush with outside edge of case (Fig,
(11) Check and fill fluid levels as required. 9
17).
(3) Install rear torque shaft bearing and outer snap
ring.
DRIVE PINION S i l l AN i/O R
(4) Install overrunning clutch case onto torque tube.
R IIR iV IR R U N N IN i CLUTCH SEAL
Tighten bolts to 28 N*m (250 in. lbs.).
The rear drive line module must be removed to
(5) Install torque shaft inner snap ring.
service these seals. The drive pinion seal is located in
(8) Slide dog clutch onto shaft and install snap ring.
the front carrier cover, behind the overrunning clutch
(7) Slide overrunning clutch inner race onto shaft
rear seal (Fig. 1). The overrunning clutch seal must
and install retaining snap ring (tapered end of inner
be removed to gain access to the input pinion seal. Do
race must face outward).
not reuse overrunning clutch sea l
(8) Clean sealing surfaces and apply a bead of Mopar
Gasket Maker P/N 4818083, Loctite Gasket Elimina­
tor No.518 or equivalent and reinstall the overrun­
ning clutch housing to the rear carrier case. Install
retaining bolts and tighten to 28 N-m (250 in. lbs.).
 3-16
rea r c a r r ie r c o m p o n e n t id e n tific a tio n

REAR SUSPENSION AND DRIVELINE

rumer
919.9 rc:»

OUTPUT SHAFT

SEAL RING

RETAINING
SNAP RING

OUTPUT
SHAFT

HEX HEAD

SELECTIVE SHIM

SPACER-DRIVE
PINION

SEAL RING

CARRIER END
COVER'

DIFFERENTIAL
SHAFT
p in io n
SELECTIVE
SHIM
PiPPEKNENIlAl
BODY CASE TAPERED
ROLLER
BEARING

LOCK NUT

SNAP RING OVERRUNNING

CLUTCH
OVERRUNNING
CLUTCH SPACER

9103-57 *
 f l l l l l i S P i i i i i i AND ilP E L iiE .3-17

MHO VAL j— ... ---------- 5

■. (1) Remove rear drive line module from vehicle.
(2) Remove overrunning clutch case to rear carrier
bolts (Fig. 1).
\
\© \

REAR '
CARRIER CASE

O V E iiU N N IN G
CLUTCH CASE
9103-259

Fig. I Overrunning Clutch Case to Hear Carrier Bolts

(3) Separate overrunning clutch case from differen­

tial carrier case (Fig. 2).
m m CARRIER
CASE

OVERRUNNING CLUTCH
. \ OUTER RACE " 9103-245

Fig. 4 Overrunning Clutch Outer m am fimftmmi

(8) Using Spline Socket Too! 6534 and a wrench,

remove pinion nut (Fig. 5)... ,

OVERRUNNING
CLUTCH CASE
9103-260

Fig- 2 Separate Cases

SPECIAL TOOL
(4) Remove overrunning clutch outer race snap ring 6534 9103-188
(Fig. 3). Fig. 5 fmmmw Plnlm Nut
 (7) Remove front carrier cover retaining screws (Fig.
6)

Fig. 8 Removing Drive Pinion Spacer

CAUTION: Shim should be installed with front carrier

Fig. 6 Front Carrier Cover Retaining Screws cover. This will eliminate the potential of cutting the
O-Ring with the shim.
(8) Remove front carrier cover from carrier case
(Fig. 7). (10) Reinstall front carrier cover into carrier case
(Fig. 9). Install carrier retaining bolts and tighten to
FRONT CARRIER
COVER
12 N-m (105 in. lbs.).

PI NION

‘ SHIM

Fig. 7 Front Carrier Cover FRONT CARRIER COVER""**-------------" " 9103-248

(9) Place a block of wood under the end of the pinion Fig. 9 Reinstalling Front Carrier Cover
shaft. Tap end of pinion against the wood to drive the
pinion spacer off of the pinion shaft (Fig. 8). (11) Use seal puller 7794-A (Fig. 10) to remove the
overrunning clutch seal and drive pinion seal (to gain
access to the drive pinion seal, the overrunning clutch
seal must first be removed). The overrunning clutch
seal must be replaced after the drive pinion seal is
installed, do not reuse old seal.
 Fig. 10 Removing Seals
INSTALLATION
(1) Clean and inspect seal area.
(2) Apply a light coat of oil onto the drive pinion
seal and install with Seal Installer 6507. Seal must be
installed with the spring side in towards the rear
carrier case (Fig 11).
CAUTION: If the drive pinion spacer is grooved or
damaged it must be replaced. A new drive pinion
bearing shim may be required. Refer to “Drive Pin­
ion Bearing Shim Selection” in this section before
continuing with this procedure.
(3) Apply a light coat of oil onto the drive pinion
spacer and slide onto the pinion shaft with the ta­
pered side facing outward (Fig. 12).
Fig. 12 Installing Drive Pinion Spacer onto Pinion
(4) Apply a light coat of oil onto the overrunning
clutch seal and install with Seal Installer 6508. Seal
must be installed with the spring side away from the
rear carrier case (Fig. 13).
(5) Install pinion nut and tighten to 203 N-m (150 ft.
lbs.).
(6) Install overrunning clutch outer race and snap
ring.
(7) Apply loctite sealer to overrunning clutch seal­
ing surface and reinstall the overrunning clutch case
to rear carrier case.
(8) Reinstall rear drive line module assembly into
the vehicle.
(9) Check and fill all fluids as required.
DRIVE PINION BEARING SHIM SELECTION
This procedure must be performed when ever the
drive pinion spacer has been replaced.
(1) Using a one inch micrometer, measure the thick­
ness of the original spacer (Fig. 1).
 For Example: The new spacer is 0.010 thicker than
the original spacer. The original shim measures 0.205.
Subtracting 0.010 from 0.205 equals a new shim thick­
ness of 0.195.

REAR DRIVELINE MODULE DIFFERENTIAL

SIDE GEARS
(1) Disconnect both half shafts from rear driveline
module.
(2) Using two prybars, pop out output shaft.
(3) Remove output shaft.
(4) Remove end cover retaining bolts.
(5) Remove differential end cover.
(6) Remove differential assembly from rear drive-
line case.
(7) Remove ring gear bolts and separate differential
case from differential body.
(8) Using a punch and hammer remove the differen­
tial pinion shaft pin.
(9) Slide differential pinion shaft out of differential
case.
(10) Inspect and replace pinion gears, pinion shaft
Pig. 1 Measuring Driwe Pinion Spacer Thickness or pinion washers as required.
(11) Reverse steps 7 thru 10 to assemble differen­
(2) Measure the thickness of the new spacer the
tial. Torque the ring gear bolts to 95 N-m (70 ft. lbs.).
same way that the original spacer was measured.
(12) Install differential assembly into driveline mod­
The difference in the measurements of the old spacer
ule case.
and the new spacer will'determine which shim to use.
(13) Clean and inspect sealer surfaces.
If the new drive pinion spacer is the same thickness
(14) Apply Mopar Gasket Maker P/N 4318083, Loctite
as the original driwe pinion spacer use the original
Gasket Eliminator No. 518 or equivalent and install
shim. . “
end cover. Tighten to 28 N*m (250 in. lbs.).
If the new drive pinion spacer is thinner than the
(15) Tighten bolts in the sequence shown in Fig. 2.
original drive pinion spacer, a thicker shim will have
Retighten first bolt after all others are tight.
to be used to compensate for the difference in size.
(18) Install output shafts.
(a) Determine the difference in size between the
new spacer and the original spacer. Record this
dimension.
(b) Measure the thickness of the original shim.
Record this dimension.
(c) Add together the two dimensions recorded in
steps (a) and (b). Use a new shim that is equal to this
size.
For Example: The new spacer is 0.010 thinner than
the original spacer. The original shim measures 0.205.
Adding 0.205 and 0.010 equals a new shim thickness
of 0.215.
If the new drive pinion spacer is thicker than the
original drive pinion spacer, a thinner shim will have
to be used to compensate for the difference in size.
(a) Determine the difference in size between the
new spacer and the original spacer. Record this
dimension.
(b) Measure the thickness of the original shim.
Record this dimension.
(c) Subtract the dimensions recorded in steps (a)
from the dimension recorded in step (b). Use a new
shim that is equal to this size. ' ^ ' ,
 (17) Reconnect both half shafts.
(18) Fill differential with lubricant.
CASE COVER SERVICE
DIFFERENTIAL CARRIER END COVER (RESEAL)
(1) Remove left half shaft.
(2) Using two prybars, pop out output shaft (Fig. 1).
(5) Remove differential end cover.
(6) Clean and inspect sealer surfaces.
(7) Apply Mopar Gasket Maker P/N 4318083, Loctite
Gasket Eliminator No.518 or equivalent and install
end cover. Tighten to 28 N-m (250 in. lbs.).
(8) Tighten bolts in the sequence shown in Fig. 3.
Retighten first bolt after all others are tight.

REAR CARRIER
l 3 9103-93
CASE

Fig. 1 Output Flange Removal Fig. 3 Bolt Tightening Sequence.

(3) Remove output shaft. (9) Fill differential with lubricant.

(4) Remove end cover retaining bolts (Fig. 2).
OVERRUNNING CLUTCH COVER (RESEAL)
CARRIER END (1) Remove rear drive line module assembly from
COVER
vehicle.
(2) Mark hoses and cut two clamps that hold the
hoses. Disconnect vacuum hoses to vacuum motor.
(3) Remove overrunning clutch cover assembly
mounting bolts (Fig. 4).

9103-95
Fig. 2 Remove End Cover Bolts
Fig. 4 Mounting Bolts
 (4) Lift overrunning clutch cover off of overrunning
clutch housing.
(5) Clean and inspect sealing surfaces.
(6) Apply Mopar Gasket Maker P/N 4318083, Loctite
Gasket Eliminator No. 518 or equivalent and reinstall
cover and vacuum hose clip. When installing cover be
sure that the overrunning clutch fork engages into
the overrunning clutch dog.
(7) Install overrunning clutch cover mounting bolts
and tighten bolts to 28 N-m (250 in. lbs.).
(8) Reinstall rear drive line module assembly into
vehicle.
(9) Check and fill fluid levels as required. Use only
MOPAR TYPE 7176 Automatic Transmission Fluid
or equivalent in the overrunning clutch case.

OVERRUNNING CLUTCH CASE TO

REAR CARRIER CASE (RESEAL)
(1) Remove rear drive line module assembly from
vehicle.
(2) Drain fluid from overrunning clutch case.
(3) Remove overrunning clutch case to rear carrier
bolts (Fig. 5). Fig. 6 Separate Rear Carrier Case from
Overrunning Clutch Case

(5) Clean and inspect sealing surfaces.

(6) Apply a bead of Mopar Gasket Maker, Loctite
Gasket Eliminator No.518 or equivalent to sealing
surfaces and reassemble.
(7) Reinstall rear drive line module assembly.
(8) Check and fill fluid levels as required. Use only
MOPAR TYPE 7176 Automatic Transmission Fluid
or equivalent in the overrunning clutch housing.

CLUTCH CASE
9103-259

Fig. 5 Overrunning Clutch Case to Rear Carrier Bolts

(4) Separate overrunning clutch case from rear car­

rier unit (Fig. 6).
TORQUE TUBE
TORQUE TUBE REMOVAL AND INSTALLATION
(1) Remove rear drive line module assembly from
vehicle.
(2) Remove viscous coupling.
(3) Remove snap ring and torque tube bearing shield
(Fig. 1).
TORQUE TUBE FRONT BEARING
REMOVAL AND INSTALLATION
The rear drive line module must be removed to
service this bearing.
(1) Remove rear drive line module assembly from
vehicle.
(2) Remove viscous coupling.
(3) Remove overrunning clutch cover assembly.
(4) Drain fluid from overrunning clutch case.
(5) Remove overrunning clutch case to rear carrier
case bolts (Fig. 3).

Fig. 1 Remove Torque Shaft Snap Ring and Torque

Tube Shield
REAR
(4) Remove torque tube to overrunning clutch case CARRIER HOUSING
bolts (Fig 2).

OVERRUNNING
CLUTCH CASE 9103-78

Fig. 3 Overrunning Clutch Housing to

Rear carrier Bolts

(6) Separate overrunning clutch case from differen­

tial carrier case (Fig. 4).

Fig. 2 Torque Tube Bolts

(5) Slide torque tube off of torque shaft.

(6) For Installation, Reverse Removal Procedure.
 REAR CARRIER OVERRUNNING OVERRUNNING
CASE CLUTCH INNER CLUTCH CASE
RACE

9103-85

Fig. 6 Remove Overrunning Clutch Race

(9) Remove shaft snap ring and slide dog clutch off
OVERRUNNING of the shaft.
CLUTCH CASE
(10) Remove torque shaft rear bearing snap ring.
9103-79
(11) Remove overrunning case to torque tube bolts
Fig. 4 Separate Rear Carrier case from (Fig. 7).
overrunning clutch case

(7) Remove overrunning clutch inner race snap ring

(Fig. 5).

OVERRUNNING
CLUTCH CASE

OVERRUNNING
CLUTCH CASE
Fig. 5 Inner Race Snap Ring Removal 9103-88

(8) Slide overrunning clutch inner race off of shaft Fig. 7 Torque Tube Bolts
(fig. 6).
(12) Separate torque tube from overrunning clutch
housing.
(13) Remove front snap ring and torque tube bear­
ing shield (Fig. 8).
 lO iQ U

BEARING
SHIELD

SNAP R IN G ' ' 9103-87

Fig. 8 Remove Torque Shaft Smp Ring and Shield

(14) Slide shaft out of torque tube.

(15) Drive bearing out of housing.
(18) To Install Bearing, Reverse Removal Procedure.

Tom ue t u b e r e a r b e a m im e Pig. § Torque Shaft Rear Bearing Snap Ring

REMOVAL AID INSTALLATION
The rear drive line module assembly must be re­ (14) Remove rear torque shaft bearing.
moved to service this bearing. (15) To Install, Reverse Removal Procedure.
(1) Remove rear drive line module assembly from
vehicle. OVERRUNNING CLUTCH
(2) Remove viscous coupling unit.
(3) Remove overrunning clutch cover assembly. vacuum m o to r
(4) Drain fluid from overrunning clutch case. REMOVAL
(5) Remove overrunning clutch case to differential (1) Remove rear drive line module assembly from
carrier bolts. vehicle.
(6) Separate overrunning clutch case from differen­ (2) Cut clamps and disconnect vacuum hose to vac­
tial carrier case. uum motor.
(7) Remove overrunning clutch inner race snap ring. (3) Remove overrunning clutch cover assembly
(8) Slide overrunning clutch inner race off of shaft. mounting bolts (Fig. 1).
(9) Remove shaft snap ring and slide dog clutch off REAR CARRIER
of the shaft.
(10) Remove torque shaft rear bearing inner snap
ring.
(11) Remove torque tube retaining bolts.
(12) Separate overrunning clutch case from torque
tube.
(13) Remove rear bearing retaining snap ring in
overrunning clutch case (Fig. 9).

Fig. f Mounting Bolts

 (4) Lift overrunning clutch cover assembly off of CAUTION: Shift fork can be installed backwards. Note
overrunning clutch case. its position before removing.
(5) Clamp assembly in soft jawed vise (Fig. 2).
OVERRUNN ING

(6) Remove two E-clips from vacuum motor shaft Replace worn or damaged parts.
(Fig. 3).
INSTALLATION
SCREW DRIVER OVERRUNNING (1) Slide vacuum shift motor into housing and
CLUTCH COVER through shift fork. Shift fork off set must be angle
away from vacuum motor (Fig. 5).

SHAFT
FORK
OFF SET

Fig. 3 Remove Two E-Clips

(7) Holding the overrunning clutch shift fork, slide 9103-99

shift motor out of housing (Fig.4).
Fig. 5 Shift Fork, Position
 (2) Install two E-clips. One onto vacuum shift motor
shaft and one on the vacuum motor bushing.
(3) Apply Mopar Gasket Maker P/N 4318083, Loctite
Gasket Eliminator No. 518 or equivalent and reinstall
cover. When installing cover be sure that the overrun­
ning clutch fork engages into the overrunning clutch
dog.
(4) Install overrunning clutch cover assembly mount­
ing bolts and tighten bolts to 28 N-m (250 in. lbs.).
(5) Reinstall rear drive line assembly into vehicle.
(6) Check and fill fluid levels as required.

OVERRUNNING CLUTCH ASSEMBLY

REMOVAL
(1) Remove rear drive line module assembly.
(2) Remove overrunning clutch cover assembly.
(3) Drain fluid from overrunning clutch case.
(4) Remove overrunning clutch case to rear carrier
case bolts (Fig 6).

Fig. 7 Separate Rear Carrier Case from

Overrunning Clutch Case

(6) Remove overrunning clutch snap ring (Fig.8).

OVERRUNNING
CLUTCH CASE 9103-78

Fig. 6 Overrunning Clutch Case to Rear Carrier Bolts

Fig. 8 Overrunning Clutch Snap Ring
(5) Separate the overrunning clutch case from the
(7) Remove spacers and overrunning clutch. Over­
rear carrier case (Fig. 7).
running clutch can be installed backwards. Keep the
spacers and overrunning clutch in order when taking
the unit apart (Fig.9).
 (10) Remove overrunning clutch inner race snap
ring (Fig.12).

OVERRUNNING
CLUTCH \ 9103-116

Fig. 9 Overrunning Clutch Removal

(8) Remove overrunning clutch outer race snap ring

(Fig. 10).
(11) Slide overrunning clutch inner race off of the
shaft (Fig. 13).

Fig. 10 Overrunning Clutch Snap Ring Removal

(9) Slide overrunning clutch outer race off of shaft

(F ig.ll). Fig. 13 Remove Overrunning Clutch Race

SNAP RI NG

Fig. 14 Dog Clutch Snap Ring

 (12) Remove dog-clutch snap ring (Fig. 14). OVERRUNNING
(13) Slide dog-clutch off of the shaft (Fig. 15). CLUTCH OUTER
RACE

OVERRUNNING Fig. 17 Turn Inner Race Counterclockwise

CLUTCH CASE DOG CLUTCH 9103-117
OVERRUNNING
Fig. 15 Dog Clutch Removal

(14) Clean and inspect all parts. Replace worn or

damaged parts.

INSTALLATION
(1) Install outer overrunning clutch race and retain­
ing snap ring.
(2) Install overrunning clutch spacers and snap ring.
CAUTION: The overrunning clutch can be installed
backwards.
(3) To check for proper installation of the overrun­ OVERRUNNING
ning clutch, temporally install the inner race into the CLUTCH INNER
RACE 9103-120
overrunning clutch with the tapered end going in first
(Fig.16). The inner race should spin when turned coun­ Fig. 18 Turn Inner Race Clockwise
terclockwise (Fig. 17) and grab when turned clockwise
(Fig.18). (4) Install dog clutch onto shaft and reinstall snap
ring.
(5) Install overrunning clutch on the shaft with the
tapered end facing outward and install snap ring.
(6) Clean sealing surfaces and apply a bead of Mopar
Gasket Maker P/N 4318083, Loctite Gasket Elimina­
tor No.518 or equivalent and reinstall the overrun­
ning clutch case to the rear carrier case. Install
retaining bolts and tighten to 28 N- (250 in. lbs.).
(7) Apply Mopar Gasket Maker P/N 4318083, Loctite
Gasket Eliminator No. 518 or equivalent and reinstall
cover. When installing cover be sure that the overrun­
ning clutch fork engages into the overrunning clutch
dog.
OVERRUNNING
(8) Install rear drive line module assembly into the
CLUTCH OUTER OVERRUNNING CLUTCH vehicle.
RACE INNER RACE 9103-118
(9) Check and fill fluid levels as required.
Fig. 16 Temporally Install Inner Race
OVERRUNNING CLUTCH CASE
REMOVAL
(1) Remove rear drive line module assembly.
(2) Remove overrunning clutch cover assembly.
(3) Drain fluid from overrunning clutch case.
(4) Remove overrunning clutch case to rear carrier
case bolts (Fig. 19).
(7) Slide overrunning clutch inner race off of the
shaft.
(8) Remove dog-clutch snap ring and slide dog-clutch
off of the shaft.
(9) Remove torque shaft rear bearing snap ring.
(10) Remove torque tube retaining bolts (Fig.21).

OVERRUNNING
CLUTCH CASE 9103-78
Fig. 21 Torque Tube Bolts
Fig. 19 Overrunning Clutch Case to Rear Carrier Bolts
(11) Separate overrunning clutch case from torque
(5) Separate the overrunning clutch housing from tube.
the rear carrier housing. (12) Remove rear bearing retaining snap ring in
(6) Remove overrunning clutch inner race snap ring overrunning clutch case (Fig. 22).
(Fig. 20).
 (13) Remove rear torque shaft bearing.
(14) Drive out front overrunning clutch seal with
special tool C-4967 (Fig. 23).

Fig. 24 Installing New Seal

(2) Install rear torque shaft bearing and snap ring.

(3) Install overrunning clutch case onto torque tube.
Tighten bolts to 28 N-m (250 in. lbs.).
(4) Install torque shaft snap ring.
INSTALLATION
(1) Install new seal with special tool MD998334. (5) Slide dog clutch onto shaft and install snap ring.
Seal should be flush with outside edge of housing (6) Slide overrunning clutch inner race onto shaft
(Fig.24). and install retaining snap ring.
(7) Clean sealing surfaces and apply a bead of Mopar
Gasket Maker P/N 4318083, Loctite Gasket Elimina­
tor No.518 or equivalent and reinstall the overrun­
ning clutch case to the rear carrier case. Install
retaining bolts and tighten to 28 N-m (250 in. lbs.).
(8) Apply Mopar Gasket Maker P/N 4318083, Loctite
Gasket Eliminator No. 518 or equivalent and reinstall
vacuum shift cover. When installing cover be sure
that the overrunning clutch fork engages into the
overrunning clutch dog.
(9) Install rear drive line module into vehicle.
(10) Check and fill all fluid levels as required.
PROPELLER SHAFT SERVICE
The propeller shaft is a hollow shaft with a plung­
ing tripod joint on the front of the shaft and a fixed
tripod joint on the rear of the shaft. There are no
serviceable parts. The shaft is serviced as an assem­
bly. The flange patterns are different at each end to
prevent installing the shaft backwards.
REMOVAL AND INSTALLATION
(1) Place vehicle in neutral and lift vehicle on hoist. could be different than other axle shaft joints located
CAUTION :Do not allow end of propeller shaft to hang
free.
(2) Remove propeller shaft rear mounting bolts and cants, joint failure will result.
support end of propeller shaft (Fig. 1).
Fig. 1 Propeller Shaft Mounting Bolts (Rear)
(3) Remove propeller shaft front mounting bolts and
remove propeller shaft assembly (Fig. 2)
CAUTION :Do not allow the propeller shaft to freely
while Installing.
(4) To Install, Reverse Removal Procedure. Be sure
flange mating faces are clean.
HALF SHAFT SERVICE
The half shaft assemblies are three piece units. Each
half shaft has one "tripod” joint at each end and a
solid interconnecting shaft. The procedure to recondi­
tion the inner or outer joint is identical.
Note that lubricant requirements and quantities
on the vehicle. Only use the correct lubricant and
amount supplied with the boot package or joint. Do
not use standard wheel bearing grease or other lubri­
REMOVAL AND INSTALLATION
(1) Lift vehicle on hoist so that the wheels hang
freely.
(2) Remove rear wheel.
(3) Remove cotter pin, nut lock and spring washer
(Fig. 1).
Fig. 1 Cotter Pin, Nut Lock, and Spring Washer
(4) Remove hub nut and washer.
CAUTION: The half shaft outer C.V. joint, when in­
stalled, acts as a bolt and secures the hub/bearing
assembly. If the vehicle is to be supported or moved
on its wheels, install and torque a bolt through the
hub. This will insure that the hub/bearing assembly
cannot loosen.
(5)Remove inner half shaft retaining bolts (Fig. 2).
 Fig. 1 Clamp Shaft In Soft Jawed Vice

(6) The half shaft is spring loaded. Compress inner

half shaft joint slightly and pull downward to clear
rear differential. Then pull half shaft assembly out­
ward to remove (Fig. 3).

HALF SHAFT BOOT

(7) For Installation, Reverse Removal Procedure.

REAR HALF SHAFT JOINT/BOOT

REPLACEMENT
(1) Remove half shaft from vehicle. Refer to "Half
Shaft Service” in this section for removal procedure.

Fig. 3 Pull Back Boot

SNAP RING
PLIERS

TRIPOD
ASSEMBLY
 REAR DRIVE LINE MODULE VACUUM SHIFT MOTOR DIAGNOSIS
REAR WHEELS NOT OVERRUNNING

REAR WHEELS
NOT
OVERRUNNING

INSPECT FOR
b u rrs , knicks ,
ETC; REPAIR AS
tE Q U liE P
INSTALL O iC
ASSEMBLY
CORRECTLY

REPLACE
YES OVERRUNNING
CLUTCH
COMPONENTS AS
REQUItEP
 NO A l l WHEEL DRIVE, IN FORWARD; PROPELLER SHAFT TURNING

9121-270

NO A l l WHEEL DRIVE FORWARD OR REVERSE

NO AWD
FOiWARD OR
REVERSE

iE P lA C I s9 POWER
YES .y VISCOUS X
HO J r TRANSFER V yes REPLACE POWER
VISCOUS ' r n i ipi £■
LUUrLC
COUPLE v UNIT y TRANSFER UNIT
V FAILED? y
FA ILED? S

NO

YES . TORQUE
REPLACE
SHAFT
TORQUE SHAFT
FAILED?

NO

REPLACE REAR YES yr REAR

TAPRIFR
>v NO >9 MA
19:99
I FSHAFT
rir% L r^n r\r «
X . YES REPLACE
HALFSHAFT AS
CARRIER UNIT V FAILED? / FAILED? y REQUIRED

9121-271
 NO ALL WHEEL DRIVE, REVERSE ONLY; PROPELLER SHMPT TURNING

YES

repair
HARNESS AS
REQUIRED

REPLACE YES r VACUUM > y NO j

FILTER
VACUUM FILTER
V PLUGGED V REPLACE yes .
VACUUM SHIFT
MOTOR

♦VEHICLES IN REVERSE
NO ALL WHEEL DRIVE, REVERSE ONLY; PROPELLER SHAFT TURNING (CONT.)
 VACUUM ACTUATION SCHEMATIC (SOLENOIDS DE-ENERGIZED)

OVERRUN N IN G :
DE-EN ERGIZED SOLENOIDS TO VENT

VACUUM ACTUATION SCHEMATIC (SOLENOIDS ENERGIZED)

LOCKED-UP:
ENERGIZED SOLENOIDS
COMMON PORTS: MIDDLE AND BOTTOM
TO VENT
 SPECIFICATIONS
REAR SUSPENSION ALIGNMENT SPECIFICATIONS (ALL)

REAR WHEEL ALIGNM ENT Acceptable A lig n m en t Range P re fe rre d Setting

CAMBER -.8 to + .4° ( - 1 ° to + 1/2°) - 0 . 2 ° (—1/4°)
TOE**
Specified in I nches .3" OUT to .3" IN 0.0"
Specified in Degrees .6° OUT to .6° IN 0 .0«
THRUST ANGLE - . 4 0 ° to + .40° - . 4 0 ° to + .4°
**T O E OUT when backed onto alignment rack is TOE IN when driving.
9103-196

FASTENER TORQUE SPECIFICATIONS

Jfcm . Ft. Lbs.

Leaf Spring to Hanger Mounting Nut 142 105
Shock Absorber Mounting Bolts
U p p e r................................................ 115 85
Lower.................................................. 108 80
Brake Assembly and Spindle
Mounting Bolts (R e a r)......................... 108 80
U-Bolts.................................................. 88 65
Shackle Nuts......................................... 47 35
Wheel Nuts.................................... 129 95
Strut Damper to Knuckle Leg........... .. 100 *75
•PLUS 1/4 (90°) Turn
9103-197

REAR WHEEL BEARING TORQUE SPECIFICATIONS

THREAD NEW TO N- FOOT

APPLICATION SIZE METERS POUNDS
Rear Hub Unit/Leaf M l 2 x 1.5 128 95
Spring Carrier
9103-70

REAR CARRIER ASSEMBLY TORQUE SPECIFICATIONS

THREAD NEW TO N - INCH FOOT

APPLICATION SIZE METERS POUNDS POUNDS
Drive Pinion Nut M30 x 1.5 210 — 155
End Cover M8 x 1.25 28 250 —

Front Cover M6 x 1.00 12 105 —

Ring Gear M10 x 1.0 95 — 70
I nspection Plug M50 x 1.5 20 180 —

9103-71
 OVERRUNNING CLUTCH AND TORQUE TUBE ASSEMBLY TORQUE SPECIFICATIONS

THREAD NEW TO N - INCH FO OT

APPLICATION SIZE METERS POUNI POUNDS

Viscous Clutch M16 x 1.5 162 — 120

Assy. Nut
Torque Tube - Ore Clutch M8 x 1.25 28 250
Ore Cover Assy. M8 x 1.25 28 250
Fill Plug V4 X 20 27 240
Ore Assy to Carrier M8 x 1.25 28 250
Solenoid Assy to M6 x 1.0 7 65
Bracket
2
o

Vac Harness Clip to q 12 105

X

Bracket
Vac Reservoir to to X 14 7 65
Bracket

9103-73

BOLT APPUCATIONS AND TORQUE SPECIFICATIONS

THREAD N EW TO N- INCH FOOT

APPLICATION SIZE m eters POUNDS PQUNPS
PTU/Engine Bracket M10 x 1.5 x 50 54 40

M8 x 1.25 x 70 28 250

PTU/ATX Bracket M8 x 1.25 x 30 28 250

Torq. Tube Isolator M10 x 1.5 x 35 54 — 40

Bracket/Underbody

Carrier Isolator MlOx 1.5x125 54 — 40

Bushing/Underbody

Front Propshaft/ M8 x 1.25 x 25 28 250

PTU & VCU

Rear halfshaft/ M10 x 1.5 x 25 61 — 45

Carrier Output Shaft

9103-74
 BRAKES
CONTENTS
Page Page
ANTI-LOCK BRAKE SYSTEM BENDIX MASTER CYLINDER .......... .............. 44
ANTI-LOCK 10 AS BODY FWD/AWD 49 PARKING BRAKES ..................... .............. 40
BRAKE DISC (ROTOR) ............................ 36 POWER BRAKES ....................... .............. 46
DISC BRAKES........................................ 27 SERVICE ADJUSTMENTS....... . ............ 3
DRUM BRAKES .................... 14 SERVICE PROCEDURES ....... .............. 25
GENERAL INFORMATION ....................... 1 WHEEL BEARINGS..................... .............. 47
HYDRAULIC SYSTEM CONTROL VALVES .. .. 22 WHEEL CYLINDERS ................... .............. 20
KELSEY HAYES DOUBLE PIN
FAMILY CALIPER ............................... 30
GENERAL INFORMATION
Throughout this group, references may be made to a sensing proportioning valve and a booster.
particular vehicle by letter or number designation. A Front brake shoes have semi metallic linings.The
chart showing the breakdown of these designations is brake system (Fig. 1 and 2) is diagonally split on both
included in the Introduction Section at the front of the Non-ABS and ABS braking system. With the left
this service manual. front and right rear brakes on one hydraulic system
Standard brake equipment consists of pin slider cal­ and the right front and left rear on the other.
iper disc front brakes, rear automatic adjusting drum The master cylinder is anodized, lightweight alumi­
brakes, a brake warning switch, master cylinder, height num. It has a bore of 24.0 mm.
RIGHT WHEEL CYLINDER

LEFT FRONT
@ = 3/8-24 THREAD

( S ) = 7/16-24 THREAD
RH1198 A

Fig.1 Proper Nut Thread Size and Tube Routing (Non-ABS Equipped Vehicles)
 HOSE END RT. FRONT

LT. REAR WHEEL CYLINDER

- 3/8-24 THREAD

- M10 x 1 THREAD

9105-90

Fig.2 Proper Nut Thread Size and Tube Routing (ABS-Equipped Vehicles)

SERVICE ADJUSTMENTS
INDEX
Page Page
Adjusting Service Brakes ............................................... 3 Stop Lamp Switch Adjustment ..................................... 7
Bleeding Brake System ................................................... 4 Test For Fluid Contamination ....................................... 5
Brake House And Tubing ............................................... 5 Testing Application Adjuster Operation ....................... 7
Master Cylinder Fluid Level ........................................... 3 Wheel Stud Nut Tightening ............................................ 5

ADJUSTING SERVICE BRAKES
Normally self adjusting drum brakes will not re­
quire manual adjustment but in the event of a brake
reline it is advisable to make the initial adjustment
manually to speed up the adjusting time.
(1) Jack up vehicle so all wheels are free to turn.
(2) Remove rear adjusting hole cover from brake
supports of vehicle.
(3) Be sure parking brake lever Is fully released.
Then back off parking brake cable adjustment so
there is slack in cable.
(4) Insert Brake A ctu atin g , Special Tool C-3784,
into star wheel of adjusting screw. Move handle of tool
upward until a slight drag is felt when road wheel is
rotated.
(5) Insert a thin screwdriver or piece of welding rod
into brake adjusting hole. Push adjusting lever out of
engagement with star wheel. Care should be taken
so as not to bend adjusting lever or distort lever
spring. While holding adjusting lever out of engage­
ment, back off star wheel to ensure a free wheel with
no brake shoe drag.
(6) Repeat above adjustment at the other rear wheel.
Install adjusting hole covers in brake supports.
(7) Adjust parking brake after wheel brake adjustment.
It Is important to follow the above sequence to
avoid the possibility of the parking brake system
causing brake drag, which could occur if the parking
brakes are adjusted before the service brakes.
 MASTER CYLINDER FLUID LEVEL MBS SHAKES
The hydraulic assembly is equipped with a plastic
NON-ABS BRAKES fluid reservoir with a filter/strainer in the filler neck.
Check master cylinder reservoir fluid level twice The Anti-Lock brake system requires that the hy­
annually. draulic accumulator be de-pressurized when checking
Master cylinder reservoirs are marked with the words the fluid level. To check the brake fluid level, the
fill to bottom of rings indicating proper fluid level following procedure should be used:
(Fig.l).
If necessary, add fluid to bring level to the bottom of (1) With the ignition off, de-pressurize the hydraulic
the primary split ring. accumulator by applying the brake pedal approximately
Use a MOPAR brake fluid or equivalent conforming 40 times, using a pedal force of approximately 220 N
to DOT 3» requirements. (50 lbs.). A noticeable change in pedal feel will occur
DO NOT use brake fluid with a lower boiling point, when the accumulator is de-pressurized. Continue to
as brake failure could result during prolonged hard apply the pedal. several times after this change in
braking. pedal feel occurs.
Use only brake fluid that was stored in a tightly- (2) Thoroughly clean both reservoir caps and sur­
sealed container. rounding area, (Fig.2) prior to cap removal, to avoid
DO NOT use petroleum-based fluid because seal dam­ getting dirt into the reservoir.
age will result.
(3) Inspect the fluid level, see instructions on top of
RESERVOIR
reservoir (to top of the white screen in front filter/
strainer).
MASTER
(4) Fill reservoir to top of white screen' in filter/
strainer as required. Use brake fluid conforming to
DOT 3 such as Mopar.

(5) Replace reservoir cap. ^ -

9105-32

FigJ Master Cylinder Fluid Level (Non-ABS)

 RESERVOIR CAPS CAUTIONS

9105-91 FILLING I NSTRUCTIONS ON CAPS

Fig.2 Master Cylinder Fluid Level (W/ABS)

BLEEDING BRAKE SYSTEM To bleed the brake system. Attach a clear plastic
hose to the bleeder screw at one wheel and feed the
PRESSURE BLEED hose into a clear jar containing fresh brake fluid (Fig.4).
Before removing the master cylinder cover, wipe it
clean to prevent dirt and other foreign matter from
dropping into the master cylinder.
CAUTION: Use bleeder tank Special Tool C-3496-B
with adapter Special Tool C-4578 to pressurize the
system for bleeding.
Follow manufacturer’s instructions for use of bleeder
tools.
When bleeding the brake system. Some air may be
trapped in the brake line or valves far upstream. As
much as ten feet from the bleeder screw (Fig.3). There­
fore, it is absolutely essential to have a fast flow of a
large volume of brake fluid when bleeding the brakes RH956
to ensure getting all the air out.
Fig.4 Proper Method for Purging Brake System

BLEEDER SCREW

CALIPER RH1200
Fig.5 Open Bleeder Screw at Least One fu ll Turn
 Next, open the bleeder screw at least one full turn
or better (Fig.5).
CAUTION: Just cracking the bleeder screw often re­
stricts fluid flow, and a slow, weak fluid discharge
will NOT get all the air out.
After 4 to 8 ounces of fluid has been forced through
the brake system. And an air-free flow is maintained
in the clear plastic hose and jar, this will indicate a
good bleed.
Repeat the procedure at all the other remaining
bleeder screws. Then check the pedal for travel. If
pedal travel is excessive or has not been improved.
Enough fluid has not passed through the system to
expel all the trapped air.
BLEEDING WITHOUT A PRESSURE BLEEDER
If a pressure bleeder is not available, a good fluid
flow can be obtained by following these steps:
(1) Pump the pedal three or four times and hold it
down before the bleeder screw is opened.
(2) Push the pedal toward the floor and hold it down
while the bleeder screw is opened.
(3) Release the pedal after the bleeder screw is closed.
(4) Repeat steps 1 through 3, four or five times, at
each bleeder screw to pass a sufficient amount of fluid
to expel all the trapped air from anywhere in the
brake system. Be sure to monitor the fluid level in the
master cylinder, so it stays at a proper level so air will
not re-enter the brake system through the master
cylinder.
Test drive vehicle to be sure brakes are operating
correctly and that pedal is solid.
TEST FOR FLUID CONTAMINATION
Indications of fluid contamination are swollen or
deteriorated rubber parts.
Swollen rubber parts indicate the presence of petro­
leum in the brake fluid.
To test for contamination, put small amount of
drained brake fluid in clear glass jar. If fluid sepa­
rates into layers, there is mineral oil contamination.
If contaminated, drain and thoroughly flush system.
Replace master cylinder, proportioning valve, caliper
seals, wheel cylinder seals and hoses.
WHEEL STUD NUT TIGHTENING
When tightening wheel stud nuts, a criss-cross tight­
ening sequence should be followed (Fig.6).
Fig. 6 Wheel Stud Nut Tightening Sequence
Tighten all stud nuts to one-half specified torque.
Repeat, fully tightening to specified torque.
BRAKE HOSE AND TUBING
INSPECTION OF BRAKE HOSE AND TUBING
Flexible rubber hose is used at both front brakes
and at the rear axle. Inspection of brake hoses should
be performed whenever the brake system is serviced
and every 7,500 miles or 12 months, whichever comes
first (every engine oil change). Inspect hydraulic brake
hoses for severe surface cracking, scuffing, or worn
spots. Should the fabric casing of the rubber hose be
exposed due to cracks or abrasions in the rubber hose
cover, the hose should be replaced immediately. Even­
tual deterioration of the hose can take place with
possible burst failure. Faulty installation can cause
twisting, and wheel, tire, or chassis interference.
The steel brake tubing should be inspected periodi­
cally for evidence of physical damage or contact with
moving or hot components.
INSTALLATION OF BRAKE HOSE
Always use factory recommended brake hose to en­
sure quality, correct length and superior fatigue life.
Care should be taken to make sure that the tube and
hose mating surfaces are clean and free from nicks
and burrs. Right and left hoses are not interchangeable.
Use new copper seal washers on all Banjo bolts and
tighten all fittings to specified torque. Connections
should be tight and properly made.
The flexible hydraulic brake hose should always be
installed on the vehicle by first attaching the Banjo
connector to the caliper assembly. Then bolt the inter­
mediate hose bracket to the strut assembly allowing
the bracket to position the hose to prevent twisting.
Attach the hose to the body bracket and steel brake
tubing. Tighten all fittings to specified torque. The
body bracket and hose end are keyed so that they will
only fit one way.
Install rear brake hoses first to the trailing arm
crossmember tubes and then to the floor pan tubes.
Minimize hose twisting.
REPAIR AND INSTALLATION OF
BRAKE TUBING
Only double wall 4.75mm (3/16 in.) steel tubing
should be used for replacement. Care should be taken
when replacing brake tubing to use the proper bend­
ing and flaring tools and to avoid kinking or routing
the tubes against sharp edges, moving components or
into hot areas. All tubes should be properly attached
with recommended retaining clips.
TYPES OF TUBING FLARES
Two different tubing flares are used on 91 M.Y.
vehicles. On all ABS brake systems the tubing con­
nections made to the hydraulic assembly use an ISO
flare. All other ABS brake system component tubing
connections are made using a double inverted flare. On
non-ABS brake systems all component tubing connec­
tions use only the double inverted flare. No ISO flares
are used. CAUTION: ALWAYS USE THE PROPER
FLARING TOOLS AND PROCEDURE, FOR THE TYPE
OF BRAKE SYSTEM THAT IS BEING SERVICED TO
INSURE THE INTEGRITY OF THE HYDRAULIC SYSTEM.
TO REPAIR OR FLARE TUBING
Using Tubing Cutter, Special Tool C-3478-A or equiv­
alent, cut off damaged seat or tubing (Fig.7). Ream
out any burred or rough edges showing on inside of
Fig.7 Cutting and Flaring of Brake Line Tubing
tubing. This will make the ends of tubing square and
ensure better seating of flared end tubing. PLACE
TUBE NUT ON TUBING PRIOR TO FLARING THE
TUBING.
DOUBLE INVERTED TUBING FLARES.
To make a double inverted flare, (Fig.8) open han­
dles of the Flaring Tool, Special Tool C-4047 or equiv­
alent and rotate jaws of tool until the mating jaws of
tubing size are centered in area between vertical posts.
Slowly close handles with tubing inserted in jaws but
do not apply heavy pressure to handle as this will lock
tubing in place.
Place gauge (Form A) on edge over end of tubing
and push tubing through jaws until end of tubing
contacts the recessed notch of gauge matching the size
of tubing. Squeeze handles of flaring tool and lock
tubing in place. Place 3/16 inch plug of gauge (A)
down in end of tubing. Swing compression disc over
gauge and center tapered flaring screw in recess of
disc. Screw in until plug gauge has seated on jaws of
flaring tool. This action has started to invert the ex­
tended end of the tubing. Remove gauge and continue
to screw down until tool is firmly seated in tubing.
Remove tubing from flaring tool and inspect seat.
Refer to routing diagram (Fig. 11) for proper routing
and clip location. Replace any damaged tube clips.
INVERTED FLARE
9105-30
Fig.8 Double Flare And ISO-Flare Tubing Connections
ISO TUBING FLARES (Fig.8)
CAUTION:AII ISO style tubing flares are of metric
dimensioning. When performing any service proce­
dures on vehicles using ISO style tubing fiares, met-
ric size tubing of 4.75 mm MUST be used along with STOP LAMP SWITCH ADJUSTMENT
metric ISO tube flaring equipment.
The stop lamp switch incorporates a self adjusting
To create a (metric) ISO style tubing flare, Using
feature. If adjustment or replacement is required, pro­
Snap-On Flaring Tool TFM-428, or equivalent. See
ceed as follows: Install the switch in the retaining
(Fig.9) and proceed with the steps listed below. Be
bracket and push the switch forward as far as it will
sure to place the tubing nut on the tube prior to
go. The brake pedal will move forward slightly (Fig.10).
flaring the tubing.
Gently pull back on the brake pedal bringing the
(1) Carefully prepare the end of the tubing to be
striker back toward the switch until the brake pedal
flared. Be sure the end of the tubing to be flared is
will go back no further. This will cause the switch to
square and all burrs on the inside of the tubing are
ratchet backward to the correct position. Very little
removed. This preparation is essential to obtain the
movement is required, and no further adjustment is
correct form of a (metric) ISO tubing flare.
necessary.
(2) Open the jaws of the Flaring Tool. Align the
mating jaws of the tubing size around the tubing to be
flared. Close the jaws of the Flaring Tool around the
tubing to keep it from coming out of the flaring tool,
but do not lock the tubing in place. See (Fig.9)
(3) Position the tubing in the jaws of the Flaring
Tool so that it is flush with the top surface of the
flaring tool bar assembly. (See Fig.9)
(4) Install the correct size adaptor for the tubing
being flared, onto the feed screw of the yoke assembly.
Center the yoke and adapter of the Flaring Tool over
the end of the tubing (apply lubricant to the adapter
area that contacts tubing) making sure that the pilot
of the adaptor is inserted in the end of the tubing.
Screw in the feed screw of the yoke assembly until the
adaptor has seated squarely on the surface of the bar
assembly. See (Fig.9) This process has created the
(metric) ISO tubing flare.

Fig.10 Stop Lamp Switch

TESTING APPLICATION ADJUSTER OPERATION

Fig.9 ISO Tubing Flare Process
Place the vehicle on a hoist with a helper in the
driver’s seat to apply the brakes. Remove the access
plug from the rear adjustment slot in each brake sup­
port plate to provide access to the adjuster star wheel.
Then, to eliminate the possibility of maximum adjust­
ment, where by the adjuster does not operate because
the closest possible adjustment has been reached, back
the star wheel off approximately 30 notches. It will be
necessary to hold the adjuster lever away from the
star wheel to permit this adjustment.
Spin the wheel and brake drum in the reverse direc­
tion and with greater than normal force apply the
brakes suddenly. This sudden application of force will
cause the secondary brake shoe to leave the anchor.
The wrap up effect will move the secondary shoe, and
the cable will pull the adjuster lever up. Upon appli­
cation of the brake pedal, the lever should move up-
LET

<6^ 30. IN. LiS. 3 N'

<§> 70 IN. LiS. 8 N<

<§> 95 IN. LIS. 11 N'

105■ IN,, LiS. 12 N«m
145 IN., LIS. 16 N*m
24 FT. LiS. .11 N«m
ward, turning the star wheel. Thus, a definite rotation adjusters do not function properly, the respective drum
of the adjuster star wheel can be observed if the auto- must be removed for adjuster servicing,
matic adjuster is working properly. If one or more

BASIC DIAGNOSIS GUIDE

CHART 1 CHART 2 CHART 3 CHART 4 CHARTS
SYMPTOM MISC. COND. ACTUATION POWER BRAKES BRAKE NOISE WHEEL BRAKES
BRAKE WARNING LIGHT ON X NO
EXCESSIVE PEDAL TRAVEL 60 X NO O
PEDAL GOES TO FLOOR 60 X
STOP LIGHT ON W ITHOUT BRAKES 3X
ALL BRAKES DRAG 5X O
REAR BRAKES DRAG 2X NO NO
GRABBY BRAKES O X
SPONGY BRAKE PEDAL X NO
PREMATURE REAR LOCKUP 40 NO NO O
EXCESSIVE PEDAL EFFORT IX O
ROUGH ENGINE IDLE O
BRAKE CHATTER (ROUGH) NO NO X
SURGE DURING BRAKING X
NOI SE DURING BRAKING X
RATTLE OR CLUNKING NOISE NO X
PEDAL PULSATES DURING BRAKING NO NO X
PULL TO RIGHT OR LEFT NO NO X
NO: NOT POSSIBLE CAUSE X: MOST LI KELY CAUSE O: POSSIBLE CAUSE
9105-33
 BRAKE SYSTEM DIAGNOSTICS
CHART 1 MISCELLANEOUS CONDITIONS

BRAKES DRAG! ISTO P LIGHTS! PREMATURE RAKES DRAG—j PEDAL GOES TO

EXCESSIVE FLOOR (POWER) I
I PEDAL EFFORT! ] REAR BRAKES [ O N ALL THE | REAR WHEEL EITHER FRONT
ONLY TIME LOCK-UP OR ALL N O W A R N IN G
II LIGHT
E

PARKING BRAKE DRAGGING. CONTAMINATED

CHECK ADJUSTMENT, WEAK REAR LINING
RETURN SPRINGS, FROZEN INSPECT
PISTO NS, AND BI NDING CABLES

IN O PERATIVE O R
MISADJUSTED
PROPORTIONING
CHECK SERVICE VALVE. REFER TO
BRAKE ADJUSTMENT HYDRAULIC SYSTEM
CONTROL VALVES
SECTIO N

APPLY BRAKES AND RELEASE,

INSPECT FOR AND CORRECT
PEDAL BINDING, STOP LIGHT
SWITCH ADJUSTMENT
TURN ON FRONT WHEEL BY
HAND; OPEN BLEEDER SCREW
AND TURN WHEEL AGAIN. I F
WHEEL TURNS, HYDRAULIC
PRESSURE WAS TRAPPED IN
SYSTEM.

YES NO

CONTAMINATED FLUID, BINDING CALIPER PI NS OR

SEALS SWOLLEN BUSHINGS REPLACE BUSHINGS

LOW ENGINE VACUUM SEE #6

BOOSTER RUNOUT (MAXIMUM ASSIST POINT)

IS OFTEN MISTAKEN FOR THE PEDAL HITTING
THE FLOOR ESPECIALLY WHEN THE CAR IS NOT
BLOCKED OR PINCHED MOVING. THE CHANGE IN PEDAL EFFORT AT
LINE OR HOSE RUNOUT IS INTERPRETED AS BOTTOMING
OR BOOSTER VACUUM HOSE THE PEDAL. CHECK BY OPENING A FITTING
AND ALLOW THE PEDAL TO MOVE FURTHER

LINING TRANSFER MASTER CYLINDER NOT

O N FRONT ROTOR, RELEASING FULLY
GLAZED L IN IN G - (COMPENSATING).
SAND ROTOR, STOP LIGHT SWITCH CHECK BOOSTER VACUUM HOSE AND
REPLACE LINING MISADJUSTED, OR PEDAL BINDING ENGINE. TUNE FOR ADEQUATE VACUUM.
 BRAKE SYSTEM DIAGNOSTICS
CHART 2 ACTUATION
IT n s n s r a n n
(IG N ITIO N O N )

f
LIGHT " O N "
IINDICATING MALFUNCTION ]
LIGHT "O F F "

~
CHECK THAT PARKING CHECK WARNING
BRAKE IS FULLY LIGHT CIRCUIT
RELEASED

APPLY PARKING BRAKE-

REMOVE MASTER CYLINDER IGNITION IN RUN
RESERVOIR CAPS-CHECK 1
POSITION
FLUID LEVEL FLUID LEVEL LOW
(BELOW RESERVOIR SEAM)

FLUID LEVELOK W ARNING LIGHT WARNING LIGHT

CHECK ENTIRE ON OK OFF NOT OK
EXAMINE DIAPHRAGM
AND FLUID FOR SIGNS
SYSTEM FOR LEAKS
.............. f ......... .......
T
PARKING, BRAKE CHECK AND REPAIR
OF CONTAMI NATION, REPAIR OR REPLACE ELECTRICAL CIRCUIT
AS REQUIRED RELEASED—LIGHT OFF
DIAPHRAGM SWOLLEN, ETC. AS REQUIRED
T
CONTAMIN ATED FLUID CHECK WIRE CONNECTED
REPLACE ALL RUBBER PARTS TO WARNING SWITCH IN
PER SERVICE MANUAL ENGINE COMPARTMENT

BASIC HYDRAULIC TEST

IGNITION IN RUN POSITION, ENGINE RUNNING (POWER BRAKE ONLY), APPLY BRAKE
PEDAL VERY SLOWLY. GRADUALLY INCREASE PEDAL EFFORT WHILE WATCHING
w a r n i n g UGH t, I n c r e a s e t c v e r y h i g h e f f o r t (b o t h feet ) h o l d h e a v y e f f o r t
FOR 30 SECONDS, RELEASE PEDAL SLOWLY.

WARNING LIGHT COMES WARNING LIGHT COMES ON ONLY

ON WITH MODERATE PEDAL AFTER HOLDING HEAVY PEDAL
EFFORT AND STAYS ON EFFORT FOR SEVERAL SECONDS, AND
WHEN PEDAL IS RELEASED. PEDAL MOVES DOW N UNDER
CONSTANT HEAVY EFFORT.

MASTER CYLINDER HAS

X
SMALL HIGH PRESSURE LEAK
INTERNAL LEAK, REPLACE IN SYSTEM. REPEAT TEST
OR REBUILD AND SEVERAL TIMES AND LOOK
BLEED BRAKES. FOR WET AREA, REPAIR
AND BLEED.

WARNING LIGHT COMES ON AT WARNING LIGHT DOES NOT COME O N -

MODERATE TO HEAVY PRESSURE SYSTEM HAS N O DEFECT! BLEEDING OR
BUT GOES OUT WHEN PEDAL ADJUSTING REAR BRAKES MAY MAKE SOME
IS RELEASED. IMPROVEMENT. IF LESS THAN 1000 MILES
ON CAR, ADDITIONAL MILEAGE WILL HELP.
X IF PEDAL PUMPS UP BUT BECOMES LOW
AIR IN SYSTEM. THE GREATER PEDAL
AFTER LEFT OR RIGHT TURNS, LOOSE FRONT
EFFORT REQUIRED TO GET THE LIGHT
WHEEL BEARINGS MAY BE THE PROBLEM.
ON, THE LESS AIR IN THE SYSTEM-
BLEED BRAKES,
BRAKE SYSTEM DIAGNOSTICS
CHART 3 POWER BRAKES
 BRAKE SYSTEM DIAGNOSTICS
CHART 4 BRAKE NOISE

DPAR MULTIPURPOSE LUBRICANT, OR EQUIVALENT. 9105-37

BRAKE SYSTEM DIAGNOSTICS

CHART 5 WHEEL BRAKES
r T T
| PULL TO RIGHT EXCESSIVE PEDAL EARLY
OR LEFT EFFORT REAR SURGES DURING
LOCK-UP BRAKING,
BRAKE CHATTER
CHECK FOR INSPECT FRONT AND
FROZEN PISTONS, REAR BRAKES FOR LINING
CONTAMINATED FROZEN PISTONS, TRANSFER HOLD RELEASE ON
LINING, CONTAMINATED LI NING, ONTO DRUM OR DISC PARK BRAKE AND
PINCHED LINES, GLAZED LINING. SAND SURFACE APPLY PARKING
LEAKING SEALS, OF DRUM OR DISC BRAKES ONLY
PLUGGED AND LINING
BANJO BOLT LOW ENGINE VACUUM
fsURGIN^ORT^jBnSPS
I STILL PRESENT
REFER TO
SEE CHART 3
GROUP 2 -
SUSPENSION INSPECT REAR BRAKE
DRUMS FOR OUT OF
MIS-ADJUSTED OR
ROUND AND OVALITY
EXCESSIVE DEFECTIVE
OR REAR DISC FOR
PEDAL TRAVEL PROPORTIONING VALVE
THICKNESS VARIATION
N O VIBRATION OR r
DEFECTIVE AUTOMATIC
PULSING
GRABBY BRAKES 1
ADJUSTER CHECK
I I NSPECT FRONT BRAKES 1
CHART 2 FOR DISC RUNOUT CONTAMINATED LINING |
ACTUATION OR THICKNESS VARIATION. 9105-38
 DRUM BRAKES
INDEX
Page Page
Brake Drum I nstallation ............................................... 18 Remove and I nstall Support Plate ............................. 18
Drum Refacing Recommendations ............................. 17 Service Procedures ........................................................ 14
General Information ...................................................... 14

GENERAL INFORMATION (3) Insert Tool C-3784 into brake adjusting hole and
engage notches of brake adjusting screw. Release brake
Rear wheel brakes (Fig.l) are two shoe, internal by prying down with adjusting tool.
expanding type with automatic application adjusters. (4) Remove rear wheel and hub and drum assembly.
The lower ends of the brake shoes are connected by a (5) Inspect brake lining for wear, shoe alignment, or
tubular star wheel adjusting screw (Figs.l and 4). contamination from grease or brake fluid.
WARNING: OUST AND DIRT ON BRAKE PARTS GEN­
ALL WHEEL DRIVE
ERATED DURING THE NORMAL USE AND WEAR OF (1) Remove rear wheel from vehicle. Access for the
MOTOR VEHICLE BRAKE SYSTEMS CAN CONTAIN adjusting lever on ALL WHEEL DRIVE APPLICA­
ASBESTOS FIBERS. BREATHING EXCESSIVE CON­ TION is through an access hole on the front of the
CENTRATIONS OF ASBESTOS FIBERS CAN CAUSE brake drum.
SERIOUS BODILY HARM, SUCH AS ASBESTOSIS (2) Insert a thin screwdriver into brake adjusting
AND CANCER. EXTREME CARE SHOULD BE EXER­ hole and hold adjusting lever away from notches of
CISED WHILE SERVICING BRAKE ASSEMBLIES OR actuating screw.
COMPONENTS. (3) Insert Tool C-3784 into brake adjusting hole and
DO NOT CLEAN BRAKE ASSEMBLIES OR COM­ engage notches of brake adjusting screw. Release brake
PONENTS WITH COMPRESSED AIR OR BY DRY by prying up with the adjusting tool.
BRUSHING; USE A VACUUM CLEANER SPECIFIC­ (4) Remove rear brake drum from the hub assem­
ALLY RECOMMENDED FOR USE WITH ASBESTOS bly. Rear hub and bearing will not come off with the
FIBERS. IF A SUITABLE VACUUM CLEANER IS NOT brake drum on all wheel drive applications.
AVAILABLE, CLEANING SHOULD BE DONE WET US­ (5) Inspect brake lining for wear, shoe alignment, or
ING A WATER DAMPENED CLOTH. contamination from grease or brake fluid.
DO NOT CREATE DUST BY SANDING, GRINDING,
AND/OR SHAVING BRAKE LININGS OR PADS UN­ BRAKE SHOE REMOVAL
LESS SUCH OPERATION IS DONE WHILE USING
PROPERLY EXHAUST VENTILATED EQUIPMENT. BRAKE SHOE ASSEMBLIES
DISPOSE OF ALL DUST AND DIRT SUSPECTED Support plate and park brake assemblies ARE NOT
TO CONTAIN ANY ASBESTOS FIBERS IN SEALED SYMMETRICALLY OPPOSITE.
BAGS OR CONTAINERS TO MINIMIZE DUST EXPO­ Right Side: Park brake cable enters support plate
SURE TO YOURSELF AND OTHERS. at rear. Cable attaches to the internal park brake
FOLLOW ALL RECOMMENDED PRACTICES PRE­ lever which is attached to the primary shoe. Right
SCRIBED BY THE OCCUPATIONAL SAFETY AND side support and cable assembly is color coded grey.
HEALTH ADMINISTRATION AND THE ENVIRONMEN­ Left Side: Park brake cable enters support plate at
TAL PROTECTION AGENCY FOR THE HANDLING, front (traditional) and attaches to the internal park
PROCESSING, AND DISPOSITION OF DUST OR DIRT brake lever which is attached to the secondary shoe.
WHICH MAY CONTAIN ASBESTOS FIBERS. Left side support and cable are color coded black.
(1) Remove rear wheel, and hub and drum assembly.
SERVICE PROCEDURES (2) Using Remover Special Tool C-3785, remove brake
shoe return springs (Fig.2). (Note how secondary shoe
BRAKE DRUM REMOVAL return spring overlaps primary shoe return spring).
(Figs.l and 2).
FRONT WHEEL DRIVE
(1) Remove rear plug from brake adjusting access
hole.
(2) Insert a thin screwdriver into brake adjusting
hole and hold adjusting lever away from notches of
adjusting screw.
 RETURN SPRING SPECIAL TOOL
PRIMARY SHOE
A N D LINING

SUPPORT RETURN ANCHOR SHOE RETURN SECONDARY

PLATE ■ SPRING PLATE ' TAB (3) SHOE A N D
SPRING
■LINING

ADJUSTER
CABLE
PARKING
BRAKE
STRUT
SHOE TO
SHOE SPRING
ADJUSTER LEVER
ADJUSTER SCREW
A N T I­ ASSEMBLY (STAR WHEEL) 9105-94
RATTLE
SPRING
SHOE Flg.2 Removing or Installing Shoe Return Springs
RETAINERS,
SHOE TO SPRING PRIMARY SHOE A N D LINING SECONDARY SHOE
A N D NAIL A N D LINING
SHOE SPRING.

ADJUSTER SCREW
ASSEMBLY SECONDARY SHOE
(STAR WHEEL) A N D LINING

PRIMARY SHOE
A N D LINING 9105-93

Fig. I Rear Wheel Brake

(3) Slide eye of automatic adjuster cable off anchor
and then unhook from adjusting lever. Remove cable,
overload spring, cable guide and anchor plate.
(4) Disengage adjusting lever from spring by sliding
forward to clear pivot, then working out from under
spring. Remove spring from pivot. Remove shoe to
shoe spring from secondary shoe web and disengage
from primary shoe web. Remove spring.
(5) Disengage primary and secondary shoes and re­
move adjusting star wheel assembly from shoes.
(8) Remove brake shoe retainers, springs and nails
using Remover Special Tool C-4070, (Fig.3), and re­
move from support.
(7) Remove parking brake lever from secondary shoe,
left side or primary shoe, right side. Remove shoes.
(8 ) Disengage parking brake lever from parking
brake cable.
SHOE RETAINERS,
SPRING A N D NAIL
SPECIAL TOOL C-4070 9105-95
Pig.3 Returning or Installing Shoe Retainers,
Springs, and Walls
CLEANING AND INSPECTION
Wipe with a water dampened cloth the metal por­
tions of the brake shoes. Examine the lining contact
pattern to determine if the shoes are bent. The lining
should show contact across the entire width, extend­
ing from heel to toe. Shoes showing contact only on
one side should be replaced. Shoes having sufficient
lining but lack of contact at toe and heel may be
improperly ground. ■.
Clean the support, using a suitable solvent, ■ then
inspect for rough or rusted shoe contact areas. ■Clean
and inspect the adjusting screws for damaged threads,
then apply a thin film of lubricant to the threads,
socket and washer (Fig.7). Replace adjuster screw as­
sembly if corrosion of any part inhibits very free
operation.
Install new brake shoe return springs and holddown
springs where the old springs have been subjected to
overheating or if their strength is questionable. Spring
paint discoloration or distorted end coils indicate a
spring that had been overheated.

BRAKE SHOE INSTALLATION

Lubricate the six shoe tab contact pads on support
plate with a thin film of MOPAR Multi-Purpose Lu­
bricant, or equivalent (Fig. 4).

SUPPORT
PLATE

Fig.5 Removing or Installing Parking Brake

Strut and Spring

(4) Slide parking brake strut into slot in parking

brake lever. Slide anti-rattle spring over free end of
strut (Fig. 5).
(5) Engage parking brake lever with cable. Install
parking brake lever into rectangular hole of second­
ary brake shoe (left side) or primary shoe (right side)
(Fig.6).

Fig.4 Shoe Contact Pads on Support

(1) Slide primary shoe against support plate, at the

same time engage shoe web with wheel cylinder pis­
ton and against anchor. Using Installer Special Tool
C-4070, install shoe retaining nail, retainer, and spring
(Fig.3).
(2) Install anchor plate over anchor, then install eye
of adjuster cable over anchor (Fig.5).
(3) Engage primary shoe return spring in web of
shoe and install free end over anchor, using Spring
Installer, Special Tool C-3785 (Fig. 2).

Fig. 6 Installing Parking Bake Cable

 DRUM REFACING RECOMMENDATIONS
WASHER SOCKET STAMPED LETTER
Drum Refacing Measure the drum runout and di­
ameter with an accurate gauge. There should be no
variation in the drum diameter greater than 0.090
mm (0.004 inch). Drum runout should not exceed 0.15
mm (0.006 inch) out of round. If the drum runout or
diameter variation exceed these values the drum should
be refaced. For best results in eliminating the irregu­
larities that cause brake roughness and surge, the
BUTTON NUT RH227A amount of material removed during a single cut should
be limited to 0.13 mm (0.005 inch). When the entire
Fig. 7 Adjuster Screw Assembly braking surface has been cleaned a final cut of 0.0254
mm (0.001 inch) will assure a good drum surface pro­
(6) Slide secondary shoe into position and engage
viding the equipment used is capable of giving the
with wheel cylinder piston and free end of strut. In­
precision required for resurfacing brake drums. Deeper
stall shoe retaining nail, retainer, and spring using
cuts are permissible for the sole purpose of removing
Installer, Special Tool C-4070 (Fig.3).
deep score marks. Do not reface more than 1.52 mm
(7) Insert protruding hole rim of cable guide into
(0.60 inch) over the standard drum diameter.
hole in secondary shoe web. Holding guide in position,
All drums will show markings of maximum allow­
engage secondary shoe return spring through both,
able diameter (Fig. 1). For example, a drum will have
hole in guide, and hole in web. Using Installer, Spe­
a marking of MAX. DIA. 231.0 mm (9.09 inch). This
cial Tool C-3785, install spring over anchor. (Be sure
marking includes 0.76 mm (0.030 inch) for allowable
cable guide remains flat against shoe web and that
drum wear beyond the recommended 1.52 mm (0.060
secondary spring overlaps primary Fig.l). Using pliers,
inch) of drum refaclng.
squeeze ends of spring loops (around anchor) until
parallel.
(8) Install adjusting star wheel assembly between
primary and secondary shoes, with star wheel next to
secondary shoe (Fig.l). The left star wheel adjusting
stud end is stamped (L) (indicating its position on the
vehicle) and the star wheel is cadmium plated (Fig. 7).
The right star wheel is black and the adjusting stud
end is stamped (R). Install shoe to shoe spring be­
tween shoes (Fig.l). (Engage primary shoe first).
(9) Install adjusting lever spring over pivot pin on
shoe web. Install adjusting lever under spring and
over pivot pin. Slide lever slightly rearward to lock in
position.
(10) Thread adjuster cable over guide and hook end
of overload spring in lever (Fig.l). (Be sure eye of
cable is pulled tight against anchor and in a straight
line with guide). Check operation of automatic appli­
cation adjuster by pulling adjuster cable rearward,
star wheel should rotate upwards.

Fig.1 Drum Maximum Diameter Identification

BRAKE DRUM INSTALLATION
(1) I n s ta ll d ru m asse m b ly on spin d le.
.(2) I n s ta ll o u te r b e a rin g , t h r u s t w a sh e r, a n d n u t.
(8) T ig h te n w h eel b e a rin g a d ju stin g n u t to 27 to 34
N-m (240 to 300 in . lbs.) w h ile r o ta tin g h u b . T h is se a ts
th e b e a rin g s.
(4) B ack off a d ju s tin g n u t, 1/4 tu r n (90°) th e n tig h te n
a d ju stin g nut fin g e r tig h t.
(5) P o sitio n lock on n u t w ith one p a ir of slo ts in lin e
w ith c o tte r p in hole. In s ta ll c o tte r pin.
(8) In s ta ll g re a s e cap a n d w h eel a n d tir e assem b lies.
T ig h te n w h eel s tu d n u ts to 115 N*m (85 ft. lb s.) on a ll
m odels. I n s ta ll w h eel covers.
(7) A d ju st b ra k e s a s d escrib ed u n d e r S ervice A d ju st­
m e n ts a t fro n t o f th is section.
REMOVE AND iiS IA ll SUPPORT PLATE
FRONT WHEEL DRIVE
iliOVE
(1) W ith w h eel a n d b ra k e d ra m rem oved, rem ove
b ra k e shoe assemblies a n d d isco n n ect b ra k e cable.
' "(2) U sin g a s u ita b le tool su ch a s a n a irc ra ft ty p e
hose clam p o r a 14m m box w re n c h compress the flared
legs o f cable r e ta in e r a n d p u ll b ra k e cable o u t of
Fig.2 Flemming Brake Cable from Support Plate
(3) D isco n n ect h y d ra u lic b ra k e tu b e from w heel
cy lin d er.
(4) R em ove su p p o rt p la te to w h eel c y lin d e r a tta c h ­
in g n u ts a n d w a sh e rs.
(5) R em ove su p p o rt p la te a n d sp in d le m o u n tin g
screw s.
(8) R em ove su p p o rt p la te , sp in d le a n d g a sk e t from
r e a r axle.
ALL WHEEL DRIVE
REMOVE
(1) W ith w heel a n d b ra k e d ru m rem oved, rem ove
b ra k e shoe a ssem b lies a n d disco n n ect b ra k e cable.
(2) Rem ove th e r e a r ax le h a lf s h a ft from th e vehicle.
R efer to G roup 3 R e a r A xle in th is serv ice m a n u a l.
(3) U sin g a su ita b le tool su ch as a n a irc ra f t ty p e
hose clam p com press th e fla re d leg s of cable r e ta in e r
a n d p u ll b ra k e cable o u t o f su p p o rt p la te (Fig.2).
(4) D isconnect h y d ra u lic b ra k e tu b e from w heel
cylinder.
(5) Rem ove su p p o rt p la te to w h eel cy lin d e r a tta c h ­
in g n u ts a n d w a sh ers.
(6) Rem ove su p p o rt p la te a n d r e a r b e a rin g h u b u n it
m o u n tin g bolts. (Fig.3)
Fig.3 Fiemme and Install Support Plate
and Bearing Hub Bolts
(8) Remove re a r b e a rin g h u b u n it, su p p o rt p la te a n d
g a s k e t from th e r e a r axle.
FRONT WHEEL DRIVE
INSTILL
(1) In s ta ll su p p o rt p la te , sp in d le a n d g a s k e t to r e a r
axle.
(2) A pply s e a la n t su ch a s M opar Gasket-In-A-Tube
or e q u iv a le n t a ro u n d w h eel c y lin d e r m o u n tin g su rface
(Fig.4).
 (3) Install wheel cylinder and attach hydraulic brake
tube.
(4) Insert parking brake cable into support plate
and attach cable to parking brake lever.
(5) Install brake shoes on support plate.
(6) Install brake drum and wheel. Adjust and bleed
brakes.

ALL WHEEL DRIVE

INSTALL
(1) Install gasket, support plate and rear bearing
hub unit onto the rear axle (Fig.3)
(2) Apply sealant such as Mopar Gasket-In-A-Tube
or equivalent around wheel cylinder mounting surface
(Fig.4).
(3) Install wheel cylinder and attach hydraulic brake
tube.
(4) Install the rear axle half shaft. Refer to Group 3
Rear Axle in this service manual for procedure and
torque values.
(5) Insert parking brake cable into support plate
and attach cable to parking brake lever.
Fig.4 Apply Sealant on Support Plate (6) Install brake shoes on support plate.
(7) Install brake drum and wheel. Adjust and bleed
brakes.
 WHEEL CYLINDERS
INDEX
Page Page
General Information ...................................................... 20 Service Procedures 20
Installing Wheel Cylinders ........................................... 21

GENERAL INFORMATION (2) Disconnect brake tube from wheel cylinder (Fig.
1).
The piston boots are of the push-on type and pre­ (3) Remove wheel cylinder attaching bolts, then pull
vent moisture from entering the wheel cylinder. wheel cylinder assembly out of support (Fig. 2).
To perform service operations or inspections of the
wheel cylinders, it will be necessary to remove the DISASSEMBLING WHEEL CYLINDERS
cylinders from the support plate and disassemble on To disassemble the wheel cylinders, (Fig. 3) proceed
the bench. as follows:
(1) Pry boots away from cylinders and remove.
CAUTION: Wheel cylinders with cup expanders must
(2) Press in on one piston and force out piston, cup,
have cup expanders after any service procedures
spring (with cup expanders), cup and piston.
(reconditioning or replacement).
(3) Wash wheel cylinder, pistons, and spring in clean
brake fluid or alcohol; clean thoroughly and blow dry
SERVICE PROCEDURES with compressed air. Inspect cylinder bore and piston
for scoring and pitting. (Do not use a rag as lint from
REMOVING WHEEL CYLINDERS the rag will adhere to bore surfaces.)
With brake drums removed, inspect the wheel cyl­
inder boots for evidence of a brake fluid leak. Block
brake pedal in stroke position, visually check the boots
for cuts, tears, or heat cracks, and if any of these
conditions exist, the wheel cylinders should be com­
pletely cleaned, inspected and new parts installed. (A
slight amount of fluid on the boot may not be a leak,
but maybe preservative fluid used at assembly.)
(1) In case of a leak, remove brake shoes, (replace if
soaked with grease or brake fluid.)
SUPPORT

CYLI NDER
ATTACHING BOLTS

Fig.2 Remove or Install Wheel Cylinder

f / Wheel cylinder bores and pistons that are badly
(WHEEL CYLINDER
scored or pitted should be replaced. Cylinder walls
that have light scratches, or show signs of corrosion,
can usually be cleaned with crocus cloth, using a cir­
cular motion. Black stains on the cylinder walls are
caused by piston cups and will not impair operation of
cylinder.
Fig. 1 Brake Tube Disconnected
PUSH-ON BOOT PISTON CUP iCLIP
EXPANDERS
AND SPUING

PUSH-ON BOOT

CYLINDER BLEEDER SCREW CUP PISTON m im

F/g.3 Hear Wheel Cylinder

ASSEMBLING WHEEL CYLINDERS

Before assembling the pistons and new cups in the
wheel cylinders, dip them in clean brake fluid. If the
boots are deteriorated, cracked or do not fit tightly on
the pistons or the cylinder casting, install new boots.
(1) Coat cylinder bore with clean brake fluid.
(2) Install expansion spring with cup expanders in
cylinder. Install cups in each end of cylinder with
open end of cups facing each other.
(3) Install piston in each end of cylinder having the
flat face of each piston contacting the flat face of each
cup, already installed.
(4) Install a boot over each end of cylinder. Use care
not to damage boot.

INSTALLING WHEEL CYLINDERS

(1) Apply Mopar Gasket In-A-Tube or equivalent
sealant around wheel cylinder mounting surface (Fig.4).

Flg.4 Apply Sealant on Support Plate

(2) Slide wheel cylinder into position on support.

Install mounting screws and tighten as specified.
(3) Connect brake tube to wheel cylinder.
(4) Install brake shoes on support plate.
(5) Install brake drum and wheel. Adjust and bleed
brakes.
 HYDRAULIC SYSTEM CONTROL VALVES
INDEX
Page
ABS Brake Proportioning Valve Operation 23
GENERAL INFORMATION
All Non ABS models have a hydraulic system pres­
sure differential warning light switch and a height
sensing proportioning valve, in the brake system (Figs.l
and 3). The switch is attached to the frame rail below
the master cylinder.
PRESSURE DIFFERENTIAL WARNING LIGHT
SWITCH
The hydraulic brake system, on non-ABS vehicles,
is split diagonally. The left front and right rear brakes
are part of one system. And the right front and left
rear are part of another. Both systems are routed
through, but hydraulically separated by a Pressure
Differential Switch. The function of the Pressure Dif­
ferential Switch is to alert the driver of a malfunction
in the brake system.
If hydraulic pressure is lost in one system, the warn­
ing light switch will activate a red light on the instru­
ment panel, when the brake pedal is depressed. At
this point the brakes require service. However, since
the brake systems are split diagonally the vehicle will
retain 50% of its stopping capability in the event of a
failure in either half.
Fig. I Brake Warning Switch Location
Page
General Information 22
The warning light switch is the latching type. It will
automatically center itself after the repair is made
and the brake pedal is depressed.
The instrument panel bulb can be checked each
time the ignition switch is turned to the start position
or the parking brake is set.
HEIGHT SENSING DUAL PROPORTIONING
UNIT OPERATION
Non ABS vehicles use a height sensing proportion­
ing valve in addition to the pressure differential switch.
The height sensing proportioning valve is mounted on
the left rear frame rail forward of the spring assembly
(Fig. 2). An actuator assembly is connected between
the valve lever and a plastic retainer inserted into the
actuator bracket.
The height sensing proportioning valve modulates
the pressure to the rear brakes, sensing vehicle load
condition through movement of the actuator bracket.
Optimum front to rear brake balance is maintained
regardless of the vehicle load condition. Under a light
load condition, line pressure to the rear brakes is
minimized. As the load condition increases, so does
the pressure to the rear brakes.
 Fig.2 Height Sensing Proportioning Valve Assembly

CAUTION: The use of after market load leveling or ABS BRAKE PROPORTIONING VALVE OPERATION
capacity increasing devices is prohibited. Use of air
shock absorbers or helper springs will cause the On vehicles using the ABS braking system, screw
valve to inappropriately reduce the rear brake power in proportioning valves are used in place of the con­
potentially resulting in increased stopping distance. ventional differential pressure/proportioning valve.
Each rear brake circuit has its own screw-in propor­
The proportioning valve section operates by tra
tioning valve which is attached to the rear brake
mitting full input pressure to the rear brakes up to a
outlet ports of the hydraulic assembly. These valves
certain point. Called the split point. Beyond that point
limit brake pressure to the rear brakes after a certain
it reduces the amount of pressure increase to the rear
pressure is reached. This improves front to rear brake
brakes according to a certain ratio.
balance during normal braking.
Thus, on light pedal applications. Approximately
equal brake pressure will be transmitted to the front
and rear brakes. While at higher pressures, the pres­
sure transmitted to the rear brakes will be lower than
to the front brakes. This will prevent premature rear
wheel lock-up and skid.
The height sensing proportioning valve changes the
split point of the valve, based on vehicle rear suspen­
sion height. When the rear height is low, the valve
interprets this as extra load and raises the split point
to allow more rear braking. When the rear suspension
height is high, the split point is lowered and rear
braking reduced.
ABS PROPORTION Screw in proportioning valves can be identified by
VALVE the numbers stamped on the body of the valve. The
first digit represents the slope, the second digit repre­
sents the split (cut-in) point, and the arrow represents
the flow direction of the valve. Be sure that the num­
bers listed on the replacement valve are the as on
the valve that is being removed. See (Fig.3) for detail
of the valve identification.

Fig.3 ABS PROPORTIONING VALVE IDENTIFICATION

PROPORTIONING VALVE APPUCATIONS

VEHICLE PROPORTIONING VALVE VALVE PROPORTIIO
FAMILY APPLICATION MATERIAL SPLIT SLOPE

AS BODY 14" DISC— DRUM HEIGHT SENSOR ALUMINUM *HSPV

FWD-LWB 15" DISC— DRUM HEIGHT SENSOR ALUMINUM *HSPV .3

PLATED 30 BAR
FWD-SWB 15" DISC— DRUM ABS SCREW IN BLACK 435 PSI .45

AS BODY 15" DI SC— DRUM HEIGHT SENSOR ALUMINUM *HSPV .3

PLATED 40 BAR
FWD-LWB 15" DISC— DRUM ABS SCREW IN BLACK 580 PSI .45

AS BODY 15" DI SC— DRUM HEIGHT SENSOR ALUMI NUM *HSPV

PLATED 20 BAR
AWD-SWB 15" DISC— DRUM ABS SCREW I N BLACK 290 PSI .45

AS-BODY 15" DISC— DRUM HEI GHT SENSOR ALUMINUM •HSPV

\ PLATED 25 BAR
AWD-LWB 15" DISC— DRUM ABS SCREW IN BLACK 363 PSI .45

WHERE 1 BAR IS EQUAL TO 14.5 PSI

*HSPV = HEIGHT SENSIN G PROPORTIONING VALVE
 SERVICE PROCEDURES
INDEX
Page Page
Brake Warning System .................................................. 25 Testing ABS Proportioning Valves ............................. 26
Height Sensing Proportioning Valve ........................... 25

BRAKE WARNING SYSTEM INSTALLATION AND ADJUSTMENT (FIG.4)

After installing a new height sensing proportioning
CHECKING THE BRAKE WARNING SWITCH valve, bleed both hydraulic circuits at the rear brakes.
UNIT The rubber stone/snow shield must be installed when­
The brake warning light will come on when the ever the valve is serviced. This shield protects the
parking brake is applied with the ignition key turned valve and hydraulic lines from stone impact and the
ON. The same light will also illuminate should one of packing of snow and slush.
the two service brake systems fail. (1) Lift vehicle with a frame contact hoist or other
To test the service brake warning system, raise the means so that the rear suspension is hanging free
vehicle on a hoist and open a wheel cylinder bleeder with the shock absorbers disconnected from the axle.
while a helper depresses the brake pedal and observes Remove the tires and wheels from the rear axle. Be
the warning light. If the light fails to light, inspect for sure that the rear springs do not contact the hoist,
a burned out bulb, disconnected socket, or a broken or or an improper adjustment may result. Loosen both
disconnected wire at the switch. If the bulb is not front spring hanger pivot bolts.
burned out and the wire continuity is uninterrupted, (2) Loosen adjustment nut on the actuator assembly
check the service brake warning switch operation with (Fig. 2). Prior to adjustment, be sure that actuator
a test lamp between the switch terminal. Be sure to assembly hook is properly seated on valve lever.
fill master cylinder and bleed brake system after cor­ (3) Pull actuator assembly towards the spring hanger
rection has been made, if necessary. until the valve lever bottoms on the valve body, hold
in this position.
HEIGHT SENSING PROPORTIONING VALVE (4) Tighten the adjustment nut to 5 N-m (25 in. lbs.)
torque. Adjustment is now complete.
TESTING THE HEIGHT SENSING VALVE UNIT (5) Install wheel and tires and connect shock
When a premature rear wheel skid is obtained on absorbers.
brake application. It could be an indication that the (6) Lower vehicle to floor and with full weight of
fluid pressure to the rear brakes is above the desired vehicle on the wheels, tighten both front spring hanger
output. And that a malfunction has occurred within pivot bolts to 129 N-m (95 ft. lbs.) torque. Road test
the proportioning valve unit that should be tested. vehicle.
To test the proportioning valve, proceed as follows:
(1) Loosen and remove the actuator assembly ad­
justment nut. Disconnect the assembly from the valve
lever and remove.
(2) Install one gauge and T of set C-4007-A in the
line from either master cylinder port to the brake
valve assembly.
(3) Install the second gauge of set C-4007-A to ei­
ther rear brake outlet port between proportioning valve
assembly and the rear brake line. Bleed both hydrau­
lic circuits and the gauges.
(4) Have a helper exert pressure on the brake pedal
(holding pressure) to get a reading on the valve inlet
gauge and check the reading on the outlet gauge. The
inlet pressure should be 3445 kPa (500 psi) and the
outlet pressure should be 689-1380 kPa (100-200 psi).
If not, replace the valve and tighten mounting bolts to
28 N-m (250 in. lbs.) torque. If the valve tests OK
install actuator assembly, adjust and road test vehicle.
 HEIGHT SENSING PROPORTIONING VALVE
SNOW/STONE SHIELD

ADJUSTMENT NUT

RR05E36 ACTUATOR BRACKET ASSEMBLY

Flg.4 Height Sensing Proportioning Valve Assembly

TESTING ABS PROPORTIONING VALVES inlet and outlet pressures do not agree with the fol­
All ABS components use an ISO flare. Use the cor­ lowing chart, replace the valve. See (Fig.5) in Hydrau­
rect adapters when installing gauges. lic Control Valves Section for ABS proportioning valve
(1) Install one gauge and (T) between the hydraulic identification.
assembly and the male end (Inlet) of the valve.
(2) Install the second gauge at the female end (Out­ PROPORTIONING VALVE PRESSURES ABS-BRAKES
let) of the valve (Fig.5).
(3) Have a helper exert pressure on the brake pedal _ Inlet Output
(holding pressure) to get a reading on the valve inlet Proportioning Pressure
Slope Pressure
Valve PSI
gauge. PSI
(4) Check the reading on the outlet gauge. If the 20 BAR* .45 1000 PSI 560 PSI - 640 PSI
25 BAR .45 1000 PSI 600 PSI - 680 PSI
30 BAR .45 1000 PSI 640 PSI - 720 PSI
35 BAR .45 1000 PSI 685 PSI - 765 PSI
40 BAR .45 1000 PSI 725 PSI - 805 PSI
45 BAR .45 1000 PSI 765 PSI - 845 PSI

20 BAR .3 1000 PSI 460 PSI - 540 PSI

25 BAR .3 1000 PSI 510 PSI - 590 PSI
30 BAR .3 1000 PSI 560 PSI - 640 PSI
35 BAR .3 1000 PSI 610 PSI - 690 PSI
40 BAR .3 1000 PSI 660 PSI - 740 PSI
45 BAR .3 1000 PSI 715 PSI - 795 PSI

‘ WHERE 1 BAR I S EQUAL TO 14.5 PSI

 DISC BRAKES
INDEX
Page
General Information 27
GENERAL INFORMATION
The single piston, floating caliper disc brake assem­
bly consists of the driving hub, braking disc (rotor),
caliper, shoes and linings, and an adapter on vehicles
without an integral knuckle (Fig.l).
The double pin Kelsey-Hayes caliper is mounted
through bushings and sleeves by two through bolts
threaded into the steering knuckle (Fig.2)
WARNING: THESE TWO PISTONS ARE NOT INTER­
CHANGEABLE. THE DIMENSIONS OF THESE PIS­
TONS ARE DIFFERENT. IMPROPER USE COULD
CAUSE COMPLETE BRAKE FAILURE.
Two machined abutments on the adapter or steer­
ing knuckle, position and align the caliper fore aiid
aft. The guide pins and bushings control the move­
ment of the caliper and the piston seal, to assist in
maintaining proper shoe clearance.
Page
Service Precautions ...................................................... 29
The Kelsey Hayes single guide pin caliper has three
anti-rattle clips. One clip is on top of the inboard shoe.
The other clip is on the bottom of the outboard shoe.
The lasts clip is on the top of the caliper.
The Kelsey-Hayes double sleeve caliper has an anti­
rattle clip attached to the outer shoe and an inner
shoe-piston retainer clip.
All of the braking force is taken directly by the
adapter or the steering knuckle.
The caliper is a one piece casting with the inboard
side containing a single piston cylinder bore.
The phenolic piston is 60 mm (2.36 inch) in diameter.
A square cut rubber piston seal is located in a ma­
chined groove in the cylinder bore and provides a
hydraulic seal between the piston and the cylinder
wall (Fig. 3).
A molded rubber dust boot installed in a groove in
the cylinder bore and piston, keeps contamination from
the cylinder wall and piston.
 The boot mounts in the cylinder bore opening and
in a groove in the piston (Fig. 3). This prevents con­
tamination in the bore area.
As lining wears, reservoir level will go down. If
fluid has been added, reservoir overflow may occur
when the piston is pushed back into the new lining
position. Overflowing can be avoided in this case by
removing a small amount of fluid from the master
cylinder reservoir.
BRAKE HOSE BLEEDER
Fig. 2 Disc Brake Caliper Mounting
SH O E AN D LINING WEAK
If a visual inspection does not adequately determine
the condition of the lining, a physical check will be
necessary. To check the amount of lining wear, re­
move the wheel and tire assemblies, and the calipers.
Remove the shoe and lining assemblies. (See Brake
Shoe Removal).
Combined shoe and lining thickness should be mea­
sured at the thinnest part of the assembly.
When a shoe and lining assembly is worn to a thick­
ness of approximately 7.95 mm (0.313 inch) it should
be replaced.
Replace both shoe assemblies (inboard and outboard)
on the front wheels. It is necessary that both front
wheel sets be replaced whenever shoe assemblies on
either side are replaced.
If a shoe assembly does not require replacement,
install, making sure each shoe assembly is returned
to the original position. (See Brake Shoe Installation).
PISTON * CYLI NDER BORE CALIPER
HO U SING
PISTON SEAL
BRAKE
PRESSURE
ON
_____ \
• DUST BOOT ' PR747B
Fig. 3 Piston Seal Function for Automatic Adjustment
SERVICE PRECAUTIONS BAGS OR CONTAINERS TO MINIMIZE DUST EXPO­
SURE TO YOURSELF AND OTHERS.
WARNING: DUST AND DIRT ON BRAKE PARTS GEN­ FOLLOW ALL RECOMMENDED PRACTICES PRE­
ERATED DURING THE NORMAL USE AND WEAR OF SCRIBED BY THE OCCUPATIONAL SAFETY AND
MOTOR VEHICLE BRAKE SYSTEMS CAN CONTAIN HEALTH ADMINISTRATION AND THE ENVIRONMEN­
ASBESTOS FIBERS. BREATHING EXCESSIVE CON­ TAL PROTECTION AGENCY FOR THE HANDLING,
CENTRATIONS OF ASBESTOS FIBERS CAN CAUSE PROCESSING, AND DISPOSITION OF DUST OR DIRT
SERIOUS BODILY HARM, SUCH AS ASBESTOSIS WHICH MAY CONTAIN ASBESTOS FIBERS.
AND CANCER. EXTREME CARE SHOULD BE EXER­
Grease or any other foreign material must be kept
CISED WHILE SERVICING BRAKE ASSEMBLIES OR
off the caliper assembly, surfaces of the braking disc
COMPONENTS.
and external surfaces of the hub, during service
DO NOT CLEAN BRAKE ASSEMBLIES OR COM­
procedures.
PONENTS WITH COMPRESSED AIR OR BY DRY
Handling the braking disc and caliper should be
BRUSHING; USE A VACUUM CLEANER SPECIFIC­
done in such a way as to avoid deformation of the disc
ALLY RECOMMENDED FOR USE WITH ASBESTOS
and scratching or nicking the brake linings (pads).
FIBERS. IF A SUITABLE VACUUM CLEANER IS NOT
If inspection reveals that the square sectioned cali­
AVAILABLE, CLEANING SHOULD BE DONE WET US­
per piston seal is worn or damaged, it should be re­
ING A WATER DAMPENED CLOTH.
placed immediately.
DO NOT CREATE DUST BY SANDING, GRINDING,
During removal and installation of a wheel and tire
AND/OR SHAVING BRAKE LININGS OR PADS UN­
assembly, use care not to strike the caliper.
LESS SUCH OPERATION IS DONE WHILE USING
Before vehicle is moved after any brake service work,
PROPERLY EXHAUST VENTILATED EQUIPMENT.
be sure to obtain a firm brake pedal.
DISPOSE OF ALL DUST AND DIRT SUSPECTED
TO CONTAIN ANY ASBESTOS FIBERS IN SEALED
 KELSEY HAYES DOUBLE PIN FAMILY CALIPER
INDEX
Page Page
Assembling Caliper ........................................................ 33 Disassembling Caliper ................. 32
Brake Shoe Installation ............................................... 31 Service Procedures ....................... 30
Cleaning and Inspection ............................................. 33

SERVICE PROCEDURES
BLEEDER SCREW

BRAKE SHOE REMOVAL

Raise vehicle on jackstands or centered on a hoist.
Remove front wheel and tire assemblies.
Remove caliper guide pin bolts (Fig.l).
BLEEDER SCREW.

'RATCHET AND SO CKET

SCREWDRIVER 9105-56
Flg.2 Loosening Family Caliper Assembly From Adapter
Flg.1 Removing or Installing Guide Pin Bolts
Remove caliper from disc by slowly sliding caliper
After removing the caliper guide pin bolts. Wedge
assembly out and away from braking disc (Fig.3).
the caliper away from the braking disc with a screw­
driver to break the gasket adhesive seals (Fig.2). BRAKING
DISC

ANTIRATTLE
CLIP

CALIPER

RF215B

Fig.3 Removing or Installing Caliper

 Support caliper firmly to prevent weight of caliper
from damaging the flexible hose (Fig.4).

BRAKING DI SC

BRAKING DISC

RN197
SHOE ASSEMBLY
Fig.6 Removing or Installing Braking Disc

BRAKE SHOE INSTALLATION

Fig.4 Storing Caliper
Lubricate both adapter ways with a liberal amount
Remove the outboard shoe assembly from the adapter, of Mopar Multipurpose Lubricant, or equivalent.
the disk and the shoe assembly (See Figures 5,6 and
Remove the protective paper from the noise sup­
7). pression gasket on both the inner and outer brake
OUTBOARD SHOE shoe assembl • -
Install the new inboard brake shoe assembly on the
adapter being careful not to get any grease from the
adapter way on the surface of the brake lining mate­
rial, (See Fig. 7)

BRAKING
DI SC

Fig.5 Removing and Installing Outboard

Shoe Assembly

RF219B

Fig.7 Removing or Installing Inboard Shoe Assembly

 Reinstall the Braking Disk on the hub, (See Fig.8) CAUTION:' Excessive wise pressyr© will cays® bore
Slide the new outboard brake shoe assembly on the distortion and binding of piston.
adapter, (See Fig.5)
Support caliper and remove dust boot and discard
Cjterully lower caliper over the braking disk and
(Fig. 1).
brake shoe assemblies.
Install the caliper guide pins and tighten to 34 to 37 CALIPER'
N-m (25 to 35 ft. lbs.). Extreme caution should b©
taken not to cross the threads of the caliper guide
pin bolts.
Install the wheel and tire assembly. Tighten the
wheel mounting stud nuts in proper sequence until all
nuts are torqued to half specification. This is impor­
tant. Then repeat the tightening sequence to the full
specified torque. (See specifications at the end of this
section)
Remove jackstands or lower hoiM, Before moving
vehicle, be sure it has a firm pedal,
Road test the vehicle and make several stops to
wear off any foreign material on the brakes and to
seat the brake shoe linings.

CLEANING AND INSPECTION

Cheek for piston seal leaks (brake fluid in and around
boot area and inboard lining) and for any ruptures of
piston dust boot. If boot is damaged, or fluid leak is
visible, disassemble caliper assembly and install a
new seal and boot,(and piston if scored). Refer to pro­
cedures titled Disassembling Caliper. 9f§9 | Removing Piston Duet- Boot
Check the caliper dust boot and caliper pin bush­
ings to determine if they are in good condition. Re­ Using a plastic trim stick, work piston seal out of
place if they are damaged, dry, or found to be brittle. its groove in piston bore (Fig. 2). Discard old seal. Do
Refer to Caliper Service. not use a screwdriver or other metal tool for this
operation, because of possibiitf of scratching pis­
DISASSEMBLING CALIPER ton bor# or byrrlng edges of seal groowe.

Remove caliper from braking disc.(see Brake Shoe

Removal) Hang assembly on a wire hook, away from PLASTIC TRIM STICK
braking disc, so that hydraulic fluid will not get on
/
braking disc.(See Fig.4) Place a small piece of wood
between the piston and caliper fingers.
Carefully depress brake pedal to hydraulically push
piston out of bore. (Brake pedal will fall away when
piston has passed bore opening.) Then prop up the
brake pedal to any position below the first inch of
pedal travel, to prevent loss of brake fluid.
If both front caliper pistons are to be removed, dis­
connect flexible brake line at frame bracket after re­
GROOVE
moving piston. Plug brake tube and remove piston
from opposite caliper. Using the same process as above
for the first piston removal.
WARNING: UNDER NO CONDITION SHOULD AiR
PRESSURE BE USED TO REMOVE PISTON FROM
BORE. PERSONAL INJURY COULD RESULT FROM
SUCH PRACTICE,
Disconnect brake flexible hose from the caliper. To PR782A

disassemble, mount caliper assembly m a vise equipped

with protective jaws. Fig. 2 Removing Piston Seal
 The double pin caliper uses a sealed for life bushing CLEANING AND INSPECTION
and sleeve assembly. If required this assembly can be
serviced using the following procedure. Clean all parts using alcohol or a mutable solvent
(1) Push out and then pull the inner sleeve from the and wipe dry. Clean out all drilled passages and
inside of the bushing using your fingers as shown in bores.(Whenever a caliper has been disassembled, a
(Fig.3) new boot and seal must be installed at assembly).
Inspect the piston bore for scoring or pitting. Bores
that show light scratches or corrosion, can usually be
cleared with crocus cloth.
Bores that have deep scratches or scoring should be
honed, using Honing Tool, Special Too) (J-4095, or
equivalent providing the diameter of the bore is not
increased more than 0.0254 mm (0.001 inch) (Fig.l).

Fig. 3 Removing Inner Sleeve

(2) Using your fingers collapse one side of the bush­

ing while pulling on the opposite side to remove the
bushing from the caliper assembly see (Fig.4).

Fig.l Honing Piston Bore

If the bore does not clean up within this specifica­

tion, a new caliper housing should be installed. Install
a new piston if the old one is pitted or scored.
When using Honing Tool, Special Tool C-4095, coat
the stones and bore with brake fluid. After honing
the bore, carefully clean the seal and boot grooves
with a stiff nonmetallic rotary brush.
Use extreme care in cleaning the caliper after hon­
ing. Remove all dirt and grit by flushing the caliper
with brake fluid; wipe dry with a clean, lint free cloth
and then clean a second time.

ASSEMBLING CALIPER
Clamp caliper in vise (with protective caps on vise
jaws).

9105-58 CAUTION: Excessive vise pressure will cause bore

distortion and binding of piston.
Fig. 4 Removing Bushings From Caliper
 Dip new piston seal in clean brake fluid and install
in groove in bore. Seal should be positioned at one
area in groove and gently worked around the groove,
using fingers until properly seated.
NEVER USE AN OLD PISTON SEAL. (Be sure that
fingers are clean and seal is not twisted or rolled)
(Fig.l).
CALIPER
SEAL
GROOV
PW7B5
Flg.1 Installing New Piston Seal
Coat new piston boot with clean brake fluid leaving
a generous amount inside of boot.
Position dust boot over piston after coating with
brake fluid.
Install piston into bore pushing it past the piston
seal until it bottoms in the bore (Fig.2)'
CALIPER
BOOT ’ P,STON RK207
Fig.2 Pushing Piston into Bom
CAUTION: Force must be applied to the piston uni­
formly to avoid cocking and binding of the piston In
the bore of the caliper.
Position dust boot in counterbore.
Using a hammer and Installer Piston Caliper Boot,
Special Tool C-4G83 and Handle, Special Tool C-4171,
drive boot into counterbore of the caliper (Fig.3).
HAMMER
SPECIAL
TOOL C-4689
CALIPER
9105-42
Fig.3 Installing Boot in Caliper
Use the following steps to install the Guide Pin
Sleeve Bushings into the caliper assembly.
(1) Fold the bushing in half lengthwise at the solid
middle section of the bushing.
(2) Using your fingers insert the folded bushing into
the caliper assembly. Making sure the solid section of
the bushing is fully seated into the bushing hole of
the caliper assembly. (See Fig.4) Do not use a sharp
object to perform this step do to possible damage to
the bushing.
(3) Unfold the bushing using your fingers or wooden
dowel until the bushing is fully seated into the caliper
assembly with the flanges seated evenly on both sides
of the bushing holes in the caliper assembly. (See
Fig.4)
 CALI PER
9105-59 BUSHING
Fig.4 Installing Sleeve Bushings
Install the Guide Pin Sleeve into the guide bushing
using the following procedure (Fig.5)
(1) Install the sleeve into one end of the bushing
until the seal area of the bushing is past the seal
grove in the sleeve.
(2) Holding the convoluted end of the bushing with
one hand. Push the sleeve through the bushing until
the one end of the bushing is fully seated into the seal
grove on the one end of the sleeve.
CALIPER SLEEVE
BUSHING
9105-60
Fig.5 Installing Caliper Sleeves
(3) Holding the sleeve in place work the other end of
the bushing over the end of the sleeve and into the
seal grove. Be sure the other end of the bushing did
not come out of the seal grove in the sleeve.
Before installing caliper assembly on vehicle,inspect
braking disc. Conditions as described in Checking Brak­
ing Disc for Runout and Thickness paragraph. Install
caliper assembly.
Install brake hose to caliper. New seal washers
must always be used when installing brake hose to
caliper.
Bleed the brake system (see Bleeding Brake System).
 BRAKE DISC (ROTOR)
INDEX
Page Page
Braking Disc Removal ........ ......................................... 38 Refinishing Braking Disc .............................................. 38
General Information ...................................................... 36 Refinishing L im its .......................................................... 39
Inspection Diagnosis .................................................... 36 Service Procedures ............................... ........................ 36
Installing Braki ng D is c ........ ......................................... 38

GENERAL INFORMATION SERVICE PROCEDURES

Any servicing of the braking disc requires extreme CHECKING BRAKING DISC FOR RUNOUT
care to maintain the braking disc within service toler­ AND THICKNESS
ances to ensure proper brake action. On vehicle, braking disc (rotor) runout is the combi­
nation of the individual runout of the hub face and
CAUTION:lf the BRAKING DISK (ROTOR) needs to
the runout of the disc. (The hub and disc are separa­
be replaced with a new part, the protective coating
ble). To measure runout on the vehicle, remove the
on the braking surfaces of the rotor MUST BE RE­
wheel and reinstall the lug nuts tightening the disc to
MOVED with an appropriate solvent, to avoid con­
the hub. Mount Dial Indicator, Special Tool C-3339
tamination of the brake linings.
with Mounting Adapter, Special Tool SP-1910 on steer­
Also when replacing a rotor with a new part do ing arm. Dial indicator plunger should contacting disc
NOT reface the new rotor. Rotor already has the re­ (braking surface) approximately one inch from edge of
quired micro finish when manufactured. disc (See Fig.l). Check lateral runout (both sides of
disc) runout should not exceed 0.13 mm (0.005 inch).
INSPECTION DIAGNOSIS
SPECIAL TO OL ONE INCH DISC
Before refinishing or refacing a braking disc, the
disc should be checked and inspected for the following
conditions:
Scoring, rust, impregnation of lining material and
worn ridges.
Runout or wobble.
Thickness variation (Parallelism).
Dishing or distortion (Flatness).
If a vehicle has not been driven for a period of time,
the discs will rust in the area not covered by the
lining and cause noise and chatter.
Excessive wear and scoring of the disc can cause
temporary improper lining contact if ridges are not re­
moved before installation of new brake shoe assemblies.
Some discoloration or wear of the disc surface is
normal and does not require resurfacing when linings
are replaced.
Excessive runout or wobble in a disc can increase
pedal travel due to piston knock back. This will in­
crease guide pin bushing wear due to tendency of
caliper to follow disc wobble.
Thickness variation in a disc can also result in Fig.1 Checking Disc for Runout
pedal pulsation, chatter and surge due to variation in
If runout is in excess of this specification, check the
brake output, this can also be caused by excessive
lateral runout of the hub face. Before removing disc,
runout in disc or hub.
make a chalk mark across both the disc and one wheel
Dishing or distortion can be caused by extreme heat
stud, on the high side of runout, so you’ll know ex­
and abuse of the brakes.
actly how the disc and hub was originally mounted
(Fig. 2). Remove disc from hub.
 Runout should not exceed 0.08 mm (0.003 inch). If
runout exceeds this specification, hub must be re­
placed. See Suspension Group 2. If hub runout does
CHALK
not exceed this specification, install disc on hub with
MARK chalk marks two wheel studs apart (Fig. 4). Tighten
nuts in the proper sequence and torque to specifica­
tions. Finally, check runout of disc to see if runout is
now within specifications.

RN199

Fig.2 Marking Braking Disc and Wheel Stud

Install Dial Indicator, Special Tool C-3339 and

Mounting Adaptor, Special Tool SP-1910 on steering
knuckle. Position stem so it contacts hub face near
outer diameter. Care must be taken to position stem
outside the stud circle but inside the chamfer on the CHALK
hub rim. Clean hub surface before checking. (See MARK RN201
Fig.3)
Fig. 4 Index Braking Disc and Wheel Stud
HUB SURFACE SPECIAL TOOL
C-3339 If runout is in excess of specifications, install a new
disc or reface disc, being careful to remove as little as
possible from each side of disc. Remove equal amounts
from each side of disc. Do not reduce thickness below
minimum thickness cast into the un-machined surface
of the rotor.

SPECIAL TOOL
SP-1910

9105-44

Fig.3 Checking Hub for Runout

 Pig. 5 Checking Disc for Thickness
Thickness variation measurements of disc should be
made in conjunction with runout. Measure thickness
of disc at twelve (12) equal points with a micrometer
at a radius approximately 25.4 mm (one (1) inch) from
edge of disc (Fig.5). If thickness measurements vary
by more than 0.013 mm (0.0005 inch) disc should be
removed and resurfaced (Figs. 6 and 7), or a new disc
installed. If cracks or burned spots are evident in the
disc, disc must be replaced.
Light scoring and/or wear is acceptable. If heavy
scoring or warping is evident, the disc must be refin­
ished or replaced (See Refinishing (Refacing) Braking
Disc). If cracks are evident in the disc, replace the
disc.
BRAKING ilSC REMOVAL
(1) Raise vehicle on hoist or jackstands. Remove
wheel and tire assembly.
(2) Remove caliper assembly, as described under
Brake Shoe Removal this Group, (but do not discon­
nect brake line). Suspend caliper from wire hook or
loop to avoid strain on flexible hose.
(3) Remove braking disc from the hub.
INSTALLING BRAKING DISC
(1) Slide braking disc on hub. Clean both sides of
braking disc with alcohol or suitable solvent.
(2) Install caliper assembly, as described in Brake
Shoe Installation paragraph.
REFINISHING BRAKING DISC
RESURFACING BRAKING DISC
This operation can be used when the disc surface is
rusty or has lining deposits.
 A sanding disc attachment will remove surface con­ (Fig. 8). This surface may be as shown in Fig. 8 or on
tamination without removing much material. an alternate surface.
It will generally follow variations in thickness which This marking includes 0.76 mm (0.030 inch) allow­
are in the disc. able disc wear beyond the recommended 0.76 mm(0.030
inch) of disc refacing.
REFACING BRAKING DISC
Refacing of the braking disc is not required each
time the shoe assemblies are replaced.
If the braking disc surface is deeply scored or warped
or there is a complaint of brake roughness the rotor
should be refaced (Figs. 6 or 7).
When refacing a braking disc the required 0.10 mm
(0.004 inch) TIR (Total Indicator Reading) and 0.013
mm (0.0005 inch) thickness variation limits MUST
BE MAINTAINED. Extreme care in the operation of
braking disc turning equipment is required.
The collets, shafts and adapters in the lathe and the
bearing cups in the rotor MUST be clean and free
from any chips or contamination.
When mounting the disc on the lathe, strict atten­
tion to the manufacturer’s instructions is required.
If the disc is not mounted properly the run-out will
be worse after refacing than before refacing.
The use of a double straddle cutter (Fig. 6) which
machines both sides of the disc at the same time is
highly recommended.
The following chart shows the location of measure­
ments and specifications when servicing the braking
disc. Fig. 8 Minimum Thickness Markings
All braking discs have markings for minimum al­
lowable thickness cast on an un-machined surface
REFINISHING LIMITS

ROTOR REFINISHING LIMITS

Minimum Thickness Disc Micro
__________________ Thickness iation_____________Runout*___________Finish

Braking Disc 22.13-21.87 mm 20.4 mm (.803 in.) .013 mm (.0005 in.) .13 mm (.005 in.) 15-80 RMS
(.870-.861 in.)

*TI R - Total Indicator Reading (measured on vehicle)

9105-100
 PARKING BRAKES
INDEX
Page
Front Parking Brake C a b le ............................................ 42
General Information ...................................................... 40
Parking Brake Pedal Assembly ................................... 42
GENERAL INFORMATION
The rear wheel service brakes also act as parking
brakes. The brake shoes are mechanically operated by
an internal lever and strut connected to a flexible
stainless steel cable. The different length rear cables
are connected to the front cable by an equalizer/adjuster
assembly which is enclosed in a covered anchor bracket.
The front cable extends to the parking brake pedal
assembly (Figs. 1 and 4).
Cable routing and brake shoe actuation (for parking
Page
Rear Parking Brake Cable ............................................ 43
Service Procedures ........................................................ 42
brake) is changed. The right rear cable enters the
support from the rear, with the internal lever at­
tached to the primary (front) shoe where it pivots to
push the strut into the secondary (rear) shoe. The left
brake is traditional, the cable enters the support from
the front, the lever is attached to the secondary (rear)
shoe to push the strut into the primary (front) shoe.
The left and right brake shoes look similar, BUT
THEY ARE NOT INTERCHANGEABLE. The back­
ing plates and cables are color coded; left is black,
right is grey.
 LET TIGHTENING TORQUE
SCREW V A 4> 110 IN. LBS. 12 N*m
<$> 9 9 IN. LBS. 23 N*m

CABLE GUIDE

GUIDE RETAINER

BRAKES
COVEi
PLUG

9915.ft

5-41
Fig. 1 Parking Iiiiftii Cable Routing
SERVICE PROCEDURES
ADJUSTING PARKING BRAKE
The service brakes must be properly adjusted before
adjusting the parking brake.
Remove plastic cover by pressing in the fingers of
the cover through holes in bracket (Fig. 1).
Before loosening cable adjusting nut, clean threads
with brush and lubricate with grease.
Release the parking brake pedal then back off cable
adjusting nut so there is slack in the cable.
Push parking brake pedal all the way to the floor.
Mark bent nail adjuster approximately 8 mm (1/4
inch) from bracket (Fig. 2).
Tighten adjusting nut until mark moves into align­
ment with edge of bracket. Important: Replace bent
nail with a new part if nail end hook has moved all
the way to the bracket.
Replace plastic cover and tethered plug.
Apply and release the parking brake to see that the
rear wheels rotate freely without dragging.
EQUALIZER
Fig. 2 Equallzer/Bent Nall Adjuster Assembly
PARKING IRAKI P liA l ASSEMBLY
REMOVE
Loosen cable adjusting nut and disconnect front ca­
ble from adjuster.
Remove sill molding/cowl side scuff panel and steer­
ing column cover. Increase access by removing fuse
box, if required.
Disconnect brake release cable and electrical con­
nector for light switch. Remove pedal assembly at­
taching bolts.
Remove front cable strand button from clevis. Tap
cable housing end fitting out of assembly.
INSTALL
Install cable retainer into pedal assembly bracket.
Install cable into retainer and strand button into
clevis.
Bolt pedal assembly into place. Install release cable
and electrical connector for light switch.
Install fuse box, steering column cover and sill
molding/cowl side scuff panel.
Connect front cable and adjust parking brake.
PRiNI PARKING BRAKE CABLE ■
REM OVE
Loosen cable adjusting nut and disengage front ca­
ble from adjuster and housing from- anchor bracket.
Remove cable housing retainer by sliding a 14 mm
box wrench over retainer end compressing the three
fingers. Alternate method is to use an aircraft type
hose clamp and screwdriver (Fig. 3).
Remove cable guide brackets from frame rail and
loosen cable housing at pedal assembly.
Lift floor mat for access to floor pan and force seal
out of hole (into vehicle).
Pull cable end forward and disconnect button from
clevis. Tap cable housing end fitting out of pedal as­
sembly bracket.
Pull cable assembly through hole.
Fig. 3 Removing Brake Cable from Support Plate
INSTALL
Feed cable assembly through hole in floor from in­
side vehicle (Fig. 4).
Install cable retainer into brake pedal assembly
bracket and then install cable housing end fitting into
retainer.
 Engage cable strand button into clevis.
Install floor pan seal and floor mat.
Insert brake cable and housing into anchor bracket
making certain that housing retainer fingers lock the
housing firmly into place.
Install cable guide brackets.
Assemble adjuster to front cable.
Adjust parking brake.
Fig. 4 Parking Brake Pedal
REAR PARKING BRAKE CABLE
REMOVE
With vehicle jacked up on suitable hoist remove
wheel and tire.
Back off cable adjusting nut to provide slack and
disconnect rear cable from equalizer bracket.
Remove cable from anchor bracket. Remove cable
housing retainer by sliding a 14 mm box wrench over
retainer end compressing the three fingers. Alternate
method is to use an aircraft type hose clamp and
screwdriver (Fig. 3).
Remove cable wrap-around clips where applicable.
Disconnect cable guide wires where applicable.
Remove brake drum and hub from spindle.
Disconnect cable from brake internal lever.
Remove cable housing retainer using same method
as at anchor bracket.
INSTALL
Insert cable into support plate and attach to brake
internal lever.
Insert cable housing into brake support plate mak­
ing certain that housing retainer fingers lock the hous­
ing firmly into place.
Install brake drum, wheel and tire.
Insert cable housing into anchor bracket making
certain that housing retainer fingers lock the housing
firmly into place.
Attach cable guide wires and wrap-around clips
where applicable.
Connect equalizer bracket.
Adjust service brakes and then adjust parking brake.
 MASTER CYLINDER
INDEX
Page Page
General Information 44 Service Procedures 44
Reservoir R eplacem ent 44

GENERAL INFORMATION voir with a rocking motion onto master cylinder

housing.
The tandem master cylinder (Fig. 1) has a glass Be sure reservoir is positioned properly. All letter­
reinforced nylon reservoir and an anodized aluminum ing should be properly read from the left side of the
body. master cylinder.
Do not hone the bore of the cylinder, as this will Make sure bottom of reservoir touches top of grommet.
remove the anodized surface.
The reservoir is indexed to prevent installation in
the wrong direction. The cap diaphragms are slit to
allow pressure to equalize.
The secondary outlet tube from the master cylinder RESERVOIR
is connected to the valve mounted under the master
cylinder. The front part of this block supplies the
right rear and left front brakes. The rear portion of
the block connects to the primary outlet tube and
supplies the right front and left rear brakes.

SPLI
T RINGS RESERVO IR

Fig. 2 Removing Reservoir

RESERVOIR
GROMMETS

. PRIMARY SECONDARY
PISTO N ASSEMBLY PISTON ASSEMBLY RH1390

Fig. 1 Aluminum Master Cylinder

RESERVOIR REPLACEMENT
See Master Cylinder Removal.
Clean housing and reservoir. MASTER
Remove caps and empty brake fluid. CYLINDER
PR598
Position master cylinder in vise.
Rock reservoir from side to side and remove from Fig. 3 Removing Grommets
master cylinder housing (Fig. 2).
Do not pry off with tool, damage to reservoir may
SERVICE PROCEDURES
result.
MASTER CYLINDER
Remove housing-to-reservoir grommets (Fig. 3).
Install new housing-to-reservoir grommets in mas­ REMOVE
ter cylinder housing. Disconnect primary and secondary brake tubes from
Lubricate reservoir mounting area with brake fluid. master cylinder, install plugs at outlets.
Place reservoir in position over grommets. Seat reser- Remove nuts attaching master cylinder to power
brake unit.
 Slide master cylinder straight out, away from power
brake unit.

BLEEDING MASTER CYLINDER

Clamp master cylinder in vise and attach bleeding
tubes Tool C-4546.
Use residual valve on outlet of each bleeder tube.
Fill both reservoirs with approved brake fluid.
Depress push rod slowly and then allow pistons to
return. Repeat several times until all air bubbles are
expelled (Fig. 4).
Remove bleeding tubes from cylinder, plug outlets
and install caps.
Remove from vise and install master cylinder.
It is not necessary to bleed the entire hydraulic
system after replacing the master cylinder, providing
that the master cylinder had been bled and filled
upon Installation.

PR604A

Fig. 4 Bleeding Master

INSTALL
Position master cylinder over studs of power brake
unit, align push rod with master cylinder piston.
Install attaching nuts and tighten to specification.
Connect brake tubes and tighten to specification.
 POWER BRAKES
INDEX
Page Page
General Information . . . . . . . 46 Service Procedures -■ 47

GENERAL INFORMATION
A 270 mm brake booster is used on these vehicles.
Different systems and engine combinations require AIR INTAKE PLENUM AIR CLEANER
different vacuum hose routings. Vehicles equipped with BRAKE BOOSTER
the Chrysler 2.5L engine use a charcoal filter in the
hose between the booster and the throttle body (Fig.l).
Vehicles equipped with the optional 3.0L and 3.3L
engine use a preformed vacuum hose connected di­
rectly to the intake manifold (Fig.2 and 3).
MUFFLER

BRAKE BOOSTER HOSE -BRAKE BOOSTER TO

AIR INTAKE PLENUW
RR05E33

Fig. 2 Power Brake Unit/Vacuum Hose Connections

3ML Engine

HOSE-SRAKE BRAKE
BOOSTER TO BOOSTER
TURBO INTAKE TURBOCNARGED
MANIFOLD
VIEW IN DIRECTION
OF ARROW Z 9005-11

Fig. I Power Brake UnltlVaeuum Hose

Connections 2.5L TBI and 2.5L Turbocharged Engines
Fig. 3 3.3£ Engine Power Brake Unit/
Vacuum nose Connections
SIRViCi PROCEDURES '' ' ing holes are slotted) on the dash panel, then tilt
inboard and up to remove.
P O m m B R A K E UNIT
INSTALL
REiOfE Position power brake booster onto dash panel.
Remove n u ts a tta c h in g m a s te r cylinder' to pow er
Install and tighten four mounting nuts to 23-34 N-m
b ra k e u n it. . . .
(200-300 in. lbs.) torque.
C a re fu lly slid e m a s te r c y lin d e r off m o u n tin g stu d s
Install steel heater water line and clutch cable
a n d allow to r e s t a g a in s t fe n d e r sh ie ld .
bracket, if so equipped.
Disconnect v a c u u m hose from pow er b ra k e check
Carefully position master cylinder on power brake
v a lv e . DO NOT REMOVE CH ECK VALVE FROM
unit.
BOOSTER.
Install and tighten mounting nuts to 23-34 N-m
F ro m u n d e r in s tru m e n t p an el, position a sm all screw ­
(200-300 in. lbs.) torque.
d riv e r b e tw e e n th e c e n te r ta n g on th e r e ta in e r clip
Connect vacuum hose.
a n d th e p in in th e b ra k e ped al.
Using lubriplate, or equivalent, coat the bearing
R o ta te sc re w d riv e r en o u g h to allow r e t a i n e r . clip
surface of pedal pin.
c e n te r ta n g to p a ss ov er e n d o f b ra k e p e d a l p in a n d
Connect push rod to pedal pin and install new re­
p u ll r e ta in e r clip fro m p in . D iscard r e ta in e r clip.
tainer clip.
R em ove fo u r pow er b ra k e a tta c h in g n u ts.
Check stop light operation.
U n fa s te n b ra c k e ts on ste e l h e a te r w a te r lin e a t d a sh
p a n e l a n d le ft fra m e ra il. On Manual Transmission CAUTION: Do not attempt to disassemble power brake
vehicles, u n fa s te n c lu tc h cable b ra c k e t a t shock to w er unit as this booster is serviced as a complete as­
a n d m ove aside. sembly only.
le th e pow er b ra k e u n it u p a n d to th e left (m ount-

: . w heel i

FRONT WHEEL IEAR1NSS ' '' . . ' REMOVAL AND INSTALLATION

F ro n t w h eel d riv e v eh icles a re eq u ip p ed w ith p e r­
m a n e n tly se a le d fro n t w h eel b e a rin g s. T h e re is no
perio d ic lu b ric a tio n o r m a in te n a n c e ' reco m m ended for
th e s e u n its . H o w ev er if d u rin g se rv ic in g of th e b ra k e
sy stem , serv ice to th e fro n t w h eel b e a rin g is re q u ire d
re fe r to G ro u p 2, S u sp e n sio n in th is serv ice m a n u a l.
BEAR WHEEL BEARINGS (FRONT WHEEL DRIVE)
NORMAL SERVICE
The lubricant in the rear wheel bearings should be
inspected whenever the hubs are removed to inspect
or service the brake system, or at least every 30,000
miles (48 000 km). The bearing should be cleaned and
repacked with a High Temperature Multipurpose E.P.
Grease whenever the disc brake rotors are resurfaced.
For the servicing, removal and installation of the
rear wheel bearings follow the procedure listed below.
(1) Remove the rear tire and wheel assembly.
(2) On rear disc brake equipped vehicles remove the
caliper and rotor. Support the caliper out of the way.
Do not allow the caliper to hang by the hydraulic
hose. See disc brake section in this group for caliper
removal procedure.
(3) Remove grease cap, cotter pin, nut lock, nut,
thrust washer and outer wheel bearing.
(4) Carefully slide hub or drum from spindle. Do not
drag inner bearing or grease seal over stub axle (thread,
bearing, and oil seal may be damaged.) Using an
appropriate tool remove the grease seal and inner
bearing from the drum or hub. Discard grease seal, a
new seal should be used when reinstalling the inner
bearing. (See Fig.l)

INSPECTION
Check lubricant to see that it is adequate in quan­
tity and quality. If the grease is low in quantity,
contains dirt, appears dry or has been contaminated
with water that produces a milky appearance to the
grease, the bearings must be cleaned and repacked.
Do not add grease to a wheel bearing that already
has grease packed in it. Relubricate completely. Mix­
ing of different types of greases in wheel bearings
should be avoided since it may result in excessive
thinning and leakage of the grease.

Fig. 1 Rear Wheel Bearings
(5) Thoroughly clean all old grease from the outer
and inner bearings, bearing cups and hub cavity (See
Fig.l). To clean bearings, soak them In an appropri­
ate cleaning solvent. Strike the flat surface of the
bearing inner race against a hardwood block several
times, immersing the bearings in solvent between
the blows to jar loose and wash old particles of
hardened grease from bearings. Repeat this opera­
tion until bearings are clean. Bearings can be dried
using compressed air but do not spin the bearings.
After cleaning, oil the bearings with engine oil. Insert nut with one pair of slots in line with the cotter pin
the bearing into its appropriate cup, apply pressure
to the bearing while rotating it to test them for pitting
and roughness. Replace all worn or defective bear­
ings. If bearing shows signs of pitting or roughness
they should be replaced. Bearings must be replaced
as a set, both the cup and the bearing need to be
replaced at the same time. If bearings are suitable
for further use, remove engine oil from bearings us­
ing appropriate solvent and dry bearings. Repack
the bearings using a Multi-Purpose NLGI. Grade 2
EP Grease such as Mopar or equivalent, and place
them in a clean covered container until ready for
installation. If a bearing packer is not available, hand
pack grease into all cavities between bearing cage
and rollers.
(6) If bearings and cups are to be replaced, remove
cups from the drum or hub using a brass drift or
suitable remover.
(7) Replace bearing cups with appropriate installing
tool.
(8) Install inner bearing in grease coated hub and
bearing cup, and install new grease seals using the
appropriate seal installer.
(9) Coat hub cavity and cup with grease.
(10) Before installing hub or drum assembly, in­
spect stub axle and seal surface for burrs or rough­
ness, and smooth out all rough surfaces.
(11) Coat the stub axle with Multi-Purpose NLGI,
Grade 2 EP grease such as Mopar or equivalent.
(12) Carefully slide the hub of drum assembly onto
the stub axle. Do not drag seal or inner bearing over
the threaded area of the stub axle.
(13) Install outer bearing, thrust washer and nut.
(14) Tighten the wheel bearing adjusting nut to 27
to 34 N-m (240 to 300 in. lbs.) while rotating hub or
drum assembly. This seats the bearings.
(15) Back off adjusting nut 1/4 turn (90°) then tighten
adjusting nut only finger tight.
(16) Position the nut lock over the bearing adjusting
hole in the stub axle, and install cotter pin.
(17) Install the grease caps and the wheel and tire
assemblies. Tighten wheel stud nuts to 115 N-m (85 ft.
lbs.) on all models, reinstall wheel covers if so equipped.
 ANTI-LOCK BRAKE SYSTEM BENDIX ANTI-LOCK 10 AS BODY FWD/AWD
INDEX
Page Page
Anti-Lock Brake System Components ....................... 52 Major Components (Fig. 1) .......................................... 50
Anti-Lock Brake System Definitions........................... 50 Mechanical Diagnostics and
Anti-Lock Operation and Perform ance....................... 50 Service Procedures .................................................... 66
Anti-Lock System Relays and Warning Lamps ........ 59 Normal Braking System Function ............................... 50
Computer System Service Precautions ..................... 65 On-Car ABS Service ...................................................... 67
Controller Anti-Lock Brake (CAB) ............................... 58 Specifications ................................................................. 79
Diagnostic Connector .................................................... 59 System Diagnosis ...................................................... .... 64
Electronic Components ................................................ 75 System Diagnostic Features ........................................ 67
General Information ...................................................... 49 System Self-Diagnostics................................................ 51
General Service Precautions ....................................... 65 Vehicle Performance...................................................... 51
Hydraulic Circuits and Valve Operation ..................... 61 Warning Systems Operation.......................................... 51

GENERAL INFORMATION Lock Braking is desirable because a vehicle which is

stopped without locking the wheels will retain direc­
The purpose of the Anti-Lock Brake System (ABS) tional stability and some steering capability. This al­
is to prevent wheel lock-up under heavy braking con­ lows the driver to retain greater control of the vehicle
ditions on virtually any type of road surface. Anti- during heavy braking.

DISC BRAKES
9105-101

Fig. 1 Four-Wheel Anti-Lock Brake System

ANTI-LOCK BRAKE SYSTEM DEFINITIONS hydraulic assembly reservoir., and pressurizes it for
storage in two accumulators for power assist and Anti-
In this section of the manual several abbreviations Lock braking.
are used for the components that are in the Anti-Lock
Braking System They are listed below for your reference. ANTI-LOCK OPERATION AND PERFORMANCE
• CAB—Controller Anti-Lock' Brake
• ABS—Anti-Lock Brake System The ABS represents the current state-of-the-art in
• PSI—Pounds per Square Inch (pressure) vehicle braking systems and offers the driver increased
safety and control during braking. This is accomplished
• WSS—Wheel Speed Sensor
by a sophisticated system of electrical and hydraulic
components. That differ from conventional vacuum
NORMAL BRAKiNi SYSTEM FUNCTION
boosted hydraulic actuation systems. As a result, there
are several performance characteristics that may at
Under normal braking conditions, the ABS System
first seem different but should be considered normal.
functions much the same as a' standard brake system
These characteristics are discussed below.More tech­
with a diagonally split master cylinder. The primary
nical details are discussed further in this section.
difference is that power assist is provided by hydrau­
lic power assist instead of the conventional vacuum
PEDAL FEEL
assist.
The ABS System utilizes hydraulic power assist for
If" a wheel locking tendency is noticed during a
both normal power assisted braking and to provide a
brake application, the system will enter Anti-Lock
source of high pressure hydraulic fluid during Anti-
mode. During Anti-Lock braking, hydraulic pressure
Lock Braking. In general, pedal feel will be similar to
in the four wheel circuits is modulated to prevent any
that of a conventional vacuum boosted brake system.
wheel from locking. Each wheel is designed with a set
If during an Anti-Lock stop additional force is applied
of electrical valves and hydraulic line to provide mod­
to the brake pedal, or the brake pedal is released and
ulation, although for vehicle stability, both rear wheel
reapplied rapidly, the driver may notice a very hard
valves receive the same electrical signal. The system
pedal feel. This is due to isolation of the master cylin­
can build, hold or reduce pressure at each wheel, de­
der during A.B.S. operation as wheel brake pressure
pending on the signals generated by the wheel speed
is fed from the hydraulic booster.
sensors (WSS) at each wheel and received at the
Controller-Anti-Lock Brake (CAB).
ANTI-LOCK OPERATION
During Anti-Lock Braking, brake pressures are mod­
MAJOR COMPONENTS (FIG.1)
ulated by cycling electric valves. The cycling of these
valves can be heard as a series of popping or ticking
The following is a list of major system components.
noises. In addition, the cycling may be felt as a pulsa­
Details of all components can be found later in this
tion in the brake pedal, although no pedal movement
section.
will be noticed. If Anti-Lock operation occurs during
hard braking, some pulsation may be felt in the vehi­
HYDRAULIC ASSEMBLY
cle body due to fore and aft movement of the suspen­
The Hydraulic Assembly provides the function of an
sion as brake pressures are modulated.
integral master cylinder and hydraulic booster assem­
Although ABS operation is available at virtually all
bly and contains the wheel circuit valves used for
vehicle speeds. It will automatically turn off at speeds
brake pressure modulation.
below 3 to 5 mph. Therefore wheel lock-up may be
perceived at the very end of an Anti-Lock stop and
WHEEL SPEED SENSORS
should be considered normal.
A Wheel Speed Sensor is located at each wheel to
transmit wheel speed information to the Controller
TIME NOISE & MARKS
Anti-Lock Brake (CAB).
Although the ABS system prevents complete wheel
lock-up, some wheel slip is desired in order to achieve
CONTROLLBR-ANTI-LOCK Brake (CAB)
optimum braking performance. During brake pres­
The (CAB) is a small control computer which re­
sure modulation, as brake pressure is increased, wheel
ceives wheel speed information, controls Anti-Lock
slip is allowed to reach up to 30%. This means that
operation and monitors system operation.
the wheel rolling velocity is 80% less than that of a
free rolling wheel at a given vehicle speed. This slip
PUMP/MO TOR ASSEMBLY
may result in some tire chirping, depending on the
The Pump/Motor Assembly is an electrically driven
road surface. This sound should not be interpreted as
pump that takes low pressure brake fluid from the
total wheel lock-up.
 . Complete wheel lock-up normally leaves black tire
marks on dry payment. However, Anti-Lock Braking
will not leave dark black tire marks since the wheel
never reaches a locked condition. Tire marks may
however be noticeable as light patched marks.
VEHICLE PERFORMANCE
Anti-Lock Brakes provide thfe driver with some steer­
ing control during hard braking. However there are
conditions where the system does not provide any
benefit. In particular, hydroplaning is still possible
when the tires ride on a film of water, resulting in the
tire leaving the road surface rendering the vehicle
virtually uncontrollable. In addition, extreme steering
maneuvers at high speed or high speed cornering
beyond the limits of tire adhesion to the. road surface
may cause vehicle skidding, independent of vehicle
braking. For this .reason, the ABS system is termed
Anti-Lock instead of Anti-Skid.
One of the significant benefits of the ABS system is
that of steering control during hard braking or during
braking on slippery surfaces. It is therefore possible to
steer the vehicle while braking on virtually any road
surface.
SYSTEM SELF-DIAGNOSTICS
The ABS system has been designed with Self Diag­
nostic Capability. There are two self checks the sys­
tems performs every time the vehicle is started. First,
when the key is turned on the system performs an
electrical check called Start-Up Cycle. During this
check, the Brake Wattling Lamp and the Anti-Lock
Warning Lamp are illuminated. Then turned off at
the end of the test, after about 1 to 2 seconds. As soon
as the vehicle reaches a speed of about 3 to 4 miles per
hour. The system performs a functional check called
Drive-Off. During Drive-Off. hydraulic valves are ac­
tivated briefly to test their function. Drive-Off can be
detected as a series of rapid clicks upon driving off the
first time the car is started. If the brake pedal is
applied during Drive-Off, the test is by-passed. Both
of these conditions are a normal part of the system
self test. Most fault conditions will set an ABS Fault
Code in the (CAB), which can be retrieved to aid in
fault diagnosis. Details can be found in Diagnosis
Section.
WARNING SYSTEMS OPERATION
The ABS system uses two methods for notifying the
driver of a system malfunction. These include the
standard Red Brake Warning Lamp and an amber
Anti-Lock Warning Lamp, both located in the instru­
ment cluster. The purpose of these two lamps are
discussed in detail below.
BRAKE WARNING LAMP
■The Red Brake Warning Lamp, located in the in­
strument cluster, will Turn On to warn the driver of
brake system conditions which may result in reduced
braking ability. The lamp is also turned on when the
parking brake is not fully released. Conditions which
may cause the Brake Warning Lamp to Turn On
include: .
• Parking brake not fully released. If the parking
brake is applied or not fully released. The switch on
the parking brake pedal assembly will ground the
Brake Warning Lamp circuit and cause the lamp to
turn on. On vehicles equipped with mechanical in­
strument clusters, the Anti-Lock Lamp will turn on if
the vehicle is driven above 3 miles per hour with the
Parking Brake applied.
• Low brake fluid. The fluid level sensor in the hy­
draulic assembly reservoir will ground the Brake Warn­
ing Lamp circuit if low brake fluid level is detected. In
addition, ABS will be deactivated above 3 miles per
hour and the Anti-Lock Warning Lamp will be illumi­
nated. If the vehicle is equipped with EV1C, a low
fluid condition will also cause the Low Brake Fluid
message to appear.
• Low accumulator pressure. In the event of low accu­
mulator pressure, the dual function pressure switch in
the hydraulic assembly will signal the (CAB) to ground
the Brake Warning Lamp circuit and cause the lamp
to turn on. Low accumulator pressure may result in
loss of power assist.
• Hydraulic assembly or (CAB) faults. The hydraulic
assembly or (CAB) may turn on the Brake Warning
Lamp if certain faults are detected in either the hy­
draulic assembly or the (CAB), or in the normal brake
system.
• Bulb check. As a bulb check, the Brake Warning
Lamp will illuminate whenever the ignition switch is
placed in the crank position.
Illumination of the red Brake Warning Lamp may
Indicate reduced braking ability. A vehicle that has
the Brake Warning Lamp ON should not be driwen
except to perform diagnostic procedures described
In Section 2 of this manual, lo s t conditions that
turn m the red Brake Warning Lamp will also turn
m the Anti-Lock Warning Lamp, conseqyentiy disa­
bling the anti-lock function.
AMTbLOGK WARNING LAMP
The Anti-Lock Warning Lamp is located in the in­
strument cluster and is amber in color. The Anti-Lock
Warning Lamp is illuminated when the (CAB) detects
a condition which results in a shutdown of Anti-Lock
function. The Anti-Lock Warning Lamp is normally
on until the (CAB) completes its self tests and turns
the lamp off. For example, if the (CAB) is discon­
nected, the lamp is on.
 Display of the ANTI-LOCK warning lamp without
the red BRAKE warning lamp Indicates only that
Anti-Lock function has been disabled. Power assisted
normal braking is unaffected.
NORMAL OPERATION OF WARNING LAMPS
With the ignition in the Crank position, the BRAKE
warning lamp will turn on as a bulb check. The Am­
ber Anti-Lock Warning Lamp will turn on for as little
as 1 second to as long as 30 seconds.
If the car has not been started for several hours, for
example after sitting overnight. The Red Brake Warn­
ing Lamp and the Amber Anti-Lock Warning Lamp
may both be turned on for as long as 60 seconds after
turning the ignition on. This condition is caused by
the loss of accumulator charge when the vehicle is
parked for extended periods, particularly in cold
weather. When the key is then turned on. The Pump/
Motor assembly must recharge the hydraulic accumu­
lator to its normal operating pressure. As recharging
is completed, both warning lamps will remain on until
LEFT REAR HYDRAULIC BLADDER
PROPORTIONING VALVE ACCUMULATO R
accumulator pressure reaches about (1,000 psi). Both
lamps should remain off at all other times, indicating
normal operation.
ANTI-LOCK BRAKE SYSTEM COMPONENTS
The following is a detailed description of the Anti-
Lock Brake System components. For information on
servicing the other Non-ABS related components that
may be refered to in this section. See the Standard
Brakes Section which refers to the specific component.
HYDRAULIC ASSEMBLY
The ABS system uses an integral Hydraulic Assem­
bly (Fig.2) which includes a Booster/Master Cylinder,
Modulator, Hydraulic Bladder Accumulator and Fluid
Reservoir. The Hydraulic Assembly is located on the
dash panel cowl on the drivers side of the vehicle. The
following is a description of the components which
make up the Hydraulic Assembly.
FLUID LOW
RESERVOIR PRESSURE
TUBE

TRANSDU CERS AND

SWITCHES CONNECTOR

MODULATOR
CONNECTOR

BOOST PRESSURE
TRANSDUCER

DUAL
FUNCTION
PRESSURE RIGHT REAR DIFFERENTIAL MASTER
SWITCH PROPORTIONING VALVE PRESSURE SWITCH CYLINDER 9105-102

Fig.2 Hydraulic Assembly

FLUID RESERVOIR
A one piece Fluid Reservoir is attached to the hy­ PRECHAiGID ACCUMULATOR
draulic assembly with rubber seals and 3 retaining BRAKE SYSTEM PRESSUiE — 200© PSi
pins. The Fluid Reservoir (Fig.2) is internally sepa­
rated into three fluid sections. The majority of the
brake fluid is contained in the Fluid Reservoir and
hydraulic bladder accumulator (Fig.2) Additional fluid
is contained in the pump/ motor assembly accumulator.

B o m rm fM A s rm c y l in d e r
The Booster/Master Cylinder portion of the hydray-
lic assembly is an integral component and should
newer be disassembled. The Booster/Master Cylinder
uses a diagonally split configuration during normal
braking. The two circuits are hydraulically isolated so
a leak or malfunction in one circuit will allow contin­
ued braking ability in the other.
When force is applied to the brake pedal, the input HYDRAULIC BLADDER
pushrod applies force to the boost control valve. As ACCUMULATOR
the boost control valve is moved, it allows the pressur­
ized fluid from the accumulator to flow into the mas-' 9105-12
ter cylinder booster chamber. The pressure generated
in the booster is directly proportioned to the brake Pig. 3 Hydraulic-fluid Accumulator
pedal force exerted by the driver. This pressure in the
booster servo in turn applies pressure to the primary DUAL FU NCTION P H E S S m E SW ITC H
master cylinder piston which in turn applies pressure The Dual Function Pressure Switch is located on
to the secondary master cylinder piston. The pressure the bottom of the hydraulic assembly and monitors
generated in the primary and secondary circuits are Accumulator Pressure. The primary function is to con­
used to apply the brakes during normal braking. trol operation of the Pump/Motor assembly and thus
maintain proper accumulator operating pressure. When
WARNING; THE HYDRAULIC ACCUMULATORS CON­
accumulator pressure falls to. or,below 11,082 kPa
TAIN BRAKE FLUID AND NITROGEN GAS AT HIGH
(1600 psi,) the Pump/Motor switch (internal to the
PRESSURE. CERTAIN PORTIONS OF THE BRAKE
dual function pressure switch) will close. This pro­
SYSTEM ALSO CONTAIN BRAKE FLUID AT HIGH
vides a ground,-through Pin 1 of the Transducer and
PRESSURE. REMOVAL OF DISASSEMBLY MAY
Switch 10 way electrical connector to the Pump/Motor
RESULT IN PERSONAL INJURY AND IMPROPER
relay coil. The energized coil pulls the relay contacts
SYSTEM OPERATION. REFER TO THE APPROPRI­
closed,,, providing battery voltage to run the Pump/
ATE SERVICE MANUAL FOR PROPER SERVICE
Motor. When Accumulator Pressure reaches 13,790
PROCEDURES.
kPa (2,000 psi,) the switch opens, de-energizing the
Pump/Motor Relay which turns off the Pump/Motor.
H YD RAU LIC BLADDER AC CU m U LATO m
NOTE: THE (CAB) DOES NOT REGULATE OR CON­
A Hydraulic Bladder Accumulator is used to store
TROL ACCUMULATOR PRESSURE. .
brake fluid at high pressure. The pressurized fluid is
The second purpose of, the Dual Function Pressure
used for Anti-Lock operation and for power assisted
Switch is to provide a signal to the (CAB) when the
normal braking. The accumulator uses an elastomer
Accumulator Pressure falls below 6,895 kPa (1,000
bladder configuration with a nitrogen pre-charge of
psi). A Warning Pressure Switch, internal to the Dual
about 6,895 kPa (1,000 psi.) With no brake fluid in
Function Pressure Switch, is normally closed above
the system, the nitrogen gas pre-charge applies ap­
6,895 kPa (1,000 psi.) This sends a ground signal to
proximately 6,895 kPa (1,000 psi.) to one side of the
pin 17 at the (CAB). At or below 6,895 kPa (1,000 psi.)
diaphragm (Fig.3)
the Warning Pressure Switch opens. Internally, the
Under normal operation, the Pump/Motor assembly
(CAB) (pin 17) detects 12 volts and thus low pressure.
charges the accumulator to an operating pressure of
At this warning pressure, the (CAB) will disable the
between 11,032 and 13,790 kPa (1600 psi to 2,000
Anti-Lock Braking functions, light the Red Brake
psi.) As pressurized brake fluid enters the accumula­
Warning Lamp and the Amber Anti-Lock Warning
tor, pushing against the opposite side of the diaphragm,
Lamp. After two minutes of continuous detection, a
the nitrogen gas is compressed and increases in
low accumulator fault is stored.
pressure.
Grounding for the Dual Function Pressure Switch is
 Dual Function Pressure Switch Wiring
provided through Pin 1 of the Transducer and Switch 10
way electrical connector and the Modulator Assembly.
PRESSURE TRANSDUCERS
Two Pressure Transducers are used for brake sys­
tem fault detection. Both transducers generate a volt­
age signal (between 0.25 volts and 5.0 volts) which is
proportional to pressure. These signals are compared
by the (CAB) and used to detect brake system faults
that would require Anti -Lock Braking to be disabled.
The Boost Pressure Transducer is mounted on the
bottom of the hydraulic assembly, see (Fig. 2) and
monitors booster servo pressure. The Primary Pres­
sure Transducer is mounted on the left side of the
hydraulic assembly and monitors primary master cyl­
inder pressure.
DIFFERENTIAL PRESSURE SWITCH
A non-latching Differential Pressure Switch is used
to detect a pressure difference greater than 2,068 kPa
(300 psi.) between the primary and secondary master
cylinder hydraulic circuits. If detected, the Differen­
tial Pressure Switch grounds the output of the pri­
mary pressure transducer (circuit B-218). This results
in a 0.0 volt signal from the Primary Pressure Trans­
ducer which is sensed by the (CAB) as a differential
pressure fault. The (CAB) will then light the BRAKE
warning lamp and the Anti-Lock Warning Lamp and
disable the Anti-Lock function, (see Fig.2) for location
of the differential pressure switch.
 PRESSURE SWITCH AND PRESSURE TRANSDUCER WIRING

B218-PRIMARY PRESS./DIFF. PRESS.

B219-BOOST PRESSURE >105-104

PROPORTIONING VALVES PUMP/MOTOR ASSEMBLY

The ABS system uses screw-in Proportioning Valves
in place of the conventional Height Sensing Propor­
tioning Valves. Each rear brake circuit has its own
screw-in Proportioning Valve which is attached to the
rear brake outlet ports of the hydraulic assembly (see
Fig.2). These valves lim it brake pressure to the rear
brakes after a certain brake pressure is reached. This
improves front to rear brake balance during normal
braking.
FILTERS-SERVICEABILITY
There is a screen filter in each of the two master
cylinder fill ports. There is also a low pressure filter
for the pump/motor. The filter is integral to the Pump/
Motor low pressure hose.
FLUID LEVEL SWITCH
A Low Fluid Switch is located in the hydraulic
assembly fluid reservoir, (see Fig. 2). The switch con­
sists of a float and magnetic reed switch which closes
when low fluid is detected. The Low Fluid Switch is
used as an input, to the BRAKE warning lamp, the
(CAB), and the EVIC (if so equipped). When a low
fluid condition exists the switch will close, grounding
the low fluid circuit and illuminating the BRAKE
warning lamp. The (CAB) will disable the Anti-Lock
Function and light the Anti-Lock Warning Lamp if
the vehicle is in motion above 3 mph. If the vehicle is
not in motion,the Anti-Lock Warning Lamp will NOT
be lit.
The Pump/Motor Assembly is mounted to the trans­
axle below the hydraulic assembly,(see Fig.4). Inte­
gral to the Pump/Motor Assembly is an accumulator
using a sliding piston configuration with a nitrogen
pre-charge of 3,172 kPa (460 psi.) The Pump/Motor is
an electrically driven pump which takes low pressure
brake fluid from the hydraulic assembly fluid reser­
voir and pressurizes it. The pressurized fluid is then
stored in the piston accumulator and hydraulic blad­
der accumulator for power assist and Anti-Lock Brak­
ing. Operation of the Pump/Motor is controlled by the
Dual Function Pressure Switch through the Pump/
Motor Relay. Rubber isolators are used to mount the
pump to its bracket for noise isolation. The Pump/
Motor Assembly is connected to the Hydraulic Assem­
bly with a low pressure return hose and a high pressure
hose. A filter is located in the low pressure return
line.

HEAT SHIELD
Flg.4 Pump/Motor Assembly And Heat Shield
WHEEL SPEED SENSORS
One Wheel Speed Sensor (WSS), is located at each
wheel (Fig.5, 6 and 7) and sends a small (AC) signal
to the control module (CAB). This signal is generated
by magnetic induction. When a toothed sensor ring
Tone Wheel passes a stationary magnetic sensor Wheel
Speed Sensor. The (CAB) converts the (AC) signal
generated at each wheel into a digital signal. If a
wheel locking tendency is detected, the (CAB) will
then modulate hydraulic pressure to prevent the
wheel(s) from locking.
Fig.5 Front Wheel Speed Sensor FWD!AWD
The front Wheel Speed Sensor is mounted to a boss
on the steering knuckle, for both the Front Wheel
Drive and All Wheel Drive applications. The Tone
Wheel is part of the outboard constant velocity joint.
The Rear Wheel Speed Sensor, on Front Wheel Drive
applications. Is mounted to the rear brake Backing
Plate (Fig.6). And the rear Tone Wheel is an integral
part of the rear wheel brake drum.
The All Wheel Drive, rear wheel speed sensor is
mounted to the rear carrier axle (Fig.7) The Rear
Tone Wheel on this application is part of the outboard
constant velocity joint.
The speed sensor air gap all applications is NOT
adjustable.
The four, Wheel Speed Sensors are serviced individ­
ually. The Front Wheel Drive and All Wheel Drive
Tone Wheels are serviced as an assembly with the
outboard constant velocity joint. The Front Wheel Drive
rear Tone Wheels are serviced as an assembly with
the rear brake drum hub.
Correct Anti-Lock System operation is dependent
on wheel speed signals from the wheel speed sensors.
The vehicles’ wheels and tires must all be the same
size and type to generate accurate signals. In addi­
tion, the tires must be inflated to the recommended
pressures for optimum system operation. Variations
in wheel and tire size or significant variations in
inflation pressure can produce inaccurate wheel speed
signals.
FRAME SUPPORT WHEEL SPEED SENSOR FRAME RAIL
Fig.6 Rear Wheel Speed Sensor FWD
LOOKING INTO HYDRAULIC UNIT
lOUTING CUP
BRAKE MOUNTING
DRUM BRACKET 9105-106
Fig.7 ftear Wheel Speed Smnsm AWD
CONTROLLER ANTI-LOCK BRAKE (CAB)
The Anti-Lock Brake Controller is a sr^all micro­
processor based device which monitors the D r a k e sys­
tem and controls th e ' system while it functions in
Anti-Lock Mode. The CAB is' located under the bat­
tery tray (Fig.8) and uses a 60-way system connector.
The power source f o r th%CAB is through,the ignition
switch to pin 60 of the controller. With the ignition in
the RUN or ON position. THE FRONT WHEEL DRIVE
SHIELD SBEC
CONTROLLER IS DIFFERENT FROM THE ALL WHEEL
DRIWE CONTROLLER. IF THE CONTROLLER NEEDS
TO BE REPLACED BE SURE THE CORRECT CON­
TROLLER IS USED. THE CONTROLLER ANTi-LOCK
BRAKE IS NOT ON THE CCD BUS
The primary functions of the (CAB) are:
• (1) Detect wheel locking tendencies.
• (2) Control fluid modulation to the brakes while in
Anti-Lock mode.
• (3) Monitor the system for proper operation.
• (4) Provide communication to the DRB II while in
diagnostic mode.
The (CAB) continuously monitors the speed of each
wheel, through the signals generated at the Wheel
Speed Sensors, to determine if any wheel is beginning
to lock. When a wheel locking tendency is detected,
the-(CAB) will isolate the master cylinder from the
wheel brakes. This is done by activating the Isolation
¥alves. -The (CAB) then commands the appropriate
Build or Decay valves to modulate brake fluid pres­
sure in some or all of the hydraulic circuits. The fluid
used for modulation comes from the booster servo cir­
cuit. The (CAB) continues to control pressure in indi­
vidual hydraulic circuits until a locking tendency is
no longer present
The (ABS) system is constantly monitored by the
(CAB) for proper operation. If the (CAB) detects a
fault, it can disable the Anti-Lock function. Depend­
ing on the fault, the(CAB) will light one or both of the
warning lamps.
The (CAB) contains a System Diagnostic Program
which triggers the indicator lights when a system
fault is detected. Faults are stored in a diagnostic
program memory. There are 19 fault codes which may
be stored in the (CAB) and displayed through the
DRB II. These fault codes will remain in the (CAB)
memory even after the ignition has been turned off.
These fault codes will remain in memory until they
are cleared with the DRB II, or automatically after
(50) ignition switch on/off cycles.

CONTROLLER ANTI-LOCK BRAKE (INPUTS)

• Four wheel speed sensors.
• Boost pressure transducer.
• Primary pressure transducer.
SPEED CONTROL
• Low fluid level switch.
SERVO • Differential pressure switch.
• Parking brake switch.
• Dual function pressure switch (warning pressure only)
• Stop lamp switch.
FRAME RAIL • Ignition switch.
60 WAY
• System relay voltage.
CONNECTOR ATTACHING BOLTS (3) 9105-107 • Ground.
• Low Accumulator
Fig.8 Location Controller Anti-Lock Brake (CAB)
C O N W M L t m ANTI-LOCK BRAKE fOWTPUTSJ
• Ten modulator valves-3 decay, 3 build and 4 isolation.
• BRAKE warning lamp.
• Anti-Lock Warning Lamp.
• System relay actuation.
• Diagnostic communication.
DIAGNOSTIC CONNECTOR
The Bendix Anti-Lock system diagnostic connector
is located in the fuse box panel. Which is located on
the bottom portion of the dash, left of the steering
column. The diagnostics connector is a 8 way, blue
connector.
ANTI-LOCK SYSTEM RELAYS AND WARNING LAMPS
PUMP/MO TOR RELAY
Pump/Motor power is supplied by the Pump/Motor
Relay. The relay is located behind the left head light.
The relay coil is energized by a ground from the Dual
Function Pressure Switch. See (Fig.9) for relay location.
The (CAB) by itself, also has the ability to turn on
the Anti-Lock Warning Lamp. The (CAB) can turn on
the Anti-Lock Warning Lamp by providing a ground
at pin 15.
ANTI-LOCK WARNING LAMP ON
System Relay and Anti-Lock Warning Lamp Relay
De-Energized.
When the Anti-Lock Warning Lamp is on, there is
no voltage flow from the (CAB) at pin 57. The system
relay coil is NOT energized. No current flows to pins
47 and 50 (modulator valve power), or to the Anti-Lock
Warning Lamp relay coil. Thus, the Anti-Lock Warn­
ing Lamp Relay is not energized. The Anti-Lock Warn­
ing Lamp is grounded through the Anti-Lock Warning
Lamp relay contacts. The Anti-Lock Warning Lamp is
illuminated.

SYSTEM RELAY
The (ABS) Modulator Valves and Anti-Lock Warn­
ing Lamp Relay are controlled through a System Re­
lay. The System relay is located behind the left
headlight (See Fig.9) The system relay provides power
to the (CAB) for modulator valve operation (pins 47
and 50) after the start-up cycle when the ignition is
turned on.

ANTI-LOCK WARNING LAMP RELAY

The Anti-Lock Warning Lamp is controlled by the
Anti-Lock Warning Lamp Relay. (See Fig.9) for loca­
tion behind the left headlight. With the relay de­
energized, the lamp is lit. When the system relay is
energized by the (CAB), the Anti-Lock Warning Lamp
relay is energized, and the lamp is turned off. Thus,
the lamp will be lit if the (CAB) is disconnected or if a
system fault causes (ABS) function to be turned off, or
if the system relay fails open.

ANTI-LOCK WARNING LAMP OFF

System Relay (norrrially open) and Anti-Lock Warn­
ing Lamp Relay (normally closed) Energized. Fig.9 Pump/Motor and Anti-Lock System Relays
When the (CAB) energizes the system relay by
providing 12 volts to pin 57. The voltage flow in the
coil closes the systeiii relay. Current is then provided
to pins 47 and 50 of the (CAB) to provide power to the
modulator valves. This voltage also energizes the Anti-
Lock Warning Lamp Relay coil. The current flow in
the yellow light relay coil opens the Anti-Lock Warn­
ing Lamp Relay Switch. This breaks the ground path
to the Anti-Lock Warning Lamp and the lamp is turned
off.
I

9105-109
HYDRAULIC CIRCUITS AND VALVE OPERATION
Through the following operation descriptions and
diagrams. The function of the various hydraulic con­
trol valves in the ABS system will be described. The
fluid control valves mentioned below, control the flow
of pressurized brake fluid to the wheel brakes during
the different modes of Anti-Lock Braking.
For explanation purposes we will assume all speed
sensors are sending the same wheel speed informa­
tion, requiring the same modulation at the same rate.
NORMAL BRAKING
ISOLATION VALVES
Open to primary and secondary master cylinder fluid
supply (Fig.10)
FLUID
LEVEL
SWITCH
RESERVOIR
DECAY AND BUILD VALVES
Closed (Fig.10)
The brake pedal is applied. The travel of the brake
pedal closes primary, secondary and booster servo cir­
cuits from fluid supply at the fluid reservoir. Brake
fluid from the primary and secondary circuits flows
through the open isolation valves and applies the wheel
brakes. Fluid from the booster servo circuit does not
flow to the wheel brakes. The fluid flow is blocked by
the closed build valves and check valves.
POWER ASSIST
The boost control valve shuttles between its three
positions to provide power assisted braking (Fig.10).
BOOST
CONTROL
VALVE

xtfr
I...

i 1 79 61
.
1
i k sv j PISTON (..s.>

ACC 'M)
pu m p / m o t o r
BLADDER
ACCUMULATOR

PROP
VALVE

ISOLATION
VALVE
9105-18

f l f . f i Normal Braking - Hydraulic Control

 FLU ID
LEVEL
SWITCH
p J U L .

W
mk ¥ mmk
jprm
initial
m ty lM m .c y l. m
PUMP/MOTOR

PROP
VALVE

9105-19

Fig.11 Build Pressure - Hydraulic Control

ABS BRAKING-BUILD PRESSURE POWER ASSIST

ISOLATION VALVES
Closed, isolating wheel brakes from master cylinder
primary and secondary fluid supplies and open to
booster servo circuit pressure through open build valves
(Fig. 11)
DECAY VALVES
Closed (Fig. 11)
BUILD VALVES
Open, allowing booster servo circuit pressure to flow
to wheel brakes through the isolation valves (Fig 11).
The boost control valve shuttles between its three
positions to provide power assisted braking (F ig.ll).
ABS BRAKING-HOLD PRESSURE
ISOLATION VALVES
Closed, isolating the wheel brakes from the master
cylinder primary and secondary fluid supplies. Build
and decay valves are closed preventing any fluid from
reaching the open isolation valves (Fig. 12).
DECAY AND BUILD VALVES
Closed (Fig. 12).
 FLUID
LEVEL
SWITCH

9 9
w r g p u r p PISTON \
M.CYL. m DUAL
FUNCTION >aa^
ACC.
(M )
_n _ PRESSURE \ PUMP/MOTOR
DIFFERENTIAL jP
fllO O S T E t% SWITCH BLADDER
p rfs s iirf
PRESSURE ^ / \S E iV O ACCUMULATOR
SWITCH BOOST \

PROP
VALVE

9105-17

Fig.12 Hold Pressure - Hydraulic Control

ABS BRAKING-DECAY PRESSURE DECAY VALVES

ISOLATION VALVES
Closed, isolating the wheel brakes from the master
cylinder primary and secondary fluid supplies (Fig.13)
Open, allowing release of fluid pressure through
decay valve to the fluid reservoir (Fig.13)
BUILD VALVE
Closed, blocking booster servo circuit fluid to wheel
brakes (Fig.13).
 PROP
VALVE
ISOLATION '
VALVE BUILD
s /
1h ® ......
pCA ¥_
jp j
* I
PROP I ISOLATION
\
VALVE ' VALVE
9105-20

Fig. 13 Decay Pressure - Hydraulic Control

SYSTEM DIAGNOSIS GENERAL INFORMATION

WARNING: SOME OPERATIONS IN THIS SECTION
REQUIRE THAT HYDRAULIC TUBES, HOSES AND
FITTINGS BE DISCONNECTED FOR INSPECTION OR
TESTING PURPOSES. THIS BRAKE SYSTEM USES
A HYDRAULIC ACCUMULATOR WHICH, WHEN FULLY
CHARGED, CONTAINS BRAKE FLUID AT HIGH PRES­
SURE. BEFORE DISCONNECTING ANY HYDRAULIC
TUBE, HOSE OR FITTING. BE SURE THAT THE
ACCUMULATOR IS FULLY DE-PRESSURIZED AS
DESCRIBED IN THIS SECTION. FAILURE TO DE-
PRESSURIZE THE ACCUMULATOR MAY RESULT IN
PERSONAL INJURY AND/OR DAMAGE TO PAINTED
SURFACES.
CAUTION: Certain components of the Anti-Lock Brake
System (ABS) are not intended to be serviced indi­
vidually. Attempting to remove or disconnect certain
system components, may result in personal injury
and/or improper system operation. Only those com­
ponents with approved removal and installation pro­
cedures in this manual should be serviced.
This section contains information necessary for di­
agnosis of mechanical conditions which can affect the
operation of the Bendix Anti-Lock 10 Brake System.
Specifically, this section should be used to help diag­
nose mechanical conditions which result in any of the
following:
CAUTION: Review this entire section prior to per­
forming any mechanical work on a vehicle equipped
with the Bendix Anti-Lock 10 brake system. For in­
formation on precautions pertaining to potential com­
ponent damage, vehicle damage and personal injury.
(1) Anti-Lock warning lamp illuminated
(2) BRAKE warning lamp on
(3) Lack of Power Assist or Excessive Pedal Travel
(4) Brakes Lock on Hard Application
Diagnosis of conditions which are obviously mechan­
ical in nature. Such as brake noise, brake pulsation,
or vehicle vibration during normal braking. Should be
directed to Group 5 Brakes in the service manual.
This also pertains to problems involving the parking
brake system.
In order to effectively diagnose an Anti-Lock Brake
System (ABS) condition. It is important to read Sec­
tion 1 of this manual, Anti-Lock Brake System De­
scription. And to follow the diagnostic procedures
outlined in this section.
Many conditions that generate customer complaints
may be normal operating conditions, but are judged to
be a problem due to unfamiliarity with the ABS sys­
tem. These conditions can be recognized without per­
forming extensive diagnostic work. Given adequate
understanding of the operating principles and perfor­
mance characteristics of the ABS system. See Section
1 of this manual to familiarize yourself with the oper­
ating principles of the ABS system.
DEFINITIONS
Several abbreviations are used in this manual. They
are presented here for reference.
• CAB—Controller Anti-Lock Brake
• ABS—Anti-Lock Brake System
• PSI—Pounds per Square Inch (pressure)
• WSS—Wheel Speed Sensor
COMPUTER SYSTEM SERVICE PRECAUTIONS
The ABS system uses an electronic control module,
the (CAB). This module is designed to withstand nor­
mal current draws associated with vehicle operation.
However care must be taken to avoid overloading the
(CAB) circuits. In testing for open or short circuits, do
not ground or apply voltage to any of the circuits
unless instructed to do so by the appropriate diagnos­
tic procedure. These circuits should only be tested
using a high impedance multi-meter, special tools or
the DRB II tester as described in this section. Power
should never be removed or applied to any control
module with the ignition in the ON position. Before
removing or connecting battery cables, fuses, or con­
nectors, always turn the ignition to the OFF position.
GENERAL SERVICE PRECAUTIONS
TEST DRIVING ABS COMPLAINT VEHICLES
Most ABS complaints will require a test drive as a
part of the diagnostic procedure. The purpose of the
test drive is to duplicate the condition.
Before test driving a brake complaint vehicle, es­
pecially if the BRAKE warning lamp is on, test the
brakes at low speed to be sure that the car will stop
normally. Remember that conditions that result in
illumination of the BRAKE warning lamp may indi­
cate reduced braking ability. The following proce­
dure should be used to test drive an ABS complaint:
(1) Ignition on. Turn the ignition to the ON position
without starting the car and wait until the BRAKE
warning and ANTI-LOCK warning lamps turn off.
This will allow the pump to charge the accumulator to
operating pressure. If the warning lamp(s) do not turn
off, proceed to step 3.
(2) Ignition off for 15 seconds.
(3) Start car. Wait for displays to return to normal
operating mode before proceeding.
(4) With Shift lever in PARK, slowly depress brake
pedal and release.
(5) Drive vehicle a short distance. During this test
drive, be sure that the vehicle achieves at least 20
mph. Brake to at least one complete stop and acceler­
ate slowly to at least 20 mph.
(6) If a functional problem with the A.B.S. system is
determined while test driving a vehicle refer to the
Bendix Anti-Lock 10 Diagnostics Manual for required
test procedures and proper use of the DRB II tester.
The following are general precautions which should
be observed when servicing and diagnosing the ABS
system and/or other vehicle systems. Failure to ob­
serve these precautions may result in ABS system
damage.
(1) If welding work is to be performed on the vehicle
using an arc welder, the (CAB) should be disconnected
before the welding operation begins.
(2) The (CAB) and hydraulic assembly 10 way con­
nectors should never be connected or disconnected with
the ignition on.
(3) Some components of the ABS system are not
serviced separately and must be serviced as complete
assemblies. Do not disassemble any component which
is designated as non-serviceable.
(4) Always de-pressurize the Hydraulic Accumula­
tor when performing any work which requires dis­
connecting any hydraulic tube, hose or fitting. The
ABS system uses brake fluid at high pressure. Fail­
ure to de-pressurize the accumulator may result in
personal injury and/or damage to painted surfaces.
Brake fluid will damage painted surfaces. If brake
fluid is spilled on any painted surfaces, wash off with
water immediately.
DE-PRESSURIZING HYDRAULIC
ACCUMULATOR
The ABS pump/motor assembly will keep the hy­
draulic accumulator charged to a pressure between
approximately 11,032 and 13,790 kPa (1600 and 2000
psi) anytime the ignition is in the ON position. The
pump/motor assembly cannot run if the ignition is off
or if either battery cable is disconnected.
Unless otherwise specified, the hydraulic accumula­
tor should be de-pressurized before disassembling any
portion of the hydraulic system. The following proce­
dure should be used to de-pressurize the hydraulic
accumulator:
(1) With ignition off, or either battery cable discon­
nected, pump the brake pedal a minimum of 40 times
using approximately 50 pounds of pedal force. A no­
ticeable change in pedal feel will occur when the accu­
mulator is discharged.
(2) When a definite increase in pedal effort is felt,
pump the pedal a few additional times. This will re­
move all hydraulic pressure from the system.
WHEEL SPEED SENSOR CABLES
Proper installation of wheel speed sensor cables is
critical to continued system operation. Be sure that
cables are installed and routed properly. Failure to
install cables in retainers, as shown in Section 3 of
this manual, may result in contact with moving parts
or over extension of cables, resulting in an open circuit.
MECHANICAL DIAGNOSTICS AND SERVICE
PROCEDURES
SPECIAL SERVICE TOOLS
Some diagnostic procedures in this section require
the use of special service tools. Each of these tools is
described below.
DRB II DIAGNOSTIC TESTER
Some of the diagnostic procedures that are explained
in this section require the use of the DRB II DIAG­
NOSTICS TESTER to insure that proper diagnostics
are performed. Refer to those sections for proper test­
ing procedures and the DRB II manual for its proper
operational information.
MST-6163 PRESSURE TESTER (FIG. 1)
Some diagnostic procedures in this manual require
the use of the MST-6163 pressure gauge and adaptor
9105-22
Fig, 1 Pressure Gauge and Adapter Installed on
Hydraulic Assembly
to measure accumulator pressure during certain phases
of operation. The pressure gauge and adaptor should
be installed as follows:
(1) De-pressurize the accumulator by pumping the
brake pedal a minimum of 40 times with the ignition
off, as described in this section.
WARNING: FAILURE TO DE-PRESSURIZE THE AC­
CUMULATOR PRIOR TO PERFORMING THIS OPER­
ATION MAY RESULT IN PERSONAL INJURY AND/OR
DAMAGE TO PAINTED SURFACES.
(2) Remove hydraulic assembly accumulator port
plug, located on right hand side of hydraulic assem­
bly. (See Fig. 1)
(3) Install adaptor in accumulator port and tighten
to 10 N-m (7.5 ft. lbs.) torque.
(4) Install adaptor onto the pressure gauge hose and
tighten the fitting to 15 N-m (11 ft. lbs.) torque.
(5) Install pressure gauge and adaptor assembly
onto the adaptor installed in the hydraulic assembly
accumulator port. Then install the retaining d ip into
the grove on the accumulator port adaptor. MAKE
SURE THAT THE RETAINING CLIP IS INSTALLED
ONTO THE ACCUMULATOR PORT ADAPTOR BE­
FORE REPRESSURIZING THE HYDRAULIC SYSTEM.
WARNING: WHEN REMOVING PRESSURE GAUGE
AND ADAPTOR, BE SURE TO DE-PRESSURIZE THE
HYDRAULIC ACCUMULATOR. TIGHTEN ACCUMULA­
TOR PORT PLUG TO 12 N-m (9 FT. LBS.).
It is not necessary to bleed the hydraulic assembly
after installation and removal of the pressure gauge
unless additional tubes, hoses, or fittings were re­
moved or loosened.
INTERMITTENT FAULTS
As with virtually any electronic system, intermit­
tent faults in the ABS system may be difficult to
accurately diagnose.
Most intermittent faults are caused by faulty elec­
trical connections or wiring. Wheji an intermittent
fault is encountered, check suspect circuits for:
(1) Poor mating of connector halves or terminals not
fully seated in the connector body.
(2) Improperly formed or damaged terminals. All
connector terminals in a suspect circuit should be
carefully reformed to increase contact tension.
(3) Poor terminal to wire connection. This requires
removing the terminal from the connector body to
inspect.
If a visual check does not find the cause of the
problem, operate the car in an attempt to duplicate
the condition and record the Fault Code.
Most failures of the ABS system will disable Anti-
Lock function for the entire ignition cycle even if the
fault clears before key-off. There are a few failure
conditions, however, which will allow ABS operation
to resume during the ignition cycle in which a failure
occurred if the failure conditions are no longer present.
The following conditions may result in intermittent
illumination of the BRAKE warning and/or Anti-Lock
Warning Lamps. All other failures will cause the
lamp(s) to remain on until the ignition switch is turned
off. Circuits involving these inputs to the (CAB) should
be investigated if a complaint of intermittent warning
system operation is encountered.
• Low system voltage. If low system voltage is de­
tected by the (CAB), the (CAB) will turn on the Anti-
Lock Warning Lamp until normal system voltage is
achieved. Once normal voltage is seen at the (CAB),
normal operation resumes.
• Low Brake Fluid. A low brake fluid condition will
cause the RED BRAKE warning lamp to illuminate.
When the fluid sensor again indicates an acceptable
fluid level, the RED BRAKE warning lamp will go
out. This condition may exist during hard cornering
or while driving the vehicle on grades. If the vehicle is
in motion above 3 M.P.H. the AMBER ANTI-LOCK
warning lamp will also be turned on.
• Low Accumulator Pressure. Low Accumulator Pres­
sure will cause both the BRAKE warning and Anti-
Lock Warning Lamps to illuminate. Once normal
operating pressure is achieved, the lamps will extin­
guish and the system will return to normal operation.
Additionally, any condition which results in inter­
ruption of power to the (CAB) or hydraulic assembly
may cause the BRAKJS warning and Anti-Lock Warn­
ing Lamps to illuminate intermittently.
All of the conditions (or faults) mentioed above, can
store a fault code in the (CAB) module.
SYSTEM DIAGNOSTIC FEATURES
SYSTEM SELF DIAGNOSIS
The ABS system is equipped with diagnostic capa­
bility which may be used to assist in isolation of ABS
faults. The features of the diagnostics system is de­
scribed below.
CONTROLLER ANTI-LOCK BRAKE (CAB)
Fault codes are kept in a Non-Volatile memory un­
til either erased by the technician using the DRB II or
erased automatically after 50 ignition cycles (key ON-
OFF cycles). The only fault that will not be erased
after 50 (KEY CYCLES) is the (CAB) fault, see CAB
FAULT. More than one fault can be stored at a time.
The number of key cycles since the most recent fault
was stored is also displayed. Most functions of the
(CAB) and (ABS) system can be accessed by the tech­
nician for testing and diagnostic purposes by using
the DRB II.
START-UP CYCLE
The START-UP CYCLE takes place immediately
after the ignition switch is turned on. It is an electri­
cal check of basic electrical functions such as the sys­
tem relay and anti-lock warning lamp relay. During
this check, the anti-lock warning lamp is lit and then
is turned off at the end of the test. The test takes
approximately 1 - 2 seconds to complete.
DRIVE-OFF CYCLE
The DRIVE-OFF CYCLE takes place when the ve­
hicle reaches about 3 miles per hour the first time
after an ignition reset. During this test, the modula­
tor solenoid valves are activated briefly to test their
function. The DRIVE-OFF CYCLE will be bypassed if
you drive-off with the service brake depressed.
LATCHING VERSUS NON-LATCHING FAULTS
Some faults detected by the (CAB) are latching. The
fault is latched and (ABS) function is disabled until
the ignition switch is reset. Thus (ABS) is disabled
even if the original fault has disappeared. Other faults
are non-latching; any warning lights that are turned
on are only on as long as the fault condition exists. As
soon as the condition goes away. The Anti-Lock Warn­
ing Light is turned off. Although a fault code will be
set in most cases. (Examplerlow accumulator fault will
not be stored for a time of 2 minutes after the fault is
detected).
BENDIX ABS SYSTEMS DIAGNOSTICS
The Bendix Anti-Lock 10 Brake System diagnostics.
Beyond the basic mechanical diagnostics, systems and
components covered earlier in this section, is accom­
plished by the use of the DRB II diagnostic tester. See
testing procedures outlined in the Bendix Anti-Lock
10 Diagnostics Manual for the 1991 M.Y.
Please refer to the above mentioned manual for any
further diagnostic or service procedures that are re­
quired on the Bendix Anti- Lock 10 Brake System.
0N-CAR ABS SERVICE
WARNING: FAILURE TO FULLY DE-PRESSURIZE THE
HYDRAULIC ACCUMULATOR BEFORE PERFORMING
SERVICE OPERATIONS, COULD RESULT IN INJURY
TO SERVICE PERSONNEL AND DAMAGE TO PAINTED
SURFACES. SEE SECTION 2 FOR ADDITIONAL
WARNINGS AND CAUTIONS.
GENERAL SERVICE PRECAUTIONS
The following are general precautions which should
be observed when servicing the Anti-Lock Brake Sys­
tem and/or other vehicle systems. Failure to observe
these precautions may result in Anti-Lock brake sys­
tem damage.
If welding work is to be performed on the vehicle,
using an electric arc welder, the (CAB) connector should
be disconnected during the welding operation.
The (CAB) connector should never be connected or
disconnected with the ignition on.
Many components of the Anti-Lock brake system
are not serviceable and must be replaced as an assem­
bly. Do riot disassemble any component which is not
designed to be serviced.
DE-PRESSURIZING HYDRAULIC
ACCUMULATOR
The pump/motor assembly will keep the hydraulic
accumulator charged to a pressure between approxi­
mately 11,032 and 13,790 kPa (1600 and 2000 psi)
any time that the ignition is in the ON position. The
pump/motor assembly cannot run if the ignition is off
or if either battery cable is disconnected.
Unless otherwise specified, the hydraulic accumula­
tor should be de-pressurized before disassembling any
portion of the hydraulic system. The following proce­
dure should be used to relieve the pressure in the
hydraulic accumulator:
(1) With ignition off, or either battery cable discon­
nected, pump the brake pedal a minimum of 40 times,
using approximately 222 N (50 lbs.) pedal force. A
noticeable change in pedal feel will occur, when the
accumulator is discharged.
(2) When a definite increase in pedal effort is felt,
pump pedal a few additional times. This will remove
all hydraulic pressure from the system.
CHECKING BRAKE FLUID LEVEL
CAUTION: Use only DOT 3 brake fluid, do not use
any fluid which contains a petroleum base. Do not
use a container which has been used for petroleum
based fluids or a container which is wet with water.
Petroleum based fluids will cause swelling and dis­
tortion of rubber parts in the hydraulic brake system
and water will mix with brake fluid, lowering the fluid
boiling point. Keep all fluid containers capped to
prevent contamination.
The hydraulic assembly is equipped with a plastic
fluid reservoir with a filter/strainer in the filler neck.
The Anti-Lock brake system requires that the hy­
draulic accumulator be de-pressurized when checking
the fluid level. To check the brake fluid level, the
following procedure should be used:
(1) With the ignition off, de-pressurize the hydraulic
accumulator by applying the brake pedal approximately
40 times, using a pedal force of approximately 220 N
(50 lbs.). A noticeable change in pedal feel will occur
when the accumulator is de-pressurized. Continue to
apply the pedal several times after this change in
pedal feel occurs.
(2) Thoroughly clean both reservoir caps and sur­
rounding area, prior to cap removal, to avoid getting
dirt into the reservoir.
(3) Inspect the fluid level, see instructions on top of
reservoir (to top of the white screen in front filter/
strainer).
(4) Fill reservoir to top of white screen in filter/
strainer as required. Use brake fluid conforming to
DOT 3 such as Mopar.
(5) Replace reservoir cap.
BLEEDING BRAKE SYSTEM
The Anti-Lock brake system must be bled anytime
air is permitted to enter the hydraulic system, due to
disconnection of brake lines or hoses for service. It is
important to note that excessive air in the brake sys­
tem may set a primary pressure/delta P fault in the
(CAB). Refer to Diagnosis, for further information.
Pressure bleeding and manual bleeding procedures
are used when brake lines or hoses are disconnected.
Also, after the replacement of the hydraulic assembly
or caliper.
During bleeding operations, be sure that the brake
fluid level remains close to the FULL level in the
reservoir. Check the fluid level periodically during
the bleeding procedure and add DOT 3 brake fluid as
required.
PRESSURE BLEEDING (FIG. 1)
The brake lines may be pressure bled, using a stan­
dard diaphragm type pressure bleeder. Only diaphragm
type pressure bleeding equipment should be used to
prevent air, moisture, and other contaminants from
entering the system. The following procedure should
be used for pressure bleeding of the master cylinder
and wheel circuits (Fig.l)
(1) Ignition should be turned off and remain off
throughout this procedure.
(2) De-pressurize the hydraulic accumulator by pump­
ing the brake pedal a minimum of 40 times, as de­
scribed in this section.
WARNING: Failure to de-pressurize hydraulic accu­
mulator, prior to performing this operation, may re­
sult in personal injury and/or damage to painted
surfaces.
(3) Remove both reservoir caps.
(4) Install pressure bleeder adapter, on one reser­
voir port and dummy cap on the other port of the
reservoir (Fig.l)
(5) Attach bleeding equipment to bleeder adapter.
Charge pressure bleeder to approximately 138 kPa
(20 psi).

Fig. 1 Pressure Bleeding Brake System
(6) Connect a transparent hose to the caliper bleed
screw (Fig.2). Submerge the free end of the hose in a
clear glass container, which is partially filled with
clean, fresh brake fluid.
(7) With the pressure bleeder turned on, open the
caliper bleed screw 1/2 to 3/4 turn and allow fluid to
flow into the container. Leave bleed screw open until
clear, bubble-free fluid flows from the hose. If the
reservoir has been drained or the hydraulic assembly
removed from the car prior to the bleeding operation,
slowly pump the brake pedal one or two times while
the bleed screw is open and fluid is flowing. This will
help purge air from the hydraulic assembly. Tighten
bleeder screw to 10 N-m (7.5 ft. lbs.) torque.
(8) Repeat Step 7 at all wheel brakes. Wheel brakes
should be bled in the following order.
a) Left rear.
b) Right rear.
c) Left front.
d) Right front.
(9) After bleeding at all four wheel brakes, remove
the pressure bleeding equipment and bleeder adapter
by closing the pressure bleeder valve and slowly un­
screwing the bleeder adapter from the hydraulic as­
sembly reservoir. Failure to release pressure in the
reservoir will cause spillage of brake fluid, and could
result in injury or damage to painted surfaces.
(10) Using a syringe or equivalent method, remove
excess fluid from the reservoir to bring the fluid level
to full level.
(11) Install the reservoir caps and turn on the igni­
tion to allow the (ABS) pump to charge the accumulator.
MANUAL BLEEDING
Brake lines can be bled, using the manual bleeding
method. Manual bleeding is a two person operation,
one to pump the brake pedal and the other to bleed
each wheel brake. The following procedure should be
used:
Fig.2 Bleeding Brake System
De-pressurizing the hydraulic accumulator is done
by following the steps described below.
(1) Verify that the ignition switch is in the off
position.
(2) Depressurize the hydraulic accumulator by pump­
ing the brake pedal a minimum of 40 times as de­
scribed in this section.
WARNING: FAILURE TO DE-PRESSURIZE HYDRAU­
LIC ACCUMULATOR, PRIOR TO PERFORMING THIS
OPERATION, MAY RESULT IN PERSONAL INJURY
AND/OR DAMAGE TO PAINTED SURFACES.
(3) Connect a transparent hose to each bleed screw
(Fig.2). Submerge the free end of the hose in a clear
glass container, which is partially filled with clean,
fresh brake fluid.
(4) Slowly pump the brake pedal several times, us­
ing full strokes of the pedal and allowing approxi­
mately five seconds between pedal strokes. After two
or three strokes, continue to hold pressure on the
pedal, keeping it at the bottom of its travel.
(5) With pressure on the pedal, open the bleed screw
1/2 to 3/4 turn. Leave bleed screw open until fluid no
longer flows from the hose. Tighten the bleed screw
and release the pedal.
(6) Repeat Steps 3 and 4 until clear, bubble-free
fluid flows from the hose.
(7) Repeat the above sequence at each of the wheel
brakes, wheel brakes should be bled in the following
order:
a) Left rear.
b) Right rear.
 c) Left front. HIGH PRESSURE HOSE PUMP MOTOR BATTERY
d) Right front.

PUMP/MOTOR SERVICE (FIG.3)

REMOVAL
(1) De-pressurize hydraulic accumulator by pump­
ing brake pedal a minimum of 40 times, as described
in this section.
WARNING: FAILURE TO DE-PRESSURIZE HYDRAU­
LIC ACCUMULATOR, PRIOR TO PERFORMING THIS
OPERATION, MAY RESULT IN PERSONAL INJURY
AND/OR DAMAGE TO PAINTED SURFACES.
(2) Remove fresh air intake ducts (2) from engine
induction system.
(3) Loosen the low pressure hose clamp at the hy­
draulic unit.
(4) Disconnect the high pressure fluid line clip from
the battery tray (See Fig.4).
(5) Disconnect electrical connectors (including the PUMP MOTOR
one on the pump/motor) which runs across engine ASSEMBLY 9105-111
compartment in the vicinity of the pump/motor high
and low pressure hoses. Fig.4 Brake Tube and Hose Routing
(6) Disconnect high and low pressure hoses from
hydraulic assembly. Cap spigot on reservoir. (9) Remove front heat shield.
(7) Disconnect pump/motor electrical connector from (10) Lift pump/motor assembly from bracket and
engine mount. remove assembly from the vehicle.
(8) Remove pump heat shield bolt from front of
pump bracket. INSTALLATION
(1) Install pump/motor assembly in reverse order of
removal.
HEAT SHIELD CAUTION:Be sure the high pressure hose clip to
the battery tray is securely fastened when hose is
reinstalled (See Fig.4).
(2) Tighten the pump/motor assembly fluid lines to
the torque values shown below.
• Low pressure hose plamp. 1 N-m (10 in. lbs.)
• High pressure hose fitting to pump/motor assembly.
16N-m (145 in.lbs.) Fig.4.

PRESSURE AMD RETURN HOSES (FIG.5)

REMOVAL
(1) Remove pump/motor, see Pump/Motor Service.
(2) Cut the 4 tie strips that secures the hoses and
wiring harness.
(3) Remove banjo bolt from pump/motor and remove
hose assemblies.

INSTALLATION
(1) The rubber O-Rings used on the high and low
9105-26 pressure hose connections to the pump/motor assem­
bly should be lubricated with brake fluid prior to
Fig.3 Pump/Motor Mounting connecting hoses to pump/motor assembly.
(2) Position hose assemblies on pump/motor and in­
stall banjo bolt (Fig.6).
 (3) Carefully route wiring harness along side the harness (Fig. 5).
hoses. (5) Install pump/motor assembly, see Pump/Motor
(4) Install 4 tie straps around the hoses and wiring Service. : - . ' ■

TIE STRAPS
HIGH AND LOW PRESSURE
HOSES ONLY. NOT'ELECTRICAL

corns

9105-112

Fig.8 Positioning Tie Straps

HIGH PRESSURE HOSE PUMP MOTOR BATTERY
Fig.6 Brake Tube and Hose Routing at Hydraulic Unit
HYDRAULIC ASSEMBLY
REMOVAL
De-pressurize hydraulic accumulator by pumping
the brake pedal a minimum of 40 times, as described
in this section.
WARNING: FAILURE TO DE-PRESSURIZE HYDRAU­
LIC ACCUMULATOR, PRIOR TO PERFORMING THIS
OPERATION, MAY RESULT IN PERSONAL INJURY
AND/OR DAMAGE TO PAINTED SURFACES.
(1) Remove fresh air intake duct and air cleaner
from vehicle.
(2) Remove the windshield washer fluid bottle from
the vehicle.
(3) Disconnect all electrical connectors from the hy­
draulic assembly.
(4) Remove as much fluid as possible from the reser­
voir on the hydraulic assembly.
(5) Remove pump high pressure hose fitting from
hydraulic assembly.
(6) Disconnect pump return hose from steel tube.
Cap the end of the steel tube.
(7) Disconnect all brake tubes from hydraulic as­
sembly (Fig.6).
(8) From under the instrument panel, position a
small screwdriver between the center tang on the
retainer clip and the pin in the brake pedal. Rotate
the screwdriver enough to allow the retainer clip cen­
ter tang to pass over the end of the brake peal pin.
Discard the retainer clip (Fig.7).
(9) Remove four hydraulic assembly mounting nuts
(Fig.7).
(10) Remove hydraulic assembly.
INSTALLATION
(1) Position hydraulic assembly on vehicle.
(2) Install and tighten mounting nuts to 28 N-m (250
in. lbs.) torque.
(3) Using lubriplate or equivalent, coat the beari :
surface of pedal pin.
(4) Connect push rod to pedal pin and install a new
retainer clip. HYDRAULIC ASSEMBLY PUSH ROD
MUST BE ASSEMBLED TO BRAKE PEDAL PIN AS
SHOWN IN (FIG.7).
(5) Install brake tubes on the hydraulic assembly
and torque to their specified values (See Torque Speci­
fications). If proportioning valves were removed from
the hydraulic assembly, install and tighten to 40 N-m
(30 ft. lbs.) torque.
HYDRAULIC
ASSEMBLY
PIVOT
SHAFT
PUSH
RODS.
NOTE: PUSH ROD MUST BE
INSTALLED IN POSITION
SHOWN HERE.
Fig.7 Removing or Installing Hydraulic Assembly
(6) Install return hose on steel tube. Tighten the
return hose clamp to 1 N-m (10 in.lbs.)
(7) Install high pressure hose to hydraulic assem­
bly. Tighten the hose, to hydraulic assembly fitting to
16 N-m (145 in. lbs)
(8) Fill reservoir to top of screen.
(9) Connect all electrical connectors to the hydraulic
assembly.
(10) Bleed the entire brake system, see Bleeding
Brake System in this section.
(11) Install fresh air intake duct, air cleaner and
washer bottle.
(12) Check the brake fluid level in the hydraulic
assembly. (See checking brake fluid level).
RESERVOIR (F IG S )
REMOVAL
(1) De-pressurize hydraulic accumulator by pump­
ing brake pedal a minimum of 40 times, as described
in this section.
WARNING: FAILURE TO DE-PRESSURIZE HYDRAU­
LIC ACCUMULATOR, PRIOR TO PERFORMING THIS
OPERATION, MAY RESULT IN PERSONAL INJURY
AND/OR DAMAGE TO PAINTED SURFACES.
(2) Remove as much brake fluid as possible from the
reservoir, using a syringe or equivalent method.
RETAINER
CUP
9105-113
(3) Remove bladder accumulator and high pressure
pump hose banjo fitting on the hydraulic assembly.
(4) Remove the three locking pins from the hydrau­
lic assembly which hold retain the hydraulic reservoir
to the assembly.
(5) Remove reservoir from hydraulic assembly by
CAREFULLY prying between reservoir and hydraulic
assembly with a blunt prying tool. Use a rocking
motion to help disengage reservoir from grommets
while prying. BE EXTREMELY CAREFUL TO AVOID
DAMAGING OR PUNCTURING RESERVOIR DURING
THIS PROCEDURE.
(6) Remove the fluid level sensor switch from the
reservoir.
(7) Using fingers, remove reservoir grommets from
hydraulic assembly, and discard. Care must be taken
to ensure contamination does not enter the ports.
INSTALLATION
(1) Thoroughly lubricate the new reservoir grom­
mets with clean brake fluid and install on reservoir
outlet ports. Always use the new grommets supplied
with reservoir.
(2) Install fluid level sensor switch in reservoir.
(3) Press reservoir into hydraulic assembly BY HAND,
using a rocking motion to help seat reservoir into
hydraulic assembly. Be sure that grommets are fully
seated in the hydraulic assembly three grommets. DO
NOT ATTEMPT TO POUND RESERVOIR INTO HY­
DRAULIC ASSEMBLY, USING A HAMMER.
(4) Reinstall the 3 reservoir to hydraulic assembly
locking pins.
(5) Reinstall the high pressure hose, banjo fitting
onto the hydraulic assembly and torque the fitting to
13 N-m (10.0 ft.lbs).
(6) Reinstall the hydraulic bladder accumulator onto
the hydraulic assembly, and torque the fitting to 40
N-m (30 ft. lbs).
(7) Fill the hydraulic assembly reservoir to the top
of the filler screen with fresh, clean DOT 3 brake
fluid.
BLADDER ACCUMULATOR
REMOVAL
(1) Depressurize the accumulator by pumping the
brake pedal a minimum of 40 times as described ear­
lier in this section
WARNING; FAILURE TO DE-PRESSURIZE THE HY­
DRAULIC ACCUMULATOR PRIOR TO PERFORMING
THIS OPERATION, MAY RESULT IN PERSONAL IN­
JURY AND/OR DAMAGE TO PAINTED SURFACES
OF THE VEHICLE.
(2) Loosen accumulator fitting at the hydraulic as­
sembly and remove accumulator from the hydraulic
assembly (Fig.8)
INSTALLATION
(1) Reinstall the accumulator onto the hydraulic
assembly and torque to 40 N-m (30 ft. lbs.)
(2) Turn on ignition and let hydraulic system pres­
surize checking for leakage at the hydraulic assembly
to accumulator fitting.
PROPORTIONING VALVES (FIG.8)
CAUTION: Proportioning valves should never be
disassembled.
REMOVAL
(1) Remove fresh air intake duct and air cleaner.
(2) Remove pressure and return hose, from hydrau­
lic unit. (See Pressure and Return Hose Section)
(3) Remove brake tube and fitting from proportion­
ing valve.
(4) Remove proportioning valve from hydraulic
assembly.
INSTALLATION
(1) Install proportioning valve on hydraulic assem­
bly and tighten to 40 N-m (30 ft. lbs.) torque.
(2) Install brake tube on proportioning valve. Tighten
tube nut to 15 N-m (11 ft. lbs.) torque.
(3) Install pressure and return hoses. (See Pressure
and Return Hose Section)
(4) Install fresh air intake duct and air cleaner.
(5) Bleed the affected brake line, see Bleeding Brake
System in this section.
 Flg.8 Hydraulic Assembly

ELECTRONIC COMPONENTS REMOVAL

CONTROLLER ANTI-LOCK BRAKE (Fig.9)
SHIELD
(1) Turn vehicle ignition off.
(2) Remove speed control servo from vehicle.
SBEC
(3) Disconnect the wiring harness 60 way connector
from the Controller Anti-Lock Brake Module (CAB).
VERIFY THAT THE VEHICLE IGNITION IS OFF BE­
FORE REMOVING THE 60 WAY CONNECTOR.
(4) Remove the 3 (CAB) module mounting bolts.
(5) Remove the (CAB) module from the vehicle.

INSTALLATION
(1) The Controller Anti-Lock Brake (CAB) module
installation is done in the reverse order of removal.
• Tighten the 60 way (CAB) electrical connector re­
taining bolt to 5 N-m (40 in. lbs.).
• Tighten the (CAB) module to fender shield attach­
SPEED CONTROL ing bolts to 12 N-m (105 in.lbs.).
SERVO

60 WAY
CONNECTOR ATTACHING BOLTS (3) 9105-107

Fig.9 Location Controller Anti-Lock Brake (CAB)

 Excessive runout of the tonewheel can cause erratic
wheel speed sensor. Replace assembly if runout ex­
ceeds approximately 0.25 mm (0.010 inch).

FRONT WHEEL SPEED SENSOR (FIG.11)

REMOVAL
(1) Raise vehicle and remove wheel and tire assembly.
(2) Remove screw from clip that holds sensor assem­
bly to fender shield.
(3) Carefully, pull sensor assembly grommet from
fender shield.
(4) Unplug connector from harness.
(5) Remove the 2 screws that secure the speed sen­
sor wire routing tube to the fender well.
(6) Remove the 2 sensor assembly grommets from
the retainer bracket, on the strut damper.
(7) Remove sensor head screw.
(8) Carefully, remove sensor head from steering
knuckle. If the sensor has seized, due to corrosion, DO
NOT USE PLIERS ON SENSOR HEAD. Use a hammer
and a punch and tap edge of sensor ear, rocking the
sensor side to side until free.

Fig.10 Pump/Motor and Anti-Lock System Relays

SYSTEM RELAY, ANTI-LOCK WARNING LAMP

RELAY AND PUMP/MO TOR RELAYS (FIG.10)
REMOVE/INSTALL
The service procedure for removing and Installing
both the System Relay, Yellow Light Relay and Pump/
Motor are the same. Though the System Relay and
Yellow Light Relay are a single module, and the
Pump/Motor Relay is a separate component.
(1) Disconnect the wiring harness electrical connec­
tor from the relay housing. (See Fig.10)
(2) Remove the attaching screw holding the relay
housing to the fender shield. (See Fig.10)
(3) Install the new relay assembly. By inserting the
tab on the assembly into the hole in the inner fender.
Then secure the relay assembly to the fender shield
with its attaching screw.
(4) Install the wiring harness onto the relay assem­
bly. By firmly pushing the connector onto the relay
until the locking tabs are fully engaged.
9105-114
WHEEL SPEED SENSORS
Fig.11 Front Wheel Speed Sensor Routing FWDIAWD
INSPECTION
Inspect tonewheel for missing or broken teeth, this INSTALLATION
can cause erratic sensor signals. (1) Connect the wheel speed sensor connector to th e .
Tonewheel should show no evidence of contact with wiring harness.
the wheel speed sensor. If contact was made, deter­ (2) Push sensor assembly grommet into hole in fender
mine cause and correct.
shield. Install clip and screw. Torque screw to 4 N-m (3) Unplug speed sensor connector from vehicle wir­
(35 in. lbs.). ing harness.

(3) Install sensor grommets in brackets on strut (4) Remove the 4 arrow head clips which route the
damper. speed sensor wiring along the underbody (Fig. 12).

(4) Install sensor tube to fender well using the 2 (5) Remove the wiring to frame rail attaching bracket
screws, torque to 4 N-m (35 in. lbs.). (Fig. 12).

(5) Coat the speed sensor with High Temperature (6) Loosen and remove the rear axle U-bolt nuts.
Multi-purpose E.P. Grease before installing into the Which retain the rear axle sensor assembly mounting
steering knuckle. Install screw tighten to 7 N-m (60 in. bracket. Remove the bracket from the vehicle.
lbs.)
(7) Remove sensor head screw (Fig.12).
FRAME SUPPORT WHEEL SPEED SENSOR FRAME RAIL
CABLE
CAUTION: Proper installation of wheel speed sensor
cables is critical to continued system operation. Be
sure that cables are installed in retainers. Failure to
install cables in retainers, as shown in this section,
may result in contact with moving parts and/or over
extension of cables, resulting in an open circuit.

(8) Carefully, remove sensor head from rear brake

backing plate assembly. If the sensor has seized, due
to corrosion, DO NOT USE PLIERS ON SENSOR
HEAD. Use a hammer and a punch and tap edge of
GROMMET sensor ear, rocking the sensor side to side until free.

INSTALLATION FRONT WHEEL DRIVE.

HYDRAULIC (1) Position the rear axle sensor assembly and bracket
BRAKE LINE
on the rear axle (Fig.12) Install the rear axle U-bolt
WHEEL SPEED SENSOR and torque the nuts to 88 N-m (65 ft. lbs.).
CABLE AND BRACKET 9105-105
(2) Install the speed control sensor head into rear
Fig.12 Rear Wheel Speed Sensor Routing FWD backing plate. On the driver side the sensor wire is
routed between the brake tube and the wheel brake.
REAR WHEEL SPEED SENSOR (FIGS.12 AND 13) Torque the speed sensor to backing plate attaching
REMOVAL FRONT WHEEL DRIVE bolt to 7 N-m (60 in.lbs.)
(1) Raise vehicle and remove rear wheel and tire
assembly.

(2) Remove rear speed sensor wiring grommet re­

taining bracket. Remove grommet from underbody and
pull harness through hole in underbody. (See Fig.12)
 (3) Bend the sensor assembly rubber hose section
toward the front of the vehicle. Position the anti­
rotation tab of the sensor assembly frame rail bracket.
Install the screw that attaches the frame rail bracket
to the frame and torque to 5 N-m (50 in. lbs).
(4) Connect the sensor assembly wiring to the vehi­
cle rear wiring harness. Push the sensor assembly
wiring grommet back into the rear drain hole.
(5) Position the rear sensor assembly grommet re­
taining bracket (Fig.12) making sure the bracket does
not pinch the sensor wiring. Install the 2 bracket
mounting screws and torque to 5 N-m (50 in.lbs.).
(6) Route the speed sensor wiring along the vehicle
frame rail and install the 4 arrow head clips.
(7) Install the rear wheel assembly and torque the
wheel stud nuts to 129 N-m (95 ft.lbs.)
REMOVAL ALL WHEEL DRIVE
ROUTING CLIP WHEEL SPEED
Fig.13 Rear Wheel Speed Sensor Routing AWD
(1) Raise vehicle and remove rear wheel and tire
assembly.
(2) Remove rear speed sensor wiring grommet re­
taining bracket. Remove grommet from underbody and
pull harness through hole in underbody. (See Fig.13)
(3) Unplug speed sensor connector from vehicle wir­
ing harness.
(4) Remove the 4 arrow head clips which route the
speed sensor wiring along the underbody (Fig.13).
(5) Remove the wiring to frame rail attaching bracket
(Fig.13).
(6) Remove the 2 rear bolts which secure the sensor
assembly rear axle bracket to the rear axle. Remove
the bracket assembly from the vehicle by rotating the
bracket and removing it from under the brake tube.
(7) Remove sensor head screw (Fig.13).
(8) Carefully, remove sensor head from rear axle
assembly. If the sensor has seized, due to corrosion,
DO NOT USE PLIERS ON SENSOR HEAD. Use a
hammer and a punch and tap edge of sensor ear,
rocking the sensor side to side until free.
INSTALLATION ALL WHEEL DRIVE.
(1) Position the rear axle sensor assembly bracket
under the brake tube (Fig.13). Hand start the out­
board bracket attaching bolt. Align the brake tube
clip and sensor assembly bracket and secure with bolt.
Torque both bolts to 17 N-m (145 in. lbs.)
(2) Coat the sensor head with High Temperature
Multi-Purpose E.P. Grease. Install the speed control
sensor head into the rear axle and install bolt. Torque
the speed sensor to rear axle attaching bolt to 7 N- (60
in.lbs.)
(3) Bend the sensor assembly rubber hose section
toward the rear of the vehicle. Position the anti-rotation
tab of the sensor assembly frame rail bracket. Install
the screw that attaches the frame rail bracket to the
frame and torque to 5 N-m (50 in. lbs).
(4) Connect the sensor assembly wiring to the vehi­
cle rear wiring harness. Push the sensor assembly
wiring grommet back into the rear drain hole.
(5) Position the rear sensor assembly grommet re­
taining bracket (Fig.13) making sure the bracket does
not pinch the sensor wiring. Install the 2 bracket
mounting screws and torque to 5 N-m (50 in.lbs.).
(6) Route the speed sensor wiring along the vehicle
frame rail and install the 4 arrow head clips.
(7) Install the rear wheel assembly and torque the
wheel stud nuts 29 N-m (95 ft.lbs.)
 SPECIFICATIONS
SPECIFICATIONS METRIC

FRONT BRAKES

Type . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . , Single Piston — Pin Slider — Disc

Caliper Bore Diam eter......................................... . . . 54 mm
Adjustment....................... ................................. .. , . . Automatic ■ ..
Piston M aterial................................................ ............................... . . . Glass Filled Phenolic • ■ . ■ ■■■
Piston Boot Type. . . . . .................................................................. .... Press in EPDM Rubber
Disc Type All Bodies ....................................... ...................... . . . . , . , . Vented
Disc Diameter —Outside A P ........................... ..................... . . . , 240 mm Standard —260 mm Heavy Duty
AA, AC/ AG & AJ . . . . ............................ 260 mm Standard
Runout —Maximum Allowable T.I.R. . . . ....................................... 1016 - '
Parallelism —Total Variation in
Thickness in 360° of-Rotation ....................................................... , . . .01270 mm

REAR BRAKES — DRUM , ' •' ' ' '' :

T y p e ................................................................................................. . Leading Trailing

Adjustment......................................................... .. , - , Automatic
Drum Diameter —AP ...................................................................... . . . 200 mm Standard
AA . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . , , 220 mm Standard
AC . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 220 mm Heavy Duty and C-45
Wheel Cylinder Diameter AA# AP & A G ......... ............................. . . 15.9 mm

REAR BRAKES — DISC WITH SEPARATE PARKING BRAKE

Type . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Single Piston With Internal Park Brake

(Drum in Hat)
Caliper Bore Diam eter............................................................... .. . . 34 mm 14 in. Wheel
36 mm 15 in. Wheel
Adjustment.................................................... ................. .. , , Disc Brake—Automatic
Parking Brake —Manual
Pi ston M aterial............................................................................. .. . . , Glass Filled Phenolic
Piston Boot Type .................................................. .. .. Press in EPDM Rubber
Disc Type . . .................................................................................. .. . , . Solid — 14 in. Wheel
Vented — 15 in. Wheel
Disc Diameter — Outsi d e ......................... ...................... ................. , , 270 mm — 14 in. Wheel
286 mm — 15 in. Wheel
Diameter — Parking Brake Drum . . . . . . . . . . . . . . . . . . . . . . . . - . 171.9 mm to 172.15 mm
 BRAKE ACTUATION SYSTEM
ACTUATION : ............................................................................................................. Power Brakes Standard
Hydraulic System............................................................................................. Dual-Diagonally Split
MASTER CYLINDER:
Type.............................................. Dual-Tandem—Two Piece
Body Mat eri al . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Anodized Aluminum
Reservoir Material . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Glass Reinforced Nylon
lore and Stroke . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21.0 mm x 32.8 mm
24.0 rout x 33.4 mm
.875 in. x 33.4 mm
Displacement Spl i t. . . . . . . . . . . 50/50
Outlet Port Threads . . . . . . . . . . 3/8 x 24
Outlet f itting Type . . . . . . . . . . . 45 Inverted Flare
Pedal Ratio . . . . . . . . . . . . . . . . 3.3 & 5 JO for AC/AY WIABS
BOOSTER:
Make . . . . . . . . . . . . . . . . . . . . Bendix/(ATE) IO SH
Mounting Studs . . . . . . . . . . . . . M i x 1.25
Type........................................... 205 mm Tandem
Boost @ 20" H G ......................... 4048 N-m in all Vehicles
Type........................................... Hydraulic Power
loos! . . . . . . . . . . . . . . . . . . . . Hydraulic/Electric
DIFFERENTIAL WARNING SWITCH:
Material . . . . . . . . . . . . . . . . . . Brass
Function . . . . . . . . . . . . . . . . . . Warning Light Switch (Latching)
COMBINATION HYDRAULIC VALVE:
Material . . . . . . . . . . . . . . . . . . Brass/Aluminum
Function . . ................................... Proportioning Valve and Warning
Light Switch (Latching)
9105-47
 TIGHTENING REFERENCE

NEW TO N FOOT NEW TO N IN C H

BRAKE SYSTEM C O M PO N EN TS
METERS PO UNDS METERS POUNDS

HYDRAULIC BRAKE LI NES: — — — —

TUBES TO ALL FITTINGS (I F NOT SPECIFIED) — — 13-20 115-175

HOSES TO CALIPERS (BANJO BOLT) 2 6 -4 0 19-29 — —

FRONT BRAKE HOSE INTERMEDIATE BRACKET — — 8-13 75-115

MASTER CYLINDER: — — — —

MASTER CYLINDER TO BOOSTER FRONT COVER — — 2 2 .6 -3 4 2 0 0 -3 0 0

POWER BRAKE: — — — —

POWER BRAKE BOOSTER ASSEMBLY TO DASH — — 2 2 .6 -3 4 2 00 -3 00

WHEEL CYLINDERS: — — — —

TO SUPPORT PLATE — — 8 M IN 75 M IN

WHEEL CYLINDER BLEEDER SCREW — — 7-11 60-100

BRAKE SUPPORT PLATE: — — — —

PLATE TO REAR AXLE M O UNTING 61-81 4 5 -6 0 — —

WHEEL STUD NUTS: — — — —

ALL VEHICLE LINES 129 95 — —

CALIPERS: — — — —

ADAPTER M O U NTIN G BOLTS 176-258 130-190 — —

GUIDE PI NS K-H 3 4 -4 7 2 5 -3 5 — —

BEARING RETAINER M OUNTING BOLT — — 2 2 .6 -3 4 2 0 0 -3 0 0

CALIPER BLEED SCREW — — 9-19 80-170

BRAKE LIGHT SWITCH: — — — —

M O U NTIN G BRACKET SCREW — — 5 .5 -8 .2 4 8 -7 2

PARKING BRAKE PEDAL ASSY. TO SI DE COWL — — 2 2 .6 -3 4 2 00 -3 00

PARKING BRAKE HANDLE TO FLOOR — — 2 2 .6 -3 4 2 00 -3 00

 COOLING SYSTEM
CONTENTS
Page Page
ACCESSORY DRIVE BELTS ......................... 24 SERVICE PROCEDURES 10
ENGINE BLOCK HEATER ............................ 29 SPECIFICATIONS ....... 31
GENERAL INFORMATION .......................... 1
GENERAL INFORMATION
Throughout this group, references may be made to a • When Engine is warm: Thermostat is open, engine
particular vehicle by letter or number designation. A has bypass flow and flow through radiator.
chart showing the breakdown of these designations is Its primary purpose is to maintain engine tempera­
included in the Introduction Section at the front of ture in a range that will provide satisfactory engine
this service manual. performance and emission levels under all expected
driving conditions. It also provides hot water (coolant)
COOLING SYSTEM for heater performance and cooling for automatic trans­
mission oil. It does this by transferring heat from
The cooling system consists of a radiator, coolant, engine metal to coolant, moving this heated coolant to
electric fan motor, shroud, pressure cap, thermostat, the radiator, and then transferring this heat to the
coolant reserve system, transmission oil cooler, a wa­ ambient air.
ter pump to circulate the coolant, hoses, and clamps to olant flow circuits for 2.5L engine equipped vehi­
complete the circuit. cles are shown in Figure 1. Figure 2 shows 3.0L en­
• When Engine is cold: Thermostat is closed, engine gine coolant routing. Figure 4 shows 3.3L Engine
has no flow through the radiator has bypass flow only. Coolant routing.
HEATED INTAKE MANIFOLD
ENGINE COLD ENGINE WARM ALWAYS HAS FLOW
NOTE: HEATER COOLANT FLOW
CIRCUIT IS ALWAYS OPEN
THERMOSTAT CLOSED JHEROMSTAT OPEN / EXCEPT WHEN IN MAX. A /C OR
RADIATOR BY-PASSED OFF MODES THEN COOLANT
FLOWS THROUGH
HEATER BYPASS

BYPASS
VALVE
(A/C ONLY)

9007-24

Fig. 1 Cooling System Operation 2.5L Engines

 Fig. 2 Cooling System Operation 3.0 Engine

Excluding heated intake manifold hose routing (hose

is routed from waterbox directly to heater), all other I NLET PIPE CYLINDER TRANSMISSION
system functions are essentially the same as shown
for standard engines.

3.0L WATER PIPES

The 3.0L engines use metal piping beyond the lower
radiator hose to route (suction) coolant to the water
pump, which is located in the V of the cylinder banks.
These pipes are also provided with inlet nipples for
thermostat bypass and heater return coolant hoses,
and brackets for rigid engine attachment. The pipes
employ O-rings for sealing at their interconnection
and to the water pump (Fig. 4).

O-RINGS
9007-1

Fig. 3 Engine Inlet Coolant Pipes

 THERMOSMT- BY'PASS

« A T £ ft
CORE

RADIATOR

WATER
PUMP 9007-23

Fig. 4 Cooling System Operation 3.31 Engine

E stablish w h a t "driving" conditions c a u s e d this com plaint. A bn orm al loads on th e cooling system , such a s th e follow ing m ay b e
th e problem: ,

1. Prolonged Idle, Very High Ambient Temperature, Slight Toil Wind ot Idle, Slow Traffic, Traffic Jams, High Speed,
Steep ' -
Driving techniques that avoid overheating are;
(a) Idle with A /C off when temperature gauge is at end of normal range.
(b) Do not increase engine speed for more air flow and coolant flow because the electric motor fan systems are not respon­
sive to engine RPM. The added cooling from higher coolant flow rate is more than offset by increased heat rejection (engine heat
added to coolant).

2. Trailer Towing:
Consult owner's manual— Trailer Towing. Do not exceed limits.

3. Air Conditioning: Add-on or After Market:

If add-on or after market A /C is involved maximum cooling components should be installed for the model involved per
manufacturer's specifications.
Further diagnostic checks should not be required.

4. Recent Service or Accident Repair:

Determine if any recent service has been performed on the vehicle that may affect the cooling system such as engine adjust­
ment (wrong timing), loose or slipping water pump belt, brakes (possibly dragging), changed parts (possibly wrong), recored
radiator or cooling system refilling (possibly under-filled or trapped air).
If investigation rev eals none of the above as cause for overheating complaint refer to the following symptoms chart.

Symptom Action
Blinking Engine Warning Light Normal with temporary operation with heavy load, towing a light trailer, high outdoor
Or High Gauge Indication— temperatures, and/or on a steep grade.
Without Coolant Loss
Coolant Loss Improper refilling procedures can result in trapped air in the system. Subsequent opera­
tion of the pressure cap and coolant recovery system will deaereate the cooling system. A
low coolant level will result in the Coolant Reserve Tank. Add coolant. If condition persists
see System Diagnosis.

Fan Never Runs Consult Electrical, Group 8.

Fan Always Runs Normal with A /C compressor clutch engaged. Otherwise consult Electrical Group 8 .
Hot Car (Not Engine) Check heat shielding, exhaust system, emission controls, ignition timing— fu el/air ratio,
Heat Damage misfiring.
Hot Carpet, Seat, Trunk
Hot Catalytic Converter
Smoke, Burnt €>i#r
Hot Engine A moderate amount of sound of heating metal can be expected with any car. However, a
Crack ling Sounds crackling sound from the thermostat housing, a hot smell and/or severe local hot spots on
Hot Smell an engine can indicate blocked coolant passages. Inspect for plugged water passages,
Severe Local Hot Spots bad casting, core sand and plugging, a cracked block or head, or a blown head
an engine can indicate blocked coolant passages, gasket. Usually accompanied with
coolant loss.

Coolant Color Coolant color is not necessarily an indication of adequate temperature or corrosion
protection.

Coolant Recovery Bottle
—Level Changes
—Coolant NOT Returning
Level changes are to be expected as coolant volume changes with engine temperature. If
the level in the bottle is between the Maximum and Minimum marks at normal engine
operating temperature, the level should return to within that range after operation at
elevated temperatures.
Coolant will not return to the radiator if the radiator cap vent valve does not function, if
an air leak destroys vacuum, or if the overflow passage is blocked or restricted.
Inspect all portions of the overflow passage, pressure cap, filler neck nipple, hose, and
passageways within the bottle for vacuum leak only. Coolant return failure will be evident
by a low level in the radiator. Bottle level should increase during heat-up.
 CONDITION—AND CHICKS DIAG NO SIS

m m m m m m 9b m b i re a d s m w

3 0 ° TO 40®
pAUGE HAVE
IS NORMAL

Fig. 1—Normal Gauge Travel

(1) V erify g a u g e , (Fig. 1) Is te m p e r a tu r e really (1) See Electrical, Group 8 and check tem perature
lo w ? sending unit. Repair/Replace gauge.

(2) Is c o d e 17 s e t in d ia g n o s tic s? (2) Yes— Thermostat, No— Other

(3) D oes it r e a d co ld ? (3) Wiring disconnect wrong sending unit used,

sending unit for HOT lite, not gauge.

(4) C o o la n t le v e l low in c o ld a m b i e n t. (A lso poor (4) Check radiator and CRS for level— inspect for
h e a t e r p e rfo rm a n c e ) leaks.

(5) C o o lan t level O.K. (5) Check heater controls, doors— see Group 24,
Heaters and Air Conditioning.

S9U9I ill 9 91 HIGH—Without Pmmum C«ifi

Blow off w ithout Coolant or Steam from CIS MAXIMUM UP
Tank and to Ground MAXIMUM N O tM A l
HOT WEATHER
HEAVY LOAD

Fig. 2—Gauge Reading—Hot W eather—Heavy Load

(1) Is it really reading h ig h ? (1) See Figure 2.

(2) If at "H” without other signs of boiling. (2) Look for Grounded gauge, sending unit or w ire. See
Group 8, Electrical.

(3) Coolant level low in Radiator and CRS (3) a — Fill full remembering to air vent (2.5L Engine),
b— Inspect for leaks, repair.
c— Assure Pressure Cap was shut tight and seals at top ■.
and bottom of neck are functioning properly. :

(4) Coolant level low in Radiator but not in CRS. (4) a— Fill full remembering to air vent (2.5L Engine),
b— Inspect for leaks and repair.
c— Inspect for leaks in CRS to radiator connection,
d— Assure cap seals at top and bottom.
CONDITION—AND CHICKS
(5) Check freeze point.
(6) Assure C o olan t Flow .
(7) Other possible causes.
Tampovatur* Gauge Reads Hot w ifi Pressure to p
Mowoff and Steam and coolant to CRS and to Ground
(1) Coolant Level Low in Radiator and CRS
(2) Check Coolant Freeze point.
(3) Assure Coolant Flow.
(4) Thermostat failed shut.
(5) Head Gasket Leak.
DIAGNOSIS
(5) a— Adjust to 50/50 Glycol and w ater.
b— If no reading or below —50°F, mixture is too rich
clean system before refilling
(6) a— Look for flow through filler neck with some coolant
removed and thermostat open
(6) b— Repair w ater pump if necessary. See W ater
Pump Section.
(7) a— High speed only
— Radiator or Condenser air side plugged
— Radiator core tubes plugged
— Add on A /C without proper radiator
— Engine out of tune (specifications)
— Brakes dragging
— Bug screen
— Trailer towing or hill climbing
b—High «nd Low S p roi
— Thermostat failed partially shut particularly if ambient
temperature is below 70 °F and vehicle has high mileage.
— Condenser or radiator air side plugged.
— Add on A /C .
c—low S9»e«9...9 0 9 hlfli «p9««l
..For? not operating.
— Check Diagnostics.
— Check Fan M otor by wiring to battery, when disconnected
from harness.
— Check, Group 8, Electrical.
(1) a— Fill Cooling System Full and Vent Air.
b— Inspect for Leaks— repair.
c— Assure Pressure cap was shut and seals,
d— If low in radiator but not in CRS, also check
connection to filler neck and pressure cap sealing.
(2) Adjust to 50/50 Glycol and w ater. —35 °F.
(3) a— Look for flow through radiator filler neck with coolant
lowered and thermostat open.
b— When accompanied with “metal cracking
sound"— consider core sand and/or bad head casting.
(4) Especially in cold to medium ambient temperatures.
(5) Use block leak checker.
COOUNG SYSTEM DIAGNOSIS
 COOLING SYSTEM DIAGNOSIS

CONDITION—AND CHECKS ■ DIAGNOSIS . ■ .

(3) Is there a head gasket leak that puts exhaust gas in (3) Test with block leak checker and replace if necessary.
system? (This acts like trapped air with same effect as (2) b— Coolant in engine oil.
above). c— White steam coming out of exhaust.

(4) Water pump impeller loose on shaft, slips sometimes. (4) Replace.

(5) Air leak on suction side of w ater pump entraining Air; (5) Find Leak and Repair.
see 2 above.

W arning Light Glows All th e Time (No G auge)

(1) Check temperature sending unit. The sending uni t for a (1) It is probably a sending unit for gauge, NO T for a ligl
light is a sw itch and has a screwdriver slot in the electrode
that is used for calibration. The gauge sending units do NOT
have a screwdriver slot. ,

P ressure Cap Blow Off, w ith ste am to CRS an d coolant

to ground w ith o u t high read in g . T em p eratu re G auge
ab o v e norm al

(1) Check pressure cap relief pressure. (1) Replace if lower than 14 psi.

C oolant Loss to G round w ith o u t P ressure Cap Blow Off

(1) Leaks. (1) a— Pressure test system while shaking hoses.

b— W ater pump seal— see "water pump", this Group.

C oolant Loss P ast P ressure Cap Top S eal — Glycol se en

on Filler Neck .

(1) With normal gauge reading. (1) a... Cap not on tight.
b— Top seal leaking,
c— Cap diaphragm "oil canned",
d— Filler neck damaged,
e— Rubber seal out of position.

(2) With high gauge reading or low gauge reading on new (2) a— CRS Hose kinked.
vehicle. b CRS tank and plastic tube plugged,
c— Pressure Cap Rubber seal out of position.

D etonation or Pre-Ignition W hen N othing to Cause it In

Engine or Ignition

(1) Check coolant freeze point— If no reading on Vu-check
or below —50°F. freeze point. Be aw are that 100% Glycol
makes engine metal run hotter even without a hot gage
reading.
(1) a— Adjust coolant to 50/50 Glycol and water ( —35 °F).
b— If 100% glycol has been found in the system, clear
and flush the system before replacing with 50/50 glycol
and water.
9107-7
 COOUNG SYSTEM DIAGNOSIS

QONDmON—AND CHICKS DIAGNOSIS

Hoses Observed Collapsing on C ool Down

(1) Check p r e s s u re c a p V en t Valve. (1) a— Must be free to move. Gasket swell can prevent valve
from opening,
b—-Replace cap.

(2) C heck CRS h o s e fo r kinking o r plugging. (2) Repair as required.

(3) Inside of c a p plugged w ith sto p lea k p ellet, g re e n silica (3) Clean cap.
gel, o r fib erg la ss.

Fan inns A ll th e Time

{1) C heck fa n re la y . (1) See Group 8 f Electrical

Fan Noisy
(1) C heck fo r lo o se fan . (1) Repair as necessary

(2) C heck fo r fa n c le a ra n c e to a d ja c e n t p a rts.

(3) Check fo r lo o se mount fa s te n e rs .

(4) C heck fo r b e n t fan b la d e s,

(5) C heck fo r fa n b la d e s sp in n ing on hub.

(6) C heck fo r a ir obstructions on ra d ia to r o r c o n d e n s e r.

Inadequate A ir Conditioning P erformance—»

Cooling System Suspected
(1) Check fo r plugged air side of condenser and radiator— (1) Wash out w ith low velocity w ater.
front and rear.

(2) Assure fan runs whenever A /C compressor clutch (2) Repair as necessary.
is engaged.

(3) Check fo r missing air seals— recirculating a i r path.

(4) Assure correct cooling system parts.

Battery Dead, Suspect Fan Current Draw as Cause

(1) With a good fully charged battery. (1) a— Assure fan control is operating properly,
b— See Charging System in Electrical, Group 8.

Not Smell, Suspect Cooling System

(1) Was temperature gauge high? (1) a— Yes, See "Gauge Reads High",
b— N o, See 2, 3, 4, and 5.

(2) Heat shields all in place? (2) a— Yes, See 3, 4 and 5.

b— Repair as required.

(3) Fan control operating properly? (3) a— Yes, See 4 and 5.

b— N o, See "Fan", this Group.

(4) Heat exchanger air side plugged? (4) Clean as required.

(5) Engine missing or running rich? - (5) Repair as required.

9107-8
 COOLING SYSTEM DIAGNOSIS
GONDITION—AND CHECKS DIAGNOSIS, ...

Poor Driveability Suspect Failed open Thermostat

(1) C heck d iag n o stic s— is c o d e 17 s e t? (!) a— If yes, change thermostat.

Peor H eater ^ r f e r m c n c # —Sw sp#€t Failed Open

Thermostat?

(1) D oes g a u g e r e a d low ? (1) a — S e e 3a.

(2) C heck co o la n t level. (2) a — S e e 3a.

(3) C heck d ia g n o stic s— is c o d e 17 s e t? (3) a— If yes, change thermostat. If no— check Heater bypass
valve which should be closed except in Max A /C or off
mode, if not, see Heater and Air Conditioning, Group 24.

Steaming, Observe W ater Vapor Through © rill or Head

Gap a t Standstill a t Idle—-in Wet W eather

(1) This is normal— it is moisture— snow— w ater on the (1) Normal condition— no service required.
outside of the radiator that evaporates when the thermostat
opens to put hot w ater into the radiator. This usually occurs
in cold w eather and no fan or air flow to blow it aw ay.
9107-9

SERVICE PROCEDURES
WATER PUMPS
A quick test to tell whether or not the pump is
working is to see if the heater warms properly. A
defective pump will not be able to circulate heated
coolant through the long heater hose.
The water pump on all models can be replaced
without discharging the air conditioning system.

WATER PUMP 2.SL ENGINE

The 2.5L engine water pump has a diecast alumi­
num body and housing with a stamped steel impeller.
The 2.5L pump uses an O-ring gasket between body
and housing. The assembly bolts directly to the block.
Cylinder block to water pump sealing is provided by a
rubber O-ring.

Fig. 1 Water Pump 2.5L Engines

REMOVAL
(1) Drain cooling system. Refer to Draining Cooling
System in this group.
(2) If equipped with air conditioning, see Solid Mount
Accessory Bracket in (Standard Service Procedures)
Group 9, Engine:
(a) Remove air conditioning compressor and alter­
nator from solid mount bracket and set aside. It is not
necessary to discharge the a/c system.
(b) Remove solid mount bracket.
(3) If the vehicle is not equipped with air condition­
ing, remove alternator and mounting bracket.
(4) Disconnect lower radiator and heater hoses from
pump.
(5) Remove water pump attaching screws to engine
(F ig .l).
DISASSEMBLY
(1) Remove three screws holding pulley to water
pump.
(2) Remove nine screws holding water pump body to
housing. Remove the pump body from housing.
(3) Clean gasket surfaces on water pump housing
and engine block.
(4) Remove and discard O-ring gaskets and clean
O-ring grooves.
Fig. 2 2.5L Water Pump Components
INSPECTION
Replace water pump body assembly if it has any of
these defects:
(1) Cracks or damage on the body.
(2) Water leaks from the shaft seal, evident by cool­
ant traces below the vent hole.
(3) Loose or rough turning bearing.
(4) Impeller rubs either the pump body or the
housing.
ASSEMBLY
Body assembly and housing are serviced as separate
components.
(1) Install new O-ring gasket in body O-ring groove.
(2) Assemble pump body to housing and tighten
nine screws to 12 N-m (105 in. lbs.).
(3) Rotate pump by hand to check for freedom of
movement.
(4) Position water pump pulley to water pump.Install
three screws and tighten to 30 N-m (250 in.lbs.).
(5) Position new O-ring in housing to block O-ring
groove.
INSTALLATION
(1) Install water pump on engine. Tighten top three
screws (Fig. 1) to 30 N-m (250 in. lbs.) and lower screw
to 68 N-m (50 ft. lbs.).
(2) Reinstall bypass/heater hose and lower radiator
hose.
(3) Reinstall alternator and air conditioning com­
pressor bracket(s). For solid mount bracket see stan­
dard service procedures in Group 9 Engine.
(4) Reinstall alternator and air conditioning
compressor.
(5) Refill cooling system. See Refilling Cooling
System.
(6) Install drive belt, See Accessory Drive Belts, this
Group.
WATER PUMP 3.0L ENGINE
The 3.0L pump bolts directly to the engine block,
using a gasket for pump to block sealing (Fig. 3) The
pump is serviced as a unit.
The water pump is driven by the timing belt. See
Timing System in Group 9, Engine for component
removal providing access to water pump.

Fig. 3 Water Pump 3.0L Engine
REMOVAL
(1) Drain cooling system. Refer to Draining Cooling
System in this Group.
(2) Remove mounting bolts. Sys
(3) Separate pump from water inlet pipe (Figs. 3
and 4) and remove.
INSPECTION
Replace the water pump if it has any of the follow­
ing defects.
(1) Damage or cracks on the pump body.
(2) Coolant leaks, if the shaft seal is leaking, evi­
dent by traces of coolant leaks from vent hole A in
(Fig. 4).
(3) Impeller rubs inside of pump.
(4) Excessively loose or rough turning bearing.
Fig. 5 Water Pipe O-Ring
INSTALLATION
(1) Clean all gasket and O-ring surfaces on pump
and water pipe inlet tube.
(2) Install new O-ring on water inlet pipe (Fig. 5).
Wet the O-ring (with water) to facilitate assembly.
CAUTION: Keep the O-ring free of oil or grease.
(3) Install new gasket on water pump and install
pump inlet opening over water pipe, press assembly to
cause water pipe insertion into pump housing.
(4) Install pump to block mounting bolts and tighten
to 27 N-m (20 ft. lbs.)
(5) See Timing System in Engine, Group 9 and
install timing belt. Reassemble engine.
(6) Fill cooling system. See Refilling Cooling System.
WATER PUMP 3.3L ENGINE
The 3.3L pump has a die cast aluminum body and a
stamped steel impeller. It bolts directly to the chain
case cover, using an O-ring for sealing. It is driven by
the back surface of the Poly-V Drive Belt.
Fig. 6 Water Pump 3.3L Engine
REMOVAL
(1) Drain cooling system. Refer to Draining Cooling
System in this group.
(2) Remove Poly V Drive Belt.
(8) Remove right front lower fender shield.
(4) Remove pump pulley holts and remove pulley.
(5) Remove pump mounting screws (Fig. 6). Remove
pump.
(6) Remove and discard O-ring seal.
(7) Clean O-ring groove and O-ring surfaces on pump
and chain case cover. Take care not to scratch or
gouge sealing surface.
INSPECTION
Replace the water pump if it has any of the follow­
ing defects.
(1) Damage or cracks on the pump body.
(2) Coolant leaks; if the seal is leaking, evident by
traces of coolant leaks from vent hole.
(3) Loose or rough turning bearing.
(4) Impeller rubs either the pump body or chain
case cover.
Fig. 7 Wafer Pump fioilf . cles. The temperature gauge will indicate-this, Refer
ilS flll
(1) Install new O-ring in O-ring groove (Fig. 7),
(2) Install pump to chain case cover. Torque screws
to 12 N-m (105 in. lbs.)
(8) Rotate pump by hand to check for freedom of
movement.
(4) Position pulley on pump. Install screws and torque
to 30 N*m (250 in. lbs.)
(5) Install drive belt. See Accessory Drive Belts this
group.
(8) Install right front lower fender shield.
(7) Refill Cooling System. See Refilling Cooling
System.
ENGINE THERMOSTAT
The 2.5L engine thermostats are located on the front
of the engine (radiator side) in the waterbox which is
part of the cylinder head construction (Fig. 8).
These thermostats do not have an air bleed notch.
The 3.0L engine thermostat is located in a water box,
formed in the timing belt end of the intake manifold.
This thermostat has an air bleed valve, located in the
thermostat flange (Fig. 9).
The 8.3L engine thermostat is located in a water
box, formed in the drive belt side of the intake mani­
fold (Fig. 11). ' ‘ ■' .
DESCRIPTION AMD OPEBATION ' .
.The engine cooling thermostats are wax pellet driven,
reverse poppet choke type. They are designed to pro­
vide the fastest warm up possible by preventing leak­
age through them and to guarantee a minimum engine
operating temperature of 88 to 93°C (192 to 199°F).
They also automatically reach wide open so they do
not restrict flow to the radiator as temperature of the
coolant rises in hot weather to around 104°C (220°F).
Above this temperature the coolant temperature is
controlled by the radiator, fan, and ambient tempera­
ture, not the thermostat.
O P E R A TIO N AND T E ST IN G
The thermostat is operated by a wax filled con­
tainer (pellet) which is sealed so that when heated to
a predetermined temperature. The wax expands enough
to overcome the closing spring and water pump- pres­
sure, which forces the valve to open. Coolant leakage
into the pellet will cause a thermostat to fail open. Do
not attempt to free up a thermostat with a screwdriver.
The open too soon type failure mode is included in
the onboard diagnosis. 'The check engine light will -not
be lit by an open too soon condition, but if it has failed
open, code 17 will be set..Do not change a thermostat
for lack of heat by gauge or heater performance, un­
less code 17 is present, see diagnosis for other proba­
ble causes. Failing shut is the normal long term mode
of failure, and normally, only on high mileage vehi­
to diagnosis in this section.
HEMOVAL
(1) Drain cooling system down to thermostat level
or below. ' ’
(2) Remove thermostat housing holts and housing
(Figs. 8» 9 and 10).
(3) Remove thermostat, discard gasket and clean
both gasket sealing surfaces.
 INSTALLATION —3.0L ENGINE
Center thermostat in water box pocket. Check that
the flange is seated correctly in the countersunk por­
tion of the intake manifold water box (Figs. 9 and 10).
Install new gasket on water box. Install housing over
gasket and thermostat and tighten bolts to 12 N-m
(133 in. lbs. torque).

FLANGE AIR VENT FLANGE IN

Fig. 8 Thermostat, Housing, and Water Box—

2.5L Engine

12 N-m

Fig. 10 Thermostat Installed—3.0L Engine

Fig. 9 Thermostat, Housing, and Water Box-

3.0L Engine

INST ALL A T IO N -2 .5 L ENGINE

Place a new gasket (dipped in clean water) on water
box surface, center thermostat in water box on gasket.
Place housing over gasket and thermostat, making
sure thermostat is in the thermostat housing. Bolt Fig. 11 Thermostat, Housing and Waterbox—
housing to water box (Fig. 8 ). Tighten bolts to 28 N-m 3.3L Engine
(250 in. lbs.). Refill cooling system (see Refilling
System).
INSTALLATION—3.3L
Place a new gasket (dipped in water) on the water
box surface, center thermostat into opening in the
intake manifold. Place housing over gasket and ther­
mostat, making sure thermostat is in recess provided
(Fig. 11). Bolt housing to intake manifold, tighten
bolts to 28 N-m (250 in. lbs.). Refill cooling system (see
Refilling System).
COOLANT
The cooling system is designed around the coolant.
The coolant must accept heat from engine metal, in
the cylinder head area near the exhaust valves. Then
carry this heat to the radiator where the tube/fin
assemblies of these components can give it up to the
air.
PERFORMANCE
Performance is measurable. For heat transfer pure
water excels (Formula = 1 btu per minute for each
degree of temperature rise for each pound of water).
This formula is altered when necessary additives to
control boiling, freezing, and corrosion are added as
follows:
• Pure Water (1 btu) boils at 100°C (212°F) and freezes
at 0°C (32°F)
• 100% Glycol (.7 btu) can cause a hot engine and
detonation and will raise the freeze point to 22°C
(-8°F).
• 50/50 Glycol and Water (.82 btu) is the recommended
combination that provides a freeze point of -37°C(-35°F).
The radiator, water pump, engine water jacket, radia­
tor pressure cap, thermostat, temperature gauge, send­
ing unit and heater are all designed for 50/50 glycol.
Where required, a 56 percent glycol and 44 percent
water mixture will provide a freeze point of-59°C (-50°F).
CAUTION: Richer mixtures cannot be measured with
field equipment which can lead to problems associ­
ated with 100 percent glycol.
SELECTION AND ADDITIVES
The use of aluminum cylinder heads, intake mani­
folds, and water pumps requires special corrosion pro­
tection. Mopar Antifreeze, Prestone H, Peak or antifreeze
containing Alugard 340-2, or their equivalent are rec­
ommended for best engine cooling without corrosion.
When mixed only to a freeze point of -37°C (-35°F) to
-59°C (-50°F). If it looses color or becomes contami­
nated, drain, flush, and replace with fresh properly
mixed solution.
SERVICE
Coolant should be changed at 52,500 miles or three
years, whichever occurs first, then every two years or
30,000 miles.
ROUTINE LEVEL CHECK
Do not remove radiator cap for routine coolant
level inspections.
The coolant reserve system provides a quick visual
method for determining the coolant level without re­
moving the radiator cap. Simply observe, with the
engine idling and warmed up to normal operating
temperature, that the level of the coolant in the re­
serve tank (Figs. 15) is between the minimum and
maximum marks.
ADDING ADDITIONAL COOLANT
The radiator cap should not be removed. When
additional coolant is needed to maintain this level, it
should be added to the coolant reserve tank. Use only
50/50 concentration of ethylene glycol type antifreeze
and water.
SERVICE COOLANT LEVEL
The cooling system is closed and designed to main­
tain coolant level to the top of the radiator.
When servicing requires a coolant level check in the
radiator, the engine must be off and not under pres­
sure. Drain several ounces of coolant from the radia­
tor drain cock while observing the Coolant Recovery
System (CRS) Tank. Coolant level in the CRS tank
should drop slightly. Then remove the radiator cap.
The radiator should be full to the top. If not, and the
coolant level in the CRS tank is at the MIN mark
there is a air leak in the CRS system. Check hose or
hose connections to the CRS tank, radiator filler neck
or the pressure cap seal to the radiator filler neck for
leaks.
LOW COOLANT LEVEL AERATION
Low coolant level in a cross flow radiator will equal­
ize in both tanks with engine off. With engine at
running operating temperature the high pressure in­
let tank runs full and the low pressure outlet tank
drops. If this level drops below the top of the transmis­
sion oil cooler, air will be sucked into the water pump:
• Transmission oil will become hotter.
• High reading shown on the temperature gauge.
• Air in the coolant will also cause loss of flow through
the heater.
• Exhaust gas leaks into the coolant can also cause
the same problems?
DEAERATION
Air can only be removed from the system by gather­
ing under the pressure cap. On the next heat up it
will be pushed past the pressure cap into the CRS
tank by thermal expansion of the coolant. It then
escapes to the atmosphere in the CRS tank and is
replaced with solid coolant on cool down.
COOLING SYSTEM DRAIN,
CLEAN FLUSH AND REFILL
Drain, flush, and fill the cooling system at the mile­
age or time intervals specified in the Maintenance
Schedule in this Group, i f t h e 'solution is dirty or
rusty or contains a considerable amount of sediment,
clean and flush with a reliable cooling system cleaner.
Care should be taken in disposing of the used engine
coolant from your vehicle. Check governmental regu­
lations for disposal of used engine coolant.
DRAINING COOLING SYSTEM
To drain cooling system move temperature selector
for heater to full heat with engine running (to provide
vacuum for actuation). Without reroowifig radiator pres­
sure cap and with system not under pressure, Shut
engine off and open draincock. The coolant recovery
tank (Fig. 15) should empty first, then remove radia­
tor pressure cap. (if not, see Testing Cooling System
for leaks). To vent 2.5L engine remove the plug above
thermostat housing (Fig. 12). To vent 3.3L engine
remove the engine temperature sending unit (Fig. 13)
Fig. 12 Thermostat Homing Draln/FIII Plug—
2.51 Engine
Removal of a plug or other component is required
because these thermostats do not have a air vent and
prevents air flow through it. This allows the coolant
to drain from the engine block.
Fig. 13 Engine Temperature Sending Unit
3.31 Draln/FIII
CLEANING ■-
Drain cooling system (see: Draining Cooling- Sys­
tem) and refill with clean water (see Refilling Cooling
System). Run engine with radiator cap installed until
upper radiator hose is hot. Stop engine and drain
water from system. If water is dirty, fill, run and
drain system again until water runs clear.
m w e m e f l u s h in g .
Reverse flushing of the cooling system is the forcing
of water through the cooling system, using air pres­
sure in a direction opposite to that of the normal flow
of water. This is usually only necessary with very
dirty systems with some evidence of partial plugging.
RADIATOR ' '
Drain cooling system and remove radiator hoses
from engine. Install suitable flushing gun in radiator
lower hose. Fill radiator with clean water and turn on
air in short blasts.
CAUTION: Internal radiator pressure must not ex­
ceed 138 kPa (20 psi) as damage to radiator may
result. Continue this procedyre until water runs clear.
E iilil
Drain radiator (see: Draining Cooling System)and
remove hoses from radiator. Remove engine thermo­
stat and reinstall thermostat housing. Install suitable
flushing gun to thermostat housing hose. Turn on
water, and when engine is filled, turn on air, but no
higher than 138 kPa (20 psi) in short blasts. Allow
engine to fill between' blasts of air. Continue this
procedure until water runs clean. Reinstall thermo­
stat using a new housing gasket. Fill cooling system
(See Refilling).
CHEMICAL CLEANING
One type of corrosion encountered with aluminum
cylinder heads is aluminum hydroxide deposits. Cor­
rosion products are carried to the radiator and depos­
ited when cooled off. They appear as dark grey when
wet and white when dry. This corrosion can be removed
with a two part cleaner (oxalic acid and neutralizer)
available in auto parts outlets. Follow manufacturers
directions for use.

REFILLING
First clean system to remove old glycol, see Cooling
System Cleaning.
Fill system, using antifreeze described in Coolant.
Fill 50% of capacity with 100% glycol. Then complete
filling system with water. The 2.5L engine requires
venting by removal of the plug on top of the water box
(Fig. 12). The 3.3L Engine requires removal of the
Engine Temperature Sending Unit on the front of the
cylinder head (Fig. 13). When coolant reaches this
hole;
• Install vent plug and tighten to 20 N-m (15 ft. lbs.)
for 2.5L Engines.
• Install Engine Temperature Sending Unit and tighten
to 7 N-m (60 in. lbs.) for 3.3L Engines.
Continue filling system until full, this prqvides bet­
ter heater performance. Be careful not to spill cool­
ant on drive belts or the alternator.
Fill coolant reserve system to at least the MAX Fig. 14 Pressure Testing Cooling System
mark with 50/50 solution. It may be necessary to add
coolant to the reserve tank to maintain coolant level If there are no external leaks, after the gauge dial
between the MAX and MIN mark after three or four shows a drop in pressure, detach the tester. Start
warm-up, cool down cycles and trapped air has been engine and run the engine to normal operating tem­
removed. perature in order to open the thermostat and allow
the coolant to expand. Re-attach the tester. If the
TESTING SYSTEM FOR LEAKS needle on the dial fluctuates it indicates a combustion
leak, usually a head gasket leak.
With engine not running, wipe the radiator filler WARNING: WITH TOOL IN PLACE PRESSURE BUILDS
neck sealing seat clean. The radiator should be full. UP FAST. ANY EXCESSIVE AMOUNT OF PRESSURE
Attach the Tester Radiator Pressure Tool to the BUILT UP BY CONTINUOUS ENGINE OPERATION
radiator, as shown in (Fig. 14) and apply 104 kPa (15 MUST BE RELEASED TO A SAFE PRESSURE POINT.
psi) pressure. If the pressure drops more than 2 psi in NEVER PERMIT PRESSURE TO EXCEED 138 kPa (20
2 minutes inspect all points for external leaks. psi).
All hoses, radiator and heater, should be shaken
while at 104 kPa (15 psi) since some leaks occur only If the needle on the dial does not fluctuate,race the
while driving due to engine rock, etc. engine a few times. If an abnormal amount of coolant
or steam emits from the exhaust system at the tail
pipe, it may indicate a leak that can be a faulty head
gasket, cracked engine block, or cracked cylinder head.
There may be internal leaks which can be deter­
mined by removing the oil dip-stick. If water globules
appear intermixed with the oil it will indicate a inter­
nal leak in the engine. If there is an internal leak, the
engine must be disassembled for repair.
COOLANT RECOVERY SYSTEM (CRS)
This system works in conjunction with the radiator
pressure cap to utilize thermal expansion and contrac­
tion of the coolant to keep the coolant free of trapped
air. It provides a volume for expansion and contrac­
tion, provides a convenient and safe method for check­
ing coolant level and adjusting level at atmospheric
pressure without removing the radiator pressure cap.
It also provides some reserve coolant to cover minor
leaks and evaporation or boiling losses. All vehicles
are equipped with this system and take various shapes
and forms. (Fig. 15) shows a typical system in the
typical location.
RADIATO R SCREW

Fig. 16 Radiator Pressure Cap Filler Neck

RADIATOR CAP TO FILLER NECK SEAL

SYSTEM (CRS) TANK 9107-49
Fig. 15 Typical Coolant Recovery System
See Coolant Level Check Service and Deaeration,
and Pressure Cap sections for operation and service.
Vehicles equipped with the electric monitor system
use a level sensor in the CRS tank, see Group 8,
Electrical, for service.
RADIATOR PRESSURE CAP
Radiators are equipped with a pressure cap which
releases pressure at some point within a range of
97-124 kPa (14-18 psi).
The system will operate at higher than atmospheric
pressure which raises the coolant boiling point allow­
ing increased radiator cooling capacity.
There is also a vent valve in the center of the cap.
This valve also opens when coolant is cooling and
contracting allowing coolant to return to radiator from
coolant reserve system tank by vacuum through con­
necting hose. If valve Is stuck shut, the radiator hoses
will be collapsed on cool down. Clean the vent valve
(Fig. 16) to ensure proper sealing when boiling point
is reached.
There is also a gasket in the cap to seal to the top of
the filler neck so that vacuum can be maintained for
drawing coolant back into the radiator from the cool­
ant reserve tank.
PRESSURE RELIEF CHECK
The pressure cap upper gasket (seal) pressure relief
can be checked by removing the overflow hose at the
radiator filler neck nipple (Fig. 16). Attach the Radia­
tor Pressure Tool to the filler neck nipple and pump
air into the radiator. Pressure cap upper gasket should
relieve at 69-124 kPa (10-18 psi) and hold pressure at
55 kPa (8 psi) minimum.
WARNING: THE WARNING WORDS DO NOT OPEN
HOT ON THE RADIATOR PRESSURE CAP IS A
SAFETY PRECAUTION. WHEN HOT, PRESSURE
BUILDS UP IN COOLING SYSTEM. TO PREVENT
SCALDING OR INJURY, THE RADIATOR CAP SHOULD
NOT BE REMOVED WHILE THE SYSTEM IS HOT
AND/OR UNDER PRESSURE.
There is no need to remove the radiator cap at any
time except for the following purposes:
(1) Check and adjust antifreeze freeze point.
(2) Refill system with new anti-freeze.
(3) Conducting service procedures.
(4) Checking for vacuum leaks.
WARNING: IF VEHICLE HAS BEEN RUN RECENTLY,
WAIT 15 MINUTES BEFORE REMOVING CAP. THEN
PLACE A SHOP TOWEL OVER THE CAP AND WITH­
OUT PUSHING DOWN ROTATE IT COUNTER­
CLOCKWISE TO THE FIRST STOP. ALLOW FLUIDS
TO ESCAPE THROUGH THE OVERFLOW TUBE AND
WHEN THE SYSTEM STOPS PUSHING COOLANT AND
STEAM INTO THE CRS TANK AND PRESSURE DROPS
PUSH DOWN AND REMOVE THE CAP COMPLETELY.
SQUEEZING THE RADIATOR INLET HOSE WITH A
SHOP TOWEL (TO CHECK PRESSURE) BEFORE
AND AFTER TURNING TO THE FIRST STOP IS
RECOMMENDED.
PRESSURE TESTING RADIATOR CAP
Dip the pressure cap in water, clean any deposits off
the vent valve or its seat and apply cap to end of
Radiator Pressure Tool. Working the plunger, bring
the pressure to 104 kPa (15 psi) on the gauge. If the
pressure cap fails to hold pressure of at least 97 kPa
(14 psi) replace cap. See CAUTION below.
If the pressure cap tests properly while positioned
on Radiator Pressure Tool (Fig. 17), but will not hold
pressure or vacuum when positioned on the radiator.
Inspect the radiator filler neck and cap top gasket for
irregularities that may prevent the cap from sealing
properly.
CAUTION: Radiator Pressure Tool is very sensitive
to small air leaks which will not cause cooling sys­
tem problems. A pressure cap that does not have a
history of coolant loss should not be replaced just
because it leaks slowly when tested with this tool.
Add water to the tool. Turn tool upside down and
recheck pressure cap to confirm that cap is bad.
Replacement cap must be of the type designed for
coolant reserve system with a completely sealed dia­
phragm spring, and rubber gasket to seal to filler
neck top surface. This design assures coolant return to
radiator.
RADIATORS
The radiators are downflow types (vertical tubes)
with design features that provide greater strength as
well as sufficient heat transfer capabilities to keep the
engine satisfactorily cooled.
CAUTION: Plastic tanks, while stronger then brass
are subject to damage by impact, such as wrenches
etc., or by excessive torque on hose clamps.
In case of plastic tank damage, plastic tank and/or
O-rings are available for service repair. Tank replace­
ment should be accomplished by qualified personnel
with proper equipment.
RADIATOR DRAINCOCK SERVICE
REMOVAL
(1) Turn the drain cock stem counterclockwise to
unscrew the stem. When the stem is unscrewed to the
end of the threads, pull the stem (Fig.l) from the
radiator tank and draincock body.

PRESSURE ■w
TESTER

J9107-28

Fig. 17 Pressure Testing Radiator Cap

INSPECTION
Hold the cap in hand, right side up. (Fig. 16) The
vent valve at the bottom of the cap should open. If the
rubber gasket has swollen and prevents the valve
from opening, replace the cap. Fig.1 Draincock Disassembled (Typical)
Hold the cleaned cap in hand upside down. If any
light can be seen between vent valve and rubber gas­
ket, replace cap. Do not use a replacement cap that
has a spring to hold the vent hut.

Fig.2 Removing Draincock Body (Typical)
(2) Remove the draincock body from the radiator shroud attaching nuts, and lift shroud up and out of
tank by squeezing the sides together with a pair of
needle nose pliers (Fig. 2). Then, pull the body from
the inlet tank.
INSTALLATION
(1) Check the draincock to be sure the body is in­
stalled loosely on the stem (Fig. 3). If the stem is
screwed into the body, the draincock cannot be in­
stalled into the tank opening.
(2) Push the loosely assembled draincock assembly
body into the tank opening until it snaps into place.
(3) Tighten the draincock stem by turning clockwise
to 2.0-2.7 N-m (18-25 in. lbs.) torque.
Fig. 3 Draincock Assembled for Installation (Typical)
RADIATOR COOLANT FLOW CHECK
To determine whether coolant is flowing through
the cooling system, use the following procedure:
(1) If engine is cold, idle engine until normal operat­
ing temperature is reached. Then feel the upper radia­
tor hose. If it is hot, coolant is circulating.
(2) Drain a small quantity of coolant from the radia­
tor to expose a few radiator tubes that can be seen by
looking down through the radiator filler neck. With
engine idling at normal operating temperature, if cool­
ant is flowing out of the exposed tubes, coolant is
circulating.
REMOVAL
(1) Disconnect negative battery cable from battery.
WARNING: DO NOT REMOVE THE CYLINDER BLOCK
OR THE RADIATOR DRAINCOCK WITH THE SYS­
TEM HOT AND UNDER PRESSURE BECAUSE SERI­
OUS BURNS FROM COOLANT CAN OCCUR.
(2) Drain cooling system. Refer to Draining Cooling
System of this section.
(3) Remove hose clamps and hoses from the radiator
(Fig. 4). Remove coolant reserve system tank to filler
neck tube.
(4) Remove automatic transmission hoses, if equipped.
(5) Remove fan and fan support assembly by discon­
necting fan motor electrical connector. Remove upper
bottom shroud attachment clips separating shroud from
radiator. Fan damage should always be avoided.
(6) Remove upper radiator mounting screws. Dis­
connect the engine block heater wire if equipped.
(7) Radiator can now be lifted free from engine com­
partment. Care should be taken not to damage radia­
tor cooling fins or water tubes during removal.
INSTALLATION
(1) Slide radiator down into position behind radiator
support (yoke) with a force of approximately 10 lbs. to
seat the radiator lower rubber isolators in the mount
holes provided.
(2) The upper brackets must be preloaded with 10
lbs. force down to prevent impact loading of the rub­
ber isolators. Rubber grommets are used at the top on
some designs which do not require a preload. Tighten
radiator mounting bolts to 11.9N-m (105 in. lbs.) Fig.
4).
(3) Connect automatic transm ission hoses (if so
equipped).
(4) Slide fan shroud, fan and motor down into clips
on lower radiator flange. Attach upper shroud screws.
(5) Install upper and lower radiator hoses (including
coolant reserve hoseXFig. 4) and fan motor electrical
connection. See Refilling Cooling Systems.
(6) Connect negative battery cable.
 UPPER ISOLATOR TQRQUE
PANEL A T T 9 N*m (105 IN. LBS.)
B r 8.5 N *m l75 IN. LBS.)~
C 1.8 N*m (17 IN L B S j-

CLOSURE
PANEL

HEAT OUTLET
SHIELD HOSE
3.0 /3 .3 1 ENGINES
INLET HOSE

3.3L ENGINE - VIEW IN DllECTlON

OUTLET HOSE O f A R IO W Z
tA D lA T O i 2.5L ENGINE
FAN MODULE
3.01
' ENGINE
OUTLET HOSE FRONT ENGINE MOUNT 9107-39

Fig. 4 Radiator, ALL

RADIATOR HOSES
The 2.5L engine lower radiator hose MUST be clipped
to front engine mounting bracket to protect hose from
fan and road damage. (Fig.4)
The hoses are removed using screwdriver, or hex
wrench on hose clamp. A' torque wrench MUST be used
when tightening hose clamps.
CAUTION: To prevent hose or clamp damage. Tighten
to 4.1 N*m (35 In. lbs.) using a torque wench. Do not
overtighten.
A hardened, cracked, swollen or restricted hose should
be replaced. Do not damage radiator inlet and outlet
when loosening hoses. '; '
Radiator hoses should be routed without any kinks
and indexed as designed. The use of molded hoses is
recommended.
FANS ■■
All models use electric motor driven cooling system
fans. The fan modules include a motor support which
may (depending on model) include a shroud. The mod­
ule is fastened to the radiator by clips or bolts, see
(Fig. 4). '- . .
All fan motors are one -speed. Attempts to-reduce
high temperature gauge reading by increasing engine
speed, at the same vehicle .spied,... can increase high
temperature.
FAN SERVICE. '
There-are no repairs to be made to the fan. If the
fan is warped, cracked, .or .otherwise damaged, it must
be replaced with only the recommended part for ade­
quate strength, performance-and safety.
REM OVAL ■ , ■
Disconnect electric motor lead. Remove fan, motor
and shroud or support as an assembly from radiator
support.
To remove fan from motor shaft, bench support the
motor and motor shaft, while removing the fan retain­
ing clip, so that the shaft and motor, will not be dam­
aged by excessive force,. Surface or burr removal may
be required to remove fan from motor shaft. (Fig. 5).
Do not permit the fen blades to touch the bench.
 TEMPERATURE GAUGE INDICATION
At idle with Air Conditioning off the temperature
gauge will rise slowly to about 5/8 gauge travel, the
fan will come on and the gauge will quickly drop to
about 1/2 gauge travel this is normal.

ELECTRIC FAN MOTOR

To check out the electric fan motor, disconnect the
fan motor wire connector and connect it with #14
gauge wires to a good 12-volt battery observing cor­
rect polarity per (Fig. 6). If the fan runs normally, the
motor is functioning properly. If not, replace motor
using the removal and installation instructions con­
tained in the Fan Section. If the motor is noticeably
overheated(i.e.; wire insulation melted, motor charred)
the system voltage may be too high. Check charging
system, see Group 8A, Battery/Starting/Charging Sys­
tem Diagnostics.

INSTALLATION
Slide the fan on motor shaft. Support motor and
shaft as above, while installing fan retaining clip.
Install assembly into pocket on lower radiator tank.
Attach shroud clips or support nuts and washers. Con­
nect fan motor lead. For wiring diagrams of fan motor
systems see Electrical Group 8.

RADIATOR FAN CONTROL

Fan control is accomplished two ways. The fan al­
ways runs when the air conditioning compressor clutch
is engaged. In addition to this control, the fan is turned
on by the temperature of the coolant which is sensed
by the coolant temperature sensor which sends the
message to the onboard computer. The computer turns
on the fan through the fan relay. See Group 8W for
circuity and diagnostics provided.
Switching through the on-board computer provides
fan control for the following conditions; Fig. 6 Electric Fan Motor (Typical)
• The fan will not run during cranking until the en­
gine starts no matter what the coolant temperature is.
ELECTRIC FAN MOTOR TEST
• Fan will always run when the air conditioning clutch EQUIPMENT REQUIRED
is engaged. • Diagnostic Tool DRB II or equivalent
• The fan will run at vehicle speeds above about 40 • Volt/Ohm Meter
mph only if coolant temperature reaches 110°C (230°F).
• Wiring Diagrams Manual
It will turn off when the temperature drops to 104°C
(220°F). At speeds below 40 mph the fan switches on
TEST PROCEDURE
at 99°C (210°F) and off at 93°C (200°F).
(1) Run the engine to normal operating temperature
• This is to help prevent steaming. The fan will run (2) Check wiring connector in C25, C9, and C26 for
only below 16°C (60°F) ambient. Between 38°C (100°F) proper engagement, see Wiring Diagrams.
to 97°C (195°F) coolant temperature, at idle and then (3) Using a diagnostic tool, plugged into the diag­
only for three minutes. nostic connector rearward of the battery, check the

On-Board Diagnostics (OBD) in the Single Board En­
gine Control (Engine Controller) for fault codes, see
Group 14, Fuel Injection for instructions.
(4) If fault code 88-12-35-55 is detected, proceed to
Step 5.
(5) With the ignition switch in the run position, test
for battery voltage at single pin connector at the fan
relay. Voltage reading OK, proceed to Step 6a. Volt­
age at 0-1 volt, proceed to Step 6b.
(8a) With the ignition off, disconnect the 60-way
connector from the Engine Controller (outboard of bat­
tery) and return the ignition to the run position. Test
for battery voltage at cavity 31 of the 60-way connec­
tor (Fig. 7). Voltage reading OK and female terminal
is not damaged, replace the Engine Controller. Volt­
age reading 0, repair open or short in C27 circuit.
(8b) With the ignition off, disconnect the 60-way
connector from the Engine Controller (outboard of
battery)and return the ignition to the run position.
Test for battery voltage at the single pin connector at
the fan relay. Voltage reading OK, replace the Engine
Controller. Voltage reading 0-1 volt, proceed to Step
7.
(7) With ignition in the run position, test for battery
voltage at the blue wire (C27) in the 3-way connector
of the fan relay. Voltage reading OK, replace the fan
relay. Voltage reading 0, repair open or short, in C27
circuit.
(8) Turn ignition off, connect the 80-way connector
at the Engine Controller, and test the system.
Pig. 7 Engine Controller 60-Way
Connector fmm Terminal End
COOOIG SYSTEM 7-23
PAN SHROUD
AH air conditioning equipped vehicles have fan
shrouds to improve fan air flow efficiency. These fan
shrouds cover less than full radiator frontal area to
prevent the shroud from restricting airflow at high
speeds.
The shroud supports the electric fan motor and fan.
All other non A/C vehicles have a fan motor support
assembly instead of a shroud. For removal and instal­
lation see Radiator Removal Section.
AUTOMATIC TRANSMISSION OIL COOLERS
Oil coolers are of two types, internal oil to coolant
type, mounted in the radiator left tank (Fig. 8) or
external oil-to-air type mounted ahead of or below the
radiator, (Fig. 8).
Rubber oil lines feed the oil cooler and the auto­
matic transmission. Use only approved transmission
oil cooler hose. Since these are molded to fit space
available, molded hoses are recommended.
 TRANSMISSION OIL
TO AIR AUXILIARY
COOLER

SCREW
TRANSMISSION TO
O IL COOLER HOSE
ASSEMBLY

RADIATOR
ASSEMBLY RADIATOR
CLAMPS ASSEMBLY
TRANSMISSION TO
OIL COOLER HOSE
ASSEMBLY

VIEW IN DIRECTION
OF ARROW Z 9007-29

Fig. 8 Transmission Oil Coolers

ACCESSORY DRIVE BELTS

INDEX
Page Page
2 .5L Engine Belts Remove/Install— Adjust 25 3.3L Engine Accessory Drive Belt Remove/Install . . . 28
3 .0L Engine Belts Remove/Install— Adjust 26 General Information ...................................................... 25
 ACCESSORY DRIWE BELTS 'DIAGNOSIS
C ondition Possible Cause C o rre c tio n

INSUFFICIENT (a) Belt too loose. Adjust belt tension.

ACCESSORY OUTPUT DUE (b) Belt excessively glazed or worn. Replace and tighten as specified.
TO BELT SLIPPAGE

BELT SQUEAL W H E N (a) Belts too loose. (a) Adjust belt tension.
ACCELERATING ENGINE (b) Belts glazed. (b) Replace belts.

BELT SQUEAK AT IDLE
(a) Belts too loose. fa) Adjust belt tension.
(b) Dirt and paint imbedded in belt, (b) Replace belt.
fc) Non-uniform belt. (c Replace belt.
(d) Misaligned pulleys. (d Align accessories (file brackets or use
spacers as required).
(e) Non-uniform groove or eccentric (e) Replace pulley.
pulley.

BELT ROLLED OVER IN (a) Broken cord in belt. . Replace belt.

6 1 0 0 W I OR BELT JUMPS OFF (b) Belt too loose, or too tight. Aajust belt tension.
(c) Misaligned pulleys. Align accessories.
(d) Non-uniform groove or eccentric Replace pulley.
pulley.
9107-27

GENERAL INFORMATION lOitUE EQUIVALENT METHOD

Adjustable accessory brackets provided with a 13mm
PROPER BELT TENSION (1/2 in.) square hole for a torque wrench can use an
Satisfactory performance of the belt driven accesso­ equivalent torque value for belt adjustment.
ries depends on proper belt tension.Three tensioning Equivalent torque values for adjusting these acces­
methods are given in order of preference: sory drive belts are specified on the Belt Tension Chart.
• Belt tension gauge method.
BELT REPLACEMENT UNDER ANY O i ALL O f THE
• Torque equivalent method. FOLLOWING CONDITIONS IS REQUIRED, EXCESSIVE DRIVE
• Belt deflection method. WEAR FRAYED CORDS SEVERE GLAZING. BELT

Because of space limitations in the engine compart­
ment of front wheel drive vehicles, the belt tension
gauge method is usually restricted to use after the
vehicle has been raised on a hoist and the splash
shield has been removed.
BELT TENSION GAUGE METHOD
For conventional belts, affix the Burroughs gauge
(Tool C-4162) to the belt.
For Poly-V belt, 2.5L engine, alternator/water pump
belt use a Poly-V Burroughs gauge.
Adjust the belt tension for a New or Used belt as
prescribed in the Belt Tension Chart.
BELT DEFLECTION METHOD
Place a straight edge across two adjacent pulleys
and adjust belt tension with a force (push-pull) of 44N
(10 lbs.) applied at the mid-point produces a belt de­
flection as specified in the Belt Tension Chart.
A small spring scale can be used to establish the
44N (10 lbs.) load.
"V * RIBBED BELT SYSTEM WITH ACROSS
BACK DRIVE PULLEY MAY DEVELOP
MINOR CRACKS ACROSS THE RIBBED PARAllfcl
SIDE (DUE TO REVERSE BENDING).THESE
MINOR CRACKS ARE CONSIDEiED NORMAL
AND ACCEPTABLE. CRACKS PARALLEL ARE NOT,
DO NOT USE ANY TYPE OF BELT DRESSING
OR RESTOiEi ON "V" RIBBED BELTS. 9007-17
Fig. f Driwe Belt Inspection
2.5L ENGINE BELTS REMOVE/INSTALL-ADJUST
AIR CONDITIONING COMPRESSOR
(1) Loosen the idler bracket pivot screw A and lock­
ing screws B (Fig. 2) to remove and install belt and/or
adjust belt tension.
(2) Adjust belt tension by applying torque to square
hole C on idler bracket. Adjust tension to specification
given in Belt Tension Chart.
(3) Tighten in order, first, locking screws B then
pivot screw A to 54 N-m (40 ft. lbs.)
 LOCKING
© SCREW
/ T \ SQUARE OPENING
W ADJUST

BELT REPLACEMENT
UNDER ANY OR ALL
OF THE FOLLOWING
CONDITIONS IS REQUIRED
EXCESSIVE WEAR
FRAYED CORDS
SEVERE GLAZING

"V" RIBBED BELT SYSTEM WITH

BACK DRIVE PULLEY MAY DEVELOP
MINOR CRACKS ACROSS THE RIBBED
SIDE (DUE TO REVERSE BENDING)
THESE MINOR CRACKS ARE CONSIDERED ADJUSTING
NORMAL AND ACCEPTABLE. CRACKS SCREW
PARALLEL ARE NOT

ACROSS

PARALLEL

IDLER BRACKET LOCKING NUT

© PIVOT SCREW (T-BOLT) 9107-42

Fig. 2 Accessory Drive Belts 2.5L Engine

POWER STEERING P U M P S TYPE then turn the adjusting screw to raise or lower the
(1) From on top of the vehicle loosen locking screw G. idler pulley (Figs. 3 and 4).
(2) From under the vehicle loosen the pivot screw
and pivot nut H. JACK SCREW
(3) After installing a new belt adjust belt tension
with 1/2 in. breaker bar installed in adjusting bracket.
See tension specification in Belt Tension Chart.
(4) Tighten locking screw G to 54 N-m (40 ft.lbs.).
(5) Tighten pivot screw H and the pivot nut to 54
N-m (40 ft. lbs.)

ALTERNATOR BELT
(1) Loosen alternator pivot nut D.
(2) Loosen T-Bolt locking nut E and adjusting screw
F to remove and install Poly V belt and/or adjust belt
tension.
(3) Tighten pivot nut D to 41 N-m (40 ft. Lbs.).
(4) Tighten adjusting screw F to adjust belt tension
to specification shown in Belt Tension Chart.
(5) Tighten T-Bolt locking nut E to 34 N-m (40 ft.
lbs.)

3.0L ENGINE BELTS REMOVE/INSTALL-ADJUST

AIR CONDITIONING BELT
To remove and install the air conditioning compres­
sor drive belt, first loosen the idler pulley lock nut,
 To adjust the air conditioning drive belt, loosen the ALTERNATOR/POWER STEERING PUMP BELT
idler pulley nut (Fig. 3) and adjust belt tension by The Poly-V altemator/power steering pump belt is
tightening adjusting screw (Figs. 3 and 4). Tighten provided with a dynamic tensioner (Fig. 5) to main­
pulley nut to 57 N'm (40 ft. lbs.) after adjustment. tain proper belt tension. To remove or install this belt,
insert a 1/2 inch breaker bar in the opening provided
BELT DEFLECTION AND ADJUSTMENT and release tension by rotating the tensioner counter­
WARNING: BELTS MUST BE CHECKED WITH EN­ clockwise (Fig. 5).
GINE NOT RUNNING.
The belt can be adjusted by measuring the deflec­
tion of the belt at the mid-point between two pulleys
under a ten-pound push or pull. A small spring scale
can be used to establish the ten-pound belt load.
Belt deflection under a ten-pound push or pull should
be between 6 mm (1/4 in.) to 8mm (5/16 in.) at the
location shown in (Fig. 3). Deflection on a new belt
should be between 6mm (1/4 in.) to 8 mm (5/16 in.) a
belt is considered used after 15 minutes of engine
operation and set to between 6 mm (1/4 in.) and 8 mm
(5/16 in.) under a ten-pound load.

Fig.5 Release BeltTensioner

Fig.4 AirConditioning BeltIdler

 BELT TENSION CHART

ACCESSORY DRIVE BELT GAUGE DEFLECTION TORQUE

2.5L ENGINE
NEW 125 LB. 8MM (5/16 IN.) 54 N *M (40 FT. LBS.)
AIR CONDITIONING COMPRESSOR
USED 80 LB. I1MM (7/16 IN.) 41 N *M (30 FT. LBS.)
NEW 130 LB. 3MM (1/8 IN.) 149 N»M (110 FT. LBS.)
ALTERNATOR/WATER PUMP POLY “V"
USED 80 LB. 6MM (1/4 IN.) 108 N»M (80 FT. LBS.)
NEW 105 LB. 6MM (1/4 IN.) 102 N»M (75 FT. LBS.)
POWER STEERING PUMP
USED 80 LB. I1MM (7/16 IN.) 75 N *M (55 FT. LBS.)
3.0L ENGINE
NEW 125 LB. 8MM (5/16 IN.)
AIR CONDITIONING COMPRESSOR
USED 80 LB. 6MM (1/4 IN.)
ALTERNATOR/WATER PUMP/POWER NEW DYNAMIC TENSIONER
STEERING PUMP USED
3.3L ENGIN
AIR CONDITIONING COMPRESSOR NEW DYNAMIC TENSIONER
ALTERNATOR/WATER PUMP/POWER USED
STEERING PUMP

9007-31

3.3L ENGINE ACCESSORY DRIVE BELT

REMOVE/INSTALL ACCESSORY DRIVE
BELT TENSIONER
ALTERNATOR, POWER STEERING PUMP,
AIR CONDITIONING COMPRESSOR AND
WATER PUMP DRIVE BELT
The Poly-V Drive belt is provided with a dynamic
tensioner (Fig. 6) to maintain proper belt tension. To
remove or install this belt.
(1) Raise vehicle on hoist.
(2) Remove right front splash shield.
(3) Release tension by rotating the tensioner clock­
wise (Fig. 6).
(4) Reverse above procedure to install.

9107-26

Fig. 6 Accessory Drive Belt—3.3L Engine

 ENGINE BLOCK HEATER
DESCRIPTION AND OPERATION
On all models an engine block heater is available as
an optional accessory. The heater is operated by ordi­
nary house current (110 Volt A.C.)through a power
cord located behind the radiator grille.This provides
easier engine starting and faster warm-up when vehi­
cle is operated in areas having extremely low temper­
atures. The heater is mounted in a core hole (in place
of a core hole plug) in the engine block, with the
heating element immersed in coolant (Fig. 7).
The power cord must be secured in its retainer
clips, and not positioned so it could contact linkages
or exhaust manifolds and become damaged.
If unit does not operate, trouble can be in either the
power cord or the heater element. Test power cord for
continuity with a 110-volt voltmeter or 110-volt test
light; test heater element continuity with an ohmme-
ter or 12-volt test light.
REMOVAL
(1) Drain coolant from radiator and cylinder block.
Refer to Cooling System Drain, Clean, Flush and Re­
fill of this section for procedure.
(2) Detach power cord plug from heater.
(3) Loosen screw in center of heater. Remove heater
assembly.
INSTALLATION
(1) Thoroughly clean core hole and heater seat.
(2) Insert heater assembly with element loop posi­
tioned upward.
(3) With heater seated, tighten center screw se­
curely to assure a positive seal.
(4) Fill cooling system with coolant to the proper
level, vent air, and inspect for leaks. Pressurize sys­
tem with Radiator Pressure Tool before looking for
leaks.
 7-30
MAIN HARNESS

COOLING SYSTEM
C O iD
ASSEMBLY

RADIATOR
ASSEMBLY

TIES

CORO ASSEMBLY

VIEW IN DIRECTION
99W m DIRECTION
OF A llO W Z OF ARROW Y
2JL S i£»^ f 107-45

Pig. 7 2 .5 ,3,0 and 3.31 Engine Blmk Hmtem

 SPECIFICATIONS

2 .5 L 3 .0 L 3 .3 L

THERMOSTAT HOUSING BOLT NUT (ALSO

28 N-m (250 IN. LBS.) 12 N'm (113 IN. LBS.) 28 N ’ m (250 IN. LBS.)
RETAIN S DIP STICK TUBE) 2.5L

UPPER (3)
WATER PUMP M OUNTING BO LTS 28 N ’ m (250 IN. LBS.) ALL 11.9 N ’ m (105 IN. LBS.)
LOWER (1) 27 N ’ m (240 IN. LBS.)
72 N ’ m (40 FT. LBS.)

WATER PUMP COVER TO HOUSING BOLTS 12 N ’ m (105 IN. LBS.)

WATER PUMP PULLEY SCREWS 28 N ’ m (250 IN. LBS. 28 N ’ m (250 IN. LBS.)

WATER I NLET PIPE (BRACKET TO CYLINDER

11 N ’ m (94 IN. LBS.)
HEAD SCREWS

TRANSMISSION OIL COOLER HOSE CLAMP 2.0 N ’ m (18 IN. LBS.)

FAN SUPPORT BOLTS 11.9 N*m (105 IN. LBS.) 11.9 N ’ m (105 IN. LBS.) 11.9 N ’ m (105 IN. LBS.)

FAN MOTOR M OUNTING NUT 6.8 N ’ m (60 IN. LBS.) 6.8 N ’ m (60 IN. LBS.) 6.8 N ’ m (60 IN. LBS.)

UPPER RADIATOR MOUNTING BRACKET NUT 11.9 N ’ m (105 IN. LBS.)

9107-48

Torque Specification

ENG INE 2.5L 3.0L 3.3L

(COO LANT)
♦CAPACITY
LITERS 9.0 9.5 9.5
U.S. QTS. 9.5 10.0 10.0

‘ CAPACITY, Includes Heater and Coolant Recovery System

9107-50

Cooling System Capacity

 ELECTRICAL
GROUP INDEX
Page Page
ALTERNATOR SERVICE ............................ 8C POWER SEATS ................................... 8R
BATTERY/STARTER SERVICE ................... 8B POWER WINDOWS .............................. 8S
BATTERY/STARTING/CHARGING SYSTEMS RADIO, ANTENNA AND SPEAKERS 8F
DIAGNOSTICS ..................................... 8A REAR WJNDOW DEFOGGER .................. 8N
HORNS ................................................... 8G RESTRAINT SYSTEM ............. .......... 8M
IGNITION SYSTEM ................................... 8D SPEED CONTROL................................. 8H
INSTRUMENT PANEL AND GAUGES 8E TURN SIGNAL AND FLASHERS .............. 8J
LAMPS ................................................... 8L WINDSHIELD WIPERS AND WASHERS 8K
POWER LOCKS ....................................... 8P WIRING DIAGRAMS .............................. 8W
POWER MIRRORS ................................... 8T
BATTERY/STARTING/CHARGING SYSTEMS DIAGNOSTICS
CONTENTS
Page Page
ALTERNATOR TEST PROCEDURES GENERAL INFORMATION .......................... 1
ON VEHICLE . 17 IGNITION OFF DRAW (IO D )......................... 10
BATTERY TEST PROCEDURES ON-VEHICLE . 3 STARTER TEST PROCEDURES
FAULT CODES— ON BOARD DIAGNOSTICS . 21 ON VEHICLES........................................ 12
GENERAL INFORMATION
The Battery, Starting, and Charging Systems oper­ by turning the ignition switch to ON-OFF-ON-OFF-ON
ate in conjunction with one another, and must be without starting the engine. The CHECK ENGINE
thoroughly tested as a complete system. To enable the LAMP on the instrument cluster will flash in prede­
vehicle to start and charge properly, it must have a termined sequences to indicate Fault Codes. However,
battery that will perform to specifications. The starter the Check Engine Lamp cannot express fault codes for
motor, alternator, wiring, and electronics also must all failures. Fault codes are easier to obtain and more
perform within specifications. Group 8A will cover complete with the use of Diagnostic Tool (DRB II).
Starting (Fig. 1) and Charging System (Fig. 2) diag­ This tool is plugged into the diagnostic connector lo­
nostic procedures. These will be covered from the most cated in the engine compartment (Fig. 2). Refer to the
basic conventional methods to On Board Diagnostics instructions provided with the (DRB II) tool being
(OBD) built into the vehicle’s electronics. The need for used. For numbered Fault Codes, refer to Fault Code
conventional testing equipment has not been elimi­ Descriptions in the General Diagnosis section of Group
nated by the introduction of OBD. Frequent use of an 14, Fuel System for more information.
ammeter, volt/ohmmeter, battery charger, carbon pile
rheostat (load tester), and 12 volt (low wattage) test
light will be required.
All front-wheel-drive vehicles are equipped with OBD
and all OBD sensing systems are monitored by the
Engine Control computer. The Engine Control com­
puter will store in electronic memory, any detectable
failure within the monitored circuits. It will retain
this information for a period of 50 engine starts, then
erase the memory if the failure does not reoccur dur­
ing that period. This will also translate a monitored
failure in the form of a FAULT CODE when a readout
command is given. A readout command can be made
Fig. 2 Charging System Components—Typical
 BATTERY TEST PROCEDURES ON-VEHICLE
INDEX
Page Page
Battery Charging .............................................................. 6 General Information ................. ................ ................ .. 3
Battery Load Test ............................................................ 5 State of Charge Test .................................................. .. 4
Battery Open Circuit Voltage T e s t ................................... 5 Test In d ic a to r.......................................... .............................. 3
Causes of Battery Discharging....................................... 4

GENERAL INFORMATION WARNING: DO NOT ASSIST BOOST, CHARGE, ADD

WATER, OR LOAD TEST BATTERY WHEN ELEC­
The battery stores, stabilizes, and produces electri­ TROLYTE LEVEL IS BELOW THE TOP OF THE PLATES.
cal current to operate various electrical systems in the PERSONAL INJURY MAY OCCUR.
vehicle. The determination of whether a battery is
When the electrolyte level is below the top of the
good or bad is made by the batteries ability to accept a
plates (yellow or bright color indicator in sight glass)
charge. It must also produce high-amperage current
(Figs. 4 and 5), the battery must be replaced. See
output over an extended period. The capability of the
TEST INDICATOR in this group. The battery must be
battery to store electrical current comes from a chemi­
completely charged (green color in sight glass) and
cal reaction. This reaction takes place between the
the top, posts, and terminals should be properly cleaned
sulfuric acid solution (electrolyte) and the lead + /-
before diagnostic procedures are performed. Also see
plates in each cell of the battery. As the battery dis­
Group 8B, BATTERY/STARTER SERVICE, for addi­
charges, the plates collect the acid from the electro­
tional information.
lyte. When the charging system charges the battery,
the acid is forced out of the plates into the electrolyte.
The amount of acid (specific gravity) in the electrolyte
TEST INDICATOR
can be measured with a hydrometer. A factory in­
A test indicator (hydrometer) viewed through a sight
stalled battery is equipped with a built-in hydrometer
glass, is built into the top of battery case (Figs. 3, 4
(test indicator) (Figs. 3, 4 and 5) to assist in determin­
and 5). This provides visual information for battery
ing the batteries state-of-charge. The factory installed
testing. The test indicator (sight glass) is to be used
battery is also sealed. Water can not and should not
with diagnostic procedures described in this group.
be added.
It is important when using the Test Indicator that
battery be relatively level and have a clean top to see
correct indications. A light may be required to view
POSITIVE V E N T iS ^ ig T E S T SBI'VEN T N EGATIVE
P O S T **! I ki Kir* ..... POST indicator.
WARNING: DO NOT USE OPEN FLAME NEAR BAT­
TERY. EXPLOSIVE GASES FORM ABOVE BATTERY.
SIGHT
GLASS

BATTERY
TOP
MAINTENANCI
FREE I
BATTERY 898A-1
GREEN
Fig. 3 Battery Construction and Test Indicator BALL 898A-2

The battery is vented to release gases that are cre­ Fig. 4 Built In Test Indicator
ated when the battery is being charged. The battery
top, posts, and terminals should be cleaned when other
under hood maintenance is performed (Fig. 3).
STATE OF CHARGE TESTS CAUSES OF BATTERY DISCHARGING
USINQ TEST INDICATOR It is normal to have a small (5 to 30 milliamperes)
The built-in test indicator (hydrometer) (Figs. 3, 4 continuous electrical draw from the battery. This draw
and 5) measures the specific gravity of the electrolyte. will take place with the ignition in the OFF position,
Specific Gravity (SG) of the electrolyte will indicate and the courtesy, dome, storage compartments, and
state-of-charge (voltage). The test indicator WILL NOT engine compartment lights OFF. The continuous draw
indicate cranking capacity of the battery. Refer to is due to various electronic features or accessories
BATTERY LOAD TEST in this group for more infor­ that require electrical current with the ignition OFF
mation. Look into the sight glass (Figs. 4 and 5) and to function properly. When a vehicle is not used over
note the color of the indicator (Fig. 5). Refer to the an extended period (approximately 20 days) the MAIN
following description as color indicates: FUSIBLE LINK CONNECTOR (Fig. 6) should be dis­
connected. This is located behind the battery on the
GREEN = 75 to 100% state-of-charge
engine wiring harness. This w ill prevent battery
The battery is adequately charged for further test­ discharging.
ing and may be returned to use. If the vehicle will not
crank for a maximum 15 seconds, refer to BATTERY
LOAD TEST in this group for more information.
BLACK OR DARK = 0 to 75% state-of-charge
The battery is INADEQUATELY charged and must
be charged until green dot is visible, (12.4 volts or
greater) before the battery is tested or returned to
use. Refer to CAUSES OF BATTERY DISCHARG­
ING in this group for more information.
YELLOW OR BRIGHT COLOR
WARNING: DO NOT CHARGE, ASSIST BOOST, LOAD
TEST, OR ADD WATER TO THE BATTERY WHEN
YELLOW OR BRIGHT COLOR DOT IS VISIBLE. PER­
SONAL INJURY MAY OCCUR.
A yellow or bright color dot indicates water (electro­
lyte) level in battery is below the test indicator (Fig.
5). Water can not be added to a maintenance free
battery. The battery must be replaced. A low electro­
lyte level may be caused by an over charging condi­
tion. Refer to ALTERNATOR TEST PROCEDURES
ON VEHICLE in this group. Fig. 6 Main Fusible Link Connector

ABNORMAL BATTERY DISCHARGING

(1) Corroded battery posts, cables or terminals.
(2) Loose or worn alternator drive belt.
(3) Electrical loads that exceed the output of the
charging system due to equipment or accessories in­
stalled after delivery.
(4) Slow driving speeds (heavy traffic conditions) or
prolonged idling with high-amperage electrical sys­
tems in use.
(5) Defective electrical circuit or component causing
excess IGNITION OFF DRAW (IOD). Refer to IGNI­
TION OFF DRAW (IOD) in this group.
(6) Defective charging system.
(7) Defective battery.
BATTERY OPEN CIRCUIT VOLTAGE TEST BATTERY LOAD TEST
An open circuit voltage (no load) test will indicate
A fully charged battery must have reserve cranking
the state of charge in a battery that will endure (pass)
capacity. This will enable the starter motor and igni­
a load test of 50% cold crank rating. See BATTERY
tion system enough power to start the engine over a
LOAD TEST in this group. If a battery has an open
broad range of ambient temperatures. A battery load
circuit voltage reading of 12.4 volts or greater, and
test will verify the actual cranking performance based
will not endure a load test, it is defective and replace­
on the cold crank rating of the battery.
ment would be required. To test open circuit voltage,
perform the following operation: WARNING: IF BATTERY SHOWS SIGNS OF FREEZ­
(1) Remove both battery cables, NEGATIVE first. If ING, LEAKING, LOOSE POSTS, OR EXCESSIVELY
the battery has been boosted, charged, or loaded just LOW ELECTROLYTE LEVEL, DO NOT TEST. ACID
prior to this operation, allow the battery a few min­ BURNS OR EXPLOSIVE CONDITION MAY RESULT.
utes to stabilize.
(1) Remove both battery cables, NEGATIVE first.
(2) Using a voltmeter connected to the battery posts
Battery top, cables and posts should be clean. If green
(see instructions provided with voltmeter being used)
dot is not visible in indicator, charge the battery. See
measure the open circuit voltage (Fig. 7).
BATTERY CHARGING PROCEDURES in this group.
This voltage reading will indicate the battery state
(2) Use a suitable Volt-Ammeter-Load tester (Fig.
of charge. It will not reveal battery cranking capacity.
8) connected to the battery posts (Fig. 9). Refer to
Refer to the BATTERY OPEN CIRCUIT VOLTAGE
operating instructions provided with the tester being
chart in this group.
used. Check the open circuit voltage (no load) of the
battery. Voltage should be equal to or greater than
BATTERY OPEN CIRCUIT VOLTAGE
12.4 volts with green dot visible in test indicator.

Open C irc u it V o lts Percent Change

11.7 volts o r less 0%

12.0 25%
12.2 50%
1 75%
12.6 o r m o re 100%
918A-3

Fig. 8 Volt-Ammeter-Load Tester—Typical

898A7

Fig. 7 Testing Open Circuit Voltage

898A-9
 (3) Rotate the load control knob (Carbon pile rheo­ LOAD TEST TEMPERATURE
stat) to apply a 300 amp load. Apply this load for 15
seconds to remove the surface charge from the bat­ M in im u m V oltage Temperature
tery, and return the control knob to off (Fig. 10).
F° c°
(4) Allow the battery to stabilize for 15 seconds, and
verify open circuit voltage. 9.6 70 a n d a b o v e 21 a n d a b o v e
(5) Rotate the load control knob (on the tester) to 9.5 16
maintain 50% of the battery cold crank rating for a
9.4 50 10
minimum 15 seconds (Fig. 11). (See cold crank rating
in BATTERY SPECIFICATIONS at the back of this 9.3 40
group). 9J -1
30
After 15 seconds, record the (loaded) voltage read­
ing and return the load control to off. 8 .9 20 —7
(6) Voltage drop will vary according to battery tem­ 8.7 10 -1 2
perature at the time of the load test. Battery tempera­
8.5 0 -1 8
ture can be estimated by the temperature of exposure
918A-4
over the preceding several hours. If the battery has
been charged, boosted, or loaded a few minutes prior
BATTERY CHARGING
to test, the battery would be slightly warmer. Refer to
the LOAD TEST TEMPERATURE chart in this group
A battery is considered fully charged when it will
for proper loaded voltage reading.
meet all of the following requirements:
(7) If battery passes load test, it is in good condition
(1) It has an open circuit voltage charge of at least
and further tests are not necessary. If it fails load test, 12.4 volts. See the OPEN CIRCUIT VOLTAGE chart
it should be replaced.
in this group.
(2) It passes the 15 second load test. See BATTERY
LOAD TEST in this group.
(3) The built in test indicator dot is GREEN (Fig. 5).
See TEST INDICATOR in this group.
The battery can not be refilled with water. It must
be replaced.
WARNING: DO NOT CHARGE A BATTERY THAT HAS
EXCESSIVELY LOW ELECTROLYTE LEVEL. BATTERY
MAY SPARK INTERNALLY AND EXPLODE.
EXPLOSIVE GASES FORM OVER THE BATTERY.
DO NOT SMOKE, USE FLAME, OR CREATE SPARKS
NEAR BATTERY.
DO NOT ASSIST BOOST OR CHARGE A FROZEN
898A-10 BATTERY. BATTERY CASING MAY FRACTURE.
Fig. 10 Remove Surface Charge from Battery BATTERY ACID IS POISON, AND MAY CAUSE SE­
VERE BURNS. BATTERIES CONTAIN SULFURIC ACID.
AVOID CONTACT WITH SKIN, EYES, OR CLOTHING.
IN THE EVENT OF CONTACT, FLUSH WITH WATER
AND CALL PHYSICIAN IMMEDIATELY. KEEP OUT
OF REACH OF CHILDREN.
CAUTION: Disconnect the battery NEGATIVE cable
first (Fig. 12) before charging battery to avoid dam­
age to electrical systems. Do not exceed 16.0 volts
while charging battery. Refer to the instructions sup­
plied with charging equipment

Battery electrolyte will bubble inside of battery case
while being charged properly. If the electrolyte boils
violently or is discharged from the vent holes while
charging, immediately reduce charging rate or turn
off charger and evaluate battery condition. Battery
damage may occur if charging is excessive.
Some battery chargers are equipped with polarity
sensing devices to protect the charger or battery from
being damaged if improperly connected. If the battery
state of charge is too low for the polarity sensor to
detect, the sensor must be bypassed for charger to
operate. Refer to operating instructions provided with
battery charger being used.
CAUTION: Charge battery until test indicator appears
green. Do not overcharge.
It may be necessary to jostle the battery or vehicle
to bring the green dot into view in the test indicator
when the state-of-charge has reached 12.4 volts.
After the battery has been charged to 12.4 volts or
greater, perform a load test to determine cranking
capacity. See BATTERY LOAD TEST in this group. If
the battery will endure a load test, return the battery
to use. If battery will not endure a load test, it must
be replaced. Properly clean and inspect battery hold
downs, tray, terminals, cables, posts, and top before
completing service. Also refer to Group 8B, BATTERY/
STARTER SERVICE.
CHARGING TIME REQUIRED
The time required to charge a battery will vary
depending upon the following factors:
SIZE OF BATTERY
A completely discharged large heavy-duty battery
requires more than twice the recharging time as a
completely discharged small capacity battery.
TEMPERATURE
A longer time will be needed to charge a battery at
-18°C (0°F) than at 27°C (80°F). When a fast charger is
connected to a cold battery, current accepted by bat­
tery will be very low at first. Then, in time, the bat­
tery will accept a higher rate as battery warms.
CHARGER CAPACITY
A charger which can supply only five amperes will
require a much longer period of charging than a char­
ger that can supply 30 amperes or more.
STATE-OF-CHARGE
A completely discharged battery requires more charg­
ing time than a partially charged battery. Electrolyte
is nearly pure water in a completely discharged bat­
tery. At first, the charging current amperage will be
low. As acid is forced from the plates inside the bat­
tery, the current amp rate will rise. Also, the specific
gravity of the electrolyte will rise, bringing the green
dot (see TEST INDICATOR in this group) into view.
 BATTERY CHARGING TIME

O w n in g Amperage S Amps 10 Amps 2® A m p* 30 A m p*

Srcuit Voltage

!5
12.25 to 12.39 6 Hrs. 3 Hrs. 1.5 Hrs, 1 Hr.
12.00 to 12.24 8 Hrs. 4 Hrs. 2 Hrs. 1 5 Hrs.
11.95 to 12.09 12 Hrs. 6 Hrs. 3 Hrs. 2 Hrs.
10.00 to 11.95 14 Hrs. 7 Hrs. 3.5 Hrs. 2.5 Hrs.
1 S ee C h arging C om pletely Dis c h a rg e d B attery
918A-5

WARNING: NEVER EXCEED 20 AMPS WHEN CHARG­ before it accepts a current in excess of a few milliam-
ING A COLD -1°C (30°F) BATTERY. PERSONAL IN­ peres. Such low' current may not be detectable on amp
JURY MAY RESULT. meters built into many chargers.
(2) Connect charger leads. Some chargers feature
CHARGING COMPLETELY DISCHARGED polarity protection circuitry which prevents operation
BATTERY unless charger is connected to battery posts correctly.
The following procedure should be used to recharge A completely discharged battery may not have enough
a completely discharged battery. Unless procedure is voltage to activate this circuitry. This may happen
properly followed, a good battery may be needlessly even though the leads are connected properly. Refer to
replaced. instructions provided with battery charger being used.
(8) Battery chargers vary in the amount of voltage
CHARGE RATE and current they provide. For the time required for
battery to accept measurable charger current at vari­
ous voltages, refer to CHARGE RATE chart in this
Voltage group. If charge current is still not measurable at end
Hours
of charging times, the battery should be replaced. If
charge current is measurable during charging time,
16.0 volts or more up to 4 hrs.
the battery may be good, and charging should be com­
pleted in the normal manner.
14.0 to 15.9 volts up to 8 hrs.

13.9 volts or less : up to 16 hrs.

918A-6
(1) Measure voltage at battery posts with a voltme­
ter, accurate to 1/10 volt (Fig. 13). If below 10 volts,
charge current will be low and it could take some time
 BATTERY DIAGNOSTICS

STARTER W O N 'T C 19 9IR VISUAL INSPECTION . ■

CHECK FOR OBVIOUS DAMAGE SUCH AS CRACKED OR
BROKEN CASE THAT SHOWS LOSS OF ELECTROLYTE,
BROKEN/CRACKED TERMINAL DAMAGE, LOOSE OR CORRODED
F.C. = 1 CONNECTIONS, CLEAN AND TIGHTEN CONNECTORS
REPLACE BATTERY*
IF
«T:9 f f 1 I l STILL W O N 'T 9 I9 9 S R
PROCEED TO STARTER TEST MO O i V l O y S DAMAGE
PROCEDURES ON VEHICLE IN THIS GROUP
1

CHECK TEST INDICATOR/OPEN CIRCUIT VOLTAGE fE S f IN D IC A T O R /O P E N 199911!? VOLT AGE TEST

POSSIBLE CAUSE— IOD-REFER
TO IGNITION OFF DRAW SECTION
ELIMINATE EXCESS IOD
F .C = 3
* CHARGE BATTERY— REFER
TO CHARGING BATTEiY
W O N 'T ACCEPT € i .S9IICIS
F.C, = 4
1. NO GREEN BALL SHOWING
2. OPEN CIRCUIT VOLTAGE BELOW 12.40'
VOLTS. SEE CHARGING COMPLETELY
DISCHARGED BATTEiY
1. TURN HEADLAMPS ON F O i 15 SECONDS
2. TURN HEADLAMPS O f IF F O i 2 MINUTES T O ALLOW
BATTEiY VOLTAGE TOi STABILIZE
3. REMOVE NEGATIVE, TliEN. POSITIVE CAiLE.
YELLOW OR BRIGHT INDICATOR
F.C. = 2
NO EXCESS IOD FOUND DO NOT CHARGE, BOOST, OR
TEST, ELECTROLYTE BELOW
INDICATOR. REPLACE BATTERY,
GREEN BALL SHOW ING A N D CHECK CHARGING SYSTEM
CHARGE OPEN CIRCUIT VOLTAGE
ACCEPTED ABOVE 12.40 VOLTS**
STARTER STILL W O N 'T CRANK
PROCEED TO STARTER TEST
PROCEDURES ON VEHICLE IN
THIS GROUP
LOAD TEST VOLT AGE CHARGE

X MINIMUM
ESTIMATED ' REQUIRED
m m TEST ELECTROLYTE VOLTAG
DISCHARGE BATTERY AT 300 AMPERES FOR 15 SECONDS. ALLOW BATTEiY TEMPERATURE UNDER
TO RECOVER F O i 15 SECONDS. CONNECT VOLTMETER AND AMPERE LOAD 15 SEC. LOAD
EQUAL TO 1 /2 THE COLD CRANKING AMPERE RATING OF THE BATTERY FOR 9.6
15 SECONDS. OBSERVE VOLTAGE AT 15 SECONDS WITH LOAD ON. 60° F (16°C) 9.5
MOTE; ESTIMATE TEMPERATURE O F BATTEIY. SOT (1 6 T ) 9.4
REFER TO LOAD f I S f VOLTAGE C H A W . 40 °F {4 °C) 9.3
30°F (-1°C) 9.1
20°F (-7°C) 8 .9
VOLTAGE AT O i ABOVE VOLTAGE BELOW 10°P ( — 12°C) 8 .7
9.6 VOLTS AT ROOM 9.6 VOLTS AT ROOM 0°F ( — 18°C) 8 .5
(70 DEG. F) TEMP. (70 DEG. F) TEMP.
VOLTMETER M U S I BE ACCURATE
3 T
FAILED LOAD TEST
TO 1710 VOLT

PASSED LOAD TEST

F .C = 5
RETURN BATTEiY TO USE
* REPLACE BATTERY FAILURE CODE (F .C ) C H A W

FAILURE CODE (F.C.) CONDITION

i 1 NUMBER
STARTER S I ILL W 9 9 9 ? C1AM1C BiOKEN/CRACKEP
PROCEED TO STARTER TEST YELLOW/BRiGHT INDICATOR
PROCEDURES ON VEHICLE IN IGNITION OFF DRAW
THIS GROUP BATTERY WON'T ACCEPT CHARGE
MOTES: : 9 1 9 1 9 91.? 9 1 9 9 9 9 O i REPLACING A BATTERY, CHIC1C BATTERY FAILED LOAD TEST
THE VEHICLE'S CHARGING- SYSTEM, AMD CLEAN AN D
* * € H i€ K if lG 9 9 1 9 O ltCIJiT V O W AGE WILL M O N ITO R
TIGHTEN 1 9 9 9 9 9 ? CONNECTORS (REFER ¥ 0 9 9 9 9 9 9 9 9 !
"GREEN BALL" INDICATIO N FOR ALL 6 CELLS ?
SECTIONS O F THIS SERVICE M A N U A L ).
 IGNITION OFF DRAW (IOD)
GENERAL INFORMATION (1) Verify that all electrical accessories are OFF.
Turn off all lights, close trunk lid, close glove box
A normal electrical system will draw from 5 to 30 door, turn off sun visor vanity lights, close all doors
milliamperes from the battery. This is with the igni­ and remove ignition key. Allow the Illuminated Entry
tion in the OFF position, and all non-ignition con­ System (if equipped) to time out (approximately 30
trolled circuits in proper working order. The amount seconds).
of IOD will depend on body model and electrical com­ (2) Verify the engine compartment lamp bulb is
ponents. A vehicle that has not been operated for an working by opening/closing hood. Remove the bulb.
extended period of time (approximately 20 days) may (3) Disconnect NEGATIVE battery cable (Fig. 2).
discharge the battery to an inadequate level. In this
case, the MAIN FUSIBLE LINK CONNECTOR should
be disconnected. The Main Fusible Link connector is
located rearward of the battery on the engine wiring
harness (Fig. 1).
If the IOD is excessive (over 30 milliamperes), the
defect must be found and corrected before condemning
the battery. In most cases the battery can be charged
and returned to service. See BATTERY CHARGING
in this group.

(4) Connect a typical 12-volt test light (low wattage

bulb) between the NEGATIVE cable clamp and the
NEGATIVE battery post (Fig. 1). The test light may
be BRIGHTLY lit for up to three minutes or may not
be lit at all (depending on the body model or electronic
components on the vehicle).
The term BRIGHTLY used throughout the follow­
ing tests, implies the brightness of the test light will
be the same as if it were connected across the battery
posts.
The test light or the milli-amp meter MUST be
positively connected to the battery post and the bat­
tery cable during all IOD testing.
Do not allow the test light or the milli-amp meter to
become disconnected during any of the IOD tests. If
NEGATIVE this happens, the electronic timer functions will be
BATTERY activated and all IOD tests must be repeated from the
POST 918A-1 beginning. Clamp the test light at both ends to pre­
vent accidental disconnection.
Fig. 1 1OD Test After three minutes time has elapsed, the test light
should turn OFF or be DIMLY lit (depending on the
IGNITION OFF DRAW (IOD) TESTS
electronic components on the vehicle). If the test light
VEHICLES WITHOUT ELECTRONIC AUTOMATIC TRANSMIS­ remains BRIGHTLY lit, do not disconnect test light.
SION (ULTRADRIVE) Disconnect each fuse or circuit breaker (refer to Group
Testing for HIGHER AMPERAGE IOD must be per­ 8, Wiring Diagrams) until test light is either OFF or
formed first to prevent damage to most milli-amp DIMLY lit. This will eliminate higher amperage IOD.
meters. It is now safe to install milli-amp meter to check for
A standard 12 volt (low amp, low watt) test light low amperage IOD.
and a milli-amp meter that is equipped with two leads , Possible sources of high IOD are usually vehicle
(a non-inductive type) will be used for the following lamps (trunk lamp, glove compartment, luggage com­
tests. partment, etc.).
The milli-amp meter should be able to handle up to
two amps.
 If test light is still BRIGHTLY lit after disconnect­
ing each fuse and circuit breaker, disconnect the wir­
ing harness from the alternator. Refer to ALTER­
NATOR TESTING in this group. Do not disconnect
test light.
CAUTION: This last test (higher amperage IOD) must
be performed before proceeding with low amperage
IOD tests. The higher amperage IOD must be elimi­
nated before hooking up milli-amp meter to check
for low amperage IOD. If higher amperage IOD has
not been eliminated, milli-amp meter may be dam­
aged. Most milli-amp meters will not handle over one
or two amps. Do not hook up meter if test light is
glowing brightly. Refer to maximum amperage speci­
fications and instructions supplied with milli-amp
meter.
After higher amperage IOD has been corrected, low
amperage IOD may be checked.
MAXIMUM IOD = 30 MILLIAMPERES
(5) With test light still connected, connect milli-amp
meter between battery negative post and negative
battery cable (Fig. 3). Do not open any doors or turn
on any electrical accessories with the test light dis­
connected and the milli-amp meter connected. Meter
may be damaged.
N EGATIVE AMMETER
NEGATIVE
BATTERY
POST 918A-2
Fig. 3 Low Amperage IOD Test
(6) Disconnect test light. Milli-amp meter reading
should be less than 30 milliamperes. If low amperage
IOD is not within specifications, disconnect:
(a) The 60 way connector at the Engine Control­
ler computer located outboard of the battery. See
Group 8D, IGNITION, for more information.
(b) The 25 way connectors on the Body Controller
computer (if equipped).
(c) The circuits to clock and radio.
(d) The wiring harness from the alternator. Refer
to ALTERNATOR TESTING in this group.
Check each component until excessive IOD is found.
Each time the test light or milli-amp meter is dis­
connected and connected, all electronic timer func­
tions will be activated. Tests must be repeated from
the beginning.
Test light or meter MUST remain connected for all
tests.
VEHICLES WITH ELECTRONIC AUTOMATIC
TRANSMISSION (ULTRADRIVE)
Vehicles equipped with this device will have tempo­
rary high IOD of 5 amps or more for up to 25 minutes.
This higher IOD can often mask another problem and
should be considered when performing IOD testing.
Testing for higher IOD (if equipped with any of
these devices), will be the same as in the previous
IOD tests. However, certain additional procedures
should be followed.
If equipped with this option, and high or low IOD is
suspected, allow an additional 25 minutes (minimum)
of electronic shut off time.
To defeat the timer, disconnect the 60 way connec­
tor on Transmission Controller computer. This com­
puter is located on the right inner fender.
 STARTER TEST PROCEDURES ON VEHICLE
INDEX
Page Page
Diagnostic Preparation ................................................. 12 Starter Feed Circuit Resistance Test 13
General Information ...................................................... 12 Starter Feed Circuit Tests .............. . 12
Starter Control Circuit Tests ....................................... 15

GENERAL INFORMATION
The starting system consists of an ignition switch,
starter relay, neutral safety switch (automatic trans­
mission), wiring harness, battery, and a starter motor
with an integral solenoid. These components form two
separate circuits. A high amperage circuit that feeds
the starter motor up to 300+ amps, and a control
circuit that operates on less than 20 amps (Fig. 1).

IGNITION SWITCH

A £ 898A-8
BATTERY ^AUTOMATIC TRANSMISSION I
J NEUTRAL SAFETY SWITCH I Fig. 2 Volt Ampere Tester—Typical
. --------------------------------- ,
(1) Connect a volt-ampere tester (Fig.2) to the bat­
tery terminals (Fig. 3). Refer to the operating instruc­
STARTER RELAY tions provided with the tester being used.
r
MOTOR
STARTER
SOLENOID HI'" 898A-14

Fig. 1 Starting System Components

DIAGNOSTIC PREPARATION
Before proceeding with starting system diagnostics,
verify the following conditions:
(1) Battery top, posts, and terminals are clean.
(2) Alternator drive belt tension and condition.
(3) Battery state-of-charge.
(4) Battery will endure load test.
(5) Battery cable (+/-) connections at the starter
motor and engine block, and their condition.
(6) Wiring harness connector and terminal condition. Fig. 3 Volt-Ampere Tester Connections—Typical
(7) Properly grounded.
(2) Disable ignition system as follows:
STARTER FEED CIRCUIT TESTS
VEHICLES WITH CONVENTIONAL
The following procedure will require a suitable volt- DISTRIBUTORS;
ampere tester (Fig. 2). Disconnect the ignition coil cable from the distribu­
tor cap. Connect a suitable jumper wire between the
CAUTION: Ignition system must also be disabled to
coil cable end-terminal and a good body ground (Fig.
prevent engine start while performing the following
4).
tests.

VEHICLES WITH DIRECT IGNITION SYSTEM
(DIS):
Disconnect the ignition coils electrical connector
(Fig.5).
ALTERNATOR TO INTAKE
IGNITION COILS ELECTRICAL
CONNECTOR 9014-26
Fig. 5 Ignition Coils Electrical Connection
(3) Verify that all lights and accessories are OFF,
and the transmission shift selector is in PARK (auto­
matic) or NEUTRAL (manual) and set parking brake.
(4) Rotate and hold the ignition switch (key) in the
START position. Observe the volt-ampere tester (Fig.
6 ).
If voltage reads above 9.6 volts and amperage draw
reads above 250 amps, proceed to starter feed circuit
resistance test.
If voltage reads 12.4 volts or greater and amperage
reads 0 to 10 amps, proceed to starter control circuit
test.
CAUTION: Do not overheat the starter motor or draw
the battery voltage below 9.6 volts during cranking
operations.
Fig. 6 Starter Draw Tests
(5) After starting system problems have been cor­
rected, verify the battery state-of-charge (charge bat­
tery if necessary). Disconnect all testing equipment
and connect coil cable or ignition coil connector. Start
the vehicle several times to assure the problem has
been corrected.
STARTER FEED CIRCUIT RESISTANCE TEST
Before proceeding with this operation, review DI­
AGNOSTIC PREPARATION and STARTER FEED
CIRCUIT TESTS in this group. The following opera­
tion will require a voltmeter, accurate to 1/10 of a
volt.
CAUTION: Ignition system must also be disabled to
prevent engine start while performing the following
tests.
(1) Disable ignition system as follows:
VEHICLES WITH CONVENTIONAL
DISTRIBUTORS:
Disconnect the ignition coil cable from the distribu­
tor cap. Connect a suitable jumper wire between the
coil cable end-terminal and a good body ground (Fig. 4).
VEHICLES WITH DIRECT IGNITION SYSTEM
(DIS):
Disconnect the ignition coils electrical connector
(Fig.5).
(2) With all wiring harnesses and components con­
nected properly, perform the following:
 (a) Connect positive lead of the voltmeter to the
negative battery post, and negative lead to the nega­
tive battery cable clamp (Fig. 7). Rotate and hold the
ignition switch key in the START position. Observe
the voltmeter. If voltage is detected, correct poor con­
tact between cable clamp and post.
(b) Connect positive lead of the voltmeter to the
positive battery post, and negative lead to the positive
battery cable clamp (Fig. 7). Rotate and hold the igni­
tion switch key in the START position. Observe the
voltmeter. If voltage is detected, correct poor contact
between the cable clamp and post.
(c) Connect positive lead of voltmeter to negative
battery terminal, and negative lead to engine block
near the battery cable attaching point (Fig. 8). Rotate
and hold the ignition switch (key) in the START posi­
tion. If voltage reads above 0.2 volt, correct poor con­
tact at ground cable attaching point. If voltage reading
is still above 0.2 volt after correcting poor contacts,
replace ground cable.
vniTM FTFR
(3) Remove starter heat shield (if equipped) to gain
access to the starter motor and solenoid connections,
and perform the following:
(a) Connect positive voltmeter lead to the starter
motor housing and the negative lead to the negative
battery terminal (Fig. 9). Hold the ignition switch key
in the START position. If voltage reads above 0.2 volt,
correct poor starter to engine ground.
(b) Connect positive voltmeter lead to positive
battery terminal, and negative lead to battery cable
terminal on starter solenoid (Fig.10). Rotate and hold
the ignition switch key in the START position. If
voltage reads above 0.2 volt, correct poor contact at
battery cable to solenoid connection. If reading is still
above 0.2 volt after correcting poor contacts, replace
positive battery cable.
If resistance tests detect no feed circuit failures,
remove the starter motor and proceed to BENCH TEST­
ING STARTER SOLENOID.
Fig. 10 Test Positive Battery Cable Resistance—Typical
STARTER CONTROL CIRCUIT TESTS term inal (iiu iiib e i* four) (F ig., 12). If e n g in e cranks,
sta rte r relay is good,
The starter control circuit consists of starter sole­ (7) If engine does.not crank, connect a second jum per
noid, starter relay, ignition switch, neutral safety switch wire to sta rte r relay between -ground term inal and to
(automatic transmission), and all related wiring and a good ground (number fwe) (Fig. 13). Repeat test. If
connections. engine cranks, sta rte r relay is good. However, tra n s­
mission, linkage may be out of adjustm ent or neutral
CAUTION: Before performing any starter tests, the
safety switch is defective. Refer to Group 21, T rans­
ignition system must be disabled.
mission. if engine does not crank, sta rte r -relay is
Vehicles equipped with a conventional distributor: defective and m ust be replaced.
Disconnect coil wire from distributor cap center tower.
Secure wire to a good ground to prevent engine from SOLENOID TERMINAL
starting (Fig. 4).
If equipped with Direct Ignition System (DIS), un­
plug the coils electrical connector (Fig.5).
"7 STARTER
STARTER SOLENOID TEST POSITIVE MOTOR
Connect a heavy jumper wire on starter relay be­ CAiLE
TO STARTER FIELD- '' " '
tween battery terminal (number one) (Fig. 11) and TERMINAL' -
solenoid terminal (number three) (Fig. 11). If engine \ 1 b a tt.©
cranks, starter solenoid is good. Proceed to starter NEGATIVE BATTERY RELAY ^ I^ ^ S T A R T E R
relay test. CAILE RELAY
91 Jl
If engine does not crank, or solenoid clicks, check
-G ®
wiring and connectors from relay to starter for loose
or corroded connections. Repeat test and if engine still
fails to crank properly, trouble is in starter motor and 1G. /sw.(4)
r, 908A-3
must be removed for repairs.
Fig. 12 Melt#' Test with One Jumper Wire
SOLENOID TERMINAL
SOLENOID TERM INAL,

T
POSITIVE
CABLE
HEAVY
TO STARTER STARTER JUMPER TO STARTER FIELD
STARTEi
FIELD TERMINAL MOTOR WIRE TERMINAL MOTOR
* ^ BATTERY ( f )
NEGATIVE BATTERY BATTERY RELAY
CABLE RELAY FEED FEED STARTER
RELAY

r H
BATTERY STARTEi HEAVY JUMPER
RELAY 908A-2 . - WIRE G®
IG. SW.(4) 908A-4

Fig. I I Starter Solenoid Test

Fig. 13 Relay Test with Two Jumper Wires
STARTER RELAY TEST
IGNITION SWITCH TEST
(1) Position autom atic transaxle gear selector in
After testing starter solenoid and relay, test igni­
neutral or park position.
tion switch and wiring. See Group 8, Wiring Dia­
(2) Position m anual transaxle gear selector in neutral.
grams. Check all wiring for opens or shorts, and all
(3) Set park brake.
connectors for being loose or corroded.
(4) Do not remove relay connector.
(5)'Check for battery Yoltage between sta rte r relay
BENCH TESTING STARTER SOLENOID
battery term inal (number one) (Fig. 12) and a good
(1) Disconnect field coil wire from field coil terminal
ground w ith a test lamp.
(Fig. 14 or 15).
(6) Connect a jum per wire on the sta rte r relay be­
(2) Check for continuity between solenoid terminal
tween battery (number one) (Fig. 12) and ignition
and field coil terminal w ith # continuity tester. Conti­
nuity should be detected (Fig. 16 or 17).
(3) Check for continuity between solenoid term inal
and solenoid housing (Fig. 18 or 19). Continuity should
be detected. If continuity is detected, iolenoid is good.
■ (4) If there is'no'C ontinuity in' either test, solenoid
has an open circuit and is defective. On BOSCH s ta rt­
ers, replace the solenoid: On N1PPONDENSO s ta rt­
ers, replace the starter assembly. • ■ ■■"

Pig. 17 Continuity Test Between Solenoid

SOLENOID Terminal and Field Coil Terminal—Nlppondenso
SOLENOID
TERMINAL ■
BATTEiY TERMINAL

FIELD COIL TEiMiNAL SOLENOID

AND CONNECTOR
RH478

Pig. 14 Field Coll Wire Termlnal-Bosch

FIELD COIL SOLENOID
TERMINAL OHMMETER 1H480A
1AITERY
TERMINAL Fig. 18 Continuity Test Between Solenoid-
Terminal and solenoid Case—Bosch
SOLENOID
TERMINAL
FIELD COIL
CONNECTOR
STARTEi MOTOR
ASSEMBLY SOLENOID

RR8BD31

Fig. 15 Field Coll Wire Terminal—Nlppondenso

i iS I D 3 3

' SOLENOID.
Fig. f S Continuity Test Between Solenoid
Terminal and Solenoid Case—Nlppondenso

iH 4 ? § A

Fig. f 6 Continuity Test §9199991 Solenoid

Terminal and Field Coil Termlnat—Bosch
 STARTER SYSTEM DIAGNOSTICS
19:9999:191 SYMPTOM 19919199*9 §99991391 S f9!9 fC 99

STARTER FAILS TO STARTER FAILS TO STARTEi ENGAGES, STARTER ENGAGES STARTER POES NOT
ENGAGE. NO SOUNDS ENGAGE. SOLENOID FAILS TO TURN ENGINE. • . DRIVE CLUTCH DISENGAGE AFTER
O i RELAY CLICKS DOME LIGHT DIMS SPINS OUT ' ENGINE STARTS'

90991199 9 9 9 9 9 POSSIBLE CAUSE 9999999 99999 9 9 9 » it l.I CAUSE

1 1 ■ . 1
STARTER CONTROL RESISTANCE TOO RESISTANCE TOO DRIVE 'dUTCH IGNITION SW1TC
CIRCUIT FACULTY. HIGH IN STARTER HIGH IN STARTER FAULTY ' ' . MISADJUSTED
SEE GROUP 8W # FEED CIRCUIT FEED CIRCUIT
WIRING DIAGRAMS
1 i i 1
IGNITION SWITCH STARTER CONTROL STARTER RELAY BROKEN TEETH IGNITION SW1TC
M1SADJUSED O i CIRCUIT FAULTY FAULTY ON RING GEAR ■ FAULTY
FAULTY SEE GROUP 8W,
WIRING DIAGRAMS
1
NEUTRAL SAFETY STARTER RELAY STARTER ASSEMBLY STARTER ASSEMBLY ■ $
SWITCH (AUTO TRANS.) FAULTY FAULTY FAULTY FAULTY
FAULTY OR
MISADJUSTED
i
GEAR SELECTOR STARTER ASSEMBLY STARTER ASSEMBLY
PtNDL SWITCH FAULTY FAULTY
(A-604 TRANS.)
FAULTY
1
STARTER RELAY •REFER TO APPROPR IATE GROUP AND SECTION OF THIS MANUAL
FAULTY ■■ FOR PROPER SEiVICIE AND TEST PROCEDURES FOR THE
COMPONENTS 1N¥CXVED
STARTER1ASSEMBLY
FAULTY
918A-8

ALTERNATOR TEST PROCEDURES ON VEHICLE

INDEX
Page Page
Alternator Current Output Test ................................... 19 Alternator Output Wire Resistance Test ................... 17

ALTERNATOR OUTPUT WIRE RESISTANCE TEST
Alternator output wire resistance test will show
amount of Voltage Drop across alternator output wire
between alternator BAT + terminal and positive Bat­
tery post.
PREPARATION
(1) Before starting test, make sure vehicle has a
fully charged battery. Tests and procedures to check
for a fully charged battery are shown in the BAT­
TERY section of this Group.
(2) Turn ignition switch OFF.
(3) Disconnect battery NEGATIVE cable.
(4) Disconnect alternator B + output wire from al­
ternator output battery terminal.
(5) Connect a 0-150 ampere scale DC ammeter in
series between alternator BAT + terminal and discon­
nected alternator output wire (Fig. 1 and 2). Connect
positive lead to alternator BAT + terminal and nega-
tive lead to disconnected alternator output wire (Fig.
1 and 2).
(6) Connect positive lead of a test voltmeter (Range
0-18 volts minimum) to disconnected alternator out­
put wire. Connect negative lead of test voltmeter to
positive battery cable at positive post (Fig. 1 and 2).
(7) Remove fresh air hose between Engine Control­
ler computer and air cleaner (if necessary).
(8) Connect one end of a suitable jumper wire to a
good ground, and the other end to the (green) K20
terminal at the back of the alternator (Figs. 1 and 2).
CAUTION: Do not connect (blue) A21 circuit to ground.
Fusible link Will burn.
(9) Connect an engine tachometer and connect bat­
tery negative cable.
 GROUND

CHASSIS -
GROUND
918A-9

Fig. 1 Alternator Output Wire Resistance Test—Typical

GROUND ( - ) B+

A M B IENT TEMPERATURE M A X IM U M
AT BATTERY °C (°F ) VOLTAGE

- 18 to 10°C (0 to 50 °F) 14.45 V to 14.95 V

10 to 38 °C (50 to 100°F) 13.85 V to 14.45 V

38 to 66 °C (100 to 150°F) 13.75 V to 13.85 V

66 to 93°C (150 to 200°F) 13.75 V

9 1 8 A -1 5

Fig. 2 Alternator Wiring Connections—Typical Fig. 3 Volt/Amp Tester Connections—Typical

(10) Connect a volt/amp tester equipped with a vari­ TEST

able carbon pile rheostat between battery terminals
(Fig. 3). Be sure carbon pile is in OFF position before
connecting leads.
(1) Start engine. Immediately after starting, reduce
engine speed to idle.
(2) Adjust engine speed and carbon pile to maintain
20 amperes flowing in circuit. Observe voltmeter read­
ing. Voltmeter reading should not exceed 0.5 volts.
RESULTS
If a higher voltage drop is indicated, inspect, clean
and tighten all connections between alternator BAT +
terminal and battery positive post. A voltage drop test
may be performed at each connection to locate a con­
nection with excessive resistance. If resistance tests
are satisfactory, reduce engine speed, turn off carbon
pile, and turn off ignition switch.
(1) Disconnect battery negative cable.
(2) Remove test ammeter, voltmeter, carbon pile,
and tachometer.
(3) Remove Jumper Wire.
(4) Connect alternator output wire to alternator
BAT + terminal.
(5) Connect battery negative cable.
(6) Connect fresh hose between Engine Controller
computer and air cleaner (if removed).
ALTERNATOR CURRENT OUTPUT TEST
The current output test determines whether or not
the alternator is capable of delivering its rated cur­
rent output. For minimum output amperage, see AL-
CASE GROUND FIELD BATTEiY
TERMINALS VOLTAGE
2 JL
TERNATOR SPECIFICATIONS at the back of this
group.
For alternator maximum voltage at individual tem­
peratures, see ALTERNATOR OUTPUT VOLTAGE
SPECIFICATIONS at the back of this group.
PREPARATION
(1) Before starting any tests, make sure vehicle has
a fully charged battery. Tests and procedures to check
for a fully charged battery are shown in BATTERY
section of this group.
(2) Disconnect battery NEGATIVE cable.
(3) Disconnect alternator output wire at the alter­
nator BAT + terminal (Fig. 4 and 5).
(4) Connect a 0-150 ampere scale DC ammeter in
series between alternator BAT + terminal and discon­
nected alternator output wire. Connect Positive lead
to alternator BAT+ terminal and negative lead to
disconnected alternator output wire (Fig. 4 and 5).
(5) Connect positive lead of a test voltmeter (range
0-18 volts minimum) to alternator BAT+ terminal
(Fig. 4 and 5).
IGNITION SWITCH
A21-DB —J

I JUMPER WIRE
TO GROUND

TEST TEST
ALTERNATOR VOLTMETER AMMETER
ALTERNATOR
BATTERY
/^.TERMINAL

DISCONNECTED
GROUND
ENGINE GROUND 4 - ALTERNATOR
CONTROLLER OUTPUT
JUBSt

CHASSIS -
CARBON PILE GROUND
RHEOSTAT
G tO U N P ( - ) B+
Fig. 5 Alternator Wiring Connections—Typical
(8) Connect negative lead of test voltmeter to a good
ground.
(7) Connect an engine tachom eter and connect b at­
tery negative cable.
(8) Connect a volt/amp tester equipped with a vari­
able carbon pile rheostat between battery term inals
(Fig. 8). Be sure carbon pile is in OFF position before
connecting leads.
Fig. 6 Volt/Amp Tester Connections—Typical
(9) Remove fresh air hose between Engine Control­
ler computer and air cleaner (if necessary).
(10) Full field the alternator. Connect one end of a
suitable jumper wire to a good ground. Connect the
other end of the wire to the (green) K20 circuit term i­
nal a t the back of the alternator (Fig. 4 and 5).
CAUTION; Do not connect (blue) A21 circuit to ground,
pysible link will byrn.
TEST
(1) S tart engine. Imm ediately after starting, reduce
engine speed to idle.
(2) Adjust carbon pile and engine speed in incre­
m ents until an engine speed of 1250 rpm, and a volt­
m eter reading of 15 volts is obtained.
CAUTION; Do not allow battery voltage to exceed 16
volts.
(3) The alternator amperage m ust m eet the m ini­
mum output requirem ents for the particular altern a­
tor being tested. Refer to ALTERNATOR SPECIFI­
CATIONS a t the back of this group for m inim um
amperage outputs.
RESULTS
(1) If reading is less th an specified, and alternator
output wire resistance is not excessive, alternator
should be replaced. See Group 8C» ALTERNATOR for
removal and installation.
(2) After current output test is completed, reduce
engine speed, tu rn off carbon pile, and tu rn off igni­
tion switch.
(3) Disconnect battery negative cable.
(4) Remove test am m eter, voltm eter, tachom eter and
carbon pile.
(5) Remove Jum per Wire between K20 term inal
and ground.
(8) Connect alternator output wire to alternator
BAT+ term inal.
(7) Connect negative battery cable.
(8) Connect fresh air hose between Engine Control­
ler computer and air cleaner (if removed).
 FAULT CODES—ON BOARD DIAGNOSTICS
INDEX
Page Page
Diagnostic Testing Using Fault Codes . . . . . . . . . . . . 22 General Description/Information 21
DRBii Diagnostic Testing . . . . . . . . . . . . . . . . . . . . . . . 25

GENERAL D E S C R lP IlO N /lN F O R illlO N

Another way of diagnosing charging system prob­
lems can be accomplished using the ON-BOARD DI­ 60-WAY* WIRE
AGNOSTIC SYSTEM FAULT CODES. CONNECTOR

A F ault Code indicates a potential problem in a

monitored circuit, or a condition caused by a faulty
'component, A F ault Code can be retrieved by turning
the ignition switch ON-OFF-ON-OFF-ON (without
starting the engine), and counting the possible flashes
of the CHECK ENGINE. LAMP in the instrum ent
cluster.

EXAMPLES:
If the Check Engine Lamp flashes four times, pauses,
and flashes one more tim e, a Code 41 is indicated.
If the Check Engine Lamp flashes four times, pauses,
and flashes six more tim es, a Code 46 is indicated.

ENGINE CONIiillEi COMPUTER

The Engine Controller computer is equipped with
SINGLE MODULE ENGINE CONTROLLER (SMEC) RR14G15
On-Board Diagnostic features and monitors all engine
control circuits during a run/drive period. If a circuit Pig. 7 Engine Control Computer m d
or system does not perform properly, the Engine Con­ Diagnostic Connector
troller computer will file (in memory) a predeterm ined
F ault Code. This can be used to assist in diagnosing a ■ Refer to the ALTERNATOR FAULT CODE chart
problem. After 50 to 100 ignition switch ON/RUN for relationships of alternator/charging system F ault
cycles, the memory will be erased if the fault does not Code numbers.
reoccur.
The Engine Controller computer is located in the
engine com partm ent outboard of the battery (Fig. 7).
 ALTERNATOR FAULT CODES

1 :1 9 9 9

Fault In fifW When Monitored i f

f 99*» L am p C irc u it 111® Logic Module WIhmi P u t I n t o M e m o r y

Indi­ B attery Feed to All th e tim e w h e n If th e b a tte ry fe e d to th e logic m o d u le h a s b e e n

12 cation No th e Logic M odule th e ignition sw itch is disconnected w ithin th e last 50-100 e n g in e s ta rts .
C ontroller on.

A lte rn a to r fie ld All th e time w h e n 1 Engine C ontroller computer output for alternator field
41 Faylt Control (Charg­ ignition sw itch is on. does not respond to the voltage regulator control signal.
ing System )

B attery Voltage Ail th e tim e w h e n th e If the battery sense voltage is more than 1 volt
46 Fault Yes Sensing (Charg­ e n g in e is running. above the desired control voltage for more than
ing System ) 20 seconds.

B attery V o ltag e Engine rpm a b o v e If the battery sense voltage is less than 1 volt belo
47 Fault Yes Sensing (C harg­ 1,500 rpm. the desired control voltage for more than 20 seconds
ing System ) and o
Indi­
55 cation No Indicates end of diagnostic mode.
918A-12

DIAGNOSTIC TESTING USING FAULT CODES q u a t e / l o w c h a r g i n g —u s i n g o n b o a r d d i ­

a g n o s t ic FAULT CODES or ALTERNATOR
For diagnostic testing when using the fault codes, CHECK FOR OVERCHARGING—USING ON BOARD
refer to either of the two diagnostic charts on the fol- DIAGNOSTIC FAULT CODES
lowing pages: ALTERNATOR CHECK FOR INADE-
ALTERNATOR CHECK FOR INADEQUATE/LOW CHARGING—USING ON BOARD DIAGNOSTIC FAULT CODES
 ALTERNATOR CHECK FOR OVERCHARGING—USING ON BOARD DIAGNOSTIC FAULT CODES

ON-BOARD DIAGNOSTIC FAULT

CODE FLASHES 41 O i 46

1
CHECK BATTERY CONDITION ■
SEE BATTEiY TESTING IN
THIS G iO U P — REPAIR AS
AMBIENT TEMPERATURE MAXIMUM CHARGING
NECESSARY
AT BATTERY °C ( #F) VOLTAGE
— 18 to 10°C (0 to SO T) 14.45V to 14.95V
10 to 38 °C (50 to 100 °F) 13.85V to 14.45V
WITH ENGINE iU N N IN G 38 to 66 °€ (100 to 150 °F) 13.75V to 13.85V
CHECK BATTERY VOLTAGE 66 to 93 °C (150 to 200 °F) 13.75V
TO VERIFY OVERCHARGE

if
GROUND( ; B+ DISCONNECTED

Fig. 9 Alternator Wiring Connections Fig. 11 Electrical Resistance Test

TEST 60-WAY DRB II DIAGNOSTIC TESTER

TESTING FAULT CODES
A more accurate device to retrieve fault codes is
Diagnostic Tool (D1BII). This diagnostic tool, plugged
into the diag»t§tic connector (Fig. 7) located rearw ard
of the battery, will display fault descriptions. The
DRB II can also test various circuits and component
functions. Refer to the instructions provided w ith the
(DEB 11) tool being used. Descriptions of F ault Codes
for other vehicle systems can be found in the General
Diagnosis section of Group 14, Fuel System.

K20 CIRCUIT 918A-13

Fig. 10 Engine Controller Connector

 SPECIFICATIONS—ALTERNATOR

* *CASE t.D . PULLEY E N G IN E

TYPE FAG N U M B E R GROOVES USAGE OUTPUT

BOSCH 90 HS 4557431 4 2.5L 84 AMP

BOSCH 90 RS 5234231 4 2,51 88 AMP

DENSO 90 HS 5234031 4 2.5L 86 AMP

DENSO 90 HS 5234032 6 3.3L 90 AMP

DENSO 120 HS 5234208 4 2.5L 98 AMP

DENSO 120 HS 5234033 6 3.0L-3.3L 102 AMP

* WITH ALTERNATOR FULL FIELDED AT 1250 RPM

*# CASE I.D. TAG NUMBER IS LOCATED ON BOTTOM OF ALTERNATOR CASE

918C-4

SPECIFICATIONS—STARTER/BATTERY
STARTER
M a n u fa ctu rer Nippondenso iosch
Engine A p p lic a tio n , . . . . . . ... ........ 3,01/3,31/3.81 3.01 2.2-2.5L
P art Number a n d P o w er Rating . . . . . . . . . . 1.4 Kw 1.1 Kw 1.1 Kw
V o ltag e . . . . . . . . . . . . . . . . . . . . . . . . . . . . . H 12 2 12
No. of Fields . . . . . . . . . . . . . . ...... .... 4 P e rm a n e n t M a g n e t
No. of Poles . . . . . .................... 4 6 6
1 4 4
Drive . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Conventional P la n eta ry P la n eta ry
G e a r Train G e a r Train ?ear Train
F re e Running Test
V o lta g e .......................................................... 11 11 11
Amperage Draw . . . . . . . . . . . . . . . . . . . . . 73 Amps 73 Amps 69 Amps
Minimum Speed RPM. . . . , . . . . . . . . 3601 RPM 3473 RPM 3447 RPM
Solenoid Closing V o ltag e . . . . . ......... 5 Volts 7.5 Volte 7.5 Volts
C ranking A m p e ra g e D raw Test . 50-220 Amps* 150-220 Am ps*
* Engine should b e up to o p e ra tin g te m p e r a tu re . Extrem ely h e av y oil o r tight e n g in e will in c re a s e s t a r te r a m p e r a g e d ra w .

Cold Cranking t# s« rw ®
(Amps) Resting @ 0°F
200 A m p 0 Amp ,
250 A m p 500 Amp Minutes
315 A m p 120 M inutes
CRANKING RATING is the current a battery can deliver for 30 seconds and maintain a terminal voltage of 7.2 volts or greater at
specified temperature.
RESERVE CAPACITY RATING is the length of time a battery can deliver 25 amps and maintain a minimum terminal voltage
of 10.5 volts a t 27 °C (80 °P).
918B-4
 SPECIFICATIONS—ALTERNATOR OUTPUT VOLTAGE

AMBIENT TEMPERATUIE M A X IM U M CHARGING

AT BATTERY °C {°F) VOLTAGE

- 18 to 10°€ (0 to 50°F) 14.45 V to 14.95 ¥

10 to 38 °C (50 to 100 °f) 13.85 V to 14.45 V

38 to 66 °€ (100 to 150°F) 13.75 V to 13.85 V

66 to 9 3 9 : (150 to 200°P) 13.75 V

9I8A-15

TORQUE SPECIFICATIONS

com ponent f t . Lbs. In. Lbs. N«m

A lte rn a to r M ounting Bolts

2.21/2.51 Engine 40 54

3.3L/3.8L Engi n e 40 54

3,01 Engine — Upper Bolt 30 41

Lower Bolt 250 28

Alternator B + T erm inal Nut 75 9

Battery Hold D ow n C lam p Bolt 125 14

S ta rte r M ounting B olts/N uts 40 54

918A-18
 BATTERY/STARTER SERVICE
CONTENTS
Page Page
BATTERY SERVICE PROCEDURES . 1 STARTER SERVICE PROCEDURES . 3
BATTERY SERVICE PROCEDURES
GENERAL INFORMATION
This section will cover Battery removal and instal­
lation procedures only. For diagnostic procedures, see
Group 8A, BATTERY/STARTING/CHARGING SYS­
TEMS DIAGNOSTICS.

POSITIVE ;TESt = V E N T NEGATIVE

POST IN DICATOR S ^S/PO ST

(3) Remove battery hold down clamp (Fig. 3) and

jELECTROlYTEHiKill^ttGREEN remove battery from vehicle.
GROUPS
LEVEL * * * * i -BALL CAUTION: Do not allow baking soda solution to en­
ter vent holes, as damage to battery can result.
(4) Clean top of battery with a solution of warm
MAINTENAI water and baking soda. Apply solution with a bristle
FREE I brush and allow to soak until acid deposits loosen
BATTERY 898A1
(Fig. 4). Rinse with clear water and blot dry with
Fig. 1 Maintenance Free Battery paper toweling. Dispose of toweling in a safe manner.
See WARNINGS on top of battery.
Factory installed batteries (Fig. 1) do not have re­
movable battery cell caps. Water can not be added to HOLD
factory installed battery. Battery is sealed, except for
small vent holes in the top. Chemical composition
inside of battery produces an extremely small amount
of gases at normal charging voltages. Factory installed
battery is equipped with test indicator (Fig. 1) that
displays colored balls to indicate battery state-of-charge.
Green Indicator = Full charge
Black Indicator = Discharged
Yellow Indicator = Battery replacement required.

BATTERY VISUAL INSPECTION AND SERVICE

(1) Make sure ignition switch is in OFF position
and all accessories are OFF.
(2) Disconnect and remove battery terminals at bat­
tery. Remove NEGATIVE cable first (Fig. 2).
WARNING: TO PROTECT HANDS FROM BATTERY
ACID, A SUITABLE PAIR OF RUBBER GLOVES (NOT
THE HOUSEHOLD TYPE) SHOULD BE WORN WHEN
REMOVING BATTERY. SAFETY GLASSES SHOULD
ALSO BE WORN.
 (5) Inspect battery case and cover for cracks or leak­
age. If leakage is present battery m ust be replaced.
(8) Inspect battery tray (Fig. 3) for damage caused
by acid from battery. If acid damage is present, it will
be necessary to clean area w ith same solution de­
scribed in Step (4).
(8) Clean inside surfaces of term inal clamps w ith a
suitable battery term inal cleaning tool (Fig. 8). Re­
place damaged or frayed cables and broken term inal
clamps.
(3) Inspect battery for proper or damaged hold down
ledge.
(10) Install battery in vehicle m aking sure th a t
battery is properly positioned on battery tra y (Fig, 3).
(11) Install battery hold down clamp, m aking sure
th a t it is properly positioned on battery.
(12) Place felt grease w asher onto Positive (+ ) b at­
tery post.
(13) Connect cable clamps to battery post m aking
sure top of clamp is flush w ith top of post (Fig. 7).
Install POSITIVE cable first.
(14) Tighten clamp nu t securely

BATTERY BATTEiY
CABLE CAiLE
CLEANING
TOOL MX75

Fig. 4 Cleaning Battery

(7) Clean battery post with a suitable battery post

cleaning tool (Fig. 5).

BATTERY
POST
CLEANER RK112

Fig. 6 Cleaning Battery Cable Terminal

POSITIVE
CABLE

BATTERY

TEST INDICATOR 908B-5

 STARTER SERVICE PROCEDURES
INDEX
Page Page
Field Coil Reduction Gear S ta rte r................................. 3 Starter Component Replacement ................................. 5
General Information ........................................................ 3 Starter Motor Removal and Installation ....................... 3
Permanent Magnet Reduction Gear S t a r t e r .................. 3 Supply Circuit and Control Circuit ............................. 3

GENERAL INFORMATION NEGATIVE NEGATIVE CABLE

BATTERY
This section will cover STARTER removal, installa­ POST
tion and overhaul procedures. For diagnostic proce­
dures, see Group 8A, BATTERY/STARTING/CHARG­
ING/SYSTEMS DIAGNOSTICS.

STARTING SYSTEM DESCRIPTION

Starting system components: Battery, starter mo­
tor, starter relay switch, solenoid, ignition switch, con­
necting wires and battery cables. A neutral safety
switch is used with automatic transmissions.
Fig. 1 Remove or Install Battery Cable
PERMANENT MAGNET REDUCTION GEAR STARTER
A Bosch permanent magnet starter motor is avail­
able on 2.5L and 3.0L engines on all vehicles. A plan­
etary gear train transmits power between starter motor
and pinion shaft. The fields consist of six permanent
magnets.

FIELD COIL REDUCTION GEAR STARTER

A Nippondenso reduction gear, field coil, starter
motor is available on 3.0L, and 3.3L engines.

SUPPLY CIRCUIT AND CONTROL CIRCUIT

Both starter systems consists of two separate cir­
cuits. A high amperage supply to feed the starter
motor, and a low amperage circuit to control the starter
solenoid.
STARTER MOTOR REMOVAL AND INSTALLATION
BOSCH STARTER 2.SL ENGINE
(1) Disconnect battery NEGATIVE cable (Fig. 1).
(2) Remove heat shield clip and heat shield (Fig. 2),
if equipped.
Fig. 2 Starter Heat Shield
(3) Remove battery cable at starter.
(4) Disconnect solenoid lead wire from solenoid.
(5) Remove bolts attaching starter to flywheel hous­
ing, and rear bracket (to engine or transaxle) and
remove starter assembly (Fig. 3).
To install, reverse the preceding operation.
 Fig. 3 Bosch Starter—2.5L Engine Fig. 5 Wire Terminal Connections—Bosch Starter

BOSCH OR NIPPONDENSO ST ARTE R - (4) Remove starter from vehicle (Bosch, Fig. 8)
3.0L OR 3.3L ENGINE (Nippondenso, Fig. 9).
(1) Disconnect NEGATIVE battery cable (Fig. 1). To install, reverse the preceding operation.
(2) Remove three starter attaching bolts at transaxle
bell housing (Fig. 4).
(3) Remove two wire connector terminal nuts and
remove connector (Bosch, Fig. 5) (Nippondenso, Fig. 6
or 7).

Fig. 6 Wire Terminal Connections—

3.0L Engine—Nippondenso Starter

Fig. 7 Wire Terminal Connections—

3.3L Engine—Nippondenso Starter
 Pig. I Remove or Install Gear Housing
PINION GEAR AND CLUTCH
GEAR

DRIVE
GEAR

jTNA I))
PINION GEAR BEARING BEARING SHAFT SOLENOID § „
9C AND CAGE ACCESS HOLE HOUSING RR8BD19

Fig. 9 Remove or Install Starter Motor—Typical Fig. 2 Remove or Install Drive and Pinion Gears
GEAR AND CLUTCH GEAR
STARTER COMPONENT REPLACEMENT ASSEMBLY CAVITY HOUSING

N IP P O N D E N S O S T A R T E R G E A R A N D C L U T C H PINION
GEAR
RE101AL AND ilSTALLATiOl
(1) Remove the two gear housing attaching screws
and separate the gear housing from the solenoid hous­
ing (Fig. 1). The pinion gear, pinion gear bearing, and
drive gear will be loose between the solenoid housing
and gear housing (Fig. 2). When reinstalling pinion
gear and bearing, wipe w ith a clean rag and coat with
lightw eight high tem perature wheel bearing grease.
Place the lubricated bearing and gear over bearing
shaft in the gear housing (Fig. 8).
(2) Remove the sta rte r gear and clutch assembly BEARING,
I j
SHAFT RR8BD21
from the solenoid housing (Fig. 4).
To assemble, reverse the preceding operation.
RR8BD20 RN 359

Fig. 4 Gear and Clutch Assembly Fig. 2 Field Coil Terminal

BOSCH STARTER SOLENOID

REMOVAL AND INSTALLATION
(1) Remove field terminal nut (Fig. 1).
(2) Remove field terminal (Fig. 2).
(3) Remove field washer (Fig. 3).
(4) Remove three solenoid mounting screws (Fig. 4).
(5) Remove the solenoid from the starter assembly.
To install, reverse the preceding operation.

Fig. 3 Field Terminal Washer

Fig. 1 Field Terminal Nut

 Fig, 7 Rubber Seal

BOSCH STARTER GEAR AND CLUTCH

REMOVAL AND INSTALLATION
(1) Remove solenoid assembly (Fig. 5).
(2) Remove two through-bolts securing t i e starter
drive end housing to the motor housing (Fig. 8) and
separate housings.
(3) Remove rubber seal (Fig. 7)
(4) Pull the gear and clutch assembly from the drive
end housing (Fig. 8).
To install, reverse the preceding operation.

Fig. 8 Starter Drive Gear Train

 SPECIFICATIONS
STARTER
Manufacturer N ipp o n d en so Bosch
Engine Appl i c a t i on. . . . . . . . . . . . . . . . . . . . . 3.01/3.31/3.81 3.01 2.51
P a rt N u m b e r a n d P o w er Rating . . . . . . . . . . 1.4 Kw ] .] Kw LI Kw
V o lta g e . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12 12 V*
No. of Fields . . . . . . . . . . . . . . . . . ........ 4 Permanent Meg
No. of Poles . . . . . . . . . . . . . . . . . . . . . . . . . . 4 6 6
B rushes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4 f 4
Drive . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . C onventional P la n eta ry Planetary
G e a r Train G e a r Train Gear Train
f r e e Running Test
Vo l t a g e . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11 11 11
A m p e r a g e D raw . . . . . . . . . . . . . . . . . . . . . 73 A m ps 73 A m ps 69 Amps
M inim um S p e e d RP M. . . . . . . . . . . . . . . f .. 9 9 ! RPM 3473 RPM 3447 RPM
Solenoid Closing V oltag e . . . . . . . . . . . . . . . 7.5 Volts 7.5 Volts 7.5 Volts
C ranking A m p e ra g e D raw Test . 150-220 Am ps* 150-220 Am ps*
* E ngine should b e up to o p e ra tin g temperature. E xtrem ely h e av y oil o r tight e n g in e w i ll in c r e a s e s t a r te r a m p e r a g e d ra w .

BATTERY
Load T®st Cold Cranking le se rw e
(Amps) Rating @ O 0F
200 A m p 400 A m p 100 Minutes
250 A m p 0 Amp 110 Minutes
315 A m p 625 Amp 120 Minutes
CRANKING RATING is th e c u rre n t a b a tte ry con d e liver for 30 se c o n d s a n d m aintain a term in al voltage of 7.2 volts < r at
specified te m p e ra tu r e .
RESERVE CAPACITY RATING is the length of tim e a b a tte ry can deliver 25 a m p s and maintain a minimum terminal voltage
of 10.5 volts at 27 °C (80 #F).
918B-5

TORQUE SPECIFICATIONS

Pf. U m . in* Lfe*.

Alternator Mounting Bolts

2.21/2.51 Engine 40 54

3.3L/3.8L Engine ' 40

3.01 Engine — Upper Bolt 30 41

Lower Bolt 250 28

Alternator B + Terminal Nut 75 9

Battery Hold Down Clamp Bolt : 125 14

Starter Mounting Bolts/Nuts . 40 54

 ALTERNATOR SERVICE
CONTENTS
Page Page
ALTERNATOR— 2.5L ENGINE . 1 ALTERNATOR— 3.3L ENGINE ....................... 3
ALTERNATOR— 3.0L ENGINE . 2 GENERAL INFORMATION.................. ......... 1
GENERAL INFORMATION
This section will cover alternator removal and in­
stallation only. Information covering on-vehicle test­
ing can be found in Group 8A, BATTERY/STARTING/
CHARGING SYSTEMS DIAGNOSTICS. To identify
the alternator, refer to the ALTERNATOR SPECI­
FICATION chart at the back of this section. TORQUE ATTACHING
NUTS AND BOLTS TO
ALTERNATOR— 2.5L ENGINE 54.2 N-m
(40 FT.LBS.)

REMOVAL AND INSTALLATION

A/C Compressor removal is necessary on some mod­
els in order to remove the alternator.
(1) Disconnect battery NEGATIVE cable (Fig. 1).

A/C COMPRESSOR
AND CLUTCH ASSEMBLY RP167

Fig. 2 AIC Compressor Removal and Installation—

2.5L Engine

(c) Without disconnecting the A/C refrigerant lines,

If Equipped With Air Conditioning:
(a) Remove the A/C drive belt. See Group 7, COOL­
ING SYSTEM.
(b) Remove the two nuts and two bolts retaining
the A/C compressor to the A/C compressor-to-engine
mounting bracket (Fig. 2).
position the A/C compressor to allow alternator re­
moval. Warning: The A/C refrigerant system is under
pressure even when the engine is off. Refer to the
Safety Precautions and Warnings section in HEAT­
ING AND A/C, Group 24, before performing any ser­
vice operation.
(2) Remove the alternator drive belt. See Group 7,
Cooling System.
(3) Remove the two alternator mounting bolts (Fig.
3) and position the alternator to gain access to all of
the wire connectors.
 (4) Disconnect Bosch alternator. Remove B + termi­
nal nut, field terminal nuts, and ground harness hold
down nuts (Fig. 4). Remove wire connector assembly.
(5) Disconnect Nippondenso alternator. Remove nuts
from field terminals, ground terminal, wire harness
and B + terminal (Fig. 5). B + terminal nut must be
removed last, to prevent damage to terminal insulator.
(6) Remove the alternator from the vehicle.
To install, reverse the preceding operation.

ALTERNATOR MOUNT BRACKET 2.2 - 2.5L ENGINE SPACER

Fig. 5 Remove or Install Wire Connector Assembly—

Nippondenso Alternator

ALTERNATOR— 3.0L ENGINE

Fig. 3 Remove or Install Mounting Bolts
REMOVAL AND INSTALLATION
(1) Disconnect battery NEGATIVE cable (Fig. 1).
(2) Remove alternator drive belt. See Group 7, Cool­
ing System.
(3) Remove the alternator mounting bolts and sepa­
rate the alternator from the mounting bracket (Fig.
7).

Fig. 4 Remove or Install Wire Connector Assembly—

Bosch Alternator
Fig. 7 Remove or Install Alternator
Mounting Bolts—3.0L Engine

(4) Remove the B + terminal nut, field terminal

nuts, and ground/wire harness hold-down nuts. Re­
move wire connectors.
(5) Remove the alternator from the vehicle.
To install, reverse the preceding operation.
ALTERNATOR— 3.3L ENGINE ALTERNATOR ALTERNATOR SUPPORT
MOUNTING BRAC
REMOVAL AND INSTALLATION
(1) Disconnect battery NEGATIVE cable (Fig. 1).
(2) Remove alternator drive belt. See Group 7, Cool­
ing System.
(3) Loosen (but do not remove) the nut on the sup­
port bracket at exhaust manifold (Fig. 8).
SUPPORT BRACKET EXHAUST

Fig. 9 Alternator/Alternator
Support Bracket—3.3L Engine

(10) Remove alternator support bracket (Fig. 9).

(11) Position alternator and remove alternator wiring.
(12) Remove alternator.
To install, reverse the preceding operation.
BRACKET 918C1

Fig. 8 Support Bracket for Alternator-

Tensioner-Power Steering Bracket

(4) Remove the altemator-tensioner-power steering

bracket bolt (Fig. 8).
(5) Remove the tensioner stud nut and the tensioner
(Fig. 9).
(6) Remove the alternator mounting bolts (Fig. 9).
(7) Remove and position the power steering reser­
voir from the alternator mounting bracket. Do not
remove the power steering hoses from the reservoir.
(8) Remove the three alternator support bracket
bolts (Fig. 8).
(9) Remove intake plenum-to-altemator mounting
bracket bolt.
 SPECIFICATIONS—ALTERNATOR

T IP I * *C A S i I.D. pulley ENGINE ‘ m in im u m

TAG N U M B E R GIOQWIS USAGE OUTPUT
BOSCH 90 HS 4557431 4 2.5L 84 AMP

BOSCH 90 RS 5234231 4 2,51 88 AMP

DENSO 90 HS 5234031 4 2.5L 86 AMP

DENSO 90 HS 5234032 6 3.3L 90 AMP

DENSO 120 HS 5234208 4 2.5L 98 AMP

DENSO 120 HS 5234033 6 3,01-3.31 102 AMP

♦ WITH ALTERNATOR FULL FIELDED AT 1250 RPM

* * CASE I.D. TAG NUMBER IS LOCATED ON BOTTOM OF ALTERNATOR CASE

918C-4

TORQUE SPECIFICATIONS

com ponent ft, Lbs. In. Lbs. Nnvt

A lte rn a to r Mounting Bolts

2.2L/2.5L Engine 40 54

3.3L/3.8L Engine 40 54

3.0L E ngine — U pper Bolt 30 41

L ow er Bolt 250 28

A lte rn a to r B + T erm inal Nut 75 9

B attery Hold D ow n Clam p Bolt 125 14

S ta rte r M ounting B olts/N uts 40 54

918A-18
 -------------------------------------------------- IGNITION SYSTEMS 8D-1

IGNITION SYSTEMS
CONTENTS
Page
COMPONENT IDENTIFICATION— DIRECT IGNITION SYSTEMS ....................... %
CONVENTIONAL IGNITION SYSTEMS 1 SERVICE PROCEDURES— ................ _
COMPONENT IDENTIFICATION- CONVENTIONAL IGNITION SYSTEMS . .. 12
DIRECT IGNITION SYSTEMS ............ . 24 SERVICE PROCEDURES—
CONVENTIONAL IGNITION SYSTEMS .......... 1 DIRECT IGNITION SYSTEMS ................... 33
DIAGNOSTIC PROCEDURES— SPECIFICATIONS ....................................... 39
CONVENTIONAL IGNITION SYSTEMS ....... 9
DIAGNOSTIC PROCEDURES—
DIRECT IGNITION SYSTEMS ................... 31
CONVENTIONAL IGNITION SYSTEMS
COMPONENT IDENTIFICATION—CONVENTIONAL IGNITION SYSTEMS
INDEX
Page Page
Auto Shutdown (ASD) Relay ..................................... 7 Manifold Absolute Pressure (MAP) Sensor ............... 7
Coolant Temperature Sensor ..................................... 7 Optical Distributor System— 3.0L Engines ............... 6
Distributor Cap— 2.5L TBI and 3.0L Engines ......... 2 Rotor—2.5L and 3.0L Engines.................................. 2
General Information .......................... ....................... 1 Single Board Engine Controller (SBEC) ............. . 1
Hall Effect Pick-Up—2.5L Engines .......................... 6 Spark Plugs ................................................................ 3
Ignition Coil ............................................................... 5 Spark Plug Cables .................................................. 2

GENERAL INFORMATION During the crank-start period the Engine Control­

ler will provide a set amount of advanced tim in g to
The information in this group describes the basic assure a quick efficient start.
Ignition System diagnostic procedures for the 2.5L The amount of electronic spark advance provided by
TBI and 3.0L engines, in general. the Engine Controller is determined by three input
Information concerning On Board Diagnostics can factors, coolant temperature, engine rpm , and ava il­
be found in Group 14, Single Point Fuel Injection, or able manifold vacuum.
Multi Point Fuel Injection. The Engine Controller also receives inform ation from
Specifications for ignition related items can be found the Oxygen Sensor and electronically adjusts the a ir-
in Specifications at the rear of this section. fuel mixture to assure the most efficient fuel bum
General maintenance information for ignition re­ possible.
lated items can be found in Lubrication & Mainte­
nance (Group O). This information can also be found FASTENER 60 WAY ELECTRICAL
LOCATIONS CONNECTOR
in the Owner's Manual.

SINGLE BOARD ENGINE CONTROLLER (SBEC)

In this service manual, the Single Board Engine
Controller (SBEC) is referred to as the engine controller.
The Engine Controller controls the entire ignition
system (Fig. 1). It gives the capability of igniting the
fuel mixture according to different engine conditions
during a run-drive period. The engine controller does
this by delivering an almost infinite amount of spark
advance curves. The Engine Controller has a built in
microprocessor that continually receives input from
the engine monitoring sensors. The computer then
electronically advances or retards the ignition timing
to provide even driveability during operation.
DISTRIBUTOR CAP— 2.5L TBI AND 3.0L ENGINES
Remove distributor cap and inspect the inside for
INSUFFICIENT
flashover, cracking of carbon button, lack of spring SPRING
tension on carbon button, cracking of cap, and burned, TENSION
worn term inals. (Fig. 2) Also check for broken distrib­
utor cap towers. If any of these conditions are present
the distributor cap and/or cables should be replaced.

CHARRED OR
ERODED

PHYSICAL
CONTACT
WITH CAP J908D-48

Fig. 3 Rotor Inspection—Typical

SPARK PLUG CABLES

Fig. 2 Distributor Cap inspection
Spark Plug cables are sometimes referred to as sec­
If replacem ent of the distributor cap is necessary,
ondary ignition wires. The ■wires transfer electrical
transfer spark plug wires from the original cap to the
current from the distributor to individual spark plugs
new cap one a t a time. Ensure th a t each wire is
a t each cylinder. The spark plug cables are of nonme-
installed into the tower of the new cap th a t corres­
tallic construction and have a built in resistance. The
ponds to its tower position in the original cap. Fully
cables provide suppression of radio frequency emis­
seat the wires into the towers.
sions from the ignition system.
Light scaling of the term inals, caused by the arcing
Check the high tension (secondary ignition) cable
of the spark from the rotor can be cleaned w ith a
connections for good contact a t the coil and distributor
sharp knife. If heavy scaling of the term inals is pres­
cap towers and a t the spark plugs. Term inals should
ent, the distributor cap should be replaced.
be fully seated. The nipples and spark plug covers
A cap th a t is greasy or dirty or has a powder-like
should be in good condition. Nipples should fit tightly
substance on the inside should be cleaned with a solu­
on the coil and distributor cap towers and spark plug
tion of warm w ater and a mild detergent. Scrub with
cover should fit tig h t around spark plug insulators.
a soft brush, thoroughly rinse, and dry w ith a clean
Cable connections th a t are loose will corrode and in­
soft cloth.
crease the resistance and perm it w ater to enter the
towers causing ignition m alfunction. To maintain
ROTOR— 2.5L T li A l i 3 J L E liiN E S proper sealing between the towers and nipples, ca­
ble and nipple assemblies should not be removed
Inspect rotor for cracks, excessive burning of the
from the distributor cap towem unless nipples are
tip. (Fig. 3) If any of these conditions are present, the
damaged or cable testing indicates high resistance
rotor should be replaced.
or broken insulation.
If heavy scaling of the rotor tip is present, the rotor
should be replaced. CAUTION: Do not pull spark plug cables from dis­
tributor cap of all four cylinder engines. The cables
must be released from inside the distributor cap.
(Fig. 4).
 POSITIVE-LOCKING
Chances are the plug pictured could be cleaned, the
TERMINAL ELECTRODE gap electrodes filed, regapped, and reinstalled with
good results.
AMAL
e w fc W M 'iQ
Id fouling or carbon deposits (Fig. 5 right). This
dry black appearance is fuel carbon and can be due to
over rich fuel-air mixture, fv /* Hogged air cleaner.
However, if only one or two plugs in a set are fouled
/ VI ^ like this it is a good idea to check for worn or improp­
,tijs, erly installed valve guide seals, or faulty ignition
\f i pS9 cables. This condition also results frciM prolonged op­
eration at idle.
9 /
K " - :,4 X
.x.^w^G31

Fig. 4 Spark Pfog (Secondary) Cattfe?

and Removal—All Four Cylinder Conventlc
Ignition Engi

SPARK PLUGS
Resistor spark plugs are used in all engines and
have resistance values of 6,000 to 20,000 ohms (when
checked w ith a t least >lt tester).
Remove the spark plugs and exam ine them for
burned electrodes and fouled, cracked or broken, poi
lain insulators. Keep plugs arranged in the order in
which they were removed from the engine. An iso­
lated plug displaying an abnormal condition indicates
that a problem exists in the corresponding cylinder.
Replace spark plugs at the intervals recommended in
Group O,
Spark plugs that have low milage may be cleaned
and reused if not otherwise defective. Refer to the
Spark Plug Condition section of this group. After clean­
ing, file the center electrode flat with a small point
file or jewelers file. Adjust the gap between the elec­
trodes to the dimensions specified in the chart at the
end of this section.
Always tighten spark plugs to the torque specified
in the chart at the end of this section. Overtorquing
can cause distortion resulting in a change in the spark
plug gap.
2 9 - V / K .
Fig. 5 Normal and Cold Fouling
ING
v7Vet fouling (Fig. 6 left) tells you that the plug has
drowned in excess oil or fuel. In an old engine, suspect
worn rings or excessive cylinder wear. Remember that
break-in fouling of new engines may occur before
normal oi! vw* ^ 9, acbtev**?. in now w r#c$n?fy
"99' .r-. . iOvM'*; ptiAp: 1. ’!9 f e
and reinstalled.
OVERHEATING
■erheating (Fig. 6 right) is indicated by white or
light gray insulator which appears blistered. Elec­
trode wear rate will be considerably in excess of 0.025
mm (0.001 in.)/l,60G km (1,000 miles). Over-advanced
ignition timing detonation and cooling system stop­
pages can overheat the spark plug.

spark p tm c m m r m m
Spark plug appearance or conditions can reflect a
wide variety of engine conditions as follows:

n o r m a l c o n d it io n s
Normal conditions (Fitf. ri This plug has been
running at the correct temperature in a healthy en­
gine. The few deposits present will probably be light
tan or gray in color with most regular grades of com­ ■^ 9 9 .. : - ' ^ xy / /
mercial gasoline. Electrode burning will not be in :> 9 ; !
evidence; gap growth will average not more than about
Fig. 6 Wet Fouling and Chwiwulimj
0.025 mm (0.001 in.) per 1,600 I1/M3G miles).
OIL OR ASH ENCRUSTED GROUND
If one or more plugs are oil or oil ash encrusted, the
engine should be evaluated for the true cause of oil
entry into the combustion chamber. (Fig, I,1

Pig. 8 Electrode Gap Bridging

SCAVENGER DEPOSITS
Fuel scavenger deposits m ay be either w hite or yel­
low (Fig. 9). They m ay appear to be harm ful, but this
is a norm al condition caused by chemical additi¥es in
certain fuels. These additives are designed to change
the chemical nature of deposits and decrease spark
plug m isfire tendencies. Notice th a t accum ulation on
the ground electrode and shell area m ay be heavy but
the deposits are easily remowed. Spark plugs w ith
scavenger deposits can be considered norm al in condi­
tion and can be cleaned using standard procedures.
HIGH SPEED MISS
W hen replacing spark plugs because of a high speed GROUND
miss condition; wide open throttle operation should ELECTRODE
be avoided for approximately 80 km (50 miles) after COVERED
installation of mew plugs.
This will allow deposit shifting in the combustion
chamber to take place gradually and avoid plug de­
stroying splash fouling shortly after the plug change.

ELECTRODE GAP BRIDGING

Electrode gap bridging may be traced to loose de­
posits in the combustion chamber. These deposits
accum ulate on the spark plugs during continuous stop-
and-go driving. When the engine is suddenly sub­
jected to a high torque load,. the deposits partially
liquefy and bridge the gap between the electrodes
(Fig. 8). This short circuits the electrodes. Spark plugs
w ith electrode gap bridging can be cleaned using stan­ Fig. i Scavenger Deposits
dard procedures.
CHIPPED ELECTRODE INSULATOR
A chipped electrode insulator usually results from
bending the center electrode while adjusting the spark
plmg electrode gap. Under certain conditions, severe
detonation can also separate the insulator from the
center electrode (Fig. 10). Spark plugs w ith th is condi­
tion m ust be replaced.
GROUND SPARK PLUG OVERHEATING
O verheating is indicated by a white or gray center
electrode insulator th a t also appears blistered (Fig.
12). The increase in electrode gap will be considerably
in excess of 0.001 in per 1000 miles of operation. This
suggests th a t a plug w ith a cooler heat range rating
should be used. Over advanced ignition tim ing, deto­
nation and cooling system malfunctions can also cause
spark plug overheating.
BLISTERED
WHITE OR

J908P-13

Pig. I# Chipped Electrode Ineuletor

PREIGNITION DAMAGE
Preignition damage is caused by excessive combus­
tion chamber tem perature. First, the center electrode
dissolves. The ground electrode dissolves somewhat
later (Fig. 11). Insulators appear relatively deposit
free. Determ ine if the spark plug has the correct heat
range rating for the engine, if ignition tim ing is over J908P-16
advanced or if other operating conditions are causing
engine overheating. (The heat range rating refers to Fig. 12 Spark Plug Overheating
the operating tem perature of a particular type spark
plug. Spark plugs are designed to operate w ithin spe­
IGNITION COIL
cific tem perature ranges depending upon the thick­
The ignition coils used on the 2.5L and 3.0L engines
ness and length of the center electrode porcelain
are epoxy type coils (Fig 13). These coils are not oil
insulator.)
filled. The windings are embedded in an epoxy com­
GROUND pound. This provides the coil with heat and vibration
ELECTRODE resistance so th a t they can be mounted on the engine.
The 2.5L engines have the coil m ounted on the
therm ostat housing on the front of the engine. The
3.0L engines have the coil mounted on the rear of the
intake manifold.

Fig. 11 Pm ignitim Damage


Fig. 13 Ignition Coil
HALL EFFECT PICK-UP— 2.5L ENGINES
The hall effect pick-up (Fig. 14) is located in the
distributor assembly. It supplies the engine rpm and
ignition timing data to the engine controller. This
allows the engine controller to advance or retard the
ignition spark as required by the engine running
condition.
Fig. 14 Hall Effect Distributor—2.5L Engines
OPTICAL DISTRIBUTOR SYSTEM— 3.0L ENGINES
The engine controller receives its engine speed and
crankshaft position signals from an optical distributor
(Fig 15). The signals are used to control fuel iiyection,
ignition timing, and idle speed. The timing member in
the distributor is a thin disk, driven at half engine
speed from the forward (left) bank camshaft. The disk
has 2 sets of slots in it. The outer, high data rate, set
of slots occurs at intervals of 2 degrees of crankshaft
rotation. It is used for ignition timing at engine speeds
up to 1200 rpm to increase timing accuracy. During
cranking and idle, engine speed changes with the fir­
ing pulses of each cylinder. The high data rate signal
is used to trigger the ignition at the correct crank­
shaft position regardless of these speed changes. The
inner, low data rate, set contains 6 slots, which are
correlated to crankshaft top-dead-center for each cyl­
inder. This set is used to trigger the fuel injection
system, and at engine speeds above 1200 rpm where
speed changes due to individual firing pulses is small,
this set of slots is also used for ignition timing.
ROTOR DISTRIBUTOR
Fig. 15 Optical Distributor—3.0L Engine
Light emitting diodes (LED’s) and photo diodes are
mounted in facing positions on opposite sides of the
disk in line with the slots. Masks over the LED’s and
the photo diodes focus the light beams onto the photo
diodes. As each slot passes between the diodes, the
light beam is turned on and off. This creates an alter­
nating voltage in each photo diode which is converted
into on-off pulses by an integrated circuit within the
distributor. These pulses are transmitted to the en­
gine controller.
The distributor also delivers the firing pulses from
the coil to each individual cylinder through a cap and
rotor. A cover between the rotor and case protects
against high voltage damage to the electronic cir­
cuitry and optical system contamination.
COOLANT TEMPERATURE SENSOR
The Coolant Temperature Sensor (Fig 16) is a de­
vice which monitors coolant temperature (which is the
same as engine operating temperature). It is mounted
near the thermostat housing. This sensor provides
data on engine operating temperature to the engine
controller.
WIRING TERMINALS THREADS

Fig. 17 MAP Sensor—2.SL TBI Engines

Fig. 16 Coolant Temperature Sensor

Incorporated in the digital microprocessor electron­

ics are some unique spark advance schedules which
occur during cold and warm engine operation. They
have been added to reduce engine emission and im­
prove driveability. Because they change at different
engine operating temperatures during warm-up, all
spark advance testing should be done with the engine
fully warmed. This data allows the engine controller
to demand slightly richer air-fuel mixtures and higher
idle speeds until normal operating temperatures are
reached. The sensor is a variable resistance (thermis­
tor) with a range of 40°F to 265°F.
Fig. 18 MAP Sensor—3.0L Engine
MANIFOLD ABSOLUTE PRESSURE (MAP) SENSOR AUTO SHUTDOWN (ASD) RELAY
The Manifold Absolute Pressure (MAP) sensor (Figs.
When there is no ignition signal present with the
17 and 18) is a device which monitors manifold vac­ ignition key in the RUN position, there is no need for
uum. It is mounted underhood and is connected to a
fuel delivery. When this condition occurs, the auto
vacuum nipple on the throttle body (2.5L TBI en­
shutdown relay (Fig. 19) interrupts power to the elec­
gines), or to the intake manifold nipple (3.0L engines)
tric fuel pump, fuel injectors, and ignition coil.
and is electrically connected to the engine controller.
The sensor transmits information on manifold vac­
uum conditions and barometric pressure to the engine
controller. The MAP sensor data on engine load is
used with data from other sensors to determine the
correct air fuel mixture.
STARTER RELAY- AUTO SHUTDOWN
(ASD) RELAY

LEFT SIDE OF ,
VEHICLE
A/C CLUTCH RELAY

SHOCK
TOWER

RIGHT SIDE OF
9180*49 VEHICLE

Fig. 19 Relay Identification

* --------------------------------------------------------------------------- — — ------- IGNITION SYSTEMS
DIAGNOSTIC PROCEDURES—CONVENTIONAL IGNITION SYSTEMS
Coolant Temperature Sensor T e s t ...............................
Failure To Start Test— 2 .5L TBI
and 3 .0 L Engines ......................................................
Ignition Coil ....................................................................
See On Board Diagnostics in the General Diagno­
sis section of Group 14, Single Point Fuel Injection
and Multi Point Fuel Injection.
IGNITION COIL
The ignition coil is designed to operate w ithout an
external ignition resistor. Inspect the coil for arcing.
Test coil according to coil tester m anufacturer’s in­
structions. Test coil primary resistance. Test coil sec­
ondary resistance. Replace any coil that does not meet
specifications.
Every time an ignition coil is replaced because of a
burned tower, carbon tracking, arcing a t the tower, or
damage to the nipple or boot on the coil end of the
secondary cable, replace cable. Any arcing at the tower
will carbonize the nipple so that placing it on a new
coil will invariably cause another coil failure.
If secondary cable shows any signs of damage, cable
should be replaced w ith a new cable and nipple since
carbon tracking on the old cable can cause arcing, and
therefore, ruin a new coil.
TESTING FOR SPARK AT COIL—
2.5L T il A N i 3.0L ENGINES
WARNING: BE SURE TO APPLY PARKING BRAKE
AND/OR BLOCK WHEELS BEFORE PERFORMING
ANY ENGINE RUNNING TESTS.
Remove coil secondary cable from distributor cap.
Hold end of cable about 6 mm (1/4-inch) away from a
A GOOD
ENGINE
GROUND
CHECK HERE
F O i SPARK
8D-9
INDEX
Page Page
10 Manifold Absolute Pressure (MAP) Sensor T e s t ___ 11
Poor Performance Test .................................................. 10
9 Testing for Spark At Coil— 2 .5 L T B I
9 and 3 .0L Engines ...................................................... 9
good engine ground (Fig. 1). Crank the engine and
look for a spark at coil secondary cable.
CAUTION: Spark plug wire may be damaged if this
test is performed with more than 1/4 inch clearance
between the cable and engine ground.
If there is a spark at coil secondary cable it must be
constant. If it is, have helper continue to crank engine
and while slowly moving coil secondary cable away
from ground, look for arcing at the coil tower. If arc­
ing occurs replace coil. If spark is not constant or
there is no spark, proceed to the failure to start test.
If spark is good and there is no arcing at the coil
tower the ignition system is producing the necessary
high secondary voltage. However, make sure that this
voltage is getting to the spark plugs by checking the
distributor rotor, cap, spark plug cables, and spark
plugs. If they are okay, then the ignition system is not
the reason why the engine will not start. It will be
necessary to check the fuel system and engine me­
chanical items.
FAILURE TO START TEST—
2.5L TBI AND 3.0L ENGINES
Before proceeding with this test make sure Test­
ing For Spark At Coil has been performed. Failure to
do this may lead to unnecessary diagnostic time and
wrong test results.
WARNING: BE SURE TO APPLY PARKING BRAKE
AND/OR BLOCK WHEELS BEFORE PERFORMING
ANY ENGINE RUNNING TESTS.
(1) Determine that sufficient battery voltage (12.4
volts) is present for the cranking and ignition systems.
(2) Crank the engine for 5 seconds while monitoring
the voltage at coil (+). (Figs. 2 and 3) If the voltage
remains near zero during the entire period of crank­
o ing, see Group 14 for On-Board Diagnostic checks.
f ' O These checks will help diagnose problems with the
■Q engine controller and auto shutdown relay.
O
[0
7
IGNITION
COIL 918D-18
DISTRIBUTOR SPLASH
SHIELD

TERMINAL SIDE
SHOWN 898D-3

Fig. 5 60-Way Electrical Connector, Engine Controller

(6) Using the special jumper (Fig. 4), momentarily

918D-19 ground terminal #19 of the 60-way connector (Fig. 5).
A spark should be generated when the ground is
Fig. 2 Coil Terminals—2.5L Engines removed.
(7) If spark is generated, replace the engine controller.
(8) If no spark is seen, use the special jumper to
ground the (-) coil terminal directly.
(9) If spark is produced, inspect wiring harness for
an open condition.
(10) If no spark is produced, replace the ignition
coil.

POOR PERFORMANCE TEST

Before proceeding with test make sure Testing For
Spark At Coil has been performed. Failure to do this
HIGH TENSION- IGNITION COIL may lead to unnecessary diagnostic time and wrong
CABLE =ELECTRICAL CONNECTION test results.
x
WARNING: BE SURE TO APPLY PARKING BRAKE
908D-4 AND/OR BLOCK WHEELS BEFORE PERFORMING
Fig. 3 Coil Terminals—3.0L Engine ANY ENGINE RUNNING TESTS.
Check and adjust basic timing (refer to the specifi­
(3) If voltage is at near-battery voltage and drops to
cation section of this group and see service procedures).
z^ro after 1-2 seconds of cranking, see Group 14 for
Refer to Group 14, General Diagnosis On Board
On-Board Diagnostic check for the distributor refer­
Diagnostics.
ence pickup circuit to the engine controller.
(4) If voltage remains at near battery voltage dur­
COOLANT TEMPERATURE SENSOR TEST
ing the entire 5 seconds, with the key off, remove the
engine controller 60-way connector. Check the 60-way (1) With key off, disconnect wire connector from
for any terminals loose from connector (push-outs). coolant temperature sensor (Fig. 6).
(5) Remove the connector to coil (+ ) and connect a (2) Connect one lead of ohmmeter to one terminal of
jumper wire between battery ( + ) and coil ( + ). coolant temperature sensor.
(3) Connect the other lead of ohmmeter to remain­
ing connector of coolant temperature sensor. The ohm­
CAPACITOR CONNECT THIS meter should read as follows;
CLIP TO COIL • Engine/Sensor at normal operating temperature
NEGATIVE around 200°F should read approximately 700 to 1,000
ALLIGATOR
GROUND CLIP ohms.
THIS MOMENTARILY
CLIP GROUND THIS
• Engine/Sensor at room temperature around 70°F,
CLIP TO COILN ohmmeter should read approximately 7,000 to 13,000
NEGATIVE ohms.
See On Board Diagnostics in the General Diagno­
ALLIGATOR CLIP sis section of Group 14, or refer to the appropriate
RBI 003
diagnostic manual for further test procedures.
 MANIFOLD ABSOLUTE PRESSURE (MAP)
SENSOR TEST
See On Board Diagnostics in the General Diagnosis
section of Group 14, or refer to the appropriate diag­
nostic manual for further test procedures.

Fig. 6 Coolant Temperature Sensor Test

 SERVICE PROCEDURES—CONVENTIONAL IGNITION SYSTEMS
INDEX
Page Page
Coolant Temperature Sensor—2.5L TBI I gnition Coil Service— 2.5L TBI Engines................... 13
and 3.0L Engines 12 Ignition Coil Service— 3.0L Engines ......................... 13
Distributor Service— 3 .0 L Optical System ............... 18 Ignition Timing Procedure— 2 .5L TBI
Distributor Service Hall Effect System— and 3 .0 L Engines ...................................................... 15
2.5L TBI Engines .............................................. 16 Manifold Absol ute Pressure (MAP)
Engine Controller ................................................. 12 Sensor Service— 2 .5L TBI and 3 .0 L Engines___ 23
Hall Effect Pick-Up Assembly Replacem ent............ 18 Spark Plug Cable S ervice.............................................. 13
Idle RPM Test— 2.5L TBI and 3 .0 L Engines .......... 14 Spark Plug Service ........................................................ 14

ENGINE CONTROLLER COOLANT TEMPERATURE SENSOR—

REMOVAL
When replacement of Engine Controller is neces­
sary proceed as follows:
(1) Remove air cleaner duct or air cleaner assembly.
(2) Remove battery.
(3) Remove (2) module mounting screws (Fig. 1).
(4) Remove 60 way wiring connector from the en-
gitie controller and remove controller.
DIAGNOSTIC
CONNECTOR>
2.5L TBI AND 3.0L ENGINES
REMOVAL
(1) Disconnect 2-Way Electrical Connector from sen­
sor. Remove sensor from engine (Figs. 2 and 3).
(2) Engine coolant may be lost.
INSTALLATION
(1) Install sensor and torque to 20 ft. lbs. for 2.5L
Engines and 60 in. lbs. for 3.0L Engines. Reconnect
ENGINE 2-way electrical connector (Figs. 2 and 3).
CONTROLLER
(2) Replace any lost engine coolant (Refer to Group
7 Cooling System).

COOLANT
TEMPERATURE
SENSOR

BATTERY/ 918D-55
BATTERY
Fig. 1 Removing Engine Controller NEGATIVE
GROUND
IGNITION ELECTRICAL ^
INSTALLATION COIL CONNECTORS 918D-21
(1) Connect 60 Way Electrical connector to Engine
C ontroller (Fig. 1). Fig. 2 Coolant Temperature Sensor—2.5L TBI Engines
(2) Mount Engine Controller to inside left front fender
(fig . 1). In stall and tighten two (2) mounting screws.
(3) Install the battery.
(4) In s ta ll air cleaner duct or air cleaner assembly.
 INSTALLATION
(1) Install ignition coil into the coil bracket. Torque
the screws to 9.5 N-m (85 in. lbs.).
(2) Connect the wiring harness connector.
(3) Connect the coil to distributor ignition cable.

IGNITION COIL SERVICE— 3.0L ENGINES

REMOVAL
(1) Remove air cleaner assembly.
(2) Disconnect the coil to distributor ignition cable
(Fig. 5).
(3) Disconnect the w iring harness connector from
the coil.
(4) Remove the screws holding the coil in place and
remove the coil.

FUEL SUPPLY AND ENGINE TEMPERATURE \

RETURN HOSES ‘ SENDI NG UNIT \ 908D-13

Fig. 3 Coolant Temperature Sensor—3.0L Engine

IGNITION COIL SERVICE— 2.5L TBI ENGINES

REMOVAL
(1) Disconnect the coil to distributor ignition cable
(Fig. 4).
(2) Disconnect the wiring harness connector from
the coil.
(3) Remove the screws holding the ignition coil to
the coil bracket.
Fig. 5 ignition Co/f-3.0L

INSTALLATION
(1) Loose install the ignition coil to the intake m an­
ifold. Torque the intake manifold fastener to 13 N’m '
(115 in.lbs.). Torque the ignition coil bracket fasteners
to 10 N*m (96 in. lbs.)
(2) Connect the wiring harness connector.
(3) Connect the coil to distributor ignition cable.
(4) Install the air cleaner assembly. Torque the air
cleaner fasteners to 25 N*m (225 in. lbs.)

SPARK PLUG CAILE SERVICE

Clean high tension cables w ith a cloth moistened
with a non-flammable solvent and wipe dry. Check for
brittle or cracked insulation.
W hen testing secondary cables for punctures and
cracks w ith an oscilloscope follow the instructions of
the equipm ent m anufacturers.
If an oscilloscope is not available, secondary cables
can be tested as follows:
CAUTION: Do not leave any one spark plug cable CABLE RESISTANCE CHART
disconnected any longer than necessary during test
or possible heat damage to catalytic converter will M IN IM U M M A X IM U M
occur, Total test time must not exceed ten minutes.
250 Ohms Per Inch 1OCX) Ohms Per Inch
(a) Engine not running, connect one end of a test 3000 Ohms Per Foot 12,000 Ohms Per foot
probe (i.e. a piece of wire with insulated alligator clips
on each end) to a good ground, other end free for J90SP-43
probing.
With engine running, move test probe along
entire length of all cables (approximately 0 to 1/8 inch
gap). If punctures or cracks are present there will be a
noticeable spark jum p from the faulty area to the
probe. The cable running from the coil to the distribu­
To test coil to distributor cap high tension cable,
tor cap may be checked in the same m anner. Cracked,
remove distributor cap with the cable intact. Do not
leaking or faulty cables should be replaced.
remove cable from the cap. Connect the ohm meter
When installing mw cable assemblies, install new
between center contact in the cap and remove the
high tension cable and nipple assembly ©wer cap or
cable at coil tower and check cable resistance. If resis­
coif tower. When entering the terminal into the tower,
tance is not within tolerance, replace the cable. Also,
pysh lightly, then pinch the large diameter of nipple
check for a loose connection a t the tower or for a
to release trapped air between the nipple and tower.
faulty coil.
Continue pushing on the cable and nipple until ca­
Inspect coil tower for cracks or carbon tracking.
bles are properly seated in the cap towers. Snap
should be heard as terminal goes into place.
Use the same procedure to install cable in coil
SPARK PLUG SERVICE
tower. Wipe the spark plug insulator clean before
REMOVAL AND INSTALLATION
reinstalling cable and cover.
At the time of removal or installation, remember
Use the following procedure when removing the high
the following points.
tension cable from the spark plug. First, remove the
(1) When removing spark plug cables, grasp cable
cable from the retaining bracket. Then grasp the ter­
at cable cap.
minal as close as possible to the spark plug rotate
(2) Torque the spark plugs to 28 N*ra (20 ft. lbs.).
slightly and use a straight and steady pull. Do not
pull on the wire itself as this will damage the con­
INSPECTION
ductor and terminal connection. Do not use pliers
Inspect the spark plugs for the following items. Clean
do m i pul! the cable at an angle, Doing so will
or replace if necessary.
damage the insulation, cable terminal or the spark
(1) Cracked or damaged threads or insulator.
plug insulator. Wipe spark piyg insulator clean be­
(2) Worn electrodes.
fore reinstalling cable and cover.
(3) Damaged or worn gasket.
Resistance type cable is identified by the words Elec­
(4) Condition of burnt electrode and amount of car­
tronic Suppression printed on the cable jacket.
bon deposit.
t an ohmmeter to check resistance type cable for
open circuits, loose terminals or high resistance as
SPARK PLUG GAP ADJUSTMENT
follows:
Check the plug gap with plug gap gauge. If gap is
(a) Remove cable from spark plug.
not within the limit shown in the specifications chart
(b) Lift distributor cap from distributor with ca­
at the end of this section, adjust by carefully bending
bles in tact. Do not remove cables from cap. The ca­
the ground electrode.
bles must be removed from the spark plugs.
(c) Connect the ohmmeter between spark plug
end terminal and the corresponding electrode inside
IDLE RPM TEST— 2.5L TBI AND 3.0L ENGINES
the cap, making sure ohmmeter probes are in good
WARNING: BE SURE TO APPLY PARKING BRAKE
contact. Resistance should be within tolerance shown
AND/OR BLOCK WHEELS BEFORE PERFORMING
in the cable resistance chart. If resistance is not within
ANY ENGINE RUNNING TESTS.
tolerance, remove cable at cap tower and check the
cable. If resistance is still not within tolerance, re­ Engine idle set rpm should be tested and recorded
place cable assembly. Test all spark plug cables in as it is when the vehicle is first brought into shop for
same manner. testing. This will assist in diagnosing complaints of
engine stalling, creeping and hard shifting on vehicles
equipped with automatic transmissions.
 Refer to Group 14, General Diagnosis On Board
Diagnostics for the throttle body minimum airflow
check procedure.

IGNITION TIMING PROCEDURE—

2.5L TBI AND 3.0L ENGINES
WARNING: BE SURE TO APPLY PARKING BRAKE
AND/OR BLOCK WHEELS BEFORE PERFORMING
ANY ENGINE RUNNING TESTS.
To obtain optimum engine performance, the distrib­
utor must be correctly positioned on the engine to give
proper ignition timing.
Test procedures are as follows:
(1) Connect a suitable Power Timing Light to num­
ber one cylinder (refer to equipment manufacturer’s
instructions for correct connecting procedures).
Do not puncture cables, boots or nipples with test
probes. Always use proper adapters. Puncturing the
spark plug cables with a probe will damage the ca­ FUEL SUPPLY AND ENGINE TEMPERATURE S.
bles. The probe can separate the conductor and cause RETURN HOSES I SENDING UNIT \ 908D-13
high resistance. In addition breaking the rubber in­
sulation may permit secondary current to arc to Fig. 7 Coolant Temperature Sensor—3.0L Engine
ground.
(4) Aim Power Timing Lamp at front crankshaft
(2) Start engine and run until operating tempera­
pulley (3.0L engines), (Fig. 9) or the Transaxle (2.5L
ture is obtained.
engines), (Fig. 8) or read magnetic timing unit. If
(3) With engine at normal operating temperature,
flash occurs when timing mark is before specified de­
disconnect coolant temperature sensor (Figs. 6 and 7).
gree mark, timing is advanced. To adjust, turn dis­
Radiator fan and I/P lamp should come on.
tributor housing in direction of rotor rotation.

TIMING
W INDOW
 RR8DG17

Fig. 9 Timing Scale—3.01 Engine Fig. 11 Distributor Hold-Down—3.0L Engine

If flash occurs when tim ing m ark is after specified DISTRIBUTOR SERVICE H IL L EFFECT ■
degree m ark, tim ing is retarded. To adjust, tu rn dis­ SYSTEM— 2 J L TBI ENGINES . ■
tributor housing against direction of rotor rotation.
Refer to Vehicle Emission Control Inform ation (VECI) REMOVAL , .
Label for correct tim ing specification. If tim ing is within (1) Disconnect distributor pick-up lead wires a t w ir­
± 2° of value specified on the label, proceed to step (7). If ing harness connector (Fig. 12).
outside specified tolerance, proceed to next step.
(5) Loosen distributor hold-down arm screw ju st
enough so the distributor housing can be rotated in its
m ounting-(Figs. 10 and 11). Turn distributor housing
until specified label value is reached. Tighten the
hold-down arm screw and recheck tim ing.
(6) Turn the engine off. Remo¥e tim ing light or
m agnetic tim ing u n it and tachom eter. Reconnect cool­
an t tem perature sensor connector. Erase fault codes
using the Erase Fault Code Option on the DRBli.

Fig. 10 Distributor Hold-Down—2.SL TBI Engines

Fig. 12 Pickup Lead Connector and Splash Shield
 (2) Remove splash shield retaining screws (Fig. 13).
(3) Remove splash shield (Fig. 13).

DISTRIBUTOR
CAP

HOLD DOW N
SCREWS (2)

DISTRIBUTOR
ROTOR
HOUSING

RN173

Fig, IS Distributor Cap

(5) Lift off distributor cap (Fig. 15).

Fig. 13 Splash Shield (8) Rotate engine crankshaft until the distributor
rotor is pointing toward the cylinder block. Use this
(4) Loosen distributor cap retaining screws (Fig.
as reference when reinstalling distributor.
14).
(7) Remove distributor hold-down screw (Fig. 16).

DISTRIBUTOR SCREWDRIVER
CAP VENT
DISTRIBUTOR
CAP
DISTRIBUTOR
CAP
RETAINING
SCREWS (2)

HOLD DOW N SCREW ^ s 4"- v II II \\ ’\ fv —--J RN165

i 'i i i i / \ il If

Fig. 16 Distributor Hold-Down

RN172A (8) Carefully lift the distributor from the engine.

Fig. 14 Distributor Cap Retaining Screws INSTMLLMTION

(1) Position distributor in engine. M ake certain th a t
the O-ring is properly seated on distributor. If O-ring
is cracked or nicked replace with new one.
(2) Carefully engage distributor drive w ith auxil­
iary shaft drive so th a t when distributor is installed
properly, rotor will be pointing towards cylinder block.
If engine has been cranked while distribytor is re­
mowed, it will be necessary to establish proper rela­
tionship between the distributor shat and Number 1
piston position as follows:
 (a) Rotate the crankshaft until number one piston (3) Remove Hall effect pick-up assembly (Fig. 18).
is at top of compression stroke. Pointer on clutch hous­
ing should be in line with the O(TDC) mark on flywheel.
(b) Rotate rotor to a position just ahead of the
number one distributor cap terminal.
(c) Lower the distributor into the opening, engag­
ing distributor drive with drive on auxiliary shaft.
With distributor fully seated on engine, rotor should
be under the cap number 1 tower.
(3) Install the distributor cap (Fig. 15) (make sure
all high tension wires snap firmly in the cap towers).
(4) Install hold-down arm screw and finger tighten
(Fig. 14).
(5) Install splash shield (Figs. 12 and 13).
(6) Connect distributor hall effect pick-up lead wire
at wiring harness connector.
(7) Set ignition timing to specification. Refer to Ig­
nition Timing.

HALL EFFECT PICK-UP ASSEMBLY REPLACEMENT

REMOVAL
(1) Remove splash shield and cap. See Distributor
Removal.
(2) Remove rotor from shaft (Fig. 17). Fig. 18 Hall Effect Pickup Assembly

INSTALLATION
(1) Place Hall Effect Pick-up Assembly into distrib­
utor housing (Fig. 18).
Hall effect pick-up assembly leads may be dam­
aged if not properly reinstalled.
(2) Install rotor (Fig. 17).
(3) Install cap and splash shield. See Distributor
Installation.

DISTRIBUTOR SERVICE— 3.0L OPTICAL SYSTEM

REMOVAL
(1) Disconnect distributor lead wire at wiring har­
ness connector (Fig. 1).
 (2) Loosen distributor cap retaining screws.
(3) Lift off distributor cap (Fig. 2).
(4) Rotate engine crankshaft until the distributor
rotor is pointing toward the Intake Plenum. Scribe a
mark on plenum at this point to indicate position of
the rotor as a reference when reinstalling distributor.
(5) Remove distributor hold down nut (Fig. 3).
(6) Carefully lift the distributor from the engine.
DISASSEMBLY
(Fig. 2).
INSTALLATION
(1) Position distributor in engine. Make certain that flashover, cracking of carbon button, cracking of cap,
the O ring is properly seated on distributor. If O ring
is cracked or nicked replace with new one.
(2) Carefully engage distributor drive with cam­
shaft drive so that when distributor is installed prop­
erly, rotor will be in line with previously scribe line
on Air Intake Plenum. If engine has been cranked
while distributor is removed, it will be necessary to
establish proper relationship between the distributor
shaft and Number 1 piston position as follows:
(a) Rotate the crankshaft until number one piston
is at top of compression stroke.
(b) Rotate rotor to number one rotor terminal
(Fig. 4).
(c) Lower the distributor into the opening, engag­
ing distributor drive with drive on camshaft. With
distributor fully seated on engine, rotor should be
under the number 1 terminal (Fig. 4).
Fig. 4 Distributor Cap Terminal Routing—
View from Top of Cap
(3) Install the distributor cap (Fig. 2) (make sure all
high tension wires are firmly in the cap towers).
(4) Install hold-down nut and finger tighten (Fig. 3).
(5) Connect distributor lead wire at wiring harness
connector (Fig. 1).
(6) Set ignition timing to specification (refer to Igni­
tion Timing).
(1) Remove two (2) distributor cap mounting screws
(2) Remove distributor cap (Fig. 2), and inspect for
or burned term inals. If any of these conditions exist, SCIEW
replace cap.
(3) Remove rotor screw (Fig. 5) and inspect for crack­
ing or burned electrode. If any of these conditions
exist, replace rotor.

DISTRIBUTOR
LEAD WIRE RR8DG7

Fig. 7 Lead Wire Clamp

(6) Remove disk assembly screw (Fig. 8).

SCREW

(4) Remove protective cover from distributor hous­

ing (Fig. 8). SPACE!

SCREWDRIVER COVER

UNIT RR8PG8
SCREWS
Fig. 8 Disk Mssembly Screw

(7) Remove disk spacers and disk (Fig. 9). Disk and
spacers are keyed. Check disk for warpage, cracks or
damaged slots (Fig. 10).
RR8DG6
UNIT'
Fig. 6 Cower

(5) Remove lead wire clamp screw and remove lead

wire (Fig. 7). DISK

SPACER

RR8DG9
 HIGH DATA RATE DISTRIBUTOR LEAD
SLOTS WIRE OPENING

UPPER AND LOWER

SPACEiS

LOW DATA RATE

SLOTS

BEARING jJEIAINiNG
RR8DG10 ■ SCREWS (2) RR8DG12

Fig. 10 Disk and Spacers Fig. 12 Bearing Retainer Scmms

(8) Remove bushing and 3 Photo Optic Sensing unit (10) Make reassembly alignm ent m arks on gear and
fasteners. Remove un it from distributor housing (Fig. shaft (Figs. 13 and 14).
11).

UNIT SCREWS (3)

ASSEMBLY

BUSHING

RR8DG11

Fig. 11 Photo Optic Sensing Unit A ssem bly

and Bushing DISTRIBUTOR
DRIVE HOUSING
(9) Remove 2 bearing retainer screws (Fig. 12). GEAR\

DRIVE
SHAFT

DRIVE GEAR AND

SHAFT MARKS
 (11) With a pin punch drive out distributor drive (13) Remove distributor shaft and bearing assembly
gear roll pin (Fig. 15). (Fig. 17)

(12) Remove distributor drive gear (Fig. 16). REASSEMBLY

To reassemble reverse preceding procedure.

Fig. 16 Drive Gear

DISTRIBUTOR CAP SCiEW (3)

PHOTO OPTIC
ROTOR SENSING UNIT

t o n PIN

SPACER (2) SCREW RR8DG21

Fig. 18 Distributor—3.0L Engine

MANIFOLD ABSOLUTE PRESSURE (MAPI

SENSOR SERVICE— 2 J L TBi AND 3.0L ENGINES
DISTRIBUTOR
(1) Remove vacuum hose and remove m ounting
screws from sensor (Figs. 19 and 20).
(2) Remove w iring harness and remove sensor.
(3) Reverse the above procedure for installation.
Check th a t vacuum hose is attached to vacuum source.

'M AP SENSOR
3-WAY
ELECTRICAL
CONNECTOR SENSOR

Fig. 20 M m lfoId Absolute Pressure (MAP) Sensor—

3.01 Engine

Fig. 19 Manifold Absolute Pressure (MAP) Sensor—

2.51 TBI Englnea
 DIRECT IGNITION SYSTEMS
COMPONENT IDENTIFICATION—DIRECT IGNITION SYSTEMS
INDEX
Page Page
Auto Shutdown (ASD) Relay . . . . . . . . . . . . . . . . . . . . 29 Ignition Coil . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6 28
Camshaft Reference Sensor . . . . . . . . . . . . . . . . . . . . 28 Manifold Absolute Pressure (MAP) Sensor . . . . . . . . 29
Coolant Temperature Sensor . . . . . . . . . . . . . . . . . . . . 29 Single Board Engine Controller (SBEC) . . . . . . . . . . . 25
Crankshaft Timing Sensor . . . . . . . . . . . . . . . . . . . . . . 28 Spark Plug Cables . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25
Detonation (Knock) Sensor . . . . . . . . . . . . . . . . . . . . . 29 Spark Plugs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25
General Information . . . . . . . . . . . . . . . . . . . . . . . . . . . 24

GENER1L INFORMATION
TOiQUE CONVERTER DRIVE PLATE
The information in this group describes the basic
Ignition System diagnostic procedures for the 3.3L
engines, in general.
Information concerning On Board Diagnostics can
be found in Group 14—Multi Point Fuel Injection.
Specifications for ignition related items can be found
in Specifications at the rear of this section.
General maintenance information for ignition re­
lated items can be found in Lubrication & Mainte­
nance (Group O). This information can also be found
in the Owner’s Manual.
The Direct Ignition System is a distributorless sys­
tem. This system’s three main components are the coil
pack, crankshaft timing sensor, and camshaft refer­
ence sensor. The crankshaft and camshaft sensors are
hall effect devices. These devices use the change in a Fig. I Drlweplsto
magnetic field (from an internal magnet) to sense
whether a slot is present on the camshaft sprocket or CAMSHAFT SPROCKET
a window is present on the torque converter driveplate.
When a slot or window is sensed, the sensors switch
(sensor) input voltage from high (5 volts) to low (less
than .3 volts). As the slot or window passes, the input
voltage is switched back to high (5 volts). These changes
in input voltage allow the engine controller to com­
pute engine speed, crankshaft position, and camshaft
position.
The engine controller receives its engine speed and
crankshaft position signal from a sensor located on
the transaxle housing. This crankshaft position sensor
senses slots located around an extension on the torque
converter drive plate. (Fig. 1) A camshaft sensor lo­
cated on the chain case cover supplies cylinder identi­
fication information by sensing slots located on the
camshaft sprocket. (Fig. 2)

SINGLE BOARD ENGINE CONTROLLER (S8EC)
In this service m anual, the Single Board Engine
Controller (SBEC) is referred to as the engine controller.
The Engine Controller controls the entire ignition
system (Fig. 3). It gives the capability of igniting the
fuel m ixture according to different engine conditions
during a run-drive period. The engine controller does
this by delivering an almost infinite am ount of spark
advance curves. The Engine Controller has a built in
microprocessor th a t continually receives input from
the engine m onitoring sensors. The computer then
electronically advances or retards the ignition tim ing
to provide even driveability during operation.
During the crank-start period the Engine Control­
ler will provide a set am ount of advanced tim ing to
assure a quick efficient start.
The am ount of electronic spark advance provided by
the Engine Controller is determ ined by three input
factors, coolant tem perature, engine rpm, and avail­
able manifold vacuum.
The Engine Controller also receives information from
the Oxygen Sensor and electronically adjusts the air-
fuel m ixture to assure the most efficient fuel bum
possible.
FASTENER ^ 60 WAY ELECTRICAL
LOCATIONS \ ." ..^.... .. CONNECTOR
918D-48
Fig. 3 Single Board Engine Controller
SPARK PLUG CABLES
Spark Plug cables are sometimes referred to as sec­
ondary ignition wires. The wires transfer electrical
current from the coil pack to individual spark plugs at
each cylinder. The spark plug cables are of nonmetal-
lic construction and have a built in resistance. The
cables provide suppression of radio frequency emis­
sions from the ignition system.
Check the high tension cable connections for good
contact a t the coil and a t the spark plugs. Term inals
should be fully seated. The nipples and spark plug
covers should be in good condition. Nipples should fit
IG liliO l S Y S IiiS ID-25
tightly on the coil, and the spark plug cover should fit
tig h t around spark plug insulators. Cable connections
th a t are loose will corrode and increase the resistance
and perm it w ater to enter the towers causing ignition
malfunction.
SPARK PLUGS
Resistor spark plugs are used in all engines and
have resistance values of 8,000 to 20,000 ohms (when
checked w ith a t least a 1000 volt tester).
Remove the spark plugs and exam ine them for
burned electrodes and fouled, cracked or broken porce­
lain insulators. Keep plugs arranged in the order in
which they were removed from the engine. An iso­
lated plug displaying an abnorm al condition indicates
th a t a problem exists in the corresponding cylinder.
Replace spark plugs a t the intervals recommended in
the m aintenance chart in Group O.
Spark plugs th a t have low milage may be cleaned
and reused if not otherwise defective. Refer to the
Spark Plug Condition section of this group. After clean­
ing, file the center electrode flat with a small point
file or jewelers file. Adjust the gap between the elec­
trodes to the dimensions specified in the chart at the
end of this section.
Always tighten spark plugs to the torque specified
in the chart at the end of this section. Overtorquing
can cause distortion resulting in a change in the spark
plug gap.
SPARK PLUG CONDITIONS
Spark plug appearance or conditions can reflect a
wide variety of engine conditions as follows:
NORMAL CONDITIONS
Normal conditions (Fig. 4 left). This plug has been
running at the correct temperature in a healthy en­
gine. The few deposits present will probably be light
tan or gray in color with most regular grades of com­
mercial gasoline. Electrode burning will not be in
evidence; gap growth will average not more than about
0.025 mm (0.001 in.) per 1,600 km (1,000-miles).
Chances are the plug pictured could be cleaned, the
gap electrodes filed, regapped, and reinstalled w ith
good results.
COLD FOWLING
Cold fouling or carbon deposits (Fig. 4 right). This
dry black appearance is fuel carbon and can be due to
over rich fuel-air m ixture or a clogged air cleaner.
However, if only one or two plugs in a set are fouled
like this it is a good idea to check for worn or improp­
erly installed valve guide seals, or faulty ignition
cables. This condition also results from prolonged op­
eration at idle. ' .-
 Fig. 4 Normal and Cold Fouling

WET FOULING
Wet fouling (Fig. 5 left) tells you that the plug has
drowned in excess oil or fuel. In an old engine, suspect
worn rings or excessive cylinder wear. Remember that
break-in fouling of new engines may occur before
normal oil control is achieved. In new or recently
overhauled jobs, such fouled plugs can be cleaned
and reinstalled.

OVERHEATING Fig. 6 Oil or Ash Encrusted

Overheating (Fig. 5 right) is indicated by white or
HIGH SPEED MISS
light gray insulator which appears blistered. Elec­
When replacing spark plugs because of a high speed
trode wear rate will be considerably in excess of 0.025
miss condition; wide open throttle operation should
mm (0.001 in.)/l,600 km (1,000 miles). Over-advanced
be avoided for approximately 80 km (50 miles) after
ignition timing detonation and cooling system stop­
installation of new plugs.
pages can overheat the spark plug.
This will allow deposit shifting in the combustion
chamber to take place gradually and avoid plug de­
stroying splash fouling shortly after the plug change.

ELECTRODE GAP BRIDGING

Fig. 5 Wet Fouling and Overheating
OIL OR ASH ENCRUSTED
If one or more plugs are oil or oil ash encrusted
(Fig. 6), the engine should be evaluated for the true
cause of oil entry into the combustion chamber.
Electrode gap bridging may be traced to loose de­
posits in the combustion chamber. These deposits
accumulate on the spark plugs during continuous stop-
and-go driving. When the engine is suddenly sub­
jected to a high torque load, the deposits partially
liquefy and bridge the gap between the electrodes
(Fig. 7). This short circuits the electrodes. Spark plugs
with electrode gap bridging can be cleaned using stan­
dard procedures.
GROUND
Fig. 7 Electrode Gap Bridging
SCAVENGER DEPOSITS
Fuel scavenger deposits may be either white or yel­
low (Fig. 8). They may appear to be harm ful, but this
is a normal condition caused by chemical additives in
certain fuels. These additives are designed to change
the chemical nature of deposits and decrease spark
plug m isfire tendencies. Notice th a t accum ulation on
the ground electrode and shell area may be heavy but
the deposits . sily removed. Spark plugs with
scavenger deposits can be considered normal in condi­
tion and can be cleaned using standard procedures.
GROUND
ELECTRODE
COVERED
Fig«8 Scawenget Deposits
CHIPPED ELECTRODE INSULATOR
A chipped electrode insulator usually results from
bending the center electrode while adjusting the spark
plug electrode gap. U nder certain conditions, severe
detonation can also separate the insulator from the
center electrode (Fig. 9). Spark plugs with this condi­
tion m ust be replaced.
GROUND
J908D-13
Fig- i Chipped Electrode Insulator
PREIGNITION DAMAGE
Preignition damage is caused by excessive combus­
tion chamber tem perature. First, the center electrode
dissolves the ground electrode dissolves somewhat la t­
te r (Fig. 10). Insulators appear relatively deposit free.
Determ ine if the spark plug has the correct h eat range
rating for the engine, if ignition tim ing is over ad­
vanced or if other operating conditions are causing
engine overheating. (The heat range ratin g refers to
the operating tem perature of a particular type spark
plug. Spark plugs are designed to operate w ithin spe­
cific tem perature ranges depending upon the thick­
ness and length of the center electrodes porcelain
insulator.)
GROUND
ELECTRODE
SPARK PLUG OWERHEATING Through the use of a crankshaft pick-up, overall
O verheating is indicated by a white or gray center system accuracy has been improved, and w ith no ac­
electrode insulator th a t also appears blistered (Fig. cessory drive shaft, m echanical spark scatter has been
11). The increase in electrode gap will be considerably elim inated.
in excess of 0.001 in per 1000 miles of operation. This
PAPER
suggests th a t a plug with a cooler heat range rating SPACER
should be used. Over advanced ignition tim ing, deto­
nation and cooling system m alfunctions can also cause
spark plug overheating,
BLISTERED
WHITE OR

CONNECTOR 908D-2

Fig. 13 Camshaft Reference Sensor

IGNITION COIL
WARNING: THE DIRECT IGNITION SYSTEM GENER­
ATES APPROXIMATELY 40,000 VOLTS. PERSONAL
INJURY COULD RESULT FROM CONTACT WITH THIS
SYSTEM.

J908D^16
Fig. 11 Spark Plug Overheating
CRANKSHAFT TIMING SENSOR
The crankshaft tim ing sensor (Fig. 12) senses 12
slots cut into the transm ission driveplate extension.
Basic tim ing is set by the position of the last slot in
each group. This is a fixed basic tim ing system with
no m eans of adjustm ent.
The Direct Ignition System (DIS) uses a molded coil
(Fig. 14). The coil is m ounted on the end of the intake
manifold. High tension leads route to each cylinder
from the coil. The coil fires two spark plugs every
power stroke. One plug is the cylinder under compres­
sion, the other cylinder fires on the exhaust stroke.
The engine controller determines which of the coils to
charge and fire a t the correct time.
The coil incorporates a low primary resistance (0.5-0.7
ohm) which allows the engine controller to fully charge
the coil for each firing.

CONNECTOR
906P-3

Fig. 12 Crankshaft Sensor

CAMSHAFT REFERENCE SENSOR

Fuel Injection Synchronization and cylinder identi­
fication is provided through the cam shaft reference
sensor (Fig. 13), The unique combination of slots on
the cam shaft gear is used by the engine controller to
identify cylinders to enable initiation of fuel and spark,
for sta rt and run conditions.
COOLANT TEMPERATURE SENSOR ELECTRICAL
CONNECTION
The Coolant Tem perature Sensor (Fig. 15) is a de­
vice which m onitors coolant tem perature (which is the
same as engine operating tem perature). It is mounted
near the therm ostat housing. This sensor provides
data on engine operating tem perature to the engine
controller.

WIRING TERMINALS THREADS

THREADS 9014-91

Fig. 16 Detonation (Knock) Sensor

engines). The sensor provides inform ation used by the

engine controller to modify spark advance in order to
Fig. 15 Coolant Temperature Sensor elim inate detonation.1

Incorporated in the digital microprocessor electron­ i l N i P O U ABSOLUTE PRESSURE (MAP) SENSOR

ics are some unique spark advance schedules which
occurs during cold and warm engine operation. They
have been added to reduce engine emission and im­
prove driveability. Because they change a t different
engine operating tem peratures during warm-up, all
spark advance testing should be done w ith the engine
fully warmed. This data allows the engine controller
to demand slightly richer air-fuel m ixtures and higher
idle speeds until norm al operating tem peratures are
reached. The sensor is a variable resistance (therm is­
tor) with a range of 40°F to 265°F.
The Manifold Absolute Pressure (MAP) sensor (Fig.
17) is a device which m onitors manifold vacuum. It is
m ounted on the intake manifold and is electrically
connected to the engine controller. The sensor tra n s­
m its inform ation on manifold vacuum, conditions and
barom etric pressure to the engine controller. The MAP
sensor data on engine load is used w ith data from
other sensors to determ ine the correct a ir fuel m ixture.
MANIFOLD ABSOLUTE HEATED OXYGEN SENSOR

DETONATION (KNOCK) SENSOR

The detonation sensor is a device th a t generates a
signal when spark knock occurs in the combustion
chambers. (Fig. 18) This sensor is mounted in a posi­
tion on the engine block where detonation in each
cylinder can be detected. (It is located on the rear of
the block under the exhaust manifold on the 3.3L

AUTO SHUTDOWN (ASD) RELAY

When there is no ignition signal present w ith the
ignition key in the RUN position, there is no need for
fuel delivery. W hen th is condition occurs, the auto
shutdown relay (Fig. 18) interrupts power to the elec­
tric fuel pump, fuel injectors, and ignition coil.
STARTER RELAY- AUTO SHUTDOWN
(ASD) RELAY

LEFT SIDE O f
VEHICLE
A C CLUTCH RELAY

SHOCK
TOWER

RIGHT SIDE OF
9180-49 VEHICLE

Fig. 18 Rmtiv Identification

 DIAGNOSTIC PROCEDURES—DIRECT IGNITION SYSTEMS
INDEX
Page Page
Check Coil Test— 3 .3 L Engine ................................... 31 Failure To Start Test— 3 .3L Engine ........................... 31
Coolant Temperature Sensor T e s t ............................... 32 Manifold Absolute Pressure (MAP) Sensor T e s t ___ 32
Crankshaft Sensor and Camshaft Sensor Tests ___ 32 Testing For Spark At Coil .............................................. 31
Detonation (Knock) Sensor Tests ............................... 32

TESTING FOR SPARK AT COIL
WARNING: THE DIRECT IGNITION SYSTEM GENER­
ATES APPROXIMATELY 40,000 VOLTS. PERSONAL
INJURY COULD RESULT FROM CONTACT WITH THIS
SYSTEM.
Since there are 3 independent coils in the package,
each coil must be checked individually. Remove the
cable from the # 2 spark plug. Insert a clean spark
plug into the spark plug boot, and ground plug to the
engine. (Fig. 1)
CAUTION: Spark plug wire damage may occur if
the spark plug is moved more than 1/4 inch away
from the engine ground.
(2) Refer to Figs. 2 and 3 and measure the resis­
tance on the primary side of each coil (0.5-0.7 ohm).
Measure between the B + pin and the pin correspond­
ing to the cylinders in question. Replace the coil if
resistance is not within tolerance.
(3) Remove ignition cables from the secondary tow­
ers of the coil. Measure the secondary resistance of
the coil between the grouped cylinders at the coil
towers. Resistance should be 7,000 to 15,800 ohms.
Replace the coil if resistance is not within tolerance.
IGNITIO N COILS ELECTRICAL
CONNECTION

CAM SENSOR ELECTRICAL

CONNECTION

Fig. 2 Ignition Coil Electrical Connection

Fig. 1 Testing For Spark

Crank the engine and look for spark across the

electrodes of the spark plug. Repeat the above test for
the five remaining cylinders. If there is no spark dur­
ing all cylinder tests, proceed to the failure to start
test.
If one or more tests indicate irregular, weak, or no
spark, proceed to Check Coil Test. Fig. 3 Ignition Coil Terminal Identification

CHECK COIL TEST— 3.3L ENGINE FAILURE TO START TEST— 3.3L ENGINE
(1) Determine that sufficient battery voltage (12.4
Remember: cylinders 1 & 4, 2 & 5, and 3 & 6 are
volts nominal) is present for the cranking and ignition
grouped together.
systems.
(1) Remove the ignition cables and measure the
(2) Connect a voltmeter to the wiring harness coil
resistance of the cables (3,000 to 12,000 ohms per
connector at the B + pin (Fig. 4).
foot). Replace any cable not within tolerance.

Fig. 4 Wiring Harness Coll Connector
(3) Crank the engine for 5 seconds while monitoring
the voltage at the B + connector terminal. If the volt­
age remains near zero during the entire period of
cranking, see Group 14 for On Board Diagnostic checks.
These checks will help diagnose problems with the
engine controller and auto shutdown relay.
(4) If voltage is at near-battery voltage, and drops to
zero after 1-2 seconds of cranking, see Group 14 for
On-Board Diagnostic check for the Camshaft and
Crankshaft sensor circuits to the engine controller.
(5) If voltage remains at near-battery voltage dur­
ing the entire 5 seconds, turn the key off, remove the
engine controller 60-way connector. Check the 60-way
for any terminals loose from the connector (push-out).
COOLANT TEMPERATURE SENSOR TEST
(1) With key off, disconnect wire connector from
coolant temperature sensor (Fig 5).
Fig. 5 Coolant Temperature Sensor Test
(2) Connect one lead of ohmmeter to one terminal of
coolant temperature sensor.
(3) Connect the other lead of ohmmeter to remain­
ing connector of coolant temperature sensor. The ohm­
meter should read as follows;
• Engine/Sensor hot at normal operating temperature
around 200°F should read approximately 700 to 1,000
ohms.
• Engine/Sensor at room temperature around 70°F,
ohmmeter should read approximately 7,000 to 13,000
ohms.
See On Board Diagnostics in the General Diagno­
sis section of Group 14, or refer to the appropriate
diagnostic manual for further test procedures.
MANIFOLD ABSOLUTE PRESSURE (MAP)
SENSOR TEST
See On Board Diagnostics in the General Diagnosis
section of Group 14, or refer to the appropriate diag­
nostic manual for test procedures.
CRANKSHAFT SENSOR AND CAMSHAFT
SENSOR TESTS
See On Board Diagnostics in the General Diagnosis
section of Group 14, or refer to the appropriate diag­
nostic manual for test procedures.
DETONATION (KNOCK) SENSOR TESTS
Refer to the appropriate diagnostic manual for test
procedures.
 SERVICE PROCEDURES—DIRECT IGNITION SYSTEMS
INDEX
Page Page
Camshaft Sensor Service .............................................. 35 Ignition Switch and Key Cylinder Service ................ 36
Coolant Temperature Sensor ....................................... 33 Ignition Timing Procedure ............................................ 35
Crankshaft Sensor Service ........................................... 35 Manifold Absolute Pressure (MAP)
Detonation (Knock) Sensor Service ........................... 34 Sensor S e rv ic e ............................................................ 36
Engine Controller .......................................................... 33 Spark Plug Cable Service — ..................................... 34
Idle RPM Test ................................................................ 35 Spark Plug Service ........................................................ 34
Ignition Coil Service ...................................................... 36

ENGINE CONTROLLER COOLANT TEMPERATURE SENSOR

REMOVAL REMOVAL
When replacement of Engine Controller is neces­ (1) Remove electrical connector from Direct Ignition
sary proceed as follows: System (DIS) coil unit. (Fig. 2).
(1) Remove air cleaner duct or air cleaner assembly.
(2) Remove battery. ALTERNATOR TO INTAKE
MANIFOLD BOLT IGNITION COILS FASTENERS (4)
(3) Remove (2) module mounting screws. (Fig. 1)
(4) Remove 60 way wiring connector from the En­
gine Controller and remove controller.
DIAGNOSTIC ENGINE
CONNECTOR CONTROLLER

IGNITION COILS ELECTRICAL

CONNECTOR 9014-26

Fig. 2 Ignition Coil Removal

(2) Remove fasteners from coil.

(3) Rotate coil away from coolant temperature sensor.
BATTERY' 918D-55
(4) Remove 2-way electrical connector from sensor
Fig. 1 Removing the Engine Controller (Fig. 3).

INSTALLATION
(1) Connect 60 Way Electrical connector to Engine
Controller (Fig. 1).
(2) Mount Engine Controller to inside left front fender
(Fig. 1). Install and tighten two (2) mounting screws.
(3) Install the battery.
(4) Install air cleaner duct or air cleaner assembly.

Pig, 3 Coolant Temperature Sensor
(5) Remove sensor. Engine coolant may be lost.
INSTALLATION
(1) Install sensor, torque to 7 N*m (60 in. lbs.).
(2) Install sensor electrical connector.
(3) Install DIS coil unit and torque fasteners to 12
N-m (105 in. lbs.) Insert electrical connector.
(4) Replace any lost- engine coolant (Refer to Group
7 Cooling System).
DETONATION (KNOCK) SENSOR SERVICE
re m o v a l
(1) Disconnect the detonation sensor electrical
connector.
(2) Remove the detonation sensor.
INSTALLATION
(1) Install the detonation sensor. Torque to 9.4 N*m
(7 ft. lbs.).
(2) Connect the electrical connector.
SPARK PLUG CABLE SERVICE
Clean high tension, cables with a cloth moistened
w ith a non-flammable solvent and wipe dry. Check for
brittle or cracked insulation.
When testing cables for punctures and cracks with
an oscilloscope follow the instructions of the equip­
m ent m anufacturers.
If an oscilloscope is not available, cables can. be
tested as follows:
CAUTION: Do not leave any one spark plug cable
disconnected any longer than necessary during test
or possible heat damage to catalytic converter will
occur. Total test time must not eiceed ten minutes.
(a) Engine not running, connect one end of a test
probe (i.e. a piece of wire w ith insulated alligator clips
on each end) to a good ground, other end free for
probing.
WARNING; THE DIRECT IGNITION SYSTEM GENER­
ATES APPROXIMATELY 40,000 VOLTS. PERSONAL
INJURY COULD RESULT FROM CONTACT WITH THIS
SYSTEM.
(b) W ith engine running, move test probe along
entire length of all cables (approximately 0 to 1/8 inch
gap). If punctures or cracks are present there will be a
noticeable spark jum p from the faulty area to the
probe. Cracked, leaking or faulty cables should be
replaced.
Use the following procedure when removing the high
tension cable from the spark plug. First, remove the
cable from the retaining bracket. Then grasp the te r­
m inal as close as possible to the spark plug rotate
slightly and use a straight and steady pull. Do not
yse pliers and do not pull the cable at an angle.
Doing so will damage the insulation, cable term inal
or the spark plug insulator. Wipe spark plug insula­
tor clean before reinstalling cable and cower.
Resistance type cable is identified by the words Elec­
tronic Suppression printed on the cable jacket.
Use an ohm meter to'check resistance type cable for
open circuits, loose term inals or high resistance as
follows:
(a) Remove cable from spark plug.
(b) Remove cable from the coil tower.
(c) Connect the ohm m eter between spark plug
end term inal and the coil end term inal. Resistance
should be w ithin tolerance shown in the cable resis­
tance chart. If resistance is not w ithin tolerance, re­
place cable assembly. Test all spark plug cables in
same m anner.
CABLE RESISTANCE CHART
M IN IM U M M A X IM U M
250 Ohms Per Inch 1000 Ohms Per Inch
3000 Ohms Per Foot 12,000 Ohms Per foot
J90SP-43
SPARK PLUG S IR V IC I
REMOVAL AND INSTALLATION
At the tim e of removal or installation:
(1) When removing spark plug cables, grasp cable
at cable cap.
(2) Torque the spark plugs to 27.1 N*m (20 ft. lbs.).
INSPECTION (2) Remove crankshaft tim ing sensor retaining bolt.
Inspect the spark plugs for the following items. Clean (3) Pull crankshaft timing sensor straight up out of
or replace if necessary. the transaxle housing.
(1) Cracked or damaged threads or insulator. (4) If the removed sensor is to be reinstalled, clean
(2) Worn electrodes. off the old spacer on the sensor face. A NEW SPACER
(3) Damaged or worn gasket. must be attached to the sensor face before installa­
(4) Condition of burnt electrode and amount of car­ tion. If the sensor is being replaced, confirm that the
bon deposit. paper spacer is attached to the face of the new sensor.
(5) Install sensor in transaxle and push sensor down
SPARK PLUG GAP ADJUSTMENT until contact is made with the drive plate. Hold in
Check the plug gap with plug gap gauge. If gap is this position and install and torque retaining bolt to
not within the lim it listed in the specifications chart 11.9 N-m (105 in. lbs.).
at the end of this section, adjust by carefully bending (6) Connect crankshaft timing sensor lead wire at
the ground electrode. wiring harness connector.

IDLE RPM TEST CAMSHAFT SENSOR SERVICE

WARNING: BE SURE TO APPLY PARKING BRAKE (1) Disconnect camshaft reference sensor lead at
AND/OR BLOCK WHEELS BEFORE PERFORMING wiring harness connector. (Fig. 5)
ANY ENGINE RUNNING TESTS.
Engine idle set rpm should be tested and recorded
as It is when the vehicle is first brought into shop for
testing. This will assist in diagnosing complaints of
engine stalling, creeping and hard shifting on vehicles
equipped with automatic transmissions.
Refer to Group 14, On Board Diagnostics for the
throttle body minimum airflow check procedure.

IGNITION TIMING PROCEDURE

WARNING: BE SURE TO APPLY PARKING BRAKE
AND/OR BLOCK WHEELS BEFORE PERFORMING
ANY ENGINE RUNNING TESTS.
Ignition timing cannot be changed or set on the
3.3L engine. Refer to Group 14, General Diagnosis On
Board Diagnostics. Fig. 5 Camshaft Sensor

CRANKSHAFT SENSOR SERVICE (2) Loosen camshaft timing sensor retaining bolt.
Loosen enough to allow slot in sensor to slide past the
(1) Disconnect crankshaft timing sensor pick-up lead
bolt.
at wiring harness connector. (Fig. 4)
(3) Pull sensor up out of the chain case cover. Do
not pull on the sensor lead. Removal force will be
high due to the O-ring seal on the sensor. A light tap
to top of sensor prior to removal may reduce the re­
moval force.
(4) If the removed sensor is to be reinstalled, clean
off the old spacer on the sensor face. A NEW SPACER
must be attached to the face before installation. In­
spect O-ring for damage, replace if necessary. If the
sensor is being replaced, confirm that the paper spacer
is attached to the face and O-ring is positioned in
groove of the new sensor.
(5) Apply a couple drops of oil to O-ring prior to
installing. Install sensor in the chain case cover and
push sensor down until contact is made with the cam
timing gear. Hold in this position, and torque the
retaining bolt to 11.9 N-m (105 in. lbs.).
 (6) Connect cam reference sensor lead wire at wir­
ing harness connector. Position the lead wire in such
a fashion to keep it away from the accessory belt.
IGNITION COIL SERVICE
(1) Remove spark plug cables from coil (Fig. 6).
ALTERNATOR TO INTAKE
IGNITION COILS ELECTRICAL
CONNECTOR 9014-26
Fig. 6 Ignition Coil Removal and Installation
(2) Remove electrical connector.
(3) Remove ignition coil fasteners.
(4) Reverse the above procedure for installation.
Torque fasteners to 12 N-m (105 in. lbs.)
MANIFOLD ABSOLUTE PRESSURE (MAP)
SENSOR SERVICE
(1) Remove wiring harness from sensor (Fig. 7).
MANIFOLD ABSOLUTE HEATED OXYGEN SENSOR
PRESSURE {AAAPI SENSOR 4-WAY ELECTRICAL CONNECTOR
Fig. 7 Manifold Absolute Pressure (MAP) Sensor
(2) Remove sensor from intake manifold.
(3) Reverse the above procedure for installation.
IGNITION SWITCH AND KEY CYLINDER SERVICE
The ignition switch is located on the steering col­
umn. The Key In Switch is located in the ignition
switch module. For diagnosis of the Key In Switch,
refer to Section 8M.
REMOVAL
(1) Disconnect negative battery cable.
(2) Tilt column only remove tilt lever (counter­
clockwise).
(3) Carefully remove both upper and lower covers.
Requires removal of 3 screws (Torx T-20 required).
(4) Remove 3 ignition switch mounting screws (tam­
per proof torx bit Snap-on TTXR15A2 or equivalent
required) (Fig 1).
Fig. 1 1gnition Switch Screw Removal
(5) Gently pull switch away from the column. Re­
lease connector locks (2) on the 7 terminal wiring
connector, then remove the connector from the igni­
tion switch.
(6) Release connector lock on the 4 terminal connec­
tor, then remove the connector from the ignition switch.
(7) Remove the key cylinder from the ignition switch,
(a) With the key inserted and the ignition switch
in the lock position, use a small screwdriver to de­
press the key cylinder retaining pin flush with the
key cylinder surface (Fig. 2).
 SMALL • . switch halo light ring) rotate the key counterclock­
SCREWDRIVER wise to the lock position and remove the key.
(d) Remove key cylinder. (Fig.'4)

KEY CYLINDER
RETAINING PIN

KEY CYLINDER
RETAINING PIN

HALO LIGHT
RING

\ IGNITION
, SWITCH 908D-17
IGNITION Fig. 4 Key Cylinder Ftemowal
SWITCH 908D-1S
INSTALLATION
Pig. 2 Key Cylinder Retaining Pin (1) Install 2 wiring connectors to'the switch. Make
sure' that the switch locking tabs are fully seated in
(b) Rotate the key clockwise to the off position.
the wiring connectors.
The key cylinder should now be unseated from the
(2) Mount ignition;switch to the column (3 screws).
ignition switch assembly (Fig. 3).
For column shift columns; the shifter must be in the
Park position and the park lock' dowel' pin on the
ignition switch assembly must engage -with the col­
umn park lock slider "linkage (Fig. 5). Verify ignition
switch is in lock position.(flag is parallel with the
ignition switch terminals) (Fig. 8). Apply a d ab 'of
grease to flag and pin. Position park lock link and
slider to mid-travel. Position ignition switch against
lock housing face, making sure pin is inserted into
park lock link contour slot. Torque retaining screws to
2 N*m (17 ± 5 in. lbs.)

FASTENER LOCATING
LOCATIONS PIN

PARK LOCK
DOWEL PIN

COLUMN
LOCK
FLAG
IGNITION
SWITCH
ELECTRICAL
CAUTION: Do not try to remove the key cylinder y©t CONNECTION
908D-18
(c) With the key cylinder in the unseated position
(key cylinder bezel about 1/8 inch above the ignition

#
 IGNITION SWITCH DESIGNATIONS
LOCATING PIN HOLE

IGNITION SWITCH CONNECTOR

LOOKING INTO SWITCH
o m m j bo d ies

€ # Y AND P BODIES
WIRE W ill
CAWlfY
APPLICATION
COLOR
• • 1 YELLOW STARTER RELAY
• • 2 PAtK BLUE IGNITION iUN/STAiT

Fig. 6 Ignition Switch Mounting Pad • • 3 GRAY/HACK

RiAKE WAitMl
LAMP
(3) Assemble cover to the column (3 screws). Torque • 4 PINK/BLACK
retaining screws to 2 N-m (17 ± 5 in. lbs.) IGNITION SWITCH
• PINK O i BATTERY FEE
(4) Tilt column only—install tilt lever (clockwise). PINK/WHITE
(5) Re-install negative battery cable. BLACK/ORANGE
• • 5 RUN ACCESSOiY
(6) Re-install key cylinder. OR BLACK/TAN
(a) With the key cylinder and the ignition in the HACK Oi?
• • 6 ACCESSORY
lock position, gently insert the key cylinder into the IIACK/WHIIE
ignition switch assembly until it bottoms. IGNITION SWITCH
• • 7 RED
(b) Insert key, while gently pushing on the key BATTEiY FEED
cylinder inward toward the ignition switch, rotate the 9180-15
key clockwise to the end of travel.
(7) Check for proper operation of push-to-lock, halo
lighting, Accessory, Lock, Off, Run, Start, column lock,
and shift lock (if applicable).
 SPECIFICATIONS
The following specifications are published from the
latest information available at the time of publica­
tion. If anything differs from the specifications on the
Vehicle Emission Control Information Label, use the
specifications on the label. Figures 1, 2, and 3 are
shown to illustrate the proper routings for the spark
plug wires.

O 0

GEAR
DRIVE

FIRING ORDER-1-3-4-2
DISTRIBUTOR-CLOCKWISE ROTATION
Fig. 1 Spark Plug Wire Routing—2.SL Engines
RP31
Fig. 3 Spark Plug Wire Routing—3.3L Engines
DIRECT IGNITION SYSTEM SPECIFICATIONS

DISTRIBUTOR Ignition Timing is not adjustable

ROTATIO N
for the Direct Ignition System (DIS) • .
J x
Engine 31 .
. ' Engine Code ' EGA ■

GEAR Transmission Automatic

DRIVE
' Firing Order 1-2-3-4-5-6

918D-50

FIRING ORDER
1-2-3-4-5-6

Fig. 2 Spark Plug Wire Routing—3.0L Engine

 DISTRIBUTOR SPECIFICATIONS

IGNITION COILS

Coil P rim ary Resistance Secondary Resistance

21°C-27°C (70°F-80°F) 21°C-27°C (70°F—80°F)

(Epoxy) 0.97-1.18 ohms 11,300-15,300 ohms

4 Cylinder—Diamond

(Epoxy)
4 Cylinder—Toyodenso 0.95-1.20 ohms 11,300-13,300 ohms

(Epoxy)
3. OL—Diamond 0.97-1.18 ohms 11,000-15,300 ohms

3.3L/3.8L—Diamond 0.52 -0 .6 3 ohms 11,600-15,800 ohms

3.3 L/3.8L—Toyodenso 0.51-0.61 ohms 11,500-13,500 ohms

 SPARK PLUGS

Engine Spark Plug Application G ap Torque Size

2.5L RN 12 YC All 0.033 to 0.038 in. 28 N-m (20 ft. lbs.) 14 mm (3/4") reach

RN 11 YC4 All 0.039 to 0.044 in. 28 N-m {20 ft. lbs.) 14 mm (3/4") reach

3.0L

BPR5ES-11 All 0.039 to 0.044 in. 28 N-m (20 ft. lbs.) 14 mm (3/4") reach

3.8L RN 16 YC5 All 0.048 to 0.053 in. 28 N-m (20 ft. lbs.) 14 mm (3/4") reach

918D-53

SENSOR SPECIFICATIONS

Com ponent N um ber of Resistance a t F° Thread Compound Thread Size Torque

Terminals

27 N n
(20 ft.-lb
7,000 to 13,000 Ohms
2.5L Engi
About 21 °C, 70° F
Coolant Temperature Preapplied
2 3/8-18 NPTF
Sensor (Nonrequired) 7 N-m
700 to 1,000 Ohms
(60 in. lbs.)
About 9 3 °C, 2 0 0 ° F
3.0L and 3.3L
Engines

7,000 to 13,000 Ohms

About 21 °C, 70° F
Charge Temperature Preapplied 5.6 N-m
2 3/8-18 NPTF
Sensor (Nonrequired) (50 in.-lbs.)
700 to 1,000 Ohms
About 93°C, 2 0 0 ° F
 INSTRUMENT PANEL AND GAUGES
CONTENTS
Page Page
CLUSTER AND GAUGE SERVICE.................. 2 SWITCH AND PANEL COMPONENT
GAUGES ................................................... 7 SERVICE 12
GENERAL INFORMATION .......................... 1 WARNING LAMP SYSTEM TESTS 10
OVERHEAD CONSOLE ................................ 17
GENERAL INFORMATION
INSTRUMENT CLUSTERS
The mechanical cluster is a electronic cluster with ,»v11»1111//, H,r>v 1B,K
.'A 5 & / -=>0 5P B O
analog displays. The body computer sends the me­ to 7 O'':-*} ,0070 ' V
chanical cluster the gauge readings and warning mes­ iso 80 ^ y m
sages over the CCD Bus.
The electronic cluster receives virtually all of its UNLEADED FUEL ONLY
information to display from the body computer and
IPOOR 11CHECK ilWASHE^j I
engine controller via the Chrysler Collision Detection | AJAR 11ENGINE jj FLUID |j ( lp-9-_9-g-Z.g.l. lo lM H I l O | I

(CCD) Serial Data Bus. The odometer memory is no

longer retained in the cluster. This is now retained in
the body computer
The mechanical cluster without tachometer (Fig. 1)
includes a 160 km/h (100 mph) speedometer, trip odom­
eter, fuel, temperature gauges and warning indica­
tors. The warning lamps include: low fuel, check gauges,
door ajar, low washer fluid, check engine, gate ajar,
volt and low oil pressure.
Fig. 2 Mechanical Cluster With Tachometer
The electronic cluster (Fig. 3) contains analog bar
type gauges for, oil pressure, temperature, voltage,
tachometer and fuel. The vehicle graphic shows door
ajar, lift gate ajar and low washer fluid.

i s t n

s=ap80
e
S ^ l F I

U a
a
I 9 'I M PH
a j S ii I HP k m /h
8 B8 8 .8

UNLEADED FUEL ONLY f «nn<sai«htil

TRIP U S /M RESET { ™ BRIPDfcJ

Fig. 3 Electronic Cluster *

Fig. 1 Mechanical Cluster Without Tachometer
The mechanical cluster with tachometer (Fig. 2)
will include a 160 km/h (100 mph) speedometer, trip
odometer, gauges for fuel level, coolant temperature,
oil pressure, and charging system voltage. Also, in­
cluded is a 7,000 rpm tachometer. The warning lamps
include: low fuel, check gauges, door ajar, low washer
fluid, check engine and gate ajar.
MAGNETIC GAUGES
All the gauges on instrument clusters are the mag­
netic type gauges. When the ignition switch is in the
OFF position each gauge should rest at m below the
low graduation.
ELECTRONIC DIGITAL CLOCK
The electronic digital clock is in the radio. The clock
and radio each use the display panel built into the
radio. A digital readout indicates the time in hours
and minutes whenever th e 'ignition sw itch'is in the
ON or ACC position.
When the ignition switch is in the OFF position, or
when the radio frequency is being displayed, time
keeping is accurately maintained.
 The procedure for setting the clock varies slightly
with each radio. The correct procedure is described
under the individual radio operating instructions re­
ferred to in the owner’s manual supplied with the
vehicle.
MAINTENANCE REQUIRED REMINDER
This system is designed to act as a reminder that
scheduled vehicle emissions maintenance should be
performed. The lamp is located in the Message Cen­
ter. It is not intended to indicate a warning or that a
state of emergency exists which must be corrected to
insure safe vehicle operation. The components covered
by the system include the EGR system, PCV valve,
and Oxygen sensor.
For further information, refer to Group 25, Emissions.
CLUSTER AND GAUGE SERVICE
CAUTION: Disconnect battery cable, before servic­
ing instrument panel. When power is required for
test purposes, reconnect battery cable for test only.
Disconnect battery cable after test and before con­
tinuing service procedures.
MECHANICAL CLUSTER SERVICE
In order to test the gauges and mechanical cluster a
DBR II will be needed, an the Body Diagnostic Proce­
dures Manual.
ELECTRONIC CLUSTER SERVICE
Refer to Body Diagnostic Procedures Manual when
using DRB II.

SEAT BELT WARNING SYSTEM SELF DIAGNOSTIC SYSTEM

For testing of this system refer to Group 8M, Re­
straint Systems.
SEAT BELT WARNING LAMP
The seat belt warning lamp is located in the warn­
ing indicator module assembly. Refer to Warning In­
dicator Module Assembly Lamp Replacement for lamp
replacement.
The electronic cluster has an internal diagnostic
routing to isolate problems within the cluster.
Perform cluster Self-Diagnostic Test to determine
whether problem is within cluster or outside of clus­
ter. Start test by depressing and holding US/M and
Reset buttons then turn the ignition switch ON. Refer
to Fig. 4 and 5.

OVERHEAD CONSOLE
The overhead console includes 2 map reading lamp
and a digital electronic display. The electronic display
© © © © © © ©
shows 7 conditions:
• Compass/temperature. ® ® ® ® ® © ©
• Trip odometer (ODO).
• Average miles per gallon (ECO). VIEW FROM WIRE END
• Instant miles per gallon (ECO).
• Distance to empty (DTE).
• Elapsed time (ET).
CLUSTER CONNECTOR
• Blank display.
1 NO CONNECTION 8 LOW OIL SWITCH
As the driver pushes the step button they will dis­
2 BATTERY 9 BUS ( —)
play individually.
3 DECODE 1 10 BUS ( + )
The US/M button changes the display from US to
metric units. For complete operating instructions, re­ 4 NO PIN n IGNITION
fer to owner’s manual provided with vehicle. 5 DECODE 2 12 NO CONNECTION
The map reading lamps are turned on and off by 6 ILLUMINATION 13 NO CONNECTION
pressing the lens cover indent. The rear lamps operate 7 GROUND 14 GROUND ILLUMINATION
as courtesy lamps when the doors are open or closed. 918E-74
 SIMULTANEOUSLY PRESS TRIP AND TRIP RESET BUTTONS

L_ s^ —

RELEASE TRIP AND TRIP RESET BUTTONS

i T 1
CHECK EitftONEOtJS
NO DISPLAY DIGITS DISPLAYED
DISPLAYED IN DISPLAY
IN ODOMETER
ODOMETER IN ODOMETER

♦
CHECK FUSES AND tEPEAT CLUSTEi IS IN
VERIFY IGNITION AND VEHICLE START test m o d e
BATTEiY VOLTAGE SEQUENCE CONTINUE TEST
AND GROUND AT
CLUSTER CONNECTOR

i— PRESS
IF VOLTAGE US/MET BUTTON
- rvrfCviVw r .n n n
u e r VJvA/U
REPLACE CLUSTER
NOTE: SPEEDOMETER REMAINS 1IIA N K
|f

1 I r

"COTE" DISPLAYED “ CODE" DISPLAYED "COTE" DISPLAYED "CODE" DISPLAY

IN ODOMETIt FOR IN 9 9 9 9 9 9 9 FOR IN ODOMETER FOR IN OPOM ETil
10 SECONDS 10 SECONDS 10 SECONDS FOR 10 SECONE
FmiOWED BY 900, FOLLOWED BY FOLLOWED BY
90S. 920. 940, 9 9 921. 999 AT 110, 999 AT
AT 3 SECOND 3 SECOND 3 SECOND
INTERVALS INTERVALS INTERVALS

USING DRB II PRESS US/MET

tEPLACE REPLACE PROBLEM BUTTON
BODY COMPUTER ELECTRONIC RELATED TO
YES 921 - BODY CLUSTER 'FUEL GAUGE
COMPUTER 110- CLUSTER
DISCONNECT FAILURE ALL DISPLAYS ■
ODOMETER
BATTEiY
FAILURE 999- END -ILLUMINATE
999 - END FOR 6 SECONDS
CONTINUE TO ' THEN 5 IS
CHECK FUEL GAUGE DISPLAYED IN
CONTINUITY CIRCUIT TEST SPEEDOMETER
FROM
ELECTRONIC
INSTRUMENT
CLUSTER TO
BODY CdMPUTER
CHECK C % BUS
USING DRB li 1 1
AND ENGINE 900 - LACK OF ALL ALL SEGMENTS SOME SEGMENTS
CONTROLLER MESSAGES LIGHT DO NOT LIGHT
905 - BUS 9 9 9
PAilU iE ♦
NO CONTINUITY 920 - LACK OF
REPAIR WIRES MESSAGES 1 CLUSTER
FROM BODY
COMPUTER
OK. REPLACE 940 • LACK OF
APPROPRIATE MESSAGES
MODULE: BODY FROM
COMPUTER ENGINE
ENGINE CONTROLLER
CONTROLLER 999 - END
 PRESS US/MET PRN©DL OR
FUEL GAUGE BUTTON BUTTON MODULE
CIRCUIT TEST DO NOT ILLUMINATE

INDIVIDUAL
SEGMENTS ARE OTHER PANEL NO: TURN HEAD
FUEL GAUGE
DISPLAYED IN COMPONENTS LAMP SWITCH:
READING AND
SEQUENCE, THEN 6 ILLUMINATE ON-OPP-ON
CLUSTER
IS DISPLAYED IN
ASTERISK NOT
SPEEDOMETER*
---------
FLASHING YES: MO:
CONDITION
REMOVE CLUSTER INTERMITTENT'
STILL
PUSH SLIDER ■ SHORT CIRCUIT
PRESENT
SEGMENTS IN TO FULL BRIGHT IN 1-2
CHECK FUEL ALL SEGMENTS
DISPLAY ARE
LEVEL INPUT INDIVIDUALLY
SHORTED
SIGNAL AT LIGHT
TOGETHER YES: RADIO
BODY COMPUTER MEASURE VOLTAGE
AT PIN 6 ILLUMINATE
m NO: REPLACE
PULSE WIDTH
* f MODULATION
REPLACE PRESS US/MET MODULE
CLUSTER BUTTON SHORT CIRCUIT
RESISTANCE GREATER THAN IN E-2 REPLACE
AT FUEL LEVEL
MODULE
INPUT PIN
BETWEEN ilS lS TANCE
2 AND 150 OHMS SPEEDOMETER AND
AT FUEL LEVEL ODOMETER SYMBOLS
INPUT PIN IS LESS CHECK
ARE DISPLAYED IN CONTINUITY
THAN 2 OHMS O i SEQUENCE THEN
GREATER THAN FftOM PIN 6
FUEL LEVEL 7 DISPLAYED IN
150 OHMS ' YES: REMOVE TO PIN 4 OF
INPUT SIGNAL SPEEDOMETER* .
CLUSTER MASK. PULSE WIDTH
IS GOOD MODULATION
CAREFULLY PULL
MASK 3 TO 4 MODULI
PROBLEM IS IN INCHES FROM
DISCONNECT FUEL WIRING AND/OR CLUSTER.
SENSOR INPUT FUEL TANK SYMBOLS
DISCONNECT
TO BODY SENDING UNIT INDIVIDUALLY
PRNOL AND
COMPUTER ILLUMINATE
BUTTON WIRING
CONNECTORS

E1C FUEL TEST IS COMPLETE

GAUGE CLUSTER HAS
EMPTY TWO SYMBOLS PROVEN GOOD
ILLUMINATE
SIMULTANEOUSLY.
REMOVE BUTTON
SYMBOLS SHORTED TO RETURN
YES: SHORT MODULE AND
TOGETHER CLUSTER TO NORMAL
FUEL INPUT PRNDL
TO GROUND AUNG MOPE,
REPLACE PRESS US/MET
CLUSTER BUTTON
REPLACE
EiC: FUEL
PRNDL BULB
GAUGE FULL

REINSTALL
BUTTONS AND
YES: PROBLEM
NO: REPLACE PRNDL. INSURE
IN FUEL
BODY COMPUTER THAT SURFACE
SENDING UNIT
OF TUBES IS
CLEAN

CONNECT ALL
CONNECTORS

REINSTALL
MASH

Pig, 5 Electronic Cluster Self-Diagnostic Test—Continued

 LAMPS
1 LEF • 2 AIRBAG
2 ANTI-LOCK 3 RIGHT TURN SIGWAt
3 HAKE 5 LEFT TURN SIGNAL
4 MAINTENANCE 6 ANTM0CK
REQUIRED 7 IGNITION
5 HI BEAM 8 seat s a r
6 SEAT BELT § MKAM
7 AIRBAG 10 MAINTENANCE
8' RIGHT TURN SIGNAL REQUIRED
11 GROUND
12
13
14 BRAKE

Fig. 6 Warning Indicator Module

Successful completion of the SELF-DIAGNOSTIC

TEST indicates that the problem is in the wiring,
connectors or sensors out side of the cluster.

CONDITION
Mechanical cluster is not functional with engine
running.
The cluster is indicating that it is not receiving any
CCD Bus messages if:
• Check gauge lamp is ON.
• Tachometer, speedometer and gauges are at low scale.
• Check Bus wiring going to the cluster and body
computer.

WARNING INDICATOR MODULE REPLACEMENT

OR LAMP REPLACEMENT
(1) Remove warning indicator grille by prying up
with a flat blade tool (Fig. 6).
(2) Remove 3 mounting screws from the warning
indicator module assembly.
(3) Replace lamp.
^ 918E-85
(4) For installation reverse above procedures.
Fig. 7 Instrument Panel Steering Column Cover
INSTRUMENT PANEL CLUSTER BEZEL
REPLACEMENT (4) Remove instrument cluster bezel and discon­
(1) Remove warning indicator grille by prying up nect POD switch wire connectors (Fig. 8).
with a flat blade tool.
(2) Remove 3 mounting screws from the warning indi­
cator module assembly and disconnect wire connector.
(3) Remove steering column cover (Fig. 7). Set park­
ing brake and shift gear sector into low.
 (6) Remove lens.
(7) For installation reverse above procedures.

INSTRUMENT PANEL CLUSTER REPLACEMENT

(1) Remove warning indicator grille by prying up
with a flat blade tool.
(2) Remove 3 mounting screws from the warning indi­
cator module assembly and disconnect wire connector.
(3) Remove steering column cover (Fig. 7). Set park­
ing brake and shift gear selector into low.
(4) Remove cluster bezel and disconnect wire con­
nectors.
(5) Remove 4 screws securing cluster. Rotate cluster
and disconnect connector, to access PRNDL attaching
screws. Remove 2 screws attaching PRNDL to cluster
(Fig. 10).

& INSTRUMENT
CLUSTER BEZEL 918E-7I

Fig. 8 Instrument Cluster Bezel

(5) Remove POD switches by unsnapping from the

back side of the cluster bezel.
(6) For installation reverse above procedures.

INSTRUMENT PANEL CLUSTER LENS

REPLACEMENT
(1) Remove warning indicator grille by prying up
with a flat blade tool.
(2) Remove 3 mounting screws from the warning indi­
cator module assembly and disconnect wire connector.
(3) Remove steering column cover (Fig. 7). Set park­
ing brake and shift gear selector into low. BIND GUIDE TUBE
(4) Remove cluster bezel and disconnect wire con­
nectors. STEERING WHEEL REMO VED FOR CLARITY 918E-92

(5) Remove 6 screws securing lens to cluster hous­

ing (Fig. 9). Fig. 10 Removal of PRNDL

SCREW LOCATIONS (6) Remove cluster.

(7) For installation reverse above procedures.
• When installing cluster, do not kink or bind PRNDL
guide tube assembly.
• Move shift lever to Neutral and check pointer posi­
tion. Adjust if necessary to center on N. Check pointer
position in D, L and P. Refer to Fig. 11 for adjusting.

Fig. 11 Adjusting PRNDL
CLUSTER PRINTED CIRCUIT BOARD
REPLACEMENT
(1) Remove warning indicator grille by prying up
with a flat blade tool.
(2) Remove 3 mounting screws from the warning indi­
cator module assembly and disconnect wire connector.
(3) Remove steering column cover (Fig. 7). Set park­
ing brake and shift gear selector into low.
(4) Remove cluster bezel and disconnect POD switch
wire connectors.
(5) Remove 4 screws securing cluster. Rotate cluster
and disconnect connector, to access PRNDL attaching
screws. Remove 2 screws attaching PRNDL to cluster
(Fig. 10).
(6) Remove cluster.
(7) Remove 6 screws and attack cover (Fig. 12).
(8) Disconnect odometer connector and remove screw
attaching printed circuit board and board.
(9) For installation reverse above procedures.
• When installing cluster, do not kink or bind PRNDL
guide tube assembly.
• Move shift lever to Neutral and check pointer posi­
tion. Actfust if necessary to center on N. Check pointer
position in D, L and P. Refer to Fig. 11 for adjusting.
CLUSTER LAMPS BULB REPLACEMENT
MECHANIAL CLUSTER ONLY
(1) Remove warning indicator grille by prying up
with a flat blade tool.
(2) Remove 3 mounting screws from the warning indi­
cator module assembly and disconnect wire connector.
(3) Remove steering column cover (Fig. 7). Set park­
ing brake and shift gear selector into low.
(4) Remove cluster bezel and disconnect POD switch
wire connectors.
(5) Roll cluster out of instrument panel without
disconnecting PRNDL.
(6) Remove integral bulb and socket from rear of
cluster (Fig. 13).
LAMP DESIGNATION
A GATE A J A i F CHECK GAUGES
i WASHER FLUID G LOW OIL
C CHECK ENGINE H LOW FUEL
D DOOR AJAR J VOLT
E ILLUMINATION
918E-76
Fig. 13 Mechanical Cluster Bulb Location
(7) For installation reverse above procedures.
GAUGES
To test the gauges and mechanical cluster a DRB II
will be needed and the Body Diagnostic Procedures
Manual.
It is not necessary to remove instrument cluster
from vehicle for gauge replacement.
 When removing gauge from cluster, gauge must
be pulled straight out, without twisting or damage
to gauge pins may result.
FUEL GAUGE REPLACEMENT
(1) Remove warning indicator grille by prying up
with a flat blade tool.
(2) Remove 3 mounting screws from the warning
indicator module.
(3) Remove steering column cover (Fig. 7). Set park­
ing brake and shift gear selector into low.
(4) Remove cluster bezel and disconnect POD switch
wire connectors.
(5) Remove cluster lens.
(6) Remove 4 screws attaching gauge to cluster (Fig.
14 and 15).
(6) Remove 4 screws attaching gauge to cluster (Fig.
14 or 15).
(?) Remove voltm eter gauge.
(8) For installation reverse above procedures.
TEMPERATURE GAUGE REPLACEMENT
(1) Remove w arning indicator grille by prying up
w ith a flat blade tool.
(2) Remove 3 m ounting screws from the w arning
indicator module.
(3) Remove steering column cover (Fig. 7). Set park­
ing brake and shift gear selector into low.
(4) Remove cluster bezel and disconnect POD switch
wire connectors.
(5) Remove cluster lens.
(8) Remove 4 screws attaching gauge to cluster (Fig.
14 or 15).
(7) Remove tem perature gauge.
(8) For installation reverse above procedures.

OIL PRESSURE GAUGE REPLACEMENT

(1) Remove w arning indicator grille by prying up
w ith a flat blade tool.
(2) Remove 3 m ounting screws from the w arning
indicator module.
(3) Remove steering column cover (Fig. 7). Set park­
ing brake and shift gear selector into low.
(4) Remove cluster bezel and disconnect POD switch
Fig. 14 Gauge Assembly Without Tachometer wire connectors.
(5) Remove cluster lens.
J3~ (6) Remove 4 screws attaching gauge to cluster (Fig.
14 or 15).
« 5 e 40 so so (7) Remove oil pressure gauge.
V
JK g 7 >> 3 0 ^ ^ 70
- (8) For installation reverse above procedures.

TACHOMETER REPLACEMENT
(1) Remove w arning indicator grille by prying up
he loo 0570
J w ith a flat blade tool.
(2) Remove 3 m ounting screws from the w arning
indicator module.
'RETAINING SCREWS— - " ^ 9181-78
(3) Remove steering column cover (Fig. 7). Set park­
Pig. 15 Gauge Assembly With Tachometer ing brake and shift gear selector into low.
(4) Remove cluster bezel and disconnect POD switch
(7) Remove fuel gauge. wire connectors.
(8) For installation reverse above procedures. (5) Remove cluster lens.
(6) Remove 4 screws attaching gauge to cluster (Fig.
VOLTMETER REPLACEMENT. 14 or 15).
(1) Remove warning indicator grille by prying up (7) Remove tachom eter gauge.
with a flat Wade tool. ■ (8) For installation reverse above procedures.
(2) Remove 3 mounting screws from t ie warning
indicator module. SPEEDOMETER ASSEMBLY REPLACEMENT
(3) Remove steering column cover (Fig. 7). Set park­ (1) Remove w arning indicator grille by prying up
ing brake and shift gear selector into low. w ith a flat blade tool.
(4) Remove cluster bezel and disconnect POD switch (2) Remove 3 m ounting s c r e w s from the w arning
wire connectors. indicator module.
(5) Remove cluster lens. (3) Remove steering column cover (Fig. 7). Set park­
ing brake and shift gear selector into low.
 (4) Remove cluster bezel and disconnect POD switch
wire connectors.
(5) Remove cluster lens.
(6) Remove 4 screws attaching gauge to cluster (Fig.
14 or 15).
(7) Remove speedometer gauge.
(8) For installation reverse above procedures.

ODOMETER ASSEMBLY REPLACEMENT

(1) Remove warning indicator grille by prying up
with a flat blade tool.
(2) Remove 3 mounting screws from the warning
indicator module.
(3) Remove steering column cover (Fig. 7). Set park­
ing brake and shift gear selector into low.
(4) Remove cluster bezel and disconnect POD switch
wire connectors.
(5) Remove 4 screws securing cluster. Rotate cluster
and disconnect connector, to access PRNDL attaching
screws. Remove 2 screws attaching PRNDL to cluster
(Fig. 10).
(6) Remove cluster.
(7) Remove 6 screws and attack cover (Fig. 12).
(8) Disconnect odometer motor connector on rear of
cluster (Fig. 16). SENSOR TRANSAXLE

(9) Remove lens.

(10) Remove screws attaching gauge to cluster.
(11) Remove 3 screws and odometer.
(12) For installation reverse above procedures.
• When installing cluster, do not kink or bind PRNDL
guide tube assembly. PI NIO N 908E-12
• Move shift lever to Neutral and check pointer posi­
Fig. 18 Distance Sensor and Speedometer Pinion
tion. Adjust if necessary to center on N. Check pointer
position in D, L and P. Refer to Fig. 11 for adjusting.(2) Remove sensor retaining bolt.
(3) Pull sensor and pinion gear assembly out of
DISTANCE SENSOR REPLACEMENT transaxle. If necessary, carefully pry loose with a flat
(1) Remove harness connector from sensor and make blade screwdriver.
sure the weather seal is on harness connector (Figs. (4) Remove pinion gear from sensor.
17 and 18). (5) For installation reverse above procedures. Seat
sensor assembly by hand to insure proper gear en­
gagement. Tighten retaining bolt to 7 N-m (60 in. lbs.).
D ISTA N C E S E N S O R T E S T
For testing of the distance sensor and related com­
ponents, when using DEB 11 refer to Body Diagnostic
Procedures Manual.
SENDING U NIT T E S T
When a problem occurs with a cluster gauge, before
disassembling the cluster to check the gauge, check
for a defective sending unit or wiring.
(1) Sending units and wiring can be checked by
grounding the connector leads, at the sending unit, in
the vehicle.
(2) With the ignition in the ON position, a grounded
input will cause the fuel or temperature gauge to read
at or above maximum.
FUEL T A N K SEN DING UN IT T E S T
(1) Disconnect wiring from fuel tank sending unit.
(2) Connect wiring to a known good sending unit
(Fig. 19).
Fig. 19 Fuel Pump level Assembly (Typical)
(3) Check fuel gauge as described in the following
steps. Allow at least 2 minutes at each test point for
gauge to settle.
(a) Move float arm of sending unit to its empty
stop and turn ignition key to ON position. The gauge
should read Empty or below.
(b) Move sending unit float arm to full stop. The p a rk in g b ra k e . I f la m p fa ils to lig h t, in sp e c t for a
gauge should read Full or above.
CONDITION
(1) If fuel gauge does not meet specifications, check
following items as possible causes:
(a) W irin g a n d co n n ectio n s b e tw e e n g a u g e se n d ­
in g u n it a n d body co m p u ter.
(b) C h eck for loose g a u g e a d a p to r n u ts on th e
in s tru m e n t c lu ste r p rin te d c irc u it board . T ig h te n g au g e
a d a p te r n u ts a s n e c e ssa ry .
(c) I f th e body co m p u te r a n d p rin te d c irc u it b o a rd
check o k ay th e fu e l g a u g e is d efective.
(2) I f fu el g a u g e m e e ts sp e c ificatio n s ch eck fu el ta n k
a n d o rig in a l fu el p u m p le v el assembly a s follow s:
(a) C a re fu lly rem o v e fu el le v el u n it from ta n k .
(b) R efer to se n d in g u n it re m o v a l G ro u p 14, F u el.
(c) C on n ect s e n d in g u n it w ire as d e sc rib e d in th e
te s t pro ced ure.
(3) I f fu el g a u g e now ch eck s w ith in sp ecificatio n s,
o rig in a l se n d in g u n it is e le c tric a lly o k ay , ch eck fol­
lo w in g a s possible cause:
(a) G ro u n d w ire from s e n d in g u n it to le ft sid e
cowl for c o n tin u ity .
(b) fu el p u m p lev el a sse m b ly is deform ed. M ak e
s u re se n d in g u n it flo a t a rm m oves freely .
(c) F u e l p u m p le v el a sse m b ly im p ro p e rly in s ta lle d ,
in s ta ll pro p erly .
(d) M o u n tin g fla n g e on fu el ta n k for fu el p u m p
lev el assem b ly is deform ed.
(e) F u e l ta n k b o tto m deform ed c a u sin g im p ro p e r
p o sitio n in g o f fu el p u m p le v el assem b ly . R ep lace o r
r e p a ir ta n k a n d re c h e c k se n d in g u n it.
WARNING LAMP SYSTEM TESTS
A ll w a rn in g la m p s com e on w h e n th e ig n itio n sw itch
is f ir s t tu r n to th e O N p o sitio n . T h ey w ill s ta y on for a
few seconds to see if la m p s a re w o rk in g .
BRAKE S Y S T E M W ARNING LAM P T E S T
T h e b ra k e w a rn in g la m p illu m in a te s w h e n p a rk in g
b ra k e is ap p lie d w ith ig n itio n k e y tu r n e d O N .T he
sam e lig h t w ill also illu m in a te sh o u ld one o f th e tw o
serv ice b ra k e sy ste m s fa il w h e n b ra k e p e d a l is a p ­
p lied . To te s t sy ste m tu r n ig n itio n k e y O N a n d ap p ly
b u rn e d o u t b u lb , d isco n n ected so ck et, a b ro k e n o r d is­
con n ected w ire a t sw itch . T h e la m p also lig h ts w h e n
th e ig n itio n sw itc h is tu r n e d to s ta r t.
To te s t serv ice b ra k e w a rn in g sy ste m , ra is e v eh icle
on a h o is t a n d o pen a w h eel c y lin d e r b le e d e r w h ile a
h e lp e r d e p re sse s b ra k e p e d a l a n d o b serv es w a rn in g
lam p. I f la m p fa ils to lig h t, in sp e c t for a b u rn e d o u t
b u lb , d isco n n ected socket, a b ro k e n o r d isco n n ected
w ire a t sw itc h (Fig. 20 a n d 21).
 TURN IG NITIO N KEY O N
(DO NO T START ENGINE
■RELEASE P A R K IN G BRAKE]

I
] APPLY SERVICE BRAKES
(WARNING LIGHT
SHOULD NOT G O ON)
9*
TEST SERVICE BRAKE
WARNING
SYSTEM FUNCTION*
W A R N IN G LIGHT G O ES APPLY PARKING BRAKE
ON (WARNING LIGHT
1 WARMING' LIGHT'GOES I I ..................................1999?...........1
I 1991S 9 9 9 G O O N 1
L ° “ _ |
BRAKE SYSTEM 1 9 9 9 8 9 9 I
T
LEAKING FLUID 1 FAILS IO G O O N I BRAKE SYSTEM OPEN CIRCUIT IN WIRING
LEAKING FLUID TO SERVICE BRAKE SWITCH

. ? .. .... .... ^
GROUNDED WIRING BULB BURNED OUT GROUNDED WIRING OR
LOOSE BULKHEAD
SHORTED BRAKE WARNING
CONNECTOR
SWITCH
L _ _ _ _
DISCONNECTED OR FAULTY ......¥ ...... ...
SHORTED PARKING BRAKE
OR BRAKE WARNING SWITCH BULB SOCKET FAULTY BRAKE SYSTEM FAULTY SERVICE BRAKE
■ PROPORTIONING SWITCH
r ~ ~ ~ VALVE .UNIT*
FAULTY BRAKE SYSTEM BROKEN WIRE OR WIRE
PROPORTIONING DISCONNECTED AT PARKING FAULTY SERVICE BRAKE
*TESTS ARE DESCRIBED
VALVE UNIT* BRAKE SWITCH SYSTEM PROPORTIONING
IN APPROPRIATE
SECTION OF SERVICE VALVE UNIT*
t l AMI i A i
FAULTY PARKING
BRAKE SWITCH
918E-19

Fig. 20 Brake System Warning Lamp Diagnosis

TEMPERATURE WARNING LAMP TEST
To test the temperature warning lamp, turn the
ignition switch to the ON position. Disconnect the
wire from the temperature switch on the engine and
momentarily touch the wire to ground. When the wire
is grounded the bulb of the indicator should illum i­
nate. If the bulb fails to illuminate, indications are of
a faulty circuit in the system, body computer is
malfunctioning or possibly the indicator bulb is faulty.
Repair or replace as necessary.

LOUT OIL PRESSURE WARNING LAMP TEST

The low oil pressure warning lamp will illuminate
when the ignition key is turned to the ON position.
The lamp also illuminates when the engine oil pres­
1 ^ PR1451 sure drops below a safe oil pressure level.
To test the system, turn the ignition key to the ON
Fig. 21 Brake Warning Lamp Switch position. If the lamp fails to light, inspect for broken
or disconnected wires at the oil pressure combination
If bulb is not burned out and wire continuity is
unit located at the front of the engine (Figs. 22 and
proven, replace brake warning switch. The switch is
23).
located in brake line Tee fitting mounted on frame
rail in engine compartment below master cylinder
(Fig. 21).
CAUTION: If wheel cylinder bleeder was opened check
master cylinder fluid level.
 SENDING UNIT
(GAUGE)

SWITCH
(LIGHT)

S98E-2

Fig. 24 Combination Oil Sending Unit Terminals

(4) Start the engine. If there is oil pressure, the

898E-1 ohmmeter should read an open circuit.
(5)' To test the sending unit, measure the resistance
Fig. 22 Combination Oil Sending Unit between the sending unit terminal and the metal hous­
DIPSTICK TUBE COMBINATION ing. The ohmmeter should read open.
OIL PRESSURE SWITCH — (6) Start the engine. The ohmmeter should read
AND SENDING UNIT between 30 and 55 ohms, depending on engine speed,
oil temperature, and oil viscosity.
(7) If the above results are not obtained, replace the
switch.

SWITCH AND PANEL COiPONENI SERVICE

HEADLAMP/W IPER POD SW ITC H

R E P LA C E M E N T
(1) Remove warning indicator grille by prying up
with a flat blade tool (Fig. 8).
(2) Remove 3 mounting screws from the warning
OIL FILTER { / / m um s indicator module assembly.
(3) Remove steering column cover (Fig. 7), Set park­
Fig. 23 Combination Oil Sending Unit—3.0L Engine ing brake and shift gear selector into low.

If the wire at the connector checks good, pull con­

nector loose from the unit and with a jumper wire fP = ^
ground switch terminal in the connector to the en­ 8
Cl I |B8
8 ,oO
gine. With the ignition key turned to the. ON position, w W
check the warning lamp. If lamp still fails to light, A ~|B 7 A F* |oO
Y Y
inspect for a burned out'bulb or disconnected socket in
the cluster. c
|B 6 A L2J
C4 | |B 5
o
COMBINATION OIL SEN DING UNIT T E S T S N
N
C 5| 1 B4 y I e=J.
The combination oil unit has 2 functions (Figs. 22 E- C 6| |B 3
and 23): C
T C 7| |B2
■ (1) The normally closed circuit keeps the oil pres­
sure warning lamp on until there is oil pressure. 0 C 8| IB1
1
(2) The sending unit provides a resistance that var­
ies with oil pressure.
A1 A2 A3 A4 A5 A6
(3) To test the normally closed oil lamp circuit,
disconnect the locking connector and measure the re­
sistance between the switch terminal and the metal
housing (Fig. 24). The ohmmeter should read zero 7-WAY CONNECTOR
ohms.
 (2) Remove switch carrier from the panel (Fig. 28).
7 WAY CONNECTOR

fRR / fJpN LO Hi

k 1 * 1 3 *
g lg g l
I
la

7 6 5 4 3 2 1 10 9 8 6 5 4 3 2 1
918E-2

REAR WASHER Fig. 28 Accessory Switch Carrier

SWITCH

REAR WIPER (3) Disconnect wire connectors.

SWITCH 918K-2 (4) For installation reverse above procedures.

Fig. 26 Wiper Switch ACCESSORY SWITCH CARRIER LAMP

REPLACEMENT
(4) Remove cluster bezel and disconnect POD switch
(1) Remove center bezel using a trim stick (Fig. 27).
wire connectors.
(2) Remove switch carrier from the panel (Fig. 28).
(5) Remove switch by unsnapping from the back
(3) Remove lamp.
side of the cluster bezel (Fig. 25 and 26).
(4) For installation reverse above procedures.
(6) For installation reverse above procedures.
A/C AND HEATER CONTROL REPLACEMENT
ACCESSORY SWITCH CARRIER REPLACEMENT
(1) Remove center bezel using a trim stick. (Fig. 27).
(1) Remove center bezel using a trim stick (Fig. 27).
(2) Remove cigar lighter element.
(3) Remove accessory switch carrier.
(4) Remove 2 screws and pull control assembly rear­
ward. Reach behind control and disconnect the wiring
harnesses, vacuum lines and temperature control ca­
ble (Fig. 29).
(5) For installation reverse above procedures.

A/C AND HEATER CONTROL LAMP

REPLACEMENT
(1) Remove center bezel using a trim stick. (Fig. 27).
(2) Remove cigar lighter element.
(3) Remove accessory switch carrier.
(4) Remove 2 screws and pull control assembly rear­
ward. Reach behind control and disconnect lamp (Fig.
29).
(5) For installation reverse above procedures.
 A/C CONTROL TEMPERATURE
CAiLE
A/C-HEAIEi
SWITCH

BLOWER
SWITCH

918E-88
VACUUM CONNECTOR
Fig. 30 Wear AIC Heater Control Switch

A/C-HEATER .INSTRUMENT PANEL ASSEMBLY

CONTtOt
918E-87

Fig. 23 A/C Heater Control

H E A TE R C O N TR O L BLO W ER SW ITC H
REPLACEMENT
(1) Remove center bezel using a trim stick. (Fig. 27).
(2) Remove cigar lighter element.
(3) Remove accessory switch carrier.
(4) Remove 2 screws and pull control assembly rear­
ward. Reach behind control and disconnect blower
switch.
(5) For installation reverse above procedures.

R E A R A/C-HEAFER S W IT C H R E P L A C E M E N T
For the blower switch on the instrument panel, re­
fer to Accessory Switch Carrier Replacement (Fig. 28).
918E-82
The rear A/C-heater switch assembly in the left
rear quarter trim panel (Fig.80).
Fig. 31 Forward and Center Console
(1) Using a trim stick pry switch from left quarter
trim panel. (3) Remove screws attaching console to instrument
(2) Disconnect wire connectors. panel:
(3) For installation reverse above procedures. • Two upper comers.
• Two behind ash receiver.
FORWARD C O N SO LE
• Two at the lower bracket.
(1) Remove center bezel using a trim stick.
(2) Remove ash receiver/cup holding assembly from (4) Pull console rearward and disconnect wire con­
console (Fig. 31). nector and bulb.
(5) Remove console.
(8) For installation reverse above procedures. '
CENTER STORAGE MODULE ing column, leave insert free.
(1) Remove center bezel using a trim stick. (3) Remove steering column, refer to Group 19,
(2) Remove ash receiver/cup holding assembly from Steering.
console (Fig. 31). (4) Remove lower right instrument panel silencer
(3) Open the storage bin door and remove the check (Figs. 33).
strap pins so that door swings fully open.
• RELEASE LOCK TAB
(4) Remove 4 mounting screws and storage module.
BEFORE REMOVING
(5) For installation reverse above procedures. INSERT— RELOCK
AFTER INSTALLATION
ASH RECEIVER ASSEMBLY
Depress the ash receiver/cupholder assembly stops
and remove by sliding rearward.

INSTRUMENT PANEL REPLACEMENT

WARNING: CHOCK WHEELS WHEN LOWER PANEL
IS TO BE ROLLED DOWN. THE STEERING COLUMN
IS REMOVED AND TRANSMISSION MAY BE OUT OF
PARK. RELEASE THE PARK BRAKE BEFORE THE
RELEASE CABLE IS DISCONNECTED. DISCONNECT­
ING PARK BRAKE CABLE WHILE PARK BRAKE IS
ENGAGED MAY CAUSE PERSONAL INJURY.
(1) Remove steering column cover (Fig. 7). Set park­
ing brake and shift gear selector into low.
(2) Disconnect PRNDL at column.
(a) Unhook PRNDL cable eyelet from column ac­
tuating arm (Fig. 32). 918E-62
(b) Release column insert lock tab.
(c) Squeeze legs together and lift insert from steer­ Fig. 32 PRNDL Release

Flg. 33 Instrument Panel

 (5) Remove forward console if necessary.
(8) Remove instrument panel speaker grills.
(7) Remove A-pillar intermediate and sill scuff gar­
nish moldings.
(8) Unfasten the hood release mechanism from the
side cowl.
(9) Unfasten the pack brake handle bracket.
(10) Disconnect the brake light switch, parking brake
switch and bulk head wiring connectors.
(11) Under the hood disconnect the ABS connector
and resistor block. Unseat the grommet at the dash
panel and feed wiring back into passenger compartment.
'(12) Remove the 2 nuts securing the instrument
panel, at the steering column support brace.
(13) Loosen the instrument panel roll up bolts.
(14) Remove screws securing instrument panel at
the left cowl side ramp bracket.
(15) Remove the 6 screws securing the instrument
panel at the fence line.
(16) Lift upward on instrument panel to clear roll
up ramp. Roll the instrument panel back and hang it
from the short position of the roll up hook.
(17) With instrument panel hanging in the short
position disconnect the left side body wiring connections.
(18) Roll the instrument panel to the long position
ob the roll up hook and perform the following operations:
(a) Disconnect the antenna cable.
(b) Disconnect the blower motor lead connection.
(c) Disconnect the temperature control cable from
the A/C or heater unit.
(d) Disconnect the vacuum lines from the climate
control assembly.
(e) Disconnect the right side body wiring connectors.
(19) Remove instrument panel from vehicle.
(20) For installation reverse above procedures.
DOOft C O U R T E S Y LAM P/REFLECTOR
R E P LA C E M E N T
(1) Detach door trim panel and all wiring.
(2) Remove 3 screws to remove lamp or reflector.
(3) For installation reverse above procedures.
DOOR C O U R T E S Y LAM P BU LB RE P LA C E M E N T
(1) Use a flat edge tool to pry lens off the lamp
assembly. Start at top and bottom forward portion of
lamp lens and move rearward.
(2) Replace bulb.
(3) To install lens press until snap attachments
engage.
DOME LAM P
(1) Pry the lens from bezel.
(2) Replace bulb.
(3) To install lens press until snap attachments
engage.
LIFTGATE LAM P B U L B S R E P L A C E M E N T
To service liftgate lamp bulb: The lens is part of
speaker grille and can not be remove separately.
(1) Remove the speaker grille/lamp assembly from
the trim panel by prying with a screw driver. There
are 2 slots provided at the lower comers of the speaker
grille.
(2) Disconnect wire connector.
(3) There is an insulator assembly on the back side
of grille. Use a screw driver to lift the insulator from
the grille.
(4) Replace bulb.
(5) For installation reverse above procedures.
CLOWEBOE LIGHT SW ITC H R E P L A C E M E N T
(1) Pry glovebox light switch from the glovebox.
(2) Disconnect wire connector."
(3) For installation reverse above procedures.
F RO N T HEADER READING LAM P
The front header reading lamps are turned ON and
OFF by pressing on their individual lens cover indents.
F RO N T HEADER READING LAM P
REP LACE M EN T/LAM P R E P L A C E M E N T
(1) Pull the lamp assembly down, along the sides
from the bracket. Four metal clips hold the lamp in
the bracket (Fig. 34).
LENS/SWiTCH
Fig. 34 Header Reading Lamp
(2) Disconnect the wire harness connector from the
lamp assembly.
(3) After the lamp assembly is free of the vehicle,
pull the metal center reflector to gain access to the
lamp.
(4) For installation reverse above procedures.
PRNDL R E P LA C E M E N T
(1) Remove warning indicator grille by prying up
with a flat blade tool.
(2) Remove 3 mounting screws from the warning indi­
cator module assembly and disconnect wire connector.
(3) Remove steering column cover (Fig. 7). Set park­
ing brake and shift gear selector into low.
 (4) Remove cluster bezel and disconnect wire con­
nectors.
(5) Remove 4 screws securing cluster. Rotate cluster
and disconnect connector, to access PRNDL attaching
screws. Remove 2 screws attaching PRNDL to cluster
(Fig. 10).
(6) Remove cluster.
(7) Unhook PRNDL cable eyelet from column actu­
ating arm (Fig. 32).
(8) Release column insert lock tab, squeeze legs
together and lift insert from steering column, leave
insert free.
(9) Remove PRNDL assembly.
(10) For installation reverse above procedures.
• When installing cluster, do not kink or bind PRNDL
guide tube assembly.
• Move shift lever to Neutral and check pointer posi­
tion. Adjust if necessary to center on N. Check pointer
position in D, L and P. Refer to Fig. 11 for adjusting.
OVERHEAD CONSOLE
MAP READING LAMPS
The 4 map lamps are actuated by pressing on the
individual lens. The rear console lamps also serve as
courtesy lamps. Whenever a door is opened the illumi­
nated entry system is activated or the headlamp POD
switch is slid to the full right position (Fig. 1).
Fig. 1 Overhead Console
Bulb Replacement
(1) Remove lens by inserting a screw driver tip
between the rounded ends of the lens and the housing
to pry lens until it swings out.
(2) Remove bulb by pulling straight down.
(3) Install new bulb by pushing firmly into socket.
(4) Snap lens into position taking care to orient the
tabs on the lens with the slots in the housing.
LAMP TEST
(1) Close vehicle doors.
(2) Press each lamp lens. Right hand lens should
light passenger lamp and left hand lens should light
drivers lamp.
(3) If either of the rear lamps fail to illuminate,
open vehicle doors.
(a) If rear lamp does not illuminate check for a
burned out bulb.
(b) If front lamp illuminates when doors are open
check switch and wiring (Fig. 2).
 Fig. 2 Map Lamp Diagnosis
COMPASS MINI-TRIP COMPUTER (CMTC)
CMTC is a module that combines Traveler and Com­
pass/Temperature feathers. Actuating the step switch
will cause the CMTC to change mode of operation
when ignition is ON. Example: OFF/Blank, Compass/
Temperature, Trip odometer, Average time and back
to OFF/Blank.
THERMOMETER AND COMPASS
Engine temperature can increase the displayed tem­
perature. The CMTC is designed to dampen tempera­
ture readings when the vehicle is moving at a rate
slower than 18 miles per hour.
The outside temperature is measured from a sensor
mounted in the front of the vehicle. If the temperature
is more than 55°C (131°F) or the temperature sending
line is shorted to ground, the temperature display
should read SC. If the temperature is less than -40°C
(-40°F), or the sending line is an open circuit, the
display should read OC.
If the calibration data stored in the Body Controller
is not received, the compass will read only NE North-
East. The CMTC is self calibrating and requires no
adjusting, the word CAL is displayed to indicate that
the compass is in the fast calibration mode. CAL will
turn off after the vehicle has gone through three com­
plete circles with out stopping, in an area free of
magnetic disturbance. If module displays temperature
while the compass is blank, turn off ignition and de­
magnetize the vehicle. After demagnetizing, check
compass calibration number. If greater than 15, de­
magnetize again. If compass still goes blank after
demagnetizing then replace module.
VARIANCE PROCEDURE
Variance is the difference between magnetic North
and geographic North refer to Fig. 3 for variance
number. To adjust the compass variance set the CMTC
to compass/Temperature mode and depress both the
US/Metric and step buttons for 5 seconds. The word
VAR and the last variance zone will be displayed.
Depress the US/METRIC button to select the desired
zone. Depress the step button to set the new variance
zone and resume normal operation. If both buttons are
held for 10 seconds instead of 5 seconds the CMTC
will set variance to 8 and enter the fast calibration
mode.

Fig. 3 Variance Settings
TRAVELER MESSAGES
Traveler data is obtained from the Body Controller
on the CCD lines. If the brightness level is improper
or the data displayed is wrong then check CCD com­
munication by following test. Step the CMTC to the
elapsed time ET mode and simultaneously press both
the US/METRIC and step buttons to reset the module.
If the elapsed time clock does not reset or fails to
up-date then check the CCD lines and Body Control­
ler before replacing CMTC. The DRB II is recom­
mended for checking out the CCD lines and Body
Computer.
DEMAGNETIZING PROCEDURE
Every vehicle has its own magnetic field. This mag­
netic field is created by the various processes a steel
roof goes through when the vehicle is built. A mag­
netic field can also be created if the roof is subjected to
a magnet, example magnetic C.B. antenna, magnetic
tipped screwdriver, etc. If the roof becomes magnet­
ized use a demagnetizer tool 6029 to demagnetize the
roof.
In this demagnetizing procedure you will use the
demagnetizing tool to demagnetize the roof and mount­
ing screws in the overhead console. It is important
that you follow the instructions below exactly. The
mounting screws and the mounting brackets around
the compass area are steel, and therefore aid in the
demagnetizing of the roof panel.
(1) Be sure the ignition switch is in the OFF posi­
tion before you begin the demagnetize procedure.
(2) Plug the demagnetizing tool into a standard
110/115 volt AC outlet, keeping the demagnetizing
tool at least 12 inches away from the compass area
when plugging it in.
(3) Slowly approach and contact the console mount­
ing screw with the plastic coated tip of the tool for at
least 2 seconds.
(4) With the demagnetizing tool still energized, slowly
back it away from the screw until the tip is at least 12
inches from the screw head.
(5) After you have pulled at least 12 inches from the
last screw, remove the demagnetizing tool from the
inside of vehicle and disconnect it from the electrical
outlet.
(6) Place an 8-1/2 X 11 inch piece of paper length­
wise on the roof of vehicle directly above compass. The
purpose of the paper is to protect the roof panel from
scratches and define the area to be demagnetized.
(7) Plug in the demagnetizing tool, keeping it at
least 2 feet away from the compass unit.
(8) Slowly approach the center of the roof panel at
the windshield with the demagnetizing tool plugged
in.
(9) Contact the roof panel with the tip of the tool.
Using slow sweeping motions of 1/2 inch between
sweeps. Move the tool approximately 4 inches either
side of the centerline and at least 11 inch back from
the windshield.
(10) With the demagnetizing tool still energized,
slowly back away from the roof panel until the tip is
at least 2 feet from the roof before unplugging the
tool.
(11) Recalibrate compass.
SELF-DIAGNOSTIC TEST
(1) With the ignition switch in the OFF position
simultaneously press the COMP./TEMP. button and
the US/METRIC button.
(2) Turn ignition switch ON.
(3) Continue to hold both buttons until the display
performs a walking segment test. This checks for open
or shorted segments. To repeat the test press the COMP.
/TEMP, button.
(4) Press the US/Metric button, all segments will
light for about 2 seconds. To repeat the test press the
COMP./TEMP. button.
(5) Press the US/METRIC button to return to nor­
mal operation.
OVERHEAD CONSOLE REPLACEMENT
(1) Unscrew the mounting screws (Fig. 4).
 COMPASS MODULE REPLACEMENT
(1) Remove overhead console and disconnect wiring.
(2) Remove 2 forward screws and pry rear of com­
pass module from the console housing so 1 of the 2
compass pins clear the console. Rotate module out of
the console (Fig. 5).

MOUNTING BAR

Fig. 4 Overhead Console Mounting

(2) Slide console forward toward windshield until

the console unhooks from roof bracket.
(3) Disconnect wire harness from console.
(4) For installation reverse above procedures.
Fig. 5 Compass Module Removal

(3) For installation reverse above procedures.

 RADIO, ANTENNA AND SPEAKERS
CONTENTS
Page Page
ANTENNA ................................................... 4 SPEAKERS ................................................. 6
RADIOS ..................................................... 1
RADIOS
CAUTION: Do not operate the radio with speaker
leads detached since damage to the transistors may
result.

INDEX
Page Page
Description ........................................................................ 1 Manual A ntennas.............................................................. 4
Installation ........................................................................ 4 Removal ............................................................................. 4
Interference Elim ination.................................................. 1 Test ..................................................................................... 1

DESCRIPTION
For operation of the factory installed standard and
optional radios, refer to the Operating Instructions
Manual supplied with the vehicle.
All vehicles are equipped with an Ignition-Off Draw
Connector which is used when the vehicles are origi­
nally shipped from the factory. This connector, which
is located near the battery, helps to prevent battery
discharge during storage. For specific connector type
and location, refer to Wiring Diagrams.
PR513
This connector is included in the radio memory cir­
cuitry and should be checked if the memory of time or Fig. 1 Resistance Type Spark Plug Cables
radio station programming is inoperative.
If radio noises are evident, be sure the capacitor
INTERFERENCE ELIMINATION lead wires are making good contact on their respec­
tive terminals and are securely mounted. Faulty or
A number of components are utilized on vehicles deteriorated spark plug wires should be replaced.
equipped with a radio, to suppress radio frequency
interference (static). TEST
Capacitors are mounted in various locations, on the
alternator (either internal or external), internal to the Whenever a radio malfunction occurs, first verify
instrument cluster, and internal to the windshield that the radio wire harness is properly connected to
wiper motor. all connectors before starting normal diagnosis and
Ground straps are mounted from radio chassis to repair procedures. Refer to Radio Diagnosis Chart (Fig.
cowl, engine to cowl, across engine mount on right 2), and/or Radio Connector Circuit Chart (Fig. 3).
hand side. On vehicles with air conditioning there is a
strap from evaporator valve to cowl. These ground
straps should be securely tightened to assure good
metal to metal contact. Ground straps conduct very
small high frequency electrical signals to ground and
require clean large surface area contact.
Radio resistance type spark plug cables in the high
tension circuit of the ignition system complete the
interference suppression (Fig. 1).
 RADIO
RADIO M O iS i
RADIO ■R A M O R K E P n O m
INOPERATIVE RECEPTION 9 9 9 9 1 199999119 J 1 RECEPTION 1

1
OUTSIDE ELECTRICAL SHORTED SEE SOUND LOOSE POWER
BLOWN FUSE SYSTEM BOOK O i ANTENNA
INIEifEtENCE ANTENNA LEAD-iN
IN GLOVE BOX CONNECTIONS

T ~~T**- — —

CHECK ANTENNA LO O SE RADIO

ANTENNA MOUNTING AND FAI FAULTY SPEAKER (POOR GROUND)
OPEN OR SHOITED CONNECTIONS MOUNTING

FAULTY RECEIVER,
I NOISE DOES NOT NOISE VARIES BROKEN OR
POWER CONNECTION
W Ait¥ WITH ‘ WITH FAULTY RADIO* SHORTED ANTENNA
O i SPEAKER
ENGINE SPEED ENGINE SPEED LEAD-IN WIRE
CONNECTIONS
! = = = □□= = = = I T
CHECK ACCESSOIY
ELECTRICAL MOTORS, TEST FAULTY
FAULTY SPEAKER 1 SPEAKERS 1
SOLENOIDS AND CHARGING
SPEAKER
SWITCHES AS SYSTEM
RADIO FREQUENCY
NOISE SOURCES IF ONE O i MORE
SPEAKERS ARE
INOPERATIVE CHECK
FAULTY RADIO* FAULTY RADIO*
FAULTY RADIO* SPEAKER WIRING FOR
SHORT CIRCUIT
BEFORE REPLACING
* REFER REPAIR O F RADIO TO AN AUTHORIZED SERVICE, STATION THE RADIO 918F-1

Fig, 2 Radio Diagnosis

LEGEND: E2-ILLUM1NATION XSO-MONO COMMON XS4-R1GHT PNl/Dft FEED X58-RIGHT REAR iETURN
l7 -p a rk LAMPS X51-LEFT REAR FEED X55-LEFT PNL/Di iETURN XSf-MONO FEED
XI-BATTERY X52-RIGHT REAR FEED X56-R1GHT PNL/DR RETURN X60-FEED (RADIO SWITCHED)
X12-ACC/RUN X53-LEFT PNL/Di FEED X57-LEFT REAR RETURN X61-MUTE
REMOVAL (2) Remove two screws that attach the radio to the
panel.
(1) Remove bezel by opening glove box and prying (3) Remove the ground strap screw.
behind the bezel. (Fig. 4). (4) Remove the antenna plug.
(5) Remove the two wiring connectors.

INSTALLATION
(1) Connect wiring connector (Fig. 4).
(2) Install antenna plug.
(3) Install ground strap with screw.
(4) Install two screws that attach the radio to the
panel.
(5) Install bezel by snapping bezel back in place.

Fig. 4 Radio and Bezel

ANTENNA
MANUAL ANTENNAS
TESTING
Antenna performance may be tested by substituting
a known good antenna. It is also possible to check
short or open circuits with an ohmmeter or continuity
light once the antenna cable is disconnected from the
radio as follows:
(1) Continuity should be present between the an­
tenna mast and radio end pin of antenna cable plug
(Fig. 5).
 ADAPTER

ANTENNA
BODY

RADIO

ANTENNA
CABLE

VIEWIN PIRECTIQM
OF ARROW Z 918F-3

Fig. 5 Radio Antenna Cable

(2) No continuity should be observed between the (3) Remove cap nut with Antenna Nut Wrench
ground shell of the connector and radio end pin. C-4816 (Fig. 7).
(3) Continuity should be observed between the ground
shell of the connector and the mounting hardware on
the vehicle fender.

REMOVAL
(1) Remove side cowl cover and disconnect antenna
cable by pulling apart.
(2) Remove antenna mast by unscrewing mast from
antenna body (Fig. 6).

TOOL

ANTENNA
MAST

ANTENNA
ADAPTER PR517 A

Fig. 7 Removing or Tightening Antenna Cap Nut

(4) Remove antenna adapter (Fig. 7).

(5) From under fender remove antenna lead and
body assembly (Fig. 5).

AD™
Fig. 6 Antenna Mast Removal & Installation
INSTALLATIO N (2) No continuity should be observed between the
(1) Install antenna body and cable from underneath ground shell of the connector and radio end pin.
fender (Fig. 5). (3) Continuity should be observed between the ground
(2) Install adapter and cap nut. Tighten cap nut to shell of the connector and the mounting hardware.
14 N-m (125 in. lbs.) with Antenna Nut Wench C-4816.
Wiggle cable over Its entire length to reveal intermit­
(3) Install antenna mast into antenna body until
tent short or open circuits during steps (1), (2) and
slefeve bottoms on antenna body.
(4) Route cable through body hole, make sure the (3).
grommet is seated to the body plug in cable to
connector.

BENCH TEST FOR ANTENNA MALFUNCTION

It is also possible to check short or open circuits
with an ohmmeter or continuity light once the an­
tenna has been removed from the vehicle.
(1) Continuity should be present between the tip of
the mast and radio end pin (Fig. 8).

Fig. 8 Antenna Bench Test Points

SPEAKERS
INDEX
Page Page
Front Door Speakers ....................................................... 7 Rear Speakers .................................................................. 7
Front Speaker.................................................................... 6 Relay/Choke Infinity Speakers ....................................... 8

CAUTION: Do not operate the radio with speaker FRONT SPEAKER

leads detached since damage to the transistors may
result. REMOVAL
(1) Remove speaker grille by pushing forward until
the back edge is clear of the pad (Fig.9).
 (2) Remove two screws that retain the speaker. (2) Remove four speaker mounting screws. Pull
(3) Remove the speaker and disconnect the wiring speaker forward and remove speaker wiring connector.
connector.
INSTALLATION
INSTALLATION (1) Attach speaker wiring connector. Install the four
(1) Connect wiring to speaker. speaker mounting screws.
(2) Mount speaker with two screws. (2) Insert grille retaining legs into the hole at the
(3) Snap in speaker grille by pushing forward and lower side. Snap the upper side of the grille into place.
then pulling it back to seat into the pad.
REAR SPEAKERS
FRONT DOOR SPEAKERS
REMOVAL
REMOVAL (1) Remove the speaker grille by prying from the
(1) Remove speaker grille by prying at top with a underside (Fig. 10).
flat tool.

BO DY TO
HEATED
LIFTGATE
REAR W IN D O W
CONNECTORS
CONNECTOR
HEATED
REAR W IN DOW
CONNECTOR
CENTER HIGH
MOUNTED STOP
LAMP

GROUND
REAR
WIPER/ SPEAKER
WASHER
MODULE TO
LICENSE
LAMP

LIFTGATE
SPEAKER LATCH SWITCH

LIFTGATE RELEASE LIFTGATE RELEASE

SO LE N O ID
SOLENOID CONNECTOR

91 8W -36

Fig. 10 Rear Speaker System

 (2) Remove four screws attaching speaker to door.
(3) Disconnect speaker wiring connector.

INSTALLATION
(1) Connect speaker wiring connector.
(2) Attach speaker to door with four screws.
(3) Attach speaker grille to door.

RELAY/CHOKE— INFINITY SPEAKERS

No Bass, test across the connector for continuity. If
no continuity Replace Relay/Choke Assembly (Fig. 11).
The Relay/Choke is located under the left side of the
Instrument Panel on the Dimmer Module bracket.

Fig. 11 Relay/Choke—Infinity Speaker

 HORNS
CONTENTS
Page Page
DIAGNOSIS TESTING ................................... 2 HORNS SWITCH REPLACEMENT . 4
GENERAL INFORMATION.............................. 1 HORNS WILL NOT SOUND . . . . . 1
HORNS SOUND CONTINUOUSLY .................. 2
GENERAL INFORMATION
NEGATIVE
The horn circuit consists of a horn switch, horn
relay, and horns. On all models the relay plugs into
the relay bank. The horn circuit feed is from the fuse
box to the number 1 terminal on the horn relay. When
the horn switch is depressed, this completes the ground.
A set of contacts in the horn relay close, which allows
current to flow to the hom(s).

918G-3

Fig. 2 Testing for Good Ground

If the test lamp fails to illuminate, check for a

defective horn relay. Substituting a known good horn
relay in the circuit. If the test lamp illuminates when
Fig. 1 Horn System depressing the horn switch, the original relay is defec­
tive. If the lamp fails to illuminate with a known good
HORNS WILL NOT SOUND relay, unplug that relay. Connect a jumper wire from
the battery terminal to the horn terminal on the relay
If the horns do not sound, check for a blown horn
terminal board (Fig. 3). If the lamp which is connected
fuse cavity 7 in the fuse block. If the fuse is blown,
in place of the horns, fails to illuminate inspect for an
replace it with the same fuse type. In case the horns
open circuit between the horn fuse and the horn ter­
fail to sound, and the newly replaced fuse blows when
minal. Then on the relay terminal board and between
depressing the horn switch, a short circuit in the horn
relay terminal board and the horn terminals. Should
or the horn wiring between the fuse terminal and the
horn is responsible. JUMPER WIRE
If the fuse is intact, disconnect wire connector at
horn and connect one lead of a test lamp to the wire
connector and the other lead to a good body ground HORN RELAY
(Fig. 2). Depress the horn switch. Should test lamp
illuminate, the horn is ungrounded or faulty. Ground­
ing can be verified by making a temporary jumper
wire connection between horn ground wire and nega­
tive battery terminal. If horn fails to sound with ground
jumper intact, horn reconnected, and horn button or
rim depressed the horn is defective.

r-i 3ATTESY TERMI NAL

FUSE #2 HO RN TERMINAL
BLOCK #3 SWITCH TERMINAL
the lamp illuminate, a defective horn switch or an Remove steering wheel hom pad and disconnect
open circuit in the wiring between the relay terminal wire from hom switch. Repeat the above test and if
and the horn switch is at fault. the test lamp still illuminates, wire is shorted and
Should the lamp illuminate, a defective horn switch should be repaired. If test lamp does not illuminate,
or an open circuit in the wiring between the relay hom switch is defective and must be replaced.
terminal and the hom switch is at fault.
DIAGNOSIS TESTING
NORNS SOUND CONTINUOUSLY
Horn does not sound, hom sounds intermittently, or
CAUTION: Corttifwoys sounding of horns may m um hom sounds continuously go to Hom Diagnosis Chart
relay to fail. (Fig. 5).
Should th e' horns sound continuously, unplug the
hom relay from the terminal board inside the passen­
ger compartment. Plug in a known, good relay. If the
horns stop blowing, relay is defective and must be
replaced. Should the horns still sound, proceed as fol­
lows. Connect one lead to test lamp to terminal 1 on
the relay plug-inboard and the other lead to terminal
3 (Fig. 4). 'Should the lamp illuminate, either the
wire from the hom switch is shorted to ground or the
hom switch is defective.
FUSE BLOCK

HORN RELAY

#1 BATTERY TERMINAL
# 2 HORN TERMINAL
TEST LAMP # 3 SWITCH TERMINAL i f 227

Fig. 4 Testing Hom for Continuous Sound

 h orn m m not HORN SOUNDS HORN SOUNDS
SOUND
l [ INTERMITTENTLY
i r CONTINUOUSLY

GROUNDS HORN | ..fiClfls..S i99ll® W .111991991|

TEST FUSE CONTACT RING ■HORN mtm AMD DISCONNHGrl
WIOM HORNS 1

USE TEST LIGHT BETWEEN

RISK OK HORN RELAY SOCKETS 1 AND 3
fuse r l o w n
(SEE INSET DIAGRAM)

X
USE TEST LIGHT AT ' HORN CIRCUIT
HORNS (DEPRESS HORN WIRING SHORTED TISf LIGHT OFF f 1ST LIGHT 091
BUTTON O i RIM) TO GROUND

INTERNAL WIRE TO HORN

FAULTY

r TOT LIGHT OFF f 1ST LIGHT ON SHORT CIRCUIT

IN HORN
HORN RELAY BUTTON SWITCH
GROUNDED O i ' .
HORN BUTTON
SWITCH GROUNDED
REPLACE HORN
HORN NOT* SHORTED
RELAY WITH A
GROUNDED HORN RELAY
KNOWN G O O D ONE

FAULTY HORN W RONG

r TIST LIGHT ON ADJUSTMENT FUSE. SIZE

FAULTY FAULTY HORN

ORIGINAL
RELAY

f 1ST LIGHT O ff
i
UNPLUG
REPLACEMENT RELAY
FROM SOCKET AND
CONNECT A JUMPER
WIRE BETWEEN RELAY
SOCKET 1 AND 2
SEE INSET DIAGRAM

f 1ST LIGHT OFF f I S f LIGHT 991

I I IS IMPORTANT THAT HORNS
BE ADEQUATELY GROUNDED. GROUNDING
CAN BE VERIFIED BY MAKING A
INSPECT FOR TEMPORARY JUMPER’WIRE CONNECTION
OPEN CIRCUIT FAULTY HORN BETWEEN HORN BRACKET (SCRATCH
SWITCH OR THROUGH PAINT) AND THE NEGATIVE
IN WIRING
FROM FUSE WIRING BATTERY TERMINAL.
BETWEEN RELAY
BLOCK THROUGH
TERMINAL AND
RELAY BOARD TO
HORN TERMINAL HORN SWITCH
HORN SWITCH REPLACEMENT HORN

(1) Disconnect isolate negative battery cable in en­

gine compartment.
(2) On premium steering wheels (Fig. 6):

Fig. 7 Standard Steering Wheel Horn Pad

(4) To install, reverse the above procedures. Use

caution not to pinch wires.

HORN SWITCH (2) HORN BUTTON

RETAINING SCREWS (2)
918G-4

Fig. 6 Premium Steering Wheel Horn Pad

(a) Remove four retaining nuts from back of steer­

ing wheel and Remove pad assembly.
(b) Ply out two trim cover buttons on back of
steering wheel to access retaining screws for the hom
switch.
(c) Remove two screws and disconnect hom wires
located in the lower portion of steering wheel. Feed
wires through the access ports and remove hom switch.
(3) On Sport steering wheels (Fig. 7): Remove two
retaining screws from back of wheeling wheel and
remove hom pad.
 SPEED CONTROL SYSTEM
CONTENTS
Page Page
CHECKING FOR FAULT CODE ....................... 5 ROAD TEST ........................................ . . . 5
DIAGNOSIS PROCEDURES .......................... 2 SERVO U N IT ............................................... 8
ELECTRICAL TEST ...................................... 5 SPEED CONTROL SWITCH .......................... 9
ELECTRICAL TESTS AT SPEED CONTROL SWITCH T E S T ................... 7
ENGINE CONTROLLER .............................. 6 STOP LAMP SPEED CONTROL
ELECTRICAL TESTS AT SERVO ..................... 6 SWITCH TEST ........................................ 7
GENERAL INFORMATION.............................. 1 VACUUM SUPPLY TEST .............................. 8
INOPERATIVE SYSTEM ............................... 5
GENERAL INFORMATION
The speed control system is electronically controlled
and vacuum operated. The electronic control is inte­
grated into the engine controller, located next to bat­
tery. The controls are located on the steering wheel
and consist of the ON/OFF, RESUME/ACCEL and
SET/DECEL buttons (Fig.l). For identification and
location of the major components (Fig. 2 through 4).

STOP LAMP
AND SPEED
CONTROL SWITCH

SWITCH SHOWN
WITH
BRAKE PEDAL
RELEASED

VIEW IN DIRECTION
VIEW IN DIRECTION
OF ARROW Y
OF ARROW Z 918H-8

Fig. 2 Speed Control System—2.2L and 2.5L

918H-13

Fig. 1 Speed Control Switch

 TO ACTIVATE: t ie ON/OFF button to the depressed
latched position, ON, the speed control function is
now ready for use.
VACUUM TO DEACTIVATE; A soft tap of the brake pedal, nor­
RESERVOIR mal brake application or depressing the clutch pedal
while the system is engaged will disengage speed con­
trol without erasing memory. A sudden increase in
engine rpm may be experienced if the clutch pedal is
depressed while the speed control system is engaged.
Pushing the ON/OFF button to the unlatched position
or turning off the ignition erases the memory.
TO SET SPEED: When the vehicle has reached the
desired speed push the SET/DECEL button to engage
system which will then automatically maintain the
desired speed.
TO DECELERATE: When speed control is engaged,
holding the SET/DECEL button depressed allows the
vehicle to coast to a lower speed setting.
SPEED CONTROL^
TO RESUME; After disengaging the speed control sys­
SERVO
CABLE BRACKET VIEW IN DIRECTION
tem by tapping the brake pedal or clutch pedal, push
VIEW IN DIRECTION
918H-10 O f ARROW Y OF ARROW X
the RESUME/ACCEL button to return vehicle to the
previously set speed.
Fig. 3 Speed Control System—3,§L TO ACCELERATE: While speed control is engaged,
hold the RESUME/ACCEL button depressed and re­
THROTTLE lease at a new desired speed. This will allow the
CABLE BRACKET
Y K . BODY
vehicle to continuously accelerate and set at a higher
speed setting.
TAP-UP: When the speed control system is engaged,
tapping the RESUME/ACCEL button will increase
the speed setting by 2 mph (3 km/h). The system will
VIEW IN PilECTION respond to multiple tap-ups.
O f ARROW Y
VIEW IN DIRECTION TO ACCELERATE for PASSING: Depress the acceler­
OF ARROW Z SPEED ator as you would normally. When the pedal is re­
CONTROL leased the vehicle will return to the speed setting in
CABLE y memory.

DIAGNOSIS PROCEDURES
Whenever a speed control malfunction occurs, first
verify that the speed control wire harness is properly
^ VACUUM connected to all connectors before starting normal di­
RESEiVOii agnosis and repair procedures. Refer to Electronic Speed
BATTEiY
Control System Diagnosis Chart or Speed Control Cir­
TRAY cuit (Fig. 5).
SUPPOiT 918H-11

Fig. 4 Speed Control System—3.3L

The system is designed to operate at speeds above

35 mph (50 km/h).
WARNING: THE USE OF SPEED CONTROL IS NOT
RECOMMENDED WHEN DRIVING CONDITIONS DO
NOT PERMIT MAINTAINING A CONSTANT SPEED,
SUCH AS IN HEAVY TRAFFIC OR ON ROADS THAT
ARE WINDING, ICY, SNOW COVERED, OR SLIPPERY.
SYSTEM DIAGNOSIS
SYSTEM DIAQNOSIS—Continued

FAULTY ELECTRICAL
CIRCUIT*
 Inspection should also be made to verify that both
ends of the speed control cable are securely attached.
PARK/ If either end is loose, the speed control system will be
NEUTRAL inoperative.
SWITCH
-& CHECKING FOR FAULT CODE
1
Bz- DISTANCE (1) When trying to verify a speed control system
Q = < d SENSOR electronic malfunction:
IGNITION FUSE
(a) Connect a DRB II if available.
CIOCK- SPEED CONTROL (b) Plug DRB II into the diagnostic connector in
SPR1NG SWITCH
O N /O FF
the engine compartment.
(c) Check that either a Fault Code 34 or Fault
RESUME Code 15 is indicated.
SET
(d) An inoperative speed control may still occur
without either fault code being indicated.
(e) With key inserted in ignition switch, cycle
S/C VAC SERVO SOLENOIDS STO P switch to ON position three times. On third cycle,
S/C VENT =0 LIGHT
S/C SAFETY m SWITCH leave switch in ON position.
ENGINE (f) After switch has been cycled three times, ob­
CONTROLLER serve CHECK ENGINE indicator on instrument clus­
918H-15 ter. If a Fault Code is present, indicator will flash
(blink) in a series which will show which Fault Code
Fig. 5 Speed Control Circuit is the problem. EXAMPLE: A series of three flashes
in rapid succession, a slight pause, then four flashes
A poor connection can cause a complete or intermit­
in rapid succession would indicate Fault Code 34.
tent malfunction and is also the only connection in
(2) If no Fault Code appears, or Fault Code 34 is
the circuit, that can not be tested. For this reason, a
observed perform:
loose connection may be misdiagnosed as a component
• The tests in the Electrical Test at Servo section.
malfunction.
Also, check all vacuum connections for tightness • The tests in the Steps 1, 2, 3 and 4 of the Electrical
and cracked hoses. Test at Engine controller. To determine the source of
the problem.
ROAD TEST (3) If a fault code 15 is observed, perform the test for
a faulty distance sensor, refer to Group 8E, Instru­
Road test vehicle to verify reports of speed control ment Panel.
system malfunction. The road test should include at­ (4) Correct any problems found when performing
tention to the speedometer. Speedometer operation these tests and recheck for Fault Code if changes were
should be smooth and without flutter at all speeds. made.
Flutter in the speedometer indicates a problem which (5) If no problems were found in step (2), replace
might cause surging in the speed control system. The engine controller.
cause of any speedometer deficiencies should be cor­
rected before proceeding. ELECTRICAL TEST:

INOPERATIVE SYSTEM Electronic speed control systems may be tested us­

If road test verifies a report on an inoperative sys­
tem and of satisfactory speedometer operation, an in­
spection should be made for loose electrical and vacuum
connections at the servo.
Check for correct installation of the vacuum check
valve in the hose from servo to vacuum source. The
word VAC on the valve must point toward the vac­
uum source.
Corrosion should be removed from electrical termi­
nals and a light coating of Mopar Multi-Purpose Grease,
or equivalent, applied.
ing two different methods. One involves use of a DRB
II. If this test method is desired, please refer to the
Powertrain Diagnostic Test Procedures for charging
and speed control system manual.
The other test method uses a voltmeter. The volt­
meter method is described in the following tests.
If any information is needed concerning wiring, re­
fer to Group 8W, Wiring Diagrams.
CAUTION: When test probing for voltage or continu­
ity at electrical connectors, care must be taken not
to damage connector, terminals, or seals. If these
components are damaged, intermittent or complete
system failure may occur.
ELECTRICAL TESTS AT SERfO
WARNING: ON VEHICLES EQUIPPED WITH AIRBAG,
SEE GROUP 8M, RESTRAINT SYSTEMS FOR AIR­
BAG, STEERING WHEEL OR COLUMN REMOVAL
PROCEDURES.
(1) Turn ignition switch to the ON position. With
the speed control switch in the ON position, set up a
voltmeter to read battery voltage and connect the
negative lead to a good chassis ground.
(2) Disconnect the four-way connector going to the
servo (Fig. 6). Using a voltmeter test pin 2 of the main
harness four-way connector for battery voltage. If volt­
age is OK go to step 3.
PIN 3 PIN 2
FROM TERMINAL END
PIN 1 PIN 4
RN 2 PIN 3
§981+5
Fig. i Servo Harness Connector
(3) Perform the following tests.
(a) Test battery for voltage, check fuse.
(b) Disconnect the six-way connector at the stop
lamp switch and test pin 8 for battery voltage, if
voltage is OK perform the stop lamp switch test.
(c) If the stop lamp switch tests OK; repair wire
between the servo and the stop lamp switch.
(d) if no voltage at pin 3 at the 8-way stop lamp
connector, disconnect the four-way speed control con­
nector and test pin 1 for battery voltage.
' (e) If voltage is OK perform the speed control
switch test.
(f) No voltage at pin 1 of the four-way speed
control switch connector:
(g) Test pin 2 of the six-way stop lamp switch
connector for battery voltage. If no voltage repair wir­
ing as necessary.
(h) If speed control switch is OK, test continuity
across the clockspring.
(i) If clockspring OK, repair as required, wire
between stop lamp switch and clockspring.
(j) If no voltage at pin 1 of the 4-way speed control
switch connector
• Test for battery voltage between the ignition and
the fuse.
• Check continuity between the fuse and clock spring.
(4) Connect a jumper wire between pin 2 of the
four-way connector and pin 2 of the speed control
servo (Fig. 6). The other three pins from the servo
should show battery voltage. If not, replace the servo.
(5) Using an ohmmeter, connect one lead to a good
body ground and with the other lead touch pin 1 in
the four-way connector of the main hamess.The meter
should show continuity. If not, repair the ground cir­
cuit as necessary.
ELECTRICAL TESTS IT ENGINE CONTROLLER
(1) Unplug 60-way connector from the engine con­
troller, located next to the battery (Fig. 7).
ENGINE
CONTROLLER
MODULE
60-WAY
CONNECTOR
•SPEED CONTROL
SERVO RR8HC3
Fig. 7 Engine Controller end Connector Loc&tlon
(2) Connect negative lead of voltmeter to a good
body ground near the engine controller.
(3) Place ignition switch in the ON position for the
following tests. Refer to Fig. 8 for controller terminal
locations.

Fig, 8 Engine Controller 60-Mfay Connector
Shown from Terminal End
(8) Using an ohmmeter, connect one lead to a good
body ground and touch the other lead to pin 29. With
the brake pedal released, the meter should show con­
tinuity. When the pedal is depressed, the meter should
show open circuit,
(9) Using an ohmmeter, touch one lead to a good
body ground and touch the other lead to pin 30. The
meter should show continuity when transmission is in
DRIVE and no continuity when in PARK or NEU­
TRAL. If not test Neutral Start and Back-Up switch
using DRB II.
SPEED CONTROL SWITCH TEST

• Place speed control switch in the OFF position. Touch To check the switch, remove the switch from its
the positive lead of the voltmeter to pin 53,the voltme­ mounting position. Using an ohmmeter, and referring
ter should read 0 volts. to the Switch Continuity (Fig. 9), determine if conti­
nuity is correct. If there is no continuity at any one of
• Place speed control switch in the ON position. Touch
the switch positions, replace the switch.
the positive lead of the voltmeter to pin 53, the volt­
meter should read battery voltage. If no voltage, re­
CONNECTOR TERMINAL END
pair the wire between Pin 53 and Pin 3 of the speed
control servo (Fig. 8).
(4) Touch the positive lead of the voltmeter to pin
33. As in step (3), the voltmeter should read 0 volts
with the switch in the OFF position and battery volt­
age with the switch in the ON position. If no voltage,
repair the wire between pin 33 and 4 of the speed
control servo.
(5) Touch the positive lead of the voltmeter to the
terminal in pin 48, With the speed control switch in
the OFF position, the voltmeter should read 0 volts.
With the switch in the ON position, the voltmeter
should read battery voltage. Pressing the SET button SWITCH
should cause the voltmeter to change from battery
voltage to 0 volts for as long as the switch is held. If SPIED CONTROL SWITCH
not, perform the speed control switch test. If the switch C O N IiN i
is not at fault, repair the wire between pin 48 and the
SWITCH PO SITION CONTINUITY BETWEEN
speed control switch.
(8) Touch the positive lead of the voltmeter to pin OFF PIN 1 AND PIN 4
50. The voltmeter should read 0 volts with the speed PIN 1 AND PIN 4
control switch in either the OFF or ON position. With ON PIN 1 AND PIN 2
PIN 2 AND PIN 4
switch in the ON position pressing RESUME button
should change from 0 volts to battery voltage for as ON AN D SET PIN 1 AND PIN 2
long as the switch is held. If not, perform the speed ON AN D RESUME PIN 1 AND PIN 3
control switch test. If the switch is not at fault, then
repair the wire between pin 50 and the speed control 918H-14
switch.
(7) Touch the positive lead of the voltmeter to pin Fig. 9 Speed Control Switch Continuity
49. The voltmeter should read 0 volts with the switch
in the OFF position. With the switch in the ON posi­ STOP LAMP SPEED CONTROL SWITCH TEST
tion, the voltmeter should read battery voltage. If no
voltage, repair the wire between pin 49 and the speed (1) Disconnect the six way connector at the stop
control switch. lamp switch (Fig. 10). Using an ohmmeter, continuity
may be checked at the switch side of the connector as
follows:
 (a) With brake pedal released, there should be
continuity:
• Between pin 1 and pin 4. . ■
• Between pin 3 and pin .6 .
• No continuity between pin 2 and pin 5.
(b) With brake pedal depressed, there should be
no continuity:
• Between pin 1 and pin 4.
• Between pin 3 and pin 6.
• Continuity between pin 2 and pin 5,
(2) If the above results are not obtained, the stop
lamp switch is' defective or out of adjustment.
(3) Stop lamp switch adjustment is detailed in Group
5, Brakes.
VACUUM SUPPLY TEST
(1) Disconnect vacuum hose at the servo and install
a vacuum gauge in the hose (Fig. 11).
(2) Start engine and observe gauge at idle. Vacuum
gauge should read at least ten inches of mercury.
Shut off engine, the vacuum should continue to hold
10 inches of mercury.
(3) If vacuum does not meet this requirement, check
and correct the following vacuum leaks in the vacuum
lines, check valve, vacuum reservoir or poor engine
performance.
SERVO UNIT
REM OVAL
(1) Remove two nuts attaching speed control cable
and mounting bracket to servo.
(2) Remove two screws attaching servo mounting
bracket to U-Nuts on battery tray.
(3) Remove servo mounting bracket.
(4) Disconnect electrical connectors and vacuum hose.
(5) Pull cable away from servo to expose retaining
clip and remove clip attaching cable to servo.
IN ST A L L A T IO N
(1) With throttle in full open position align hole in
speed control cable sleeve with hole in servo pin and
install retaining clip.
(2) Connect vacuum hose to servo.
(3) Connect electrical connector.
(4) Position mounting bracket and install two screws
attaching bracket to battery tray, tighten to 12 N-m
(105 in. lbs.).
(5) Insert servo studs through holes in speed control
cable and mounting bracket.
(8) Install nuts, tighten to 9 N#m (80 in. lbs.).
SPEED CONTROL SWITCH
The speed control switch is mounted in the steering
wheel and wired through the clock spring device un­
der the steering wheel hub (Fig.l).
WARNING: IF REMOVAL OF AIR BAG MODULE IS
NECESSARY, REFER TO GROUP 8M, RESTRAINT
SYSTEMS.
REMOVAL
(1) Turn off ignition.
(2) Remove two (2) screws from back side of steering
wheel.
(3) Rock switch away from air bag or horn pad
while lifting switch out of steering wheel.
(4) Disconnect 4-way electrical connector.
INSTALLATION
(1) Turn off ignition.
(2) Connect 4-way electrical connector from clock
spring to switch.
(3) Place switch in steering wheel, sliding the for­
ward edge of switch under air bag or horn pad. Line
up locating pins on switch with holes in steering wheel
frame.
(4) Attach switch to wheel with two screws starting
with the screw at the left end of the switch.
 TURN SIGNALS AND HAZARD WARNING FLASHER
CONTENTS
GENERAL INFORMATION.............................. 1 MULTI-FUNCTION SWITCH TESTS ................
HAZARD WARNING SYSTEM ......................... 1 TURN SIGNAL FLASHER LOCATION ..............
MULTI-FUNCTION SWITCH .......................... 3
GENERAL INFORMATION
WARNING: ON VEHICLES EQUIPPED WITH AIRBAG,
SEE GROUP 8M, RESTRAINT SYSTEMS FOR AIRBAG
REMOVAL PROCEDURES.
TURN SIGNALS
The turn signals are actuated with a lever on the
left side of the steering column just behind the steer­
ing wheel. When the driver wishes to signal his inten­
tions to change direction of travel, he moves the lever
upward to cause the right signals to flash and down­
ward to cause the left signals to flash.
After completion of a turn the system is deactivated
automatically. As the steering wheel returns to the
straight ahead position, a canceling cam (two lobes
molded to the clockspring mechanism) comes in con­
tact with the cancel actuator on the turn signal (multi­
function) switch assembly. Either cam lobe, pushing
on the cancel actuator, returns the switch to the off
position.
If only momentary signaling such as indication of a
lane change is desired, the switch is actuated to a left
1
3
or right intermediate detent position. In this position
the signal lamps flash as described above, but the
switch returns to the OFF position as soon as the
lever is released.
When the system is activated, one of two indicator
lamps mounted in the instrument cluster flashes in
unison with the turn signal lamps, indicating to the
driver that the system is operating.
HAZARD WARNING SYSTEM
Refer to 8E, Instrument Panel.
MULTI-FUNCTION SWITCH TESTS
The multi-function switch contains electrical cir­
cuitry for turn signal headlamp beam select, and
headlamp optical hom. This integrated switch assem­
bly is mounted to the left hand side of the steering
column. Should any function of the switch fail, the
entire switch assembly must be replaced. Refer to Fig.
1 for diagnosis.
 1
IM D lC A TO i LAMP SYSTEM DOES
SYSTEM i OES NOT ILLUMINATES BRIGHTLY« SYSTEM 19 9 9 1 MOT MOT CANCEL
FLASH O N ONE SIDE EXTERNAL LAMP FLASH 0 M EITHER SIDE AFTER C O M P L ifiO M
DOES NO T LIGHT Of mmm

OPEN CIRCUIT IN
WIRE TO EXTERNAL LAMP
FAULTY EXTERNAL St
1 if
BiOKEN CANCELLING
FAULTY FUSE
FINGER ON SWITCH

EXTERNAL LAMPS f
OPERATE PROPERLY, IM P iO P E i ALIGNED
N O INDICATOR FAULTY FLASHER CANCELLING CAM
POOR G iO U N D AT LAMP LAMP OPERATION UNIT DRIVE PIN TO LOCATING
HOLE IN STEERING
WHEEL HUB
1r
FAULTY INDICATOR BULB
IN INSTRUMENT CLUSTER
OPEN CIRCUIT IN WIRING 3SE BROKEN OR MISSING
TO EXTERNAL LAMP BULKHEAD <CONNECTOR CANCELLING CAM

if
INDICATOR LAMP LOOSE O i FAULTY
FAULTY CONTACT
ILLUMINATES BRIGHTLY, IX - REAR WIRING HARNESS
IN SWITCH
TERNAL LAMP GLOWS DIMLY O i TERMINALS
WITH SLOW O i M O FLASH

LOOSE O I C O iiO D E P OPEN CIRCUIT TO

EXTERNAL LAMP FLASHER UNIT
CONNECTION

OPEN CIRCUIT IH FEED

POOR G tO U N P CIRCUIT
WIRE TO TURN
AT EXTERNAL LAMP
SIGNAL SWITCH

FAULTY SWITCH
CONNECTIONS

OPEN O i GROUNDED
_ CIRCUIT IN WIRING
FAULTY CONNECTION
TO EXTERNAL LAMPS
IN SWITCH
 To te s t. the switch, first disconnect the negative (4) Remove multi-function switch tamper proof
battery cable, then remove the upper and lower col­ mounting screws (Fig.4).
umn covers to gain access to the switch connector.
Remove switch connector. Using an ohmmeter, test
for continuity (no resistance) between the terminals of
the switch as shown in the following continuity charts
(Fig 2 or 3).

VIEW FROM TERMINAL SIDE

SWITCH PO SITION CONTINUITY BETWEEN
LOW BEAM 18 AND 19
HIGH BEAM 19 AND 20
OPTICAL HORN 20 AND 21
908J-5

Fig. 4 Multi-Function Switch

SWITCH PO SITIONS
TURN SIGNAL CONTINUITY BETWEEN
(5) Gently pull switch away from column. Loosen con­
nector screw. The screw will remain in the connector.
NEUTRAL 12 AND 14 AND 16
(6) Remove wiring connector from multi-function
LEFT 13 AND 14 AND 15 switch.
LEFT 12 AND 16
RIGHT 11 AND 12 AND 13 INSTALLATION
RIGHT 14 AND 16 (1) Install wiring connector to switch and tighten
918J-1
connector retaining screw to 2 N-m (17 in. lbs.) torque.
(2) Mount multi-function switch to column and
Fig. 2 Turn Signal Continuity tighten retaining screws, to 2 N'm (17 in. lbs.) torque.
(3) Install steering column covers. Tighten retain­
> CONTROL STALK ing screws to 2 N*m (17 in. lbs.) torque.
(4) Tilt column only install tilt lever;
(8) Re-install battery negative cable.
(8) Check all functions of switch for proper operation.

TURN SIGNAL FLASHER LOCATION

The turn signal flasher plug-in type unit, and is
on the fuse block (Fig. 5).

MULTI-FUNCTION
SWITCH 918 J‘5

Fig. 3 Beam Select Switch Continuity

MULTI-FUNCTION SWITCH
REMOVAL
(1) Disconnect battery negative cable.
(2) Tilt column only remove tilt lever.
(3) Remove both upper and lower steering column
covers.
 WINDSHIELD WIPER AND WASHER SYSTEMS
CONTENTS
Page Page
GENERAL INFORMATION .......................... 1 WINDSHIELD WIPER MOTOR AND
WINDSHIELD WASHERS ............................ 12 LINKAGE ASSEMBLY
WINDSHIELD WIPER BLADE AND.................................. SERVICE PROCEDURES 5
ARM SERVICE PROCEDURES ................. 3
GENERAL INFORMATION
WARNING: ON VEHICLES EQUIPPED WITH AIRBAG, ate set of brushes.
SEE GROUP 8M, RESTRAINT SYSTEMS FOR STEER­ The intermittent wipe system in addition to low and
ING WHEEL OR COLUMN REMOVAL PROCEDURES. high speed, has a delay mode. The delay mode has a
range of 2 to 15 seconds. This is accomplished by a
The windshield wipers can be operated with the
variable resistor in wiper switch and is controlled
windshield wiper switch only when the ignition switch
electrically by a relay.
is in the ACCESSORY or IGNITION position. A fuse
The wiper system completes the wipe cycle when
located in the fuse block protects the circuitry of the
the switch is turned OFF. The blades park in the
wiper system and the vehicle.
lowest portion of the wipe pattern (Fig. 1).
The wiper motor has permanent magnet fields. The
speeds are determined by current flow to the appropri­
 com .
PLENUM
GRILLE

. W MMEI
R IS IIV C liA N D
W M PASSEM M

WASHEI
PUMP

Or
VIEW IN DltECTION
O f A IIO W ¥

WIPER MOTOR
HOSE

com

VIEW IN DIRECTION
VIEW IN CIRCLE X OF ARROW 2 918K-10
 WINDSHIELD WIPER BLADE AND ARM SERVICE PROCEDURES
Front and Rear Wiper Arm Replacement ..................... 3
Wiper Arm Adjustment ...................................................
WIPER BLADES
Wiper blades exposed to the weather for a long
period of time tend to lose their wiping effectiveness.
Periodic cleaning of the wiper blade is suggested to
remove the accumulation of salt and road film. The
wiper blades, arms and windshield should be cleaned
with a sponge or cloth and a mild detergent or non­
abrasive cleaner. If the blades continue to streak or
smear, they should be replaced.
WIPER BLADE ELEMENT CHANGE
REMOVAL
(1) Turn wiper switch ON, position blades to a con­
venient place by turning the ignition switch ON and
OFF.
(2) Lift wiper arm to raise blade off glass.
(3) Remove blade assembly from arm by inserting a
small screwdriver blade into release slot of wiper blade
and depressing slightly (Fig. 2), or push release but­
ton (Fig. 3).
RELEASE SLOT
WIPER ARM
PI
NCH-RELEASE ^
Fig. 2 Wiper Blade and Element
INDEX
Page Page
Wiper Blade Element Change ....................................... 3
3 Wiper Blades .................................................................... 3
(4) To remove wiping element from blade assembly:
• Pinch lock on end blade assembly and pull wiping
element (blade) out of end bridge claws (Fig. 2).
• Second type by lifting tab on one end links and
squeezing link to remove from center bridge,and slide
end link off element from claws of other link (Fig. 3).
• Third type by grasping rubber element where chan­
nel is rubber and pull rubber element and vertibra
out for replacement (Fig. 4).
CLAW
TO GRASP
AND PULL
RUBBER
ELEMENT' CHANNEL 918K-8
Fig. 4 Wiper Blade and Element
(5) For installation reverse above procedures.
(6) Check each release point for positive locking
when installing blade element and blade assembly.
FRONT AND REAR WIPER ARM REPLACEMENT
REMOVAL
Lift the arm to permit the latch (Fig. 5) to be pulled
out to the holding position then release the arm. The
918K-9 arm will remain off the glass in this position. Remove
the arm from the pivot by using a rocking motion.
PR1512
INSTALLATION (1-1/2 inch) parallel, with lower edge of liftgate glass
For proper installation of wiper arm, refer to Wiper (Fig.7).
Arm Adjustment.

WIPER ARM ADJUSTMENT

FRONT ARM ADJUSTMENT
(1) Cycle the wiper motor into the PARK position.
(2) Check the tips of the blades in blackout area.
From the bottom edge of the windshield to the blade
should be no closer than 25 mm (1 inch) (Fig 6).

(3) Operate the wipers if the requirements are not Fig. 7 Installing Liftgate Wiper Arm
met, check linkage and pivot assembly for worn parts.
(2) Operate the wiper on dry glass with the engine
REAR ARM ADJUSTMENT off. The tip of the wiper blade should be within 22mm
(1) With the motor in park position, mount the arm (7/8 inch) to 60 mm (2 3/8 inch) above lower edge of
on the motor shaft. Choose a serration engagement liftgate glass.
that properly locates tip of the blade about 38 mm
WINDSHIELD WIPER MOTOR AND LINKAGE ASSEMBLY SERVICE PROCEDURES
INDEX
Page Page
Combination Front and Rear Liftgate Wiper Motor Test ............................................ 8
Wiper/Washer Control Pod Switch ......................... 10 Two Speed Function Tests ............................................ 7
Intermittent Function T e s t s ............................................ 9 Wiper Motor Assembly ..................................................... 9
Intermittent Wipe Module Location ........................... 11 Wiper Motor System Test Procedures ....................... 5
Liftgate Motor Assembly ................................... : . . . . 9

WIPER MOTOR SYSTEM TEST PROCEDURES The following is a list of general wiper motor sys­
tem problems, the tests that are to be performed to
WARNING: ON VEHICLES EQUIPPED WITH AIRBAG, locate the faulty part, and the corrective action to be
SEE GROUP 8M, RESTRAINT SYSTEMS FOR STEER­ taken. These tests will cover both two speed and inter­
ING WHEEL OR COLUMN REMOVAL PROCEDURES. mittent wipe functions, refer to Windshield Wiper Mo­
tor Diagnosis (Fig. 8).
 MOTOR RUNS

I MOTOR HUMS I BLADES SLAP

BLADES DO AGAINST
not mm BUT OUTPUT* BLADES
CitANiC DOES C H A f T li w indshield
NOT TUIW MOULDINGS
OM P tY S L A S S j
I I
mmm w ill
1 IN A N Y 1 1 BLADES 9 9 1 mm stop LINKAGE NOT FOREIGN
1 PO SITION 1 | W H IN SWITCH i FASTENED SUBSTANCE SUCH ARMS LOOSE
1 NO T 19119 1
1 WHEN SWITCH 1 IS TURNED PROPEtLY TO AS BODY POLISH ON PiVOT SHAFT
( PROPERLY I OFF
■1 ' IS TURNED 1
H MOTOR OUTPUT ON GLASS OR
SHAFT BLADES X
A il ARM
FAULTY ^ T w is t e d a i w
OPEN PARK INCORRECT IMPROPERLY
SWITCH ' DEFECTIVE HOLDS 11/
WIRING CIRCUIT POSITION POSITIONED ON
MOTOt WRONG ANGl PIVOT SHAFT
TO GLASS
A IM S LOOSE
X
FAULTY SWITCH DEFECTIVE LOOSENESS OF
O N PiVOT SHAFT MOTOR • BENT O i THE MOTOR
1 M O T O I WILL 1 DAMAGED CRANK OR OTHER
L— — f— BLADES
1 NOT RUN 1 DRIVE PARTS
LOOSE LINKAGE
DEFECTIVE AT MOTOR
MOTOR CONNECTION BLADE ELEMENTS
| WIPER KNOCK
M EXTREME
9991

NEW
REPLACE
FUSE
FUSE
GOOD
T — — J
t

REPLACE FUSE
MOTOR BLOWS

OUTPUT OUTPUT L— “ T .
SHAFT SHAFT _____ __._ ?
STATIONARY ROTATES
CHECK CHECK
WIRING SWITCH
X
LOOSE BAD
REPLACE ARMS LOOSE
MOTOR LINKAGE
MOTOR ON PiVOT SHAFT
C iA N K CONNECTION
TWO SPEED FUNCTION TESTS
CONDITION
Motor will not run in any switch position.
PROCEDURE
(1) Check for a blown fuse in the fuse block.
(a) If fuse is good, proceed to step 2.
(b) If fuse is defective, replace and check motor
operation in all switch positions.
^(c) If motor is still inoperative and the fuse does
not Mow, proceed to step 2.
(d) If replacement fuse blows, proceed to step 5.
(2) Place switch in LOW speed position.
(3) Listen to motor. If you cannot hear it running,
proceed to Step No. 4. If you hear it running, check
motor output shaft. If output shaft is not turning,
replace motor assembly. If it is turning, drive link to
output shaft or linkage is not properly connected. Re­
place worn parts and/or properly connect drive link to
the motor output shaft.
(4) Connect a voltmeter between motor 'terminal 3
and ground strap (Fig. 9). If there is no voltage or
very little voltage (less than one volt) present, move
negative test lead from the ground strap to negative
battery terminal.
(a) If an increase in voltage is noticed, the prob­
lem is a bad ground circuit. Make sure the motor
mounting is free of paint and that nuts or bolts are
tight.
(b) If there is still no indication of voltage, the
problem is an open circuit in the wiring harness or
wiper switch.
(c) If no noticeable increase greater than 3 volts is
observed, the problem is a faulty motor assembly.
(5) Disconnect motor wiring connector and replace
fuse.
(a) if fuse does not blow, motor is defective.
(b) If fuse blows, switch or wiring is at fault.
CONDITION.
Motor runs slowly at all speeds.
PROCEDURE
(1) Disconnect wiring harness connector at motor.
Remove wiper arms and blades. Connect an ammeter
between battery and terminal 3 on motor (Fig. 10).
Fig. 10 Mmmeter Between Terminal 3 and Battery
(a) If motor runs and average ammeter reading is
more than 8 amps, proceed to step 2.
(b) If motor runs and average ammeter reading is
less than 8 amps, proceed to step 3.
(2) Check to see if wiper linkage or pivots are bind­
ing or caught. Disconnect drive link from motor.
(a) If motor now runs and draws less than 3 amps,
repair linkage system.
. (b) If motor continues'to draw more than 3 amps,
replace motor assembly.
(3) Check motor wiring harness for ■ shorting be­
tween high and low speed wires as follows:
(a) Connect a voltmeter or test lamp to *motor
ground strap.
(b) Set wiper switch to LOW position.
(c) Connect other lead of voltmeter to terminal 4
of the wiring harness.
(d) If voltage is present, there is a short in the
wiring or wiper switch.
(e) If no voltage is present set wiper switch to
HIGH position.
(f) Move voltmeter lead from terminal 4 to termi­
nal 3 of the wiring harness.
(g) If voltage is present, there is a short in the
wiring or wiper switch.
CONDITION
Motor will run at high speed, but not at low speed.
Motor will run at low speed, but not at high speed.
PROCEDURE'
(1) If motor will not run on high speed, put switch
in HIGH position and connect a test lamp between
motor Terminal 4 and' ground, refer to Fig. 11.
 CONDITION
TERMINAL TEST
Motor will stop wherever it is, when switch is put
in OFF position. Wipers do not continue running to
PARK position.

PROCEDURE
(1) Remove motor wiring connector and clean termi­
nals. Reconnect connector and test motor. If problem
persists, proceed to Step 2.
(2) Set wiper switch to OFF position. Disconnect
motor wiring connector. Connect a voltmeter or test
lamp to the motor ground strap. Connect the other
lead to terminal 2 of wiring connector.
(a) If voltage is not present, check for an open
circuit in the wiring harness or wiper control switch.
(b) If voltage is present, proceed to step 3.
Fig. 11 Test Lamp Between Terminal 4 and Ground (3) Connect an ohmmeter or continuity tester be­
tween terminals 3 and 1 (Fig. 13).
(2) If motor will not run on low speed, put switch in
LOW position and connect a test lamp between motor
Terminal 3 and ground.
(3) If test lamp does not light at motor terminal,
there is an open in wiring or switch. If test lamp
lights at motor terminal, replace motor assembly.

CONDITION
Motor will keep running with switch in OFF position.

PROCEDURE
Remove wiring harness. Connect jumper from Ter­
minal 1 to Terminal 3 of wiper motor (Fig. 12). Con­
nect second jumper from Terminal 2 to battery. If
motor runs to PARK position and stops,wiper switch
is faulty. If motor keeps running and does not park,
replace motor assembly.
Fig. 13 Ohmmeter Between Terminals 3 and 1

(a) If there is continuity between these terminals,

the problem is a defective motor.
(b) If there is no continuity, the problem is an
open circuit in the wiper control switch or wiring
harness.

LIFTGATE WIPER MOTOR TEST

%
The following test is used in order to locate and
then repair liftgate wiper motor defects. Refer to Group
8W, Wiring Diagrams for liftgate wiper motor wiring
schematic.
(1) Disconnect feed wire connector from wiper motor
(Fig. 14).

Fig. 12 One Jumper Wire Between Terminal 1 and 3.

One Jumper Wire Between Terminal 2 and
Battery Positive

Fig. 14 UHgate Wiper Motor and Bracket Assembly
(2) With ignition switch in ON position, check for
battery voltage at blue wire.
(3) With ignition switch in ON position and wiper
switch ON, check for battery voltage at blue and brown
wire. If battery voltage is not present in steps 2 and 3,
check fuse, liftgate wiper switch and wiring.
(4) With ignition switch in ON position, and wiper
switch in OFF position, check for battery voltage be­
tween blue and brown wires. If battery voltage is not
present check ground wire to liftgate switch.
(5) If battery voltage is present in steps 2 and 3,
replace motor.
WIPER MOTOR ASSEMBLY
REMOVAL
(1) Remove windshield wiper arms (Fig. 5).
(2) Open hood assembly.
(3) Remove cowl top plenum grille.
(4) Remove hoses from hose connectors.
(5) Remove cowl plenum chamber plastic screen.
(6) Remove wiper pivot retaining screws.
(7) Push pivots down into plenum chamber.
(8) Remove nut from wiper motor output shaft and
remove linkage assembly.
(9) Disconnect wiper motor wiring harness.
(10) Remove mounting screw and nuts from wiper
motor.
(11) Remove wiper motor.
(12) Perform disassembly and service on pieces as
necessary.
INSTALLATION
(1) Install wiper motor and torque mounting screw
and nuts 7 to 8 N*m (60 to 70 in. lbs.).
(2) Install pivots and linkage into the cowl top mount­
ing positions.
(3) Install pivot screws and torque 7 to 8 N’m (60 to
70 in. lbs.).
(4) Position wiper motor drive crank on motor shaft
and torque retaining nut 10 to 11 N-m (90 to 100
in.lbs.).
(5) Install cowl plenum chamber plastic screen.
(6) Route and connect windshield washer hoses to
hose connectors.
(7) Install cowl top plenum grille.
(8) Install wiper arm assembly and for proper ad­
justment, refer to Wiper Arm Adjustment.
LIFTGATE MOTOR ASSEMBLY
REMOVAL
(1) Remove liftgate wiper arm assembly,refer to
Wiper Arm Replacement.
(2) Unlock and open the liftgate.
(3) Remove liftgate trim panel, refer to Group 23,
Liftgate Trim Panel Removal.
(4) Remove five liftgate motor mounting screws (Fig.
14).
(5) Disconnect wiring harness from liftgate motor
connector.
(6) Remove motor assembly from liftgate.
INSTALLATION
(1) Position motor assembly into liftgate.
(2) Connect wiring harness to liftgate motor.
(3) Install five liftgate motor mounting screws. Torque
screws 7 to 8 N*m (60 to 70 in. lbs.).
(4) Install liftgate trim panel.
(5) Close liftgate.
(6) Install wiper arm assembly, refer to Wiper Arm
Adjustment.
INTERMITTENT FUNCTION TESTS
CONDITION
Excessive delay, more than 30 seconds or inade­
quate variation in delay.
PROCEDURE
Variations in delay should be as follows:
(1) Minimum delay control to extreme counterclock­
wise position before first detent of one half to two
seconds.
(2) Maximum delay control to extreme clockwise
position before off detent of ten to thirty seconds.
(3) If there is excessive delay or no variations in
delay proceed to intermittent wipe switch test.
CONDITION
In DELAY mode wipers run continually when wash is
operated but do not provide an extra wipe when the
wash control is released.
PROCEDURE
Replace the control unit.
CONDITION
Wipers start erratically during DELAY mode.
PROCEDURE
(1) Verify that the ground connection at the instru­
ment panel is making good connection, free from paint
and is tight.
(2) Verify that the motor ground strap is making
good contact and that the motor mounting bolts are
tight.
(3) Verify that the wiring ground connections for
the intermittent wipe control unit and the wiper switch
are tight.
(4) If condition is not corrected, replace control unit.
COMBINATION FRONT AND REAR
WIPER/WASHER CONTROL POD SWITCH
OPERATION AND TESTING
The front wiper control portion of this assembly is a
horizonal, sliding action with five clearly defined de­
tent positions OFF, MAX, DELAY, MIN DELAY, LO
and HI which provides the following functions (Fig.
15).
7 WAY CONNECTOR
REAR WASHER
SWITCH
L ^ re ar w i p e r
SWITCH
Fig. 15 POD Switch
(1) OFF position.
• The left most detent of the switch.
• Turns OFF the front wiper and allows the front
wiper blades to return to their PARK position. • There
shall be continuity between terminals A6 and A4. If
not replace POD switch.
(2) Intermittent MAX DELAY position.
• Position at the left end of a variable resistor and
provides the maximum delay signal level to the body
controller, which directly operates the front wipers in
the delay mode.
• There shall be continuity between terminals A7 and
A5, A3 and B3.
• There shall be a resistive valve of 210,000 to 390,000
ohms between terminals A1 and B3.
• If not replace POD switch.
(3) Intermittent MIN DELAY position.
• Position at the right end of the variable resistor and
provides the minimum delay interval signal level to
the body controller.
• There shall be continuity between terminals A7 and
A5, A3 and B3. .
• There shall be a resistive valve of 350 to 850. ohms
between A1 and B3.
• When the slide is moved from MAX DELAY to MIN
DELAY and vice versa continuity between terminals
A7 and A5, A3 and 13 shall be maintained. The
resistive valve between terminals A1 and B3 will de­
crease as the control is moved from max delay to min
delay or increase when moved from min delay to max
delay.
• If not replace the POD switch.
(4) Continuous LOW (LO) position.
• Position which turns ON the front wiper motor in
the continuous LOW speed mode.
• There shall be continuity between terminals A4 and
13.
• If not replace POD switch.
(5) Continuous HIGH (HI) position.
• Position which turns ON the front wiper motor in
the continuous HIGH speed mode.
• There shall be continuity between terminals A2 and
B3. ' '‘
• If not replace POD switch.
(8) The front washer switch portion of this assembly
is a push ON, momentary action and provides:
• Power to the washer motor when the front washer
button is depressed.
• Power to the body controller to turn the front wiper
system ON when the front washer button is depressed.
918K-2 • There shall be continuity between terminals B4 and
B3 when the front washer button is depressed.
• If not replace POD switch.
(7) The Rear Wiper switch portion of this assembly
is a push ON, push OFF latching action and provides:
• A ground signal to the rear wash/wipe module to
turn the rear wiper system ON when rear wiper but­
ton is latched down.
• There shall be continuity between terminals B5 and
B2 when the rear wiper button is depressed and latched
down.
• When the rear wiper button is latched, the ON indi­ INTERMITTENT WIPE MODULE LOCATION
cator lamp will light only when headlamps are on.
• If not replace POD switch. The intermittent wipe module is located to the right
(8) The Rear Washer switch portion of this assem­ of the steering column on the back side of the lower
bly is a push ON, momentary action and provides: instrument panel (Fig. 16).
• A ground signal to the rear wash/wipe module to
turn the rear washer system ON when the rear wash
button is depressed.
• There shall continuity between terminals B5 and
B l only when the front washer button is depressed.
• If not replace POD switch.
(9) Two bulbs control the illumination of the switch
assembly. The bulbs are feed by terminals B6 (power)
and B5 (ground).

POD SWITCH REMOVAL

(1) Remove eight screws mounting the cluster bezel
to the instrument panel.
(2) Tilt column down if possible for ease.
(3) Gently pull cluster bezel out, to gain access to
the switch assembly’s snap fingers and push switch
out through mounting hole for POD switch assembly.
(4) Remove wiring connectors for POD switch assembly.

POD SWITCH INSTALLATION

(1) Position cluster bezel for assembly and pull wir­
ing connectors through mounting hole for POD switch
assembly.
(2) Install wiring connectors to POD switch assem­
bly and verify the functions of the front and rear
wipe/wash system.
(3) Install POD switch assembly into cluster bezel
insuring that the snap fingers fully retain the POD
switch assembly.
(4) Assemble Cluster bezel into instrument panel
using eight screws.
(5) Verify the functions of front and rear wipe/wash
system.
 WINDSHIELD WASHERS
INDEX
Page Page
General Information ..................................................... 12 Washer Nozzle ................................................................ 13
Liftgate Washer Reservoir ........................................... 13 Washer Reservoir............................................................ 12
Liftgate Washer Reservoir P u m p ................................. 14 Washer Reservoir Pump ...........................................

GENERAL INFORMATION
All models are equipped with electric operated wind­
shield washer pumps.
The wash function can be accessed in the OFF posi­
tion of the wiper control switch. Holding the wash
button depressed when the switch is in the OFF posi­
tion will operate the wipers and washer motor pump
continuously until the washer button is released. Re-
leasing the button will stop the washer pump but the
wipers will complete the current wipe cycle followed
by an average of two more wipe cycles ( ± 1) before the
wipers park and the module turns off.
Whenever a windshield washer malfunction occurs,
first verify that the windshield washer wire harness is
properly connected to all connectors before starting
normal diagnosis and repair procedures. Refer to Wind­
shield Washer Diagnosis Chart (Fig. 17).

PUMP RUNS— WASHER DOES I

pumpmovoi
19919 N O T 199! 1
^
PUMP NOT NOT OPERATE listen tmmm
I PUMPING FLUID PROPERLY mw
LOOSE WIRING
■ TliMiNALS.
NO FLUID IN • PINCHED Oi CORRODED
RESERVOIR LEAKY HOSES TEiMINALS.
____________

LEAKY Oi RESTRICTED BROKEN WIRES

NOZZLE JETS MOTOR RUNS-
PLUGGED OR ■ OPERATES 1 PUMP PUMPING PLASTIC HOSE
---------_
"' -------- ,
FROZEN | INTERMITTENTLY 1 FLUID CONNECTOR
3 -----
SYSTEM OPERATES POOR GROUND
BROKEN Oi LOOSE WIRIN POOR ELECTRICAL
LOOSE HOSE CONNECTIONS WITHOUT CONNECTIONS
INTERRUPTION
t
FAULTY SWITCH
FAULTY PUMP FAULTY SWm SYSTEM OUTPUT DEFECTIVE PUMP
ADEQUATE

w m m m system
FAULTY MOTOR
0 §€
918K-4

Pig. IF Windshield Washer Diagnosis

W ISH E R RESERVOIR outlet to prevent the liquid from running out while
removing the reservoir from engine compartment.
ftemowAL
(1) Unlock and open the hood. INSTALLATION
(2) Remove two sheet metal screws attaching the (1) Connect washer hose, wiring harness and install
reservoir in plenum, the reservoir in the plenum chamber.
(3) Disconnect the wiring harness from the reser­ (2) install two sheet metal attaching screws. Torque
voir pump and sensor, if equipped. to 3 N-m (28 in. lbs.).
(4) Disconnect the washer hose and block the liquid
WASHER RESERVOIR PUMP
REMOVAL
(1) Remove washer reservoir and pump assembly,
refer to Reservoir Removal.
(2) Notice position of pump, then using a 19mm (3/4
in.) socket through the liquid filler opening, loosen
the pump filter and nut.
(3) Disconnect the outside portion of the pump.
(4) Remove inner and outer portions of the pump.
INSTALLATION
(1) Install rubber grommet into place in bottom of
reservoir.
(2) Position pump into place, install nut and filter
through filler opening tighten with 19mm (3/4 in.)
socket.
(3) Install reservoir and pump assembly, refer to
Reservoir Installation.
Fig. 18 Uftgate Washer System
(3) Disconnect the wiring harness from the washer
pump.
(5) Disconnect the washer hose from reservoir sys­
tem, block the liquid outlet to prevent the liquid from
running out while removing the reservoir.
(6) Remove one upper reservoir screw.
WASHER NOZZLE
These models are equipped with two washer nozzles
attached to the wiper arms. Each arm emits five
streams across the wiper pattern. No adjustment is
required. If nozzle performance is unsatisfactory they
should be replaced. The right and left upper nozzles
are identical, and the lower two are the same.
To replace unsnap nozzle from wiper arm and dis­
connect hose. When installing make sure that both
the nozzle and the hose guard are securely snapped
into position.
LIFTGATE WASHER RESERVOIR
REMOVAL
(1) Unlock and open the liftgate.
(2) Remove two side aperture panel and reservoir
mounting screws (Fig. 18).
(7) Remove reservoir and pump assembly through
the side aperture panel access hole. Work filler tube
off reservoir. Empty the reservoir outside of vehicle.
INSTALLATION
(1) Install reservoir and pump assembly through
the side aperture panel access hole. Work filler tube
onto reservoir.
 (2) Install loosely one upper reservoir screw.
(3) Connect the washer hose to the reservoir system.
(4) Connect the wiring harness to the washer pump.
(5) Install two side aperture panel reservoir mount­
ing screws.
(6) Fill reservoir and test system.
LIFTGATE WASHER RESERVOIR PUMP
REMOVAL
(1) Remove washer reservoir and pump assembly,
refer to Washer Reservoir Removal.
(2) With mechanical fingers, loosen pump filter andINSTALLATION
nut through liquid filler opening.
(3) Disconnect the outside portion of the pump.
(4) Remove inner and outer portions of the pump,
and remove pump.
INSTALLATION
(1) Install rubber grommet into place in bottom of body and liftgate.
reservoir.
(2) Position pump into place, install nut through
filler opening and tighten with mechanical fingers.
(3) Install reservoir and pump assembly, refer to
Reservoir Installation.
WASHER NOZZLE
REMOVAL
(1) Pull washer nozzle out of mounting grommet
(Fig. 18).
(2) Disconnect hose from nozzle.
(1) Connect the hose to the nozzle.
(2) Moisten the nozzle and hose.
(3) Insert nozzle into mounting grommet.
(4) Align nozzle.
(5) Open liftgate.
(6) Verify engagement of hose grommets to vehicle
 LAMPS
CONTENTS
Paop ■ Pa00
DAYTIME RUNNING LAMP MODULE— HEADLAMP AIMING .................................. 10
CANADA O NLY 8 HEADLAMP TIME DELAY SYSTEM .......... 8
EXTERIOR LAMP SERVICE PROCEDURES 3 ILLUMINATED ENTRY SYSTEM.................. 8
GENERAL INFORMATION 1 INTERIOR LAMPS/LAMP SWITCHES .......... 7
GENERAL INFORMATION
Each vehicle is equipped with various lamp assem­ BULB IDENTIFICATION
blies which are used for illuminating and/or indicat­
ing purposes. A good ground is mandatory for proper Bulb identification and application for exterior and
lighting circuit operation. Circuit grounding is pro­ interior lamps can be found at the back of this group.
vided by the lamp socket when it comes in contact
with the metal body, or through a separate ground DIAGNOSTIC PROCEDURES
wire linking the lamp socket to the body on plastic
lamp assemblies. Always begin any electrical system failure diagno­
When changing lamp bulbs, check the socket for sis by testing all of the related fuses and circuit break­
corrosion. If corrosion is present, clean it off with a ers in the fuse block and engine compartment. Also
wire brush, and coat the inside of the socket lightly refer to Group 8W, Wiring Diagrams for electrical
with MOPAR multi-purpose grease or petroleum jelly. schematics.
Conventional and halogen headlamp sealed beams
BODY IDENTIFICATION units are physically and electrically interchangeable,
but it is recommended that they not be intermixed on
Throughout this group, code references are made to a given vehicle.
various body lines. Example: AS/H, AS/K, AS/D. To
determine the vehicle model by it’s code, refer to the
MODEL CHART in the Introduction Section of this
manual.
HEADLAMP DIAGNOSIS

918L-26
 EXTERIOR LAMP SERVICE PROCEDURES
INDEX
Page Page
Center High-Mounted Stop Lamp (CHMSL) .............. ....7 Headlamp Lens/Housing Assembly—
Fog Lamps ........................................................................ ....5 Aero Type H ead lam p .................................................... 3
Front Park/Turn Signal and Side Marker Headlamps— Sealed Beam Type ................................... 3
Lamps— With Aero Head l amps ................................. ....4 License Plate Lamp/Bulb ............................... ................ 6
Front Park/Turn Signal and Side Marker Rear Tail, Stop, Turn Signal, Back-Up
Lamps— With Sealed Beam Headlam ps.......................5 and Side Marker Lamps .............................................. 6
Headlamp Bulb— Aero Type Headlamp ...........................3

HEADLAMP— SEALED BEAM TYPE
connector.
REMOVAL AND INSTALLATION
(1) Remove the headlamp trim mounting screws
and remove headlamp trim (Fig. 1).
(3) Pull out sealed beam unit and unplug electrical
(4) Remove sealed beam.
To install, reverse the preceding operation.
HEADLAMP BULB— AERO TYPE HEADLAMP
BULB REMOVAL AND INSTALLATION
(1) Open hood.
(2) Locate and remove the electrical connector be­
hind the headlamp assembly in the engine compart­
ment (Fig. 3).
(3) Rotate the bulb retaining ring (Fig. 3) counter­
clockwise one quarter turn and remove the retaining
ring, bulb holder and bulb from the lens assembly.
Note the bulb holder alignment notches.
BULB BULB
SOCKET RETAINING
RING

918L-44 ELECTRICAL
CONNECTOR
Fig. 1 Headlamp Trim Removal and Installation—
With Sealed Beam Type Headlamps

(2) Remove screws from headlamp retaining ring

PLASTIC
(Fig. 2). Do not disturb the headlamp aiming/adjuster LENS/ BASE UNLOCK
screws (Fig. 2). REFLECTOR 918L-34

Fig. 3 Aero Headlamp Bulb

VERTICAL
ADJUSTER
CAUTION: Do not touch the bulb with fingers or any
possibly oily surface, reduced bulb life will result.
To install bulb, reverse the preceding operations.
SEALED
BEAM HEADLAMP LENS/HOUSING ASSEMBLY-
AERO TYPE HEADLAMP
REMOVAL AND INSTALLATION
Lens fogging is a normal condition and does not
require service, as moisture will vent from tubes
behind the lens.
.RETAINING
RING RP800
(1) Open hood.
(2) Remove the trim molding over the top of headlamp
lens.
 (3) Remove Park/Turn Signal Lamp Assembly. See (3) Remove outer lamp mounting screw (Fig. 6).
FRONT PARK/TURN SIGNAL AND SIDE MARKER
LAMPS—WITH AERO HEADLAMPS (Removal and
Installation).
(4) Remove wire connector from headlamp bulb.
(5) Locate three plastic blocks (one block at 'top of
headlamp-two at bottom of headlamp) (Fig. 4). Rotate
the plastic blocks 90 degrees to align with notches on
lens assembly (Fig. 4).

(4) Remove vertical lamp mounting screw (Fig. 7).

(8) Remove headlamp lens/housing assembly.

(7) Remove bulb holder and bulb from lens assembly.
To install, reverse the preceding operation.
CAUTION: Do not touch the by lb with fingers or any
possibly oily surface, reduced bulb life will result.

FRONT PA R I/TU RN SIGNAL AND SIDE -

MARKER LAMPS— WITH AERO HEADLAMPS
LAMP ASSEMBLY OR B U LB (S )-
REMOVAL AND INSTALLATION
(1) Open hood. (5) Slide lamp assembly outward (Fig. 8).
(2) Remove grille/lamp mounting screw (Fig. 5).

Fig. 8 Lamp Assembly Removal and Installation—

With Aero Type Headlamps
 (6) Remove bulb(s) or lamp assembly (Fig. 9). (3) Slide the lamp assembly forward (Fig. 11). Lamp
is clipped at outboard end.

Fig. 9 Bulb Removal and Installation

To install, reverse the preceding operation.

FRONT PARK/TURN SIGNAL AND SIDE

MARKER LAMPS— WITH SEALED BEAM HEADLAMPS
LAMP ASSEMBLY OR BULB(S)-REMOVAL
AND INSTALLATION
(1) Open hood.
(2) Remove the lamp mounting screw (Fig. 10).
Fig. 11 Front Lamp Assembly Removal and
Installation—With Sealed Beam Headlamps
(4) Remove bulb or lamp assembly.
To install, reverse the preceding operation.

FOG LAMPS
FOG LAMP BULB REMOVAL
AND INSTALLATION
(1) Remove lamp mounting screws (Fig. 12).

Fig. 10 Front Lamp Mounting Screw—

With Sealed Beam Headlamps
 (2) Remove lamp assembly from lamp holder.
(3) Disconnect electrical connectors.
(4) Pinch the spring retainer together (Fig.
release bulb from lamp assembly.

LAMP ASSEMBLY REMOVAL

AND INSTALLATION
(1) Follow steps (1) through (4) of bulb removal
(2) Un-snap the lamp assembly from lower mount­
ing bracket. Lower mounting bracket removal is not
necessary.
To install, reverse the preceding operation.
9I8L-48
LICENSE PLATE LAMP/BULB
Fig. 13 Fog Lamp Bulb Removal and Installation
BULB OR LAMP REMOVAL AND INSTALLATION
To install, reverse the preceding operation.
(1) Remove two lamp mounting screws. Remove lamp/
CAUTION: Do not touch the bulb with fingers or any bulb assembly (Fig. 15).
possibly oily surface, reduced bulb life will result. (2) Separate bulb from lamp assembly.
To install, reverse preceding operation.
REAR TAIL, STOP, TURN SIGNAL, BACK-UP
AND SIDE MARKER LAMPS
BULB REMOVAL AND INSTALLATION
(1) Open rear deck lid.
(2) Remove two screws at top of lamp assembly (Fig.
14).
(3) Tilt lamp assembly from the top (Fig. 14).
(4) Remove bulb(s).
To install, reverse the preceding operation.
LAMP MOUNTING SCREWS 918L-32
CENTER HIGH-MOUNTED STOP LAMP (CHMSL)
BULB OR LAMP ASSEMBLY REMOVAL
AND IN S TA LLA TIO N
(1) Open the rear lift gate.
(2) Remove the lift gate trim covering the CHMSL.
See Group 23, Body.
(3) Rotate bulb socket and remove bulb(s) (Fig.
16).
(4) To remove lamp assembly, remove two lamp
mounting screws (Fig. 16).
To install, reverse the preceding operation.

INTERIOR LAMPS/LAMP SWITCHES

SERVICE PROCEDURES
For removal and installation of instrument panel
lamps and switches, refer to the Switch and Panel
Component Service section in Group 8E, Instrument
Panel and Gauges.
For removal and installation of other interior lamps,
or interior lamp switches, refer to the appropriate
sections of this service manual.
HEADLAMP SWITCH
For service procedures on the headlamp switch, re­
fer to the Switch and Panel Component Service sec­
tion in Group 8E, Instrument Panel. Also refer to
Group 8W, Wiring Diagrams.
HEADLAMP DIMMER SWITCH
The headlamp dimmer switch on all vehicles is in­
corporated in the Turn Indicator Multi-Function switch.
Service procedures can be found in Group 8J, Turn
Signal and Flashers, and Group 8W, Wiring Diagrams.
 DAYTIME RUNNING LAMP MODULE—CANADA ONLY
Operation: When the engine is started and the
headlamp switch is in the OFF position, the high
beam electrical circuit in the headlamps will be acti­
vated. Headlamps will appear approximately 50 per­
cent dimmer than usual.
When the headlamp switch is in the ON position,
lamp operation is normal.
The Daytime Running Lamp Module is located in
the engine compartment to the rear of the right front
strut tower (Fig. 17).
For diagnostics and component relationships, refer
to Group 8W, Wiring Diagrams.

Fig. IF Oaftime Running Lamp Module—Canada Only

REMOVAL A ID INSTALLATION
(1) Locate the Module in the engine compartment
(Fig. 17). Remove attaching screw, disconnect wiring
connector aind remove Module.
To install, reverse the preceding operation.

HEADLAMP TIME DELAY SYSTEM

GENERAL INFORMATION— SYSTEM OPERATION
The Body Controller computer controls the Headlamp
Time Delay system, if equipped.
Operation: By turning off the ignition switch first,
and then turning off the headlamp switch, the Body
Controller will allow the headlamps to remain ON for
60 seconds before they automatically turn off and the
headlamp doors close.
DIAGNOSTIC PROCEDURES
Refer to the PRE-DIAGNOSTIC TEST section of
the appropriate BODY DIAGNOSTIC PROCEDURES
service manual.

ILLUMINATED ENTRY SYSTEM

GENERAL INFORMATION
The Illuminated Entry System actuates the cour­
tesy lamps (except for the illuminated ignition switch)
by lifting either front door exterior handle. Lamp illu­
mination is terminated approximately 30 ±2 seconds
later, or by turning the ignition switch to the run
position, whichever occurs first.
Front door handle switches and the Body Controller
computer are used to control the system. For removal/
installation procedures on the door handles/switches,
refer to Group 23, Body.
DIAGNOSTIC PROCEDURES
For diagnostics, refer to the ILLUMINATED EN-
TRY DIAGNOSIS chart in this section. Also refer to
the ILLUMINATED ENTRY SYSTEM section of the
appropriate BODY DIAGNOSTIC PROCEDURES ser-
vice manual, or see Group 8W, Wiring Diagrams.
 ILLUMINATED ENTRY DIAGNOSIS

ROLL D OW N FRONT W IN D O W S - LIFT O TH ER -

LOCK FRONT DOORS FRONT DOOR HANDLE

COURTESY LAMPS INOPERABLE

WHEN FRONT DOOR HANDLE IS LIFTED CHECK COURTESY LAMP OPERATION
(DOORS STILL CLOSED) WHEN DOOR IS OPEN

IF ILLUMINATED ENTRY
COURTESY LAMP OPERATION OK
SYSTEM N O W OPERATES
CHECK W IRING CONNECTIONS
AND SWITCH OF OTHER DOOR
(SEE GROUP 8, WIRING DIAGRAMS)

YES NO

ILLUMINATED ENTRY SYSTEM

STILL W O N 'T OPERATE
REPAIR COURTESY LAMPS

CHECK FOR 5 VOLTS AT PIN 7

OF 25 WAY (BLUE) CONNECTOR ON REMOVE TRIM PANEL COVER
BODY CONTROLLER-DO NOT DISCONNECT OVER BODY CONTROLLER
BODY CONTROLLER CONNECTOR

CLOSE ALL DOORS—PROVIDE A GROUND

5 VOLTS DlETECTED? YES TO PIN 25 OF 25 WAY (BLUE)
CO N NEC TO R-D O NOT DISCONNECT
BODY CONTROLLER CONNECTOR

NO

DO LAMPS OPERATE?
--------------------- — ........ I

REPLACE BODY CONTROLLER

I I I NO j

CHECK FOR 0 VOLTS AT REPLACE BODY CONTROLLER |

PIN 7 WITH EITHER DOOR HANDLE
LIFTED AND HELD
REPAIR OPEN CIRCUIT FROM
BODY CONTROLLER CONNECTOR
5 VOLTS STILL DETECTED? TO COURTESY LAMPS

YES COURTESY LAMPS REMAIN O N

LONGER THAN 30 + / - 2 SECONDS
WHEN EITHER FRONT DOOR HANDLE
IS LIFTED
DISCONNECT BODY CONTROLLER C O N N E C TO R -
CHECK FOR OPEN AND SHORT CIRCUITS
BETWEEN BODY CONTROLLER CONNECTOR REPLACE BODY CONTROLLER
AND DOOR SWITCHES-ALSO CHECK DOOR
SWITCHES (SEE GROUP 8, W IRING DIAGRAMS)
 HEADLAMP AIMING
GENERAL INFORMATION
Headlamps may be aimed either with mechanical
aimers or by using a screen (Fig. 18).
Use Headlight Aimer (C4466-A) or an equivalent,
and follow the instructions supplied with the equip­
ment for proper headlamp aiming.
The preferred setting is 0 for the horizontal adjust­
ment and 0 for the vertical.
Conventional and halogen headlamp sealed beams
units are physically and electrically interchangeable,
but it is recommended that they not be intermixed on
a given vehicle.
1. HEADLAMP ALIGNMENT SCREEN
HEADLAMP AIMING— PRELIMINARY CHECKS 2. 25 FEET FRO M SCREEN
3. LAMP HORIZ O NTAL CENTERLINE (TAPE)
(1) Test dimmer switch operation.
(2) Observe operation of high beam indicator light
4. RIGHT LAMP VERTICAL CENTERLINE (TAPED)
mounted in instrument cluster. 5. LEFT LAMP VERTICAL CENTERLINE (TAPE)
(3) Inspect for badly rusted or faulty headlamp as­ 6. VEHICLE CENTERLINE
semblies. These conditions must be corrected before a
918L-25
satisfactory adjustment can be made.
(4) Check tire inflation.
(5) Thoroughly clean headlight lenses. Fig. 18 Headlamp Alignment Screen
(6) Check vehicle for any excess baggage, etc.
(7) Measure the distance from the center of headlamp
(7) If gasoline tank is not full, place a weight in rear
to the floor. Transfer this measurement to the screen
of vehicle to simulate weight of a full tank (6-1/2
(with tape) to form a horizontal reference line (Fig.
pounds per gallon).
18) (number 3).
(8) Measure the center-to-center distance between
HEADLAMP/FOG LAMP ADJUSTMENT USING the headlamps. Divide this measurement in half. Trans­
AIMING SCREEN fer this measurement to the screen (with tape) to form
two vertical reference lines (Fig. 18) (numbers 4 and
SETTING UP ALIGNMENT SCREEN
5).
(1) Place vehicle in a darkened area on a known
(9) Turn headlamps on low-beam and cover the
level floor.
headlamps not being aimed. CAUTION: Do not leave
(2) Tape a reference line on the floor 7.62 meters (25
the plastic headlamp lens (if equipped with Aero
feet) away from and parallel to the screen (Fig. 18).
type headlamps) covered longer than necessary. Dam­
(3) Position the vehicle squarely to the screen with
age to lens may result. Rotate top adjusting screw for
the headlamps positioned directly over the taped 25
vertical headlamp adjustment, and side screw for hor­
foot reference line.
izontal adjustment.
(4) Rock vehicle sideways to allow vehicle to assume
The preferred setting is 0 for the horizontal adjust­
its normal position.
ment and 0 for the vertical.
(5) Jounce the front suspension through three oscil-
(10) A properly aimed low beam will appear on the
’ations by applying body weight to bumper.
aiming screen similar to the pattern shown in (Fig.
(6) Tape a vertical reference line (Fig. 18) (number
19).
3) on the screen so it is aligned with centerline of the
vehicle.
 VERTICAL (TAPED) ♦ACCEPTABLE A L IG N M E N T RANG! - (II) A properly aimed fog lamp (up/down adjust­
CENTERLINE AHEAD ALL D I M E N S IO N S ARE M ment) will project a beam pattern on the aiming screen
OF LEFT HEADLAMP IN CH ES AT 2 5 F l i t similar to the pattern shown in (Fig. 20). Each fog
lamp should also be centered (left/right adjustment) to
TOP EDGE OF LAMP
HIGH INTENSITY ZONE. VEHICLE (TAPED) the taped vertical line ahead of each lamp.
MUST BE WITHIN CENTERLINE r _ —_
THIS AREA f VERTICAL CENTER LINE CEtsITER VERTICAL CENTER LINE
AHEAD O f LEFT C>P AHEAD OF RIGHT
FOG LAMP VEHilCLE FOG LAMP
T , HORIZONTAL CENTER
LAMP HORIZONTAL
CENTERLINE (TAPED) LINE OF POGLAMPS
4
INSPECT RIGHT LAMP
SAME AS LEFT

HIGH INTENSITY
AREA 8981-4

LEFT EDGE OF LAMP Fig. 20 Fag Lamp Adjustment Pattern

HIGH INTENSITY ZONE VERTICAL (TAPED) CENTERLINE
MUST BE WITHIN AHEAD O f RIGHT HEADLAMP
THIS AREA
LOW BEAMS ONLY 9181-28

Fig. 19 Aim Inspection Limits—Low Beams

EMTERIOR LAMPS

APPLICATION NUMBER APPLICATION NUMBER

Back-up Lamps . . . . . . . . . . . . . . . . . . . . . . . . . . 921 License Plate Lamp . . . . . . . . . . . . . . . . . . . . . . . . . . 168
Center High Mounted Stop Lamp (CHMSL) . . . . . 921 Front Park/Torn Signal
Fog Lamp. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . H3 (Without Side Marker Lamps) . . . . . . . . . . . . . . . 3157
front Side Marker Lamp . . . . . . . . . . . . . . . . . . . 168 Front Park/Turn Signal/Side
Headlamp Marker Lamps . . . . . . . . . . . . . . . . . . . . . . . . . . 2057
Aero Type . . . . . . . . . . . . . . . . . . . . . . . . . . 9004 Tail/Stop/Turn Signal/Side
Sealed Beam Type . . . . . . . . . . . . . . . . . . . . HP4666 Marker Lamp . . . . . . . . . . . . . . . . . . . . . . . . . . . 3157
or HP6545
 INTERIOR LAMPS

APPLICATION NUMBER APPLICATION NUMBER

DIMMER CONTROLLED LAMPS
A 1C Heater Control . . . . . . . . . . . . . . . . . . . . . . . . . 37 Gear Shift Selector . . . . . . . . . . . . . . . . . . . . . . 73
Ash Receiver . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 37 Headlamp Switch Symbol
Auxiliary Heater . . . . . . . . . . . . . . . . . . . . . . . . . . . 37 (Service at Authorized Service Center)
Cigar Lighter Heater Only Control . . . . . . . . . . . . . . . . . . . . . 158
(See Ash Receiver) Instrument Cluster Illumination . . . . . . . . . . . . . . PC194
Fog Lamp Switch Symbol . . . . . . . . . . . . . . . . . . . . 37 Radio
front W/Wiper Indicator (Service at Authorized Service Center)
(Service at Authorized Service Center) le a r Window Defogger Switch . . . . . . . . . . . . . 5268053
Rear Wiper Switch
(Service at Authorized Service Center)

APPLICATION NUMBER APPLICATION NUMBER

NONDIMMING LAMPS
Dome Lamp . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Door Courtesy Lamp . . . . . . . . . . . . . . . . . . . . . . .
Glove Box. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Ignition Key Lamp
(Service at Authorized Service Center)
front Reading Lamp . . . . . . . . . . . . . . . . . . . . . . .
. 211-2 Liftgate . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 562
. 562 Overhead Console . . . . . . . . . . . . . . . . . . . . . . . 212-2
. 1861 Under Hood Lamp. . . . . . . . . . . . . . . . . . . . . . . 105
Under Seat St orage. . . . . . . . . . . . . . . . . . . . . . 194
Visor Vanity Lamp . . . . . . . . . . . . . . . . . . . . . . . 6501966
. 212-2

9181-42

INTERIOR LAMPS
APPLICATION NUMBER APPLICATION NUMBER
INDICATOR LAMPS
Anti-Lock Brake Indicator . . . . . . . . . . . . . . . . . . . . PC194 High learn Indicator . . . . . . . . . . . . . . . . . . . . . . . PC194
Brake Warning Indicator . . . . . . . . . . . . . . . . . . . . PC194 Low Washer fluid Indicator . . . . . . . . . . . . . . . . . . PC194
Check Engine indicator. . . . . . . . . . . . . . . . . . . . . . PC194 Low Fuel Indicator . . . . . . . . . . . . . . . . . . . . . . . . . PC194
Check Gages I ndicator. . . . . . . . . . . . . . . . . . . . . . PC194 Maintenance Required . . . . . . . . . . . . . . . . . . . . . . 194
Coolant Temp Warning . . . . . . . . . . . . . . . . . . . . . . PC194 Oil Pressure Indicator. . . . . . . . . . . . . . . . . . . . . . . PC194
Door Open Indicator . . . . . . . . . . . . . . . . . . . . . . . PC194 Seat Belt Indicator . . . . . . . . . . . . . . . . . . . . . . . . . . PC194
Gate Open . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . PC 194 Decklid Open Indicator . . . . . . . . . . . . . . . . . . . . . PC194
Hazard . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 194 Turn Signal Indicator . . . . . . . . . . . . . . . . . . . . . . . PC194
 -----------------------------------------------------------RESTRAINT SYSTEM 8M-1

SEAT BELT WARNING SYSTEM

GENERAL INFORMATION
Page Page
CHIME MODULE REPLACEMENT.................. 3 HEADLAMPS LEFT O N ................................ 1
CHIME SYSTEM DIAGNOSIS ....................... 2 HEADLAMP SWITCH REPLACEMENT ............ 3
CHIME WARNING/REMINDER SYSTEM ........ 1 KEY LEFT IN IGNITION .................... .......... 1
CONDITION............................................... 2 PROCEDURE............................................. 2
FASTEN SEAT BELTS.................................. 1 SEAT BELT BUCKLE REPLACEMENT............. 3
CHIME WARNING/REMINDER SYSTEM
The chime warning/reminder system includes sig­
nals for fasten seat belts, headlamps left on and key
left in ignition (Fig. 1).

PU228

Fig. 1 Chime Warning/Reminder System

HEADLAMPS LEFT ON KEY LEFT IN IGNITION

An audible chime tone indicates that headlamps An audible chime tone indicates that key was left in
were left on. ignition.

FASTEN SEAT BELTS HEADLAMPS LEFT ON

The ignition switch must be in the off position for
several minutes before testing the fasten seat belts.
Turn the ignition switch to the ON position with the
driver’s seat belt unbuckled. The seat belt warning
lamp should light for four to eight seconds and the
tone should sound three to five times.
To test the headlamps left on function, turn head­
lamps on with drivers door open. Chime should sound
until headlamps are turned off or drivers door is closed.
KEY LEFT IN IGNITIO N
To test the key left in ignition function, insert key
into the ignition and open drivers door. Chime should
sound until key is removed from ignition or drivers
door is closed.
CHIME SYSTEM DIAGNOSIS
CONDITION
No tone when ignition switch is turned on and driv­ TERMINAL 4 TERMINAL 5
ers seat belt is unbuckled. I GNITIO N SEAT BELT
SWITCH BUCKLE SWITCH
PROCEDURE
(1) Check drive’s seat belt buckle switch for a ground
when unbuckled.
(2) Check for battery feed at terminal 6 and ignition
feed at terminal 4 of chime module (Fig. 2 and 3).
TERMINAL I
KEY, HEADLAMP
TERMINAL DOOR SWITCH
SEAT BELT
WARNING LAMP RP602

Fig. 2 Chime Module Terminal Identification

~RR8M C4

Fig. 3 Chime Module Wiring Diagram

(3) Check for tone in any other function. CONDITION

Fasten seat belt lamp or tone continue for more
CONDITION than ten seconds after seat belts are fastened and
drivers door is closed.
No fasten seat belt lamp when ignition switch is
turned on.
PROCEDURE
(1) Check left door jamb switch.
PROCEDURE (2) Check chime module.
(1) Check for burned out bulb.
(2) Check for battery feed at terminal 6 and lamp CONDITION
output at terminal 3 of chime module. No tone when headlamps are on and drivers door is
(3) Check for ignition feed at terminal 6 of chime open.
module.
PROCEDURE CHIME MODULE REPLACEMENT
(1) Check left door jamb switch for good ground
when drivers door is open. The audible tone generator is located under the
(2) Check wiring connector for good contact at chime lower instrument panel between the radio and steer­
module. ing column (Fig. 4).
(3) Check for battery feed at terminal 6 of chime
module.'
(4) Check headlamp switch.

CONDITION
No tone when key is left in ignition and drivers
door is open.

PROCEDURE
(1) Check left door jamb switch for good ground
when drivers door is open.
(2) Check wiring connector for good contact at chime
module.
(3) Check for battery feed at terminal #6 of chime
module (Fig. 3).
(4) Check key-in switch.

CONDITION
Chimes continue when headlamps are turned off Fig. 4 Chime Module
and/or key is removed from ignition.
HEADLAMP SWITCH REPLACEMENT
PROCEDURE
(1) Check wiring for a grounded condition between Refer to Group 8E, Instrument Panel and Gauges.
headlamp switch, key-in switch and chime module.
(2) Check chime module. SEAT BELT BUCKLE REPLACEMENT
Refer to Group 23, Body.
 REAR WINDOW DEFOGGER
CONTENTS
Page
CONTROL SWITCH/TIMER
RELAY MODULE
CONTROL SWITCH/TIMER
RELAY MODULE T E S T............................
GENERAL INFORMATION............................
GENERAL INFORMATION
The electrically heated rear window defogger (Fig.
1) is available on single rear door wagons and vans.
The system consists of two vertical bus bars and a
series of electrically connected grid lines on the inside
surface of the rear window.
When the switch is turned to the ON position, cur­
rent is directed to the rear window grid lines. The
heated grid lines in turn heat the rear window to
clear the outside surface of the glass.
CAUTION: Since grid lines can be damaged or scraped
off with sharp instruments, care should be taken in
cleaning the glass or removing foreign materials,
decals or stickers. Normal glass cleaning solvents or
hot water used with rags or toweling is recommended.
CONTROL SWITCH/TIMER RELAY MODULE
The control switch and timer relay are integrated
into a control switch mounted assembly. An indicator
lamp illuminates when the switch is activated. Actu­
ating the switch energizes the electronic timing cir­
cuit which allows current to flow through the grid
system for approximately 10 minutes, or until either
the control switch or ignition is turned off. If the
Page
REAR WINDOW GRID LINES TEST ............... 2
1 REPAIR GRID LINES, TERMINALS
AND PIGTAILS ....................................... 3
2 SYSTEM TEST .......................................... 1
1
liftgate release switch is actuated, the power to con­
trol switch is momentarily opened until liftgate switch
is released, but the indicator lamp will stay illuminated.
SYSTEM TEST
Electrically heated rear window defogger operation
can be checked on the vehicle in the following manner:
(1) Turn the ignition ON.
(2) Turn rear window defogger control switch ON.
(3) Using a ammeter on the battery, turn the Defog­
ger control switch to the ON position, a distinct in­
crease in amperage draw should be noted.
(4) The rear window defogger operation can be
checked by feeling the glass. A distinct difference in
temperature between the grid lines and adjacent clear
glass can be detected in 3 to 4 minutes of operation.
(5) Using a DC voltmeter (Fig. 2) contact terminal
B with the negative lead, and terminal A with the
positive lead. The voltmeter should read 10-14 volts.
(6) Only steps (3) and (4) or (5) above will confirm
system operation. Indicator light illumination means
that there is power available at the output of the
relay only, and does not necessarily verify system
operation.
(7) If turning the switch ON produced no distinct
current draw on the ammeter the problem should be
isolated in the following manner:
(a) Confirm that ignition switch is ON.
(b) Ensure that the heated rear window feed pig­
tail is connected to the wiring harness and that the
ground pigtail is in fact grounded.
(c) Ensure that the fusible link or circuit breaker
is operational.
(8) When the above steps have been completed and
the system is still inoperative, one or more of the
following is defective:
(a) Control Switch/Timer Relay Module
(b) Check for loose connector or a wire pushed out
of connector.
(c) Rear window grid lines (all grid lines would
have to be broken, or one of the feed pigtails not
connected to the bus bar, for no ammeter deflection).
(9) If turning the switch ON produces severe volt­
meter deflection, the circuit should be closely checked
for a shorting condition.
 (10) If the system operation has been verified but CONTROL SWITCH/TIMER RELAY MODULE TEST
indicator bulb does not light, replace the switch.
(11) For detailed wiring information, refer to Group Control switch/timer relay module may be tested
8W, Wiring Diagrams. in-vehicle or bench tested. In vehicle testing is accom­
plished in the following manner:
REAR W IN iO W GRID L U E S TEST (1) Remove the switch, relay assembly from the
instrument panel or console, see Group 8E, Instru­
The horizontal grid lines and vertical bus bar lines ment Panel and leave the switch connector plugged in
printed and baked on inside surface of rear window (Fig. 3).
glass comprise an electrical parallel circuit. The elec­
trically conductive lines are composed of a silver ce­
ramic material which when baked on glass becomes
bonded to the glass and is highly resistant to abra­
sion. It is possible, however, that a break may exist or
occur in an individual grid line resulting in no cur­
rent flow through the line. To detect breaks in grid
lines, the following procedure is required:
(1) Turn ignition and control switch ON. The indi­
cator light should come on.
(2) Using a DC voltmeter with 0-15 volt range,contact
vertical bus bar connecting grid lines on passenger
side of vehicle at terminal A (Fig. 2) with negative
lead of voltmeter. With positive lead of voltmeter,
contact vertical bus bar on driver side of vehicle at 7 6 5 4 3 2 1 10 9 8 6 5 4 3 2 1
terminal B (Fig. 2). The voltmeter should read 10-14 918E-2

volts.
Fig. 3 Defogger Switch—Typical

(2) Turn ignition ON.

VOLTMETER (3) Using a DC voltmeter, with 0-15 range, check
voltage at terminals 2, 4 and 1. (Figs. 3 and 4).Termi­
nals 2 and 4 should confirm a voltage of 10 to 14 volts
to ground. Terminal 1 should confirm voltage to ground.
When terminals 2 and 4 show no voltage, trace circuit
upstream of switch/relay module for problem, exam­
ple; wiring cut, fusible link or circuit breaker inopera­
tive, bulkhead connector not operative, etc.. If terminal
1 indicates voltage, place switch in Off position. If
voltage at terminal 1 is still indicated or indicator
lamp remains on, the switch/relay module should be
replaced.

Pig, 2 Grid Line Test

(3) With negative lead of voltmeter, contact a good

body ground point. The voltage reading should not
change. A different reading indicates a poor ground
connection.
(4) Connect negative lead of voltmeter to terminal
A on passenger side bus bar and touch each grid line
at Mid-Point with positive lead. A reading of approxi­
mately 8 volts indicates a line is good. A reading of 0
volts indicates a break in line between Mid-Point C
and terminal B. A reading of 10-14 volts indicates a
break between Mid-Point C and ground terminal A.
Move toward break and voltage will change as soon as
break is crossed.
 SWiTCH/iELAY
PI N 2
FUSE
-T-.
BREAK GRID LINE
TO BATTERY || PIN
p|| 4 (W M n
ON
TQ IGNITION
INDICATING

HEADLAMP 1 / g x „
u
f r n -^
T T
I l.e .d .

ON OFF

PIN 6~
X
PIN 5

POINT "A"
MIDPOINT "C ’
(TYPICAL)
I POINT "B"
GROUND
7
MASKING TAPE PR!509A

CONNECTOR Fig. 5 Grid Line Repair—Typical

(5) Apply conductive epoxy through slit in masking

POWER
CONNECTOR REAR WINDOW GRID LINE STRUCTURE 918N-1
Fig. 4 Systems Electrical Circuit—Typical
(4) If the relay checks out to this point, momentar­ nal from falling off use a wooden wedge to secure it.
ily operate switch to ON position. The indicator lamp
should come on and remain on for approximately 10
minutes. Terminal 1 should confirm voltage. If the
indicator lamp fails to light or voltage at terminal 1 is
not confirmed replace switch/relay module.
Bench checking of the relay may be accomplished in
the following manner. By following the in-vehicle pro­
cedure except Step 2: With a DC power supply, apply
12 volts to terminal 2 and 4 and ground terminal 5.
REPAIR GRID LINES, TERMINALS AND PIGTAILS
The repair of grid lines and replacement of the
terminal is possible using the Mopar Repair Package
or equivalent.
(1) Clean area surrounding grid line or terminal by
gently rubbing area with steel wool.
(2) Wipe area with clean cloth soaked in alcohol or
similar solvent. It is necessary that all contaminants
be removed from repair area.
(3) Remove package separator clamp and mix plas­
tic conductive epoxy thoroughly.
(4) For grid line, mark off area to be repaired with
masking tape (Fig.5).
tape. Overlap both ends of the break.
(6) For a terminal replacement, apply a thin layer
of epoxy to area where terminal was fastened.
(7) Apply a thin layer of epoxy on terminal and
place terminal on desired location. To prevent termi­
(8) Carefully remove masking tape from grid line.
CAUTION: Do not allow the glass surface to exceed
204°C (400°F), glass may fracture.
(9) Allow epoxy to cure 24 hours at room tempera­
ture or use heat gun with a 260°-371°C (500°-700°F)
range for 15 minutes. Hold gun approximately 254mm
(10 inches) from repaired area.
(10) After epoxy is properly cured remove wedge
from terminal and check the operation of the rear
window defogger.
WARNING: REPAIR KIT MAY CAUSE SKIN OR EYE
IRRITATION. CONTAINS EPOXY RESIN AND AMINE
TYPE HARDENER, HARMFUL IF SWALLOWED. AVOID
CONTACT WITH SKIN AND EYES. FOR SKIN, WASH
AFFECTED AREAS WITH SOAP AND WATER. DO
NOT TAKE INTERNALLY. IF TAKEN INTERNALLY,
INDUCE VOMITING; CALL A PHYSICIAN IMMEDI­
ATELY. IF IN CONTACT WITH EYES, FLUSH WITH
PLENTY OF WATER. USE WITH ADEQUATE VENTI­
LATION. DO NOT USE NEAR FIRE OR FLAME. CON­
TENTS CONTAINS 3% FLAMMABLE SOLVENTS.
WARNING: KEEP OUT OF REACH OF CHILDREN.
 POWER LOCKS
CONTENTS
Page
CIRCUIT BREAKER TEST ............................ .. 1
CIRCUIT TEST SLIDING DOOR .................... .. 2
DOOR LATCH WITH INTEGRAL LO CK-
FRONT DOOR........................................ .. 3
ELECTRIC MOTOR TEST ............................ .. 2
GENERAL INFORMATION............................ .. 1
LIFT GATE OPERATION .............................. .. 2
GENERAL INFORMATION
Both front doors and sliding side door, when electri­
cally equipped, can be locked or unlocked electrically
by operating the switch on a front door panel.
All doors can be locked or unlocked mechanically
with the locking knob.
Both front doors and sliding door can be locked or
unlocked mechanically from the outside with the key
or electrically as described above. The both front doors
can also be unlocked by actuation of their respective
inside remote door handle.
The lift gate release consists of a latch with internal
solenoid and push button switch. The solenoid is ener­
gized only when the push button is depressed.
DOOR LOCK IN H IB IT
When the key is in the ignition switch in the ON or
OFF position, with the driver’s door open the Body
Controller will ignore the command to lock the power
door locks. Once the key is removed, or the driver’s
door is closed, the Body Controller will allow the power
door locks to lock.
POWER DOOR LOCKS
When vehicle is equipped with power door locks, the
system includes an automatic door locking feature.
Which is actuated through the vehicle’s body control­
ler. To activate the power locks, the controller must
receive signals from the door ajar switches at all four
doors closed. The distance sensor shows that the vehi­
cle speed exceeding 15 mph. The transmission pres­
sure switch shows that the throttle is open 10 percent
or more. If any one of these conditions is not met, the
power locks will not function automatically. The power
lock motors are also equipped with a thermal protec­
tion system which prevents the motors from burning
out. The motors may chatter if they are continuously
activated.
The sliding door can be locked or unlocked electri­
cally when the door is closed. The sliding door can
also be locked electrically when the door is open as
Page
LOCK MOTOR REPLACEMENT
LIFTGATE DOOR 4
LOCK MOTOR REPLACEMENT
SLIDING DOOR 3
POWER DOOR LOCKS 1
SWITCH TEST 1
SWITCH VOLTAGE TEST 1
follows: By activating the power lock switch to the
lock position while door is open, and the key is not in
the ignition switch. The front doors will lock and send
a signal to the body controller to lock the sliding door
upon closing.
SWITCH VOLTAGE TEST
The following wiring test sequence determines
whether or not voltage is continuous through the body
harness to switch.
(1) After removing switch from trim panel for test­
ing purposes, carefully separate multiple terminal block
on wiring harness from switch body. Connect one lead
of test light to black wire terminal and touch other
test light lead to red wire terminal. If the test light
comes on, the wiring circuit between the battery and
switch is functional. If light does not come on, check
30 amp circuit breaker or for a open circuit.
CIRCUIT BREAKER TEST
Find correct circuit breaker on fuse block. Pull out
slightly but be sure that circuit breaker terminals
still contact terminals in fuse block. Connect ground
wire of voltmeter to a good ground. With probe of
voltmeter positive wire, check both terminals of cir­
cuit breaker for 12 volts. If only one terminal checks
at 12 volts, circuit breaker is defective and must be
replaced. If neither terminal shows 12 volts, check for
open or shorted circuit to circuit breaker.
SWITCH TEST
For switch testing, remove the switch from its mount­
ing location. Using an ohmmeter, refer to (Fig. 1) to
determine if continuity is correct in the Lock and
Unlock switch positions. If these results are not ob­
tained, replace the switch.
 NEGATIVE POSITIVE

SWITCH CONTINUITY
POSITION BETWEEN
PINS 1 & 4
O ff
PINS 2 &

PINS 3 & 4
UNLOCK
PINS 2 &

PINS 2 1 3
LOCK
PINS 1 &

PIN SIDE OF SWITCH

Fig. 1 Door Lock Switch Continuity

CIRCUIT TEST SLIDING DOOR

Conned one lead of a test light to the upper contact
on the B—pillar and the other lead to the lower con­
tact. If the test light comes on when the lock switch is Pig, 2 Sliding Door lock Motor
depressed, the wiring circuit to the contacts is good. If
the test light does not come on, perform the circuit
breaker test, check connectors at the right side cowl,
or check for a broken wire.
With the sliding door partially open, connect jumper
wires from contacts on door to contacts on B—pillar.
Connecting these contacts should lock or unlock door
when switch is depressed.
If lock and unlock occurs, the fault is at the door
and pillar switch contacts. Check for proper shim at
door contact plate. If lock and unlock does not occur,
remove door trim panel and check for voltage at motor
connector.

ELECTRIC MOTOR TEST

Make certain battery is in normal condition before
circuits are tested.
To determine which motor is faulty, check each
individual door for electrical lock and unlock or dis­
connect the motor connectors one at a time, while
operating the door lock switch. In the event that none
of the motors work, the problem maybe caused by a
shorted motor, or a bad switch. Disconnecting the Pig. 3 Front Door Lock Motor
defective motor will allow the others to work.
To test an individual door lock motor, disconnect
LIFT S IT E OPERATION
the electrical connector from the motor. To lock the
TEST
door, connect a 12 volt power source to the positive
(1) Confirm solenoid lead wire is connected and 10
pin of the lock motor and a ground wire to the other
volts or more are available at solenoid (Fig. 4).
pin (Fig. 2, and 3). To unlock the door reverse the wire
connections at the motor pin terminals. If these re­
sults are NOT obtained, replace the motor.
 (2) Provide proper ground through latch mounting
screws.
(3) Remove latch and examine plunger, to insure it
is undamaged and properly attached, the plunger should
spring back when pressed.
(4) Insure that solenoid plunger travel is adequate
approximately 16 mm (0.625 in.).
ADJUSTMENT
Adjust lift gate latch and striker so that liftgate
latches with a moderate slam. Should latch fail to
lock, replace latch assembly.
With ignition switch in ON or ACCESSORY posi­
tion, push lift gate switch to a ensure proper operation.
DOOR LATCH WITH INTEGRAL LOCK— FRONT DOOR
REMOVAL
(1) Remove inside door release handle, window reg­
ulator handle and door trim panel.
(2) Roll door watershield away from lower rear cor­
ner of door to reveal inside panel access opening.
(3) Disconnect latch links and remove door latch
with integral lock motor (Fig. 5).
Fig. 5 Front Door Assembly
(4) Disconnect motor from wiring harness.
(5) Remove motor mounting bracket screws and re­
move motor assembly from mounting.
INSTALLATION
(1) Connect motor link at latch and connect wires.
(2) Attach motor to door inside panel and install
screws.
(3) Reset watershield at lower rear comer of door.
(4) Install window regulator handle, door inside re­
lease handle bezel and door trim panel.
LOCK MOTOR REPLACEMENT SLIDING DOOR
REMOVAL
(1) Remove two inside handle bezel screws.
(2) Remove complete door trim panel.
(3) Remove motor link at locking lever.
(4) Disconnect motor power connector.
(5) Remove motor mounting screws and motor from
door.
INSTALLATION
(1) Attach motor to control assembly plate and in­
stall pop rivets.
(2) Connect motor link to locking lever and connect
motor power connector.
(3) Install door trim panel and inside handle bezel.
 LOCK MOTOR REPLACEMENT LIFTGATE DOOR
REMOVAL
(1) Remove liftgate trim panel
(2) Remove motor link at locking lever.
(3) Disconnect motor power connector.
(4) Remove motor mounting screws and motor from
door.

INSTALLATION
(1) Install motor, torque screws to 3 N-m (25 in. lbs.).
(2) Connect motor link to locking lever and connect
motor power connector.
(3) Install door trim panel.

Fig. 6 Sliding Side Door Wiring and

Component Identification
 POWER SEATS
CONTENTS
ADJUSTER ............................................... ...3
CIRCUIT BREAKER TEST ............................ ...1
GENERAL INFORMATION............................ ...1
HARNESS VOLTAGE T E S T .............................. 1
HORIZONTAL AND VERTICAL
TRANSMISSIONS ................................... ... 3
GENERAL INFORMATION
Driver’s power seat can be adjusted in six different
directions up, down, forward, back, tilt forward, or tilt
rearward.
A three arm ature permanent magnet reversible mo­
tor is coupled through cables to worm gear box assem­
blies located in the seat tracks, providing the various
seat movements.
The electrical circuit is protected by a 30 amp cir­
cuit breaker located on the fuse block.
Page
MOTOR.................................................... 3
MOTOR CABLE AND HOUSING .................... 2
MOTOR TESTS .......................................... 1
SEAT ASSEMBLY ....................................... 2
SWITCH TEST ............................................... 2
TEST PROCEDURES................................... 1
(2) Connect one lead of test light to ground termi­
nal, black wire (BK) of center section, and touch other
test light lead to red wire (RD) terminal.
(3) If test light comes on, harness to switch is good.
If test light does not come on, perform circuit breaker
test.
MOTOR TESTS
(1) Remove switch from mounting position and dis­
connect from harness (Fig. 1).

TEST PR O C E iU R E S
Before any testing is attempted the battery should
be carefully charged and all connections and term i­
nals cleaned and tightened to insure proper continuity
and grounds.
With dome lamp on, apply switch in direction of
failure. If dome lamp dims the seat motion is trying to
work indicating mechanical jamming. If dome lamp
does not dim, then proceed with the following electri-
cal tests. MOTOR INSULATOR POLARITY
+ POLARITY - POLARITY SEAT MOVEMENT
CIRCUIT B R E M E R TEST PIN 3 PIN 8 FOtWARD
PIN 8 PIN 3 tEARWARP
Find correct circuit breaker on fuse block. Pull out PIN 5 PIN 6 REAR UP
slightly but be sure th at circuit breaker terminals PIN 6 PIN 5 REAR DOWN
still contact terminals in fuse block. Connect ground PIN 1 PIN 2 FRONT UP
wire of voltmeter to a good ground. With probe of PIN 2 PIN 1 FRONT DOWN
voltmeter positive wire, check both terminals of cir­ PIN 4 — FEED
cuit breaker for battery voltage. If only one terminal PIN ? G iO U N D
checks at battery voltage, circuit breaker is defective 918R-2
and must be replaced. If neither terminal shows bat­
tery voltage, check for open or shorted circuit to cir­ Fig. 1 Power Seat Switch Connector
cuit breaker.
(2) To check the front motor, connect a covered
jumper wire between cavity number 2 and cavity num­
HARNESS VOLTAGE TEST ber 9. Connect a second jumper wire between cavity
number 6 and cavity number 5. If the motor does not
The following test will determine whether or not
operate, reverse the jumpers (2 to 5 and 6 to 9). If
voltage is continuous through the body harness to the
motor still does not operate check wiring between
switch.
switch connector and motor assembly. If wiring checks
(1) Remove power seat switch from mounting posi­
good replace motor assembly.
tion and disconnect switch from wiring harness.
 SWITCH POSITION CONTINUITY BETWEEN •

B-N, B-J, B-M, FORWARD/AFT — ►

OFF
B-E, B-L
UP

VERTICAL UP B-M# B-E, A -N # A-J

VERTICAL DOWN B~N# B-J, A-M, A-E

HORIZONTAL FORWARD B-K, A-L

HORIZONTAL AFT B-L, A-K

FRONT TILT UP B-M# A-N

FRONT TILT DOWN B-N, A-M TERMINALS SHOWN AS VIEWED

FiOM REAR O f SWITCH
REAR TiLI UP B-E, A-J

REAR TILT DOWN B-J, A-E

9081-5

Fig. 2 Switch Continuity

(3) To check the center motor, connect a covered
jumper wire between cavity number 2 and cavity num­
ber 8. Connect a second jumper wire between cavity 6
and cavity number ?. If the motor does not operate,
reverse the jumpers (2 to 7 and 8 to 8). If motor still
does not operate check wiring between switch connec­
tor and motor assembly. If wiring checks good replace
motor assembly.
(4) To check the rear motor, connect a covered jumper
between cavity number 2 and cavity number 10. Con­
nect a second jumper wire between cavity number 6
and cavity number 3. If the motor does not operate,
reverse the jumpers (2 to 8 and 6 to 10). If motor still
does not operate, check wiring between switch connec­
tor and motor assembly. If wiring checks good replace
motor assembly.
(5) To check the seatback recliner motor (if equipped),
connect a covered jumper wire be tween cavity num­
ber 2 and cavity number 1. Connect a second jumper
wire between cavity number 6 and cavity number 11.
If the motor does not operate, reverse the jumpers (2
to 11 and 6 to 1). If motor still does not operate check
wiring be tween switch connector and .-motor assem­
bly. If wiring checks good replace motor assembly.
(8) If all motors and the seat operate properly, per­
form Switch Test.
SWITCH TEST
To check the switch, remove the switch from its
mounting position. Using an ohmmeter, and referring
to the Switch Continuity, determine if continuity is
correct. If there is no continuity at any one of the
switch positions, replace the switch.
SEAT ASSEMBLY
m m ow M L
(1) Remove adjuster attaching bolts and nuts from
floor pan. Move adjuster as required for access.
(2) Disconnect battery ground cable.
(3) Disconnect wiring harness power lead at carpet.
(4) Remove assembly from vehicle.
INSTALLATION
(1) Position seat assembly in vehicle.
(2) Connect wiring harness.
(3) Install and tighten mounting bolts and nuts.
(4) Connect battery ground cable and check seat
operation.
MOTOR CABLE AND HOUSING
REMOVAL
It is recommended that anytime a cable is to be
replaced th at the motor assembly be removed also for
ease of replacement.
(1) After motor has been disconnected, remove corbin
clamp from cable housing.
(2) Remove cables from motor by removing two screws
from bracket, then slide cables out of motor.
INSTALLATION
(1) Insert cable and housing into bracket and install
corbin clamp.
(2) Synchronize left and right hand adjuster positions,
(3) Position cables in motor with bracket in posi­
tion, then secure with two screws.
(4) Install motor assembly.
HORIZONTAL A ID VERTICAL TRANSMISSIONS
Transmissions are not removable and no m ainte­
nance is required. If transmission fails replace entire
seat adjuster assembly.
ADJUSTER
REMOVAL
(1) Remove seat assembly from vehicle following
procedure outlined under Seat Assembly Removal.
(2) Lay seat on its back on a clean surface.
(3) Remove bolts attaching adjuster to seat assembly.
(4) Disconnect wiring harness at switch if seat
mounted switch is used.
INSTALLATION
(1) Lay seat on its back on a clean surface.
(2) Position adjuster to seat assembly and install
attaching bolts.
(3) Connect wiring harness at switch.
(4) Install seat assembly following procedure out­
lined under Seat Assembly Installation.
MOTOR
REM OVAL
Anytime the motor, cable and housing assemblies,
or vertical and horizontal transmission assemblies,
require maintenance, the assemblies must be synchro­
nized to insure easy and proper operation.
(1) Remove seat assembly from vehicle following
procedure outlined under Seat Assembly Removal.
(2) Lay seat on its back on a clean surface.
(8) Remove motor mounting screws.
(4) Carefully disconnect housing and cables from
motor assembly.
INSTALLATION
(1) Place motor assembly into position.
(2) Carefully connect cables and housings to motor
assembly.
(3) Install mounting screws.
(4) Install bolt holding motor assembly to adjuster.
(5) Install seat assembly following procedure out­
lined under Seat Assembly Installation.
 POWER WINDOWS
CONTENTS
Page Page
GENERAL INFORMATION . . . . . . . . . . . . . . . . . . 1 SERVICE PROCEDURES . . . . . . . . . . . . . . . . . . . 3
POWER VENT W INDOWS . . . . . . . . . . . . . . . . . 3 TEST PROCEDURES . . . . . . . . . . . . . . . . . . . . . . 1
GENERAL INFORMATION
Window lift motors are of the permanent" magnet It is necessary that the window be free to slide up
type. A positive and negative battery connection to and down in the glass channels or tubes and tracks. If
either of the two motor terminals will cause the motor the window is not free to move up and down, the
to rotate in one direction. Reversing current through window lift motor will not be able to move the glass.
these same two connections will cause the motor to To determine if the glass is free is to disconnect the
rotate in the opposite direction. electric window regulator lift plate from the glass
Each individual motor is grounded through the mas­ (Fig. 1) and then slide the window up and down by
ter switch by a black wire attached to the left cowl hand.
panel.
POWER. WINDOW WINDOW
MOTOR AND REGULATOI
MOTOR AND GLASS
RETAINING RIVETS
REGULATOR

PLATE
RETAINING
NUT

WINDOW
LIFT PLATE

VIEW IH DIRECTION
OF ARROW W

RP769

Fig. I Power Window Regulator

TEST PROCEDURES.
SWITCH VOLTAGE TEST
The following wiring test sequence determines
whether or not voltage is continuous through the body
harness to switch.
(1) After removing switch from trim panel for test­
ing purposes, carefully separate multiple terminal block
on wiring harness from switch body. Connect one lead
of test light to black wire terminal and touch other
test light lead to tan wire terminal. If the test light
comes on, the wiring circuit between the battery and
switch is functional. If light does not come on, check
30 amp circuit breaker or for a broken wire.
SWITCH TEST
To check the switch, remove the switch from its
mounting position. Using an ohmmeter, and referring
to the Switch Continuity (Figs. 2 and 3), determine if
continuity is correct. If there is no continuity at any
one of the switch positions, replace the switch.
 WINDOW LIFT MOTOR TEST
(1) Connect positive (+ ) lead from a test battery to
either of the two motor terminals.
(2) Connect negative (-) lead from test battery to
remaining motor terminal.
(3) The motor should now rotate in one direction to
either move window up or down.
(a) If window happens to already be in full UP
PIN IDENTIFICATION PIN SIDE OF SWITCH
position and motor is connected so as to rotate in UP
SWITCH
direction no movement will be observed.
CONTINUITY BETWEEN
POSITION (b) Likewise, motor connected to DOWN direction
OFF
PINS 1 AND 2 PINS 2 AND 4 rotation, no movement will be observed if window is
PINS 2 AND 3 PINS 2 AND 6 already in M l down position.
A PINS 1 AND 5 PINS 2 AND 4 (4) Reverse battery leads (steps 1 and 2) and win­
dow should now move. If window does not move, re­
1 PINS 1 AND 2 PINS 4 AND 5 move motor. See below for motor removal from vehicle.
(5) If window moved completely up or down, motor
C PINS 3 AND 5 PINS 2 AND 6
should be reversed one more time (step 4) to complete
D PINS 5 AND 6 PINS 2 AND 3 a full window travel inspection.
918S-3

Fig. 2 Master Switch Continuity

SWITCH
POSITION BETWEEN

OFF PINS

A PINS 3 & 4
PINS 2 & 5

1 PINS 2 & 3
PINS 1 I 4

PIN IDENTIFICATION
PIN SIDE OF SWITCH

918S-2

Fig. 3 Front Door Window or Wear Vent Window

Switch Continuity
 SERVICE PROCEDURES
GEAR AND PINION REPLACEMENT
AND LUBRICATION
The window glass and mechanism is moving freely.
The window motor works, but the glass does not move
up or down. Replace the motor gear and pinion.
When gear and pinion assembly is replaced in gear
box, lubrication of gear box, gear pinion and seal is
necessary if these parts have been disassembled.
In the event there is no lubricant in gear box, fill
with MOPAR multi-mileage lubricant or equivalent.
Apply a liberal amount of lubricant to inside area of
seal and sealing surface at center area of gear and
pinion coupling. Also lubricate center gearbox shaft
and worm gear as shown in (Fig. 4).
MOTOR AND REGULATOR REPLACEMENT
REMOVAL AND INSTALLATION
(1) Raise or lower window to the proper access hole
position and remove screw that attaches the flex rack
to the drive arm (Fig. 1).
(2) Remove the regulator attaching rivets by knock­
ing out the rivet center mandrel and drilling rivet
with a 1/4 inch diameter drill.
POWER VENT WINDOWS
GENERAL INFORMATION
AS-body vehicles have, as an option, power rear
vent windows. The windows are operated by switches
mounted in the overhead console. A separate switch is
used for each of the windows.
The vent window motors are of the permanent mag­
net type. A positive and negative battery connection
to either of the two motor terminals will cause the
motor to rotate in one direction. Reversing current
through these same two connections will cause the
motor to rotate in the opposite direction.
SWITCH TEST
For power vent window switch testing, see power
windows Switch Test.
VENT WINDOW MOTOR TEST
(1) Connect positive (+ Head from a test battery to
either of the two motor terminals.
(2) Connect negative (-) lead from test battery to
remaining motor terminal.
(3) The motor should now rotate in one direction to
either move the window OPEN or CLOSED.
WORM POWER WINDOW
GEAR MOTOR
ASSEMBLY
GEAR BOX
SHAFT
GEAR BOX
SEAL
GEAR AND
PINION RP770
Fig. 4 Motor Gearbox Lubrication
(3) Maneuver the motor end of the flex drive regula­
tor outside of the large inside panel access hole and
rotate regulator out of door.
(4) For installation reverse above procedures.
(a) If window happens to already be in the full
CLOSED position and motor is connected to rotate
towards the CLOSED position no movement will be
observed.
(b) Likewise, motor connected to rotate OPEN, no
movement will be observed if the window is already in
full OPEN position.
(4) Reverse battery leads (opposite steps 1 and 2)
and window should now move, or move in the opposite
direction. If window does not move, remove motor and
cable assembly.
(5) If window moved completely OPEN and CLOSED,
motor should be reversed one more time (reverse leads
from step 4) to complete a full window movement
inspection.
CABLE AND CRANK MECHANISM
REMOVAL
(1) Remove windshield side garnish molding.
(2) Remove rear seat(s).
(3) Remove front door and liftgate scuff plates.
(4) If servicing right side cable, remove side door
scuff plate and upper track cover.
(5) Remove B-pillar garnish molding and seat belt.
(6) Remove upper and lower trim panels for the left
side or one piece trim panel for the right side.
 CRANK LEFT SIDE QUARTER RIGHT SIDE
MECHANISM PANELS

MOTORS 898S-9

Fig. 5 Motor and Cable Assemblies

(7) Remove two bolts attaching crank mechanism to
quarter panel (Fig. 5).
(8) Remove three screws attaching cable to motor.
(9) Disengage pivot from quarter glass.
(10) Remove cable retaining clip and remove cable
assembly.
INSTALLATION
(1) Position cable to motor making sure cable pulley
engages with motor and install three screws (Fig. 6). cover.
CONNECTOR
MOTOR
(2) Engage pivot to quarter glass.
(3) Install crank mechanism bolts and pull mecha­
nism rearward while tightening (Proper alignment is
required for smooth non-binding operation).
(4) Install cable retaining clip.
(5) Install upper and lower trim panels for the left
side or one piece trim panel right side.
(6) Install B pillar garnish molding and seat belt.
(7) Install side door scuff plate and upper track
(8) Install front door scuff plate, liftgate scuff plate,
rear seat(s) and windshield side garnish molding.

MOTOR REPLACEMENT
The following procedure describes replacement of a
defective motor without removing the cable assembly
from the vehicle.

REMOVAL
(1) Remove rear quarter trim panel.
(2) Disconnect wiring connector.
(3) Remove three screws attaching motor to cable
(Fig. 6).
BRACKET (4) Remove two bolts attaching motor bracket to
BOLTS 898S-10 quarter panel.
(5) Remove motor.
IN ST A L L A T IO N (2) Install motor bracket to quarter panel bolts.
(1) Position motor to cable assembly making sure (3) Connect wiring connector,
cable pulley engages with motor and install three (4) Install rear quarter trim panel,
screws.
 POWER MIRRORS
CONTENTS
Page Page
GENERAL INFORMATION............................ 1 MIRROR MOTOR TEST .............................. 1
HEATED M IRROR...................................... 1 MIRROR SWITCH REPLACEMENT................. 2
MIRROR ASSEMBLY REPLACEMENT ............ 2 MIRROR SWITCH TE S T.............................. 1
GENERAL INFORMATION (4) If results shown in chart are not obtained, check
for broken or shorted circuit, or replace mirror assem­
Electrically-operated remote control mirrors are avail­ bly as necessary.
able as an option on AS-body vehicles. The mirrors
are controlled by a single switch assembly located on MIRROR SWITCH TEST
the driver’s door mirror trim bezel.
AS-body vehicles use a toggle-type switch which (1) Remove power mirror switch from mounting
is rotated clockwise (Right mirror) or counterclock­ position.
wise (Left mirror) for mirror selection, and moved (2) Disconnect wiring harness at switch connector.
UP, DOWN, RIGHT, or LEFT for mirror movement (3) Using a ohmmeter, test for continuity between
direction. the terminals of the switch as shown in the Mirror
The motors which operate the mirrors are part of Switch Continuity Chart (Fig. 2).
the mirror assembly and cannot be serviced separately.
MIRROR SWITCH CONTINUITY
MIRROR MOTOR TEST M irror S electo r K n o b In "L" Position
MOVE LEVER CONTINUITY ill.W1I9I
(1) Remove door trim panel. Refer to Group 23,
PINS 3 AND 8
Body. ▲ PINS 1 AND 4
(2) Disconnect wiring harness connector to the Power 12 3 4
PINS 3 AND 2
Mirror. ► PINS 7 AND 4
(3) Using two jumper wires, one connected to a PINS 3 AND 1
12-volt source, and the other connected to a good body ▼ PINS i AND 4
ground, refer to the Mirror Test Chart for wire hook­ PINS 3 AND 7
PINS 2 AND 4
ups at the switch connector (Fig. 1).
M i r r o r S electo r K n o b In " I ” P osition
5 6 7 8 MOVE LEVER CONTINUITY 19991991
MIRROR TEST PINS 3 AND 8
SWITCH COMMECTOi ▲ PINS 5 AND 4
MIRROR t l ACTIOM PINS 3 AND 6
► PINS 7 AND 4
I t Volts G r o u n d Right Loft
PIN 5 PIN 8 UP PINS 3 AND 5
▼ PINS 8 AND 4
PIN 5 PIN 4 UP
PINS 3 AND 7
PIN 8 PIN 5 DOWN 4 PINS 6 AND 4
PIN 4 PIN 5 DOWN 918T-9
PIN 7 PIN 6 RIGHT
PIN 3 PIN 6 RIGHT Fig. 2 Mirror Switch Test
PIN 6 PIN 7 LEFT
PIN 6 PIN 3 LEFT If results shown in the chart are not obtained, re­
DOOR COMMICTO 1 place the switch.
12 V olt* G r o u n d
PIN 4 PIN 2 UP HEATED MIRROR
PIN 2 PiN 4 DOWN
PIN 6 PIN 5 RIGHT Heated mirrors are available with Power Mirrors
PIN 5 PIN 6 LEFT and Rear Window Defogger only. The heated mirror is
PIN 1 PIN 3 ATER controlled by the rear window defogger switch. The
918T-2 heated mirror is on when the rear window defogger is
on.
TEST PROCEDURES
(1) The mirror should be warm to the touch.
(a) If not check fuses.
(b) Test voltage at rear window defogger switch.
• If no voltage repair wire.
• Apply voltage to one wire and ground the other,
refer to Fig. 1 for pin numbers. Mirror should become
warm to the touch.
• If not remove mirror glass and test the wires for
continuity. If no continuity repair wires.
• If wires are OK, replace mirror glass.
• To test defogger switch refer to Group 8N, Rear
Window Defogger.
MIRROR ASSEMBLY REPLACEMENT
(1) Remove door trim panel and weather shield.
Refer to Group 23, Body.
(2) Reach inside door and disconnect mirror wiring
at connector.
(3) Remove two mirror trim bezel retaining screws,
and pull bezel away from door (Fig. 3).
(4) Remove three mirror retaining nuts.
(5) Pull mirror loose from door, and feed wiring
harness out through hole in outer door panel.
(6) For installation, reverse above procedures.

MIRROR SWITCH REPLACEMENT

(1) Remove driver’s door trim panel and weather
shield. Refer to Group 23, Body.
(2) Reach inside door and disconnect mirror switch
connector.
(3) Remove mirror control knob from switch.
(4) Remove two mirror trim bezel retaining screws.
(5) Pull bezel loose from door and loosen alien-head
lock screw on back side of bezel (Fig. 3).

Fig. 3 Power Mirror

(6) Remove switch from bezel.

(7) For installation, reverse above procedures.
 WIRING DIAGRAMS
GENERAL INFORMATION
INDEX
Page Page
Connectors ........................................................................ ... 3 Main Circuit Identification .............................................. 2
Distributor Secondary W irin g ......................................... ... 1 Splice Locations .............................................................. ... 3
Fusible L ink Replacement ............................................. ... 4 Symbols, Fuses and Abbreviations ............................... ... 5
Fusible Links .................................................................... ... 4 Wire Code Identification......................................................2
Locating A System or Com ponent................................. ... 3 Wiring Repair .................................................................... ....4

The wiring diagrams contain the latest information SPARK TERMINAL SPARK TERMINALS TERMINAL PATH
at the time of publication.
Throughout this group references may be made to a
particular vehicle by letter or number designation. A
chart showing the breakdown of these designations is
included in the Introduction Section at the front of
this service manual.

DISTRIBUTOR SECONDARY WIRING

Distributor secondary wiring is shown in Figures 1,
2, 3, and 4. For additional information on distributor
operation refer to the appropriate section of the ser­
vice manual.

WIRE TOWER
FIRING ORDER 1-2 3-4-5-6 AND NUMBER
ROTOR COUNTERCLOCKWISE ROTATION
DISTRIBUTOR CAP VIEWED FROM TOP RR8WH15

Fig. 2 Distributor Cap 3.0L V6 Engine

FIRING ORDER-1-3-4-2
DISTRIBUTOR-CLOCKWISE ROTATION RP31

Fig. 1 Distributor Secondary Wiring 2.SL Engine

 S I AMD A ID STANDARD
com m COLOR COLOR
CCM91 TRACER COLOR TRACER
CODE
COLOR CODE

Bl BLUE WI OR ORANGE BK

BK BLACK WI PK PINK BK OR WT

BR BROWN WI RD RED WT

Di DARK WI IN TAN WT
BLUE

DG DARK WT ¥1 VIOLET WT
GREEN

GY GRAY BK WT WHITE BK

Li LIGHT BK YL YELLOW BK
BLUE

LG LIGHT BK * WITH TRACER

GREEN

908W-190 918W-136

Fig. 4 Ignition System Secondary Wiring Pig. § Wire Color Code Chart
3.3L V6 Engine
MAIN CIRCUIT IDENTIFICATION
WIRE CODE IDENTIFICATION
To identify which main circuit code applies to a
Each wire shown in the diagrams contains a code system, refer to the Main Circuit Identification Code
(Fig. 5) which identifies the main circuit, part of the Chart. This chart shows the main feed circuits only
main circuit, gauge of wire, and color. The color is and does not show the secondary codes th at apply to
shown as a two letter code which can be identified by some vehicles.
referring to the Wire Color Code Chart (Fig. 6). If the
wire has a tracer and it is a standard color an asterisk
will follow the main wire color. If the tracer is Ban-
standard the main wire color will have a slash (/) after
it followed by the tracer color.

18 LR/YL*

COLOR O F WIRE
(Light H u e with Yellow Tracer)

. GAUGE O F WIRE
(18 G a uge )

PART O F MAIN CIRCUIT

(Varies D epending on Equipment)

• MAIN CIRCUIT IDENTIFICATION

918W-16
 UN CIRCUIT ID_.
a i B attery Positive Circuit.
A2 Battery Negative Circuit.
B Back Up Lamp Circuit.
B3 Hazard Warning Flasher Feed.
C Air Conditioning and Heater Circuits, Heated
Rear Window, Radiator Fan Motor.
D Emergency, Stop Lamp and Turn Signal Circuits,
Lamp Outage, Brake Pad Sensor, Diagnostic
Connector.
1 Instrument Panel Cluster, Switches and
Illumination Circuits.
F Power Assist Systems, Seats, Windows, and
Door Locks.
G Gauges, Warning- Lamp Circuits and Voice
Alert.
H Horn Circuit.
J1 Ignition Switch Feed Circuit.
J2 Ignition System Run Circuit.
J3 Starter Relay to Ballast Resistor.
J1§ Ignition Switch Accessory Feed.
K Logic and Power M o du les.
LOCATING A SYSTEM OR COMPONENT
In order to locate a system or component in the
diagrams refer to the alphabetical index at the front
of the diagrams to determine the diagram sheet
number.
Sheet numbers are located at the lower right or left
hand corner of each sheet. Page numbers at the top
of the page do not apply to diagram sheets.
When looking for a components location refer to the
wiring and components section.
SPLICE LOCATIONS
Splice locations are indicated in the diagrams by a
diamond with a splice circuit code within it (Fig.7
example 1). If there is more than one splice per circuit
a small box will be connected to it with the splice
number in it (Fig. 7 example 2). In order to locate a
particular splice in the wiring harness determine the
splice number from the wiring diagrams then refer to
the splice location index.
L Lighting Circuit feed (Exterior Lamps).
Ml Lighting Circuit feed (interior Lamps).
M2 Lighting Circuit Ground (Interior Lamps).
P Brake Checking Circuit.
G2 Accessory Buss Bar Feed (Fuse Block).
Q 3 Battery Buss Bar Feed (Feed).
1 3 Alternator Circuit to Electronic Regulator (Field).
1 6 Alternator Circuit Feed.
S Starter Motor and Starter Relay Circuit.
T Tachometer.
V Windshield Wiper and Washer Circuit.
W Power Window Circuit.
X Grounds For Radio Speakers, Cigar Lighter,
Lamps, Clock, Speed Control, Power Antenna,
Power Amplifier, Power Windows, Power
Mirrors, Deck Lid Release and Doqr Locks.
¥ 5 EFI or Turbo Ground.
21 Turbo Fuel Injectors EFI and Turbo Ignition Coil
.and Fuel Pump Motor.
908W-223
<8> <3s
EXAMPLE 1 EXAMPLE 2
918W-18
Fig. 7 Wiring Splice Examples
CONNECTORS
The connectors shown in the diagram sheets are
viewed from the terminal end unless otherwise speci­
fied. For viewing bulkhead, engine controller, and trans­
mission controller connectors refer to the back of the
wiring diagrams.
FUSIBLE LINKS (6) Allow to cool and wrap the new splice with a
minimum of 3 layers of electrical tape.
Vehicle wiring harnesses are equipped with fusible (7) Remove 1 inch of insulation from the remaining
links to protect against harness damage in the event end of the new fusible link and the existing wire.
of a short in the system. Fusible links are color coded (8) Solder the connection using rosin core type solder.
to indicate wire gauge and size. Refer to the fusible (9) Allow to cool and wrap the connection with a
link chart for color and gauge identification (Fig. 8). minimum of three layers of electrical tape.
(10) Tie wrap the new fusible link to the existing
W ire an d G au g e Color Code C o lo r ones to prevent chafing or damage to the insulation
Black
from vibration.
12 Ga. SK

14 G a . RD Red BLOWN FUSIBLE LINK-7. CUT OFF HERE

CUT OFF HERE

16 G a . DB D ark Blue

18 G a . GY G ra y

20 G a . Oi O range MAIN HARNESS

WT W hite
STRIP ONE INCH INSTALL ANY STRIP ONE INCH
918W-19
OF INSULATION EXISTING OF INSULATION
FROM BOTH WIRES TIE WRAPS FROM BOTH WIRES
Fig. 8 Fusible Link Chart

FUSIBLE LINK REPLACEMENT

CAUTION: Do not replace blown fusible links with a
standard wire. Only use fusible type wire with
hypalon insulation or damage to the electrical sys­
tem could occur. Also make sure correct gauge of
wiring is used. Refer to the wiring diagrams for proper Fig. 9 Fusible Link Repair
gauge and color.
WIRING REPAIR
When a fusible link blows it is important to find out
what the problem is. They are placed in the electrical When replacing or repairing a wire, it is important
system for protection against dead shorts to ground that the correct gauge be used as shown in the wiring
which can be caused by a component failure or vari­ diagrams. The wires must also be held securely in
ous wiring failures. Do not just replace the fusible place to prevent damage to the insulation.
link to correct the problem.
When diagnosing a faulty fusible link it is impor­ WIRING REPAIR PROCEDURE
tant to check the wire carefully. In some instances the (1) Remove 1 inch of insulation from each end the
link may be blown and it will not show through the wire.
insulation, the wire should be checked over its entire (2) Spread the strands of the wire apart on each
length for internal breaks. part of the exposed wire (Fig. 10 example 1).
(3) Push the two ends of wire together until the
FUSIBLE LINK REPLACEMENT strands of wire are close to the insulation (Fig.10
(1) Disconnect battery negative cable. example 2).
(2) Cut off any remaining portion of the blown fus­ (4) Twist the wires together (Fig. 10 example 3).
ible link flush with the multiple connection insulator. (5) Solder the connection together using rosin core
Taking care not to cut into other fusible links. type solder only. Do not use acid core solder.
(3) Remove 1 inch of insulation from the main har­ (6) Allow the connection to cool and wrap with a
ness wire about 1 inch away from the multiple con­ minimum of three layers of electrical tape.
nection insulator (Fig. 9).
(4) Remove 1 inch of insulation from one end of the
new fusible link and wrap it around the main harness
wire that was stripped.
(5) Heat the splice with a high temperature solder­
ing gun, apply rosin core solder until it flows freely,
and remove the soldering gun. Do not use acid core
type solder.
SYMBOLS, FUSES AND ABBREVIATIONS
Various symbols are used throughout the wiring
diagrams. These symbols can be identified by refer­
ring to the symbol identification chart (Fig. 11). Cer­
tain abbreviations are also used in the diagrams. These
have been developed in such a way that there mean­
ing should be clear. Refer to the abbreviations chart
for an explanation of the terms used (Fig. 12). For
fuse and relay bank information refer to (Fig 13).
CAUTION: When replacing a blown fuse it is impor­
tant to replace it with a fuse having the correct am­
perage rating. The use of a fuse with a rating other
than indicated may result in an electrical overload. If
a proper rated fuse continues to blow, it indicates a
problem that should be corrected.
 LEGEND OF-SYMBOLS USED O N W IRING DIAGRAMS

+ POSITIVE. CONNECTOR

— NEGATIVE — > MALE CONNECTOR

' GRO UND >— FEMALE CONNECTOR

FUSE DENOTES WIRE CONTINUES ELSEWHERE

DENOTES WIRE G O ES TO O N E OF TW O
' G A N G FUSES WITH BUSS BAR
T 5 Z CIRCUITS
CIRCUIT BREAKER SPLICE

• — ) I— • CAPACITOR SP U C I IDENTIFICATION

n OHMS THERMAL ELEMENT

•A A A -* RESISTOR | *TIMER | TIMER

VARIABLE RESISTOR MULTIPLE CONNECTOR

1Y Y Y 1
m w

l_ J
O ♦
SERIES RESISTOR OPTIONAL
W IRING WITHOUT

COIL #IY'# W IN D IN G S
Y

—ijifiy— i 1
- vSS£SL r
STEP UP COIL
BB'-BB DIGITAL READOUT

OPEN CONTACT - 0 - SINGLE FILAMENT LAMP

•9 E T * CLOSED CONTACT DUAL FILAMENT LAMP

- o -

CLOSED SWITCH L.E.D. - LIGHT EMITTING DIODE

OPEN SWITCH THERMISTOR

r c CLOSED GANGED SWITCH GAUGE

OPEN GANGED SWITCH

- 0 -
SENSOR

TW O POLE SINGLE THROW SWITCH FUEL INJECTOR

Q «6 DENOTES WIRE GOES THROUGH

PRESSURE SWITCH
BULKHEAD DISCONNECT

DENOTES WIRE G O E S THROUGH

SOLENOID SWITCH # l9 | STRG |

3* I COLUMN F‘.. . STEERING COLUMN CONNECTOR

-------- #14 DENOTES WIRE G O ES THROUGH
MERCURY SWITCH ST

J . PANEL
INSTRUMENT PANEL CONNECTOR
#7 DENOTES WIRE G O ES THROUGH GROMMET
DIODE OR RECTIFIER — ENG — —
TO ENGINE COMPARTMENT

BY-DIRECTIONAL Z E N E i DIODE DENOTES WIRE G O ES THROUGH GROMMET

< MOTOR HEATED GRID ELEMENTS

ARMATURE AND BRUSHES

0 908W-191
A.B.S. Anti-Lock B ra k es iGN ignition SW Switch
A /C -Air C o n d itio n e r ILLUM Illum i nat ion IACH T a c h o m e te r
ACC A c c essory l/P In stru m e n t Panel T/B T hrottle Body
ALT A lte rn a to r INC In c re a se d T il T hrottle Body
AMP A m pere IND Indicator Injection
ASD A u t o m a t ic S hutd o w n INJ injector TCC Torque C o n v e rte r
■Clutch
ASSY A s se m b ly INTER interior
TEMP Temperature
A.T. A u to m atic LB Light Blue
T ra n s m iss ion T/L Tail Lamp
LCD Liquid C rystal
AUD A udio Display TRANS T ransm ission
AUTO A u to m a tic LD Light Duty TPS ■ T hrottle Position
S e n so r
AUX Auxilary LG Light G r e e n
TYP Typical
BAT B attery LH Left H and
V Volt
BUEV Bi-Level LO Low
VAC V acuum
BK Black LP Lamp
VLV V alve
BIU Blue LPS Lamps
VT Violet
BRK B rake LT Light
LTR Lighter W/ W ith
BR Brown
BU Back-up MAN M anual
w /o W ithout

BUZZ Buzzer MAP M anifold A b s o lu te w/s W indshield

P re s s u re W /W a s h e r W in d o w W a s h e r
CAL C alifornia
MAT M anifold Air W OO W in d o w
CAN C anada
T em p eratu re WT W hite
C/BRKi Circuit B re a k e r
MAX M axim um WRG W iring
CIRC Circuit
MED M edium YL Yellow
CLSTER C luster
MiN M inim um
C Control
AAPl M ulti-Point Fuel
COM P C o m p re s s o r
Injection
C ON N C o n n e c to r
MRKR M arker
CPS C ra n k sh a ft Position
M /I M anual
S e n so r
Transmission
CTSY C ourtesy
MULT M ultiple
Di Dark Blue
N /A Not A p p lic a b le
DG Dark G r e e n
NAT N a tu ral
DIAG D iagnostic
NEUI N e u tral
DIM D im m er
NO N orm ally O p e n
DIR D irectional
NC N orm ally Closed
DIST D istributor
Oi O ran g e
DM D om e
PK Pink
Di Door
PRESS Pressure
PRl D a y tim e Running
PRK Park
Lamps
EPi P/S P o w e r S te erin g
Electronic Fuel
Injection PWR Pow er
EGR E xhaust G a s RCVi R eceiver
Recirculation REF R e fe re n c e
ELEC Electric RESIST R e sistan c e
EMR Emissio n M a in te n a n c e m Right H and
R e m inde r SBEC Single B oard
ENG Engine E ngine C ontroller
FLASH flash er S/C S p e e d Control
PRI front SCi Serial
C om m u n ic atio n s
GRP G ro u n d
Interface
GRN G reen
SEN S e n so r
GY Gray
SEND Sender
HA2 H a z a rd
SIG Signal
HP H eavy Duty
SIL Silver
HP LP H e a d la m p
SKI Socket
HI High
SOL Solenoid
HIR H e a te r
SPEEDO S p eed o m eter
918W-21
 8W-8
CAVITY FUSE ITEMS FUSED CAVITY FUSE ITEMS FUSED

I 20 AMP HAZARD f tASHERS 24 20 AMP BACK-UP LAMPS

WIRING DIAGRAMS
2 10 AMP HEATED MIRRORS 25 C/IRKR POWER WINIX:)WSf POWER VENT WINDOWS

3 20 AMP BODY IAMPS 26 30 AMP A /C HEATER BLOWER MOTOR

4 NOT USED 27 C/BRKR TOWER DOOR LOCKS

5 20 AMP WINDSHIELD WIPERS 28 NOT USED

FUSEBLOCK AMPS FUSE COLOR CODE

6 20 AMP TURN SIGNAL LAMPS
2 PK PINK
7 10 AMP RADIO 7.5 ¥T VIOLET
10 RP RED
8 NOT USED
20 YL YELLOW
9 7.5 AMP ILLUMINATION LAMPS 25 NAL NATURAL
30 LG LIGHT GREEN
10 2 AMP LEFT TAIL LAMPS

11 2 AMP RIGHT TAIL IAMPS RELAY

BANK
12

13 ^IP
NOT USED

REAR WINDOW WIPER/WASHER

tOCATIC LOCATION 5
_ _
LOCATIONS
_
L
_

14 2 AMP SPEED CONTROL o

NOT
LOW BE USED VAN CONV
(STAND/
15 10 AMP GAUGES, WARNING LAMPS 0

16 NOT USED C/BRKR o

LOCATION 2 LOCATION 6 LOCATION 9
o
PARK LAMPS NAME PAIR LOCK
(STANDARD) LOCK
BRAND
17 10 AMP LEFT LOW BEAM HEADLAMP speakers

18 10 AMP RIGHT LOW BEAM HEADLAMP o

LOCATION 3
o
LOCATION 7 LOCATION 10

HORN REAR A/C POWER

STANDARD UNIIOCK
19 20 AMP STOP LAMPS

LOCATION 11
20 20 AMP REAR A /C AND HEATER LOCATION 4
o j= d = y
0
21 20 AMP FOG IAMPS COMBO-FLASHER
‘ V HEADLAMP
(STANDARD)
^ CIRCUIT
22 20 AMP PAM LAMPS BREAKER
1
23 20 AMP BATTERY 9 1 8 W -2 2

Fig. 13 Fuse Block and Relay Bank AS

 COMPONENT IDENTIFICATION
INDEX
Caption Fig. Caption
All Wheel Drive W irin g .................................................. 17 Instrument Panel Wiring ___
Anti-Lock Brake System Wiring ................................. 21 Instrument Panel A/C Wiring
Body Left Side Wiring .................................................. 1,5 Overhead Console Wiring . . .
Body Right Side Wiring .................................................. 9 Power Seat Wiring .................
CHMSL Wiring .............................................................. 15 Rear Heater A/C W irin g ........
Cowl Panel Wiring ........................................................ 10 Roof Wiring Left S i d e .............
Door Wiring .................................................................... 11 Roof Wiring Right Side ........
Engine Wiring 2.5L EFI ................................................ 25 Steering Column W irin g ........
Engine Wiring 3.0L EFI . .............................................. 26 Tailgate Wiring .......................
Engine Wiring 3.3L EFI ................................................ 27 Transmission Wiring 2.5L EFI
Engine Compartment Wiring 2.5L EFI ..................... 19 Transmission Wiring 3.0L EFI
Engine Compartment Wiring 3.0L and 3.3L EFI . . . 20 Transmission Wiring 3.3L EFI
Front End W irin g ............................................................ 18 Underbody Wiring ...................
Ground Strap Location.................................................. 28 Underhood Lamp Wiring —
 TO RIGHT SIDE
TO ROOF WIRING TO
REAR DOME OVERHEAD
LAMP CONSOLE
TO
OVERHEAD
CONSOLE

TO
FLOOR PAN'
W IRING DOME-
LAMP ASSEMBLY
VIEW X
(DOME LAMP)
9 1 8 W -2 4
Fig. 2 Roof Wiring Lett Side

TO OVERHEAD
'CONSOLE
TO
A - PILLAR
TO
REAR
DOME
LAMP

TO FLOOR
PAN WIRING TO REAR
LIGHTING
TO RO O F TO SUNROO F TO SUNROO F TO ROOF
WIRING W IRING W IRING W IRING

918 W -26

Fig. 4 Overhead Console Wiring

POWER VENT
W IN D O W
MOTOR

DOOR
SWITCH

TO FLOOR
PAN W I RING
 TO POWER
SEAT
9 1 8 W -2 8

Fig. 6 Rear 4/C Heater Wiring

 9 1 8 W -3 0

Fig. 8 Instrument Panel A/C Wiring

TO ROOF CONTACT
W I RING ASSEMBLY
TO I NSTRUMEN T DOOR
PANEL W I RIN G LOCK

DOOR
JAMB
TO UNDERSEAT SWITCH
STORAGE LAMP (SLIDING
DOOR)
 TO FLOOR
PAN W IR IN G

Fig. 10 Cowl Panel Wiring

DOOR
HANDLE TO
ASSEMBLY ILLUMINATED POWER DOOR
ENTRY LOCK SWITCH
C O N NECTO R
V IEW IN DIRECTION
OF A RROW Z

ILLUMINATED
ENTRY SWITCH ILLUMINATED
ENTRY S W ITCH
C O N N E C TO R

POWER W IN D O W
A N D POWER
MIRROR
CONNECTO RS

COURTESY
LAMP POWER W IN D O W
C O N N E C T IO N M O TO R
 NAME
TO BRAND TO RIGHT
REAR SPEAKER POD ASSEMBLY TO
HEATER GROUND (8 WAY) CLOSTER TO LEFT
TO
AND A /C (14 WAY) POD (8 WAY)
RADIO
UNIT
(10 WAY) (7 WAY)
TO GLOVE TO LEFT
BOX LAMP SWITCH POD (7 WAY)
TO LIFTGATE
AND HEATED
REAR WINDOW
(7 WAY)
TO RIGHT TO LEFT
DOME AND SILL AND BODY
COWL WIRING WIRING

TO
SPEAKER
CHOKE
RIGHT (2 WAY)
48 WAY
TO VAN
CONNECTOR
CONVERSION
BRACKET
W IRING
TO BLOWER TO
MOTOR (5 WAY) DIMMING
MODULE
TO ENGINE (2 WAY)
COMPARTMENT
(2 WAY) TO
PARK
BRAKE
TO BLOWER SWITCH
MOTOR
(2 WAY) TO
DIAGNOSTIC STOP LAMP
TO CONNECTOR SWITCH
IGNITION (6 WAY)
TO SWITCH TO
MULTI-FUNCTION (8 WAY) SPEED
SWITCH STEERING TO CONTROL
COLUMN CONNECTOR KEYLIGHT
(5 WAY)
(24 WAY) SWITCH
(4 WAY)
Fig. 12 Instrument Panel Wiring
 COLUMN
ASSEMBLY

TO IGNITION CLOCK
SWITCH (7 WAY) SPRING
ASSEMBLY

TO KEY
LIGHT SWITCH
(4 WAY)
SPEED
VIEW IN DIRECTION CONTROL
OF ARROW Z CONNECTOR
(5 WAY)
TO
M AIN
HARNESS
TURN
SIGNAL
LEVER

MULTI-FUNCTION
SWITCH (24 WAY)

9 1 8 W -35

Fig. 13 Steering Column Wiring

HEATED BODY TO
REAR W IN D O W LIFTGATE
CONNECTORS
CONNECTOR
HEATED
REAR W IN D O W
CONNECTOR
CENTER HIGH
MOUNTED STOP
LAMP

GROUND
REAR
WIPER/ SPEAKER
WASHER
MODULE TO
LICENSE
LAMP

LIFTGATE
SPEAKER LATCH SWITCH

LIFTGATE RELEASE LIFTGATE RELEASE

SOLENOID CONNECTOR SOLENOID
 9 1 8 W -3 9

Fig. 17 All Wheel Drive Wiring

A /C A M B IENT
. TEMPERATURE
SENSOR

OVERHEAD
CONSOLE AMBIENT
TEMPERATURE SENSOR

TO FOG
LAMP
HEADLAMP
C O N NECTO R
FOG LAMP
CONNECTO R

AERO HEADLAMP
LOAD LEVELING MOTOR
TO FOG
A N D CONNECTO R
PARK A N D LAMP
TURN S IGNAL
C O N NECTO R

V IEW IN DIRECTION
OF ARROW Z
 8W-20
TO UNDERHOOD IGNITION OFF-DRAW
LAMP CONNECTOR
LOW WASHER
FLUID SENSOR STARTER

WIRING DIAGRAMS
A /C ELAY
DAMPED WINDSHIELD FUEL PUMP RELAY
PRESSURE WIPER MOTOR
RADIATOR
SWITCH 1
FAN RELAY SINGLE
A /C CLUTCH BOARD
CYCLING SWITCH ENGINE
CONTROLLER

MAP SENSOR'

DIAGNOSTIC
CONNECTOR

TO
FRONT
END
AERO LIGHTING
HEADLAMP
SPEED
CONNECTOR
PURGE CONTROL
GROUND' 'SOLENOID A/C SERVO
CLUTCH
A /C HEATER
A /C RELAY
BLOWER MOTOR RESISTOR
FAN
A /C RELAY
FAN PARK AND
TURN SIGNAL
MOTOR TO MAIN
LAMPS
CONNECTOR HARNESS

DAYTIME RUNNING
LIGHTS. RELAY

AMBIENT TEMPERATURE
RIGHT SENSOR CONNECTOR
HEADLAMP LEVELING TO ENGINE
MOTOR AND WIRING
CONNECTOR
VIEW IN DIRECTION VIEW IN DIRECTION
OF ARROW X OF ARROW Z

Fig. 19 Engine Compartment Wiring 2.5L EFI

 TO UNDERHOOD LOW WASHER
LAMP FLUID SENSOR IGNITION OFF DRAW
WINDSHIELD 'CONNECTOR
A /C WIPER MOTOR STARTER RELAY
DAMPED FUEL PUMP RELAY
PRESSURE
SWITCH. RADIATOR FAN RELAY
SINGLE
BOARD
ETAX
ENGINE
CONTROLLER
CONTROLLER

TO INSTRUMENT DIAGNOSTIC
PANEL WIRING CONNECTOR

AERO PURGE
HEADLAMP SOLENOID
GROUND TO
CONNECTOR
PARK AND FRONT
TURN SIGNAL END
LAMPS CONNECTOR A /C
LIGHTING
CLUTCH
A /C SAFETY RELAY
FAN SHUTDOWN 'SPEED
BACK-UP RELAY BLOWER
MOTOR CONTROL
LIGHT MOTOR
RESISTOR SERVO
RELAY-

DAYTIME RUNNING
LIGHTS RELAY

LO-NOTE
AMBIENT TEMPERATURE
HORN
SENSOR CONNECTOR

VIEW IN DIRECTION
OF ARROW X
RIGHT
HEADLAMP LEVELING
MOTOR AND
CONNECTOR HI-NOTE
HORN VIEW IN DIRECTION OF ARROW Z

Fig. 20 Engine Compartment Wiring 3.0L and 3.3L EFI

 8W-22
WIRING DIAGRAMS
RELAY
ABS
SYSTEM ABS
YELLOW
LIGHT
RELAY

A IS
HYDRAULIC PUMP
ASSEMBLY MOTOR
RELAY

ABS
PUMP MOTOR
CONNECTORS

^ TO FRONT
END LIGHTING

SPEED CONTROL SERVO

A IS CONTROLLER

Pig. 21 AntbLoek B nke System Wiring

BEYOND THIS
POINT SEE
VIEW I •STARTEi

SPEED
SENSOR BATTEIY

TO MAIN
HAINES
VIEW X
(AUTO TRANS)

TO
■MAIN
HARNESS
IEYOND THIS POINT
SEE VIEW X

GROUND

WIRING DIAGRAMS
mm
THROTTLE
UNLOCK
SOLENOID
NEUTRAL START'
AND BACK-UP
VIEW Z LAMP SWITCH
{AUTO TRANS)

8W-23
918W -44
 VIEW IN DIRECTION
OF ARROW Y VIEW I N TO RADIATOR
BATTERY DIRECTION OF FAN
ARROW W MOTOR
(STANDARD
TRANSMISSION)

TO BATTERY
GROUND ON
ENGINE
TO OIL
PRESSURE FRONT OUTPUT SPEED
SWITCH MOTOR SENSOR
MOUNT (BROWN SEAL)

STARTER

NEUTRAL SAFETY
SWITCH

TO MAIN
VIEW IN DIRECTION PRNDL
HARNESS
OF ARROW X SWITCH
STARTER (NATURAL CONNECTOR)
TRANSMISSION SOLENOIDS
AND PRESSURE SWI TCHES
 BATTERY
GROUND

TO VIEW X

TURBINE SPEED
SENSOR

< 3 ^

TO
BATTERY
OIL PRESSURE
SWITCH
OUTPUT
— SPEED
SENSOR
CRANKSHAFT
POSITION
SENSOR
NEUTRAL
TRANSMISSION SAFETY
SOLENOI DS AND SWITCH
PRESSURE SWITCHES

WIRING DIAGRAMS
DETONATION PRNDL
SENSOR SW I TCH

SPEED SENSOR
SPEED CONNECTOR
SENSOR

VIEW IN DIRECTION OF ARROW X

8W-25
918W -46
 AUTOMATIC IDLE
SPEED MOTOR A /C HIGH PRESSURE CUT OUT
CONNECTOR

INJECTOR SENDING UNIT COOLANT

TEMPERATURE GAUGE TEMPERATURE SENSOR
BATTERY GROUND
THROTTLE BODY
GROUND
10 WAY
CONNECTOR

VIEW IN DIRECTION
OF ARROW Z
.TO HEATED
OXYGEN SENSOR
THROTTLE BODY
GROUND

ALTERNATOR

INJECTOR
CONNECTOR

TO
BATTERY

D I STRIBUTOR
CONNECTOR
THROTTLE
BODY
CONNECTOR
(10 WAY)

VIEW I N DIRECTION
OF ARROW W
EGR
THROTTLE
SOLENOID
POSITION SENSOR
 COIL

THROTTLE
POSITION
SENSOR ALTERNATOR

10 WAY
CONNECTOR

TO BATTERY

6 WAY
CONNECTOR

MAP SENSOR
DISTRIBUTOR

OXYGEN
SENSOR
ENGINE GROUND
CONNECTOR

COOLANT
TEMPERATURE
SENSOR
FUEL RAIL
CONNECTOR
DISTRIBUTOR
HEATED OXYGEN
CONNECTOR
SENSOR

WIRING DIAGRAMS
OIL PRESSURE
SENDING UNIT/
SW I TCH

SENDING
UNIT A /C COMPRESSOR
TEMPERATURE
GAUGE

8W-27
918W -48
 8W-28
TO CHARGE NEGATIVE
AUTO EGR TERMINAL ALTERNATOR
IDLE THROTTLE SOLENOID TEMPERATURE ASSEMBLY
SPEED POSITION SWITCH
SENSOR SENSOR

WIRING DIAGRAMS
TROTTLE BODY

EGR
SOLENOID

THROTTLE
POSITION
SENSOR

AUTO
IDLE
SPEED
SENSOR

011 TO
A/C HIGH FILTER cxSmTROL ENGINE
WATER COMPARTMENT
PRESSURE CABLE BY-PASS
CHARGE OUTPUT SWITCH STARTER BRACKET W tlM m m S m WIRING
VIEW IN DIRECTION VIEW IN DIRECTION MOTOR TUBE
TEMPERATURE Of ARROW Z BRACKET OF ARROW X
SWITCH
POWER STEERING ENGINE GROUND . BOLT BOLT*
PUMP MOUNT

BOLT

BOLT ALTERNATOR 908W-24O

Fig. 28 Ground Stmp location
 SPLICE LOCATION
INDEX
Splice Number Fig. Splice Number Fig.
A1 3.0L, 3 . 3 L .................................................................. 15 K4 3 .0 L .3 .3 L .................................................................. 15
A1 2.5L ....................................... ..................................... 13 K4 2.5L ............................................................................. 13
A03 ................................................................................... 11 K4-1 2.5L ......................................................................... 19
A03-1 .............................................................................. 11 K4-1 3.3L ......................................................................... 22
A04 ................................................................................... 11 K4-1 3.0L ......................................................................... 20
A04-1 3.0L, 3.3L ............................................................ 15 K4-2 3.0L ......................................................................... 20
A04-1 2.5L ...................................................................... 13 K4-2 2.5L ......................................................................... 14
A10 3.0L, 3 . 3 L ................................................................ 17 K4-3 3.3L ......................................................................... 21
A11 2 . 5 L .......................................................................... 13 K6 3 . 3 L ............................................................................. 22
A14 2 . 5 L .......................................................................... 13 K6 3.0L ............................................................................. 20
A14 3.0L, 3 . 3 L ................................................................ 15 K6 2 . 5 L ............................................................................. 14
A15 .................................................................................. 18 K7 3.3L ............................................................................. 22
A16 3.0L, 3 . 3 L ................................................................ 15 K11 3 . 0 L ........................................................................... 20
A16 2 . 5 L .......................................................................... 13 K11 3 . 3 L ........................................................................... 22
A18 .................................................................. ................ 10 K12 3 . 0 L ........................................................................... 20
A20 3.0L, 3 . 3 L ................................................................ 17 K12 3 . 3 L ........................................................................... 22
A21 2 . 5 L .......................................................................... 13 K13 3 . 3 L ........................................................................... 22
A21-1 3.0L, 3.3L ............................................................ 15 K13 3 . 0 L ........................................................................... 20
A21-1 3.0L, 3.3L ............................................................ 17 K22 3 . 3 L ........................................................................... 22
A21-1 2.5L ...................................................................... 13 K24 ................................................................................... 18
A21-2 3.0L, 3.3L ............................................................ 15 L1 ......................................................................................... 6
A21-2 2.5L ...................................................................... 13 L02 ................................................................................... 11
A21-3 ................................................................................ 9 L3 ..................................................................................... 23
A21-4 2.5L ...................................................................... 14 L3 2.5L ............................................................................. 23
A21-4 3.0L, 3.3L ............................................................ 16 L7-1 ..................................................................................... 2
A22 .................................................................................. 10 L7-2 ..................................................................................... 2
A 6 1 3 .0 L , 3 . 3 L ................................................................ 17 L07 ................................................................................... 10
A61 2 . 5 L .......................................................................... 13 L07-1 ................................................................................... 6
A61-1 3.3L ...................................................................... 22 L20 ................................................................................... 11
A61-1 3.0L ...................................................................... 20 L39 ................................................................................... 23
A61-2 3.3L ...................................................................... 22 L44 ................................................................................... 11
A61-3 3.0L ...................................................................... 20 L44 2.5L ........................................................................... 14
B47 3.0L, 3 . 3 L ................................................................ 17 L50 ..................................................................................... 9
C07 ..................................................................................... 9 L50-1 ................................................................................... 1
C15 .................................................................................. 11 L60 ................................................................................... 11
C20 2 .5 L .......................................................................... 14 L61 ..................................................................................... 9
C23 2 .5 L .......................................................................... 14 L62 ..................................................................................... 2
D1 3.0L, 3 . 3 L .................................................................. 15 L63 ..................................................................................... 6
D1-1 ................................................................................. 10 L94 ..................................................................................... 9
D2 3.0L, 3 . 3 L .................................................................. 15 M1 ....................................................................................... 9
D2-1 .................................................................................. 9 M1-1 ................................................................................. 12
E2 ..................................................................................... 11 M1-2 .................................................................... .............. 8
E2-1 ................................................................................ 10 M2 ..................................................................................... 10
E02 ..................................................................................... 9 M2-1 ................................................................................... 6
E17 .................................................................................. 10 M2-2 ................................................................................... 6
E92 .................................................................................. 10 M2-3 ................................................................................... 1
F20 2 . 5 L .......................................................................... 13 M11 Power Sunroof ........................................................ 5
F20 ................................................................................... 11 M11 ................................................................................... 11
F20-1 .................................................................................. 6 M11-1 ................................................................................. 4
F 2 0 - 2 ................................................................................... 1 M11-2 ............................................................................... 11
F 2 1 - 3 ................................................................................ 11 P33 ................................................................................... 12
F 2 1 - 5 ................................................................................ 12 P33-1 ............................................................................... 10
F35 .................................................................................. 11 P34 ................................................................................... 12
F62 ..................................................................................... 9 P34-1 ................................................................................. 9
G07 3.0L, 3.3L .............................................................. 15 Q41 ..................................................................................... 3
G07 2.5L ........................................................................ 13 T13 3 . 3 L ........................................................................... 21
G19 3.0L, 3.3L .............................................................. 17 T16 3.0L, 3 . 3 L ................................................................ 16
G5 ..................................................................................... 11 T40 3.0L, 3 . 3 L ................................................................ 15
G6 ....................................................................................... 9 T 41 3.0L , 3 . 3 L ................................................................ 15
G9 3.0L, 3.3L ................................................................ 17 V03 ................................................................................... 10
G9-1 ................................................................................ 11 V07 ..................................................................................... 9
Fig. Splice Number :ig-
10 Z1-1 3.0L, 3.3L 17
11 Z1-3 . . . . . . . . . . . 9
18 Z1-4 . . . . . . . . . . .
14 Z1-5 . . . . . . . . . . . 9
10 Z1-6 . . . . . . . . . . . 5
12 Z1-7 . . . . . . . . . . . 6
1 Z1-8 . . . . . . . . . . . 2
10 Z2 . . . . . . . . . . . . 9
12 Z3 . . . . . . . . . . . . 9
1 Z1-10 . . . . . . . . . . 1
10 Z1-11 . . . . . . . . . . 1
9 Z1-12 . . . . . . . . . . 2
9 Z1-12 . . . . . . . . . . 8
10 Z1-13 . . . . . . . . . . 6
17 Z1-15 . . . . . . . . . . 12
19 Z1-16 . . . . . . . . . . 23
7 Z11 2.5L . . . . . . . 13
14 Z11 3.01, 3.3L 15
23 Z12 3.0L, 3.31 15
16 Z12 2.5L . . . . . . . 13
20 Z13 3.0L, 3.3L 16
19 Z14 3.0L, 3.3L 15
 918W-203

Fig. 3 Roof Splices (Right Side)

 918 W-205
Fig. 5 Floor Pan Splices
 918W-207

Fig. 7 Rear Heater A/C Splices

Fig. 9 Instrument Panel Splices
Fig. 10 Instrument Panel Splices
Fig. 11 Instrument Panel Splices
Fig. 15 Engine Compartment Splices 3.0L, 3.3L
 918W-219
Fig. 19 Engine Splices 2.5L
 918W-221

Fig. 21 Engine Splices 3.3L

(2.5L ONLY)

VIEW IN DIRECTION
O F ARROW Z 918W-223

Fig. 23 Front End Splices

 WIRING DIAGRAMS AS-BODY H-K
ALPHABETICAL INDEX
Wiring Diagram
Name Sheet Number
ABS Pump Motor Relay .............................................. 35
ABS Warning L amp Relay ......................................... 37
A/C Heater System 2.5L E n g in e ......................... 27, 28
A/C Clutch Relay ...................................................... 28
A/C Damped Pressure Switch ............................... 27
A/C Fan M o to r............................................................ 28
A/C Fan Motor Relay ................................................ 27
A/C High Pressure Cut-Out Switch ....................... 27
Blower Motor .............................................................. 27
Clutch ........................................................................... 28
Compressor ................................................................ 28
Control Switch ............................................................ 27
D io d e ............................................................................. 28
Electronic A/C Cycling Switch ............................... 27
Fuse ............................................................................. 28
Lamp-Switch Illum ination.......................................... 27
Radiator Fan Motor .................................................. 28
Radiator Fan Relay .................................................. 28
Resistor ....................................................................... 27
Switch Illumination .................................................... 27
A/C Heater System 3.0L & 3.3L Engine .......... 29, 30
A/C Clutch Relay ...................................................... 30
A/C Damped Pressure Switch ............................... 29
A/C Fan Cut-Out Switch ......................................... 29
A/C Fan M o to r............................................................ 30
A/C Fan Motor Relay ................................................ 29
Ambient Air Temperature Sensor ......................... 29
Blower Motor ........................... ................................... 29
Clutch ........................................................................... 30
Compressor ................................................................ 30
D io d e ............................................................................. 30
High Pressure Cut-Out Switch ............................... 29
Radiator Fan Motor .................................................. 30
Radiator Fan Relay .................................................. 30
Resistor ...................................................................... 29
Switch Illumination .................................................... 29
Alternator-Bosch .......................................................... 5, 7
Alternator-Nippondenso.............................................. 5, 7
Ambient Air Temperature Sensor ............................. 29
Ambient Switch-Overhead C o n s o le ........................... 85
Anti-Lock Brake System ......................... 34, 35, 36, 37
ABS Pump Motor Relay .......................................... 35
ABS Warning Lamp Relay ..................................... 35
Connector 60 Way .................................................. 124
Diagnostic C o n n ecto r................................................ 37
Left Front Wheel Sensor ......................................... 34
Left Rear Wheel Sensor ......................................... 34
Pump Motor ................................................................ 35
Right Front Wheel S e n s o r....................................... 34
Right Rear Wheel Sensor ....................................... 34
System Relay ............................................................ 36
Auto Shutdown Relay 2.5L Engine ........................... 14
Automatic Idle Speed Motor 2.5L E n g in e ................. 12
Automatic Idle Speed Motor 3.0L E n g in e ................. 20
Automatic Idle Speed Motor 3.3L E n g in e ................. 24
Automatic Shutdown Relay 2.5L Engine ................. 14
Automatic Shutdown Relay 3.0L Engine ................. 19
Automatic Shutdown Relay 3.3L Engine .......... .. 23
Automatic Transmission Switch ................................... 9 Distance Sensor 3.3L Engine.................................. 25
Wiring Diagram
Name Sheet Number
Back-Up Lamp Switch 2.5L Engine.......................... 8
Back-Up Lamp R e lay ........... ................................... 90
Battery ........................................................ 1, 4, 6, 22
Brake Warning Indicator Lam p................................ 72
Body Computer..................... 101, 102, 103, 104, 105
Cluster ............................ ................................... 104
F u s e ............................................................ 101,102
Left P o d ...................................................... 103, 104
Park Brake Switch ............................................. 105
Right Pod .............................. .............................. 103
Warning Lamp Center .............................. 102, 104
Body to Instrument Panel Connector
(16 way) .............................................................. 121
Bulkhead Disconnect Connector
(50 way) ............................................. 106,107,108
Cam Sensor.............................................................. 26
Cargo Lam p............................................................. 82
Charge Temperature Sensor .................................. 24
Charging System........................................... 4, 5, 6, 7
Alternator ............................................................ 5, 7
Battery ................................................................ 4 ,6
Cigar Lighter .......................... ................................. 44
Circuit Breaker Electric Door Locks ...................... 78
Circuit Breaker Electric Windows............................ 79
Circuit Breaker Headlamps .............................. 44, 50
Clock ............................................................ 58, 60, 62
Cluster Illumination Lamp ................................. 52
Combo Flasher ........................................................ 50
Console-Overhead ...................................... 84, 85, 86
Ambient Switch .................................................... 85
Connector.............................................................. 84
Fuse ..................................................................... 85
Ground .................................................................. 84
Left Vent Switch ................................................... 86
Right Vent Switch ................................................. 86
Twin Map Lamps ........................................... 84, 85
Control-Rear H eater................................................ 65
Control-Rear Heater Lamp .............................. ....... 65
Coolant Sensor 2.5L Engine.................................... 15
Coolant Sensor 3.0L Engine.................................... 21
Coolant Sensor 3.3L Engine.................................... 26
Courtesy Lamps ................................................. 81, 82
Crank Sensor .......................................................... 25
Cut-Out Switch-A/C ..................................... . 27, 29
Cycling Switch-A/C Electronic ................................ 27
Daytime Running Light Module Wiring ................... 94
Detonation Sensor 3.3L Engine .............................. 25
Diagnostic Connector 2.5L EFI Engine ................. 14
Diagnostic Connector 3.0L EFI Engine ................. 19
Diagnostic Connector 3.3L EFI Engine ................. 23
Diagnostic Connector Electronic Transmission . . . . 56
Diagnostic Solenoid-Exhaust Gas .......................... 13
Dimmer Switch-Headlamp ................................ 41, 50
Dimming Module ............................................... 50, 51
Diode Courtesy Lamps ........................................... 81
Direct Ignition System ............................................. 26
Distance Sensor 2.5L Engine EFI .......................... 15
Distance Sensor 3.0L Engine.................................. 21
Wiring Diagram
Name________________________________ Sheet Number
Dome and Courtesy Lamps ................................. 8 1,8 2
Door and Liftgate Ajar Warning System ...................
Door Switches ............................................................
Liftgate Switch ............................................................
Left and Right Front Switches ...............................
Sliding Door Switch ..................................................
Electric Heated Rear Window Defogger System ..
Indicator Lamp ..........................................................
L.E.D...............................................................................
Switch ...........................................................................
Switch Illumination L a m p s .......................................
Electronic Automatic Transaxle ................... 31, 32, 33
Back-Up Lamp Relay ................................................
Connector ................................................................
Control Module ............................................ 3 1 , 3 2 , 3 3
Neutral Safety S w itc h ................................................
PRNDL Switch ..........................................................
Safety Shutdown Mini R e la y ...................................
Transaxle S o len o id s ..................................................
Turbine Input Speed S e n s o r...................................
Turbine Output Speed Sensor ...............................
Electronic C lu s te r.................................................... 55, 56
Connector 14 Way ..................................................
Diagnostic C o n n ecto r................................................
Fuse .............................................................................
Ground .........................................................................
Electronic Fuel Injection System
2.5L EFI E n g in e ............................. 12, 13, 14, 15, 16
Automatic Shutdown R e la y .....................................
Connector 60 W ay-SBEC .....................................
Diagnostic C o n n e cto r................................................
Distance Sensor ........................................................
D istributor.............................................................. .
Engine Coolant Sensor ...........................................
Exhaust Gas Recirculation Solenoid .....................
Ground .........................................................................
Heated Oxygen Sensor ...........................................
Ignition Coil ................................................................
Injector .........................................................................
MAP Sensor ..............................................................
Purge Solenoid ..........................................................
Single Board Engine Controller .. 12, 13, 14, 15, 16
Throttle Position Sensor .........................................
Electronic Fuel Injection System
3.0L Engine ................................... 17,18,19,20,21
Automatic Shutdown R e la y .....................................
Connector 60 W ay-SBEC .....................................
Diagnostic C o n n ecto r..............................................
Distance Sensor ........................................................
D istributor....................................................................
Engine Coolant Sensor ...........................................
Heated Oxygen Sensor ...........................................
Injectors ......................................................................
MAP Sensor ..............................................................
Purge Solenoid ..........................................................
Single Board Engine Controller .. 17, 18, 19, 20, 21
Throttle Position Sensor .........................................
Electronic Fuel Injection System
3.3L Engine ................................... 22, 23, 24, 25, 26
Automatic Shutdown R e la y .....................................
Cam S e n s o r................................................................
Charge Temperature Sensor .................................
Connector 60 Way-SBEC .....................................
Crank Sensor ............................................................
Diagnostic C o nn ecto r................................................ 23
Wiring Diagram
Name Sheet Number
Diagnostic Sensor ............................................... 25
73 Direct Ignition System ......................................... 26
73 Engine Coolant Sensor ....................................... 26
73 Heated Oxygen Sensor ....................................... 24
73 Injectors ................................................................ 26
73 MAP Sensor ........................................................ 24
70 Purge Solenoid ..................................................... 22
70 Single Board Engine Controller .. 22, 23, 24, 25, 26
70 Temperature Sending Unit .................................. 26
70 Throttle Position Sensor ...................................... 24
70 Electronic Transaxle Control Module ..................... 96
Field Coil Starter Motor .................................. 8, 9, 10
33 Flasher-Hazard Warning ......................................... 50
119 Flasher-Turn Signal ................................................. 50
Fog Lamps ....................................................... 68, 69
31 Four Wheel Drive Vacuum Solenoid System .. . 98, 99
32 Front Door Ajar Switches ....................................... 73
32 Front Door Courtesy Lamps .................................... 81
32 Front Door Jamb Switch Left .................................. 81
31 Front Door Jamb Switch Right ................................ 82
31 Front End Lighting ............................................. 41, 42
Fuel Pump M o to r............................................. 88, 100
118 Fuel Tank Sending Unit .................................. 88, 100
56 Fuse Application Chart ..................................... 1, 2, 3
55 Fuse B lo c k .............................................................. 112
55 Fuses
Fuse 1 .......................................................... 1, 6, 53
Fuse 2 ............................................................. 3, 76
14 Fuse 3 ......... 2, 4, 6, 58, 60, 62, 70, 71, 76, 78, 81
109 Fuse 5 ............................ 11, 46, 49, 53, 58, 60, 62
14 Fuse 6 ............................ 11, 46, 49, 53, 58, 60, 62
15 Fuse 7 ............................ 11, 46, 49, 53, 58, 60, 62
15 Fuse 9 ................................................. 1, 50, 54, 70
15 Fuse 13 ........................ 3 ,4 , 1 1 , 1 3 , 6 6 , 7 2 ,7 4 ,9 1
13 Fuse 14 ........................ 3, 4, 11, 13, 43, 66, 72, 74
12 Fuse 15 .............................. 3, 4, 11, 13, 66, 72, 74
12 Fuse 17 ............................................................ 2, 50
14 Fuse 18 ............................................... 2,41 ,50 ,92
16 Fuse 19 ...................................................... 1, 43, 64
13 Fuse 20 ............................................................ 1, 64
13 Fuse 21 ............................................... 1,44,50,62
Fuse 22 ............................................... 1, 44, 50, 62
12 Fuse 23 ............................................... 1, 44, 50, 62
Fuse 24 ............. 3, 8, 9, 11, 28, 30, 64, 70, 89, 94
Fuse 26 ......................................... 3, 11, 27, 29, 57
19 Fusible Links ................................ 1, 2, 3, 4, 5, 6, 7, 8
110 Ground Straps ............................................. 58, 60, 62
19 Hazard Warning S ystem .................................... 53, 54
21 Flasher .................................................................. 50
21 Fuse ..................................................................... 53
21 Switch ................................................................... 53
18 Headlamp Dimmer Switch ................................ 41, 50
17 Headlamp Switch .................................................... 49
20 Headlamp Switch Controlled Interior Lamps . . . 51, 52
18 Headlamps ........................................... 41,42,92,93
Heated Mirrors ................................................... 75, 76
20 Heated Oxygen Sensor 2.5L EFI Engine ............... 12
Heated Oxygen Sensor 3.0L Engine ..................... 18
Heated Oxygen Sensor 3.3L Engine ..................... 24
23 Heater System 2.5L, 3.0L and 3.3L E ngine........... 57
26 Blower Motor ........................................................ 57
24 Fuse ..................................................................... 57
111 Resistor ........... .................................................... 57
25 Switch ................................................................... 57
High Beam Indicator Lamp ...................................... 72
Wiring Diagram
Name __________________________ Sheet Number
Horn System .................................................................. 44
Horns ........................................................................... 44
Horn R e la y .................................................................. 44
Horn Switch ................................................................ 44
Ignition Coil 2.5L EFI Engine ..................................... 14
Ignition Coil 3.0L Engine .............................................. 19
Ignition Off Disconnect .............................................. 4, 6
Ignition Switch ................................................................ 11
Instrument Panel Illumination L amps ....................... 52
Instrument Panel to Body Wiring
Connector 16-Way .................................................. 121
Instrument Panel to Steering Column
Wiring Connector-24 W a y ..................................... 113
Lamps
A/C and Heater Control ............................................ 52
Anti-Lock Warning Indicator ................................... 72
Ash Receiver Lamp .................................................. 51
Back-Up Lamps .................................................. 89, 90
Brake Warning Indicator L a m p ............................... 72
Cargo L a m p ................................................................ 82
Center High Mount Stop Lamp ............................. 90
Cigar Lighter L a m p .................................................... 51
Cluster Illumination Lamps ..................................... 52
Courtesy L a m p s .................................................. 81, 82
Dome Lamps .............................................................. 82
Front Door Courtesy Lamps ................................... 81
G l ove Box Lamp ........................................................ 82
Headlamp-Left .................................................... 4 2 , 9 3
Headlamp-Right .................................................. 41, 92
Headlamp Switch L a m p ............................................ 49
Heated Rear Window Defogger
Indicator Lamp .......................................................... 70
Heated Rear Window Defogger Switch Lamp . . . 52
High Beam Indicator Lamp ..................................... 72
Instrument Panel Illumination Lamps ................... 52
Key Light Switch Lamp ............................................ 81
Left Front Turn Signal Lamp ........................... 42, 93
Left Pod Lamp .................................................... 52, 81
Left Turn Signal Indicator Lamp ..................... 53, 72
License Lamps .......................................................... 90
Liftgate Courtesy Lamp ............................................ 82
Liftgate Release Switch Lamp ............................... 52
Low Beam Relay Lamp ............................................ 49
Maintenance Required Lamp ................................. 72
Map Lamp ............................................................ 84, 85
Overhead Console Illumination L a m p s ................. 52
Parking Brake Warning Lamp ............................... 72
Parking Lamp-Left .............................................. 42, 93
Parking L am p -R ig h t............................................ 41, 92
Rear Dome Lamp ...................................................... 82
Rear Cargo L a m p ............................. ........................ 82
Rear Courtesy Lamp ................................................ 82
Rear End Lighting System ............................... 89, 90
Rear Heater A/C Control Lamp ............................. 65
Rear Heater Control Lamp ..................................... 65
Right Front Turn Signal Lamp ......................... 41, 92
Right Pod Lamp ........................... ............................ 51
Right Turn Signal Indicator Lamp ................... 53, 72
Seat Belt Warning Lamp .......................................... 72
Side Marker Lamp-Left F ro n t........................... 42, 93
Side Marker Lamp-Left Rear ................................. 89
Side Marker Lamp-Right Front ....................... 41, 92
Side Marker Lamp-Right Rear ............................... 90
Stop Lamp-Left Rear ................................................ 89
Stop Lamp-Right R e a r .............................................. 90
Wiring Diagram
Name_____________________________ Sheet Number
Tail Lamp-Left Rear ............................................. 89
Tail Lamp-Right R e a r........................................... 90
Turn Signal Indicator L am ps................................ 72
Turn Signal Lamp-Left Front ........................ 42, 93
Turn Signal Lamp-Left Rear ................................ 89
Turn Signal Lamp-Right Front ...................... 41,92
Turn Signal Lamp-Right R e a r.............................. 90
Twin Map Lamps .......................... ................ 84, 85
Underhood Lamp ................................................. 95
Visor Lam ps.......................................................... 82
Liftgate Courtesy Lamp ........................................... 82
Liftgate Latch Switch ............................................... 82
Liftgate Release Switch Lamp ................................ 71
Liftgate Release System ......................................... 71
Fuse ..................................................................... 71
Indicator Lamp ..................................................... 71
Solenoid ................................................................ 71
Switch ................................................................... 71
Liftgate Wiper and Washer System ................. 66, 67
Motor-Washer ...................................................... 67
M otor-W iper.......................................................... 67
Switch ................................................................... 66
T im e r..................................................................... 66
Low Washer Fluid Switch ........................................ 45
Map Lamp ................................................................ 84
Map Lamp Switch ................................................... 84
Map Sensor 2.5L EFI Engine .................................. 13
Map Sensor 3.bL E ng in e......................................... 20
Map Sensor 3.3L E ngine......................................... 24
Modules
Daytime Running Light ....................................... 94
Intermittent W ip e ................................................... 45
Overhead Console ............................................... 84
Single Board Engine Controller
2.5L EFI E ng in e .......................... 12, 13, 14, 15, 16
Single Board Engine Controller
3.0L Engine ................................ 17, 18, 19, 20, 21
Single Board Engine Controller
3.3L Engine ................................ 22, 23, 24, 25, 26
Motors
A/C Fan .......................................................... 28, 30
Blower-A/C .................................................... 27, 29
Blower-Heater ...................................................... 57
Fuel Pump ................................................... 88, 100
Idle Speed ............................................... 12, 20, 24
Intermittent Wipe Washer .................................... 45
Intermittent Wipe Windshield Wiper ................... 46
Liftgate W a sh e r.................................................... 67
Liftgate Wiper ...................................................... 67
Power Door Locks ......................................... 77, 78
Power Mirror ................................................... 75, 76
Power Seat .......................................................... 87
Power Vent .......................................................... 86
Power Window ............................................... 79, 80
P um p..................................................................... 35
Radiator Fan Motor .......................... 28, 30, 96, 97
Starter 2.5L Engine ............................................... 8
Starter 3.0L Engine ......................................... 9,10
Starter 3.3L Engine ............................................. 10
N ame Brand Speaker Relay .................................. 62
N eutral Safety Switch 2.5L Engine .......................... 8
Neutral Safety Switch E A T X .................................... 31
Oil Pressure Switch .................................... 38, 39, 40
Oil Pressure S ystem .................................... 38, 39, 40
Sending Unit ........................................... 38, 39, 40
Wiring Diagram Wiring Diagram
Name_____________________________ Sheet Number Name_________________________________Sheet Number
Switch ...................................................... 38, 39, 40 T im e r ............................................................................. 66
Overhead C onsole............................................. 84, 85 Switch ........................................................................... 66
Ambient Switch .................................................... 85 Rear Lighting System With Trailer T o w ............. 89, 90
Fuse ..................................................................... 85 L eft Back-Up Lamp .................................................. 89
Twin Map Lamps ................................................. 84 L eft License Lamp .................................................... 90
Parking Brake Warning Lamp ................................ 72 Left Side Marker Lamp ............................................ 89
Parking Brake Warning Lamp Switch ................... 105 Left Turn Signal Lamp .............................................. 89
Park Lamp Relay .................................................... 50 Left Tail Lamp ............................................................ 89
Part Throttle Unlock S olenoid.................................. 16 Right Back-Up Lamp ................................................ 90
Power Door Lock S ystem ............................ . 77, 78 Right License Lamp .................................................. 90
Circuit Breaker .................................................... 78 Right Side Marker Lamp .......................................... 90
Left Front Door Motor ......................................... 77 Right Stop L a m p ........................................................ 90
Left Front Door S w itc h ......................................... 77 Right Turn Signal L a m p ............................................ 90
Lock Relay ............................................................ 78 Right Tail L a m p .......................................................... 90
Right Front Door Motor ....................................... 77 Relays
Right Front Door Switch ..................................... 77 ABS Pump Motor Relay .......................................... 35
Sliding Door Contacts ......................................... 78 ABS Warning Relay .................................................. 37
Sliding Door Motor ............................................... 78 A/C Clutch Relay ................................................ 28, 30
Unlock Relay ........................................................ 78 A/C Fan Motor Relay ........................................ 27, 29
Power Window Connector and Automatic Shutdown Relay ....................... 14, 19, 23
Switch Functions................................................... 79 Back-Up Lamp R e la y ................................................ 33
Power Remote Mirrors ..................................... 75, 76 Combo-Flasher Relay .............................................. 50
Left M o to rs ............................................................ 75 Horn R e la y ................................................................... 44
Right Motors ........................................................ 76 Low Beam Relay ...................................................... 49
Switch ................................................................... 75 Name Brand Speaker R e la y ................................... 62
Power Seat System ................................................. 87 Park Lamp Relay ...................................................... 50
Circuit Breaker .................................................... 87 Power Lock Relay .................................................... 78
Front Vertical Motor ............................................. 87 Power Unlock R e la y .................................................. 78
Horizontal Motor ................................................... 87 Radiator Fan Relay .................................................. 30
Rear Vertical Motor ............................................. 87 Rear A/C and Fog Lights R e la y ............................. 64
Switch ................................................................... 87 Safety Shutdown Relay ............................................ 32
Power Window Lift System .............................. 79, 80 Starter Relay .................................................... 8, 9, 10
Circuit Breaker .................................................... 79 System Relay ............................................................ 36
Left Front Master Switch ..................................... 79 Van Conversion R e la y .............................................. 91
Left Front Motor ................................................... 79 Seat Belt Warning System .......................................... 74
Left Front S w itch ................................................... 79 Sensors
Pump Motor .......................................................... 35 A/C Ambient Tem p...................................................... 29
Right Front Motor ................................................. 80 Charge Temp ............................................................ 24
Right Front Switch ............................................... 80 Detonation ................................................................... 25
Purge Solenoid 2.5L EFI Engine ............................ 13 Distance 2.5L E n g in e ................................................ 15
Purge Solenoid 3.0L E n g in e ................................... 18 Distance 3.0L E n g in e ................................................ 21
Purge Solenoid 3.3L E n g in e .................................... 22 Engine Coolant 2.5L E n g in e ................................... 15
Radiator Fan Motor ........................................... 96, 97 Engine Coolant 3.0L E n g in e ................................... 18
Radiator Fan Relay ........................................... 96, 97 Engine Coolant 3.3L E n g in e ................................... 26
Radiator Fan System W/Heater ...................... 96, 97 Heated Oxygen 2.5L Engine ................................. 12
Radio-AM/FM Stereo ............................................... 58 Heated Oxygen 3.0L Engine ................................. 18
Radio-AM/FM Stereo Cassette ........................ 60, 62 Heated Oxygen 3.3L Engine ................................. 24
Radio Speakers AM/FM Stereo or Left Front Wheel ........................................................ 34
C assette............................................. 59, 61, 62, 63 Left Rear Wheel ........................................................ 34
Rear Heater A/C System .................................. 64, 65 Low Windshield Washer Fluid ............................... 45
Blower Motor ........................................................ 65 Map 2.5L Engine ...................................................... 13
Blower Switch-Front ............................................. 64 Map 3.0L Engine ...................................................... 20
Blower Switch-Rear ............................................. 65 Map 3.3L Engine ...................................................... 24
Fuses ................................................................... 64 Right Front Wheel .................................................... 34
Heater A/C A ssem bly........................................... 65 Right Rear Wheel ...................................................... 34
Lamp-Switch Illumination Front .......................... 64 Throttle Position 2.5L Engine ................................. 12
Lamp-Switch Illumination R e a r............................ 65 Throttle Position 3.0L Engine ................................. 20
Microtemp Sensor ............................................... 65 Throttle Position 3.3L Engine ................................. 24
Mode Servo Motor ............................................... 65 Single Board Engine Controller-SBEC
Mode Servo Switch ............................................. 65 60 Way Connector 2.5L E n g in e ........................... 109
R e la y..................................................................... 64 Single Board Engine Controller-SBEC
Rear Foglamps .................................................... 68 60 Way Connector 3.0L E n g in e ........................... 110
Rear Liftgate Wiper and Washer System ....... 66, 67 Single Board Engine Controller-SBEC
Fuse ..................................................................... 66 60 Way Connector 3.3L E n g in e ............ .............. 111
M o to rs................................................................... 67
Wiring Diagram
Name________________________________ Sheet Number
Solenoids
Exhaust Gas Recirculation 2.5L EFI Engine — 13
Liftgate Release ........................................................ 71
Purge 2.5L E.F.I. E n g in e ......................................... 13
Purge 3.0L Engine .................................................... 18
Purge 3.3L Engine .................................................... 22
Speed Control S y s te m .................................................. 43
Control Switch ............................................................ 43
Fuse ............................................................................. 43
S e rv o ............................................................................. 43
Stop Lamp Switch .................................................... 43
Splices
Splice AO .................................................................. 5, 7
Splice A1 .................................................................. 5, 7
Splice A2 .................................................................. 5, 7
Splice A3 .................................................................. 5, 7
Splice A3-1 ................ ............................................... 44
Splice A4 .................................................................. 4, 6
Splice A4-2 .............................................................. 4, 6
Splice A6 .................................................................. 5, 7
Splice A10 .................................................................. 35
Splice A 11 ................................................................ 5, 7
Splice A14 ................................................................ 5 ,7
Splice A14-1 ............................................................ 5 ,7
Splice A14-2 ............................................................ 5 ,7
Splice A15 ................................................................ 4 ,6
Splice A16 .................................................................. 28
Splice A16-1 ............................................................ 5 ,7
Splice A18 .................................................................. 91
Splice A20 .................................................................. 35
Splice A21 ............................................................ 18, 22
Splice A21-1 .................................................. 13,18,22
Splice A 2 1 -2 .................................................. 13, 18, 22
Splice A21-3 ........................................................ 11,66
Splice A21-4 .............................................................. 13
Splice A22 .................................................................. 11
Splice A61 .................................................... 16,17,25
Splice A61-1 .............................................................. 26
Splice A61-2 .............................................................. 26
Splice A61 -3 .............................................................. 17
Splice C 7 .............................................................. 27, 29
Splice C15 .................................................................. 70
Splice C20 ............................................................ 28, 30
Splice C23 ............................................................ 28, 30
Splice D1 .................................................................... 33
Splice D1-1 ................................................................ 56
Splice D2 .................................................................... 33
Splice D2-1 ................................................................ 56
Splice E2 .................................................................... 51
Splice E2-1 ................................................................ 52
Splice E92 ................................................................ 103
Splice F20 .................................................................. 64
Splice F20-1 .............................................................. 66
Splice F20-2 .............................................................. 66
Splice F 2 0 - 4 .................................................................. 8 Splice X56 .................................................................. 59
Splice F21-1 .............................................................. 79
Splice F21-3 .............................................................. 86
Splice F35 .................................................................. 44
Splice F62 .................................................................. 44
Splice G5 .................................................................... 72
Splice G6 .................................................................... 38
Splice G7 .................................................................... 25
Splice G9 .................................................................... 35
Splice G9-1 ........................................................ 1 1, 1 04
Wiring Diagram
Name__________________________ Sheet Number
Splice G19 .................................................................. 37
Splice K4 ...................................................... 1 5 , 2 1 , 2 5
Splice K4-1 .................................................... 1 5 , 2 1 , 2 4
Splice K4-2 ................................................................ 15
Splice K6 ...................................................... 13, 20, 24
Splice K7 .................................................................... 25
Splice K11 ............................... ............................. 1 7 , 2 6
Spl ice K12 ............................................................ 1 7 , 2 6
Splice K13 ............................................................ 1 7 , 2 6
Splice K22 .................................................................. 20
Splice K24 .................................................................. 21
Splice L1 .................................................................... 89
Splice L2 ............................................................ 50, 104
Splice L3 .................................................................... 50
Splice L7 ........................................................ ............ 50
Splice L7-1 .......................................................... 54, 90
Splice L 7 - 2 .................................................................. 90
Splice L20 .................................................................. 50
Splice L39 .................................................................. 69
Splice L44 .................................................................. 69
Splice L50 .................................................................. 89
Splice L50-1 ................................................................ 90
Splice L60 .......................................................... 53, 104
Splice L61 ............................... ................................ 104
Splice L62 .................................................................. 90
Splice L63 .................................................................. 89
Splice L94 ................................................................ 104
Splice M1 .................................................................... 81
Splice M1-1 ................................................................ 77
Splice M1-2 ................................................................ 82
Splice M2 .......................................................... 8 1 , 1 0 2
Splice M2-1 ................................................................ 81
Splice M2-2 ................................................................ 81
Splice M2-3 ................................................................ 82
Splice M11 ................................... ............................... 81
Splice M 11-2 .............................................................. 82
Splice P33 .................................................................. 78
Splice P33-1 .............................................................. 77
Splice P34 .................................................................. 78
Splice P34-1 .............................................................. 77
Splice T 16 .................................................................. 32
Splice T41 .................................................................. 10
Splice V3 .................................................................... 45
Splice V 7 ............................................................ 45, 103
Splice V 1 0 .......................................................... 45, 101
Splice V23 .................................................................. 66
Splice X13 .................................................................. 63
Splice X13-1 .............................................................. 63
Splice X13-2 ............................................................. 63
Splice X15 .................................................................. 63
Splice X15-2 .............................................................. 63
Splice X53 .................................................................. 59
Splice X54 .................................................................. 59
Splice X55 .................................................................. 59
Splice Z0-1 .......................................................... 14, 22
Splice Z O -2 .................................................................... 4
Splice Z1 ..................................................................... 69
Splice Z1-1 .................................................................. 35
Splice Z1-2 .......................................................... 4 2 , 9 3
Splice Z 1 - 3 .................................................................. 48
Splice Z 1 - 4 .................................................................. 48
Splice Z 1 - 5 .................................................................. 47
Splice Z1- 6 .................................................................. 80
Wiring Diagram
Name_____________________________ Sheet Number
Splice Z1- 7 ............................................................ 89
Splice Z 1 -8 ............................................................ 90
Splice Z1 -10 ........................................................ 90
Splice Z1-11 ........................................................ 90
Splice Z1-12 ........................................................ 89
Splice Z1-13 ................................................. 88,100
Splice Z1-15 ........................................................ 76
Splice Z1-16 ........................................................ 69
Splice Z1-17 ........................................................ 28
Splice Z2 ...................................................... 47,101
Splice Z3 .............................................................. 48
Starter System 2.5L TBI Engine .............................. 8
M o to r....................................................................... 8
R e la y ....................................................................... 8
Starter System 3.0L Engine ..................................... 9
M o to r....................................................................... 9
R e la y ....................................................................... 9
Starter System 3.0L and 3.3L Engine
with Electronic Transmission .............................. 10
M o to r..................................................................... 10
R e la y ..................................................................... 10
Steering Column to Instrument Panel
Wiring Connector 25 W a y .................................. 113
Stop Lamp Switch .................................................. 43
Switches
A/C Clutch 2.5L EFI Engine ................................ 28
A/C Clutch 3.0L & 3.3L Engine .......................... 30
A/C Damped P ressure......................................... 29
A/C Fan Cut Out .................................................. 29
A/C Heater B lo w e r......................................... 27, 29
Ambient-Overhead Console ................................ 85
Automatic Transaxle Neutral Safety ................... 31
Back-Up Lamp 2.5L Engine .................................. 8
Brake Stop Lamp ................................................. 43
Brake Warning Lamp ......................................... 105
Cargo L a m p .......................................................... 82
Courtesy Lamp ............................................... 81,82
Damped Pressure-A/C......................................... 29
Dimmer-Headlamp ............................................... 50
Dome Lamp-Rear ................................................. 82
Door Ajar-Left ...................................................... 73
Door Ajar-Right .................................................... 73
Door Jamb-Left .................................................... 81
Door Jam b-R ight.................................................. 82
Door Lock-Electric ............................................... 77
Hazard Warning .................................................. 49
Headlam p.............................................................. 49
Headlamp Dimmer ............................................... 50
Heated Rear Window Defogger .......................... 70
Horn ..................................................................... 44
Ignition .................................................................. 11
Intermittent W ip e .................................................. 45
Key-in ................................................................... 81
Left Front Door J a m b ........................................... 81
Left Front Illuminated E n try .................................. 83
Left V e n t................................................................ 86
Liftgate Ajar .......................................................... 73
Liftgate Latch Switch ........................................... 82
Liftgate Release .................................................. 71
Liftgate Wiper and Washer .................................. 66
Map Lamp ...................................................... 84, 85
Neutral Safety ...................................................... 31
Oil-Low Pressure..................................... 38, 39, 40
Optical H o rn .......................................................... 50
Park Brake W a rning ........................................... 105
Power Door Locks ............................................... 77
Wiring Diagram
Name________________________________ Sheet Number
Power Seats .............................................................. 87
Power Windows .................................................. 79, 80
Power Remote M irro rs .............................................. 75
PRNDL ......................................................................... 32
Rear Heater A/C ................................................ 64, 65
Right Front Door Jamb ............................................ 82
Right Front Door Illuminated Entry ....................... 83
Right Vent .................................................................. 86
Seat Belt Warning .................................................... 81
Seats-Electric ............................................................ 87
Sliding Door ................................................................ 82
Speed Control ............................................................ 43
Speed Control Brake ................................................ 43
Stop Lamp .................................................................. 43
Temperature S e n d in g ................................. 38, 39, 40
Turn Signal ................................................................ 49
Underhood Lamp ...................................................... 95
V e n t ............................................................................... 86
Window Lift ................................................................ 79
Windshield Washer Low Fluid ............................... 45
Windshield W iper-Interm ittent................................. 45
Temperature Sending Unit ..................... 26, 38, 39, 40
Throttle Position Sensor 2.5L EFI Engine ............... 12
Throttle Position Sensor 3.0L Engine ....................... 20
Throttle Position Sensor 3.3L Engine ....................... 24
Trailer Tow Connector ................................. .. 8 9,9 0
Turn Signal System ................................................ 53, 54
Flasher ......................................................................... 50
Fuses ........................................................................... 53
Lamps-Front .......................................... 4 1 , 4 2 , 9 2 , 9 3
Lamps-Rear ................................................................ 54
Switch Control ............................................................ 53
Underhood Lamp .......................................................... 95
Underhood Lamp Switch .............................................. 95
Vacuum Solenoids ........................................................ 98
Van Conversion Wiring ............ ................................... 91
Fuse ............................................................................. 91
Van Conversion Relay .............................................. 91
Vent System .................................................................. 86
Left M o to r..................................................................... 86
Left Switch .................................................................. 86
Left Switch Connector .............................................. 86
Overhead Console .................................................... 86
Right Motor ................................................................ 86
Right S w itc h ................................................................ 86
Right Switch C o n n e cto r............................................ 86
Visor Courtesy Lamp .................................................... 82
Warning Lamp Module System ................................. 72
Warning Lamp C o n n e cto r.......................................... 120
Window Lifts Electric .............................................. 79, 80
Circuit Breaker .......................................................... 79
Motors .................................................................. 79, 80
Switch .................................................................. 79,80
Window-Rear Wash and W ip e r ........................... 66, 67
Fuse ............................................................................. 66
M o to rs ........................................................................... 67
Switches ....................................................................... 66
T im e r ............................................................................. 66
Windshield Wiper-Intermittent ............................. 45, 46
Fuse ............................................................................. 46
Low Washer Fluid Lamp ......................................... 45
Low Washer Fluid Lamp Sensor ........................... 45
Washer Motor ............................................................ 45
Washer Switch .......................................................... 45
Wiper Motor ................................................................ 46
Wiper Switch .............................................................. 45
* * * * * * T H IS PA G E IS b la n k ******
 FUS1BLE LINK
18 GAUGE
(GRAY)

FUSIBLE LINK
10 GAUGE
FUSIBLE LINK FUSIBLE (DARK GREEN)
22 GAUGE (WHITE) LINK
REAR OF BATTERY FUSIBLE LINK 18 GAUGE
A15 14PK 20 GAUGE (GRAY)
(ORANGE)
FUSE #1
20 AMP
(YELLOW)
A/C SYSTEM
SH 2i» 30
t
Ai
12RD/
L9 BK*
18BK*

1
HAZARD
FLASHER
SH 53 FUSE #21
21
20 AMP
FUSE #22 (YELLOW)
20 AMP FUSE #19 -*1 FUSE #20
f?
5f?
(YELLOW)
19 IJ 20
20 AMP
20 AMP
F61 (YELLOW) (YELLOW)
18WT/
OR*
F32 F36
FOG LAMPS 18PK/ 16WT*
SH 69 PB#
%S^%
STOP LAMP REAR HEATER
SWITCH AND A/C SYSTEM
REAR SH 43 SH §4
LIGHTING
SH 8 i f90
23
FUSE #23
20 AMP
(YELLOW)
L7 18BK/YL*

FRONT
f?
F82
END iSRD
LIGHTING
FUSE #9 SH 41,42 i
7.5 AMP HORN
(BROWN) SH 44
CIGAR
LIGHTER
SH 44
RADIO
SPEAKERS
SH 62
 FUSIBLE LINK
r 20 GAUGE
FUSIBLE LINK
(RED) 18 GAUGE
r
A10 (GRAY)
20RD
A4
18GY

ABS SYSTEM
SH 34, 35,.36,
A3 12RD*

t
37
A3 12RD#
A4
12BK/
1 25 AMP RD*
^ CIRCUIT BREAKER (PLUGS
! _ INTO LOCATION 11 OF FUSE #3
- J RELAY BANK) 20 AMP
(YELLOW)

L20 14LG/WT* M1
2 7 ^ _ i 30 AMP CIRCUIT 18PK
BREAKER (PLUGS L2Q 14LG/WT* 1
INTO CAVITY #27
OF FUSEBLOCK) 1 PFtL
MODULE
X
COURTESY
f?
F35
OPTICAL
HORN
SH 94 LAMPS
SH 81, 82
12RD SH 50 RADIO
X SH 58, 60,
POWER SEATS HEADLAMP 62
SH 8? DIMMER SWITCH ELECTRONIC
POWER DOOR SH 50 CLUSTER
LOCK MOTOR SH 55
SH 78 L4 OVERHEAD
CONSOLE
14VT/
WT* SH 84
BODY
COMPUTER
SH 102 .

RD*
1
LT LOW BEAM RT LOW BEAM
SH 42 SH 41

918W-9 AS-HK 2
 FUSIBLE LINK
18 GAUGE (GRAY)
n
CHARGING SYSTEM
AO 10RD

(SEE SH 4, 5, 6, 7)

L A1 200R
FUSIBLE LINK
20 GAUGE (ORANGE)
IGNITION STARTER
—— A21 14DB -H SWITCH SYSTEM
SH 8 SH 5, 6, 7

A31 14BK*
15 FUSE #15
10 AMP A22 12BK/OR*
(RED)

G5
20DB*
X 30 AMP
14 ZJ FUSE #14 FUSE #24 26 = J FUSE #26 CIRCUIT
WARNING LAMP 2 AMP 20 AMP 30 AMP
CENTER SH 72
BODY COMPUTER
(GRAY) (YELLOW) (LIGHT
GREEN)
t BREAKER
(PLUGS
SH 102
ELECTRONIC
'¥34
20WT/
¥
F20 Cl
f?
F21
INTO
CAVITY
CLUSTER ' 16WT 12DG 12TN #25 OF
RD* FUSEBLOCK)
SH 55
X i
SPEED CONTROL BACK-UP LAMPS HEATER OR AIR POWER WINDOWS
SH 43 SH 89 CONDITIONING SH 79, 80
HEATED REAR BLOWER MOTOR
WINDOW SWITCH SH 27, 29, 57
TO EBL SH 70
SWITCH FOG. LAMPS
SH 70 A/C FAN RELAY
T
C15
SH 27, 29

12BK*

FUSE #2 13 hJ FUSE #13 FUSE #5 FUSE #8 FUSE #7

10 AMP 20 AMP 20 AMP 20 AMP 10 AMP
(RED) (YELLOW) (YELLOW) -j (YELLOW) (RED)
1?
C li ¥23 V6 L5 X12
20LB/ 16BR/ 18DB 18BK/ 20RD*
YL PK* PK#
vJ-'N vK i. J.
HTD POWER LIFTGATE WINDSHIELD TURN SIGNAL RADIO FEED
MIRROR WIPER WASHER WIPER FLASHER SH 58, 60, 62
SH 75» 76 SH' 88 SH 48 SH 53
VAN CON¥ERSlON RELAY
SH 91
 FUSIBLE LINK
(HYPALON WIRE)
(REAR OF
BATTERY) A(
 TO
STARTER SYSTEM
(SEE SH 9,10)
ENGINE GROUND
(AIR PUMP BRACKET
MOUNTING BOLT)

140
14BR
X
TO
STARTER RELAY A15
20 OR
(SEE SH 9,10)
T° VAN C A18 A18 12RD/BK* -flh— A4 18GY —
CONVERSION/ 14RQ/PK* -< f
(SEE SH 91) #3 TO SAFETY
FUSIBLE LINK E
_ l / SHUT DOWN
P— A14 18RD* 4 RELAY
(HYPALON WIRE)
(REAR Of E l (SEE SH 32)
TO UNDERHOOD #48 (REAR OF BLACK A4
BATTERY)
LAMP BATTERY) 12BK/
(SEE SH 95) RD*

A4 12BK/RD*
#23
E l
A15 IGNITION
14 PK FUSE #1 OFF
(20 AMP) DISCONNECT TO
e TO LEFT
L - c ,£ Li ISBK * —| POD SWITCH 4 ^1^21
(SEE SH 49) SPLICE
(SEE SH 7)

918W-9 AS-HK 0
 ALTERNATOR ■ BOSCH 40/90 ALTERNATOR
GROUND 21 SBK (RIGHT SIDE FORWARD OF ENGINE)
(UPPER RIGHT ___
OF ENGINE) ■=■

TO
^>21
SPLICE
{SEE SH 18, 22)
r- A21 18DB
T
A21 BLACK
18DB

k
K20 18DG

NiPPONPENSO 40/90 ALTERNATOR

(RIGHT SIDE FORWARD OF ENGINE)
(REAR OF
TO K20 (REAR OF BATTERY)
PARK AND 18DG BATTERY)
FOG LAMPS'y ~ \
Ai ,
(SEE SH 89) 12~
NATURAL'
BK* TO SINGLE
BOARD ENGINE
#2
Is
!5
Ai
u _ | CONTROLLER
CAVITY 20
10RD/ (SEE SH 17, 25)
BK TO
ANIiLOCK
TO $ BRAKES
STARTER (3.3L ONLY)
SYSTEM (SEE SH 35)
(SEE SH FUSIBLE LINK
Alt (HYPALON WIRE)
12, 13) 6BK/GY
(REAR OF BATTERY)
T
^ FUSIBLE TO SPLICE
12RD LINK'
(SEE SH 30)
AO §BK

A2 12PK* -)>— A2 12PK*

FUSIBLE LINK TO IGNITION
(HYPALON WIRE) SWITCH
(REAR OF BATTERY) l j [ j #49 (SEE SH 11)
FUSIBLE LINK A1 200R — A1 12RD —) ) — A1 12RD#
(HYPALON WIRE)
(REAR OF BATTERY) < TO SBEC
A14 18RD* —§ (SEE SH 19, 23)

, TO SHUTDOWN
A14 16RD* ^ 4 RELAY
(SEE SH 19, 23)
FUSIBLE LINK A. . . . ( TO I.O.D.
(HYPALON WIRE) (SEE SH 6)
(REAR OF BATTERY)
TO <A3>T1 SPLICE
A 3 18GY } ) — A3 12RD*
(SEE SH 44)
 FIELD COIL
STARTER MOTOR
(REAR OF ENGINE)

TO BACKUP
LAWPS
(SEE SH 89)

DARK GRAY
(REAR Of
BATTERY) TO SINGLE BOARD
ELECTRONIC CONTROLLER
. (SEE SH 18)
TO A/C FAN
MOTOR RELAY
(SEE SH 2?)
TO A/C CYCLING
SWITCH
(SEE SH 27)

FUSE #24
(20 AMP) TO IGNITION
< 6 ^ 7 ....
(SEE SH 84) F20 16WT A22 12BK/OR jf/ (SEE
SWITCH
SH 11)
STARTER SYSTEM (2.5 ENGINE) AS-HK 8
918W -9
TO CHARGING,
SYSTEM A0 6RD
(SEE SH §) TO CHARGING
TO SINGLE
BOARD ENGINE SYSTEM
$ CONTROLLER (SEE SH ?)

TO BACK-UP
LAWPS '
(SEE SH 89J

P20 18WT

TO A/C
FAN RELAY
(SEE SH 2?)

STARTER SYSTEM (3.0L ENGINE)

WITH 3 SPEED AUTOMATIC
 TO
CHARGING C _ _ ^ ^ A1 12BK
SYSTEM
{SEE SH 7)

TO
BATTERY AO SRD
(SEE SH S) At
12BK

140 14BR
V-
1
AtS
14BK AO 6RP — ^

TO CHARGING i T40 14BR—lE ^ I?

SYSTEM STARTER WOTOR — i 3.0 LITRE ONLY
(SEE SH 6 ) (REAR OF ENGINE)
BLACK
i
(REAR OF AO 6RD-
BATTERY)
FUSIBLE
(SEE SH 4) !
LINK TO I T 401 4B R -
CHARGING I 3.3 LITRE ONLY
A15 2O0R A15 14PK - A15 16PK SYSTEM
(SEE SH 6 )
#23
1 3
TO NEUTRAL
A1 12BK
SAFETY SW ITCH C- T41 18BR/YL
(SEE SH 31)

TO TRANSAXLE T41 18BR/YL# S \

CONTROLLER
CAVITY 41 T41 20BR/YL*
T40 (SEE SH 31)
14BR T40' 14BR " •
TO SINGLE f — T41 2GBR/YL' A41 18YL
BOARD ENGINE A1 12BK
CONTROLLER
CAVITY 30 . L4L 1! BR/YL#
(SEE SH 20, 24)
STARTER RELAY
(LEFT SHOCK HOUSING)

TO TRANSAXLE f — A41 14YL

CONTROLLER
CAVITY 8
(SEE SH 31)

T™ NS- ’" L
(SEE SH 111 - #3'

STARTER SYSTEM WITH ELECTRONIC

TRANSAXLE (3.0L & 3.3L ENGINE)
 FUSE #13
(20 AMP) 4 TO SPLICE ■
; (SEE SH 66 )

TO SPEED
CONTROL
(SEE SH 43|

TO POWER
WINDOW LIFT
(SEE SH 79)

TO TURN
SIGNAL
FLASHER
(SEE SH 53)

¥ 6 18DB
(SEE SH 48)

IGNITION SWITCH
 (CENTER REAR
K33 18GY/RD# OF ENGINE)
Z12 18BK/TN*
BLACK

KBO 18YL/BK* (TOP REAR

K40 18BR* OF ENGINE)
K59 1PVT/BK*

HEATED
OXYGEN SENSOR
(CENTER OF
r r m i n n ENGINE ON GROUND
EXHAUST
MANIFOLD)
n n r r
AUTOMATIC IDLE
K40 K39 K60 K59 SPEED MOTOR
(ON THROTTLE
BODY)

K40 18BR*
K39 18GY/RD*

BLACK
K6 20VT/WT* BLACK
K22 tSOR/PB* (RIGHT REAR K4 18BK/LB* -J
OF ENGINE)
K4 18BK/LB*

THROTTLE POSITION 'LlUfc f

TO <^6^ SPLICE
SENSOR
(RIGHT SIDE OF (SEE SH TO TO TO
THROTTLE BODY) • DIAGNOSTIC
fS sti CONNECTOR
(SEE SH 14)
BLACK— \ SPLICE . SPLICE
(RIGHT REAR (SEE SH 58) (SEE SH 56)
OF ENGINE)
TO ENGINE
DiSCONNE
(SEE SH 14)
T
Z11
|_^TO<K6> SPLICE 18BK*

1 (SEE SH 13)

K4 18BK/LB*
SPLICE
(SEE SH 16)

SINGLE BOARD ENGINE CONTROLLER FOR 60 WAY SINGLE BOARD

(SBEC) ENGINE CONTROLLER CONNECTOR
(LEFT FENDER SIDE SHIELD) (SEE SH 109)
 TO SPLICE
) } - V23 18BR/PK*
0
(SEE SH ii)
A21 14DB —<< ) ) - ¥34 20WT/RD*
TO SPEED

)> - G5 20DB/W T* —
9 CONTROL
(SEE SH 43)
FUSE #13 TO
(20 AMP)
TO IGNITION FUSE #14
SWITCH (2 AMP)
FUSE #15 SPLICE
(FRONT OF A21 (SEE SH 11) (SEE SH 72)
RIGHT SIDE 14DB (10 AMP)
SHIELD) , TO BATTERY
A21 14DB — —— i DISCONNECT
TO CHARGING (SEE SH 18)
SYSTEM
(SEE SH 4) -TO DIAGNOSITC
A21 A21 14DB 4 CONNECTOR
14DB (SEE SH 14)
, TO AUTO
A21 14DB 4 SHUTDOWN RELAY
EXHAUST GAS (SEE SH 14)
RECIRCULATION
x DIAGNOSTIC SOLENOID TO THROTTLE
A21 K6 20VT/WT POSITION
14DB SENSOR
A21 14DB (SEE SH 12)
I K35 20GY/YL*

BLACK-
TO RADIATOR
FAN RELAY
(SEE SH
27,29)
K6 20VT/WT J
PURGE SOLENOID
(FRONT OF RIGHT
SIDE SHIELD) (RIGHT
SHOCK K6 20VT/WT*
KS2 20PK/BK*
A21 14DB I
J TOWER)
K1 20DG/RD*
K4 18BK/LB*
BLACK I

G24
20GY/
PK*
#15 L K4 1SBK/LB* T O <K 4jil SPLICE
K52
2GPK/ (SEE SH 12)
BK* □
TO WARNING K1
LAMP G24 K3S 20PG/
CENTER 20QY/ 20GY/ RD*
(SEE SH 72) PK* YL*

52 56
A 35 9 1
SINGLE BOARD ENGINE CONTROLLER FOR 60 WAY SINGLE BOARD
(SBEC) ENGINE CONTROLLER CONNECTOR
(LEFT FENDER SIDE SHIELD) (SEE SH 109)
 (RIGHT FENDER
SIDE SHIELD)

TO
NEGATIVE
BATTERY Z0 10BK
TERMINAL
(SEE SH 4)

BLACK
(REAR OF
BATTERY)
 REAR OF BATTERY
(DK GRAY)
(REAR OF
TRANSMISSION)
• K4 18BK/LB*
•bS> G? 20WT/QR

BLACK
G7 2QWT/OR*
K4 18BK/LB*

TO HEATED
OXYGEN SENSOR t _ K4 tSBK/LB*
(SEE SH 12) K4) G? K4
18BK 18BK
K4 18BK/LB*
T° s r " i8bk,lb‘
TO THROTTLE nK4
POSITION SENSOR K4 18BK/LB* 18BK/
(SEE SH 12) LB*

*A-s
K4
BLACK (REAR OF 18BK/
BATTERY) LB*

DISTRIBUTOR
ENGINE COOLANT (RIGHT FRONT
I SENSOR (TOP OF ENGINE)
| LEFT OF ENGINE)
G7
K4 18BK/LB* K24 20WT/DR*
18QY/ DISTANCE
BK* SENSOR (REAR OF
TRANSMISSION)
K2 20TN/WT*

K7
180R K4 K24
K4 K2 18BK/ 18GY/
TO STARTER LB* BK*
SYSTEM 18BK/ 20TN/
(SEE SH 8) LB* W T*

■ T41
T
20BR/
YL*
X
30 4? 24
SINGLE BOARD ENGINE FOR 80 WAY SINGLE BOARD ENGINE
CONTROLLER (SBEC) CONTROLLER CONNECTOR
(LEFT FENDER SIDE SHIELD) (SEE SH 109)'
 TO. HEATED
OXYGEN T O AUTO SHUT­
SENSOR DOWN RELAY
(SEE SH 12) (SEE SH 14)

INJECTOR (T O P OF
THROTTLE BODY)

K64 180R/BK *
PARK
THROTTLE A21 14DB
UNLOCK
A61 SOLENOID
14DG/
BK* r iF f

A61 14DG/BK .J K11

18WT/
DB*

A21 K64
14DB 180R /
BK*

T O IGNI­
Y
'
A61
TION COIL 14DG/
(SEE SH 14) BK*
> 1
SI?
Oo i»o O
o o o © O
j .
T O FUEL
TANK ELEC­ PK GRAY - < J P r f il
TRICAL FUEL (REAR O F \
TO
PUMP MOTOR BATTERY) \
CHARGING
(SEE SH S i)
SYSTEM
(SEE SH 8)
TO SPLICE

(SEE SH 8)

T
P20 K20 K11
18WT/
16WT 18DG
DB#
(SEE SH 13)
>X
y V
X
/ V
1
1 20 16 54

SiNGLi E BOARD ENGINE CON- FOR 00 WAY SINGLE BOARD ■ '

TRC>LLER (SBEC) (LEFT ENGINE CONTROLLER C O N - ■ '
■ FE NDER SIDE SHIELD) NECTOR (SEE SH 109)
 TO FUEL TANK (TOP OF THROTTLE (TOP OF THROTTLE (TOP OF THROTTLE
ELECTRICAL BODY) BODY) BODY)
FUEL PUMP MOTOR
(SEE SH 88 )

TO AUTO
SHUTDOWN
RELAY
(SEE SH 19)

TO CHARGING
' SYSTEM
(SEE SH ?)

K20 16DG/
18PG

20 8 14 15 16 46 2§
SINGLE BOARD ENGINE CONTROLLER FOR SINGLE BOARD ENGINE
fSBEC) CONTROLLER CONNECTOR
(LEFT FENDER SIDE SHIELD) (SEE SH 110)
 TO
CHARGING ,
SYSTEM A14 16RD/WT* -
(SEE SH 7) V
i FUSIBLE
ELECTRONIC \ LINK
TRANSAXLE
ONLY

\ IGNITION A61 14DG/BK*

COIL A21 14DB

TO
K51 20PS/YL*' CHARGING
TO K51 20DB/YL* SYSTEM
(SEE SH 7)
SPLICE V— A61 18DG/BK* — I K51 20DB/YL*
(SEE SH 17)
AUTO
SHUTDOWN
BLACK O o e o
RELAY
(LEFT FENDER
0 • e o0
TO SIDE SHIELD)
TO
RADIATOR
SPLICE FAN RELAY
(SEE SH 18) (SEE SH 30)
— Z12 12BK/TN*
T T
[— Z11 18BK*

TO AIR
CONDITIONING
SYSTEM '
(SEE SH 30) .
.T ( FRONT
OF
Z12 C27 K19 RIGHT A14
16BK/ 20DB/ 18GY SHOCK 16RD/
TN* PK TOWER) wr*

Z12 C20 C13 . D20

16BK/ 18BR 20PB/ 20L6
TN* OR*
i i
11 12 27 31 34 19 51 25 45 3
SINGLE BOARD ENGINE CONTROLLER FOR SINGLE BOARD ENGINE CONTROLLER
(SBEC) CONNECTOR
(LEFT FENDER SIDE SHIELD) • (SEE SH 110)
 AUTOMATIC
IDLE SPEED MOTOR

K40 K39 K69 K60 K22 K6 SPLICE

18BR/ 18QY/ 18VT/ 18YL/ 180R / 20V T / (SEE SH 18)
TO SINGLE
L K1 20DG/RD* -4 BOARD ENG,NE
# CONTROLLER
% X x x ^ %X N
2 (SEE SH 18)
1> X/ sr > f 1r >
30 40 39 59 60 22 8
SINGLE BOARD ENGINE CONTOLLER FOR SINGLE BOARD ENGINE CONTROLLER
(SBEC) CONNECTOR
(LEFT FENC »EE SH 1
 DISTRIBUTOR
(RIGHT FRONT
t/7 1BAD OF ENGINE)
BLACK
 TO ANTI-LOCK TO TO
BRAKE DIAGNOSTIC RADIATOR
SYSTEM CONNECTOR FAN RELAY
(SEE SH 35) (SEE SH 23) (SEE SH 30)

TO CHARGING
SYSTEM
(SEE SH 7}

TO (LEFT FRONT C
AUTO OF ENGINE) BATTERY
SHUT DOWN
RELAY
(SEE SH 23)

TO SPLICE .
Z13 18BK/RD* (SEE SH 32)
TO SPLICE
214 18BK/YL* (SEE SH 32)'
Z12 12BK/TN*

Z11 18BK/WT* Z11 16BK*

A21 14DB i
J A D k '/R k '*
K52 20PK/BK 1

PURGE TO AIR
SOLENOID CONDITIONING
SYSTEM
(SEE SH 30)
| 3
A21 A21 Z11
14DB 14DB 16BK/
KS2 WT*
20PK/ vL X
BK* TO ELECTRONIC TO ELECTRONIC
TRANSAXLE TRANSAXLE
TO IGNITION NEUTRAL SAFETY CONTROL MODULE
SWITCH SWITCH CAVITY 11
(SEE SH 11) (SEE SH 31) (SEE SH 31)

SINGLE BOARD ENGINE CONTROLLER FOR SINGLE BOARD ENGINE CONTROLLER

(SBEC) CONNECTOR
LEFT FENDER SIDE SHIELD) (SEE SH 111)
AUTOMATIC IDLE
SPEED MOTOR

SINGLE BOARD ENGINE CONTROLLER FOR SINGLE BOARD ENGINE

(SBEC) CONTROLLER CONNECTOR
(LEFT FENDER SIDE SHIELD) (SEE SH 111)
 18BK/ (ON REAR OF
LB* TRANSMISSION)
TO FUEL RAIL
(SEE SH 28)

TO ELECTRONIC
TRANSAXLE
CONTROLLER
CAVITY 45
(SEE SH 31)

TO FUEL TANK
ELECTRICAL FUEL
PUMP MOTOR
(SEE SH 43, 100)
T
A61
14DG/
SK*

TO AUTO
SHUTDOWN
RELAY
(SEE SH 23)

8 47 42 7 24 4 20 46 26

SINGLE BOARD ENGINE CONTROLLER FOR SINGLE BOARD ENGINE

(SBEC) (LEFT FENDER SIDE SHIELD) CONTROLLER CONNECTOR
(SEE SH 111)
 I FUSE #26
A22 (30 AMP)
12BK /
OR*

J . 25 \ 28^>
TO IGNITION
eiA/iTr*u iDiiMi t f

AS-HK 27 (2.5L ENGINE) 918W-9

 AIR COND ITIONING
COMPRESSOR

AIR CONDITIONING
SYSTEM (2.5L ENGINE)
 f
A22
12BK/
OR*
X
TO IGNITION
SWITCH (RUN)
(SEE SH 11)

(SEE SH 47)
( S E E S H 5 2 ) ["
C? 12BK/TN*
C21 18DB/OR*
C? 12BK/IN* I - C4 1STN
X / i
C5 1 6 L Q
r— C5 18LG —\ GROMMET
" T (UPPER RIGHT C6 MLB
C4 16TN y OF DASH
C? 12BK/TN
£ PANEL)
J—i □ 21 12BK
U □ AIR CONDITIONING
T AND HEATER
F t BLACK
C7
C6 MLB
12B K /T N *
BLOWER
MOTOR RESISTOR
AIR CONDITIONING SYSTEM
(3.0L & 3,31 ENGINE)
 Zt 18BK
AIR CONDITIONING
P20 18WT COMPRESSOR
RADIATOR FAN MOTOR ENGINE GROUND
P20 {FRONT OF CAR) (UPPER LEFT
1SWT OF ENGINE)

Zf
12BK

(LEFT OF
COMPRESSOR)

BLACK

(SEE
TO IGNITION SH 89) DIODE L- C3 12DB/BK* -i
SWITCH
(SEE SH 11)
RIGHT
HEADLAMP
GROUND
21
12BK
H ,_ £ L -
f o° >MO|
©©• o C23 12DG
I oo •• ©
o © o 4- ----
o O
0s _ ■Jl—^
(RE OF
(REAR AIR
DARK-< BATTERY)
BA1 CONDITIONING
GRAY V FAN MOTOR
7—HbOSt!— Zt
flST T f^ --------- ,
C23 12BK
12DG (FRONT OF
p • o jf Oj
VEHICLE)

TO SINGLE Z1 12BK
BOARD ENGINE
C27 20DB/PK* -) CONTROLLER V C13 20DB/QR*
' CAVITIES 31, 34
(SEE SH 19, 23)
C13 20DB/OR* I
C27 20P8/PK#1 I
C3 12DB/BK* I
I
C25 12LG A21 14DB ^
A21 14DB A16 12GY I'
A16 12GY
C . (LEFT FENDER
RADIATOR 12DG SIDE SHIELD)
FAN RELAY
(LEFT SHOCK TOWER) AIR CONDITIONING
SPLICE CLUTCH RELAY
A21 14DB — — — —|T O
(SEE SH 19, 22)
A1612GY
x TO CHARGING C23
At 6 12GY — ( SYSTEM TO ^2*> SPLICE $----- A21 14DB
(SEE SH ?) 12DG

AIR CONDITIONING
918W-9 SYSTEM (3.0L & 3.3L ENGINE) AS-HK 30
 TO THROTTLE
POSITION
SENSOR
(SEE SH 20, 24)
T
K22
NEUTRAL SAFETY 180R/
SWITCH (FRONT OF DB*
TO SINGLE
TRANSMISSION)
BOARD ENGINE

TURBINE INPUT
SPEED SENSOR
(FRONT OF
TRANSMISSION)

TURBINE OUTPUT
SPEED SENSOR
(FRONT OF
TO STARTER
TRANSMISSION)
RELAY
(SEE SH 10)

T
T41 T41
18BR/ 18BR/
YL# YL*

41 11 45 51 12 8 13 52 14

ELECTRONIC AUTOMATIC TRANSAXLE FOR CONTROL

CONTROL MODULE MODULE CONNECTOR
(RIGHT FENDER SIDE SHIELD) (SEE SH 119)
 BLACK SAFETY
T15 18LG SHUTDOWN
MINI-RELAY
(RIGHT SIDE FENDER
A14 16RD
SIDE SHIELD) T1C i fi l fy
A14 18RD

Z13 18BK/RD#

T16 12RD

TRANSAXLE
SOLENOIDS &
PRESSURE SWITCH
(FOR CONNECTOR SEE SH 126) TO CHARGING.
TO
SYSTEM ■'
3 1 8 5 6 (SEE'SH 7) I.O .D . '
(SEE SH 8)
_x_ ^ Z* x, sU
f T
TI ' r yi xr yi I
TO
150
18DG
T9 119
18WT
im
18BR
T16
12RP Si
180R/ WHITE
BK*
SPLICE
(SEE SH 19, 23)

T • T1 18LG*
212 ZO
- 12BK/ 10BK T42 18VT*
JM* Z13 18BK/RD*
PRNDL SW
(FRONT OF /
TRANSMISSION) ✓
/

A14
18RP

T 47 120 IS3 116 Z14 Z13 T16

18YL/ 18LB 18PK 18RD 18BK/ ' 18BK/ 18LG
YL* RD*

y
yV
50
BK*

x .
yf%,
4?
,
/ s.
9
1
!

yfs.
20
,
y
19
1
I

59
j

80
v
1
I

yf^
16
„
y
17
t _________
i J
__ ______ 4
53 54
v yfK
i
67
JK
yX
68
1
.ill.
42
ill
9±9
1 - 56 15

■ ELECTRONIC AUTOMATIC TRANSAXLE FOR CONTROL

CONTROL MODULE MODULE CONNECTOR
(RIGHT FENDER SIDE SHIELD) (SEE SH 119)
 ELECTRONIC AUTOMATIC TRANSAXLE FOR CONTROL
CONTROL MODULE (EATX) MODULE CONNECTOR
(RIGHT COWL PANEL) (SEE SH 119)
i 45 3 2

TO NEUTRAL
SAFETY SWITCH i
D2 (SEE SH 31) #
20WT/
BKft
L1 18VT/BK*
T2 M IN /U K *

F20 18WT

T3 14VT
F20
T3 18¥T 18WT
BACK-UP LAMP RELAY
(RIGHT REAR SIDE FENDER) F2§
18WT
TO AIR TO
CONDITIONING BACK-UP
SYSTEM LAMPS
(SEE SH 29) (SEE SH 89)
JACKETED JACKETED {SEE SH §4)
TWISTED TWISTED
PAIR PAIR

TO TO
<023
SPLICE SPLICE
JPLIC
(SEE SH 56) (SEE
E SH 56)

T
D2
T
D1
20WT/ 20¥T/
BKA BR*

25 4§
SINGLE BOARD ENGINE CONTROLLER FOR 80 WAY SINGLE BOARD ENGINE
(SBEC) CONTROLLER CONNECTOR
(LEFT FENDER SIDE SHIELD) (SEE SH 109. 110, 111)
 ....v v ......... . TWISTED PAIR
B6 20WT/DB
RIGHT
FRONT
WHEEL
SENSOR
& . .\ \
;? 9 .. .

LEFT
FRONT
WHEEL
SENSOR

W i
— f/— 1
9994.r
REAR
WHEEL
SENSOR
II • \\

LEFT
REAR
WHEEL
SENSOR

1-3 1-4 1-2 1-1 1-9 1-8 1-7 1-8

(UNDER BATTERY TRAY)

FOR 60 WAY ANTI-LOCK

ANTI-LOCK BRAKE SYSTEM BRAKE SYSTEM CONTROLLER
CONTROLLER CONNECTOR (SEE SH 124)
 (ON DASH PANEL} LOCK
ANTI-LOCK BRAKE BRAKE SYSTEM
SYSTEM HYDRAULIC CONNECTOR '
MODULATOR (SEE SH 124)

2-5 2-6 2-7 2-9 2-10

 {ON DASH PANEL) FOR ANTI-LOCK
ANTI-LOCK BRAKE BRAKE SYSTEM
SYSTEM HYDRAULIC CONNECTOR
(SEE SH 124)
MODULATOR
3-1 3-2 3-3 3-4 3-5 3-10 3-9 3-8 3-? 3-6

ANTI-LOCK BRAKE SYSTEM

 BLUE

DIAGNOSTIC
CONNECTOR
(LOCATED ON
LIFT LOWER
REINFORCEMENT)

D12
200R

D11 D12
20W T/ 2§OB
VI*

#43 #44

TO
D ll D12
20WT/ 20OR
VT*
SPLICE
(SEE SH 22 )

A21 D11 D12

20LG/ 16RD/ 16RD/ 14DB 20WT/ 200R
OIR* LI3* LI3* V*I *

✓
V JxX JXX J kV J^ xX J/ XV

(UNDER BATTERY TRAY) 1 -1 5 1 -50 1-4? 1 -8 0 1-11 1 -12

ANTI-LOCK BRAKE SYSTEM l o c k b r ^ e Ys y s t e w

m M T D A I 1 CD CONTROLLER C O N N E C -
U U IM 1 K U L L b h Tq R (SEE SH 149)

ANTI-LOCK BRAKE SYSTEM

 CLUSTER
- 66© 22GY/YL* TO BODY
WHITE v COMPUTER BLUE GRAY^
% o
(ila d iooonooooooTS
paa ao o o oa o o ]

TO BODY
COMPUTER

G20
2 0 V I/
YL#

SPLICE
(SEE SH 33)

OIL
PRESSURE
SWITCH
= {FRONT OF
ENGINE)
 CLUSTER
- G60 22GY/YL* TO BODY
WHITE . COMPUTER m JE GRAY ... j f L
s p o o o o o o
X f^Joc " looooaaDODolK
....... ..... . _ _ J L j-if-ii
pooooooooooI OQQOOOO

TO BODY
COMPUTER

G20 Gi
20VT/ 20GY
YL#

#17

El ^ G60 22GY/YL*

G20 G6
20VT/ 20QY #16
YL#
El

>...
> BLACK DK GRAY — '
...IffrSll_ (REAR OF (REAR OF
f o n) oOl J * IBATTERY) BATTERY)
1

j>o
w

SPLICE
(SEE SH 33)

20GY/ —i
YL*
skN J X
TEMPERATURE XK ... .....JL
SENDING UNIT OIL
(RIGHT SIDE 1i m-i PRESSURE
OF ENGINE) SWITCH
If HONT OF
T ENGINE)
 CLUSTER
- 660 22GY/YL* TO BODY
w COMPUTER BLUE GRAYV

f^foD
poD oaooaaooj

TO BODY
COMPUTER

L G80 22GY/YL#

DK GRAY
(REAR OF
BATTERY)

SPLICE
(SEE SH 33)

TEMPERATURE
SENDING UNIT ..OIL
■ (RIGHT SIDE PRESSURE
OF ENGINE) SWITCH
= (FRONT O f
ENGINE)
 TO HEAPLAWP
SWITCH
(SEE SH S§) OPTICAL HORN
HEADLAMP
DiHHER SWITCH

TO WARNING
LAMP MODULE
(SEE SH 72)
'T
Q34
mmm
1K#

RIGHT
PARK AND
TURN
SIGNAL
LAWP
(RIGHT SIDE CLOSURE
PANEL UPPER)
RIGHT
SIDE RIGHT
HAFtKER HEADLAMP
LAWP GROUND

FRONT END LIGHTING

 LEFT
HEADLAMP
GROUND
= (LEFT SIDE
CLOSURE
PANEL-FRONT
OF BATTERY)

TO TURN TO FUSE #1?

SIGNAL HEADLAMP
SWITCH SWITCH
(SEE SH 44J SYSTEM

TL61
(SEE SH 50)

T
18LQ L43
#21 20VT

#13 LEFT
r 5
HEADLAMP
u81 E3'
(AERO)
1810
13 16RD
PARKLAMP RELAY <
(SEE SH 50)
L? -z .
19BK/ i i
YL#
i \
#!§
n f >L?
I7 Zf
20BK
18BK/
YL# f |J
TO SPEED TO WINDSHIELD

L? t« B K /Y l#
L?
r L61
n
21
CONTROL
(SEE SH 43)
WASHER PUMP
WOTOFt
(SEE SH 45)
LS1 18LQ 18BK/ 18LO 1§BK
YL#
21 22BK
L81 18LQ
Z01 22SK
LEFT
L? 1«1K/YL# L07 18BK/YL PARK AND
TURN
L61 18LG SIGNAL
201 22BK LAMP •
I
LO? 18BK/YL ©
L? 18BK/YL# LEFT
SIDE
MARKER
LAMP

FRONT END LIGHTING

 TO
IGNITION < A21 14DB
SWITCH r
(SEE SH 11)
l 14o 'W”
w\J a \\..... ¥34 20WT/FtD#

FUSE #14
(2 A MR)

SINGLE BOARD 60 WAY

ENGINE CONTROLLER SINGLE MODULE
(SBEC) ENGINE- CONTROLLER
(LEFT FENDER CONNECTOR
SIDE SHIELD) (SEE SH 109, 110, 111) ¥34
29 49 53 . 33 50 48 20WT/
RD*
“ 37” nU TO HORN
T T Y Y Y . Y RELAY X3 20BK/RD*
K2S ¥32 ¥38 ¥38 ¥33 ■ ¥31 (SEE SH 44)
#41 20WT/ 20YL/ 20L6/ 20TN/ 2iW T/ 20BR/
PK* RD* RD* RD* ■ LG# RD*
n ^ #10
#i° i yq
. ¥32 22YL/RD* 20BK/
I ” x - *« . ✓ BD*
20WT / ¥31 20BR/RD*
PK* E l 0 NATURAL
¥33 20WT/LG*
¥36 20TN/RD*
¥35 20LG/RD*
. i TO
ISO WT/TN*
CLOCKSPRiNG

SPLICE ¥33- ¥32 ■ ¥34'

20BK (SEE SH 89) 20WT 20YL/ 20DB
m*
SPLICE
(SEE SH 48)
¥30 22DB/RD |So qml
L- F32.18PK/D B* llL H raJL B
BLACK \ NATURAL

BLACK ■
(REAR ■ ‘I,:
1
OP ' ■RESUME
BATTERY) ih - •
• OHm
9

. 'Z1 20SK —
^ SPEED - ► •
CONTROL OFF
¥30 20DB/RP* - i SWITCH
SPLICE
(SEE SH 64) 13
SPEED L #
CONTROL • •
o .
L - K29 18WT/PK# SER¥0
¥38 20LG/RD# — (UNDER
STOP LAMP AND SPEED' BATTERY
¥36 20TN/RD* • o
. CONTROL SWITCH TRAY)
(MOUNTED ON STEERING
COLUMN SUPPORT)
SPEED CONTROL AND STOP LAMP SWITCH
 HORN
(LO-NOTE)
TO ' A0§ tORD/BK*
CHARGING SYSTEM
(SEE SH 5,7) D/BK*

TO OPTICAL HORN
(SEE SH 50)
})- Xtit 18DG/RD . A03
X 12FID*
TO STOP LAMP
Z01 18BK (SEE SH 43)
FUSE CAVITY #27
(30 AMP CIRCUIT
BREAKER)

TO POWER LOCK
UNLOCK RELAY
(LOCATION 10)
(SEE SH 78)

X02 L - F35 12RD —W [

18DG/ TO POWER LOCK
LOCK RELAY
*02 18DG/RD (LOCATION 10) F35 \
(SEE SH 78) 12RD \

Z01 18BK X02

18DG/ HORN RELAY IN
RD* RELAY MODULE A0§
X2 18D G /R D *I (LOCATION 3) 12RD/
Z1 18BK (SEE SH 114) F35 BK*
.J 12RD

BLACK
X03 20BK/RD*
NATURAL
TO NBS RELAY TO POWER SEAT
(LOCATION 6) (SEE SH 87)
(SEE SH 62)
CLOCKSPRINQ TL.___ F62 16RD

X3
18BK TO DIAGNOSTIC,
CONNECTOR y— F62 18RD
(SEE SH 58)

X3 18BK
F82 16RD

HORN SWITCH TO
(ON SFLERING
COLUMNS

SPLICE
— X3 18BK (SEE SH 47)

Z1 16BK —^

r
CIGAR 1
LIGHTER I Z01 16BK |
BLACK
BLACK
FUSE #23
(20 AMP)
 Z01 16BK LEFT
V10 20BR ~ k 3 9 ] _ HEADLAMP
GROUND
Z01 20BK
Z01 20BK 201
20BK (SEE SH 42) G29 20BK/TN*
\ WINDSHIELD WASHER
\ PUMP MOTOR

M
Z01 20BK
WINDSHIELD WASHER
LOW FLUID LEVEL SENSOR
(TOP OF WINDSHIELD
WASHER RESERVOIR)

V I0 18BR
T
¥10
18BR
¥09 1SDG/¥L#
1
¥06
¥10 18DB
18BR
(ON-OFF)
FRONT WASH

INTERMITTENT H•
WIPER SWITCH
(ON STEERING L-
COLUMN) ¥ 0 3 1SBR*
¥09
18DQ/
YL* ■ V0? 18DG#

.. t:p .. " »■ ¥0? 18DG#

H• £ > ¥04 18RD/YL'

L- ■o - V031SBR#
"<f

(jQFP
1 ¥§8 18DB

¥§6 18DB
L. — _ — — —

- ¥ 0 9 18P 6/Y L * TO
DIMMING
- ¥ 0 4 18RDj IJ IU E02 2CJOR MODULE
(SEE SH 51)
RIGHT FOG LAMP
- ¥ 0 3 18BR* (SEE SH 51)
REAR WASH
" ¥ 0 3 18BR* TO LIFTGATE
-V 0 ? 1SDQ* - } } ~ ¥22 18BR/YL* WIPER AND
“ ¥0? 18DG* RR WIPE DELAY
WASHER SYSTEM
- ) ) - ¥21 1SDB/PtD# (SEE SH 66)
- BLACK

E02 200R
Z03 2QBK/OR
¥10 18BR
¥08 18DB
¥06 18DB
¥21 1SDS/RP*
*¥22 1SBR/YL
GRAY GREEN
(LEFT LOWER
SIDE OF I.P.)
BODY GROUND
(LEFT SIDE Z01 18BK
KICK PANEL)
G29 20BK/TN* Q29 20BK/TN*

El #30

TO BODY
COMPUTER
V10 18BR (SEE SH 101)

V06 18DB
V09 18DG/YL*

V07 18DG*

■ VOS tflDG

El #35'

V07 18DQ*

V04 18RD/YL ¥64 18ftD/YLA V04

18RD/
- V0318BR* ¥03 ISBR* - YL*

“1
VOS V03 VOS
18DG 18BR 18DB
V0618DB Jv J KJ s >\V
s fs yl K S V
P2 H L P1
SUPRESSOR RESISTOR
(MOUNTED (MOUNTED
ON MOTOR) ON MOTOR)
P2 H

y
FUSE #5
i t - :
(20 AMP)
I PARK
— SWITCH

Y INTERMITTENT WIND­
A31 SHIELD WIPER MOTOR
14SK# (PLENUM LEFT SIDE)
J-
TO IGNITION
SWITCH
(SEE SH 11)

INTERMITTENT WIPER SYSTEM

 TO BODY TO ELECTRONIC
COMPUTER 22 18BK/LG* 22 18BK/LG* CLUSTER
(SEE SH 101) (SEE SH 55 )

TO DIAGNOSTIC
CONNECTOR
(SEE SH 101 )

TO A/C AND TO HEADLAMP

HEATER SWITCH
CONTROLS (SEE SH 50 )
{SEE SH 27,29)

TO ASH
RECEIVER
LAMP
{SEE SH 51)

TO CIGAR
TO RIGHT LIGHTER
COWL LAMP
WIRING (SEE SH 51 )
(SEE SH 76)
TO CIGAR
LIGHTER
GROUND
(SEE SH 44 )

INSTRUMENT PANEL GROUND SYSTEM

 Z3 18 8K/OR*
23
18 BK/
TO GLOVE } TO WIPER
BOX LAMP V" 23 20 BK/OR* I SWITCH
(SEE SH 82) ' (SEE SH 45)

TO ELECTRONIC
CLUSTER
(SEE SH 55)

TO WARNING TO REAR WINDOW

LAMP CENTER 23 20 BK/OR* DEFOGGER SWITCH
(SEE SH 72) (SEE SH 70)

TO COMBOTO VAN ! .TO NAME'

FLASHER CONVERSION TO POWER TO POWER BRAND SPEAKER
RELAY RELAY LOCK RELAY UNLOCK RELAY RELAY
(SEE SH 50) (SEE SH 91) (SEE SH 78)" (SEE SH.78) (SEE SH 82)

TO LEFT
| SILL WIRING
(SEE' SH 80)

GREEN
(LOWER LEFT
TO KEY SIDE OF i.P .)
LIGHT SWITCH f — Z1 20BK
(SEE SH 81) TO SPfJCE
m m m rm i
TO MULTI
FUNCTION J— 21 18BK
<823
SWITCH 1 (SEE SH 80)
Z1 Z1
(SEE SH 113) 20BK
X
20BK
x Z1 18BK J
TO DIMMING TO STOP-LAMP
MODULE AND SPEED
(SEE SH 51) CONTROL SWITCH
(SEE SH 43)

INSTRUMENT PANEL GROUND SYSTEM

— L58 18PK* CIRCUIT t o ^ 0> T ] spuce
BREAKER
|25 AMP) (SEE SH 441
- 12© 14LG/WT*
y - A03 12RD# ^

OPTICAL
HORN

TO
FRONT
END
LIGHT­
ING
(SEE SH
41, 42)

— E17 20YL*
TO BATTERY
(SEE SH 5, 7)

FUSE #9 TO BODY COMPUTER

(7.8 AMP) fSEE SH 103!

HEADLAMP SWITCH
 TO FUSE #9 ON
(REAR OF E01 22TN HEADLAMP SWITCH SYSTEM
I.P. LEFT (SEE SH 49)
SIDE) I 200R - E02 2 0 0 R

DIMMER E92 2CJOR* -

MODULE
E l 7 18YL* -

201 2m% -
E22 200R/WT*
E02 200R
E92
RED 200R*
E92 200R* E92 E02
E22 200R/W T*
200R* 1 200R
E02 200R
TO BODY
E01 22TN
.— —J 1 COMPUTER
(SEE SH 4)
TO
TO STEREO LEFT POD E02 200R
DISPLAY J- DIMMER
(SEE SH 58, 60, 82) SLIDE
TO CONTROL
(SEE SH 49)
BODY
GROUND SPLICE E02
(LEFT (SEE SH 48) 200R
SIDE
KICK Z01
18BK TO BODY C _ E17
PANEL)
COMPUTER > 20YL*
~~7>-Jn ^ (SEE SH 103)
m nA hm nj
fb u u u u u u i/ TO DIMMER
SLIDE E17 E02 200R
_____________ n _ CONTROL
20YL*
Q Q O C□ Q O O O
(SEE SH 49)
a o a c3 Q Q D Q
nrLJ_ J
■---------- ! = ^
(LOWER
TO WARNING BLACK
LEFT
SIDE OF 203 LAMP CENTER
(SEE SH 48) (SEE SH 72)
■-p .) y

Z03 20BK/OR* T
TO CLUSTER
203 2QBK/OR*
(SEE SH 55) CIGAR
LIGHTER
LAMP
- 0 * > - E02 20QR
(SEE SH 47)
BLACK
RIGHT Z01 208K
POD
LAMP

ASH E02 200R

GRAY RECEIVER
LAMP ■

HEADLAMP SWITCH CONTROLLED INTERIOR LAMPS

 Ell i.SWITCH
ILLUMINATION
E02 20DR E02 200R .. . .w
✓ / ...
.
■ LiFTGATE
TO CIGAR LIGHTER LAMP
E02 200R RELEASE
(SEE SH 51)
SWITCH
TO ASH RECEIVER LAMP WQm ILLUMINATION
(SEE SH 51) E02 E02
200R 200R

E02 200R Z03 2QBK/OR* —

a GRAY

0
CLUSTER ILLUMINATION TO
LAMP > r

SPLICE
E02 200R ---- ......) )^g^Z01 18BK (SEE SH 48)

LEFT POD LAMP I

Z01 Z01
18BK 18BK
— E02 200R
X
BLACK TO LEFT POD
(SEE SH 49)

(RIGHT SIDE
OF I.P .)
BODY
m m m m m GROUND
(RIGHT SIDE
(RIGHT
1GHT SIDE I KICK PANEL)
KICK PANEL) E02
1SOR 19BK
!¥ ¥ ¥ ¥ ¥ ¥ ¥ !
U.li.U.1.11.111!....I
TO REAR
HEATER AND m sm sm m
A /C SYSTEM
(SEE SH §4)

E02 E02
aS sI
180R 200R
SPLICE
(SEE SH 4?)

r* Z03 2QBK/OR . 1
— Z01 18BK

BODY GROUND
(ABOVE OVER­
Z01 18BK -<<

OVERHEAD.
0
A/C & HEATER
CONTROL
HEAD CONSOLE) CONSOLE
ILLUMINATION LAMPS
LAMPS

HEADLAMP SWITCH CONTROLLED INTERIOR LAMPS

918W -9 . AS-HK 52
 FUSE #8
(20 AMP)

TO TURN 105 18BK/PK*

SIGNAL & , TO IGNITION
L09 18BK* A31 14BK*
HAZARD SWITCH n SWTiCH
(LEFT POD) (SEE SH 11)
L85 18PK*
(SEE SH 49)
L09 1SBK* A15 14PK

TO COMBO FUSE #1
FLASHER (20 AMP)
L91 18DB/PK (SEE SH 80)
TO
HEADLAMP L32 18PK
SWITCH
(LOCATED L60 18TN L60 18TN
IN LEFT POD)
(SEE SH 49)

LSI 18TN LSI 18LG

L61 2©3 L80 L61 L it L60 L62 L83

18LQ 20BK/ 18TN 18LQ 18LQ 18BR/ 18DG/
OR* m* RD*
s
s
x
S. XV sV
,9 ± 9
JL JL
TURN SIGNAL
RIGHT / / K LEFT A N
TURN ( EI ) TURN { h » ) SWITCH ■
SIGNAL S iG N A L^S (LOCATED IN
STEERING COLUMN
r BODY MULTI-FUNCTION
LAMP WARNING CENTER COMPUTER SWITCH)

#11, 12, 14, 1 5 /

k NATURAL

L61 18LQ
STRG
COLUMN

(REAR CEN­
203 2QBK/OR* L60 18TN TER OF i.P .)

STOP/TURN AND HAZARD

FLASHER SYSTEM
 BLACK

A t 5 14PK A15 14BK

#23

TO RIGHT
L80 18TN im 18TN “5 PARK LAMP
(SEE SH 41)
|1 » | #22
TO LEFT
L61 18LG L81 18LG PARK LAMP %
g -— L62 18BR/RD*
(SEE SH 42) — L7 18BK/YL*
#21
□ — Z1 18BK

- 7 -------------------------
RIGHT REAR
STOP AND TURN
SIGNAL LAMP

?}— L63 18DG/RD*

?}— L7 18BK/YL*
? }— Z1 18BK

' S ' . ?______________ i

LEFT REAR
L§2 L83 STOP AND TURN
18BR/ 18DQ/
m* m* SIGNAL LAMP

s
y— ——
TO DIMMING
ooa oa d boo
MODULE
a a a o a ca a o
(SEE SH 51)
/
GREEN
aREE T
E01
m iw w iiw m 22TN
m m m m s X
n
(LEFT SIDE
OF I.P.)

L62 18BR/RD* - 1

TO l/P WIRING
(SEE SH 48)
—‘— (LEFT REAR
GROUND — QUARTER PANEL)

STOP/TURN AND HAZARD

FLASHER SYSTEM
 TO SPLICE
L? 18BK/YL* -$ <s>
(SEE SH 50)

FUSE #9
(7.5 AMPI

TO BODY
COMPUTER
(SEE SH 104)
“ » ---------- E1 22TN
DIMMING
MODULE
3□ □ □ □ □ □ □ □ □ □ □ □ I
- » --------- E2 200R P□e□ □ □ □ □ □ □ □ □ □ □ a D
TO SPLICE
|— A4 12BK/RD* — $ < ^>

(SEE SH 70)
= poi B0DY
1 1 GROUND
(LEFT M1 18PK
SIDE KICK
PANEL)
|9 < Z 1 V 0 8 B K D13 D14 m
180R/ 18LB 2§GY
DB#
/§ >
J - 06 20QY
20<

n n n /ijr l/r a
U IT U U U U U U
Gi
20GY
a o o a ca o n a
a o a a ca a a a
....................

Z2
18BK/
8BK/ Q5 y \
f A P
L 0 > (SEE SH 47} (SEE SH 72)

Z2 QS Z3 E2 Ml 013 D14 Gi
18BK/ 2Qm * 2§BK/ 200R 18PK 180R/ 18LB 20GY
LG* I OR* I 1 I I
A A A A A A A A
T T *T T T T
7 n 14 i 2 3 5 I
 ILLUMINATION LAMP

TO DIMMING
MODULE
(SEE SH 81)

HEATER BLOWER
MOTOR RESISTOR
 (REAR CENTER GRAY
OF I.P.)

a a c□ C3 O C1 C3 Q o o a o a a a

o a q p Ijp o q p cp a a o o a q
y —— - n y —- 1

BLACK

X54
20VT X52 X5S
20DB/ 20DB/
WT* on*

X51 X5?
2§BR/ 20BR/
YL# LB*
XSS 20BR/WT*
X5§ 20DB/RD* XSS 20PB/RD#

X51 20BR/YL* X51 20BR/YL*

X52 20D8/WT* X52 20DB/WT*

— X53 20DQ

— X54 2 0 V I X54 20VT —

X5? 20BR/LB# X57 20BR/LB*

X58 20DB/€)R# XSfl 2QDB/OR*

X54
20¥T

P O T p o t

M M j
LEFT FRONT SPEAKER RIGHT FRONT SPEAKER
(LEFT INSTRUMENT PANEL) (RIGHT INSTRUMENT PANEL)

2 SPEAKER STEREO RADIOS

 TO IGNITION
SWITCH ' i
(SEE SH 11) '

FUSE #7
(10 AMP)

TO DIMMING
MODULE
(SEE SH 5©)

T
E22
200R/
SPLICE
(SEE SH 50)

W T*

X55 22BR/WT*

XSS 20DB/RD*

X51 20BR/YLit •
(SEE SH 81) X52 20DB/WT*
X53 2©DG —
M l 18PK X54 20VI —
r— X5? 20BR/LB* •
X58 20DB/QR#

GRAY.
□□□□□□□ □□□□□□ c
BLACK

A ' I
FUSE # 3 L CONNECTOR REAR J \ f “ ^CO^NECTOTREAR
(20 AMP) OF RADIO OF RADIO
ELECTRONIC TUNE
STEREO
RADIO WITH CLOCK

/IX X X X x x x x :t/ 0 -^
GROUND STRAP

SPLICE
(SEE SH 70) ELECTRONICALLY TUNED STEREO RADIO
WITH STANDARD SPEAKERS
 RT
BODY
#4
X5? 20BR/LB* X67 20BR/LB*
BLACK
RT
BODY #11
- X82 20DB/WT* X62 20DB/WT*

XSt 20BR/YL* - ■ X61 20BR/YL*

RT X58 20DB/QR*
BODY
#9
X58 20PB/OR*
I t
RT
BODY #6

LEFT REAR SPEAKER RIGHT REAR SPEAKER n fm m fm

(IN TAILGATE STANDARD! (NOT USED| (IN TAILGATE STANDARD) %.IlftM llii.ill
— GRAY
GREEN
] (REAR CENTER Q C□ C
□ o a c□ c□ a
OF i.P .) o cpCp a o pc pa
[L
— U“ IT "

X55
22BR/ X5? X61
WT* X56 X53 20BR/ 20BR/
X54
2008/ 20DQ 20VT LB* YL*
X55 22BR/WT RD*

X56 20DB/RD' X8S X52

X58 20PB/RP*
20DB/ 20PEJ/
OR* WT*
■ X51 20BR/YL* X51 20BR/YL*
X82 20DB/WT* X52 20DB/WT*
— X63 20PG
— X54 20VT X54 20VT —
■ X5? 20BR/LB XS? 20BR/LB*
X58 2QDB/OR* X58 2QDB/OR*

K E ?

M i
J
LEFT FRONT SPEAKER RI GHT FRONT SPEAKER
(LEFT INSTRUMENT PANEL) (RIGHT INSTRUMENT PANEL)

ELECTRONICALLY TUNED STEREO RADIO

WITH STANDARD SPEAKERS
 LEFT FRONT SPEAKER RIGHT FRONT SPEAKER
(LEFT INSTRUMENT PANEL) (RIGHT INSTRUMENT PANEL)
TO IGNITION
SWITCH C
(SEE SH ) J TO CHARGING
m m SYSTEM
•n n # • o n « (SEE SH 57)

FUSE #7
(10 AMP)

FUSE #23
(20 AMP)

TO SPLICE
y \ TO
<L7> DIMMING
MODULE
(SEE SH 50) (SEE SH 50) X55 20BR/RD*
T
E22
200R/ X56 20DB/RD*
L7 WT*
18BK/
YL* X55 20BR/RD
(SEE SH 44) F62
— X58 20DB/RD*
16RD
X15 14 BK/DG*
X51 20BR/YL*
X15 • X52 20DB*
14 BK/
- X53 20PG
/ (SEE SH 81) DG*
— X54 20VT
■ X57 20BR/LB*
M1 • X58 2QDB/OR*
18 GRAY
PK
A □□□□□□□ 1 ( □□□□□□□I
1
FUSE #3 ^ - X60 20DG/RD* n
(20 AMP) V GRAY

i
-------------------------- j \ NAME
CONNECTOR REAR V I CONNECTOR REAR BRAND
TA4 OF RADIO ,----- L.
ELECTRONIC TUNE
OF'RADIO SPEAKER
RELAY
STEREO (LOCATION 6)
12 BK/ TO SPLICE (SEE SH 114)
RD* RADIO WITH CLOCK

i (SEE! SH 48)
SPLICE X1 18RD/LG*
^ Z® " i
(SEE SH 70)
GROUND STRAP *= = “
I Zt 18BK

ELECTRONICALLY TUNED STEREO RADIO

 #1
□ (SEE SH 5)’
TO
{ BATTERY
A03 12RD* A03 12RD* A0312RD* / FEED
(SEE SH 5, 7)

A03
12RD#
(PART OF
POWER BLACK
ACC. SW.
PACKAGE) F06 18WT/OR*
C50 18BR/LG* L39 18LB

FUSE #20 C60 16BK/LB*

(20 AMP) L44 20VT/RD*
C70 16DQ —
€50 t6B K /LG #
C40 16BR/ - i €60 18BK/LB#
YL* C70 16DG
C40 18BR/YL*
nr
F36
11 TO W P >4l SPLICE
A/C RELAY ■ (SEE'SH 48) ■
(LOCATION 7)
(SEE SH 114)
TO HEADLAMP
SWITCH
(LEFT POD)
(SEE SH 49)

T
E02

2t v ^6>
E02 200R —• (SEE SH 57 )

E02 1SOR —
P20 18WT —
— Z01 16BK*
m n n h S ^ I— GRAY
lA jW U U U V
(LEFT SIDE OF I.P.)
€50 18BK/LG* —
C60 18BK/LB* —
TO TO C70 16DG —
UFTGATE/ BACKUP
EBL LAMPS OR*
(SEE SH 70) (SEE SH 89)
TO
IGNITION { , (POWER
SWITCH F A22 12BK/OR* — A22 12BK/OR# 4 VENTS)
(SEE SH 11) FUSE #25
(SEE SH 86)

REAR HEATER AND A/C SYSTEM

 REAR HEATER AND A/C ASSEMBLY (BLACK BOX)

MODE
REAR BLOWER SLIDE SWITCH
SLIDE SWITCH
MODE
OFF SERVO
MOTOR
LO

MED

Hi

. Y MICRO ,
I f TEMP I Z01
I f SENSOR I 18BK*
REAR
SWITCH
BLOWER MOTOR ILLUM

Z01 1§BK*

€50 €70 €60 Z01 F20

€ h E02
18BK/ 1SDG 18BK/ 1SBK* 16WT 1BOR
LG* LB*

Z01 F2i E02

16BK* 16WT 1SOR
C?0
16DQ

IP
ILU.
iA n >

BLACK

■ E02 1SOR
F20 16WT
Z01 16BK*

BLACK
C50 18BK/LG* — — — —
C60 18BK/LB# — — — — — — —
— C70 16DQ — — — — — — —

REAR HEATER AND A/C SYSTEM

TO RIGHT POD SWITCH
(SEE SH 45) TO IGNITION

LIFTGATE WIPER AND WASHER SYSTEM

LiFTGATE WIPER MOTOR
(CENTER OF LIFTGATE)

..
¥20 18BK/WT*
F20 18WT

* GROUND TO
LIFTGATE
* 3
\ \ (ON WASHER
RUN PARK BOTTLE IN LEFT
INTEGRAL WIPER REAR QUARTER
¥13 ¥18 PARK SWITCH IN AREA)
18BR 18DB SEQUENCE WITH
WIPER BLADE
SWEEP

16BR/ 16DB/
LG* PK*

F2G
18WT

¥13
16BR/
LG* LT
BODY
¥20 #7
16BK/ — — — — —
WT#

LIFTGATE WIPER AND WASHER SYSTEM

LEFT REAR RIGHT REAR
FOG LAMP FOG LAMP

FOG LAMPS
 FOG LAMPS SWITCH

TO A/C
FAN
CUT-OUT
SWITCH
(SEE SH 29)

RIGHT
FOG
LAMP

FOG LAMPS
 TO IGNITION
SWITCH {
(SEE SH 11) TO BODY
COMPUTER
(SEE SH 102)

TO A/C FAN
T
RELAY FUSE #24 ^0^18PK
(SEE SH 27, 29) (20 AMP) (ON LIFTGATE)
(SEE SH 8 1 ) %

M01
TO BACK UP 18PK
LIGHT RELAY

m
4
(SEE SH 89) EBL
FUSE #3 GROUND
TL P20 18WT F20 18WT (20 AMP)
-RED
BLACK
r— E01 22TN — Z01 14BK
TO
E02
FUSE #9 DIMMING TO CHARGING HEATED REAR
/V 200
200R
(7.5 AMP) MODULE SYSTEM WINDOW DEFOGGER
(SEE SH 4» 6)
(SEE SH 51)
(SEE SH 51)% F20
18WT T
A04
12BK/
E02 A04
RD#
f-y \ 200
20QR 12BK/
RD*
TO PARK #48
(SEE SH 5 2 f t
LAMP RELAY
(SEE SH 50) El
“ f^ o“ ^ ray n 203 18BK/OR* A04
« w r Z 04 TO 12BK/
RD#
JL riu
E02 F20
SPLICE
(SEE SH 48) 200R 18WT

Z03 C15
18BK/OR* _12BK
u !8BK{OR_ 12BK* ^ \\ wHEATED REAR
|n d o w SW|TCH (LEFT SIDE
A04
OF I.P.)
D*
IM M J lIlIiJ l
BLACK —
o o o o o o o o
I
AIM 12BK/RP*

C16 12BK*

1 B-
GRAY 1 I
MECHANICAL
[0 I
ON/OFF J j * , ai 1
SWITCH 3 (LEFT .0 1
" SIDE Co i
|0 1 FUSE #2
Of
TO HEATED MIRRORS (i i (10 AMP)
(SEE SH 76) - LP J
REAR WINDOW DEFOGGER
 002 TO BODY
14LG# COMPUTER
(SEE SH 102)
#8
LT
LIFTGATE RELEASE BODY
SOLENOID
Q02
14LG*

(CENTER REAR GRAY

-L - OF LIFTGATE)

f
/ GROUND THRU LIFT
L— GATE PANEL FOR
LIFTGATE GROUND
CIRCUIT

LIFTGATE RELEASE
 BLUE
GRAY
□ □ □ □ □ □ □ □ □ □ □ a ifr
I o o p a o o a a o o D o a5
G13 18DB/RD* TO CLUSTER
qoooooq
TO BODY G5
TO ' COMPUTER 20DB# (SEE SH 55)' q o o q o o o
IGNITION ' (SEE SH 102) — rd
SWITCH
{SEE SH 11) G5 20PB*
T FUSE #16
A21 (10 AMP)
14DB

G13 L ji. # TO
18D 8/
PtP# ^& 1| BRAKE
WARNING
SPLICE
(SEE SH 104)
TO

Q19 20LG/BK* Q19 20LG/BK — ( 4 ANTI-LOCK

SPLICE
(SEE SH'37) □
#4

G13 18DB/RD*’ — <4 — i SEAT BELT

WARNING LAMP CENTER

FOR WARNING LAMP
CENTER CONNECTOR
#15 (SEE SH 120)
TO SINGLE
BOARD ENGINE
■ CONTROLLER t- G24 iu is t / G24 22GY/PK* MA(NT REQD
CAViTY 56 • #.
(SEE SH13, 18, 23) •

TO \^6 1 / SPLICE (
LEFT TURN
L61 18LG SIGNAL
TO TURN (SEE SH 104) '
1 HAZARD
FLASHER
SYSTEM TO SPLICE
RIGHT TURN
L60 18TN SIGNAL
(SEE SH 104)
#18

□
L33 16RD - » — G34 16RD/BK* — (£ HI BEAM

[ L33 16RD
TO

L3
El
#8 L3
Z2L> f — Z3 2Q BK/O R* — < 4

16RD/ 14RD/ SPLICE

OR# . ' OR* (SEE SH 48)
vK
TO X
TO
FRONT END
DIMMER
LIGHTING
SWITCH
(SEE SH 41)
(SEE SH 41)
WARNING LAMP CENTER
 GROUND
(RIGHT SIDE
KICK PANEL) ■

L - 0 7 4 1 § T N /R P # Q74 19TN/RD*

GREEN
(RIGHT SIDE RIGHT FRONT
OF i.P .| DOOR AJAR
SWITCH
 r— A21 14DB -<<

TO CLUSTER
(SEE SH 58| GRAY

TO
IGNITION
SWITCH
(SEE SH 14J
0 6 2§DB/WT#

BLUE
TO INSTRUMENT
TO WARNING PANEL WIRING
LAMP CENTER (SEE SH 48)
(SEE SH 72)
T
21
12BK (LEFT SIDE KICK
PANEL)
BODY GROUND
(SEE SH 80)
r— Z1 18BK 21 16BK

21 18BK

SEAT BELT
SWITCH
(IN BUCKLE)

Q10 18BK
(RIGHT SIDE OF
SEAT RISER
REINFORCEMENT)

G10
2010/
RP#
(SEE SH 81)

I.II til...fiM
..
.II... II... I
I. . . . I. . . . if. . . II. . . Li. . . I. . . . I. .

GREEN
(LEFT SIDE
OF I.P .)
BLUE

oooooooooooo] G10
£oopaoooooopoofl 20LG/
RD*
G13 18DB/RD# J
TO BODY
COMPUTER — — — G10 20LQ/RD*
(SEE SH 102)
' BUTTON CIR SEL (LEFT) CIR'SEL (RIGHT) MIRROR
DIRECT

A AE, BCDF, HL, GJ AE, BCDF, HK, Gi RIGHT

B BE, ACDF, HL, GJ BE, ACDF, HK, Gi UP

CE» ABDF, HL, GJ CE. ABDF, HK, GI DOWN

D DE, ABCP, HL, GJ DE, ABCP, HK» GI LEFT

POWER MIRROR SYSTEM

— PSi 18WT* -
— P81 18LQ/WT#

RIGHT
HEATED
MIRROR
I t 18BK
Ml 1SPK

P82 18YL*
P84 18011*

C1«
18LB/YL

21 18BK

M1 — Zt 12BK —# —
18PK
__ A_
a 0 q 0 a 0 a cb
FUSE #3 0 0 a a a a 0 a
FUSE #2
(20 AMP} (10 AMP) cznzksm m
33 V
BLACK
(RIGHT SIDE
6 .....0... C
OF i.P .) m im m m
x s u iM s u w
TO SPLICE

<8^3 s n 16BK
(SEE SH 80)
TO SPLICE TO BODY
EBL SWITCH GROUND
(SEE SH 70) (RIGHT
<$> •KICK
{SEE SH 5) PANEL)
POWER MIRROR SYSTEM
 P33 1SOR/BK* 1
i
LEFT FRONT i
DOOR LOCK MOTOR P34 18PK/BK*

A -» — P33 180R/BK*

-» —

LOCK

LEFT FRONT RIGHT FRONT

DOOR LOCK SWITCH DOOR LOCK SWITCH

LEFT DOOR CONNECTOR RIGHT DOOR CONNECTOR

AND DOOR LOCK SWITCH FUNCTION AND DOOR LOCK SWITCH FUNCTION

B+ B- DOOR LOCK B+ B- DOOR LOCK

POLARITY POLARiTY FUNCTION POLARITY POLARiTY FUNCTION
OR/VT* PK/VT* LOCK OR/VT* PK/VT* LOCK
PK/VT* O R /V I* UNLOCK PK/VT* O R /V I* UNLOCK
PK — FEED PK — FEED
 BLACK*

SLIDING SIDE
DOOR LOCK
MOTOR

P36 1
m n
UI
n n1
rq |
a-0 1
n n
Po o
p:16 d oL
18(m i
v P 0 of

{SEE
SH 81)

<A 3^1 A3 12RD/WT

(SEE SH 48)
 (CENTER
OF DOOR)

LEFT FRONT
DOOR WINDOW •
LIFT MOTOR

Q16 14BR#

21
12BK

Q26 14VT/WT* Q2S 14VT/WT*

F21 12TN F21 12TN

F21
LEFT WINDOW 12TN p —— —
LiPTMASTER
SWITCH
Q2S 14¥T/W T# CONNECTOR m m m m m
m s m i .it.j!..ry
Q16 14 BR/WT# GRAY
F21 12TN
• 21 12BK
Q11 14LB
VIEW LOOKING THRU
TOP OF SWITCH F21 12TN

TO 21 14BK
MASTER SWITCH OVERHEAD
F21

B+
PWR WINDOWS

B- WINDOW/
MOVEMENT
12TN
CONSOLE
(SEE SH §5)
r
TO FUSE #24
BACKUP LAMP
A22
12BK/
LB WT LEFT UP (SEE SH 89) OR
WT LB LEFT DOWN
B R /W I* VT/WT* RIGHT UP
F21 12TN —{i A22 12BK/OR*
VT/WT* BR/WT* RIGHT DOWN
TN «_ FEED FUSE CAVITY #25 A22
(30 AMP) CIRCUIT 12BK/
— BK GROUND
BREAKER TO iqnITION ( 0 ,R*
SWITCH J---- '
(SEE SH 11)
AS-HK 79 POWER WINDOW LIFT SYSTEM 918W-9
 RIGHT FRONT
DOOR WINDOW
LIFT MOTOR

RIGHT DOOR

B+ B- 'INDOW AND
POLARITY POLARITY EME
VT BR N-FROW DOOR S ’
BR VT UP-FROM DOOR SWITCH
V I/W T * BPt/WT* ITCH
br/w t * VT/WT* UP-FROW MASTER SWITCH
TN _ FEED
LEFT FRONT RIGHT FRONT LEFT
DOOR DOOR POD SWITCH BLACK
COURTESY COURTESY
LAMP LAMP

LEFT FRONT TO BODY

V TO SEATBELT COMPUTER DIODE ASS'Y
21 16BK — # SWITCH DOOR JAWS SWITCH LT. RR. OTR.
(SEE SH 102)
(SEE SH 511 — 21 18BK —
 SLIDING SIDE GLOVE BOX r
DOOR SWITCH M1 18PK LAMP AND 21 18BK
-E 3 {l L SWITCH (

SPLICE Lt
(SEE SH 81) /
r— 23 —| [9 \Z 1 „
vK 20BK/ 1 (SEE SH 47)

M51 18YL/RD*
21 18BK

G 2 i 20LB
RIGHT FRONT
f ih A f w m (
vK
DOOR JAMB
SWITCH
M2 u u u u u u u u TO OVERHEAD
18YL BLACK• “ T ir e 18PK BODY
CONSOLE GROUND
(RIGHT
Ml SIDE OF (SEE SH 85) (RIGHT KICK
18PK IP .) PANEL)
M1 18PK
M il 18PK/LB*
M1 18PK
M l 18PK —
1... Ill fi
■= - 18PK
M2 18YL
I LIFTGATE
M l 18PK LATCH

G26 a SWITCH
Us
T_J

20LB TO OVERHEAD i

M2 (SEE SH 85)
18YL BLUE

rOSSESlSddooociolS
(t^OO^O□ □ □ □ □ □ 0 0 |
LEFT RIGHT
ILLUMINATED ILLUMINATED
TO BODY VISOR VISOR
COMPUTER
(SEE SH 102, 103)

M2 18YL/RD# M2 18YL
LT M2 18YL
1- BODY "

.... .91. .. M11 18PK/LB M11 18PK/LB* -

1.IT M il 18PK/LB* —
' BODY

M11 J E 3 J k
18PK/ B LA C K ~< 1 p— — , B L A C K --< \ .
LB* .

— M11 18PK/LB M il M2 M11 M2

18BK 188K 188K 18BK

REAR DOME AND

CARGO LIGHT L@ J L@ J
LEFT RIGHT
M2 18YL* LIFTGATE LIFTGATE
COURTESY COURTESY
LAMP LAMP

COURTESY LAMP SYSTEM

 TO BODY
COMPUTER
(SEE SH 103)

ILLUMINATED ENTRY SYSTEM

 OVERHEAD CONSOLE

OVERHEAD CONSOLE LAMPS

 LEFT RIGHT
X02 18GY TWIN HAP
M11 18PK/LB* COURTESY LAMP
- M01 18PK - TOUCH SWITCH UNIT
(IN ROOF CONSOLE)
— MQ2 18YL -

X2 18GY
Ml 18PK
M2 18YL
M11 1SPK/LB#
. M11 M11
1 f X 18RD IBRD f
(DOME)
(SEE SH 81) M11 18PK/LB*
V J TWIN MAP \ /
-^COURTESY LAMPS X -—
(IN ROOF CONSOLE)
"1 c TO<A > SPLICE
RR. LAMPS :
mu tiP K / ie *
(COURTESY SW GND)
— m m ispK (S E E S H 8 1 )
>TO SPLICE
— F21 12TN M11 18PK/LB* — — — — — <€»
— m m 18YL (COURTESY LAMP FEED)
^ TO SPLICE (SEE SH 81)
GREEN F21 12TN
(LEFT SIDE (POWER WINDOW)
OF I.P.) {SEE SH 79)

Q32 18BK/LB* G31 18VT/LG*

G31 tSVT/LQ * G32 18BK/LB*

- D02 18WT
BLACK
D01 18VT/BR* D01 18VT/BR*

— E i2 18QR

(SEE'SH 86)
(SEE SH 56) G31 G32
I8 V T / 18 B K /
D01 '
002 18WT* LG# LB#
18VT/.
D02 BR*
1SWT*
B LAC K’
(LEFT SIDE =02
(SEE V OF I.P.) OOR /
SH 81) (SEE SH 52) SERIAL SERIAL'.,,
E02 200R
| BUSS- B U S S + |
E02 TO BODY
200R TO SPLICE
TO ■ COMPUTER
✓ DIMMING (SEE SH 50) y (SEE SH 101)
MODULE PARK LAMP FEED
(SEE SH 50,51)
— — — _ _ J
AMBIENT SWITCH
E01 22TN — L0? 18BK/YL* —
(RADIATOR FAN MOTOR FRA WE)
RED
OVERHEAD CONSOLE LAMPS
 21 14GY Q28 14VT/WT* Z1 14GY
016 14BR/WT*
021 14WT C H - Q 26 14YL/DQ*
_ 21 14BK
F21 14DB — Q41 14WI 2 o 1 F21 14DB
r0^ Z1 14GY
— Q21 14WT
|— Q 1 1 MLB 0 3O H - 14GY
jiT L i 4
E 1E i i l l
o n ntB* Q 16 MLB*
OVERHEAD CONSOLE
LEFT VENT CONNECTOR RIGHT VENT
SWITCH (REAR OF CONSOLE) SWITCH
CONNECTOR CONNECTOR.

OVERHEAD CONSOLE

TO
OVERHEAD
CONSOLE TO
(SEE SH 84) r OVERHEAD
1 CONSOLE
T
Zt ■
(SEE SH 84)

18BK

BLACK

RED
011 18LB* — Q28 14YL/DG*
(AT MOTOR) p 0 W E R REAR Q UA RTER WINDOW
 ^SUi
+POLARITY -POLARITY SEAT MOVEMENT
YL/LB* RD/LB* FORWARD
P21 14RD/LG#
RD/LB* YL/LB* REARWARD
P19 14YL/LG* YL/WT* REAR UP
p _ _ _ _
PIS 14YL/LB* RD/WT* REAR DOWN
P it 14YL/WT * YL/LQ* FRONT UP
r_ _ _ _
ToF RD/LG* FRONT DOWN
RD PEED
o B B — BK GROUND
CJ 5 „ 6
8 B I
P13 14RD/WT* P13 14RP/WT*
P21 14RD/LG* P21 14RD/LG*
P19 14YL/LQ*
a EEL
PI 9 14YL/LG*
P13 14RD/WT*
F35 14RD P11 14YL/WT* ♦YL/W T*
P17 14RD/LB* P15 14YL/LB*
PI 5 14YL/LB*
21 14BK P17 14RD/LB* P17 14RDLB*

(UNDER SEAT) /
FRONT CENTER / REAR /
SWITCH SWITCH / SWITCH /
/
/
/
/
/
/
/
m r m ' d /
/
/
/
M/ xlx' N /
NX
Y Y Y /
P21 P15 P17 P11 P13 /
14RD/ 14YL/ • 14RD/ 14YL/ 14RD/ /
LG* LB* LB* WT* LG* /
/
P21 14RP/LG*
FRONT
VERTICAL
PI 9 14YL/LG*
P17 14RD/LB*

HORIZONTAL

GRAY {f* P15 14YL/LB*

(LEFT SIDE P13 14RD/WT*

OF I.P.) TO REAR
VERTICAL
Zt 14BK
< £ 3 <f P11 14YL/WT*
SPLICE POWER SEAT
(SEE SH 4§) MOTORS
CAVITY #27
(30 AMP CIRCUT BREAKER)
, TO IGNITION
2? »- 4 SWITCH
(SEE SH 14)
 TO

TO INSTRUMENT
CLUSTER 0
SPLICE
(SEE SH 56) GRAY BODY
fSEE SH 16)
GROUND
T
A61
| LEFT
14DG/
BK* FRAME)
TO HEADLAMP
#45 SWITCH U Z i 120K
(SEE SH 49!

|t<Pt (LEFT SIDE

G4 20DB OF i.P .|
(SEE SH 56) a a a a a a
BLACK
a a a a a
6 611....11166:
j. Q O O O O D Q O
(SEE SH 58) ] ^ A A A iin n n n
a a a a a a a a
uuuuuuuu
GREEN■
(LEFT SIDE' m m n m m
OF i.P .) m m m m s

TO BODY
COMPUTER
fSEE SH 101) BLUE
FUEL TANK SENDING TOP OF FUEL
TOP OF FUEL UNIT WITH LOW FUEL TANK REAR
TANK REAR SWITCH
 TO
HEADLAMP
SWITCH
(SEE SH 49)

WIRE
CAPPED
FOR
TRAILER
TO TOW
IGNITION LEFT TAIL, STOP, WIRING
SWITCH TURN AND SIDE
LEFT BACKUP LAMP MARKER LAMP
(SEE SH 11)
REAR LIGHTING & TRAILER TOW
 RIGHT

0 LICENSE
| LAMP

21
18BK

(NEAR
LICENSE
LAMP)

— 21 18BK
TO WARNING
LAMP MODULE
(SEE SH 72) 11
18V I /
PK#

\ y -> a r l:
RIGHT TAIL, STOP,!
TURN AND SIDE
RIGHT BACKUP LAMP MARKER LAMP

918W -9
REAR LIGHTING & TRAILER TOW AS-HK 90
 TO
IGNITION A21 14DB
SWITCH '
(SEE SH 11)
IGNITION

8
TO FEED
FUSE #13
20 AMP
< >
SPLICE
(SEE SH 5)

T
A4 ¥23
«v<9si ./CV 16BR/
TO
LIFTGATE
A14 12RD/BK —§ ¥23 16BR/PK# WIPER/
1 WASHER
(SEE SH 4, 8) Q3 ¥23 (SEE SH 88)
14TN 18BR/
PK*

A18 >k _
✓ v 5 4
12RD/
PK# ¥AN
1 CON¥ERSiON
RELAY
(LOCATION 8)
(SEE SH 114)

#3
□

U r (SEE SH 48)
i— A18 14RD/PK*

TO

o a a a a a □ & > B\
a a o a o a a SPLICE
(SEE SH 80)
A18 BLACK
14RD/
PK* m rm w m
s

21
16BK

BODY
•O-l GROUND

BATTERY
PEED

VAN CONVERSION WIRING

 TO TURN
i SIGNAL SWITCH
(SEE SH 53)

TO FUSE #17
HEADLAMP
SWITCH SYSTEM
(SEE SH 50)
LEFT
HEADLAMP
(AERO)

|— Zt 16BK Z01 20BK — J

T X - 21 20B.K TO SPEED CONTROL

(SEE SH 43)
TO WINDSHIELD WASHER
| / *— Z1 20BK — 4
PUMP MOTOR (SEE SH 46)
J ^ 3

Z01 22BK
L81 18LQ
LEFT PARK
L07 18BK/YL'
AND TURN
Z01 22BK SIGNAL LAMP
L61 18LG

L07 1SBK/YL

LO? 18BK/YL*

LEFT SIDE
Z01 22BK MARKER LAMP

FRONT END LIGHTING

WITH DAYTIME RUNNING LIGHTS
 TO HEAD­
LAMP SWITCH
(SEE SH 49)

L20
14LQ/
WT# TO SPEED TO SINGLE BOARD
SENSOR ENGINE CONTROLLER
#46 (SEE SH 43) (SEE SH 15, 21, 25)
TO HEADLAMPS
(SEE SH 92)

607
T
G07
20WT/ 20WT/
DAYTIME RUNNING OR* OPt#
LIGHT MODULE DIRECT
CONNECTION
TO MODULE

G07 2QWT/OR
(ENGINE COMPARTMENT TO <20j> SPLICE
LEFT SIDE) 201 18BK
(SEE SH 69)

TO IGNITION
SWITCH
(SEE SH 11)

T
A22
12BK/
F20
18WT
(SEE SH 27,29)
TO < L 4 # SPLICE
<$>
(SEE SH 69)

TO WARNING P* 0 N TO BACK-UP
° t r ® ~ x la m p RELAY
LAMP CENTER
(SEE SH 72) #?7 18WT 1 (SEE SH 89)

A22 H
12BK/
OR*
F20
liWT

F20
18WT - U
■'(SEE SH 64)
FUSE #24
(20 AMP)

DAYTIME RUNNING LIGHT MODULE WIRING

 16BK/
RD*

(LEFT SIDE
A
HOOD INNER PANEL)

BLACK

UNDERHOOD
LAMP
(RIGHT SIDE
HOOD INNER
PANEL)

UNDERHOOD LAMP
 RADIATOR TO IGNITION
FAN MOTOR SWITCH
(SEE SH 11)

A21
14DB

Z01 C25
12BK 14LG
E I #47

(SEE SH 4) %

C2? 20DB/PK €25 12LG

BLACK
(REAR OF O o o o O
BATTERY)
A21 14DB
□

GRAY / A18 12GY

ENGINE GROUND — —_ ————_ —J
(UPPER LEFT
OF ENGINE)
A21 14DB (SEE SH 13)

RADIATOR FAN
MOTOR RELAY
(LEFT SHOCK
TOWER)

TO SINGLE BOARD
X. C27 20DB/PK
ENGINE CONTROLLER
CAVITY 31
(SEE SH 14)

( TO BATTERY
A16 12GY At8 12GY ”> (SEE SH 5)
RADIATOR TO IGNITION

12GY

< TO BATTERY
"1 (SEE SH 5)
 € TO BACK
4 UP LAMPS
LI . (SEE SH 89)
18VI/
BK#

If
(SEE SH 89)
LI 18VT/BKft
. r f f
LI 18VT/BK* Uu 11 18VT/BK*
0 OJ
L1 I I

It
18VT/ {CONNECTOR LOCATED D Dc
Bl<# UNDER VEHICLE
NEAR FUEL TANK)
D Dc
0 d5
BLACK IJo1un 1nd

GREEN
(LEFT SIDE
OF I.P.)

L1 18VT/BK#

21 18BK

TO HEADLAMP
Z1 12BK -4 SWITCH
' (SEE SH 49)

'GROUND
(LEFT
KICK
PANEL)

Z1 18BK

VACUUM VACUUM
SOLENOID SOLENOID
A B

4 WHEEL DRIVE VACUUM SOLENOID SYSTEM

 L1 18VT/BK* BLACK
T2 14TN/BK
i J e*s z F V
HEC3 Btti A21 14DB
T41 18BR/YL*
T3 14VT T3 18VT
T3 18VI NEUTRAL SAFETY SWITCH /
P20 18WT ■ (FRONT OF /
L. _ _ _ — — — — — —— — — —

BACK-UP LAMP RELAY \ TRANSMISSION)

(RIGHT REAR SIDE FENDER) \
LI 18VT/BK*

T3 18VT
P2t>
18WT T2

r
14TN/ T41 18 BR/YL*
r F20 18WT #27 BK*
□
TO STARTER
RELAY
AIR (SEE SH 10)
CONDITIONING TO BACK
SYSTEM UPLAMPS
(SEE SH 29) (SEE SH 89)

TO TO

<9> <$> TO STARTER

SPLIC
PLiCE
l SPLICE RELAY
(SEEESH 21) (SEE SH 15) (SEE SH 10)

K24
T TK4
T
A'41
18GY/ 18BK/ 18YL
BK* LB*
x J% Jx JV J
i I 1X XS / V Xs yX
T T 1
45 51 2 3 8 11 41
FOR CONTROL
- ‘ ELECTRONIC AUTOMATIC TRANSAXLE CONTROL MODULE MODULE -
CONNECTOR
‘■ (SEE SH 119)

4 WHEEL DRIVE VACUUM SOLENOID SYSTEM

 TO SPLICE

TO INSTRUMENT BODY
CLUSTER GROUND
(SEE SH 56)
GRAY
p o o o o o o T

(SEE SH 56)

(SEE SH 5§J

TO BODY
COMPUTER
(SEE SH 101)

TOP OF FUEL FUEL TANK TOP OF FUEL

TANK REAR SENDING UNIT TANK REAR
WITH LOWFUEL
SWITCH
 TO SINGLE BOARD
ENGINE CONTROLLER TO EATX MODULE
TO LOWLEVEL CAVITY #26, 46 CAVITY #4, 43
FLUID SENSOR (SEE SH 12, 17, 25) (SEE SH 33)
(SEE SH 46)
 TO RIGHT DOOR
JAM SWITCH
TO SEATBELT (SEE SH 82)
SWITCH
(SEE SH 74) M2
(RIGHT 18YL
TO LEFT DOOR OF SIDE
TO WARNING AJAR SWITCH I.P.J S w ir u W ih
LAMP CENTER (SEE SH 73) GREEN I n j u u u u u ij ]
TO FUEL TANK r.„ ....... i—Jii Ulr-i__
BLUE WIRING a a o a c3 o o a
(SEE SH 88) a d o a c□ a a a

Ml 18BK TO LEFT DOOR

J AM SWITCH
(SEE SH 8) TO

G75 G4
T
G16
18TN 18DB 18BK/ SPLICE
LB* (SEE SH 81
66
M2
18YL

n R A f ir iA A n
w u v v u u u GREEN
7 .........
G8 2008- (LEFT
SIDE
fuLl—L_ OF I.P.)
i o db a a i

22
18BK/
U3#

'JZZZZPnyf
a o a cb o o a a
o o o ca a a a a

A21 (SEE SH 88)

n n r u w m 14DB
*k J¥¥¥¥¥¥¥|
TO IGNITION
Z1 SWITCH Q13
18BK
GREEN- (SEE SH 11) 18DB/
RD*
J, GRAY M2 '
M2
TO Ml G5 18YL 18YL
Q10 G16
18BK 20DB 20LG/ G?5 €34 20BK/ a* Os
& 5«l RD* 18TN 20DB LB* TO C/LAMP M2
SPLICE
(SEE SH 47 ) JL X JL i WIRING
(SEE SH 81)
18YL
A
T T T T 6
8 8 23 14 1 5 13 25
FOR CONNECTOR
BODY COMPUTER (BLUE) (SEE SH 117) 25 PIN CONNECTOR
 TO LEFT TO RIGHT
ILLUMINATION ILLUMINATION
ENTRY ENTRY
(SEE SH 83) (SEE SH 83)

200R* 20YL* 1SDG* 18DG/ 200R/ 20LB 18YL/ 18WT

YLA WTA RD#

3 12 1? 21 2 22 16
FOR CONNECTOR 25 PIN CONNECTOR
BODY COMPUTER (BLUE) (SEE SH 11?)
 TO ABS PUMP MOTOR
TO TEMPERATURE (SEE SH 35)
GAUGE SENDING UNIT
(SEE SH 38, 39, 40)

TO LOWBEAM' RELAY
■(LOCATION 1)
(SEE SH 49)
1

Q20 G80 Gi
22VT 22GY 20GY
YL* YL*

J.xN JXxN /J XV JXxV JXXv /JXV XV

X
XX
X IX /K // XV

25 11 23 S) 12 1 7 19 20 21
FOR CONNECTOR
BODY COMPUTER (NATURAL) (SEE SH 118) 25 PIN CONNECTOR .
TO LEFT DOOR TO RIGHT DOOR
LOCK SWITCH LOCK SWITCH
{SEE SH ??) {SEE SH ??)
TO SLIDING DOOR
AJAR SWITCH
(SEE SH 73)
f t
I o 1 ©
TO
TO LIFT GATE
P35 G7§ LATCH SWITCH
1SOR 18TN (SEE SH 73)
SPLICE
¥T# YL# (SEE SH 100)

(RIGHT
m n /w m |¥ ¥ lf¥ ¥ ¥ ¥ l SIDE OF
uuuuuuuu im im s m A ! i.P)
GRAY BLACK
(RIGHT a a o c□ O Q Q Q
CENTER a a a qp a a a a
OF LP) nn-j* ■------------
TO RIGHT FRONT
DOOR AJAR
P35 SWITCH G76
1SOR (SEE SH 73) 18TN BLACK

PARK BRAKE
SWITCH
¥I#
T
G74
YL*

GREEN 18TN
RD#

! _
(RIGHT
R fL R / t n m n CENTER m m s w m v i
U U U l JU U U U OF i.P) m m m u m
TO LIFTGATE
BLACK RELEASE SWITCH
(SEE SH 71) T
GREEN

Q11 j iT ln . i= a jm -r i
20WT*

T T
GREEN
(REAR
CENTER
OF i.P)
o o

QDDOQOQQ
:3=aii
o q q q £
q o

GRAY
Q33 P36 G74 G78 G78 G42
20BR 180R 18TN 18TN 18TN 20DB
LB* ¥T# RD# YL* BK# YL#
I A A A A A
✓
T T t T
17 22 10 1 14 2 15
BODY COMPUTER (NATURAL) FOR CONNECTOR 25 PIN CONNECTOR
(SEE SH 116)
CAV WIRE CODE INSTRUMENT PANEL CIRCUITS SHEET
1 A3 12RD/WT* IGNITION SWITCH FEED (BATTERY FEED)
2 A8 12RD/BK* BATTERY FEED - PARK LAMPS
3 A18 14RD/PK* ¥AN CONVERSION (BATTERY SUPPLYJ
4 Q19 20LG/BK* ABS WARNING LAMP
5 —
6 L3 14RD/OR# HEADLAMP HIGH BEAM 41
7 V30 22DB/RD* SPEED CONTROL 43
8 ¥31 20BR/RD* SPEED CONTROL 43
9 ¥33 20WT/LG* SPEED CONTROL 43
10 ¥32 20YL/RD* SPEED CONTROL 43
¥32 20YL/RD* SPEED CONTROL 43
11 D2 ISWT/BK* CCD BUS (-1 58
12 D1 18VT/BR* 56
13 L43 20VT _ _ _ _ _ _ _ _ _ 42
14 L44 20VT/RD* 41
15 G24 22QY/PK* 72 TERMINAL END
18 G34 18RD/BK* DAYTIME RUNNING LIGHT MODULE TO 72 OF DISCONNECT
Hi-BM HMD
17 620 22¥T/YLA TEMPERATURE SEND 38, 39,40 44 34 21 22 16
18 OIL PRESSURE LAMP 38, 39,40 43 33 27 21 18
19 OIL PRESSURE SEND 38, 39,40

o
42 32 28 20 14
20 L39 18LB FUSED FOG LAMP FEED 89 41 13
21 .61 18LQ LEFT TURN SIGNAL LAMP 54 40 J2
22 L80 18TN RIGHT TURN SIGNAL LAMP 54 39 H □
23 A18 14PK HAZARD FLASHER 54 38 10
24 ¥4 18RP/YL* WIPER MOTOR HIGH SPEED 4§ 37 31 25 n .9
25 ¥3 18BFI/WT* WIPER MOTOR LOWSPEED 46 36 30 24 18 s
28 L? 18SK/YL* PARKING LAMPS 42 35 29 23 1? ?
2? F20 18WT BACK-UP LAMP SWITCH FEED r- “ — m T
28 LI tSVT/BK* BACK-UP LAMP 89
29 ¥10 18BR WINDSHIELD WASHER MOTOR 45
30 G2§ 22BK/TN* LOWWASHER FLUID 46
31 A41 14YL IGNITION START 11 _ SMALL
32 X2 tSPQ/RD* INDEX
HORNS p _ _ _44_
33 C21 18DB/OR* AIR CONDITIONING LARC
34 G4 208Y/BK* BRAKE WARNING LAMP 164 INDEX
38 ¥5 18DQ WINDSHIELD WIPER SWITCH H— — —
48
—
36 ¥ 8 18PB WINDSHIELD WIPER MOTOR
V6 18DB WINDSHIELD WIPER MOTOR 46
3? B3 20LQ/DB* i T e pt T ^ 34
38 B4 20L6 34
39 St 20YL/DB* RIGHT m WHEEL SENSOR 34
40 B2 20YL RIGHT m WHEEL SENSOR 34
41 K29 20WT/PK* BRAKE SENSE 43
42 LSO 18WT/OR* SPEED SENSOR 8§
43 D11 20WT/VT* 3?
44 .D12 200R DIAG. ANTi-LOCK BRAKES 3?
45 A61 14DG/BK* FUEL PUMP FEED 88, 100
- L20 14LQ/WT* BATTERY PEED 50
4? A21 14DB IGNITION RUN/START 4
48 A4 12BK/RD* HEATED REAR WINDOW 4. 6
< At 12RD IGNITION SWITCH PEED ?
I 12PK/BK IGNITION SWITCH PEED _ _ _ § ^

50 WAY BULKHEAD DISCONNECT

 CA¥ WIRE CODE INSTRUMENT PANEL CIRCUITS SHEET
1 IGNITION SWITCH PEED 5, 7
2 7eIrV"feed'™ 5. ?
3 A18 12RD/BK* VAN CONVERSION 91
4 _ —
5 — _ _
6 LEFT HEADLAMP 41
□ § DRL ONLY 41
7 ¥30 20PB/RD* SPEED CONTROL 43
8 SPEED CONTROL 43
9 V33 20WT/LG* SPEED CONTROL 43
10 SPEED CONTROL . 43
11 D2 20WT/BK* CCD BUS (-) 58
12 D1 20VT/BR* CCD BUS f+) 58
13 L43 20VT FUSE TO LT HEADLAMP 42

A 14 “TiTiivT/RD*- " FUSE TO RT HEADLAMP

15 G24 20GY/PK* EMISS MAINT REMINDER LAMP
16 L33 18RD
17 G20 20VI/YL*
18 G8 20GY
DRL
WATER TEMPERATURE SENDING UNIT
OIL PRESSURE SWITCH
41
72
72
38,39,40
38,39,40
19 G60 20GY/YL* OIL PRESSURE SENDING UNIT 38,39,40
20 L33 18LB FUSED FOG LAMP FEED. . 89

J
M n n
21 L61 18LG
22 L80 18TN
23 A16 14PK
LEFT TURN SIGNAL LAMP
RIGHT TURN SIGNAL LAMP
BATTERY-HAZARD FLASHER
24 iWTiiD^YL*” - WIPER MOTOR-HIGH SPEED
64
54
54
48
25 V3 18BR/WT WIPER MOTOR-LOW SPEED 48
SMALL LARGE 26 L? 1SBK/YL* SPLICE-SIDEMARKER AND PARK 42
L7 18BK/YL* AND TURN SIGNAL LAMPS
2? P20 18W BACK-UP LAMP SWfTC 89
28 L1 18VT/BK* BACK-UP LAMP SWITCH 89
29 ¥10 20BR WINDSHIELD WASHER MOTOR 5
30 G29 20BK/TN* LOWWASHER FLUID INDICATOR LEVEL SENSOR 48
31 A41 18YL STARTER RELAY-IGNITION 11
32 X2 18DG/RD* HORN 44
33 C21 18DB/OR* AIR CONDITIONING 27,29
34 G9 20GY/BK* BRAKE WARNING LAMP SWITCH 104
35 PWliDG- - ~ WINDSHIELD WIPER MOTOR 46
36 ¥8 18DB WINDSHIELD WIPER MOTOR 48
37 _ —

38 __ —

39 — _

40 — — _ _

41 K29 ISWI/PK* 80-WAY BRAKE SENSE 43 -

TERMINAL END 42 —

OF DISCONNECT 43 — —

44 — — —

45 FUEL PUMP FEED 88

46 120 14LG/WT* BATTERY FEED 60 ‘
47 A21 14DB SPLICE-IGNITION RUN CIRCUIT 4
48 A4 12BK/RD* ELECTRICALLY HEATED REAR WINDOW 4,8
49 A1 12RD IGNITION SWITCH 7
50 A2 12PK* IGNITION SWITCH 5,7

50 WAY BULKHEAD DISCONNECT

(2.5L ENGINE)
 €A¥ WIRE CODE INSTRUMENT PANEL CIRCUITS SHEET
1 A3 n m * IGNITIONSWITCH FEED
2 AS 10RD BATTERY FEED 5, ?
3 A18 12RD/BK* ¥AN CON¥ERSfON 91
4 Q19 2QLG/OR* ABS WARNING 72
5 —
6 L33 16RD LEFT HEADLAMP 41
6 L3 16RD/OR* DRL ONLY 41
7 Y30 20DB/RD* SPEED CONTROL 43
E l 8 ¥31 20BR/RDA SPEED CONTROL 43
9 ¥33 20WI/LG SPEED CONTROL 43
10 ¥32 20YL/RD* SPEED CONTROL 43
11 CCD BUS (-) 58
12 Dt 20¥I/BR* CCD BUS 1r1 56
13 TUSE TO LT HEADLAMP 42
L44 20¥T/RD* ‘ FUSE TO RT HEADLAMP 41
15 G24 20GY/PK* EMISS MAINT REMINDER LAMP 72
18 T ^ l i S F - ^ DRL 72
1? Q20 20¥T/YL* WATEffTEMPER^VrURE SENDING UNIT 38,39,40
18 OIL PRESSURE SWITCH 38,39,40
19 G80 20GY/YL* OIL PRESSURE SENDING UNIT 38,39,40
20 L39 18LB FUSED FOG LAMP FEED 69
21 L61 18LG I LEFT TURN SIGNAL LAMP 64
22 L80 18TN RIGHT TURN SIGNAL LAMP 64
23 A15 14PK 64
24 I ¥4 18RD/YL* 46
25 ¥3 18BR/WT WIPER MOTOR-LOW SPEED 46
28 • L7 18BK/YL# SPLICE-SIDEMARKER AND PARK 42
L? 18BK/YL# AND TURN SIGNAL LAMPS 42
SMALL LARGE 27 P20 18WT BACK-UP LAMP SWITCH 89
F20 18WT 89
28 L1 tSYT/BK* BACK-UP LAMP SWITCH p _ _ _
29 ¥10 208R WINDSHIELD WASHER MOTOR
30 G29 20BK/TN* LOW WASHER FLUID INDICATOR LE¥EL SENSOR r_ _46 _
31 A41 18YL STARTER RELAY-IGNITION
A41 18YL STARTER RELAY-IGNITION 11
32 X2 18DG/RD* HORN p _
44
_ _

33 C21 18DB/OR* AIR CONDITIONING

34 69 20GY/BK* BRAKE WARNING LAMP SWITCH 104
35 ¥8 18DG WINDSHIELD WIPER MOTOR 46
38 ¥6 18DB WINDSHIELD WIPER MOTOR 4§
3? B3 20LG/DB* LEFT RR WHEEL SENSOR 34
38 B4 20LG* LEFT RR WHEEL SENSOR 34
39 B1 20YL/PS* RIGHT RR WHEEL SENSOR 34
40 B2 20YL* RIGHT RR WHEEL SENSOR 34
41 K29 18WT/PK* §0~WAY BRAKE SENSE 43
TERMINAL END 42 L50 18WT/TN* SPEED INDICATOR 89
OF DISCONNECT 43 D11 2QWT/YI* DIAG. ANTI-LOCK BRAKES 37
D12 20OR DIAG. ANTI-LOCK BRAKES 37
A61 14DG/BK’ FUEL PUMP FEED 88,100
L20 14LG/WT' BATTERY FEED 50
A21 14DB SPLICE-IGNITION RUN CIRCUIT 4
A4 12BK/RD* ELECTRICALLY HEATED REAR WINDOW 4,6
A1 12RD IGNITION SWITCH 7
A2 12PK* IGNITION SWil 5,7

50 WAY BULKHEAD DISCONNECT

{3.01 & 3.3L)
CAV WIRE CODE IGNITION SYSTEM CIRCUITS SHEET NO.
Kt 20DG/RP* . 13
K2 20IM/Bf<9 r—TEMPERATURE SENSOR SIGNAL 15
3 14
4 SIGNAL GROUND 15
5 12
6 Kg 20VT/WT* ' WAP SENSOR SIGNAL 13
7 r”- 15
8 r . 16
9 a T 'u o b ' ^ IGNITION START/RUN 13
10 —
11 r'*T*2.fiiK?T9r" 14
12 1*2 16BK/TN* 14
13 — — —
14 — _
__ — _
16 r K11 18WT/DB* INJECTOR 15 1 21 41
1? —
18 —
13 K19 18GY IGNITION COIL 14
20 K20l8DGi 15
_
22 h-^FlioRTDi7 THROTTLE POSITION SENSOR 12
23 _ — _
24 K24 18GY/BK* DISTRIBUTOR PICKUP SIG NAL 15
26 i *~~D2T^0PK] 14
2C ^~~^T~2Wt7br*” C C D BUS (+} 12
2? A/C CLUTCH INPUT 14
28 r — — —
29 K29 18WT/PK* BRAKE SWITCH SIGNAL 43
30 PARK/NEUTRAL SWITCH SIGNAL 15
31 C27 20PK RADIATOR FAN RELAY 14
— _
33 Y36 20IN/RP* SPEED CONTROL (VACUUM) 43
34 A/C CLUTCH RELAY SIGNAL 14
35 K35 20GY/YL* 13
38 __
3? — _
38 — j —_ _ _ .
39 12
40 I K40 18BR/WT* AUTOMATIC IDLE SPEED MOTOR (AIS-1) 12 VIEWED PROMWIRE END
41 K41 18BK/D6* OXYGEN SENSOR SIGNAL 12 OF CONNECTOR
421 —
— —
44 — — _
48 ^ ~ ~ D 2 Q 2 0 L ^ SCI (RECEIVE) 14
46 D2 20WT/8K* CCD BUS (-) 12
G? 20WT/QR* 15
48 ¥31 20BR/RD* 43
49 V32 20YLJRD^_ SPEED
_ _ _CO_NTROL
_ _ ON/OFF
_ 43
50 .'WlWTTLrF1 43
51 K51 20DB/YL* 14
52 I K52 20Pk/8K* . 13
53 ¥35 20LG/RD* SPEED CONTROL (VENT! 43
54 K54 200ft/BK* 16
58 — —
56 G24 20GY/PK# EMISS WAiNT REWINDER LAMP 13
57 __ —
58 __ __ __
1 18VT/SK* AUTOMATIC IDLE SPEED MOTOR (AlS-4) 12
60 ) 18YL/BK* 12
CAV WIRE CODE IGNITION SYSTEM' CIRCUITS SHEET NO.
1 K1 20DG/RD* MAP SENSOR SIGNAL 18
2 K2 20IN/BK* TEMPERATURE SENSOR SIGNAL 20
3 .A14 1§RD* DIRECT BATTERY FEE
4 K4 18BK/IB* SIGNAL GROUND
5 Z11 16BK/WT* SIGNAL GROUND
6 K6 20VT/WT* MAP SENSOR SIG NAL
7 K7 ISOR 8 VOLT OUTPUT
8 A61 18DG/BK* INJECTO.
9 A21 14DB IGNITION START/RUN
10 _

11 Z12 18BK/TN* POWER GROUND 19

12 Z12 16BK/TN* POWER GROUND 19
13 _ —

14 K13 18YL/WT* INJECTOR 17

15 K12 18TN INJECTOR 17
18 K11 18WT/DB* INJECTOI 17
17 . —

18 — _

19 K1918GY IGNITION COIL 19

20 K20 18DG ALTERNATOR 17
21 — — _

22 K22 180R/DB* THROTTLE POSITION SENSOR 20

23 —

24 K24 18GY/BK* DISTRIBUTOR PICKUP SIGNAL 20

25 P21 20PK SCI (TRANSMIT! 19
26 D1 20VT/BR* CCD BUS (+) 17
27 €20 18BR A/C CLUTCH INPl 19
28 _ — —

29 K23 18WT/PK* 43
30 T41 20BR/YL* 20
31 €27 20PK*
32 — _

33 ¥36 20TN/RD* SPEED CONTROL fVACUUMI

34 €13 2QDB/OR* A/C CLUTCH RELAY SIGNAL 19
35 — —

38 — -
VIEWED FROM WIRE
37 — . __
END OF CONNECTOR
38 _ - _

39 K39 18GY/RD* AUTOMATIC IDLE SPEED MOTOR fAiS-3) 20

40 K40 18BR* AUTOMATIC IDLE SPEED MOTOR fAIS-11 20
41 OXYGEN SENSOR SIGNAL 18
42 — _

43 _ _ _ _ _

44 K44 18TN/YL* DISTRIBUTOR 20

48 D20 20LG SC! fRECElVE) 19
46 D2 20WT/BK CCD BUS (—) 17
47 DISTANCE SENSOR SIGNAL 20
48 ¥31 20BR/RD* SPEED CONTROL SET 43
49 ¥32 20YL/RD* SPEED CONTROL ON- 43
SO V33 20WT/LG* SPEED CONTROL RESUME 43
51 K51 20DB/YL* AUTO SHUTDOWN SIGNAL 19
52 K52 20PK* PURGE SOLENOID SIGNAL 18
$3 V35 20LG/RD* SPEED CONTROL (VENTI 43
54
55
56 G24 20GY/PK* EM1SS M A i m REMINDER LAMP 18
57 _

58 — —

59 K59 18VT/BK* AUTOMATIC IDLE SPEED MOTOR IA1S-4) 20

80 K60 18YL* AUTOMATIC IDLE SPEED MOTOR (AIS-2) 20
CAVl WIRE CODE" IGNITION SYSTEM CIRCUITS SHEET NO.
1 “kTIddgTrd7 MAP SENSOR SIGNAL 24
2 K2 20TN/BK* '24
3 A1418RD* DIRECT BATTERY FEED ................. .. 23
4 K4 1SBK/IB* SIGNAL GROUND 25
5 Z11 16BK/WI* SIGNAL GROUND 22
6 K8 20VT/WT* ........ 24......
7 K7 180R 28
a A61 16DG/BK* INJECTOR 25
9 A21 14DB IGNITION START/RUN 22
10 _ —
11 Z12 16BK/TN* POWER GROUND ...... 23.....
12 Z12 tiBK/TN* POWER GROUND 23
13 — _
14 K13 18YL/WT# ...................... ........24._...
15 1C12 18TN I INJECTOR 24
18 K11 18WT/DB* 6 INJECTO
| ^ R 24 !
“TT K17 18DB/YL* p—~ ““ 24
18 24
19 IGNITION COIL 24
20 m iiT iD i- ” ALTERNATOR 23'
21 CHARGE TEMP SENSOR 24
22 K22 1SOR/DB* THROTTLE POSITION SENSOR 24
23 - _
24 K24 18GY/BK* DISTRIBUTOR PICKUP SIGNAL 25
25 D2t 20PK SCI (TRANSMIT) 25
28 CCD BUS (+) 25
2? A/C CLUTCH INPUT .... ....23.. .....
28
29 K2Q 18WT/PK* BRAKE SWITCH SIGNAL 43
30 T41 20BR/YL* PARK/NEUTRAL SWITCH SIGNAL 24
31 €27 20PK* RADIATOR FAN RELAY 23
32 — — —
33 [ V36 20TN/RD*” SPEED CONTROL (¥ACUUM) ' 43
34 C13 20DB/DR* A/C CLUTCH RELAY SIGNAL 23
35 — — —
3§ —
37 —. VIEWED FROM WIRE
__ _ _ END OF CONNECTOR
38
39 K39 18GY/RD* AUTOMATIC IDLE SPEED MOTOR (AIS-3) 24
40 K4§ 18BR* AUTOMATIC IDLE SPEED MOTOR IAJS-1) . .24
41 K41 18BK/DG* .OXYGEN..SENSOR.SiClNAL 24
42 K42 18BK/LG* DETONATION SENSOR SIGNAL 25
43 — — —
44 K44 1STN/YLA DISTRIBUTOR 26
48 D20 2016 SCI fRECEi¥E! 23
48 P2 20WT/BK 25
47 DISTANCE
r-'i p g r ^ ^SENSOR
6— SIGNAL 25
48 ¥31 20SR/RP^ 43
49 ¥32 20YL/RD* SPEED CONTROL ON-OFP 43
50 ¥33 2§WT/LG# 43
51 K51 20DB/YL* 23
52 K52 20PK* PURGE SOLENOID SIGNAL 22
83 ¥36 20LG/RD* SPEED CONTROL f¥ENTI 43
54
88 — _
56 G24 20GY/PK* EMSS MA1NT REMINDER LAMP 23.
57
58 — — —
89 K59 18¥T/BK* AUTOMATIC IDLE SPEED MOTOR (AIS-41 ...... 24......
80 AUTOMATIC IDLE SPEED MOTOR (AIS-2)
 W liil|,|ilG iiiS I l f -183

HEADLAMP A3 12RD*
IGNITION START/RUN A21 14DB BLOWER MOTOR C1 12DG
DIMMED ILLUMINATION FEED El 22TN POWER WINDOWS F21 12TN -
LAMP FEED L? 18BK/YL* IGNITION ACCESSORY/RUN A22 12BK/OR* - ]
RADIO FEED X12 20RD/WT* — POWER SEATS, LOCK &HORN F35 12RD —
TURN SIGNAL FEED L5 18BK/PK' r HEADLAMP (LO) L4 14VT/WT*
WiPER MOTOR ¥§ 18DB — r~ LEFT HEADLAMP L43 20VT
IGNITION ACCESSORY FEED A31 14BK* -i RIGHT HEADLAMP L44 20VT/RD*
HAZARD FEED L9 18BK* — PARK LAMPS A6 12RD/BK*
BATTERY FEED A15 14PK

•i • m • I li M • d 1, #4 —
HEATED MIRROR i 113 17 i |S
FEED €16 20LB/YL# - i i! l l21
EBL SWITCH CIS 12BK* r«m J • • a !• *+ li*l « - H
BODY F a4 12BK/RD* - 10 14 JKZJ2L.
18
_____ I I22
____. 28
LAMPSL 18PK—~ ■S3]
M1 • •
11
E lS
I 115
i Hif i • +
I 119
!!• • f ,
2?
• • • • • • W f H M •4 IE
12 18 20 2 28
SEE -
FOG LAMPS
OWNERS 18WT/OR*
F61
o MANUAL
527075 ■ PARK LAMPS
F63 18PK/RD*
IGNITION START/RUN Q5 20DB* FEED F82 18RD
SPEED CONTROL ¥34 20WT/RP* - ^ LAMPS/WIPER F20 18WT
IGN ACCESSORY/RUN
REAR WIPER ¥23 16BR/PK* A22 12BK/OR*
STOP LAMP F32 18PK/PB*
A/C F38 18WT#
B A T J FEED A3 12RD*

FUSE # AMPS COLOR' SHEET #

1 20 YELLOW 3
2 10 RED 70, 76
20 YELLOW ' ‘ 76, 81
4 — NOT USED
5 20 YELLOW 46
"T- ~ ~ ~ ~ ~ 1 20 5
? 10 ' RED 58, SO, 62
8 —
9 7.5 BROWN . 50
10 — NOT USJEI _
11 _ NOT USE! —
12 _ NOT USED • _ .
13 20 YELLOW . 68 "
14 2 GRAY ■ ; ■ 43
15 10 RED ■ ' 72 ^
16 — NOT USED ■■ ' _
17 10 RED ■ 50,
18 10 RED ■41.-
19 20 YELLOW' 43
20 20 YELLOW 84
21 20 YELLOW 69
22 20 YELLOW 50
23 20 YELLOW 44
24 20 YELLOW
25 30 CIRCUIT BREAKER ~?t " .. ..
28 30 .T GREEf 27, 29, 57
27 30 CIRCUIT BREAKER 44
28 — D ~
 H B lIIB S G D H O D tl]
( ^ ) EU GU 0 0
__1 j “ “| j .I
24 23| 22

STRG
eOLUWN

CAV WIRE CODE IGNITION SYSTEW CIRCUITS

1 — NOT USED
2 —
NOT USED
? —
NOT USED
4 —
NOT USED
5 NOT USED
R —
NOT USED. .
? — NOT USED
s —
NOT USED
i NOT USED
10 NOT USED
11 L60 18TN RT FT TURN SIGNAL
12 162 18BR/RD* RT RR STOP &TURN S1G LP
13 159 18TN/LG* FLASHER FEED
14 LS3 1SDG/RD* LT RR STOP I TURN.S1Q.LP..............
15 LSI 18LG LT FT TURN SIGNAL
16 L63 18BR STOP LAMP PEED
17 21 18BK GROUND
18 L4 14VT/WT HEADLAMP tLO-BEAM!
19 L2 14LG HEADLAMP DIMMER SWITCH
20 13 14RD/OR* HEADLAMP fHl-BEAW!
21 L2<J 14LG/WT# OPTICAL HORN
22 —
NOT USED
23 — NOT USED
24 NOT USED

MULTI-FUNCTION SWITCH CONNECTOR

 NAWE
BRAND
SPEAKER
RELAY

A18 14RD/PK
VAN L94 20DR/WT*
¥23 18BR/PK' LOW
L20 14LG/WT* BEAM
RELAY Z1 18BK —
L2§ 14LG/WT* RELAY
_ Q3 14TN —
L2 14LG _
” P33 140R/BK*
Z1 14BK L9? 18BR/OR*"
POWER PARK
LOCK Z1 18BK - PS3 1 8 B K /R D A
LAMPS
RELAY Zt 18BK F63 18P K /R D * RELAY
P3512RD “
_ P38 200R/WT* L7 18BK/YL* .
~ P34 14PK* X3 20BK/RD* “
Z1 14BK — HORN
POWER Z1 18BK — F35 14RD
RELAY
UNLOCK Z1 18BK F62 18RD
RELAY F35 12RD X2 14DG/RD* .
_ P36 18PK/VT*
L55 1 8 P K /B K * "
COMBO-
L91 1 8 D B /P K * FLASHER
MULTI-FUNCTION 21 18BK RELAY
SWITCH CIRCUIT L32 18PK -
BREAKER

REAR A/C
AND FOG
LAWPS
RELAY

RELAY BLOCK
CAV CIRCUIT DESCRIPTION
1 E2 180R PIMMABLE LAMP FEED
2 D1 18VT/BR* SERIAL BUSS B+
3 D2 18WT* SERIAL BUSS B-
4 G32 18BK/LB* EXT TEMP SENSOR RETURN
5 G31 18VT/LG* EXT TEMP SENSOR SIGNAL
6 M2 18YL DOOR JAMB SWITCHES
7 Q41 18WT IGNITION FEED
8 _ NOT USED
9 21 18BK GROUND
10 NOT USED
11 Z1 18BK GROUND
12 M11 18PK/LB* SWITCHED COURTESY LAMP FEED
13 Ml 18PK 3 AND VISOR LAMP FEED
 C f ^ 11 10 9 8 7 6 5 4 3 2 T^i
[9 J □ □ □ □ □ □ □ □ □ □ □ □

□ □ □ □ □ □ □ □ □ □ □ □ a
25 24 23 22 21 20 19 18 17 16 15 14 13

V WHITE

CAV CIRCUIT DESCRIPTION SHEET

1 G74 18TN/RD# DOOR AJAR SWITCH RT FRONT DOOR 106
2 678 18TN/BK* UPTGATE/DECK LID AJAR SWITCH 105
3 NOT USED __

4 69 20GY/BK* BRAKE WARNING 104

6 NOT USED —

i NOT USED __

7 160 18TN RT FRONT TURN SIGNAL 104

8 NOT USED —

9 D14 1818 DECODE - HIGH INST CLUSTER 104

10 P35 18 OR/VT* POWER DOOR LOCK B+ LOCK 108
11 GiO 22GY/YL* OIL PRESSURE SENDING UNIT 104
12 D13 180R/DB* DECODE - LOW INST CLUSTER 104
13 — NOT USED _

14 G76 1STN/YL* DOOR AJAR SWITCH REAR DOOR 105

15 G42 20DB/YL* SIGNAL GROUND 105
16 IT USED —

1? Gtt 20WT/BK* PARK BRAKE SWITCH 105

18 — NOT USED
19 L61 1816 LT FRONT TURN SIGNAL 104
20 L94 200R/WT* LO BEAM RELAY COIL 104
21 L2 1§LG HEADLAMP DIMMER SWITCH FEED 104
22 Q33 20BR/LB* SP - SENSE - GND FROM LIFT GATE 105
23 G§ 20GY LOWOIL PRESSURE WARNING 104
24 — NOT USED
25 620 22VT/YL# WATER TEMP SENDING UNIT 104
 __________ _ _ _ _ _ _

□ □ □ □ □ □ □ □ □ □ □ □

□ □ □ □ □ □ □ □ □ □ □ □ a
25 24 23 22 21 20 19 18 17 16 15 14 13

i . BLUE

CA¥ CIRCUIT DESCRIPTION SHEET

1 G75 18TN DOOR AJAR SWITCH LEFT FRONT DOOR 102
2 G26 20LB KEY-IN BUZZER CHIME 103
3 E17 20YL/BK* ELEC DISPLAY 103
4 E92 200R/BK* SW POD TO iLLUM MOD DIMMING CONTROL .103
8 G4 20DB FUEL TANK SENDING UNIT 102
i GS 20D8/WI* IGN RUN/START FEED 102
7 D1 18VT/BR* SERIAL SUSS B+ ■ 101
s COURTESY, DOME, ¥lSOR LAMPS 102
9 — NOT USED
10 ¥8 18DG WIPER MOTOR FEED 101
11 ¥8 18DB WiPER MOTOR 101
12 ¥7 18DG/WT* PULSE WIPE PARK (B-) DWELL 103
13 G16 20BK/LB* CHIME GROUND 102
14 Q10 20LG/RD* SEAT BELT WARNING 102
15 G29 22BK/TN* LOWWASH FLUID INDICATOR 101
16 M22 18WT ILLUMINATED ENTRY RELAY GROUND 103
17 ¥9 18DG/YL* PULSE WIPE INTERMITTENT 103
18 ¥10 18BR WASH PUMP MOTOR 101
19 22 18BK/LG* GROUND 101
20 P2 18WT/BK* SERIAL BUSS B- 101
21 P38 20QR/WT* AUTO DOOR LOCK RELAY COIL B+ 103
22 M51 ISYl/RD* KEY IN LIGHT GROUND 103
23 G13 1SDB/RD* SEAT BELT LAMP 102
24 — NOT USED
25 M2 18YL GROUND FOR COURTESY LAMPS 102
CAV CIRCUIT DESCRIPTION .
1 NOT USED
2 Ml 18PK ILLUMiN
3 D13 1SOR/DB# DECODE-LOW INST CLUST TO BCOMP
4 _ NOT USED
5 D14 18LB m W ^P
6 E2 200R l/P DiMMABLE ILLUM
? 22 18BK/LG* GROUND
§ 66 206Y LOWOIL PRESSURE
9 D2 18WT/BK* SERIAL BUSS B+
10 D1 18VT/BR*
11 G5 20DB/WT* IGN RUN/START
12 — NOT USED
13 — NOT USED
14 Z3 2QBK/OR* GROUND
 CAV WIRE CODE IGNITION SYSTEM CIRCUITS SHEET
1 11 16LG* PRNDl SWITC 32
2 | T2 14 fN'BK* BACK UP LIGHT REL£ 33
3 13 14VT BACK UP LIGHT RELAY 33
4 D2 20WT/BK* CCD BUS(-) 33
5 CCD BUS(+) 33
§ — — —
7 — — _
8 A41 YL STARTER REI 31
9 19 ISOR/BK7 ! 32
10 _
11 A21 14DB NEUTRAL SAFETY SWITCH 31
12 K22 180R/DB* fSMEC) SINGLE MODULE CONTROLLER 31
13 [ T13 1QDB/BK* SPEED SENSOR GROUND 31
_ 18LG/WT* OUTPUT SPEED SENSOR
14 r 114 31
15 SAFETY SHUTDOWN RELAY 32
16 [ T16 16RD 32
1? 116 18RP SAFETY SHUTDOWN RELAY 32
18 —
19 T19 18WT TRANS. SOLENOIDS &PRESSURE SWITCH 32
20 120 18LB TRANS. SOLENOIDS &PRESSURE SWITCH 32
21 _ _
22 —
23
24
25 —
28 _ _
27 - —
28 — _ —
29 —
30 —
31 —
82 — •
33 — __
34 — —
35 — — _
36 —
37 — - _
VIEWED FROM WIRE 38 _ _
39 .. —
40 _ __ —
41 T41 18BR/YL* NEUTRAL SAFETY SWITCH 31
42 142 18VT* PRNDL SWITCH 32
43 D1 20VT/BR* 33
44 D2 20WT/BK* 33
45 K24 18GY/BK* DISTRIBUTOR 31
46 — _ —
47 147 18YL/BK* | TRANS, SOLENOIDS &PRESSURE SWITCH 32
48 _
49 —
60 ISO 18DG “ “I TRANS. SOLENOIDS &PRESSURE SWITCH 32
51 K4 18BK/LB* 31
52 T62 18RD/BK* h.TUREMN^^ 31
83 I 214 18BK/YL* I SIGNAL GROUND 32
54 214 18BK/YI* SiGNAL GROUND 32
55 — _ .
58 A14 16RD* 32
57 rZ13l8BK/RD* 1 32
68 Z13 18BK/RP* SIGNAL GROUND 32
59 T69 18BK TRANS. SOLENOIDS &PRESSURE SWITCH 32
80 rf60l8BR 32
 CAV CIRCUIT DESCRIPTION
1 — NOT USED
2 — NOT USED
3 180 18 TN RT FT TURN SIGNAL
4 _ NOT USED
5 L61 18 LG LT FT TURN SIGNAL
6 G19 20 LG* ANTI-LOCK BRAKE WARNING
7 G5 20 DB* IGN RUN/START FEED
8 G13 18DB/RD* .SEAT BELT LAMP
9 G34 16RD/BK* Hi BEAM IND
10 G24 22GY/PK* EMISSION MAlNTiNA 4P
11 Z3 2GBK/OR* GROUND
12 NOT USED
13 NOT USED
14 99 20GY* BRAKE WARI

918W-9 WARNING LAMP CENTER CONNECTOR AS-HK 120

 _T L r u
□ □ □ □ □ □ □ □
3

GREEN

CAV CIRCUIT DESCRIPTION SHEET NO.

1 __ NOT USED
2 ISO 18WT/TN* STOP LAMP SWITCH 89
3 G75 18TN LEFT FRONT DOOR AJAR SWITCH r3
4 M11 18PK/LB* SWITCHED COURTESY LAMP FEED 81
5 G78 18IN/BK* LIFTGATE AJAR SWITCH 73
8 M2 18YL GROUND FOR COURTESY LAMPS it
7 G4 20DB FUEL TANK SENDING UNIT 88, 100
8 — NOT USED
9 LI 18VT/BK* BACK UP LAMP FEED 89
10 L1 18VT/BK* BACK UP LAMP FEED 89
L1 18VT/BK* BACK UP LAMP FEED §9
11 L82 18BR/RD* BT RRTURN ..AND STOP LAMP 89
12 Q10 20LG/RD* SEAT BELT WARNING SWITCH 74
13 Q16 20BK/LB* CHIME GROUND 102
14 Li3 11DG/RD* .. It RR.TURN. AND STOP LAMP 89
15 G42 20DB/YL* p SIG
_ NAL
_ _GROUND
_ 100
18 — —

LEFT BODY CONNECTOR

CAV CIRCUIT DESCRIPTION SHEET NO.
1 21 18BK GROUND 49
21 18BK GROUND 49 LEFT POD
2 E2 20DR l/P ILLUMINATION ............... 49 CONNECT
3 L53 1SIN/LG* FLASHER FEED 49 c=
4 L53 18BK STOP LAMP PEED 49
8 LSD 18WT/TN* STOP LAMP S W .................................. ....... 49 ..
§ L55 18PK/BK* SW PEED FROM HAZARD UNIT 49
? L9 18BK/WT* FUSED HAZARD FLASHER PEED 49
a L5 1SBK/PK* TURN SIGNAL FLASHER UNIT 49

CAV CIRCUIT DESCRIPTION SHEET NO.

1 V22 18BR/YL* WASH DELAY - RR WiPER 45
2 ¥21 18DB/RD* ON/OFF SW - RR WiPER 45 RIGHT POD
CONNECT
3 V8 18DB WINDSHIELD WIPER MOTOR 45
V8 18DB WINDSHIELD WiPER MOTOR 45
4 V10 18BR WASH PUMP MOTOR 45
5 23 2QBK/OR* GROUND 45 a
6 E2 20OR i/P ILLUMINATION 45
? _ NOT USED —

8 NOT USED — .

STEERING COLUMN SWITCH

TO PANEL WIRING
CAV CIRCUIT DESCRIPTION SHEET - LT
1 L7 18BK/YL* LICENSE LAMP FEED 90 BODY
2 Z1 12BK GROUND 90
3 €1512BK* EBL 70
4 G78 18TN/SK* DECK LID AJAR SWITCH 73
6 NOT USED —

6 M11 18PK/LB* SWITCHED COURTESY LAMP FEED 82

7 ¥20 16BK/WT* WASH PUMP GROUND 6?
8 Q2 14LG/BK* LIFTGATE RELEASE 71
9 : .I S o t T I s e d - - —

10 L50 18WT/TN* 90
11 M2 18YL r_
LIFTGATE JAMB SWITCH
_ 82
12 _ _

13 — NOT USED —

.._
CAV CIRCUIT SHEET RT
1 ¥21 1SPB/RD* RR WIPER ON/OFF SIGNAL 86 BODY
2 — —

3 — NOT USED —

4 X57 1SBR/LB* LEFT REAR SPEAKER B~ 61, 63

8 NOT USED —

8 X58 18DB/OR* RIGHT REAR SPEAKER B- 61, 83

7 V22 18BR/YL* RR WIPER DELAY 68
a F20 18WT REAR WiPER PARK 66
i X51 18BR/YL LEFT REAR SPEAKER B+ 61, 83
10 _ NOT USED
11 X52 18DB/WT* RIGHT REAR SPEAKER 8+ 81, 63
12 — NOT USED
13 — NOT USED _
 CAV WIRE CODE IGNITION SYSTEM CIRCUITS SHEET
1 Bt 20YL/DB* BIGHT REAR WHEEL SENSOR(-) 34
2 82 20YL RIGHT REAR WHEEL SENSORf+f 34
3 B3 20LG/DB* LEFT REAR WHEEL SENSOR(-) 34
4 ^B4l0Ucr' LEFT REAR WHEEL SENSORf#) 34
5 21 16BK GROUND 35
?6 87 86 20WT/DB*
20WI
RIGHT FRONT WHEEL SENSOR(-)
RIGHT FRONT WHEEL SENSOR(+)
34
34
8 B8 20RD/DB* LEFT FRONT WHEEL SENSOR(-) 34
9 ! B9 20RP LEFT FRONT WHEEL SENSOR(+) 34
10 B210 20RD/BK* I ABS TRANSDUCER RETURN(-1 35
11 D11 20WT/VT* DIAGNOSTICS 37
12 D12 200R ~ "H DIAGNOSTICS 3?
13 L50 18WT/TN* STOP LAMP SWITCH 38
14 G9 20GY/BK* BRAKE WARNING LAMP SWITCH 36
16 G19 23 LG/OR* ABS WARNING LAMP 37
16 NOT USED —
1? B217 14RD LOW ACCUMULA- 36
18 B218 20WT/DR* PRIMARY PRESSURE / PPA 35
19 B219 20DB I fABS) 35
20 T40 14BR STARTER RELAY CONTACT TO SOLENOID 35
21 — NOT USED _
22 — NOT USED —
23 NOT USED _
24 J NOT USED _
26 — I NOT USED ~ ~ _
26 _ NOT USED
2? — NOT USED
28 _ NOT USED —
; _ .. ........... ""So.f.ui
30 NOT USED __
31 _ T USED —
32 ~~ IED _
33 _ T USED
34 — NOT USED —
36 — r~ NOT USED —
36 _ NOT USED —
3? __ l “ NOT USED —
38 __ NOT USED —
VIEWED FROM WIRE 39 NOT USED __
END OF CONNECTOR 40 — T USED __
41 T USED __
42 B242 20BR* LEFT FRONT BUILD VALVE 36
43 ri24F20DG/BK* ^LEFT FRONT DELAY VALVE 3§
44 — NOT USED __
45 B245 20WT/LG* LEFT FRONT ISOLATE VALVE
48 RIGHT FRONT BUILD VALVE
4? B4? 18RD/LB* MODULE FEED 37
48 B248 20DG* RIGHT FRONT DELAY VALVE p _36_
49 B249 20WT/TN* RIGHT FRONT ISOLATE VALVE
50 B4? 18RD/LB* MODULE FEED
61 B251 20WT* LEFT REAR ISOLATE VALVE 36
52 i W s F w b m t h * 38
53 — NOT USED —

54 B254 2GDG/OR* RIGHT AND LEFT REAR DELAY VALVE 38

55 B255 20WT/PK* RIGHT AND LEFT REAR ISOLATOR VALVE 36
56 NOT USED —

5? B57 20BR/BK* ABS SYSTEM RELAY COIL FEED 38

50 B258 20GY/LB* TRANSDUCER PEEPf+1 35
59 NOT USED
60 A21 14DB IGNITION START RUN
 O
CAV CIRCUIT DESCRIPTION SHEET
1 • B82 12BR* ABS PUMP M OT OR FEED 35
2 Z1 14BK GROUND 35
2 1

CAV CIRCUIT DESCRIPTION SHEET

1 Z1 1SBK GROUND 35
2 8210 20RP/BK* TRANSDUCER RETURN (-) 35
3 NOT USED
/
4 G9 20GY* BRAKE WARNING LAMP 35 O o o o o
5 B21 14GY ABS PUMP MOTOR CONTROL 35 O 0 0 o o
V ________ TL
i T40 14BR STARTER RELAY CONTACT 35 *
V J
7 B268 20GY/LB* TRANSDUCER FEED (+) 35 10 9 8 7 6
8 B219 20DB (ABS) 35
9 B218 2CIWT/OR* PRIMARY PRESSURE/DPA 35
10 B21714RD LOWACCUMULATOR 35

CAV CIRCUIT DESCRIPTION SHEET

1 B245 20WT/LG* LEFT FRONT ISOLATE VALVE 38
2 B24320DG/BK* LEFT FRONT DECAY VALVE 38
3 B242 20BR* LEFT FRONT BUILD VALVE 38
4 B254 2QDG/OR* RIGHT AND LEFT REAR DECAY VALVE 38 f | S T T ,T a ] '
5 B255 20WT/PK* RIGHT AND LEFT REAR ISOLATOR VALVE 36
OOo o O
§ B249 20WT/TN* RIGHT FRONT ISOLATE VALVE 36 V_ — _________ _________
7 B248 20DG/WT* RIGHT FRONT DECAY VALVE 36 10 9 8 7 8
8 B246 20BR/RD* RIGHT FRONT BUILD VALVE 36
9 B252 20BR/TN* RIGHT AND LEFT REAR BUILD VALVE 36 DK GRAY
10 B251 2€JWI# LEFT REAR ISOLATE VALVE 38

ABS PUMP MOTOR

CONNECTORS
CAV CIRCUIT DESCRIPTION
1 T47 18YL* KICK-DOWN PRESSURE SWITCH
2 ISO 18DG LOWREV PRESSURE SWITCH
3 T9 1SOR* OVERDRIVE PRESSURE SWITCH
4 T16 16RD SWITCHED BATTERY FEED
5 T59 18PK UD SOLENO!
§ ISO 18BR OD SOLENOID
7 T20 18LB LR/LU SOLENOID
8 T19 18WT KICK DOWN/LOWAND REVEP

TRANSAXLE SOLENOID CONNECTOR

 ENGINE
CONTENTS
Page
2.5L ENGINE . . . . . . . . . . . . . . . . . . . . . . . . . .
3.0L ENGINE . . . . . . . . . . . . . . . . . . . . . . . . . .
STANDARD SERVICE PROCEDURES
Page
Crankshaft Sprocket Bolt Access Plug . . . . . . . . . . . . .
Engine Performance . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Engine Diagnosis . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Form-in-Place Gaskets . . . . . . . . . . . . . . . . . . . . . . . . . .
Honing Cylinder Bores . . . . . . . . . . . . . . . . . . . . . . . . . .
Lash Adjuster (Tappet) Noise Diagnosis . . . . . . . . . . .
FORM-IN-PLACE GASKETS
There are numerous places where form-in-place gas­
kets are used on the engine. Care m ust be taken when
applying form-in-place gaskets to assure obtaining the
desired results. Bead size, continuity, and location are
of great importance. Too thin a bead can result in
leakage while too much can result in spill-over which
can break off and obstruct fluid feed lines. A continu­
ous bead of the proper width is essential to obtain a
leak-free joint.
Two types of form-in-place gasket m aterials are used
in the engine area. Mopar Silicone Rubber Adhesive
Sealant and anaerobic gasket m aterials, each have
different properties and cannot be used interchangeably.
MOPAR SILICONE RUBBER ADHESIVE
SEALANT
Mopar Silicone Rubber Adhesive Sealant or equiva­
lent, normally black in color, is available in three
ounce tubes. Moisture in the air causes the Mopar
Silicone Rubber Adhesive Sealant m aterial to cure.
This m aterial is norm ally used on flexible m etal
flanges. It has a shelf life of one year and will not
properly cure if over age. Always inspect the package
for the expiration date before use.
ANAEROBIC GASKETS
The second form-in-place gasket m aterial used is
anaerobic m eaning it cures in the absence of air when
squeezed between two m etallic surfaces. It will not
cure if left in the uncovered tube. It is normally red in
color and is available in 6 cc tubes. The anaerobic
m aterial is for use between two smooth machined
surfaces. It should not be used on flexible metal flanges.
Page
8 3 JL ENGINE . . . . . . . . . . . . . . . . . . . . . . . . . . 88
51 STANDARD SERVICE PROCEDURES . . . . . . . . 1
INDEX . .
Page
2 Measuring Main Bearing Clearance and
2 Connecting Rod Bearing'Clearance . . . . . . . . . . . . . 3
6 Repair of Damaged or Worn Threads . . . . . . . . . . . . . . 4
1 Rubber-Isolated Engine Mounts . . . . . . . . . . . . . . . . . . 2
2 Solid Mount Compressor Bracket . . . . . . . . . . . . . . . . . 4
4
DISASSEMBLY
Parts assembled w ith form-in-place gaskets maybe
disassembled without unusual effort. In some instances,
it may be necessary to lightly tap the part with a
m allet or other suitable tool.to break the seal between
the m ating surfaces. A flat gasket scraper may also be
lightly tapped into the joint but care m ust be taken
not to damage the m ating surfaces.
SURFACE PREPARATION
Scrape clean or wire brush all gasket surfaces re­
moving all loose m aterial. Inspect stamped parts to
assure gasket rails are flat. Flatten rails with a ham ­
mer on a flat plate if required. Gasket surfaces m ust
be free of oil and dirt. M ake sure old gasket m aterial
is removed from blind attaching holes.
FORM-lfl-PLACE GASKET APPLICATION
A ssem bling.parts using a form-in-place gasket re­
quires care but it is as easy as using precut gaskets.
The anaerobic gasket m aterial should be applied
sparingly 1mm or less th an .06 inch diam eter of seal­
ant to one gasket surface. Be certain the m aterial
surrounds each m ounting hole. Excess m aterial can
easily be wiped off. Components should be torqued in
place w ithin 15 m inutes. The use of a locating dowel
is recommended during assembly to prevent sm earing
the m aterial off location.
The Mopar Silicone Rubber Adhesive Sealant gas­
ket m aterial or equivalent should be applied in a
continuous bead approximately 3mm (.12 inch) in di­
ameter. All m ounting holes m ust be circled. Uncured
Mopar Silicone Rubber Adhesive Sealant may be re­
moved with a shop towels. Components should be
torqued in place while the M opar Silicone Rubber
Adhesive Sealant is still wet to the touch (within 10
minutes). The usage of a locating dowel is recom­
mended during assembly to prevent sm earing of m a­
terial off location.
CRANKSHAFT SPROCKET BOLT ACCESS PLUG
An Access plug is located in the right inner fender
shield. Remove the plug and insert proper size socket,
extension and rachet, when crankshaft rotation is
necessary.
RUBBER-ISOLATED ENGINE MOUNTS
Square, modified X type engine mounts are used at
both ends and front (radiator side) of the power plant.
These mounts are soft and resilient in controlled di­
rections and allow normal power plant vibration to
occur w ithout directly transferring it to the body
structure.
The mounts insulators are encased inside a square
shell, the shell acts as a fail-safe device by preventing
excessive engine motion, even if the engine mount is
damaged.
ENGINE PERFORMANCE
If a loss of performance is noticed, ignition tim ing
should be checked. If ignition tim ing is retarded by 9,
18 or 27° indicating 1, 2 or 3 (timing belt) teeth may
have skipped, then, camshaft and accessory shaft tim ­
ing with the crankshaft should be checked. Refer to
Engine Timing Sprockets and Oil Seals of the Engine
Section.
To provide best vehicle performance and low est ve­
hicle emissions, it is most im portant th a t the tune-up
be done accurately. Use the specifications listed on
the Vehicle Emission Control Information label found
in the engine compartment.
(1) Test cranking amperage draw. See Starting Mo­
tor Cranking Amperage Draw Electrical Section of
this m anual.
(2) Tighten the intake manifold bolts to specifications.
(8) Perform cylinder compression test.
a. Check engine oil level and add oil if necessary.
b. Drive the vehicle until engine reaches normal
operating tem perature.
c. Select a route free from traffic and other forms
of congestion, observe all traffic laws, and accelerate
through the gears several tim es briskly.
CAUTION; Do not overspeei the engine The higher
engine speed may help clean out valve seat deposits
which can prevent accurate compression readings.
d. Remove all spark plugs from engine. As spark
plugs are being removed, check electrodes for abnor­
mal firing indicators fouled, hot, oily, etc. Record cyl­
inder num ber of spark plug for future reference.
e. Disconnect coil wire from distributor and se­
cure to good ground to prevent a spark from starting a
fire (Conventional ignition System). For Direct Igni­
tion System DIS disconnect the coil connector.
£ Be sure throttle blade is fully open during the
compression check.
g. Insert compression gage adaptor into the #1
spark plug hole in cylinder head. Crank engine until
maximum pressure is reached on gage. Record this
pressure as #1 cylinder pressure.
h. Repeat Step G for all rem aining cylinders.
i. Compression should not be less th an (689kPa)
100 psi and not vary more than 25% from cylinder to
cylinder.
j. If one or more cylinders have abnorm ally low
compression pressures, repeat steps 4b through 4h.
k. If the same cylinder or cylinders repeat an
abnormally low reading on the second compression
test, it could indicate the existence of a problem in the
cylinder in question.
The recommended compression pressures are to
be used only as a guide to diagnosing engine prob­
lems. An engine should not be disassembled to de­
termine the cause of low compression unless some
malfynctiort Is present.
(4) Clean or replace spark plugs as necessary and
adjust gap as specified in Electrical Group 8. Tighten
to specifications.
(5) Test resistance of spark plug cables. Refer to
Ignition System Secondary Circuit Inspection Electri­
cal Section Group 8.
(8) Inspect the prim ary wire. Test coil output volt­
age, prim ary and secondary resistance. Replace parts
as necessary. Refer to Ignition System and m ake nec­
essary adjustment.
(7) Ignition tim ing should be set to specifications,
(See Specification Label in engine compartment).
(8) Test fuel pump for pressure and vacuum. Refer
to Fuel System Group 14, Specifications.
(9) The air filter elem ents should be replaced as
specified in Lubrication and M aintenance, Group 0.
(10) Inspect crankcase ventilation system as out
lined in Lubrication and M aintenance, Group 0. For
emission controls see Emission Controls Group 25 for
service procedures.
(11) Inspect and adjust accessory belt drives refer­
ring to Accessory Belt Drive in Cooling System, Group
7 for proper adjustments.
(12) Road test vehicle as a final test.
HONING CYLINDER BORIS
Before honing, stuff plenty of clean shop towels un­
der the bores, over the crankshaft to keep abrasive
m aterials from entering crankcase area.
(1) Used carefully, the cylinder bore resizing hone
€-823 equipped w ith 220 grit stones, is the best tool
for this job. In addition to deglazing, it will reduce
taper and out-of-round as well as removing light scuff­
ing, scoring or scratches. Usually a few strokes will
clean up a bore and maintain the required limits.
(2) Deglazing of the cylinder walls may be done
using a cylinder surfacing hone, Tool C-3501, equipped
with 280 grit stones (C-3501-3810) if the cylinder bore
is straight and round. 20-60 strokes depending on the
bore condition will be sufficient to provide a satisfac­
tory surface. Inspect cylinder walls after each 20
strokes. Using a light honing oil available from major RN860
oil distributors. Do not use engine or transmission
oil, mineral spirits or kerosene. Fig. 2 Plastic Gauge Placed in Lower Shell
(3) Honing should be done by moving the hone up
and down fast enough to get a cross-hatch pattern.
When hone marks intersect at 50-60 degrees, the cross
hatch angle is most satisfactory for proper seating of
rings (Fig. 1).

RN861

Fig. 3 Clearance Measurement

MEASURING MAIN BEARING CLEARANCE AND

(4) A controlled hone motor speed between 200-300
RPM is necessary to obtain the proper cross-hatch
angle. The number of up and down strokes per minute
can be regulated to get the desired 50-60 degree an­
gle. Faster up and down strokes increase the cross-
hatch angle.
(5) After honing, it is necessary that the block be
cleaned again to remove all traces of abrasives.
CAUTION: Be sure ail abrasives are removed from
engine parts after honing. It is recommended that a
solution of soap and hot water be used with a brush
and the parts then thoroughly dried. The bore can be
considered clean when it can be wiped clean with a
white cloth and cloth remains clean. Oil the bores
after cleaning to prevent rusting.
CONNECTING ROD BEARING CLEARANCE
PLASTIC-GAGE METHOD
Engine crankshaft bearing clearances can be deter­
mined by use of Plastic-Gage or equivalent. The fol­
lowing is the recommended procedure for the use of
Plastic-Gage:
(1) Remove oil film from surface to be checked.
Plastic-Gage is soluble in oil.
(2) The total clearance of the main bearings can
only be determined by removing the weight of the
crankshaft. This can be accomplished by either of two
methods:
a. With the weight of the crankshaft being sup­
ported by a jack under the counterweight adjacent to
the bearing being checked.
b. (Preferred method) Shimming the bearings ad­
jacent to the bearing to be checked in order to remove
the clearance between upper bearing shell and the
crankshaft. This can be accomplished by placing a
minimum of 0.254mm (.010 inch) shim (e.g.cardboard,
matchbook cover, etc.) between the bearing shell and
the bearing cap on the adjacent bearings and snug­
ging bolts to 14-20 N-m (10-15 ft.lb.)
• When checking #1 main brg shim #2 main brg
• When checking # 2 main brg shim #1 & 3 main brg
• When checking #3 main brg shim # 2 & 4 main brg
• When checking # 4 main brg shim # 3 & 5 main brg
• When checking # 5 main brg shim # 4 main brg
REMOVE ALL SHIMS BEFORE REASSEMBLING (9) Faulty lash adjuster.
ENGINE (a)'Check for sponginess while still installed in
cylinder head. Depress p art of rocker arm ju st over
(3) Place a piece of Plastic-Gage across the entire
adjuster. Norm al adjusters should feel very firm.
width of the bearing shell in the cap approximately
Spongy adjusters can be depressed to the bottomed
6.35mm (1/4 inch) off center and away from the oil
position easily.
holes (Fig. 2). (In addition, suspect areas can be checked
(b) Remove suspected lash adjusters, pry off re­
by placing the Plastic-Gage in the suspect area). Torque
tainer cap and disassemble Do not reuse retainer caps.
the bearing cap bolts of the bearing being checked to
Do not interchange parts and m ake sure th a t care and
the proper speciflcatidns.
cleanliness is exercised in the handling of parts.
The checking of connecting rod clearances does
(c) Clean out d irt and varnish w ith solvent.
not require shimming of the crankshaft. However,
(d) Reassemble w ith engine oil.
before assembling the rod cap with Plastic-Gage in
(e) Check for sponginess.
place, the crankshaft must be turned until the con­
(f) If still spongy, replace w ith new adjuster.
necting rod to be checked starts moving toward the
top of the engine. Only then should the cap be as­
sembled and torqued to specifications. Do not rotate
REPAIR i f DAMAOED OR WORN THREADS
the crankshaft while assembling the cap or the Plastic-
Damaged or worn threads (including alum inum head
Gage may be smeared, giving inaccurate results.
spark plug threads) can be repaired. Essentially, this
(4) Remove the bearihg cap and compare the width
repair consists of drilling out worn or damaged threads,
of the flattened Plastic-Gage (Fig.3) with the metric
tapping the hole w ith a special Heli-Coil (or equiva­
scale provided on the package. Locate the band closest
lent) Tap, and installing an insert into the tapped
to the same width. This band shows the amount of
clearance in thousandths of a millimeter. Differences hole. This brings the hole back to its original thread
size.
in readings between the ends indicate the amount of
Heli-Coil tools and inserts are readily available from
taper present. Record all readings taken. Refer to En­
automotive parts jobbers.
gine Specifications. Plastic-Gage generally is accom­
panied by two scales. One scale is in inches, the
other is a metric scale.
SOLID MOUNT COMPRESSOR BRACKET
(5) Plastic-Gage is available in a variety of clear­
When service procedures require solid m ount bracket
ance ranges. The 0.025-0.076mm (.001-003 inch) is
removal and installation for example: cylinder head
usually the most appropriate for checking engine bear­
removal, etc., it is im portant th a t bracket fasteners
ing proper specifications.
num bered 1 through 7 (Fig. 4) be removed and in­
stalled in sequence, as instructed in Remove and Install.
LASH ADJUSTER (TAPPET) NOISE DIAGNOSIS
m m o w E ACCESSORIES
A tappet-like noise may be produced from several
(1) Remove (and install/adjust) belts, Refer to Acces­
items. Check the following items.
sory Drive Belts in Cooling System, Group 7.
(1) Engine oil level too high or too low. This may
(2) Remove a ir conditioning coitipressor (in vehicle
cause aerated oil to enter the adjusters and cause
with lines and set aside ) (Fig. 4).
them to be spongy.
(3) Remove alternator pivot bolt and remove alter­
(2) Insufficient running tim e after rebuilding cylin­
nator (in vehicle: tu rn wiring side up and disconnect,
der head. Low speed running up to 1 hour may be
then rotate alternator, pulley end towards engine and
required.
remove).
D uring this tim e, tu rn engine off and let set for a
(4) Remove a ir conditioner compressor belt idler.
few minutes before restarting. Repeat this several times
after engine has reached normal operating temperature.
(3) Low oil pressure.
(4) The o il'restrictor pressed into the vertical oil
passage to the cylinder head Balance Shaft Engines
Only is plugged w ith debris.
(5) Air ingested into oil due to broken or cracked oil
pump pick up.
(8) Worn valve guides.
(7) Rocker arm ears contacting valve spring retainer
(2.5L engines).
(8) Rocker arm loose, adjuster stuck or a t maximum
extension and still leaves lash in the system.
 SOLID MOUNT
COMPRESSOR
BRACKET

<$> 102 (75 FT. LBS.)

Z•
3

31 N*m (280 IN1. LIS.)

<$>

<§> 28 N*m (250 IN . LBS.)

< § > 54 N*m (40 FT. LBS)
41 N«rn (30 FT. LBS.)
< i>
FASTENERS NUMBERED
1 THRU 7 - SEE TEXT
FOR TIGHTENING SEQUENCE
9109-111

Fig. 4 Solid Mount Compressor Bracket 2.SL Engines

REMOVE SOLID MOUNT BRACKET (FIG. 4) INSTALL SOLID MOUNT BRACKET

(1) Remove right engine mount yoke screw (Refer to
Engine Remove Fig. 3) securing isolator support bracket
to engine mount bracket.
(2) Remove five side mounting bolts #1, # 4 , #5,
#6, and # 7 (Fig. 4).
(3) Remove front mounting nut, #2, and remove (or
loosen*) front bolt #3*.
*In vehicle: fully loosen bolt and remove with assembly.
(4) Rotate solid mount bracket away from engine
and slide on stud (#2 nut mounting stud) until free.
Front mounting bolt and spacer will be removed with
bracket.
Front mounting bolt and spacer need to be installed
simultaneously with bracket.
(1) Install bracket on front (#2 nut) mounting stud
and slide bracket over timing belt cover into position.
(2) Loosen assembly bracket to engine fasteners
(numbered #1 through #7 in Fig. 4).
(3)CAUTION: Fasteners MUST BE TIGHTENED IN
SEQUENCE and to specified torque as follows:
• First Bolt #1 to 30 N-m (30 in. lbs.)
• Second Nut #2 and Bolt # 3 to 54 N-m (40 ft. lbs.).
• Third Bolts #1 (second tightening) # 4 and #5 to 54
N-m (40 ft. lbs.).
• Fourth Bolts # 6 and # 7 to 54 N-m (40 ft. lbs.).
(4) Install alternator and compressor. Tighten com­
pressor mounting bracket bolts to 54 N-m (40 ft. lbs.).

Condition
ENGINE WILL NOT START
ENGINE STALLS OR ROUGH IDLE
' (f)
ENGINE LOSS O f POWER
ENGINE MISSES O N ACCELERATION
1MG1ME M ISSIS AT HIG H SPUD
ENGINE DIAGNOSIS
Possible Cause ■
(a) Weak battery.
(b) Corroded or loose battery
connections.
(c) Faulty starter.
(d) Moisture on ignition w i res and
distributor cap.
(e) Faulty ignition cables.
(f) Faulty coil or control unit.
(g) Incorrect spark plug gap.
(h) Incorrect ignition timing.
(i) Dirt or w ater i n fuel system.
(j) faulty fuel pump.
(a) Idle speed set too low.
(b) Idle mixture too lean or too rich.
(c) Leak In intake manifold.
(d) Worn distributor rotor.
(e) Incorrect i gniti on wiring.
faulty coil.
(g) EGR valve leaking.
(a) Incorrect ignition timing.
(b) Worn distributor rotor.
(c) Worn distributor shaft.
(d) Dirty or incorrectly gapped spark
plugs.
(e) Dirt or w ater in fuel system.**
(f) Faulty fuel pump.
(g) Incorrect valve timing.
(h) Blown cyli nder bead gasket.
( i) Low compression.
(j) Burned, warped or pitted valves.
(k) Plugged or restricted exhaust
system.
(1) Faulty ignition cables.
(m)Faulty coil.
(a) Dirty, or gap too wide in spark
plugs.
(b) Incorrect ignition timing.
(c) Dirt in fuel system.
(d) Burned, warped or pitted valves.
(e) Faulty coil.
(a) Dirty, or gap set too w ide in spark
p lug.
(b) Worn distributor shaft.
(c) Worn distributor rotor.
(d) Faulty coil.
(e) Incorrect ignition timing.
(f) Dirt or w ater in fuel system or
filter.
Correction
(a) Test battery specific gravity.
Recharge or replace as necessary.
(b) Clean and tighten battery
connections. Apply a coat of light
mineral grease to terminals.
(c) Refer to Electrical, Group 8. ,
(d) Wipe wires and cap clean and
dry.
(e) Replace any cracked or shorted
cables.
(f) Test and replace if necessary.*
(g) Set gap.*
(h) Refer to "Ignition Timing."
(i) Clean system.
(j) Install new fuel pum p.**
(a) See Electronic Fuel Injection.**
(b) See Electronic Fuel Injection.**
(c) Inspect intake manifold gasket
and vacuum hoses replace if
necessary.**
(d) Install new rotor.
(e) Install correct wiring.
(f) Test and replace if necessary.*
(g) Test and replace if necessary.#
(a) Refer to "Ignition Timing."*
(b) Install new rotor.
(c) Remove and repair distributor.*
(d) Clean plugs and set gap.*
(e) Clean system.**
(f) Install new pump.
(g) Refer to "Checking Valve
Tim ing."***
(h) Install new head g asket.***
(i) Test compression of each
cylinder.***
(j) Install new valves.***
(k) Install new parts as necessary.
(1) Replace any cracked or shorted
cables.
(m)Test and replace as necessary.*
(a) Clean spark plugs and set gap.*
(b) Refer to "Ignition Timing."*
(c) Clean fuel system.
(d) Install new valves.***
(e) Test and replace if necessary.*
(a) Clean spark plugs and set gap.*
(b) Remove and repair distributor.*
(c) Install new rotor.
(d) Test and replace if necessary.*
(e) Refer to "Ignition Timing."*
(f) Clean system and replace filte r.**
9109-2
 ENGINE DIAGNOSIS
Condition Possible Cause
(a) Thin or diluted oil-low pressure.
(b) Worn valve guides
(c) Excessive run-out of valve seats on
valve faces.
CONNECTING HOD NOISE (a) Insufficient oil supply.
(b) Low oil pressure.
(c) Thin or diluted oil.
(d) Excessive bearing clearance.
(e) Connecting rod journals out-of­
round.
(f) Misaligned connecting rods.
M A IN BKARING N O IS I (a) Insufficient oil supply.
(b) Low oil pressure.
(c) Thin or diluted oil.
(d) Excessive bearing clearance.
(e) Excessive end play.
(f) Crankshaft journal out-of-round
worn.
(g) Loose flyw heel or torque converter.
OIL COMSWMWIOM OR IP lltlC PIJJIIS (a) PCV system malfunction.
OIL PCIiJlJli (b) Worn, scuffed, or broken rings.
(c) Carbon in oil ring slot.
(d) Rings fitted too tight in grooves.
(e) Worn valve guides.
(f) Valve stem seal unseated or defective.
OIL P l l i S l l i l IlltClP (a) Low oil level.
(b) Faulty oil pressure sending unit.
(c) Clogged oil filter.
(d) Worn parts in oil pump.
(e) Thin or diluted oil.
(f) Excessive bearing clearance.
(g) Oil pump relief valve stuck.
(h) Oil pump cover bent or cracked.
* Refer to the "Electrical and Instruments' ' Group 8 for service procedures.
** Refer to the "Fuel System” Groyp 14 fo r service procedures.
***R efer to the "Engine" Group 9 fo r service procedures.
#Refer to the "Emission Control Systems" group 25 fo r service procedures.
Correction
(a) Change oil.
(b) Ream and install new valves with
O /S Stems.***
(c) Grind valve seats and valves.***
(a) Check engine oil lev el.***
(b) Check engine oil level. Inspect oil
pump relief valve and spring.***
(c) Change oil to correct viscosity.
(d) Measure bearings for correct
clearance.***
(e) Replace crankshaft or regrind
journals.***
(f) Replace bent connecting rods.***
(a) Check engine oil lev el.***
(b) Check engine oil level. Inspect oil
pump relief valve and spring.***
(c) Change oil to correct viscosity.
(d) Measure bearings for correct
clearances.***
(e) Check No. 3 main bearing for w ea r
on flanges.***
(f) Replace crankshaft or regrind
journals.
(g) Tighten to correct torque.
(a) Check system.
(b) Hone cylinder bores and install new
rings.***
(c) Install new rings.***
(d) Remove the rings. Check grooves. If
groove is not proper width, replace
piston. * * *
(e) Ream guides and replace valves
with oversize.
(f) Repair or replace.
(a) Check engine oil level.
(b) Install new sending unit.
(c) Install new oil filter.
(d) Replace worn parts or pump.
(e) Change oil to correct viscosity.
(f) Measure bearings for correct
clearance.***
(g) Remove valve and inspect, clean,
and reinstall.
(h) Install new oil pump.
 2.5L ENGINE
INDEX
Page Page
Balance Shafts .............................................................. 31 Engine Specifications.................................................... 48
Camshaft, Crankshaft and Intermediate Shafts General Information ...................................................... 8
Timing Procedure ...................................................... 17 Installing Engine ............................................................ 12
Camshaft Service .......................................................... 21 Intermediate Shaft Service .......................................... 33
Crankshaft Oil Seals Service ....................................... 28 Lash Adjuster (Tappet) Noise ..................................... 22
Crankshaft Service ........................................................ 29 Lubrication System ........................................................ 43
Cylinder Bore .................................................................. 37 Oil Pan ............................................................................. 43
Cylinder Block, Piston and Connecting Rod Oil Filter ........................................................................... 47
Assembly Service ...................................................... 36 Oil Pump Service .......................................................... 43
Cylinder Head ................................................................ 20 Servicing Oil Seals ........................................................ 15
Cylinder Head and Valve Assembly Service ............ 19 Timing Belt Removal .................................................... 14
Cylinder Head Service .................................................. 19 Timing System and Seals ........................................... 14
Engine Core P lu g s .......................................................... 40 Valve Components Replace—
Engine Mount Rubber Insulators ............................... 12 Cylinder Head Not Removed ................................... 22
Engine Removal ............................................................ 10 Valve Service .................................................................. 23

GENERAL INFORMATION
2.5L Engine Specification
Type . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .In Line 4 Cylinder SOHC
Bore anil Strok®
2 . 5 1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8 7 . 5 . x 104 mm (3.44 x 4.09 inch)
Displacement
2 . 5 1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2.51 (153 Cubic Inch)
Compression Ratio
(Fuel Induction System)
2 .5 1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .8.9:1 (T il)
Torque
2.5L . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 183 N*m (135 Lbs.-Ft.) @ 2,800
Firing O rder . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-3-4-2
lubrication . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Pressure Feed-Full Flow Filtration
Engine O il C apacity . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3.8 Liters (4.0 qts.) without oil f i lter change,
4.25 Liters (4.5 qts.) with oil filter change.
Cooling System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Liquid Cooled-Forced Circulation
Cylinder Block . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Cast Iron
C rankshaft. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Cast Nodular Iron
Cylinder Head . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Aluminum Alloy with "Fast Burn" Design Combustion
Chambers
Camshaft . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Nodular Iron with Roller Followers
Pistons . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Cast Aluminum Alloy (w/Strut)
Piston (Top) R elief . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Dished w /V a lv e Cut
Connecting Rods . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Forged Steel
9109-112

BLOCK: All four cylinder cast iron blocks have CRANKSHAFT: A nodular cast iron crankshaft that
cast-in recesses in the bottom of each cylinder bore to is used in 2.5L engine. These engines have 5 main
provide connecting rod clearance; especially for 2.5L bearings, with number 3 flanged to control thrust.
engines. The bores are also siamese to minimize en­ The 60 mm diameter main and 50 mm diameter crank
gine length. A partial open deck is used for cooling pin journals (all) have undercut radiuses fillets th at
and weight reduction with oil filter, water pump, and are deep rolled for added strength. To optimize bear­
distributor mounting bosses molded into the front (ra­ ing loading 4 counterweights are used. Hydrodynamic
diator side) of the block. Nominal wall thickness is 4.5 seals (installed in diecast aluminum retainers) pro­
mm. Five main bearing bulkheads and a block skirt vides end sealing, where the crankshaft exits the block.
extending 3 mm below the crankshaft center line add Anaerobic gasket material is used for retainer-to-block
to the blocks high rigidity with light weight. sealing. No vibration damper is used. A sintered iron
timing belt sprocket is mounted on the crankshaft
nose. This sprocket provides motive power; via timing
belt to the camshaft and intermediate shaft sprockets
(also sintered iron) providing timed valve, distribu­
tor, and oil pump actuation.
PISTONS: Some Chrysler pistons have cast-in steel
struts at the pin bosses for autothermic control. All
2.5L p isto n s h a v e v alv e c u ts to prov ide valve c le a r­
ance. Some pistons are dished to provide various com­
pression ratios. Standard 2.5L engines are designed
for 8.9:1 compression ratios respectively. The stan­
dard 2.5L piston is dished and is a new lightweight
design to further enhance engine smoothness. All stan­
dard 2.5L engines use pressed-in piston pins to attach
forged steel connecting rods.
CYLINDER HEAD: The cylinder head is cast alumi­
num with in-line valves arranged with .alternating
exhaust and intake. The intake and exhaust ports are
located in the rearward, facing side of the head. The
intake ports feed fast-burn design combustion cham­
bers with spark plugs located close to the center line
of the combustion chamber for optimum efficiency. An
integral oil gallery within the cylinder head supplies
oil to the hydraulic lash adjusters, camshaft, and valve
mechanisms.
CAMSHAFT: The nodular iron camshaft has five
bearing journals. Flanges at the rear journal control
camshaft end play. A sintered iron timing belt sprocket
is mounted on the cam nose, and a hydrodynamic oil
seal is used for oil control at the front of the camshaft.
ACCESSORY SHAFT: The iron accessory shaft has
two bearing journals and is housed in the forward
facing side of the block. A hydrodynamic seal, in­
stalled in an aluminum housing attached to the block,
provides retention, shaft thrust, and oil control. The
accessory shaft is driven by the timing belt through a
sintered iron sprocket mounted on the nose of the
accessory shaft. The accessory shaft in turn drives the
oil pump and distributor.
VALVES: The valves are actuated by roller cam
followers which pivot on stationary hydraulic lash
adjusters. The valve train with 40.6 mm (1.60 inch)
diameter intake valves and 35.4 mm (1.39 inch) diam­
eter exhaust valves employ viton rubber valve stem
seals. Valve springs, spring retainers, and locks are
conventional.
BALANCE SHAFTS: 2.5L engines are equipped with
two balance shafts installed in a carrier attached to
the lower crankcase. The shafts interconnect through
gears to rotate in opposite directions. These gears are
driven by a short chain from:the crankshaft, to rotate
a t tw o tim e s c ra n k s h a ft speed. T h is c o u n te rb a la n c e s
certain engine reciprocating masses.
INTAKE MANIFOLDS; All intake manifolds are alu­
minum castings. N.A. engines use a four branch de­
sign. This long branch fan design enhances low and
midspeed torque and also features an integrally cast
water crossover passage to warm incoming fuel/air
mixture, plus EGR mounting boss and PCV inlet.
E1HAUSI MANIFOLDS: All exhaust manifolds are
made of nodular cast iron for strength and high tem­
peratures. All naturally aspirated (N.A.) engines exit
exhaust gasses through a machined, articulated joint
connection to the exhaust pipe. All manifolds intermesh
with the intake manifold'at the cylinder head.
N.A. engines use a four branch design with cylin­
ders one and four joined and cylinder two and three
joined to exit at the outlet.
ENGINE LUBRICATION system is full flow filtration,
pressure feed type. The oil pump is mounted within
the crankcase and driven by the auxiliary shaft. Pres­
surized oil is then routed through the main oil gal­
lery, running the length of the cylinder block, supplying
main and rod bearings with further routing ( for 2.5L
engines ) to the lower balance shaft assemblies. Pis­
tons are lubricated from directed holes in connecting
rod assemblies. Camshaft and valve mechanisms are
lubricated from a full-length cylinder head oil gallery
supplied from the crankcase main oil gallery.
8909-40 2.5L ENGINE

Fig. 1 Engine

SERVICE PROCEDURES
ENGINE REMOVAL (1) Disconnect battery.
(2) Scribe hood hinge outline on hood and remove
(g) 12 N’ m (105 IN . LBS.) hood.
(3) Drain cooling system.
(4) Remove hoses from radiator and engine.
(5) Remove radiator and fan assembly (Fig. 2).
(6) Remove air cleaner and hoses.
(7) Remove air conditioning compressor mounting
bolts and set compressor aside (if so equipped).
(8) Remove power steering pump mounting bolts
and set pump aside (if so equipped).
(9) Remove oil filter.
(10) Disconnect fuel line, heater hose and accelera­
tor cable.
(11) Remove alternator mounting bolts and set al­
ternator aside.
(12) Disconnect all electrical connections at alterna­
tor, throttle body, and engine.
RIGHT ENGINE MOUNT ASSEMBLY
TIGHTEN YOKE NUJ FIRST f — ®
TIGHTEN YOKE SCREW SECOND

( I ) YOKE SCREW

RIGHT
RAIL "
FRONT CR05SMEMBER

f RONT MOUNT
ASSEMBLY
TORQUE
A - 169 N*m (125 FT. LBS.)
B - 133 N«m (100 FT. LBS.)
C - 102 N»m (75 FT. LBS.)
D - 6 8 N*m (50 FT. LBS.)
E - 54 N«m (40 FT. LBS.)
F - 21 N»m (16 FT. LBS.)
D R |V E R S |p E
PASS SIDE W ■
W = 12 mm
X = 7 mm
FRONT MOUNT ASSEMBLY
TIGHTEN FOUR BRACKET SCREWS
IN SEQUENCE - 1,2,3.4 TO TORQUE
V IEW IN DIRECTION
OF ARROW Y 9109-114

Fig. 3 Engine Mounting

(13) Automatic Transmission

(a) Disconnect exhaust pipe at manifold.
(b) Disconnect starter and lay aside.
(c) Remove transmission case lower cover.
(d) Mark flex plate to torque converter.
(e) Remove screws holding torque converter to
flex plate.
(14) Attach C clamp on front bottom of torque con­
verter housing to prevent torque converter from com­
ing out.
(15) Install transmission holding fixture.
(16) Remove right inner splash shield (Fig. 4).
(17) Remove ground strap.
(18) To lower engine separate right engine bracket
from yoke bracket To raise engine remove long bolt
through yoke and insulator. IF INSULATOR TO RAIL
SCREWS ARE TO BE REMOVED, MARK INSULA­
TOR POSITION ON SIDE RAIL TO INSURE EXACT
REINSTALLATION (Fig. 3).
(19) Remove transmission case to cylinder block
mounting screws.
 (20) Remove front engine mount screw and nut. Check and reposition right engine mount insulator
(21) Remove left insulator through bolt (from inside (left engine mount insulator is floating type and will
wheelhouse) or insulator bracket to transm ission adjust autom atically (Fig. 5). Adjust drive tra in posi­
screws. tion, if required, for the following conditions:
(22) Remove engine from vehicle. (a) Drive shaft distress: See Driveshafts in Sus­
pension, Group 2.
INSTALLING ENGINE (b) Any front end structural damage (after repair).
(c) Insulator replacement.
(1) Install hoist to the engine and lower engine into
the engine compartment. ENGINE MOUNT INSULATOR ADJUSTMENT
SEE: ENGINE MOUNT RUBBER INSULATORS, (1) Remove the load on the engine motor mounts by
THIS GROUP. carefully supporting the engine and transm ission as­
(2) Align engine mounts and install but do not sembly with a floor jack.
tighten until all mounting bolts have been installed. (2) Loosen the right engine mount insulator vertical
Tighten to 54 N*m (40 ft. lbs.). fasteners, and the front engine mount bracket to front
(3) Install transmission case to cylinder block mount­ crossmember screws and nuts.
ing screws. Tighten to 95 N-m (70 ft. lbs.). Left engine mount insulator is sleeved over shaft
(4) Remove engine hoist and transmission holding and long support bolt to prowid© lateral movement
fixture. adjustment with engine weight removed or not,
(5) Secure ground strap. (3) Pry the engine right or left as required to achieve
(6) Install right inner splash shield. the proper drive shaft assembly length. See Drive
(7) Connect sta rte r. See Electrical Group 8 for Shaft in Suspension Group 2 for driveshaft identifica­
installation. tio n and related assembly length measuring.
(8) Connect exhaust system. See Exhaust Group 11 (4) Tighten right engine m ount insulator vertical
for installation. bolts to 37 N*m (27 ft. lbs.), tighten front engine mount
(9) Automatic Transmission Remove C clamp from screws and nuts to 54 N*m (40 ft. lbs.) and center left
torque converter housing. Align flexplate to torque engine mount insulator.
converter and install mounting screws. Tighten to 54 (5) Recheck drive shaft length.
N*m (40 ft. lbs.).
(10) Reinstall power steering pump (if equipped). SHAFT MASS
See Cooling System Group 7 for belt tension adjustment.
(11) Install alternator. Refer to Cooling System Group
7 for belt installation.
(12) Connect fuel line, heater hose, and accelerator
cable.
(13) Connect all electrical connections at alternator,
throttle body and engine.
(14) Install oil filter. Refill engine crankcase with
proper oil to correct level.
(15) Reinstall air conditioning compressor (if equipped).
See Heater and Air Conditioning, Group 24 for instal­
lation.
(16) Reinstall air cleaner and hoses.
(17) Reinstall radiator and shroud assembly. Install (14 TO 17 mm) 9109-18
radiator hoses. Fill cooling system. Refer to Cooling
System Group 7 for filling procedure. Pig. 5 Left Insulator Movement
(18) Install hood.
(19) Connect battery.
(20) Start engine and run until operating tempera­
ture is reached.
(21) Adjust transmission linkage if necessary.

ENGINE MOUNT RUBBER INSULATORS

Insulator location on frame rail (right side) and

transmission bracket (left side) are adjustable to allow
right/left drive train adjustment in relation to drive
shaft assembly length.
Fig. 1 Timing System and Seals
 (5) Remove both halves of timing belt cover and lay
aside (Fig. 4)
TIMING BELT REMOVAL (6) Place a jack under engine.
(7) Separate right engine mount (Fig. 5) and raise
engine slightly.
(8) Loosen timing belt tensioner (Fig. 6) and remove
timing belt.

(1) Raise vehicle on a hoist and remove right inner

splash shield (Fig. 2).
Fig. 4 Timing Belt Cover
ENGINE BRACKET

TIGHTEN YOKE NUT FIRST

TIGHTEN YOKE SCREW SECOND

< $ > 1 3 6 N m (100FT. LBS.)

< |> 102 N m (75 FT. LBS.) \/)

<§>68 N*m (50 FT. LiS.)

RIGHT YOKE
BiA tK E T I
INSULATOR
9109-126
SIDE RAIL'
Fig. 3 Crankshaft and Water Pump Pulley

(2) Remove screws retaining water pump pulley and

bolts retaining crankshaft pulley (Fig. 3) and lay pul­
ley aside. MARK
INSULATOR
(3) Remove nuts holding cover to cylinder head.
POSITION 9109-116
(4) Remove screws holding cover to cylinder block.
 R E M O V E WITH
SPECIAL IO G I
HOLDER. C-4685
10MM SCREW
C-4685-B2.
#<HEX" (TENSION/ CD} INSERT
ADJUSTMENT)^ C-4685-C2

SCREW
61 N-m '0
(45 FT. LiS.
m

TENSIONER
LOOSEN screw; #
ROTATE "HEX" TO ..
REMOVE BELT 8909-8
INSTALL
Pig. 6 Remove Timing Belt WITH SPECIAL TOOL
12MM SCREW
C-4685-C1 —
SERVICING OIL SEALS
(1) W ith tim ing belt removed, remove crankshaft THRUST BEARING
AND WASHER,
sprocket bolt. PLATE L-4524-C4, 9109-107
(2) Remove crankshaft sprocket using Tool C-4685,
Insert and 5.9 inch screw (Fig. 7). Pig. 7 Crankshaft Sprocket
(3) Install crankshaft sprocket using plate L-4524,
T hrust Bearing/washer and 5.9 inch screw (Fig. 7).

9009-37
 (4) Hold engine sprocket with Tool C-4687 (with
adaptor Tool C-4687-1) while removing/installing screw
(Fig. 9) The 2.5L Engine camshaft/intermediate shaft
sprockets have an off-set hub and are identified with
a six-hole pattern (Fig. 8).
Fig. 9 Removing/Installing Camshaft or
Intermediate Shaft Sprocket Screw
Fig. 10 Crankshaft, Intermediate Shaft
and Camshaft Oil Seal
REMOVAL
(5) Remove crankshaft seal using Tool C-6341. Re­
move intermediate and camshaft seals using Tool
C-4679 (Fig. 10).
CAUTION: Do not nick shaft seal surface or seal
bore.
(6) Shaft seal lip surface must be free of varnish,
dirt or nicks. Polish with 400 grit paper if necessary.
(7) Install engine crankshaft seal into retainer us­
ing Tool C-6342. Install Intermediate and Camshaft
seals using Tool C-4680. Install seals until flush (Fig.
11 ).
Fig. 11 Installing Crankshaft,
Intermediate Shaft, and Camshaft Seal
CAMSHAFT, CRANKSHAFT AND INTERMEDIATE
SHAFTS TIMING PROCEDURE
Fig. 12 Crankshaft and
Intermediate Shaft Timing
(1) Turn crankshaft and intermediate shaft until
markings on sprockets are in line,see arrows (Fig. 12).
(2) Turn camshaft until arrows on hub are inline
with No. 1 camshaft cap to cylinder headline. Small
hole (arrow Fig. 13) must be in vertical center line.
(3) Install timing belt (see Fig. 14 for proper timing
belt tension).
COVER COVER TIM ING
TOOL C -4703
(4) Rotate crankshaft two full revolutions and re­
check timing. Valve Timing Check; (timing belt cover
installed).With number one cylinder at TDC small
hole in sprocket must be centered in timing belt cover
hole (Fig. 13).
CAUTION: Do not allow oil or solvents to contact the
timing belt as they can deteriorate the rubber and
cause tooth skipping.
(5) Remove spark plugs and rotate crank to TDC
position.
(6) Put belt tension tool C-4703 horizontally on large
hex of timing belt tensioner pulley and loosen ten-
sioner lock nut.
(7) Reset belt tension tool C-4703 index if necessary
to have axis within 15° of horizontal (Fig. 14).
(8) Turn engine clockwise from TDC two crank rev­
olutions to TDC. Do not reverse rotate crankshaft or
attempt to rotate engine using cam or accessory
shaft attaching screw.
(9) Tighten lock nut on tensioner holding weighted
wrench in position to 61 N-m (45 ft. lbs.).
 12 N#m
(105 IN, IBS.

VALVE BUMPERS
COVER
END SEAL

, 25 N m
CURTAIN
(215 IN. LIS.;

HEAD BOLTS
4 STEP TOiQUE SEQUENCE
— SEE TEXT —

ROCKER ARM
(ROLLER FOLLOWER)
PLUG

LOCKS

SPRING

VALVE STEM
SEAL

VALVE
GUIDE
CYLINDER HEAD AND VALVE ASSEMBLY SERVICE (3) Install cover and end seal assembly to head and
tighten to 12 N-m (105 in.lbs.) torque.
CYLINDER HEAD COVER AND CURTAIN 3 mm (.12 I N.) DIAMETER BEAD RTV EXTEND INTO RADII
BOTH ENDS
A curtain aiding air/oil separation is installed on
the cylinder head below the cylinder head cover (Figs.
1 and 2).

COVER n
O
3 mm C.12 DIAMETER BEAD RBI 82
Fig. 3 Cylinder Head Valve Cover Rail Sealing

CYLINDER HEAD SERVICE

CAMSHAFT—IN-VEHICLE SERVICE
Removal and installation of cylinder head or cam­
shaft require separation of camshaft timing sprocket
from camshaft. To maintain camshaft, intermediate
shaft, and crankshaft timing during service proce­
dures, the timing belt is left indexed on the sprocket
while the assembly is suspended under light tension
(Fig. 3).

RR09B81

Fig. 2 Cylinder Head Cover and Curtain

INSTALLATION
Install curtain manifold side first with cutouts over
cam towers and contacting cylinder head floor, then
press opposite distributor side into position below cyl­
inder head rail. Curtain is retained in position with
rubber bumpers (Fig. 1).

COVER SEALING
Before installation, clean cylinder head and cover
mating surfaces. Make certain rails are flat.
(1) Install new end seals on valve cover.
(2) Apply form-in-place Mopar Silicone Rubber Ad­
hesive Sealant or equivalent gasket material to cylin­
der head cover rail (Fig. 3). Refer to procedure detailed When removing the sprocket from the camshaft,
in form-in-place gasket section of Standard Service you must maintain adequate tension on the sprocket
Procedures, in this Group. and belt assembly to prevent the belt from disengag­
ing with the intermediate or crankshaft timing sprock­
Caution: Do not allow oil or solvents to contact the
ets. See Timing System and Seals for removal and
timing belt as they can deteriorate the rubber and
installation of camshaft sprocket.
cause tooth skipping.
CAUTION: Failure to maintain adequate tension on
camshaft, intermediate, and crankshaft sprocket belt
can result in lost engine timing. If timing is lost, refer
to Timing System and Seals and (Fig. 4).
Fig. 5 Engine Sprocket Timing
CYLINDER HEAD
REMOVAL
(1) Perform fuel system pressure release procedure
before attem pting any repairs. Refer to Fuel System
Group 14
(2) Disconnect negative battery cable. Drain cooling
system. Refer to Cooling System, Group,,7.
(3) Remove air cleaner and disconnect all vacuum
lines, electrical wiring and fuel lines from throttle
body.
(4) Remove throttle linkage.
(5) Loosen power steering pump and remove belt.
(6) Remove power brake vacuum hose from intake
manifold. . . ■
(7) Remove w ater hoses from w ater crossover.
(8) Raise vehicle and remove exhaust pipe -from
manifold,
(9) Remove power steering pump assembly and set
aside. ■ .
(10) Disconnect coil wiring connector and coil wire
from coil.
(11) Disconnect dipstick tube from thermostat hous­
ing and ROTATE bracket from stud. DO NOT bend the
bracket. ’ .
(12) See Solid Mount Compressor Bracket in STAN­
DARD SERVICE PROCEDURES, this Group.
(13) Remove cylinder head bolts.
INSPECT HEAD AND CAMSHAFT
BEARING JOURNALS
Fig. 6 Checking Cylinder Head Flatness
(1) Cylinder head must be flat within 0.1mm (.004
inch)
(2) Inspect camshaft journals for scoring and journal
caps for oversize markings. When servicing cylinder
head or camshaft, it is necessary to be certain that
oversized camshafts are used only in oversized heads.
Identity oversize components as follows:
Cylinder Head: Top of bearing caps painted green
and O/SJ stamped rearward of oil gallery plug on end
of head.
Camshaft: Barrel of camshaft painted green and
O/SJ stamped on end of shaft.
INSTALLATION
CAUTION: Head bolt diameter is 11mm. These bolts
are identified with 11 on the bead of the bolt. 10mm
bolts w ill thread into the 11mm bole |u t w ill strip the
cylinder block bolt hole.
Since the Cylinder bead bolts are torqued ysing a
new procedure they should be examined BEFORE
reyse. If the threads are necked down the bolts should
be replaced. (Fig. 7).
Necking can be checked by holding a scale or straight
edge against the threads. If all the threads do not
contact the scale the bolt should be replaced.
 F f l ........
STRETCHED THREADS ARE NOT STRAIGHT O N LINE
BOLT
THREADS ARE STRAIGHT O N LINE
UNSTRETCHED BOLT 9009-38
Fig. 7 Checking Bolts for Stretching (Necking)
(1) Tighten the cylinder head bolts in the sequence
shown in (Fig. 8). Using the 4 step torque turn method,
tighten according to the following values:
Fig. 8 Cylinder Head Tightening Sequence
• First All to 61 N-m (45 ft. lbs.)
• Second All to 88 N-m (65 ft. lbs.)
• Third All (again) to 88 N-m (65 ft. lbs.)
• Fourth + 1/4 Turn Do not torque wrench for this
step.
Bolt torque after 1/4 turn should be over 90 ft. lbs.
If not, replace the bolt.
(2) Rotate dipstick tube on bracket.
(3) Tighten bracket retaining nut to 23 N-m (200 in.
lbs.)
CAMSHAFT SERVICE
See TIMING SYSTEM AND SEALS for camshaft
seal and sprocket removal and installation, and CYL­
INDER HEAD In Vehicle Service.
8909-54
Fig. 10 Camshaft Cap Removal Sequence
REMOVAL
(1) Mark rocker arms for reinstallation in the same
position (Fig. 9).
(2) Loosen camshaft bearing cap screws several rev­
olutions (Fig. 10).
(3) Jar camshaft at rear of cam to loosen (break
free) the bearing caps. Use a soft faced mallet.
(4) Remove screws and caps such that cam does not
cock.*
*Care should be exercised not to cock the camshaft
during removal. Cocking of the camshaft could cause
damage to the cam or bearing thrust surfaces.
INSPECT
(1) Bearing cap and cylinder head journals for wear
and/or oversize, See: CYLINDER HEAD, Inspect and
Specifications.
 CAMSHAFT END PLAY
(1) Using a suitable tool, move camshaft as far rear­
ward as it will go.
(2) Zero dial indicator (Fig. 13).
(3) Move as far forward and backward as camshaft
will go.
(4) End play travel: 0.13-0.33mm (.005-.013 inch)

Fig. 11 Camshaft

(2) Camshaft bearing journals and lobe wear. Lobe

wear should not exceed .25mm (.010 inch).
To measure cam lobe wear (Fig. 11), measure lobe
diameter in two places at the largest diameter (over
the nose). Take first reading with micrometer in un­
worn area at the edge of the lobe. Take second reading
in the worn area where rocker arm contacts the lobe.
Subtract second reading from the first. The difference
is the cam lobe wear.

INSTALLATION
(1) Check bearing cap oil holes for blockage.
(2) Align camshaft bearing caps in proper sequence Fig. 13 Camshaft End Play
with Cap N o.l at timing belt end and Cap No.5 at
LASH ADJUSTER (TAPPET) NOISE
transmission end. Arrows on Caps N o.l, 2, 3, 4 must
point toward timing belt to prevent cap breakage (Fig.
A tappet-like noise may be produced from several
12).
items. See Lash Adjuster and Tappet Noise- DIAG­
(3) Apply anaerobic form-in-place gasket to No.l
NOSIS in STANDARD SERVICE PROCEDURES, this
and No.5 bearing cap per Standard Service Proce­
Group.
dures Section.
(4) Caps must be installed before camshaft seals are
installed.
VALVE COMPONENTS REPLACE—
CYLINDER HEAD NOT REMOVED
ROCKER ARM AND HYDRAULIC
LASH ADJUSTER
REMOVAL
(1) Remove valve cover.
(2) For each rocker arm, rotate cam until base circle
is in contact with rocker arm. Depress valve spring
using Special Tool C-4682 (Fig. 14) and slide rocker
arm out. Keep rocker arms in order for reassembly.

Ha
 SPECIAL TOOL C-4682

Pig. 14 Removing and Installing Valve Spring

(3) Remove hydraulic lash adjuster.

INSTALLATION
(1) Install hydraulic lash adjusters m aking sure th at
adjusters are at least partially full of oil. This is indi­
cated by little . or no plunger travel when the lash
adjuster is depressed. . VALVE SERVICE
(2) Rotate cam until base circle is in contact posi­
tion with rocker arm. Depress valve spring with Tool
C-4682 (Fig. 14) and slide rocker arm in place. Keep
rockers in order. It is possible for the valve spring
retainer locks to become dislocated when depressing
the valve spring. Check and make syre the locks are
in their proper location.
(3) Install valve cover as previously outlined.
VALVE SPRINGS AND VALVE STEM SEALS
REMOVAL ’ '
(1) Remove rocker arm s as previously outlined.
(2) Rotate crankshaft until piston is at' TDC on
compression.
(3) W ith air hose attached to adapter tool installed
in spark plug hole, apply 30-120 psi air pressure.
'(4) Using Tool C-4682 (Fig, 14) compress valve
springs and remove valve locks.
(5) Remove valve spring.
(6) Remove valve stem seal by gently prying side-to-
side with a screwdriver blade. Once dislodged from
guide post, seal may be easily removed.
■ Pig. 15 Waive Stem Seals
VALVES AND VALVE SPRINGS
iEiOWftl
(1) W ith cylinder head removed, compress valve
springs using Tool C-3422-B.
(2) Remove valve retaining locks, valve spring re­
tainers, valve stem seals and valve springs.
(3) Before removing valves, remove any burrs from
waiw© stem lock grooves to prevent damage to the
valve guides. Identify valves to insure installation in
original location.
VALVE INSPECTION
(1) Clean valves thoroughly and discard burned,
warped and cracked valves.
(2) M easure valve stems for wear.
(3) Remove carbon and varnish deposits from inside
of valve guides with a reliable guide cleaner.
• Insert valve w ith valve head positioned 10 mm (.400
inch) above cylinder head gasket surface.

INSTALLATION
(1) Install valve seals (Fig. 15) as outlined in step
two (2) of Valve Gear Reassembly-After. Valve Service.
(2) Using Tool C-4682 compress valve springs only
enough to install locks. Correct alignm ent of tool is
necessary to avoid nicking valve stems (air pressure
required), piston at TDC.
 VALVE GUIDES
Replace cylinder head if guide does not clean up
with 0.80 mm (.030 inch) oversize reamer, or if guide
is loose in cylinder head.

• Move valve to and from the indicator (Fig. 16). The

total dial indicator reading should not exceed the
RF259
amount specified in (Fig. 17). Readings should be taken
Fig. 18 Testing Valve Spring with Tool C-647
for lengthwise and crosswise (with respect to cylinder
head) movement for each valve. Ream the guides for TESTING VALVE SPRINGS
valves with oversize stems if dial indicator reading is (1) Whenever valves have been removed for inspec­
excessive or if the stems are scuffed or scored. tion, reconditioning or replacement, valve springs
should be tested. As an example, the compression length
Valve Guide Intake Exhaust of the spring to be tested is 33.34mm (1-5/16 inches).
Dial Indicator Valve Valve Turn table of Tool C-647 until surface is in line with
Readi ng, Maximum 0.5 mm 0.7 mm the 33.34mm (1-5/16 inch) mark on the threaded stud
(0.020 in.) >.027
and the zero mark on the front. Place spring over
Valve Guide Reamer stud on the table and lift compressing lever to set
Oversize Valve Guide Size
tone device (Fig. 18). Pull on torque wrench until ping
§.15 mm ( M S in.) 8.125-8,1® mm (.3198-.3208 in.) is heard. Take reading on torque wrench at this in­
0.40 mm (.015 in.) 8.375-8.400 mm (.3297-.3307 in.) stant. Multiply this reading by two. This will give the
0.80 mm (.030 in.) 8.775-8.800 mm (.34S4-.3464 in.'
spring load at test length. Fractional measurements
are indicated on the table for finer adjustments. Refer
9109-8 to specifications to obtain specified height and allow­
Fig. 17 Valve Guide Specification able tensions. Discard the springs that do not meet
specifications.
(4) Service valves with oversize stems and oversize (2) Inspect each valve spring for squareness with a
seals are available in 0.15mm, (.005 inch) 0.40mm, steel square and surface plate, test springs from both
(.015 inch) and 0.80mm(.031 inch) oversize. ends. If the spring is more than 1.5mm (1/16 inch) out
Oversize seals must be used with oversize valves. of square, install a new spring.
Reamers sizes to accommodate the oversize valve
stem are shown in (Fig. 17)
(5) Slowly turn reamer by hand and clean guide
thoroughly before installing new valve. Do not at­
tempt to ream the valve guides from standard di­
rectly to 0.80mm (.030 inch). Use step procedure of
0.15mm (.005 inch), 0.40mm (.015 inch) and 0.80mm
(.030 inch) so the valve guides may be reamed true
in relation to the valve seat. After reaming guides,
the seat runout should be measured and resurfaced
if necessary. See Refacing Valves and Valve Seats.

V alve Dimension*
intake Valve (minimum)
Stem diameter: 7.935 mm (.3124 in.)
Face angle: 45°
Valve margin: .794 mm (.031 in.)
Head diameter: 40.6 mm (1.60 i n.)
Length: 114.25 mm (4.498 in.)
Exhaust V alve (minimum)
Stem diameter: 7.881 mm (.8103 in.)
Face angle: 44 1/ 2°
Valve margin: 1.191 mm (.0469 in.)
Head diameter: 35.4 mm (1.39 in.)
Length: 114.87 mm (4.522 in.)
9109-9
Fig. 20 Valwe Dimensions
REFUGING VALVES l i i VALVE SEATS
(1) The intake and exhaust valve seats and valve
face have a 45 degree angle.
(2) Inspect the rem aining m argin after the valves
are refaced (Fig. 21). Exhaust valves with less than
1.191mm (3/64 inch) margin and intake valves with less
than ,794mm (1/32 inch) m argin should be discarded.
(3) When refacing valve seats, it is im portant th a t
the correct size valve guide pilot be used for reseating
stones. A true and complete surface m ust be obtained.
(4) M easure the concentricity of valve seat usin| .
valve seat dial indicator. Total runout should not ex­
ceed. 051mm (.002 inch) (total indicator reading).
J | ^ _ VM VE MARGIN
!I
(5) Inspect the valve seat with Prussian blue to
determine where the valve contacts the seat. To do
this, coat valve seat LIGHTLY with Prussian blue then
set valve in place. Rotate the valve w ith light pres­
sure. If the blue is transferred to the center of valve
face, contact is satisfactory. If the blue is transferred
to top edge of the valve face, lower valve seat with a
15 degrees stone. If the blue is transferred to the
bottom edge of valve face raise valve seat w ith a 65
degrees stone.
• Intake valve seat diam eter 40.45mm (1.593 inch)
• Exhaust valve seat diam eter 34.84mm (1.371 inch)
Valve seats which are worn or burned can be re­
worked, provided th a t correct angle and seat width
are m aintained. Otherwise cylinder head m ust be
replaced.
(6) When seat is properly positioned the width of
intake seats should be 1.75 to 2.25mm (0.69 to .088
inch) The width of the exhaust seats should be 1.50 to
2.00mm (.059 to .078 inch) (Fig. 22 Dimension 1).
(7) Check valve tip to valve spring seat dimensions
after grinding to seats or faces. Grind valve tip to give
49.76 to 51.04mm (1.960 to 2.009 inch) over valve
spring seat when installed in the head (Fig. 23). The
valve tip diam eter should be no less than 7.0mm (0.275
inch),if necessary, the tip chamfer should be reground
to prevent seal damage when the valve is installed.
(8) Check the valve spring installed height after
refacing the valve and seat (Fig. 24).
CAUTION: If more than .5mm (.020 inch) must be
ground from the waive tip, check the clearance be­
tween the rocker arm and the waive spring retainer if
below 1.25mm (.050 Inch), grind the rocker arm ears
according to the procedure described in Refacing
Valves and Valve Seats.
 (3) Install valve spring seats and springs and re­
tainers. Compress valve springs only enough to install
locks, taking care not to misalign the direction of
TIP DIAMETER . compression. Nicked valve stems may result from mis­
7.0mm (0.275 IN.) alignment of the valve spring compressor.
W !1
CAUTION: When depressing the valve spring retain­
ers with Special Tool C-3422-B the locks can be­
\ come dislocated. Check to make sure both locks are
in their correct location after removing tool.
49.76 ~ 51.04mm (4) Check installed height of springs. Measurement
is to be taken from the lower edge of the valve spring
/ \ SPRING SEAT
to its upper edge. Do not include the spring seat or
retainer flange. Correct height is 41.2mm to 42.7mm
RB1013B
(1.62 to 1.68 inches). If seats have been reground an
additional spring seat may be required to maintain
Fig. 23 Valve Tip to Valve Spring Seat Dimensions correct installed spring height.
(5) Install adjusters, rocker arms in order, and cam­
ROCKER ARM MINIMUM
shaft as previously described, see Camshaft-Install.
\ DEPTH MINIMUM Check for clearance between the projecting ears (ei­
VALVE TIP v V , t __
1.5mm CLEARANCE
ther side of valve tip) of the rocker arms and the valve
(.060 IN.) 1.25mm
SPRING RETAiNEi 1 — ._ (.050 IN.) spring retainers. At least 1.25 mm (.050 inch) clear­
ance must be present, if necessary, the rocker arm
ears may be ground to obtain this clearance (Fig. 24).
(6) Checking dry lash. Dry lash is the amount of
clearance that exists between the base circle of an
installed cam and the rocker arm roller when the
adjuster is drained of oil and completely collapsed.
Specified dry lash is 0.62 to 1.52 mm (.024 to .060
inch). To completely collapse adjuster for dry lash
measurement, pry off retainer cap, disassemble, drain
the adjuster of oil, reassemble, and install. After per­
RH835B
forming dry lash check, refill adjuster with oil (do not
reuse retainer cap/s) and allow 10 minutes for ad­
Fig. 24 Checking Spring Installed Height juster/s to bleed down before rotating cam.
and Spring Retainer Clearance

VALVE GEAR REASSEMBLY AFTER VALVE SERVICE

(1) Coat valve stems with lubrication oil and insert
in cylinder head.
(2) Install new valve stem seals on all valves. The
valve stem seals should be pushed firmly and squarely
over valve guide. The lower edge of the seal should be
resting on the valve guide boss.
CAUTION: When oversize valves are used, the cor­
responding oversize valve seal must also be used.
Excessive guide wear may result if oversize seals
are not used with oversize valves.
 IER TORQ
LETTER N*m IN. LBS. FT. LBS.
A 2 105 _
B 28 250
C 54 - 40
★ D ★4 1 _ ★3 0
INTERMEDIATE
E 95 - 70
SHAFT
F (PLUG - LOCTITE 277)
G 15 130 -

★SPECIFIED TORQUE
PLUS 1/4 TURN

CHAIN
COVER
 REAR CRANKSHAFT SEAL RETAINER
When retainer removal is required, provide retainer
to block sealing during re-installation. Use form-in-
place, anaerobic (cures in the absence of air) type
gasket m aterial, applied as shown in (Fig 4.)

CRANKSHAFT OIL SEALS SERVICE

(1) Pry out rear seal with screwdriver. Be careful
not to nick or damage crankshaft flange seal surface
or retainer bore (Fig. 2).

FRONT CRANKSHAFT SEAL RETAINER

See Timing System and Seals Section for tim ing
belt covers, belt and crankshaft sprocket removal and
removal and installation of oil seals.
(1) Remove retainer screws (Fig. 5).

\ msm
Pig. 3 Installing Wear Crankshaft Oil Seal

(2) Place Tool C-4881 on crankshaft (Fig. 3).

(3) Lightly coat seal O.D. with Loctite Stud N’ Bear­ 12 N-m
ing Mount or equivalent. (105 IN. LiS.) 9109-101
(4) Place seal over Tool C-4881 and tap in place
with a plastic hammer.
 For reassembly an anaerobic (form-in-place) gasket
material is applied to the retainer as shown in (Fig.
6). This material cures in the absence of air providing
retainer to block sealing.
(2)Install retainer and tighten screws to 105 in.
lbs.(12 N-m).
(4) Move crankshaft all the way to the front and
read the dial indicator.
OPTIONAL CRANKSHAFT END PLAY CHECK
(1) Move crankshaft all the way to the rear of its
travel using a screwdriver or other lever inserted be­
tween a m ain bearing cap and a crankshaft cheek
using care not to damage any bearing surface. Do not
loosen m ain bearing cap.
(2) Use a feeler gauge between num ber three th ru st
bearing and machined crankshaft surface to deter­
mine end play.

Crankshaft End-Play

New Part: .05 to 0.018 mm (.002 to .007 in.)

W ear Limit: 0.37 m m (.015 in.)
Main and Connecting Rod Bearing Clearance
New Part: .011 to .072 mm (.0004 to .0028 in.)
W ear Limit: .102 mm (.004 in.)
Crankshaft Journal Sizes

8909-19 Crankshaft Main Bearing Journal

ALL Diam eter
Fig. 6 Front Crankshaft Seal Retainer Sealing Standard 60.000 ± 0.013 mm
(2.3622 ± .0005 in.)
CRANKSHAFT SERVICE 1st Undersize 59.75 ± 0.013 mm
(2.3523 ± .0005 in.)
CHECKING CRANKSHAFT END PLAY Crankshaft Connecting Rod Journal
ALL Diameter
Standard 50.00 ± 0.013
(1.9685 ± .0005 in.)
1st Undersize 49.75 ± 0.013 in.
(1.9586 ± .0005 in.)

9109-10
Pig, 8 Crankshaft Specifications

CRANKSHAFT BEARING CLEARANCE

(1) Mount a dial indicator to front of engine, locat­

ing probe on nose of crankshaft (Fig. 7). ' RB601
(2) Move crankshaft all the way to the rear of its Fig. 9 Checking Crankshaft Oil Clearance
travel. with Plastic Gauge
(3) Zero the dial indicator.
 (1) See M easuring Main, Connecting Rod Bearing (1) Install main bearing cap N o.l on tim ing belt end
Clearance in Standard Service Procedures. (Fig. 13).
(2) Install m ain bearing cap No.5 on transm ission
CAUTION: Do not rotate crankshaft or the Piastic-
end.
Gauge maybe smeared.
MAIN BEARING
CAP BOLTS /
x 41 N»m ^ 1/4 TURN
// C30PI LBS. 1/4 TURN)
///

8909-21

Fig. 12 Installing Main Bearing Caps

Since the main bearing bolts are torqued using a

REJ599
Fig. 10 Installing Main Bearing Upper Shell
(1) Install the m ain bearing shells w ith the lubrica­
tion groove in the cylinder block (Fig. 10). The 1, 2, 4
and 5 main bearings are full groove to provide full
time oiling to the connecting rod. Only the number 3
Is half-groove.
(2) Make certain oil holes in block line up with oil
hole in bearings and bearing tabs seat in the block tab
slots.
(8) Oil the bearings and journals and install crankshaft.
new procedyre they shoytd be eiamined BEFORE
reuse. I the threads are necked down the bolts should
be replaced (Fig. 13).
Necking can be checked by holding a scale or straight
edge against the threads or by running an M11 x 1.50
nut the full length of the thread. If all the threads do
not contact the scale or if the nut does not run down
smoothly the bolt should be replaced,
(3) Before installing the bolts the threads should be
oiled with engine oil.
(4) Install both bolts in each cap finger tight, then
alternately torque each bolt to assem ble the cap
properly.
(5) Tighten the bolts to 41 N-m plus 1/4 tu rn (30
ft.lbs. plus 1/4 turn). (Fig. 12).

STRETCHED THREADS ARE NOT STRAIGHT ON LINE

BOLT
THREADS ARE STRAIGHT ON LINE
X

UNSTRETCHED BOLT 9009^33

J O '
J
o
Ǥ. 13 Checking Bolts For Stretching (Necked down)

6
BALANCE SHAFTS
2.5L e n g in e s a re eq u ip p ed with tw o b a la n c e sh a fts
in s ta lle d in a c a rrie r a tta c h e d to th e low er c ra n k c a se
(Fig. 1).
T h e s h a fts a re in te rc o n n e c te d th ro u g h g e a rs to ro ­
ta te in opposite d irectio n s. T h ese g e a rs a re d riv e n by
a sh o rt c h a in from th e c ra n k sh a ft, to r o ta te a t tw o
tim e s c ra n k s h a ft speed. T h is c o u n te rb a la n c e s c e rta in
e n g in e re c ip ro c a tin g m asses.

BALAMCE SHAFT KEmOWAL

See E n g in e L u b ric a tio n a n d T im in g S y stem of th is
gro up for removal p ro ced u re of n e c e ssa ry co m ponents
to re p a ir b a la n c e sh a fts.

Fig. 15 Driwe Chain and Sprockets

(2) R em ove b a la n c e shaft g e a r a n d c h a in sprocket

retaining screw s a n d 'Crankshaft c h a in sprocket torx
screws. R em ove chain a n d sprocket a ssem b ly . (Fig.
15).

Fig. 14 Chain Cower, Guide and Tensioner

(1) R em ove c h a in cover, g u id e a n d te n s io n e r (Fig.

14). A lso see C a r rie r A ssem bly R em oval for serv ice
p ro c e d u re s re q u ir in g on ly te m p o ra ry re lo c a tio n of
assem b ly .

(3) R em ove g e a r cover r e ta in in g s tu d (double e n d ed

to also r e ta in c h a in guide). R em ove cover a n d b a la n c e
sh a ft g e a rs (Fig. 16). ■ ' ' '' ; ' '
 TIMING
(1) With balance shafts installed in carrier (Fig. 17)
position carrier on crankcase and install six attaching
bolts and tighten to 54 N-m (40 ft. lbs.).
REAR
COVER (2) Turn balance shafts until both shaft key ways
are up Parallel to vertical centerline of engine. Install
short hub drive gear on sprocket driven shaft and long
hub gear on gear driven shaft. After installation gear
and balance shaft keyways must be up with gear
timing marks meshed as shown in (Fig. 18).

CARRIER

v— ---- ----------------------- —-— RN293A

W m ] BALANCE -------------T
T H SHAFT I RN292
Fig. 17 Balance Shaft(s) Remove/Install
(4) Remove carrier rear cover and balance shafts.
(Fig. 17).
(5) Remove six carrier to crankcase attaching bolts
to separate carrier (Fig. 1).
CARRIER ASSEMBLY
REMOVAL
The following components will remain intact during
carrier removal. Gear cover, gears, balance shafts and
the rear cover.
(1) Remove chain cover and driven balance shaft
chain sprocket screw.
(2) Loosen tensioner pivot and adjusting screws, move
driven balance shaft inboard through driven chain
sprocket. Sprocket will hang in lower chain loop.
(3) Remove carrier to crankcase attaching bolts to
remove carrier.
BALANCE SHAFT CARRIER ASSEMBLY
INSTALLATION
Balance shaft and carrier assembly installation is
the reverse of the removal procedure. During installa­
tion crankshaft to balance shaft timing must be
established.
Fig. 18 Gear Timing
(3) Install gear cover and tighten double ended stud/
washer fastener to 12 N-m (105 in. lbs.).
(4) Install crankshaft sprocket and tighten socket
head torx screws to 13 N-m (130 in. lbs.).
(5) Turn crankshaft until number one cylinder is at
Top Dead Center (TDC). The timing marks on the
chain sprocket should line up with the parting line on
the left side of number one main bearing cap. (Fig.
19).
(6) Place chain over crankshaft sprocket so that the
nickel plated link of the chain is over the timing mark
on the crankshaft sprocket (Fig. 19).
(7) Place balance shaft sprocket into the timing
chain (Fig. 15) so that the timing mark on the sprocket
(yellow dot) mates with the (lower) nickel plated link
on the chain
(8) With balance shaft keyways pointing up 12
o’clock) slide the balance shaft sprocket onto the nose
of the balance shaft. The balance shaft may have to be
pushed in slightly to allow for clearance.
 MARK ON SPROCKET INSTALL CHAIN WITH

TENSIONER BOLT

MUSI LINE­
UP WITH
NOTCH

(LOWER) NiCK lE^lAIEPllNIC

8 LINKS CC/WiSE
FROM f O f UPPER LINK 8909-23 PIVOT BOLT"^ " 1 ^ 9109-45

Fig. 19 Balance Shaft Timing , Fig. 20 Chain Tension Adjustment

THE TIMING MARK O i THE SPROCKET,THE (LOW­ INTERMEDIATE SHAFT SERVICE..

ER) NICKEL PLATED LINK, AND THE ARROW ON
THE SIDE OF THE GEAR COVER SHOULD LINE UP CAUTION: The oil pump and distributor myst be re­
IF THE BALANCE SHAFTS ARE TIMED CORRECTLY. mowed before attempting to remove intermediate shaft.
(9) If th e sp ro ck ets a re tim e d co rrectly in s ta ll th e
b a la n c e s h a ft bo lts a n d tig h te n to 28 N-m (250 in. lbs.). ADAPTOR €-4687-1 '
A wood block placed b etw een c ra n k c a se a n d c ra n k ­
sh a ft c o u n te rb a la n c e w ill prevent c ra n k s h a ft a n d g e a r
ro ta tio n .

CHAIN TENSIOmiNG
(1) In s ta ll c h a in te n s io n e r loosely assem b led .
(2) P o sitio n g u id e on double en d ed stu d m a k in g
su re ta b on th e gu ide fits in to slo t on th e g e a r cover.
In s ta ll a n d tig h te n n u t/w a s h e r assem b ly to 12 N-m
(105 in. lbs.).
(3) P lace a sh im 1m m (.039 inch) th ic k x 70m m
(2.75 inch) long or b e tw e e n te n sio n e r a n d ch ain . P u sh
te n s io n e r a n d sh im u p a g a in s t th e ch ain . Apply firm
pressure (5.5 to 6.6 lbs.) directly behind the adjyst- 8909-24
ment slot to take up all slack (ch ain m u s t h a v e shoe
ra d iu s c o n ta c t as show n in Fig. 20).
(4) W ith t h e load ap plied , tig h te n top te n sio n e r b olt
first, th e n b otto m p iv o t bolt. T ig h te n b o lts to 12 N*m
(105 in. lbs.). R em ove shim .
(5) I n s ta ll c a rrie r covers a n d tig h te n screw s to 12
N*m (105 in. lbs.).
 (1) Hold sprocket with Tool C-4687 and adaptor
Tool C-4687-1 when removing or installing screw (Fig.
21 ).
(2) See Timing System and Seals for intermediate
seal removal and replacement.
(3) Remove retainer screws (Fig. 22).
(4) Remove retainer and lay aside.
(5) Remove intermediate shaft.
INSTALL-INTERMEDIATE SHAFT
(1) Lubricate distributor drive gear when installing.
1.5 mm (.06 I N.) DIAMETER BEAD ANAEROBIC GASKET
(2) Apply anaerobic (form-in-place) gasket material
as shown in (Fig. 23) and install intermediate shaft
retainer.
(3) Install retaining screws and torque to 12 N-m
(105 in. lbs.).
INTERMEDIATE SHAFT BUSHING SERVICE
TOOL
Fig. 24 Intermediate Shaft Bushing, Front
(1) Remove bushing using Tool C-4697-2 with Tool
Handle C-4171 (Fig. 24).
(2) Install bushing using Tool C-4697-1 and Tool
Handle C-4171 until tool is flush with block.
Fig. 25 Intermediate Shaft Bushing—Rear
(1) Remove bushing using Tool C-4686-2 and Tool
Handle C-4171 (Fig. 25).
(2) Install bushing using Tool C-4686-1 and Tool
Handle C-4171 until tool is flush with block.
Interm ediate Shaft Journal and Bushing Sizes
.
larg e Journal 42.670/42.695 mm (1.679/1.680 in.)
Small J-ourna 670/19.695 mm (.774A775 in.)
Bushing-Bore Diameter
Large Bushing 42.730/42.750 mm (1.682/1.683 in.)
Small Bushing_________19.720/19.750 mm (.776Z.777 in.)
Maximum Clearance Allowed
Large .035/.080 mm (.0013/.003 in.)
Small .025/.080 mm (.0009/.003 in.)

9109-11

Fig. 26 Intermediate Shaft Journal Specifications

CYLINDER BLOCK, PISTON UNO
CONNECTING ROD ASSEMBLY SERVICE

M A N IF O L D SIDE

1!

DISTRIBUTOR SIDE

Pig. 2 Piston Marking

PISTON IDENTIFICATION \\\.y ( | I :. 4 RB609A

(1) M a rk p isto n w ith m a tc h in g c y lin d e r n u m b e r a s
show n (Fig. 2). Fig. 4 Piston Flings—Hemming and installing
(2) M a rk connecting rod a n d cap before rem oving.
(3) V alv e c u t to w a rd m an ifo ld side of e n g in e.
(4) S q u irt hole on co n n ectin g rod m u s t face tim in g
b e lt en d of en g in e. ^-

VALVE CUTS TOWARD MANIFOLD SIDE

FEELER GAUGE

8909-44

PISTON RING SERVICE

(1) ID m a rk on face of u p p e r a n d in te rm e d ia te p is­
to n rin g s m u s t p o in t to w a rd p isto n crow n.
(2) U sin g a s u ita b le r in g ex p a n d e r, rem ov e o r in ­
s ta ll u p p e r a n d in te rm e d ia te p isto n rin g s (Fig. 4).
(8) F o r in s ta lla tio n of th e oil rin g , s t a r t w ith oil rin g
ex p a n d e r. P la c e e x p a n d e r in low er oil r in g groove a n d
in s ta ll oil ra ils . R efer to (Fig. 12) for rin g en d gap
po sitio n s.
C h eck p isto n rin g to p isto n rin g groove cle a ra n c e
w ith fe e le r g a u g e (Fig. 5).
 Fig. 6 Piston Ring Gap Fig. 8 Checking Cylinder Bore with Bore Gauge

(1) Using a piston, push piston ring into cylinder PISTON TO BORE SIZING
bore approximately 16mm (.62 inch) from bottom (Fig. Correct piston to bore clearance must be established
6 ). in order to assure quiet and economical operation.
Chrysler engines use pistons designed specifically
N atu rally Piston Groove for each engine model. Clearance and sizing locations
Aspirated Clearance W ia r Lim it vary with respect to engine model. Refer to (Fig. 10)
(1) Upper Piston 0.038 to 0.078 m m 0 .1 0 mm and the following sizing chart to determine the appro­
Ring (.0015 to .0031 in.) (.004 in.) priate sizing location and recommended piston to bore
(2 ) Intermediate 0.038 to 0.093 mm 0.10 mm
Piston Ri ng
clearance.
(.0015 to .0037 in.) (.004 in.)
(3) Oil Control Should be free in groove, not to exceed For sizing, bores are measured perpendicular to the
Ring 0 .2 mm (.008 in.) side clearance. length of the engine. This is known as the crosswise
N atu rally or A direction shown in (Fig. 8).
Aspirated lin g G ap Wear Limit (1) Measure in direction A then direction B at the
Upper Ring 0.25 to 0.51 mm 1.0 mm following points; (Fig. 8).
(.0 1 0 to .020 in.) (.039 in.) • 10mm (3/8 inch) from top
Intermediate 0.28 to 0.48 min 1.0 mm
Ring (.011 to .021 in.) (.039 in.) • Middle of cylinder wall
Oil Control 0.38 to 1.40 mm 1.88 mm • 10mm (3/8 inch) from bottom
Ri ng (.015 to .055 in.) (.074 in.)

9109-118
Fig. 7 Piston Ring Specifications

CYLINDER BORE
(1) Cylinder bore out of round:
• .050mm (.002 inch) maximum
(2) Cylinder bore taper:
• .125mm (.005 inch) maximum
 MEASURE
t
FRONT
TO FRONT OF ENGINE BORE j_
CROSSWISE-
ONLY
FOR PISTON O
SIZING
o
o
VALVE CLEARANCE NOTCHES
O l PISTON
• FRONT
PISTON PI N OFFSET

SIZI NG LOCATION "SL"

10 MM
(3/8 IN.)
PISTON , L
SIZE
DIA. ##S"

MIDDLE USE FOR

OF SIZING
BORE . PISTON C Il PISTON PIN ROD SQUIRT HOLE
TOWARD VALVE NOTCHES
(TIMING., IELT END O f
ENGINE)
10 MM
(3/8 IN.) 9109-62 9009-42

Fig, 9 Check Points in Cylinder Bore Fig. 11 Piston Installation and Sizing Information

S k irt Sizing Piston to GAP O f

Engine Type Location Cylinder Clearance W e a r L im it LOWER SIDE RAIL
f S L” ) * * (Mmm P art)

47.5mm O.025-O.O5Omm 0.070mm

2.5L TBI (1.87 in.) (0.0010-0.0020 in.) (0.0027 in.)

* Refer to Specifications for Available Piston Sizes

**"SL" = Sizing Location FRONT OF ENGINE

91 09-1 19

NO. 2 RING GAP GAP OF

AND SPACER UPPER SIDE RAIl
EXPANDER GAP RB281

Fig. 12 Piston Ring End Gap Position

Align piston ring end gaps as-shown in (Fig. 12).


(1) Rotate crankshaft so that connecting rod journal
is on center of cylinder bore.
(2) Use suitable thread protectors on connecting rod
bolts before inserting piston and connecting rod as­
sembly into cylinder block. Care must be taken not to
nick connecting rod journals.
(3) Using a suitable piston ring compressor tool,
install piston and connecting rod assembly into cylin­
der block (Fig. 13).
(4) Lightly oil connecting rod bolt threads with en­
gine oil before starting nut. Tighten nut to 54 N’m
plus 1/4 turn (40 ft. lbs. plus 1/4 turn). Do not use a
torque wrench for this step
___-RB613^,
Fig. 14 Checking Connecting Rod Bearing Clearance
CONNECTING RODS
(1) Follow procedure specified in the Standard Ser­
vice Procedures Section for Measuring Main Bearing
Clearance and Connecting Rod Bearing Clearance (Fig.
14).
CAUTION: Do not rotate crankshaft or the Plastic-
Gage may be smeared.
The rod bearing bolts should be examined before
reuse. If the threads are necked down the bolts should
be replaced. Necking can be checked by holding a
scale or straight edge against the threads. If all the
threads do not contact the scale the bolt should be
replaced.
THREADS ARE NOT STRAIGHT O N LINE
STRETCHED
BOLT
THREADS ARE STRAIGHT ON LINE
UNSTRETCHED BOLT 9009-38
 (2) Before installing the nuts the threads should be ENGINE CORE PLUGS
oiled with engine oil.
(3) Install nuts on each bolt finger tight than alter­ REMOVAL
nately torque each nut to assemble the cap properly. Using a blunt tool such as a drift or a screwdriver
(4) Tighten the nuts to 54 N-m PLUS 1/4 turn (40 ft. and a hammer, strike the bottom edge of the cup plug
lbs. PLUS 1/4 turn). Do not use a torque wrench for (Fig. 18). With the cup plug rotated, grasp firmly with
last step. pliers or other suitable tool and remove plug (Fig. 18).
(5) Using a feeler gauge, check connecting rod side
CAUTION: Do not drive cup plug Into the casting as
clearance (Fig. 17).
restricted cooling can result and cause serious en­
gine problems.
Connecting Rod Bearing Clearance
New Part I l f to .087 mr
(.0008 to .0034 in.)
W ear Limit 107 mm (.0042 in.)
Connecting Rod Side Clearance
Mew Port 2 mr
(.005 to .013 in.)
W ear Limit 0.37
(.015 in.)
9109-15
Fig 16 Connecting Rod Specifications

Fig. 18 Core Hole Plug Removal

INSTALLATION
Thoroughly clean inside of cup plug hole in cylinder
block or head. Be sure to remove old sealer. Lightly
coat inside of cup plug hole with sealer. Make certain
the new plug is cleaned of all oil or grease. Using
proper drive plug, drive plug into hole so that the
sharp edge of the plug is at least 0.5mm (.020 inch)
inside the lead-in chamfer (Fig. 18).
It is in not necessary to wait for curing of the seal­
ant. The cooling system can be refilled and the vehicle
placed in service immediately.
 2? N *m
(240 IN, LBS.)
 BEARING CAP
CAVITY
, JIT HOLE

CAMSHAFT
LUBRICATION

CAMSHAFT CYLINDER-
JOURNAL HEAD OIL
SLOT GALLERY

HYDRAULIC
LIFTERS

M AIN
GALLERY

BALANCE
SHAFT
GALLERY
LUBRICATION SYSTEM OIL PAN RAIL TO BLOCK SEALING
For 2.5L engines side gaskets (Fig. 1) are employed
A formed steel oil pan provides lower engine protec­ for rail sealing.
tion as well as serving as the engine oil reservoir. Pan
side flanges to block are sealed with gaskets. The 2.5L
engine pickup is unsupported and the lower end has a
box type strainer (Fig. 4).

PRESSURE LUBRICATION
Oil drawn up through the pickup tube is pressur­
ized by the pump and routed through the full flow
filter to the main oil gallery running the length of the
cylinder block. Modified oil pickup, pump and check
valve provide increased oil flow to the main oil gallery.

MAIN/ROD BEARINOS
A diagonal hole in each bulkhead feeds oil to each
main bearing. Drilled passages within the crankshaft
route oil from main bearing journals to crankpin
journals.

ACCESSORY SHAFT
INSTALLATION
Two separate holes supply the accessory shaft.
(1) Apply Mopar Silicone Rubber Adhesive Sealant
or equivalent at the front seal retainer parting line
BALANCE SHAFTS
(Fig. 3).
For 2.5L engine balance shafts lubrication an addi­
(2) Install the oil pan side gaskets to the block. Use
tional hole interconnects with a passage in one leg of
heavy grease or Mopar Silicone Rubber Adhesive Seal­
the balance shaft carrier to route oil down to the
ant or equivalent to hold in place.
carrier oil gallery. This gallery directly supplies the
(3) Apply Mopar Silicone Rubber Adhesive Sealant
balance shafts front bearings and internal machined
or equivalent to ends of new oil pan end seals at
passages in the shafts routes oil from front to rear
junction of cylinder block pan rail gasket (Fig.3).
shaft bearing journals.
(4) Install pan and tighten screws to 23 N-m (200 in.
lbs.).
CAMSHAFT/HYDRAULIC LIFTERS
A vertical hole at the number five bulkhead routes
OIL PUMP SERVICE
(through a restrictor) pressurized oil up past a cylin­
der head bolt to an oil gallery running the length of
the cylinder head. Hydraulic adjusters are supplied
directly from this gallery while diagonal holes supply
oil to the camshaft journals. The camshaft journals
are partially slotted to allow a predetermined amount
of pressurized oil to pass into the bearing cap cavities
with small holes directed to spray lubricate the cam­
shaft lobes.

SPLASH LUBRICATION
Oil returning to the pan from pressurized compo­
nents supplies lubrication to the valve stems. Cylin­
der bores and wrist pins are splash lubricated from
directed holes in the connecting rods.

OIL PAN
REMOVAL
(1) Drain engine oil and remove oil pan.
(2) Clean oil pan and all gasket surfaces.
OIL PICKUP
(1) Remove screw on pump cover holding oil pick-up T EDGE
tube to oil pump. (Fig.4)
(2) Remove oil pick-up tube.When reinstalling make
sure to use a new O-Ring on pickup tube.

MOUNTING SCREWS
23 N*m
(200 IN. LIS.) . RU249A
' Fig. § Checking Rotor End Clearance
MACH1NCD SURFACES INSPECTION
(BLOCK AND PUMP INTERFACE, (1) Check rotor end'clearance w ith fe e le r g a u g e a s
show n in (Fig. 6 ).
PUMP INSTALLATION
(2) L im its:
INSTALL PUMP • 0.03m m (.001 inch) min
FULL DEPTH AND iOTATE
BACK AND FORTH SLIGHTLY • 0.09mm (.0035 inch) max.
TO ENSURE POSITIVE
FULL SURFACE CONTACT ■
BETWEEN PUMP MOUNTING
FACE AND BLOCK MACHINED
SURFACES - WHILE CONTINUING
TO SUPPORT THE PUMP, INSTALL
AND TIGHTEN MOUNTING SCREWS RH1098A

Fig. 5 Oil Pump Assembly

REMOVAL
(1 ) Remove tw o (2) screw s h o ld in g oil p u m p to cy lin ­
d e r block asse m b ly (Fig. 5).

INSTALLATION
(1) A pply s e a le r (Loctite 515 or e q u iv a le n t) to p um p
body-to-block in te rfa c e (m ach in ed surface).
(2) L u b ric a te oil p u m p ro to r & s h a ft a n d d riv e g ear.
(3) In s ta ll p u m p fu ll d e p th a n d ro ta te b ack a n d
fo rth s lig h tly to e n s u re p ro p e r p o sitio n in g a n d a lig n ­
m e n t th ro u g h fu ll su rfa c e c o n ta c t of p u m p a n d block
m a c h in e d in te rfa c e su rfa c e s (Fig. 5).
CAUTION: Pump must to® held In fully seated posi­
tion (described atoowe) while Instilling screws.
(4) T ig h te n screw s to 23 N*m (200 in. lbs.). (1) Thickness: 23.96mm (.9435 inch) min Outer
Diameter: 62.7mm (2.469 inch ) min
(2) Install with large chamfered edge in pump body
(Fig. 7).
 s tr a ig h t m m

FEELER GAUGE

RB253A

Fig. 10 Oil Pump Cmmr

(1) Clearance: 0.076mm (.008 inch) max.
(1) Clearance: 0.20mm (.008 inch) max
SPI1NG COP

T *
RELIEF VALVE
Fig. 11 Oil Pressure Relief Valve
(1) Oil pressure relief valve spring: Free length:
49.5mm (1.95 inch). Load: 89 N at 34mm. Load: (20
lbs. at 1.34 inch).

/V .I

(1) Clearance: 0.35mm (.014 inch) max.

Fig. 12 Measuring Inner Rotor Thickness

(1) Thickness: 23.96mm (.9435 inch) Minimum
 8 9 0 9 -u , -8909-35

Fig. 13 Crankshaft and Intermediate Shaft Timing Fig. 15 Checking Oil Pump Pressure—Typical

(1) Turn crankshaft and intermediate shaft until CHECKING ENGINE OIL PRESSURE
markings on sprockets are in line (arrows Fig. 13). (1) Remove pressure sending unit and install Adap­
tor Tool S94 with gauge assembly C-3292 (Fig. 15).
(2) Warm engine at high idle until thermostat opens.
(3) Oil Pressure: Curb Idle 25 kPa (4 psi) minimum
3000 RPM 170-550 kPa (25-80 psi).

RB634A
Fig. 14 Oil Pump Shaft Alignment

(2) Slot in oil pump shaft must be parallel to center

line of crankshaft when intermediate shaft and crank­
shaft are properly timed.

9109-24
OIL FILTER
ANTI-DRAIN BACK VALVE (FIG. 16)
Installation: Apply liquid (Teflon Type) sealant to
valve-to-block threads. Tighten assembly to 55 N’m
(40 ft. lbs.).
FILTER (FIG. 16)
When servicing oil filter avoid deforming the filter
can by installing the remove/install tool band strap
against the can-to-base lockseam. The lockseam join­
ing the cam to the base is reinforced by the base
plate.
(1) Turn counter clockwise to remove.
(2) To install, lubricate new filter gasket. Check
filter mounting surface. The surface must be smooth,
flat and free of debris or old pieces of rubber. Screw
filter on until gasket contacts base. Tighten to 1 turn.
ENGINE SPECIFICATIONS

Type . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . In-line OHV, OHC

N umber of Cylinders . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
Bore . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 87.5mm
(3.44/3.45 in.)
Stroke. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 104mm
(4.09 in.)
Compression Ratio . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8.9:1
f iring Order. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-3-4-2
Basic Ignition Timing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Refer to Emission Control Information Label on Vehicle
Valve Timing
Intake Valve
0p#r»s (BIDC) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4#
Opens (ATDC). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . —
Closes(ABDC) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60°
Exhaust Valve
Opens (BBDC) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4O0
Closes(ATDC) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12°
Valve Over l ap. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8 °

Intake Valve Duration . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 236°

Exhaust Valve Duration . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 232 °

Description Standard S#rvlc®

Dimension Limit
Compression Pressure . . . . . . . . . . . . . . . . . . . . . Minimum 689.5 kPa (100 psi)
Maximum Variation Between Cylinders . . . . . . 25%
Valve Clearance— Hot Engine............................. Hydraulic
Lash Adjusters
Flatness of Cylinder Head Gasket Surface........ 0.1mm
(.004 in.)
Cylinder Head Gasket (Thickness Compressed) 1.73rom (.068 in.)
Camshaft
Journal Diameter ( A ll) ...................................... 34.939/34.960mm
(1.375/1.376 in.)
(Oversize— A l l ) ................. 35.439/35.460mm
(1.395/1.396 in.)
Cam Lobe We a r . . . . . . . . . . . . . . . . . . . . . . . . . . . 0.25mm (.010 in.)
End Play . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0J3/0.33mm 0.50mm
(.005/.013 in.) (.020 in.)
Valves
Thickness of Valve Head (Margin)
In ta ke................................................................... 1.5mm (.06 in.) ,793mm (.03 in.)
Exhaust . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.5mm (.06 in.) 1.19mm (.05 in.)
Valve Stem to Guide Clearance
Intake §.O22/O.065fnm
(.0009/.0026 in.)
Exhaust . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0.076/0.119mm
(.0030/.0047 in.)
Valve Spring Free Length
Standard ............................................................. 60.8 mm
(2.39 in.)
Valve Spring Load, Intake and Exhaust
Valve Open @ 30.99mm (1.22 in.)
Al l . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 890/961 N
(195/215 lbs.)
Valve Close @ 41.91mm (1.65 in.)
All.............................. 480/534 N
(108/120 lbs.)
Valve Spring Perpendicularity
All:
Intake and Exhaust . . . . . . . . . . . . . . . . . . . . . . 2.0mm (.079 in.; 2.0mm (.079 in.)
 ENGINE SPECIFICATIONS
S tandard Senile©
Description Dimension Limit
Interm ediate Shaft
Large Journal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 42.670/42.695mm
Bushing (Large) Inside Diameter . . . . . . . . . . . . . . . . . . . . . . 42.730/42.750mm
Small Journal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19.670/ 19.695mm
Bushing (Small) inside Diameter . . . . . . . . . . . . . . . . . . . . . . 19.720/19.750mm
Piston
Outside Diameter
2.5L St andard. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 87.430/87.481mm
(3.442/3.444 in.)
Piston Rings
Ring Side Clearance
No. 1 Ring— Standard . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0.038/0.078 mm ' 0.10mm
(.0015/.0031 in.) (.004.. in.)
No. 2 Ri ng- St andar d. . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0.038/0.093mm 0.10mm
(.0015/.0037 in.) (.004 in.) ■
Piston Ring End Gap ■' •
No, 1 Ring— Standard . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0.25/0.51 mm 1.0mm
(.010/.020 in.). (.039 in.)
No. 2 Ring— Standard . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0.28/0.53mm . 1.0 mm
(.0 1 1 /.0 2 1 in.) (.03? in.)-
Oil Ring Side Rai l— All . . . . . . . . . . . . . . . . . . . . . . . . . . . . ........ 0.3 8 /1 .40mm 1.88mm
(.015/.055 in.) (.074 in.)
Connecting Rod
Parallelism and Twist Combined . . . . . . . . . . . . . . . . . . . . . . ........ 0.08mm 0.08mni
(.003 in.) (.003 in.)
Connecting Rod Side Clearance . . . . . . . . . . . . . . . . . . . . . . . ........ 0.13/0.32mm
(.005/.013 in.)
Bearing Clearance—Standard . . . . . . . . . . . . . . . . . . . . . . . . O.019/O.O87mm 0.10mm
(.0008/.0034 in.) ■ (0.004 in.)
Cylinder lo r®
Out of Round . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . — .050mm (.002 in.)
Bore Taper . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ... — .125mm (.005 in.)
Crankshaft
Connecting Rod Journal O. D. . . . . . . . . . . . . . . . . . . . . . . . . . 4 9 >979/50,005m m
(1.968/1.969 in.)
Main Bearing Journal O.D. 59.987/60.013mm
(2.362/2.363 in.)
Bearing Surface Out-of-Round 0.008mm (.0003 in.) 0.013mm (.005 in.)
Bearing Surface Taper . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0.008mm (.0003 in.) 0.01 rum (.0004 In.)
Main Bearing Clearance . . . , ............................................... 8.011 /.072mm 0.10mm
(.0004/.0028 in.) (.0.004 i n.)
End Play . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0.05/0.18 mm 0.35mm
(.002/.007 in.) (.014 in.)
Oil Pump
Relief Valve Opening Pressure.............................................. . . . . . 414 kPa (60 psi) 56© kPo (80 psi)
Outer Rotor O.D. to Housing Bore Clearance........................ ........ 0.25mm (.010 in.) 0.35mm (.014 in.)
Outer Rotor Thickness . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ........ ' 23.98/24.00mm 23.96mm
(.944/.945 in.) (.9435 in.)
inner Rotor to Outer Rotor Tip Clearance . . . . . . . . . . . . . . . ........ 0.10mm 0.20mm
(.004 i n.) (.008 in.)
Inner and Outer Rotor to Housing C learance....................... ........ 0.03/0.08 mm 0.09mm
(.001/.003 in.) (.0035 in.)
Pump Cover Flatness . . . ......................................................... ........ 0.05mm 0.076mm
(.002 in. max.) (.003 in.)
Relief Spring Free Length........................................................ ........ 49.5mm 49.5mm
(1.95 in.) (1.95 in.)
Relief Spring Load ...................................................................... ........ 89 N @ 34mm
(20 lbs. ® 1.34 in.)
Oil Pressure Switch Minimum
Actuating Pressure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14 kPa (2 psi)
Oil Pressure—All
Minimum Values— Engine Fully Warmed
At Curb Id le ................................................................................ 30 kPa
(4 psi)
At 3000 RPM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 170-550 kPa
(25-80 psi)
*A t minimum cranking speed (130 RPM)— start er speed, also See "ENGINE PERFORMANCE" in STANDARD SERVICE PROCEDURES.
 ENGINE TORQUE SPECIPICMTIONS

M SCUPflO N 166! PI. U S . IN. US*

Cylinder Head Cover Screw ........................... 12 105

Cylinder Head Bolt - 4-Step l6 'l« 6 61 45
89 65
89 65
1/4 turn + 1/4 turn
Camshaft Sprocket Bolt....................................... 88 65
Camshaft Bearing Cap Bolt................................. 25 215
Crankshaft Sprocket fo il..................................... 115 85
Main Bearing Cap Bolt....................................... *41 + 1/4 tu.rn 30 + 1/4 turn
Connecting Rod tearing Cap Nut........................ + 1/4 turn 40 + 1/4 turn
Front Crankshaft Oil Seal Retainer Screw............. 12 105
Rear Crankshaft Oil Seal Retainer Screw 12 105
Intermediate Shaft Sprocket Bolt........................... 88 65
Intermediate Shaft Retainer Screw........................ 12 105
Upper Timing Belt Cover Screw............................ 4 40
Lower Timina Belt Cover Screw............................. 4 40
Intake Manilold Bolt............................................. 23 200
Exhaust Manifold Nut........................................... 23 200
Thermostat Housing Screw.................................... 28 250
Water Pump Housing Screw - Upper................... 28 250
Water Pump Housing Screw - Lower................... 54 40
Oil Pan Screw (M8 Screws)................................... 23 200
Oil Pan Screw (M6 Screws)................................... 12 105
Oil Pump Mounting Screw..... .............................. 23 200
Oil Pump Cover Screw.......................................... 12 105
Oil Pump Strainer-to-Cover Screw........................ 28 250
Oil Pan Drain Plug................................. ............. 27 240
Spark Plug............................. .............................. 35 26
Balance Snaft Carrier;
Front Chain Cover Screw................................... 12 105
Chain Tensioner Adjustment Screw................. . 12 105
Chain Tensioner Pivot Screw..... ....................... 12 105
Chain Snubber Stud and Washer................ . 12 105
Chain Snubber Nut........................................... 12 105
Gear Cover Screw .......................................... 12 105
Gear (and Sprocket) to Balance Shaft............... 28 250
Sprocket to Crankshaft - Torx Drive Cap Screw. 15 130
Rear Cover Screw............................................. 12 105
Carrier-to-Block Bolt......................................... 54 40
Cup Plug; Sealant Loctite 277.........................

’After reaching the torque specified, turn an additional 1/4 turn to achieve proper tightness.
 3.0L ENGINE
INDEX
Page Page
Accessory Drive Service ........................................... 55 Engine Specifications............................................... 85
Auto Lash Adjuster .................................................. 62 General Information ................................................. 52
Camshaft Service .................................................... 62 Engine Installation ................................................... 53
Crankshaft and Cylinder Block, Oil Filter and B racket............................................... 84
Assembly Service ................................................. 74 Oil Pan ..................................................................... 81
Cylinder Block .......................................................... 79 Oil Pump Service ..................................................... 82
Cylinder Head .......................................................... 65 Piston and Connecting Rod
Cylinder Head and Camshaft S ervice...................... 61 Assembly Service ................................................. 69
Engine Lubrication System ..................................... 81 Timing Belt Inspection— In Vehicle ........................ 57
Engine Mount Rubber Insulators ............................ 54 Timing Belt Service ................................................. 59
Engine Removal ......................................... ............. 53 Valve Service ............................................................ 66
GENE1AL INFORMATION . ■ ■ >■

3.0L V-6 ENGINE

Type ............................................ 6tfv SOHC (Per Bank)
Bore ................................................................... . . . 91.0 mm (3.59 Inch)
Stroke. . . ............ .... . .......................................................76.0 mm (2.99 Inch)
Compression Ratio . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8.85:1 :
D isp lacem ent........ ............................... ........................................ ......... 3.0 Lifers (181 Cubic Inch)
Torque ............................... . . ... ....................... I/O lb. Ft. # 2800 RPM •
Firing O rd e r.............................................................................................. 1-2-3-4-5-6
Lubrication ................... .......... ................................................................. Pressure Feed-Full flow filtra t i on
(Direct Crankshaft Driven Pump)
Engine Oil Capacity . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4.25 Liter (4.5 Qts.) Including Oil Filter, 3.8 Liter (4.0 Qts.)
W i thout Oil filter.
Cooling System .............................................. .......................................... Liquid Cooled-Forced Circulation
(Pump-Timing Belt Driven)
Cylinder Block . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Cast Iron
Crankshaft. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Cast (Ductile Cast Iron)
Cylinder Head . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Aluminum Alloy
Connecting Rods Forged Steel
Pistons....................................................................................................... Aluminum Alloy (w/Strut)

9109-30

BLOCK: The cylinder block is a light weight design shaft on center. To improve combustion speed the cham­
created by reducing thickness in many parts and a bers are a compact spherical design with a squish
short 10 mm (3/8 inch) block skirt. High rigidity is a r e a o f a p p ro x im a te ly 80% o f th e p isto n to p a re a . T h e
provided with ribs cast in the outer wall, a full length cylinder heads are common to either cylinder bank by
water jacket, and a monoblock or beam type, main reversing the direction of installation.
bearing cap. This single unit four bearing cap is de­ CAMSHAFTS: Two overhead camshafts provide valve
signed to control vibration of the cylinder block parti­ a c tu a tio n , one fro n t (ra d ia to r sid e o f c y lin d e r b a n k )
tion walls. and one rear. The front camshaft is provided with a
CRANKSHAFT: A six th ro w , five w e ig h t c ra n k s h a ft d is trib u to r d riv e a n d is lo n g er, a n d w h ile b o th c a m ­
is supported by four main bearings with number three sh a fts are supported by four bearing journals, thrust
being the thrust bearing. The six separate connecting for the front camshaft is taken at journal two and the
rod th ro w s p in s red u ce to rq u e flu c tu a tio n s w h ile a r e a r a t jo u rn a l th re e . F ro n t a n d r e a r c a m sh a ft d riv in g
torsional vibration damper is used to control torsion sprockets are interchangeable. The sprockets and the
caused vibration of the crankshaft. Rubber lipped seals engine water pump are driven by a single notched
are used at front and rear. The front seal is retained timing belt.
in the oil pump case and the rear is retained in a ROCKER ARM SH A FTS: T h e sh a fts a re re ta in e d by
block-mounted housing. the camshaft bearing journal caps. Four shafts are
PISTON S: A re a lu m in u m allo y w ith a ste e l strut, u sed , one for e a c h in ta k e a n d e x h a u s t ro c k e r a rm
short height, and thin wall so as to be autothermic assembly on each cylinder head. The hollow shafts
and light weight. The piston head with valve recesses, provide a duct for lubricating oil flow from the cylin­
in combination with the cylinder head, forms a com­ der head to the valve mechanisms.
pact spherical head with clearance for total valve lift ROCKER ARM S: A re o f lig h t w e ig h t d ie -c a st w ith
with pistons at top dead center. The piston skirt, top roller type follower operating against the cam shaft.
and second ring lands are finished with curvilinear The valve actuating end of the rocker arms are ma­
tapered roughness for oil retention and high resis­ chined to retain hydraulic lash adjusters, eliminating
tance to scuffing. Piston pins, press-fitted into place, valve lash adjustment.
join the pistons to the connecting rods. VALVES: A re m a d e o f h e a t r e s is ta n t s te e l a n d a re
CYLINDER HEAD: The alloy cylinder heads feature further treated to resist heat.
cross-flow type intake and exhaust ports. Valve guides VALVE SPRIN G S: A re esp ecially design ed to be short.-
a n d in s e rts a re h a rd e n e d c a s t iro n . V alv es o f h e a t T h e v a lv e s p rin g w ire cro ss-sectio n |p ov al sh a p e d a n d
resistance steel are arranged in a V with each cam- p ro v id es th e sa m e s p rin g te n s io n a s lo n g e r sp rin g s.
!V alve sp rin g retainers, locks a n d seals a re conventional.
 INTAKE MANIFOLD: The aluminum alloy manifold
is a cross type with long runners to improve inertia.
The runners, attaching below at the cylinder head,
also attach above and support an air plenum. The air
plenum chamber absorbs air pulsations created dur­
ing the suction phase of each cylinder.
EXHAUST MANIFOLDS: Both manifolds are a log
style made of ductile cast iron. Exhaust gasses, col­
lected from the front cylinder bank, leave the front
manifold through an end outlet and are fed through
SERVICE PROCEDURES
ENGINE REMOVAL
(1) Disconnect battery.
(2) Mark hood position at hinges and remove hood.
(3) Drain cooling system. Refer to Cooling System
Group 7 for draining procedure.
(4) Disconnect all electrical connections.
(5) Remove coolant hoses from radiator and engine.
(6) Remove radiator and fan assembly.
(7) See Fuel System Group 14, For procedures to
release fuel pressure, disconnect fuel lines and accel­
erator cable.
(8) Remove air cleaner assembly.
(9) Hoist vehicle and drain engine oil.
(10) Remove air conditioning compressor mounting
bolts and set compressor aside.
(11) Disconnect exhaust pipe at manifold.
(12) Remove transmission inspection cover and mark
flex plate to torque converter position.
(13) Remove screws holding torque converter to flex
plate and attach C-clamp on bottom of converter hous­
ing to prevent torque converter from coming out.
(14) Remove power steering pump mounting bolts
and set pump aside.
(15) Remove two lower transmission to block screws.
(16) Remove starter.
(17) Lower vehicles and disconnect vacuum lines
and ground strap.
(18) Install transmission holding fixture.
(19) Attach engine lifting hoist and support engine.
(20) Remove upper transmission case to block bolts.
(21) See Engine Mounting in (Fig. 1) and separate
mount/insulators as follows:
(a) Mark RIGHT insulator on right rails supports.
Remove insulator to rails screws.
(b) Remove FRONT engine mount through bolt
and nut.
(c) Remove LEFT insulator through bolt from in­
side wheelhouse or insulator bracket to transmission
screws.
(22) Remove engine.
an upper crossover tube to the rear manifold. The
collected exhaust from both manifolds are combined,
and exit to the exhaust pipe through an articulated
joint.
ENGINE LUBRICATION: System is a full flow fil­
tration, pressure feed type. The oil pump is mounted
in the chaincase cover. The pump inner rotor is driven
by the crankshaft. The engine oil pan contains a baf­
fle plate to control oil level fluctuation during engine
operation.
INSTALLATION
(1) Attach hoist and lower engine into engine
compartment.
(2) Align engine mounts and install but do not
tighten until all mounting bolts have been installed.
Tighten bolts to torque specified in (Fig. 1).
(3) Install transmission case to cylinder block, tighten
bolts to 102 N-m (75 ft. lbs.)torque.
(4) Remove engine hoist and transmission holding
fixture.
(5) Remove C clamp from torque converter housing.
Align flex plate to torque converter and install mount­
ing screws. Tighten to 75 N-m (55 ft. lbs.)
(6) Install transmission inspection cover.
(7) Connect exhaust system at manifold.
(8) Install starter.
(9) Install power steering pump and air condition­
ing compressor. For belt installation Refer to Acces­
sory Belt Drive in Cooling System Group 7.
(10) Lower vehicle and connect all vacuum lines.
(11) Connect all electrical connections including
ground strap.
(12) Connect fuel lines and accelerator cable.
(13) Install radiator and fan assembly. Connect fan
motor electrical lead. Install radiator hoses. Fill cool­
ing system. Refer to Cooling System Group 7 for fill­
ing procedure.
(14) Fill engine crankcase with proper oil to correct
level.
(15) Install hood.
(16) Connect battery.
(17) Start engine and run until operating tempera­
ture is reached.
(18) Adjust transmission or linkage if necessary.
 r ig h t EN GINE MOUNT
ASSEMBLY
TIGHTEN YOKE NUT FIRST
TIGHTEN YOKE SCREW SECOND

RIGHT ENGINE
SUPPORT ASSEMBLY

W - 12 MM
X = 7 MM

X DRIVER SIDE
A - 169 N*m (125 FT. LBS.
B - 133 N»m (100 Ft. LBS.)
C - 102 N*m (75 FT. LBS.)
68 N»m (50 FT. LBS.)
E- 54 N»m (40 FT. LBS.) FRONT ENGINE
F- 21 N«m (16 FT. LBS.) SUPPORT ASSEMBLY
G - 23 N»m (200 IN. LBS.) VIEW IN DIRECTION
OF ARROW X 9109-132

Fig. 1 Engine Mounting

ENGINE MOUNT RUBBER INSULATORS
Insulator location on frame rail right side and trans­
mission bracket left side are adjustable to allow right/
left drive train adjustment in relation to drive shaft
assembly length.
Check and reposition right engine mount insulator,
left engine mount insulator centers itself with engine
weight removed. Adjust drive train position, if re­
quired, for the following conditions:
• Drive shaft distress: Refer to Driveshaft in Suspen­
sion, Group 2.
• Any front end structural damage after repair.
• Insulator replacement.
(3) Pry the engine right or left as required to achieve
the proper drive shaft assembly length. Refer to
Driveshaft in Suspension Group 2 for drive shaft iden­
tification and related assembly length measuring.
(4) Tighten right engine mount insulator vertical
bolts to 81 N-m (60 ft. lbs.), tighten front engine mount
fasteners to 54 N-m (40 ft. lbs.) and center left engine
mount insulator.
(5) Recheck drive shaft length.
SHAFT MASS

ENGINE MOUNT INSULATOR ADJUSTMENT

(1) Remove the load on the engine motor mounts by
carefully supporting the engine and transmission as­
sembly with a floor jack.
(2) Loosen the right engine mount insulator vertical
fasteners, and the front engine mount bracket to front
crossmember fasteners.
Left engine mount insulator is sleeved over shaft
and long support bolt to provide lateral movement
(14 TO 17 mm)
adjustment with engine weight removed or not (Fig.
2).
ACCESSORY DRIVE SERVICE
TORQUE
A — 54 N*m (40 FT. LBS.)
n (30 FT. LBS.)
C — 28 N*m (250 IN. LBS.)

TENSIONER
ASSEMBLY (g)

POWEt
STEERING
PUMP
BRACKET VIEW IN
DIRECTION OF ARROW Z

IDLER
FULLY

9109-32

Fig. I Accessories Mounting Brackets

ACCESSORY DRIVE BELTS JACK SCREW

REMOVAL
(1) L oosen A d ju stin g Lock N u t (Fig. 2).
(2) T u rn a d ju stin g ja c k screw co u n terclo ck w ise to
red u ce b e lt te n sio n . R em ove belt*
 (8) In s ta lla tio n : A d ju st b e lt te n sio n to 5/18 deflec­
tio n b e tw e e n p u lle y s (Fig. 2).
(4) I n s ta ll b r e a k e r b a r in to 1/2 s q u a re o p en in g im
te n sio n e r. / ///
SCREW 3 N*m (24 IN. LIS.k
(5) R o ta te te n s io n e r co u nterclock w ise to rem ove a n d
in s ta ll b e lt (Fig. 4).

BELT REPLACEMENT UNDER ANY OR ALL O f THE

FOLLOWING CONDITIONS IS iEQUliED, EXCESSIVE DRIVE
WEAR FRAYED CORDS SEVERE GLAZING. BELT

"V## MURED BELT SYSTEM WITH ACROSS

BACK DRIVE PULLEY MAY DEVELOP
PARALLEL
MINOR CRACKS ACROSS THE RIBBED
SIDE (DUE TO REVEiSE IENDiNG).THESE
MINOR CRACKS ARE CONSIDERED NORMAL
AND ACCEPTABLE. CRACKS PARALLEL ARE NOT.
DO NOT USE ANY TYPE OF BELT DRESSING
PR RESTORER ON "V" RIBBED BELTS. 9007-17

Pig. 3 Driwe Belt Inspection

SPLASH
L ACCESSORY DilVE BELT SHIELD
TENSIONEi

Fig. 5 flight Inner Splash Shield—Typical

BOU-WASHER
ASSEMBLY

CRANKSHAFT B O lf
22 mm OR
1/2" SQUARE

CRANKSHAFT
SPROCKET
BOLT TORQUE
ROTATE CLOCKWISE 151 N#m
TO ilLEASE TENSION 9109-34 (112 FT. LBS.)
TOiSIONAL PAMPER
Fig. 4 Alternator/Power Steering Belt
CRANKSHAFT
e n g in e M o m r e m m e r PULLEY i
9109-35 CRANKSHAFT PULLEY A
REMOVAL
(1) R em ove a ir co n d itio n in g com p resso r to m o u n t­ Fig. 6 Crankahaft Driwe Pulleys
in g b ra c k e t screw s a n d la y com p resso r a sid e (Fig. 1)
(2) R em ove screw s a tta c h in g a ir c o n d itio n in g com ­ (4) Remove tw o s te e rin g p u m p to e n g in e mounting
p re sso r m o u n tin g b ra c k e t a n d a d ju sta b le d riv e b e lt b ra c k e t screw s a n d one r e a r su p p o rt lock n u t.
te n s io n e r from block a n d e n g in e m o u n tin g b ra c k e t. (5) L ay p ow er s te e rin g p u m p asid e.
R em ove b o th a ssem b lies. (8) R aise v eh icle a n d rem o v e r ig h t in n e r s p la sh
(3) R em ove s te e rin g pump/alternator b e lt te n s io n e r sh ie ld (Fig. 5)
' m o u n tin g b o lt a n d rem o ve a u to m a tic b e lt te n sio n e r. (7) R em ove c r a n k s h a ft d riv e p u lle y s a n d forsio -
d a m p e r (Fig. 8).
(8) L ow er v eh icle a n d p lace a ja c k u n d e r e n g in e.
(9) S e p a ra te e n g in e m o u n t in s u la to r from e n g in e
m o u n t b ra c k e t (Fig. 7). R a ise e n g in e slig h tly .
(10) Remove e n g in e m o u n t b ra c k e t (Fig. 7)
 TIGHTEN YOKE NUT FIRST
TIMING BELT INSPECTION— IN VEHICLE
TIGHTEN YOKE SCREW SECOND
(1) R em ove th e u p p e r fro n t o u te r tim in g b e lt cover
by lo o sen in g th e th re e a tta c h in g b o lts. (Fig. 8).
(2) In sp e c t b o th sid es of th e tim in g b e lt drive &
b ack. R eplace b e lt if a n y o f th e follow ing c o n d itio n s
e x ist.
• H a rd e n in g of b ack ru b b e r b ack sid e is glossy w ith ­
o u t re silie n c e a n d le a v e s no in d e n t w h e n p re sse d w ith
fin g e rn a il.
• C ra c k s on ru b b e r back.
• C ra c k s or p e e lin g of c an v as.
• C ra c k s on rib root.
• C ra c k s on b e lt sides.
• M issin g te e th .
• A b n o rm al w e a r o f b e lt sides. T h e sid es a re n o rm a l if
th e y a re sh a rp a s if cut by a k n ife (Fig. 10).
A — 133 N*m (100 FT. LBS.) (3) I f n o n e o f th e above c o n d itio n s a re seen on th e
B— 102 N*m (75 FT. LBS. b e lt, th e b e lt cover can be re in sta lle d .
C— 68 N*m (50 FT. LBS.)
D— 54 N'm (40 FT. LBS.) 9109-36

Fig. 7 Right Engine Mount and Engine Mount Bracket

(11) Remove timing belt covers (Fig. 8).

BRACKET COVER (REAR

vHARNESS CUP REFERENCE)
^AR I BRACKET
COyER D \ HARNESS CLIP

1 UPPER FRONT
COVER (OUTER)

TORQt
ALL-14 N»m I(115 IN. LBS
A M6 x 2 0 C M6 x 25
i M 6x55 D M6 x 10 RR09B9
 ALTERNATOR
BRACKET

TIMING BELT COVEft

(UPPER O U Iii- 8 )

ENGINE
SUPPORT
SiACKIT
TIMING BELT COVER
(INNER-A)

TIMING BELT COVER

{y P P li OUTERS)

TIMING BELT COVER

(FRONT LOWER)

• TORSIONAL PAMPEt
- CRANKSHAFT PUliY (A)
• CRANKSHAFT PULLY (I) 11(993
F ig . § T i m i n g B e l t S y s t e m
 TIMING BELT SERVICE
REMOVAL
(1) Mark belt running direction for installation (Fig.
11).
(2) Loosen timing belt tensioner bolt (Fig. 13) and
remove timing belt.
(3) Remove crankshaft sprocket flange shield (Fig.
6 ).

CAMSHAFT SPROCKETS
REMOVAL
(1) Hold camshaft sprocket with Spanner Tool
MB990775 loosen and remove bolt and washer (Fig.
12).
(2) Remove camshaft sprocket from camshaft.

INSTALLATION
(1) Place camshaft sprocket on camshaft.
(2) Install bolt and washer to camshaft. Using Span­
ner Tool MB990775 hold camshaft sprocket and torque
bolt to 95 N-m (70 ft. lbs.) (Fig. 12).

Fig. 10 Timing Belt Inspection

 (3) T u rn tim in g b e lt te n s io n e r co u n ter-clo ck w ise fu ll
tra v e l in 'a d ju stm e n t slo t a n d tig h te n b o lt-to tempo­
rarily hold th is p o sitio n (Fig. 14).

INSTM LLATIO N ^Tim iN G BELT

(1) I n s ta ll tim in g b e lt on c ra n k s h a ft sp ro c k e t firs t
TIMING BELT TENSIONER a n d w h ile k e e p in g b e lt tig h t on tension side (Fig. 11)
in s ta ll b e lt on th e front (radiator side), c a m s h a ft
sp rock et.
(2) T h en , in s ta ll on th e w a te r p u m p p u lle y a n d on
th e r e a r c a m sh a ft sp ro c k e t a n d fin a lly on th e tim in g
b e lt te n sio n e r.
(3) A pply ro ta tin g force to th e f r o n t ca m sh a ft sprocket
in opposite d ire c tio n to te n sio n th e b e lt te n sio n side
a n d check t h a t a ll tim in g m a rk s a re lin e d u p (Fig.
11).
(4) I n s ta ll c ra n k s h a ft sp ro c k e t fla n g e (Fig. 9).
(5) Loosen te n s io n e r bolt, a n d allow s p rin g to te n ­
sio n tim in g b elt.
(8) T u rn c ra n k s h a ft tw o fu ll tu r n s in clockw ise d i­
rectio n . Turn smoothly and ■ in clockwise direction
ONLY.
(7) A g a in lin e u p th e tim in g m a rk s on th e sp ro ck ets
a n d tig h te n th e tim in g b e lt te n s io n e r lo c k in g b o lt to
25 N-m (250 in. lbs.) to rq u e .
(8) R eassem b ly b e lt covers, e n g in e B ra c k e t, I n s u la ­
to r, c ra n k s h a ft p u lle y s, accessories a n d accesso ry d riv e
b e lts in re v e rse ord er.

Fig. 13 Timing Belt Tensioner

(1) In s ta ll tim in g b e lt te n sio n e r a n d te n sio n e r sp rin g.

(2) H ook s p rin g u p p e r e n d to w a te r p u m p p in a n d
low er e n d to te n s io n e r b ra c k e t w ith hook o u t (Fig. 13).
 BREATHER tO CKEi ROCKER ARM
HOSE COVER-1 SHAFT
ASSEMBLY

ROCKER
COVER
A

LASH ADJUSTER

COVER

DISTRIBUTOR
ADAPTOR

O-RING 9009-45
Fig. I Cylinder Hoad-Camshaft-Valvea

CYLINDER HEAD AND CAMSHAFT SERVICE

CYLINDER HEAD COVER
COVER
REMOVE GASKET 10 N-m
(1) Remove air cleaner assembly. APPLY (8 8 IN. LBS.)
(2) Disconnect battery and relocate spark plug wires. SEALANT
(3) Remove vacuum connections.
(4) Remove rocker cover screws and remove cover
(Fig. 2).

INSTALL
(1) Clean cylinder head and cover mating surfaces.
Install new gasket. mm (1/16 INCH) BEAD
(2) See (Fig. 2) and apply sealant such as Mopar OF i f V 3 /8 INCH LONG
Silicone Rubber Adhesive Sealant to cover ends. IN FOUR PLACES
(3) Install cover and tighten cover bolt washer and
gasket assembly to 10 N-m (88 in. lbs.).
 CAMSHAFT S IR !iC I
SEE AUTO LASH ADJUSTER FUNCTION CHECK
BEFORE DISASSEMBLY

lEiOW Al
(1) I n s ta ll a u to la s h a d ju s te r re ta in e rs . (Fig. 4).
(2) Remove d is trib u to r e x te n sio n (Fig. 1).
(3) W h en re m o v in g c a m sh a ft b e a rin g cap s do n o t
rem ove th e b o lts from th e b e a rin g caps. R em ove th e
ro c k e r a rm , ro c k e r s h a fts a n d b e a rin g cap a s a n
assem bly .

CAMSHAFT INSPECTION

Fig. 3 Auto Lash Adjuster Check

AUTO LASH ADJUSTER

T h e a u to m a tic la s h a d ju s te rs a re p recisio n u n its
in s ta lle d in m a c h in e d o p en in g s in th e v alv e a c tu a tin g
e n d s of th e ro c k e r arm s. Do n o t d isa sse m b le th e a u to
la s h a d ju ste r.

FUNCTION CHECK
C heck a u to a d ju s te rs for free p la y by in s e rtin g a
sm a ll w ire th ro u g h th e a ir bleed h ole in th e ro ck er
a rm a n d WERY LIGHTLY p u sh th e a u to a d ju s te r .ball
check dow n (Fig. 3). W hile lig h tly h o ld in g th e check
b a ll dow n m ove th e ro c k e r u p a n d dow n to check for
free play . I f th e r e is no p la y re p lace th e a d ju ste r.

Pig. 5 Check Camshafts

(1) In sp e c t c a m sh a ft b e a rin g jo u rn a ls for d a m a g e

a n d b in d in g (Fig. 5). I f jo u rn a ls a re b in d in g ,a lso check
th e cy lin d e r h e a d for d a m a g e (Fig. 1). A lso check
c y lin d e r h e a d oil h oles for clogging.
(2) F ro n t c y lin d e r h e a d c a m sh a ft check th e to o th
surface of the distributor drive gear teeth of the cam­
shaft and replace if abnormal wear is evident (Fig. 5).
(3) Check the cam surface for abnormal wear and
damage and replace if defective. Also measure the
cam h e ig h t (Fig. 5) a n d re p la c e if o u t of lim it, stan­
dard v a lu e is 41.25 m m (1.624 inch), w e a r lim it is MEASSEMBLE
40.75 m m (1.604 inch).

CAMSHAFT INSTALL
(1) L u b ric a te c a m sh a ft jo u rn a ls a n d cam s w ith e n ­
g in e oil a n d in s ta ll c a m sh a ft on c y lin d e r head . ARROW MARK (BEARING CAP)

Pig. 6 Inspect Rocker Mrms

ROCKER ARMS ■
(1) C heck ro c k e r a rm s fo r w e a r o r d a m a g e (Fig. 6).
R eplace a s n e c e ssa ry . A lso see A u to L a sh A d ju ster.
OIL HOLE ffO IDENTIFY INLET
FROM OUTLET SHAFTS)

INLET SIDE ' /

rs 3E
RR09B97 MARK (BEARING CAP)
ARROW
ii OIL IS TRANSFERRED TO THE
ii EXHAUST SHAFT THROUGH
fig. i Camshaft Bearing Caps Position
EXHAUST Ii THE CAM BEARING CAP
(OUTLET) SIDE (1) A lig n th e c a m sh a ft b e a rin g caps w ith arro w s
ii
i i_ (d ep en d in g on c y lin d e r bank) d ire c te d a s ' sh ow n in
I p. ^ (Fig. 8) a n d in n u m e ric a l ord er.
RR09B21
Fig. 7 Rocfcer Arm Shaft Identification

m m m arm shafts
T h e ro c k e r a rm s h a ft is hollow and is u se d a s a
lu b ric a tio n oil duct. T h e ro ck er a rm shaft on th e in let NOTCH
side h a s a 3m m d ia m e te r oil p a ssa g e h ole from th e
cy lin d e r h ead . T h e exhaust s id e /d o e s n o t have th is
oil p a ssa g e (Fig. 7).
(1) C heck th e ro c k e r a rm m o u n tin g p o rtio n of th e
sh a fts for w e a r o r d am ag e. R eplace i f h e a v ily dam­
aged o r w orn. '
(2) C h eck oil h o les for clogging w ith sm a ll w ire,
c lean as re q u ire d (Fig. 7).
 Fig. 10 Assemble Rocker Arm and Shafts

Identify number one bearing cap number one and (5) Install distributor drive adaptor assembly (Fig.
number four caps are similar (Fig. 9). 11).
(1) Install rocker shafts into bearing cap number
one with end notches positioned as shown in (Fig. 9) 15 N»m
that the machined portion of the rocker shaft is facing (130 IN. LBS)
down.
(2) Insert attaching bolts to retain assembly.

REASSEMBLE ROCKER ASSEMBLY

(1) Install the rocker arms, bearing caps and springs.
Springs are the same and can be used at all locations
on the rocker arm shafts (Figs. 8 and 10). Insert bolts
in number four bearing cap to retain assembly.
DISTRIBUTOR
INSTALL ROCKER ARM SHAFT ASSEMBLY DRIVE
ADAPTOR
(1) Apply sealant at bearing cap ends as shown in
(Fig. 8).
(2) Install the rocker arm shaft assembly making RR09B25
sure that the arrow mark on the bearing cap and the
arrow mark on the cylinder head are in the same
direction (Fig. 8).
The direction of arrow marks on the front and rear
assemblies are opposite to each other.
(3) Tighten bearing cap bolts in the following order
to 10 N*m (85 in. lbs.). First #3, then #2, #1 and #4.
(4) Repeat step 3 increasing the torque to 20 N-m
(180 in.lbs.).
*-------------------------- ENGINE 9-65

CAMSHAFT OIL SEAL SERVICE CAMSHAFT END SEAL (PLUG)

Fig. 13 Install Camshaft End Seal—Plug

(1) Install end seal plug with Special Tool MD998306.

(Fig.13).

CYLINDER HEAD
REMOVAL
(1) See Timing System this group for disassembly
(1) Apply light coat of engine oil to the camshaft oil
and remove camshaft sprockets.
seal lip.
(2) See Camshaft Rocker Arms Removal.
(2) Install the oil seal using camshaft oil seal in­
(3) Remove upper intake manifold assembly. Refer
staller tool MD998713 (Fig. 12).
to Intake and Exhaust Manifolds, Group 11.
(4) Remove distributor.
(5) Remove exhaust manifolds and cross over Refer
to Intake and Exhaust Manifolds, Group 11.
 CAUTION: This is a combined total dimension of
stock removal from cylinder head if any and block
top surface.

fH 4 © 8 I I 5 @ 1

_ 10 mm
ALLEN HEX 1515
<P
TIM ING
CYLINDER HEAD
BOLT AND WASHER 10 mm
BELT
ALLEN HEX
END
i @4 <P
TIMING
CYLINDER HEAD
BOLT AND WASHER .
BELT
END
M) 8 m 5
RR09B98

Fig. 14 Cylinder Head Bolt Removal Sequence

(6) Remove cylinder head bolts in sequence shown RR09B99

in (Fig. 14) and remove cylinder head.
Fig. 16 Cylinder Head Bolt Tightening Sequence
INSPECTION INSTALLATION
(1) Clean surfaces of head and block, install head
gasket over locating dowels.
(2) Install head on locating dowels.
(3) Install 10mm Allen Hex head bolts with washers.
(4) Tighten bolts in the order shown in (Fig. 16).
When tightening the cylinder head bolts, tighten grad­
ually, working in two or three steps and finally tighten
to specified torque of 95 N-m (70 ft. lbs.).

VALVE SERVICE
VALVE AND VALVE SPRINGS

RR09B29

Fig. 15 Check Cylinder Head

(1) Before cleaning, check for leaks, damage- and

cracks.
(2) Clean cylinder head and oil passages.
(3) Check cylinder head for flatness (Fig. 15).
(4) Cylinder head must be flat within;
• Standard dimension = less than 0.05mm (.002 inch)
• Service Limit = 0.2mm (.008 inch)
• Grinding Limit = Maximum of 0.2 mm (.008 inch)
is permitted.
 (1) W ith s u ita b le v alv e sp rin g co m pressor, rem ove
sp rin g r e ta in e r locks, re ta in e r , v a lv e sp rin g , sp rin g
s e a t a n d v a lv e (Fig. 17). VALVE DIM ENSIO NS
INTAKE VALVE (MINIMUM)
STEM DIAMETER: 7.960 mm (.313 in.)
FACE ANGLE: 45°
VALVE MARGINi .700 mm (.028 in.)
LENGTH: 103.0 mm (4.055 in.)
EXHAUST VALVE (MINIMUM)
STEM DIAMETER: 7.930 mm (.312 in.)
FACE ANGLE: 45°
VALVE MAitGiN: 1.50 mm (.059 in.)
LENGTH: 102.70 mm (4.043 in.)
VALVE GUIDE NEW If
CLEARANCE
INTAKE 0.03 TO 0.06 mm mm
0 .1 0
(.001 TO .002 in.) (.004 in.)
EXHAUST 0.05 TO 0.09 mm 0.15 mm
(.002 TO .0035 in.) (.006 in.)
WAIVE S P U N © SPECIFICATION
' FREE LENGTH NEW 49.8 mm (1.960
' ' SERVICE LIMIT 48.8 mm (1.921
(1) R em ove v a lv e ste m se a ls w ith s u ita b le tool (Fig. SQUARENESS ' ‘ NEW 2° MAXIMUM
18). Do n o t re u s e v a lv e ste m seals. SERVICE LIMIT 4° MAXIMUM
SWING TENSION
VALVES INSTALLED HEIGHT 40.4 mm AT 33 KG
(1.59. in. 73 LBS.)
9109-60

Fig. 20 9Afi9§ Specification

LENGTH

(1) C heck v a lv e ste m tip for p ittin g o r d e p re ssio n a t

p o in t A (Fig. 19).
(2) C heck for w e a r a n d rid g e w e a r a t P o in t B.
(3) C heck for e v e n c o n ta c t (a t face c e n te r) w ith
v alv e se a t, P o in t C.
(4) C h eck m a rg in . R eplace v alv e if m a rg in is o u t of
sp ecificatio n (Fig. 20)
(5) M e a su re v a lv e ste m to g u id e c le aran ce.
(6) M e a su re V alv e s p rin g free le n g th a n d s q u a re ­
n ess. R efer to (Fig. 20) for sp ecifications.
 ENAMELED
END
SPRING
RETAINER

< =
O r
STEM
RR09B35 ‘ SEAL

Fig. 22 Waive Seat Reconditioning

Q = :
I1

VALVE S IA T INSPECTION
In sp e c t th e v a lv e s e a t w ith P ru s s ia n b lu e to deter­
cr~ n
SPRING
SEAT

mine w h e re th e v a lv e co n ta c ts th e se a t. To do th is ,
1R 09I37
co at v alv e s e a t LIGHTLY w ith P ru s s ia n b lu e th e n s e t
v a lv e in place. R o ta te th e v alv e w ith lig h t p re ssu re . I f Fig. 24 Installed Vmivrn Spring Position
th e b lu e is tr a n s fe rre d to th e c e n te r o f v alv e face,
co n ta c t is satisfactory. If the blue is tr a n s fe rre d to top (1) I n s ta ll v a lv e s p rin g w ith th e e n a m e lle d e n d s
edge o f th e . v a lv e face, lo w er v alv e s e a t w ith a 15 facin g th e ro c k e r a rm s (Fig. 24).
d e g re e s sto n e. I f th e b lu e is tra n s fe rre d to th e bo tto m
CAUTION: During reassembly, compressing the waive
edge o f v alv e face ra is e v a lv e s e a t w ith a 85 d eg ree
spring more than necessary to install valve spring
sto n e.
retainer locks can cayse the retainer to be forced
against the stem seal and damaging it.

x '
RR09B36

Fig. 23 Install Valve Stem Seals

(1) Install valve spring seat.

(2) Using suitable tool install seal by tapping lightly
until seal is in place. (Fig. 23).
PISTON AND CONNECTING ROD
ASSEMBLY SERVICE

"R" FORWARD FOR

CYLINDERS 1-3-5

Fig. 2 Mark Pistons Fig. 3 Mark Matching Parts

(1) Mark Identify Pistons.The pistons are not inter- (1) Mark connecting rod and cap with cylinder num-
changeable from bank to bank . (Fig. 2). ber (Fig. 3).
 (1) M e a su re a p p ro x im a te ly 2 m m (.080 in ch ) above
th e b otto m of th e p isto n s k ir t a n d across th e th r u s t
face. (Fig. 6), See B o rin g C y lin d e r in C y lin d e r Block.

(1) Remove p isto n rin g s (Fig. 4).

(1) W ipe cy lin d e r bo re clean . I n s e r t rin g a n d p u sh

down with piston to ensure it is square in bore. The
Pig. 5 Checking Cylinder Bom Size ring gap measurement must be made with the ring
positioning at least 16mm (.63 inch) from bottom of
(1) M e a su re th e ■ c y lin d e r bore a t th r e e lev els in cylinder bore. Check gap with feeler gauge (Fig. 7).
d ire c tio n s A a n d B (Fig, 5). Top m e a s u re m e n t sh o u ld Refer to (Fig. 8) for specification. .
be 12m m (.50 in ch) down' a n d bottom' m e a s u re m e n t
sh o u ld be 10m m (.38 inch) up.
(2) S ta n d a rd b o re dim ension: 91.1m m (3.5866 inch)
(3) M a x im u m out-of-ro un d o r ta p e r: 0 .02 m m (.0008
inch)
 (1) The N o.l and No.2 piston rings have a different
RING POSITION RING WEAR LIM IT cross section. Install rings with manufacturers mark
UPPER tIN G 0.30 TO 0.45 mm 0 . 8 mm and size mark facing up, to the top of the piston. (Fig.
(.012 TO .018 in.) (.031 in.)
10).
INTERMEDIATE 0.25 TO 0.40 mm 0 . 8 mm
RING (.010 TO .016 in.) (.031 in.) CAUTION: Install piston rings in the following order:
OIL CONTROL 0.30 TO 0.90 mm 1 .0 mm
RING (.012 TO .035 in.) (.039 in.) (1) Oil ring expander.
RING POSITION © itO O W i M A XIM U M
(2) Upper oil ring side rail.
CLEARANCE CLEARANCE (3) Lower oil ring side rail.
UPPER RING 0.05 TO 0 .0 9 'min .1 0 min
(4) No. 2 Intermediate piston ring.
(.002 TO .0035 in.)'- (.004 in.) (5) No. 1 Upper piston ring.
INTERMEDIATE • -0:02 TO 0.06 mm .1 0 mm
. .RING (.0007 TO .002 in.) (.004 in.) SIDE RAIL
OIL CONTROL RING-THREE PIECE. OIL RING SIDE RAILS MUST BE
FREE TO ROTATE AFTER ASSEMBLY.
9109-37
Fig. 8 Piston Ring Specification Chart

Fig. 11 Installing Side Rail

(1) Install the side rail by placing one end between

the piston ring groove and the expander. Hold end
firmly and press down the portion to be installed until
side rail is in position. Do Not use a piston ring
expander. (Fig. 11). .
(2) Install upper side rail first and then the lower
(1) Check piston ring to groove clearance; Refer to side rail.
Piston Ring Specification Chart (Fig. 8)

9109-105

Fig. 12 Installing Upper and Intermediate Rings

(1) Install No. 2 piston ring and then No. 1 piston

ring (Fig. 12).
 SIDE RAIL NO. 1
UPPIt RINGGAP

PISTON
PIN

sSIDE RAIL
NO. 2 RING LOWER
GAP AND SPACER
m m m m gap RI1C98JI1

F lf . 13 Piston Ring End Gap Position

(1) Position piston ring end gaps as shown in (Fig.

13).
(2) Position oil ring expander gap at least 45° from
the side rail gaps but not on the piston pin center or
on the thrust direction. Fig. 15 Connecting Rod and Cap

(1) Check alignment marks made during disassem­

bly and that bearing position notches new or used
parts are as shown in (Fig. 15).

CONNECTING ROD CLEARANCE

(1) Following procedures specified in the Standard
Service Procedures Section for Measuring Main Bear­
ing Clfearance and Connecting Rod Bearing Clear­
ance. (Fig. 16). Refer to (Fig. 18) for specifications.
(2) Tighten nuts to 52 N-m (38 ft. lbs.).
(3) Remove connecting rod cap and measure Plastic-
Gage (Fig. 16).
CAUTION: Do not rotate crankshaft or the Plastic-
9109-106 Gage may be smeared.

Fig. 14 Identify Piston/Rod Assembly for

Cylinder Installation

Connecting rod front mark 72 must always face

forward, toward timing belt end. (Fig. 14)
(1) Install the piston and connecting rod assembly
into there respective bore from the cylinder block top.
CAUTION: Piston assemblies are not to be inter­
changed from bank to bank.
 C O N N IC T IN O ftO D lliflllMWlcl O IL CLEARANCE
NEW m w f i .020 TO .067 mm
{*0008 TO .0028 in.)
CONNECTING ROD SIDE CLEARANCE
-NEW PART:' 0.10 TO 0.25 mm
■' (.004 TO .010 in.)
. . WEAR LIMIT: 0.4 wm
(.015 in.) , .
9109-38

Fig. 18 Connecting Rod Clearance Specifications

Fig. 16 Connecting Rod Checking Bearing Clearance

CONNECTING ROD SIDE CLEARANCE

Using a feeler gauge, check connecting rod side
clearance (Fig. 17). Refer to (Fig. 18) for specification.
CRANKSHAFT AND CYLINDER BLOCK,
ASSEMBLY SERVICE

10 N-m
(104 IN. LBS.)

OIL PUMP
ASSEMBLY

25

*L = LENGTH IN mm
MAIN BEARING
*TORQUE = 15 N.m
MONOBLO CK CAP
(104 IN. LBS.)

83 N-m
(61.5 FT. LBS.)
RR09B53

Fig. 1 Crankshaft and Cylinder Block

CRANKSHAFT SERVICE
L = LENGTH IN mm (INCH)
The crankshaft is supported in four main bearings.
TORQUE— ALL— 15 N-m L = 55
All upper bearing shells in the crankcase have oil (130 IN. LBS.) (2 1/8 IN.)
grooves. All lower bearing shells in stalled in the
monoblock main bearing cap are plain. Crankshaft
end play is controlled by thrust washers on the num­
ber three main bearing journal.

CRANKSHAFT— REMOVAL
(1) Remove front mounted oil pump assembly and
gasket (Figs. 1 and 2).
 rN
RR09B57

Fig. 3 Rear Seal Assembly Fig. S Measure Main Bearing I.D.

(2) Remove rear oil seal retainer and seal as assem­ CRANKSHAFT END-PLAY
bly (Fig. 3). NEW PART: .05 TO 0.25 mm (.002 TO .0010 in.)
(3) Release monoblock main bearing cap bolts evenly. WEAR LIMIT: 0.30 mm (.012 in.)
Remove lower bearing shells and identify for reassembly. MAIN BEARING OIL CLEARANCE
(4) Lift out crankshaft and remove upper thrust NEW PART: .020 TO .048 mm (.0008 TO .0018 in.)
washers from each side of number three main bearing WEAR LIMIT: ,10 mm (.0039 in.)
in the crankcase. (Fig. 1). CRANKSHAFT JOURNAL SIZES
CRANKSHAFT MAIN BEARING JOURNAL
INSPECTION ALL DIAMETER
Visually check the main and connecting rod bearing STANDARD 59.980 mm
journals for wear, scuffs or scoring and replace if (2.361 in.)
necessary. CRANKSHAFT CONNECTING ROD JOURNAL
ALL DIAMETER
STANDARD 50.00 mm
CRANKSHAFT OIL CLEARANCE (1.968 in.)
MECHANICAL MEASUREMENT 9109-39
(1) Measure the journal outside diameter and the
Fig. 6 Crankshaft Clearance Specification
main bearing inside diameter (Figs. 4 and 5). If the
clearance exceeds the specifications limit (Fig. 6). Re­ PLASTIGAUGE MEASUREMENT
place the main bearing(s) and if necessary replace the (1) Remove oil from journal and bearing shell.
crankshaft. (2) Install crankshaft
(3) Cut plastigauge to same length as width of the
bearing and place it in parallel with the journal axis.
(Fig. 7).
(4) Install the main bearing cap carefully and tighten
the bolts to specified torque.
CAUTION: Do not rotate crankshaft or the plastigauge
will be smeared.
 CRANKSHAFT BEAMNGS
INSTALLATION .
(1) I n s ta ll u p p e r m a in bearing sh e lls m a k in g c e r­
ta in oil ho les are in a lig n m e n t, and b e a rin g ta b s seat
in block tabs. All upper bearings have oil grooves
(Fig. 9).
THRUST BEARINGS. C ra n k s h a ft th r u s t b e a rin g s
are installed at journal #3 separately from the radial
bearings. Identify type A and type B as shown in (Fig.
9). Type A have end positioning tabs, while Type B
are plain. One p a ir each of A and B thrust washers
are installed in the block and one pair in the main
b e a rin g cap (Fig. 9).

Fig. 7 MmBum Oil C lm n n m with Plmtlgmge

(5) C a re fu lly rem me t i e b e a rin g cap a n d m e a su re

'th e width o f th e plastigauge a t th e w id e st p a r t u s in g
th e scale on th e p la s tig a u g e p ack ag e. (Fig." 8) Refer to
sp ecificatio n (Fig. 6) for proper cle a ra n c e s. Also see
M e a su rin g M a in mud C o n n e c tin g Rod Bearing Clear­
ance in S ta n d a rd Service P ro ced u res.

THiyST
BEARING ,#iw
(WITHOUT TAB)
Fig. 9 Install Main Bearings
(2) Apply a thin film of grease to plain side of thrust
washers and position them on each side of number
three main bearing. Grooved surface towards crankshaft.
(3) Oil the bearings and journals and install crankshaft.
(4) Install lower main bearing shells without oil
grooves in monoblock cap.
(5) Install one pair of A and B thrust washers in
PLAIN
MONO SHOCK
MAIN BEARING
CAP
& RR09B102
cap. Refer to Thrust Bearings (Fig. 9).
(6) Carefully install bearing cap with arrows (Fig.
10) toward timing belt end.
(7) Oil the bearing cap bolt threads, install and
tighten bolts progressively in sequence shown in (Fig.
9) to 80 N-m (60 ft. lbs.) torque.
CHECKING CRANKSHAFT END PLAY CRANKSHAFT OIL SEALS SERVICE
(1) Mount a dial indicator to front of engine, locat- rear CRANKSHAFT SEAL RETAINER
m g p ro be on no se of c ra n k s h a ft (Fig. 11). ■ (l) I n s ta ll r e a r c ra n k s h a ft oil seal' in "housing w ith
(2) Move crankshaft all the way to the rear of its Special Tool MD998718 (Fig. 12).
travel.
(3) Zero the dial indicator.
(4) Move crankshaft all the way to the front and
read the dial indicator. Refer to (Fig. 6) for specification.

9009-53
 (1) Apply form-in-place (Mopar Silicone Rubber Ad­
hesive Sealant or equivalent) gasket material to oil
seal housing (Fig. 13) per procedure detailed in form-
in-place gasket section in Standard Service Procedures.
(2) Apply light coating of engine oil to the entire
circumference of oil seal lip.
(3) Install seal assembly on cylinder block and tighten
bolts to 12 N-m (104 in. lbs.)

Fig. 15 Crankshaft Front Oil Seal

CYLINDER BLOCK
Inspect cylinder block for scratches, cracks and rust
FRONT CRANKSHAFT OIL PUMP AND OIL SEAL
or corrosion, and repair or replace as required.
(1) Install oil pump gasket and oil pump case (Figs.
(1) Clean cylinder block and check top surface for
1 and 13).
distortion with a straight edge and thickness gauge
CAUTION: Install bolts, depending on length in loca­ (Fig. 16).
tions shown in (Fig. 13). (2) Top surface must be flat within:
• Standard Valve: 0.05 mm (.002 inch)
(1) Using front crankshaft oil seal installer Special
Tool MB998306 install oil seal in oil pump (Fig. 15). • Service Limit 0.1 mm (.003 inch)
CAUTION: Maximum of 0.2mm (.008 inch) is permit­
L = LENGTH IN mm (INCH) ted. This is a combined total dimension of stock
TORQUE— ALL— 15 N-m L = 55 removal from cylinder head (if any) and block top
(130 IN. LBS.) (2 1/8 IN.) surface.
 (1) Examine cylinder walls for scuffs, scoring and
measure cylinder bore for out-of-round or taper. If
defective, bore cylinder to oversize. Measure at points
shown in (Fig. 17).

BORING CYLINDER
Four oversize pistons are available (0.25mm (.010
inch) 0.50mm (.020 inch) 0.75mm (.030 inch) and 1.0mm
(.039 inch). Determine oversize piston on basis of larg­
est cylinder bore.

RR09B67

Fig. 18 Measure Piston

(1) Bore to specified clearance between the piston

O.D. and cylinder. The measuring point of the piston
O.D. is shown in (Fig. 18).
(2) Based on measured piston O.D., calculate boring
finish dimension. Boring finish dimension equals pis­
ton O.D. plus 0.03 to 0.05 mm (.0012 to .002 inch)
(clearance between piston O.D. and cylinder) minus
0.02 mm which is the boring margin.
(3) Bore all cylinders to calculated boring finish
dimension. Then bore the final finish dimension (pis­
ton O.D. plus cylinder clearance).
(4) Check clearance between piston and cylinder,
clearance should be 0.03 to 0.05 mm (.0012 to .002
inch).
 CAMSHAFT
CYLINDER WALLS JOURNALS
SPLASH LUBRICATED
FROM DIRECTED HOLES
IN CONNECTING iODS

FILTER

MAIN
GALLERY

NO. 2 CAMSHAFT
CAP (FRONT AND REAR)
RECEIVES O il FROM
CYLINDER MEAD TO
SUPPLY ROCKERS, LASH PUMP
ADJUSTERS, CAMSHAFT
JOURNALS PICKUP

1109168
Fig. I Engine Oiling

ENGINE LUBRICATION SYSTEM OIL

PICKUP
T h e lu b ric a tio n sy ste m is a fu ll flow filtra tio n p re s­
su re feed ty p e. Oil, sto re d in th e oil p a n , is ta k e n in
a n d d isc h a rg e d by a in te r n a l g e a r ty p e o i l ' p u m p d i­
re c tly coupled to th e c ra n k s h a ft a n d its p re ss u re is
re g u la te d by a re lie f valve. T h e oil is fed th ro u g h a n
oil filte r a n d to th e c ra n k s h a ft jo u rn a ls from th e oil
g a lle ry in th e c y lin d e r block. T h is gallery also feeds
oil u n d e r p re s su re to th e c y lin d e r h e a d s. I t th e n flows 22 N-m
from a c a m sh a ft b e a rin g cap one e ach c y lin d e r h e a d (191 IN. LBS.)
th ro u g h p a ssa g e s in t|ie ro c k e r sh a fts a n d is fed to th e
ro c k e r a rm p iv o ts, a u to la s h a d ju ste rs , a n d c a m sh a ft
jo u rn a ls (Fig. 1). r
O I L DRAIN PLUG SENSOR OR
40 N-m (30 FT. LBS.) PLUG RR09B104

Fig. 2 Oil Pan

OIL PAN
The oil pan is made of sheet metal and is provided
with a baffle-plate to prevent fluctuations in the oil
level while the vehicle is running.
 CRANKSHAFT OUTER ROTOR

Fig. 3 Oil Pan Sealing

OIL PAN SEALING AND INSTALLATION

Oil pan to crankcase sealing is provided with Mopar
Silicone Rubber Adhesive Sealant or equivalent gas­
ket material. See Form-In-Place Gaskets in Standard
Service Procedures. Fig. 5 Oil Pump-Installed
(1) Apply sealant as shown in (Fig. 3).
(2) Install pan and tighten screws to 6 N-m (50 in. REMOVAL
lbs.) in sequence shown in (Fig. 4). Remove 5 bolts that attach oil pump to block (Fig.
6 ).

L = LENGTH IN mm (INCH)
TORQUE— ALL— 15 N-m L = 55

Fig. 4 Oil Pan Screw Tightening Sequence

OIL PUMP SERVICE

The oil pump assembly is mounted on the timing
belt end of the cylinder block with the inner pump
rotor indexed and installed on the crankshaft nose.
(Fig. 5).
The oil pump case also retains the crankshaft front
oil seal and provides oil pan front end closure.
Check oil pressure using gauge at oil pressure switch
location. Refer to Specifications.
 0.10 TO 0.18 mm
004 TO 0.007 INCH)

PUMP
COVER
OIL PUMP
CASE

SCREW
9 N-m
RR09B108
INNER (104 IN. LBS.)
ROTOR 'OUTER Fig. 9 Checking Clearance-Between Outer Rotor
tO IO R
and Case
q ^RELIEF PLUNGER
SEAL
|*-S P R IN G 0.04 TO 0.09 mm
‘ PLUG— 49 N-m (36 FT. LBS.) (0.0015 TO 0.0035 INCH)
RR09B106
Fig. 7 Oil Pump Components
INSPECTION OIL P U iP
(1) C heck oil p u m p case for d a m a g e a n d rem ove
r e a r cover.
(2) R em ove p u m p ro to rs a n d in sp e c t case for exces­
siv e w ear.
(3) M e a su re c le a ra n c e b e tw e e n case a n d in n e r ro to r
(Fig. 8).

INNER
ROTOR
RR09B109

Fig. 10 Checking Rotor End Clearance

OIL RELIEF PLUNGER

(1) Check that the oil relief plunger slides smoothly.
(2) Check for broken relief spring.

INSTALLATION
(1) Clean block and pump surfaces.
(2) Install new gasket (Fig. 7) make sure correct
SUBTRACT MEASUREMENT "A" FROM MEASUREMENT "B", length bolts are used (Fig. 6).
If OVER 0.006 IN., REPLACE OIL PUMP ASSEMBLY. (3) Torque bolts to 13 N-m (120 in.lbs.).
RR09B107

Fig. i Inner Rotor to Case

(1) I n s e r t th e ro to r in to th e oil p u m p case (Figs. 9

a n d 10) a n d m e a su re c le a ra n c e w ith a feeler g a u g e as
in d icated .
(2) R eplace if o u t of lim its.
 OIL FILTER AND BRACKET
BRACKET
INSPECTION
(1) Check the oil filter mounting surface. The sur­
face must be smooth, flat and free of debris or old
pieces of rubber (Fig. 11).
(2) Check bracket for cracks and oil leaks.

OIL FILTER
(1) Turn counter clockwise to remove.
(2) To install, lubricate new filter gasket. Screw
filter on until gasket contacts base. Tighten 1 turn.

Fig. 11 Oil Filter and Bracket

 ENGINE SPECIFICATIONS
S tan d ard
Type. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60° V SOHC (Per Bank)
Number of Cylinders . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6

Stroke . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Compression Ratio . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8.85:1
Displacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.0 Liters (181 Cubic inches)
Firing Order . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ................ 1-2-3-4-5-6
Basic Ignition Timing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Refer to Emission Control Information on Label in Vehicle
Valve timing
Intake —Open . . . . . . . . . . . . . . . . . . . . . . . . ................ 19° I T DC
—Close . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 59° ABDC
Exhaust —Open . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5 9° BBDC
—Close . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19° ATDC

D escrip tio n
S ta n d a rd Service
D im en sio n li m it
Compression Pressure. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 178 psi @ 250 RPM _
Maximum Variation Between Cylinders . . . . . . . . . . . . . . . . . 1.0 K q k m 2 (14 PSI) 25%
Valve Clearance—Hot Engine . . . . . . . . . . . . . . . .
Adjusters
C y lin d e r H # a d
Flatness of Gasket Surface . . . . . . . . . . . . . . . . . . —
Grinding Limit of Gasket Syrface. . . . . . . . . . . . . . . . . . . . . . — 0.2 mm (0.008 inch)
M anifold—Flatness of Installing Syrface
Intake . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0.2 mm (0.0008 inch)
Exhaust . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0.3 mm (0.001 inch)
Volves
Thickness of Valve Head (Margin)
in ta k e ........... ........................................................ 0.7 mm (0.027 inch)
Exhaust . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.5 mm (0.059 inch)
Valve Stem to Guide Clearance
Intake . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0.03 to 0.06 mm 0.10
(0.001 to 0.002 inch) (0.004 inch)
Exhaust . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0.15 mm
(0.0019 to 0.003 inch) (0.006 inch) •
Valve Face Angle . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 45° to 45° 30# —
Valve Overall Length
Intake . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . _
(4.055 inches)
Exhaust . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 102.7 mm —
(4.043 inches)
Valve Stem Diameter
Intake .................................................................... . . . . . . . . 7.960 to 7.975 mm —
(0.313 to 0.314 inch)
Exhaust . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7.930 to 7.950 mm : —
(0.312 to 0.3125 inch)
Vlalve G u id e
Overall Length
Intake . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 44 mm —
(1.732 inches)
Exhaust . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 48 mm —■“
(1.889 inches)
O.D. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . —
(0.514 to 0.5143 inch)
IP . ................................. —
(0.314 to 0.315 inch)
Yoiw© S # a t
Seat Syrface Angle . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 44° to 4 4 0.3' —
Contact Width 0.9 to 1.3 mm — •
(0.035 to 0.051 inch)
Sinkage . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . — 0. 2 mm
(0.078 inch)
Yoiw© S p rin g
Free Height . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 48.8
(1.960 inches)
Loaded Hei ght. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40.4 mm at 33 kg
(1.59 inch at 73 lbs.)
Perpendicularity
Intake and Exhaust . . . . . . . . . . . . . . . . . . . . . . 4 ° Maximum
 Stondord Serv
Description Dimension Limit
Piston
O.D. . . . . . . . . . . . . . . . . . 91.06 to 91.09mm
(3.585 to 3.586 inches)
Piston to Cylinder Clearance 0.03 to 0.05mm
(0.0012 to 0.002 inch)
Ring End Gap ■
No. 1 . . . . . . . . . . . . . 0.30 to 0.45mm 0.8mm
(0.012 to 0.018 inch) (0.03 inch)
No. 2 . . . . . . . . . . . . . 0.25 to 0.40mm 0.8mm
(0.010 to 0.016 inch) (0.03 inch)
Oil . . . . . . . . . . . . . . . 0.30 to 0.90mm 1.0mm
■ (0.012 to 0.035 inch) (0.039 inch)
Ri ng Side Clearance
No. 1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0.05 to 0.09mm 0.1mm
(0.002 to 0.0035 inch) (0.0039 i nch)
No. 2 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0.02 to 0.06mm 0.1mm
(0.0008 to 0.002 inch) (0.0039 inch)
Oversi ze Service Pistons . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0.25 to 0.50mm
(0.010 to 0.020 i nch)
0.75 to 1.00mm
(0.030 to 0.039 inch)
Connecting Rod
Length — Center to Center . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 140.9 to 141.0mm
(5.547 to 5.551 inches)
Parallelism —Twist . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0.05mm
. ‘■ (0.0019 inch)
Torsion. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0.1mm
(0.0039 inch)
Big End Thrust Clearance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0.10 to 0.25mm 0.4mm
(0.004 to 0.010 inch) (0.016 inch)
Crowkshoft
End Play . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0.05 to 0.25mm 0.3mm
(0.002 to 0.010 inch) (0.012 i nch)
Main Journal Diameter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 59.980 to 60.000mm
(2.361 to 2.362 inches)
Pin Diameter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 49.980 to 50.000mm
(1.968 to 1.969 inches)
Bearing Surface Out-of-Round . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0.03mm Max.
(0.001 inch) Max.
Bearing Surface Taper . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0.005mm Max.
(0.0002 inch) Max.
Bearing Oil Clearance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . (0.015 to 0.050 mm)
(0.0006 to 0.002 inch)
Undersize Service Bearings. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0.25 to 0.50 —0.75mm
^ B , (0.010 to 0 .0 2 0 ^ 0 .0 3 0 inch)
Cylinder Blm k
I.D. (lore) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 91.10 to 91.13mm
(3.586 to 3.587 inches)
Flatness of Top Surface . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0.05mm 0.1mm
(0.002 inch) (0.0039 inch)
Grinding Limit of Top Surface 0.2mm 0.2mm
......................................................... (0.008 i nch) (0.008 i nch)
* Includes/Combined With Cylinder Head Grinding
Oil Pump
Relief Valve Opening Pressure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5.0 to 6.0 kg/cm2
" . (71.45 to 85.75 psi)
Outer Rotor to Case Clearance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0.10 to 0.18mm ■ 0.18mm
(0.004 to 0.007 inch) (0.007 inch)
Rotor End Clearance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0.04 to 0.09mm 0.09mm
(0.0015 to 0.0035 inch) (0.0035 inch)
Inner Rotor Pilot to Case Clearance . . . . . . . . . . . . . . . . . . . . . . . . . . . 0.03 to 0.07mm 0.15mm
(0.001 to 0.0028 inch) (0.006 inch)
9109-41
 ENGINE TORQUE SPECIFICATIONS

Description N-m Ft. Lbs. In. Lbs.

Engine Support Bracket.................. 45 35

Crankshaft Pully A (Crankshaft Bolt) 151 112
Crankshaft Pully B ........................... 25 250
Crankshaft Bearing C a p .................. 80 60
Connecting Rod C a p ....................... 52 38
Camshaft Sprocket........................... 95 70
Timing Belt Tensioner....................... 25 250
Alternator Bracket........................... 25 250
Rocker Cover.................................... 10 88
Distributor A daptor......................... 13 120
Camshaft Bearing C a p .................... 20 180
Cylinder Head Bolt (C o ld ).............. 108 80
Oil Pan............................................. 6 50
Oil Drain Plug.................................. 40 30
Oil Pickup......................................... 22 191
Oil Pump Assembly......................... 15 130
Oil Seal Rear Housing.................... 11 95
9109-133
 3.31- V-6 ENGINE
INDEX
Page Page
Camshaft ................................................................ 102 Hydraulic Tappets ................................................. 98
Camshaft Bearings ................................................ 103 Installing Piston and Connecting
Connecting R ods.................................................... 109 Rod Assembly .................................................... 108
Crankshaft Oil Seals S ervice.................................. 112 Intake Manifold Sealing......................................... 94
Crankshaft Service ................................................. 110 Oil F ilte r.................................................................. 116
Cylinder B lo c k ........................................................ 105 Oil Pan Service ...................................................... 113
Cylinder Heads ...................................................... 92 Oil Pump Service ................................................... 114
Engine Core Oil and Cam Plugs ............................ 103 Rocker Arms and Shaft Assembly ........................ 92
Engine Mount Rubber Insulators .......................... 91 Service Procedures................................................. 90
Engine Lubrication System ................................... 113 Timing Chain Cover, Oil Seal and C h a in ............... 99
Engine Specifications ........................................... 117 Valve Service .......................................................... 94
General Information ............................................... 88 Valve Timing ......... ................................................ 99

GENERAL INFORMATION
3.3L ENGINE SPECIFICATIONS

T yp e ................................................................ . . . . . . . . . . . . . . . . . . . . . . . 6 0 ° ¥-6 Engine

Bore . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .93.0 mm (3.66 Inch)
. . . . . . . . . . . . . . . . . . . . . . . .81.0 mm (3.19 Inch)
Compression Ratio . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8.9:1
Displacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 . 3 Liters (201 Cubic Inch)
Brake Horsepower . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 147 @ 4800 RPM
. . . . . . . . . . . . . . . . . . . . . . . . 185 Lb. Ft. @ 3600 RPM
. . . . . . . . . . . . . . . . . . . . . . . . 1-2-3-4-S-6

(Direct Crankshaft Driven Pump)

Filter, 3.8 Lifer (4.0 Qts.)

Without Oil Filter

9109-124

Pig. 1 3.31 f - 6 Engine
ENGINE; T h e 3.3L (201 C ubic. Inch es.) d isp la c e ­
m e n t e n g in e s a re 80° ¥ ty p e six c y lin d e r pow er p la n t
w ith c a st iro n c y lin d e r block a n d a lu m in u m c y lin d e r
h ead s. F irin g o rd e r for th e s e e n g in e s is 1-2-3-4-5-6.
H ig h tu rb u le n c e c y lin d e r h e a d s allo w a 8.9-1 co m p res­
sion ra tio .
CRANKSHAFT; T h e n o d u la r iro n c ra n k s h a ft is su p ­
p o rted by fo u r m a in b e a rin g s, w ith n u m b e r tw o b e in g
th e th r u s t b e a rin g . C ra n k s h a ft e n d se a lin g is p ro ­
vid ed by fro n t a n d r e a r ru b b e r seal.
PISTO N S; T h e p isto n s a re c a st aluminum alloy.
T h re e rin g s a re used. P isto n p in s, p re ss fitte d in to
place, jo in th e p isto n s to forged s te e l c o n n ectin g rods.
CAM SHAFTS; T h e c a st iro n c a m sh a ft is m o u n te d in
four ste e l b a c k e d b a b b itt b e a rin g s. A t h r u s t p la te lo­
ca te d in fro n t of th e firs t b e a rin g , a n d b o lted to th e
block, c o n tro ls en d play . S ile n t tim in g c h a in d riv e s
th e c a m sh a ft. T h is c h a in is enclosed by a c a s t alumi­
num cover w h ich also c a rrie s a fro n t c ra n k s h a ft se a l,
prov id es fro n t oil p a n clo sure, w a te r p u m p m o u n tin g .
CYLINDER HEADS; C ylin der h e a d s incorporate valve
sh ro u d in g to c re a te tu rb u le n c e -p ro d u c in g co m b u stio n
c h a m b e rs, d escrib ed a s fa s t b u m , S in te re d v a lv e s e a t
in s e rts a re u sed. A ste e l fla n g e d com position ty p e
9009-1
g a s k e t is u se d b e tw e e n h e a d a n d block,
VALVE C O V ERS; T h e covers a re se a le d w ith ste e l
rein fo rced silico n ru b b e r g a sk e ts.
INTAKE MANIFOLD; T h e in ta k e m a n ifo ld is a tu n e d
tw o-piece se m i-p e rm a n e n t m old aluminum c a stin g w ith
in d iv id u a l p rim a ry r u n n e r s le a d in g fro m a p le n u m to
th e cy lin d ers. T h e m an ifo ld is d e sig n e d to bo o st to rq u e
in th e 8600 rp m r a n g e a n d c o n trib u te s to th e e n g in e ’s
b ro ad , fla t to rq u e curve, w h ich w a s d e sire d for ex cel­
le n t e n g in e tractability, re sp o n se and usable power
output.
T he in ta k e m an ifo ld is also cored w ith u p p e r level
E G R p a ssa g e s for b a la n c e d c y lin d e r to c y lin d e r E G R
d is trib u tio n .
VALVE TRAIN; V alv e t r a in d e sig n in c o rp o ra te s th e
use of hydraulic roller tappets. Rocker arms are in­
stalled on a rocker arm shaft attached to the cylinder
h e a d w ith fo u r b o lts a n d re ta in e rs . Y ito n v alv e ste m
seals provide valve sealing. Unique beehive style valve
spring are used with lightweight retainers for im­
proved high RPM performance.
EXHAUST MANIFOLDS; E x h a u s t m a n ifo ld s a re log
ty p e w ith a cro sso ver a n d is a tta c h e d d ire c tly to th e
cylinder heads.
SEiflCE PROCEDURES
ENGINE REMOVAL
(1) D isco n nect b a tte ry .
(2) M a rk hood p o sitio n a t h in g e s a n d remove hood.
(3) Drain cooling system. Refer to Cooling System,
G roup 7 for p ro ced u re.
(4) D isco nn ect a ll e le c tric a l connections,
(5) Remove co o lan t h oses from ra d ia to r a n d eng ine.
(6) R em ove r a d ia to r a n d fa n assem bly .
(7) See F u e l S y stem , G roup 14, to re le a s e fuel p re s ­
su re . Disconnect fuel lines and accelerator cable.
(8) Remove air cleaner assembly.
(9) Hoist vehicle and drain engine oil.
(10) Remove air conditioning compressor mounting
b o lts a n d s e t co m pressor aside.
(11) Disconnect exhaust pipe at manifold.
(12) Remove transmission inspection cover and mark
flex plate to torque converter position. For disassem­
bly p ro ced u re for th e a ll w heel d riv e v eh icle re fe r to
Group 21 Transaxle.
(13) Remove screws holding torque converter to flex
plate and attach C-clamp on bottom of converter hous­
ing to p r ev e n t torq u e co n v erter from c o u n tin g out.
(14) Remove power steering pump mounting bolts
and set pump aside.
(15) Remove two lower transmission to block screws.
(16) Remove starter.
(17) Lower vehicles and disconnect vacuum lines
and ground strap.
(18) Install transmission holding fixture.
(19) Attach engine lifting hoist and support engine.
(20) Remove upper transmission case to block bolts.
(21) See Engine Mounting in (Fig. 1) and separate
mount/insulators as follows:
(a) M a rk R IG H T in s u la to r on r ig h t r a ils su p p o rts.
Remove insulator to rails screws.
(b) Remove FRONT engine mount through bolt
and nut.
(c) R em ove L E F T in s u la to r th ro u g h b o lt from in ­
side wheelhouse or insulator bracket to transmission
screws.
(22) R em ove e n g in e.
INSTALLATION
(1) A tta c h h o is t a n d lo w e r e n g in e in to e n g in e
compartment.
(2) A lig n e n g in e m o u n ts a n d in s ta ll b u t d o n o t
tighten until all mounting bolts have been installed.
Tighten bolts to torque specified in (Fig. 1).
(3) Install transmission case to cylinder block, tighten
b o lts to 1 0 2 N*m (75 ft. lbs.)torque.
(4) Remove engine hoist and transmission holding
fixture.
(5) R em ove C -clam p-from to rq u e c o n v e rte r h o u sin g .
Align flex plate to torque converter and install mount­
ing screws. Tighten to 75 N*m (55 ft. lbs.)torque. Refer
to G roup 21 tr a n s a x le for th e a ll w h eel d riv e in s ta lla ­
tio n proced ure.
(6 ) I n s ta ll tra n s m is s io n in sp e c tio n cover.
(7) C on n ect e x h a u s t sy ste m a t m an ifo ld .
(8) Install starter.
(9) I n s ta ll po w er s te e rin g p u m p a n d a ir co n d itio n ­
in g com pressor. F o r b e lt in s ta lla tio n see Accessory
Belt Drive in Cooling System Group 7.
(10) L ow er v eh icle a n d co n n ect a ll v a c u u m lin e s.
(11) Connect all electrical connections including
g ro u n d stra p .
(12) Connect fuel lines and accelerator cable.
(13) In s ta ll r a d ia to r a n d fa n assem b ly . R eco nn ect
fa n m o to r e le c tric a l lead . R e in s ta ll r a d ia to r h oses. F ill
cooling system. See Cooling System Group 7 for filling
procedure.
(14) F ill e n g in e c ra n k c a s e w ith p ro p e r oil to c o rre c t
level.
(15) In s ta ll hood.
(16) Connect battery.
(17) S ta r t e n g in e a n d r u n u n til o p e ra tin g te m p e ra ­
tu r e is reach ed .
(18) A d ju st tra n s m is s io n o r lin k a g e i f necessary.
 RIGHT ENGINE MOUNT TORQUE
ASSEMBLY A 68 N*m (50 FT. LBS.)
TIGHTEN YOKE NUT FIRST
B 136 N-m (100 FT. LBS.)
TIGHTEN YOKE SCREW
C 102 N-m (75 FT. LBS.)
SECOND
D 23 N-m (200 IN. LBS.)
E m (40 F I LBS.)

RIGHT ENGINE
SUPPOiT
W = 12 MM
ASSEMBLY
X = 7M M
w -*h -♦•X

RIGHT
FRONT im L
INSULATOi
! CROSSMEMBER

VIEW IN DIRECTION
O f ARROW Y

RJGHI
RAIL

■ FRONT
INSULATOR
ASSEMBLY 9109-53

Flff. I Engine Mounting

ENGINE MOUNT RUBBER INSULATORS (3) P ry th e e n g in e r ig h t or le ft a s re q u ire d to ach iev e

In s u la to r lo catio n on fra m e r a il (rig h t side) a n d
tra n s m is s io n b ra c k e t (left side) a re a d ju sta b le to allow
rig h t/le ft drive tr a in a d ju s tm e n t in re la tio n to d riv e
s h a ft asse m b ly le n g th .
C h eck a n d re p o sitio n r ig h t e n g in e m o u n t in s u la to r
(left e n g in e m o u n t in s u la to r c e n te rs its e lf w ith en g in e
w e ig h t rem oved). A d ju st d riv e t r a i n positio n, if r e ­
q u ire d , for th e follow ing conditions:
• D riv e sh a ft d istre ss: See D riv e sh a ft in S u sp en sio n ,
G roup 2.
• A ny fro n t e n d s tr u c tu r a l d a m a g e (a fte r re p a ir).
• In s u la to r re p la c e m e n t.
th e p ro p e r d riv e s h a ft asse m b ly le n g th . See D riv e sh a ft
in S u sp en sio n G ro up 2 for d riv e s h a ft id e n tific a tio n
a n d re la te d a ssem b ly le n g th m e a su rin g .
(4) T ig h te n r ig h t e n g in e m o u n t in s u la to r v e rtic a l
b o lts to 81 N-m (60 ft. lbs.) to rq u e , tig h te n fro n t e n g in e
m o u n t fa s te n e rs to 54 N-m (40 ft. lbs.) to rq u e , a n d
c e n te r left e n g in e m o u n t in su la to r.
(5) R echeck d riv e s h a ft le n g th .
SHAFT MASS

em m c m o u n t in s u l a t o h a d j u s t m e n t
(1) R em ove th e lo ad on th e e n g in e m o to r m o u n ts by
c a re fu lly s u p p o rtin g th e e n g in e a n d tra n s m is s io n a s­
sem bly w ith a floor ja c k .
(2) L oosen th e r ig h t e n g in e m o u n t in s u la to r v e rtic a l
fa s te n e rs, a n d th e fro n t e n g in e m o u n t b ra c k e t to fro n t
cro ssm em b er fa ste n e rs.
Left engine mount Insulator Is sleeved owershaft
and long support bolt to provide lateral- movement
{14 TO 17 mm)
adjustment with engine weight remowed or not (Fig.
2). . ■
ROCKER ARMS AID SHAFT ASSEMBLY CYLINDER HEADS
REM OVAL The alloy aluminum cylinder heads shown in (Fig.
(1) R em ove u p p e r in ta k e m an ifo ld assem bly . R efer 4) are held in place by 9 bolts. The spark plugs are
to In ta k e a n d E x h a u s t M anifolds, G ro up 11. located in peak of the wedge between the valves.
(2) D iscon n ect s p a rk p lu g w ires by p u llin g on th e
boot s tr a ig h t o u t in lin e w ith plug.
(3) D iscon nect closed v e n tila tio n sy ste m a n d evapo­ INTAKE VALVE EXHAUST VALVE SPARK PLUG
ration co n tro l sy ste m from cy lin d e r h e a d cover.
(4) R em ove c y lin d e r h e a d cover a n d g a sk e t.
(5) R em ove fo u r ro c k e r s h a ft b o lts a n d re ta in e rs .
(6) R em ove ro c k e r a rm s a n d s h a ft assem b ly .
(7) If ro c k e r a rm asse m b lie s a re d isa sse m b le d for
c le a n in g o r re p la c e m e n t. A ssem b le ro c k e r a rm s in
th e re o rig in a l p o sitio n re fe r to (Fig. 3) for ro c k e r a rm
for p o sitio n in g on th e sh a ft.

9009-12
Fig. 4 Cylinder Head Assembly

REMOVAL
(1) Drain cooling system refer to Cooling System
Group 7 for procedure and disconnect negative battery
cable.
Remove intake manifold, and throttle body. Refer to
Group 11 Exhaust System and Intake Manifold.
(2) Disconnect coil wires, sending unit wire, heater
hoses and by-pass hose.
(3) Remove closed ventilation system, evaporation
Fig. 3 Rocker Arm Location Left Blank control system and cylinder head covers.
(4) Remove exhaust manifolds.
INSTALLATION (5) Remove rocker arm and shaft assemblies. Re­
(1) I n s ta ll ro c k e r a rm a n d s h a ft asse m b lie s w ith th e move push rods and identify to insure installation in
sta m p e d ste e l r e ta in e r s in th e fou r p o sitio n s, tig h te n original locations.
to 28 N-m (250 in . lbs.) (Fig. 3). (6) Remove the 9 head bolts from each cylinder head
and remove cylinder heads.(Fig. 5).
WARNING: THE ROCKER ARM SHAFT SHOULD BE
IORQUED DOWN SLOWLY, STARTING WITH THE
CENTERMOSI BOLTS. ALLOW 20 MINUTES TAP­
PET BLEED DOWN TH E AFTER INSTALLATION OF
THE ROCKER SHAFTS BEFORE ENGINE OPERATION.
(2) C le a n c y lin d e r h e a d cover g a s k e t surface. In ­
sp ect cover for d isto rtio n a n d s tr a ig h te n if necessary.
(3) C le a n h e a d r a il if n ecessary . I n s ta ll a new g a s­
k e t a n d tig h te n c y lin d e r h e a d cover fa s te n e rs to 12
N*m (105 in. lbs.).
(4) I n s ta ll closed c ra n k c a se v e n tila tio n sy ste m a n d
evaporation control sy stem .
(5) I n s ta ll s p a rk p lu g w ires.
(8) I n s ta ll u p p e r in ta k e m an ifo ld assem b ly . R efer to
E x h a u s t S y ste m s a n d In ta k e M anifolds G rou p 11.
 (1) Before cleaning, check for leaks, damage and
cracks.
(2) Clean cylinder head and oil passages.
(3) Check cylinder head for flatness (Fig. 6).
(4) Inspect all surfaces with a straightedge if there
is any reason to suspect leakage. If out of flatness
exceeds .019mm (.00075 inch), times the span length
in inches in any direction, either replace head or lightly
machine the head surface. As an example, if a 12 inch
span is 1mm (.004 inch) out of flat, allowable is 12 x
.019mm (.00075 inch) equals .22mm (.009 in.) This
amount of out of flat is acceptable.
*Maximum of 0.2 mm (.008 inch) for grinding is
permitted.
CAUTION: This is a combined total dimension of
stock removal from cylinder head and block top
surface.
RR09B29
Fig. 6 Check Cylinder Head
INSTALLATIO N
(1) Clean all surfaces of cylinder block and cylinder
heads.
(2) Install new gaskets on cylinder block. (Fig. 7.)
GASKET LOCATION
' IDENTIFICATION MUST BE SEEN
lird / fc=*
The Cylinder head bolts are torqued using the
torque yield method they should be examined BE­
FORE reuse. If the threads are necked down the
bolts should be replaced (Fig. 8). Necking can be
checked by holding a scale or straight edge against
the threads. If all the threads do not contact the scale
the bolt should be replaced.
STRETCHED THREADS ARE NOT STRAIGHT ON LINE
BOLT
THREADS ARE STRAIGHT ON LINE
UNSTRETCHED BOLT 9009-38
Fig. 8 Checking Bolts for Stretching (Necking)
(3) Tighten the cylinder head bolts 1 thru 8 in the
sequence shown in (Fig. 9). Using the 4 step torque
turn method, tighten according to the following values:
• First-All to 61 N-m (45 ft. lbs.)
• Second-All to 88 N-m (65 ft. lbs.)
• Third-All (again) to 88 N-m (65 ft. lbs.)
• Fourth + 1/4 Turn Do not use a torque wrench for
this step
Bolt torque after 1/4 turn should be over 122 N-m(90
ft. lbs.). If not, replace the bolt.
8 II \ ' HI! 4 2 9009-10
° I t
Fig. 9 Cylinder Head Tightening Sequence
(5) Tighten head bolt number 9 (Fig. 9) to 33 N-m
(25 ft. lbs.) after head bolts 1 thru 8 have been tighten
to specifications.
(6) Inspect push rods and replace worn or bent rods.
(7) Install push rods, rocker arm and shaft assem­
blies with the stamped steel retainers in the four
positions, tighten to 28 N-m (250 in. lbs.) (Fig. 10).
 - (8) Place new cylinder head cover gaskets in posi­
tion and install cylinder head covers. Tighten to 12
N*m (105 in. lbs.).
STAMPED RETAINERS
manifold is in place, inspect to make sure seals are
In place. Refer to Group 11 Exhaust System and In­
take Manifold to complete Intake Manifold Assembly.
(5) Install exhaust manifolds and tighten bolts to 27
N-m (20 ft. lb.) and nuts to 20 N-m (15 ft. lbs ).
(6) Adjust spark plugs to specification in Electrical
Section, Group 8, and install the plugs.

9009-13

Pig. 10 Rocker Arm Shaft Retainers

INTAKE MANIFOLD SEALING

The intake manifold gasket is a one-piece stamped
steel gasket with a sealer applied from the manufac­
turer. This gasket has end seals incorporated with it.
WARNING INTAKE MANIFOLD GASKET IS MADE OF
VERY THIN METAL AND MAY CAUSE PERSONAL
INJURY, HANDLE WITH CARE.
(1) Clean all surfaces of cylinder block and cylinder
heads.
(2) Place a drop (approximately 1/4 in. diameter) of
Mopar Silicone Rubber Adhesive Sealant or equiva­
lent, onto each of the four manifold to cylinder head
gasket corners (Fig. 11).

Fig. 13 Intake Manifold Removal and Installation

(3) Carefully install the intake manifold gasket (Fig.
12). Torque end seal retainer screws to 12 N-m (105 in.
lbs.).
(4) Install intake manifold and (8) bolts and torque
to 1 N-m (10 in. lbs.). Then retorque bolts to 22 N-m
(200 in. lbs.) in sequence shown in (Fig. 13). Then
retorque again to 22 N-m (200 in. lbs.). After intake
VALVE SERVICE
VALVES AND VALVE SPRINGS
The valves are arranged in line in the cylinder
heads and inclined 18 degrees. The rocker shaft sup­
port and the valve guides are cast integral with the
heads.
REMOVAL
(1) With cylinder head removed, compress valve
springs using Valve Spring Compressor Tool C-3422-B
with adapter 6412 as shown in (Fig. 14).
(2) Remove valve retaining locks, valve spring re­
tainers, valve stem cup seals and valve springs.
 (3) Before removing valves,remove any burrs Iro n
vaive stem lock grooves to prevent damage to the
valve guides. Identify valves to insure installation in
original location.

EXHAUST
VALVE

WAIVE IN S P E C TIO N ' '

(1) Clean valves thoroughly and' discard burned,
warped and cracked valves.
(2) Measure valve stems for wear. Refer to specifica­
tions (Fig. 17). Valve stems are chromeplated and
should not be polished.
(3) Remove carbon and' varnish deposits from inside
of valve guides with a reliable guide cleaner.
(4) Measure valve, stem guide clearance as follows:
(a) Install valve into cylinder head so it is 14mm 9009-71.
(.551 inch) off the valve seat. A small piece of hose Fig. f § Intake tu rf Exhaust Walwes
may be used to hold valve in place.
(b) Attach dial indicator Tool 0-3339 to cylinder Valve Guide Intake Exhaust
head 'and set it at right angle of valve stem being Dial Indicator Valve Valve
measured (Fig. 15). Reading, Maximum 0.247 mm 0.414 mm
(c) Move valve to and from the indicator. Refer to (0.009 i n.) (0.016 In.)
specifications (Fig. 17). Vaive Guide Reamer
Ream the guides for valves with oversized stems if Oversize Valve Guide Size
dial indicator reading is excessive or if the stems are 0.15 mm (.005 in.) 8.125-8.150 mm (.3198-.3208 in.
scuffed or scored. 0.40 mm (.015 in.) 8.375-8.400 mm (.3297-.3307 in;
(5) Service valves with oversize stems and over size 0.80 mm (.090 i n.) S.775-8.800 mm (.34S4-.3464 in.
seals are available in 0.15mm (.005 inch), 0.40mm,
9
(.015 inch) and 0.80mm (.030 inch) oversize.
Oversize seals must be used w ith oversize valves. FIg. 17 Valve Guide Specification
Reamers to accommodate the oversize valve stem
are as follows: (6) Slowly turn reamer by hand and clean guide
thoroughly before installing new valve. Do not at­
tempt to ream the valve guides from standard di­
rectly to 0.80mm (.030 inch) Use step procedure of
0.15mm (.005 inch), 0.40mm (.015 inch) and 0.80mm
(.030 inch) so the valve guides may be reamed true
in relation to the valve seat. After reaming guides,
the seat runout should be measured and resurfaced
if necessary. See Refacing Valves and Valve Seats.
VALVE GUIDES
Replace cylinder head if guide does not clean up
with 0.80mm (.030 inch) oversize reamer, or if guide
is loose in cylinder head.
V o lv t Dimensions
In take V alve (m inimum)
Stem diameter: 7.935 m m (.3124 In.)
Face angle: 44 1/2®
Valve margin: .794 mm (.031 in.)
Head diameter: 45.5 mm (1.79 in.)
Length: 125.38 mm (4.936 in.)
Exhaust V alve (m inimum)
Stem d i am eter: 7.906 mm (.3112 in.)
Face angle: 44 1/2°
Valve m arg i n: 1.191 mm (.0469 in.)
Head diameter: 37.5 mm (1.476 in.)
Length: 126.00 mm (4.964 in.)
9109-47
Fig. 18 Valve Dimensions
REFACINQ VALVES AMD VALVE SEATS
The intake and exhaust valves have a 44-1/2 to 45
degree face angle. The valve seats have a 45 to 45-1/2
degree face angle. The valve face and valve seat an­
gles are shown in (Fig. 19).
VALVES
(1) Inspect the remaining margin after the valves
are refaced Refer to specifications (Fig. 18).
VALVE SEATS
CAUTION: Do not un-shroud valves during valve seat
refacing (Fig. 20).
(1) When refacing valve seats, it is important that intake seats should be 1.75 to 2.25mm (0.69 to .088
the correct size valve guide pilot be used for reseating inch) The width of the exhaust seats should be 1.50 to
stones. A true and complete surface must be obtained.
ZUi
A-SEAT WI DTH (INTAKE 1.75 TO 2.25mm (.069 TO .088 IN.)
EXHAUST: 1.50 TO 2.00mm (.059 TO .078 IN.)
B- FACE ANGLE (I NTAKE & EXHAUST: 44 1/2°)
C-SEAT ANGLE (INTAKE & EXHAUST: 45°-45 1/2°)
D-SEAT CONTACT AREA
9009-88
REFACING STONE
MUST NOT CUT
'INTO VALVE SHROUD
_ V
O
9009-17
Fig. 20 Refaclng Valve Seats
(2) Measure the concentricity of valve seat using a
dial indicator. Total runout should not exceed ,051mm
(.002 inch) total indicator reading.
(3) Inspect the valve seat with Prussian blue to
determine where the valve contacts the seat. To do
this, coat valve seat LIGHTLY with Prussian blue then
set valve in place. Rotate the valve with light pres­
sure. If the blue is transferred to the center of valve
face, contact is satisfactory. If the blue is transferred
to top edge of valve face,lower valve seat with a 15
degree stone. If the blue is transferred to the bottom
edge of valve face raise valve seat with a 65 degrees
stone.
Valve seats which are worn or burned can be re­
worked, provided that correct angle and seat width
are maintained. Otherwise cylinder head must be
replaced.
(4) When seat is properly positioned the width of
2.00mm (.059 to .078 inch) (Fig. 19).
(5) Check the valve spring installed height after
refacing the valve and seat: (Fig. 22).
TESTING VALVE SPRINGS
(1) Whenever valves have been removed for inspec­
tion, reconditioning or replacement, valve springs
should be tested (Fig. 21). As an example; the com­
pression length of the spring to be tested is 33.34mm
(1-5/16 inches). Turn table of Tool C-647 until surface
is in line with the 33.34mm (1-5/16 inch) mark on the
threaded stud and the zero mark on the front. Place
spring over stud on the table and lift compressing
lever to set tone device. Pull on torque wrench until
ping is heard. Take reading on torque wrench at this
instant. Multiply this reading by two. This will give
the spring load at test length. Fractional measure­
ments are indicated on the table for finer adjustments.
Refer to specifications to obtain specified height and
allowable tensions. Discard the springs th at do not
meet specifications.
RF259
Fig. 21 Testing Valve Spring with Tool C-647
SPRING RETAINER,
SPRING
SEAT
9109-69
Fig. 22 Checking Valve Installed Height
VALVE IN S TALLATIO N
(1) Coat valve stems with clean engine oil and in­
sert them in cylinder head.
(2) If valves or seats are reground, check installed
valve spring height (Fig. 22).
(3) Install new cup seals on all valve stems and over
valve guides (Fig. 22). Install valve springs and valve
retainers.
(4) Compress valve springs with Valve Spring Com­
pressor Tool C-3422-B, with adapter 6412 install locks
and release tool. If valves and/or seats are reground,
measure the installed height of springs, make sure
measurements is taken from top of spring seat to
the bottom surface of spring retainer. If height is
greater than 1-19/32 inches, (40.6mm), install a 1/32
inch (.794mm) spacer in head counterbore to bring
spring height back to normal 1-17/32 to 1-19/32 inch
(39.1 to 40.6mm).
RETAINER
BEE HIVE
STYLE SPRING
VALVE
VALVE SPRING
SEAT SPACER f f ? 109-54
Fig. 23 Installing Valve, Cup Seal,
Spring and Retainer
REPLACE VALVE STEM SEALS OR
VALVE SPRINGS, CYLINDER HEAD
NO T REMOVED
(1) Perform fuel system pressure release procedure
before attempting any repairs.
(2) Disconnect negative battery cable.
(3) Remove Air Cleaner Cover and hose assembly.
(4) Remove Intake Manifold; Refer to Intake/Exhaust
Manifold 3.3L Engine Group 11 Exhaust System and
Intake Manifolds of this manual for removal procedure.
(5) Remove cylinder head covers and spark plugs.
(6) Remove connector wire from ignition coils.
(7) Using suitable socket and flex handle at crank­
shaft pulley retaining screw, turn engine so the num­
ber 1 piston is at Top Dead Center on the compression
stroke.
(8) Remove rocker arms with rocker shaft and in­
stall a dummy shaft. The rocker arms should not be
disturbed and left on shaft.
(9) With air hose attached to spark plug adapter
installed in number 1 spark plug hole, apply 90 to 100
psi air pressure (620.5 to 689kPa). This is to hold
valves into place while servicing components.
(10) Using Tool C-4682 or Equivalent compress valve
spring and remove retainer valve locks and valve
spring.
(11) Install cup shields on the exhaust valve stem
and position down against valve guides.
(12) The intake valve stem seals 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, com­
press the spring only enough to install the locks.
CAUTION: Do not pinch seal between retainer and
top of valve guide.
(13) Follow the same procedure on the remaining 5
cylinders using the firing sequence 1-2-3-4-5-6. Make
sure piston In cylinder Is at TDC on the walw® spring
that is being covered.
(14) Remove spark plug adapter tool .
(15) Remove dummy shaft and install rocker shaft
assembly and tighten screws to 28 N*m (250 in. lbs.).
(18) Install rocker a n a covers tighten screws to 14
N*m (120 in. Ibs.) and connector to ignition coils.
(17) Install Intake Manifold; Refer to Intake Mani­
fold Installation 3 J L Engine, Group 11 Exhaust Sys­
tem and Intake Manifold.
HYDRAULIC T IP P E T S
The valve train includes roller tappet assemblies,
aligning yokes and yoke retainer.
Roller tappet alignment is maintained by machined
flats on tappet body being fitted in pairs into six
aligning yokes. The yokes are secured by an align­
ment yoke retainer (Fig. 24)
Fig. 24 Roller Tappets Aligning Yoke anti Retainer
p h e l im in a m y s t e p t o c h e c k in g
THE HYDRAULIC TAPPETS
Before disassembling any part of the engine to cor­
rect tappet noise, read the oil pressure at the gauge.
Install a reliable gauge at pressure sending unit if
vehicle has no oil pressure gauge and check the oil
level in the oil pan. The pressure should be between
30 and 80 psi (208.8 to 551.8 kPa) at 2000 rpm.
The oil level in the pan should never be above the
MAX mark on dipstick, or below the MIN mark. Either
of these two conditions could be responsible for noisy
tappets. Oil Level Check: stop engine after reaching
normal operating temperature. Allow 5 minutes to
stabilize oil level, check dipstick.
OIL LEVEL TOO HIGH
If oil level is above the MAX mark on dip stick, it is
possible for the connecting rods to dip into the oil
while engine is running and create foam. Foam in oil
pan would be fed to the hydraulic tappets by the oil
pump causing them to lose length and allow valves to
seat noisily.
OIL LEVEL TOO LOW
Low oil level may allow pump to take in air which
when fed to the tappets, causes them to lose length
and allows valves to seat noisily. Any leaks on intake
side of pump through which air can be drawn will
create the same tappet action. Check the lubrication
system from the intake strainer to the pump cover,
including the relief valve retainer cap. When tappet
noise is due to aeration, it may be interm ittent or
constant, and usually more than one tappet will be
noisy. When oil level and leaks have been corrected,
engine should be operated at fast idle for sufficient
time to allow all of the air inside of the tappets to be
bled out.
TAPPET NOISE DIAGNOSIS
(1) To determine source of tappet noise, operate
engine at idle with cylinder head covers removed.
(2) Feel each valve spring or rocker arm to detect
noisy tappet. The noisy tappet will cause the affected
spring and/or rocker arm to vibrate or feel rough in
operation.
Worn waive guides or cocked springs are some­
tim es mistaken fo r noisy tappets. If such is the case,
noise may b© dampened by applying side thrust on
the waive spring. If noise is not appreciably reduced.
It can be assymed the noise is in the tappet. Inspect
the rocker arm push rod sockets and push rod ends
for wear.
(3) Yalve tappet noise ranges from light noise to a
heavy click. A light noise is usually caused by exces­
sive leakdowa around th e . unit plunger which will
necessitate replacing the tappet, or by the plunger
partially sticking in the tappet body cylinder. A heavy
click is caused either by a tappet check valve not
seating, or by foreign particles becoming wedged be­
tween the plunger and the tappet body, causing the
plunger to stick in the down position. This heavy click
will be accompanied by excessive clearance between
the valve stem and rocker arm as valve closes. In
either case, tappet assembly should be removed for
inspection and cleaning.
TAPPET REMOVAL
(1) Refer to Cylinder Head Removal of this section
to remove intake manifold and cylinder heads for ac­
cess to tappets for service.
(2) Remove yoke retainer and aligning yokes.
(3) Use Tool C-4129 to remove tappets from their
bores. If all tappets are to be removed, identify tap­
pets to insure installation in original location.
If the tappet or bore in cylinder block is scored,
scuffed, or shows signs of sticking, ream the bore to
next oversize and replace w ith oversize tappet.
CAUTION: The plunger and tappet bodies are not
Interchangeable. The plunger and waive must always
be fitted to the original body. It is adwisabie to work
on one tappet at a tim e to avoid mixing of parts.
Mixed parts are not com patible. Do not disassemble
a tappet on a d irty work bench.
DISASSEMBLY (FIG. 2 5)
(1) Pry out plunger retainer spring clip.
(2) Clean varnish deposits from inside of tappet
body above plunger cap.
(3) Invert tappet body and remove plunger cap,
plunger, flat or ball d e c k valve, check valve spring,
check valve retainer and plunger spring. Check valve
could be flat or ball.
PLUNGER
CHECK RETAINER
BALL SPRING CUP
PLUNGER
TAPPET RETAiNEi
BODY
CHECK VALVE PLUNGER
SPRING CAP RK637
Fig. 25 Hydraulic Roller Tappet Assembly
CLEANING AND ASSEMBLY
(1) Clean all tappet parts in a solvent that will
remove all varnish and carbon.
(2) Replace tappets th at are unfit for further service
with new assemblies.
(3) If plunger shows signs of scoring or wear and
valve is pitted, or if valve seat on end of plunger
indicates any condition that would prevent valve from
seating, install a new tappet assembly.
(4) Assemble tappets (Fig. 25).
INSTALLATIO N
(1) Lubricate tappets.
(2) Install tappets in their original positions.
(3) With roller tappets, install aligning yokes with
(Fig. 23).
(4) Install yoke retainer and torque screws to 12
N-m (105 in. lbs.) (Fig. 23).
(5) Install cylinder heads. Refer to cylinder head
installation of this section for procedure.
(8) Start and operate engine. Warm up to normal
operating temperature.
CAUTION: To prevent damage to valve mechanism,
engine m ust not be run above fast idle until all hy­
draulic tappets haw§ fille d w ith o il and haw© become
quiet.
VALVE T iiili
(1) Remove front valve cover and all 6 spark plugs.
(2) Rotate engine until the #2 piston is at TDC of
the compression stroke.
(3) Install a degree wheel on the crankshaft pulley.
(4) With proper adaptor, install a dial into #2 spark
plug hole. Using the indicator find TDC on the com­
pression stroke.
(5) Position the degree wheel to zero.
(8) Remove dial indicator from spark plug hole.'
(7) Place a 5.08mm (.200 inch) spacer between the
valve stem tip of #2 intake valve and rocker arm pad.
Allow tappet to bleed down to give a solid tappet
effect.
(8) Install a dial indicator so plunger contacts the
#2 intake valve spring retainer as nearly perpendicu­
lar as possible. Zero the indicator.
(9) Rotate the engine clockwise until the in take
valve has lifted .254mm (0.010 inch).
CAUTION: Do not turn crankshaft any further clock­
wise as intake waiwe m ight bottom and result In seri­
ous damage.
(10) Degree wheel should read 3 degrees BTDC to 4
degrees ATDC.
TIMING CHAIN COVER, OIL SEAL AND CHAIN
COVER
REMOVAL
(1) Disconnect battery.
(2) Drain cooling system. Refer to Cooling System
Group 7 for procedure.
(3) Support engine and remove right engine mount.
(4) Raise vehicle on hoist. Drain engine oil.
(5) Remove oil pan and oil pump pick-up. It may
necessary to remove transmission inspection cover.
(6) Remove right wheel and inner splash shield.
(7) Remove drive belt. Refer to Cooling System Group
7 for procedure.
(8) Remove A/C compressor and set aside.
(9) Remove A/C compressor mounting bracket.
(10) Remove crankshaft pulley. (Fig. 1)
(11) Remove idler pulley from engine bracket.
(12) Remove engine bracket. (Fig. 2)
(13) Remove cam sensor from chain case cover. (Fig.
3)
(14) Remove chain case cover (Fig. 3)
 (6) Using a suitable puller mm me the crankshaft
pulley. Be careful not to damage the crankshaft' surface.

-CAM SENSOR

CHAIN CASE COVER

9009-21

Fig. f Removing Crankshaft Pulley

9009-22

Fig. 3 Timing Chain Case Cover

1 1 1 1 1 1 1 1 * • j n 1 1 1 1 11

1 1 1 1 1 1 1 1 1 » 1 1 1 1 i 11

S I M i
Fig. 2 Engine Bracket
\ 9009-80
MEASURING TIM IN G CHMIN FOR STRETCH
(1) Place a scale'next to timing chain so that any Fig. 4 Measuring Timing Chain Wear and Stretch
movement of chain may be measured.
(7) Position a new crankshaft sprocket on the shaft,
(2) Place a torque wrench and socket on camshaft
install sprocket with suitable tool and mallet. Be sure
sprocket attaching bolt and apply torque in direction
sprocket is seated into position.
of crankshaft rotation to take up slack; 41 N*m (30 ft.
(8) Rotate crankshaft sprocket so the timing mark
lb.) with cylinder head installed or 20 N-m (15 ft. lb.)
is to the 12 o’clock position.
with cylinder heads removed. With a torque applied
(9) Place timing chain around camshaft sprocket
to the cam shaft sprocket'bolt, crankshaft s h o y li not
and place the timing mark to the 6*o clock position.
be perm itted to move, it may be necessary to block
(10) Place timing chain around crankshaft sprocket
crankshaft to prewent rotation.
and install camshaft sprocket into position.
(3) Holding a scale with dimension reading even
(11) Using straight edge to check alignment of tim ­
with edge of a chain link. Apply torque in the revei
ing marks (Fig. 5).
direction 41 N-m (30 ft. lbs.) with cylinder heads in­
(12) Install camshaft bolt and washer. Tighten to 47
stalled or 20 N*m (15 ft. lbs.) with cylinder heads
removed and note amount of chain movement (Fig. 4).
N-m (35 ft.lbs.).
(13) Rotate crankshaft 2 revolutions. Timing marks
(4) Install a new timing chain, if its movement
should line up. If timing marks do not line up remove
exceeds 3.175mm (1/8 inch) (Fig. 4).
cam sprocket and realign.
(5) If chain is not satisfactory, remove camshaft
(14) Check camshaft endplay. With new thrust plate
sprocket attaching bolt, and remove timing chain with
specification is .0127 to .304 mm (.005 to .012 inches.).
camshaft sprocket.
Old thrust plate specification is .31 mm (.012 inch.)
maximum. If not within these limits install new thrust COOLANT COOLANT
plate. PASSAGE
(15) Install timing chain snubber. Tighten retaining
screws to 12 N-m (105 in.lbs.). These bolts are 20mm
long fo r this model fea r, they should not be inter­
changed w ith prewious year engines.

OIL PUMP TO ENGINi l^ O I L PUMP W

9009-23 OUTLET ASSEMBLY 9009-58

Fig. § Timing Chain Case Cover Gaskets and O-Rings

Pig. 5 Alignment o f Timing Marks
i /•>••-
INSTALLATION
(1) Be sure mating surfaces of chain case cover and
cylinder block are clean and free from burrs. Crank­ SEA'U
shaft oil seal must be removed to insure correct oil
pump engagement.
(2) Use a new cover gasket, O-rings. (Fig. 6).
(3) Rotate crankshaft so th at the oil pump drive
flats are vertical.
(4) Position oil pump inner rotor so the mating flats
are in the same position as the-crankshaft drive flats
(Fig. 8).
(5) Install cover onto crankshaft. Make sure the oil
pump is engaged on the crankshaft correctly or severe
damage may result. CRANKSHAFT SEAL INSTALLING
.y TOOL C -4992 9009^26
(8) Install chain case cover screws and torque to 27
N-m (20 ft. lbs.). Fig. 7 Install Crankshaft Oil Seal
(7) Install crankshaft oil seal (Fig. 7).
(8) Install crankshaft pulley (Fig. 8).
 (9) Install engine bracket (Fig. 2) torque screws to
54 N-m (40 ft. Ibs.).
(10) Install idler pulley on engine bracket.
(11) Install cam sensor Refer to Ignition System
Group 8D for installation procedure.
(12) Install A/C compressor mounting bracket.
(13) Install A/C compressor.
(14) Install drive belt Refer to Cooling'System Group
7 for installation procedure.
(15) Install inner splash shield and wheel.
(18) Install oil pump pick-up and oil pan and trans­
mission inspection cover if removed.
(17) Install engine mount.
(18) Fill crankcase with oil to proper level.
(19) Fill cooling system Refer to Cooling System
Group 7 for procedure.
(20) Connect battery.
TIMING CHAIN COVER EXTERNAL OIL SEAL
REiOVAL
(1) Raise vehicle on hoist. Remove right wheel and
inner splash shield.
(2) Remove drive belt. (Refer to Cooling System
Group 7) for procedure.
(3) Remove crankshaft pulley. (Fig. 1)
(4) Using Tool 0-4391 to remove oil seal. (Fig. 9) Be
careful not to damage that crankshaft seal surface of
cover.
Fig. 9 Removing Crankshaft Oil Sml
INSTALLATION
(1) Install new seal by using Tool C-4992 (Fig. 7)
(2) Place seal into opening with seal spring towards
the inside of engine. Install seal until flush with cover.
(3) Install crankshaft pulley using plate L-4524.
Thrust Bearing/washer and 5.9 inch screw. (Fig. 8)
(4) Install drive belt (Refer to Cooling System Group
7) for installation procedure.
(5) Install inner splash shield and wheel.
CAMSHAFT
REMOVAL^ENGINE REMOVED FROM VEHICLE
Remove intake manifold, cylinder head covers, cyl­
inder heads, timing chain case cover and timing chain.
(1) Remove rocker arm and shaft assemblies.
(2) Remove push rods and tappets; identify so each
part will be replaced in its original location.
(3) Remove camshaft thrust plate, (Fig. 10)
(4) Install a long bolt into front of camshaft to facili­
tate removal of the camshaft; remove camshaft, being
careful not to damage cam bearing with the cam lobes.
Fig. 10 Camshaft Thrust Plate
CHAIN
SPROCKET
BOLT AND
WASHER
9009-29
Fig. I I Camshaft and Sprocket Mssembly
INSTALLATION
(1) Lubricate camshaft lobes and camshaft bearing
journals and insert the camshaft to within 2 inches of
its final position in cylinder block.
Whenever an engine has been rebuilt and/or a new
camshaft and/or new tappets have been installed,
add one pint of Chrysler Crankcase C onditioner or
eqyivaient to engine oil to aid in break In.. The o il ers part of Tool C-3132-A at back of each bearing shell
m ixture should be left in engine fo r a minimum of to be removed and drive out bearing shells (Fig. 13).
805km -(500 mile.s) and .drained at the next normal oil
change. . INSTALLATIO N
- (2) Install camshaft thrust plate with two screws as (1) Install new camshaft bearings with Tool C-3132-A
shown in (Fig, 10).- Tighten to 12 N-m (105 in. lbs.) by sliding the new camshaft bearing shell over proper
torque. adapter.
(3)- Place both camshaft sprocket and. crankshaft (2) Position rear bearing in the tool. Install horse­
sprocket on the. bench 'With timing marks on exact shoe lock and by reversing removal procedure, care­
imaginary center line through both camshaft and crank­ fully drive bearing shell into place.
shaft bores. (3) Install remaining bearings in the same manner.
(4) Place timing chain around both sprockets. Bearings must be carefully aligned to bring oil holes
(5) Turn crankshaft and camshaft to line up with into full register with oil passages from the main
keyway location in crankshaft sprocket and in cam­ bearing. Number two bearing must index with the oil
shaft sprocket. passage to the left cylinder head and Number three
(6) Lift sprockets and chain keep sprockets tight bearing must index with the oil passage to the right
against the chain in position as described. cylinder head. If the camshaft bearing shell oil holes
(7) Slide both sprockets evenly over their respective are not in exact alignment, remove and reinstall them
shafts use a straightedge to check alignment of timing correctly. Install a new core hole plug at the rear of
marks (Fig. 12). camshaft. Be sure this plug does not leak.
(8) Install the camshaft bolt. Tighten bolt to 54 N-m
(40 ft. lbs.).
(9) Rotate crankshaft 2 revolutions. Timing marks
should line up. If timing marks do not line up, remove
cam sprocket and realign.
(10) Measure camshaft end play. End Play should
measure .0127 to .304 m m -(.005 to .012 inches.) .310
mm (.012 inch.Max.). If not within limits install a
new thrust plate.
(11) Each tappet reused must be installed in the
same position from which it was removed. When cam­
shaft is replaced, all of the tappets must be replaced.

ENGINE CORE OIL AND CAM PLUGS

REMOVAL
Using a blunt tool such as a drift and a hammer,
strike the bottom edge of the cup plug. With the cup
plug rotated, grasp firmly with pliers or other suitable
tool and remove plug (Fig. 14).
CAUTION: Do not drive cup plug into the casting as
restricted cooling can result and cause serious en­
Fig. 12 Alignment of Timing Marks gine problems.
CAMSHAFT BEARINGS
ENGINE REMOVED FROM VEHICLE
REMOVAL
(1) With engine completely disassembled, drive out
rear cam bearing core hole plug.
(2) Install proper size adapters and horse shoe wash­
 INSTALLATION
Thoroughly clean inside of cup plug hole in cylinder
CYLINDER
/ block or head. Be sure to remove old sealer. Lightly
9 - BLOCK coal inside of cup plug hole with Loctite Stud N* Bear­
r ing Mount or equivalent. Make certain the new plug
is cleaned of all oil or grease. Using proper drive plug,
SECOND drive plug into hole so that the sharp edge of the plug
REMOVE PLUG is at least 0.5mm (.020 inch) inside the lead-in chamfer.
WITH PLIERS
It is not necessary to wait for curing of the sealant.
FIRST The cooling system can be refilled and the vehicle
STRIKE HERE placed in service immediately.
WITH HAMMEI

DRIFT

1N297

Fig. 14 Com Hole Plug Removal

CYLINDER BLOCK CLEANING AND IN S P E C TIO N
(1) Clean cylinder block thoroughly and check all
PISTON—REMOVAL core hole plugs for evidence of leaking.
(1) Remove top ridge of cylinder bores with a reli­ (2) If new core plugs are installed, see Engine Core
able ridge reamer before removing pistons from cylin­ Oil and Cam Plugs.
der block. Be sure to keep tops of pistons covered (3) Examine block for cracks or fractures.
during this operation. Pistons and connecting rods
must be removed from top of cylinder block. When
removing piston and connecting rod assemblies from
the engine, rotate crankshaft so that each connect­
ing rod is centered in cylinder bore.
(2) Inspect connecting rods and connecting rod caps
for cylinder identification. Identify them if necessary.
(Fig. 2)
(3) Remove connecting rod cap. Install connecting
rod bolt protectors on connecting rod bolts (Fig. 3).
Push each piston and rod assembly out of cylinder
bore.
Be careful not to nick crankshaft journals.
(4) After removal, install bearing cap on the mating
rod.

Fig.4 Checking CylinderBore Size

Fig.2 IdentifyConnecting Rod to Cylinder
COVER ROD BOLTS
WITH A SUITABLE COVERING
WHEN REMOVI NG OR I NSTALLING
is PI STON ASSEMBLY
CYLINDER BORE IN S P E C TIO N
The cylinder walls should be checked for out-of­
round and taper with Tool C-119 (Fig. 4). If the cylin­
der walls are badly scuffed or scored, the cylinder block
should be rebored and honed, and new pistons and rings
fitted. Whatever type of boring equipment is used,
boring and honing operation should be closely coordi­
nated with the fitting of pistons and rings in order
that specified clearances may be maintained. Refer to
Honing Cylinder Bores outlined in the Standard Ser­
vice Procedures for specification and procedures.
(1) Measure the cylinder bore at three levels in
directions A and B (Fig. 5). Top measurement should
be 12mm (.50 inch) down and bottom measurement
should be 12mm (.50 inch.) up from bottom of bore.
Refer to (Fig. 6) for specifications.

(SL
9009-65
 • FRONT

12 mm
(1/2 IN.)

Fig. 7 Piston Measurements

Pistons and cylinder bores should be measured at

MIDDLE USE FOR normal room temperature, 70°F. (21 °C).
OF SIZING
BORE PISTON
PISTO N PIN S
The piston pin rotates in the piston only, and is
retained by the press interference fit of the piston pin
12 mm in the connecting rod. The piston pin is not to be
(1/2 IN.) 9009-66 removed damage to the piston may result.
Fig. 5 Checking Points in Cylinder Bore FITTIN G RINGS
(1) Wipe cylinder bore clean. Insert ring and push
Maximum
Out-of Maximum down with piston to ensure it is square in bore. The
Engine Standard Iter® Round Taper ring gap measurement must be made with the ring
3.31 92.993-93.007 mm .076 mm .51 mm positioning at least 12mm (.50 inch) from bottom of
3.3661-3.661? inch. (.003 inch.) (.002 inch.) cylinder bore. Check gap with feeler gauge (Fig. 8).
Standard Piston S I*# Refer to specifications (Fig. 9).
3.31 92.950-92.968 mm (3.6594-3.6602 inch.) (2) Check piston ring to groove clearance: (Fig. 10).
Piston to Bore Clearance: .025-.057 min (.0009 to .0022 inches.) Refer to specification (Fig. 9).
Measurements taken at Piston Size location.
Maximum Allow able O versize Bor# is .508 min (.020 inches.)
9109-138

Fig. 6 Cylinder Bore and Piston Specifications

FINISHED PISTO NS
All pistons are machined to the same weight in
grams, regardless of oversize, to maintain piston bal­
ance. For cylinder bores which have been honed or
rebored new piston and connecting rod assemblies are
furnished for service.
CAUTION: Pistons are not to be disassembled.These
components are serviced as Piston and Connecting
Rod assembly ONLY.

FITTIN G PISTO NS
Piston and cylinder wall must be clean and dry.
Piston diameter should be measured 90 degrees to
piston pin at size location shown in (Fig. 7). Cylinder
bores should be measured halfway down the cylinder
bore and transverse to the engine crankshaft center
line shown in (Fig. 5). Refer to (Fig. 6) for specifications.
 Ring P osition Ring Gap i i a r U n it CAUTION: Install piston rings in the following order:
Upper Ring 0.30 to 0.55 mm 1.0 mm (1) Oil ring expander.
(.012 to .022 in.) (.039 In.) (2) Upper oil ring side rail.
Intermediate 0.30 to 0.55 mm 1.0 mm (3) Lower oil ring side rail.
Ri ng (.012 to M 2 in.) (.039 in.)
(4) No. 2 Intermediate piston ring.
Oil Control §.25 to 1.00 mm 1.88 mm (5) No. 1 Upper piston ring.
Ring (.010 to .039 in.) (.074 i n.)
(2) Install the side rail by placing one end between
M flxtntifNt
Ring Position G roove Clearance C learance the piston ring groove and the expander. Hold end
Upper Ring 0.030 to 0.085 mm .10 mm
firmly and press down the portion to be installed until
(.001 to .0090 in.) (.004 in.) side rail is in position. Do not use a piston ring
intermedia!© 0.030 to 0.095 m m .10 mm expander. (Fig. 12).
Ring (.001 to .0037 i n.) (.004 in.) (3) Install upper side rail first and then the lower
Oil Control 0.014 to .266 mm .266 mm side rail.
Ring (.0005 to .009 in.) (.009 in.) (4) Install No. 2 piston ring and then No. 1 piston
9109-48 ring (Fig. 13).
Fig. 9 Piston Ring Specifications

GAUGE

9009-50 Fig. 12 InstallingSide Rail

Fig. 10 Measuring Piston Ring Side Clearance
PISTO N RINGS—INSTALLATIO N
(1) The No. 1 and No. 2 piston rings have a different
cross section. Install rings with manufacturers I.D.
mark facing up, to the top of the piston. (Fig. 11)
 INSTALLING PISTON A N D . ■' . ,
CONNECTING ROD ASSEMBLY . '
(1) Before installing pistons, and connecting rod as­
semblies into the bore, besure that compression ring
gaps are staggered so- that neither is in line with oil
ring rail gap.
(2) Before installing the ring compressor, make sure
the oil ring expander ends are butted, and the rail
gaps located as shown in (Fig. 15).

(5) Position piston ring end gaps as shown in (Fig.

14).
(6) Position oil ring expander gap at least 45° from
the side rail gaps but not on the piston pin center or
on the thrust direction. Staggering ring gap is impor­
tant for oil control.

GAP O f 11612
LOWER SIDE RAIL
NO. 1 Fig. 15 Installing Piston
RING GAP
(3) Immerse the piston head and rings in clean
engine oil, slide the ring compressor, over the piston
and tighten with the special wrench. Be sure position
FRONT O f ENGINE of rings does not change during this operation.

NO. 2 RING GAP GAP OF

AND SPACER UPPER SIDE RAIL
EXPANDER GAP RB281
 qi GASKET LOCATION
'^IDENTIFICATION MUST BE SEEN
PISTON NOTCHES MUST FACE TOWARD __ r~i
THE FRONT OF ENGINE ~ f\ ! 9009-85
Fig. 16 Piston LD. Notches
(4) Install connecting rod bolt protectors on rod bolts.
(Fig. 3)
(5) Rotate crankshaft so th at the connecting rod
journal is on the center of the cylinder bore. Insert rod
and piston into cylinder bore and guide rod over the
crankshaft journal.
(6) Tap the piston down in cylinder bore, using a
hammer handle. At the same time, guide connecting
rod into position on connecting rod journal.
(7) The notch or groove on top of piston must be
pointing toward front of engine. (Fig. 16)
(8) Install rod caps. Install nuts on cleaned and
oiled rod bolts and tighten nuts to 54 N-m (40 ft. lb.)
Plus 1/4 turn.
__ -R B 6 13J
Fig. 17 Checking Connecting Rod Bearing Clearance
CONNECTING RODS
INSTALLATIO N OF CONNECTING
ROD BEARINGS
Fit all rods on one bank until complete. Do not
alternate from one bank to another, they are not
interchangeable from one bank to another.
The bearing caps are not interchangeable and should
be marked at removal to insure correct assembly.
The bearing shells must be installed so th at the
tangs are in the machined grooves in the rods and
caps.
Limits of taper or out-of-round on any crankshaft
journals should be held to .025mm (.001 inch). Bear­
ings are available in .025mm (.001 inch), .051mm (.002
inch), .076mm (.003 inch), .254mm (.010 inch) and
.305mm (.012 inch) undersize. Install the bearings In
pairs. Do not use a new bearing half with an old
bearing half. Do not file the rods or bearing caps.
(1) Follow procedure specified in the Standard Ser­
vice Procedure Section for Measuring Main Bearing
Clearance and Connecting Rod Bearing Clearance (Fig.
17).
The rod bearing bolts should be examined before
reuse. If the threads are necked down the bolts should
be replaced. (Fig. 20)
Necking can be checked by holding a scale or
straight edge against the threads. If all the threads
do not contact the scale the bolt should be replaced.
(2) Before installing the nuts the threads should be
oiled with engine oil.
(3) Install nuts on each bolt finger tight then alter­
nately torque each nut to assemble the cap properly.
(4) Tighten the nuts to 54 N-m PLUS 1/4 turn (40 ft.
lbs. PLUS 1/4 turn).
(5) Using a feeler gauge, check connecting rod side
clearance (Fig. 18). Refer to (Fig. 19) for specifications.
 Connecting Rod Bearing Clearance
New Part: .019 to .087 mm
(.0008 to .0034 in.)
Wear Limit: .104 mm (.0041 in.)
Connecting Rod Side Clearance
New Part: m
(.005 to .013 in.)
Wear Limit: 0.38 mm
(.015 in.)
9109-49

Fig. 19 Connecting Rod Specifications

Upper and lower Number 2 bearing halves' are

UN STRETCH ED BOLT . ^
Fig. 20 Check fo r Stretched Rod Bolts
CRANKSHAFT SERVICE
CRANKSHAFT M AIN BEARINGS
Bearing caps are not interchangeable and should be
marked at removal to insure correct assembly. (Fig. 1)
Upper and lower bearing halves are NOT interchange­
able. Lower main bearing halves of 1, 3 and 4 are
interchangeable. Upper main bearing halves of 1, 3
and 4 are interchangeable.
flanged to carry the crankshaft thrust loads and are
NOT interchangeable with any other bearing halves
in the engine (Fig. 2). All bearing cap bolts removed
during service procedures are to be cleaned and oiled
9009-38
before installation. Bearing shells are available in
standard and the following undersizes: 0.025mm (.001
inch), .051mm (.002 inch), .076mm (.003 inch), .254mm
(.010 inch), and .305mm (.012 inch). Never install an
undersize bearing th at will reduce clearance below
specifications. • •• ■

CRANKSHAFT MAIN JOURNALS

The crankshaft journals should be checked for ex­
cessive wear, taper and scoring. (Fig. 6) Limits of
taper or out-of-round on any crankshaft journals should
be held to .025mm (.001 inch). Journal grinding should
not exceed ,305mm (.012 inch) under the standard
journal diameter. Do OT grind thrust faces of Number
2 main bearing. Do NOT nick crank pin or bearing
fillets. After regrinding, remove rough edges from
crankshaft oil holes and clean out all passages. Fig, 2 Main Bearing Identification
CAUTION: W ith the nodylar cast Iron crankshafts
used it is im portant that the final paper or cloth
iEiOVIL
(1) Remove oil pan and identify bearing caps before
polish after any journal regrind be in the same direc­ removal.
tion as normal rotation in the engine. (2) Remove bearing caps one at a time. Remove
upper half of bearing by inserting Special M ain Bear­
ing Tool C-3059. (Fig. 3) into the oil hole of crankshaft.
(3) Slowly rotate crankshaft clockwise, forcing out
upper half of bearing shell. .......
 CRANKSHAFT END PLAY CHECK^OPTIONAL
(1) Move crankshaft all the way to the rear of its
travel using a screwdriver or other lever inserted be­
tween a main bearing cap and a crankshaft cheek
using care not to damage any bearing surface.D©
notloosen main bearing cap.
(2) Use a feeler gauge between number 3 thrust
bearing and machined crankshaft surface to deter­
mine end play. Refer to (Fig. 5) for specification.

Crankshaft End-Play

New Part: .09 to 0.24 mm (.003 to .009 in.)

W ear Limit: 0.37 mm (.015 in.)

Main and Connecting Rod Bearing Clearance

New Part: .019 to .077 mm (.0007 to .0030 in.)

Fig, 3 Hemming and Installing Upper Main W ear Limit: .102 mm (.004 i n.)
Bearing With Special Tool C-3059
Crankshaft Journal Sizes
INSTALLATION
Only one main bearing should be selectively fitted Crankshaft Main Bearing Journal
while all other main tearing caps are properly tightened. ALL Diam eter
When installing a new upper bearing shell, slightly Standard 64.00 ± 0.013 mm
chamfer the sharp edges from the plain side. (2.519 ± .0005 in.)
(1) Start bearing in place, and insert Main Bearing
Tool 0-3053 into oil hole of crankshaft (Fig. 8) Crankshaft Connecting Rod Journal
(2) Slowly rotate crankshaft counter-clockwise slid­
ALL Diameter
ing the bearing into position. Remove Special Main
Standard 58.00 ± 0.013
Bearing Tool 0-3053.
(2.283 ± .0005 in.)

CHECKING CRANKSHAFT END PLAY 9109-123

(1) Mount a dial indicator to front of engine, locat­
ing probe on nose of crankshaft (Fig. 4). Fig. 5 Crankshaft specification
(2) Move crankshaft all the way to the rear of its
travel. CRANKSHAFT OIL CLEARANCE
(3) Zero the dial indicator. (1) Measure the journal outside diameter as shown
(4) Move crankshaft all the way to the front and in (Fig. 6). Refer to specification (Fig. 5).
read the dial indicator. Refer to (Fig. 5) for specification.

RR09B56
PLASTIGAUGE (OIL CLEARANCE)
MEASUREMENT
(1) Remove oil from journal and bearing shell.
(2) Install crankshaft,
(3) Cut plastigauge to same length as width of the
bearing and place it in parallel with the journal axis
(Fig. 7).
(4) Install the main bearing cap carefully and tighten
the bolts to specified torque.
CAUTION: Do not rotate crankshaft or the plastlgayge
w ill be smeared.
(5) Carefully remove the bearing cap and measure
the width of the plastigauge at the widest part using
the scale on the plastigauge package (Fig. 7). Refer to
specification (Fig. 5) for proper clearances.If the clear­
ance exceeds the specified limits. Replace the main
bearing(s) and if necessary have the crankshaft ma­
chined to next undersize. Also see Measuring Main INSTALLATION
and Connecting Rod Bearing Clearance in Standard (1) Place Special Seal Pilot Tool C-4881 on crank­
Service Procedures. shaft (Fig. 3).
(2) Lightly coat seal O.D. with Loctite Stud N5Bear­
ing Mount or equivalent.
(3) Place seal over Special Seal Pilot Tool C-4881
and tap in place with a plastic hammer.

REAR CRANKSHAFT SEAL RETAINER

When retainer removal is required, remove retainer
clean engine block and retainer of old gasket. Make
sure surfaces are clean and free of oil. Install new
gasket and tighten screws to 12 N-m (105 in. lbs.)

CAUTION; Do not rotate crankshaft or the Plastlc-

Gayge may be smeared.

CRANKSHAFT OIL SEALS SERVICE

REM OVAL
(1) Pry out rear seal with screwdriver. Be careful
not to nick or damage crankshaft flange seal surface
or retainer bore (Fig. 8).
 ROCKER SHAFT OIL FLOWS TO ONLY ONE BRACKET ON
EACH HEAD. BRACKET IS SECOND FROM
REAR ON RIGHT HEAD. BRACKET IS
SECOND FROM FRONT O N LEFT HEAD

OIL SUPPLY THRU HOLLOW

PUSH ROD FROM LIFTER

CRANKSHAFT OUTER ROTOR

KOCKEI SHAFT
BRACKET
INNER ROTOR

RELIEF
VALVE

OIL SCREEN 9009^86

Fig. I Engine Oiling System

ENGINE LUBRICATION SYSTEM
The lubrication system is a full flow filtration pres­
sure feed type. Oil stored in the oil pan is taken in
and discharged by a internal gear type oil pump di­
rectly coupled to the crankshaft. Its pressure is regu­
lated by a relief valve located in the Chain Case
Cover. The oil is pumped through an oil filter and
feeds a main oil galley.This oil gallery feeds oil under
pressure to the main and rod bearings, camshaft bear­
ings. Passages in the cylinder block feed oil to the
hydraulic lifters and rocker shaft brackets which feeds
the rocker arm pivots (Fig. 1).
(4) Clean oil screen and pipe in clean solvent. In­
spect condition of screen.
INSTALLATIO N
(1) Install oil pick-up tube into Cha|n Case Cover
tighten screw to 28N*m (250 in.lbs.) (Fig. 2).
(2) Apply a 1/8 inch bead of Mopar Silicone Rubber
Adhesive Sealant or equivalent, onto the seam be­
tween the Chain Case Cover and Engine Block and
the Rear Seal Retainer and the Engine Block (Fig. 3).
(3) Use a new pan gasket (Fig. 4).
(4) Install pan and tighten screws to 23N*m (200 in
lb.).

OIL P IN SERVICE
REMOVAL
(1) Disconnect negative battery cable, remove en­
gine oil dipstick.
(2) Raise vehicle. Drain engine oil.
(3) Remove oil pan screws and remove oil pan.

CLEANING AND INSPECTION

(1) Clean oil pan in solvent and wipe dry with a
clean cloth. Clean all gasket material from mounting
surfaces of pan and block.
(2) Inspect oil drain plug and plug hole for stripped
or damaged threads and repair as necessary. Install a
new drain plug gasket. Tighten to 27 N-m (20 ft. lb.).
(3) Inspect oil pan mounting flange for bends or
distortion. Straighten flange if necessary.

(3) Lower vehicle and install oil dipstick.
(4) Connect negative battery cable.
(5) Fill crankcase with oil to proper level.
OIL PU M P SERVICE
It is necessary to remove the oil pan, oil pickup and
chain case cover (CCC) to service the oil pump rotors.
The oil pump pressure relief valve can be serviced by
removing the oil pan and oil pickup tube. Refer to
Timing Chain Cover Removal and Installation of this
section for procedures.
DISASSEMBLY
(1) To remove the relief valve, proceed as follows:
(a) Drill a 3.175mm (1/8 inch) hole into the relief
valve retainer cap and insert a self-threading sheet
metal screw into cap.
(b) Clamp screw into a vise and while supporting
chain case cover (CCC), remove cap by tapping CCC
using a soft hammer. Discard retainer cap and remove
spring and relief valve (Fig. 5).
Pig. 5 Oil Pressure Relief Valwe
(2) Remove oil pump cover screws, and lift off cover.
(3) Remove pump rotors.
(4) Wash all parts in a suitable solvent and inspect
carefully for damage or wear (Fig. 6).
CHAIN CASE OIL PUMP SCREW
INSPECTION AND REPAIR
(1) Clean all parts thoroughly. Mating surface of
the chain case cover (CCC) should be smooth. Replace
pump cover if scratched or grooved.
(2) Lay a straightedge across the pump cover sur­
face (Fig. 7). If a .076mm (.003 inch) feeler gauge can
be inserted between cover and straight edge, cover
should be replaced.
(3) Measure thickness and diameter of outer rotor.
If outer rotor thickness measures 7.36mm (.3005 inch)
or less (Fig. 8), or if the diameter is 79.78mm (3.141
inches) or less, replace outer rotor.
(4) If inner rotor measures 7.64mm (.301 inch) or
less replace inner rotor and shaft assembly (Fig. 9).
 (10) If oil pressure is low and pump is within speci­
fications, inspect for worn engine bearings or other
reasons for oil pressure loss.

OIL P U M P ASSEMBLY AND IN S TA LLA TIO N

(1) Assemble pump, using new parts as required.
(2) Tighten cover screws to 12N-m (105 in. lbs.).
(3) Prime oil pump before installation by filling
rotor cavity with engine oil.
(4) Install chain case cover slowly refer to Timing
Chain Cover Installation of this section.

Fig.9 Measuring Inner Rotor Thickness

Fig.8 Measuring Outer Rotor Thickness

(5) Slide outer rotor into CCC, press to one side with
fingers and measure clearance between rotor and CCC
(Fig. 10). If measurement is 56mm (.022 inch) or more,
replace CCC only if outer rotor is in spec.
(6) Install inner rotor into CCC. If clearance be­
tween inner and outer rotors (Fig. 11) is ,203mm (.008
inch) or more,replace both rotors.
(7) Place a straightedge across the face of the CCC,
between bolt holes. If a feeler gauge of .102mm (.004
inch) or more can be inserted between rotors and the
straightedge, replace pump assembly (Fig.l2).ONLY if
rotors are in specs.
(8) Inspect oil pressure relief valve plunger for scor­
ing and free operation in its bore. Small marks may
be removed with 400-grit wet or dry sandpaper.
(9) The relief valve spring has a free length of ap­
proximately 49.5mm (1.95 inch) and should test be­
tween 19.5 and 20.5 pounds when compressed to 34mm
(1-11/32 inches). Replace spring th at fails to meet
specifications (Fig. 5).
 Fig. 11 Measuring Clearance Between Rotors

OIL FILTER
When servicing oil filter avoid deforming the filter
can by installing the remove/install tool band strap
against the can to base lockseam. The lockseam
joining the can to the base is reinforced by the base
plate.
(1) Using Tool C-4065, unscrew filter from base and
discard (Fig. 13).
(2) Wipe base clean, then inspect gasket contact
surface.
(3) Lubricate gasket of new filter with clean engine
oil.
(4) Install and tighten filter to 20 N-m (15 ft. lbs.)
torque after gasket contacts base. Use filter wrench if
necessary.
(5) Start engine and check for leaks.
ENGINE SPECIFICATIONS

Type ......................................................... 60° V-6 Engine

Bore . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 93.0 mm (3.66 inches)
Stroke . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 81.0 mm (3.19 inches)
Compressi on Ratio . . . . . . . . . . . . . . . . . . . . . 8.9:1
Displacement . . . . . . . . . . . . . . . . . . . . . . . . . 3.3 Liters (201 cubic inches)
Brake Horsepower . . . . . . . . . . . . . . . . . . . . . 147 @4800 RPM
Torque . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 185 Ibs.-ft. @3600 RPM
Firing Or der . . . . . . . . . . . . . . . . . . . . . . . . . . 1-2-3-4-5-6
M i nimum Compression Pressure, see
"Engine Performance" in Standard Service
■Procedures . . . . . . . . . . . . . . . . . . . . . . . . 689.5 kPo (100 psi)
Maximum Variation Between Cyli nders . . . . . 25%

C y lin d e r N u m b e r ( fr o n t to R e a r)
front lank . . . . . . . . . . . . . . . . . . . . . . . . . . 2, 4, 6
Rear lank . . . . . . . . . . . . . . . . . . . . . . . . . . 1# 3#5

C y lin d e r Block
Cylinder lore (Standard) . . . . . . . . . . . . . . . . . 96.0 mm (3.779 inches)
Cylinder lore Out-of-Round
(Maximum Allowable Before Reconditioning) 0.076 mm (0.003 inch)
Cylinder Bore Taper
(Maximum Allowable Before Reconditioning) 0.051 mm (0.002 inch)
Reconditioning Working Limits
(For Taper and Out-of-Round) ..................... 0.001 inch
Maximum Allowable Oversize (Cylinder Bores) 0.020 inch
Tappet Bore Diameter . . . . . . . . . . . . . . . . . . 0.9051 inch-0.9059 inch

Pistons
Type M aterial.................................................... Aluminum Alloy Tin Coated
Clearance at Size Location............................. 0.02 5-0.05 7 mm (0.001 to 0.0022 inch)
Weight (Std. Through 0.020 Oversize) ........... 381 ±5 gms
Pistons For Service (Serviced a t Piston and. . . STD., 0.025 mm (.001 inch) 0.51 mm (.020 inch)
Connecting Rod Assembly) Oversize

Piston Plus
TyPe ........................................................ Press Fit in Rod (Serviced as an Assembly)
Diameter........................................................... 22.88 mm (0.9009-0.9007 inch)
Length................................................................ 67.2 5-67 .7 5 mm (2.648^2.667 inches)
Clearance in Piston (Light Thumb Push @70° F) 0.006-0.019 mm (0.0002-0.0007 inch)
Clearance in Rod . . . . . . . . . . . . . . . . . . . . . (Interference)

Piston Rings
Number of Rings Per Piston.............................. 3
Compression.................................................. 2
O i l ......................... ........................................ 1
Oil Ring Type . . . . ....................................... 3-Piece, Steel Rail, Chrome-Face
Ring Width
Compression.................. ............................... 1.46-1.5 mm (0.0575-0.0591 inch)
Oil—Steel Rails............................................. 0.510 mm (0.0201 inch)
Ring Gap
Compression.................................................. 0.30 0-0.55 0 mm (0.0118-0.0217 inch)
Oil—Steel Rails............................................. 0.250-1.00 mm (0.0098-0.0394 inch)
Ring Side Clearance
Compression.................................................. 0 .030-0.095 mm (0.0012-0.0037 inch)
Oil—Steel Rails............................................. 0.014-0.226 mm (0.0005-0.0089 inch)
Service Rings
Ring Gap
Compression . . . . . . . . . . . . . . . . . . . . . 0.30 0-0.55 0 mm (0.0018-0.0217 inch)
Oil—Steel R a ils ......................................... 0.250-1.00 mm (0.0098-0.0394 inch)
Ring Side Clearance
Compression.................................................. 0 .030-0.095 mm (0.0012-0.0037 inch)
Oil—Steel Rails............................................. 0.014-0.226 mm (0.0005-0.0089 inch)
CONNECTING RODS
(Serviced a s Piston an d Rod Assembly)
Side C learance............................................................................................................... 0 .1 2 7 -0 .381mm (0.005-0.015 inch)

CONNECTING ROD BEARINGS

Type.................. Aluminum Lead (Bi-Metal)
Clearance Desired . . . . . . . . . . . . 0.01 9-0.076mm (0.00075-0.003 inch.)
Maximum Allowable . . . . . . . . . . 0.076mm (0.003 inch.)
Bearings for Servi ce. . . . . . . . . . . Std., 0.025mm (0.001), 0.051mm (0.002)
0.076mm (0.003), 0.254mm (0.010),
0.305 mm (0.012 inches.)

CRANKSHAFT
Type........................................................ Cast Nodular Iron
Bearings . . . . . . . . . . . . . . . . . . . . . . . . . . . Aluminum Lead (Bi-Metal)
Thrust Taken By . . . . . . . . . . . . . . . . . . . . . . No. 2 Main Bearing
End Play . . . . . . . . . . . . . . . . . . . . . . . . . . . 0 .0 7 6 - 0 .228m m (0.003-0.009 inch.)
M aximum Allowable . . . . . . . . . . . . . . . . . 0.38mm (0.015 inch.)
Diametral Clearance Desired #1, 2, 3 and 4 . 0 .01 9-0.050mm (0.0007^0.0022 inch.)
Maximum Diametral Clearance #1, 2, 3 and 4 0.055mm (0.0022 inch.)

MAIN BEARING JOURNALS

Diameter . . ............................................................ 64mm (2.519 inch.)
Maximum Allowable Out-of-Round and/or Taper 0.025mm (0.001 inch.)
Bearings for Service.............................................. Std., 0.025mm (0.001), 0.051mm (0.002)
0.076mm (0.003), 0.254mm (0.010),
0.305mm (0.012 inches.)

CONNECTING ROD JOURNALS

Diameter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 58mm (2.283 inch.)
Maximum Allowable Out-of-Round and/or Taper . . . . . . . . . . . . . . . . . . . . . . . . . . 0.025mm (0.001 inch.)

CAHSHAF?
Drive Chain
Bearings......................................................... Steel Backed Babbitt
Number ......................................................... 4
Diametral C learance.................................... ■0 .0 25 -0 .101mm (0.001-0.004 inch.)
Maximum Allowable Before Reconditioning 0.127mm (0.005 inch.)
Thrust Taken B y ................................................ Thrust Plate
End P la y ........................................................... 0 .12 7-0.304mm (0.005-0.012 inch.)
Maximum Allowable.................................... 0.304mm (0.012 inch.)

CAMSHAFT JOURNALS
Diameter
No. 1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5 0 .7 2 4 -5 0 .755mm (1.997-1.999 inch.)
No. 2 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50.317-50.368mm (1.980-1.982 inch.)
No. 3 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4 9 .9 3 6 -4 9 .987mm (1.965-1.967 inch.)
N o . 4 .................................... ........................................................................................ 4 9 .5 3 0 -4 9 .5S1 mm (1,949-1.952 inch.)
Cam shaft Hearings
Diameter
No. 1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5 0.80-50.82 mm (2.000-2.001 inches)
. No. 2 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50.39-50.41 mm (1.984-1.985 inches)
No. 3 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4 9.60-49.63 mm (1.953-1.954 inches)
No. 4 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4 9.53-49.58 mm (1.950-1.951 inches)

Valve Timing
Intake Opens (BTC) .............................. 0° '
Intake Closes (A B C ).................... .................... 60°
Exhaust Opens (BBC) . . . . . . . . . . . . . . . . . . 48°
Exhaust Closes (ATC) . . . . . . . . . . . . . . . . . . 12 °
Valve Overlap . . . . . . . . . . . . . . . . . . . . . . . 12 °
■ ,o
Intake Valve Duration . . . . . . . . . . . . . . . . . .
Exhaust Valve Duration................* .................. 240°

Tim ing Chain

Number of Li nks. . . . . . . . . . . . . . . . . . . . . . 64
Pitch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .375 inch
W idth . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .750 inch

Tappets
TyPe ................... ................... ....... .........
Body Di amet er . . . . . . . . . . . . . . . . . . . . . . .
Clearance to Block . . . . . . . . . . . . . . . . . . . .
Service Tappets Available . . . . . . . . . . . . . . .
Cylinder Head
Roller Hydraulic
2 2.9 4-22 .9 6 mm (0.9035-0.9040 inch)
0 .02 7-0.06 0 mm (0.0011-0.0024 inch)
Std., 0.025 mm (0.001), 0.20 mm (0.008)# 0.762 mm
(0.030 inches)

Valve Seat Run-Out (Maximum) . . . . . . . . . . 0.760 mm (0.003 inch)

Intake Valve Seat Angle 45-45-1/2°
Seat W idth (Finished) . . . . . . . . . . . . . . . . 1.75-2.25 mm (0.069^0.088 inch)
Exhaust Valve Seat Angle . . . . . . . . . . . . . . . 45-45-1/2°
Seat W idth (Finished) . . . . . . . . . . . . . . . . 1.50-2.00 min (0.057-0.078 inch).
Cylinder Head Gasket (Thickness Compressed) 1.78 mm (0.070 inch)

Valve Guides
Type.............................................................. Powdered Metal Inserts
Guide Bore Diameter . . . . . . . . . . . . . . . . . . 7 .79 5-8.00 0 mm (0.313-0.3149 inch)

Voiwes—(Intake)
Head Diameter . . . . . . . . . . . . . . . . . . . . . . 45.5 mm (1.79 inches)
Length Overall (New) . . . . . . . . . . . . . . . . . . 125.385-126.025,mm (4.936-4.961 inches)
Stem Diameter (Standard) . . . . . . . . . . . . . . 7 .935-7.953 mm (0.312-0.313 inch)' '
Stem to Guide Clearance . . . . . . . . . . . . . . . 0 .025-0.095 mm (0.001-0.003 inch)
Maximum Allowable (By Rocking Method) . . . 0.247 mm (0.010 inch)
Face Angle . . . ................................................ 44-1/2°
Valves for Service (Oversized Stem Diameter) Std., 0.015 mm (0.005), 0.40 mm (0.015), 0.80 mm
(0.030 inches)
Lift (Zero Lash)............................. .................... 10.16 mm (0.400 inch)
Minimum Valve Length After Grinding Tip . . . 124.892 (4.916 inches) 9109-136
VALVES (EXHAUST)

Head Diameter. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 37.5mm (1.476 inch.)

Length Overall (New) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 126.095-126.645mm (4.964-4.986 inch.)
Stem Diameter (Standard) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7.906-7.924mm (0.3112-0.3119 inch.)
Stem to Guide Clearance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0 .0 5 1 -0 .175mm (0.002-0.006 inch.)
Maximum Allowable by Rocking Method . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0.414mm (0.016 inch.)
face A n g le .................................... ............................................................................ .. 44-1/2*
Valves for Service (Oversize Stew Di ameter). . . . . . . . . . . . . . . . . . . . . . . . . . . Std., 0.015mm (0.005), 0.40mm
(0.015), 0.80mm (0.030 inches.)
Lift (Zero Lash) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10.16mm (0.400 inch.)
Minimum Valve Length After Grinding T ip ........... ................................................... .. 125.512mm (4.941 inch.)

KNGINK VALVE SPR IN G S Intake/Exhaust

Num ber...................................................... 12
Free Length (Approx.) 48.5mm (1.909 inch.)
Wire Diam eter........................................... 4.75mm (0.187 inch.)
Number of coils . . ..................................... 6.8
Load When Compressed to —Valve Closed 5 8 -6 3 lbs. @ 1.570 inch.
— Valve Open. 136-145 lbs. @ 1.14 inch.
Valve Spring Installed Height
(Spring Seat to Retainer) . . . . . . . . . . . 39.1-40.6mm (1-17/32-1-19/32 inch.)

E N G IN E L U B tlC A T tO N

Pump Type . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Rotary Full Pressure .

Capacity . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.8 Liters (4 qts.) W i thout Oil Filter Change,
4.25 Liters (4.5 qts.) With Oil Filter Change.
Pump Dri ve. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Crankshaft
Minimum Pressure, Engine Fully Warmed Up at Idle . . . . . . . . . . . . . . . . . . . . . 34.47 kPa (5 psi)
3000 RPM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 205-551. kPa (30^80 psi)
Oil Filter Bypass Valve Setting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 62-103 kPa (9-15 psi)
Oil Pressure Switch Minimum Actuating Pressure . . . . . . . . . . . . . . . . . . . . . . . . 13.79-27.58 kPa (2-4 psi)
Oil Filter Type . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Full Flow
Note: If Pressure Is 0 at Idle, Do Not Run Engine at 3000 RPM.

OIL PUMP— INSPECTION LIMITS FOR REPLACEMENT

Oil Pump Cover Out of Flat . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0.076mm (0.003 inch or more)

Outer Rotor Thickness . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7.63mm (0.3005 inch or less)
Outer Rotor Diameter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 79.78 (3.141 inch or less)
Inner Rotor Thickness. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7.64mm (0.301 inch or less)
Clearance Over Rotors —Outer . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0.10mm (0.004 inch or more)
— I nner. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0.10mm (0.004 inch or more)
Outer Rotor Clearance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0.56mm (0.022 inch or more)
Tip Clearance Between Rotors . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0.20mm (§.008 inch or more)
 Thread Inch
SIin Meters Founds Pounds
3/8 "— 16 41 30
7/16"— 14 68 50
3 /8 " — 16 41 30
5/16"— 18 23 200
3/8 "— 16 41 30
Alternator Bracket Bolt 3/e "— 16 41 30
3 / i " — 16 41 30
M l Ox 1.5 54 40
Camshaft Thrust Plate M6x1 12 105
Chain Case Cover Bolt M8x1.25 47 20
M l 0x1.5 54 40
3/S "— 24 54+ 1/4 turn 40 + 1 /4 turn
MIOx. * 54 40
M8x1.25 33 25
M l 1x1.5 45,65,
65+ 1/4 turn
Cylinder Head Covers—Bolt . . . . . . . . . . . . M6xl.O 12 105
Exhaust Manifold Screw.............................. M8x1.25 23 200
Exhaust Crossover Pipe Flange Nut/Bolt ., M10x1.5’ 33 25
Intake Manifold Bol t . . . . . . . . . . . . . . . . . . . M8x1.25 23 200
Intake Manifold Gasket Retaining Screws . m x i 12 105
Intake M anifold Plenum Bol t . . . . . . . . . . . . MBxl .75 28 2®
M l 1x1.5 41 + 1 /4 turn 30+ 1/4 turn
3 /4 "— 16 41 30
O il Level Sensor Plug . 3/4x16 27 20
1/2 "—20 27 20
O il Pan Screw . M6x1.0 12 105
i / r 'N P i f 7 60
M6x1.00x18 12 105
M8x1.75 28 250
5/16"— 18 28 250
Spark Plug , 14 mm 41 30
7/16*— 14 68 50
MIOxl.5 54 40
Tappet Retainer Yoke Screw . . . . . . . . . . M6x1 12 105
Temperature G auge Sending U n it........ 1/8 "— NPIP 7 60
Ti ming Chain Snubber Screw. . . . . . . . . . MAx1 12 105
Water Pump to (Chain Case Cover) Bolt. M6xi.o 12 105

*All Critical Fasteners Should Be Clean and Lightly Oiled.

 EXHAUST SYSTEM AND INTAKE MANIFOLD
CONTENTS
Page Page
EXHAUST SYSTEM DIAGNOSIS 3 SERVICE PROCEDURES.......... .................. 4
GENERAL INFORMATION 1 TORQUE SPECIFICATION........................... 20
GENERAL INFORMATION
Throughout this group, references may be made to a EXHAUST SYSTEMS
particular vehicle by letter or number designation. A
chart showing the breakdown of these designations is The exhaust systems are produced in several config­
included in the Introduction Section at the front of urations, depending on engine and vehicle (Fig. 1).
this service manual. One system has an underfloor catalytic converter, other
systems require front mounted catalytic converters.
Most six cylinder engines require an underfloor con­
verter/resonator assembly. Tail pipes, mufflers, and
resonators are sized and tuned to each vehicle/powertrain
combination.

SHOULDER CROSSMEMBER
BO LT (4)

CONVENTIONAL
SYSTEM

SHOULDER
BOLT (2)

EXHAUST
AAANIFOLD
(REFERENCE)

SHOULDER
BOLT (2)

ALL WHEEL
DRIVE SCREW RESONATOR
SYSTEM
MUFFLER
CATALYTIC CONVERTERS
There is no regularly scheduled maintenance on
any Chrysler catalytic converter. If damaged, the con­
verter must be replaced.
CAUTION: Due to exterior physical similarities of
some catalytic converters with pipe assemblies, ex*
treme care should be taken with replacement parts.
There is internal converter differences required in
some parts of the country (particularly California
vehicles).
EXHAUST NUT
Fig. 2 Ball-Joint Connection
SPECIAL EXH AUST BALL-JOINT COUPLING
A special exhaust ball-joint coupling (Fig. 2) is used
to secure the exhaust pipe to the engine manifold.
This living joint actually moves back and forth as the
engine moves, preventing breakage that could occur
from the back-and-forth motion of a transverse mounted
engine.
The exhaust ball joint consists of two bolts, two
springs, and a ball joint seal ring which is a separate
part from the exhaust pipe.
EXHAUST GAS RECIRCULATION (EGR)
To assist in the control of oxides of nitrogen (NOx)
in engine exhaust, all engines are equipped with an
exhaust gas recirculation system. The use of exhaust
gas to dilute incoming air/fuel mixtures lowers peak
flame temperatures during combustion, thus limiting
the formation of NOx.
Exhaust gases are taken from opening in the ex­
haust manifold passage to the intake manifold. RE­
FER TO SECTION 25 OF THIS MANUAL FOR A
COMPLETE DESCRIPTION, DIAGNOSIS AND SER­
VICE PROCEDURES ON THE EXHAUST GAS RE­
CIRCULATION SYSTEM AND COMPONENTS.
HEAT SHIELDS
Heat shields (Fig. 3) are needed to protect both the
vehicle and the environment from the high tempera­
tures developed in the vicinity of the catalytic converters.
See Body and Sheet Metal, Group 23 for service
procedures.
Avoid application of rust prevention compounds
or undercoating materials to exhaust system floor
pan heat shields on cars so equipped. Light over
spray near the edges is permitted. Application of
coating will greatly reduce the efficiency of the heat
shields resulting in excessive floor pan temperatures
and objectionable fumes.
The combustion reaction caused by the catalyst re­
leases additional heat in the exhaust system. Causing
temperature increases in the area of the reactor under
severe operating conditions. Such conditions can ex ist
when the engine misfires or otherwise does not oper­
ate at peak efficiency. Do not remove spark plug wires
from plugs or by any other means short out cylinders
if exhaust system is equipped with catalytic converter.
Failure of the catalytic converter can occur due to
temperature increases caused by unburned fuel pass­
ing through the converter.
The use of the catalysts also involves some non-
automotive problems. Unleaded gasoline must be used
to avoid poisoning the catalyst core.Do not allow en­
gine to operate at fast idle for extended periods (over 5
minutes). This condition may result in excessive ex­
haust system/floorpan temperatures.
 SCREWS

TOE
BOARD
HEAT
SHIELD

KICK-UP
CONVERTER HEAT SHIELD
HEAT SHIELD
EXHAUST PIPE
HEAT SHIELD
MUFFLER HEAT
ALL WHEEL DRIVE VEHICLES SHIELD SCREWS (17) 9111-23

Pig. 3 H m t Shields

EXHAUST SYSTEM DIAGNOSIS

Condition Possible Coino
BXCBS8IVC EXHAUST MCMil (a) Exhaust manifold cracked or broken
(UNDER MOOD) (b) Manifold to cylinder head leak
(c) EGR Valve Leakage
a, EGR Valve -to Manifold Gasket
b, EGR Valve to EGR Tybe Gasket
c, EGR Tube to Manifold Tybe Nut
(d) Exhaust Flex Joint
a, Spring height, installed not correct
b, Exhaust seal i ng ring defective
(e) Pipe and shell noise from front
exhaust pipe
Correction
(a) Replace manifold
(b) Tighten manifold and/or replace gasket
(c)
a, Tighten nuts or replace gasket
b, Tighten nuts or replace gasket
c, Tighten tube nut
(d)
a, Check spring height, both sides
(specification is 32.5 mm, 1.28' inch)
look for source of spring height vari­
ation if out of specification.
b, Inspect seal for dam age on round
spherical surface. If no dam age is
evident, check for exhaust obstruction
causing high back pressure on heavy
acceleration.
(•) Characteristic of single wall pipes.

EXCESSIVE EXHAUST NOISE
(a) Leaks at pipe joints
(b) Burned or blown or rusted out muffler,
tailpipe of exhaust pipe.
(c) Restriction in muffler or tailpipe
(d) Converter material in muffler
(a) Tighten clamps at leaking joints
(b) Replace muffler or muffler tailpipe or
exhaust pipe.
(c) Remove restriction, if possible or replace
as necessary.
(d) Replace muffler and converter assemblies,
Check fuel injection and ignition systems
for proper operation.

9111-7
 SERVICE PROCEDURES
EXHAUST PIPES, MUFFLERS A ID TAILPIPES
INSULATOR (2) SCREW (2)
REMOVAL
(1) Raise vehicle on hoist and apply penetrating oil
to clamp bolts and nuts of component being removed.
(2) Remove clamps and supports (Figs. 4, 5, and 8)
from exhaust system to permit alignment of parts
during assembly.
(3) When removing tailpipe, raise rear of vehicle to
relieve body weight from rear springs to provide clear­
ance between pipe and rear axle parts.
(4) Clean ends of pipes and/or muffler to assure
mating of all parts. Discard broken or worn insula­
tors, rusted clamps, supports and attaching parts.
When replacement Is required on any com ponent
of the exhaust system. It Is most im portant that orig­
inal equipm ent parts (or their ©quiwaient) be used;
• To insure proper alignment with other parts in the
system.
• Provide acceptable exhaust noise levels and does
not change exhaust system back pressure that could MUFFLER
affect emissions and performance. (FiONT) 9111-24

Fig. 5 Muffler to Fall Pipe

INSULATOR

CONVERTOR OR RESONATOR PIPE

MUFFLER

KEY MUST BE
BOTTOMED
IN SLOT

NUTS
m (270 IN. LBS.)
FWD ' ^ 1 ° N*
RH1283
W U FRAME
TAIL PIPE RAIL RP811
Fig.4 Exhaust (Converter/Resonator)
Pipe to Muffler
Fig. 6 Rear Tail Pipe Bracket and Inaulator
INSTALLATION
(1) Assemble pipes, muffler supports and clamps
loosely to permit alignment of all parts.
(2) Beginning at front of system, align and clamp
each component to m aintain position and proper clear­
ance with underbody parts. ' ’ 1 • "■
(3) Tighten all clamps and supports to the proper
torques and’clearances.
INTAKE AND EXHAUST MANIFOLDS—
TBI ENGINE
IN TA K E MANIFOLDS!
Naturally Aspirated Die-cast aluminum long-branch
fan design with remote plenum. The throttle body is
installed on the upper plenum of the manifold.
EXHAUST MANIFOLDSs
All high strength iron casting th at intermesh with
the intake manifold. For standard engines a four branch
design collects and directs exhaust gases to the coni­
cal (articulated joint connection) outlet.
THROTTLE BODY AIR HEATER
The throttle body air heater (Fig. 1) is attached to
the exhaust manifold and is removable.
Inspect air heater connector tube; replace if dam­
aged. Refer to Emission Control Systems, Group 25,
for diagnostic and service procedures on the air con­
trol valve and temperature sensor located in the air
cleaner.
WIRING HARNESS AIR CLEANER
GROUND ASSEMBLY
AIR HEATER
CONNECTOR RR25G7
Fig. 1 Air Heater TBI Engines
INTAKE AND EXHAUST MANIFOLDS
SERVICE— TBI ENGINE
Intake and exhaust manifolds use a one piece gas­
ket. Service procedures requiring removal and instal­
lation ( of either ) must include both manifolds.
FUEL SYSTEM PRESSURE RELEASE
PROCEDURE
The Fuel System is under a constant pressure of
at least 265 kPa (39 psi). Before servicing the fuel
pump, fuel lines, fuel filter, throttle body or fuel in­
jector, the fuel system pressure must be released.
(1) Loosen fuel filler cap to release fuel tank pressure.
(2) Disconnect injector wiring harness from engine
harness.
(3) Connect a jumper wire to ground term inal Num­
ber 1 of the injector harness (Fig. 2) to engine ground.
(4) Connect a jumper wire to the positive terminal
Number 2 of the injector harness (Fig. 2) and touch
the battery positive post for no longer than 5 seconds.
This releases system pressure.
(5) Remove jumper wires.
(6) Continue fuel system service.
TERMINAL #1
TERMINAL #1
TERMINAL # 2
TERMINAL #2
2.5L ENGINE 3.0L ENGINE
TERMINAL #2 TERMINAL #1
3.3L ENGINE
9114-14 7
Fig.2 InjectorHarness Connectors
REMOVAL
(1) Perform fuel system pressure release procedure
before attempting any repairs.
(2) Disconnect negative battery cable. Drain cooling
system. Refer to Cooling System, Group 7 for procedure.
(3) Remove air cleaner and disconnect all vacuum
lines, electrical wiring and fuel lines from throttle
body.
(4) Remove throttle linkage.
(5) Loosen power steering pump and remove belt.
(6) Remove power brake vacuum hose from intake
manifold.
 (7) Disconnect EGR tube from intake manifold and
remove water hoses from water crossover.
(8) Raise vehicle and remove exhaust pipe from
manifold.
(9) Remove power steering pump assembly and set
aside.
(10) Remove intake manifold retaining screws. (Fig.
3)
(11) Lower vehicle and remove intake manifold.
(12) Remove exhaust manifold retaining nuts. (Fig.
3)
(13) Remove exhaust manifold.
Fig.3 Intakeand Exhaust Manifold
Attaching Points—2.5L Engines
CLEANING AMD INSPECTIO N
(1) Discard gaskets and clean all gasket surfaces on
both manifolds and on cylinder head.
(2) Test gasket surfaces of manifolds for flatness
with a straight edge. Surfaces must be flat within
0.15mm per 300mm (.006 in. per foot) of manifold
length.
(3) Inspect manifolds for cracks and distortion.
INSTALLATIO N
(1) Install a new intake and exhaust manifold gas­
ket. Coat steel gasket lightly with Gasket Sealer on
manifold side. Do not coat composition gasket with
(any) sealer.
(2) Set exhaust manifold in place. Tighten retaining
nuts starting at center and progressing outward in
both directions to 23 N-m (200 in. lbs.) torque (Fig. 3).
Repeat this procedure until all nuts are at specified
torque.
(3) Set intake manifold in place.
(4) Raise vehicle and tighten retaining screws start­
ing at center and progressing outward in both direc­
tions to 23 N*m (200 in.lbs.) torque (Fig. 3). Repeat
this procedure until all screws are at specified torque.
(5) Reverse removal procedures 1-9 for installation.
(6) With the DRBII use ASD Fuel System Test to
pressurize system to check for leaks.
CAUTION: When using the ASD Fuel System Test,
The Auto Shutdown (ASD) Relay will remain ener­
gized for 7 minutes or until the ignition switch Is
turned to the OFF position, or Stop All Test is selected.
 15 N*m
(130 IN. LBS.)
A ll INTAKE
PLENUM

20 N*m
(174 IN. LBS.)

. EXHAUST
INTAKE (CROSS) CROSSOVER
MANIFOLD PIPE

22 N"m
( I f l IN. LBS.)

HEAT
SHIELD

15 Nm
■ • (130 IN. LBS.)
20 N*m
HEAR EXHAUST (174 IN. LBS.)
MANIFOLD FRONT

Fig. 1 3.0L Intake and Exhaust'Manifolds'

INIAXE AND EXHAUST MANIFOLDS
3 J L ENGINE
The intake system consists of a large air intake
plenum of aluminum alloy and a cross type intake
manifold.(Fig. 1)
 The exhaust manifolds are made of ductile cast iron
with the front bank and rear bank independent of TE R M IN A H I
each other. The exhaust from the front bank exhaust T E tM IN A l #1
TERMINAL #2
manifold is led through on exhaust c ro s s o v e r pipe to TERMINAL #2
be combined with the rear bank exhaust at the ex­
haust outlet to the exhaust pipe (Fig. 2)..

AIR INTAKE EXHAUST

PLENUM CROSSOVER
PIPE 2.5L ENGINE 3.01 ENGINE
CROSS TYPE
INTAKE
MANIFOLD

TERMINAL #2 TERMINAL #1

1=>

3.3L ENGINE
9114-147

Pig. 3 Injector Harness C m m ctm s

EXHAUST
MANIFOLD
EXHAUST (FRONT)
MANIFOLD
fiEAR) t i l 112
AIR CLEANER GASKET BOLT (2)
Pig. 2 Manifolds 3.01 Engine TO THROTTLE BODY
HOSE
INTAKE PLENUM/MANIPOLD
REMOVAL
(1) Perform fuel system pressure release procedure
(before attempting any repairs).
(2) Disconnect negative battery cable. Drain-cooling
system. See Cooling System, Group ?.
(3) Remo¥e air cleaner to throttle body hose (Fig. 4).

FUEL SYSTEM PRESSURE RELEASE

PROCEDURE
Th© MPI fuel-aystem is y n ie r a constant pressure AIR CLEANER
of approxim ately 330 kPa (48 psi). Before serwlclng ASSEMBLY
the fuel pump, fuel lines, fuel filte r, th rottle body or FRESH AIR
fuel Injector, the fuel system pressyre m ust be MODULE DUCT t i!4 G 3 §
released.
(1) Loosen fuel filler cap to release fuel tank pressure.
(2) Disconnect injector wiring harness from engine
harness.
(3) Connect a jumper wire to ground terminal Num­
ber 1 of the injector harness (Fig. 3) to engine ground.
(4) Connect a jumper wire to the positi¥e terminal
Number 2 of the injector harness (Fig. 3) and touch
the battery positive post for no longer than 5 seconds.
This releases system pressure.
(5) Remove jumper wires.
(6) Continue fuel system service.

Fig.5 ThrottleCable Attachment
(4) Remove throttle cable and transaxle kickdown
linkage (Fig. 5).
(5) Remove automatic idle speed (AIS) motor and
throttle position sensor (TPS) wiring connectors from
throttle body. (Fig. 6).
(6) Remove vacuum hose harness from throttle body
(Fig. 6).
(7) Remove PCV and Brake booster hoses from Air
Intake Plenum.
Fig. 6 Electricaland Vacuum Connections
to Throttle Body
908D-4
Fig. 7 Ignition CoilRemoval
(8) Remove Ignition Coil from Intake Plenum (Fig.
7).
(9) Remove wiring connectors from coolant tempera­
ture sensor (Fig. 8).
(10) Remove vacuum connections from Air Intake
Plenum vacuum connector.
(11) Remove fuel hoses from fuel rail (Fig. 8).
WARNING: WRAP SHOP TOWELS AROUND HOSES
TO CATCH ANY GASOLINE SPILLAGE.
A FUEL PRESSURE
FUEL SUPPLY AND ENGINE TEMPERATl '
RETURN HOSES I SENDING UNIT 908D-13
Fig.8 Coolant Temperature Sensor
ElectricalConnections
 COVERED INTAKE
MANIFQLD

Fig. 9 AirIntake Plenum to

Intake ManifoldAttaching Bolts
FUEL INJECTORS
(12) Remove eight Fasteners from Air Intake Ple­ WIRING CONNECTORS RR14G431
num to Intake Manifold (Fig. 9).
(13) Remove Air Intake Plenum (Fig. 10). Fig. 12 FuelInjector Wiring Harness
(14) Cover intake manifold with suitable cover when
COVERED INTAKE*
servicing. MANIFOLD
(15) Remove vacuum hoses from fuel rail and fuel
pressure regulator (Fig. 11).

AIR INTAKE PLENU M

^ ..-.|1:;
FUEL INJECTORS *
•WIRING HARNESS!

"w iZS T
Fig. 13 Fuel Pressure Regulator to Fuel Rail Assembly
INTAKE n- (16) Disconnect Fuel Injector wiring harness from
GASKET RUNNERS 9014-89
engine wiring harness (Fig. 12).
(17) Remove fuel pressure regulator attaching bolts
Fig. 10 Removing AirIntake Plenum and remove regulator from rail (Fig. 13). Be careful
LOWER MANIFOLD MU ST BE COVERED DURING SERVICE not to damage the rubber Injector O -rings upon re­
moval from the ports.
w (18) Remove fuel rail attaching bolts and lift fuel
rail assembly from intake manifold.
(19) Separate radiator hose from therm ostat hous­
ing and heater hose from heater pipe.
(20) Remove eight nut and washer assemblies and
remove intake manifold (Fig. 1).

CANI STER PURGE

9 0 1 4-51
VAPOR HOSE

Fig. 11 Vacuum Connections forFuel Railand

Fuel Pressure Regulator
 MOUNTING SURFACE

Fig. 15 Check IntakePlenum Mounting Surfaces

Fig. 14 Check Intake (Cross)Manifold Intake Plenum Mounting Surface

Mounting Surface Standard: .15mm (.004 inch.)
Maximum: ,30mm (.008 inch.)
IN S PECTIO N
Check for:
• Damage and cracks of each section (Fig. 14). Cylinder Head Mounting Surface
Standard: .10mm (.003 inch.)
• Clogged water passages in end cross overs.
Maximum: .20mm (.005 inch.)
• Check for distortion of the cylinder head mounting
surface using a straightedge and thickness gauge (Fig. 9111-11
15). Refer to (Fig. 16) for Specifications
Fig. 16 IntakePlenum m d Cylinder Head
Mounting Surface Specifications
INSTALLATION
(1) Position new intake manifold gaskets on cylin­
der head and install intake (cross) manifold.
(2) Install eight nuts and washers and tighten in
several steps in order shown in (Fig. 17) to 20 N*m
(174 in. lbs.).
 RR11B5
Fig. 17 Nut Tightening Sequence for
Intake(Cross) Manifold
(3) Make sure the injector holes are clean and all
plugs have been removed.
(4) Lube injector O-ring with a drop of clean engine
oil to ease installation.
(5) Put the tip of each injector into their ports. Push
the assembly into place until the injectors are seated
in the ports.
(6) Install the three fuel rail attaching bolts and
torque to 13 N'm (115 in. lbs.).
(7) Install fuel pressure regulator onto fuel rail.
Install attaching bolts to intake manifold. Torque reg­
ulator nuts and bracket bolts to 10 N-m (95 in. lbs.)
(Fig. 13).
(8) Install fuel supply and return tube hold-down
bolt and the vacuum crossover tube hold-down bolt
and torque to 10 Non (95 in. lbs.).
(9) Connect fuel injector wiring harness to engine
wiring harness (Fig. 12).
(10) Connect vacuum harness to fuel pressure regu­
lator and fuel rail assembly (Fig. 11).
(11) Remove covering from lower intake manifold
and clean surface.
(12) Place intake manifold gaskets with beaded seal­
ant side up on lower manifold. Put air intake in place.
Install attaching fasteners eight and tighten in several
steps in sequence shown (Fig. 18) to 13 N-m (115 in.
lbs.).
Fig. 18 Intake Plenum Tightening Sequence
(13) Connect fuel line to fuel rail (Fig. 8). Torque
hose clamps to 1 N-m (10 in. lbs.).
(14) Connect vacuum harness to air intake plenum.
(15) Connect and coolant temperature sensor elec­
trical connector to sensor (Fig. 8).
(16) Connect PCV and brake booster supply hose to
intake plenum.
(17) Connect automatic idle speed (AIS) motor and
throttle position sensor (TPS) electrical connectors (Fig.
6 ).
(18) Connect vacuum vapor harness to throttle body
(Fig. 6).
(19) Install throttle cable and transaxle kickdown
linkage (Fig. 5).
(20) Install air inlet hose assembly (Fig. 4).
(21) Install radiator to thermostat housing hose and
heater hose to heater pipe nipple.
(22) Fill cooling system, see Refilling System in
Cooling, Group 7.
(23) Connect negative battery cable.
(24) With the DRBII use ASD Fuel System Test to
pressurize system to check for leaks.
CAUTION: When using the ASD Fuel System Testjhe
Auto Shutdown (ASD) Relay will remain energized
for 7 minutes or until the ignition switch is turned to
the OFF position, or Stop All Test is selected.
EXHAUST MANIFOLDS
REMOVAL
(1) Raise vehicle and disconnect exhaust pipe from
rear (cowl side) exhaust manifold at articulated joint.
(2) Disconnect Oxygen Sensor lead wire at the rear
exhaust manifold (Fig. 19).
(3) Remove bolts attaching cross-over pipe to mani­
fold (Figs. 1 and 20).
(4) Remove nuts attaching rear manifold to cylinder
head and remove manifold.
 STANDARD: .15 mm (.004 inch)
LIMIT: .3 mm (.008 inch)

9111-10

Fig. 19 Separate ArticulatedJoint, Fig.21 Check Exhaust Manifold Mounting Surface

Disconnect Oxygen Sensor Wire
INSTALLATION
Install the gaskets with the numbers 1-3-5 embossed
on the top on the rear bank and those with numbers
2-4-6 on the front (Radiator side) bank (Fig. 22).
(1) Install rear exhaust manifold and tighten at­
taching nuts to 20 N-m (175 in. lbs.).
(2) Attach exhaust pipe to exhaust manifold and
tighten shoulder bolt to 28 N-m (250 In. Lbs.)
(3) Attach crossover pipe to exhaust manifold and
tighten bolt to 69 N-m (51 Ft. Lbs.)
(4) Connect heated oxygen sensor lead (Fig. 19).
(5) Install front exhaust manifold and attach ex­
haust crossover.
(6) Install front manifold heat shield and tighten
attaching screws to 15 N-m (130 in. lbs.) (Fig. 1).

<=>
TIMING IEIT REAR RANK
END
Fig.20 Crossover Pipe
(5) Lower vehicle and remove screws attaching front 099C 5) I
heat shield to front manifold (Fig. 1).
(6) Remove bolts fastening crossover pipe to front
<9
exhaust manifold and nuts fastening manifold to cyl­
FRONT RANK
inder head. Remove assemblies. TIMING 1ELT
END RR11B10
INSPECTION
(1) Inspect exhaust manifolds for damage or cracks
and check distortion of the cylinder head mounting
surface and exhaust crossover mounting surface with
a straightedge and thickness gauge (Fig. 21).
INTAKE/EXHAUST MANIFOLD 3.3L ENGINE GASKET

REMOVAL
(1) Perform fuel system pressure release procedure
(before attempting any repairs).
(2) Disconnect negative battery cable. Drain cooling
system. See Cooling System, Group 7.
(3) Remove air cleaner to throttle body hose assem­
bly (Fig. 2).
(4) Remove throttle cable (Fig. 3). Remove wiring
harness from throttle cable bracket.
(5) Remove automatic idle speed (AIS) motor and
throttle position sensor (TPS) wiring connectors from
throttle body (Fig. 4).

FUEL S YSTEM PRESSURE

RELEASE PROCEDURE
The MPI fuel system is under a constant pressure
of approximately 330 kPa (48 psi). Before servicing
the fuel pump, fuel lines, fuel filter, throttle body or
fuel injector, the fuel system pressure must be
released.
(1) Loosen fuel filler cap to release fuel tank pressure. Fig. 2 Throttle Body Assembly 3.3L
(2) Disconnect injector wiring harness from engine
harness.
(3) Connect a jumper wire to ground terminal Num­
ber 1 of the injector harness (Fig. 1) to engine ground.
(4) Connect a jumper wire to the positive terminal
Number 2 of the injector harness (Fig. l)and touch the
battery positive post for no longer than 5 seconds.
This releases system pressure.
(5) Remove jumper wires.
(6) Continue fuel system service.

TERMINAL #2 TERMINAL #1
 CANI STER PURGE ELECTRIC EXHAUST GAS MANIFOLD ABSOLU TE HEATED OXYGEN SENSOR
(PORTED) VACUUM NIPPLE RECIRCULATION (EGR) PRESSURE (MAP) SENSOR 4-WAY ELECTRICAL CONNECTOR
TRANSDUCER

THROTTLE POSITION SENSOR

(TPS) 3-WAY
ELECTRICAL CONNECTOR : 9014-23
Fig.6 MAP Sensor ElectricalConnector
(10) Remove cylinder head to intake plenum strut
(Fig. 5).
AUTOMATIC I DLE SPEED (AIS) (11) Disconnect MAP Sensor and heated Oxygen
MOTOR 3-WAY ELECTRICAL CONNECTOR / 9014-34 Sensor electrical connection. Remove the engine
mounted ground strap (Fig. 6).
Fig.4 Electricaland Vacuum Connection (12) Remove the fuel hose quick connect fittings
to ThrottleBody from the fuel rail by pushing in on the plastic ring
(6) Remove vacuum hose harness from throttle body located on the end of the fittings. Gently pull the
(Fig. 4). fittings from the fuel rail (Fig. 7).
(7) Remove PCV and brake booster hoses from air WARNING: WRAP A SHOP TOWEL AROUND HOSES
intake plenum (Fig. 5). TO CATCH ANY GASOLINE SPILLAGE.
(8) Remove EGR tube flange from intake plenum
(Fig. 5).
(9) Disconnect Charge Temperature Sensor electri­
cal connector. Remove vacuum harness connectors from
Intake Plenum (Fig. 5).

PLASTIC
O-RING RINGS

OPEN END
WRENCH ............................. ' ’ '9014-48
Fig.5 Electricaland Vacuum Connections
To Intake Manifold
 FUEL RAIL RETAINER
ALTERNATOR TO INTAKE BRACKET SCREW
MANIFOLD BOLT — IGNITION COILS FASTENERS (4)

r
f LOWE I INTAKE MANIFOLD MUST IE COVERED
P U IIN G SERVICE — 9014-38

Fig. 10 Fuel fla il Attaching Bolts

(18) Remove vacuum harness connector from Fuel

IGNITION COILS ELECTRICAL
CONNECTOR 9014-26
Fig. 8 Ignition Colls
f (13) Remove direct ignition system (DIS) coils and
alternator bracket to intake manifold bolt (Fig. 8).
(14) Remove intake manifold bolts and rotate mani­
fold back over rear valve cover (Fig. 9).
(15) Cover intake manifold with suitable cover when
servicing (Fig. 10).
Pressure Regulator.
(17) Remove fuel tube retainer bracket screw and
fuel rail attaching bolts (Fig. 10). Spread the retainer
bracket to allow fuel tube removal clearance.
(18) Remove fuel rail injector wiring clip from the
alternator bracket (Fig. 11).
(19) Disconnect cam sensor, coolant temperature sen­
sor, and engine temperature sensors (Fig. 11).
(20) Remove fuel injector wiring clip from intake
manifold water tube.
FUEL TUBE
RETAINER
T

9014-37

V
ALTERNATOR
BRACKET
'

Fig. 12 Fuel RailRemoval
(21) Remove fuel rail. Be careful not to damage the
rubber injector O-rings upon removal from their ports
(Fig. 12).
(22) Remove upper radiator hose, bypass hose and
rear intake manifold hose (Fig. 13).
(23) Remove intake manifold bolts. Remove intake
manifold.
(24) Remove intake manifold seal retainers screws
(Fig. 14). Remove intake manifold gasket.
9009-35
Fig. 14 Intake Manifold Gasket
IN S PE C TIO N
Check for:
• Damage and cracks of each section.
• Clogged water passages in end crossovers.
INSTALLATION
(1) Clean all surfaces of cylinder block and cylinder
heads.
(2) Place a drop (approx imately 1/4 in. diameter) of
Mopar Silicone Rubber Adhesive Sealant or equiva­
lent, onto each of the four manifold to cylinder head
gasket comers (Fig. 15).
WARNING: INTAKE MANIFOLD GASKET IS MADE
OF VERY THIN METAL AND MAY CAUSE PERSONAL
INJURY, HANDLE WITH CARE.
(3) Carefully install the intake manifold gasket (Fig.
14). Torque end seal retainer screws to 12N-m (105 in.
lbs.).
 (4) Install intake manifold and eight bolts and torque
to 1 N-m (10 in. lbs.). Then retorque bolts to 22 N-m
(200 in. lbs.) in sequence shown in (Fig. 13). Then
retorque again to 22 N-m (200 in. lbs.).After intake
manifold is in place, inspect to make sure seals are
(27) Lubricate the ends of the chassis fuel tubes
with 30 wt oil. Connect fuel supply and return hoses
to chassis fuel tube assembly, pull back on the quick
connect fitting to ensure complete insertion.(Fig. 7).
(Refer to Fuel Hoses, Clamps and Quick Connect Fit ­

in place. tings in Group 14 Fuel Systems).

(5) Make sure the injector holes are clean and all (28) Install throttle cable (Fig. 3).
plugs have been removed. (29) Connect fuel injector wiring harness.
(6) Lube injector O-ring with a drop of clean engine (30) Install air cleaner and hose assembly (Fig. 2).
oil to ease installation. (31) Connect negative battery cable. Fill Cooling
(7) Put the tip of each injector into their ports.Push System. See Cooling System, Group 7.
the assembly into place until the injectors are seated (32) With the DRBII use ASD Fuel System Test to
in the ports (Fig. 12). pressurize system to check for leaks.
(8) Install the four fuel rail attaching bolts and
CAUTION: When using the ASD Fuel System Test,
torque to 22 N’m (200 in. lbs.) (Fig. 10).
The Auto Shutdown (ASD) Relay will remain ener­
(9) Install fuel tube retaining bracket screw and
gized for 7 minutes or until the ignition switch is
torque to 4 N-m (35 in. lbs.) (Fig. 10).
turned to the OFF position, or Stop All Test is selected.
(10) Reconnect cam sensor, coolant temperature sen­
sor and engine temperature sensors (Fig. 11).
EXHAUST MANIFOLDS
(11) Install fuel injector harness wiring clips on the
alternator bracket and intake manifold water tube REMOVAL
(Fig. 11). (1) Raise vehicle and disconnect exhaust pipe from
(12) Connect fuel pressure regulator vacuum line. rear (cowl side) exhaust manifold at articulated joint.
(13) Remove covering on lower intake manifold and (2) Separate EGR tube from rear manifold and dis­
clean surface. connect Heated Oxygen Sensor lead wire (Fig. 16).
(14) Place intake manifold gasket on lower mani­ (3) Remove Alternator/Power Steering Support Strut
fold. Put upper manifold into place and install bolts (Fig. 16).
finger tight. (4) Remove bolts attaching cross-over pipe to mani­
(15) Install the alternator bracket to intake mani­ fold (Fig. 16).
fold bolt and the cylinder head to intake manifold
strut bolts. (Do not torque.)
(16) Torque intake manifold bolts to 28 N-m (250 in.
lbs.) following torque sequence in (Fig. 9).
(17) Torque alternator bracket to intake manifold
bolt to 54 N-m (40 ft. lbs.) (Fig. 8).
(18) Torque the cylinder head to intake manifold
strut bolts to 54 N-m (40 ft. lbs.) (Fig. 5).
(19) Connect ground strap, MAP and heated oxygen
sensor electrical connectors (Fig. 6).
(20) Connect charge temperature sensor electrical
connector (Fig. 5).
(21) Connect vacuum harness to intake plenum (Fig.
5).
(22) Using a new gasket, connect the EGR tube
flange to the intake manifold and torque to 22N-m
(200 in. lbs.).
Fig. 16 EGR Tube, Heated Oxygen Sensor and
(23) Clip wiring harness into the hole in the throttle Alternator/Power Steering Strut
cable bracket.
(24) Connect the wiring connectors to the throttle (5) Remove bolts attaching rear manifold to cylin­
position sensor (TPS) and Automatic Idle Speed (AIS) der head and remove manifold.
motor (Fig. 4). (6) Lower vehicle and remove screws attaching front
(25) Connect vacuum harness to throttle body (Fig. heat shield to front manifold (Fig. 17).
4). (7) Remove bolts fastening crossover pipe to front
(26) Install the direct ignition system (DIS) coils. exhaust manifold and nuts fastening manifold to cyl­
Torque fasteners to 12 N-m (105 in. lbs.) (Fig. 8). inder head. Remove assemblies (Fig. 18).
EXHAUST SYSTEM AND INTAKE MANIFOLD 11-19

INSPECTION
(1) Inspect exhaust manifolds for damage or cracks
and check distortion of the cylinder head mounting
surface and exhaust crossover mounting surface with
a straightedge and thickness gauge (Fig. 19).
STANDARD: .15 mm (.004 inch)
LIMIT: .3 mm (.008 inch)

9111-10

Fig. 19 Check Exhaust Manifold Mounting Surface

INSTALLATION
(1) Install rear exhaust manifold and tighten at­
taching bolts to 23 N-m (200 in. lbs.).
(2) Attach exhaust pipe to exhaust manifold and
tighten shoulder bolt to 28 N-m (250 in. lbs.).
(3) Attach crossover pipe to exhaust manifold and
tighten bolt to 33 N-m (25 ft. lbs.) and connect oxygen
sensor lead (Fig. 16).
(4) Install EGR Tube and Alternator/Power Steer­
ing Strut (Fig. 16).
(5) Install front exhaust manifold and attach ex­
haust crossover (Fig. 18).
(6) Install front manifold heat shield and tighten
attaching screws to 23 N-m (200 in. lbs.) (Fig. 17).
 TORQUE SPECIFICATION

Heat Shield Mounting Scr ews. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8 N*m ( 75 in. lbs.)

Heat Shield Mounting Nu t s . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5 N*m ( 45 in. lbs.)
Insulator Mounting Bolts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 28 N*m (250 in, lbs.)
U-Bolt Nuts & Uni-Clamp Nut . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . -■ 30 N*m (270 in. lbs.)
Intake Manifold Screws—2.5L . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23 N*m (200 in. lbs.)
Exhaust Manifold Nuts—2.5L . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23 N*m (200 in. lbs.)
Exhaust Flange Nuts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 28 N*m (250 in. lbs.)
Air Intake Plenum Screws—3.0L . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15 N*m (130 in. lbs.)
Intake (Cross) Manifold—3.0L . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20 N*m (174 in. lbs.)
Exhaust Manifold Nuts—3.0L . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22 N*m (191 in. lbs.)
Exhaust Manifold Heat Shield Screws—3.0L . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15 N#m (130 in. lbs.)
Crossover Bolt—3.0L . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 69 N*m ( 51 ft. lbs.)
Exhaust Manifold Mounting Stud 3.3L . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23 N*m (200 in. lbs.)
Exhaust Manifold Mounting Screws 3 JL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23 N*m (200 in. lbs.)
Exhqust Manifold Crossover Bolts 3.3L . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 33 N*m ( 25 ft. lbs.)
Exhaust Manifold Crossover Nuts 3.3L . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 33 N*m ( 25 ft. lbs.)
Heat Shield Mounting Screws 3.3L. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23 N*m (200 in. lbs.)
intake Manifold Attaching Screws 3.3L. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ' 23 N*m (200 in. lbs.)
Intake Manifold Upper/Lower Attaching Screws . . . . . . . . . . . . . . . . . . . . . . . . . - 28 N*m (250 in. lbs.)
Intake Manifold to Cylinder Head Strut 3.3L. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 54 N*m ( 40 ft. lbs.)
Intake Manifold G asket Retainer Screws 3.3L . . . . . . . . . . . . . . . . . . . . . . . . . . . . ■ 12 N*m (105 in. lbs.)
9111-25
 FRAME
CONTENTS
Page Page
ALL WHEEL DRIVE VAN/WAGON FRONT WHEEL DRIVE VAN/WAGON
CROSSMEMBER 5 CROSSMEMBER 5
FRAME DIMENSIONS................................. 1 GENERAL INFORMATION............................. 1
GENERAL INFORMATION mensions are from center to center of Principal Locat­
ing Point (PLP), or from center to center of PLP and
In this section, references are made to Vehicle Fam­ fastener location.
ily (Body) codes. To determine the vehicle family iden­
tification code, refer to the Introduction Group at the VEHICLE PREPARATION
front of this manual. Position the vehicle on a level work surface. Using
screw or bottle jacks, adjust the vehicle PLP heights
FRAME DIMENSIONS to the specified dimension above a level work surface.
Vertical dimensions can be taken from the work sur­
Frame dimensions are listed in metric scale then face to the locations indicated (Figs. 1, 2, 3 or 4).
converted to inch scale listed in parenthesis. All di-
 SIDE VIEW

MEASURING PO INT DESIGNATIO NS

A - Head of Rear Mounting Bolt for front Crossmember D.S. - DRIVER SIDE
B - Center of 25 mm (1") Round Hole - Front P.S. - PASSENGER SIDE
Center of frame Rail • - BOLTS
C - Center of 15 mm ( % \ " ) Round Hoi© - Rear o - HOLES
Center of Frame Rail • - PLP LOCATIONS
D - Front Inner Bolt of forward Spring Shackle
E - Outer Tip of Bolt - Rear Shock Mounting Bolt
2846mm (111.0 in.) wheel base
F - Rear Center of 32 x 17 min (11 x fl/i##} Oval Hole
van/wagon
G - Head of Bolt on Rearward Spring Shackle
H - Center of 18 mm (f,/16") Round Hole
I - Inside Bolt for Rear Bumper Bracket
Tip of Rear Mounting Bolt for Front Crossmember D.S. - DRIVER SIDE
Center of 25 mm (1") Round Hole P.S. - PASSENGER SIDE
Center of 25 mm (1") Round Hoi© • - BOLTS
front Inner Bolt of Forward Spring Shackle O - HOLES
Outer Tip of Bolt - Rear Shock Mounting Bolt • - PIP LOCATIONS
Rear Center of 32 x 17 mm (1M x 1!/ i 6") Oval Hole
Head of Boil on Rearward Spring Shackle
Center of 18 mm (n/16") Round Hoi#
D.S. - Outer Bolt for Rear Bumper Bracket 3024mm (119.1 in) wheel base
P S. - Outer Bolt for Rear Bumper Bracket van/wagon

Pig. 2 Dimensions Hear of Croaamamben—Long Wheel Base Van/Wagon

 BALL
JOINT
JL 1446
•*(56.9)

front Tip of Bolt •

CENTER LINE * Tip of Upper loll ■
Bracket
1 -- D.S. - Head of Lower Bolt -
Transmission Mount
B1 - P.S. - Head of Lower Bolt -
Transmission Mount
C - Center of 25 mm (1") Round
Inches in parenthesis Hole
A r m Pivot
Center of Lower Ball Joint
Head of front Mounting Bolt for
Front Subframe
Head of Rear Mounting Bolt for
Front Subframe
Center of 25 mm (1") Round
Hole - Front Center of Frame
Rail 9113-5

Fig. 3 Dimensions Forward of Gage Hole Hear of Crossmember—All Van/Wagons

FRONT WHEEL DRIVE VAN/WAGON CROSSMEMBER
CROSSMEMBER REMOVAL (FIG. 5)
(1) Hoist vehicle and support on safety stands. Refer
to Group 0, Lubrication and Maintenance for proper
procedures.
(2) Remove front wheels.
(3) Disconnect lower ball joints from the knuckle
assembly. Refer to Group 2, Suspension for proper
procedures.
(4) Disconnect power steering hose tie-down from
rear upper edge of crossmember, if equipped.
(5) Remove bolts holding steering gear to cross­
member. Refer to Group 19, Steering for proper
procedures.
(7) Support crossmember on a suitable lifting device.
(8) Remove nuts holding rear of crossmember to the
frame.
(9) Remove bolts holding crossmember to frame from
above lower control arms.
(10) Separate the crossmember from the vehicle.
(11) Transfer lower control arms and sway elimina­
tor shaft to new crossmember, if crossmember is being
replaced. Refer to Group 2, Suspension for proper
procedure.
(4) Disconnect power steering hose tie-down from
rear upper edge of crossmember, if equipped.
(5) Remove bolts holding steering gear support bridge
to crossmember.
(8) Remove bolt holding engine bobble stm t to
crossmember.
(7) Support crossmember on a suitable lifting device.
(8) Remove nuts holding rear of crossmember to the
frame.
(9) Remove bolts holding crossmember to frame from
above lower control arms.
(10) Separate the crossmember from the vehicle.
(11) Transfer lower control arms and sway elimina­
tor shaft to new crossmember, if crossmember is being
replaced. Refer to Group 2, Suspension for proper
procedure.
m ossM E M B m in s t a l l a t io n
Reverse the preceding operation.

CROSSMEMBER IN STALLATIO N
Reverse the preceding operation.

Fig.5 Front Wheel Drive Van/Wagon Crossmember

ALL WHEEL DRIVE VAN/WAGON CROSSMEMBER
CROSSMEMBER REMOVAL (FIG. 6)
(1) Hoist vehicle and support on safety stands. Refer
to Group 0, Lubrication and Maintenance for proper
procedures.
(2) Remove front wheels.
(3) Disconnect lower ball joints from the knuckle
assembly. Refer to Group 2, Suspension for proper
procedures.
 FUEL SYSTEM
CONTENTS
Page
ACCELERATOR PEDAL AND
THROTTLE CABLE ......................... 27
COMPONENT IDENTIFICATION—
2.5L TBI ENGINES ......................... 29
COMPONENT IDENTIFICATION—
3.0L ENGINES .............................. 62
COMPONENT IDENTIFICATION—
3.3L ENGINES . . . ....................... 93
FUEL DELIVERY SYSTEM -
ALL WHEEL DRIVE ....................... 10
FUEL DELIVERY SYSTEM -
FRONT WHEEL DRIVE .................... 3 SINGLE POINT FUEL INJECTION—
FUEL TANK— ALL WHEEL DRIVE 22
FUEL TANK— FRONT WHEEL DRIVE 16
GENERAL DIAGNOSIS—
2.5L TBI ENGINES ......................... 40
GENERAL INFORMATION
Throughout this group, references may be made to a
particular vehicle by letter or number designation. A
chart showing the breakdown of these designations is
included in the Introduction Section at the front of
this service manual.
The Fuel System consists of the fuel tank, fuel pump,
fuel filter, throttle body, fuel injectors, fuel lines and
vacuum lines.
The Fuel Delivery System consists of the fuel pump
module, fuel filter, fuel lines and fuel hoses.
The Fuel Tank Assembly consists of the feel tank,
fuel pump module, filler tube, and a pressure-vacuum
filler cap.
Also, to be considered part of the fuel system is the
Evaporation C ontrol System, which is designed to
reduce the emission of fuel vapor into the atmosphere.
The description and function of the Evaporation Con­
trol System is found in Group 25 of this manual.
FUEL REQUIREMENTS '
Your vehicle was designed to meet all emission reg­
ulations and provide excellent fuel economy when us­
ing high quality unleaded gasoline having a minimum
octane rating of 87.
Light spark knock at low engine speeds is not harm ­
ful to your engine. However, continued heavy spark
knock at high speeds can cause damage and should be
reported to your dealer immediately. Engine damage
resulting from operating with a heavy spark knock
may not be covered by the new vehicle warranty.
Page
GENERAL DIAGNOSIS— 3.0L ENGINES 71
GENERAL DIAGNOSIS— 3.3L ENGINES 103
GENERAL INFORMATION .................. 1
MULTI-POINT FUEL INJECTION—
3.0L ENGINES .................................. 62
MULTI-POINT FUEL INJECTION­
S ' ENGINES ............ .................. 93
SERVICE PROCEDURES—
2.5L TBI ENGINES ............................. 53
SERVICE PROCEDURES— 3.0L ENGINES .. .. 85
SERVICE PROCEDURES— 3.3L ENGINES .. .. 117
2.5L TBI ENGINES ............................. 29
In addition to using unleaded gasoline with the
proper octane rating, gasolines th at contain deter­
gents, corrosion and stability additives are recom­
mended. Using gasolines th at have these additives
will help improve fuel economy, reduce emissions, and
maintain vehicle performance. Generally, premium un­
leaded gasolines contain more additive than regular
unleaded.
Poor quality gasoline can cause problems such as
hard starting, stalling, and stumble. If you experience
these problems, try another brand of gasoline before
considering service for the vehicle.
GASOLINE/OXYGENATE BLENDS
Some fuel suppliers blend gasoline with materials
that contain oxygen such as alcohol and MTBE (Methyl
Tertiary Butyl Ether). The type and amount of oxy­
genate used in the blend is important.
The following are generally used in gasoline blends:
Ethanol - (Ethyl or Grain Alcohol) properly blended,
is used as a mixture of 10% ethanol and 90% gasoline.
Gasoline blended with ethanol may be used in your
vehicle.
Methanol - (Methyl or Wood Alcohol) is used in a
variety of concentrations when blended with unleaded
gasoline. You may find fuels containing 3% or more
methanol along with other alcohols called cosolvents.
Do not yse gasolines containing Methanol.
Use of methanol/gasoline blends may result in start­
ing and driveability problems and damage critical fuel
system components.
 Problems th at are the result of using methanol/
gasoline blends are not the responsibility of Chrysler
Motors and may not be covered by the new vehicle
warranty.
MTBE - Gasoline and MTBE (Methyl Tertiary Butyl
Ether) blends are a mixture of unleaded gasoline
blended with up to 15% MTBE. Gasoline blended with
MTBE may be used in your vehicle.
Clean Air Gasoline
In some areas of the country where carbon monox­
ide levels are high, gasolines are being treated with
oxygenated m aterials such as MTBE and ethanol.
Chrysler Motors supports these efforts toward cleaner
air. You can help by using these blends as they be­
come available.
Materials Added to Fuel
Indiscriminate use of fuel system cleaning agents
should be avoided. Many of these m aterials intended
for gum and varnish removal may contain active sol­
vents of similar ingredients th at can be harmful to
gasket and diaphragm m aterials used in fuel system
component parts.
 FUEL DELIVERY SYSTEM—FRONT WHEEL DRIVE
INDEX
Page Page
Chassis Fuel Tubes .................................................... 8 Fuel Pump Installation— Front Wheel Drive ............. 7
Fuel Filter—Front Wheel Drive .................................. 8 Fuel Pump/Level Unit Assembly—
Fuel Hoses, Clamps, and Quick Front Wheel Drive ................................................... 5
Connect Fittings .................................................... 3 Fuel Pump Pressure Test—Front Wheel Drive ......... 5
Fuel Level Sending Unit Diagnosis............................ 7 Fuel Pump Removal— Front Wheel Drive................... 6
Fuel Level Sending Unit Service— Fuel System Pressure Release Procedure ................. 3
Front Wheel Drive .................................................. 7 General Information .............................. ........ .......... 3
Fuel Pump Inlet Strainer Service—
Front Wheel Drive ............................ ...................... 6

GENERAL INFORMATION
TERMINAL #1
The front wheel drive van and the all wheel drive TERMINAL #1
TERMINAL 02
van use different fuel delivery systems. The front wheel
TERMINAL #2
drive van uses a metal fuel tank mounted in the rear
of the vehicle. The all wheel drive van uses a plastic
fuel tank located on the left side of the vehicle. The
fuel pumps and the chassis fuel tubes are different
between the front wheel drive and the all wheel drive
2.5L ENGINE 3.0L ENGINE
vehicles due to the differences in fuel tank locations.
Both the front wheel drive and the all wheel drive
fuel pump modules have an internal fuel reservoir, a
fuel level sending unit, and a fuel strainer mounted
on the pump housing. Both systems use quick connect TERMINAL #2 TERMINAL#!
fittings at the fuel tank and at the engine. The fuel
filter location is the same for both front wheel drive
and all wheel drive vehicles.

FUEL SYSTEM PRESSURE RELEASE PROCEDURE

(1) Loosen fuel filler cap to release fuel tank pressure.
(2) Disconnect injector wiring harness from engine
or main harness.
(3) Connect a jumper wire to ground term inal Num­
ber 1 of the injector harness (Fig. 1) to engine ground.
(4) Connect a jumper wire to the positive terminal
Number 2 of the injector harness (Fig. 1) and touch
the battery positive post for no longer than 5 seconds.
This releases system pressure.
(5) Remove jumper wires.
(6) Continue fuel system service.
3.3L ENGINE
9114-147
Fig. 11njectorHarness Connectors
FUEL HOSES, CLAMPS, AND
QUICK CONNECT FITTINGS
Inspect all hose connections (clamps and quick con­
nect fittings) to make sure they are secure and no
leaks are present. Hoses should be replaced immedi­
ately if there is any evidence of degradation that could
result in failure.
Avoid contact with clamps or other components th at
cause abrasions or scuffing. Ensure th at the rubber
hoses are properly routed to prevent pinching and to
avoid heat sources.
The hoses used on fuel injected vehicles are of spe­
cial construction due to the possibility of contami­
nated fuel in this system. If it is necessary to replace
these hoses, only hoses marked EFM/ EFI may be
used.
The hose clamps used are of a special rolled edge
construction to prevent the edge of the clamp cutting
into the hose. Only these rolled edge type clamps may
be used in this system, all other types of clamps may
cut into the hoses and cause high pressure fuel leaks.
e new original equipment type hose clamps, torque
hose clamps to 1 N*m (10 in. lbs.).
The fuel line fittings used are quick connect'type
fittings. These fittings are designed to speed up the
installation and removal of the fuel lines. (Fig. 2)
PLASTIC HOSE
RING
CLAMP
CRIMP TORQUE HOSE CLAMPS TO
FERRULE 918D-47
_ IEES^EET~
Pig. 2 Quick Connect Fuel Fittings
Quick connect fittings consist of a metal casing, a
black plastic release ring, a metal locking retainer,
and internal o-rings.
The quick connect fittings may be removed from the
fuel tube nipple by pushing in on the plastic ring
located on the end of the fitting. An open end wrench
may be used to aid in disassembly.
W ien the fuel tube nipple is inserted into the quick-
connect fitting, the shoulder of the nipple is locked in
place by the locking retainer, and the internal O-rings
seal the tube.
The fuel tub© nipples m ust be firs t lubricated w ith
clean 30 weight engine o il prior to reconnecting the
quick-conned fittin g .
After connecting a quick-conned fittin g , the con­
nection should be werlfied by pulling on the lines to
ensure that the lock is secure.
TUBE/PITTING DISASSEMBLY
(1) Disconnect the negative battery cable.
(2) Remove the fuel tank gas cap to release any fuel
tank pressure.
(8) Perform fuel system pressure release procedure.
(4) Remove any loose dirt from quick connect fittings.
WARNING; WRAP SHOP TOWELS AROUND HOSES
TO CATCH ANY GASOLINE SPILLAGE.
(5) Press black plastic release ring in and pull quick
connector from the fuel tube. (Use open end wrench if
necessary).
(6) Cover the quick connector to prevent contam­
ination.
■ TUBE/PITTING ASSEMBLY
(1) Inspect the quick connect fitting to ensure th at
the black plastic release ring is in the OUT position. If
the locking retainer is stuck in the RELEASE position
due to mushrooming of the release ring, or dirt accu­
mulation, the fitting should be replaced.
(2) Lubricate the male end of the fuel tube with 30
wt. oil.
(3) Insert quick connector fitting.
(4) Pull quick connector back to ensure complete
connection. If the connection is not complete, check
the black plastic release ring to make sure it is not
causing the locking retainer to jam in the release
position.
(5) Use ASD Fuel System Test to pressurize the fuel
system. Check for leaks.
CAUTION; Whan ysing the ASD Fuel System Test,
the Auto Shutdown (ASD) Relay w ill remain ener­
gized fo r 7 m lnyfes o r u ntil the test Is stopped, or
until the Ignition sw itch is turned to the O ff poslth
TUBE/PITTING SERVICE
If a quick connect fitting needs to be serviced, the
following procedure must be followed:
■' (1) Disconnect the battery negative battery cable.
(2) Perform the fuel system pressure release.
(3) Remove the quick connect fitting from the*fuel
tube by pushing in on the plastic ring located on the
end of the fitting. Gently pull the fitting from the fuel
tube.
WARNING: WRAP SHOP TOWELS AROUND HOSES
TO CATCH ANY GASOLINE SPILLAGE.
(4) Cut off the cripnp ferrules at each end of the
hose, taking care not to damage the quick connect
fitting or the fuel tube.
(5) Discard the ferrules and hose. Discard the quick
connect fitting if it is defective.
(8) Replace the hose using hose marked EPM/ EFI.
This type of hose must be used due to its special
construction.
(7) Replace the quick connect fittings (if necessary)
with the correct size and type.
(8) Attach the replacement hose to the quick con­
nect fitting and fuel tube using the correct hose clamps.
The hose clamps used are of a special rolled edge
construction to prevent the edge of the clamp cutting
into the hose. Only these rolled edge type clamps may
be used in this system, all other types of clamps may
cut into the hoses and cause high pressure fuel leaks.
(9) Torque the hose clamps to 1 N m (10 in. lbs.).
(10) Use ASD Fuel System Test to pressurize the
fuel system. Check for leaks.
CAUTION; When using the ASD Fuel System Test,
the Auto Shutdown (ASD) Relay w ill remain ener­
gized fo r 7 m inutes or until the test is stopped, or
until the ignition sw itch is tyrned to the O ff position.
FUEL PUMP/LEVEL UNIT ASSEMBLY- FUEL SYSTEM PRESSURES
FRONT WHEEL DRIVE
The fuel pump/level unit assembly consists of the 2.5LTBI 265 kPa 39 psi
fuel pump, reservoir body, and level unit.
The reservoir body takes the place of the internal
fuel tank reservoir. The purpose of the reservoir is to 3.0L 330 kPa 48 psi
provide fuel at the pump intake during all driving
conditions, especially those when low fuel levels are
present. 3.3L 330 kPa 48 psi
The fuel pump used in this system is a positive
displacement, gerotor immersible pump with a perma­ 9114-134
nent magnet electric motor. (Fig. 3) The fuel is drawn
in through an inlet screen and pushed through the FUEL PUMP PRESSURE T E S T -
electric motor to the outlet. The pump contains two FRONT WHEEL DRIVE
check valves. One valve is used to relieve internal
fuel pump pressure and regulate maximum pump out­ (1) Fuel system pressure must be released each time
put. The other check valve is located in the fuel re­ a fuel hose is to be disconnected. Perform fuel system
turn line. It restricts fuel movement in either direction pressure release.
when the pump is not operational. Voltage to operate (2) Remove fuel supply hose quick connector from
the pump is supplied through the Auto Shutdown the chassis lines (at the engine).
Relay. (3) Connect Fuel Pressure Gauge C-4799 to Fuel
The level unit is attached to the side of the fuel Pressure Test Adapter 6539 and install between fuel
pump assembly. The level unit consists of a float, an supply hose and chassis fuel line assembly. (Fig. 4)
arm, and a variable resistor. As the fuel level in­
creases, the float and arm move up. This decreases the
sending unit resistance, causing the fuel gauge on the
instrum ent panel to read full.
All front wheel drive fuel systems use the same fuel
pump/level unit with an maximum output of approxi­
mately 930 kPa (135 psi). Pressure is regulated at the
fuel rail or throttle body by a fuel pressure regulator.
Fuel system pressures are shown in the Fuel System
Pressure chart.
Before servicing the fuel tank, fuel pump, fuel lines,
fuel filter, level unit, throttle body, or parts of the fuel
rail, the fuel pressure must be released. Perform fuel
system pressure release procedure.

Fig.4 Gauge and Adapter

(4) Using diagnostic tester, with the key in the Run
position, use ASD Fuel System Test, this will activate
the fuel pump and pressurize the system. If the gauge
reads the correct pressure listed in the Fuel System
Pressure chart, further testing is not required. If pres­
sure is not correct, record the pressure and remove
STRAINER TUBE 9114-133 gauge. Use ASD Fuel System Test to reactivate the
fuel pump. Ensure fuel does not leak from the chassis
fuel hose connection point.
CAUTION: When using the ASD Fuel System Test,
the Auto Shutdown (ASD) Relay will remain ener­
gized for 7 minutes or until the test is stopped, or
until the ignition switch is turned to the Off position.
 (5) If fuel pressure is below specifications, install
■Fuel Pressure Gauge C-4799 and Fuel Pressure Adapter
6433 in the fuel supply line. (Fig. 5) Install gauge and
adapter between the fuel tank and fuel filter at the
rear of vehicle.
SPECIAL TOOL 6433
clean container. (Fig. 6) Repeat test. If pressure is
now correct, check for restricted fuel return line. If no
change is observed, replace fuel pressure regulator.
FUEL PUMP REMOVAL— FRONT WHEEL DRIVE
It is necessary to remove fuel tank from vehicle to
service fuel pump. Follow fuel tank removal procedure.
(1) Using a hammer and a brass drift, carefully tap
lock ring counter clockwise to release pump (Fig. 7).
(2) Remove fuel pump and O-ring seal from tank.
Discard old seal.
HAMMER FUEL FUEL PUMP

9114-141

Fig. 5 Fuel Pressure Adapter

(8) Repeat test. If pressure is at least 5 psi higher

than previously recorded pressure, replace fuel filter.
If mo change is observed, gently squeeze return hose.
If pressure increases, replace pressure regulator. If no
change is observed, problem is either a plugged inlet
strainer or defective fuel pump.
(7) If pressure is above specifications, install Fuel
Pressure Gauge C-4799 and Fuel Pressure Adapter
8433 in the fuel supply line. (Fig. 5) Install gauge and
adapter between the fuel tank and fuel filter at the
rear of vehicle. Remove the fuel return line hose from Fig. 7 Fuel Pump Service
the fuel pump at fuel tank. Connect Fuel Pressure
Test Adapter 6541 to the return line. P u t the other
FUEL PUMP INLET STRAINER SERVICE—
end into an approved gasoline container (minimum 2
FRONT WHEEL DRIVE
gallon size) so th at all return fuel will flow into con­
REMOVAL
tainer. Repeat test. If pressure is now correct, replace
(1) Gently bend locking tabs on fuel pump reservoir
fuel pump assembly.
assembly to clear locking tangs on the fuel pump
(8) If pressure is still above specifications, remove
filter. (Fig. 8)
fuel return hose from chassis fuel tubes (at engine).
(2) Pull strainer off.
Attach Fuel Pressure Test Connect Adapter 8541 to
(3) Remove strainer o-ring from the fuel pump res­
the fuel return hose and place other end of hose in
ervoir body.
SPECIAL ■ FUEL RETURN
INLET FLOAT LOCKING

9114-88
INSTALLATION
(1) Lubricate the strainer o-ring with Mopar; Sili­
cone Spray Lube.
(2) Insert strainer o-ring into outlet of filter so that
it sits evenly on the step inside the filter outlet.
(3) Push strainer onto the inlet of the fuel pump
reservoir body, making sure that the locking tabs on
the reservoir body lock over the locking tangs on the
filter.
FUEL LEVEL SENDING UNIT DIAGNOSIS
liefer to Group 8—Electrical
FUEL LEVEL SENDING UNIT SERVICE—
FRONT WHEEL DRIVE
REMOVAL
(1) Bend locking tabs and remove electrical connec­
tor from the bottom of the fuel pump electrical connec­
tor. (Fig 9)
(2)' Remove term inal locking cover (red). Remove
sending unit wiring term inals from the electrical
connector.
(3) Use a wide blade screwdriver to push on the
sending unit body. Use another wide blade screw­
driver to release the sending unit locking tab. (Fig.
10)
(4) Slide the entire fuel level sending unit off of the
fuel pump/reservoir body.
(8) Carefully pull the wires through the eoverplate
and reservoir body.
FUEL PUMP
Fig. 10 Fuel le m l Sending Unit
INSTALLATION
(1) Carefully bend the level unit wires and lay into
the slot on the back or the level unit.
(2) Slide the level unit into the slots on the fuel
pump/reservoir assembly. Feed the wires through the
triangular hole in the fuel pump/reservoir body. Make
sure that the tab on the level unit locks into the
detent in th e fuel pump/reservoir assembly.
(3) Slip wires into tab on the fuel pump/reservoir
assembly.
(4) Carefully install the level unit wiring terminals
into the electrical connector. Install term inal locking
cover.
(5) Install the electrical connector into the bottom of
the fuel pump electrical connector. Ensure th at the
connector is fully locked into position.
FUEL PUM P INSTALLATION— FRONT WHEEL DRIVE
(1) Wipe seal area of tank clean and place a new
O-ring seal in position on pump.
(2) Positior fuel pump in tank with locking ring.
(3) Using a hammer and brass drift, drive ring around
clockwise to lock pump in place.
CAUTION: Extreme care shoyld be exercised not
to ©wertlghteii pym p as It mmld leak.
(4) Install tank.
FUEL FILTER— FRONT WHEEL DRIVE
REMOVAL
(1) Perform fuel system pressure release.
(2) Remove filter retaining screw and remove filter
assembly from rail (Fig. 11).
(3) Loosen outlet hose clamp on filter and inlet hose
clamp on rear fuel tube.
(4) Wrap a shop towel around hoses to absorb fuel.
Remove hoses at filter and fuel tube. Discard clamps.
FUEL FILTER
INSTALLATION
(1) Install inlet hose on fuel tube and torque new
clamp to 1 N-m (10 in. lbs.).
(2) Install outlet hose on filter outlet fitting and
torque new clamp to 1 N-m (10 in. lbs.).
(3) Position filter assembly on rail (Fig. 4) and torque
mounting screw to 8 N-m (75 in. lbs.).
CHASSIS FUEL TUBES
Fuel system component locations and chassis fuel
tube routings are shown in Fig. 12.
FUEL TANK
ASSEMBLY

FUEL SYSTEM
9114-148

14-9
 FUEL DELIVERY SYSTEM—ALL WHEEL DRIVE
INDEX
Page Page
Fuel Filter Service— All Wheel Drive ....................... 15 Fuel Pump/Level Unit Assembly—
Fuel Hoses, Clamps and All Wheel Drive ....................................................... 12
Quick Connect Fittings........................................... 10 Fuel Pump Module Installation—
Fuel Level Sending Unit Diagnosis ......................... 14 All Wheel Drive ....................................................... 14
Fuel Level Sending Unit Service— Fuel Pump Module Removal— All Wheel D rive ........ 13
All Wheel Drive ....................................................... 14 Fuel Pump Pressure Test— All Wheel Drive ............ 12
Fuel Pump Inlet Strainer Service— Fuel System Pressure Release Procedure ................ 10
All Wheel Drive ................................................ . . . 13 General Information ................................................... 10

GENERAL INFORMATION
TERMINAL #1
The front wheel drive van and the all wheel drive TERMINAL #1
TERMINAL #2
van use different fuel delivery systems. The front wheel TERMINAL #2
drive van uses a metal fuel tank mounted in the rear
of the vehicle. The all wheel drive van uses a plastic
fuel tank located on the left side of the vehicle. The
fuel pumps and the chassis fuel tubes are different
between the front wheel drive and the all wheel drive
2.5L ENGINE 3.0L ENGINE
vehicles due to the differences in fuel tank locations.
Both the front wheel drive and the all wheel drive
fuel pump modules have an internal fuel reservoir, a
fuel level sending unit, and a fuel strainer mounted
on the pump housing. Both systems use quick connect TERMINAL #2 TERMINAL #1
fittings at the fuel tank and at the engine. The fuel
filter location is the same for both front wheel drive
and all wheel drive vehicles.

FUEL SYSTEM PRESSURE RELEASE PROCEDURE

(1) Loosen fuel filler cap to release fuel tank pressure.
(2) Disconnect injector wiring harness from engine
or main harness.
(3) Connect a jumper wire to ground terminal Num­
ber 1 of the injector harness (Fig. 1) to engine ground.
(4) Connect a jumper wire to the positive terminal
Number 2 of the injector harness (Fig. 1) and touch
the battery positive post for no longer than 5 seconds.
This releases system pressure.
(5) Remove jumper wires.
(6) Continue fuel system service.
3.3L ENGINE
9114-147
Fig. 1 1njector Harness Connectors
FUEL HOSES, CLAMPS, AND
QUICK CONNECT FITTINGS
Inspect all hose connections (clamps and quick con­
nect fittings) to make sure they are secure and no
leaks are present. Hoses should be replaced immedi­
ately if there is any evidence of degradation that could
result in failure.
Avoid contact with clamps or other components that
cause abrasions or scuffing. Ensure that the rubber
hoses are properly routed to prevent pinching and to
avoid heat sources.
The hoses used on fuel iryected vehicles are of spe­
cial construction due to the possibility of contami­
nated fuel in this system. If it is necessary to replace
these hoses, only hoses marked EFM/EFI may be used.
The hose clamps used are of a special rolled edge
construction to prevent the edge of the clamp cutting
into the hose. Only these rolled edge type clamps may
be used in this system, all other types of clamps may
cut into the hoses and cause high pressure fuel leaks.
Use new original equipment type hose clamps, torque
hose clamps to 1 N’m (10 in. lbs.).
The fuel line fittings used are quick connect type
fittings. These fittings are designed to speed up the
installation and removal of the fuel lines.(Fig. 2)
Fig. 2 Quick Connect Fuel Fittings
Quick connect fittings consist of a metal casing, a
black plastic release ring, a metal locking retainer,
and internal o-rings.
The quick connect fittings may be removed from the
fuel tube nipple by pushing in on the plastic ring
located on the end of the fitting. An open end wrench
may be used to aid in disassembly.
When the fuel tube nipple is inserted into the quick-
connect fitting, the shoulder of the nipple is locked in
place by the locking retainer, and the internal O-rings
seal the tube.
The fuel tube nipples must be first lubricated with
clean 30 weight engine oil prior to reconnecting the
quick-connect fitting.
After connecting a quick-connect fitting, the con­
nection should be verified by pulling on the lines to
ensure that the lock is secure.
TUBEIFITTINQ DISASSEMBLY
(1) Disconnect the negative battery cable.
(2) Remove the fuel tank gas cap to release any fuel
tank pressure.
(3) Perform fuel system pressure release procedure.
(4) Remove any loose dirt from quick connect fittings.
WARNING: WRAP SHOP TOWELS AROUND HOSES
TO CATCH ANY GASOLINE SPILLAGE.
(5) Press black plastic release ring in and pull quick
connector from the fuel tube. (Use open end wrench if
necessary).
(6) Cover the quick connector to prevent contam­
ination.
TUBEIFITTINQ ASSEMBLY
(1) Inspect the quick connect fitting to ensure that
the black plastic release ring is in the OUT position. If
the locking retainer is stuck in the RELEASE position
due to mushrooming of the release ring, or dirt accu­
mulation, the fitting should be replaced.
(2) Lubricate the male end of the fuel tube with 30
wt. oil.
(3) Insert quick connector fitting.
(4) Pull quick connector back to ensure complete
connection. If the connection is not complete, check
the black plastic release ring to make sure it is not
causing the locking retainer to jam in the release
position.
(5) Use ASD Fuel System Test to pressurize the fuel
system. Check for leaks.
CAUTION: When using the ASD Fuel System Test,
the Auto Shutdown (ASD) Relay will remain ener­
gized for 7 minutes or until the test is stopped, or
until the Ignition switch is turned to the Off position.
TUBEIFITTINQ SERVICE
If a quick connect fitting needs to be serviced, the
following procedure must be followed:
(1) Disconnect the battery negative battery cable.
(2) Perform the fuel system pressure release.
(3) Remove the quick connect fitting from the fuel
tube by pushing in on the plastic ring located on the
end of the fitting. Gently pull the fitting from the fuel
tube.
WARNING: WRAP SHOP TOWELS AROUND HOSES
TO CATCH ANY GASOLINE SPILLAGE.
(4) Cut off the crimp ferrules at each end of the
hose, taking care not to damage the quick connect
fitting or the fuel tube.
(5) Discard the ferrules and hose. Discard the quick
connect fitting if it is defective.
(6) Replace the hose using hose marked EFM/ EFI.
This type of hose must be used due to its special
construction.
(7) Replace the quick connect fittings (if necessary)
with the correct size and type.
(8) Attach the replacement hose to the quick con­
nect fitting and fuel tube using the correct hose clamps.
The hose clamps used are of a special rolled edge
construction to prevent the edge of the clamp cutting
into the hose. Only these rolled edge type clamps may
be used in this system, all other types of clamps may
cut into the hoses and cause high pressure fuel leaks.
(9) Torque the hose clamps to 1 N-m (10 in. lbs.).
(10) Use ASD Fuel System Test to pressurize the
fuel system. Check for leaks.
CAUTION: When using the ASD Fuel System Test,
the Auto Shutdown (ASD) Relay will remain ener­
gized for 7 minutes or until the test Is stopped, or
until the ignition switch is turned to the Off position.
FUEL P U i P / l E V E l UNIT 1 S S E 1 B L Y — The all wheel drive fuel systems use a fuel pump/
IL L WHEEL DRIVE level unit with an maximum output of approximately
930 kPa (135 psi). Pressure is regulated to 330 kPa
. The fuel pump module consists of the fuel pump, (48 psi) at the fuel rail by a fuel pressure regulator.
reservoir body, and level unit. Before servicing the fuel tank, fuel pump, fuel lines,
The reservoir body takes the place, of the internal fuel filter, level unit, or parts of the fuel rail, the fuel
fuel tank reservoir. The purpose of the reservoir is to pressure must be released. Perform fuel system pres­
provide fuel at the pump intake during all driving sure release procedure.
conditions, especially those when low fuel levels are
present. FUEL PUMP PRESSURE TEST— ALL WHEEL DRIVE
The fuel pump used in this system is a positive
displacement, gerotor immersible pump with a perma­ (1) Fuel system pressure must be released each time
nent magnet electric motor. (Fig. 3) The fuel is drawn a fuel hose is to be disconnected. Perform fuel system
in through a filter sock and pushed through the elec­ pressure release.
tric motor to the outlet. The pump contains two check (2) Remove protective cover from service valve on
valves. One valve is used to relieve internal fuel pump the fuel rail.
pressure and regulate maximum pump output. The (3) Connect Fuel Pressure Gauge C-4799 to fuel rail
other check valve is located in the fuel return line. It service valve. (Fig. 4)
restricts fuel movement in either direction when the
pump is not operational. Voltage to operate the pump
is supplied through the Auto Shutdown Relay.
The level unit is attached to the side of the fuel
pump assembly. The level unit consists of a float, an
arm, and a variable resistor. As the fuel level in­
creases, the float and arm move up. This decreases the
sending unit resistance, causing the fuel gauge on the
instrum ent panel to read fall.
The fuel pump module is a spring loaded design.
The module must be compressed to be installed into SERVICE
the fuel tank. This ensures th at the pump will rest on
the bottom of the fuel tank.

Fig. 4 Pressure Test Gauge

(4) Using diagnostic tester, with the key in the Run

position, use ASD Fuel System Test, this will activate
the fuel pump and pressurize the system. If the gauge
reads the correct pressure listed in the Fuel System
Pressure chart, further testing is not required. If pres­
sure is not correct, record the pressure and remove
gauge. Use ASD Fuel System Test to reactivate the
fuel pump. Ensure fuel does not leak from the fuel rail
service valve. Reinstall protective cover onto fuel rail
service valve.
CAUTION: When using the ASD Fuel System Test,
the Auto Shutdown (ASD) Relay will remain ener­
gized for 7 minutes or until the test is stopped, or
until the ignition switch is turned to the Off position.
(5) If fuel pressure is below specifications, install
Fuel Pressure Gauge C-4799 and Fuel Pressure Adapter
6433 in the fuel supply line. (Fig. 5) Install gauge and
adapter between the fuel tank and fuel filter at the
rear of vehicle.
 SPECIAL TOOL 6433
FUEL PUMP MODULE REMOVAL—
ALL WHEEL DRIVE
It is necessary to remove fuel tank from vehicle to
replace fuel pump. Follow fuel tank removal procedure.
(1) Unclip fuel vapor hose and fuel drain hose from
fuel tank. (Fig 7)

9114-141

Fig. 5 Fuel Pressure Adapter

(6) Repeat test. If pressure is at least 5 psi higher

than previously recorded pressure, replace fuel filter.
If no change is observed, gently squeeze return hose.
If pressure increases, replace pressure regulator. If no
change is observed, problem is either a plugged inlet
strainer or defective fuel pump.
(7) If pressure is above specifications, install Fuel
Pressure Gauge C-4799 and Fuel Pressure Adapter
6433 in the fuel supply line. (Fig. 5) Install gauge and
adapter between the fuel tank and fuel filter at the
rear of vehicle. Remove the fuel return line hose from
the fuel pump at fuel tank. Connect Fuel Pressure
Test Adapter 6541 to the return line. Put the other (2) Remove fuel pump module band clamp.(Fig. 8)
end into an approved gasoline container (minimum 2
gallon size) so that all return fuel will flow into con­
tainer. Repeat test. If pressure is now correct, replace
fuel pump assembly.
(8) If pressure is still above specifications, remove
fuel return hose from chassis fuel tubes (at engine).
Attach Fuel Pressure Test Connect Adapter 6541 to
the fuel return hose and place other end of hose in
clean container. (Fig. 6) Repeat test. If pressure is
now correct, check for restricted fuel return line. If no
change is observed, replace fuel pressure regulator.

SPECIAL FUEL RETURN

(3) Remove the fuel pump module from fuel tank.

Discard flat rubber seal.

FUEL PUMP INLET STRAINER SER VIC E-

ALL WHEEL DRIVE
REMOVAL
9114-88 (1) Remove the fuel pump from the fuel tank. Refer
to Fuel Pump Module Removal in this section.
(2) Bend locking tabs on the strainer to clear lock­
ing tangs on the fuel pump module. (Fig. 9)
(3) Pull strainer off.

STRAINER TABS 9114-145
Fig. 9 Fuel Strainer Service
INSTALLATION
(1) Align the orientation tabs in the strainer with
the slot in the bottom of the fuel pump module.
(2) Push strainer onto the inlet of the fuel pump
module. Make sure that the locking tabs on the filter
lock over the locking tangs on the pump module.
(3) Install the fuel pump module into the fuel tank.
Refer to Fuel Pump Module Installation in this section.
FUEL LEVEL SENDING UNIT DIAGNOSIS
Refer to Group 8—Electrical
FUEL LEVEL SENDING UNIT SER VIC E-
ALL WHEEL DRIVE
REMOVAL
(1) Remove the fuel pump from the fuel tank. Refer
to Fuel Pump Module Removal in this section.
(2) Remove the two screws holding fuel level send­
ing unit in place. (Fig. 10)
(3) Disconnect electrical leads.
Fig. 10 Fuel Level Sending Unit
INSTALLATION
(1) Connect electrical leads to the fuel level sending
unit.
(2) Install level sending unit and tighten screws.
(3) Install the fuel pump module into the fuel tank.
Refer to Fuel Pump Module Installation in this section.
FUEL PUMP MODULE INSTALLATION—
ALL WHEEL DRIVE
(1) Wipe seal area of tank clean and place a new
seal in position on pump.
(2) Position fuel pump module so that the arrow on
the edge of the module is between the two lines molded
into the fuel tank. (Fig. 11)
CAUTION: Fuel pump module must be properly
aligned during installation.
Fig. 11 Fuel Pump Alignment
(3) Compress fuel pump module. Install band clamp
and torque to 4.5 ±0.5 N-m (40 in. lbs.).
(4) Install fuel tank. Refer to fuel tank installation
of this section.
FUEL FILTER SERVICE— IL L WHEEL iR iV E
memovML
(1) Perform fuel system pressure release procedure.
(2) Remove converter support bracket. (Fig. 12)
CONVERTER
SUPPORT
BRACKET

Fig. 13 Fuel Filter

(5) Remove filter retaining screw and remove filter

assembly from rail.
XTH V l 14-11 -
CAUTION: Wrap shop towels around hoses to catch
Fig. 12 Support Bracket any gasoline spillage.
(6) Remove hoses from fuel filter. Discard clamps.
(3) Remove exhaust pipe heat shield.
(4) Loosen outlet and inlet hose clamps on filter.
INSTALLATION
(Fig. 13)
(1) Loose install inlet and outlet fuel hoses to fuel
filter.
(2) Position filter assembly on rail and torque mount­
ing screw to 8 N-m (75 in.lbs.).
(3) Torque new fuel hose clamps to 1 N-m (10 in.
lbs.).
(4) Install exhaust pipe heat shield.
(5) Install exhaust pipe support bracket.
 FUEL TANK—FRONT WHEEL DRIVE
INDEX
Page Page
Fuel Hoses, Clamps, and Quick General Information . . . . . . . . . . . . . . . . . . . . . . . . . . . 18
Connect Fittings ......................... ........................ 16 No-Lead Fuel Tank Filler T u b e -
Fuel Pump— Front Wheel Drive ....................... .. 20 Front Wheel Drive . . . . . . . . . . . . . . . . . . . . . . . . . . . 17
Fuel Tank— Front Wheel Drive ................................. 18 Pressure-Vacuum Filler Cap—
Fuel Tank Pressure Relief/Rollover Front Wheel Drive . . . . . . . . . . . . . . . . . . . . . . . . . . . 17
Valve— Front Wheel Drive ..................................... 20

GENERAL INFORMATION be used in this system, all other types of clamps may
cut into the hoses and cause high pressure fuel leaks.
Chrysler Motors built vehicles pass a foil 380° rollover Use new original equipment type hose clamps, torque
test without fuel leakage. To accomplish this, fuel and hose clamps to 1 N*m (10 in. lbs.).
vapor flow controls are required for all fuel tank The fuel line fittings used are quick connect type
connections. fittings. These fittings are designed to speed up the
All front wheel drive vehicles have a fuel tank pres­ installation and removal of the fuel lines.(Fig. 1)
sure -relief/rollover valve mounted on the top of the
fuel tank. This valve functions as a pressure relief
valve while the vehicle is upright, but contains a
check valve that prevents fuel from escaping from the
fuel tank when the vehicle is turned over.
The fuel'filler cap also acts as a pressure/vacuum
valve. When the air pressure inside the fuel tank gets
too high or too low, the fuel filler cap opens to relieve
the difference in air pressure.
An evaporation control system is used to reduce the
emissions of fuel vapors into the atmosphere by evap­
oration and reduce the unburned hydrocarbons, emit­
ted by the vehicle engine. When fuel evaporates from
the fuel tank, the vapors pass through vent hoses or
tubes to a charcoal canister where they are temporar­
ily held until they can be drawn into the intake mani­
fold when the engine is running.

FUEL HOSES, CLAMPS, AND Quick connect fittings consist of a metal casing, a
QUICK CONNECT FITTINGS black plastic release ring, a metal locking retainer,
and internal o-rings.
Inspect all hose connections (clamps and quick con­
The quick connect fittings may be removed from the
nect . fittings) to make sure they are secure and no
fuel tube nipple by pushing in on the plastic ring
leaks are present. Hoses should be replaced immedi­
located on the end of the fitting. An open end wrench
ately if there is any evidence of degradation that could
may be used to aid in disassembly.
result in failure.
When the fuel tube nipple is inserted into the quick-
Avoid contact with clamps or other components that
connect fitting, the shoulder of the nipple is locked in
cause abrasions or scuffing. Ensure that the rubber
place by the locking retainer, and the internal O-rings
hoses are properly routed to prevent pinching and to
seal the tube.
avoid heat sources.
The fuel tube nipples must be first lubricated with
The hoses used on fuel injected vehicles are of spe­
clean 30 weight engine oil prior to reconnecting the
cial construction due to the possibility of contami­
quick-connect fitting.
nated fuel in this system. If it is necessary to replace
After connecting a quick-connect filing, the con­
these hoses, only hoses marked EPM/ EFI may be
nection should be verified by pulling on the lines to
used.
ensyre that the lock is secure.
The hose clamps used are of a special rolled edge
construction to prevent the edge of the clamp cutting
into the hose. Only these rolled edge type clamps may
TUBE/FITTING DISASSEMBLY (7) Replace the quick connect fittings (if necessary)
(1) Disconnect the negative battery cable. with the correct size and type.
(2) Remove the fuel tank gas cap to release any fuel (8) Attach the replacement hose to the quick con­
tank pressure. nect fitting and fuel tube using the correct hose clamps.
(3) Perform fuel system pressure release procedure. The hose clamps used are of a special rolled edge
(4) Remove any loose dirt from quick connect fittings. construction to prevent the edge of the clamp cutting
into the hose. Only these rolled edge type clamps may
WARNING: WRAP SHOP TOWELS AROUND HOSES
be used in this system, all other types of clamps may
TO CATCH ANY GASOLINE SPILLAGE.
cut into the hoses and cause high pressure fuel leaks.
(5) Press black plastic release ring in and pull quick (9) Torque the hose clamps to 1 N ’m (10 in. lbs.).
connector from the fuel tube. (Use open end wrench if (10) Use ASD Fuel System Test to pressurize the
necessary). fuel system. Check for leaks.
(6) Cover the quick connector to prevent contam­
CAUTION: When using the ASD Fuel System Test,
ination.
the Auto Shutdown (ASD) Relay will remain ener­
gized for 7 minutes or until the test is stopped, or
TUBE/FITTING ASSEMBLY
until the ignition switch is turned to the Off position.
(1) Inspect the quick connect fitting to ensure that
the black plastic release ring is in the OUT position. If
the locking retainer is stuck in the RELEASE position
NO-LEAD FUEL TANK FILLER T U B E -
due to mushrooming of the release ring, or dirt accu­
FRONT WHEEL DRIVE
mulation, the fitting should be replaced.
All catalyst equipped vehicles have a special fuel
(2) Lubricate the male end of the fuel tube with 30
tank filler tube. The fuel filler opening is smaller in
wt. oil.
diameter than those used for non-catalyst vehicles to
(3) Insert quick connector fitting.
permit entry of only the smaller no-lead fuel nozzles.
(4) Pull quick connector back to ensure complete
In addition a deflector, which is opened by the no-lead
connection. If the connection is not complete, check
fuel nozzle, deters the addition of fuel by means other
the black plastic release ring to make sure it is not
than the proper nozzle.
causing the locking retainer to jam in the release
The fuel filler tube on these models is equipped
position.
with a one way ball check valve designed to prevent
(5) Use ASD Fuel System Test to pressurize the fuel
fuel spit back which may occur while filling the tank.
system. Check for leaks.
A label is attached to the instrument panel under
CAUTION: When using the ASD Fuel System Test, the fuel gauge that reads UNLEADED FUEL ONLY as
the Auto Shutdown (ASD) Relay will remain ener­ a reminder to the driver. A similar label is located
gized for 7 minutes or until the test is stopped, or near the fuel tank filler.
until the ignition switch is turned to the Off position.
PRESSURE-VACUUM FILLER C A P -
TUBE/FITTING SERVICE FRONT WHEEL DRIVE
If a quick connect fitting needs to be serviced, the
following procedure must be followed: The loss of any fuel or vapor out of the filler neck is
(1) Disconnect the battery negative battery cable. prevented by the use of a safety filler cap which will
(2) Perform the fuel system pressure release. release only under significant pressure 10.9 to 13.45
(3) Remove the quick connect fitting from the fuel kPa (1.58 to 1.95 psi). The vacuum release for all gas
tube by pushing in on the plastic ring located on the caps is between .97 and 2.0 kPa (.14 and .29 psi). This
end of the fitting. Gently pull the fitting from the fuel cap must be replaced by a similar unit if replacement
tube. is necessary, in order for the system to remain effective.
WARNING: WRAP SHOP TOWELS AROUND HOSES CAUTION: Remove filler cap prior to removing or
TO CATCH ANY GASOLINE SPILLAGE. repairing fuel lines to relieve tank pressure.
(4) Cut off the crimp ferrules at each end of the
hose, taking care not to damage the quick connect
fitting or the fuel tube.
(5) Discard the ferrules and hose. Discard the quick
connect fitting if it is defective.
(6) Replace the hose using hose marked EFM/ EFI.
This type of hose must be used due to its special
construction.
 FUEL TANK CAPACITIES Number 2 of the injector harness (Fig. 3) and touch
the battery positive post for no longer than 5 seconds.
This releases system pressure.
front Wheel 76 Liters 20 U.S. Gallons
Drive (5) Remove jumper wires.
(6) Continue fuel system service.
All Wheel 68 Liters 18 U.S. Gallons
Drive

Nominal refill-capacities are shown. A variation may be

observed from car to car dye to manufacturi ng tolerance
and refill procedure.

9114-135

FUEL TANK— FRONT WHEEL DRIVE

2.5L ENGINE 3.0L ENGINE
DRAINING FUEL TANK
(1) Remove fuel filler cap and perform fuel system
pressure release.
(2) Disconnect battery ground cable.
TERMINAL #2 TERMINAL#!
(3) Raise vehicle on hoist.
(4) Remove drain tube rubber cap located on rear of
fuel tank and connect either a portable holding tank
or a siphon hose to drain tube.(Fig. 2)
(5) Drain fuel tank dry into holding tank or a prop­
erly labeled gasoline safety container.
3.3L ENGINE
9114-147

Fig. 3 Injector Harness Connectors

Fig. 2 Fuel Drain Tube
FUEL SYSTEM PRESSURE RELEASE
The TBI fuel system is under a constant pressure of
approximately 270 kPa (39 psi). The 3.0L and 3.3L
fuel systems are under a constant pressure of approxi­
mately 330 kPa (48 psi). Before servicing the fuel
tank the fuel pressure must be released as follows:
(1) Loosen fuel filler cap to release any fuel tank
pressure.
(2) Disconnect injector wiring harness from engine
harness.
(3) Connect a jumper wire to ground terminal Num­
ber 1 of the injector harness (Fig. 3) to engine ground.
(4) Connect a jumper wire to the positive terminal
REMOVAL
(1) Position vehicle on hoist.
(2) Disconnect battery ground cable.
(3) Remove fuel filler cap before disconnecting any
lines. The tank could be under a small pressure.
(4) Drain fuel tank dry into the holding tank or a
properly identified Gasoline safety container. As out­
lined in Draining Fuel Tank in this section.
(5) Remove screws that hold filler tube to inner and
outer quarter panel. (Fig. 4)
(6) Raise vehicle and disconnect wiring and quick
connects from the tank.
(7) Use a transmission jack to support the fuel tank
and remove the bolts from the fuel tank straps.
(8) Lower tank slightly and carefully work filler
tube from tank.
(9) Lower the fuel tank. Disconnect pressure relief?
rollover valve hose. Remove clamp and remove fuel
filler tube vent hose. Remove the fuel tank from the
vehicle.
INSTALLATIO N HAMMER FUEL FUEL PUMP
(1) Position fuel tank on transmission jack. Connect
pressure relieCrollover valve hose. Connect fuel filler
tube vent hose and replace clamp.
(2) Raise tank into position and carefully work filler
tube into tank. Transmission fluid may be used as an
aid to assembly.
(3) Torque strap bolts to 54.2 N-m (40 ft. lbs.). Re­
move transmission jack.
CAUTION: Be sure straps are not twisted or bent
before or after tightening strap nuts.
(4) Connect wiring connector. Lubricate the metal
tubes on the fuel pump with clean 30 wt. engine oil.
Install the quick connect fuel fittings, pulling back on
the fittings to ensure a complete connection. If service
is required, see Fuel Hoses, Clamps, and Quick Con­
nect Fittings in this section.
(5) Install and torque filler tube to inner and outer INSTALLATION
quarter panel screws to 1.9 N-m (17 inch-pounds). On (1) Wipe seal area of tank clean and place a new
affected models be sure to install the gasket between O-ring seal in position on pump,
the filler tube and the inner quarter panel, before (2) Position fuel pump in tank with locking ring.
installing the mounting screws. (8) Using a hammer and brass drift, drive ring around
(6) Replace cap on drain tube using new hose clamp. clockwise to lock pump in place.
(7) Fill fuel tank, replace cap, and connect battery
CAUTION: Extreme care should be exercised not
ground cable.
to owertfghten pump as It could leak.
(8) Use ASD Fuel System Test to pressurize the fuel
system. Check for leaks. (4) Install tank.
CAUTION: When using the ASD Fuel System Test,
the Auto Shutdown (ASD) Relay will remain ener­
FUEL TANK PRESSURE RELIEF/ROLLOVER
gized for 7 minutes or until the test is stopped, or
VALVE— FRONT WHEEL DRIVE
until the ignition switch is turned to the Off position.
REMOVAL
(1) Remove fuel tank (refer to fuel tank removal).
FUEL PUMP— FRONT WHEEL DRIVE (2) Wedge the blade of a screwdriver between the
rubber grommet and the fuel tank where the support
REMOVAL
rib is located. Do not wedge between the valve and
11 is necessary to remove fuel tank from vehicle to
the grommet or damage to the valve may result upon
service fuel pump. Follow fuel tank removal procedure.
removal.
(1) Using a hammer and a brass drift, carefully tap
(3) Use a second screwdriver as a support to pry the
lock ring counter clockwise to release pump (Fig. 5).
valve and grommet assembly from the tank (Fig. 6).
(2) Remove fuel pump and O-ring seal from tank.
Discard old seal.
 (4) To remove the grommet from the valve simply
place the valve upright on a flat surface and push
down on the grommet peeling it down off the valve.

INSTALLATION
(1) Install the rubber grommet in the fuel tank and
work it around the curled lip. (Fig. 7)
(2) Lubricate the grommet with power steering fluid
only and push the valve downward into the grommet.
Twist valve until properly positioned.
(3) Install fuel tank (refer to fuel tank installation).

Fig. 7 Installing Pressure Relief/Rollover Valve

 FUEL TANK--ALL WHEEL DRIVE
INDEX
Page Page
Fuel Hoses, Clamps, and Quick General I nformation ................................................... 22
Connect Fittings ..................... ............................... 22 No-Lead Fuel Tank Filler Tube—
Fuel Pump Module Installation— All Wheel Drive ....................................................... 23
All Wheel Drive ....................... ............................... 26 Pressure-Vacuum Filler Cap—
Fuel Pump Module Removal— All Wheel D rive........ 26 All Wheel Drive ......................... ............................. 23
Fuel Tank— All Wheel D rive....................................... 24
Fuel Tank Pressure Relief/Rollover
Valve—All Wheel D rive........................................... 26

GENERAL INFORMATION in to th e hose. O n ly these ro lle d ed ge ty p e clam p s m ay

ed in th is sy ste m , a ll o th e r ty p e s o f c lam p s m ay
Chrysler Motors built vehicles pass a full 360° rollover c u t in to th e hoses a n d c a u se h ig h p re s s u re fu el le a k s.
test without fuel leakage. To accomplish this, fuel and U se n ew original e q u ip m e n t ty p e hose clam p s, to rq u e
vapor flow controls are required for all fuel tank h ose c lam p s to 1 N m (10 in . lbs.).
connections. T he fu el lin e fittin g s u se d a re q u ic k co n n ect ty p e
All wheel drive vehicles have a fuel tank pressure fittin g s . T h ese f ittin g s a re d e sig n e d to sp eed u p th e
relief/rollover valve mounted on the top of the fuel In s ta lla tio n a n d re m o v a l o f th e fu el lines.(Fig. 1)
pump. This valve functions as a pressure relief valve
while the vehicle is upright, but contains a check
valve that prevents fuel from escaping from the fuel
tank when the vehicle is turned over.
The fuel filler cap also acts as a pressure/vacuum
valve. When the air pressure inside the fuel tank gets
too high or too low, the fuel filler cap opens to relieve
the difference in air pressure.
An evaporation control system is used to reduce the
emissions of fuel vapors into the atmosphere by evap­
oration and reduce the unburned hydrocarbons emit­
ted by the vehicle engine. When fuel evaporates from
the fuel tank, the vapors pass through vent hoses or
tubes to a charcoal canister where they are temporar­
ily held until they can be drawn into the intake mani­
fold when the engine is running.

FUEL HOSES, CLAMPS, AND

QUICK CONNECT FITTINGS Q u ick co n n ect fittin g s c o n sist o f a m e ta l casin g , a
b la c k p la stic re le a se rin g , a m e ta l lo ck in g r e ta in e r,
In sp e c t a ll hose co n n ectio n s (clam ps a n d q u ic k con­
a n d in te r n a l o-rings.
n e c t fittin g s) to m a k e s u re th e y a re se c u re a n d n©
T h e q u ick co n n ect fittin g s m a y b e rem o v ed from th e
le a k s a re p re s e n t. H oses sh o u ld be re p la c e d im m e d i­
fuel tube nipple by pushing in on the p la stic ring
a te ly if th e re is a n y evidence o f d e g ra d a tio n th a t could
lo cated on th e e n d o f th e fittin g . A n open e n d w ren ch
re s u lt in fa ilu re .
m a y b e u se d to a id in d isa sse m b ly .
A void c o n ta c t w ith clam p s o r o th e r com p on en ts t h a t
W h en th e fu el tu b e n ip p le is in s e rte d in to th e quick-
cau se a b ra sio n s o r scuffing. E n s u re th a t th e ru b b e r
conneet fitting, the shoulder of the nipple is locked in
h oses a re p ro p e rly ro u te d to p re v e n t p in c h in g a n d to
p lace by th e lo ck in g re ta in e r , a n d th e in te r n a l O -rin g s
avoid h e a t sources.
seal the tube.
T h e ho ses u se d on fu el in jected v eh icles a re o f spe­
The fuel tube nipples must be first lubricated with
cial c o n stru c tio n d u e to th e p o ssib ility o f c o n ta m i­
clean 30 weight engine oil prior to reconnecting the
n a te d fuel in th is sy stem . I f it is n e c e ssa ry to re p la c e
qulck-connect fitting.
th e se hoses, on ly hoses m a rk e d EFM/ E F I m ay be
After connecting a qui'ck-connect filing, the con-
used.
nection should be verified by pulling on the lints to
T he ho se clam p s u se d a re o f a sp ecial ro lle d edge
#n«yr# that the Imk Is secure.
c o n stru c tio n to p re v e n t th e edge o f th e clam p c u ttin g
TUBE/FITTING DISASSEMBLY
(1) Disconnect the negative battery cable.
(2) Remove the fuel tank gas cap to release any fuel
tank pressure.
(3) Perform fuel system pressure release procedure.
(4) Remove any loose dirt from quick connect fittings.
WARNING: WRAP SHOP TOWELS AROUND HOSES
TO CATCH ANY GASOLINE SPILLAGE.
(5) Press black plastic release ring in and pull quick
connector from the fuel tube. (Use open end wrench if
necessary).
(6) Cover the quick connector to prevent contam­
ination.
TUBE/FITTING ASSEMBLY
(1) Inspect the quick connect fitting to ensure that
the black plastic release ring is in the OUT position. If
the locking retainer is stuck in the RELEASE position
due to mushrooming of the release ring, or dirt accu­
mulation, the fitting should be replaced.
(2) Lubricate the male end of the fuel tube with 30
wt. oil.
(3) Insert quick connector fitting.
(4) Pull quick connector back to ensure complete
connection. If the connection is not complete, check
the black plastic release ring to make sure it is not
causing the locking retainer to jam in the release
position.
(5) Use ASD Fuel System Test to pressurize the fuel
system. Check for leaks.
CAUTION: When using the ASD Fuel System Test,
the Auto Shutdown (ASD) Relay will remain ener­
gized for 7 minutes or until the test Is stopped, or
until the ignition switch Is turned to the Off position.
TUBE/FITTING SERVICE
If a quick connect fitting needs to be serviced, the
following procedure must be followed:
(1) Disconnect the battery negative battery cable.
(2) Perform the fuel system pressure release.
(3) Remove the quick connect fitting from the fuel
tube by pushing in on the plastic ring located on the
end of the fitting. Gently pull the fitting from the fuel
tube.
WARNING: WRAP SHOP TOWELS AROUND HOSES
TO CATCH ANY GASOLINE SPILLAGE.
(4) Cut off the crimp ferrules at each end of the
hose, taking care not to damage the quick connect
fitting or the fuel tube.
(5) Discard the ferrules and hose. Discard the quick
connect fitting if it is defective.
(6) Replace the hose using hose marked EFM/ EFI.
This type of hose must be used due to its special
construction.
(7) Replace the quick connect fittings (if necessary)
with the correct size and type.
(8) Attach the replacement hose to the quick con­
nect fitting and fuel tube using the correct hose clamps.
The hose clamps used are of a special rolled edge
construction to prevent the edge of the clamp cutting
into the hose. Only these rolled edge type clamps may
be used in this system, all other types of clamps may
cut into the hoses and cause high pressure fuel leaks.
(9) Torque the hose clamps to 1 N-m (10 in. lbs.).
(10) Use ASD Fuel System Test to pressurize the
fuel system. Check for leaks.
CAUTION: When using the ASD Fuel System Test,
the Auto Shutdown (ASD) Relay will remain ener­
gized for 7 minutes or until the test is stopped, or
until the ignition switch is turned to the Off position.
NO-LEAD FUEL TANK FILLER T U B E -
ALL WHEEL DRIVE
All catalyst equipped vehicles have a special fuel
tank filler tube. The fuel filler opening is smaller in
diameter than those used for non-catalyst vehicles to
permit entry of only the smaller no-lead fuel nozzles.
In addition a deflector, which is opened by the no-lead
fuel nozzle, deters the addition of fuel by means other
than the proper nozzle.
The fuel filler tube on these models is equipped
with a one way ball check valve designed to prevent
fuel spit back which may occur while filling the tank.
A label is attached to the instrument panel under
the fuel gauge that reads UNLEADED FUEL ONLY as
a reminder to the driver. A similar label is located
near the fuel tank filler.
PRESSURE-VACUUM FILLER C A P -
ALL WHEEL DRIVE
The loss of any fuel or vapor out of the filler neck is
prevented by the use of a safety filler cap which will
release only under significant pressure 10.9 to 13.45
kPa (1.58 to 1.95 psi). The vacuum release for all gas
caps is between .97 and 2.0 kPa (.14 and .29 psi). This
cap must be replaced by a similar unit if replacement
is necessary, in order for the system to remain effective.
CAUTION: Remove filler cap prior to removing or
repairing fuel lines to relieve tank pressure.
 FUEL TANK CAPACITIES th e b a tte r y positive post for no lo n g e r th a n 5 seconds.
T h is re le a se s sy ste m p re ssu re .
' (5) R em ove ju m p e r w ires. ’
Front Wheel
76 Liters 20 U.S. Gallons (6) C o n tin u e fu el sy ste m serv ice.
Drive

Ail Wheel
68 Liters 18 U.S. Gallons TERMINAL #1
Drive
TERMINAL #1 =
TERMINAL #2
Nominal refill capacities are shown. A variation may be TERMINAL #2
observed from car to car due to manufacturing tolerance
and refill procedure.

-9114-135

FUEL TANK-ALL WHEEL DRIVE 2.5L ENGINE 3.01 ENGINE

DRAINING FWEL TANK .. ,

(1) Remove fu el fille r cap a n d p erfo rm fu el sy ste m
p re s su re re le a se . TERMINAL#2 •’ TERMINAL#!
(2) D iscon n ect b a tte r y g ro u n d cable.
(3) R aise v eh icle on h o ist.
(4) Remove d ra in tu b e ru b b e r cap. T h e cap is lo­
c a te d above th e r e a r d iffe re n tia l to rq u e tu b e , on th e
in b o a rd sid e o f th e fu el ta n k . C o n n ect e ith e r a p o rta ­
b le h o ld in g ta n k o r a sip h on hose to d ra in tube.(Fig. 2)
- (5) D ra in fu el ta n k d ry in to h o ld in g ta n k o r a p ro p ­ 3.3L ENGINE
e rly la b e le d g a s o lin e sa fe ty ..container. 9114-147
Fig. 3 Inlector Harneaa Connectora

REMOVAL
(1) P o sitio n ''vehicle Gn h o ist.
(2) D isco nn ect b a tte r y g ro u n d cable.
. 13) Remove fu el fille r .cap befo re d isc o n n e c tin g a n y
lin es. T h e ta n k could b e .under a small p re ssu re .
(4) D ra in ta n k in to a h o ld in g ta n k o r a p ro p e rly
id e n tifie d Gasoline sa fe ty c o n ta in e r a s .outlined in th e
D ra in in g F u e l T a n k p o rtio n o f th is sectio n.
(5) R em ove screw s t h a t h o ld .fille r tu b e to th e in n e r
a n d o u te r q u a r te r p a n e l. .
(6) R aise vehicle,. ■
(7) Remove fasteners h o ld in g th e p a rk b ra k e cab le
su p p o rt b ra c k e t a ssem b ly i n place.(Fig. 4)

Fig. 2 Fm l Tank Drain Cap

FUEL SYSTEM P R E S S U R E RELEASE

T h e 3.3L fu el sy ste m is u n d e r a c o n s ta n t p re s s u re of
a p p ro x im a te ly 330 k P a (48 psi). B efore se rv ic in g th e
fu el ta n k th e fu el p re ss u re m u s t be re le a s e d a s follows:
(1) Loosen fu el fille r cap to re le a s e a n y fu el ta n k
p re ssu re .
(2) D isco nn ect in je c to r w irin g h a rn e s s from e n g in e
h a rn e ss.
(3) C o nn ect a ju m p e r w ire to ground te rm in a l N u m ­
b e r 1 o f th e in je c to r h a rn e s s (Fig. 3) to e n g in e g ro un d . FUEL TANK
FUEL TANK
(4) C on n ect a ju m p e r w ire to th e p o sitiv e te rm in a l STRAP BOLT STiAP
N u m b e r 2 o f th e in je c to r h a rn e s s (F ig. 3) a n d to u c h
 (8) Use a transmission jack to support the fuel tank (13) Pull fuel filler vent hose through the frame
and remove the bolts from the fuel tank straps.(Fig. 5) rail.
(14) Lower the fuel tank and remove the fuel filler
FUEL tube from the fuel tank.

INSTALLATION
(1) Position fuel tank on transmission jack and in­
sert fuel filler tube.
(2) Raise fuel tank while inserting fuel filler vent
hose through hole in frame rail.
(3) Ensure that the black release rings are in the
OUT position (loose and free floating) on the supply
and return fuel hose quick connect fittings.
(4) Lubricate the ends of the chassis fuel tubes (sup­
ply and return only) with 30 wt. oil.
(5) Connect fuel supply, return, and vent hoses to
the chassis fuel tube. Pull on the quick connect fit­
tings to ensure complete insertion. Connect fuel pump
electrical connector to the fuel pump. Install drain
tube cap.
CAUTION: When making connections with the quick
connect type fittings, always pull back on the fitting
to ensure complete locking. If the fitting will not fully
connect, check to make sure that the black release
Fig. 5 All Wheel Drive Fuel Tank ring is not jammed into the metal casing of the fit­
ting. If the fitting fails, replace it with a new one of
(9) Loosen fuel filler tube vent hose clamp and re­ the correct size.
move hose from tube. (6) Raise fuel tank into position, carefully working
(10) Lower tank slightly. filler tube and fuel filler vent tube into position.
(11) Clean the quick connectors to remove any dirt. (7) Install fuel tank support straps and torque fas­
(Use air pressure or an appropriate cleaning agent).
teners to 54.2 N-m (40 ft.lbs.). Remove the transmis­
Disconnect fuel supply and return hoses from the chas­
sion jack.
sis fuel tubes by pushing in on the black plastic re­
lease ring and pulling on the connector. Disconnect CAUTION: Be sure straps are not twisted or bent
the fuel vent hose. Plug hoses to prevent contamination. before or after tightening strap nuts.
(12) Remove electrical connector from the fuel (8) Connect fuel filler vent hose and tighten hose
pump.(Fig. 6)
clamp.
(9) Install park brake cable support bracket. Torque
FUEL the fasteners to 22.6 N-m (200 in. lbs.).
FILLER
(10) Lower vehicle.
VENT
S TUBE (11) Install and torque filler tube to inner and outer
quarter panel screws to 1.9 N-m (17 in. lbs.). On af­
fected models, be sure to install the gasket between
the filler tube and the inner quarter panel before
installing the mounting screws.
(12) Fill fuel tank, replace cap, connect battery
ground cable and check system operation.
(13) Test for leaks using the Diagnostic Readout
Box II (DRB II). With ignition key in the Run posi­
tion, use ASD Fuel System Test. This will activate the
fuel pump and pressurize the system.
SUPPLY RETURN 9114-15 CAUTION: When using the ASD Fuel System Test,
the Auto Shutdown (ASD) Relay will remain ener­
gized for 7 minutes or until the test is stopped, or
until the ignition switch is turned to the Off position.
FUEL PUMP MODULE REM OVAL-
ALL WHEEL DRIVE
It is necessary to remove fuel tank from vehicle to
replace fuel pump. Follow fuel tank removal procedure.
(1) Unclip fuel vapor hose and fuel drain hose from
fuel tank. (Fig 7)
Fig. 7 Hose Tank Clips
(2) Remove fuel pump module band clamp.(Fig. 8)
(3) Remove the fuel pump module from fuel tank.
Discard flat rubber seal.
FUEL PUMP MODULE INSTALLATION-
ALL WHEEL DRIVE
(1) Wipe seal area of tank clean and place a new
seal in position on pump.
CAUTION: Fuel pump module must be properly
aligned during Installation.
(2) Position fuel pump module so that the arrow on
the edge of the module is between the two lines molded
into the fuel tank. (Fig. 9)
L,NES 9114-143
Fig. 9 Fuel Pump Alignment
(3) Compress fuel pump module. Install band clamp
and torque to 4.5 ± 0.5 N-m (40 in. lbs.).
(4) Install fuel tank. Refer to fuel tank installation
in this section.
FUEL TANK PRESSURE RELIEF/ROLLOVER
VALVE— ALL WHEEL DRIVE
REMOVAL
(1) Remove fuel tank (refer to fuel tank removal).
(2) Wedge the blade of a screwdriver between the
rubber grommet and the fuel pump
(3) Pry the valve and grommet assembly from the
pump (Fig. 10).
Fig. 10 Removing Pressure Relief/Rollover Valve
(4) To remove the grommet from the valve simply
place the valve upright on a flat surface and push
down on the grommet peeling it down off the valve.
INSTALLATION only and push the valve downward into the grommet.
(1) Install the rubber grommet in the fuel pump. Twist valve until properly positioned.
(2) Lubricate the grommet with power steering fluid (3) Install fuel tank (refer to fuel tank installation).

ACCELERATOR PEDAL AND THROTTLE CABLE

INDEX
Page Page
Accelerator Pedal Service 27 Throttle Cable Service 27

ACCELERATOR PEDAL SERVICE
CAUTION: Be careful not to damage or kink throt­
tle or speed control core wire during installation or
removal of accelerator pedal or cables.
REMOVAL
(1) Working from the engine compartment, rotate
the throttle body throttle lever toward wide open and
remove the throttle cable from the throttle body cam.
(2) From inside the vehicle, hold up the pedal and
remove the cable retainer and throttle cable from the
upper end of the pedal shaft. (Fig. 1)
(3) Working from the engine compartment, remove
nuts from accelerator pedal assembly studs. Remove
assembly from vehicle.
GROMMET
CABLE
ASSEMBLY
DASH
PANEL
(3) From the engine compartment, rotate the throt­
tle body lever toward wide open and install the throt­
tle cable.
THROTTLE CABLE SERVICE
CAUTION: Be careful not to damage or kink throt­
tle or speed control core wire during Installation or
removal of accelerator pedal or cables.
REMOVAL
(1) Working from the engine compartment, rotate
the throttle body throttle lever toward wide open and
remove the throttle cable from the throttle body
cam.(Figs. 2, 3, and 4)
(2) From inside the vehicle, hold up the pedal and
remove the cable retainer and throttle cable from the
upper end of the pedal shaft.(Fig. 1)
(3) From the engine compartment, pull the housing
and fitting out of the dash panel grommet. The grom­
met should remain in the dash panel.
(4) Remove the throttle cable from throttle bracket
by carefully compressing both retaining ears simulta­
neously. Then gently pull the throttle cable from throt­
tle bracket.
THROTTLE
BODY RETAINER
CUP
CABLE
MOUNTING
BRACKET

THROTTLE
CABLE — m k . CONTROL
RETAINER CABLE
GROMMET REAR VIEW

DASH
PANEL 9114-152 THROTTLE ACCELERATOR PEDAL
CABLE« "t- RETURN SPRING
BUNDLER TRANSMISSION
Fig. 1 Accelerator Pedal Removal or Installation
KICKDOWN
CABLE 9014-50
INSTALLATION
(1) Position assembly on dash panel and install re­ Fig. 2 Throttle Cable Attachment to
taining nuts. Torque to 11.8 N-m (105 in. lbs.). Throttle Body Fuel Injected Engines
(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.
 INSTALLATION
(1) From the engine compartment, push the housing
end fitting into the dash panel grommet.
THROTTLE THROTTLE (2) Install the cable housing (throttle body end) into
BODY CABLE the cable mounting bracket on the engine.
(3) From inside the vehicle, hold up the pedal and
install throttle cable and cable retainer in the upper
end of the pedal shaft.
(4) From the engine compartment, rotate the throt­
tle body throttle lever toward wide open and install
the throttle cable.
THROTTLI
LEVER
THROTTLE CABLE
9 ' throttle
CABLE
BRACKET
N JHROTTLi VIEW IN DIRECTION
N CABLE OF ARROW Y
VIEW IN DIRECTION THROTTLE CABLE
OF ARROW Z BRACKET ASSEMBLY 8914-3

Fig. 3 Throttle Cable Attachment to

Throttle Body 3.0L Engine

Fig. 4 Throttle Cable Attachment to

Throttle Body 3.3L Engine
 SINGLE POINT FUEL INJECTION—2.5L TBI ENGINES
COMPONENT IDENTIFICATION—2.5L TBI ENGINES
INDEX
Page Page
Air Conditioning (A/C) Clutch Relay— Fuel Injector— Engine Controller Output .................... 34
Engine Controller Output . .................. ................... 33 Fuel Pressure R e g u la to r............................................ 36
Alternator Field— Engine Controller Output ............ 35 General Information ................................................. .. 29
Auto Shutdown (ASD) Relay— Heated Oxygen Sensor ( 0 2 Sensor)—
Engine Controller Output ................... ................. . 34 Engine Controller Input ............................................... 32
Automatic Idle Speed (AIS) Motor— Ignition Coil— Engine Controller Output .................... 34
Engine Controller Output ..................... ................. 34 Manifold Absolute Pressure (MAP) Sensor—
Battery Voltage— Engine Controller Input ............... 32 Engine Controller Input ........................ ........ ............. 32
Brake Switch— Engine Controller Input ................... 33 Modes of Operation .......................................................... 36
Canister Purge Solenoid— Part Throttle Unlock Solenoid—
Engine Controller Output ....................................... 33 Engine Controller Output ............................................ 35
Check Engine Lamp— Engine Controller Output ___ 33 Radiator Fan Relay— Engine Controller Output ....... 35
Coolant Temperature Sensor— Speed Control Solenoids—
Engine Controller Input ......................................... 32 Engine Controller Output ............................................ 35
Diagnostic Connector— Engine Controller Input . . . . 35 Tachometer— Engine Controller O u t p u t........... ........... 35
Distributor (Hall Effect) Pick-Up— Throttle Body ....................................................... ............... 36
Engine Controller Input ......................................... 31 Throttle Position Sensor (TPS)—
Electric Exhaust Gas Recirculation Transducer Engine Controller Input ............................................... 31
(EET)— Engine Controller Output ......................... 35 Transmission Park/Neutral Switch—
Emission Maintenance Reminder (EMR) Lamp— Engine Controller Input ............................................... 32
Engine Controller Output ................. ..................... 35 Vehicle Distance (Speed) Sensor—
Engine Controller ...................................................... 29 Engine Controller Input ............................................... 33

GENERAL INFORMATION these inputs, air-fuel ratio, ignition timing or other

controlled outputs are adjusted accordingly.
The Electronic Fuel Injection System (Fig. 1) is a The engine controller tests many of its own input
computer regulated single point fuel injection system and output circuits. If a fault is found in a major
that provides precise air/fuel ratio for all driving con­ system, this information is stored in the memory. In­
ditions. At the center of this system is a pre-programmed formation on this fault can be displayed to a techni­
computer known as a Single Board Engine Controller cian by means of the instrument panel Check Engine
(SBEC). The SBEC is referred to as the engine con­ lamp or by connecting the Diagnostic Readout Box II
troller in this service manual. The engine controller (DRB II) and reading descriptions of any faults which
regulates ignition timing, air-fuel ratio, emission con­ have been stored.
trol devices, cooling fan, charging system, speed con­
trol, and idle speed. The engine controller can adapt ENGINE CONTROLLER
its requirement to meet changing operating conditions.
Various sensors provide the input necessary for the The engine controller (Fig. 2) contains the circuits
engine controller to correctly regulate the fuel flow at necessary to drive the ignition coil, fuel injector, and
the fuel injector. These include the Manifold Absolute the alternator field. . ' .,, ■
Pressure, Throttle Position, Oxygen Sensor, Coolant
Temperature, and Vehicle Distance sensors. In addi­
tion to the sensors, various switches and relays pro­
vide important information and system control. These
include the Neutral-Safety Switch, Air Conditioning
Clutch Relay, and Auto Shut Down Relay.
All inputs to the engine controller are converted
into signals which are used by the computer. Based on
 ENGINE CONTROLLER INPUTS ENGINE CONTROLLER OUTPUTS
DIAGNOSTIC
T T -------------- " 1 ---------------- TOOL

FUEL PUMP
NEUTRAL CHECK ENGINE
HEATED SAFETY SWITCH IGNITION COIL LA ^p
OXYGEN SENSOR

r— r COOLANT

THROTTLE
POSITION
f TEMPERATURE
SENSOR
BATTERY ENGINE FUEL AUTOMATIC
SENSOR CONTROLLER INJECTOR IDLE
ALTERNATOR SPEED MOTOR

MANIFOLD
ABSOLUTE
PRESSURE
SENSOR ■
t
DISTANCE
SENSOR
5 50R
SPEED
CONTROL
SWITCH
EMISSION
MAINTENANCE
REMINDER
(EM I)
LAMP
11IJ
RADIATOR
FAN
RELAY

SPEED CONTROL SOLENOIDS

A/C CUTOUT
RELAY
AUTO SHUTDOWN
RELAY

TACHOMETER

IGNITION
REFERENCE LOCKUP TORQUE CONVERTER
PICKUP ■ SOLENOID
ELECTRIC
EXHAUST
GAS
PURGE RECiiCULATlON
SOLENOID TRANSDUCER (1 9114-156
DISTRIBUTOR

Fig. 1 Electronic fu e l Infection Components

computes the fuel injector pulse width (the amount of

9180-48
Fig. 2 Engine Controller
The engine controller is a digital computer contain­
ing a microprocessor. The module receives input sig­
nals from various switches and sensors. These are
listed below under Engine Controller Inputs. It then
time that the injector is energized by the engine con­
troller), spark advance, ignition coil dwell, idle speed,
purge, and cooling fan turn on and alternator charge
rate.
Engine Controller Outputs are components that are
operated or controlled based on the values received
from the engine controller inputs. These outputs are
listed below.
The Automatic Shut Down (ASD) relay is mounted
externally, but is turned on and off by the engine
controller. Distributor pick-up signal goes to the en­
gine controller. In the event of no distributor signal,
the ASD relay is deactivated after approximately one
second and power is shut off from the fuel injector,
fuel pump, ignition coil, and oxygen sensor heater
element.
The engine controller te sts.many of its own input
and output circuits. If a fault is found in a major
system, this information is stored in the engine con­
troller. Information on this fault can be displayed to a
technician by means of the instrument panel check
engine lamp or by connecting the Diagnostic Readout DISTRIBUTOR (HALL EFFECT) PICK-UP—
Box II (DRB II) which will directly display any fault ENGINE CONTROLLER INPUT
code descriptions.
The engine controller contains a voltage converter The engine speed input is supplied to the engine
which converts battery voltage to a regulated 8.0 volts controller by the distributor pick-up. The distributor
and 5.0 volts output. The 8.0 volt output is used to uses an internal shutter and hall effect sensor to cre­
power the distributor. The 5.0 volt output is used to ate a pulsing signal that is sent to the engine control­
power the Throttle Position Sensor, Manifold Abso­ ler. These electronic pulses are converted to engine
lute Pressure (MAP) Sensor, and logic circuits. rpm information.
Engine Controller Inputs:
THROTTLE POSITION SENSOR (TPS)—
• Distributor (Hall Effect) Pick-up
ENGINE CONTROLLER INPUT
• Throttle Position Sensor
• Transmission Park/Neutral Switch (automatic The Throttle Position Sensor (TPS) is mounted on
transmission) the throttle body and senses the angle of the throttle
• Battery Voltage blade opening.(Fig. 3) The voltage that the sensor
• Manifold Absolute Pressure (MAP) Sensor produces increases or decreases according to the throt­
• Heated Oxygen Sensor tle blade opening. This voltage is transmitted to the
engine controller. It is used along with data from
• Coolant Temperature Sensor
• Vehicle Distance (Speed) Sensor
• Brake Switch
• Air Conditioning Controls
• Speed Control System Controls
Engine Controller Outputs:
• Check Engine Lamp
• Canister Purge Solenoid
• Air Conditioning Clutch Relay
• Auto Shutdown (ASD) Relay
• Fuel Injectors
• Automatic Idle Speed (AIS) Motor
• Ignition Coil
• Electric Exhaust Gas Recirculation Transducer (EET)
(California only)
• Speed Control Solenoids
• Radiator Fan Relay
• Part Throttle Unlock Solenoid (Automatic Trans­
mission)
• Alternator Field
• Diagnostic Connector
• Tachometer Output
• Emission Maintenance Reminder (EMR) Lamp
other sensors to adjust the air-fuel ratio for varying
conditions. These conditions include acceleration, de­
celeration, idle, and wide open throttle operations.
TRANSMISSION PARK/NEUTRAL SWITCH—
ENGINE CONTROLLER INPUT
The neutral safety switch is located on the trans­
mission housing. It provides an input to the engine
controller that indicates whether the automatic trans­
mission is in Park, Neutral, or a drive gear selection.
This input is used to determine idle speed (varying
with gear selection), fuel injector pulse width, and
ignition timing advance.
BATTERY VOLTAGE— ENGINE CONTROLLER INPUT
The engine controller monitors the battery voltage
input to determine fuel injector pulse width and alter­
nator field control. If battery voltage is low the engine
controller will increase injector pulse width (the pe­
riod of time that the injector is energized).
MANIFOLD ABSOLUTE PRESSURE (MAP) SENSOR—
ENGINE CONTROLLER INPUT
The Manifold Absolute Pressure (MAP) sensor is a
device which monitors manifold vacuum. (Fig. 4) It is
mounted underhood on the dash panel and is con­
nected to a vacuum nipple on the throttle body and
electrically to the engine controller. The sensor trans­
mits information on manifold vacuum conditions and
barometric pressure to the engine controller. The MAP
sensor data on engine load is used with data from
other sensors to determine the correct air fuel mixture.
Fig. 4 Manifold Absolute Pressure (MAP)
Sensor Location
HEATED OXYGEN SENSOR (0 2 SENSOR)—
ENGINE CONTROLLER INPUT
The Oxygen Sensor (0 2 Sensor) is a device which
produces an electrical voltage when exposed to oxygen
present in the exhaust gasses. (Fig. 5) The sensor is
mounted in the exhaust manifold and is electrically
heated internally for faster switching when the en­
gine is running. When there is a large amount of
oxygen present (lean mixture), the sensor produces a
low voltage. When there is a lesser amount present
(rich mixture) it produces a higher voltage. By moni­
toring the oxygen content and converting it to electri­
cal voltage, the sensor acts as a rich-lean switch.
The voltage is transmitted to the engine controller
which changes the fuel injector pulse width to adjust
the air-fuel mixture. Refer to Group 25 for more
Information.
GROUND ELECTRICAL CONNECTOR RR14G133
Fig. 5 Heated Oxygen Sensor
COOLANT TEMPERATURE SENSOR—
ENGINE CONTROLLER INPUT
The Coolant Temperature Sensor is a device which
monitors coolant temperature as an indication of en­
gine operating temperature. (Fig. 6) It is mounted in
the thermostat housing. This sensor provides the data
on engine operating temperature to the engine con­
troller. This allows the engine controller to demand
slightly richer air-fuel mixtures and higher idle speeds
until normal operating temperatures are reached. This
sensor is also used for radiator fan control.
WIRING TERMINALS THREADS
VEHICLE DISTANCE (SPEED) SENSOR—
ENGINE CONTROLLER INPUT
The vehicle distance sensor is located in the transaxle
extension housing. (Fig. 7) It is used to sense vehicle
motion. This sensor generates 8 pulses per axle shaft
revolution. These pulses are used (together with a
closed throttle signal from the throttle position sen­
sor) to differentiate between a closed throttle deceler­
ation condition and a normal idle (vehicle stopped)
condition. Under deceleration conditions, the engine
controller controls the AIS motor to maintain a de­
sired manifold absolute pressure (MAP) value. Under
idle conditions, the engine controller adjusts the auto­
matic idle speed (AIS) motor to maintain a desired
engine speed.
Fig. 7 Vehicle Distance (Speed) Sensor
BRAKE SWITCH— ENGINE CONTROLLER INPUT
The brake switch is used as an engine controller
input during deceleration and full stop conditions. To­
gether with other inputs, the brake switch is used to
maintain engine idle speed by controlling the auto­
matic idle speed motor (AIS) position. The brake switch
is mounted on the brake pedal support bracket.
CHECK ENGINE LAMP—
ENGINE CONTROLLER OUTPUT
The Check Engine Lamp comes on each time the
ignition key is turned on and stays on for 3 seconds as
a bulb test.
If the engine controller receives an incorrect signal
or no signal from the following list, the Check Engine
Lamp is turned on.
• Coolant Temperature Sensor
• Manifold Absolute Pressure Sensor
• Throttle Position Sensor
• Battery Voltage Input
• An Emission Related System (California vehicles)
• Charging system
This is a warning that the engine controller has
gone into Limp in Mode in an attempt to keep the
system operational. It signals an immediate need for
service.
In Limp In Mode, the Engine controller compen­
sates for the failure of certain components by substi­
tuting information from other sources.
The Check Engine Lamp can also be used to display
fault codes. Cycle the ignition switch on, off, on, off,
on within five seconds and any fault codes stored in
the Engine controller w ill be displayed. See the Fault
Code Description area in this section for a list of the
fault codes.
CANISTER PURGE SOLENOID—
ENGINE CONTROLLER OUTPUT
The Purge Solenoid is controlled by the engine con­
troller. The solenoid is mounted on the right side of
the engine compartment.(Fig. 8) During warm-up and
for a specified time period after hot starts the engine
controller grounds the Purge Solenoid causing it to
energize. This prevents vacuum from reaching the
charcoal canister valve. When the engine reaches a
specified operating temperature and the time delay
interval has past, the solenoid is de-energized by turn­
ing off the ground. Once this occurs vacuum will flow
to the canister purge valve and purge fuel vapors
through the throttle body. At closed throttle, the fuel
vapors will flow through the positive crankcase venti­
lation (PCV) vacuum line. The Purge Solenoid will
also be energized during certain idle conditions, to
update the fuel delivery calibration.
Fig. 8 Canister Purge Solenoid
AIR CONDITIONING (A/C) CLUTCH RELAY—
ENGINE CONTROLLER OUTPUT
The air conditioning clutch relay is controlled by
the engine controller and A/C switch and is powered
by the radiator fan relay. (Fig. 9) This relay is in the
energized closed (oh) position during engine operation
when A/C switch is closed and blower switch is on.
When the engine controller senses low idle speeds or
wide open throttle through the throttle position sen­
sor, it will de-energize the relay, open it’s contacts and
prevent air conditioning clutch engagement.
Fig. 9 Relay Identification
AUTO SHUTDOWN (ASD) RELAY—
ENGINE CONTROLLER OUTPUT
When there is no distributor signal present with the
ignition key in the RUN position, there is no need for
fuel delivery. When this condition occurs, the auto
shutdown relay interrupts power to the electric fuel
pump, fuel injectors, ignition coil, and 02 Sensor heater
element.
FUEL INJECTOR— ENGINE CONTROLLER OUTPUT
The Fuel Injector is an electric solenoid driven by
the engine controller. (Fig 10)
The engine controller, based on sensor inputs, de­
termines when and how long the fuel injector should
operate. When electrical current is supplied to the
injector, a spring loaded needle or armature is lifted
from its seat. This allows fuel to flow through the
orifice and deflect off the sharp edge of the injector
nozzle. This action causes the fuel to form a 45° cone
shaped spray pattern before entering the air stream
in the throttle body.
Fuel is supplied to the injector constantly at regu­
lated 100 Kpa (39 psi). The unused fuel is returned to
the fuel tank.
Fig. 10 Fuel Injector
AUTOMATIC IDLE SPEED (AIS) MOTOR—
ENGINE CONTROLLER OUTPUT
The Automatic Idle Speed Motor (AIS) is operated
by the engine controller. Data from the Throttle Posi­
tion Sensor, Speed Sensor, and Coolant Temperature
Sensor are used by the engine controller to adjust
engine idle to predetermined speed. Various switches
(Neutral/Safety, Brake) also provide input for idle speed.
The AIS adjusts the air portion of the air-fuel mixture
through an air bypass in the throttle body. The AIS
varies the air bypass to increase or decrease air flow
to maintain engine speed due to engine loads or ambi­
ent conditions. Deceleration die out is also prevented
by increasing airflow when the throttle is closed quickly
after a driving (speed) condition. The AIS Motor is
located on the front of the throttle body.
IGNITION COIL— ENGINE CONTROLLER OUTPUT
The engine controller supplies voltage to the posi­
tive side of the ignition coil through the auto shut­
down (ASD) relay. (Fig. 11) When the relay is energized,
the coil can be fired by the engine controller. The
engine controller fires the coil by providing a ground
path.

Fig. 11 Ignition Coll
ELECTRIC EXHAUST GAS RECIRCULATION
TRANSDUCER (EET)—
ENGINE CONTROLLER OUTPUT
The electric exhaust gas recirculation transducer
(EET) is a back pressure transducer and an electric
vacuum solenoid combined into a single unit. (Fig. 12)
It is mounted near the EGR valve. The electric vac­
uum solenoid portion of the EET receives its electrical
signal from the engine controller. Using this signal,
the solenoid regulates the vacuum flowing through to
the transducer portion of the EET. The back pressure
transducer measures the amount of exhaust gas back
pressure on the exhaust side of the EGR valve and
varies the strength of the vacuum signal applied to
ELECTRIC
TRANSDUCER 9114^30
Fig. 12 Electric Exhaust Gm Roclreulatlon Transducer
the EGR valve. The transducer uses this back pres­
sure signal to provide the correct amount of exhaust
gas recirculation under all conditions.
SPEED CONTROL SOLENOIDS—
ENGINE CONTROLLER OUTPUT
T h e en g in e co n tro lle r u se s its in p u ts to d e te rm in e
speed control vent and vacuum solenoid activation.
Refer to Group 8H for information on this system.
RADIATOR P IN RELAY—
ENGINE CONTROLLER OUTPUT
The radiator fan relay is located on the left side of
the engine compartment. The engine controller sig­
nals the radiator fan relay to supply power to the
radiator fan when the engine coolant reaches a prede­
termined temperature or when the ..air conditioning
system is turned on. For more information, refer to
Group 7, Cooling Systems.
PART THROTTLE UNLOCK SOLENOID—
ENGINE CONTROLLER OUTPUT
The engine controller controls the lock-up of the
torque convertor through the part throttle unlock
solenoid. The transm ission is locked up only in
direct drive mode. Refer to Group 21 for transmission
information.
ALTERNATOR FIELD—
ENGINE CONTROLLER OUTPUT
The engine controller regulates the charging sys­
tem voltage within a range of 12.9 to 15.0 volts. Refer
to Group 8A for charging system information.
DIAGNOSTIC CONNECTOR—
ENGINE CONTROLLER OUTPUT
The diagnostic connector provides the technician
with a means to connect the DRB II in order to diag­
nose or test the vehicle.
TACHOMETER— ENGINE CONTROLLER OUTPUT
The engine controller uses its inputs to compute
engine speed, and sends a signal to the tachometer.
Refer to Group 8E for more information.
-EMISSION MAINTENANCE REMINDER (EMR) ■
LAMP— ENGINE CONTROLLER OUTPUT
The Emissions Maintenance Reminder System (EMR)
is incorporated into the engine controller. The engine
controller records the vehicle mileage and stores it
into memory every 8 miles. At that time, the engine
controller checks for the 80,000, 82,500, and 120,000
mileage trip points. When the current mileage matches
one of the above mentioned trip points, the EMR lamp
on the instrument panel is activated.
Certain components are to be replaced at the indi­
cated mileage, or when the emissions maintenance
reminder lamp remains lit continuously with the key
in the on position, whichever occurs first. After per­
forming the required maintenance, the EMR lamp
must be reset to turn the lamp off.
For more information, refer to Group 25 or the ap­
propriate diagnostic manual.
FUEL PRESSURE REGULATOR
The pressure regulator is a mechanical device lo­
cated at the top of the throttle body. (Fig. 13) Its
function is to maintain a constant 265 kPa (39 PSI)
across the fuel injector tip. The regulator uses a spring
loaded rubber diaphragm to uncover a fuel return
port. When the fuel pump becomes operational, fuel
flows past the injector into the regulator, and is re­
stricted from flowing any further by the blocked re­
turn port. When fuel pressure reaches 265 kPa (39
PSI) it pushes on the diaphragm, compressing the
spring, and uncovers the fuel return port. The dia­
phragm and spring will constantly move from an open
to closed position to keep the fuel pressure constant.
Fig. 13 Fuel Pressure Regulator
THROTTLE BODY
The Throttle Body Assembly replaces a conventional
carburetor and is mounted on top of the intake mani­
fold. (Fig. 14) The throttle body houses the Fuel Injec­
tor, Pressure Regulator, Throttle Position Sensor, and
Automatic Idle Speed Motor. Air flow through the
throttle body is controlled by a cable operated throttle
blade located in the base of the throttle body. The
throttle body itself provides the chamber for metering,
atomizing, and distributing fuel throughout the air
entering the engine.
MODES OF OPERATION
As input signals to the engine controller change,
the engine controller adjusts its response to the out­
put devices. For example, the engine controller must
calculate a different injector pulse width and ignition
timing for idle than it does for wide open throttle
(WOT). There are several different modes of operation
that determine how the engine controller responds to
the various input signals.
Modes of operation are of two different types. OPEN
LOOP and CLOSED LOOP.
During OPEN LOOP modes the engine controller
receives input signals and responds according to pre­
set engine controller programming. Input from the
oxygen (0 2) sensor is not monitored during OPEN
LOOP modes.
During CLOSED LOOP modes the engine controller
does monitor the oxygen (0 2) sensor input. This input
indicates to the engine controller whether or not the
calculated iiyector pulse width results in the ideal
air-fuel ratio of 14.7 parts air to 1 part fuel. By moni­
toring the exhaust oxygen content through the 0 2
sensor, the engine controller can fine tune the injector
pulse width to achieve optimum fuel economy com­
bined with low emissions.
The single point fuel injection system has the fol­
lowing modes of operation:
• Ignition switch ON
• Engine start-up
• Engine warm-up
• Cruise
• Acceleration
• Deceleration
• Wide Open Throttle
• Ignition switch OFF
The ignition switch on, engine start-up (crank), en­
gine warm-up, and wide open throttle modes are
OPEN LOOP modes. The acceleration, deceleration,
and cruise modes, with the engine at operating tem­
perature are CLOSED LOOP modes (under most oper­
ating conditions).
FUEL SYSTEM 14-37
IGNITION SWITCH ON MODE
This is an OPEN LOOP mode. When the single
point fuel injection system is activated by the ignition
switch, the following actions occur:
• The engine controller determines atmospheric air
pressure from the MAP sensor input to determine
basic fuel strategy.
• The engine controller monitors the coolant tempera­
ture sensor and throttle position sensor input. The
engine controller modifies fuel strategy based on this
input.
When the key is in the ON position, the auto shut­
down (ASD) relay is not energized. Therefore batt<
voltage is not supplied to the fuel pump, ignition coil,
fuel injector or oxygen sensor heating element.
ENGINE START-UP MODE
This is an OPEN LOOP mode. The following actions
occur when the starter motor is engaged.
If the engine controller receives a distributor signal
it will energize the auto shutdown (ASD) relay to
supply battery voltage to the fuel pump, fuel injector
ignition coil, and oxygen sensor heating element. If
the engine controller does not receive a distributor
input, the ASD relay will be deenergized after approx­
imately one second.
The following must be true for the engine controller
to set a pneumatic fault code into memory:
• Engine is operating and idling within ± 64 RPM of
the target RPM.
• Current engine RPM is greater then the START
FUEL engine RPM.
• Vehicle is not moving.
• The difference between atmospheric pressure read­
ings taken currently and during the Key-On mode is
not great enough.
Once the ASD relay has been energized, the engine
controller:
• Supplies a ground path to the injector and the iiyec­
tor is pulsed four times per engine revolution instead
of the normal two pulses per revolution.
• Determines iiyector pulse width based on coolant
temperature, barometric pressure, and the number of
engine revolutions since cranking was initiated.
• Monitors the coolant temperature sensor, distribu­
tor pick-up, MAP sensor, and throttle position sensor
to determine correct ignition timing.
ENGINE WARM-UP MODE
This is a OPEN LOOP mode. The following inputs
are received by the engine controller:
• coolant temperature
• manifold absolute pressure (MAP)
• engine speed (distributor pick-up)
• throttle position
• A/C switch
• battery voltage
The engine controller provides a ground path for
the injector to precisely control iiyector pulse width
(by switching the ground on and off) and fires the
injector twice per engine revolution. The engine con­
troller controls engine idle speed (by adjusting the
automatic idle speed motor) and ignition timing.
CRUISE OR IDLE MODE
When the engine is at operating temperature this is
a CLOSED LOOP mode. During cruising speed the
following inputs are received by the engine controller:
• coolant temperature
• manifold absolute pressure
• engine speed
• throttle position
• exhaust gas oxygen content
• A/C control positions
• battery voltage
The engine controller provides a ground path for
the iiyector to precisely control iiyector pulse width
and fires the injector twice per engine revolution. The
engine controller controls engine idle speed and igni­
tion timing. The engine controller controls the air/fuel
ratio according to the oxygen content in the exhaust
gas.
ACCELERATION MODE
This is a CLOSED LOOP mode. The engine control­
ler recognizes an abrupt increase in throttle position
or MAP pressure as a demand for increased engine
output and vehicle acceleration. The engine controller
increases iiyector pulse width in response to increased
fuel demand.
DECELERATION MODE
This is a CLOSED LOOP mode. During decelera­
tion the following inputs are received by the engine
controller:
• coolant temperature
• manifold absolute pressure
• engine speed
• throttle position
• exhaust gas oxygen content
• A/C control positions
• battery voltage
The engine controller may receive a closed throttle
input from the throttle position sensor (TPS) at the
same time it senses an abrupt decrease in manifold
pressure from the manifold absolute pressure (MAP)
sensor. This indicates a hard deceleration. The engine
controller may reduce iiyector firing to once per en­
gine revolution. This helps maintain better control of
the air-fuel mixture (as sensed through the 0 2 sensor).
 The engine controller grounds the exhaust gas re­
circulation (EGR) and evaporative purge solenoids stop­
ping EGR and canister purge functions during a
deceleration condition.
WIDE OPEN THROTTLE MODE
This is an OPEN LOOP mode. During wide-open-
throttle operation, the following inputs are received
by the engine controller:
• coolant temperature
• manifold absolute pressure
• engine speed
• throttle position
When the engine controller senses wide open throt­
tle condition through the throttle position sensor (TPS)
it will:
• Provide a ground for the electric EGR transducer
(EET) solenoid. This prevents the EGR system from
functioning.
• De-energize the air conditioning relay. This disables
the air conditioning system.
The exhaust gas oxygen content input is not ac­
cepted by the engine controller during wide open throt­
tle operation. The engine controller will adjust injector
pulse width to supply a predetermined amount of ad­
ditional fuel.
IGNITION SWITCH OFF MODE
This is an OPEN LOOP mode. When the ignition
switch is turned to the OFF position, the following
occurs:
• All outputs are turned off.
• No inputs are monitored.
• The engine controller shuts down.
 GENERAL DIAGNOSIS—2.5L TBI ENGINES
INDEX
Page Page
Circuit Actuation Test Mode ..................................... 50 Systems Test ................................. ............................ 50
Faul t Code Description.............................................. 46 Throttle Body Minimum Air Flow
Fuel System Diagram ................................................ 40 Check Procedure...................................... ............... 51
On Board Diagnostics ................................................ 45 Visual Inspection....................................... ................. 41
State Display Test Mode ........................................... 50 60-Way Engine Controller Wiring Connector............ 51

FUEL SYSTEM DIAGRAM

Refer to the Component Identification portion of
this section for a more complete description of the
components shown in Fig. 1.
ENGINE CONTROLLER INPUTS ENGINE CONTROLLER OUTPUTS
DIAGNOSTIC

AUTO SHUTDOWN
RELAY

LOCKUP TORQUE CONVERTER

ELECTRIC SOLENOID
EXHAUST
GAS
PURGE RECIRCULATION
SOLENOID TRANSDUCER (EET) 9114-156
DISTRIBUTOR
VISUAL INSPECTION EET VACUUM — U a .ELECTRIC EGR
C O N N E C T IO N * ^ ^TR ANSD UCER
(EET)
A visual inspection for loose, disconnected, or mis-
routed wires and hoses should be made before at­
tempting to diagnose or service the fuel injection
system. A visual check will help spot these faults and
save unnecessary test and diagnostic time. A thor­
ough visual inspection will include the following checks:
(1) Check Ignition Coil Electrical Connections (Fig.
2 ).

9114-157
Fig. 4 Electric EGR Transducer (EET)
(6) Verify that the 3-way electrical connector is at­
tached to the MAP sensor (Fig. 5).
(7) Verify manifold absolute pressure sensor vac­
uum hose is attached at MAP sensor. (Fig. 5).

Fig. 2 Ignition Coll

(2) Verify that the electrical connector is attached

to the Canister Purge Solenoid (Fig. 3).
(3) Verify that vacuum connection at Canister Purge
Solenoid is secure and not leaking.

Fig. 5 Manifold Absolute Pressure (MAP)

Sensor Location

(8) Verify that alternator wiring and belt are cor­

rectly installed and tightened.
(9) Verify that hoses are securely attached to vapor
canister (Fig. 6).
VAPOR CANISTER SIGNAL PURGE HOSE
CANISTER HOSE

(4) Verify that the electrical connector is attached TANK VENT

to the Electric EGR Transducer (EET) (Fig. 4). HOSE
(5) Verify that vacuum connection at the Electric
EGR Transducer is secure and not leaking (Fig. 4).
 (10) Verify that the throttle body wiring harness is (16) Verify that hoses are attached to electric EGR
connected to main harness. transducer (EET) (California only) (Fig. 10).
(11) Verify that 4-way connector is attached to AIS
motor. (Fig. 7).
(12) Verify that the 3 way connector is attached to
the throttle position sensor. (Fig. 7).
(13) Verify that the 2-way connector is attached to
the fuel injector (Fig. 7).
THROTTLE P O S IT IO N
SENSOR 3 -W A Y
CONNECTOR

MAP SENSOR
CONNECTION 9114-32

Fig. i Throttle Body Vacuum Ports—>

Front
BRAKE CANISTER
BOOSTER A PURGE'HOSE
A U T O M A T IC IDLE SPEED VACUUM ^
(A IS ) M O T O R 4 -W A Y HOSE
CONNECTOR 9114-31

Fig. 7 Throttle Body Wiring Connections

(14) Verify that hose from PCV valve is securely

attached to the intake manifold vacuum port (Fig. 8).

ELECTRIC
EGR
TRANSDUCER
(EET) .
ELECTRIC EGR . j|f=r-
TRANSDUCER (EET) CONNECTION^ 9114-158
Fig. 10 Throttle Bodf Vacuum Ports—Rear

(17) Verify that heated air door vacuum connection

... jftk- is connected and not leaking.
TO
C A N ISTE POWER BRAKE POWER BRAKE /
PURGE BOOSTER HOSE. BOOSTER
6 6 , , I L*
\ CRANKCASE
VENT VALVE
HOSE TO
VALVE COVER

CRANKCASE
VENT VALVE HOSE '
ASSEMBLY TO INTAKE
MANIFOLD

Fig. 8 Vacuum Hoae from Intake Manifold

to PCV Walwe

(15) Verify that vacuum connections on the front

and rear of Throttle Body are secure and not leaking
(Figs. 9, and 10). Fig. I I Power Brake m d Speed Control
Vacuum Connection
 DISTRIBUTOR ELECTRICAL ^COOLING FAN ELECTRICAL
CONNECTION
(18) Verify power brake and speed control vacuum
connectors are tight (Fig. 11).
(19) Verify that all ignition cables'are in correct
order and seated into place (Fig. 12).

SWITCH AND SENDING UNIT

ELECTRICAL CONNECTION —

Fig. 14 Distributor, Oil Pressure Switch, and

Radiator Fan Electrical Connections
9114-33 (25) Verify neutral safety switch electrical connec­
tor is in place (Fig. 15). Automatic Only.
Fig. 12 Ignition Cable Routing and Connection (26) Check Torque Convertor Lockup Solenoid Elec­
trical Connection (Fig. 15) Automatic only.
(20) Verify that electrical connector is attached to
Coolant Temperature Sensor (Fig. 13).
(21) Verify that battery negative ground eyelet is
mounted to the cylinder head (left side). (Fig. 13).
LOCK-UP SOLENOID ELECTRICAL . NEU TRAL/PARK SAFETY
COOLANT CONNECTOR SWITCH

DIPSTICK HOLE RR14G33

Fig. 15 Automatic Transmission

Electrical Connections

(27) Verify that the 60-way connector is fully in­

serted into the socket on the Engine Controller (Fig.
16).

Fig. 13 Coolant Temperature Sensor

(22) Verify that 3-way connector is attached to dis­

tributor (Fig. 14).
(23) Verify radiator fan electrical connection is fully
inserted.
(24) Verify oil pressure switch electrical connections
is fully inserted (Fig. 14).
 (29) Verify engine harness to main harness connec­
tions are fully inserted.
(30) Check two way Distance Sensor Connector (Fig.
18).

Fig. 18 Distance Sensor Wiring Connection

(31) Verify that engine ground strap is attached at

the engine and dash panel (Figs. 19 and 20).

Fig. 16 Engine Controller Electrical Connector

(28) Verify that all electrical connectors are fully

inserted into relays and that battery connections are
clean and tight (Fig. 17).

Fig. 19 Engine Ground Strap at Intake Manifold

DASH S S ELECTRIC
PANEL (4 © (C EGR
TRANSDUCER
(EET)

GROUND/ ®
STRAP'

9114-150
 (32) Verify that 4-way connector is attached for
Heated Oxygen Sensor (Fig. 21).
Fig. 21 Heated Oxygen Sensor Electrical Connection
(33) Check Hose and Wiring Connections at Fuel
Pump. Check that wiring connector is making contact
with terminals on pump.
ON BOARD DIAGNOSTICS
The engine controller has been programmed to mon­
itor many different circuits of the fuel injection sys­
tem. This monitoring is called On Board Diagnosis. If
a problem is sensed with a monitored circuit often
enough to indicate an actual problem, a fault is stored
in the engine controller for eventual display to the
service technician. If the problem is repaired or ceases
to exist, the engine controller cancels the Fault Code
after 50 to 100 vehicle key on/off cycles.
Certain criteria must be met for a fault code to be
entered into the engine controller memory. The criteria
may be a specific range of engine RPM, engine tem­
perature, and/or input voltage to the engine controller.
It is possible that a fault code for a monitored cir­
cuit may not be entered into memory even though a
malfunction has occurred. This may happen because
one of the fault code criteria for the circuit has not
been met. For example, assume that one of the fault
code criteria for the MAP sensor circuit is that the
engine must be operating between 750 and 2000 RPM
to be monitored for a fault code. If the MAP sensor
output circuit shorts to ground when engine RPM is
above 2400 RPM (resulting in a 0 volt input to the
engine controller) a fault code will not be entered into
memory. This is because the condition does not occur
within the specified RPM range.
There are several operating conditions that the en­
gine controller does not monitor and set fault codes
for. Refer to Monitored Circuits and Non-Monitored
Circuits in this section.
Stored fault codes can be displayed either by cycling
the ignition key On - Off - On - Off - On, or through
use of the Diagnostic Readout Box II (DRB II). The
DRB II connects to the diagnostic connector in the
vehicle (Fig. 1).
MONITORED CIRCUITS
The engine controller can detect certain fault condi­
tions in the fuel injection system.
Open or Shorted Circuit - The engine controller can
determine if the sensor output (input to controller) is
within proper range, and if the circuit is open or
shorted.
Output Device Current Flow - The engine controller
senses whether the output devices are hooked up. If
there is a problem with the circuit, the controller
senses whether the circuit is open, shorted to ground,
or shorted high.
Oxygen Sensor - The engine controller can deter­
mine if the oxygen sensor is switching between rich
and lean once the system has entered closed loop.
Refer to Modes of Operation in this section for an
explanation of closed loop operation.
NON-MONITORED CIRCUITS
The engine controller does not monitor the follow­
ing circuits, systems and conditions that could have
malfunctions that result in driveability problems. Fault
codes may not be displayed for these conditions. How­
ever, problems with these systems may cause fault
codes to be displayed for other systems. For example,
a fuel pressure problem will not register a fault di­
rectly, but could cause a rich or lean condition. This
could cause an oxygen sensor fault to be stored in the
engine controller.
Fuel Pressure - Fuel pressure is controlled by the
vacuum assisted fuel pressure regulator. The engine
controller cannot detect a clogged fuel pump inlet
filter, clogged in-line fuel filter, or a pinched fuel
supply or return line. However, these could result in a
rich or lean condition causing an oxygen sensor fault
to be stored in the engine controller.
Secondary Ignition Circuit - The engine controller
cannot detect an inoperative ignition coil, fouled or
worn spark plugs, ignition cross firing, or open spark
plug cables.
Engine Timing - The engine controller cannot detect
an incorrectly indexed timing chain, camshaft sprocket
and crankshaft sprocket. The engine controller also
cannot detect an incorrectly indexed distributor. How­
ever, these could result in a rich or lean condition
causing an oxygen sensor fault to be stored in the
engine controller.
Cylinder Compression - The engine controller
cannot detect uneven, low, or high engine cylinder
compression.
Exhaust System - The engine controller cannot de­
tect a plugged, restricted or leaking exhaust system.
Fuel Injector Malfunctions - The engine controller
cannot determine if the fuel iiyector is clogged, the
pintle is sticking or the wrong iiyector is installed.
However, these could result in a rich or lean condition
causing an oxygen sensor fault to be stored in the
engine controller.
Excessive Oil Consumption - Although the engine
controller monitors the exhaust stream oxygen content
through the oxygen sensor when the system is in closed
loop, it cannot determine excessive oil consumption.
Throttle Body Air Flow - The engine controller can­
not detect a clogged or restricted air cleaner inlet or
filter element.
Evaporative System - The engine controller will not
detect a restricted, plugged or loaded evaporative purge
canister.
Vacuum Assist - Leaks or restrictions in the vac­
uum circuits of vacuum assisted engine control sys­
tem devices are not monitored by the engine controller.
However, these could result in a MAP sensor fault
being stored in the engine controller.
Engine Controller System Ground - The engine con­
troller cannot determine a poor system ground. How­
ever, a fault code may be generated as a result of this
condition.
Engine Controller Connector Engagement - The
engine controller cannot determine spread or dam­
aged connector pins. However, a fault code may be
generated as a result of this condition.
HIGH AND LOW LIM ITS
The engine controller compares input signal volt­
ages from each input device with established high and
low limits that are programmed into it for that device.
If the input voltage is not within specifications and
other fault code criteria are met, a fault code will be
stored in memory. (Other fault code criteria might
include engine RPM lim its or input voltages from
other sensors or switches that must be present before
a fault condition can be verified).
FAULT CODE DESCRIPTION
When a fault code appears, it indicates that the
Engine Controller has recognized an abnormal condi­
tion in the system. Fault codes can be obtained from
the Check Engine lamp on the Instrument Panel or
from the Diagnostic Readout Box II (DRBII). Fault
codes indicate the results of a failure but do not iden­
tify the failed component directly.
 FAULT CODE DESCRIPTION

fault D l i 11 Display Description of Fault €®d#

11 No Reference Signal No di stri butor reference signal detected during engine cranking.
During Cranking

1 3 + #* Slow Change in Idle No variation in MAP Sensor signal is detected.

MAP Signal

or

No Change in MAP from No difference is recognized between the engine MAP reading
Start to Run and the barometric pressure reading at start-up.

14 + * * MAP Voltage Too Low MAP sensor input below minimum acceptable voltage.

or

MAP Voltage Too High MAP sensor input above maximum acceptable voltage.

15** No Vehicle Speed No distance sensor signal detected during road load conditions.
Signal

17 Engine is Cold Too Engine coolant temperature remains below normal operating
3 temperatures during vehicle travel (Thermostat).

21** 0 2 Signal Stays at Neither rich or lean condition is detected from the oxygen
Center sensor input.

or

0 2 Signal Shorted to Oxygen sensor input voltage maintained above normal

Voltage operating range.

2 2 + #* Coolant Sensor Coolant temperature sensor input above the maximum

Voltage Too High acceptable voltage.

or

Coolant Sensor Coolant temperature sensor input below the minimum

Voltage Too Low acceptable voltage.
 FAULT CODE DESCRIPTION

Fault C m d m DIB II Display D escription of Fault C m d m .

24+** Throttle Position Throttle position sensor input above the maximum
Sensor Voltage High acceptable voltage.

or

Throttle Position Throttle position sensor input below the minimum

Sensor Voltage Low acceptable voltage.

25** Automatic Idle Speed A shorted condition detected in one or more of the AIS
Motor Circuits control circuits.

27 Injector #1 Control Injector #1 output driver does not respond properly to the
Ci rcuit control signal.

31** Purge Solenoid An open or shorted condition detected in the purge

Circuit solenoid circuit.

32** EGR Solenoid Circuit An open or shorted condition detected in the EGR
solenoid circuit. (All except Federal with Auto Trans.)

or

EGR System Failure Required change in Fuel/Air ratio not detected during diagnostic
test. (California only)

33 A/C Clutch Relay An open or shorted condition detected in the A/C clutch
Circui t relay circuit.

34 Speed Control An open or shorted condition detected in the speed control

Solenoid Circuits vacuum or vent solenoid circuits.

35 ■ Radiator Fan Relay An open or shorted condition detected in the radiator fan
Circuit relay circuit.

37 ' Torque Converter An open or shorted condition detected in the torque converter
Unlock Solenoid CKT part throttle unlock solenoid circuit, (automatic transmission only)
 FAULT CODE DESCRIPTION

fowl! Codo D l l (( Display Description of fowl! Codo

41 + #* Alternator Field Not An open or shorted condition defected in the alternator

S w itch ing P r o p e r l y field control ci rcui t.

42 Auto Shutdown Relay An open or shorted condition detected in the auto shutdown
Control Circuit relay circuit.

46+** Charging System Battery voltage sense input above target charging voltage
Voltage Too High "’ during engine operation.

47 + * * Charging System Battery voltage sense input below target charging voltage during
Voltage Too Low engine operation and no significant change in voltage
detected during active test of alternator output.

51** 0 2 Signal Stays Oxygen sensor signal input indicates lean fuel/air ratio condition
Below Center (Lean) during engine operation.

52** 0 2 Signal Stays Oxygen sensor signal input indicates rich fuel/air ratio condition
Above Center (Rich) during engine operation.

53 Internal Controller Internal engine controller fault condition detected.

Failure

62 Controller Failure Unsuccessful attempt to update EMR mileage in the controller

EMR Miles Not Stored EEPROM.

63 Controller failure Unsuccessful attempt to write to an EEPROM location by

EEPiOM Write Denied the controller.

55 N/A Completion of fault code display on CHECK ENGINE lamp.

+ Check Engine Lamp On

** Check Engine Lamp On (California Only)
SYSTEMS TEST S T A T E D IS P L A Y S E N S O R S
Connect the DRB II tester to the vehicle and access
Be syre to apply parking brake and/or block wheels the State Display screen. Then access Sensor Display.
before performing idle check m adjustment, or any The following is a list of the engine control system
engine running tests. functions accessible through the Sensor Display screen.
Battery Temp Sensor
O B T AIMING FAULT CODES Oxygen Sensor Signal
(1) Connect DRBIl'to the diagnostic connector lo­ Coolant Temperature
cated in the engine compartment near the engine Coolant Temp Sensor
controller. Throttle Position
(2) Start the engine if possible, cycle the transmis­ Minimum Throttle
sion selector and the A/C switch i f applicable.'Shut off Battery Voltage
the engine. MAP Sensor Reading
(3) Turn the ignition switch on, access Read Fault AIS Motor Position
Screen. Record all the fault messages shown on the Added Adaptive Fuel
DRBII. Observe the check engine lamp on the instru­ Adaptive Fuel Factor
ment panel. The lamp should light for 3 seconds then Barometric Pressure
go out (bulb check). Min Airflow Idl Spd
Payit code ensyre; access erase fault code data. Engine Speed
Fault #1 Key-On Info
ST1TE DISPLAY TEST MODE Module Spark Advance
Speed Control Target
The switch inputs used by the engine controller Fault # 2 Key-On Info
have only two recognized states, HIGH and LOW. For Fault # 3 Key-On Info
this reason, the engine controller cannot recognize the Speed Control Status
difference between a selected switch position versus Charging System Goal
an open circuit, a short circuit, or a defective switch. Theft Alarm Status
If the change is displayed, it can be assumed that the Map Sensor Voltage
entire switch circuit to the engine controller is func­ Vehicle Speed
tional. From the state display screen access either Oxygen Sensor State
State Display Inputs and Outputs or State Disp *. MAP Gauge Reading
Sensors. Throttle Opening
Total Spark Advance
S T A T E D IS P L A Y I N P U T S AND O U T P U T S
Connect the DRB 11 tester to the vehicle and access CIRCUIT ACTUATION TEST MODE
the State Display screen. Then access Inputs and Out­
puts. The following is a list of the engine control The purpose of the circuit actuation test mode is to
system functions accessible through the Inputs and check for the proper operation of output circuits of
Outputs screen. devices which the engine controller cannot internally
Park/Neutral Switch (automatic transmission only) recognize. The engine controller can attempt to acti­
Speed Control Resume vate these outputs and allow an observer to verify
Brake Switch proper operation. Most of the tests available in this
Speed Control On/Off mode provide an audible or visual indication of device
Speed Control Set operation (click of relay contacts, spray of fuel, etc.)
A/C Switch Sense With the exception of an intermittent condition, if a
B1 Voltage Sense device functions properly during its test, it can be
S/C (Speed Control) Vent Solenoid assumed that the device, its associated wiring, and its
S/C (Speed Control) Vacuum Solenoid driver circuit are in working order.
PTU Solenoid
A/C Clutch Relay O BTAINING CIRCUIT A C T U A T IO N T E S T
EGR Solenoid Connect the DRB 11 tester to the vehicle and access
EMR Lamp the Actuators screen. The following'is a list of the
Auto Shutdown Relay engine control system functions accessible through Ac­
Radiator Fan Relay tuators screens.
, Purge Solenoid Stop All Tests
Check Engine Lamp Ignition Coil #1
Fuel Injector #1
 AIS Motor Open/Close (9) Restart the engine, allow engine to idle for at
Radiator Fan Relay least one minute.
A/O Clutch Relay (10) Using the DRBII, Access Min Airflow Idle Spd
Auto Shutdown Relay in the sensor read test mode.
Purge Solenoid (11) The following will then occur:
S/C Servo Solenoids • AIS motor will fully close.
Alternator Field • Idle spark advance will become fixed.
Tachometer'Output • Idle fuel will be provided at a set value.
PTU Solenoid (Automatic Only) .
• Engine RPM will be displayed on Diagnostic Read­
EGR Solenoid
out Box II (DRBII).
All Solenoids/Relays
ASD Fuel System Test (12) Check idle RPM with tachometer. If idle RPM
is within the specifications listed below, then the throt­
THROTTLE BODY MINIMUM AIR FLOW tle body min. air flow is set correctly.
CHECK PROCEDURE
IDLE SPECIFICATIONS
(1) Connect Diagnostic Readout Box II (DRBII).
(2) Remove air cleaner assembly. Plug the heated Odometer Reading Engine Idle RPM
air door vacuum hose.
(3) Warm engine in Park or Neutral until the cool­
ing fan has cycled on and off at least once. Below 1000 Miles 2.5L 650-1250 RPM
(4) Hook-up timing check device and tachometer.
(5) Disconnect the coolant temperature sensor and
set basic timing to 12°BTDC ± 2°BTDC. Above 1000 Miles 2.5L 1050-1250 RPM
(6) Shut off engine. Reconnect coolant temperature
sensor.
(7) Disconnect the PCV valve hose from the intake 9114-163
manifold nipple.
(8) Attach Air Metering Fitting #6457 (Fig. 23) to If idle RPM is not within specification replace throt­
the intake manifold PCV nipple. tle body.
(13) Shut off engine.
(14) Remove Miller Tool #6457 from intake mani­
fold PCV nipple. Reinstall the PCV valve hose.
(15) Remove DRBII.
(16) Reinstall air cleaner assembly. Reinstall heated
air door vacuum hose.
(17) Disconnect timing check device and tachometer.

IGNITION TIMING PROCEDURE

Refer to Group 8D Ignition System
9114-68
60-WAY ENGINE CONTROLLER WIRING CONNECTOR
Refer to the engine controller wiring connector dia­
grams (Fig. 24) for information regarding wire colors
and cavity numbers.
 14-52
WIRE DESCRIPTION
CAV
COLOR
1 DG/RP* MAP SENSOR SIGNAL
2 TN/BK* COOLANT SENSOR

FUEL SYSTEM
3 RD/WT* DIRECT BATTERY VOLTAGE
4 IK/LB* SENSOR RETURN
5 BK/WT* SIGNAL GROUND
6 VT/WT* 5 . 0 VOLT OUTPUT {MAP AN D TPS)
7 OI 9 . 0 VOLT OUTPUT (DISTRIBUTOR PICKUP)
8 WT
■ '9 01 A21 SUPPLY
10
11 BK/TN* POWER GROUND
12 I K /I N * POWER GROUND
13
14
' 15
16 WT/DB* INJECTOR DRIVER #1
17
18
19 BK/GY* IGNITION COIL DI
20 DG ALTERNATOR !
21
22 O R /D I* THROTTLE PO SIT IO N SENSOR
23
24 GY/IK* IGNITION REFERENCE PICK
25 PK SCI TRANSMIT
26 VI/I1T C C D ( + ) BUS
27 li A/C SWITCH SENSE
28
29 WT/PK* BRAKE SWITCH
30 BR/YL* PARKIN El
31 PI/PK * A T O i FAN RE
32 BKIPK* CHICK ENGIh
33 IN /R D * SPEED CONTROL VACUUM SO LE N O
34 DB/OR* A/C CLUTCH RELAY
35 GY/YL* EGR SOLENOID
36
 SERVICE PROCEDURES—2.5L TBI ENGINES
INDEX
Page Page
Automatic Idle Speed (A.I.S.) Motor Service .......... 60 Fuel Injector Service ................................................. 58
Canister Purge Solenoid Service............................... 60 Fuel Pressure Regulator Service ............................... 57
Electric Exhaust Gas Recirculation Fuel System Pressure Release Procedure ................ 53
Transducer (EET) Service ............. ................... 60 Heated Oxygen Sensor ( 0 2 Sensor) Service . ............ 61
Engine Controller Service........... ................ ............. 61 Manifold Absolute Pressure Sensor Service ___. . . 60
Fuel Fitting Service .................................................. 57 Throttle B o d y.............................................................. 55
Fuel Hoses, Clamps, and Quick Throttle Body Service ................................................. 55
Connect Fittings ............... ................................... 53 Throttle Position Sensor Service............................... 59

FUEL SYSTEM PRESSURE RELEASE PROCEDURE
Before servicing the fuel pump, fuel lines, fuel
filter, throttle body, or fuel Injector, the fuel system
pressure must be released.
(1) Loosen fuel filler cap to release fuel tank pressure.
(2) Disconnect injector wiring harness connector.
(Fig. 1)
(3) Connect a jumper wire to ground terminal Num­
ber 1 of the iiyector harness to engine ground.
(4) Connect a jumper wire to the positive terminal
Number 2 o f the iqjector harness and touch the bat­
tery positive post for no longer than 5 seconds. This
releases system pressure.
(5) Remove jumper wires.
(6) Continue fuel system service.

FUEL HOSES, CLAMPS, AND

TERMINAL #1
QUICK CONNECT FITTINGS
TERMINAL#!
TERMINAL #2
TERMINAL #2 Inspect all hose connections (clamps and quick con­
nect fittings) to make sure they are secure and no
leaks are present. Hoses should be replaced immedi­
ately if there is any evidence of degradation that could
result in failure.
2.5L ENGINE 3.0L ENGINE Avoid contact with clamps or other components that
cause abrasions or scuffing. Insure that the rubber
hoses are properly routed to prevent pinching and to
avoid heat sources.
TERMINAL #2
The hoses used on fuel injected vehicles are of spe­
TERMINAL#!
cial construction due to the possibility of contami­
nated fuel in this system. If it is necessary to replace
these hoses, only hoses marked EFM/ EFI may be
used.
The hose clamps used on fuel injected vehicles are
of a special rolled edge construction to prevent the
3.3L ENGINE edge of the clamp cutting into the hose. Only these
9114-147 rolled edge type clamps may be used in this system,
all other types of clamps may cut into the hoses and
cause high pressure fuel leaks.
 Use new original equipment type hose clamps, torque
hose clamps to 1 N-m (10 in. lbs.).
The fuel line fittings used are quick connect type
fittings. These fittings are designed to speed up the
installation and removal of the fuel lines. (Fig. 2)
Quick connect fittings consist of a metal casing, a
black plastic locking ring, a metal locking retainer,
and internal o-rings.
The quick connect fittings may be removed from the
fuel tube nipple by pushing in on the plastic ring
located on the end of the fitting. An open end wrench
may be used to aid in disassembly.
When the fuel tube nipple is inserted into the quick-
connect fitting, the shoulder of the nipple is locked in
place by the locking retainer, and the internal O-rings
seal the tube.
The fuel tube nipples must be first lubricated with
clean 30 weight engine oil prior to reconnecting the
quick-connect fitting.
After connecting a quick-connect fitting, the con-
nectlon should be verified by pulling on the lines to
ensure that the lock Is secure.
TUBE/FITTING DISASSEMBLY
(1) Disconnect the negative battery cable.
(2) Remove the fuel tank gas cap to release any fuel
tank pressure.
(3) Perform fuel system pressure release procedure.
(4) Remove any loose dirt from quick connect fittings.
WARNING: WRAP SHOP TOWELS AROUND HOSES
TO CATCH ANY GASOLINE SPILLAGE.
(5) Press black plastic release ring in and pull quick
connector from the fuel tube. (Use open end wrench if
necessary).
(6) Cover the quick connector to prevent contam­
ination.
TUBEIFITTINQ ASSEMBLY
(1) Inspect the quick connect fitting to ensure that
the black plastic release ring is in the OUT position. If
the locking retainer is stuck in the RELEASE position
due to mushrooming of the release ring, or dirt accu­
mulation, the fitting should be replaced.
(2) Lubricate the male end of the fuel tube with 30
wt. oil.
(3) Insert quick connector fitting.
(4) Pull quick connector back to ensure complete
connection. If the connection is not complete, check
the black plastic release ring to make sure it is not
causing the locking retainer to jam.
(5) Use ASD Fuel System Test to pressurize the fuel
system. Check for leaks.
CAUTION: When using the ASD Fuel System Test,
the Auto Shutdown (ASD) Relay will remain ener­
gized for 7 minutes or until the test is stopped, or
until the ignition switch Is turned to the Off position.
TUBEIFITTINQ SERVICE
If a quick connect fitting needs to be serviced, the
following procedure must be followed:
(1) Disconnect the battery negative battery cable.
(2) Perform the fuel system pressure release.
(3) Remove the quick connect fitting from the fuel
tube by pushing in on the plastic ring located on the
end of the fitting. Gently pull the fitting from the fuel
tube.
WARNING: WRAP SHOP TOWELS AROUND HOSES
TO CATCH ANY GASOLINE SPILLAGE.
(4) Cut off the crimp ferrules at each end of the
hose, taking care not to damage the quick connect
fitting or the fuel tube.
(5) Discard the ferrules and hose. Discard the quick
connect fitting if it is defective.
(6) Replace the hose using hose marked EFM/ EFI.
This type of hose must be used due to its special
construction.
(7) Replace the quick connect fittings (if necessary)
with the correct size and type.
 (8) Attach the replacement hose to the quick con­ THROTTLE BODY SERVICE
nect fitting and fuel tube using the correct hose clamps.
The hose clamps used are of a special rolled edge REMOVAL
construction to prevent the edge of the clamp cutting (1) Remove air cleaner.(Fig. 3)
into the hose. Only these rolled edge type clamps may (2) Perform fuel system pressure release.
be used in this system, all other types of clamps may (3) Disconnect negative battery cable.
cut into the hoses and cause high pressure fuel leaks.
(9) Torque the hose clamps to 1 N-m (10 in. lbs.).
(10) Use ASD Fuel System Test to pressurize the
fuel system. Check for leaks.
CAUTION: When using the ASD Fuel System Test,
the Auto Shutdown (ASD) Relay will remain ener­
gized for 7 minutes or until the test Is stopped, or
until the ignition switch is turned to the Off position.

THROTTLE BODY
CAUTION: This fuel system is under a constant
pressure of 265 kPa (39 psi). When servicing the fuel
portion of the throttle body it will be necessary to
bleed fuel pressure before disconnecting any tubes.
Always reassemble throttle body components with
new O-rings and seals where applicable. Never use Fig. 3 Throttle Body and Air Cleaner Assembly
silicone lubricants on O-rings or seals, damage may
(4) Disconnect vacuum hoses and electrical connec­
result. Use care when removing fuel tubes to prevent
tors. (Fig. 4)
damage to quick connect fittings or tube ends.
 FUEL P iiS S U il
REGULATOR

FUEL INJECTOR
ELECTRICAL
CONNECTOR

FUEL INLET ■
NIPPLE

AUTOMATIC IDLE
SPEED (AIS) MOTOR MAP HEATED AIR AN D THROTTLE POSITION
S IN S O i NIPPLE CANISTER: PURGE SIGNAL NIPPLE SENSOR (TPS)
 (5) Remove throttle cable and, if so equipped, the
speed control and transmission kickdown cables.
(6) Remove return spring (if equipped).
(7) Loosen valve cover mounted fuel tube clamp.
(8) Wipe quick connect fittings to remove any dirt.
Remove fuel intake and return tubes. Place a shop
towel under the connections to absorb any fuel spilled.
(9) Remove throttle body mounting screws and lift
throttle body from vehicle. Remove throttle body gas­
ket from intake manifold.

INSTALLATION
(1) Using a new gasket, install throttle body and
torque mounting screws to 20 N-m (175 in. lbs.).
(2) Lubricate the ends of the fuel supply and return
tubes with 30 wt. oil. Install fuel tubes into the throt­
tle body quick connect fittings. Pull on the tubes to
ensure that they are fully inserted and locked into
position.
(3) Tighten the valve cover mounted fuel tube clamp.
(4) Install return spring.
(5) Install throttle cable, and, if, so equipped, install
kickdown and speed control cables.
(6) Install wiring connectors and vacuum hoses.
(7) Install air cleaner. INSTALLATION
(8) Reconnect negative battery cable. (1) Replace copper washers with new washers.
(9) Test for leaks using Diagnostic Readout Box II (2) Install fuel fittings in proper ports and torque to
(DRBII). With key in the Run position use ASD Fuel 20 N-m (175 in. lbs.).
System Test, this will activate pump and pressurize (3) Lubricate ends of the fuel tubes with 30 wt. oil.
the system. Check for leaks. Insert the tubes into the quick connect fittings. Pull
back on the tubes to ensure complete connection.
CAUTION: When using the ASD Fuel System Test,
(4) Tighten the valve cover mounted fuel tube clamp.
the Auto Shutdown (ASD) Relay will remain ener­
(5) Reconnect negative battery cable.
gized for 7 minutes or until the test is stopped, or
(6) Test for leaks using Diagnostic Readout Box II
until the ignition switch is turned to the Off position.
(DRBII). With key in the Run position use ASD Fuel
System Test, this will activate pump and pressurize
FUEL FITTING SERVICE the system, check for leaks.
REMOVAL CAUTION: When using the ASD Fuel System Test,
(1) Remove air cleaner assembly. the Auto Shutdown (ASD) Relay will remain ener­
(2) Perform Fuel System Pressure Release. gized for 7 minutes or until the test is stopped, or
(3) Disconnect negative battery cable. until the ignition switch is turned to the Off position.
(4) Loosen valve cover mounted fuel tube clamp.
(7) Reinstall air cleaner assembly.
(5) Wipe any dirt from around quick connect fit­
tings. (Fig. 5) Place a shop towel under the connec­
tions to catch any spilled fuel. Remove fuel tubes from
FUEL PRESSURE REGULATOR SERVICE
quick connect fittings.
The fuel system pressure for the 2.5L TBI engine is
(6) Remove each fitting from throttle body and note
265 kPa (39 psi).
inlet diameter. Remove copper washers.
REMOVAL
(1) Remove air cleaner assembly.
(2) Perform fuel system pressure release.
(3) Disconnect negative battery cable.
(4) Remove 3 screws attaching pressure regulator to
throttle body. (Fig. 6) \
 WARNING: PLACE A SHOP TOWEL AROUND FUEL
INLET CHAMBER TO CONTAIN ANY FUEL REMAIN­
ING IN THE SYSTEM.

Fig. 7 Removing Injector Cap

(5) Pull pressure regulator from the throttle body.

(6) Carefully remove O ring from pressure regulator
and remove gasket.

INSTALLATION
(1) Place new gasket on pressure regulator and care­
fully install new O ring.
(2) Position pressure regulator on throttle body. Press
into place, install 3 screws and torque to 5 N-m (40 in.
lbs.).
SCREWDRIVER
(3) Connect battery. Test for leaks using DRBII.
RR14G52
With key in the Run position use the ASD Fuel Sys­
tem Test. This will activate pump and pressurize the Fig. 8 Removing Fuel Injector
system, check for leaks.
FUEL INJECTOR \
CAUTION: When using the ASD Fuel System Test, ELECTRICAL
the Auto Shutdown (ASD) Relay will remain ener­ TERMINALS
gized for 7 minutes or until the test is stopped, or
until the ignition switch is turned to the Off position.
(4) Reinstall air cleaner assembly.

FUEL INJECTOR SERVICE

REMOVAL
(1) Remove air cleaner assembly.
(2) Perform fuel system pressure release.
(3) Disconnect negative battery cable.
(4) Remove Torx screw holding down the injector
cap. 9014-109
(5) With two small screwdrivers lift the top off the
injector using the slots provided (Fig. 7). Fig. 9 Servicing Fuel Injector
(6) Using a small screwdriver placed in the hole in
INSTALLATION
the fjront of the electrical connector gently pry the
(1) Place a new O ring on the injector cap. The
injector from the pod (Fig. 8).
injector will have the upper and lower O rings already
(7) Make sure the injector lower O ring has been
installed (Fig. 9).
removed from the pod (Fig. 9).
 (2) Apply a light coating of clean engine oil on the O (10) Reinstall the air cleaner assembly.
rings.
FUEL PRESSURE
(3) Place assembly in the pod and align the injector REGULATOR
wiring terminals with the injector cap fastener hole
(Fig. 10).
(4) Install injector cap with locating notch aligned
with the locating lobe on the injector (Fig. 11).
(5) Push down on the cap to ensure a good seal.
(6) Rotate the cap and injector to line up the attach­ FASTENER
ment hole (Fig. 12).
FUEL PRESSURE
REGULATOR O-RING

I NJECTOR CAP INSTALLED= 9114-42

Fig. 12 Fuel Injector Installed

ALIGN W I RI NG'
TERMINALS \ \
WITH HOLE 1 THROTTLE POSITION'-SENSOR SERVICE
LOCATING
NOTCH REmOWAL
(1) Disconnect negative battery cable.
(2) Remove air cleaner.
LOCATING LOBE 9114-40 (3) Disconnect 3 way connector at throttle position
sensor.(Fig. 13)
Fig. 10 Fuel Injector Installation (4) Remove 2 screws mounting throttle position sen­
sor to throttle body. ''
(5) Lift throttle position sensor off the throttle shaft.

9114-41

Fig. 11 Installing Fuel Injector Cap 9114-165

(7) Install torx screw and torque to 4-5 N-m (35-45 Pig, 13 Serwlcing Throttle Position Sensor
in. lbs.) (Fig 15).
(8) Reconnect negative battery cable. INSTALLATIO N
(9) Test for leaks using Diagnostic Readout Box II (1) Install throttle -position sensor to throttle body,
(DRBII). With ignition key in the Run position, use position toward the front of the vehicle. Torque screws
the ASD Fuel System Test. This will activate the fuel to 2 N*m (20 in. lbs.).
pump and pressurize the system; check for leaks. (2) Connect 3 way connector at throttle position
sensor.
CAUTION: When using the ASD Fuel System Test,
(3) Install air cleaner.
the Auto Shutdown (ASD) Relay will remain ener­
(4) Connect battery cable.
gized for 7 minutes or until the test is stopped, or
until the ignition switch is turned to the Off position.
AUTOMATIC IDLE SPEED (A .I.S.) MOTOR SERVICE
REMOVAL
(1) Remove air cleaner.
(2) Disconnect negative battery cable.
(3) Disconnect 4 pin connector on AIS.(Fig. 14)
(4) Remove 2 Torx head screws (25 mm long).
(5) Remove AIS from throttle body housing, making
sure that O ring is with AIS.
AUTOMATIC IDLE
SPEED (A .I.S.) MOTOR

Fig. 15 Manifold Absolute Pressure (MAP) Sensor

CANISTER PURGE SOLENOID SERVICE

(1) Remove vacuum hose and electrical connector
ELECTRICAL
from solenoid. (Fig. 16)
CONNECTOR (2) Depress tab on top of solenoid and slide the
solenoid downward out of mounting bracket.
RP286A (3) Reverse the above procedure for installation.
Fig. 14 Servicing Automatic Idle Speed (AIS) Motor

INSTALLATION
(1) Be sure that pintle is in the retracted position. If
pintle measures more than 1 Inch (25 mm) as shown
in (Fig. 15) it must be retracted by using AIS MOTOR
OPEN/CLOSE. (Battery must be reconnected for this
operation).
(2) Install new O ring on AIS.
(3) Install new AIS into housing making sure O
ring is in place.
(4) Install 2 Torx head screws and torque to 2 N-m
(20 in. lbs.).
(5) Connect 4 pin connector to AIS.
(6) Connect negative battery cable.

MANIFOLD ABSOLUTE PRESSURE SENSOR SERVICE Fig. 16 Canister Purge Solenoid

(1) Remove vacuum hose and electrical connector
from sensor. (Fig. 15)
(2) Remove sensor mounting screws and remove
sensor.
(3) Reverse the above procedure for installation.
Check the vacuum hose and electrical connections to
the sensor.
ELECTRIC EXHAUST GAS RECIRCULATION
TRANSDUCER (EET) SERVICE
REMOVAL
(1) Disconnect the 2-way electrical connector from
the solenoid portion of the EET. (Fig. 17)
(2) Disconnect vacuum hoses.

INSTALLATION
(1) Connect vacuum hoses.
(2) Connect electrical connector.
 Remove sensor using Oxygen Sensor Socket C-4907
(Fig. 19). When the sensor is removed, the exhaust
manifold threads must be cleaned with an 18 mm X
1.5 X 6E tap. If the same sensor is to be reinstalled,
the sensor threads must be coated with an anti-seize
compound such as Loctite 771-64 or equivalent. New
sensors are packaged with compound on the threads
and no additional compound is required. Sensors must
be torqued to 27 N-m (20 ft. lbs.). For more informa­
tion refer to Group 25.

Fig. 17 Electric EGR Transducer

ENGINE CONTROLLER SERVICE

(1) Remove air cleaner duct from engine controller. 9114-1 06
(2) Remove battery.
(3) Remove module mounting screws.(Fig. 18) Fig. 19 Oxygen Sensor Socket
(4) Remove wiring connector from module and re­
move module.
(5) Reverse the above procedure for installation. SENSOR OUTPUT
(BLACK W IRE)
D IA G N O S T IC . vv -i.v E N G IN E
CONNECTORv \ CONTROLLER

POW ER A N D
4 -W A Y
GROUND RR14G133
ELECTRICAL C O N N EC T O R

Fig. 20 Heated Oxygen Sensor

THROTTLE BODY GROUND

BATTERYf 918D-55
ATED OXYGEN SENSOR
Fig. 18 Engine Controller 4-WAY CONNECTOR

HEATED OXYGEN SENSOR (0 2 SENSOR) SERVICE 8914-15

CAUTION: Care should be exercised so that no

pulling force is put on sensor wire. Use care in work­
ing around sensor as the exhaust manifold may be
extremely hot. (Figs. 20 and 21)
 MULTI-POINT FUEL INJECTION—3.0L ENGINES
COMPONENT IDENTIFICATION—3.0L ENGINES
Page
Air Conditioning Clutch Relay—
Engine Controller Output .......................................
Alternator Field— Engine Controller Output ............
Auto Shutdown (ASD) Relay—
Engine Controller Output .......................................
Automatic Idle Speed (AIS) Motor—
Engine Controller Output .......................................
Battery Voltage— Engine Controller Input ................
Brake Switch— Engine Controller In p u t....................
Canister Purge Solenoid—
Engine Controller Output .......................................
Check Engine Lamp— Engine Controller Output . . .
Coolant Temperature Sensor—
Engine Controller Input .........................................
Diagnostic Connector—
Engine Controller Output .......................................
Distributor (Optical System) Pick-Up—
Engine Controller Input .........................................
Electronic Automatic Transmission Controller—
Engine Controller Output .......................................
Emission Maintenance Reminder (EMR) Lamp—
Engine Controller Output .......................................
GENERAL INFORMATION
The Multi-point Electronic Fuel Injection system
(Fig. 1) combines an electronic fuel and spark advance
control system with a cross type intake system.
At the center of this system is a digital prepro­
grammed computer known as a Single Board Engine
Controller (SBEC). The SBEC is referred to as the
engine controller in this service manual. The engine
controller regulates ignition timing, air-fuel ratio, emis­
sion control devices, cooling fan, charging system, idle
speed and speed control. This component has the abil­
ity to update and revise its commands to meet chang­
ing operating conditions.
Various sensors provide the input necessary for the
engine controller to correctly regulate fuel flow at the
fuel injectors. These include the Manifold Absolute
INDEX
Page
Engine Controller .............................................................. .... 63
66 Fuel Injector— Engine Controller Output ......................66
67 Fuel Pressure R e g u la to r................................................... .... 68
Fuel Supply C ircu it.........................................................68
66 General Information .............................................................. 62
Heated Oxygen Sensor ( 0 2 Sensor)—
67 Engine Controller Input ................................................... 64
64 Ignition Coil— Engine Controller Output .................... .... 67
65 Manifold Absolute Pressure (MAP) Sensor—
Engine Controller Input ................................................... 64
65 Modes of Operation .............................................................. 69
65 Radiator Fan Relay— Engine Controller Output ___ __ 67
Speed Control Solenoid—
65 Engine Controller Output .......................................... ...... 67
Tachometer— Engine Controller Output ...................... .... 67
67 Throttle B o d y ....................................................................... .... 68
Throttle Position (TPS)—
64 Engine Controller Input ......................................... ... 64
Transmission Park/Neutral Switch—
67 Engine Controller Input ................................................... 64
Vehicle Distance (Speed) Sensor—
68 Engine Controller Input ................................................... 65
Pressure, Throttle Position, Oxygen Sensor, Coolant
Temperature, and Vehicle Speed Sensors. In addition
to the sensors, various switches also provide impor­
tant information. These include the Transmission
Neutral-Safety, and Air Conditioning Clutch Switch,
Brake Switch and the Speed Control Switch. These
signals cause the engine controller to change either
the fuel flow at the iiyector, ignition tim ing or other
controller outputs.
The engine controller tests many of its own input
and output circuits. If a fault is found in a major
circuit, this information is stored in the memory. In­
formation on this fault can be displayed by a techni­
cian by means of the instrument panel Check Engine
lamp or by connecting the Diagnostic Readout Box II
(DRBII) and observing the fault description directly.
 ENGINE CONTROLLER INPUTS ENGINE CONTROLLER OUTPUTS DIAGNOSTIC
TOOL

TACHOMETER
ig n it io n +e = a “ CHECK ENGINE
REFERENCE J J ltlil LAMP
PICKUP BATTERY IGNITION COIL

DISTRIBUTOR
ENGINE EMISSION
CONTROLLER MAINTENANCE
REMINDER AUTOMATIC PURGE
(EMR) I DLE SOLENOID
LAMP SPEED MOTOR
THROTTLE TRANSMISSION COOLANT ALTERNATOR
POSITION PARK/NEUTRAL TEMPERATURE
SENSOR SWITCH SENSOR

USS LOCKUP TORQUE CONVERTER

BRAKE AUTO SOLENOID
RADIATOR SHUTDOWN OR
HEATED SWITCH FAN RELAY ELECTRONIC AUTOMATIC

9
OXYGEN SENSOR RELAY A/C CUTOUT " 1 TRANSMISSION
RELAY

t
DISTANCE
SENSOR
SPEED
CONTROL
SWITCH
MANIFOLD
ABSOLUTE
PRESSURE
SENSOR FUEL INJECTORS
FUEL PUMP

SPEED CONTROL SOLENOIDS

9114-166

Fig. 1 Multipoint Fuel Injection Components

ENGINE CONTROLLER below under Engine Controller Inputs. It then com­

putes the fuel iiyector pulse width, spark advance,
The engine controller (Fig. 2) contains the circuits ignition coil dwell, idle speed, purge, and cooling fan
necessary to drive the ignition coil, fuel injector, and turn on and alternator charge rate.
the alternator field. Engine Controller Outputs are components that are
operated or controlled based on the values received
FASTENER 60 WAY ELECTRICAL
LOCATIONS CONNECTOR from the engine controller inputs. These outputs are
listed below.
The Automatic Shut Down (ASD) relay is mounted
externally, but is turned on and off by the engine
controller. Distributor pick-up signal goes to the en­
gine controller. In the event of no distributor signal,
the ASD relay is deactivated and power is shut off
from the fuel injectors, ignition coil, and oxygen sen­
sor .
The engine controller tests many of its own input
and output circuits. If a fault is found in a major
system, this information is stored in the engine con­
troller. Information on this fault can be displayed to a
technician by means of the instrument panel check
918D-48 engine lamp or by connecting the Diagnostic Readout
Box II (DRBII) and read descriptions of any faults
Fig. 2 Engine Controller which have been stored.
The engine controller contains a voltage converter
The engine controller is digital computer containing
which converts battery voltage to a regulated 8.0 volts
a microprocessor. The module receives input signals
and 5.0 volts output. The 8.0 volt output is used to
from various switches and sensors. These are listed
power the distributor. The 5.0 volt output is used to
power the Throttle Position Sensor and Manifold Ab­
solute Pressure (MAP) Sensor and logic circuits.
Engine Controller Inputs:
• Distributor (Optical System) Pick-up
• Throttle Position Sensor
• Transmission Park/Neutral Switch
• Battery Voltage
• Manifold Absolute Pressure (MAP) Sensor
• Heated Oxygen Sensor
• Coolant Temperature Sensor
• Vehicle Distance (Speed) Sensor
• Brake Switch
• Air Conditioning Controls
• Speed Control System Controls
Engine Controller Outputs:
• Check Engine Lamp
• Canister Purge Solenoid
• Air Conditioning Clutch Relay
• Auto Shutdown (ASD) Relay
• Fuel Injectors
• Automatic Idle Speed (AIS) Motor
• Ignition Coil
• Speed Control Solenoid
• Radiator Fan Relay
• Electronic Automatic Transmission Controller
• Alternator Field
• Diagnostic Connector
• Tachometer Output
• Emission Maintenance Reminder (EMR) Lamp
DISTRIBUTOR (OPTICAL SYSTEM) PICK-UP—
ENGINE CONTROLLER INPUT
The engine speed input is supplied to the engine
controller by the distributor pick-up. The distributor
uses an internal metal disc and optical sensor to cre­
ate a pulsing signal that is sent to the engine control­
ler. These electronic pulses are converted to engine
rpm information.
THROTTLE POSITION SENSOR (TPS)—
ENGINE CONTROLLER INPUT
The Throttle Position Sensor (TPS) is a variable
resistor that is mounted on the throttle body and
senses the angle of the throttle blade opening. The
voltage that the sensor produces increases or decreases
according to the throttle blade opening. This voltage
is transmitted to the engine controller. It is used along
with data from other sensors to adjust the air-fuel
ratio for varying conditions. These conditions include
acceleration, deceleration, idle, and wide open throttle
operations.
TRANSMISSION PARK/NEUTRAL SWITCH—
ENGINE CONTROLLER INPUT
The neutral safety switch is located on the trans­
mission housing. It provides an input to the engine
controller that indicates whether the automatic trans­
mission is in Park, Neutral, or a drive gear selection.
This input is used to determine idle speed, (varying
with gear selection) fuel iryector pulse width, and
ignition timing advance.
BATTERY VOLTAGE— ENGINE CONTROLLER INPUT
The engine controller monitors the battery voltage
input to determine fuel injector pulse width and alter­
nator field control. If battery voltage is low the engine
controller will increase iryector pulse width (the pe­
riod of time that the iryector is energized).
MANIFOLD ABSOLUTE PRESSURE (MAP) SENSOR—
ENGINE CONTROLLER INPUT
The Manifold Absolute Pressure (MAP) sensor is a
device which monitors manifold absolute pressure. (Fig.
3) It is mounted under hood on the alternator bracket.
It is connected to a vacuum nipple on the intake
plenum and, electrically to the engine controller. The
sensor transmits information on manifold pressure con­
ditions to the engine controller. The MAP sensor data
on engine load is used with data from other sensors to
determine the correct air-fuel mixture.
Fig. 3 Map Sensor
HEATED OXYGEN SENSOR (0 2 SENSOR)—
ENGINE CONTROLLER INPUT
The Oxygen Sensor (0 2 Sensor) is a device which
produces an electrical voltage when exposed to the
oxygen present in the exhaust gasses. (Fig. 4) The
sensor is mounted in the Rear Exhaust Manifold and
is electrically heated internally for faster switching
when engine is running. When there is a large amount
of oxygen present (lean mixture), the sensor produces
a low voltage. When there is a lesser amount present
(rich mixture) it produces a higher voltage. By moni­
toring the oxygen content, and converting it to electri­
cal voltage, the sensor acts as a rich-lean switch. The
voltage is transmitted to the engine controller, which
changes the fuel injector pulse width to adjust air/fuel
mixture. For 9999 Information refer to Group 25.
GROUND ELECTRICAL CONNECTOR RR14G133
Fig, 4 Heated Oxygen Sensor
COOLANT TEMPERATURE SENSOR—
ENGINE CONTROLLER INPUT
The Coolant Temperature Sensor is a device which
monitors coolant temperature (which is an indication
of engine operating temperature. (Fig. 5) It is mounted
in the thermostat housing. This sensor provides data
on engine operating temperature to the engine con­
troller. This data allows the engine controller to de­
mand slightly richer air-fuel mixtures and higher idle
speeds until normal operating temperatures are reached.
The sensor is a variable resistor with a range of 40°F
to 265°F. The sensor is also used to turn on the radia­
tor fan.
WIRING TERMINALS THREADS
Fig. 5 Coolant Temperature Senaor
VEHICLE DISTANCE (SPEED! SENSOR—
ENGINE CONTROLLER INPUT
A distance sensor is located in the transaxle exten­
sion housing to sense vehicle motion. This sensor gen­
erates 8 pulses per axle shaft revolution. These signals
are interpreted, in conjunction with a closed throttle
signal from the throttle position sensor, by the engine
controller to differentiate between a closed throttle
decel and a normal idle (vehicle stopped) condition.
Under decel conditions, the computer module controls
the AIS motor to maintain a desired MAP value. Un­
der idle conditions, the engine controller adjusts the
AIS motor to maintain a desired engine speed.
BRAKE SWITCH— ENGINE CONTROLLER INPUT
The brake switch is used as an engine controller
input during deceleration and full stop conditions. To­
gether with other inputs, the brake switch is used to
maintain engine idle speed by controlling the auto­
matic idle speed motor (AIS) position. The brake switch
is mounted on the brake pedal support bracket.
CHECK ENGINE LAMP—
ENGINE CONTROLLER OUTPUT
The Check Engine Lamp comes on each time the
ignition key is turned on and stays on for 3 seconds as
a bulb test.
If the engine controller receives an incorrect signal
or no signal from the following list, the Check Engine
Lamp is turned on.
• Coolant Temperature Sensor
• Manifold Absolute Pressure Sensor
• Throttle Position Sensor
• Battery Voltage Input
• An Emission Related System (California vehicles)
• Charging system
This is a warning that the engine controller has
gone into Limp in Mode in an attempt to keep the
system operational. It signals an immediate need for
service.
In Limp In Mode, the Engine controller compen­
sates for the failure of certain components by substi­
tuting information from other sources.
The Check Engine Lamp can also be used to display
fault codes. Cycle the ignition switch on, off, on, off,
on within five seconds and any fault codes stored in
the Engine controller will be displayed. See the Fault
Code Description area in this section for a list of the
fault codes.
CANISTER PURGE SOLENOID—
ENGINE CONTROLLER OUTPUT
The Purge Solenoid is controlled by the Engine Con­
troller. (Fig. 6) During warm-up and for a specified
time period after hot starts the Engine Controller
grounds the Purge Solenoid causing it to energize.
This prevents vacuum from reaching the charcoal can­
ister valve. When the engine reaches a specified oper­
ating temperature and the time delay interval has
occurred the solenoid is de-energized by turning off
the ground. Once this Occurs vacuum will flow to the
canister purge valve and purge fuel vapors through
the throttle body. The Purge Solenoid will also be
energized during certain driving conditions, this is to
update the fuel delivery calibration.

AIR CONDITIONING CLUTCH RELAY—

ENGINE CONTROLLER OUTPUT
' The air conditioning' clutch relay is controlled b j Fig. 7 Relay Identification
the engine controller and powered by the radiator fan
relay A/C switch and engine controller (except for the
FUEL INJECTOR— ENGINE CONTROLLER OUTPUT
variable-displacement system). (Figs. 7) This relay is.
The Fuel Injector is an electric solenoid powered by
in the energized closed (on) position during engine
the engine controller. (Fig. 8) The engine controller
operatio&.'when A/C switch is closed and blower switch
determines when and how-long the Injector should
is on. .When the engine controller senses wide open
operate. When an electric current is supplied to the
throttle' or low engine EPM, it will de-energize the
injector, the armature and pintle move a short dis­
relay, open, it’s contacts and prevent air conditioning
tance against a spring, opening a small orifice. Fuel is
clutch engagement. This relay is also de-energized for
supplied to the inlet of the injector by the fuel pump.
a short time after engine start up.
It then passes through the injector, around the pintle,
and out the orifice. Since the fuel is under high pres­
.AUTO SHUTDOWN (ASDj RELAY— sure a fine spray is developed in the shape of a hollow
ENGINE CONTROLLER OUTPUT “ cone. The injector, through this spraying action, atom­
izes the fuel and distributes it into the air entering
When there is no distributor signal present with the
the combustion chamber.
Ignition key in the .RUN position," there' is no need for
fuel delivery. When this condition occurs, the auto
shutdown relay interrupts power to the electrical fuel
pump, fuel injectors, and ignition coil and the 02sen­
sor heater.(Figs. 7)
 ELECTRICAL CO NN ECfO t
INJECTOR NOZZLE
WITH CHIMNEY
FUEL INLET
O-ftlNG
INJECTOR TO INTAKE L I K I N G RING
MANIFOLD O-RiNG SLOT
8914-42
Pig. 8 Fuel Injector
AUTOMATIC IDLE SPEED (AIS) MOTOR—
ENGINE CONTROLLER OUTPUT
The Automatic Idle Speed Motor (AIS) is operated
by the engine controller. Data from the Throttle Posi­
tion Sensor, Speed Sensor, and Coolant Temperature
Sensor are used by the engine controller to "adjust
engine idle to predetermined speed. Various switches
(Neutral/Safety, Brake) also provide input for idle speed.
The AIS adjusts the air portion of the air-fuel mixture
through an air bypass in the throttle body. The AIS
varies the air bypass to increase or decrease air flow
to maintain engine speed due to engine loads or ambi­
ent conditions. Deceleration die out is also prevented
by increasing airflow' when the throttle is closed quickly
after a driving (speed) condition.
IGNITION COIL— ENGINE CONTROLLER OUTPUT
The engine controller supplies voltage to the posi­
tive side of the ignition coil through the auto shut­
down (ASD) relay. (Fig. 9) When the relay is energized.
IGNITION COIL IGNITION CABLE
INTAKE
MANIFOLD.
the coil can be fired by the engine controller. The
engine controller fires the coil by providing a ground
path.
SPEED CONTROL SOLENOID—
ENGINE CONTROLLER OUTPUT
The engine controller uses its inputs to determine
speed control vent and vacuum solenoid' activation.
Refer to Group 8H for information on this system. .
RADIATOR PAN RELAY—
ENGINE CONTROLLER OUTPUT
The radiator fan relay is located on the left side of
the engine'compartment. The engine controller sig­
nals the radiator fan relay to supply power to the
radiator fan when the engine coolant reaches a prede­
termined temperature or when the air conditioning
system is turned on. For more information, refer to
Group 7, Cooling Systems.
ELECTRONIC AUTOMATIC TRANSMISSION
CONTROLLER— ENGINE CONTROLLER OUTPUT
The Electronic Automatic Transmission Controller
and the Engine Controller trade information with each
other. This information includes such things as en­
gine speed and vehicle load. Receiving this informa­
tion allows the engine controller to control the fuel
and ignition systems for best vehicle operation and
efficiency.
ALTERNATOR FIELD—
ENGINE CONTROLLER OUTPUT
The engine controller regulates the charging sys­
tem voltage within a range of 12.9 to 15.0 volts. Refer
to Group 8A for charging system information.
DIAGNOSTIC CONNECTOR—
ENGINE CONTROLLER OUTPUT
The diagnostic connector provides the technician
with a means to connect the DRB II in order to diag­
nose or test the vehicle.
TACHOMETER— ENGINE CONTROLLER OUTPUT
The engine controller uses its inputs to compute
engine speed, and sends a signal to the tachometer.
Refer to Group 8E for more information.
EMISSION MAINTENANCE REM1NOER
(EMR) LAMP— ENGINE CONTROLLER OUTPUT
The Emissions Maintenance Reminder System (EMR)
is incorporated info the engine controller. The engine
controller records the vehicle mileage and stores it
into memory every 8 miles. At that time, the engine
controller checks for the 60,000, 82,500, and 120,000
mileage trip points. When the current mileage matches
one of the above mentioned trip points, the EMR lamp
on the instrument panel is activated.
Certain components are to be replaced at the indi­
cated mileage, or when the emissions maintenance
reminder lamp remains lit continuously with the key
in the on position, whichever occurs first. After per­
forming the required maintenance, the EMR lamp
must be reset to turn the lamp off.
'For more information, refer to Group 25 or the ap­
propriate diagnostic manual.
THROTTLE BODY
The throttle'body assembly replaces a conventional
carburetor, air intake system. (Fig. 10) It is located at
the left end of the Air Intake Plenum. The throttle
body houses the Throttle Position Sensor and the Au­
tomatic Idle Speed Motor. Air flow through the throt­
tle body is controlled by a cable operated throttle
blade located in the base of-the throttle body.
. CANISTER PURGE ‘ THROTTLE POSITION
FUEL SUPPLY CIRCUIT
Fuel is pumped to the fuel rail by an electrical
pump which is mounted in the fuel tank. The pump
inlet is fitted with a filter to prevent water and other
contaminants from entering the fuel supply circuit.
Fuel pressure is controlled to a preset level above
intake manifold pressure by a pressure regulator which
is mounted =on the fuel rail. The regulator uses intake
manifold pressure as a reference.
FUEL PRESSURE REGULATOR
The pressure regulator is a mechanical device lo­
cated downstream of the fuel injector on the fuel rail.
(Fig. 11) Its function is to maintain a constant 330
kPa (48 psi) across the fuel injector tip. The regulator
uses a spring loaded rubber diaphragm to uncover a
fuel return port. When the fuel pump becomes opera­
tional, fuel flows' past the injector into the regulator,
and is restricted from flowing any further by the
blocked return port. When fuel pressure reaches 330
kPa (48 psi) it pushes on the diaphragm, compressing
the spring, and uncovers the fuel return port. The
diaphragm and spring will constantly move from an
open to closed position. to keep the fuel pressure
constant.
CANISTER PURGE
 VACUUM
9114-122
Fig. 11 Fuel Pressure Regulator
MODES OF OPERATION
As input signals to the engine controller change,
the engine controller adjusts its response to the out­
put devices. For example, the engine controller must
calculate a different injector pulse width and ignition
timing for idle than it does for wide open throttle
(WOT). There are several different modes of operation
that determine how the engine controller responds to
the various input signals.
Modes of operation are of two different types. OPEN
LOOP and CLOSED LOOP.
During OPEN LOOP modes the engine controller
receives input signals and responds according to pre­
set engine controller programming. Input from the
oxygen (0 2) sensor is not monitored during OPEN
LOOP modes.
During CLOSED LOOP modes the engine controller
does monitor the oxygen (0 2) sensor input. This input
indicates to the engine controller whether or not the
calculated injector pulse width results in the ideal
air-fuel ratio of 14.7 parts air to 1 part fuel. By moni­
toring the exhaust oxygen content through the 0 2
sensor, the engine controller can fine tune the injector
pulse width to achieve optimum fuel economy com­
bined with low emissions.
The single point fuel injection system has the fol­
lowing modes of operation:
• Ignition switch ON
• Engine start-up
• Engine warm-up
• Cruise
• Acceleration
• Deceleration
• Wide Open Throttle
• Ignition switch OFF
The ignition switch on, engine start-up (crank), en­
gine warm-up, and wide open throttle modes are
OPEN LOOP modes. The acceleration, deceleration,
and cruise modes, with the engine at operating tem­
perature are CLOSED LOOP modes (under most oper­
ating conditions).
IGNITION SWITCH ON MODE
This is an OPEN LOOP mode. When the multi
point fuel injection system is activated by the ignition
switch, the following actions occur:
• The engine controller determines atmospheric air
pressure from the MAP sensor input to determine
basic fuel strategy.
• The engine controller monitors the coolant tempera­
ture sensor and throttle position sensor input. The
engine controller modifies fuel strategy based on this
input.
When the key is in the ON position, the auto shut­
down (ASD) relay is not energized. Therefore battery
voltage is not supplied to the fuel pump, ignition coil,
fuel injectors or oxygen sensor heating element.
ENGINE START-UP MODE
This is an OPEN LOOP mode. The following actions
occur when the starter motor is engaged.
If the engine controller receives a distributor signal
it will energize the auto shutdown (ASD) relay to
supply battery voltage to the fuel pump, fuel injector
ignition coil, and oxygen sensor heating element. If
the engine controller does not receive a distributor
input, the ASD relay will be deenergized after approx­
imately one second.
 The following must be true for the engine controller
to set a pneumatic fault code into memory:
• Engine is operating and idling within ± 64 RPM of
the target RPM.
• Current engine RPM is greater then the START
FUEL engine RPM.
• Vehicle is not moving.
• The difference between atmospheric pressure read­
ings taken currently and during the Key-On mode is
not great enough.
Once the ASD relay has been energized, the engine
controller:
• Supplies a ground path to the injectors, firing two
injectors every 2/3 engine revolution.
• determines injector pulse width based on coolant
temperature, barometric pressure (MAP sensor), and
the number of engine revolutions since cranking was
initiated.
• Monitors the coolant temperature sensor, distribu­
tor pick-up, MAP sensor, and throttle position sensor
to determine correct ignition timing.
ENGINE WARM-UP MODE
This is a OPEN LOOP mode. The following inputs
are received by the engine controller:
• coolant temperature
• manifold absolute pressure (MAP)
• engine speed (distributor pick-up)
• throttle position
• A/C switch
• battery voltage
The engine controller provides a ground path for
the injectors to precisely control injector pulse width
(by switching the ground on and off). The engine con­
troller controls engine idle speed by adjusting the
automatic idle speed motor and ignition timing.
CRUISE OR IDLE MODE
When the engine is at operating temperature this is
a CLOSED LOOP mode. During cruising speed the
following inputs are received by the engine controller:
• coolant temperature
• manifold absolute pressure
• engine speed
• throttle position
• exhaust gas oxygen content
• A/C control positions
• battery voltage
The engine controller provides a ground path for
the injector to precisely control injector pulse width.
The engine controller controls engine idle speed and
ignition timing. The engine controller controls the
air/fuel ratio according to the oxygen content in the
exhaust gas.
ACCELERATION MODE
This is a CLOSED LOOP mode. The engine control­
ler recognizes an abrupt increase in throttle position
or MAP pressure as a demand for increased engine
output and vehicle acceleration. The engine controller
increases injector pulse width in response to increased
fuel demand.
DECELERATION MODE
This is a CLOSED LOOP mode. During decelera­
tion the following inputs are received by the engine
controller:
• coolant temperature
• manifold absolute pressure
• engine speed
• throttle position
• exhaust gas oxygen content
• A/C control positions
• battery voltage
The engine controller may receive a closed throttle
input from the throttle position sensor (TPS) at the
same time it senses an abrupt decrease in manifold
pressure from the manifold absolute pressure (MAP)
sensor. This indicates a hard deceleration. The engine
controller may reduce injector firing to once per en­
gine revolution. This helps maintain better control of
the air-fuel mixture (as sensed through the O2 sensor).
The engine controller grounds the electric exhaust
gas recirculation transducer (EET) and evaporative
purge solenoids during a deceleration condition. This
stops EGR and canister purge functions.
WIDE OPEN THROTTLE MODE
This is an OPEN LOOP mode. During wide-open-
throttle operation, the following inputs are received
by the engine controller:
• coolant temperature
• manifold absolute pressure
• engine speed
• throttle position
When the engine controller senses wide open throt­
tle condition through the throttle position sensor (TPS)
it will:
• Provide a ground for the electric exhaust gas recir­
culation transducer (EET). This prevents the EGR
system from functioning.
• De-energize the air conditioning relay. This disables
the air conditioning system.
The exhaust gas oxygen content input is not ac­
cepted by the engine controller during wide open throt­
tle operation. The engine controller will adjust iryector
pulse width to supply a predetermined amount of ad­
ditional fuel.
IGNITION SWITCH OFF MODE • All outputs are turned off.
This is an OPEN LOOP mode. When the ignition • No inputs are monitored.
switch is turned to the OFF position, the following
• The engine controller shuts down.
occurs:

GENERAL DIAGNOSIS—3.0L ENGINES

INDEX
Page Page
Circuit Actuation Test Mode ....................................... 82 System Tests .................................................................. 81
Fault Code Description.................................................. 77 Throttle Body Minimum Air Flow
Fuel System Diagram .................................................... 71 Check Procedure ........................................................ 82
On Board Diagnostics.................................................... 76 Visual Inspection............................................................ 72
State Display Test Mode ............................................. 81 60-Way Engine Controller Wiring Connector............ 83

FUEL SYSTEM DIAGRAM

Refer to the Component Identification portion of
this section for a more complete description of the
components shown in Fig. 1.
ENGINE CONTROLLER INPUTS ENGINE CONTROLLER OUTPUTS DIAGNOSTIC
TOOL

TACHOMETER
IGNITION +M ' CHECK ENGINE
REFERENCE JIB . LAMP
PICKUP battery IGNITION CO il

T "
DISTRIBUTOR
ENGINE EMISSION
I------ CONTROLLER MAINTENANCE 4
REMINDER AUTOMATIC PURGE
(EMR) IDLE SOLENOID
LAMP SPEED MOTOR
THROTTLE TRANSMISSION COOLANT ALTERNATOR
POSITION PARK/NEUTRAL TEMPERATURE
SENSOR SWITCH SENSOR

Ktti LOCKUP TORQUE CONVERTER

BRAKE AUTO '' SOLENOID
RADIATOR
SWITCH SHUTDOWN "" OR
HEATED FAN
A 1C CUTOUT
■ RELAY ELECTRONIC AUTOMATIC
OXYGEN SENSOR RELAY ■H i TRANSMISSION
RELAY

T
DISTANCE
SENSOR
SPEED
CONTROL
SWITCH
MANIFOLD
ABSOLUTE
PRESSURE
SENSOR FUEL INJECTORS
|»
m
FUEL PUMP

SPEED CONTROL SOLENOIDS

9114-166
VISUAL INSPECTION
A visual inspection for loose, disconnected, or mis- DISTRIBUTOR
routed wires and hoses should be made before a t­
tem pting to diagnose m service the fuel injection
system. A visual check will help spot these faults and
save unnecessary test and diagnostic tim e. A thor­
ough visual inspection will include the following checks:
(1) Check Ignition Cable Routing and Attachm ent.
(2) Check Ignition Coil Electrical Connections (Pig.
2).

MAP SENSOR
3-WAY
ELECTRICAL i '
CONNECTOR \

Fig. 4 ifap Sensor Electrical and

Vacuum Connections

(7) Check A lternator W iring Connections and Belt

Tension.
(8) Verify th a t hoses are securely attached to the
vapor canister (Fig. 5).
HIGH TENSiON= IGNITION COIL
CAILE =ELECTRICAL CONNECTION VAPOR CANISTER SIGNAL PURGE HOSE
CANISTER HOSE
ii
9080-4

Fig. 2 Ignition Coil Electrical Connection

(3) Verify th a t the 2-way connector is attached to

TANK VENT
the Purge Solenoid (Fig. 3). HOSE
(4) Verify th a t vacuum connection a t Purge Sole­
noid is secure and not leaking (Fig. 3).
9014-60
2-WAY
ELECTRICAL Fig. 5 Vapor Canister '
CONNECTOR
(9) Verify th a t engine ..ground strap is attached a t
I the engine and dash panel (Fig. 6 and 7).
(10) Check Heated Oxygen Sensor connector (Fig. 7).

9014-116
Fig. 3 Electrical Connector Canister Purge Solenoid

(5) Verify th a t the 3-way connector is attached to

the MAP sensor (Fig. 4).
(8) Check MAP sensor hose a t MAP Sensor Assem­
bly (Fig. 4), and a t Vacuum Connection a t Intake
Plenum Fitting.
 VACUUM
HEATED OXYGEN
HOSES -
SENSOR 4-WAY
CONNECTOR COOLANT
TEMPERATURE
SENSOR

ENGINE TEMPERATURE
SENDING UNIT SI 9114-167

Fig. 9 Coolant Temperature Sensor

Electrical Connections and Vacuum Hose
Connections at the Air Intake Plenum

/ DRAIN HOSE (14) Check two way electrical connector attachment

s /. 9014-81 at each fuel injector.
(15) Check Oil Pressure Sending Unit Electrical
Fig. 7 Oxygen Sensor Connector
Connection (Fig. 10).
(11) Check 4 way distributor connectors (Fig. 8). COMBINATION
OIL PRESSURE SWITCH
AND SENDING UNIT

RR14G95

7/ * s n ' \ Fig. 10 Oil Pressure Sending Unit

Electrical Connection
Fig. 8 Distributor Connector
(16) Check hose connections at throttle body (Fig.
(12) Check two way Coolant Temperature Sensor
connector (Fig. 9). 11 ).
(17) Check throttle body electrical connections (Fig.
(13) Check Vacuum Hose Connection at Fuel Pres­
11).
sure Regulator and at Intake Plenum connector (Fig.
9).
 INTAKE ELECTRIC

ASSEMBLY 9114-62

Fig. 13 EGR System Vacuum Hose Connections

(21) Check Power Brake Booster and Speed Control

(18) Check PCV hose connections (Fig. 12). Connections (Figs. 14).

Fig. 12 Positive Crankcase Ventilation (PCV) System
(19) Check EGR System Vacuum Hose connections.
(Fig. 13)
(20) Check EGR Tube to Intake Plenum connec­
tions. (Fig. 13)
Fig. 14 Power Brake Booster and
Speed Control Vacuum Hose Connections
(22) Check Engine Harness to Main Harness elec­
trical connections.
(23) Check all automatic transmission electrical con­
nections (Fig. 15 or 16).
 Fig. 15 Electronic Automatic Transmission
Electrical Connections

LOCK-UP SOLENOID ELECTRICAL NEUTRAL/PARK SAFETY

CONNECTOR SWITCH Fig. 18 Engine Controller

(26) Check Air Conditioning, Starter, and Radiator

Fan Relay Connections (Fig. 19).
AUTO SHUTDOWN
(ASD) RELAY

DIPSTICK HOLE RR14G33

Fig. 16 Automatic Transmission

Electrical Connections

(24) Check two way Distance Sensor Electrical Con­

nection (Fig. 17). LEFT SIDE OF
VEHICLE
DISTANCE DISTANCE SENSOR 2-WAY
SENSOR A/C CLUTCH RELAY
ELECTRICAL CONNECTOR

RR14G77

Fig. 17 Distance Sensor Electrical Connector

RIGHT SIDE OF
VEHICLE
(25) Check 60 Way Electrical connection at Engine
Controller (Fig. 18).
 (27) Check Battery Cable Connections.
(28) Check Hose and Wiring Connections at Fuel
Pump. Check that wiring connector is making contact
with terminals on pump.

ON BOARD DIAGNOSTICS
The engine controller has been programmed to mon­
itor several different circuits of the fuel injection sys­
tem. This monitoring is called On Board Diagnosis. If
a problem is sensed with a monitored circuit often
enough to indicate an actual problem, its Fault Code
is stored in the engine controller for eventual display
to the service technician. If the problem is repaired or
ceases to exist, the engine controller cancels the Fault
Code after 50 to 100 ignition key on/off cycles.
Certain criteria must be met for a fault code to
be entered into the engine controller memory. The
criteria may be a specific range of engine RPM, en­
gine temperature, and/or input voltage to the engine
controller.
It is possible that a fault code for a monitored cir­
cuit may not be entered into memory even though a
malfunction has occurred. This may happen because
one of the fault code criteria for the circuit has not Output Device Current Flow - The engine controller
been met. For example, assume that one of the fault senses whether the output devices are hooked up. If
code criteria for the MAP sensor circuit is that the there is a problem with the circuit, the controller
engine must be operating between 750 and 2000 RPM senses whether the circuit is open, shorted to ground,
to be monitored for a fault code. If the MAP sensor or shorted high.
output circuit shorts to ground when engine RPM is Oxygen Sensor - The engine controller can deter­
above 2400 RPM (resulting in a 0 volt input to the mine if the oxygen sensor is switching between rich
engine controller) a fault code will not be entered into and lean once the system has entered closed loop.
memory. This is because the condition does not occur Refer to Modes of Operation in this section for an
within the specified RPM range. explanation of closed loop operation.
There are several operating conditions that the en­
gine controller does not monitor and set fault codes NON-MONITORED CIRCUITS
for. Refer to Monitored Circuits and Non-Monitored The engine controller does not monitor the follow­
Circuits in this section. ing circuits, systems and conditions that could have
Stored fault codes can be displayed either by cycling malfunctions that result in driveability problems. Fault
the ignition key On - Off - On - Off - On, or through codes may not be displayed for these conditions. How­
use of the Diagnostic Readout Box II (DRB II). The ever, problems with these systems may cause fault
DRB II connects to the diagnostic connector in the codes to be displayed for other systems. For example,
vehicle (Fig. 20). a fuel pressure problem will not register a fault di­
rectly, but could cause a rich or lean condition. This
MONITORED CIRCUITS could cause an oxygen sensor fault to be stored in the
The engine controller can detect certain fault condi­ engine controller.
tions in the fuel injection system. Fuel Pressure - Fuel pressure is controlled by the
Open or Shorted Circuit - The engine controller can vacuum assisted fuel pressure regulator. The engine
determine if the sensor output (input to controller) is controller cannot detect a clogged fuel pump inlet
within proper range, and if the circuit is open or filter, clogged in-line fuel filter, or a pinched fuel
shorted.
supply or return line. However, these could result in a
rich or lean condition causing an oxygen sensor fault
to be stored in the engine controller.
Secondary Ignition Circuit - The engine controller
cannot detect an inoperative ignition coil, fouled or
worn spark plugs, ignition cross firing, or open spark
plug cables.
Engine Timing - The engine controller cannot detect
an incorrectly indexed timing chain, camshaft sprocket
and crankshaft sprocket. The engine controller also
cannot detect an incorrectly indexed distributor. How­
ever, these could result in a rich or lean condition
causing an oxygen sensor fault to be stored in the
engine controller.
Cylinder Compression - The engine controller
cannot detect uneven, low, or high engine cylinder
compression.
Exhaust System - The engine controller cannot de­
tect a plugged, restricted or leaking exhaust system.
Fuel Injector Malfunctions - The engine controller
cannot determine if the fuel injector is clogged, the
pintle is sticking or the wrong injector is installed.
However, these could result in a rich or lean condition
causing an oxygen sensor fault to be stored in the
engine controller.
Excessive Oil Consumption - Although the engine
controller monitors the exhaust stream oxygen content
through the oxygen sensor when the system is in closed
loop, it cannot determine excessive oil consumption.
Throttle Body Air Flow - The engine controller can­
not detect a clogged or restricted air cleaner inlet or
filter element.
Evaporative System - The engine controller will not
detect a restricted, plugged or loaded evaporative purge
canister.
Vacuum Assist - Leaks or restrictions in the vac­
uum circuits of vacuum assisted engine control sys­
tem devices are not monitored by the engine controller.
However, these could result in a MAP sensor fault
being stored in the engine controller.
Engine Controller System Ground - The engine con­
troller cannot determine a poor system ground. How­
ever, a fault code may be generated as a result of this
condition.
Engine Controller Connector Engagement - The
engine controller cannot determine spread or dam­
aged connector pins. However, a fault code may be
generated as a result of this condition.
HIG H AND LOW LIMITS
The engine controller compares input signal volt­
ages from each input device with established high and
low limits that are programmed into it for that device.
If the input voltage is not within specifications and
other fault code criteria are met, a fault code will be
stored in memory. (Other fault code criteria might
include engine RPM lim its or input voltages from
other sensors or switches that must be present before
a fault condition can be verified).
FAULT CODE DESCRIPTION
When a fault code appears, it indicates that the
Engine Controller has recognized an abnormal condi­
tion in the system. Fault codes can be obtained from
the Check Engine lamp on the Instrument Panel or
from the Diagnostic Readout Box II (DRBII). Fault
codes indicate the results of a failure but do not iden­
tify the failed component directly.
 FAULT CODE DESCRIPTION

Fault Coda D l l 11 D is p la y Description of Fault Cod#

11 No Reference Signal No ignition reference signal detected during engine cranking.

During Cranking

13+ * * Slow Change in Idle No variation in MAP Sensor signal i s detected.

MAP Signal

or

No Change in MAP No difference is recognized between the engine MAP reading and
from Start to Ron the barometric pressure reading at start-up.

14+ * * MAP Voltage Too Low MAP sensor input below minimum acceptable voltage.

or

MAP Voltage Too High MAP sensor input above maximum acceptable voltage.

15** No Vehicle Speed No distance sensor signal detected during road load conditions.
Signal

17 Engine Is Cold Too Engine coolant temperature remains below normal operating
Long temperatures during vehicle travel (Thermostat).

0 2 Signal Stays at Neither rich or lean condition is detected from the oxygen sensor
Center input.

or

0 2 Signal Shorted to Oxygen sensor input voltage maintained above normal operating
' Voltage range. ’ .

22 + ** Coolant Sensor ■ Coolant temperature sensor input above the maximum acceptable
■ Voltage Too High voltage.

or

Coolant Sensor Coolant temperature sensor input below the minimum acceptable
Voltage Too Low voltage.
 FAULT CODE DESCRIPTION

Foult Cod# DIB ii Display Description o f Foult C#d« ' '

24 + * * Throttle Position Throttle position sensor i nput above the maximum acceptable
Sensor Voltage High voltage.

or

Throttle Position Throttle position sensor input below the minimum acceptable
Sensor Voltage Low voltage.

Automatic Idle Speed A shorted condition detected in one or more of the AIS
Motor Circuits control circuits.

26+ * * Injector #1 Peak High resistance conditi on detected i n the INJ 1 injector
Current Not Reached bank circuit.

or

Injector #2 Peak High resistance condition detected in the INJ 2 injector

Current Not Reached bank circuit.

or

Injector #3 Peak High resistance condition detected in the INJ 3 injector

Current Not Reached bank circuit.

27 + * * Injector #1 Control . Injector #1 output driver does not respond properly to the
Circuit control signal.

or

Injector #2 Control Injector #2 output driver does not respond properly to the
Ci rcuit control signal.

or

Injector #3 Control Injector #3 output driver does not respond properly to the
Circuit control signal.

31 * * Purge Solenoid An open or shorted condition detected in the purge solenoid circuit.
Ci rcuit
 FAULT CODE DESCRIPTION

fowl! €m4 m DRB li Display Description ©f fowl! C®d#

33 A/C Clutch Relay An open or shorted condition detected in the A/C clutch
Circuit clutch relay circuit.

34 Speed Control An open or shorted condition detected in the speed control

Solenoi d Circuits vacuum or vent solenoid circuits.

35 Radiator fan Relay An open or shorted condition detected in the radiator fan
Circuit relay circuit.

41 + *# Alternator fie ld Not An open or shorted condition detected in the alternator field
Switching Properly control circuit.

42 Auto Shutdown Relay An open or shorted condition detected in the auto shutdown
Control Circuit relay circuit.

or

No ASD Relay Voltage No ASD relay voltage sensed when

Sens® at Controller the ASD relay is energized.

46 +*♦ Charging System Battery voltage sense input above target charging voltage
Voltage Too High during engine operation.

47 +** Charging System Battery voltage sense input below target charging voltage during
Voltage Too Low engine operation and no significant change in voltage detected
during active test of alternator output.

51** 0 2 Signal Stays Oxygen sensor signal input indicates lean fuel/air ratio condition
Below Center (Lean) during engine operation.

52** 0 2 Signal Stays Oxygen sensor signal input indicates rich fuel/air ratio condition
Above Center (Rich) during engine operation.

' 53 Internal Controller Internal engine controller fault condition detected.

failure

54 + ** No Sync Pickup No fuel sync signal detected during engine rotation.

Signal
 FAULT CODE DESCRIPTION

Fault Code DRB II Display Description of fault Code

62 Controller Failure Unsuccessful attempt to update EMR mileage in the controller

EMR Miles Not Stored EEPROM.

63 Controller Failure Unsuccessful attempt to write to an EEPROM location by

EE PROM Write Denied the controller.

55 N /A Completion of fault code display on CHECK ENGINE lamp.

+ Check Engine Lamp On

Engine Lamp On
* * Check (California Only)

9114-171

SYSTEM TESTS STATE DISPLAY INPUTS AND OUTPUTS

Connect the DRB 11 tester to the vehicle and access
Be sure to apply parking brake and or block wheels the State Display screen. Then access Inputs and Out­
before perform ing idle check or adjustment, or any puts. The following is a list of the engine control
engine running tests. system functions accessible .through -the •Inputs and
Outputs screen.
OBTAINING F A U L T C O m S Park/Neutral Switch
{Vi Connect DRBII to the diagnostic connector lo­ Speed Control Resume
cated in the engine compartment near the engine "Brake Switch
controller. Speed Control On/Off
(2) Start the engine if possible, cycle the transmis­ Speed Control Set
sion selector and the A/C switch if applicable. Shut off A/C Switch Sense
the engine. Zl Voltage Sense
(3) Turn the ignition switch on, access Read Fault S/C Vent Solenoid
Screen. Record all the fault messages shown on the S/C Vacuum Solenoid
DRBII. Observe the check engine lamp on the instru­ PTU Solenoid
ment panel. The lamp should light for 3 seconds then A/C Clutch Relay
go out (bulb check). EMR Lamp
Fault code erasure; access erase fault code data A uto Shutdown Relay
Radiator Fan Relay
STATE DISPLAY TEST i O i E Purge Solenoid
Check Engine Lamp
The switch inputs used by the engine controller
have only two recognized states, HIGH and LOW. For STATE DISPLAY SENSORS
this reason, the engine controller cannot recognize the Connect the DRB 11 tester to the vehicle and access
difference between h selected switch position versus the State Display screen. Then access Sensor Display.
an open circuit, a short circuit, or a defective switch. The following is a list of the engine control system
If the change is displayed, it can be assumed that the functions accessible through the Sensor Display screen.
entire switch circuit to the engine controller is func­ Battery Temp Sensor
tional. From the state display screen access either Oxygen Sensor Signal
State Display Inputs and Outputs or S tate' Display Coolant Temperature
Sensors. Coolant Temp Sensor
Throttle Position
 Minimum Throttle THROTTLE BODY MINIMUM H R FLOW
B attery Voltage CHECK PROCEDURE
MAP Sensor Beading
AIS Motor Position (1) W arm engine in P ark or N eutral until the cool­
Adaptive Fuel Factor ing fan has cycled on and off a t least once.
Barometric Pressure (2) E nsure th a t all accessories are off.
Min Airflow Idl Spd (3) Hook-up the tim ing check device and tachom eter.
Engine Speed (4) Disconnect the coolant tem perature sensor and
F ault #1 Key-On Info set basic tim ing to 12° BTDC ± 2° BTDC.
Module Spark Advance (5) Shut off engine. Reconnect coolant tem perature
Speed Control Target sensor wire.
F ault #2 Key-on Info (8) Disconnect the PCV valve hose from the PCV
F ault #3 Key-on Info valve (Fig. 21).
Speed Control Status (?) Plug the PCV valve nipple.
C harging System Goal
Theft Alarm Status
Map Sensor Voltage
Vehicle Speed
1 fgem Sensor State
MAP Gauge Reading
Throttle Opening
Total Spark Advance

CIRCUIT ACTUITION TEST MODE

The purpose of the circuit actuation test mode is to
check for the proper operation of output circuits or
devices which the engine controller cannot internally
recognize. The engine controller can attem pt to acti­
vate these outputs and allow an observer to verify
proper operation. Most of the tests available in this
mode provide an audible or visual indication of device
operation (click of relay contacts, spray fuel, etc.).
(8) Disconnect the idle purge hose from the engine
W ith the exception of an in term ittent condition, if a
vacuum harness tee (Fig. 22).
device functions properly during its test, it can be
assumed th a t the device, its associated wiring, and its IDLE
driver circuit are in working order.

OBTAINING CIRC UIT ACTUATION TEST

Connect the DRB 11 tester to the vehicle and access
the A ctuators screen. The following is a list of the
engine control system functions accessible through Ac­
tuators screens.
Stop All Tests
Ignition Coil #1
Fuel Injector #1
Fuel Injector #2
Fuel Injector #3
AIS Motor Open/Close
Radiator Fan Relay 9114-67
A/C Clutch Relay
Auto Shutdown Relay Fig. 22 3.0L Idle Purge Hose
Purge Solenoid
S/C Serv Solenoids (9) Install Air M etering F itting #645? (0.125 inch
A lternator Field orifice) in the intake manifold m ounted idle purge
All Solenoids/Relays hose.(Fig. 23)
ASD Fuel System Test
 IDLE SPECIFICATIONS
SPECIAL TOOL 6457

Odometer Reading Idle RPM

Below
625-950 RPM
1000 Miles

9114-68
Fig. 23 Air Metering Fitting #6457
(10) Connect Diagnostic Readout Box II (DRB II).
(11) Restart the engine, allow engine to idle for at
least one minute.
(12) Using the DRBII, access Min. Airflow Idle Spd.
(13) The following will then occur:
• AIS motor will fully close.
• Idle spark advance will become fixed.
• Engine RPM will be displayed on Diagnostic Read­
out Box II (DRB II)
(14) Check idle RPM with tachometer, if idle RPM
is within the below specification then the throttle
body min. air flow is set correctly.
(15) If idle RPM is not within specifications, replace
the throttle body.
(16) Shut off engine.
Above
750-950 RPM
1000 Miles
9114-69
(17) Remove Air Metering Fitting #6457 from the
intake manifold idle purge hose. Reconnect the hose
to the engine vacuum harness tee.
(18) Remove the plug from the PCV valve. Recon­
nect the PCV valve hose to the PCV valve.
(19) Disconnect the DRB II.
IG N ITIO N TIM IN G PROCEDURE
Refer to Group 8D Ignition System.
60— WAY ENGINE CONTROLLER
WIRING CONNECTOR
Refer to the engine controller wiring connector dia­
gram (Fig. 24) for information regarding wire colors
and cavity numbers.
 14-84
WIRE DESCRIPTION
CAV
COLOR
1 P6/R D * MAP SENSOR
2 TN/BK* COOLANT SENSOR

FUEL SYSTEM
3 R P /W I* DIRECT BATTERY VOLTAGE
4 BK/LB* SENSOR RETURN
5 BK/WT* SIGNAL GROUND
6 VT/WT* 5-VOLT OUTPUT (MAP A N D TPS)
7 OR 9-VOLT OUTPUT (DISTRIBUTOR PICKUP)
8 m /m * A6T VOLTAGE SENSE
9 DB A2T SUPPLY
10
11 m /m * POWER GROUND
:2 B K /IN * POWER GROUND
13
14 YL/W T* INJECTOR DRIVER #3
15 IN INJECTOR DRIVER #2
16 W T/DB* INJECTOR DRIVER#]
17
18
19 BK/GY* IG N ITIO N COIL DRIVER #1
20 DG ALTERNATOR FIELD CONTROL
21
22 O R /D I* THROTTLE POSITION SENSOR (TPS)
23
24 G Y/IK* DISTRIBUTOR REFERENCE PICKUP
25 PK SCI TRANSMIT
26 VT/BR*
27 BR A 1C SWITCH SENSE
28
29 W I/PR * BRAKE SWITCH
30 BR/YL* PARK
31 DI/PK* RADIATOR FAN RELAY
32 BK/PK* CHECK EMGIh
33 THIRD* SPEED CONTROL VACUUM SOLENO
34 D IIO R * A/C CLUTCH RELAY
35
36
 SERVICE PROCEDURES—3.0L ENGINES
INDEX
Page
Automatic Idle Speed (AIS) Motor ............................. 87
Canister Purge Solenoid Service ................................. 91
Engine Controll er Service............................................. 91
Fuel Hoses, Clamps, and Quick
Connect Fittings ........................................................ 86
Fuel Injector .................................................................. 90
Fuel Injector Rail Assembly......................................... 89
Fuel Pressure Regulator Service ................................. 90
. .■ ' Page
Fuel System, Pressure Release Procedure . . . . . . . . . 86
Heated Oxygen Sensor (02 Sensor)
Service . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 92
Manifold Absolute Pressure (MAP) ■
Sensor Service . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 91
Throttle Body . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 85
Throttle Body Serwict . . . . . . . . . . . . . . . . . . . . . . . . . . . 85
Throttle Position Sensor . . . . . . . . . . . . . . . . . . . . . . . . . 87

THROTTLE BODY SERVICE seals, damage may result. If assembly of component is

difficult, use water to aid assembly. 'Use care, when
11) Disconnect negative battery cable. removing hoses to prevent damage to hose or hose
(2) Remove air cleaner hose clamp to throttle body nipple.'.<9 ■ • • . ■
and remove hose. (Fig. 1) AIR CLEANER GA,SKET "V »)
(3) Remove throttle cable and transaxle linkage. TO THROTTLE BODY
(4) Disconnect autom atic idle speed (AIS) motor and HOSE THROTTLE
BODY
throttle position sensor (TPS) wiring connectors.
(5) Disconnect vacuum hoses from throttle body.
(6) Rem ove'throttle body to intake manifold attach­
ing nuts (2). Remove engine harness wiring bracket.
(7) Remove throttle body and gasket.
(8) Reverse the above procedures for installation.'
Torque the throttle body nuts to 25.4 N*m (225 in.
lbs.).

THROTTLE BODY
AIR CLEANER
When servicing body components, always reassem ­ ASSEMBLY
ble components with new O-rings and seals where FRESH AIR
MODULE DUCT RR14G30
applicable. (Fig. 2) Never use lubricants on O-rings or
Fig. 1 Throttle Body Assembly
CANISTER PURGE THROTTLE POSITION CANISTER PURGE
NIPPLE SENSOi (TPS) NIPPLE

AUTOMATIC IDLE SPEED

(AIS) MOTOR
9114-121
FUEL SYSTEM PRESSURE RELEASE PROCEDURE
The MPI fuel system Is under a constant pressure
of approximately 330 kPa (48 psi). Before servicing
the fuel pump, fuel lines, fuel filter, throttle body or
fuel injector, the fuel system pressure must be
released.
(1) Loosen fuel filler cap to release fuel tank pressure.
(2) Disconnect injector wiring harness from engine
harness.
(3) Connect a jumper wire to ground terminal Num­
ber 1 of the iryector harness (Fig. 3) to engine ground.
(4) Connect a jumper wire to the positive terminal
Number 2 of the injector harness (Fig. 3) and touch
the battery positive post for no longer than 5 seconds.
This releases system pressure.
(5) Remove jumper wires.
(6) Continue fuel system service.
TERMINAL #2 TERMINAL #1
3.3L ENGINE
9114-147
Fig, 3 Injector Harness Connectors
FUEL HOSES, CLAMPS, AND
QUICK CONNECT FITTINGS
Inspect all hose connections (clamps or quick con­
nect fittings) to make sure they are secure and no
leaks are present. Hoses should be replaced immedi­
ately if there is any evidence of degradation that could
result in failure.
Avoid contact with clamps or other components that
cause abrasions or scuffing. Insure that the rubber
hoses are properly routed to prevent pinching and to
avoid heat sources.
The hoses used on fuel injected vehicles are of spe­
cial construction due to the possibility of contami­
nated fuel in this system. If it is necessary to replace
these hoses, only hoses marked EFM/ EFI may be
used.
The hose clamps used on fuel injected vehicles are
of a special rolled edge construction to prevent the
edge of the clamp cutting into the hose. Only these
rolled edge type clamps may be used in this system,
all other types of clamps may cut into the hoses and
cause high pressure fuel leaks.
Use new original equipment type hose clamps, torque
hose clamps to 1 N*m (10 in. lbs.).
The fuel line fittings used are quick connect type
fittings. These fittings are designed to speed up the
installation and removal of the fuel lines.(Fig. 4)
Quick connect fittings consist of a metal casing, a
black plastic locking ring, a metal locking retainer,
and internal o-rings.
The quick connect fittings may be removed from the
fuel tube nipple by pushing in on the plastic ring
located on the end of the fitting. An open end wrench
may be used to aid in disassembly.
When the fuel tube nipple is inserted into the quick-
connect fitting, the shoulder of the nipple is locked in
place by the locking retainer, and the internal O-rings
seal the tube.
The fuel tube nipples must be first lubricated with
clean 30 weight engine oil prior to reconnecting the
quick-connect fitting.
After connecting a quick-connect fitting, the con­
nection should be verified by pulling on the lines to
ensure that the lock is secure.
TUBE/FITTING DISASSEMBLY
(1) Disconnect the negative battery cable.
(2) Remove the fuel tank gas cap to release any fuel
tank pressure.
(3) Perform fuel system pressure release procedure.
(4) Remove any loose dirt from quick connect fittings.
 WARNING: WRAP SHOP TOWELS AROUND HOSES
TO CATCH ANY GASOLINE SPILLAGE.
(5) Press black plastic release ring in and pull quick
connector from the fuel tube. (Use open end wrench if
necessary).
(6) Cover the quick connector to prevent contam­
ination.
(9) Torque the hose clamps to 1 N-m (10 in. lbs.).
(10) Use ASD Fuel System Test to pressurize the
fuel system. Check for leaks.
CAUTION: When using the ASD Fuel System Test,
the Auto Shutdown (ASD) Relay will remain ener­
gized for 7 minutes or until the test Is stopped, or
until the ignition switch is turned to the Off position.

TUBE/FITTING ASSEMBLY THROTTLE POSITION SENSOR

(1) Inspect the quick connect fitting to ensure that
the black plastic release ring is in the OUT position. If REMOVAL
the locking retainer is stuck in the RELEASE position (1) Disconnect the negative battery cable and 3 way
due to mushrooming of the release ring, or dirt accu­ throttle position sensor wiring connector.
mulation, the fitting should be replaced. (2) Remove 2 screws, mounting throttle position sen­
(2) Lubricate the male end of the fuel tube with 30 sor to throttle body.(Fig. 5)
wt. oil. (3) Lift throttle position sensor off throttle shaft.
(3) Insert quick connector fitting.
(4) Pull quick connector back to ensure complete
connection. If the connection is not complete, check
the black plastic release ring to make sure it is not
causing the locking retainer to jam.
(5) Use ASD Fuel System Test to pressurize the fuel
system. Check for leaks.
CAUTION: When using the ASD Fuel System Test,
the Auto Shutdown (ASD) Relay will remain ener­
gized for 7 minutes or until the test Is stopped, or
until the ignition switch is turned to the Off position.

TUBE/FITTING SERVICE
If a quick connect fitting needs to be serviced, the
following procedure must be followed:
(1) Disconnect the battery negative battery cable.
(2) Perform the fuel system pressure release. Fig. 5 Servicing Throttle Position Sensor
(3) Remove the quick connect fitting from the fuel
tube by pushing in on the plastic ring located on the INSTALLATION
end of the fitting. Gently pull the fitting from the fuel (1) Install throttle position sensor on throttle shaft.
tube. Install 2 mounting screws to throttle body and torque
screws to 2 N-m (17 in. lbs.).
WARNING: WRAP SHOP TOWELS AROUND HOSES
(2) Connect 3 way wiring connector.
TO CATCH ANY GASOLINE SPILLAGE.
(3) Reconnect negative battery cable.
(4) Cut off the crimp ferrules at each end of the
hose, taking care not to damage the quick connect AUTOMATIC IDLE SPEED (AIS) MOTOR
fitting or the fuel tube.
(5) Discard the ferrules and hose. Discard the quick REMOVAL
connect fitting if it is defective. (1) Disconnect negative battery cable and 4 way
(6) Replace the hose using hose marked EFM/ EFI. AIS motor wiring connector.
This type of hose must be used due to its special (2) Remove 2 screws that mount the AIS motor to
construction. the throttle body .(Fig. 6)
(7) Replace the quick connect fittings (if necessary)
with the correct size and type.
(8) Attach the replacement hose to the quick con­
nect fitting and fuel tube using the correct hose clamps.
The hose clamps used are of a special rolled edge
construction to prevent the edge of the clamp cutting
into the hose. Only these rolled edge type clamps may
be used in this system, all other types of clamps may
cut into the hoses and cause high pressure fuel leaks.
 (5) Remove automatic idle speed (AIS) motor and
throttle position sensor (TPS) wiring connectors from
throttle body. (Fig. 8).
(6) Remove vacuum hose harness from throttle body
(Fig. 8).

(3) Remove the AIS motor from throttle body (make

certain that the O-ring is on the AIS motor).

INSTALLATION
(1) New AIS motor has a new O-ring installed on it.
If pintle measures more than 1 inch (25 mm) it must
be retracted by using the AIS MOTOR OPEN/CLOSE
Test. (Battery must be reconnected for this operation.)
(2) Carefully place AIS motor into throttle body.
(3) Install 2 mounting screws and torque to 2 N-m
(17 in. lbs.).
(4) Connect 4 way wiring connector to AIS motor
and reconnect negative battery cable.
Fig. 8 Electrical and Vacuum Connection
to Throttle Body
(7) Remove the wiring connector from the coolant
temperature sensor (Fig. 9).
(8) Remove vacuum connections from air intake ple­
num vacuum connector. (Fig. 9).
(9) Remove fuel hoses from fuel rail. (Fig. 9).

FUEL INJECTOR RAIL ASSEMBLY

REMOVAL
(1) Perform fuel system pressure release procedure
(before attempting any repairs).
(2) Disconnect negative battery cable.
(3) Remove air cleaner to throttle body hose.
(4) Remove throttle cable (Fig. 7).

Fig. 9 Coolant Temperature Sensor

Electrical Connections

(10) Remove (8) fasteners from air intake plenum to

intake manifold (Fig. 10). Remove ignition coil.
 (14) Disconnect fuel injector w iring harness from
engine w iring harness (Fig. 13).

COVERED INTAKE
M A N I FOLD

Fig. f § Air Intake Plenum to

Intake Manifold Attaching Fasteners

(11) Remove a ir intake plenum (Fig. 11).

AIR INTAKE PLENUM FUEL INJECTORS

WIRING CONNECTORS RR14G43

Fig. 13 Fuel Injector Wiring Harness

(15) Remove fuel rail attaching bolts and lift fuel

rail assembly from intake manifold. Be careful not to
damage the rubber injector O-Rings upon removal
from their ports.

FUEL INJECTOR RAIL ASSEMBLY

INSTALLATION
(1) Be sure injectors are seated into the receiver cup
with lock ring in place.
GASKET RUNNERS1' ^ 9014-89
(2) Make sure the injector holes are clean and all
plugs have been removed.
Fig. 11 Removing Air Intake Plenum
(3) Lube injector O-ring with a drop of clean engine
(12) Cover intake manifold w ith suitable cover when oil to ease installation.
servicing (Fig. 12). (4) Put the tip of each injector into their ports. Push
(13) Remove vacuum hoses from fuel rail (Fig. 12). the assembly into place until the injectors are seated
in the ports.
LOWER MANIFOLD MUST BE COVERED DURING SERVICE (5) Install the (3) fuel rail attaching bolts and torque
to 13 N-m (115 in. lbs.).
(6) Install fuel supply and return tube hold- down
bolt and the vacuum crossover tube hold-down bolt
and torque to 10 N*m (95 in. lbs.).
(7) Connect fuel injector wiring harness to engine
wiring harness.
(8) Connect vacuum harness to fuel rail assembly.
(9) Remove covering from lower intake manifold
and clean surface.
(10) Place intake manifold gaskets with beaded
sealer up on lower manifold. Put air intake in place.
Install ignition coil. Install attaching fasteners (8)
v^ / jj \\i and torque to 13 N-m (115 in. lbs.) (Fig. 9).
CANISTER PURGE -v___ 0 „ . 10,
VAPOR HOSE ^ ^ 6 \K 9114' 124 (11) Connect fuel lines to fuel rail. Torque hose
clamps to 1 N-m (10 in. lbs.).
(12) Connect vacuum harness to air intake plenum
and fuel pressure regulator.
 (13) Connect coolant temperature sensor electrical
connector to sensor.
(14) Connect PCV and brake booster supply hose to
intake plenum.
(15) Connect automatic idle speed (AIS) motor and
throttle'position sensor (TPS) electrical connectors.
(16) Connect vacuum vapor harness to throttle body.
(17) Install throttle cable.
(18) Install air inlet hose assembly.
(19) Connect negative battery cable.
(20) With the DRBII use the ASD Fuel System Test
to pressurize system to check for leaks.
CAUTION: When using the ASD Fuel System Test,
the Auto Shutdown (ASD) Relay will remain ener­
gized for 7 minutes or until the test is stopped, or
until the ignition switch is turned to the Off position.
FUEL PRESSURE REGULATOR SERVICE
REMOVAL
(1) Perform fuel system pressure release procedure
(before attempting any repairs).
(2) Disconnect negative battery cable.
(3) Loosen fuel return hose clamp and remove fuel
return hose from nipple.
(4) Remove vacuum hose from fuel pressure regula­
tor. (Fig. 14)
(5) Remove screw holding fuel return tube to the
intake manifold.
(6) Remove fuel pressure regulator screws. Remove
fuel pressure regulator from engine.
VACUUM HOSE
Fig. 14 Fuel Pressure Regulator
INSTALLATION
(1) Lubricate O-ring on fuel pressure regulator with
30 wt. engine oil.
(2) Install fuel pressure regulator into fuel rail.
Torque screws to 10 N-m (90 in. lbs.).
(3) Install screw holding fuel return tube clamp in
place. Torque screw to 10 N-m (95 in. lbs.).
(4) Connect vacuum hose to fuel pressure regulator.
(5) Connect fuel return hose to fuel return tube.
Torque hose clamp to 1 N-m ( 10 in. lbs.).
(6) Connect negative battery cable.
(7) With the DRBII use the ASD Fuel System Test
to pressurize system to check for leaks.
CAUTION: When using the ASD Fuel System Test,
the Auto Shutdown (ASD) Relay will remain ener­
gized for 7 minutes or until the test is stopped, or
until the ignition switch is turned to the Off position.
FUEL INJECTOR
Fuel Rail must be removed first. (Refer to Fuel
Injector Rail Assembly Removal in this section.)
REMOVAL
(1) Disconnect injector wiring connector from injector.
(2) Position fuel rail assembly so that the fuel injec­
tors are easily accessible (Fig. 16).
(3) Remove injector clip off the fuel rail and iiyector.
Pull injector straight out of fuel rail receiver cup.
(4) Check injector O-ring for damage. If O-ring is
damaged, it must be replaced. If injector is to be re­
used, a protective cap must be installed on the injector
tip to prevent damage (Fig. 15).
(5) Repeat for remaining injectors.
Fig. 15 Fuel Injector and Rail
INSTALLATION
(1) Before installing an injector the rubber O-ring
must be lubricated with a drop of clean engine oil to
aid in installation.
 (2) Install injector top end into fuel rail receiver CANISTER PURGE SOLENOID SERVICE
cap. (Be careful not to damage O-ring during installa­
tion) (Fig. 18). (1) Remove vacuum hose and electrical connector
from solenoids. (Fig. 18)

FUEL INJECTOR

FUEL RAIL
RECEIVER CUP

9014-116
Fig. 16 Serwicing Fuel Injector
Fig. IS Canister Purge Solenoid
(3) Install injector clip by sliding open end into top
S lo t of the injector and onto the receiver cup ridge into (2) Depress tab on top of solenoid to be replaced and
the side slots of clip (Fig. 18). slide the solenoid downward out of m ounting bracket.
(4) Repeat steps for rem aining injectors. (3) Reverse above procedure to install.
(5) Connect fuel injector wiring.
ENGINE CONTROLLER SERVICE
MANIFOLD ABSOLUTE PRESSURE (MAP)
SENSOR SERVICE (1) Remove a ir cleaner duct from engine controller.
(2) Remove battery.
(1) Remove vacuum hose and remove m ounting (3) Remove two module m ounting screws (Fig. 19).
screws from sensor (Fig. 17). (4) Remove the w iring connector from module and
remove module.
(5) Reverse the above procedure for installation.
DISTRIBUTOR

'MAP SENSOR
3-WAY
ELECTRICAL
CONNECTOR \ \ ^ SENSOR X ^ ^ -^ 9 1 8 0 ^ 1 7

Fig. 17 Manifold Absolute Pressure Sensor

(2) Remove wiring harness and remove sensor.

(3) Reverse the above procedure for installation.
HEATED OXYGEN SENSOR (0 2 SENSOR) SERVICE
CAUTION: Care should be exercised so that no
pulling force is put on sensor wire. Use care in work­
ing around sensor as the exhaust manifold may be
extremely hot. (Figs. 21 and 22)
Remove sensor using Oxygen Sensor Socket C-4907
(Fig. 20). When the sensor is removed, the exhaust
manifold threads must be cleaned with an 18 mm X
1.5 X 6E tap. If the same sensor is to be reinstalled,
the sensor threads must be coated with an anti-seize
compound such as Loctite 771-64 or equivalent. New Fig. 21 Heated Oxygen Sensor
sensors are packaged with compound on the threads
, HEATED OXYGEN
and no additional compound is required. Sensors must / --------SENSOR 4-WAY
be torqued to 27 N- (20 ft. lbs.). For more information \ CONNECTOR
refer to Group 25.
SPECIAL TOOL C-4907

9114-106

/D R A IN HOSE
9014-81

Fig. 22 Heated Oxygen Sensor Electrical Connection

 MULTI-POINT FUEL INJECTION—3.3L ENGINES
COMPONENT IDENTIFICATION—3.3L ENGINES
INDEX
Page
Air Conditioning C l utch Rel ay—
Engine Controller Output ......................................... 98
Alternator Field— Engine Controller Output ............ 99
Auto Shutdown (ASD) Relay—
Engine Controller Output ......................................... 98
Automatic Idle Speed (AIS) Motor—
Engine Controller Output ......................................... 99
Battery Voltage— Engine Controller Input ................ 96
Brake Switch— Engine Controller In p u t ..................... 97
Camshaft Sensor— Engine Controller In p u t............... 95
Canister Purge Solenoid—
Engine Controller Output ......................................... 97
Charge Temperature Sensor—
Engine Controller Input ........................................... 95
Check Engine Lamp— Engine Controller Output ___ 97
Coolant Temperature Sensor—
Engine Control ler Input ........................................... 96
Crankshaft Sensor— Engine Controller Input .......... 95
Detonation (Knock) Sensor—
Engine Controller Input ........................................... 97
Diagnostic Connector—
Engine Controller Output ......................................... 99
Electronic Automatic Transmission Controller—
Engine Controller Output ......................................... 99
Emission Maintenance Reminder (EMR) Lamp—
Engine Controller Output ......................................... 99
GENERAL INFORMATION
The Electronic Fuel Injection System (Fig. 1) is a
computer regulated multi point fuel injection system
that provides precise air/fuel ratio for all driving con­
ditions. At the center of this system is a pre-programmed
computer known as a Single Board Engine Controller
(SBEC). The SBEC is referred to as the engine con­
troller in this service manual. The engine controller
regulates ignition timing, air-fuel ratio, emission con­
trol devices, cooling fan, charging system, speed con­
trol, and idle speed. The engine controller can adapt
its requirements to meet changing operating conditions.
Various sensors provide the input necessary for the
engine controller to correctly regulate the fuel flow at
the fuel injector. These include the Manifold Absolute
Pressure, Throttle Position, Oxygen, Coolant Temper­
ature, Camshaft, Crankshaft, Detonation, Charge Tem-
Page
Engine Controller .......................................................... 94
Fuel Injector— Engine Controller Output ................... 98
Fuel Injectors and Fuel Rail Assembly ..................... 100
Fuel Pressure Dampener .............................................. 101
Fuel Pressure Regulator .............................................. 100
Fuel Supply Circuit ...................................................... 100
General Information ...................................................... 93
Heated Oxygen Sensor (0 2 Sensor)—
Engine Controller Input ............................................ 96
Ignition Coil— Engine Controller Output ................... 99
Manifold Absolute Pressure (MAP) Sensor—
Engine Controller Input ....................................... ... 96
Modes of Operation .................................................. 101
Radiator Fan Relay— Engine Controller Output . . . . 98
Speed Control Solenoids—
Engine Controller Output ......................................... 99
Tachometer— Engine Controller O u tp u t.......... .. 99
Throttle Body ............................................................ .. . 100
Throttle Position Sensor (TPS)—
Engine Controller Input . ......................... .............. 95
Transmission Park/Neutral Switch—
Engine Controller Input ............................................ 95
Vehicle Distance (Speed) Sensor—
Engine Controller Input ........................................... 97
perature, and Vehicle Distance sensors. In addition to
the sensors, various switches and relays provide im­
portant information and system control. These include
the Brake Switch, Air Conditioning Clutch Relay, and
Auto Shut Down Relay.
All inputs to the engine controller are converted
into signals which are used by the computer. Based on
these inputs, air-fuel ratio, ignition timing or other
controlled outputs are adjusted accordingly.
The engine controller tests many of its own input
and output circuits. If a fault is found in a mgjor
system, this information is stored in the memory. In­
formation on this fault can be displayed to a techni­
cian by means of the instrument panel Check Engine
lamp or by connecting the Diagnostic Readout Box II
(DRBII) and reading descriptions of any faults which
have been stored.
 ENG1NE CONTROLLER INPUTS ENGINE CONTROLLER OUTPUTS-

DIAGNOSTIC
TOOL

CHECK ENGINE
IGNITION COILS LAMP

BATTERY
HAKE
CAM SENSOR SWITCH
TACHOMETER

EMISSION MAINTENANCE
ENGINE AUTOMATIC REMINDER LAMP
CONTROLLER IDLE
SPEED MOTOR
CRANK HEATED MANIFOLD
SENSOR OXYGEN
ABSOLUTE
SENSOR' PRESSURE SENSOR
PURGE
AUTO ~ ■ RADIATOR SOLENOID
SHUTDOWN A/C CLUTCH FAN
(ASD) RELAY RELAY RELAY .

THROTTLE COOLANT DETONATION

POSITION TEMPERATURE (KNOCK)
SENSOR SENSOR SENSOR

ALTERNATOR
FUEL INJECTORS
> SPEED
CHARGE DISTANCE
TEMPERATURE CONTROL ELECTRONIC AUTOMATIC SPEED CONTROL SOLENOIDS
SENSOR
SENSOR SWITCH TRANSMISSION 9114-181

Fig. 1 Electronic Fuel Injection Components

ENGINE CONTROLLER controller), spark advance, ignition coil dwell, idle

The engine controller (Fig. 2) contains the circuits
necessary to drive the ignition coil, fuel injectors, and
the alternator field.
FASTENER 60 WAY ELECTRICAL
LOCATIONS CONNECTOR
918D-48
Fig. 2 Engine Controller
The engine controller is a digital computer contain­
ing a microprocessor. The module receives input sig­
nals from various switches and sensors. These are
listed below under Engine Controller Inputs. It then
computes the fuel injector pulse width (the amount of
time that the injectors are energized by the engine
speed, purge, and cooling fan turn on and alternator
charge rate.
Engine Controller Outputs are components that are
operated or controlled based on the values received
from the engine controller inputs. These outputs are
listed below.
The Automatic Shut Down (ASD) relay is mounted
externally, but is turned on and off by the engine
controller. Crankshaft and camshaft position sensor
signals go to the engine controller. In the event of no
camshaft or crankshaft sensor signal, the ASD relay
is deactivated and power is shut off from the fuel
injector, fuel pump, ignition coil, and oxygen sensor
heater element.
The engine controller tests many of its own input
and output circuits. If a fault is found in a major
system, this information is stored in the engine con­
troller. Information on this fault can be displayed to a
technician by means of the instrument panel check
engine lamp or by connecting the Diagnostic Readout
Box II (DRBII) which will directly display any fault
code descriptions.
The engine controller contains a voltage converter
which converts battery voltage to a regulated 8.0 volts
and 5.0 volts output. The 8.0 volt output is used to
power the distributor. The 5.0 volt output is used to
power the Throttle Position Sensor, Manifold Abso­ CAMSHAFT SENSOR— ENGINE CONTROLLER INPUT
lute Pressure (MAP) Sensor, and logic circuits.
Fuel Injection Synchronization and cylinder identi­
Engine Controller Inputs:
fication is provided through the camshaft reference
• Camshaft and Crankshaft Sensors
sensor (Fig. 4). The unique combination of slots on the
• Transmission Park/Neutral Switch camshaft gear is used by the engine controller to iden­
• Throttle Position Sensor tify cylinders to enable initiation of fuel and spark, for
• Charge Temperature Sensor start and run conditions.
• Battery Voltage
PAPER
• Manifold Absolute Pressure (MAP) Sensor SPACER
• Heated Oxygen Sensor
• Coolant Temperature Sensor
• Vehicle Distance (Speed) Sensor
• Brake Switch
• Detonation Sensor
• Air Conditioning Controls
• Speed Control System Controls
Engine Controller Outputs: CONNECTOR 908D-2
• Check Engine Lamp
Fig. 4 Camshaft Sensor
• Canister Purge Solenoid
• Air Conditioning Clutch Relay TRANSMISSION PARK/NEUTRAL SWITCH—
• Auto Shutdown (ASD) Relay ENGINE CONTROLLER INPUT
• Fuel Iiyectors
• Automatic Idle Speed (AIS) Motor The neutral safety switch is located on the trans­
• Ignition Coil mission housing. It provides an input to the engine
• Speed Control Solenoids controller that indicates whether the automatic trans­
mission is in Park, Neutral, or a drive gear selection.
• Radiator Fan Relay
This input is used to determine idle speed, (varying
• Alternator Field with gear selection) fuel injector pulse width, and
• Diagnostic Connector ignition timing advance.
• Electronic Automatic Transmission Controller
• Tachometer Output THROTTLE POSITION SENSOR (TPS)—
• Emission Maintenance Reminder (EMR) Lamp ENGINE CONTROLLER INPUT

CRANKSHAFT SENSOR— The Throttle Position Sensor (TPS) is a variable

ENGINE CONTROLLER INPUT
The crankshaft sensor (Fig. 3) senses 12 slots cut
into the transmission driveplate extension. Basic tim­
ing is set by the position of the last slot in each group.
This is a fixed basic timing system with no means of
adjustment.
resistor that is mounted on the throttle body and
senses the angle of the throttle blade opening. The
voltage that the sensor produces increases or decreases
according to the throttle blade opening. This voltage
is transmitted to the engine controller. It is used along
with data from other sensors to adjust the air-fuel
ratio for varying conditions. These conditions include
acceleration, deceleration, idle, and wide open throttle
operations.

CHARGE TEMPERATURE SENSOR—

ENGINE CONTROLLER INPUT
The Charge Temperature Sensor is a device mounted
on the intake manifold which measures the tempera­
ture of the air-fuel mixture. (Fig. 5) This information
CONNECTOR is used by the engine controller to modify air/fuel
908D-3 mixture.
 WIRING MAP sensor data on engine load is used with data
TERMINALS from other sensors to determine the correct air-fuel
mixture.

CHARGE SENSOR COOLANT SENSOR

RK356
HEATED OXYGEN SENSOR (0 2 SENSOR)—
Fig. 5 Coolant and Charge Temperature Sensors ENGINE CONTROLLER INPUT
COOLANT TEMPERATURE SENSOR— The Oxygen Sensor (0 2 Sensor) is a device which
ENGINE CONTROLLER INPUT produces an electrical voltage when exposed to the
oxygen present in the exhaust gasses. (Fig. 7) The
The Coolant Temperature Sensor is a device which
sensor is mounted in the Rear Exhaust Manifold and
monitors coolant temperature as an indication of en­
is electrically heated internally for faster switching
gine operating temperature. It is mounted in the ther­
when the engine is running. When there is a large
mostat housing. This sensor provides data on engine
amount of oxygen present (lean mixture), the sensor
operating temperature to the engine controller. This
produces a low voltage. When there is a lesser amount
data (along with data provided by the Charge Temper­
present (rich mixture) it produces a higher voltage.
ature Sensor) allows the engine controller to modify
By monitoring the oxygen content and converting it to
certain conditions until normal operating tempera­
electrical voltage, the sensor acts as a rich-lean switch.
tures are reached. These conditions include slightly
The voltage is transmitted to the engine controller,
richer air-fuel mixture, revised spark advance, and
which changes the fuel injector pulse width«fco adjust
higher idle speed. The sensor is a variable resistor
air/fuel mixture. For more information refer to Group
with a range of -40°F to 265°F.
25.
BATTERY VOLTAGE—-ENGINE CONTROLLER INPUT
The engine controller monitors the battery voltage
input to determine fuel injector pulse width and alter­
nator field control. If battery voltage is low the engine
controller will increase injector pulse width (the pe­
riod of time that the injector is energized).

MANIFOLD ABSOLUTE PRESSURE (MAP)

SENSOR— ENGINE CONTROLLER INPUT
The Manifold Absolute Pressure (MAP) sensor is a
device which monitors manifold absolute pressure. (Fig.
6) It is mounted underhood directly into the intake
plenum, and is electrically connected to the engine
controller. The sensor transmits information on mani­
fold pressure conditions to the engine controller. The
VEHICLE DISTANCE (SPEED) SENSOR—
ENGINE CONTROLLER INPUT
A distance sensor is located in the transaxle exten­
sion housing to sense vehicle motion. This sensor gen­
erates 8 pulses per axle shaft revolution. These signals
are interpreted, in conjunction with a closed throttle
signal from the throttle position sensor, by the engine
controller to differentiate between a closed throttle
decel and a normal idle (vehicle stopped) condition.
Under decel conditions, the computer module controls
the AIS motor to maintain a desired MAP value. Un­
der idle conditions, the engine controller adjusts the
AIS motor to maintain a desired engine speed.
BRAKE SWITCH— ENGINE CONTROLLER INPUT
The brake switch is used as an engine controller
input during deceleration and full stop conditions. To­
gether with other inputs, the brake switch is used to
maintain engine idle speed by controlling the auto­
matic idle speed motor (AIS) position. The brake switch
is mounted on the brake pedal support bracket.
DETONATION (KNOCK) SENSOR—
ENGINE CONTROLLER INPUT
The detonation sensor is a device that generates a
signal when spark knock occurs in the combustion
chambers. (Fig. 8) It is mounted at a position on the
engine block where detonation in each cylinder can be
detected. The sensor provides information used by the
engine controller to modify spark advance in order to
eliminate detonation.
ELECTRICAL
CONNECTION
THREADS 9014-91
Fig. 8 Detonation (Knock) Sensor
CHECK ENGINE LAMP—
ENGINE CONTROLLER OUTPUT
The Check Engine Lamp comes on each time the
ignition key is turned on and stays on for 3 seconds as
a bulb test.
If the engine controller receives an incorrect signal
or no signal from the following list, the Check Engine
Lamp is turned on.
• Coolant Temperature Sensor
• Manifold Absolute Pressure Sensor
• Throttle Position Sensor
• Battery Voltage Input
• An Emission Related System (California vehicles)
• Charging system
This is a warning that the engine controller has
gone into Limp in Mode in an attempt to keep the
system operational. It signals an immediate need for
service.
In Limp In Mode, the Engine controller compen­
sates for the failure of certain components by substi­
tuting information from other sources.
The Check Engine Lamp can also be used to display
fault codes. Cycle the ignition switch on, off, on, off,
on within five seconds and any fault codes stored in
the Engine controller will be displayed. See the Fault
Code Description area in this section for a list of the
fault codes.
CANISTER PURGE SOLENOID—
ENGINE CONTROLLER OUTPUT
The Purge Solenoid is controlled by the engine con­
troller. (Fig. 9) During warm-up and for a specified
time period after hot starts the engine controller
grounds the Purge Solenoid causing it to energize.
This prevents vacuum from reaching the charcoal can­
ister valve. When the engine reaches a specified oper­
ating temperature and the time delay interval has
occurred the solenoid is de-energized by turning off
the ground. Once this occurs vacuum will flow to the
canister purge valve and purge fuel vapors will flow
through the throttle body. The Purge Solenoid will
also be energized during certain driving conditions;
this is to update the fuel delivery calibration.
2-WAY
ELECTRICAL
CONNECTOR,
SF / r. ^ r 9014-116
Fig. 9 Canister Purge Solenoid Mounting
AIR CONDITIONING CLUTCH RELAY—
ENGINE CONTROLLER OUTPUT
This relay is in the energized closed (on) position
during engine operation when the A/C switch is closed
and blower switch is on.(Fig. 11) When the engine
controller senses wide open throttle through the throt­
tle position sensor, or low engine RPM it will de­
energize the relay, open it’s contacts and prevent air
conditioning clutch engagement. The engine control­
ler will also delay the energizing of the air condition­
ing clutch relay for a certain period after engine start.

AUTO SHUTDOWN (ASD) RELAY—

ENGINE CONTROLLER OUTPUT
When there is no cam or crankshaft sensor signal
present with the ignition key in the RUN position,
there is no need for fuel delivery. When this condition
occurs, the auto shutdown relay interrupts power to
the electrical fuel pump, fuel injectors, ignition coils,
and the 0 2 sensor heater. (Fig. 10)

RADIATOR FAN RELAY—

ENGINE CONTROLLER OUTPUT
The radiator fan relay is located on the left side of
the engine compartment. (Fig. 10) The engine control­
ler signals the radiator fan relay to supply power to
the radiator fan when the engine coolant reaches a
predetermined temperature or when the air condition­
ing system is turned on. For more information, refer
to Group 7, Cooling Systems.
Fig. 10 Engine Compartment Relay Identification
FUEL INJECTOR— ENGINE CONTROLLER OUTPUT
The Fuel Injector is an electric solenoid powered by
the engine controller. (Fig. 11) The engine controller
determines when and how long the Injector should
operate. When an electric current is supplied to the
injector, the armature and pintle move a short dis­
tance against a spring, opening a small orifice. Fuel is
supplied to the inlet of the injector by the fuel pump,
it then passes through the injector into the air enter­
ing the combustion chamber.
INJECTOR TO ELECTRICAL FUEL
INTAKE MANIFOLD CONNECTOR INLET
AUTOMATIC IDLE SPEED (AIS) MOTOR—
ENGINE CONTROLLER OUTPUT
The Automatic Idle Speed Motor (AIS) is operated'
by the engine controller. Data from the Throttle Posi­
tion Sensor, Speed Sensor, and Coolant Temperature
Sensor are used by the engine controller to adjust
engine idle to predetermined speed. Various switches
(Neutral/Safety, Brake) also provide input for idle speed.
The AIS adjusts the air portion of the air-fuel mixture
through an air bypass in the throttle body. The AIS
varies the air bypass to increase or decrease air flow
to maintain engine speed due to engine loads or ambi­
ent conditions. Deceleration die out is also prevented
by increasing airflow when the throttle is closed quickly
after a driving (speed) condition.
IGNITION COIL— ENGINE CONTROLLER OUTPUT
The Direct Ignition System (D1S) uses a molded coil
(Fig. 12). The coil is mounted on the intake manifold.
High tension leads route to each cylinder from the
coil. The coil fires two spark plugs every power stroke.
One plug is the cylinder under compression, the other
cylinder fires on the exhaust stroke. The engine con­
troller determines which of the coils to charge and fire
at the correct time.
908D-1
Fig. 12 Molded Coll
SPEED CONTROL SOLENOIDS—
ENGINE CONTROLLER OUTPUT
The engine controller uses its inputs to determine
speed control vent and vacuum solenoid activation.
Refer to Group 8H for information on this system.
ALTERNATOR FIELD—
ENGINE CONTROLLER OUTPUT
The engine controller regulates the charging sys­
tem voltage within a range of 12.9 to 15.0 volts. Refer
to Group 8A for charging system information.
DIAGNOSTIC CONNECTOR—
ENGINE CONTROLLER OUTPUT
The diagnostic connector provides the technician
with a means to connect the DRB 11 in order to diag­
nose or test the vehicle.
ELECTRONIC AUTOMATIC TRANSMISSION
CONTROLLER— ENGINE CONTROLLER OUTPUT
The Electronic Automatic Transmission Controller
and the Engine Controller trade information with each
other. This information includes such things as en­
gine speed and vehicle load. Receiving this informa­
tion allows the engine controller to control the fuel
and ignition systems for best vehicle operation and
efficiency.
TACHOMETER— ENGINE CONTROLLER OUTPUT
The engine controller uses its inputs to compute
engine speed, and sends a signal to the tachometer.
Refer to Group 8E for more information.
EMISSION MAINTENANCE REMINDER (EMR)
LAMP— ENGINE CONTROLLER OUTPUT
The Emissions Maintenance Reminder System (EMR)
is incorporated into the engine controller. The engine
controller records the vehicle mileage and stores it
into memory every 8 miles. At th at time, the engine
controller checks for the 60,000, 82,500, and 120,000
mileage trip points. When the current mileage matches
one of the above mentioned trip points, the EMR lamp
on the instrum ent panel is activated.
Certain components are to be replaced at the indi­
cated mileage, or when the emissions maintenance
reminder lamp remains lit continuously with the key
in the on position, whichever occurs first. After per­
forming the required maintenance, the EMR lamp
must be reset to turn the lamp off.
For more information, refer to Group 25 or the ap­
propriate diagnostic manual.
 CANISTER PURGE (PORTED) CANISTER PURGE (MANIFOLD)
VACUUM NIPPLE VACUUM NIPPLE
CANISTER PURGE
(MANIFOLD) VACUUM NIPPLE
CANISTER PURGE (PORTED)
VACUUM NIPPLE
THROTTLE POSITION
SENSOR (TPS)

THROTTLE
LEVER

AUTOMATIC IDLE SPEED

(AIS) MOTOR 9114-70

Fig. 13 Throttle Body

THROTTLE BODY
FUEL FUEL PRESSURE DAMPENER
The throttle body assembly replaces the throttle
Wades in a conventional carburetor a ir intake system.
(Fig. 13) It is located on the left side, of the Air Intake
Plenum. The throttle body houses the Throttle Posi­
tion Sensor and the Automatic Idle Speed Motor. Air
flow through the throttle body is controlled by a cable
operated throttle blade located in the base of the th ro t­
tle body.

FUEL SUPPLY CIRCUIT

Fuel is pumped to the fuel rail by an electrical
pump which is m ounted in the fuel tank. The pump
inlet is fitted w ith a filter to prevent w ater and other
contam inants from entering the fuel supply circuit.
Fuel pressure is controlled to a preset level above
intake manifold pressure by a pressure regulator which
is m ounted on the fuel rail. The regulator uses intake
manifold pressure as a reference.
FUEL INJECTORS AND FUEL RAIL ASSEMBLY
Six fuel injectors are retained in the fuel rail by
lock rings. (Fig. 14) The rail and injector assembly is
then bolted in position with the injectors inserted in
the recessed holes in the intake manifold.
FUEL PRESSURE REGULATOR
9114-71
Fig. 14 Fuel Rail Assembly
FUEL PRESSURE REGULATOR
The pressure regulator is a mechanical device lo­
cated downstream of the fuel injector on the fuel rail.
(Fig. 15) Its function is to maintain a constant 330
kPa (48 psi) across the fuel injector tip. The regulator
uses a spring loaded rubber diaphragm to uncover a
fuel return port. When the fuel pump becomes opera­
tional, fuel flows past the injector into the regulator,
and is restricted from flowing any further by the
blocked return port. When fuel pressure reaches 330
kPa (48 psi) it pushes on the diaphragm, compressing
the spring, and uncovers the fuel return port. The
diaphragm and spring will constantly move from an open
to closed position to keep the fuel pressure constant.

SPRING VACUUM
PORT 9014-25
Fig. 15 Fuel Pressure Regulator
FUEL PRESSURE DAMPENER
The fuel pressure dampener is located downstream
of the fuel pressure regulator. Its function is to dampen
fuel pressure pulsations caused by the firing of the
fuel injectors. An internal rubber diaphragm with a
pocket of air behind it absorbs the pressure pulses.
MODES OF OPERATION
As input signals to the engine controller change,
the engine controller adjusts its response to the out­
put devices. For example, the engine controller must
calculate a different injector pulse width and ignition
timing for idle than it does for wide open throttle
(WOT). There are several different modes of operation
that determine how the engine controller responds to
the various input signals.
Modes of operation are of two different types. OPEN
LOOP and CLOSED LOOP.
During OPEN LOOP modes the engine controller
receives input signals and responds according to pre­
set engine controller programming. Input from the
oxygen (O2) sensor is not monitored during OPEN
LOOP modes.
During CLOSED LOOP modes the engine controller
does monitor the oxygen (O2) sensor input. This input
indicates to the engine controller whether or not the
calculated injector pulse width results in the ideal
air-fuel ratio of 14.7 parts air to 1 part fuel. By moni­
toring the exhaust oxygen content through the O2
sensor, the engine controller can fine tune the iiyector
pulse width to achieve optimum fuel economy com­
bined with low emissions.
The multi point fuel injection system has the follow­
ing modes of operation:
• Ignition switch ON
• Engine start-up
• Engine warm-up
• Cruise
• Acceleration
• Deceleration
• Wide Open Throttle
• Ignition switch OFF
The ignition switch on, engine start-up (crank), en­
gine warm-up, and wide open throttle modes are
OPEN LOOP modes. The acceleration, deceleration,
and cruise modes, with the engine at operating tem­
perature are CLOSED LOOP modes (under most oper­
ating conditions).
IGNITION SWITCH ON MODE
This is an OPEN LOOP mode. When the multi
point fuel injection system is activated by the ignition
switch, the following actions occur:
• The engine controller determines atmospheric air
pressure from the MAP sensor input to determine
basic fuel strategy.
• The engine controller monitors the coolant tempera­
ture sensor and throttle position sensor input. The
engine controller modifies fuel strategy based on this
input.
When the key is in the ON position, the auto shut­
down (ASD) relay is not energized. Therefore batt«
voltage is not supplied to the fuel pump, ignition coil,
fuel iiyectors, or oxygen sensor heating element.
ENGINE START-UP MODE
This is an OPEN LOOP mode. The following actions
occur when the starter motor is engaged.
If the engine controller receives an indication of
engine rotation from the crankshaft position sensor, it
will energize the Auto Shutdown (ASD) Relay. The
Auto Shutdown Relay will supply battery voltage to
the fuel pump, fuel injector ignition coil, and oxygen
sensor heating element. If the engine controller does
not receive a crankshaft position sensor input, the
ASD relay will be deenergized after approximately
one second.
The following must be true for the engine controller
to set a pneumatic fault code into memory:
• Engine is operating and idling within ± 64 RPM of
the target RPM.
• Current engine RPM is greater then the START
FUEL engine RPM.
• Vehicle is not moving.
• The difference between atmospheric pressure read­
ings taken currently and during the Key-On mode is
not great enough.
 Once the ASD relay has been energized, the engine
controller:
• Supplies a ground path to the injectors, firing them
in pairs (1 and 6, 2 and 3, 4 and 5).
• Determines injector pulse width based on coolant
temperature, barometric pressure (MAP sensor), and
the number of engine revolutions since cranking was
initiated.
• Monitors the coolant temperature sensor, crankshaft
and camshaft position sensors, MAP sensor, detona­
tion sensor, and throttle position sensor to determine
correct ignition timing.
ENGINE WARM-UP MODE
This is a OPEN LOOP mode. The following inputs
are received by the engine controller:
• coolant temperature
• manifold absolute pressure (MAP)
• engine speed (crankshaft position sensor)
• throttle position
• A/C switch
• battery voltage
The engine controller provides a ground path for
the injector to precisely control injector pulse width
(by switching the ground on and off). The engine con­
troller controls engine idle speed (by adjusting the
automatic idle speed motor) and ignition timing.
CRUISE OR IDLE MODE
When the engine is at operating temperature this is
a CLOSED LOOP mode. During cruising speed the
following inputs are received by the engine controller:
• coolant temperature
• manifold absolute pressure
• engine speed (crankshaft position sensor)
• throttle position
• exhaust gas oxygen content
• A/C control positions
• battery voltage
The engine controller provides a ground path for
the injectors to precisely control injector pulse width.
The engine controller controls engine idle speed and
ignition timing. The engine controller controls the
air/fuel ratio according to the oxygen content in the
exhaust gas.
ACCELERATION MODE
This is a CLOSED LOOP mode. The engine control­
ler recognizes an abrupt increase in throttle position
or MAP pressure as a demand for increased engine
output and vehicle acceleration. The engine controller
increases injector pulse width in response to increased
fuel demand.
DECELERATION MODE
This is a CLOSED LOOP mode. During decelera­
tion the following inputs are received by the engine
controller:
• coolant temperature
• manifold absolute pressure
• engine speed
• throttle position
• exhaust gas oxygen content
• A/C control positions
• battery voltage
The engine controller may receive a closed throttle
input from the throttle position sensor (TPS) at the
same time it senses an abrupt decrease in manifold
pressure from the manifold absolute pressure (MAP)
sensor. This indicates a hard deceleration. The engine
controller may reduce iryector firing to once per en­
gine revolution. This helps maintain better control of
the air-fuel mixture (as sensed through the 0 2 sensor).
The engine controller grounds the electric exhaust
gas transducer (EET) and evaporative purge solenoid
stopping EGR and canister purge functions during a
deceleration condition.
WIDE OPEN THROTTLE MODE
This is an OPEN LOOP mode. During wide-open-
throttle operation, the following inputs are received
by the engine controller:
• coolant temperature
• manifold absolute pressure
• engine speed
• throttle position
When the engine controller senses wide open throt­
tle condition through the throttle position sensor (TPS)
it will:
• Provide a ground for the electric exhaust gas recir­
culation transducer (EET). This prevents the EGR
system from functioning.
• De-energize the air conditioning relay. This disables
the air conditioning system.
The exhaust gas oxygen content input is not ac­
cepted by the engine controller during wide open throt­
tle operation. The engine controller will adjust iryector
pulse width to supply a predetermined amount of ad­
ditional fuel.
IGNITION SWITCH OFF MODE
This is an OPEN LOOP mode. When the ignition
switch is turned to the OFF position, the following
occurs:
• All outputs are turned off.
• No inputs are monitored.
• The engine controller shuts down.
 GENERAL DIAGNOSIS—3.3L ENGINES
INDEX
Page Page
Circuit Actuation Test Mode ..................................... 114 System Tests ................................................................ 113
Fault Code Description ............................................ 113 Throttle Body Minimum Air Flow
Fuel System Diagram .................................................. 103 Check Procedure...................................................... 114
On Board Diagnostics.................................................. 107 Visual Inspection ......................... .......................... 103
State Display Test Mode ........................................... 113 60-Way Engine Controller Wiring Connector ........ 115

FUEL SYSTEM DIAGRAM

Refer to the Component Identification portion of
this section for a more complete description of the
components shown in Fig. 1.
ENGINE CONTROLLER INPUTS ENGINE CONTRO LLER OUTPUTS

I— r IGNITION COILS
CHECK ENGINE
LAMP
DIAGNOSTIC
TOOL

BRAKE
CAM SENSOR BATTERY
SWITCH
lA C H O M EIEI

■ EMISSION MAINTENANCE
ENGINE AUTOMATIC REMINDER LAMP
CONTROLLER IDLE
SPEED MOTOR
CRANK HEATED MANIFOLD
SENSOR OXYGEN
ABSOLUTE
SENSOR PRESSURE SENSOR
PURGE
AUTO RADIATOR SOLENOID
SHUTDOWN A/C CLUTCH FAN
(ASD) RELAY RELAY RELAY

THROTTLE COOLANT DETONATION

POSITION TEMPERATURE (KNOCK)
SENSOR SENSOR SENSOR

I
CHARGE
TEMPERATURE
SENSOR
t
DISTANCE
SENSOR
SPEED
CONTROL
SWITCH
ELECTRONIC AUTOMATIC
TRANSMISSION ,
FUEL INJECTORS

SPEED CONTROL SOLENOIDS

ALTERNATOR

9114-181

Fig. 1 Multipoint Fuel Injection Components

VISUAL INSPECTION save unnecessary test and diagnostic tim e. A thor­

A visual inspection for loose, disconnected, or mis-
routed wires and hoses should be made before a t­
tem pting to diagnose or service the fuel injection
system. A ¥ismal check will help spot these faults and
ough visual inspection will include the following checks:
(1) Check Ignition Cable routing-and attachm ent.
(2) Check Direct Ignition System (DIS) coil electri­
cal connection (Fig. 2).
ALTERNATOR TO INTAKE
MANIFOLD BOLT -------- IGNITION COILS FASTENERS (4)

Fig. 4 Coolant Temperature Sensor

IGNITION COILS ELECTRICAL
CONNECTOR
Fig. 2 Ignition Coils Electrical Connection
(7) Check the vacuum hose connection at the fuel
pressure regulator (Fig. 5).
9014-26 FUEL PRESSURE REGULATOR
RETAINER

(3) Check the Cam Sensor 3-way electrical connec­

tion (Fig. 3).
(4) Check the Engine Temperature Sensor electrical
connector (Fig. 3).

Fig. 5 Fuel Pressure Regulator Vacuum Connection

(8) Check the Oil Pressure Sending Unit electrical
connection (Fig. 6).

Fig. 3 Cam Sensor Electrical Connection

(5) Check the Coolant Temperature Sensor 2-way

electrical connector (Fig. 4).
(6) Verify that the Quick Connect Fuel Fittings are
fully inserted on the fuel supply and return tubes.
 (9) Verify that the 2-way electrical connector is at­ CANISTER PURGE
tached to the Purge Solenoid (Fig. 7). VACUUM NIPPLES
(10) Verify that the vacuum connection at the Purge
solenoid is secure and not leaking (Fig. 7). THROTTLE
POSITION
2-WAY SENSOR
ELECTRICAL (TPS)
CONNECTOR

9014-116
AUTOMATIC IDLE
Fig. 7 Canister Purge Solenoid Electrical Connector SPEED (AIS) MOTOR' 9114-179

(11) Verify that the hoses are securely attached to Fig. 9 Throttle Body Electrical and
Vacuum Connections
the Vapor Canister (Fig. 8).
VAPOR CANISTER SIGNAL PURGE HOSE
(16) Check the Neutral Safety Switch wiring con­
CANISTER HOSE nection. Check the Automatic Transmission electrical
connections (Fig. 10).

Fig. 8 Vapor Canister

(12) Check the 2-way electrical connector at each

fuel injector.
(13) Verify that the Fuel Injector Harness and En­
gine Wiring Harness Connectors are fully inserted
into the Main Wiring Harness.
(14) Check the vacuum connections at the Throttle
body (Fig. 9). Fig. 10 Automatic Transmission
(15) Check the Throttle Body electrical connections Electrical Connections
(Fig. 9).
(17) Verify that the Charge Temperature Sensor
electrical connector is fully inserted (Fig. 11).
(18) Check the Vacuum Hose Harness connections
at the Intake Plenum (Fig. 11).
 Fig. 13 Crankshaft, Knock, and
Distance Sensor Electrical Connections

(23) Check the Manifold Absolute Pressure (MAP)

(19) Check the PCV system connections (Fig. 12).
sensor 3-way electrical connector (Fig. 14).
(24) Verify that the engine ground strap is attached
at the engine and dash panel (Fig. 14).
(25) Check the Heated Oxygen Sensor 4-way electri­
cal connector (Fig. 14).

PCV VALVE HOSE TO VALVE

Fig. 12 PCV System Fig. 14 MAP Sensor, Heated Oxygen Sensor,

and Ground Strap
(20) Check the Crankshaft Position Sensor 3-way
electrical connector (Fig. 13). (26) Check the Alternator Wiring Connections and
(21) Check the Knock Sensor electrical connection Belt Tension.
(Fig. 13). (27) Check the 60-way electrical connection at the
(22) Check the Distance Sensor 2-way electrical con­ Engine Controller (Fig. 15).
nection (Fig. 13).
 Pig. 17 Power Brake Booster Hose
(28) Check the relay electrical connections (Fig. 16). (31) Check the Speed Control vacuum connection
STARTER RELAY’ AUTO SHUTDOWN
(Fig. 18). * ‘
(ASD) RELAY

SPEED
CONTROL
VACUUM
HOSE

LEFT SIDE OF FUEL INJECTOR

VEHICLE WIRING HARNESS
A/C CLUTCH RELAY

\ 9014-96

Fig. 18 Spmd Control Wacuum

(32) Check Hose and W iring Connections at Fuel

SHOCK Pump. Check th a t wiring' connector is m aking contact
TOWER w ith term inals on pump.

ON BOARD DIAGNOSTICS -

RIGHT SIDE O f
The engine controller has been programmed; to mon­
918D-49 VEHICLE itor many different circuits of the fuel injection sys­
tem. This m onitoring is called On Board Diagnosis. If
Pig. 16 Relay Identification a problem is sensed w ith a monitored circuit often
enough to indicate an actual problem, a fault is stored
(29) Check B attery Cable Connections.
in the engine controller for eventual-display to the
(30) Check the Power Brake Booster Hose Connec­
service technician. If the problem is repaired or ceai
tion (without Anti-lock Brake Systems) (Fig. 17).
to exist, the engine controller cancels the Fault Code
after 50 to 100 vehicle key on/off cycles.
Certain criteria must be met for a fault code to be
entered into the engine controller memory. The criteria
may be a specific range of engine RPM, engine tem­
perature, and/or input voltage to the engine controller.
It is possible that a fault code for a monitored cir­
cuit may not be entered into memory even though a
malfunction has occurred. This may happen because
one of the fault code criteria for the circuit has not
been met. For example, assume that one of the fault
code criteria for the MAP sensor circuit is that the
engine must be operating between 750 and 2000 RPM
to be monitored for a fault code. If the MAP sensor
output circuit shorts to ground when engine RPM is
above 2400 RPM (resulting in a 0 volt input to the
engine controller) a fault code will not be entered into
memory. This is because the condition does not occur
within the specified RPM range.
There are several operating conditions that the en­
gine controller does not monitor and set fault codes
for. Refer to Monitored Circuits and Non-Monitored
Circuits in this section.
Stored fault codes can be displayed either by cycling
the ignition key On - Off - On - Off - On, or through
use of the Diagnostic Readout Box II (DRB II). The
DRB II connects to the diagnostic connector in the
vehicle (Fig. 19).
Fig. 19 Diagnostic Connector Location
MONITORED CIRCUITS
The engine controller can detect certain fault condi­
tions in the fuel injection system.
Open or Shorted Circuit - The engine controller can
determine if the sensor output (input to controller) is
within proper range, and if the circuit is open or
shorted.
Output Device Current Flow - The engine controller
senses whether the output devices are hooked up. If
there is a problem with the circuit, the controller
senses whether the circuit is open, shorted to ground,
or shorted high.
Oxygen Sensor - The engine controller can deter­
mine if the oxygen sensor is switching between rich
and lean once the system has entered closed loop.
Refer to Modes of Operation in this section for an
explanation of closed loop operation.
NON-MONITORED CIRCUITS
The engine controller does not monitor the follow­
ing circuits, systems and conditions that could have
malfunctions that result in driveability problems. Fault
codes may not be displayed for these conditions. How­
ever, problems with these systems may cause fault
codes to be displayed for other systems. For example,
a fuel pressure problem will not register a fault di­
rectly, but could cause a rich or lean condition. This
could cause an oxygen sensor fault to be stored in the
engine controller.
Fuel Pressure - Fuel pressure is controlled by the
vacuum assisted fuel pressure regulator. The engine
controller cannot detect a clogged fuel pump inlet
filter, clogged in-line fuel filter, or a pinched fuel
supply or return line. However, these could result in a
rich or lean condition causing an oxygen sensor fault
to be stored in the engine controller.
Secondary Ignition Circuit - The engine controller
cannot detect an inoperative ignition coil, fouled or
worn spark plugs, ignition cross firing, or open spark
plug cables.
Engine Timing - The engine controller cannot detect
an incorrectly indexed timing chain, camshaft sprocket
and crankshaft sprocket. However, these could result
in a rich or lean condition causing an oxygen sensor
fault to be stored in the engine controller.
Cylinder Compression - The engine controller can­
not detect uneven, low, or high engine cylinder com­
pression.
Exhaust System - The engine controller cannot de­
tect a plugged, restricted or leaking exhaust system.
Fuel Injector Malfunctions - The engine controller
cannot determine if the fuel injector is clogged, the
pintle is sticking or the wrong injector is installed.
However, these could result in a rich or lean condition
causing an oxygen sensor fault to be stored in the
engine controller.
Excessive Oil Consumption - Although the engine
controller monitors the exhaust stream oxygen content
through the oxygen sensor when the system is in closed
loop, it cannot determine excessive oil consumption.
 FAULT CODE DESCRIPTION

fault Cod# DRB (i Display Doscription off Fault Cod© - ■

11 No Reference Signal No ignition reference signal detected during engine cracking.

During Cranking

■ 13 + * * No Chang© in MAP NO'difference is recognized between the engine MAP reading

from Start to Run and the barometric pressure reading stored at start-up.

14+** MAP Voltage Too Low MAP sensor input below minimum acceptable voltage.

or

MAP Voltage Too High MAP sensor input above maxi mum acceptable voltage.

15** No Vehicle Speed No distance sensor signal detected during road load conditions.
Signal

17 Engine Is Cold Too Engine coolant temperature remains below normal operating
Long temperatures during vehicle travel (Thermostat).

21 * * 0 2 Signal Stays at Neither rich nor lean condition is detected from the oxygen
Center sensor input. " •■ ' • •• . • ■.

or

0 2 Signal Shorted to Oxygen sensor input voltage maintained above normal operating
Voltage range.

22 + ## Coolant Sensor Coolant temperature sensor input above the maximum acceptable ■
Voltage Too High voltage.

or

Coolant Sensor Coolant temperature sensor input below the minimum acceptable
Voltage Too Low voltage.
 FAULT CODE DESCRIPTION

fo w l! C #d « D l l it Display" P # *€ rip tl® n of f a u lt €© d«

23 + ** Charge Temperature Charge temperature sensor input above the maximum acceptable
Sensor Voltage High voltage.

or

Charge Temperature Charge temperature sensor input below the minimum acceptable
Sensor Voltage Low voltage.

24+** Throttle Posi tion Throttle position sensor input above the maximum acceptable
Sensor Voltage High v o lta g e .

or

Throttle Position Throttle position sensor input below the minimum acceptable
Sensor Voltage Low voltage.

25* * Automatic Idle Speed A shorted condition detected in one or more of the AIS control
Motor Circuits circuits.

26+** Injector #1 Peal High resistance condition detected in the INJ 1 injector
Current Not Reached bank circuit.

or

Injector #2 Peak High resistance condition detected in the INJ 2 injector

Current Not Reached bank circuit.

or

Injector #3 Peak High resistance condition detected in the INJ 3 injector

Current Not Reached bank circuit.
 FAULT CODE DESCRIPTION

fault C©d© DRB (1 D is p la y Description o f Fault Code

: Injector #1 Control Injector #1 output driver does not respond properly to the
Circuit control signal.

or

Injector #2 Control Injector #2 output driver does not respond properly to the
Circuit control signal.

or

Injector #3 Control Injector #3 output driver does not respond properly to the
Circuit control signal.

Purge Solenoid An open or shorted condition detected in the purge solenoid circuit.
Circuit

32* * EGR Solenoid Circuit An open or shorted condition detected in the EGR solenoid circuit.
(Light Duty —Front Wheel Drive—California only)

EGR System Failure Required change in fuel/air ratio not detected during diagnostic test.
(Light Duty—Front Wheel Drive —California only)

33 A/C Clutch Relay An open or shorted condition detected in the A/C clutch relay circuit.
Circuit

34 Speed Control An open or shorted condition detected in the speed control vacuum
Solenoid Circuits or vent solenoid circuits.

35 Radiator Fan Relay An open or shorted condition detected in the radiator fan
Circui t relay circuit.

41 + ** Alternator field Not An open or shorted condition detected in the alternator field
Switching Properly control circuit.
 FMULT CODE DESCRIPTION

Fowl! Code DRB ll/Dteplay > D escrip tio n of fo w l! Code

42 Auto Shutdown Relay An open or shorted condition detected in the auto shutdown
Control Circuit relay'circuit.

or

No ASD Relay Voltage No ASD relay voltage sensed when the ASD relay is energized.
Sense at Controller

43+ * * Ignition Coil #1 Peak primary circuit current not achieved with maximum dwell time.
Primary Circuit

or

Ignition Coil #2 Peak primary circuit current not achieved with maximum dwell time.
Primary Circuit

or

Ignition Coil #3 Peak primary circuit current not achieved with maximum dwell time.
Primary Circuit

46+ Charging System Battery voltage sense input above target charging voltage during
Voltage Too High engine operation.

47+ * * Charging System Battery voltage sense input below target charging voltage during
Voltage Too Low engine operation and no significant change in voltage detected
during active test of alternator output.

51" 0 2 Signal Stays Oxygen sensor signal input indicates lean fuel/air ratio condition
Below Center (Lean) during engine operation.

52* * ■ 0 2 Signal Stays Oxygen sensor signal input indicates rich fuel/air ratio condition
Above Center (Rich) , ■ during engine operation.

53 Internal Controller Internal engine controller fault condition detected.

Failure

54 No Sync Pickup No fuel sync signal detected during engine rotation.

Signal •• *

62 Controller Failure Unsuccessful attempt to update EMR mileage in the controller

EMR Miles Not Stored EEPROM.
 FAULT CODE DESCRIPTION
Foult Code DRB il Display
63 Controller Failure
6EPROM Write Denied
55 N/A
+ Check Engine Lamp On
* * Check Engine Lamp On (California Only)
Throttle B odf Air Flow - The engine controller can­
not detect a clogged or restricted air cleaner inlet or
filter element.
Evaporative System - The engine controller will not
detect a restricted, plugged or loaded evaporative purge
canister.
Wacyunt Assist - Leaks or restrictions in the ¥ac-
uum circuits of vacuum assisted engine control sys­
tem devices are not monitored by the engine controller.
However, thesfe could result in a MAP sensor fault
being stored in the engine controller.
Engine Controller System Ground - The engine con­
troller cannot determ ine a poor system ground. How­
ever, a fault code may be generated as a result of this
condition.
Engine Controller Connector Engagement - The
engine controller cannot determ ine spread or dam­
aged connector pins. However, a fault code may be
generated as a result of this condition.
HIGH AND LOW LIMITS
The engine controller compares input signal volt­
ages from each input device w ith established high and
low lim its th a t are programmed into it for th a t device.
If the input voltage is not w ithin specifications and
other fault code criteria are met, a fault code will be
stored in memory. (Other fault code criteria m ight
include engine RPM lim its or input voltages from
other sensors or switches th a t m ust be present before
a fault condition can be verified).
FAULT COiE DESC11PT10I
When a fault code appears, it indicates th a t the
Engine Controller has recognized an abnorm al condi­
tion in the system. F ault codes can be obtained from
the Check Engine lamp on the Instrum ent Panel or
Description of fowl! Cod®
Unsuccessful attempt to write to an EEPROM location by
the controller.
Completion of fault code display on CHECK ENGINE lamp.
9114-177
from the Diagnostic Readout Box 11 (DRBII). F ault
codes indicate the results of a failure but do not iden­
tify the failed component directly.
SYSTEM TESTS
Be sure to apply parking brake and/or block wheels
before performing Idle check or adjustment, or any
engine running tests.
OBTAINING FAULT CODES
(1) Connect DRBII to the diagnostic connector lo­
cated in the engine com partm ent near the driver side
stru t tower..
• (2) S tart the engine if possible, cycle the transm is­
sion selector and the A/C switch if applicable. Shut off
the engine.
(3) Turn the ignition switch on, access Read Fault
Screen. Record all the fault messages shown on the
DRBII. Observe the check engine lamp on the instru­
m ent panel. The lamp should light for 2 seconds then
go out (bulb check).
Fault code erasyre; access erase fault code data
STATE UISPIAY TEST MODE
The switch inputs used by the engine controller
have only two recognized states, HIGH and LOW. For
this reason, the engine controller cannot recognize the
difference between a selected switch position versus
an open circuit, a short circuit, or a defective switch.
If the change is displayed, it can be assumed th a t the
entire switch circuit to the engine controller' is func­
tional. From the state display screen access either
State Display Inputs and O utputs or State Display
Sensors.
S T A T E DISPLAY INPUTS AND OUTPUTS Throttle Opening
Connect the DEB 11 tester to the vehicle and access Total Spark Advance
the State Display screen. Then access Inputs and Out­
puts. The following is a list of the engine control CIRCUIT ACTUATION TEST MODE
system functions accessible through the Inputs and
Outputs screen. The purpose of the circuit actuation test mode is to
Park/N eutral Switch check for the proper operation of output circuits or
Speed Control Resume devices which the engine controller cannot internally
Brake Switch recognize. The engine controller can attem pt to acti­
Speed Control On/Off vate these outputs and allow an observer to verify
Speed Control Set proper operation. Most of the tests available in this
A/C Switch Sense mode provide an audible or visual indication of device
Z1 Voltage Sense operation (click of relay contacts, spray fuel, etc.).
S/C Vent Solenoid With the exception of an interm ittent condition, if a
S/C Vacuum Solenoid device functions properly during its test, it can be
A/C Clutch Relay assumed th at the device, its associated wiring, and its
EMR Lamp driver circuit are in working order.
Auto Shutdown Relay
Radiator Fan Relay OBTAINING CIRCUIT ACTUATION TEST
Purge Solenoid Connect the DRB II tester to the vehicle and access
Check Engine Lamp the Actuators screen. The following is a list of the
engine control system functions accessible through Ac­
STATE DISPLAY SENSORS tuators screens.
Connect the DRB 11 tester to the vehicle and access Stop All Tests
the State Display screen. Then access Sensor Display. Ignition Coil #1
The following is a list of the engine control system Ignition Coil #2
functions accessible through the Sensor Display screen. Ignition Coil #3
Battery Temp Sensor Fuel Injector #1
Oxygen Sensor Signal Fuel Injector #2
Coolant Tem perature Fuel Injector # 3
Coolant Temp Sensor AIS Motor Open/Close
Throttle Position Radiator Fan Relay
Minimum Throttle A/C Clutch Relay
Knock Sensor Signal Auto Shutdown Relay
B attery Voltage Purge Solenoid
MAP Sensor Reading S/C Serv Solenoids
AIS Motor Position Alternator Field
Adaptive Fuel Factor All Solenoids/Relays
Barometric Pressure ASD Fuel System Test
Min Airflow Idl Spd
Engine Speed THROTTLE BODY i i l i i U i AIR FLOW
DIS Sensor Status CHECK PROCEDURE
Fault #1 Key-On Info
Module Spark Advance (1) Warm engine in Park or Neutral until the cool­
Charge Tem perature ing fan has cycled on and off at least once.
Charge Temp Sensor (2) Ensure that all accessories are off.
Speed Control Target (3) Shut off engine.
Fault #2 Key-on Info (4) Disconnect the PCV valve hose from the intake
Fault #3 Key-on Info manifold nipple.
Speed Control Status (5) Attach Air Metering Fitting #6457 (Fig. 20)
. Overall Knock Retard (0.125 in. orifice) to the intake manifold PCV nipple.
Charging System Goal
Theft Alarm Status
Map Sensor Voltage
Vehicle Speed
Oxygen Sensor State
MAP Gauge Reading
 SPECIAL TOOL 6457 (12) If idle RPM is not within specification, replace
the throttle body.
(13) Shut off engine.
(14) Remove Air Metering Fitting #6457 from the
intake manifold PCV nipple. Reinstall the PCV valve
hose.
(15) Uncap the throttle body idle purge nipple and
reconnect the idle purge line.
(16) Remove DRB II.

9114-68 60— WAY ENGINE CONTROLLER

WIRING CONNECTOR
Fig. 20 Air Metering Fitting #6457
Refer to the engine controller wiring connector dia­
(6) Disconnect the 3/16 inch idle purge line from the
gram (Fig. 21) for information regarding wire colors
throttle body nipple. Cap the 3/16 inch nipple.
and cavity numbers.
(7) Connect Diagnostic Readout Box II (DRB II).
(8) Restart the engine. Allow engine to idle for at
least one minute.
(9) Using the DRBII, access Min. Airflow Idle Spd.
(10) The following will then occur:
• AIS motor will fully close.
• Idle spark advance will become fixed.
• Engine RPM will be displayed on DRB II.
(11) If idle RPM is within the below specification
then the throttle body Min. Airflow is set correctly.

IDLE SPECIFICATIONS

O dom eter Reading Idle RPM

Below,
650-950 RPM
1000 Mil es
 WIRE
CAV DESCRIPTION
COLOR
1 DGIRD* MAP SENSOR
2 I N / IK * COOLANT SENSOR
3 R P /W I* DIRECT BATTERY
4 IK/LB* .SENSOR RETURN
5 BK/WT* SIGNAL GROUND
6 VT/WT* .
7 OR 9-VOLT OUTPUT
8 DG/BK* A61 VOLTAGE SENSE
9 DB A21 SUPPLY
10
11 BK/TN* POW
12 BK/TN* POWER GROUND
13
14 Y L /W I* INJECTOR DRIVER #3
15 TN INJECTOR DRIVER #2
16 WT/DB* INJECTOR DRIVER#!
17 DB/TN* IG N ITIO N COiL DRIVER #2
18 D I/G Y* IG N ITIO N COIL DR
19 BK/GY* IG N ITIO N COiL DR
20 DG ALTERNATOR i
21 BK/RD* CHARGE TEMPERATURE SEr
22 O i/D i* THROTTLE POSITION SENSOR (TPS)
23
24 GYIBK* CRANKSHAFT REF. PIO
25 PK SCI TRANSMIT
26 VT/IR* CCD BUS (+)
27 BR A C SWITCH SENSE
28
29 W I/PK * BRAKE SWITCH
30 BR/YL* PARK
31 DI/PK* ATORFAN REI
32 BK/PK* CHECK ENGlt^
33 m tm * SPEED CONTROL VACUUM SOLENOl
34 D B /O i* A/C CLUTCH RELAY
35
36
 SERVICE PROCEDURES—3.3L ENGINES
INDEX
Page Page
Automatic Idle Speed (A I S) M o to r...... .................... 120 Fuel Pressure Dampener ........................................... 125
Camshaft Sensor Service ........................................... 127 Fuel Pressure Regulator............................................. 124
Canister Purge Solenoid Service ............................. 127 Fuel System Pressure Release Procedure .............. 118
Crankshaft Timing Sensor Service ........................... 127 Heated Oxygen Sensor (0 2 Sensor) Service .......... 128
Engine Controller Service ......................................... 127 Manifold Absolute Pressure (MAP)
Fuel Hoses, Clamps and Quick Sensor Service ........................................................ 126
Connect Fittings ...................................................... 118 Throttle B o d y ................................................................ 117
Fuel Injector ................................................... ............ 126 Throttle Body Rem oval............................... ................ 117
Fuel Injector Rail Assembly ............................... 120 Throttle Position Sensor ............ .................... .. — 120

THROTTLE BODY REMOVAL THROTTLE GASKET SHOCK

BODY TOWER
(1) Disconnect negative battery cable.
(2) Remove the air cleaner to throttle body hose
clamp and the nut holding the air cleaner assembly to
the air cleaner bracket. Remove the air cleaner. (Fig.
1)
(3) Remove throttle and the speed control cables.
(4) Disconnect automatic idle speed (AIS) motor and
throttle position sensor (TPS) wiring connectors.
(5) Disconnect vacuum hoses from throttle body.
(6) Remove throttle body to intake manifold attach­
ing nuts (2).
(7) Remove throttle body and gasket.
(8) Reverse the above procedures for installation. AIR CLEANER
ASSEMBLY

Fig. 1 Throttle Body Assembly

THROTTLE BODY
When servicing body components, always reassem­
ble components with new O-rings and seals where
applicable. (Fig. 2) Never use lubricants on O-rings or
seals, damage may result. If assembly of component is
difficult, use water to aid assembly. Use care when
removing hoses to prevent damage to hose or hose
nipple.
 CANISTER PURGE (PORTED) CANlSTEi PURGE (MANIFOLD)
V A fiH lM NIPPLE VACUUM NIPPLE
CANISTER PURGE
ANIFOLD) VACUUM NIPPLE
CANlSTEi PU1GE (PORTED)
VACUUM NIPPLE
THROTTLE POSITION
SENSOR (TPS)

THROTTLE
LEVER

AUTOMATIC IDLE SPEED

(AIS) MOTOR 9114-70

Pig. 2 Throttle Body

FUEL SYSTEM PRESSURE RELEASE PROCEDURE ’

TERMINAL #1
The MPI fuel system Is urnder a constant pressure TERMINAL #1 \ TERM|NAL#2
of approximately 3 3 i kPa (48 psi). Before servicing
\ TERMINAL #2 XX \ /
the fuel pymp, fuel -lines, fuel filter, throttle body
or fuel injector, the fuel system pressure must be
released. ■ ■
(1) Loosen fuel filler cap to release fuel tank pressure.
(2) Disconnect injector wiring harness from m ain
harness.
% 2.SL ENGINE
W 3.0L ENGINE

(3) Connect a jum per wire to ground term inal Num ­

ber 1 of the injector harness (Fig. 3) to engine ground.
(4) Connect a jum per wire to the positive term inal
Number 2' of the injector harness (Fig. 3) and touch TERMINAL #2 TERMINAL#!
the battery positive post for no longer th an 8 seconds.
This, releases system pressure. '
(5) Remove jum per wires.
(8) Continue fuel system service.

3.3L ENGINE
9114-147

Fig. 3 Injector Harness Connectors

FUEL HOSES, CLAMPS, AND

QUICK CONNECT FITTINGS
Inspect all hose connections (clamps or quick con­
nect fittings) to make sure they are secure and no
leaks are present. Hoses should be replaced immedi­
ately if there is any evidence of degradation that could
result in failure.
 Avoid contact with clamps or other components that
cause abrasions or scuffing. Insure that the rubber
hoses are properly routed to prevent pinching and to
avoid heat sources.
The hoses used on fuel injected vehicles are of spe­
cial construction due to the possibility of contami­
nated fuel in this system. If it is necessary to replace
these hoses, only hoses marked EFM/ EFI may be
used.
The hose clamps used on fuel injected vehicles are
of a special rolled edge construction to prevent the
edge of the clamp cutting into the hose. Only these
rolled edge type clamps may be used in this system,
all other types of clamps may cut into the hoses and
cause high pressure fuel leaks.
Use new original equipment type hose clamps, torque
hose clamps to 1 N-m (10 in. lbs.).
The fuel line fittings used are quick connect type
fittings. These fittings are designed to speed up the
installation and removal of the fuel lines.(Fig. 4)
Quick connect fittings consist of a metal casing, a
black plastic locking ring, a metal locking retainer,
and internal o-rings.
The quick connect fittings may be removed from the
fuel tube nipple by pushing in on the plastic ring
located on the end of the fitting. An open end wrench
may be used to aid in disassembly.
When the fuel tube nipple is inserted into the quick-
connect fitting, the shoulder of the nipple is locked in
place by the locking retainer, and the internal O-rings
seal the tube.
The fuel tube nipples must be first lubricated with
clean 30 weight engine oil prior to reconnecting the
quick-connect fitting.
After connecting a quick-connect fitting, the con­
nection should be verified by pulling on the lines to
ensure that the lock is secure.
TUBE/FITTING DISASSEMBLY
(1) Disconnect the negative battery cable.
(2) Remove the fuel tank gas cap to release any fuel
tank pressure.
(3) Perform fuel system pressure release procedure.
(4) Remove any loose dirt from quick connect fittings.
WARNING: WRAP SHOP TOWELS AROUND HOSES
TO CATCH ANY GASOLINE SPILLAGE.
(5) Press black plastic release ring in and pull quick
connector from the fuel tube. (Use open end wrench if
necessary).
(6) Cover the quick connector to prevent contam­
ination.
TUBE/FITTING ASSEMBLY
(1) Inspect the quick connect fitting to ensure that
the black plastic release ring is in the OUT position. If
the locking retainer is stuck in the RELEASE position
due to mushrooming of the release ring, or dirt accu­
mulation, the fitting should be replaced.
(2) Lubricate the male end of the fuel tube with 30
wt. oil.
(3) Insert quick connector fitting.
(4) Pull quick connector back to ensure complete
connection. If the connection is not complete, check
the black plastic release ring to make sure it is not
causing the locking retainer to jam.
(5) Use ASD Fuel System Test to pressurize the fuel
system. Check for leaks.
CAUTION: When using the ASD Fuel System Test,
the Auto Shutdown (ASD) Relay will remain ener­
gized for 7 minutes or until the test Is stopped, or
until the Ignition switch is turned to the Off position.
TUBE/FITTING SERVICE
If a quick connect fitting needs to be serviced, the
following procedure must be followed:
(1) Disconnect the battery negative battery cable.
(2) Perform the fuel system pressure release.
(3) Remove the quick connect fitting from the fuel
tube by pushing in on the plastic ring located on the
end of the fitting. Gently pull the fitting from the fuel
tube.
WARNING: WRAP SHOP TOWELS AROUND HOSES
TO CATCH ANY GASOLINE SPILLAGE.
(4) Cut off the crimp ferrules at each end of the
hose, taking care not to damage the quick connect
fitting or the fuel tube.
(5) Discard the ferrules and hose. Discard the quick
connect fitting if it is defective.
(6) Replace the hose using hose marked EFM/ EFI.
This type of hose must be used due to its special
construction.
(7) Replace the quick connect fittings (if necessary)
with the correct size and type.
 (8) Attach the replacement hose to the quick con­
nect fitting and fuel tube using the correct hose clamps.
The hose clamps used are of a special rolled edge
construction to prevent the edge of the clamp cutting
into the hose. Only these rolled edge type clamps may
be used in this system, all other types of clamps may
cut into the hoses and cause high pressure fuel leaks.
(9) Torque the hose clamps to 1 N-m (10 in. lbs.).
(10) Use ASD Fuel System Test to pressurize the
fuel system. Check for leaks.
CAUTION: When using the ASD Fuel System Test,
the Auto Shutdown (ASD) Relay will remain ener­
gized for 7 minutes or until the test Is stopped, or
until the ignition switch Is turned to the Off position.
/ v / O-RING RP394

THROTTLE POSITION SENSOR Fig. 6 Servicing Automatic Idle Speed Motor

REMOVAL (2) Remove 2 screws that mount the AIS motor to

(1) Disconnect the negative battery cable and 3 way
throttle position sensor wiring connector.(Fig. 5)
(2) Remove 2 screws mounting throttle position sen­
sor to throttle body.
(3) Lift throttle position sensor off throttle shaft.
the throttle body.
(3) Remove the AIS motor from throttle body (make
certain that the O-ring is on the AIS motor).
INSTALLATION
(1) New AIS motor has a new O-ring installed on it.
If pintle measures more than 1 inch (25 mm) in length
it must be retracted by using the AIS Motor Open/
Close Test. (Battery must be reconnected for this
operation.)
(2) Carefully place AIS motor into throttle body.
(3) Install 2 mounting screws and torque to 2 N-m
(17 in. lbs.).
(4) Connect 4 way wiring connector to AIS motor
and reconnect negative battery cable.

FUEL INJECTOR RAIL ASSEMBLY

REMOVAL
(1) Perform fuel system pressure release procedure
(before attempting any repairs).
(2) Disconnect negative battery cable.
Fig. 5 Servicing Throttle Position Sensor (3) Remove air cleaner and hose assembly (Fig. 7).
THROTTLE GASKET SHOCK
INSTALLATION
(1) Install throttle position sensor on throttle shaft.
Install 2 mounting screws to throttle body and torque
screws to 2 N-m (17 in. lbs.).
(2) Connect 3 way wiring connector.
(3) Reconnect negative battery cable.

AUTOMATIC IDLE SPEED (AIS) MOTOR

REMOVAL
(1) Disconnect negative battery cable and 4 way
AIS motor wiring connector.(Fig. 6)
 (2) Disconnect injector wiring harness from main
harness.
(3) Connect a jumper wire to ground terminal Num­
ber 1 of the injector harness (Fig. 9) to engine ground.
(4) Connect a jumper wire to the positive terminal
Number 2 of the injector harness (Fig. 9) and touch
the battery positive post for no longer than 5 seconds.
This releases system pressure.
(5) Remove jumper wires.
(6) Continue fuel system service.
(7) Remove vacuum hose harness from throttle body
(Fig. 10).

Fig. 8 Throttle Cable Attachment

(4) Remove throttle cable (Fig. 8). Remove wiring

harness from throttle cable bracket and intake mani­
fold water tube.
(5) Remove automatic idle speed (AIS) motor and
throttle position sensor (TPS) wiring connectors from
throttle body (Fig. 10).

FUEL SYSTEM PRESSURE RELEASE

PROCEDURE
The MPI fuel system is under a constant pressure
of approximately 330 kPa (48 psi). Before servicing
the fuel pump, fuel lines, fuel filter, throttle body or
fuel injector, the fuel system pressure must be
released.
(1) Loosen fuel filler cap to release fuel tank pressure.

Fig. 10 Electrical and Vacuum Connection

to Throttle Body

(8) Remove PCV and brake booster hoses from air

intake plenum (Fig. 5).
(9) Disconnect Charge Temperature Sensor electri­
cal connector. Remove vacuum harness connectors from
Intake Plenum (Fig. 11).
2.5L ENGINE m i N G IN E (10) Remove cylinder head to intake plenum strut
(Fig. 11).

TERMINAL #2 TERMINAL#!

3.3L ENGINE
 ALTERNATOR TO INTAKE
MANIFOLD BOLT — IGNITION COILS FASTENERS (4)

IGNITION COILS ELECTRICAL

CONNECTOR 9014-26

Fig. 13 Ignition Colls

(14) Remove intake manifold bolts and rotate mani­

(11) Disconnect MAP Sensor and heated Oxygen Sen­ fold back over rear valve cover (Fig. 14).
sor electrical connection. Remove the engine mounted
ground strap (Fig. 12).
MANIFOLD ABSOLUTE HEATED OXYGEN SENSOR

(15) Cover intake manifold with suitable cover when

(12) Remove the fuel hose quick connect fittings
from the chassis tubes by pushing in on the plastic
ring located on the end of the fittings. Gently pull the
fittings from the chassis tubes.
WARNING; WRAP A SHOP TOWEL AROUND HOSES
TO CATCH ANY GASOLINE SPILLAGE.
(18) Remove direct ignition system (D1S) coils and
alternator bracket to intake manifold bolt (Fig. 13).
servicing (Fig. 15).
(16) Remove vacuum harness connector from Fuel
Pressure Regulator.
(17) Remove fuel tube retain er bracket screw and
fuel rail attaching bolts (Fig. 15). Spread the retainer
bracket to allow fuel tube removal clearance.
 Fig. 15 Fuel Rail Attaching Bolts
(18) Remove fuel rail injector wiring clip from the
alternator bracket (Fig. 16).
(19) Disconnect cam sensor, coolant temperature sen­
sor, and engine temperature sensors (Fig. 16).
Fig. 16 Fuel Injector Wiring Clip
(20) Remove fuel rail. Be careful not to damage the
rubber injector O-rings upon removal from their ports
(Fig. 17).
Fig. 17 Fuel Rail R em o v al
INSTALLATION
(1) Make sure the injector holes are clean and all
plugs have been removed. Replace O-rings if damaged.
(2) Lube injector O-rings w ith a drop of clean engine
oil to ease installation.
(3) P ut the tip of each injector into th eir ports. Push
the assembly into place un til the injectors are seated
in the ports (Fig. 17).
(4) Install the (4) fuel rail attaching bolts and torque
to 22 N m (200 in. lbs.) (Fig. 15).
(5) Install fuel tube retaining bracket screw and
torque to 4 N-m (35 in. lbs.) (Fig. 18).
(6) Reconnect cam sensor, coolant tem perature sen­
sor and engine tem perature sensors (Fig. 16).
(7) Install fuel injector harness w iring clips on the
alternator bracket and intake manifold w ater tube
(Fig. 18).
(8) Connect fuel pressure regulator vacuum line.
(9) Remove covering on lower intake manifold and
clean surface.
(10) Place intake manifold gasket on lower m ani­
fold. P ut upper manifold into place and install bolts
finger tight.
(11) Install the alternator bracket to intake m ani­
fold bolt and the cylinder head to intake manifold
stru t bolts. (Do not torque.)
(12) Torque intake manifold bolts to 28 N#m (250 in.
lbs.) following torque sequence in (Fig. 14).
(13) Torque alternator bracket to intake manifold
bolt to 54 N*m (40 ft. lbs.) (Fig. 13).
(14) Torque the cylinder head to intake manifold
stru t bolts to 54 N*m (40 ft. lbs.) (Fig. 11).
 (18) Connect ground strap, MAP and heated oxygen (4) Remove the fuel pressure regulator retainer (Fig.
sensor electrical connectors (Fig. 12). 18).
(16) Connect charge tem perature sensor electrical
WARNING; PLACE A SHOP TOWEL UNDER FUEL
connector (Fig. 11).
PRESSURE REGULATOR TO ABSORB ANY FUEL
(17) Connect vacuum harness to intake plenum (Fig.
SPILLAGE.
11). Connect PCV system. '
(18) Clip w iring harness into the hole in the throttle (5) Remove fuel pressure regulator.(Pig. 19)
cable bracket.
(19) Connect the w iring connectors to the throttle
position sensor (TPS) and Automatic Idle Speed (AIS)
motor (Fig. 10).
(20) Connect vacuum harness to throttle body (Fig.
10).
(21) Install the direct ignition system (DIS) coils.
Torque fasteners to 12 N*m (105 in. lbs.) (Fig. 13).
(22) Install fuel hose quick connectors fittings to
chassis tubes. Push the fittings onto the chassis tubes
until they click into place. Pull on the fittings to
ensure complete insertion. Fuel supply fitting is 5/18
inch and fuel retu rn fitting is 1/4 inch.
(23) Install throttle cable (Fig. 8).
(24) Install air cleaner and hose assembly (Fig. 7).
(25) Connect negative battery cable.
(26) W ith the DRBII use ASD Fuel System Test to
pressurize system to check for leaks. fig . 19 nmwmmB m d Install Fuel Preaaure Regulator

CAUTION; When ysing the ASD Fusl System T#st, INSTALLATION

the Auto Shutdown (ASD) Relay w ill remain ener­ (1) Insure th a t the fuel pressure regulator has 2
gized fo r 7 9 9 9 9 19 9 or until the test is stopped, or plastic spacers. Insure th a t the fuel rail has 2 O-rings
until the Ignition switch Is turned to the O ff position. installed in the fuel regulator cavity (Fig. 20).

FUEL PRESSURE REGULATOR

REMOWML
(1) Perform fuel system pressure release procedure
(before attem pting any repairs).
(2) Remove the fuel pressure regulator vacuum con­
nector. (Fig. 18).

Fig. 20 Fuel Preaaure Regulator O-Rlnge

(2) Insert the fuel pressure regulator into the fuel

rail.
(3) Install the fuel pressure regulator retainer (Fig.
18).
(4) Install the retainer screw. Torque to 7 N*m (60
in. lbs.).
(5) Connect the fuel pressure regulator vacuum
connection.
(3) Remove regulator retainer screw (Fig. 18).
 (6) With the DRB II use the ASD Fuel System Test
to pressurize system to check for leaks.
CAUTION: When using the ASD Fuel System Test,
the Auto Shutdown (ASD) Relay will remain ener­
gized for 7 minutes or until the test is stopped, or
until the ignition switch is turned to the Off position.
FUEL PRESSURE DAMPENER
REMOVAL
(1) Perform fuel system pressure release procedure
(before attempting any repairs).
(2) Remove the direct ignition system (DIS) coil
pack electrical connector (Fig. 21).
ALTERNATOR TO INTAKE
MANIFOLD BOLT IG NITIO N COILS FASTENERS (4)
// / /A
IG NITIO N COILS ELECTRICAL
CONNECTOR 9 0 1 4 -2 6
Fig. 21 Ignition Coil Removal
(3) Remove DIS coil fasteners and rotate to obtain
access to the fuel pressure dampener (Fig. 23).
FUEL RAIL RETAINER FU^ g j “
BRACKET SCREW REGULATOR
9 1 1 4 -7 5
(4) Disconnect the fuel hose quick connect fitting by
pushing in on the plastic ring located at the end of the
fitting. Slide fitting off chassis fuel tube.
WARNING: PLACE A SHOP TOWEL UNDER QUICK
CONNECT FITTING TO ABSORB ANY FUEL SPILLAGE.
(5) Disconnect the coolant temperature sensor elec­
trical connection (Fig. 22).
(6) Remove the fuel rail retainer bracket screw (Fig.
23).
(7) Using 2 open end wrenches, one on the return
tube nut, the other on the fuel rail hex, loosen the
tube nut. (2 wrenches must be used or damage will
occur.) (Fig. 23)
WARNING: PLACE A SHOP TOWEL UNDER FUEL
PRESSURE DAMPENER TO ABSORB ANY FUEL
SPILLAGE.
(8) Remove the fuel pressure dampener.
INSTALLATION
(1) Insert return tube nut into fuel rail hex and
finger tighten.
(2) Place fuel return tube into fuel rail retainer
bracket. Insert the fuel rail retainer bracket screw,
and torque to 4 N-m (35 in. lbs.) (Fig. 22).
(3) Torque the fuel return tube nut to 28 N-m (250
in. lbs.).
CAUTION: Use a wrench to hold the fuel rail hex
while tightening the fuel return tube nut.
(4) Connect the 2 way electrical connector to the
coolant temperature sensor (Fig. 22).
(5) Place the DIS coils in position and install fasten­
ers. Torque to 12 N-m (105 in. lbs.) (Fig. 21).
(6) Connect the 4 way electrical connector to the
DIS coils.
 (7) Insert the fuel hose quick connect fitting onto (3) Install injector clip by sliding open end into the
the fuel tube. injector slot and onto the receiver cup ridge into the
(8) With the DRB II use the ASD Fuel System Test side slots of clip (Fig. 8).
to pressurize the system and check for leaks. (4) Repeat steps for remaining injectors.
(5) Connect fuel injector wiring.
CAUTION: When using the ASD Fuel System Test,
the Auto Shutdown (ASD) Relay will remain ener­
gized for 7 minutes or until the test is stopped, or
until the ignition switch is turned to the Off position.

FUEL INJECTOR
Fuel Rail must be removed first. (Refer to Fuel
Injector Rail Assembly Removal in this section.)

REMOVAL
(1) Disconnect injector wiring connector from injector.
(2) Position fuel rail assembly so that the fuel injec­
tors are easily accessible (Fig. 24).
(3) Remove injector clip off the fuel rail and injector.
Pull injector straight out of fuel rail receiver cup.
(4) Check injector O-ring for damage. If O-ring is
damaged, it must be replaced. If injector is to be re­ Fig. 25 Servicing Fuel Injector—Typical
used, a protective cap must be installed on the injector
tip to prevent damage. MANIFOLD ABSOLUTE PRESSURE (MAP)
(5) Repeat for remaining injectors. SENSOR SERVICE
(1) Remove wiring harness and remove sensor by
unscrewing from the intake manifold (Fig. 26).
(2) Reverse the above procedure for installation.
MANIFOLD ABSOLUTE HEATED OXYGEN SENSOR

INSTALLATION
(1) Before installing an injector the rubber O-ring
must be lubricated with a drop of clean engine oil to
aid in installation.
(2) Install iryector top end into fuel rail receiver
cap. (Be careful not to damage O-ring during installa­
tion) (Fig. 25).
CANISTER PURGE SOLENOID SERVICE (4) Remove the wiring connector from module and
remove module.
(1) Remove vacuum hose and electrical connector (5) Reverse the above procedure for installation.
from solenoids.(Fig. 27)
2-WAY
ELECTRICAL
CONNECTOR
9014-116
Fig. 27 Canister Purge Solenoid
(2) Depress tab on top of solenoid to be replaced and
slide the solenoid downward out of m ounting bracket.
(3) Reverse above procedure to install.
ENGINE CONTROLLER SERVICE
(1) Remove air cleaner duct from engine controller.
(2) Remove battery.
(3) Remove two module mounting screws (Fig. 28).
CRANKSHAFT TIMING SENSOR SERVICE
REMOVAL
(1) Disconnect crankshaft timing sensor pick-up lead
at wiring harness connector .(Fig. 29)
DISTANCE SENSOR
CONNECTION 908D-6
^ vr -
Fig. 29 Crankshaft Timing Sensor
(2) Remove crankshaft tim ing sensor retaining bolt.
(3) Pull crankshaft timing sensor straight up out of
the transaxle housing.
INSTALLATION
(1) If the removed sensor is to be reinstalled, clean
off the old spacer on the sensor face. A NEW SPACER
must be attached to the sensor face before installa­
tion. If the sensor is being re placed, confirm that the
paper spacer is attached to the face of the new sensor.
(2) Install sensor in transaxle and push sensor down
until contact is made with the drive plate. Hold in
this position and install and torque retaining bolt 11.9
N-m (105 in. lbs.).
(3) Connect crankshaft tim ing sensor lead wire at
wiring harness connector.
CAMSHAFT SENSOR SERVICE
REMOVAL
(1) Disconnect camshaft reference sensor lead at
wiring harness connector. (Fig. 30)
 CAM POSITION SENSOR
3-WAY ELECTtiCAl
sensors are packaged w ith compound on the threads
CONNECTOR and no additional com pound is required. Sensors m ust
be torqued to 27 N- (20 ft. lbs.). For more information
refer to Group 25.

SENSOR OUTPUT
(BLACK WIRE)

CAM POSITION POWER AND 4-WAY

SENSOR 908P-9 G iO U N D ELECTRICAL CONNECTOR RR14G133

Fig. 30 Camshaft Sensor Fig. 31 Heated Oxygen Sensor

MANIFOLD ABSOLUTE HEATED OXYGEN SENSOR
(2) Loosen cam shaft tim ing sensor retaining bolt. PRESSURE (MAP) SENSOR 4-WAY ELECTRICAL CONNECTOR
Loosen enough to allow slot in sensor to slide .past the
bolt.
(8) Pull senior up out of the chain" case cover. Do
not pull on the se n so r lead. Removal 'force will be
high due to the O-ring seal on the sensor. A light tap
to top of sensor prior to removal m ay reduce the re­
moval force.

INSTMLLMTION
(1) If the removed sensor is to be reinstalled, clean
off the old spacer on the sensor face. A NEW SPACER .NT^KEJAA^FOLD ELeCTr,c AL CONNECTO R
m ust be attached to the face before installation. In­
spect O-ring for damage, replace if necessary. If the
I I f I W I 918D-11
sensor is being replaced, confirm th a t the paper spacer
is attached to the face and O-ring is positioned in
groove of the new sensor. Fig. 32 Heated Oxygen Sensor Electrical Connection
(2) Apply a couple drops of oil to O-ring prior to
installing. Install sensor in the .chain case cover and
push sensor down until contact is made with the cam
tim ing gear. Hold in this position, and torque the
retaining bolt 11.9 N-m (105 in. lbs.).
(3) Connect cam shaft reference sensor lead wire a t
wiring harness connector. Position the lead wire in
such a fashion to keep it away from the accessory belt.

HEAIEi OXYSEN SENSOR

(02 SENSOR) SERVICE

CAUTION; Care should be exercised so that no

pulling fore© Is put on sensor wire. Use care In w ork­
ing a ro y n i sensor as the exhaust m anifold may be
extremely hot.(Fig. 32)
Remove sensor using Oxygen Sensor Socket C-4907
(Fig. 31). W hen the sensor is removed, the exhaust
manifold threads m ust be cleaned w ith an 18 mm X
1.5 X 8E tap. If the same sensor is to be reinstalled,
the sensor threads m ust be coated w ith an anti-seize
compound such as Loctite 771-84 or equivalent. New
 TEMPERATURE SENSOR SPECIFICATIONS

Component Number of Resistance at F° Thread Compound Thread Size Torque

Terminals

27 N-m
7,000 to 13,000 Ohms (20 ft.-lb
About 21 °C, 7 0 °F 2.5L Engi
Coolant Temperature Preapplied
2 3/8-18 NPTF
Sensor (Nonrequired) 7 N-m
700 to 1,000 Ohms
(60 in. lb
About 93°C, 2 0 0 °F
3.0L and 3.3L
Engines

7,000 to 13,000 Ohms

About 21 °C, 7 0 °F
Charge Temperature Preapplied 5.6 N-m
2 3/8-18 NPTF
Sensor (Nonrequired) (50 in.-lb
700 to 1,000 Ohms
About 93 °C, 200 °F

918D-54
 STEERING
CONTENTS
Page Page
ACUSTAR STANDARD AND TILT GENERAL INFORMATION ....................... 1
STEERING WHEEL 20 SPECIFICATIONS AND TIGHTENING
GEAR AND PUMP 1 REFERENCE ........................................ 26
GENERAL INFORMATION
Safety goggles should be worn at all times when chart showing the breakdown of these designations is
working on any steering gear or pump. included in the Introduction Section at the front of
Throughout this group, references may be made to a this service manual.
particular vehicle by letter or number designation. A

GEAR AND PUMP

INDEX
Page Page
Boot Seal ................................................................. 14 Pump Test ................................................................ 10
Checking Power Steering Fluid Level...................... 10 Reservoir (Saginaw) ................................................. 16
General Information ................................................. 1 Reservoir (ZF) .......................................................... 17
Outer Tie Rod .......................................................... 14 Seals . » 17
Power Steering Hoses............................................... 10 Steering Gear (All Wheei Drive) .............................. 11
Power Steering P u m p ............................................... 14 Steering Gear (Front Wheel Drive) .......................... 11
Power Steering Pump Pulley (Saginaw and ZF) ___ 15 (ZF) Pump ................................................................ 2
Power Steering Pumps ....................................... . 1

GENERAL INFORMATION
INNER TIE ROD RACK AND PINION INNER
The power steering gear (Fig.1) should NOT be STEERING GEAR (POWER) TIE ROD
serviced or adjusted. If a malfunction or oil leak occurs.
The complete steering gear should be replaced.
Refer to power steering gear to replace rubber boots,
if necessary.
The power steering system consists of these four
major components. Power gear, Power steering pump,
TIE ROD END
Pressure hose, and Return line. Turning the steering
wheel is converted into linear travel through the mesh­ TIE ROD END BOOTS RB986A
ing of the helical pinion teeth with the rack teeth.
Power assist steering is provided by an open center, Fig. 1 Power Steering Gear (TRW)
rotary type control valve which directs oil from the
Drive tangs on the pinion mate loosely with a stub
pump to either side of the integral rack piston.
shaft to permit maintenance of manual control if the
Road feel is controlled by the diameter of a torsion
drive belt on the power steering pump should break.
bar which initially steers the vehicle. As required
However, under these conditions, steering effort will
steering effort increases, as in a turn. The torsion bar
be increased.
twists, causing relative rotary motion between the
rotary valve body and the valve spool. This movement
directs oil behind the integral rack piston, which, in
POWER STEERING PUMPS
turn, builds up hydraulic pressure and assists in the
SAGINAW PUMP
turning effort.
Because of unique shaft bearings, flow control lev­
els or pump displacements, these pumps may not be
interchangeable with pumps from other vehicles.
 trigger orifice located in the outlet fitting. This re­
duces pressure on the spring end of the flow control
valve which then opens and allows the oil to return to
the intake side of the pump. This action lim its maxi­
mum pressure output of the pump to safe level.
Under normal operating conditions, the pressure
requirements of the pump are below maximum, caus­
ing the pressure relief valve to remain closed.

(ZF) PUMP
The ZF power steering pump (Fig.3) is NOT repair­
able. If this pump, reservoir, or cap fails or leaks, it
should be replaced. Do not attempt to repair a ZF
power steering pump or reservoir.
PR2337 To diagnose the ZF power steering pump. Use the
Fig.2 Power Steering Pump existing diagnostics charts in this section.
If a oil leak is detected at the power steering pump
Hydraulic pressure is provided for operation of the discharge fitting. Tighten the fitting to 50 N-m (37 ft.
power steering gear by the belt driven power steering lbs.). If after tightening the discharge fitting the oil
pump (Fig.2). It is a constant displacement, vane type leak does not stop. Remove the fitting and inspect or
pump with a reservoir and a pressure hose attach­ replace the O-ring. Retighten the fitting (Fig.3).
ment to the pump. The power steering pump is con­
nected to the steering gear by a pressure hose and
return line.
Rectangular pumping vanes carried by a shaft driven
rotor move the fluid from the intake to the cam ring
pressure cavities. As the rotor begins to turn, centrif­
ugal force throws the vanes against the inside surface
of the cam ring to pickup residual oil. This oil is then
forced into the high pressure area. As more oil is
picked up by the vanes. That additional oil is forced
into the cavities of the thrust plate through two cross­
over holes in the cam ring and pressure plate. The
crossover holes empty into the high pressure area
between the pressure plate and the housing end cover.
When the high pressure area is filled. Oil flows
under the vanes in the rotor slots, forcing the vanes to
follow the inside oval surface of the cam ring. As the
vanes reach the restricted area of the cam ring, oil is
forced out from between the vanes. When excess oil
flow is generated during high-speed operation. A reg­
ulated amount of oil returns to the pump intake side
through a flow control valve. The flow control valve
reduces the power required to drive the pump and
holds down temperature build-up.
When steering conditions exceed maximum pres­
sure requirements, such as turning the wheels against
the stops. The pressure built up in the steering gear
also exerts pressure on the spring end of the flow
control valve. This end of the valve houses the pres­
sure relief valve. High pressure lifts the relief valve
ball from its seat and allows oil to flow through a
 PUMP LEAKAGE DIAGNOSIS-
ACTION TO BE TAKEN:
REPLACE O-RING SEAL AND TIGHTEN HOSE FITTING NUT TO
34 N-m (25 FT. LBS.) ■ ■ ■ •

PERSISTS, REPLACE O-RING SEAL

CHECK OIL LEVEL; If LEAKAGE PERSISTS WITH THE CORRECT

LEVELAND CAP TIGHT, REPLACE THE CAP

.REPLACE PRiVESHAPT SEAL

 POWER STEERING SERVICE DIAGNOSIS

P U M P N O IS I

There is some noise in all power steering systems. One of the most common is a hissing sound evident at standstill parkin
a high frequency noise similar to that experienced while slowly closing a water tap. The noise is present in every valve ana re
from high velocity fluid passing valve orifice edges. There is no relationship between this noise and performance of the steering.
Hiss may be expected when steering wheel is at end of travel or when slowly turning at standstill.

C O N D IT IO N P O M IB U CJMJSK C O M IC V IO N

OBJECTIONAL HISS O i 1. Noisy valve in gear 1. Check for proper seal between steering
WHISTLE column coupling and dash seal.
Ensure steering colu
has no mdal-to-melal contact
within the coupling by performing an
electrical continuity crteck. (Remove
coupling for check.)
If hiss is still extremely objectionable,
replace steering gear.

RATTLE OR CLUNK 1. Gear loose on front crossmember 1. Check gear-to-crossmember moun

2. Crossmember-to-frame bolts or studs loose
3. Tie rod looseness (outer or inner)
4. Pressure hose touching other parts of vehicle
5. Noise internal to gear
bolts. Tighten to specification.
2. Torque bolts and studs to specifications.
3. Check tie rod pivot points for wear.
Replace if necessary.
4. Adjust hose to proper position by
loosening, repositioi
fitting. Do not bend tubing.
5. Replace gear.

CHIRP OR SQUEAL (IN 1. Loose belt 1. Adjust belt tension to specification.

THE AREA OF PUMP)
PARTICULARLY
NOTICEABLE AT FULL
WHEEL TRAVEL AND
DURING STANDSTILL
PARKING

f 119-2
 POWER STEERING SERVICE DIAGNOSIS

PUM P O R O m

Pump growl results from the development of high pressure fluid low. Normally this noise should not be high enough to be
objectionable. Abnormal situations, such as a low oil level causing aeration or hoses touching the vehicle oody, can create a noise
level that could bring complai nts.

C O N D IT IO N p o s s iB ii i i i i i i * C O R R IC TIO N '

WHINE OR GROWL 1. Low fluid level 1. Fill to proper level and perform
(PUMP NOISE) diagnosis. (Recheck after system is free
of aeration.)
2. Hose touching vehicle body or frame 2. Reposition hose. Replace hose if tube
ends are bent.
3. Extreme wear of pump internal parts 3. Replace pump and flush system.

SUCKING AIR SOUND
1. Loose return line clamp
2. Missing O-ring on hose connection
3. Low fluid level
4. Air leak between reservoir and pump
1. Tighten or replace clamp.
2. Inspect connection and replace o-ring as
required.
3. Fill to proper level and perform 1
diagnosis.
4. Inspect and replace reservoir as requ

SQUEAK OR RUB SOUND
1. Sound from steering column
2. Sound internal to steering gear
1. Check for squeak in steering column.
Inspect for contact between shroud
intermediate shaft, column, and wheel.
(Realign if necessary.)
2. Replace gear.

SCRUBBING/KNOCKING
1. Incorrect tire size 1. Verify tire size is the same as originally
supplied.
2. Check clearance between tires and other 2. Correct as necessary.
vehicle components, through full travel
3. Check (or interference between steering gear 3. Correct as necessary.
and other components
4. Incorrect gear supplied 4. Replace gear.

9119-3
 POWER STEERING SERVICE DIAGNOSIS

BINDS STICKS M IZ IB

CONDITION POSS1BLI fiJliytsli ^COMICTION

CATCHES, STICKS IN 1. Low fluid level 1. Fill to proper level and perform •
CERTAIN POSITIONS OR diagnosis. . . ........
DIFFICULT TO TURN w 2. Tires not properly inflated 2. Inflate tires to proper pressure.
3. Lack of lube in ball joints 3. Lubricate where possible.
4. Lack of lube i n outer tie rod ends 4 . Lubricate where possible.
5. Loose pump belt 5. Tighten or replace belt. ' '" 7
6. Faulty pump flow control (Verify caw * using 6. Replace pump.
Pump Test Procedure)
7. Excessive friction in steering column or 7. Correct condition. (See Steering Column
- intermediate shaft Service Procedure.)
8. Steering column coupling binding 8. Realign as necessary. .;
9. Excessive friction in gear 9. Replace gear.

S H A M SHIIDMft V l i l A f l i l l l

CONDITION P i l i i l l l l : f llii f l t l COMICTION

VIBRATION O f THE 1. Air in the power steering system 1. Steering shudder can be expected in new
STEERING WHEEL A N D / vehicles and vehicles with recent steering
OR DASH DURING DRY system repairs. Shudder should improve
PARK OR LOW SPEED after the vehicle has been driven several
STEERING MANEUVERS' weeks. . .
2. Ti res not properly inflated 2. Inflate tires to proper pressure.
3. Excessive engine vibration 3. Make sure that engine is running properly.
4. Faulty accessory drive belt tensioner. 4. Check dynamic belt tensioner for
(Poly-V belt systems only) abnormal vibration. (See Drive Belt
Adjustments.)
5. Overcharged air conditioner 5. Check air conditioning pump head
pressure. (See Air Conditioning
Refrigerant System Diagnosis.) ^ ":

9119-4
 POWER STEERING SERVICE DIAGNOSIS
LO W A SSIST, N O A SSIST, O R M A ID S T IIM N G
C O N D IT IO N MMM DU CAVSI
STIFF, HARD TO TURN, 1. Tires not properly inflated
SURGES, MOMENTARY 2. Low fluid level
INCREASE IN EFFORT
WHEN TURNING
3. Loose belt
4. Lack of ball joint lubrication
5. Low pressure pump (Verify using Pump Test
Procedure)
6. High internal leak gear
PO O R M Y U fkN TO C IN TB R
CONDITION P ilillifc * C A V S I
STEERING WHEEL DOES 1. Tires not properly inflated
NOT WANT TO RETURN 2. Improper front wheel alignment
TO CENTER POSITION
3. Lack of lubrication in ball joint
4. Steering column U-joints misaligned
5. Mispositioned dash cover
6. Steering wheel rubbing
7. Tight steering shaft bearings
8. Excessive friction coupling universal joint
9. High friction in the steering gear
CORRECTION
1. Inflate tires to proper pressure.
2. Add power steering fluid as required and
perform leakage diagnosis.
3. Tighten or replace belt.
4. Lubricate or replace as required.
5. Verify cause using Pump Test Procedure.
Replace pump if necessary.
6. Check steering system using test
procedure. If steering gear is at fault,
replace steering gear.
CORRECTION
1. Inflate tires to proper pressure.
2. Check and adjust as necessary.
3. Replace as required or lubricate.
4. Realign steering column U-joints.
5. Reposition dash cover.
To evaluate items 6 and 7, disconnect the
intermediate steering shaft. Turn the steering
wheel and listen for internal rubbing in
column.
6. Adjust covers.
7. Replace bearings.
8. Replace U-joints.
9. Replace steering gear.
9119-5
 POWER STEERING SERVICE DIAGNOSIS

L M H S IV IM N O . .

P O S S IB U C A U S I C O M IC T IO N .

EXCESSIVE WHEEL 1. Air in system 1. Add fluid.

KICKBACK OR TOO 2. Gear loose on crossmember 2. Check gear to crossmember mounting
MUCH STEERING WHEEL bolts. Tighten to specification.
PLAY
3. Worn/broken intermediate shaft 3. Check for worn universal joint
isolator. Replace intermediate shaft if
worm.
4. Free play in steering column . 4. Check and replace as required.
5. Loose ball joints "5. Check and replace as required.
6. Front wheel bearings loose or worn 6. Tighten hub nut or replace with new parts
as necessary.
7. Loose outer He rod ends 7. Check and replace as required.
8. Loose inner tie rod ends 8. Replace gear.
9. Defective steering gear rotary valve 9. Replace gear.

WIM1CU U A D S TO m i S1DI

CONDITION POSSIBU CAUSI COMICTION

WHEEL POES NOT 1. Radial tire lead 1. Rotate tires as recommended in Tire
WANT TO RETURN TO ' Service.
CENTER POSITION 2. Front end misaligned 2. Align front end as recommended in
Wheel Alignment Service Procedure.
3. Wheel braking 3. Check for dragging brakes as directed in
Brake Service Procedure.
4. Unbalanced steering gear valve. (If this is the 4. Checking for pull with outer tie rod end
cause, the steering efforts will be very light in disconnected. If verified, replace gear.
direction of lead and heavier in the opposite
direction)

9119-6
 POWER STEERING SERVICE DIAGNOSIS

-fU M D UJUK

C O N D IT IO N m m m m c a iim C O M K T iO N '

LOW FLUID LEVEL WITH: 1. Overfilled reservoir 1. Adjust fill level.

• NO VISIBLE SIGNS OF 2. Hose connections at pump or gear 2. Check for loose fittings and tighten to
LEAKS ON THE speci fications. If fifing $ are tight, examine
STEERING GEAR# for damaged or missing O-ring and
PUMP, ON FLOOR, OR replace as required.
ANYWHERE ELSE 3. Pump or gear leak 3. Identify location of leak and repair or
LOW FLUID LEVEL WITH: replace as indicated in Power Steering
• VISIBLE LEAK ON Pump and/or Gear sections of this
service manual.
STEERING GEAR,
PUMP, FLOOR, OR
ANYWHERE ELSE

F O A M Y m m M IL K Y flttll

C O N D IT IO N POSSIBLE f J l l f i * c o m ic n o N

AERATION AND 1. Air leaks 1. Check for air leak as described under
OVERFLOW OF FLUID sucking air and correct.
2. Low fluid level 2. Extremely cold temperatures mo/ cause
syitero aeration if tne oil level is low.
Add fluid as required.
3. Cracked pump housing 3. Remove pump from vehicle.and separate
reservoir from housing. Check expansion
plug and housing for cracks. Replace
pump as required.
4. Water contamination 4. Drain and refill fluid if there is evidence
of contamination.

9119-7
CHECKING POWER STEERING FLUID LEVEL
WARNING: FLUID LEVEL SHOULD BE CHECKED
WITH ENGINE OFF TO PREVENT INJURY FROM MOV­
ING PARTS. DO NOT USE AUTOMATIC TRANSMIS­
SION FLUID. DO NOT OVERFILL.
Wipe reservoir filler cap free of dirt. Then check
fluid level. The dipstick should indicate FULL COLD
when fluid is at normal ambient temperature, approx­
imately 21°C to 27°C (70°F to 80°F). In all pumps
replenish fluid, if necessary, with Mopar Power Steer­
ing Fluid, or equivalent.
PUMP TEST
The following procedure may be used to test the
operation of the power steering system on the vehicle.
(1) With engine off, inspect fluid level in reservoir.
Fill to correct level, if necessary.
(2) Check belt tension and adjust to specifications, if
required.
(3) Disconnect pressure hose. See Hose Remove.
(4) Connect a spare pressure hose to pump fitting.
(5) Connect spare pressure hose to gauge side of,
Gauge Special Tool C-3309E. Connect pressure hose
from gear valve to valve side of Tube Assembly/Adapter,
Special Tool L-4601 and C-3309E. Be sure that valve
on tool is on outlet side of gauge.
New fittings will be required on Tool C-3309E to
adapt to new O-RIng type hose tube ends.
(6) Open hand valve on Special Tool C-3309E.
(7) Insert thermometer in fluid reservoir. Start en­
gine and warm fluid to a temperature between 66°C
and 77°C (150°F and 170°F). Turn wheels from stop to
stop to help warm fluid. Do not hold wheels against
stop for an extended period as excessive internal
pump overheating may result.
(8) With engine at idle speed and gauge valve open,
check initial pressure. Initial pressure should be in
the 207-345 kPa (30-50 psi) range. If pressure is in
excess of 690 kPa (100 psi), check hoses for restric­
tions and/or crimped oil lines.
(9) Close the gauge valve completely three times.
Record the highest pressure attained each time.
Do not leave the gauge valve closed for more than
5 seconds as the power steering pump could be
damaged.
(10) If recorded pressures are within specifications
and range of readings is within 345 kPa (50 psi),
pump is operating properly.
(11) If pressures recorded are high, but do not re­
peat within 345 kPa (50 psi), during the three tests.
The flow control valve in pump is sticking.
(12) The power steering pump is defective and must
be replaced
(13) If pressures recorded are constant, but less than
minimum specified. The power steering pump must be
replaced
• If system contains some dirt, it must be thoroughly
flushed.
CAUTION: To prevent scrubbing flat spots on tires,
do not turn steering wheel more than five times with­
out rolling vehicle to change tire-to-floor contact area.
(14) If pump checks to specifications. Leave gauge
valve open and turn steering wheel from stop to stop,
with engine idling. Record highest pressures attained
at each wheel stop. Compare readings with the maxi­
mum pump pressure previously recorded. If this pres­
sure cannot be built up in either side of the gear, the
gear is leaking internally and must be replaced.
The power steering gear should NOT be serviced
or adjusted. If a malfunction or oil leak occurs. The
complete steering gear should be replaced.
(15) Shut off engine, remove Tool C-3309E, connect
pressure hose, and make indicated repairs.
POWER STEERING HOSES
Service all power steering hoses with vehicle raised
on hoist. Cap all open hose ends and pump and gear
ports to prevent entry of foreign material.
WARNING: POWER STEERING OIL AND PARTS AND
THE EXHAUST SYSTEM MAY BE EXTREMELY HOT
IF ENGINE HAS BEEN RUNNING. DO NOT START
ENGINE WITH ANY LOOSE OR DISCONNECTED
HOSES. DO NOT ALLOW HOSES TO TOUCH HOT
EXHAUST MANIFOLD OR CATALYST.
REMOVAL
(1) Remove fasteners from hose locating bracket
attachment points.
(2) Disconnect hose at opening nearest gear and
drain oil from pump through open end of hose.
(3) Disconnect other end of hose and remove.
(4) Discard tube end O-ring and/or washer seal.
INSTALLATION
(1) Wipe open hose ends and pump and gear ports
clean.
(2) Install new O-rings and/or washer seals and
lubricate with power steering fluid.
(3) Attach hose at the proper connections. Route
hoses smoothly in their correct position avoiding bends
or kinking. Hoses must remain away from the ex­
haust system. Do not bend tube ends.
(4) Tighten all fasteners to the correct torque:
• Pump End Banjo Bolt — 34 N-m (25 ft. lbs.)
• Pump End Tube Nut — 34 N-m (25 ft. lbs.)
• Gear End Tube Nuts (2) — 34 N-m (25 ft. lbs.)
• Crossmember Bracket Bolt — 23 N-m (17 ft. lbs.)
• Pump Bracket Nut — 40 N-m (30 ft. lbs.)
• Goar Bracket Bolt — 68 N-m (50 ft. lbs.)
(5) When used, protective sponge sleeves must be
properly positioned to prevent hose contact with other
components.
(H> After hose is installed, check for leaks. (See
Pump Installation).
STEERING GEAR (FRONT WHEEL DRIVE)
REMOVAL
(1) Remove front road wheels.
(2) Remove tie rod ends, using a suitable puller.
(3) Disconnect engine damper strut from crossmember
(if so equipped).
(4) Remove all four front suspension crossmember
attaching bolts. Lower front suspension crossmember,
using transmission jack, so that the steering gear can
be disconnected from the steering column.
(5) Remove tubes form the power steering pump to
the gear. See hose removal procedure.
STEERING GEAR (ALL WHEEL DRIVE)
STEERING GEAR ALL WHEEL DRIVE
POWER STEERING
LINES
REMOVAL
(1) Remove front road wheels.
(2) Remove the steering column assembly from the
vehicle. (STEERING COLUMN MUST BE REMOVED
TO ALLOW CLEARANCE FOR STEERING GEAR
REMOVAL ON THE ALL WHEEL DRIVE APPLI­
CATIONS). (Refer to Steering Column Removal in
this section of the manual)
(6) Remove bolts attaching gear to front suspension
crossmember.
(7) Remove gear from crossmember.
INSTALLATION
An assistant will be required, in the vehicle, to
guide the steering column coupling onto the steer­
ing gear.
(1) Reverse the above procedure.
(2) The right rear crossmember bolt is a pilot bolt
that correctly locates the crossmember. Tighten this
bolt first. Tighten all four crossmember bolts to 122
N*m (90 ft. lbs.) torque.
CAUTION: Proper torque to these crossmember bolts
Is very important.
(3) Tighten four bolts attaching steering gear to
crossmember to 68 N-m (50 ft. lbs.) torque.
(4) Check for oil leaks.
(5) Adjust toe (Refer to Group 2 Suspension).
(3) Remove tie rod ends from the steering knuckles,
using a suitable puller.
(4) Remove the 2 bolts and the 2 nuts attaching the
bridge assembly to the crossmember. The bolts and
nuts are accessible through holes in the top of the
bridge assembly (Fig.l).
 NUT BOLT

ACCESS
HOLES

STUD

BRIDGE
ASSEMBLY

TIE ROD
END
CROSSMEMBER'SUSPENDED
FROM LOWER CONTROL ARMS 9119-18

Fig.3 Crossmember Assembly Lowered In Vehicle

CROSSMEMiiR
ASSEMBLY
(6) Remove the power steering pump, pressure and
return lines from the steering gear. (See Hose Re­
9119-16 moval Procedure).
(7) Remove the bracket holding the power steering
FigA Bridge Assembly Remove/Replace hoses to the crossmember (Fig.4).
(8) Remove the 4 bolts attaching the steering gear
(5) Remove the cressmember to frame rail attaching
to the crossover bridge (Fig.4). Note the location of
bolts. Using a transmission jack, lower the Gro8smember
the bolts, they are different for the left and right
so it is suspended from the lower control arms (Fig.2
steering gear mounting brackets.
& 3). It is not necessary to totally m m m e crossmember
from vehicle. BOLT STEERING GEAt
LEFT SIDE
NUT/PLATE BOLT
NUT/PLATE ASSEMBLY RIGHT SIDE TIE iO P END

BRIDGE

CROSSMEMBER

POWER STEERING
UIACKEI HOSES
VIEW IN DIRECTION SCREW
OF AiROW 2 BRACKET
CROSSMEMBER
ASSEMBLY 9119-17
 (9) Remove the lower steering column coupling from INSTALLATION
the steering gear. By driving the roll pin from the (1) If the bridge assembly was removed from the
coupler using a suitable drift. The roll pin retains the vehicle. Lay the bridge assembly on the output shaft
coupler to the splined shaft on the steering gear (Fig.5). of the P.T.U. (Fig.7).
THIS MUST BE DONE TO HAVE ADEQUATE CLEAR­
ANCE BEFORE TRYING TO REMOVE THE STEER­
ING GEAR FROM THE VEHICLE.

Fig.7 Bridge Assembly Installed

(2) Install the steering gear into the vehicle (Fig.6)

(10) Remove the steering gear from the vehicle by wheel well.
pulling it out the driver side wheel well. Rotate the
gear to clear the frame rail as you are sliding the gear the steering gear (Fig.5). Be sure the roll pin is fully
out (Fig.6).
in the reverse order of its removal through the left
(3) Install the lower steering column coupler onto
installed through the coupler housing.
(4) Install the 4 bolts that mount the steering gear
to the bridge assembly, (Fig.4) but do not torque them.
The bolts holding the steering gear to the bridge
assembly. Must be replaced in the same steering
gear mount they were removed from. Be sure the
power steering hose bracket is reinstalled under the
right steering gear bracket.
(5) Install the power steering pump to steering gear
hoses and torque to 31 N-m (275 in.lbs.).
(6) Using a Transmission Jack, raise and install the
crossmember assembly in the vehicle and torque the
fasteners to the specs listed below (Fig.2).
CAUTION: Proper torque to these crossmember bolts
is very important.
• Crossover to frame rail screw and washer — 122
N-m (90 ft. lbs.)
• Crossover to frame rail stud nut — 122 N-m (90 ft.
lbs.).
(7) Install the bridge assembly onto the crossmember
assembly (Fig.l) and torque the fasteners to 68 N-m
(50 ft. lbs.).
 (8) Install the routing bracket for the' power steer­
ing lines (Fig.4) onto the crossmember assembly. Torque
screw to 8 N-m (70 in. lbs.).
(9) Install the outer tie rod ends on the steering
knuckles and tighten the nuts. Be sure to install the
cotter pin that retains the tie rod end nut.
(10) Start up the vehicle and check all power steer­
ing fluid hose couplings for oil leaks.
(11) Adjust toe (Refer to Group 2 Suspension).
OUTER TIE R O i (Fig. 1)
REMOVAL
(1) Loosen jam nut.
(2) Remove tie rod from steering knuckle.
(3) Remove outer tie rod.
BOOT SEAL (Fig.2)
REMOVAL
(1) Remove jam nut.
(2) Use pliers to expand outer boot clamp and remove.
(3) Use pliers to expand boot snorkel clamp (Fig.2)
and slide clamp onto breather tube.
(4) Remove inner boot clamp.
(5) Mark breather tube location before removing
boot.
After removing Inner boot clamps, a very small
screwdriver should be used to lift boot from its
groove, then the boot can be removed.
INSTALLATIO N
(1) Install parts as shown.
(2) Line up mark and breather tube.
(3) Install boot seal over housing lip with hole in
boot aligned with breather tube.
(4) Install boot snorkel clamp.
(5) Install new inner tube clamp.
(6) Lubricate tie rod boot groove with silicone type
lubricant before installing outer clamp.
The removal and installation of the above compo­
nents must be performed with the rack and pinion
assembly removed from the vehicle.

POWER 'STEERING POMP

Fig. I Outer Tie Rod
WARNING; POWER STEERING FLUID AND FARTS
INSTALLATION AND EXHAUST SYSTEM MAY BE EXTREMELY HOT
(1) Install parts as shown. IF ENGINE HAS BEEN RUNNING.
(2) Do not tighten jam nut.
(3) Make toe adjustment by.turning inner tie rod. REMOVAL
Do not twist boot. (1) Position vehicle on hoist and disconnect vapor
(4) Tighten jam nut to 75 N*m (55 ft. lbs.) torque. separator hose and two wires from air-conditioning
Lubricate tie rod boot groove with silicone type lubri­ clutch cycling switch (If so equipped).
cant before installing outer boot clamp, making sure (2) Before raising vehicle, loosen and remove drive
boot is not twisted. belt adjustment locking screw from front of pump and
pump end hose bracket nut, if so equipped (Fig. 1).
COVER STEERING HORN
(WITH SPEED WHEEL ' RELAY
CONTROL ■ GROUND
SWITCHES) WIRE
STEERING
SHAFT

NUT & SOURCE

WASHER FOR
HORN
RELAY
GROUND
SPEED
CONTROL COVER
WIRE RETAINING
HAiNESS SCREW
 System, Group 7). Tighten adjustment bolt to 41 N-m
(30 ft. lbs.) torque.
CAUTION: Excessive belt tension can cause the shaft
RIBBED (POLY "V") BELT
bushing to fail. Do not pry on reservoir.
(7) Raise vehicle and tighten lower stud nut and
pivot screw to 54 N-m (40 ft. lbs.) torque. Install belt
FRAME splash shield.
(REFERENCE) (8) Lower vehicle and connect vapor separator and
vent hoses, and two wires to air-conditioning cycling
switch, if so equipped.
(9) Fill pump reservoir to correct level with Mopar,
Power Steering Fluid, or equivalent.
CAUTION: Do not use automatic transmission fluid.
(10) Start engine and turn steering wheel several
INSTALL 1/2" times from stop to stop to bleed system. Stop engine,
BREAKER BAR check fluid level, and inspect system for leaks. See
INTO FORWARD Checking Fluid Level.
1/2" SQUARE OPENING FORWARD
IN TENSIONER LIFT BAR
TO REDUCE BELT TENSIONER 8909' 37 POWER STEERING PUMP PULLEY
(SAGINAW AND ZF) (Figs 1 and 2)
Fig.1 Power Steering Pump Mounting
REMOVAL
All fasteners used on the power steering pump (1) Remove pulley with tool as shown in (Fig.l). Do
and pump mounting brackets are metric. not hammer on pulley as this will damage pulley or
(3) Raise vehicle on hoist and disconnect return pump. Replace pulley if it is b©nt» cracked, or loose.
hose from gear tube and drain oil from pump through
open end of hose. Do not allow hoses to touch hot
exhaust manifold or catalyst.
(4) While pump is draining, remove right side splash
BLOCK V
l /TOOL €-4068

shield that protects drive belts.

• €-4068-1
(5) Disconnect both hoses from pump. Cap all open
hose ends and pump and gear ports to prevent entry of
foreign material.
(6) Remove lower stud nut and pivot screw from
pump.
(7) Lower vehicle and remove belt from pulley.
(8) Move pump rearward to clear mounting bracket
and remove adjustment bracket.
(9) Rotate pump clockwise so that pump pulley
faces rear of vehicle and pull upwards to remove
pump from vehicle.

INSTALLATIO N
(1) Install pump by reversing procedure in Step (9)
above.
(2) Install adjustment bracket onto pump with tab
in lower left front housing mounting hole. » d PR2357A
(3) Raise vehicle and install lower pump stud nut
and pivot bolt. Do not tighten. Ptg.1 Ptemowe Pulley
(4) Install new O-Rings on pressure hose and con­
INSTALLATION
nect both hoses. See Hose Installation. Tighten tube
(1) Install pulley with tool, as shown, in (Fig.2)
nut to 34 N*ra (25 ft. lbs.) torque.
without adapters. Be sure that tool and pulley remain
(5) Install drive belt into pulley groove.
aligned with shaft to prevent cocking. Press pulley
(6) Lower the vehicle and install belt adjustment
flush with end of shaft (Fig.2).
screw and adjust belt to correct tension (see Cooling
 RESERVOIR (SAGINAW)
REMOVAL
(1) Remove filler cap and drain oil from reservoir
before removing parts.
(2) Remove mounting studs and pressure discharge
fitting as shown in (Fig.l).
(3) Rock reservoir by hand or tap with soft face
mallet to remove. Discard all seals and O-rings.

INSTALLATION
(1) Clean all parts.
(2) Install parts as shown in (Fig.3). Use new O-Rings
and seals. Lubricate all seals with power steering
fluid before installation.
CAUTION: Be sure fitting O-Ring is installed in groove
nearest hex end.

Fig.2 Install Pulley

RESERVOIR (ZF)
REMOVE
(1) Remove 2 bolts (A) and 2 retaining plates (B)
SCREWDRIVER
(Fig.4)
(2) Drive pins (C) out from front (Fig.4). Do not
enlarge front access hole (used for pin location).
(3) Lift reservoir off power steering pump. Inspect
pump inlet. Replace pump if inlet is damaged or worn.

Flg.1 Remove Retaining Ring

(2) Remove end cover and pressure plate spring

(Fig.2)

I NSPECTSEALING SURFACE.
REPLACE IF DAMAGED

MAGNET
(WIPE CLEAN
W ITH CLOTH) RETAINING
RING

Flg.4 Remove or install pump reservoir (ZF) CONTROL VALVE

CONTROL ASSEMBLY (REMOVE
VALVE
INSTALL BURRS FROM VALVE
SPRING LANDS AND CLEAN)
(1) Make sure O-rings are in good condition. Apply
power steering fluid to O-ring to ease installation.
Carefully snap the reservoir in place on the power CAUTION: EXAMINE THIS PART OF DRIVE
steering pump. SHAFT. IF IT IS CORRODED, CLEAN WITH
(2) Install NEW pins (C) from the rear (Fig.4). Push CROCUS CLOTH BEFORE REMOVING. THIS
WILL PREVENT DAMAGE TO THE SHAFT
in until flush with back plate. BUSHING.
(3) Install pin retaining plates (B) and bolts (A). PR812B
Tighten bolts (A) to 10 N-m (90 in. lbs.)
Fig.2 Pump
SEALS
CAUTION :Examine drive shaft. If corroded, clean with
REMOVAL crocus cloth before removal. This will prevent dam­
(1) Remove retaining ring (Fig.l) age to the shaft bushing.
(3) With plastic hammer, tap shaft end lightly until
pressure plate is free.
(4) Remove the pump shaft seal as shown in (Fig.3)
 (4) Remove all parts as shown in (Fig.4). Discard all
seals.
(5) Inspect all wear surfaces. Replace pump if any
part has excessive wear, scuffing of scoring.

INSTALLATION
(1) Clean all parts.
(2) Install drive seal as shown in (Fig.5).
CAUTION: Excessive force will distort the seal.

VANES

\
ROTOR 7
CAM RING
PRESSURE
PLATE
THRUST PLATE
 Fig.5 Install Seal Flg.7 Install Cam Ring (Saginaw)

(3) Install new O-rings and seals. (6) Install vanes into rotor and lubricate all parts
Lubricate seals with power steering fluid before with Power Steering Fluid.
installation. DO NOT USE AUTOMATIC TRANSMIS­ (7) Install and seat pressure plate as shown in (Fig.8).
SION FLUID.
(4) Install thrust plate, shaft and rotor assembly as
shown in (Fig.6)

ROTOR LOCK RING

PR2361
Fig.6 Thrust Plate and Rotor Assembly.
(5) Install cam ring as shown in (Fig.7).
(8) Install pressure plate spring, end cover (LUBRI­
CATE WITH POWER STEERING FLUID) and re­
taining ring as shown in (Fig.9).
 INSPECT SEALING SURFACE.
REPLACE I F DAMAGED

MAGNET
(W I PE CLEAN
WITH CLOTH) RETAINING
RING

CONTROL VALVE
CONTROL ASSEMBLY (REMOVE
VALVE BURRS FROM VALVE
SPRING LANDS A N D CLEAN)

CAUTION: EXAMINE TH IS PART OF DRIVE

SHAFT. IF IT IS CORRODED, CLEAN WITH
CROCUS CLOTH BEFORE REMOVING. THIS
WILL PREVENT DAMAGE TO THE SHAFT
BUSHING.
PR812B

Fig.9 Pump Reassembly

ACUSTAR STANDARD AND TILT STEERING COLUMN

WARNING: THE AIR BAG SYSTEM IS A SENSITIVE,
COMPLEX ELECTRO-MECHANICAL UNIT. BEFORE
ATTEMPTING TO DIAGNOSE, REMOVE OR INSTALL
THE AIR BAG SYSTEM COMPONENTS YOU MUST
FIRST DISCONNECT AND ISOLATE THE BATTERY
NEGATIVE (GROUND) CABLE. FAILURE TO DO SO
COULD RESULT IN ACCIDENTAL DEPLOYMENT AND
POSSIBLE PERSONAL INJURY.
THE FASTENERS, SCREWS, AND BOLTS, ORIGI­
NALLY USED FOR THE AIR BAG COMPONENTS,
HAVE SPECIAL COATINGS AND ARE SPECIFICALLY
DESIGNED FOR THE AIR BAG SYSTEM. THEY MUST
NEVER BE REPLACED WITH ANY SUBSTITUTES.
ANYTIME A NEW FASTENER IS NEEDED, REPLACE
WITH THE CORRECT FASTENERS PROVIDED IN THE
SERVICE PACKAGE OR FASTENERS LISTED IN THE
PARTS BOOKS.
BEFORE SERVICING A STEERING COLUMN
EQUIPPED WITH AN AIR BAG, REFER TO GROUP
8M, ELECTRICAL FOR PROPER AND SAFE SER­
VICE PROCEDURES.
Safety goggles should be worn at all times when
working on steering columns.
 TILT LEVER UPPER SHROUD BRAKE PEDAL BRACKET
STEERING
WHEEL NUT

SHIM (IF REQUIRED)

COUPLER IOLT
RETAINING PIN

COVER AND
LOWER SHIELD
SHROUD
STEERING SHAFT
SEAL

DASH
PANEL

LOWER
COUPLING
SPRING
PIN

TO AIR BAG
TROUGH FEED 9119-11

I f f .I Acustar Standard and Tilt Stmrlng Column

GENERAL INFORMATION WARNING:BEFORE BEGINNING ANY AIR BAG SYS­

The Acustar tilt and standard column (Fig.l) has
been designed to be serviced as an assembly; less
wiring, switches, shrouds, steering wheel, etc. Also,
most steering column components can be serviced with­
out removing the column from the ¥ehicle.
CAUTION: Disconnect negatim (ground) otol# from
battery before servicing any c®iymn component
CAUTION; Do not attempt to remove the pins to
disassemble the tilting frochinlsift. Pamag© will occyr.
SERVICE PROCEDURES
To service the steering wheel or air bag, refer to
Group 8M, Restraint Systems. Follow all WARNINGS.
To service the switches, refer to the appropriate
section of Group 8, Electrical.
To replace the steering column assembly, refer to
Fig. 1.
TEM INSTALLATION OR REMOVAL PROCEDURES.
REMOVE AND ISOLATE THE NEGATIVE (-) BATTERY
CABLE (GROUND) FROM THE VEHICLE BATTERY.
THIS IS THE ONLY SURE WAY TO DISABLE THE AIR
BAG SYSTEM. FAILURE TO DO THIS COULD RE­
SULT IN ACCIDENTAL AIRBAG DEPLOYMENT AND
POSSIBLE PERSONAL INJURY.
STEERING COLUMN REMOVAL
(1) Make sure the front wheels are in the straight
ahead position.
(2) Disconnect the negative (ground) cable from the
battery.
(3) For vehicles equipped with a column shift, dis­
connect the link rod by prying it out of the grommet
in the shift lever (Fig.2).
 TOOL

Fig.2 Link Rod Removal From Grommet

(4) Remove the steering wheel center pad and dis­

connect electrical components such as horn leads and
speed control (if equipped) (Fig.3).

Fig.4 Removing Steering Wheel (Typical)

,___ _ MARK BREATHER
O O * TUBE LOCATION (6) Remove the upper coupling bolt retaining pin.
(7) Remove the nut and bolt from the upper cou­
BREATHER pling. Remove the upper coupling from the lower cou­
TUBE pling (Fig. 5)
STEERING CO LUMN
SNORKEL
CLAMP
- 6 VIEW IN CIRCLE 'A '
BOOT SEAL
BOOT CLAMP
(OUTER)
BOOT CLAMP (INNER) JAM NUT
USE LUBE HERE 9119-8

Flg.3 Horn Pad Removal (Typical)

(5) Remove the steering wheel retaining nut. Re­

move steering wheel with tool C-3428-B (Fig.4). Do
not bump or hammer on steering column shaft to
remove wheel.

9119-12
 (8) For column shift vehicles, place shift lever in KEY-IN SWITCH & MULTIFUNCTION
down position (PRNDL position 1) and remove PRNDL HALO LIGHT SWITCH
driver cable (Fig.6). Move lever back to UP position.

TURN SIGNAL
SWITCH & LEVER

IGNITION SPEED
SW I TCH CONTROL J918J-2

Flg.8 Steering Column Wiring

(14) Loosen the upper Support Bracket nuts to allow

some slack. This will aid in removal of the upper fixed
shroud.
(15) Remove the upper fixed shroud. Remove the
wiring harness from the column by prying out the
plastic retainer buttons (Fig.7).
(16) Remove the lower dash panel and support
bracket standoff fasteners (Fig.l).
(17) Remove the column out through the passenger
compartment. Use care to avoid damaging the paint
(10) Remove tilt lever (if equipped) from column.
or trim.
(11) Remove the upper and lower lock housing shroud
(Fig. 1). Remove the lower fixed shroud. The shroud
fasteners are Torx-head screws.
COLUMN INSTALLATION
(12) Remove the turn signal multi-function switch
(1) For column shift vehicles, install a replacement
with a 7mm socket (fig.T).
grommet from the rod side of the lever. Use pliers
and a back-up washer to snap the grommet into place
(Fig.9). Use MOPAR Multipurpose Lubricant, or equiv­
alent, to aid installation of the grommet. A replace­
ment grommet should be used whenever the rod is
disconnected from the lever.

DIRECTION OF INSTALLATION
BACK-UP WASHER

Fig.7 Multi-function Switch Wiring

(13) Remove the electrical connections from Key-in

light, Main Ignition Switch, Hom connection or Clock
Spring (Speed Control) (Fig. 8).
 (2) Install the ground clip on the left capsule slot force the steering wheel onto the shaft by driving it
(Fig.10). The plastic capsules should be pre-assembled with a heavy object. Force it down onto the shaft
in the bracket slots. Remove the shipping lock pin
(located on lower column jacket) when installing a
new steering column. Insert the column through the
floor pan opening while being careful to avoid damag­
ing the paint and the trim.
with the retaining nut.
(14) For column shift vehicles, connect the shift link
rod to the transmission shift lever. The grommet must
be installed in the lever before the rod is inserted
into the grommet. Use MOPAR Multipurpose Lubri­
cant, or an equivalent product, to aid the installation.
(15) Re-adjust the transmission shift linkage. When­
ever the steering column is loosened or removed,
the shift linkage must be adjusted and tested. Refer
to Group 21—Transmission for the shift linkage
adjustment.
(16) Slowly move the gear shift selector lever from 1
or L (low) to P (PARK) while pausing briefly at each
selector position. The indicator pointer must align with
each indicator position (P,R,N,D, and L or 1,2,3).
(17) Connect the battery ground (negative) cable.
Test the operation of the lights and horns. If applica­
ble, reset the clock and radio.

COLUMN COMPONENT SERVICE

The Acustar tilt and standard columns (Fig.l) have
Fig.10 Ground Clip & Spacer Installation been designed to be serviced as an assembly; less
wiring, switches, shrouds, steering wheel, etc. Also
(3) Position the steering column with the bracket
most steering column components can be serviced with­
slots on the attaching studs. Install, but loose assemble
out removing the column from the vehicle. For addi­
the two upper bracket washers and nuts.
tional information on electrical components refer to
(4) Make sure the front wheels are in the straight­
Group 8H Electrical.
ahead position. Align the upper and lower coupling.
(1) The gear shift lever (if equipped) can be ser­
Install the coupler retaining bolt and nut, torque to 28
viced. Use a drift and a suitable size socket to drive
N-m (250 in. lbs.). Be sure to install the upper cou­
out the pin (Fig. 11).
pling bolt retention pin (Fig.5).
(5) Clip the wiring harness on the steering column. HAMMER
Connect the multi-function switch wiring and tighten
with 7mm socket (Fig.7).
(6) Install the upper fixed shroud.
(7) Be sure both breakaway capsules are fully seated
in the slots in the column support bracket. Tighten
the two upper bracket nuts with 12 N-m (105 in. lbs.)
torque.
(8) Complete the wiring connections to the column
(Fig.8). Install the lower fixed shroud.
(10) For column shift vehicles, place shift lever in
DOWN position (PRNDL position 1). Install the PRNDL
driver cable and place lever in PARK (up) position
(Fig.6).
(11) Install the lock housing shrouds. The shroud
fasteners are Torx-head screws. Install the tilt lever
(if equipped). Fig.11 Gear Shift Removal
(12) Install the lower dash panel cover.
(13) For steering wheel installation with speed con­ (2) The PRNDL driver can be removed by drilling
trol refer to Group 8 Electrical. For non-speed control, out the rivets (Fig.12). Use care from bending when
place the steering wheel on the steering column shaft installing a new driver. Use the correct replacement
with the master splines aligned. Install the retaining rivets and install with a hand rivet gun (Fig. 13).
nut and tighten to 61 N-m (45 ft. lbs.) torque. Do not
PRNDL DRILL DRILL MOTOR C DO NOT REMOVE RETAINER
DRIVER

9019-6
Fig.12 Remove PRNDL Driver Rivets
GEARSHIFT IGNITION SWITCH
LEVER
TEST AND REPAIR
If the ignition switch effort seems to be excessive
due to binding. Follow the procedure outlined below to
determine the cause.
(1) Remove the ignition switch from the steering
column. Refer to Group 8H Electrical.
(2) Using a key cylinder, check the turning effort of
the switch.
• If the ignition switch binds look for the following
conditions.
(1) Look for rough areas or flash in the casting and
if found remove with a file.
RIVET 9019-4 (2) Remove the link and slider.
(3) Check the link to see if it has been bent and if so
Fig.13 Install PRNDL Driver Rivets replace with a new part.
Put the slider in its slot in the sleeve and verify a
OBSERVE CAUTIONS loose fit over the length of the slot. If the slider binds
in the slot at any point lightly file the slider until
CAUTION: DO NOT REMOVE
IGNITION LOCKING LI NK clearance is achieved.
• If no binding is found.
Lightly file the ramp on the ignition switch, (The
ramp fits into the casting) until binding no longer
occurs.

CAUTION: NEVER
REMOVE SHAFT
LOCK PLATE

9019-5
 SPECIFICATIONS AND TIGHTENING REFERENCE
TORQUE SPECIFICATIONS

Apply silicone grease to tie rod bellows to prevent rotation of the bellows.

TORQUE SPECIFICATIONS NEWTON METERS FOOT POUNDS

Steering Gear-To-Crossmember Bolts 68 50

Tie Rod End N u t............................... 52 38
Tie Rod End Lock N ut........................ 75 55

POWER STEERING HOSES

TORQUE SPECIFICATIONS NEWTON METERS FOOT POUNDS

Pressure Hose Tube Nuts.................................... 34 25

Return Tube Nut ................................................ 34 25
Pressure Hose Locating Bracket at Crossmember 23 17
Return Tube Locating Bracket at Crossmember ... 28 21
Pressure Hose Banjo Bolt.................................... 34 25

POWER STEERING PUMP

TORQUE SPECIFICATIONS NEWTON METERS FOOT POUNDS

Discharge Fitting (Saginaw). 75 55

Discharge Fitting (ZF).......... 50 37
Bracket Mounting Fasteners
M-10 Stud .......................... 48 35
M-10 Bolt and Nut.............. 40 30
M-8 Bolts............................ 28 21

STEERING COLUMN

TORQUE SPECIFICATION S NEWTON METERS FOOT POUNDS

Steering Wheel-to-Steering Shaft N ut. 61 45

INCH POUNDS

Column Clamp Stud...... 2 20

Column Clamp Stud Nut. 12 105
Column Clamp Bolt....... 12 105

POWER STEERING PUMP SPECIFICATIONS

Output Flow at 1500 rpm and Minimum Pressure........................................ ................... 6.4 Liters/Min. (1.7 gpm)
Pressure Relief................................................................................................ .8100 to 8450 kPa (1175 to 1225 psi)
Power Steering Oil Return Hose Length......................................................... ............................. 280mm (11 inches)
IF RETURN HOSE IS REPLACED, USE ONLY HYPALON OR CPE MATERIAL.
 TRANSAXLE
CONTENTS
Page
A-413 AND A-670 THREE SPEED TORQUEFLITE
AUTOMATIC TRANSAXLE ..................... 1 (A -6 0 4 )
A-413 AND A-670 TORQUEFLITE DIAGNOSIS
AND TESTS ........................................ 3 (A-413/A-670) .....................................
A @04 ULTRADRIVE 4-SPEED ELECTRONIC
AUTOMATIC TRANSAXLE ..................... 63
A-604 ULTRADRIVE DIAGNOSIS
AND TESTS ........................................ 66
ALL WHEEL DRIVE POWER TRANSFER
UNIT (P .T .U .)...................................... 135
BEARING ADJUSTMENT PROCEDURE
(A-604) ............................................. 132
BEARING ADJUSTMENT PROCEDURES
(A-413/A-670) ..................................... 60
A -413 AND A-670 THREE SPEED TORQUEFLITE AUTOMATIC TRANSAXLE
Page
General Information ........................................................
Hydraulic Control S ystem ................................................
GENERAL INFORMATION
The A-413 transaxle is used on vehicles with four
cylinder engines. The A-670 transaxle is designed for
V -6 applications. Both transaxles use the same ser­
vice procedures.
Safety goggles should be worn at all times when
working on these transaxles.
This transaxle combines a torque converter, fully
automatic three speed transmission, final drive gear­
ing, and differential into a compact front-wheel-drive
system. The unit is basically a "Metric” design. The
identification markings and usage of the transaxle
are charted in Diagnosis and Tests.
Transaxle operation requirements are different for
each vehicle and engine combination and some in­
ternal parts will be different to provide for this. There­
fore, when replacing parts, refer to the seven digit
part number stamped on rear of the transaxle oil pan
flange.
Within this transaxle, there are three primary areas:
(1) Main center line plus valve body.
(2) Transfer shaft center line (includes governor and
parking sprag).
(3) Differential center line. Center distances between
the main rotating parts in these 3 areas are held
precisely to maintain a low noise level through smooth
accurate mesh of the gears connecting the center lines.
The torque converter, transaxle area, and differen-
Page
MAINTENANCE AND ADJUSTMENTS
. 89
MAINTENANCE AND ADJUSTMENTS
21
POWER TRANSFER UNIT SERVICE
PROCEDURES ..................................... 136
SERVICE IN VEHICLE (A-413/A-670) ......... 24
SERVICE OUT OF VEHICLE (A413/A-670) . . . 25
SERVICE IN VEHICLE (A-604) ................... 90
SERVICE OUT OF VEHICLE (A-604) .......... 91
SPECIFICATIONS ..................................... 153
INDEX
Page
1 Operating Instructions ............................................... 2
2
tial are housed in an integral aluminum die casting.
The “differential oil sump” is common with the
“transaxle sump.” Separate filling of the differential
is NOT necessary.
The torque converter is attached to the crankshaft
through a flexible driving plate. Cooling of the con­
verter is accomplished by circulating the transaxle
fluid through an oil-to-water type cooler located in the
radiator side tank and/or an oil-to air heat exchanger.
The torque converter assembly is a sealed unit that
cannot be disassembled.
The transaxle fluid is filtered by an internal filter
attached to the lower side of the valvebody assembly.
Engine torque is transmitted to the torque converter
then, through the input shaft to multiple-disc clutches
in the transaxle. The power flow depends on the appli­
cation of the clutches and bands. Refer to "Elements
in Use Chart” in Diagnosis and Tests section. The
transaxle consists of two multiple-disc clutches, an
overrunning clutch, two servos, a hydraulic accumula­
tor, two bands, and two planetary gear sets. This
provides three forward ratios and a reverse ratio. The
common sun gear of the planetary gear sets is con­
nected to the front clutch by a driving shell. The drive
shell is splined to the sun gear and to the front clutch
retainer. The hydraulic system consists of an oil pump,
and a single valve body which contains all of the
valves except the governor valves. The transaxle sump
and differential sump are both vented through the
“dipstick”. Output torque from the main center line is
delivered through helical gears to the "transfershaft.”
This gear set is a factor of the final drive (axle) ratio.
The shaft also carries the governor and parking sprag.
An integral helical gear on the transfer shaft drives
the differential ring gear. The final drive gearing is
completed with one of three gear sets producing over­
all top gear ratios of 2.78, 3.02, or 8.22 depending on
model and application.
lo c k u p Tom m e co nverter
The lockup torque converter is standard on all vehi­
cles. The lockup mode is activated only in direct drive
and is controlled by the engine electronics. A lockup
solenoid on the valve body, is powered by the engine
controller to activate torque converter lockup.
HYDRAULIC CONTROL SYSTEM
The hydraulic control circuits show the position of
the various valves with color coded passages to indi­
cate those under hydraulic pressure for all operations
of the transaxle.
The hydraulic control system makes the transaxle
fully automatic, and has four important functions to
perform. In a general way, the components of any
automatic control system may be grouped into the
following basic groups:
The pressure supply system, the pressure regulat­
ing valves, the flow control valves, the clutches, and
band servos.
Taking each of these basic groups o r. systems in
turn, the control system may be described as follows:
PRESSURE SUPPLY SYSTEM
The pressure supply system consists of an oil pump
driven by the engine through the torque converter.
The single pump furnishes pressure for all the hy­
draulic and lubrication requirements. Oil pump hous­
ing assem blies are available w ith preselected pymp
gears.
P R E S S U R E R E G U L A T IN G V A L V E S
The pressure regulating valve controls line pressure
dependent on throttle opening. The governor valve
transmits regulated pressure to the valve body (in
conjunction with vehicle speed) to control upshift and
downshift.
The throttle valve transm its regulated pressure to
the transaxle (dependent on throttle position) to con­
trol upshift and downshift.
PLOW C O N T R O L V A L V E S
The manual valve provides the different transaxle
drive ranges as selected by the vehicle operator.
The 1-2 shift valve automatically shifts the transaxle
from first to second or from second to first, depending
on the vehicle operation.
The 2-3 shift valve automatically shifts the transaxle
from second to third or from third to second depending
on the vehicle operation.
The kickdown valve makes possible a forced down­
shift from third to second, second to first, or third to
first (depending on vehicle speed) when depressing
the accelerator pedal past the detent "feel” near wide
open throttle.
The shuttle valve has two separate functions and
performs each independently of the'other. The first is
that of providing fast release of the kickdown band,
and smooth front clutch engagement when the driver
makes a "lift-foot” upshift from second to third. The
second function of the shuttle valve is to regulate the
application of the kickdown servo and band when mak­
ing third to second kickdowns.
The by-pass valve provides for smooth application of
the kickdown band on 1-2 upshifts.
The lockup solenoid allows for the electronic control
of the lockup clutch inside the torque converter. Elec­
tronic control of the torque converter lockup includes
unlocking the torque converter at closed throttle,
during engine warm-up, and during part-throttle
acceleration.
The switch valve directs oil to apply the lockup
clutch in one position and releases the lockup clutch
in the other position.
CLUTCHESf BAND SERVOS,
AND ACCUMULATOR
The front and rear clutch pistons, and both servo
pistons are moved hydraulically to engage the clutches
and apply the bands. The pistons are released by spring
tension when hydraulic pressure is released. On the
2-3 upshift, the kickdown servo piston is released by
spring tension and hydraulic pressure.
The accumulator controls the hydraulic pressure on
the apply side of the kickdown servo during the 1-2
upshift; thereby, cushioning the kickdown band appli­
cation at any throttle position.
0PERIT1NS INSTRUCTIONS
The transaxle will automatically upshift and down­
shift. All shift speeds may vary somewhat due to pro­
duction tolerances. The quality of the shifts is very
important; all shifts should be smooth and positive
with no noticeable engine runaway.
G E A R S H I F T A N D P A R K IN G L O C K C O N T R O L S
The transaxle is controlled by a ”lever type” gear­
shift incorporated within the steering column. The
control has six selector lever positions: P (park), R
(reverse), N (neutral), and D (drive), 2 (second), and 1
(first). The parking lock is applied by moving the
selector lever past a gate to the "P” position. Do not
apply the parking lock u ntil the wehicl© has stopped;
otherwiae, a smere ratcheting noise will occur.
STARTING THE ENGINE
The engine will start with the selector lever in
either the P (park) or N (neutral) positions. As a
safety precaution when starting in the N (neutral)
position, apply the parking or foot brake. The Torque-
Flite transaxle will not permit starting the engine by
pushing or towing the vehicle.
MOUNTAIN DRIVING
When driving in the mountains with either heavy
A-413 AND A-670 TORQUEFLITE DIAGNOSIS AND TESTS
Page
Clutch and Servo Air Pressure Tests ......................
Diagnosis General ....................................................
DIAGNOSIS— GENERAL
Automatic transaxle malfunctions may be caused
by four general conditions:
(1) Poor engine performance
(2) Improper adjustments
(3) Hydraulic malfunctions
(4) Mechanical malfunctions
Diagnosis of these problems should always begin by
checking the easily accessible variables: fluid level
and condition, gearshift cable adjustment, and throt­
tle pressure cable adjustment. Then perform a road
test to determine if the problem has been corrected or
that more diagnosis is necessary. If the problem exists
after the preliminary tests and corrections are com­
pleted, hydraulic pressure tests should be performed.
FLUID LEVEL AND CONDITION
The transmission and differential sump have a com­
mon oil sump with a communicating opening be­
tween the two.
Before removing the dipstick, wipe all dirt off of the
protective disc and the dipstick handle.
The torque converter fills in both the "P” Park and
"N” 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
least one minute, with the vehicle on level ground.
This will assure complete oil level stabilization be­
tween differential and transmission. The fluid should
be at normal operating temperature (approximately
82 C. or 180 F.). The fluid level is correct if it is in the
"HOT” region (cross-hatched area) on the dipstick.
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
loads or when pulling trailers, the 2 (second) or 1
(low) position should be selected on up hill grades
which require heavy throttle for 1/2 mile or more.
This reduces possibility of overheating the transaxle
and torque converter under these conditions.
TOWING VEHICLE
Refer to Lubrication and Maintenance, "Group 0”
for towing instructions.
INDEX
Page
15 Fluid Leakage—Transaxle ....................................... 16
3 Hydraulic Pressure Tests ......................................... 5
high. When the transaxle has too much fluid, the
gears chum up foam and cause the same conditions
which occur with a low fluid level.
In either case, the air bubbles can cause overheat­
ing, fluid oxidation, and varnishing, which can inter­
fere with normal valve, clutch, and servo operation.
Foaming can also result in fluid escaping from the
transaxle vent (dipstick handle) where it may be mis­
taken for a leak.
Along with fluid level, it is important to check the
condition of the fluid. When the fluid smells burned,
and is contaminated with metal or friction material
particles, a complete transaxle overhaul is needed. Be
sure to examine the fluid on the dipstick closely. If
there is any doubt about its condition, drain out a
sample for a double check.
After the fluid has been checked, seat the dipstick
fully to seal out water and dirt.
GEARSHIFT LINKAGE
Normal operation of the neutral safety switch pro­
vides a quick check to confirm proper manual linkage
adjustment.
Move the selector level slowly upward until it clicks
into the "P” Park notch in the selector gate. If the
starter will operate the "P” position is correct.
After checking "P” position move the selector slowly
toward "N” Neutral position until lever drops at the
end of the "N” stop in the selector gate. If the starter
will also operate at this point the gearshift linkage is
properly adjusted. If adjustment is required, refer to
"Gearshift Linkage Adjustment” in "Maintenance and
Adjustments”.
THROTTLE PRESSURE CABLE (4 CYL.)
OR LINKAGE (V-6)
The throttle pressure cable adjustment is very im­
portant to proper transaxle operation. This adjust­
ment positions a valve which controls shift speed,
shift quality, and part throttle downshift sensitivity.
If the setting is too long, early shifts and slippage
between shifts may occur. If the setting is too short,
shifts may be delayed and part throttle downshifts
may be very sensitive.
LOCKUP SOLENOID WIRING CONNECTOR
If wiring connector is unplugged, the torque con­
verter will not lock-up (Fig. 1).
LOCK-UP SOLENOID ELECTRICAL . NEUTRAL/PARK SAFETY
CO NNECTO R SWITCH
DIPSTICK HOLE RR14G33
Fig. 1 Lockup Solenoid Wiring Connector
ROAD TEST
Prior to performing a road test, be certain that the
fluid level and condition, and control cable adjust­
ments have been checked and approved.
During the road test, the transaxle should be oper­
ated in each position to check for slipping and any
variation in shifting.
If vehicle operates properly at highway speeds, but
has poor through-gear acceleration, the torque con­
verter stator overrunning clutch may be slipping. If
through-gear acceleration is normal, but abnormally
high throttle opening is required to maintain highway
speeds, the torque converter stator clutch may have
seized. Both of these stator defects require replace­
ment of the torque converter.
Observe closely for slipping or engine speed flare-up.
Slipping or flare-up in any gear usually indicates clutch,
band, or overrunning clutch problems. If the condition
is far advanced, an overhaul will probably be neces­
sary to restore normal operation.
In most cases, the clutch or band that is slipping
can be determined by noting the transaxle operation
in all selector positions and by comparing which inter­
nal units are applied in those positions. The "Ele­
ments in Use Chart” provides a basis for road test
analysis.

ELEMENTS IN USE AT EACH POSITION OF THE SELECTOR LEVER

Lever Start Parking Front Rear Lockup Over­ (Kickdown) (Low-Rev.)

Position Safety Sprag running Front Rear
P - PARK X X
R - REVERSE X X
N -N E U TR A L X
D - DRIVE:
First X X
Second X X
Third X X X
2 - SECOND:
First X X
Second X X
1 - LOW (First) X X
9121-183

The rear clutch is applied in both the "D” first gear
and "1” first gear positions. Also the overrunning clutch
is applied in "D” first gear and the low/reverse band is
applied in "1” first gear position. If the transaxle slips
in "D” range first gear, but does not slip in "1” first
gear, the overrunning clutch is slipping. Similarly, if
the transaxle slips in any two forward gears, the rear
clutch is slipping.
Using the same procedure, the rear clutch and front
clutch are applied in "D” third gear. If the transaxle
slips in third gear, either the front clutch or the rear
clutch is slipping. By selecting another gear which
does not use one of those units, the unit which is
slipping can be determined. If the transaxle also slips
in reverse, the front clutch is slipping. If the transaxle
does not slip in reverse, the rear clutch is slipping.
The process of eliminating can be used to detect any
unit which slips and to confirm proper operation of
good units. However, although road test analysis can
usually diagnose slipping units, the actual cause of
the malfunction usually cannot be decided. Practically
any condition can be caused by leaking hydraulic cir­
cuits or sticking valves.
Therefore, unless the condition is obvious, like no
 ACCUMULATOR MANUAL THROTTLE
VENT LEVER SHAFT

MANUAL SHIFT
LEVER SHAFT

LOW-REVERSE
PRESSURE

GOVERNOR
PRESSURE
(BELOW
DIFFERENTIAL
COVER ON
RIGHT SIDE)

KICKDOWN
APPLY

KICKDOWN
RELEASE
(FRONT CLUTCH) LINE PRESSURE
TO COOLER

KICKDOWN APPLY
AT ACCUMULATOR PR214SC

Fig. 2 Transaxle (le ft Side)

drive in "D” range first gear only, the transaxle should
never be disassembled until hydraulic pressure tests
have been performed.
HYDRAULIC PRESSURE TESTS
Pressure testing is a very important step in the
diagnostic procedure. These tests usually reveal the
cause of most transaxle problems.
Before performing pressure tests, be certain that
fluid level and condition, and control cable adjust­
ments have been checked and approved. Fluid must
be at operating temperature (150 to 200 degrees F.).
Install an engine tachometer, raise vehicle on hoist
which allows front wheels to turn, and position ta­
chometer so it can be read.
Disconnect throttle cable and shift cable from trans­
axle levers so they can be controlled from outside the
vehicle.
Attach 150 psi gauges to ports required for test
being conducted. A 300 psi gauge (C-3293) is required
for "reverse” pressure test at rear servo.
Test port locations are shown in (Fig. 2).
TEST ONE (SELECTOR IN u1m§
(1) Attach gauges to wline” and "low-reverse” ports
(Fig. 2).
(2) Operate engine at 1000 rpm for test.
(3) Move selector lever on transaxle all the way
rearward ("1” position).
(4) Read pressures on both gauges as throttle lever
on transaxle is moved from M l clockwise position to
full counterclockwise position.
(5) Line pressure should read 52 to 58 psi with
throttle lever clockwise and ■ gradually increase, as
lever is moved counterclockwise, to 80 to 88 psi.
(8) Low-reverse pressure-should read the same as
line pressure within 3 psi.
(7) This tests pump output, pressure regulation, and
condition of rear clutch and rear servo hydraulic
circuits.
TEST TWO (SELECTOR IN m2ml
(1) Attach one gauge to "line pressure” port and
"tee” another gauge into lower cooler line fitting to
read "lubrication” pressure (Fig 2).
(2) Operate engine at 1000 rpm for test.
 (3) Move selector lever on transaxle one "detent”
forward from full rearward position. This is selector
"2” position.
(4) Read pressures on both gauges as throttle lever
on transaxle is moved from full clockwise position to
full counterclockwise position.
(5) Line pressure should read 52 to 58 psi with
throttle lev er'clockwise and gradually increase, as
lever is moved counterclockwise, to 80 to 88 psi.
(6) Lubrication pressure should be 10 to 25 psi with
lever clockwise and 10 to 35 psi with lever full
counterclockwise.
(7) This tests pump output, pressure regulation, and
condition of rear clutch and lubrication hydraulic
circuits. ' ,
TEST THREE (SELECTOR IN mDm)
, (1) Attach gauges to "line” and "kickdown release”
ports ;(Fig. 2 ).
: (2) Operate engine at 1600 rpm for test.
(3) Move selector lever on transaxle two "detents”
forward from full rearward position. This is selector
"D” position.
(4) Read pressures on both gauges as throttle lever
on transaxle is moved from full clockwise position to
full counterclockwise position.
(5) Line pressure should read 52 to 58 psi with
throttle lever clockwise and gradually increase, as
lever is moved counterclockwise to 80 to 88 psi.
(6) Kickdown release is pressurized only in direct
drive and should be same as line pressure within 3
psi, up to kickdown point.
(7) This tests pump output, pressure regulation, and
condition of rear clutch, front clutch, and hydraulic
circuits.
TEST F O U R (SELECTOR IN REVERSE)
(1) Attach 300 psi gauge to "low-reverse” port (Fig.
2).
■ -(2)-Operate .engine at 1800 rpm for test.
k (3) Move selector lever on transaxle four "detents”
forward from full rearward position. This is selector incorrect (low) throttle pressure setting, or misadjusted
WR” position. throttle cable.
(4) Low-reverse pressure should read 180 to 220 psi
with throttle lever clockwise and gradually increase, the transaxle throttle cable adjustment has been veri­
as lever is moved counterclockwise to 260 to 300 psi. fied to be correct.
(5) This tests pump output, pressure regulation, and
condition of front clutch and rear servo hydraulic
circuits.
(6) Move selector lever on transaxle to "D” position
to check that low-reverse pressure drops to zero.
(7) This tests for leakage into rear servo, due to case
porosity, which can cause reverse band bum out.
T E S T R E S U L T IN D IC A T IO N S
(1) If proper line pressure, minimum to maximum,
is found in any one test, the pump and pressure regu­
lator are working properly.
(2) Low pressure in W D, 1» and 2” but correct pres­
sure in "R” indicates rear clutch circuit leakage.
(3) Low pressure in "D and R” but correct pressure
in wl windicates front clutch circuit leakage.
(4) Low pressure in "R and 1” but correct pressure
in n2n indicates rear servo circuit leakage.
(5) Low line pressure in all positions indicates a
defective pump, a clogged filter, or a stuck pressure
regulator valve.
GO W EM NOM P R E S S U R E
Test only if transaxle shifts at wrong vehicle speeds
when throttle cable is correctly adjusted.
(1) Connect a 0-150 psi pressure gauge to governor
pressure take-off point, located at lower right side of
case, below differential cover (Fig. 2).
(2) Operate transaxle in third gear to read pressures.
The governor pressure should respond smoothly to
changes in mph and should return to 0 to 3 psi when
vehicle is stopped. High pressure at standstill (above
3 psi) will prevent the transaxle from downshifting.
THROTTLE PRESSURE
No gauge port is provided for throttle pressure. In­
correct throttle pressure should only be suspected if
part throttle upshift speeds are either delayed or oc­
cur too early in relation to vehicle speeds, with cor­
rectly adjusted throttle cable. Engine runaway on either
upshifts or downshifts can also be an indicator of
In no case should throttle pressure be adjusted until
 TRANSAXLE
LINE 68 PS'

PUMP SUCTION |7v"3

THROTTLE 30 PSI

PUMP GOVERNOR 0-68 PSi

21-7
9121-203 OIL FILTER DRIVE (FIRST) HALF THROTTLE
 21-8
SERVO

TRANSAXLE
ACCUMULATOR

PUMP
9121-204 OIL FILTER
 TRANSAXLE
PUMP

21-9
OIL FILTER
 21-10
a s ACCUMULATOR

TRANSAXLE
OIL FILTER
 TRANSAXLE
PUMP

21-11
9121-207 OIL FILTER
 21-12
ACCUMULATOR

TRANSAXLE
^ sn THROTTLE VALVE
To o o o o o o oH

” 0 0 0 o“o
j k ~—~—
KICKDOWN VALVE A
51 *“ -----

-OIL PRESSURES-
LINE 55 CONVERT ER 5-55 PSi

pump suction r r i LUBRICATION 5^30 PSi

THROTT LE 0 PS! W 7 7 1

PUMP GOVERNOR 3-55 PSi ESI

OIL FILTER SECOND (MANUAL) CLOSED THROTTLE
9121-206
 OOVFRNOR

TRANSAXLE
21-13
9121-209 OIL FILTER
 21-14
GOVERNOR
ACCUMULATOR

TRANSAXLE
 PUMP PUMP FRONT REAR TO ■ FROM"
SUCTION PRESSURE CLUTCH CLUTCH TORQUE TORQUE
APPLY APPLY CONVERTER CONVERTER

GOVERNOR
PRESSURE
TO ■■■'■
z O i l COOLER

GOVERNOR
PRESSURE
PLUG KICKDOWN
SERVO'"' OFF

g |J KICKDOWN
SERVO ON

ACCUMULATOR
OFF
LINE PRESSURE
TO GOVERNOR

‘ACCUMULATOR
ON
LOW-REVERSE"
SERVO APPLY

PU142A

Fig. 3 Mir Pressure Tests

CLUTCH AND SERVO AIR PRESSURE TESTS re a r c im c n

A "no drive” condition might exist even with correct
fluid pressure, because of inoperative clutches or bands.
The inoperative units, clutches, bands, and servos can
be located through a series of tests by substituting air
pressure for fluid pressure (Fig. 8).
The front and rear clutches, kickdown servo, and
low-reverse servo may be tested by applying air pres­
sure to their respective passages after the valve body
assembly has been removed. To make air pressure
tests, proceed as follows:
Compressed air supply m yst be free o f all d irt or
m oisture. Use a pressure of 30 psi.
Remove oil pan'and valve body See "Disassembly-
Subassembly Removal”.
FRONT CLUTCH
Apply air pressure to front clutch "apply” passage
and listen for a dull "thud” which indicates that front
clutch is operating. Hold air pressure on for a few
seconds and inspect system for excessive oil leaks.
Apply air pressure to rear clutch "apply” passage
and listen for a dull "thud” which indicates that rear
clutch is operating. Also inspect for excessive oil leaks.
If a dull "thud” cannot be heard in the clutches, place
finger tips on clutch housing and again apply air
pressure. Movement of piston can be felt as the clutch
is applied.
KICKDOWN SERVO (FRONT)
Direct air pressure into front servo "apply” passage.
Operation of servo is indicated by a tightening of front
band. Spring tension on servo piston should release
the band.
LOW AND REVERSE SERVO (REAR)
Direct air pressure into rear servo "apply” passage.
Operation of servo is indicated by a tightening of rear
band. Spring tension on servo piston should release
the band. :
If clutches and servos operate properly , "no upshift”
or "erratic shift” conditions indicate that malfunctions
exist in the valve body.
FLUID LEAKAGE— TRANSAXLE indicates a torque converter leak. Oil leaking under
the probe is coming from the transaxle pump area.
TORQUE CONVERTER HOUSING AREA (7) Remove transaxle and torque converter assem­
bly from vehicle for further investigation.The fluid
(1) Check for Source of Leakage.
should be drained from the transaxle. Reinstall oil
Since fluid leakage at or around the torque con­
pan (with RTV sealant) at specified torque.
verter area may originate from an engine oil leak, the
Possible sources of transaxle torque converter area
area should be examined closely. Factory fill fluid is
fluid leakage are:
dyed red and, therefore, can be distinguished from
(1) Torque converter hub seal.
engine oil.
(a) Seal lip cut, check torque converter hub finish.
(2) Prior to removing the transaxle, perform the
(b) Bushing moved and/or worn.
following checks:
(c) Oil return hole in pump housing plugged or
When leakage is determined to originate from the
omitted.
transaxle, check fluid level prior to removal of the
(d) Seal worn out (high-mileage vehicles).
transaxle and torque converter.
(2) Fluid leakage at the outside diameter from pump
High oil level can result in oil leakage out the vent
housing O-ring.
in the dipstick. If the fluid level is high, adjust to
(3) Fluid leakage at the pump to case bolts. Check
proper level.
condition of washers on bolts and use new bolts if
After performing this operation, inspect for leakage.
necessary.
If a leak persists, perform the following operation on
(4) Fluid leakage due to case or pump housing
the vehicle to determine if it is the torque converter or
porosity.
transaxle that is leaking.
TORQUE CONVERTER LEAKAGE
LEAKAQE T E ST PROBE Possible sources of torque converter leakage are:
(1) Remove torque converter housing dust shield.
(a) Torque converter weld leaks at the outside
(2) Clean the inside of torque converter housing
diameter (peripheral) weld.
(lower area) as dry as possible. A solvent spray fol­
(b) Torque converter hub weld.
lowed by compressed air drying is preferable.
(c) Torque converter impeller shell cracked adja­
(3) Fabricate and fasten test probe (Fig. 4) securely
cent to hub.
to convenient dust shield bolt hole. Make certain torque
(d) At drive lug welds.
converter is cleared by test probe. Tool must be clean
Hub weld is inside and not visible. Do not attempt
and dry.
to repair. Replace torque converter.

AIR PRESSURE TE ST OF TRANSAXLE

Fabricate equipment needed for test as shown in
figures 8 and 9.

WELD BREAK EDGE 1/16" MIN.

DUST MATERIAL: 5 " x l-l/2 " x

SHIELD 1/ 32" SHEET METAL
BOLT RY287

Fig. 4 Leak Locating Test Probe Tool

ON TUBE
MATERIAL: 1-1/2 INCH O.D. THIN
(4) Run engine at approximately 2,500 rpm with WALLED STEEL TUBING AND
transaxle in neutral, for about 2 minutes. Transaxle 1/8 INCH STEEL DISC RN780
must be at operating temperature.
(5) Stop engine and carefully remove tool.
(6) If upper surface of test probe is dry, there is no
torque converter leak. A path of fluid across probe

15/32" DRILL 2 HOLES
MATERIAL: 1/4" STEEL STOCK
1-1/4" WIDE RY288A
Fig. 9 Hub Seal Cup Retaining Strap
The transaxle should be prepared for pressure test
as follows after removal of the torque converter:
(1) Install a dipstick bore plug and plug oil cooler
line fitting (lower fitting).
(2) With rotary motion, install converter hub seal
cup over input shaft, and through the converter hub
seal until the cup bottoms against the pump gear
lugs. Before use, inspect hub seal cup (Fig. 8) for nicks
or burrs that could damage seal. Secure with cup
retainer strap (Fig. 9) using starter upper hole and
opposite bracket hole.
(3) Attach and clamp hose from nozzle of Tool C-4080
to the upper cooler line fitting position in case.
CAUTION: Do not, under any circumstances, pres­
surize a transaxle to more than 10 psi.
(4) Pressurize the transaxle using Tool C-4080 until
the pressure gauge reads 8 psi. Position transaxle so
that pump housing and case front may be covered
with soapy solution or water. Leaks are sometimes
caused by porosity in the case or pump housing.
If a leak source is located, that part and all associ­
ated seals, O-rings, and gaskets should be replaced
with new parts.
 VALVE BODY
SCREWS (16)

VALVE
PR2187B BODY

Fig. 3 Remove or Install Valve Body Screws Fig. 6 Remove or Install Throttle Shaft E-Clip
SEPARATOR PLATE ---------® — — @ - MANUAL VALVE LEVER WASHER

e ts
ao =e» = e B e® ®
*e •• ® ©1
H ° B ©J
»a a 0 0 |^r— — .i

TRANSFER PLATE OIL SCREEN VALVE BODY

L

RB712 \ 'fflfp ]

Fig. 4 Transfer Plate and Separator Plate Fig. 7 Throttle Shaft E-Clip, Washer, and Seal

THROTTLE
VALVE LEVER ASSEMBLY

MANUAL VALVE
LEVER ASSEMBLY

STEEL BALLS * VALVE BODY PR2192

DIAGNOSIS GUIDE-ABNORMAL NOISE
 DIAGNOSIS GUIDE—VEHICLE WILL NOT MOVE

DIAGNOSIS GUIDE-VEHICLE WILL NOT MOVE

DIAGNOSIS GUIDE-FLUID LEAKS

DIAGNOSIS GUIDE-FLUID LEAKS

VISUALLY INSPECT FOR SOURCE Of LEAK. If
THE SOURCE Of LEAK CANNOT BE READILY
DETERMINED, CLEAN THE EXTERIOR OF THE
TRANSAXLE. CHECK TRANSAXLE FLUID
LEVEL CORRECT IF NECESSARY.
□C X,
THE FOLLOWING LEAKS MAY BE CORRECTED THE FOLLOWING LEAKS REQUIRE REMOVAL
WITHOUT REMOVING THE TRANSAXLE; Of THE TRANSAXLE AND TORQUE
MANUAL LEVER SHAFT OIL SEAL CONVEiJEt FOR CORRECTION.
PRESSURE GAUGE PLUGS TRANSAXLE FLUID LEAKING FROM THE
NEUTRAL START SWITCH LOWER EDGE OF THE CONVERTER HOUSING;
OIL PAN RIV CAUSED BY FRONT PUMP SEAL, PUMP TO
OIL COOLER FITTINGS CASE SEAL, OR TORQUE CONVERTER WELD.
EXTENSION HOUSING TO CASE BOLTS CRACKED O i POROUS
. SPEEDOMETER ADAPTER "O" RING .TRANSAXLE CASE.
FRONT BAND ADJUSTING SCREW
EXTENSION HOUSING AXLE SEAL
DIFFERENTIAL BEARING RETAINE1 AXLE SEAL
REAR END COVER RIV
DIFFERENTIAL COVER RIV
EXTENSION HOUSING ##0" RING
DIFFERENTIAL BEARING RETAINER RIV
HARSH ENGAGEMENT
FROM NEUTRAL TOD 1 X X X X
R 1 1 1 X X X X
DELAYED ENGAGEMENT
FROM NEUTRAL TOD 1 X X X X X X X X X
R X I 1 X X X X X X X X X X X
RUNAWAY UPSHIFT X I X X X X X X X
NO UPSHIFT X X X X X X X X X X X
3-2 KICKDOWN RUNAWAY X X X X X X X X X
NO KICKDOWN OR NORMAL X X X X
DOWNSHIFT
SHIFTS ERRATIC X X X X X X X X X X X X X X
SLIPS IN FORWARD DRIVE
1 X X X X X X X X X X X
POSITIONS
SUPS IN REVERSE ONLY X X 1 X X X X X X X X
SUPS IN ALL POSITIONS I X X X X X X
NO DRIVE IN ANY POSITION X X X X X X
NO DRIVE IN FORWARD
X X X X X X X X
DRIVE POSITIONS
NO DRIVE IN REVERSE I 1 X X X X X X X
DRIVES IN NEUTRAL X X X X X
DRAGS Oft LOCKS 1 X X X
GRATING, SCRAPING
1 X X X X
GROWLING NOISE
IUZZ1NG NOISE X X X X
HARD TO FILL, OIL 1LOWS
X 1 1
OUT FILLER HOLE
TRANSAXLE OVERHEATS X X X X X X X X X
HARSH-UPSHIFT 1 X X X X
DELAYED UPSHIFT X X X X X X X X
NO LOCKUP X X X 1 X X X
 MAINTENANCE AND ADJUSTMENTS (A-413/A-670)
INDEX
Page Page
Band Adjustment .......................................................... 22 Lubrication......................................................................
Gearshift Linkage A djustm ent..................................... 21 Throttle Pressure Cable (Rod) Adjustment .............. 22
Hydraulic Control Pressure Adjustments ................... 23

LUBRICATION (5) Pour four quarts of MO PAH ATi' PLUS (Auto­

Inspect fluid level on dipstick every six months (Fig.
1) with engine idling and transaxle in park or neutral
position. Allow the engine to idle for at least one
minute with vehicle on level ground. This will assure
complete oil level stabilization between differential
and transmission. A properly filled transaxle will read
near the "add” mark when fluid temperature is 21
degrees Celsius (70 degrees Fahrenheit). When the
transaxle reaches operating temperature the fluid
should be in the "HOT” region.
matic Transmission Fluid) Type 7176 through the dip­
stick opening.
(6) Start engine and allow to idle for at least one
minute. Then, with parking and service brakes ap­
plied, move selector lever momentarily to each posi­
tion, ending in the park or neutral position.
(7) Add sufficient fluid to bring level to l/8inch
below the ADD mark.
Recheck fluid level after transax le is at normal op­
erating temperature. The level should be in the HOT
region (Fig. 1).

FLUID AND FILTER CHANGES

Fluid and filter changes or band adjustments are
not required for average passenger vehicle usage.
Severe usage as defined below, requires that fluid
and filter be changed, the magnet on the inside of the
transaxle pan be cleaned and bands adjusted every
24000 km (15,000 miles).
(a) More than 50% operation in heavy city traffic
during hot weather above 32 C (90 F.).
(b) Police, Taxi, Commercial Type Operation, and
Trailer Towing.
When the factory fill fluid is changed as recom­
mended above, only fluids of the type labeled MOPAR
ATF PLUS (Automatic Transmission fluid) Type 7176
should be used. A band adjustment and filter change PR2Q82D
should be made at the time of the oil change. The
magnet (on the inside of the oil pan) should be Fig. 1 Dipstick and Trmsaxle Vent
cleaned with a clean, dry cloth.
To prevent dirt from entering transaxle, make cer­
If the transaxle is disassembled for any reason, tain that dipstick is full seated into the dipstick
the fluid and filter should be changed, and the band(s)
opening.
adjusted.
GEARSHIFT LINKAGE ADJUSTMENT
DRAIN AND REFILL
(1) Raise vehicle on a hoist (See Lubrication,"Group
When It is necessary to disassemble linkage cable
0”). Place a drain container with a large opening,
from levers, which use plastic grommetfi as retain­
under transaxle oil pan.
ers, the grommets should be replaced with new
(2) Lposen pan bolts and tap the pan at one corner
grommets. Use a prying tool to force rod from grom-
to break it loose allowing fluid to drain, then remove
inet in lever, then cut away old grommet. Use pliers
the oil pan.
to snap new grommet into lever and rod into grommet.
(3) Install a new filter and gasket on bottom of the
valve body and tighten retaining screws to 5 N-m (40 CAUTION: Set parking brake.
inch-pounds).
(1) Place gearshift lever in "V ' ( PARK) position.
(4) Clean the oil pan and magnet. Reinstall pan
(2) Loosen clamp bolt on gearshift cable bracket.
using new RTV sealant. Tighten oil pan bolts to 19
(3) Column shift: Insure that preload adjustment
N-m (165 in. lbs.).
spring engages fork on transaxle bracket.
 (4) Pull the shift lever by hand all the way to the
front detent position (PARK) and tighten lock. Tighten
screw to 11 N*m (100 in. lbs.). Gearshift linkage should
now be properly adjusted.
(8) Check adjustment as follows:
(a) Detent position for neutral and drive should
be within limits of hand lever gate stops.
(b) Key start must occur only when shift lever is
in park or neutral positions.
(6) If console removal is required, disconnect bat­
tery ground cable. To remove button assembly, insert
a 1/18 inch diameter wire in hole in bottom of knob
and push up on wire. To remove knob retainer clip,
insert long-nose plier tips in clip holes, push down­
ward lightly and turn counterclockwise (action sim­
ilar to a light bulb socket). Pull knob straight up to
remove from gearshift lever. Proceed as outlined in
console removal,"Group 23”.
After console is back in place, install shift knob and
button by reversing the above procedure.
(7) All vehicles except AL-body: To remove button
assembly, completely remove knob attaching fasten­
ers. Pull knob "up” sharply. Proceed as outlined in
console removal, tfGroup 28.w
After console is back in place, install knob and
button by reversing the above procedure.
THROTTLE PRESSURE CABLE (ROD) ADJUSTMENT
With engine at operating temperature, adjust idle
speed of engine using a tachometer. Refer to "Fuel
System” Group 14 for idle speed Specifications and
adjustment.
CABLE ADJUSTMENT P R O C E D U R E (4 -C Y L .j
(1) Perform transaxle throttle pressure cable adjust­
ment while engine is at normal operating temperature.
(2) Loosen cable mounting bracket lock screw.
(3) Bracket should be positioned with both bracket
alignment tabs touching the transaxle cast surface.
Tighten lock screw to 12 N-m (105in. lbs.) see Figure
2.
(4) Release cross-lock on the cable assembly (pull
cross-lock upward) see Figure 2.
(5) To insure proper adjustment, the cable must be
free to slide all the way toward the engine, against its
stop, after the cross-lock is released.
(8) Move transaxle throttle control lever fully clock­
wise, against its internal stop, and press cross-lock
downward into locked position (Fig. 2).
(7) The adjustment is complete and transaxle throt­
tle cable backlash was automatically removed.
(8) Test cable freedom of. operation by moving the
transaxle throttle lever forward (counterclockwise) and
slowly release it to confirm it will return fully rear­
ward (clockwise).
(9) No lubrication is required for any component of
the throttle cable system.
R O D A D J U S T M E N T P R O C E D U R E (6 -C Y L .J
(1) Perform transaxle throttle pressure cable adjust­
ment while engine is at normal operating temperature.
(2) Loosen adjustment swivel lock screw.
(3) To insure proper adjustment, swivel must be free
to slide along flat end of throttle rod so that preload
spring action is not restricted. Disassemble and clean
or repair parts to assure free action, if necessary.
(4) Hold transaxle throttle lever firmly toward en­
gine, against its internal stop and tighten swivel lock
screw to 11 N-m (100 in. lbs.)
(5) The adjustment is finished and linkage back
lash was automatically removed by the preload spring.
(6 ) If lubrication is required see Lubrication,Group 0.
BAND ADJUSTMENT
K IC K D O W N B A N D ( F R O N T )
The kickdown band adjusting screw is located on
left side (top front) of the transaxle case.
(1) Loosen locknut and back off nut approximately
five turns. Test adjusting screw for free turning in the
transaxle case.
(2) Using wrench, Tool C-3880-A with adapter Tool
C-3705, tighten band adjusting screw to 5 N-m (47 to
50 in. lbs.). If adapter C-3705 is not used, tighten
adjusting screw to 8 N*m (72 in. lbs.) which is the true
torque.
(3) Back off adjusting screw the number of turns
listed in "Specifications”. Hold adjusting screw in this
position and tighten locknut to 47 N*m (35ft. lbs.)
LO W —R E V E R S E B A N D ( R E A R )
To adjust low-reverse band, proceed as follows:
(1) Loosen and back off locknut approximately 5
turns.
 (2) Using an inch-pound torque wrench, lighten ad­
justing screw to 5 N’m (41 in. lbs.) true torque.
(3) Back off adjusting screw the number of turns
listed under ^Specifications” in the rear of the Transaxle
Section in this service manual.
(4) Tighten locknut to 14 N-m (10 ft. lbs.).
HYiRAUUC CONTROL PRESSURE ADJUSTMENTS
LINE PRESSURE
An incorrect throttle pressure setting will cause
incorrect line pressure readings even though line pres­
sure adjustment is correct. Always inspect and correct
throttle pressure adjustment before adjusting the line
pressure.
The approximate adjustment for line pressure is
1-5/16 inches, measured from valve body to inner edge
of adjusting nut. However, due to manufacturing tol­
erances, the adjustment can be varied to obtain speci­
fied line pressure.
The adjusting screw may be turned with an Allen
wrench. One complete turn of adjusting screw changes
closed throttle line pressure approximately 1-2/3 psi.
Turning adjusting screw counterclockwise increases
pressure, and clockwise decreases pressure.
THROTTLE PMESSUHE
Throttle pressures cannot be tested accurately; there­
fore, the adjustment should be measured if a malfunc­
tion is evident. ,. ‘ .
(1) Insert gauge pin of Tool C-3763 between the
throttle lever cam and kickdown valve.
(2) By pushing in on tool, compress kickdown valve
against its spring so throttle valve is completely bot­
tomed inside the valve body.
(3) While compressing spring, turn throttle lever
stop screw with adapter 0 *4553. Turn until head of
screw touches throttle lever tang, with throttle lever
cam touching tool and throttle valve bottomed. Be
sure adjustment is made with spring fully compressed
and valve bottomed in the valve body.
 SERVICE IN VEHICLE (A-413/A-670)
Page
Aluminum Thread Repair . . . . . . . . . . . . . . . . . . . . . . .
General Information . . . . . . . . . . . . . . . . . . . . . . . . . . .
Governor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
GENERAL INFORMATION
Various transaxle components can be removed for
repairs without removing the transaxle from the vehi­
cle. The removal, reconditioning, and installation pro­
cedures for some of these components are covered here.
The valve body (see service out of vehicle) may be
serviced in the vehicle, as can the parking sprag,
governor assembly, and extension housing oil seal.
SPEEDOMETER PINION GEAR
When the distance sensor is removed for any rea­
son, a NEW O-ring must be installed on its outside
diameter.
REMOVAL AND INSTALLATION
(1) Remove speedometer cable (if so equipped).
(2) Remove harness connector from sensor. Make
sure weatherseal stays on harness connector.
(3) Remove bolt securing the distance sensor in the
extension housing.
(4) Carefully pull sensor and pinion gear assembly
out of extension housing.
(5) Remove pinion gear from sensor.
(8) To install, reverse the above procedure. Make
sure extension housing and sensor flange are clean
prior to installation. Always use a NEW sensor O-ring.
(7) Tighten securing bolt to 7 N*m (80 in, lbs.). Tighten
speedometer cable to 4 N*m (35 in. lbs.).
NEUTRAL STARING AND BACK-UP LAMP SWITCH
REPLACEMENT AND TEST
The neutral starting switch is the center terminal
of the 3 terminal switch. It provides ground for the
starter solenoid circuit through the selector lever in
only Park and Neutral positions.
(1) To test switch, remove wiring connector from
switch and test for continuity between center pin of
switch and transaxle case. Continuity should exist
only when transaxle is in Park or Neutral.
(2) Check gearshift cable adjustment before replac­
ing a switch which tests bad.
INDEX
Page
24 Neutral Starting and Back-Up Lamp Switch . . . . . . . . 24
24 Speedometer Pinion Gear . . . . . . . . . . . . . . . . . . . . . . 24
24
(3) Unscrew switch from transaxle case allowing
fluid to drain into a container. Move selector, lever to
Park and then to Neutral positions, and inspect to see
that the switch operating lever fingers are centered in
switch opening in the case.
(4) Screw the switch with a new seal into transaxle
case and tighten to 33 N*m (24 ft. lbs.). Retest switch
with the test lamp.
(5) Add fluid to transaxle to bring up to proper
level.
(6) The back-up lamp switch circuit is through the
two outside terminals of the 3 terminal switch.
(7) To test switch, remove wiring connector from
switch and test for continuity between the two outside
pins.
(8) Continuity should exist only with transaxle in
Reverse position.
(9) No continuity should exist from either pin to the
case.
GOVERNOR
To service the governor assembly in the vehicle, it
is not necessary to remove the transfer gear cover,
transfer gear, and governor support. The governor
may be serviced by removing the transaxle oil pan
and valve body assembly. With the oil pan and valve
body removed, the governor may be unbolted from the
governor support and removed from the transaxle for
reconditioning or replacement.
When cleaning or assembling the governor, make
sure the governor valves move freely in the bores of
the governor body.
ALUMINUM THREAD REPAIR
Damaged or worn threads in the aluminum transaxle
case and valve body can be repaired by the use of
Heli-Coils, or equivalent. Essentially, this repair con­
sists of drilling out the worn-out damaged threads,
tapping the hole with a special Heli-Coil tap, or equiv­
alent, and installing a Heli-Coil insert, or equivalent,
into the tapped hole. This brings the hole back to its
original thread size.
Heli-Coil, or equivalent, tools and inserts are read­
ily available from most automotive parts suppliers.
 SERVICE OUT OF VEHICLE (A-413/A-670)
INDEX
Page
Accumulator.................................................................44
Assembly Subassembly Installation ........................ ...39
Bearing Adjustment Procedures ......... .................... ...59
Differential Bearing ................................................ ...60
Differential Repair .................................................. ...54
Disassembly Subassembly Removal ........................ ...28
Front Clutch .................................................................40
Front Planetary & Annulus Gear .................................43
Kickdown Servo {Controlled Load) .......................... ...45
Low— Reverse (Rear) Servo ..................................... ...44
Oil Cooler Flow Check ................................................25
Oil Coolers and Tubes Reverse Flushing ....................25
OIL COOLERS AND TUBES REVERSE FLUSHING
When a transaxle failure has contaminated the fluid,
the oil cooler(s) must be flushed and the cooler bypass
valve in the transaxle must be replaced. The torque
converter must also be replaced with an exchange
unit. This will insure that metal particles or sludged
oil are not transferred back into the reconditioned (or
replaced) transaxle.
CAUTION:lf vehicle is equipped with two oil coolers
(one in the radiator tank, one in front of the radiator)
they must be flushed separately. Do not attempt to
flush both coolers at one time.
(1) Disconnect the cooler lines at the transmission.
(2) Using a hand suction gun filled with mineral
spirits, reverse flush the cooler by forcing mineral
spirits into the From Cooler line of the cooler (Fig. 1).
Catch the exiting spirits from the To Cooler line.
Observe for the presence of debris in the exiting fluid.
Continue until fluid exiting is clear and free from
debris.
Page
Output Shaft Bearing .................................................. 59
Output Shaft Repair .................................................... 50
Parking Pawl ............................................................... 49
Pump Oil Seal .......................................................... ... 34
Rear Clutch ................................................................. 41
Subassembly— Recondition— Pumps ...................... ... 39
Transaxle and Torque Converter Removal .................. 25
Transaxle Recondition ............................................. ... 34
Transfer Shaft Bearing ................................... ......... ... 61
Transfer Shaft Repair .................................................. 45
Valve Body Recondition ........................................... ... 30
(3) Using compressed air in intermittent spurts, blow
any remaining mineral spirits from the cooler, again
in the reverse direction.
(4) To remove any remaining mineral spirits from
the cooler, one (1) quart of automatic transmission
fluid should be pumped through the cooler prior to
reconnecting the hoses to the transmission.
(5) If at any stage of the cleaning process, the cooler
does not freely pass fluid, the cooler must be replaced.
OIL COOLER FLOW CHECK
After the new or repaired transmission has been
installed and filled to the proper level with automatic
transmission fluid, the flow should be checked using
the following procedure:
(1) Disconnect the From cooler line at the transmis­
sion and place a collecting container under the discon­
nected line.
(2) Run the engine at curb Idle speed, with the
shift selector in neutral.
(3) If the fluid flow is intermittent or it takes more
than 20 seconds to collect one quart of automatic trans­
mission fluid, the cooler should be replaced.
CAUTION: WITH THE FLUID SET AT THE PROPER
LEVEL, FLUID COLLECTION SHOULD NOT EXCEED
(1) QUART OR INTERNAL DAMAGE TO THE TRANS­
MISSION MAY OCCUR.
(4) If flow is found to be within acceptable limits,
reconnect the cooler line and fill transmission to the
proper level, using the approved type of automatic
transmission fluid.
TRANSAXLE AND TORQUE CONVERTER REMOVAL
Transaxle removal does NOT require engine removal.
(1) The transaxle and torque converter must be re­
moved as an assembly; otherwise, the torque converter
drive plate, pump bushing, or oil seal may be dam­
aged. The drive plate will not support a load; there-
fore, none of the weight of the transaxle should be
allowed to rest on the plate during removal.
(2) Disconnect or connect negative battery cable.
(3) Disconnect or connect throttle linkage and shift
linkage from transaxle.

I / PR2155
/
Fig. 3 Remove Bell Housing Upper Bolts

CAUTION: Raise vehicle. Remove front wheels. Re­

fer to “Suspension, Group 2” to remove or install
| ) OILHOSEFROM COOLER^ PR2154B
wheel hub nut and both driveshafts.
Fig. 1 Remove Upper and Lower Oil Cooler Hoses

If so equipped, unplug lockup torque converter

plug, located near the dipstick.

SUPPORT
FIX TURE

Remove torque converter dust cover. Mark torque

converter and drive plate with chalk, for reassembly.
Remove torque converter mounting bolts.
 FRONT ENGINE
MOUNT
I NSULATOR

£
i

PR2167 PR2170

Fig. 5 Remove or Install Access Plug In Fig. 8 Remove or Install Front Mount Insulator
Sp ------------------------------
Right Splash Shield to Rotate ----- -
Engine Crankshaft Through-Bolt and Bell Housing Bolts

. NEUTRAL/PARK

PR2171A

Fig. 6 Remove or Install Wire to Fig. 9 Positioning Transmission Jack

Neutral/Park Safety Switch

-S . O
_ _ FRONT ENGINE.
MOUNT BRACKET'

[TRANSAXLE,REARJN£ C O V |R |||* i||| PR2172A

Fig. 10 Remove or Install Left Engine Mount

Fig. 7 Remove or Install Engine Mount Bracket from
Front Crossmember

Fig. 11 Remove or Install Left Engine Mount
from Engine
Remove or install starter. Remove or install lower
bell housing bolts.
When installing transaxle, reverse the above
procedure.
If torque converter was removed from transaxle be
sure to align pump inner gear pilot flats with torque
converter impeller hub flats.
Adjust gearshift and throttle cables.
Refill transaxle with MOPAR ATF PLUS (Auto­
matic Transmission Fluid) Type 7176.
DISASSEMBLY SUBASSEMBLY REMOVAL
Prior to removing any transaxle subassemblies, plug
all openings and thoroughly clean exterior of the unit,
preferably by steam. Cleanliness through entire disas­
sembly and assembly cannot be overemphasized. When
disassembling, each part should be washed in a suit­
able solvent, then dried by compressed air. Do not
wipe parts with shop towels. All mating surfaces in
the transaxles are accurately machined; therefore, care­
ful handling of all parts must be exercised to avoid
nicks or burrs.
Fig. 1 Transaxle Oil Pan Bolts
Remove all old RTV sealant before applying new
RTV sealant.
Use only RTV sealant when installing oil pan.
Put RTV sealant on the oil pan flange (Fig. 2) and
on all oil pan bolts (underside of bolt head).
 TRANSAXLE OIL PAN

E" CLIP

PARKING ROD
PR2180

Fig. 2 Transaxle Oil Pan Fig. 5 Remove or Install Parking Rod E-Clip
SCREWDRIVER Remove or install neutral starting and back-up lamp
HANDLE
switch.

Fig. 3 Oil Filter Screws

Fig. 6 Parking Rod

 VALVE BODY ASSEMBLY
When bores, valves, and plugs are clean and dry,
the valves and plugs should fall freely in the bores.
The valve body bores do not change dimensionally
with use. Therefore, a valve body that was function­
ing properly when vehicle was new, will operate cor­
rectly if it is properly and thoroughly cleaned. There
is no need to replace valve body unless it is damaged
in handling.

Fig. 8 Valve Body and Governor Tubes

VALVE BODY RECONDITION

Tighten all valve body screws to 5 Newton-meters
(40 inch-pounds)
Do not clamp any portion of valve body or transfer
plate in a vise. Any slight distortion of the aluminum
body or transfer plate will result in sticking valves,
excessive leakage or both. When removing or install­ Fig. 1 Detent Spring Attaching Screw and Spring
ing valves or plugs, slide them in or out carefully. Do
not use force.
TAG ALL SPRINGS AS THEY ARE REMOVED FOR
REASSEMBLY IDENTIFICATION.

CLEANING AND INSPECTION

Allow all parts to soak a few minutes in a suitable
clean solvent. Wash thoroughly and blow dry with
compressed air. Make sure all passages are clean and
free from obstructions.
Inspect manual and throttle valve operating levers
and shafts for being bent, worn or loose. If a lever is
loose on its shaft, it should be replaced. Do not at­
tempt to straighten bent levers.
Inspect all mating surfaces for burrs, nicks and
scratches. Minor blemishes may be removed with cro­
cus cloth, using only a very light pressure. Using a Fig. 2 Using Tool L-4553 on Valve Body Screws
straightedge, inspect all mating surfaces for warpage
or distortion. Slight distortion may be corrected, using
a surface plate. Make sure all metering holes in steel
plate are open. Using a pen light, inspect bores in
valve body for scores, scratches, pits and irregularities.
Inspect all valve springs for distortion and collapsed
coils. Inspect all valves and plugs for burrs, nicks, and
scores. Small nicks and scores may be removed with
crocus cloth, providing extreme care is taken not to
round off sharp edges. The sharpness of these edges is
vitally important because it prevents foreign matter
from lodging between valve and valve body, thus re­
ducing possibility of sticking. Inspect all valves and
plugs for freedom of operation in valve body bores.
 SCREWDRIVER: HANDLE
THROTTLE
VA LV E LEVER PRESSURE REGULATOR
/'SIEMBLY SPRING RETAINER AND
ADJUSTING SCREW BRACKET

PR2193 ,/F

fig , ci Throttle Vzlve Lever Assembly Fig. I I Pressure Regulator m d

Adjusting Screw Bract©!
MANUAL
^Aivr

PR2194

Fig. 10 Manual Valve

VALVE BODY

ADJUSTING
SCREW

SPRING
KICKDOWN
VALVE SCREW
 SHUTTLE VALVE
SECONDARY SPRING

1-2 SHIFT' VALVE GOVERNOR PLUG

END COVER

2-3 SHIFT VALVE

GOVERNOR PLUG

SCREW (4)

END COVER
RB714

Fig. 13 Governor Plugs

REGULATOR VALVE
THROTTLE PRESSURE
PLUG

END COVER

REGULATOR VALVE THROTTLE

. PRESSURE PLUG SPRING

SCREW (3)
 SHUTTLE VALVE E-CUP
SHUTTLE VALVE
"SECONDARY SPRING

SHUTTLE
SPRING GUIDES (2) VALVE

2-3 SHIFT
VALVE SHUTTLE VALVE
PiiMAlY SPRING

2 4 SHIFT
VALVE SPRING

SHUTTLE
VALVE PLUG

END COVER:

VALVE lOPY

1-2 SHIFT VALVE SPRING

SCREWS (4) RB716

fig!, f 5 Shift Valve* and Shuttle Valwe (Non-lockup)

TRANSAXLE RECONDITION (2) To install a new seal, place seal in opening of the
pump housing (lip side facing inward). Using Tool
PUMP OIL SEAL €-4133 and Handle Tool C-4, drive new seal into hous­
REPLACEM ENT ing until tool bottoms (Fig. 2).
The pump oil seal can be replaced without removing
the pump and reaction shaft support assembly from OIL SEAL
the transaxle case. INSTALLER
TOOL C-4193
(1) Screw seal remover Tod C-3981 into seal (Fig.
1), then tighten screw portion of tool to withdraw the
seal.
PUMP OIL SEAL

OIL SEAL
REMOVER
G3981

RB718B

Fig, 2 Install Pump Oil Seal

IN P U T S H A F T E N D P L A Y
Measuring input shaft end play before disassembly
R1717 will usually indicate when a thrust washer change is
OIL PUMP
required, (except when major parts are replaced). The
thrust washer is located between input and output PUMP ATTACHING
shafts. BOLT5(7)
(1) Attach a dial indicator to transaxle bell housing
with its plunger seated against end of input shaft
(Fig. 3).
PUMP OIL USE A
SEAL STEEL
BALL DIAL
INDICATOR

Fig. 5 Pump Attaching Bolts

RS719B

Fig. 3 Measure Input Shaft End Play

Move input shaft in and out to obtain end play

reading. End play specifications are 0.19 to 1.50 min
(.008 to .060 inch).
(2) Record indicator reading for reference when re­
assembling the transaxle.

KICKDOWN
BAND
ADJUSTING SCREW
/f) f PR2205A
Fig. i Install Tool C-3782 with Adaptor* £-4437

PR2203

Fig. 4 Loosen Loclr Nut and Tighten Kickdown Band

Adjusting Screw

PR2206A
Fig. ? Oil Pump with No. 1 Thrust Waahor
 SPLIT IN GASKET PUMP GASKET
(DIFFERENTIAL OIL FEED)
/c a

FRONT , D070,
CLUTCH ASSEMBLY RB721

Fig. 8 Oii Pump Gasket Fig. 11 Front Clutch Assembly

$^#2 THRUST WASHER

KICKDOWN BAND ADJUSTING SCREW

\ \ PR2208 PR2211A

Fig. 9 Loosen Kickdown Band Adjusting Screw Fig. 12 No. 2 Thrust Washer and Rear Clutch
IFRONT CLUTCH' KICKDOWN BAND CAUTION: The Input shaft for non-lockup torque con­
verter has 2 seal rings. The lockup input shaft has
three seal rings.

OIL RETURN AND FEED HOLE \

TO DIFFERENTIAL _ > "V STRUT RB720A

Fig. 10 Kickdown Band and Strut

THRUST WASHER
(SELECT FIT) RB722A
FRONT PLANETARY _GEAR SNAP RjNG

RB726A

Fig. 14 Front Planetary Gear Snap Ring Fig. 17 Sun Gear Driving Shell

#8 THRUST WASHER (STEEL)

#7 SPACER (STEEL)

RS724A RB727

Fig. 15 Front Planetary Gear Assembly Fig. 18 Sun Gear Driving Shell Components

REAR PLANETARY
GEAR ASSEMBLY

SUN
GEAR

#9 THRUST WASHER*__ PR2217

Fig. 19 No. 9 Thrust Washer
 PR2221A

Fig. 20 Rear Planetary Gear Assembly Fig. 23 Overrunning Clutch Rollers and Springs
ADJUSTING SCREW

'# 1 0 THRUST WASHER RB728

Fig. 21 No. 10 Thrust Washer Fig. 24 Loosen or Adjust Low-Reverse Band

#11 THRUST WASHER-
^ X / OUTPUT SHAFT

rl

OVERRUNNING CLUTCH
CAM ASSEMBLY

PR2220A STRUT PR2222A

Fig. 25 Low-Reverse Band and Strut

 TOOL L-4440

POCKET INNER
GEAR

PUMP
HOUSING
SPRING (8) CRESCENT

RUBBER
OVERRUNNING CLUTCH SEAL
CAM ASSEMBLY
PR2227B

Fig. 27 Install Overrunning Clutch Rollers and Springs Fig. 3 Inner and Outer Pump Gears

ASSEMBLY SUBASSEMBLY INSTALLATION INNER FEELER GAUGE

GEAR

When rebuilding, reverse the above procedure.

OUTER
SUBASSEMBLY— RECONDITION— PUMP GEAR

PUMP
HOUSING

PR2228 B

Fig. 4 Measuring Pump Clearance (Gear to Pocket)

Also, check gear side clearance with a straight

edge and a feeler gauge (See Specifications).
FRONT CLUTCH
INSPECTION
Inspect plates and discs for flatness. They must not
WAVED SNAP RING
be warped or cone shaped.
Inspect facing material on all driving discs. Replace
discs that are charred, glazed or heavily pitted. Discs
should also be replaced if they show evidence of mate­
rial flaking off or if facing material can be scraped off
easily. Inspect driving disc splines for wear or other
damage. Inspect steel plate surfaces for burning, scor­
ing, or damaged driving lugs. Replace if necessary.
Inspect steel plate lug grooves in clutch retainer for
FRONT
smooth surfaces, plates must travel freely in grooves. CLUTCH
Inspect" band contacting surface on clutch retainer for RETAINER
scores, the contact surface should be protected from \ PR2230
•damage during disassembly and handling. Note ball Fig. 2 Thick Steel P/ate aiicf Waved Snap Ring
check in clutch retainer, make sure ball moves freely.
Inspect piston seal surfaces in clutch retainer for nicks CLUTCH PLATES
or deep scratches, light scratches will not interfere
with sealing of seals. Inspect clutch retainer inner
bore surface for wear from reaction shaft support seal FRONT CLUTCH
rings. Inspect clutch retainer bushing for wear or scores. RETAINER
Inspect inside bore of piston for score marks, if light,
remove with crocus cloth. Inspect seal grooves for nicks
and burrs. Inspect seals for deterioration, wear, and
hardness. Inspect piston spring, retainer and snap ring
for distortion.

WAVED SNAP RING

SCREWDRiVEi
DRIVING DISCS (3) m m

Fig. 3 front Clutch (S-Dlac Shown)

FRONT
CLUTCH
ASSEMBLY

PR2229

Fig. 4 Front Clutch Return Spring Snap Ring
Fig. 5 Front Clutch Return Spring and Piston
To reassemble, reverse the above procedure.
PR2234
Fig. 6 Measuring Front Clutch Plate Clearance
REAR CLUTCH
INSPECTION
Inspect facing material on all driving discs. Replace
discs that are charred, glazed or heavily pitted. Discs
should also be replaced if they show evidence of mate­
rial flaking off or if facing material can be scraped off
easily. Inspect driving disc splines for wear or other
damage. Inspect steel plate and pressure plate surface
for burning, scoring or damaged driving lugs. Re place
if necessary. Inspect plates and discs for flatness, they
must not be warped or cone-shaped.
Inspect steel plate lug grooves in clutch retainer for
smooth surfaces, plates must travel freely in the
grooves. Note ball check in piston; make sure ball
moves freely. Inspect seal rings surfaces in clutch
retainer for nicks or deep scratches; light scratches
will not interfere with sealing of the seals. Inspect
neoprene seal rings for deterioration, wear and hard-
ness. Inspect piston spring and wa¥ed snap ring for REAR CLUTCH PISTON 4^AVED SNAP
distortion or breakage. RETAINER SPRING RING

PISTON SEALS ~ \ PISTON PR2238A

REAR CLUTCH Fig. 4 Rear Clutch Piston m d Piston Spring

lPR2235A
ASSEMBLY
INPUT SHAFT ^REAR CLUTCH RETAINER
Fig. I Rear Clutch Outer Snap Ring
THICK STEEL PLATE

CLUTCH PLATES

REAR CLUTCH
RETAINER

SNAP RING
PLIERS
>NA P RING SNAP RING pR2239
(SELECTIVE)
DRIVING V Fig. 5 Remove or Install Input Shaft Snap Ring
PRESSURE PLATE \ DISCS RB731A
INPUT REAR CLUTCH
Fig. 2 Rear Clutch (3-Disc Shown) SHAFT RETAINER

REAR CLUTCH PISTON SPRING

RETAINER

SNAP RI NG

PR2240

Fig. 6 Input Shaft Snap Ring

^PR2237A I WAVED SNAP RING
Inspect teflon and/or cast iron seal rings on input
shaft for wear. Do not remove rings unless conditions
warrant. Inspect rear clutch to front clutch No. 2
thrust washer for wear. Washer thickness should be
.061 to .063 inch, replace if necessary.
 Press out input shaft, if required.
To reassemble, reverse the above procedure. SCREWDRIVER
ANNULUS
GEAR SUPPORT

FRONT
PLANETARY
ANNULUS
GEAR

RB734

Fig. 3 Annulus Gear Support Front Snap Ring

Fig. 7 Measuring Rear Clutch Plate Clearance FRONT ANNULUS FRONT

GEAR SNAP RING
FRONT PLANETARY & ANNULUS GEAR
SNAP RING-

#4 THRUST WASHER.

SNAP RING

RB735

FRONT PLANETARY Fig. 4 Front Annulus Gear Support and Snap Ring
GEAR ASSEMBLY
7 FRONT ANNULUS GEAR
RB732

Fig. 1 Front Planetary Gear Snap Ring

and No. 4 Thrust Washer
(Always Install a New Snap Ring)

ANNULUS GEAR AND SUPPORT

#5 THRUST WASHER

FRONT PLANETARY
GEAR ASSEMBLY

RB736
LOW-REVERSE (REAR) SERVO

ACCUM tJtAtOt
PLATE

SNAP RING
PLIERS

LOW-REVERSE
SERVO SPRING
RETAINER

RB737
0 i Y \ p $
Pig. I l6i6-«i6'©:6«i Seivo Snap ft/ng To assemble, reverse the above procedure,
SNAP RING
LOW REVERSE ACCUMULATOR
SERVO SPRING
RETAINER ll, ^ i \ rrT^
/S O ) \ RETURN ACCUMULATOR
— m \ smmG PLATE SNAP
SNAP RING RING PLIERS
■' / /

F/g. 2 Swap HIi!§ an# Retainer

PR2251C
RETURN SPRING^
Fig. 1 Accumulator Snap Ring
SNAP RING '

\ \\ PR2252A

Fig. 2 Accumulator Plate and Snap Ring

ACCUMULATOR
SPRING RETURN SPRING

KICKDOWN
SERVO PISTON

PISTON ROD

KICKDOWN
LEVER

RB741 / / f/[j/

Fig. 3 Accumulator Spring mm Piston Fig. 3 Kickdown Piston Return Spring and Piston

To assemble, reverse the above procedure. KICKDOWN PISTON

KICKDOWN SERVO (CONTROLLED LOAD) O-RING

SNAP RING
SNAP RING SNAP RING
PLIERS SEAL RINGS
PISTON ROD
GUIDE
KICKDOWN PISTON
ROD GUIDE PISTON ROD

PISTON RETURN SPRING

KICKDOWN
LEVER O-RING “

RB742A SNAP RING ‘

Fig- 4 Controlled Load Kickdown Setwo

ACCUMULATOR . ,
PLATE / /RB739 To assemble, reverse the above procedure.

Fig. I Kickdown Servo Snap Ring TRANSFER SHAFT REPAIR

 REAR
COVER PR2262A

Fig. 2 fiem m e or Install Rear Cover Fig. 5 Fiemme Transfer Shaft Gear

Remove old RTV before applying new RTV sealant TRANSFER SHAFT
Use RTV sealant when installing cover. GEAR

PR2263

SPECIAL TOOL Fig. i Transfer Shan Gear and (Select) Shim

L-4434 PR2260

Fig. 3 Fiemme Transfer Shaft Gear Retaining Nut

PR2264
WASHER
Fig. 7 Using Fool L-4406-f with
Adapter L-4406-3, Remove Transfer Shaft
TRANSFER SHAFT GEAR \ 2 x — "-^PR2261A Gear Bearing €91111
Fig. 4 Transfer Shaft Gear fiiuf and Washer
 PRESS

HANDLE C-4171

SPECIAL TOOL L-4410

BEARING C

^TRANSFER SHAFT GEAR

PR2265A

Fig. 8 Install Transfer Shaft Gear Bearing Cone Fig. 11 Install Governor Support Retainer Bearing Cup

TRANSFER SHAFT
OUTPUT SHAFT GEAR

GOVERNOR
SUPPORT RETAINER PR2266 PR2269

Fig. 9 Governor Support Retainer Fig. 12 Low-Reverse Band Anchor Pin

Fig. 13 Governor Assembly

Remove or install both governor valves and gover­

nor body.
 SNAP RING TRANSFER
PLIERS SHAFT

'WFWf 1"ANSFER
SHAFT PR2271A PR2274C

Fig. 14 Transfer Shaft Bearing Smp Ring Fig. 17 Transfer Shaft and Bearing Retainer

TOOL C-293-PA
TRANSFER SHAFT

TOOL C-293-52

ViSE —— r/ t i / \u i jT Z : A PR2275

Fig. 15 Remove Transfer Shaft and Fig. 18 Remme Transfer Shaft Bearing Com
Bearing Retainer Assembly
OUTPUT SHAFT GEAR
TRANSFER SHAFT
BEARING RETAINER:
ASSEMBLY PRESS

SPECIAL TOOL
1-4411

PR2273I

Fig. 16 Remme or install Transfer Shaft and BEARING CONE

Bearing Retainer Assembly Using Tool L-4512
TRANSFER SHAFT
PR2276A
Fig. 19 Install Transfer Shaft Bearing Com
 cedure” in rear of this section to determine proper
shim thickness for correct end play.

TRANSFER SHAFT GEAR

TORQUE WRENCH

SPECIAL TOOL L-4434

AND ADAPTER C-4658 RB743

Fig. 22 Tighten Transfer Shaft Gear Retaining Nut

to 271 N m (200 ft. lbs.)

vTOOL L-4432 TRANSFER SHAFT GEAR—

Fig. 20 Remove Transfer Shaft Bearing Cup : AND C - 4 6 5 8 ^ ® STEEL BALL
(USE GREASE TO HOLD
IN PLACE)

%)
PR2282A

Fig. 23 Checking Transfer Shaft End Play

PARKING PAWL

Fig. 21 Install Transfer Shaft Bearing Cup

To install transfer shaft, reverse the above procedure.

DETERMINING SHIM THICKNESS

Shim thickness need only be determined if any of
the following parts are replaced: (a) transaxle case, (b)
transfer shaft, (c) transfer shaft gear, (d) transfer shaft
bearings, (e) governor support retainer, (f) transfer
shaft bearing retainer, (g) retainer snap ring, or (h) PR2283A
governor support. Refer to "Bearing Adjustment Pro­
 Fig. 2 Support and Bolts Fig. 1 Remove Output Shaft Retaining Nut and Washer

PR2287A

Fig. 3 Parking Pawl, Return Spring, and Pivot Shaft Fig. 2 Remove Output Shaft Gear

To install, reverse the above procedure.

OUTPUT SHAFT REPAIR

Transfer shaft should be removed for repair of out
put shaft. Planetary gear sets must be removed to
accurately check output shaft bearing turning torque.

PR2288B
 ARBOR
PRESS-
RAM CAUTION: SUPPORT
ANNULUS GEAR
UNDERNEATH, NEAR
GEAR CEN TER.

Fig. 4 Remove Output Shaft Gear Bearing Cone Fig. 7 Remove Output Shaft

SPECIAL TOOL L-4406-1

WITH ADAPTERS L- 4406-2

REAR PLANETARY
ANNULUS GEAR

PR2293

Fig. 5 Install Output Shaft Gear Bearing Cone Fig. 8 Remove Rear Planetary Annulus
Gear Bearing Cone

ARBOR PRESS RAM

SPECIAL TOOL C-4637

BEARING CONE

CUP FROM
REAR PLANETARY
TOOL L-4518
ANNULUS GEAR

RB744
Fig. 6 Remove Output Shaft and
Rear Annulus Gear Assembly
 Fig. 10 Install Output Shaft into Fig. 13 Install Output Shaft Gear Bearing Cup
Rear Planetary Annulus Gear

PR2299B
PR2296
Fig. 14 Install Rear Planetary
Fig. 11 Remove Output Shaft Gear Bearing Cup Annulus Gear Bearing Cup

DETERMINING SHIM THICKNESS

Shim thickness need only be determined if any of
the following parts are replaced:
(a) transaxle case, (b) output shaft, (c) rear plane­
tary annulus gear, (d) output shaft gear, (e) rear an­
nulus and output shaft gear bearing cones, or (f)
overrunning clutch race cups.
Refer to "Bearing Adjustment Procedure” at the
rear of this section, to determine proper shim thick­
ness for correct bearing preload and turning torque.
Check output shaft bearings turning torque, using
an inch-pound torque wrench. If turning torque is 3
to 8 inch-pounds, the proper shim has been installed.
 USE GREASE TO BEARING CONE
HOLD SHIMS IN
POSITION
OUTPUT SHAFT
ASSEMBLY

Fig. 15 Install Output Shaft Assembly Fig: 18 Holding Output Shaft Gear

Fig. 16 Output Shaft and (Select) Shims in Position Fig. 19 Tighten Output Shaft Retaining Nut
to 271 N m (200 ft. lbs.)

^ OUTPUT
6 SHAFT
\
GEAR

m m sA
 DIFFERENTIAL COVER

RY295 RB747A
DIFFERENTIAL COVER BOLT

Fig. 21 Checking Bearings Turning Torque Fig. 3 Differential Cover Bolts

DIFFERENTIAL REPAIR GOVERNOR DIFFERENTIAL

PRESSURE COVER
The transfer shaft should be removed for differen­
tial repair and bearing turning torque checking.

EXTENSION HOUSING

1/8 INCH BEAD OF RTV

OIL SEAL SEALANT
DIFFERENTIAL ASSEMBLY RB748

Fig. 4 Remove or Install Differential Cover

Use RTV sealant when installing differential cover.

PR2306A

Fig. 1 Remove Extension Seal

HAMMER

PR2307A
 GOVERNOR PRESSURE PLUG EXTENSION HOUSING DIFFERENTIAL ASSEMBLY I

SPECIAL TOOL
1-4435
DIFFERENTIAL BEARING
RETAINER
PR2311 R174fA

Fig. 6 fiemowe or Install Bearing Retainer Pig. S Fiemme or Install Extension Homing

R.T.V. SEALANT RB7S0A DIFFERENTIAL ASSEMBLY

Fig. 7 Differential Bearing Retainer (Typical) F lf. f 0 Differential m d Extension

Use RTV sealant when installing differential bear­ WARNING; HOLD ONTO DIFFERENTIAL ASSEMBLY
ing retainer. TO PREVENT IT FROM ROLLING OUT OF HOUSING.
e RT¥ Sealant when installing extension housing.
EXTENSION HOUSING
BOLT S (4) SPECIAL TOOL
€-293
SPECIAL TOOL
C-4996
(NOTE POSITION)

SPECIAL TOOL
ADAPTER €-293-45
(USE 4 PIECES)
DIFFERENTIAL
ASSEMBLY

PRB13I
DIFFERENTIAL
BEARING CONE
Fig. 12 Install Differential Bearing Cone Fig. 15 Remove or Install Ring Gear
Bolts and Ring Gear

CAUTION: Always install new ring gear bolts. Bolts

must be properly torqued.

Fig. 13 Remove Differential Bearing Cone

Fig. 16 Remove Pinion Shaft Roll Pin

 DIFFERENTIAL . Four select thrust w ishers are awalabte: .032, .037,
CASE .042, and .047 Inch.
SPECIAL TOOL C-49f6
(NOTE POSITION)

PINION GEAR SIDE GEAR (2) MOVE

THRUST WASHER SIDE GEAt
(2) UP AND DOWN

PINION
RP460
GEAR (2|

Fig. IS Remove or Install Pinion Gmm, Side Geam9 DIFFERENTIAL

ASSEMBLY RP463
and Tabbed Thrust Washers, by Rotating Pinion
Gears to Opening in Differential Case
Fig. 21 Checking Side Gear End Play
SIDE GEAR (2)

M r-
SIDE GEAR THRUST
WASHER (2) CAPTION: Side gear end play must be within .001 to
[SELECT THICKNESS] .013 Inch.

iOLL PIN Four select thrust washers are available; .032, .037,
PINION GEAR nAO nA T , „ li ■ ■ ■
THRUST WASHER "042, "®4 7 . ' .

PINION
SHAFT SCREWDRIVER

PINION GEAR (2)

RP461

Fig. IS Differential Gears DIFFEiENTIAL

BEARING
■ RETAINER'
SPECIAL TOOL C-4996 DIAL INDICATOR SET
(NOTE POSITION)

PR2326 |

MOVE Fig. 22 Remove Oil Seal

SIDE GEAR
UP AND DOWN

DIFFERENTIAL
ASSEMBLY

Fig. 20 Checking Side Gear End Play

CAUTION: Side gear end play must be within .001 to

.013 Inch.
 ARBOR PRESS RAM BEARING CUP
LUBRICATION HOLE

\
SPECIAL TOOL SPECIAL TOOL L-4520
HANDLE C-4171 (INVERTED)

DIFFERENTIAL
BEARING
RETAINER
(SELECT) SHIM
TO DETERMINE
DIFFERENTIAL
I I \ BEARING PRELOAD
DIFFERENTIAL
RB758 BEARING RETAINER PR2329A

Fig. 23 Install New Oil Seal Fig. 25 Differential Bearing Retainer

BEARING
CUP
HANDLE C-4171

DIFFERENTIAL BEARING CUP

BEARING
RETAINER

PR2330A

Fig. 24 Remove Bearing Cup Fig. 26 Install Bearing Cup

DETERMINING SHIM THICKNESS When rebuilding, reverse the above procedure.

Shim thickness need only be determined if any of Remove old RTV before applying new RTV Sealant.
the following parts are replaced: Use RTV Sealant on retainer to seal retainer to case.
(a) transaxle case
(b) differential carrier
(c) differential bearing retainer
(d) extension housing
(e) differential bearing cups and cones
Refer to "Bearing Adjustment Procedure” in rear of
this section to determine proper shim thickness for
correct bearing preload and proper bearing turning
torque.
 Fig. 29 Checking Differential Bearings Turning Torque

Fig. 27 Checking Differential End Play

Fig. 28 Tool L-4436 and Torque Wrench

 BEARING ADJUSTMENT PROCEDURES (A-413/A-670)
INDEX
Page Page
Differential Bearing ................................... .................. 61 Output Shaft Bearing .................................................... 60
General Rules On Servicing Bearings ....................... 60 Transfer Shaft Bearing .................................................. 61

GENERAL RULES ON SERVICING BEARINGS (b) Shims thinner than 12.65 mm listed in the
chart are common to both the transfer shaft and out­
(1) Take extreme care when removing and in stall­ put shaft bearings.
ing bearing cups and cones. Use only an arbor press (5) Use Tool L-4434 to remove the retaining nut and
for installation, as a hammer may not properly align washer. To remove the output shaft gear use Tool
the bearing cup or cone. Burrs or nicks on the bearing L-4407.
seat will give a false end play reading, while gauging (6) Remove the two gauging shims and install the
for proper shims. Improperly seated bearing cup and proper shim combination, making sure to install the
cones are subject to low-mileage failure. 12.65, 13.15, or 13.65 mm shim first. Use grease to
(2) Bearing cups and cones should be replaced if hold the shims in place. Install the output shaft gear
they show signs of pitting or heat distress. and bearing assembly.
If distress is seen on either the cup or bearing roll­
ers, both cup and cone must be replaced. OUTPUT SHAFT BEARING SHIM CHART
Bearing end play and drag torque specifications
must be maintained to avoid premature bearing End Play
failures. (with 13.65 mm
and 1.34 mm Required
Used (original) bearing may lose up to 50% of the gauging shims Shim Total
original drag torque after break-in. instaTied) Combination Thicknes:
All bearing adjustments must be made with no mm mm inch
inch mm
other component interference or gear inter-mesh, ex­
cept the transfer gear bearing. .0 .0 13.65 + 1.34 14.99 .590
.05 .002 13.65 + 1.24 14.89 .58<
.10 .004 13.65 + 1.19 14.84 .58-
OUTPUT SHAFT BEARING .15 .006 13.65 + 1.14 14.79 .58:
.20 .008 13.65 + 1.09 14.74 .581
With output shaft gear removed. .25 .010 13.65 + 1.04 14.69 .571
.30 .012 13.65 + .99 14.64 ,57(
(1) Install a 13.65 mm (.537 inch) and a 1.34 mm .35 .014 13.65 + .94 14.59 .57-
(.053 inch) gauging shims on the planetary rear annu- .40 .016 13.15 + 1.39 14.54 .57:
lus gear hub using grease to hold the shims in place. .45 .018 13.15 + 1.34 14.49 .570
The 13.65 mm shim has a larger inside diameter and .50 .020 13.15 + 1.29 14.44 .568
must be installed over the output shaft first. The 1.34 .55 .022 13.15 + 1.24 14.39 .566
.60 .024 13.15 + 1.19 14.34 .564
mm shim pilots on the output shaft. .65 .026 13.15 + 1.14 14.29 .56:
(2) Install output shaft gear and bearing assembly, .70 .028 13.15 + 1.09 14.24 .561
torque to 271 N-m (200 ft. lbs.). .75 .030 13.15 + 1.04 14.19 .551
(3) To measure bearing end play: .80 .032 13.15 + .99 14.14 .556
.85 .034 13.15 + .94 14.09 .554
(a) Attach Tool L-4432 to the output shaft gear. .90 .036 12.65 + 1.39 14.04 .552
(b) Mount a steel ball with grease into the end of .95 .038 12.65 + 1.34 13.99 .550
the output shaft. 1.00 .040 12.65 + 1.29 13.94 .541
(c) Push and pull the gear while rotating back 1.05 .042 12.65 + 1.24 13.89 .54;
1.10 .044 12.65 + 1.19 13.84 .54;
and forth to insure seating of the bearing rollers. .046 12.65 .54:
1.15 + 1.14 13.79
(d) Using a dial indicator, mounted to the transaxle 1.20 .048 12.65 + 1.09 13.74 .541
case, measure output shaft end play. 1.25 .049 12.65 + 1.04 13.69 .539
(4) Once bearing end play has been determined, 1.30 .051 12.65 + .99 13.64 .537
refer to the output shaft bearing shim chart for the 1.35 .053 12.65 + .94 13.59 .535
required shim combination to obtain proper bearing Average Conversion .05 mm = .002 inch 9121-17
setting.
(7) Install the retaining nut and washer and torque
(a) The 12.65 mm (.498 inch), 13.15 mm (.518
to 271 N-m (200 ft. lbs.).
inch) or 13.65 mm (.537 inch) shims are always in­
(8) Using an inch-pound torque wrench, check the
stalled first. These shims have lubrication slots which
turning torque. The torque should be between 3 and
are necessary for proper bearing lubrication.
8 Inch-pounds.
 If the turning torque is too high, install a .05mm (6) Attach a dial indicator to the case and zero the
(.002 inch) thicker shim. If the turning torque is too dial indicator. Place the indicator tip on the end of
low, install a .05 mm (.002 inch) thinner shim. Repeat Tool L-4436.
until the proper turning torque is 3 to 8 inch pounds. (7) Place a large screwdriver to each side of the ring
gear and lift. Check the dial indicator for the amount
DIFFERENTIAL BEARING of end play.
CAUTION: Do not damage the transaxle case and/or
(1) Remove the bearing cup from the differential differential cover sealing surface.
bearing retainer using Tool L-4518, and remove the
existing shim from under the cup. (8) When the end play has been determined, refer to
(2) Install a .50 mm (.020 inch) gauging shim and the Differential Bearing Shim Chart for the correct
reinstall the bearing cup into the retainer. Use an shim combination to obtain the proper bearing setting.
arbor press to install the cup. (9) Remove the differential bearing retainer. Re­
Oil Baffle Is not required when making shim selection. move the bearing cup and the .50 mm (.020 inch)
(3) Install the bearing retainer into the case and gauging shim.
torque bolts to 28 N-m (250 in. lbs.). (10) Install the proper shim combination under the
bearing cup. Make sure the oil baffle is installed prop­
DIFFERENTIAL BEARING SHIM CHART erly in the bearing retainer, below the bearing shim
and cup.
(11) Install the differential bearing retainer. Seal
End Play
(with .50 mm Required the retainer to the housing with RTV sealant and
gauging shim Shim Total torque bolts to 28 N’m (250 in. lbs.).
installed) Combination Thickness (12) Using special Tool L-4436 and an inch-pound
mm inch mm mm inch torque wrench, check the turning torque of the differ­
ential. The turning torque should be between 5 and
.0 .0 .50 .50 .020
.05 .002 .75 .75 .030 18 inch-pounds.
.10 .004 .80 .80 .03: If the turning torque is too high, install a .05 mm
.15 .006 .85 .85 .034 (.002 inch) thinner shim. If the turning torque is too
.20 .008 .90 .90 •03; low, install a .05 mm (.002 inch) thicker shim. Repeat
.25 .010 .95 .95 .037
.30 .012 1.00 1.00 .039 until 5 to 18 inch-pounds turning torque is obtained.
.35 .014 1.05 1.05 .04
.40 .016 .50 + .60 1.10 .043 TRANSFER SHAFT BEARING
.45 .018 .50 + .65 1.15 .045
.50 .020 .50 + .70 1.20 .047
(1) Use Tool L-4434 to remove the retaining nut and
.55 .022 .50 + .75 1.25 .049
.60 .024 .50 + .80 1.30 .051 washer. Remove the transfer shaft gear using Tool
.65 .026 .50 + .85 1.35 .053 L-4407.
.70 .027 .50 + .90 1.40 .055 (2) Install a 2.29 mm (.090 inch) and a 1.39 mm
.75 .029 .50 + .95 1.45 .057 (.055 inch) gauging shims on the transfer shaft behind
.80 .031 .50 + 1.00 1.50 .059
.85 .033 .50 + 1.05 1.55 .061 the governor support.
.90 .035 1.00 + .60 1.60 ,063 (3) Install transfer shaft gear and bearing assembly
.95 .037 1.00 + .65 1.65 .065 and torque the nut to 271 N'm (200 ft. lbs.).
1.00 .039 1.00 + .70 1.70 .067 (4) To measure bearing end play:
1.05 .041 1.00 + .75 1.75 .069
1.10 .043 1.00 + 1.80 .071
(a) Attach Tool L-4432 to the transfer gear.
■9
1.15 .045 1.00 + .85 1.85 .073 (b) Mount a steel ball with grease into the end of
1.20 .047 1.00 + .90 1.90 .075 the transfer shaft.
1.25 .049 1.00 + .95 1.95 .077 (c) Push and pull the gear while rotating back
1.30 .051 1.00 + 1.00 2.00 .079
2.05 .081
and forth to insure seating of the bearing rollers.
1.35 .053 1.00 + 1.05
1.40 .055 1.05 + 1.05 2.10 .083 (d) Using a dial indicator, measure transfer shaft
end play.
9121-16
(5) Refer to the Transfer Bearing Shim Chart for
the required shim combination to obtain the proper
(4) Position the transaxle assembly vertically on bearing setting.
the support stand and install Tool L-4436 into the (6) Use Tool L -4434 to remove the retaining nut and
extension. washer. Remove the transfer shaft gear using Tool
(5) Rotate the differential at least one full revolu­ L-4407.
tion to ensure the tapered roller bearings are fully
seated.
 TRANSFER BEARING SHIM CHART (8) Install the retaining nut and washer and torque
to 271 N-m (200 ft. lbs.). Measure transfer shaft end
End Play play, end play should be .05 to .25 mm (.002 to .010
(with 2.29 mm inch).
and 1.39 mm Required (9) Measure bearing end play as outlined in Step
gauging shims Shim Total
installed) Combination Thickness (4). End play should be between .05 mm and .25 mm
(.002 to .010 inch).
mm inch mm mm inch
If end play is too high, install a .05 mm (.002 inch)
.0 .0 2.29 + .39 3.68 .145 thinner shim combination. If end play is too low,
.05 .002 2.29 + .39 3.68 .145
install a .05 mm (.002 inch) thicker shim combina­
.10 .004 2.29 + .39 3.68 .145
.15 .006 2.29 + .39 3.68 .145
tion. Repeat until .05 to .25 mm (.002 to .010 inch)
.20 .008 2.29 + .34 3.63 .143 end play is obtained.
.25 .010 2.29 + .29 3.58 .141
.30 .012 2.29 + .24 3.53 .139 BEARING SHIM CHART
.35 .014 2.29 + .19 3.48 .137
.40 .016 2.29 + .14 3.43 .135 Shim
.45 .018 2.29 + .09 3.38 .133 Thickness Bearing Usage
.50 .020 2.29 + .04 3.33 .131 Output Transfer Differ­
.55 .022 2.29 + .99 3.28 mm inch Shaft S h a ft ential
.60 .024 1.84 + .39 3.23 .127 _
0.94 .037 X X
.65 .026 1.84 + .34 3.18 .125
0.99 .039 X X
.70 .028 1.84 + .29 3.13 1.04 .041 X X
.75 .030 1.84 + .24 3.08 .121 1.09 .043 X X .
.80 .032 1.84 + .19 3.03 .119 1.14 .045 X X _

.85 .034 1.84 + .14 2.98 .117 1.19 .047 X X _

.90 .036 1.84 + .09 2.93 1.24 .049 X X —

.95 .038 1.84 + .04 2.88 1.29 .051 X X _

1.00 .040 1.84 + .99 2.83 .11 1.34 .053 X* X ! _

1.05 .042 1.39 + .39 2.78 .109 1.39 .055 X X* _

1.10 .044 -9 + .34 2.73 .107 1.84 ,072 X X —

1.15 .046 1.39 + .29 2.68 .105 2.29 .090 X X* _

1.20 .048 1.39 + .24 2.63 .103 12.65 .498 X _ _

13.15 .518 X _
1.25 .049 1.39 + .19 2.58 .101
13.65 .537 X* _
1.30 .050 1.39 + .14 2.53 .099 X
0.50 .020 _ _
1.35 .052 1.39 + .09 2.48 .097 0.55 .022 — _ X
1.40 .055 1.39 + .04 2.43 .095 0.60 .024 — _ X
1.45 .057 1.39 + .99 2.38 .093 0.65 .026 — _ X
1.50 .059 .94 + .39 2.33 .091 0.70 .027 _ _ X
1.55 .061 .94 + .34 2.28 .089 0.75 .029 _ _ X
1.60 .063 .94 + .29 2.23 .087 0.80 .031 _ X
9121-15 0.85 .033 _ X
0.90 .035 _ _ X
(7) Remove the two gauging shims and install the 0.95 .037 _ _ X
1.00 .039 _ — X
correct shim combination. Install the transfer gear 1.05 .041 — - X
and bearing assembly.
* Also used as gauging shims 9121-14
 A-604 ULTRADRIVE 4-SPEED ELECTRONIC AUTOMATIC TRANSAXLE
Page
General Information ......................................................
GENERAL INFORMATION
The A-604 Ultradrive electronic four-speed FWD
transaxle is the first use of fully-adaptive controls in a
production automotive transaxle. Adaptive controls are
those which perform their functions based on real­
time feedback sensor information, just as is done by
electronic anti-lock brake controls. Although the
transaxle is conventional in that it uses hydraulically-
applied clutches to shift a planetary geartrain, its use
of electronics to control virtually all functions is unique.
A-604 TRANSAXLE IDENTIFICATION
The transaxle identification code is printed on a
label. The label is located on the transaxle case next
to the solenoid assembly (Fig.l).
Refer to Figure 2 for an internal view of the A-604
transaxle assembly.
OPERATION
The transaxle provides forward ratios of 2.84, 1.57,
1.00, and 0.69 with torque converter lockup available
in 2nd, direct, or overdrive gear; the Reverse ratio is
2.21. The shift lever is conventional with six posi­
tions: P, R, N, OD, D, and L. When OD is selected the
transaxle shifts normally through all four speeds with
lockup in overdrive; this position is recommended for
most driving. The D position is tailored for use in
hilly or mountainous driving. When D is selected, the
transmission uses only 1st, 2nd, and direct gears with
2nd-direct shift delayed to 40 mph or greater. When
operating in D or L positions torque converter lockup
INDEX
63
occurs in direct gear for improved transmission cool­
ing when towing trailers and on steep grades. If high
engine coolant temperature occurs, the torque con­
verter will also lock up in 2nd gear. The L position
provides maximum engine braking for descending steep
grades. Unlike most current transaxles, upshifts are
provided to 2nd or direct gear at peak engine speeds if
the accelerator is depressed. This provides engine over­
speed protection and maximum performance.
CLUTCH AND GEAR
The A-604 Ultradrive transaxle consists of three
multiple-disc input clutches, two multiple-disc grounded
clutches, four hydraulic accumulators, and two plane­
tary gear sets. This provides four forward ratios and a
reverse ratio. Since this transaxle is expected to oper­
ate properly with today’s engines, its clutch-apply pis­
tons were designed with centrifugally-balanced oil
cavities so that quick response and good control can
be achieved at any speed. A push/pull piston is incor­
porated for two of the three input clutches.
CAUTION: Some clutch packs appear similar, but
they are not the same. Do not interchange clutch
components as they might fail.
HYDRAULICS
The hydraulics of the new transaxle provide the
manual shift lever select function, main line pressure
regulation, and torque converter and cooler flow con­
trol. Oil flow to the friction elements is controlled
directly by four solenoid valves. The hydraulics also
include a unique logic-controlled "solenoid switch valve”
which locks out the 1st gear reaction element with the
application of 2nd, direct, or overdrive gear elements.
It also redirects the 1st gear solenoid output so that it
can control torque converter lockup operation. To re­
gain access to 1st gear, a special sequence of solenoid
commands must be used to unlock and move the sole­
noid switch valve. This precludes any application of
the 1st gear reaction element with other elements
applied, unless specifically commanded the controller.
It also allows one solenoid to control two friction
elements.
Small, high-rate accumulators are provided in each
controlled friction element circuit. These serve to ab­
sorb the pressure responses, and allow the controls to
read and respond to changes that are occurring.
 REVERSE CLUTCH 24 CLUTCH

21-64
DIFFERENTIAL
ASSEMBLY

TRANSAXLE
LOW/REVERSE
CLUTCH
SOLENOIDS
Since the solenoid valves perform virtually all con­
trol functions, these valves must be extremely durable
and tolerant of normal dirt particles. For that reason
hardened-steel poppet and ball valves are used. These
are free from any close operating clearances, and the
solenoids operate the valves directly without any in­
termediate element. Direct operation means that these
units must have very high output so that they can
close against the sizeable flow areas and high line
pressures. Fast response is also required to meet the
control requirements.
Two of the solenoids are normally-venting and two
are normally-applying; this was done to provide a
default mode of operation. With no electrical power,
the transmission provides 2nd gear in "OD,” "D,” or
"L” shift lever positions. All other shift lever positions
will function normally. The choice of 2nd gear was
made to provide adequate performance while still ac­
commodating highway speeds.
SENSORS
Other electrical components include: three pressure
switches to identify solenoid application, two speed
sensors to read input (torque converter turbine) and
output (parking sprag) speeds, and position switches
to indicate the manual shift lever position. The pres­
sure switches are incorporated in an assembly with
the solenoids. Engine speed, throttle position, temper­
ature, etc., are also observed. Some of these signals
are read directly from the engine control sensors; oth­
ers are read from a multiplex circuit with the engine
controller.
ELECTRONICS
The electronic control unit is located underhood in a
potted, diecast aluminum housing with a sealed, 60-way
connector.
ADAPTIVE CONTROLS
These controls function by reading the input and
output speeds over 140 times a second and responding
to each new reading. This provides the precise and
sophisticated friction element control needed to make
smooth clutch-to-clutch shifts for all gear changes with­
out the use of overrunning clutches or other shift
quality aids. As with most automatic transaxles, all
shifts involve releasing one element and applying a
different element. In simplified terms, the upshift logic
allows the releasing element to slip back wards slightly
to ensure that it does not have excess capacity; the
apply element is filled until it begins to make the
speed change to the higher gear; its apply pressure is
then controlled to maintain the desired rate of speed
change until the shift is complete. The key to provid­
ing excellent shift quality is precision; for example, as
mentioned, the release element for upshifts is allowed
to slip backwards slightly; the amount of that slip is
typically less than a total of 20 degrees. To achieve
that precision, the controller learns the characteris­
tics of the particular transaxle that it is controlling; it
learns the release rate of the releasing element, the
apply time of the applying element, the rate at which
the apply element builds pressure sufficient to begin
to make the speed change, and so on. This method
achieves more precision than would be possible with
exacting tolerances. It can also adapt to any changes
that occur with age or environment, for example, alti­
tude, temperature, engine output, etc.
For kickdown shifts, the control logic allows the
releasing element to slip and then controls the rate at
which the input (and engine) accelerate; when the
lower gear speed is achieved, the releasing element
reapplies to maintain that speed until the apply ele­
ment is filled. This provides quick response since the
engine begins to accelerate immediately and a smooth
torque exchange since the release element can control
the rate of torque increase. This control can make any
powertrain feel more responsive without in creasing
harshness.
Since adaptive controls respond to input speed
changes, they inherently compensate for changes in
engine or friction element torque and provide good,
consistent shift quality for the life of the transaxle.
DIAGNOSTICS
These controls also provide comprehensive, on-board
transaxle diagnostics. The information available can
aid in transaxle diagnosis. For example, apply ele­
ment buildup rate indicates solenoid performance. Also
included are self-diagnostic functions which allow the
technician to test the integrity of the electronic con­
trols without requiring a roadtest. The controller con­
tinuously monitors its critical functions, records any
malfunctions, and the number of engine starts since
the last malfunction. The technician can use this in­
formation in the event of a customer complaint.
 A-604 ULTRADRIVE DIAGNOSIS AND TESTS
INDEX
Page Page
Clutch Air Pressure T e s ts ............................................. 84 Fluid Leakage— Transaxle Torque Converter
Diagnosis General .......................................................... 66 Housing Area .............................................................. 84
Hydraulic Pressure Tests .............................................. 67

DIAGNOSIS GENERAL operation. Foaming can also result in fluid escaping

from the transaxle vent where it may be mistaken for
CAUTION: Before attempting any repair on the A-604 a leak.
Electronic Automatic Transaxle, always check for fault Along with fluid level, it is important to check the
codes with the DRBII using the “Powertrain Diag­ condition of the fluid. When the fluid smells burned,
nostic Test Procedure Manual (A-604).” and is contaminated with metal or friction material
particles, a complete transaxle overhaul is needed. Be
Ultradrive automatic transaxle malfunctions may
sure to examine the fluid on the dipstick closely. If
be caused by these general conditions:
there is any doubt about its condition, drain out a
(1) poor engine performance
sample for a double check.
(2) improper adjustments
After the fluid has been checked, seat the dipstick
(3) hydraulic malfunctions
fully to seal out water and dirt.
(4) mechanical malfunctions
(5) electronic malfunctions
GEARSHIFT LINKAGE
Diagnosis of these problems should always begin by Normal operation of the PRNDL and neutral safety
checking the easily accessible variables: fluid level
switch provides a quick check to confirm proper man­
and condition, gearshift cable adjustment. Then per­
ual linkage adjustment.
form a road test to determine if the problem has been
Move the selector level slowly upward until it clicks
corrected or that more diagnosis is necessary. If the
into the "P” Park notch in the selector gate. If the
problem exists after the preliminary tests and correc­
starter will operate the "P” position is correct.
tions are completed, hydraulic pressure checks should
After checking "P” position move the selector slowly
be performed.
toward "N” Neutral position until lever drops at the
end of the "N” stop in the selector gate. If the starter
FLUID LEVEL AND CONDITION
will also operate at this point the gearshift linkage is
The transmission and differential sump have a com­ properly adjusted. If adjustment is required, refer to
mon oil sump with a communicating opening be
gearshift linkage adjustment in Maintenance and Ad­
tween the two. justments and refer to DRBII in the "Diagnostic Test
The torque converter fills in both the ”P” Park and
Procedure Manual.”
"N” Neutral positions. Place the selector lever in "P”
Park to be sure that the fluid level check is accurate.
ROAD TEST
The engine should be running at idle speed for at Prior to performing a road test, be certain that the
least one minute, with the vehicle on level ground.
fluid level and condition, and control cable adjustment
This will assure complete oil level stabilization be­
have been checked and approved.
tween differential and transmission. The fluid should
During the road test, the transaxle should be oper­
be at normal operating temperature (approximately
ated in each position to check for slipping and any
82 C. or 180 F.). The fluid level is correct if it is in the
variation in shifting.
"HOT” region (cross-hatched area) on the oil level
If vehicle operates properly at highway speeds, but
indicator. Low fluid level can cause a variety of
has poor through-gear acceleration, the torque con­
conditions because it allows the pump to take in air
verter stator overrunning clutch may be slipping. If
along with the fluid. As in any hydraulic system, air
through-gear acceleration is normal, but abnormally
bubbles make the fluid spongy, therefore, pressures
high throttle opening is required to maintain highway
will be low and build up slowly.
speeds, the torque converter stator clutch may have
Improper filling can also raise the fluid level too
seized. Both of these stator defects require replace­
high. When the transaxle has too much fluid, the
ment of the torque converter.
gears chum up foam and cause the same conditions
In most cases, the clutch that is slipping can be
which occur with a low fluid level.
determined by noting the transaxle operation in all
In either case, the air bubbles can cause over heat­
selector positions and by comparing which internal
ing, fluid oxidation, and varnishing, which can inter­
units are applied in those positions. The "Elements in
fere with normal valve, clutch, and accumulator
Use Chart” provides a basis for road test analysis.
 ELEMENTS IN USE AT EACH POSITION OF THE SELECTOR LEVER
CLUTCHES
Shift
Lever Start Park LowI
Position Safety Sprog Underdrive Overdrive Reverse 2/4 Reverse
P - PARK
R - REVERSE
N — NEUTRAL
OP - OVERDRIVE
First
Second
Direct
Overdrive
DRIVE*
First
Second
Direct
L- LOW*
First
Second
Direct
* Vehicle upshift and downshift speeds are increased when in these selector positions. 9121-121

The process of eliminating can be used to detect any

unit which slips and to confirm proper operation of CLUTCH
good units. However, although road test analysis can
usually diagnose slipping units, the actual cause of
the malfunction usually can not be decided. Practi­
cally any condition can be caused by leaking hydrau­
lic circuits or sticking valves.

HYDRAULIC PRESSURE TESTS

Pressure testing is a very important step in the
diagnostic procedure. These tests usually reveal the
cause of most transaxle problems.
Before performing pressure tests, be certain that
fluid level and condition, and shift cable adjustments
have been checked and approved. Fluid must be at UNDERDRIVE CLUTCH LOW/REVERSE CLUTCH 9021-89
operating temperature 88 to 93 degrees C. (150 to 200
degrees F.). Fig. 1 Pressure Taps
Install an engine tachometer, raise vehicle on hoist
TEST ONE (SELECTOR IN "L" 1st gear)
which allows front wheels to turn, and position ta­
(1) Attach pressure gauge to the low/reverse clutch
chometer so it can be read.
tap.
Attach 150 psi gauges to ports required for test
(2) Move selector lever to the L position.
being conducted. A 300 psi gauge (0-3233) is required
(3) Allow vehicle wheels to turn and increase throt­
for reverse pressure test.
tle opening to achieve an indicated vehicle speed to 20
Test port locations are shown in (Figure 1).
mph.
 (4) Low/reverse clutch pressure should read 115 to
145 psi.
(5) This test checks pump output, pressure regula­
tion and condition of the low/reverse clutch hydraulic
circuit and shift schedule.
TEST TWO (SELECTOR IN “D” 2ND GEAR)
(1) Attach gauge to the underdrive clutch tap.
(2) Move selector lever to the D position.
(3) Allow vehicle wheels to turn and increase throt­
tle opening to achieve an indicated vehicle speed of 30
mph.
(4) Underdrive clutch pressure should read 110 to
145 psi.
(5) This test checks the underdrive clutch hydraulic
circuit as well as the shift schedule.
TEST THREE (OVERDRIVE CLUTCH CHECK)
(1) Attach gauge to the overdrive clutch tap.
(2) Move selector lever to the circle D position.
(3) Allow vehicle wheels to turn and increase throt­
tle opening to achieve an indicated vehicle speed of 20
mph.
(4) Overdrive clutch pressure should read 74 to 95
psi.
(5) Move selector lever to the D position and in­
crease indicated vehicle speed to 30 mph.
(6) The vehicle should be in second gear and over­
drive clutch pressure should be less than 5 psi.
(7) This test checks the overdrive clutch hydraulic
circuit as well as the shift schedule.
TEST FOUR (SELECTOR IN “CIRCLE D”
OVERDRIVE GEAR}
(1) Attach gauge to the 2/4 clutch tap.
(2) Move selector lever to the circle D position.
(3) Allow vehicle front wheels to turn and increase
throttle opening to achieve an indicated vehicle speed
of 30 mph.
(4) The 2/4 clutch pressure should read 75 to 95 psi.
(5) This test checks the 2/4 clutch hydraulic circuit.
TEST FIVE (SELECTOR IN CIRCLE D
OVERDRIVE LOCKUP)
(1) Attach gauge to the lockup off pressure tap.
(2) Move selector lever to the circle D position.
(3) Allow vehicle wheels to turn and increase throt­
tle opening to achieve an indicated vehicle speed of 50
mph.
CAUTION: Both wheels must turn at the same speed.
(4) Lockup off pressure should be less than 5 psi.
(5) This test checks the lockup clutch hydraulic
circuit.
TEST SIX (SELECTOR IN REVERSE)
(1) Attach gauge to the reverse clutch tap.
(2) Move selector lever to the reverse position.
(3) Read reverse clutch pressure with output sta­
tionary (foot on brake) and throttle opened to achieve
1500 rpm.
(4) Reverse clutch pressure should read 165 to 235
psi.
(5) This test checks the reverse clutch hydraulic
circuit.
TEST RESULT INDICATIONS
(1) If proper line pressure is found in any one test,
the pump and pressure regulator are working properly.
(2) Low pressure in all positions indicates a defec­
tive pump, a clogged filter, or a stuck pressure regula­
tor valve.
(3) Clutch circuit leaks are indicated if pressures do
not fall within the specified pressure range.
(4) If the overdrive clutch pressure is greater than 5
psi in step (6) of Test Three, a worn reaction shaft seal
ring is indicated.
 A-604 PRESSURE CHECK SPECIFICATIONS

PRESSURE TAP ORDER O N CASE FROM BELLHOUSING TO EN D COVER

ALL PRESSURE SPECIFICATIONS ARE PSI

(on hoist, with front wheels free to turn)

PRESSU RE TAPS
Gear Actual
S e le c to r Under- Over­ Reverse Lockup 2/4 Low/
P o sitio n Gear Drive Drive Reverse
Clutch Clutch Clutch Off Clutch Clutch
PAR *
PARK 0-5 0-2 60-110 0-2 115-145
0 mph
REVERSE ♦
REVERSE 0-2 0-7 165-235 50-100 0-2 165-235
0 mph
NEUTRAL *
NEUTRAL 0-2 0-5 0-2 60-110 0-2 115-145
0 mph
L # FIRST 110-145 0-5 0-2 60-110 0-2 115-145
20 mph
D * SECOND 110-145 0-5 0-2 60-110 115-145 0-2
30 mph
D # DIRECT 75-95 75-95 0-2 60-90 0-2 0-2
45 mph
OD # OVERDRIVE 0-2 75-95 0-2 60-90 75-95 0-2
30 mph
OD # OVERDRIVE
0-2 75-95 0-2 0-5 75-95 0-2
50 mph LOCKUP
*Engine speed at 1500 rpm
#CAUTION: Both front wheels must be turning at same speed.
 FAULT CODE CHART “A”
o
121-123

[Planetary
0 T, r—m m 32

with the speed error code.

i f a speed error (codes 50 through 58)

Code 36 is not stored alone. It is stored
is detected i mniediately after a shift.

Worn or damaged reaction

-o

Look at the possible causes associated

NOTE:

shaft support seal rings

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21 OD clutch— pressure too low X X X X X X X X X X X X X X X

22 2/4 clutch—pressure too low X X X X X X X X X X X X X X

23 2/4 clutch and OD dutch— X X X X X X X X X X X X X

pressures too low

24 L/R clutch—pressure too low X X X X X X X X X X X X X X

25 L/R clutch and OD clutches—

X X X X X X X X X X X X X
pressures too low
26 L/R clutch and 2 /4 clutches— X X X X X X X X X X X X X
pressures too low
27 O D , 2 /4 , and L/R clutches— X X X X X X X X X X X X X
pressures too low
31 O D clutch pressure switch f
X X X X X X X
response failure
32 2 /4 pressure switch X X X X X X
response failure
33 2 /4 and O /D clutch pressure X X X X X X
response failures
37 Solenoid switch valve stuck in X X X X
the LO position
38 Partial lockup control X X X X X X X X X
out of range
47 Solenoid switch valve X X X
X
stuck in the LR position

50 Speed ratio default i n reverse X X X X X X X X X X X X X X X X X

51 Speed ratio default in 1st X X X X X X X X X X X X X X X X X

52 Speed ratio default in 2nd X X X X X X X X X X X X X X X

53 Speed ratio default in 3rd X X X X X X X X X X X X X X X

54 Speed ratio default in 4th X X X X X X X X X X X X X X X

60 In ad equ ate LR element volume X X X X X

61 In ad equ ate 2 /4 element volume X X X X X

62 In ad equ ate O D element volume X X X X X

63 In ad equ ate U D element volume X X X X

 VU “ ~ L -V2 . . . . . . .
V~3 5 9 1 9
_ , r [9 9

TRANSAXLE
21-71
 UD(1 -2 -3 ) 0 D (3-4)

21-72
VU LY2

TRANSAXLE
X X X X X SOLENOIDS ENERGIZED
PUMP FILTER ..X X X M M
PRESSURE(PSI)
■r~r-r—
h—t—*— 120-145
X X X X X X X ^5^00 0 -5 15-40 LK/LU r247LRR UD ! OD
r ^ J X X X X X X X X X X X X X> AT 1500 RPM
LU ON RESIDUAL [SUCTION X
 UD(1 -2 -3 ) 0D (3-4) R(REV)
V3
vu

TRANSAXLE
-ii

21-73
■ ■ ■
X X X X X SOLENOIDS ENERGIZED
FILTER M M * M m ppccci
rl\to a Uiprfpert
r \t\ra I)
i r n r mT ^ K mmr mirmicmn 1175-235 5 0 -1 0 0 3 5 -8 5 LRl/LU 24/LR, UD OD
IX X X X X X X 0 -5 5 -4 0 at
n I 1
I Rnn pp
3UU K m
rn
m rx xxx xxx
I ................ I X X X X X X 1
1 LINE LU OFF LU ON RESIDUAL LUBE SUCTION
 R E V E R S E BLO CK

21-74
LU SHIFT TO REV. V/SPEED OVER 8 MPH I . V4
LR=LOW REVERSE 24 = 2 -4 CLUTCH ~ i _____r
UD=UNDERDRIVE OD ^OVERDRIVE

TRANSAXLE
R =REVERSE S V = S V I TCH

S ^SOLENOID
V =VENT

1 ■

. . . . . . . Y.Y. SOLENOIDS ENERG ZED

ILJ

PRESSURE(PSI) LfVLU 24/LR, UD OD

3 5 -8 5 0 -5 5 -4 0
AT 1500 RPM
LU ON RESIDUAL LUBE SUCTI X
TRANSAXLE 21-75
 21-76
TRANSAXLE
I* I I I
V © N R
D P
L ( 5921-6
m rm
. . . . . . . . . . . i i i l l i l X X X X X
■ ■ ■ * MMMM
SOL ENOIDS ENERG ZED
__ FILTER PRESSURE(PSI)
|1 2 0 -1 45 6 0 -1 1 0 | 4 5 -1 0 0 0 -5 15-40 LK./LU 24/LR, UD OD
X X X X X X X
“ X X M M X J AT 1500 RPM
I LINE LU OFF LU ON RESIDUAL LUBE SUCTI
SECOND GEAR
V 1 ^ M V 2
PARTIAL LOCKUP
t r

TRANSAXLE
i n ------- ____ i

i
I 1 '
V ® N R
D P
L 8 9 2 1 -7
T n m

21-77
X X K K X SOLENOIDS ENERGI ZED
PRESSURE(PSI) LFVLU 24/LR,, UD
4 0 -1 0 0 0 -5 5 -3 0 OD
AT 1500 RPM
LU ON RESIDUAL LUBE SUCTION
 21-78
LR=LOV REVERSE 24 = 2 -4 CLUTCH
UD=UNDERDRI VE OD OVERDRIVE

TRANSAXLE
R =REVERSE SV=SVITCH
AC= ACCUMULATOR LU =LOCKUP
3 PT=PRESSURE TAP D =DRIBBLER
PT S =SOLENOID
V =VENT

rt— _ 1-1 rrj£

. c j LU SV VALVE

if
V lv 1 :

n RESERVO IR n u l l ----- r i u — r t r n j lA j t n i

fl REGULATOR |B W H N 1 manual! [v a l v e ! 1 *
JT-I 1(' — " T L-n il' I I I '
V
V Tv j| V I V <g) N R

L 8 92 1-8
^w^trTtriirit
X X X X X
MM X M M SOLENOI DS ENERGIZED
1PUMP FILTER PRESSURE(PSI)
T T " 4 5 -8 0 0 -5 7 5 -4 0 " ' LR|/LU [24/LR, UD OD
X X X X X X X
X X X X X X AT 1500 RPM
LU ON RFSIDUAL LUBE SUCTION X X
2 -3 ) \) R(REV)
V

TRANSAXLE
21-79
D IR E C T G E A R

21-80
FULL LOCKUP

TRANSAXLE
 TRANSAXLE
111 I i I 1
V ®N R
D P
■11
-Wm
WW-W^
MMX
X*X* x* * SOLENOIDS ENERGIZED

21-81
PRESSURE(PSI)
6 0 -9 0 4 5 -8 0 0 -5 15-40 LRl/LU 24/LR, UP OD
AT 1500 RPM
I LINE LU OFF LU ON RESIDUAL LUBE SUCTION X X
 O V ER DR IV E LR(R-N-1) UD( 1 -2 -3 ) 0D (3-4) R(REV)

21-82
|__V4 V tJ
FUL L L OCKUP
LR=LOV REVERSE 24 = 2 -4 CLUTCH
UD=UNDERDRIVE OD OVERDRIVE
R =REVERSE SV=SVITCH H

TRANSAXLE
T /C AC= ACCUMULATOR LU =LOCKUP
. B J
AC AC PT AC PT

j r r
9 -

°' ®
OFF ON

OFF ON
SV

r i_ _ _ RESERVOIR n J * ----- J l ----- r *u—! ■ ■ ■ ___ ij —l. ______ i

REGULATOR ™ \j ■ r- 1 | MANUAL! 1VALVEi |
0 4
i r — ..C3....— ■ f " ™ L-nII f W W T '~ n \ f I I I 1
v T . Tv Jl V I V ®N R
■ K p

8 9 2 1 -1 2
SOLENOIDS ENERG ZED
kPUMP FILTER PRESSURE(PSI) LfVLU 24/LR, UD
7 5 -9 5 OD
AT 1500 RPM
LINE X X X
CLUTCH AIR PRESSURE TESTS
CLUTCH MIR PRESSURE C H EC K S
Inoperative clutches can be located using a series of
tests by substituting air pressure for fluid pressure
(Figs. 2 and 3). The clutches may be tested by apply­
ing air pressure to their respective passages after the
valve body has been removed and Tool 6056 has been
installed. To make air pressure tests, proceed as follows:
The compressed air supply must be free of all dirt
and moistyre. Use a pressyre of 30 psi.
Remove oil pan and valve body. (See Valve body
removal.)
O VERD RIVE CLUTCH
Apply air pressure to the overdrive clutch apply
passage and watch for the push/pull piston to move
forward. The piston should return to its starting posi­
tion when the air pressure is removed.
R E V E R S E CLUTCH
Apply air pressure to the reverse clutch apply pas­
sage and watch for the push/pull piston to move rear­
ward. The piston should return to its starting position
when the air pressure is removed.
2/4 CLUTCH
Apply air pressure to the feed hole located on the
2/4 clutch retainer. Look in the area where the 2/4
piston contacts the first separator plate and watch
carefully for the 2/4 piston to move rearward. The
piston should return to its original position after the
air pressure is removed.
LO W /REVERSE CLUTCH
Apply air pressure to the low/reverse clutch feed
hole (rear of case, between 2 bolt holes). Then, look in
the area where the low/reverse piston contacts the
first separator plate and watch carefully for the piston
to move forward. The piston should return to its origi­
nal position after the air pressure is removed.
UNDERDRIVE CLUTCH
Because this clutch piston cannot be seen, its opera­
tion is checked by function. Air pressure is applied to
the low/reverse and the 2/4 clutches. This locks the
output shaft. Use a piece of rubber hose wrapped around
the input shaft and a pair of clamp-on pliers to turn
the input shaft. Next apply air pressure to the under-
drive clutch. The input shaft should not rotate with
hand torque. Release the air pressure and confirm
that the input shaft will rotate.
FLUID LEAKAGE— TRANSAXLE
TORQUE CONVERTER HOUSING AREA
(1) Check for source of leakage.
. Since fluid leakage at or around the torque con­
verter area may originate from an engine oil leak, the
area should be examined closely. Factory fill fluid is
dyed red and, therefore, can be distinguished from
engine oil.
(2) Prior to removing the transaxle, perform the
following checks:
When leakage is determined to originate from the
transaxle, check fluid level prior to removal of the
transaxle and torque converter.
High oil level can result in oil leakage out the vent
in the manual shaft. If the fluid level is high, adjust to
proper level.
After performing this operation, inspect for leak­
age. If a leak persists, perform the following operation
on the vehicle to determine if it is the torque con­
verter or transaxle that is leaking.

DUST MATERIAL: 5 " x l-l/2 " x
SHIELD 1/32" SHEET METAL
BOLT
Fig. 4 Leak Locating Test Probe Tool
LEAKAGE TEST PROBE
(1) Remove torque converter housing dust shield.
(2) Clean the inside of torque converter housing
(lower area) as dry as possible. A solvent spray fol­
lowed by compressed air drying is preferable.
(3) Fabricate and fasten test probe (Fig. 4) securely
to convenient dust shield bolt hole. Make certain torque
converter is cleared by test probe. Tool must be clean
and dry.
(4) Run engine at approximately 2,500 rpm with
transaxle in neutral, for about 2 minutes. Transaxle
must be at operating temperature.
(5) Stop engine and carefully remove tool.
(6) If upper surface of test probe is dry, there is no
torque converter leak. A path of fluid across probe
indicates a torque converter leak. Oil leaking under
the probe is coming from the transaxle torque con­
verter area.
(7) Remove transaxle and torque converter assem­
bly from vehicle for further investigation. The fluid
should be drained from the transaxle. Reinstall oil
pan (with RTV sealant) at specified torque.
WELD BREAK EDGE 1/16" MIN.
OR BRAZE
POLISH
OUTSIDE
OF OPEN
‘ END FOR
THIS DISTANCE
ON TUBE
MATERIAL: 1-1/2 INCH O.D. THIN
WALLED STEEL TUBING AND
1/8 INCH STEEL DISC RN780
Possible sources of transaxle torque converter area
fluid leakage are:
(1) Torque converter hub seal.
(a) Seal lip cut, check torque converter hub finish.
(b) Bushing moved and/or worn.
(c) Oil return hole in pump housing plugged or
omitted.
(d) Seal worn out (high-mileage vehicles).
(2) Fluid leakage at the outside diameter from pump
housing O-ring.
(3) Fluid leakage at the froiit pump to case bolts.
Check condition of washers on bolts and use new bolts,
if necessary.
(4) Fluid leakage due to case or front pump housing
RY287 porosity.
TORQUE CONVERTER LEAKAGE
Possible sources of torque converter leakage are:
(a) Torque converter weld leaks at the out side
(peripheral) weld.
(b) Torque converter hub weld.
Hub weld Is Inside and not visible. Do not attempt to
repair. Replace torque converter.
AIR PRESSURE TEST OF TRANSAXLE
Fabricate equipment needed for test as shown in
Figures 5 and 6.
The transaxle should be prepared for pressure test
as follows after removal of the torque converter:
(1) Plug dipstick tube and plug oil cooler line fit­
ting. Remove vent from manual shaft and in stall a
1/8 inch pipe plug.
CAUTION: Prevent manual shaft rotation during in­
stallation and removal.
(2) With rotary motion, install converter hub seal
cup over input shaft, and through the converter hub
seal until the cup bottoms against the pump gear
lugs. Secure with cup retainer strap (Fig. 6) using
starter upper hole and opposite bracket hole.
15/32" DRILL 2 HOLES
1.498
1-1/4" WIDE RY288A
 (8) Attach and clamp hose from nozzle of Tool C-4080 that pump housing and case trout may be covered
to the upper cooler line fitting position in case. with soapy solution of water. Leaks are sometimes
caused by porosity in the case or pump housing,
CAUTION: Do n©t, ynder any circumstances, pres-
■ If a leak source is located, that part and all associ­
syriz# a tlansaxle to more than 10 psi.
ated seals, O-rings, and gaskets should be replaced
(4) Pressurize the transaxle using Tool C-4080 until with new parts.
the pressure gauge reads 8 psi. Position transaxle so

DIAGNOSIS GUIDE-ABNORMAL NOISE

DIAGNOSIS GUIDE-VEHICLE WILL NOT MOVE

DIAGNOSIS GUIDE FLUID LEAKS

9121-126
 POSSIBLE CAUSE
Engine Performance X X X X X
Worn or faulty clutch(es) X X X X X X X X X X
— Underdrive clutch X X X X X X
— Overdrive clutch X X X X X
— Reverse clutch X X X X
— 2/4 clutch X X X X
— Low/reverse clutch X X X X X
Clutch(es) dragging X
Insufficient clutch plate clearance X X
Damaged clutch seals X X X
Worn or damaged accumulator seal ring(s) X X X X X
Faulty cooling system X
Engine coolant temp, too low X X
incorrect gearshift control
linkage adjustment X X X X X

Shift linkage damaged X

Chipped or damaged gear teeth X X
Planetary gear sets broken or seized X X
Bearings worn or damaged X X
Driveshaft(s) bushing(s) worn or damaged X
Worn or broken reaction shaft
support seal rings X X X X X

Worn or damaged input shaft seal rings X X X

Valve body malfunction or leakage X X X X X X X X X X X
Hydraulic pressures too low X X X X X X X
Hydraulic pressures too high X X X X
faulty oil pump X X X X X
Oil filter clogged X X X X X
Low fluid level X X X X X X X X
High fluid level X X
Aerated fluid X X X X X X X X X
Engine idle speed too low X X
Engine idle speed too high X X X X
Normal solenoid operation X
Solenoid sound cover loose X
Sticking lockup position X
Torque Converter Failure X X X
BLOWS OUT FILLER TUBE
DELAYED ENGAGEMENT

TRANSAXLE OVERHEATS
HARSH ENGAGEMENT

DURING SHIFTS ONLY

| HARSH LOCKUP SHIFT

GRATING, SCRAPING,
POOR SHIFT QUALITY

Q£
HARSH DOWNSHIFTS
FROM NEUTRAL TOD

FROM NEUTRAL TOD

HIGH SHIFT EFFORTS

DRIVES IN NEUTRAL

UJ
GROWLING NOISE

oo
NO UPSHIFT INTO
DRAGS OR LOCKS

HARO TO FILL OIL

oz
BUZZING NOISE
NOISE

HARSH UPSHIFT
SHIFTS ERRATIC

NO LOCKUP

6
OVERDRIVE

Z Z
2
BUZZING

£Z
o u
Z oz
9121-127 «
 MAINTENANCE AND ADJUSTMENTS (A-604)
INDEX
Page Page
Gearshift Linkage Adjustment 90 Lubrication 89

LUBRICATION
Inspect fluid level on indicator every six months
(Fig. 1) with engine idling and trahsaxle in park or
neutral position. Allow the engine to idle for at least
one minute with vehicle on level ground. This will
assure complete oil level stabilization between differ­
ential and transmission. A properly filled transaxle SEE SELECTION OF LUBRICANT
will read near the "add” mark when fluid temperature FOR RECOMMENDED FLUID TYPE
is 21 degrees Celsius (70 degrees Fahrenheit). When
8900-4
the transaxle reaches operating temperature the fluid
should be in the "HOT” region.
Fig. 2 Oil Level Indicator
FLUID AMD FILTER CHANGES
If the transaxle is disassembled for any reason, the
Fluid and filter changes are not required for aver­
fluid and filter should be changed.
age passenger vehicle usage.
Severe usage as defined below, requires that fluid
DRAIN AND REFILL
and filter be changed, the magnet (on the inside of the
(1) Raise vehicle on a hoist (See Lubrication, "Group
oil pan) should be cleaned with a clean, dry cloth
0”). Place a drain container with a large opening,
every 24000 km (15,000 miles).
under transaxle oil pan.
(a) More than 50%^Speration in heavy city traffic
(2) Loosen pan bolts and tap the pan at one comer
during hot weather above 32°C (90°F).
to break it loose allowing fluid to drain, then remove
(b) Police, Taxi, Commercial Type Operation, and
the oil pan.
Trailer Towing.
(3) Install a new filter and O-ring on bottom of the
When the factory fill fluid is changed, only fluids of
valve body.
the type labeled MOPAR ATF PLUS (Automatic Trans­
(4) Clean the oil pan and magnet. Reinstall pan
mission fluid) Type 7176, or DEXTRON II, should be
using new RTV sealant. Tighten oil pan bolts to 19
used. A filter change should be made at the time of
N-m (165 in. lbs.).
the oil change. Also the magnet (on the inside of the
(5) Pour four quarts of MOPAR ATF PLUS (Auto­
oil pan) should be cleaned with a clean, dry cloth.
matic Transmission Fluid) Type 7176, or DEXTRON
II, through the fill tube.
(6) Start engine and allow to idle for at least one
minute. Then, with parking and service brakes ap­
plied, move selector lever momentarily to each posi­
tion, ending in the park or neutral position.
(7) Add sufficient fluid to bring level to 1/8 inch
below the ADD mark.
Recheck fluid level after transaxle is at normal op­
erating temperature. The level should be in the HOT
region (Fig. 1).
To prevent dirt from entering transaxle, make cer­
tain that dipstick is seated into the dipstick fill tube.
GEARSHIFT LINKAGE ADJUSTMENT
When it is necessary to disassemble linkage cable
from levers, which use plastic grommets as retainers,
the grommets should be replaced with new grommets.
Use a prying tool to force rod from grommet in lever,
then cut away old grommet. Use pliers to snap new
grommet into lever and rod into grommet.
CAUTION: Set parking brake.
(1) Place gearshift lever in "P” (PARK) position.
(2) Loosen clamp bolt on gearshift cable bracket.
(3) Column shift: Insure that preload adjustment
spring engages fork on transaxle bracket.
SERVICE IH VEHICLE (A-604)
Page
Al uminum Thread R e p a ir ...........................................
Distance Sensor Gear ................................................
GENERAL INFORMATION
Various transaxle components can be removed for
repairs without removing the transaxle from the vehi­
cle. The removal, reconditioning, and installation pro­
cedures for some of these components are covered here.
The valve body (see service out of vehicle) may be
serviced in the vehicle, as can the parking sprag,
solenoid assembly, PRNDL Switch, Neutral/Safety
switch, and extension housing oil seal.
DISTANCE SENSOR GEAR
When the distance sensor is removed for any rea­
son, a NEW O-ring must be installed on its outside
diameter.
REMOVAL AMD INSTALL
(1) Remove harness connector from sensor. Make
sure weatherseal stays on harness connector.
(2) Remove bolt securing the distance sensor in the
extension housing.
(3) Carefully pull sensor and pinion gear assembly
out of extension housing.
(4) Pull the shift lever by hand all the way to the
front detent position (PARK) and tighten lock screw
to 11 N'm (100 in. lbs.). Gearshift linkage should now
be properly adjusted.
(5) Check adjustment as follows:
(a) Detent position for neutral and drive should
be within limits of hand lever gate stops.
(b) Key start must occur only when shift lever is
in park or neutral positions.
(6) To remove button assembly, completely remove
knob attaching fasteners. Pull knob up sharply. Pro­
ceed as outlined in console removal, "Group 23.”
After console is back in place, install knob and
button by reversing the above procedure.
INDEX
Page
90 General Information 90
90
(4) Remove pinion gear from sensor.
(5) To install, reverse the above procedure. Make
sure extension housing and sensor flange are clean
prior to installation. Always use a NEW sensor O-ring.
(6) Tighten securing bolt to 7 N-m (60 in. lbs.). Tighten
speedometer cable to 4 N-m (35 in. lbs.).
ALUMINUM THREAD REPAIR
Damaged or worn threads in the aluminum transaxle
case and valve body can be repaired by the use of
Heli-Coils, or equivalent. Essentially, this repair con­
sists of drilling out the worn-out damaged threads,
tapping the hole with a special Heli-Coil tap, or equiv­
alent, and installing a Heli- Coil insert, or equivalent,
into the tapped hole. This brings the hole back to its
original thread size.
Heli-Coil, or equivalent, tools and inserts are read­
ily available from most automotive parts suppliers.
 SERVICE OUT OF VEHICLE (A-604)
INDEX
Page Page
Accumulators .............................................................. 99 Output Speed S e n so r.................................................. 96
Coolers and Tubes Reverse Flushing ....................... 91 PRNDL Switch ............................................................ 95
Determining No. 4 Thrust Plate Thickness Solenoid Assembly-Replace ..................................... 94
(Input Shaft End P la y )........................................... 113 Subassembly Recondition .......................................... 115
Differential Repair ...................................................... 126 Transaxle Recondition ................................................ 100
Neutral Safety Switch ............................................... 95 Transaxle Removal and Installation ......................... 91
Oil Cooler Flow Check ............................................... 91 Valve B o d y ................................................................ .... 96
Oil Pump Seal Replace ............................................. 100

COOLERS AND TUBES REVERSE FLUSHING
When a transaxle failure has contaminated the fluid,
the oil cooler(s) must be flushed and the cooler bypass
valve in the transaxle must be replaced. The torque
converter must also be replaced with an exchange
unit. This will insure that metal particles or sludged
oil are not later transferred back into the recondi­
tioned (or replaced) transaxle.
CAUTION :lf the vehicle is equipped with two oil cool­
ers (one in the radiator tank, one in front of the
radiator) they must be flushed separately. Do not
attempt to flush both coolers at one time.
(1) Disconnect the cooler lines at the transmission.
(2) Using a hand suction gun filled with mineral
spirits, reverse flush the cooler by forcing mineral
spirits into the From Cooler line of the cooler (Fig. 1).
Catch the exiting spirits from the To Cooler line.
Observe for the presence of debris in the exiting fluid.
Continue until fluid exiting is clear and free from
debris.
(4) To remove any remaining mineral spirits from
the cooler, one (1) quart of automatic transmission
fluid should be pumped through the cooler prior to
reconnecting the hoses to the transmission.
(5) If at any stage of the cleaning process, the cooler
does not freely pass fluid, the cooler must be replaced.
OIL COOLER FLOW CHECK
After the new or repaired transmission has been
installed and filled to the proper level with automatic
transmission fluid, the flow should be checked using
the following procedure:
(1) Disconnect the From cooler line at the trans­
mission and place a collecting container under the
disconnected line.
(2) Run the engine at curb idle speed, with the
shift selector in neutral.
(3) If the fluid flow is intermittent or it takes more
than 20 seconds to collect one quart of automatic trans­
mission fluid, the cooler should be replaced.
CAUTION: WITH THE FLUID SET AT THE PROPER
LEVEL, FLUID COLLECTION SHOULD NOT EXCEED
(1) QUART OR INTERNAL DAMAGE TO THE TRANS­
MISSION MAY OCCUR.
(4) If flow is found to be within acceptable limits,
reconnect the cooler line and fill transmission to the
proper level, using the approved type of automatic
transmission fluid.

TRANSAXLE REMOVAL AND INSTALLATION

Transaxle removal does NOT require engine removal.
See Group 7-Cooling, to drain engine cooling system
and remove coolant return extension (3.0 liter engine
only).
On vehicles equipped with All Wheel Drive, the
power transfer unit (P.T.U.) must be removed before
removing the transaxle. Refer to P.T.U Removal and
Installation in this section for procedures.
(3) Using compressed air in intermittent spurts, blow
(1) The transaxle and torque converter must be re­
any remaining mineral spirits from the cooler, again
moved as an assembly; otherwise, the torque converter
in the reverse direction.
drive plate, pump bushing or oil seal may be dam­
aged. The drive plate will not support a load; there­
fore, none of the weight of the transaxle should be
allowed to rest on the drive plate during removal.
(2) Disconnect negative battery cable.
(3) Disconnect transaxle shift linkage.
(4) Install engine support fixture and support en­
gine (Fig.l).

Fig. 3 Remove Torque Converter Dust Shield

(9) Mark torque converter and drive plate with chalk,

for reassembly. Remove torque converter mounting
bolts.
(10) Disconnect electrical connectors at PRNDL
switch and neutral safety switch (Fig. 4).
Fig. 1 Engine Support Fixture

(5) Remove bell housing upper bolts.

(6) Raise vehicle. Remove front wheels. Refer to
"Suspension, Group 2” to remove wheel hub nut and
both driveshafts.
(7) Remove left plastic splash to gain access to the
transaxle (Fig. 2).

(11) Remove front engine mount insulator and

bracket.

(8) Remove torque converter dust shield to gain

access to torque converter bolts (Fig. 3).
 SENSOR TRANSAXLE

Fig. 5 Remove Front Engine Mount

(12) On vehicles equipped with D.I.S.ignition sys­

tem, remove crankshaft position sensor from bell-
housing (Fig. 6). For installation procedure refer to PIN I O N 908E-12
section 8D of this service manual.
CAUTION: Failure to remove the crankshaft position Fig. 7 Remove Distance Sensor
sensor from the bellhouslng could cause damage to
(14) Remove starter bolts and set starter aside. Do
the sensor or the torque converter drive plate during
not allow the starter to hang from battery cable (Fig.
transmission removal or installation.
8).
\w
| CRANK POSITION
SENSOR

DISTANCE SENSOR

908D-6

Fig. 6 Remove Crank Position Sensor

(D.I.S. Ignition Only)

(13) Disconnect and remove vehicle distance sensor (15) Position transm ission jack securely under
(Fig. 7). transaxle.
 When installing transaxle, reverse the above pro­
cedure.
Check and/or adjust gear shift cable.
Refill transaxle with MOPAB ATF PLUS (Auto­
matic Transmission Fluid) Type 7176 or equivalent.

SOLENOID ASSEilLY-iEPLACE
OUTPUT
1 SPEED
ENSOR

PR2171A

Pig, 9 Position Transmission Jack

(18) With transmission jack in position, remove the

left transmission mount (Fig. 10).

Pig. I Input Speed Senaor

Fig. 10 Remove Left Transmission Mount

(17) Carefully lower the transaxle assembly from

: prndl
vehicle. 8921-21 "‘SWITCH
Im 2 Input Speed Sensor Removed

TRANSMISSION
JACK
 PRNDL SWITCH
CAUTION: Switch seal washer must be seated prop­
erly before tightening switch. Failure to do so may
result In leakage of transmission fluid.

Fig. 3 Sound Cover

Fig. 1 PRNDL Switch

NEUTRAL SAFETY SWITCH

CAUTION: Switch seal washer must be seated prop­
erly before tightening switch. Failure to do so may
result in leakage of transmission fluid.

Fig. 4 Attaching Screws

OUTPUT SPEED SENSOR

Fig. 1 Output Speed Sensor O-RING OIL

FILTER
VALVE BODY
Prior to removing any transaxle subassemblies, plug
all openings and thoroughly clean exterior of the unit,
preferably by steam. Cleanliness through entire disas­
sembly and assembly cannot be overemphasized. When
disassembling, each part should be washed in a suit­
able solvent, then dried by compressed air. Do not
wipe parts with shop towels. All mating surfaces in
the transaxles are accurately machined; therefore, care­
ful handling of all parts must be exercised to avoid
nicks or burrs.
Tag all springs, as they are removed, for reassem­
8921-30
bly Identification.
Fig. 3 Oil Filter
OIL PAN
BOLTS VALVE BODY VALVE BODY ATTACHING
(USE RTV UNDER BOLTS (18)
BOLT HEADS)

8921-28
 MANUAL SHAFT SCREW

SCREWDRIVER 8921-32 8921-35

Fig. 5 Push Park Rod Rollers from Guide Bracket Fig. S M m m l Shaft Scmw
DETENT OVERDRIVE CLUTCH
SPRING (#5) HALL CHECK

f2»4 ACCUMULATOR-
RETAINING PLATE 8921-36

Fig. S Remove or Install fa ir# Body Fig. § Retaining Plate Scmw

INSTALL DETENT VALVE BODY SEPARATOR OVERDRIVE CLUTCH
POSITION PLATE (#5) UAH CHECK

TRANSFER
PLATE

PARK
ROD 8921-34. OIL SCREEN ^ ---- --------------- 8921-37

Fig. 10 Transfer Plate and Separator Plate

 RETAINER

BALL CHECK

RETAINER

RETAINER

THER..-.. -
(INSTALL AS SHOWN) 8921-67 BALL CHECK‘D 8921-38

Pig. 11 Transfer Plate Fig. 12 Ball Check and Retainer Locations

< K
ROOSTER COMB

RETAIN ER

24 ACCUMULATOR

□ □ 0 ( 6 3 W M i! ! S ® f
REGULATOR ¥AL¥E ^RETAINER
INER /
_ ^ m RETAIL
^RETAINER
SOLENOID SWITCH VALVE ffl ta W H D O

MANUAL VALVE
B = 4 t= 0 = 0 = 0
RETAINERS

LOCKUP
SWITCH VALVE c a n n o n
Tit CONTROL VALVE criitotnni
VALVES REMOVED VALVES.'INSTALLED

Fig. 13 Springs ami Wsiiwm Id m tlflm tlm

 ACCUMULATORS

Fig. 14 Remove or Install Dual Retainer Plate

Fig. 1 Accumulators
ACCUMULATOR RETURN

Fig. 2 Accumulator
When installing valve body assembly onto transaxle,
observe Figure 5 and guide park rod rollers into guide
bracket, while shifting manual lever assembly out of
the installation position.
 OIL PUMP SEAL REPLACE

Fig. 4 Low/Reverse Accumulator Plug (Cover)

Fig. 5 Low/Reverse Accumulator Piston

TRANSAXLE RECONDITION
Tag all clutch pack assemblies, as they are re­
moved, for reassembly identification.
CAUTION: Do not intermix clutch discs or plates as
the unit might then fail.

INPUT SHAFT END PLAY

Measuring input shaft end play before disassembly
will usually indicate when a # 4 thrust plate change is
required, (except when major parts are replaced). The
# 4 thrust plate is located behind the overdrive clutch
hub.
(1) Attach a dial indicator to transaxle bell housing
with its plunger seated against end of input shaft
(Fig. 1).
 d ia l in d ic a t o r CAUTION: Be sure Input speed sensor is removed
before removing oil pump.

INPUT SHAFT'

Fig. 1 Measure Input Shaft End Play

8921-53
Move input shaft in and out to obtain end play Fig. 4 Remove Oil Pump
reading. End play specifications are .13 to .64 mm
(.005 to .025 inch). cs o OIL PUMP
Record indicator reading for reference when reas­
sembling the transaxle.
PUMP
HOUSING

/ 8921-55
Fig. 6 Oil Pump Gasket
CAUTION :The cooler bypass valve must be replaced if
a transaxle failure has occurred. Do not reuse old valve
PUMP or attempt to clean old valve. When installing bypass
valve, insert with O-ring end towards rear of case.
 9121-130

Fig. 10 Front Sun Gear Assembly

Fig. 7 Remove Cooler Bypass Valve
#1 CAGED FRO NT CARRIER A N D REAR
NEEDLE BEARING ANNULUS ASSEMBLY
{TWIST AND PULL OR
PUSH TO REMOVE OR
INSTALL).

8921-59

Fig. 11 Front Carrier and Rear Annulus Assembly

Fig. 8 No. 1 Caged Needle Bearing
#7 NEEDLE / ^ /& A

#4 THRUST < ^ ----- N

WASHER 9
Fig. 13 214 Clutch Retainer Snap Ring Fig. 16 214 Clutch Return Spring

Fig. 14 Remove 214 Clutch Retainer Fig. 17 2/4 Retainer and Spring Indexed
LOW/REVERSE CLUTCH •SCREWDRIVER
REACTION
PLATE LOW/REVERSE TAPERED
SNAP RING
(TAPERED SIDE UP)

F/g. 19 Tapered Snap Ring Pig. 21 Snap Ring Installed

VIEW FROM IELLHOUS1NG

SNAP RING ENDS
TAPERED SNAP RING LOCATED IN CASE
(NOT BY REACTION
PLATE LUGS)
ACROSS FROM
OIL PAN FACE.

F lf. 22 LowlReveree Reaction Plate

SEQUENCE
®IHRU®= REMOVE
A THRU H = INSTALL DO NOT REUSE SNAP RING
/— —
TRANSAXLE CASE OIL PAN FACE ^ 8921 99
SCREWDRIVER LOW/REVERSE REACTION REAR COVER (3 __ 1/8 INCH BEAD OF
PLATE FLAT SNAP RING RTV SEALANT
AS SHOWN

DO NOT SCRATCH
CLUTCH PLATE 1

Fig. 24 Low/Reverse Reaction Plate Snap Ring Fig. 27 Rear Cover

CLUTCH PLATES I W \ CLUTCH TRANSFER SHAFT OUTPUT GEAR
' DISCS (5) GEAR

CAUTION: TAG AND IDENTIFY'

PACKS TO ASSURE
ORIGINAL PLACEMENT. 8921-74 TOOL 6259 8921-77

Fig. 25 Low/Reverse Clutch Pack Fig. 28 Remove Transfer Shaft Gear Nut

Tag low/reverse clutch pack for reassembly identi­ TRANSFER

SHAFT ''
fication.
REAR COVER REAR COVER
BOLTS

NUT WASHER \[ 8921-78

BOLTS TOOL 1-4407-6 TRANSFER SHAFT GEAR OUTPUT SHAFT ©^BEARING CUP RETAINER

TOOL 1-4407 SHIM (SELECT]

Fig. 30 Remove Transfer Shaft Gem Fig. 33 Transfer Shaft Gem and (Select) Shim
ALIGN INDEXING TAB
TO SLOT

BEARING CUP RETAINER 9121-131

Fig. 31 Install Transfer Shaft Qear Fig. 34 Bm rlng Cup Retainer

TRANSFER SHAFT 200 FT. LIS.W TORQUE WIENCH TOOL 5048
GEAR WITH JAWS
TOOL 5048-4
AND BUTTON
TOOL 1-4539-2

9021-93
 TRANSFER SHAFT
TOOL 6051 BEARING SNAP RING
©

TRANSFER;!- 9
SHAFT 8921-88

Fig. 36 Install Transfer Shaft Bearing Cone Fig. 39 Transfer Shaft Bearing Snap Ring

Fig. 37 Remove Transfer Shaft Bearing Cup Fig. 40 Transfer Shaft

HANDLE C-4171 ARBOR PRESS RAM TRANSFER SHAFT

TOOL P-334

BEARING CONE

iiijliijjiijuiii: iiiiiini'i

[ | 8921 -90
 BOLT 8921-94

Fig. 42 Install Bearing Cone Fig. 45 Output Gear Bolt and Washer
BEARIN G CUP BEARING CONE

O-RING

TRANSFER SHAFT

-OIL BAFFLE 8921-92

Fig. 43 Bearing Cup Removed Fig. 46 Remove Output Gear

OUTPUT GEAR TORQUE WRENCH

Fig. 48 Tighten Output Gear to 271 N m (200 Ft. Lbs.) Fig. 51 Install New Bearing Cone

REAR CARRIER
ASSEMBLY

8921-98 8921-101

Fig. 49 Output Gear and (Select) Shim Fig. 52 Rear Carrier Assembly

Fig. 50 Remove Bearing Cone Fig. 53 Remove Rear Carrier Bearing Cone
 Fig. 54 Install Rear Carrier Bearing Cone Fig. 57 Remove or Install Snap Ring

Fig. 55 Low/Reverse Spring Compressor Tool Fig. 58 Low/Reverse Piston Return Spring
LOW/REVERSE C L U T C H ^ SNAP RING

Fig. 59 Drive Out Anchor Shaft

CAUTION: When installing, be sure guide bracket

and split sleeve touch the rear of the transaxle case.
 GUIDE
BRACKET

ANTIRATCHET
SPRING
(MUST BE ASSEMBLED
AS SHOWN)

9121-201

Fig. 60 Anchor Shaft and Plug Fig. 63 Guide Bracket Assembled

Fig. 61 Guide Bracket Pivot Shaft Fig. 64 Guide Bracket Disassembled

 c OUTPUT BEARING
CUPS
(REPUCE IN PAIRS)

HAMMER ^ ' 5 ^ ^ 8921-118

Fig. 69 Remove Output Bearing Inner Cup

LOW/REVERSE CAUTION: Drift bearing cup all the way around.
CLUTCH PISTON ^
RETAINER

GASKET 8921-116

Fig. 67 Piston Retainer

GASKET HOLES: 9 9 LOW/REVERSE CLUTCH
MUST PISTON RETAINER Fig. 70 Remove Output Bearing Outer Cup
GASKET
 To assemble, reverse the above procedure. Be sure
to check both grounded clutch clearances (Figs. 74
and 75). Before installing the input clutches retainer,
follow the instructions in "Determining No. 4 Thrust
Plate Thickness” (Figs. 76, 77, 78, 79).
Fig. 72 Checking Output Gear Bearings End Play
Fig. 73 Checking Output Gear Bearings Turning Torque
Press down clutch pack with finger and zero dial
indicator. Low/Reverse clutch pack clearance is 1.04
to 1.65mm (.042 to .065 inch).
Select the proper low/reverse reaction plate to achieve
specifications:
LOW/REVERSE REACTION PLATE CHART
THICKNESS________________
6 .9 2 mm (.2 7 3 in.)____________________
6 .6 6 mm (.2 6 2 in.)
6 .4 0 mm (.2 5 2 in.)
6.14 mm (.242 in.)
5 .8 8 mm (.2 3 2 in.)
5 .6 2 mm (.221 in.)
5 .3 6 mm (.211 in.)
9121-4
Press down clutch pack with finger and zero dial
indicator. The 2/4 clutch pack clearance is 0.76 to
2.64mm (.030 to .104 inch). If not within specifica­
tions, the clutch is not assembled properly. There is
no adjustment for the 2/4 clutch clearance.
DETERMINING No. 4 THRUST PLATE
THICKNESS (Input Shaft End Play)
To determine the proper thickness of the No. 4 thrust
plate, select the thinnest No. 4 thrust plate. Using
petrolatum (Fig. 76) to hold thrust plate in position,
install input clutches assembly. Be sure the input
clutches assembly is completely seated (Fig. 77).
 OVERDRIVE THINNEST By removing the oil pump O-ring, you will be able
SHAFT #4 THRUST to install and remove the oil pump and gasket very
ASSEMBLY PLATE
(SELECT] easily to select the proper No. 4 thrust plate.
CAUTION: Be sure to reinstall O-ring on oil pump
after selecting the proper No. 4 thrust plate.

3 DAIS OF
PETROLATUM.
FOR RETENTION

9121-180

f lf . 76 Select Thinnest Wo. 4 Thrust Plate

\ INPUT
INPUT (TURBINE)
SPEED SENSOR
HOLE
CLUTCHES
RETAINER

Fig. 79 Measure Input Shaft End Play

Input shaft end play must be .005 to .025 inch.

For example, if end play reading is .055 inch, select
No. 4 Thrust Plate which is .071 to .074 thick. This
should provide an input shaft end play reading of .020
inch which is within specifications.
See chart below to select the proper No. 4 thrust
plate.

8921-179 No. 4 THRUST PLATE CHART

Fig. 77 View Through Input Speed Sensor Hole

CAUTION: If view through inout speed sensor hole Is

not as shown above, the input clutches assembly is
not seated properly. SHIM THICKNESS
mm inch
OIL PUMP
ASSEMBLY 0 .9 3 -1 .0 0 .0 3 7 -.0 3 9
1.1 5 -1 .2 2 .0 4 5 -0 4 8
1 .3 7 -1 .4 4 .0 5 4 -0 5 7
1 .5 9 -1 .6 6 .0 6 3 - 0 6 6
1.8 1 -1 .8 8 .0 7 1 - 0 7 4
2 .0 3 -2 .1 0 .0 8 0 -0 8 3
2 .2 5 - 2 .3 2 .0 8 9 - 0 9 1
2 .4 7 - 2 .5 4 .0 9 7 - . 100
2 .6 9 - 2 .7 6 .1 0 6 -. 109
O-RING 2 .9 1 -2 .9 8 .1 1 4 -1 1 7
3 .1 3 - 3 .2 0 .1 2 3 - 1 2 6
3 .3 5 - 3 .4 2 . 132—. 135
SUBASSEMBLY RECONDITION REVERSE CLUTCH
REACTION PLATE
INPUT CLUTCHES ASSEMBLY (INSTALL FLAT
SIDE DOWN)
DISASSEMBLY
#4 THRUST
PLATE (SELECT)
REVEISE CLUTCH
REACTION PLATE

TAP DOWN
REYEISI CLUTCH
REACTION PLATE
TO REMOVE OR 9121-137
INSTALL SNAP RING
J66 4 Rmmme Clutch Reaction Plate
REVERSE CLUTCH iEVERSE CLUTCH
INPUT SHAFT CLUTCHES PLATE DISC
RETAINER ASSEMBLY i ; i/ m] 9121-132

Fig. f Tapping Reaction Plate

REACTION
PLATE
CAUTION: TAG
AND IDENTIFY
CLUTCH PACKS
TO ASSURE
ORIGINAL
PLACEMENT

9121-130

Fig. 5 Rmeme Clutch Pack

Tag rewerse clutch pack for reassem blf identi­

9121-135 fication.
OD/REVERSE OVERDRIVE
PRESSURE CAUTION; TAG
CLUTCH PtATE AND IDENTIFY
PLATE
(STEP SIDE CLUTCH PACKS TO
DOWN)
ASSURE ORIGINAL
PLACEMENT

OVERDRIVE
SHAFT
ASSEMBLY
OVERDRIVE
9121-140 CLUTCH DISC 9121-134
Fig. 7 OD/fteverse Pressure Plate F lf. 10 OwBfdrlwe Clutch Pack
OD/REVERSE CLUTCH WAVED Tag ©Yerifiw© clutch pack for reassem blf Identi­
SNAP RING
fication.

/ i
OVERDRIVE-
SHAFT
ASSEMBLY 9121-141

f lf . i Pared Snap Ring

OVERDRIVE #3 THRUST
SHAFT PLATE
ASSEMBLY F lf, I I OwerdFlwe Shaft Mssembly
AND OD
CLUTCH
PACK
#3 THRUST
WASHER

UNDERDRIVE
SHAFT
ASSEMBLY 9121-142
 ONE UNPEftPilVE
CLUTCH DISC

9121-147

Fig. 13 No. 2 Needle Bearing Pig. I i Remove One UD Clutch Disc

OVERDRIVE/UNDERDRIVE SCREWDRIVER UNDERDRIVE CLUTCH
CLUTCHES REACTION PLATE (DO NOT SCRATCH REACTION PLATE
TAPERED SNAP RING REACTION PLATE) FIAT SNAP RING

CAUTION:
DC) NOT
REUSE
TAPERED
SNAP RING 9121-145 9121-14®

Fig. 14 ODiUD Reactton Plate Tapered Snap Ring Fig. 17 UD Clutch fla t Sm p Ring
ODIUD CLUTCH ONE UD CLUTCH
REACTION DISC
PLATE
(STEP SIDE
DOWN)

iS iS ^ 9121-149

Fig. 18 Underdrive Clutch Pack

 Tag underdrive clutch pack for reassembly identi­
fication.
CAUTION: Compress return spring just enough to
remove or install snap ring.
SNAP RING PLIERS ARBOR PRESS RAM

SNAP RING

Fig. 22 Input Hub Tapered Snap Ring

9121-150

Fig. 19 UE> Spring Retainer Snap Ring

UNDERDRIVE SNAP RING
SPRING
RETAINER

LIP SEAL

Fig. 23 Tap on Input Hub

PISTON INPUT SHAFT AND INPUT CLUTCHES

RETURN HUB ASSEMBLY RETAINER
SPRING 9121-151

Fig. 20 UD Return Spring and Retainer

PISTON

O-RING

OVERDRIVE/REVERSE PISTO N'' 9121-155

 CLUTCH ONE UP CLUTCH
PLATE DISC

CAUTION: TAG
AND IDENTIFY
CLUTCH PACKS
TO ASSURE
ORIGINAL
REPLACEMENT

9121-149

f lf . 28 Remove Input Shaft Smp Ring

ARBOR PRESS iAMv

(COMPRESS \
iETURN SPRING X
JUST ENOUGH
TO REMOVE O I INSTALL
SNAP RING)

RETURN
SPRING SPECIAL
TOOL 6057

O^ftEVEiSi
PISTON 9121-157

f lf . 26 Install Smp Ring

ODIRIVEiSI RETURN SNAP RING ASSEMBLY
PISTON SPRING Use petrolatum on all seals to ease assembly of
components.
UNPEiPRIVE ' ' ^ SNAP RING
SPRING
RETAINER

UP SEAL

O-RING 9121-158

PISTON
RETURN
SPRING
 Fig. 2 install Input Shaft Snap Ring Fig. 5 Install OD/Reverse Piston
OD/REVERSE RETURN SNAP RING
PISTON SPRING

O-RING 9121-158

Fig. 3 Return Spring and Snap Ring Fig. 6 Install Input Shaft Hub Assembly
 ARIOi PRESS SNAP RING
RAM PLIERS
PISTON
SPECIAL
TOOL 5059-
SPECIAL
TOOL 5067
SNAP RING

0PMEYEISE
9121-152 PISTON 9121-161

J66 i Underdrlwe Clutch Piston Ff§. 11 Install UD Spring Retainer and Snap Ring
PISTON SPECIAL TOOL 5067 CLUTCH ONE UD CLUTCH
RETURN PLATE DISC
SPRING

CAUTION: TAG
AND IDENTIFY
CLUTCH PACKS
TO ASSURE
ORIGINAL
INPUT SHAFT REPLACEMENT
CLUTCHES
RETAINER
ASSEMBLY 9121-181 9121-149

Fig. i Seal Compressor Tool 5067 F lf. 12 Underdriwe Clutch Pack

UNDERDRIVE SNAP RING UNDERDRIVE CLUTCH
SPRING REACTION PLATE
RETAINER FLAT SNAP RING

UP SEAL

PISTON
RETURN
SPRING 9121-151 9121-148

Fig, 10 UD Return Spring and Retainer

CAUTION: Compress return spring Just enough to

mmme or install snap ring.
ONE UNPERPRiVE Snap ring ©nds must be located w ithin one finger
CLUTCH DISC
of the Input clutch hub. B© sure that.snap ring Is
fu lly seated, by pushing with screwdriver, Into snap
ring groow# all the way around.
SCREWDRIVER

Fig. 14 Install Last UD Clutch Disc

OD/UD CLUTCH
REACTION
PLATE 9121-162
(STEP SIDE
DOWN) fig . 17 Smtlng Taper&d Snap Ring
SELECT REACTION
PLATE FOR PROPER UNDERDRIVE
CLUTCH CLEARANCE

DIAL INDICATOR

9121-146

Fig. 15 OD/UD Reaction Plate COMPRESS

CLUTCH PACK
OVERPRiVE/UNDERDRiVE SCREWDRIVER WITH FINGER
CLUTCHES REACTION PLATE (DO NOT SCRATCH TO ZERO
TAPERED SNAP RING REACTION PLATE) DIAL INDICATOR 9121-163

F lf. f S Set Up Dial Indicator for Clutch Clearance

HOOK TOOL J '

CAUTION:
DO NOT
REUSE
TAPERED
SNAP RING 9121-145

9121-182
 U nderirlve clutch p ic k cltaranc© must be 0.91 to OYERDRIVE/REVERSI
1.47mm (.036 to .058 inch). Select the proper reaction
plate to achieve specifications:

( jm m m iv E r e a c t io n p la te chart

THIC ICNiSS
6.99 mm (.275 in.)
6.50 mm (.256 in.)
6.01 mm (.237 in.)
5.52 mm (.217 in.)
9121-5
f lf . 22 OD/Reverse Pressure Plate
OVERDRIVE/
REVERSE

Pig. 23 Pressure Plate Installed

OVERDRIVE REACTION PLATE
WAVED SNAP RING ARBOR PRESS
RAM

CAUTION: FLAT
PRESS SNAP
DOWN RING
JUST
ENOUGH
^ SCREWDRIVER TO
EXPOSE
SNAP
9121-165 RING
GROOVE
HOOK TOOL OVERDRIVE/REVERSE iEVERSE CLUTCH CREWDRIVER
PRESSUiE PLATE SNAP RING
(SELECT)

iEVERSE
CLUTCH
DIAL REACTION
INDICATOR 9121-169 PLATE 9121-172

Fig. 25 Check OD Clutch Pack Clearance F lf. 28 Install Reveme Clutch Snap Ring

The ©weririwe (OD) ciytch pack clearance Is .965 SCREWDRIVER SNAP SCREWDRIVER
to 2.26 mm (.038 to .089 Inch). If not within specifica­
tions, the clutch is not assembled properly. There is
no adjustment for the OD clutch clearance.

REVERSE lEVEftSE
CLUTCH CLUTCH
PLATE DISCS

MUST
RAISE
REVERSE
REACTION
PLATE TO
iAiSE
SNAP RING 9121-173
F lf. 29 Seating Snap Ring to
Determine Reverse Clutch Clearance

COMPRESS CLUTCH PACK WITH

9121-170 FINGER TO ZERO INDICATOR

F lf. 28 Install Reverse Clutch Pack

REVERSE
CLUTCH
REACTION
PLATE
(FLAT
SIDE DOWN)

9121-174
F lf. 30 Check Reverse Clutch Pack Clearance
 The reverse clutch pack clearance is 0.76 to 1.24mm
(.030 to .049 Inch). Select the proper reverse clutch
snap ring to achieve specifications:

REVERSE CLUTCH SNAP RING CHMRT

THICKNESS
1.56 mm (.061 in.)
1.80 mm (.071 in.)
2.05 mm (.081 in.
2.30 mm (.090 in.)
9121-6
All clutch clearances in the input clutches retainer
have now been checked and approved.
To complete the assembly of the input clutches re­ Pig. 33 Install No. 3 Thrust Washer
tainer, the reverse clutch and the overdrive clutch
must be removed from the retainer. OVERDRIVE DAIS OF
SHAFT PETROLATUM
CAUTION: Do not Intermix clutch parts. Keep In ex­ ASSEMBLY (FOR RETENTION)
act same order.
Now proceed with the next phase of the assembly:
#2 NEEDLE ^ ^TAIS UP
BEARING
(NOTE 3
SMALL
TABS)

#3 THRUST
PLATE
8921-173 (NOTE 3 TABS)

Flf. 34 Install No. 3 Thrust Plate

OVERDRIVE #3 THiUST
SHAFT PLATE
ASSEMBLY
9121-175

Pig. 31 Install No. 2 Immme Bearing

#3 THiUST
WASHIR 9121-178

f l f . 35 Install Owerdrlwe Shaft Mssembfy

Now that both shaft assemblies and thrust washers

are properly installed, reinstall overdrive clutch and
reverse clutch as shown in Figures 20 through 28.
Rechecking these clutch clearances is not neces­
sary, as they were set and approved previously.
 OVERDRIVE SHAFT
ASSEMBLY

9121-179

Pig. 36 Input Clutches Assembly f l f . 3 Differential Cower Bolts

DIFFERENTIAL REPAIR DIFFERENTIAL 1/8 INCH BEAD

ASSEMBLY OF RTV SEALANT
The transfer shaft should be removed for differen­
tial repair and bearing turning torque checking.

EXTENSION HOUSING

OIL SEAL DIFFERENTIAL COVERS 8921-185

f l f . 4 Remove o r Install Differential Cower

DIFFERENTIAL
RETAINER BOLTS
PR2306A

f lf . f Remove Extension Seal

8921-186

%EXTENSION HOUSING HAMMER

 EXTENSION HOUSING

EXTENSION BOLTS 8921-189

Fig. 6 Remove or Install Bearing Retainer Fig. 8 Extension Bolts (Front Wheel Drive Vehicles)

9 9 //! /9 /A

1/8 INCH BEAD OF RTV SEALANT — 8921- 188

Fig. 7 Differential Bearing Retainer Fig. 9 Remove or Install Extension

(Front Wheel Drive vehicles)
CAUTION:Vehicles equipped with All Wheel Drive have
EXTENSION DIFFERENTIAL
a retainer plate instead of an extension housing. MBLY
Remove retainer plate bolts to remove retainer plate.
Disregard Fig. 8, 9 and 10 on vehicles equipped with g
All Wheel Drive.

1/8 INCH BEAD OF RTV SEALANT

CAUTION:Vehicles equipped with Ail Wheel Drive m e TOOL L4406-1
a larger differential bearing on the retainer plat© side WITH ADAPTERS L4406-3
of the differential assembly. Be sure to use the cor­
rect special tools when remowlng or Installing the
differential bearing.
SPECIAL TOOL
C-293
SPECIAL TOOL
C-4996
(NOTE POSITION)

SPECIAL TOOL
ADAPTEt C-293-45
(USE 4 PIECES)
DIFFERENTIAL
ASSEMBLY RING GEAR 8921-192

f l f . 14 Remove Differential Bearing Cone (All)

DlffERENTIAL
BEARING CONE RP453

f l f . I I 6 6 6 6 6 6 Differential Bearing Cone

(Front Wheel Driwe)

Fig. 15 Install Differential Bearing Cone (Ail)

Fig. 12 666666 Differential Bearing Cone TORQUE WRENCH RING GEAR

BOLTS
(All Wheel Driwe)
SPECIAL TOOL
HANDLE C-4171
ARBOR PRESS RAM
SPECIAL TOOL
L-4410
(FRONT WHEEL DRIVE
SPECIAL TOOL VEHICLES)
6536-A
(ALL WHEEL DRIVE
VEHICLES)
DlffERENTIAL
ASSEMBLY
HOLTS MUST IE
PROPERLY TORQUED 8921-194
IEAUNG CONE
Fig. 16 Torque New Ring Gem Bolts to
9121-262 95 N-m (70 F t Lbs.)
CAUTION: Always install NEW ring gear bolts. Bolts side g e a r (2)
SIDE GEAR THiUST
must be properly torqued.
WASHER (2)
HAMMER STEEL [SELECT THICKNESS]
PUNCH
ROLL PIN PINION GEAR
THiUST WASHER

PINION
SHAFT

PINION GEAR (2)

RP461
DIFFERENTIAL
CASE
RP458 Flf. 20 Differential Gears
SPECIAL TOOL €^4996 DIAL INDlCATOi SIT
Fig. 17 fiem me Pinion Shaft Roll Pin (NOTE POSITION)

PINION SHAFT

MOVE
SIDE GEAR
UP AND DOWN

SIDE GEAR- x WPPEiEWTlAl

_ _ ASSEMBLY
RP462

Flf. 21 Checking Side Gem End Play

RP459
DIFFERENTIAL CASE"
CAUTION: Sid# gear end play must be within .001 to
Fig. 18 Remove or Install Pinion Shaft .013 Inch.
DIFFERENTIAL
CASE
Four select thrust washers are available: .032, .037,
.042, and .047 inch.
SPECIAL TOOL C-4996
(NOTE POSITION)
SIDE GEAR (2)
MOVE
SIDE GEAR
UP AND DOWN

PINION
RP460
GEAR (2)#
Flf. 19 Fiemme or Install Pinion Gems, Side Geere, DIFFERENTIAL
and Tabbed Thrust Washers, by Rotating Pinion Gmm
to Opening in Differential Case ASSEMBLY
CAUTION: Side gear © ni play must be within .001 to D e t m m m i m s h i m t h ic k n e s s
.013 Inch. Shim thickness need only be determined if any of
the following parts are replaced:
Four select thrust washers are available: .032, .§37,
(a) transaxle case
.042, and .§47 inch.
(b) differential carrier
(c) differential bearing retainer
(d) extension housing
(e) differential bearing cups and cones
SCREWDRIVER Refer to "Bearing Adjustment Procedure” in rear of
this section to determine proper shim thickness for.
correct bearing preload and proper bearing turning
torque.
BEARING CUP
LUBRICATION HOLE
DIFFERENTIAL
BEARING
RETAINER

PR2326

Fig. 23 Ramova Oil 8 m l

(SELECT) SHIM
“ARBOR PiESS RAM TO DETERMINE
DIFFERENTIAL
BEARING PRELOAD

SPECIAL TOOL SPECIAL TOOL 1-452© DIFFERENTIAL

HANDLE C-4171 (INVERTED) BEARING RETAINER PR23BA

F lf. 26 Differential Bearing Retainer

DIFFERENTIAL
BEARING /Q
RETAINER

PRESS

RB758 HANDLE C-4171

F lf. 24 Install emw oil Seal

DIFFERENTIAL BEARING CUP

BEARING
RETAINER

REARING PR2330A
cm
F lf. 27 Install Bearing Cup

When rebuilding, reverse the above procedure.

Remow® old RTV before applying new RTV Sealant.
Use RTV Sealant m retainer to seal retainer to case.
 Flg. 30 Checking Differential Bearings Turning Torque

Fig. 28 Checking Differential End Play

 BEARING ADJUSTMENT PROCEDURE (A-604)
INDEX
Page Page
Differential Bearing ............................................ 13 2 Output Gear Bearing ........................................... 132
General Rules On Servicing Bearings .................. 13 2 Transfer Shaft B e a rin g ......................................... 133

GENERAL RULES ON SERVICING BEARINGS If the turning torque is too high, install a .04 mm
(.0016 inch) thicker shim. If the turning torque is too
(1) Take extreme care when removing and in stall­ low, install a .04 mm (.0016 inch) thinner shim. Re­
ing bearing cups and cones. Use only an arbor press peat until the proper turning torque is 3 to 8 inch
for installation, as a hammer may not properly align pounds.
the bearing cup or cone. Burrs or nicks on the bearing
seat will give a false end play reading, while gauging OUTPUT GEAR BEARING SHIM CHART
for proper shims. Improperly seated bearing cup and
cones are subject to low-mileage failure. End Play I n d P lo y
(with # .5 0 666 Required (w ith 4 .5 0 it«6 Required
(2) Bearing cups and cones should be replaced if g a u g in g sh im S him g a u g in g sh im Shim
they show signs of pitting or heat distress. in s ta lle d ) Installed)
If distress is seen on either the cup or bearing roll­ mm Inch mm mm Inch mm
ers, both cup and cone must be replaced.
Bearing end play and drag torque specifications must .05 .002 4.42 3 .021 3.94
.08 .003 4.38 .56 .022 3.90
be maintained to avoid premature bearing failures. .10 .004 4.38 .58 .023 3.^
Used (original) bearing may lose up to 50% of the .13 .005 4.34 .61 .024 3i
original drag torque after break-in. .15 .006 4.30 .64 .025 3.1
All bearing adjustments must be made with no .18 .007 4.30 .66 .026 3i
.20 .008 4.26 .69 ' .027 3.7
other component interference or gear inter-mesh, ex­ .23 .009 4.22 .71 .028 3.7
cept the transfer gear bearing. .25 .010 4.22 .74 .029 3.7
Oil all bearings before checking turning torque. .28 .011 4.18 .76 .030 3.7
.30 .012 4.14 .79 .031 3i
.33 ,013 4.14 .81 .032 3i
OUTPUT GEAR BEARING .36 .014 4.10 .84 .033 3.62
.38 .015 4.10 .86 .034 3.62
With output gear removed: .41 .016 4.06 .89 .035 3.58
(1) Install a 4.50 mm (0.177 inch) gauging shim on .43 ’.017 4.02 .91 .036 3.54
.46 0.18 4.02 .94 .037 3.54
the rear carrier assembly hub, using grease to hold .48 .019 3.98 .97 .038 3.50
the shim in place. Jl .020 3.94
(2) Install output gear and bearing assembly. Torque Average conversion .04 mm =.0016 inch 9121-255
to 271 N-m (200 ft. lbs.).
(3) To measure bearing end play:
DIFFERENTIAL BEARING
(a) Attach Tool L-4432 to the gear.
(1) Remove the bearing cup from the differential
(b) Push and pull the gear while rotating back
bearing retainer using Tool L-4518, and remove the
and forth to insure seating of the bearing rollers.
existing shim from under the cup.
(c) Using a dial indicator, mounted to the transaxle
(2) Install a .50 mm (.020 inch) gauging shim and
case, measure output gear end play.
reinstall the bearing cup into the retainer. Use an
(4) Once bearing end play has been determined,
arbor press to install the cup.
refer to the output gear bearing shim chart for the
Oil Baffle is not required when making shim
required shim to obtain proper bearing setting.
selection.
(5) Use Tool 6259 to remove the retaining nut and
(3) Install the bearing retainer into the case and
washer. To remove the output gear, use Tool L-4407.
torque bolts to 28 N*m (250 in. lbs.).
(6) Remove the gauging shim and install the proper
(4) Position the transaxle assembly vertically on the
shim. Use grease to hold the shim in place. Install the
support stand and install Tool C-4995 into side gear.
output gear and bearing assembly.
(5) Rotate the differential at least one full revolu­
(7) Install the retaining nut and washer and torque
tion to ensure the tapered roller bearings are fully
to 271 N-m (200 ft. lbs.).
seated.
(8) Using an inch-pound torque wrench, check the
turning torque. The torque should be between 3 and
8 inch-pounds.
 DIFFERENTIAL BEARING SHIM CHART The turning torque should be between 5 and 18
inch-pounds.
End Play If the turning torque is too high, install a .05 mm
(with .50 mm Required (.002 inch) thinner shim. If the turning torque is too
gaug in g shim Shim Total
Installed) Combination Thickness low, install a .05 mm (.002 inch) thicker shim. Repeat
mm mm until 5 to 18 inch-pounds turning torque is obtained.
inch mm inch
.0 .0 .50 .50 .020
.05 .002 .75 .75 .030
TRANSFER SHAFT BEARING
.10 .004 .80 .80 .032 (1) Use Tool 6259 to remove the retaining nut and
.15 .006 .85 .85 .

.90 .90 .035

washer. Remove the transfer shaft gear using Tool
.20 .008
.25 .010 .95 .95 .037 L-4407.
.30 .012 1.00 1.00 .039 (2) Install a 4.66 mm (.184 inch) gauging shim on
.35 .014 1.05 1.05 the transfer shaft.
.40 .016 .50 + .60 1.10 .
(3) Install transfer shaft gear and bearing assembly
.45 .018 .50 + .65 1.15 .045
and torque the nut to 271 N-m (200 ft. lbs.).
.50 .020 .50 + .70 1.20 .047
.55 .022 .50 + .75 1.25 .049 (4) To measure bearing end play:
.60 .024 .50 + .80 1.30 .051 (a) Attach Tool L-4432 to the transfer gear.
.65 .026 .50 + .85 1.35 .053 (b) Mount a steel ball with grease into the end of
.70 .027 .50 + .90 1.40 .055 the transfer shaft.
.75 .029 .50 + .95 1.45 .057 (c) Push and pull the gear while rotating back
.80 .031 .50 + 1.00 1.50 .059
.85 .033 .50 + 1.05 1.55 .061 and forth to insure seating of the bearing rollers.
.90 .035 1.00 + .60 1.60 .063
.95 .037 1.00 + .65 1.65 .065 TRANSFER BEARING SHIM CHART
1.00 .039 1.00 + .70 1.70 .067
1.05 .041 1.00 + .75 1.75 .069
1.10 .043 1.00 + .80 1.80 .071 End Play End Play
1.15 .045 1.00 + .85 1.85 .073 (with 4.66 mm Required (with 4.66 mm Required
1.20 .047 1.00 + .90 1.90 .075 gaug ing shim Shim gauging shim Shim
1.25 .049 1.00 + .95 1.95 .077 installed) installed)
1.30 .051 1.00 + 1.00 2.00 .079 mm inch mm mm inch mm
1.35 .053 1.00 + 1.05 2.05 .081
1.40 .055 1.05 + 1.05 2.10 .083 .05 .002 4.66 .79 .031 3.90
.08 .003 4.62 .81 .032 3.<;
9121-256
.10 .004 4.58 .84 .033 3.£
(6) Attach a dial indicator to the case and zero the .13 .005 4.58 .86 .034 3.82
dial indicator. Place the indicator tip on the end of .15 .006 4.54 .89 .035 3.82
Tool L-4436. .18 .007 4.50 .91 .036 3./
.20 .008 4.50 .94 .037 3./
(7) Place a large screwdriver to each side of the ring
.23 .009 4.46 .97 .038 3.7
gear and lift. Check the dial indicator for the amount .25 .010 4.46 .99 .039 3.7
of end play. .28 .011 4.42 1.02 .040 3.66
.30 .012 4.38 1.04 .041 3.66
CAUTION: Do not damage the transaxle case and/or
.33 .013 4.38 1.07 .042 3.62
differential cover sealing surface. .36 .014 4.34 1.08 .043 3.62
(8) When the end play has been determined, refer to .38 .015 4.30 1.12 .044 3.58
.41 .016 4.30 1.14 .045 3.54
the Differential Bearing Shim Chart for the correct
.43 .017 4.26 1.17 .046 3.54
shim combination to obtain the proper bearing setting. .46 .018 4.22 1.19 .047 3.50
(9) Remove the differential bearing retainer. Re­ .48 .019 4.22 1.22 .048 3.46
move the bearing cup and the .50 mm (.020 inch) .50 .020 4.18 1.24 .049 3.46
gauging shim. .53 .021 4.18 1.27 .050 3.42
(10) Install the proper shim combination under the .56 .022 4.14 1.30 .051 3.38
bearing cup. Make sure the oil baffle is installed prop­ .58 .023 4.10 1.32 .052 3.38
erly in the bearing retainer, below the bearing shim .61 .024 4.10 1.35 .053 3.34
.64 .025 4.06 1.37 .054 3.34
and cup. .66 .026 4.02 1.40 .055 3.30
(11) Install the differential bearing retainer. Seal .69 .027 4.02 1.42 .056 3.26
the retainer to the housing with RTV Sealant and .71 .028 3.98 1.45 .057 3.26
torque bolts to 28 N*m (250 in. lbs.). .74 .029 3.94 1.47 .058 3.22
(12) Using Tool C-4995 and an inch-pound torque .76 .030 3.94
wrench, check the turning torque of the differential.
 (d) Using a dial indicator, measure transfer shaft BEARING SHIM CHART
end play.
(5) Refer to the Transfer Bearing Shim Chart for
im
the required shim combination to obtain the proper Thick Bearin;
bearing setting. Transfer
O utput Diff
(6) Use Tool 6259 to remove the retaining nut and mm inch G ear Shaft ential
washer. Remove the transfer shaft gear using Tool
3.22 .127 X X —
L-4407. 3.26 .128 X X —

(7) Remove the gauging shim and install the correct 3.30 .130 X X —

shim. Install the transfer gear and bearing assembly. 3.34 .132 X X —

(8) Install the retaining nut and washer and torque 3.38 .133 X X —

to 271 N-m (200 ft. lbs.). Measure transfer shaft end 3.42 .135 X X —

3.46 .136 X X ■ —
play, end play should be .05 to .10 mm (.002 to .004 3.50 .138 X X —

Inch). 3.54 .139 X X

(9) Measure bearing end play as outlined in Step 3.58 .141 X X —

(4). End play should be between .05 mm and .10 mm 3.62 .143 X X —

(.002 to .004 inch). 3.66 .144 X X —

3.70 .146 X X —
If end play is too high, install a .04 mm (.0016 inch) 3.74 .147 X X —

thinner shim. If end play is too low, install a .04 mm 3.78 .149 X X —

(.0016 inch) thicker shim combination. Repeat until 3.82 .150 X X —

.05 to .10 mm (.002 to .004 inch) end play is obtained. 3.86 .152 X X —

3.90 .154 X X —

3.94 .155 X X —

3.98 .157 X X —

4.02 .158 X X —

4.06 .160 X X —

4.10 .161 X X
4.14 .163 X X —

4.18 .165 X X —

4.22 .166 X X —

4.26 .168 X X _ _

4.30 .169 X X —

4.34 .171 X X —

4.38 .172 X X —

4.42 .174 X X —

4.46 .175 X X —

4.50 .177 X* X —

4.54 .178 X X —

4.58 .180 X X —

4.62 .182 X X —

4.66 .183 X X* —

0.50 .020 — —

0.55 .022 — — X
0.60 .024 — — X
0.65 .026 — — X
0.70 .027 — — X
0.75 .029 — — X
0.80 .031 — — X
0.85 .033 — — X
0.90 .035 — — X
0.95 .037 — — X
1.00 .039 — — X
1.05 .041 —
* Also used as gauging shims 9121-1
 ALL WHEEL DRIVE POWER TRANSFER UN IT (P.T.U.)
GENERAL INFORMATION
The Power Transfer Unit (P.T.U.) is attached to a
modified automatic transaxle case where the right
half shaft extension housing would normally be lo­
cated. The Transfer Unit provides the power to the
rear wheels through a hypoid ring gear and pinion
set.
The Power Transfer Unit is sealed from the transaxle
and has its own oil sump. The Unit uses SAE 85W-90
gear lubricant and holds 1.15 liters (1.22 quarts).
The Power Transfer Unit fill plug is located on the
end cover (Fig. 1). Do not mistake the black plastic
inspection plug located on the P.T.U. case for the fill
plug.

Fig. 1 Fill Plug Location

Service of the Power Transfer Unit is limited to the

seals, gaskets and one ball bearing. If the ring gear
and pinion, any tapered roller bearings, case, covers,
or pinion carrier fail the entire unit must be replaced.

!
 POWER TRANSFER UNIT SERVICE PROCEDURES
INDEX
Page Page
Fluid Leak Diagnosis .......................................... 136 Power Transfer Unit Input Shaft Seal .................. 140
Output Flange Shim Selection ............................ 145 Power Transfer Unit Outer Half Shaft S e a l ........... 150
Power Transfer Unit End Cover Ball Bearing ....... 151 Power Transfer Unit Output Seal And/Or Flange . . . 143
Power Transfer Unit End Cover— Reseal .............. 139 Power Transfer Unit (P .T .U .) .............................. 137
Power Transfer Unit H alf Shaft Inner Seal ........... 147 Power Transfer Unit Rear Cover O-Ring .............. 142
Power Transfer Unit Input Shaft Cover S e a l ......... 145 Seal Identification .............................................. 136
Power Transfer Unit Input Shaft End Seal ........... 149 Transaxle Differential Carrier Seal ....................... 142

SEAL IDENTIFICATION
For accurate seal diagnosis and repair seal name
and location is critical. Refer to figures 1, 2, 3 and 4
for appropriate seal name and location.

Fig. 1 Seal Location

REAR COVER END COVER

OUTER
HALFSHAFT
SEAL
FLUID LEAK DIAGNOSIS
P.T.U. OUTPUT SEAL CASE 9121-239 When diagnosing fluid leaks on the Power Transfer
Unit assembly two weep holes are provided to diag­
Fig. 2 Seal Location nose certain seal leaks. These holes are located on the
bottom side of the assembly (Fig. 1).
 f lf , I Weep Hole locations Fig. 1 Remove Cross Member Bridge Bolts

If fluid leak is detected from either weep hole, seal

replacement is necessary. Do not attempt to repair
the leak by sealing weep holes, they must be kept
clear of sealants for proper seal operation.
If fluid is leaking from weep hole "A” (Fig. 1) the
type of fluid leaking will determine which seal needs
to be replaced. If the fluid leaking is red in color
(transmission fluid) this indicates that the Transmis­
sion differential carrier seal should be replaced. If the
fluid leaking is light brown (gear lube) this indicates
that the Power Transfer Unit input seal should be
replaced. For replacement of these seals refer to Power
Transfer Unit Service Procedures.
If fluid is leaking from ■weep hole W B” (Fig. 1) the
type of fluid leaking will determine which seal is
leaking. If the fluid leaking is red in color (transmis­
sion fluid) this indicates that the input shaft end seal Fig. 2 Remove Power Steering Hose Bracket
should be replaced. If the fluid leaking is light brown
(gear lube) this indicates that the half shaft inner seal
and P.T.U. input shaft cover seal should be replaced.
For replacement of these seals refer to Power Transfer
Unit Service Procedures.
Before condemning any seal or gasket be sure that
the rear rocker arm cover on the engine is not the
cause of the oil leak. Oil leaking from the rocker arm
cover is easily mistaken for a leaking Power Transfer
Unit.

POWER TRANSFER UNIT (P.T.U.)

REMOVAL AND INSTALLATION
(1) Raise vehicle and remove front wheels.
(2) Remove propeller shaft assembly.
 Fig. 6 Support Crossmember with Transmission Jack

FRONT
CROSSMEMBER FRAME RAIL

Fig. 4 Remove Ball Joint Bolt (Right and Left Side)

CROSSMEMBER 9121-51

Fig. 7 Remove Front Suspension

Crossmember Fasteners
CAUTION: A certain amount of oil will drain out of
the transaxle when the drive shaft is removed.
Remove right front driveshaft. Refer to “Suspen­
sion, Group 2” to remove or install wheel hub nut
and right driveshaft.

Fig. 11 Remove Distance Sensor from P.T.U.

Remove P.T.U. remote vent from left engine mount.

Fig. 9 Remove P.T.U Support Bracket and

Bobble Strut Assembly

Remove P.T.U. assembly from vehicle.

To Install, Reverse Removal Procedure.

POWER TRANSFER UNIT END COVER— RESEAL

The Power Transfer Unit must be removed from the
vehicle to perform this operation. Refer to Power Trans­
fer Unit Removal in this section for procedures.
(1) Remove P.T.U. end cover bolts (Fig. 1).
 POWER TRANSFER -FILL PLUG

flf. I P.T.U. End Cower Bolts

(2) Gently tap on end cover ears with a hammer to
separate end cover from the case (Fig. 2). (6) Reinstall P.T.U. into vehicle.
(7) Check and fill fluids as required.
END COVER
POWER TRANSFER UNIT INPUT SHAFT SEAL
The Power Transfer Unit must be removed from the
vehicle to service this seal. Refer to Power Transfer
Unit Removal in this section for procedures.

REMOVAL
(1) Remove, P.T.U. end cover bolts (Fig. 1).
POWER TRANSFER ' ' FILL PLUG

UNIT 9121-212
Fig. 2 End Cover Removal
(3) Clean and inspect sealer surfaces.
(4) Apply Mopar Gasket Maker P/N 4318083, Loctite
Gasket Eliminator No.518 or equivalent to sealing
surfaces.
(5) Reinstall cover and tighten bolts to 28 N*m (250
in. lbs.) in the sequence shown in figure 3. Retighten
first bolt after all others are tight.
CAUTION: When end cover is installed be careful
not to damage the .P.T.U. Input Shaft Cower Seal.
 (2) Gently tap on end cover ears to separate cover POWER TRANSFER UNIT
from case (Fig. 2).

9121-215

Fig. 4 Input Shaft and Ring Gear Removal

(5) Use Special Tool No. 7794-A (seal puller) to

HAMMER remove seal (Fig. 5).

POWER TRANSFER UNIT

POWER TRANSFER
UNIT 9121-212

Fig. 2 End Cover Removal

(3) Remove ring gear oil slinger (Fig. 3).

OIL TROUGH

SPECIAL TOOL
7794-A 9121-216

Fig. 5 Seal Removal

INSTALLATION
(1) Clean and inspect seal area.
(2) Lay housing on bench and install new seal with
seal driver C-4657 and handle C-4171 (Fig. 6). The
seal must be installed with the spring side facing
POWER towards the ring gear. Drive the seal in until it bot­
TRANSFER toms against the case shoulder.
UNIT

9121-214

Fig. 3 Oil Trough

(4) Remove input shaft and ring gear from case

(Fig. 4).
 INSTALLATION
(1) Using a large socket, carefully install new seal.
The spring side of the seal must face the transaxle
differential.
(2) Reinstall the P.T.U. into the vehicle.
(3) Check and fill fluids as required.

POWER TRANSFER UNIT REAR COVER O-RING

REMOVAL
Fig. 6 Seal Installation (1) Raise vehicle on hoist.
(2) Remove rear cover retaining bolts (Fig. 1).
(3) Install input shaft.
(4) Install oil trough.
(5) Apply Mopar gasket maker P/N 4318083, Loctite
Gasket Eliminator No. 518 or equivalent to sealing
surfaces of end cover and reinstall. Tighten bolts to 28
N-m (250 in. lbs.)
CAUTION: When end cover is installed be careful
not to damage the P.T.U. Input Shaft Cover Seal.
(6) Reinstall P.T.U. assembly into vehicle.
(7) Check and fill fluids as required.

TRANSAXLE DIFFERENTIAL CARRIER SEAL

The Power Transfer Unit must be removed from the
vehicle to replace this seal.

REMOVAL Fig. 1 Rear Cover Bolts

(1) Remove P.T.U. from vehicle.
(3) Index rear cover to the case for later reassembly
(2) Use a prybar to remove seal from retainer plate
(Fig. 2).
(Fig. 1). Be careful not to damage seal journal when
removing seal.
 (6) To Install, Reverse Removal Procedure.

Po w e r tr a n s f e r u n it
OUTPUT SEAL AND/OR FLANGE
The power transfer unit must be removed from the
vehicle to replace this seal.

REMOVAL
(1) Raise vehicle on hoist.
(2) Remove propeller shaft.
(3) Remove rear cover retaining bolts (Fig. 1).

OUTPUT
FLANGE
SEAI

(4) Pull rear cover out of the P.T.U. case (Fig. 3).

REAR COVER 9121-218

Fig. 1 Rear Cover Bolts

(4) Index rear cover to the case for later reassembly

(Fig. 2).

Fig. 3 Rear Cover Removal

(5) Remove rear cover O-Ring (Fig. 4).

REAR PINION 9
COVER GEAR

(5) Pull rear cover out of the P.T.U. case (Fig. 3).
 (8) Using a hydraulic press, press off output flange
from pinion.
(9) Use a hammer and chisel to remove output seal
(Fig. 8). ■ ■ ' ■

O-RING 9121-220

f lf . 3 Rear Cover Removal

(8) Remove output flange nut (Fig. 4).

OUTPUT

VISE
f lf . i Sm l Removal
HAMMER

9121-222

f lf . 4 Output Flange Nut

(7) Index the pinion to the flange (Fig. 5).

OUTPUT PAINT
FLANGE MARK

SPECIAL TOOL
5049

9121-223 REAR
COVER
CAUTION: If the output flange requires replacement,
a new shim may be required. Refer to Output Flange
Shim Selection procedure in this section to deter­
mine correct shim requirements.
INSTALLATION
(1) Install new seal with Seal Installer 5049 (Fig. 7).
(2) If original flange is used, align index marks and
press flange onto pinion. If a new flange is used disre­
gard the alignment marks on the pinion and press
flange onto the pinion.
(3) Install flange nut and tighten to 163 N-m (120 ft.
lbs.).
(4) Install rear cover. Use care not to cut rear cover
O-Ring when installing rear cover into P.T.U. housing.
(5) Install rear cover retaining bolts and tighten to
28 N-m (250 in. lbs.).
(6) Install propeller shaft.
(7) Check and fill fluids as required.
OUTPUT FLANGE SHIM SELECTION
This procedure is used when the output flange is
replaced. Replacement of the output flange requires
installation of the correct size shim to maintain bear­
ing preload. The shim must protrude from the new
output flange the same distance that the original shim
protruded from the original flange.
(1) Stand the original output flange on end with
shim side pointing up.
(2) Place original shim into groove in top of flange.
(3) Place a straight edge across the shim.
(4) Using feeler gauge, measure the distance be­
tween the straight edge and the top of the flange
(Fig. 1). Record this measurement.
9121-279
Fig. 1 Output Flange Shim Measurement
(5) Repeat steps 1 thru 4 using the new flange and
the original shim. Record this measurement.
(6) If the measurements are not equal, use a new
shim that will protrude from the new output flange
the same amount that the original shim protruded
from the original output flange.
For Example: The original shim protrudes 0.075 inch
from the original output flange. Place the original
shim into the new output flange. The protrusion of the
shim in the new flange is 0.085 inch. This indicates
that a 0.010 inch thinner shim is required to maintain
the original protrusion.
(7) Install output flange and torque flange nut to
163 N-m (120 ft. lbs.).
(8) Check the turning torque of the pinion before
installing the rear cover into the P.T.U. The turning
torque should be between 2.6 N-m and 3.0 N-m (23 in.
lbs. and 27 in. lbs.).
POWER TRANSFER UNIT INPUT SHAFT COVER SEAL
The power transfer unit input shaft cover seal is the
larger of the two seals located on the inside of the end
cover. The differential bearing cup must be removed
to service this seal.
The Power Transfer Unit must be removed from
vehicle to perform this operation.
REMOVAL
(1) Remove P.T.U. end cover bolts (Fig. 1).
POWER TRANSFER FILL PLUG
Fig. 1 P.T.U. End Cover Bolts
(2) Gently tap on end cover ears to separate cover
from case (Fig. 2).
 END COVER

Fig. 4 Seal Removal

INSTALLATION
(1) Clean and inspect seal area.
UNIT 9121-212 (2) Use special tool No. MD998803 and install seal
(Fig 5). When installing seal the spring side of the
Fig. 2 End Cover Removal seal must face toward the special tool.

(3) Use special tool No. 6514 and remove the differ­
ential bearing race located in the end cover (Fig. 3).
The race must be removed to gain access to the seal.

(3) Reinstall the original bearing race and shim

using special tool No. 6522 (Fig. 6 and 7).
Fig. 3 Bearing Race Removal

(4) Use special tool No. 7794-A to remove seal (Fig.

4).
COVER 9121-267

Fig. 6 Bearing Shim and Race

Fig. 8 Bolt Tightening Sequence

(6) Reinstall P.T.U. assembly into vehicle.

(7) Check and fill fluids as required.

POWER TRANSFER UNIT HALF SHAFT INNER SEAL

The power transfer unit half shaft inner seal is the
smaller of the two seals located on the inside of the
end cover.

REMOVAL
(1) Remove power transfer unit from the vehicle.
(2) Remove end cover bolts (Fig. 1).
CAUTION :The original shim must be installed behind
the bearing cup to maintain proper bearing preload.
(4) Apply Mopar gasket maker P/N 4318083, Loctite
Gasket Eliminator No. 518 or equivalent to sealing
surfaces of end cover.
(5) Place end cover onto P.T.U. case and install
bolts. Tighten bolts to 28 N-m (250 in. lbs.) in the
sequence shown in figure 8. Retighten first bolt after
all others are tight.
CAUTION: When end cover is Installed be careful
not to damage the P.T.U. Input Shaft Cover Seal.
 POWER TRANSFER FILL PLUG

Fig. 1 End Cover Bolts

(3) Tap on end cover ears to separate cover from

case (Fig. 2).
END COVER
EARS

INSTALLATION
(1) Clean and inspect seal area.
(2) Install seal with a 1 1/16 inch socket (Fig. 4).
The seal must be installed with the spring side of the
END COVER

HAMMER

POWER TRANSFER
UNIT 9121-212

Fig. 2 End Cover Removal

(4) Drive seal out with a hammer and small chisel

(Fig. 3).

HAMMER

Fig. 4 Seal Installation

seal facing end cover ball bearing. The seal will bot­ POWER TRANSFER FILL PLUG
tom against a machined shoulder in the cover. UNIT
(3) Clean sealing surfaces of the end cover and
P.T.U. case. Apply a bead of Mopar Gasket Maker P/N
4318083, Loctite Gasket Eliminator No. 518 or
equivalent.
(4) Place end cover onto P.T.U. case and install
bolts. Tighten bolts to 28 N*m (250 in. lbs.) in the
sequence shown in figure 5. Retighten first bolt after
all other bolts are tight.
CAUTION: When end cover is installed be careful
not to damage the P.T.U. Input Shaft Cover Seal.

OUTPUT SHAFT

END COVER 9121-211

Fig. 1 End Cover Bolts

(3) Tap on end cover ears to separate end cover from

case (Fig. 2).
END COVER
EARS

2- 7 9121-213

Fig. 5 Bolt Tightening Sequence

(5) Reinstall P.T.U. assembly.

(6) Check and fill fluids as required.

POWER TRANSFER UNIT INPUT SHAFT END SEAL

The input shaft end seal is located on the end of the
input shaft. HAMMER

REMOVAL
POWER TRANSFER
(1) Remove power transfer unit from the vehicle. UNIT 9121-212
(2) Retnove end cover bolts (Fig. 1).
Fig. 2 End Cover Removal

(4) Pry out seal with a prybar (Fig. 3).

 (5) Place end cover onto P.T.U. case and install
bolts. Tighten bolts to 28 N-m (250 in. lbs.) in the
sequence shown in figure 4. Retighten first bolt after
all others are tight.
CAUTION: When end cover is installed be careful
not to damage the P.T.U. Input Shaft Cover Seal.
(6) Reinstall P.T.U. assembly.
(7) Check and fill fluids as required.

POWER TRANSFER UNIT OUTER HALF SHAFT SEAL

The outer half shaft seal is located on the outside of
the end cover. The P.T.U. does not have to be removed
to replace this seal.

Fig. 3 Seal Removal REMOVAL

(1) Lift vehicle on hoist.
INSTALLATION (2) Remove right front half shaft from vehicle.
(1) Clean and inspect seal area. (3) Remove seal with a chisel and hammer (Fig. 1).
(2) Remove input shaft from housing and stand on
soft block of wood. Install input shaft end seal with
seal installer 5065 and handle C-4171.
(3) Lubricate seal lip after installing seal into input
HAMMER
shaft.
(4) Clean sealing surfaces of the end cover and
P.T.U. case. Apply a bead of Mopar Gasket Maker P/N END COVER
4318083, Loctite Gasket Eliminator No. 518 or
equivalent.

OUTPUT SEAL 9121-230

Fig. 1 Seal Removal

INSTALLATION
(1) Clean and inspect seal area.
(2) Install new seal with seal installer MD998334
(Fig. 2).
 (4) Remove bearing retaining snap ring (Fig. 4).

Fig. 2 Seal Installation

(3) Reinstall right front half shaft. Fig. 4 Bearing Snap Ring
(4) Check and fill fluids as required.
(5) Use bearing puller MD998346 to remove bearing
(Fig.5).
POWER TRANSFER UNIT END COVER BALL BEARING
The end cover ball bearing can be removed and
installed without removing the Power Transfer Unit
from the vehicle. When replacing the bearing the out­
put seal must be removed to gain access to the bear­
ing.

REMOVAL
(1) Raise vehicle on hoist.
(2) Remove right front half shaft from vehicle.
(3) Remove output seal with a hammer and chisel
(Fig. 3).

Fig. 5 Bearing Removal

INSTALLATION
(1) Use bearing driver L-4530 and handle C-4171-2
to install bearing.
 SPECIAL TOOL SPECIAL TOOL
L-4530 C-4171

SPECIAL TOOL
MD998334 9121-231

Fig. 6 Bearing Installation Fig. 7 Installing New Seal

(2) Install bearing retaining snap ring. (4) Reinstall right front half shaft.
(3) Install new output seal using MD998334 seal (5) Check and fill fluids as required.
installer (Fig. 7). Do not reuse the old seal.
 SPECIFICATIONS
A-413!A-670 3-SPEED AUTOMATIC TRANSAXLE
Metric U.S.
M easure M easure
Type ................................................................... Automatic Three Speed With
Torque Converter and Integral
Differential
Torque Converter Diameter........................................... 241 millimeters 9.48 inches
Oil Capacity—Transaxle and Torque Converter:
except fleet...................................................................... 8.4 Liters 8.9 qts.
fleet only ............................................... .. ..................... 8.7 Liters 9.2 qts.
Use MOPAR ATF Automatic Transmission Fluid
Type 7176 (or DEXRON II)
Cooling Method ............................................................. Water-Heat Exhanger and/or oil-to-air heat exchanger
Lubrication..................................................................... Pump (Internal-External Gear Type)
G ear Ratios:
Transmission Portion: First......................................... 2.69
Second .................................. 1.55
T h ird ...................................... 1.00
Reverse........................... . . . 2.10
Pump Clearances: Millimeter Inch
Outer Gear to Pocket.................................................. .045-. 141 .0018-.0056
Outer Gear Side Clearance...................................... .020-.046 .0008-.0018
Inner Gear Side Clearance......................................... .020-.046 .0008-.0018
End Play: Millimeter Inch
Inut Shaft .................................................................... .19-1.50 .008-.060
Front Clutch Retainer.................................................. .76-2.69 .0 3 0 -1 0 6
Front C arrier............................................................... .89-1.45 .007-.057
Front Annulus G e a r .................................................... .09-0.50 .0035-.020
Planet Pinion............................................................... .15-0.59 .006-.023
Reverse Drum ............................................................. .76-3.36 .030-. 132
Clutch Clearance and Selective Snap Rings: Millimeter Inch
Front Clutch (Non-Adjustable) Measured from
Reaction Plate to "Farthest" W ave........... 3 Disc. 2.22-3.37 .087-. 133
4 Disc. 2.29-3.71 .090-. 146
Rear Clutch (3 and 4 Disc)
Adjustable............................................... 3 Disc. .67-1.10 .026-.043
4 Disc. .67-1.10 .026-.043
Selective Snap Rings ( 5 ) ......................................... 1.22-1.27 .048-.050
1.52-1.57 .060-.062
1.73-1.78 .068-.070
1.88-1.93 .074-.076
2.21-2.26 .087-.089
Band Adjustment:
Kickdown, Backed off from 8 N-m (72 in. lbs.) . . . 2-1/2 Turns
Low-Reverse, Backed off from 5 N-m (41 in. lbs.). 3-1/2 Turns
Thrust W ashers: Millimeter Inch
Reaction Shaft Support (Phenolic)........... No. 1 1.55-1.60 .061-.063
Rear Clutch Retainer (Phenolic)................ No. 2 1.55-1.60 .061-.063
Output Shaft, Steel Backed Bronze. . (Select) No. 3 1.98-2.03 .077-.080
2.15-2.22 .085-.087
2.34-2.41 .092-.095
Front Annulus, Steel Backed Bronze . . . . No. 4 2.95-3.05 . 116- . 120
Front Carrier, Steel Backed Bronze......... ..... Nos. 5, 6 1.22-1.28 .048-.050
Sun Gear (Front)...................................... ..... No. 7 .85-0.91 .033-.036
Sun Gear (R ear)...................................... ......No. 8 .85-0.91 .033-.036
Rear Carrier, Steel Backed Bronze......... ..... Nos. 9, 10 1.22-1.28 .0948-.050
Rev. Drum, Phenolic............................... ......No. 11 1.55-1.60 .061-.063
Tapered Roller Bearing Settings: Millimeter Inch
Output S h a ft...................................................................... .0-.07 Preload .0-.0028 Preload
Transfer S h a ft................................................................... .05-.25 End Play .002-.010 End Play
Differential ........................................................................ .15-.29 Preload .006-.012 Preload
 JI61CM ULTRADRIVE 4.SPEED ELECTRONIC AUTOMATIC TRANSAXLE

Typo . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Fully-adaptive, electronically-controlled, four-speec

automatic witn torque converter and integral differentia
Torqu® Conwerter D iam eter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .241 millimeters (9.48 inches
Oil Capacity—Transaxle and Torque'Converter . . . . . . . . . . . . . . . . . . . . . . . . .8.6 Liters (18.25 pints
Oil Ty p e . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .......................MOPAR,ATF Type 7176 (or DEXRON II;
Cooling Method . . . . . . . . . . . . . . . ;. . . . . . . . . . . . . Water heat exhanger and/or air-to-oil heat exchanger
Lubrication........................................ ....................... . ..................................Pump (internal-external gear type)
S e a r Ratios:
Transmission portion: f ■
First . . . . . . . . . . . . . . . . . 2.84
Second . . . . . . . . . . . . . . . 1.57
Direct . . . . . . . . . . . . . . . . 1.00
Overdrive . . . . . . . . . . . . . .69
Rreverse . . . . . . . . . . . . . . 2.21
Overall lo p Gemr Ratio:
(in overdrive) ......................... 2.36
Pump Clearances: Millimeter Inch
Outer Gear to Pocket . . . . . . .045-141 .0018-.0056
Outer Gear Side Clearance . . .020-. 046 .0008-.0018
Inner Gear Side Clearance .. .020-.046 .000S-.0018
Tapered Roller Bearing Settings: Millimeter Inch
Output Ge a r . . . . . . . . . . . . . .02 .05 Preload .0008^.002 Preload-
Transfer Shaft . . . . . . . . . . . . .05-. 10 End Play .002-.004 End Play
Differential . . . . . . . . . . . . . . .15-.29 Preload 006-.012 Preload
Clutch Clearances: Millimeter Inch
Underdrive Clutch .091 to 1.47 .036 to .058
Overdrive Clutch . . . . . . . . . . 1.07 to 2.44 .042 to .096
Reverse Cl utch. . . . . . . . . . . . 0.76 to 1.24 .030 to .049
2/4 Clutch . . . . . . . . . . . . . . . 0.76 to 2.64 .030 to. 104
Low/Reverse Clutch . . . . . . . . 1.04 to 1.65 .042 to .065

9121-8
 A-413//WT0 TIGHTENING REFERENCE

Torqu#
Newton- Inch- Foot-
Ifm Thread Size m eters Pounds ds
A-413 Automatic Transaxlos
Bolt—Bell Housing Cover . . . . . . . . . . . . 9.8-M6-1-10 12 105
Bolt—flex Plate to Crank . . . . . . . . . . . . M 1 0 x l.5 x l8 95 — 70
Bolt—Flex Plat© to Torque Converter . . . . 10.9-M10xl.5x13.2 74 — 55
Screw Assy. Transaxle to Cyl. Block . . . . . 9.8A-M12-1.75-65 95 — 70
Screw Assy. Lower Bell Housing Cover 9.8-M6-1-10 12 105
Screw Assy. Manual Control Lever. . . . . . 9.8A-M6-1-35 12 105 —

Screw Assy. Speedometer to Extension . . 9.8A-M6-1-14 7 60 —

Connector, Cooler Hose to Radiator . . . . 1/8-27 NPTF 12 110

io lf —Starter to Transaxle Bell Housing . . M10-1.5-30 54 — 40
l o ll—Throttle Cable to Transaxle Case. . . M6-1.0-14 12 105 —

Bolt—Throttle Lever to Transaxle Shaft . . . M6-1-25 12 105 —

Bolt—Manual Cable to Transaxle Case M8-1.75-30 28 250 —

l o ll—front Motor Mount . . . . . . . . . . . . M10 54 — 40

Bolt—Left Motor Mount. . . . . . . . . . . . . . M10-1.5-25 54 — 40
Dress Up:
Connector Assembly, Cooler L in e ........... M12-1.75-122 28 250 _

Plug, Pressure C h eck................................ 1/16-27 NPTF 5 45 _

Switch, Neutral Safety . . . . . . . . . . . . . . 3/4-16UNF 34 — 25

Differential Ar#«s
Ring Gear Screw . . . . . . . . . . . . . . . . . . 12.9-M10-1.5-25 95 70
Bolt, Extension to Case . . . . . . . . . . . . . . 9.8-M8-1.25-28 28 250
Bolt, Differential Bearing Retainer to Case 9.8-M8-1.25-28 28 250 _

Screw Assy. Differential Cover to Case . . . 9.8-M8-1.25-16 19 165 —

Transfer A Output Shaft Areass
Nut, Output S h a ft.................................... M20-1.5 271 _
200
Nut, Transfer Shaft.................... ............... M20-1.5 271 — 200
Bolt, Gov to S u p p o rt................................ 9.8-M5-0.8-20 7 60 —

Bolt, Gov to Support . .............. ............... 9.8-M5-0.8-30 7 60 _

Screw Assy., Governor Counterweight . . . M8-1.25-35 28 250 —

Screw Assy., Rear Cover to Case.............. 9.8-M8-1.25-16 19 165

Plug, Reverse Band Shaft . . . . . . . . . . . . 1/4-18-NPTF 7 60 —
Pump & Kickdown Band Areas:
Bolt, Reaction Shaft Assembly.................. 9.8-M8-1.25-19 28 250 -

Bolt Assy., Pump to C a s e ........... ............. 10.9-M8-1.25-25 31 275 —

Nut, Kicldown Band Adjustment Lock . . . M12-1.75 47 — 35

Woiw# Body & Sprog Areoss
Bolt, Sprag Retainer to Transfer Case . . . 9.8-M8-1.25-23 28 250
Screw Assy., Valve Body 9.8A-M5-0.8-11 5 40
Screw Assy., Transfer Plate . . . ................ 9.8A-M5-0.8-25 5 40
Screw Assy., Filter . . . . . . . . . . . . . . . . . 9.8A-M5-0.8-30 5 40 _ _

Screw, Transfer Plate to Case . . . . . . . . . 9.8-M6-1-30 12 105 —

Screw Assy., Oil Pan to Case .................. 9.8-M8-1.25-16 19 165

Nut, Reverse Band Adjusting Lock........... M8-1.25 14 120 —
 Torque
Newton- inch* Foot-
Thread Size M eters Pounds Pounds
A 6 0 4 Electronic Automatic Transaxle*
Cooler Line Fi tti ngs. . . . . . . . . . . . . . . . . . . . 1/8 x 27 N PT 12 110
Differential Cover . . . . . . . . . . . . . . . . . . . . . M8 x 1.25 19 165 —

Differential Ring Gear . . . . . . . . . . . . . . . . . M10 x 1.0 x 25 95 — 70

Differential Bearing Retainer . . . . . . . . . . . . . M8 x 1.25 x 23 28 — 21
Rear End C o v e r................................................ M8 x 1.25 19 — 14
Extension Housing . . . . . . . . . . . . . . . . . . . . M8 x 1.25 x 33 28 — 21
Input Speed Sensor . . . . . . . . . . . . . 9 . . . . . M22 x 1.5 27 — 20
L/R Clutch Retainer . M5 x 0.8 5 40 —

Neutral Safety Swit ch. . . . . . . . . . . . . . . . . . 3/4 IN. x 16 34 — 25

O il Pan to Case . . . . . . . . . . . . . . . . . . . . . . M8 x 1.25 19 — 14
Output Gear Bolt (1.5 inch hex) . . . . . . . . . . . M18 x 1.75 271 — 200
Output Speed Sensor . . . . . . . . . . . . . . . . . . M24 x 2 27 — 20
Pressure Taps . . . . . . . . . . . . . . . . . . . . . . . . 1 /1 6 -2 7 N PTF 5 45 —

PRNDL Switch . . . . . . . . . . . . . . . . . . . . . . . M22 x 2.5 34 — 25

Pump to Case. . . . . . . . . . . . . . . . . . . . . . . . M8 x 1.25 22 — 23
Reaction Shaft to Pomp . . . . . . . . . . . . . . . . . M8 x 1.25 22 — 23
Solenoid Assy, to Case . . . . . . . . . . . . . . . . . M6 x 1.0 x 93.5 12 105 —

Transfer Plate to Case . . . . . . . . . . . . . . . . . . . M6 x 1.0 12 105 —

Transfer Gear Nut (1.25 inch hex) . . . . . . . . . M22 x 1.5 271 — 200
Valve Body & Transfer'Plate . . . . . . . . . . . . . M 5 x 0.8 5 40 —

Vent Assembly.................................................. 1/8 PIPE 12 110 —

8-Way Solenoid Connector.............................. M6 x 1.0 4 38 —

60-Way EATX Connector . . . . . . . . . . . . . . . M6 x 1.0 4 38 —

9121-12

POWER TRANSFER UNIT TIGHTENING REFERENCE

THREAD NEWTON- INCH FOOT

SIZE METERS POUNDS POUNDS

Flange Nut M16 x 1.5 162 — 120

End Cover M8 x 1.25 28 250
Rear Cover M8 x 1.25 28 250
Ring Gear M10 x 1.0 94 — 70
Fill Plug 1/2 x 20 27 240
Inspection Plug M50 x 1.5 20 180
 CONVERSION CHART

INCHES TO MILLIMETERS
All values in this table are exact
inches 0.000 0.001 0.002 0.003 0.004 0.005 0.006 0.007 0.008 0.009
millimeters
0.000 0.0254 0.0508 0.0762 0.1016 0.1270 0.1524 0.1778 0.2032 0.2286
0.010 0.2540 0.2794 0.3048 0.3302 0.3556 0.3810 0.4064 0.4318 0.4572 0.4826
0.020 0.5080 0.5334 0.5588 0.5842 0.6096 0.6350 0.6604 0.6858 0.7112 0.7366
0.030 0.7620 0.7874 0.8128 0.8382 0.8636 0.8890 0.9144 0.9398 0.9652 0.9906
0.040 1.0160 1.0414 1.0668 1.0922 1.1176 1.1430 1.1684 1.1938 1.2192 1.2446
0.050 1.2700 1.2954 1.3208 1.3462 1.3716 1.3970 1.4224 1.4478 1.4732 1.4986
0.060 1.5240 1.5494 1.5748 1.6002 1.6256 1.6510 1.6764 1.7018 1.7272 1.7526
0.070 1.7780 1.8034 1.8288 1.8542 1.8796 1.9050 1.9304 1.9558 1.9812 2.0066
0.080 2.0320 2.0574 2.0828 2.1082 2.1336 2.1590 2.1844 2.2098 2.2352 2.2606
0.090 2.2860 2.3114 2.3368 2.3622 2.3876 2.4130 2.4384 2.4638 2.4892 2.5146
0.100 2.5400 2.5654 2.5908 2.6162 2.6416 2.6670 2.6924 2.7178 2.7432 2.7686
0.110 2.7940 2.8194 2.8448 2.8702 2.8956 2.9210 2.9464 2.9718 2.9972 3.0226
0.120 3.0480 3.0734 3.0988 3.1242 3.1496 3.1750 3.2004 3.2258 3.2512 3.2766
0.130 3.3020 3.3274 3.3528 3.3782 3.4036 3.4290 3.4544 3.4798 3.5052 3.5306
0.140 3.5560 3.5814 3.6068 3.6322 3.6576 3.6830 3.7084 3.7338 3.7592 3.7846
0.150 3.8100 3.8354 3.8608 3.8862 3.9116 3.9370 3.9624 3.9878 4.0132 4.0386
0.160 4.0640 4.0894 4.1148 4.1402 4.1656 4.1910 4.2164 4.2418 4.2672 4.2926
0.170 4.3180 4.3434 4.3688 4.3942 4.4196 4.4450 4.4704 4.4958 4.5212 4.5466
0.180 4.5720 4.5974 4.6228 4.6482 4.6736 4.6990 4.7244 4.7498 4.7752 4.8006
0.190 4.8260 4.8514 4.8768 4.9022 4.9276 4.9530 4.9784 5.0038 5.0292 5.0546
0.200 5.0800 5.1054 5.1308 5.1562 5.1816 5.2070 5.2324 5.2578 5.2832 5.3086
0.210 5.3340 5.3594 5.3848 5.4102 5.4356 5.4610 5.4864 5.5118 5.5372 5.5626
0.220 5.5880 5.6134 5.6388 5.6642 5.6896 5.7150 5.7404 5.7658 5.7912 5.8166
0.230 5.8420 5.8674 5.8928 5.9182 5.9436 5.9690 5.9944 6.0198 6.0452 6.0706
0.240 6.0960 6.1214 6.1468 6.1722 6.1976 6 2230 6.2484 6.2738 6.2992 6.3246
0.250 6.3500 6.3754 6.4008 6.4262 6.4516 6.4770 6.5024 6.5278 6.5532 6.5786
0.260 6.6040 6.6294 6.6548 6.6802 6.7056 6.7310 6.7564 6.7818 6.8072 6.8326
0.270 6.8580 6.8834 6.9088 6.9342 6.9596 6.9850 7.0104 7.0358 7.0612 7.0866
0.280 7.1120 7.1374 7.1628 7.1882 7.2136 7.2390 7.2644 7.2989 7.3152 7.3406
0.290 7.3660 7.3914 7.4168 7.4422 7.4676 7.4930 7.5184 7.5438 7.5692 7.5946
0.300 7.6200 7.6454 7.6708 7.6962 7.7216 7.7470 7.7724 7.7978 7.8232 7.8486
0.310 7.8740 7.8994 7.9248 7.9502 7.9756 8.0010 8.0264 8.0518 8.0772 8.1026
0.320 8.1280 8.1534 8.1788 8.2042 8.2296 8.2550 8.2804 8.3058 8.3312 8.3566
0.330 8.3820 8.4074 8.4328 8.4582 8.4836 8.5090 8.5344 8.5598 8.5852 8.6106
0.340 8.6360 8.6614 8.6868 8.7122 8.7376 8.7630 8.7884 8.8138 8.8392 8.8646
0.350 8.8900 8.9154 8.9408 8.9662 8.9916 9.0170 9.0424 9.0678 9.0932 9.1186
0.360 9.1440 9.1694 9.1948 9.2202 9.2456 9.2710 9.2964 9.3218 9.3472 9.3726
0.370 9.3980 9.4234 9.4488 9.4742 9.4996 9.5250 9.5504 9.5758 9.6012 9.6266
0.380 9.6520 9.6774 9.7028 9.7282 9.7586 9.7790 9.8044 9.8298 9.8552 9.8806
0.390 9.9060 9.9314 9.9568 9.9822 10.0076 10.0330 10.0584 10.0838 10.1092 10.1346
0.400 10.1600 10.1854 10.2108 10.2362 10.2616 10.2870 10.3124 10.3378 10.3632 10.3886
0.410 10.4140 10.4394 10.4648 10.4902 10.5156 10.5410 10.5664 10.5918 10.6172 10.6426
0.420 10.6680 10.6934 10.7188 10.7442 10.7696 10.7950 10.8204 10.8458 10.8712 10.8966
0.430 10.9220 10.9474 10.9728 10.9982 11.0236 11.0490 11.0744 11.0998 11.1252 11.1506
0.440 11.1760 11.2014 11.2268 11.2522 11.2776 11.3030 11.3284 11.3538 11.3792 11.4046
0.450 11.4300 11.4554 11.4808 11.5062 11.5316 11.5570 11.5824 11.6078 11.6332 11.6586
0.460 11.6840 11.7094 11.7348 11.7602 11.7856 11.8110 11.8364 11.8618 11.8872 11.9126
0.470 11.9380 11.9634 11.9888 12.0142 12.0396 12.0650 12.0904 12.1158 12.1412 12.1666
0.480 12.1920 12.2174 12.2428 12.2682 12.2936 12.3190 12.3444 12.3698 12.3952 12.4206
0.490 12.4460 12.4714 12.4968 12.5222 12.5476 12.5730 12.5984 12.6238 12.6492 12.6746
inches 0.000 0.001 0.002 0.003 0.004 0.005 0.006 0.007 0.008 0.009
 WHEELS TIRES
CONTENTS
Page
SERVICE PROCEDURES...............................
TIRES ........................................................
TIRES
GENERAL INFORMATION
Throughout this group, references may be made to a
particular vehicle by letter or number designation. A
chart showing the breakdown of these designations is
included in the Introduction Section at the front of
this service manual.
Tires, as defined below and described in Figure 1,
are designed for the vehicle and provide the best over­
all performance for normal operation; the ride and
handling characteristics match the vehicle’s require­
ments. With proper care they will give excellent reli­
ability traction, skid resistance, and tread life. These
tires have load carrying capacity, when properly in­
flated, to operate satisfactorily at all loads up to and
including the specified Maximum Vehicle Capacity at
all normal highway speeds.
Tires used at low speeds, in cool climates, and with
light loads will have longer life than tires used for
high-speed driving in hot climates with heavy loads.
Abrasive road surfaces will accelerate tire wear.
Driving habits have more effect on tire life than
any other factor. Careful drivers will obtain, in most
cases, much greater mileage than severe or careless
drivers. Rapid acceleration and deceleration, severe
application of brakes, high-speed driving, taking turns
at excessive speeds, striking curbs and other obstacles
are just a few of the driving habits which will shorten
the life of any tire.
Longer wearing tires can be more susceptible to
irregular tread wear. It is very important to follow the
tire rotation interval shown in the section on Tire
Rotation to achieve a greater tread-life potential.
RADIAL-PLY TIRES
Radial-ply tires improve handling, tread life, and
ride quality and decrease rolling resistance.
Radial-ply tires must always be used in sets of four
and under no circumstances should they be used on
the front only. However, they may be mixed with
temporary spare tires when necessary, but reduced
speeds are recommended.
Radial-ply tires have the same load-carrying capac­
ity as other types of tires of the same size and use the
same recommended inflation pressures.
Page
2 WHEELS ..................................................... 6
1
SPARE TIRE (COMPACT)
The compact spare tire is designed for emergency
use only. Since this tire has an approximate tread life
of 3200 km (2,000 miles), the original tire should be
repaired and reinstalled at the first opportunity. Do
not exceed 80 km/h (50 mph) while the compact spare
tire is on the vehicle. Maintain the compact spare tire
inflation pressure at 415 kPa (60 psi).
TIRE CHAINS
Tire snow chains may be used, although limited
clearances exist with some combinations of tire size
and wheel size, as indicated under Restrictions in the
Specification Section.
The only chains approved for use are "Class S”
compact type or other traction aids that meet SAE
type "S” specifications. Chains must be the proper size
for the tires. To avoid chain damage to the vehicle or
tires:
• Install chains as tightly as possible, and then
retighfen after driving about 0.8 km (1/2 mile).
• Do not exceed 70 km/h (45 mph). See exception
below.
• Drive cautiously and avoid severe turns and large
bumps.
• Follow the chain manufacturer’s recommendations.
"Limited chain clearance” indicates that extra care
must be used to avoid damage. Be sure that:
(1) The chains are fully tightened.
(2) Vehicle speed is kept below 50 km/h (30 mph).
(3) The vehicle is lightly loaded.
 SERVICE PROCEDURES
INDEX
Page Page
Cleaning of Tires ..................................................... 2 Tire Inflation Pressures............................................ 2
Pressure Gauges ........................................................ 2 Tire Noise or Vibration ............................................ 4
Repairing Leaks ....................................................... 3 Tire Wear P a tte rn s ................................................... 4
Replacem ent Tires ................................................. 3 Tread Wear In d ic a to rs .............................................. 3
Rotation ................................................................. 3

CLEANING OF TIRES
Remove protective coating on tires before delivery
of vehicle, otherwise it could cause deterioration of
tires.
Remove protective coating by applying warm water,
letting it soak one minute, and then scrubbing the
coating away with a soft bristle brush.
Steam cleaning may also be used for cleaning.
DO NOT use gasoline or wire brush for cleaning.
DO NOT use mineral oil or an oil-based solvent.

PRESSURE GAUGES
High-quality, dial-type, air-pressure gauges are rec­
ommended. After checking with the gauge, replace
valve caps and tighten fmgertight.

TIRE INFLATION PRESSURES

Underinflation (Fig. 1) causes rapid shoulder wear
and tire flexing and can result in tire failure. PR972A

Fig. 2 Overlnflatlon Wear

Improper inflation can cause uneven wear patterns,

reduced tread life, reduced fuel economy, unsatisfac­
tory ride, or cause the vehicle to drift.
Proper tire pressure can be found on the Vehicle
Certification Label on the vehicle (See Owners Manual).
This pressure has been carefully selected to provide
for safe vehicle operation, proper vehicle stability, and
a comfortable ride. Tire pressure should be checked
"cold” once per month and more frequently when the
weather temperature varies widely, as tire pressure
decreases when the outdoor temperature drops.
Inflation pressures specified on the placards are al­
PR971B ways "cold inflation pressure”. Cold inflation pressure
is obtained after the vehicle has not been operated for
Fig. 1 Underlnflatlon Wear at least 3 hours or driven less than one mile after
being inoperative for 3 hours. Tire inflation pressures
Overinflation (Fig. 2) causes rapid center wear and may increase from 2 to 6 pounds per square inch (psi)
loss of the tire’s ability to cushion shocks. during operation. Do not reduce this normal pressure
build-up.
Cold inflation pressures must not exceed 240kPa
(35 psi) for P-Series standard load tires.
 TIRE PRESSURE FOR HIGH-SPEED OPERATION
Chrysler Motors advocates driving at safe speeds
within posted speed limits. Where speed limits or con­
ditions are such that the vehicle can be driven at high
speeds, correct tire inflation pressure is very impor­
tant. For speeds up to and including 75 mph (120
.km/h), tires must be inflated to the pressures shown
on the tire placard. For speeds in excess of 75 mph
(120 km/h),tires must be inflated to the maximum
pressure specified on the tire sidewall.
Vehicles loaded to the maximum capacity should
not be driven at continuous speeds above 75 mph (120
km/h).
WARNING; OVER OR UNDERINPLATED TIRES C A i
AFFECT VEHICLE HANDLING AND C A i FAIL SUD­
DENLY, RESULTING IN LOSS OF VEHICLE CONTROL
For police or emergency vehicles that must be driven
at continuous speeds over 90 mph (144km/h), special
high-speed tires 'must be used. Consult tire manufac­
turer for tire and inflation pressure recommendations.
REPLACEMENT TIRES
The original equipment tires on the vehicle have
been engineered to provide a proper balance of many
characteristics such as ride, noise, handling, durabil­
ity, tread life, traction, rolling resistance, and speed
capability. For this reason, we recommend that tires
equivalent to the original equipment tires be used
when replacement is needed.
Failure ‘to use equipment replacement tires may
adversely affect the safety and handling of the vehicle.
The use of oversize tires not listed in the specifica­
tion charts may cause interference with vehicle com­
ponents under extremes of suspension and steering
travel which may cause tire damage.
WARNING: FAILURE TO EQUIP THE VEHICLE WITH
TIRES HAVING ADEQUATE SPEED CAPABILITY CAN
RESULT IN SUDDEN TIRE FAILURE AND LOSS OF
VEHICLE CONTROL.
ROTATION
Tires on the front and rear axles of vehicles operate
at different loads and perform different steering, driv­
ing, and braking functions. For these reasons, they
wear at unequal rates, and tend to develop irregular
wear patterns. These effects can be reduced by timely
rotation of tires. The benefits of rotation are espe­
cially worthwhile. Rotation will increase tread life,
help to maintain mud, snow, and wet traction levels,
and contribute to a smooth, quiet ride.
Rotation is recommended at 12,000 km (7,500 miles)
and then at intervals of 24,000 km (15,000 miles)
More frequent rotation is permissible, if desired. The
reasons for any rapid or unusual wear should be cor­
rected prior to rotation being performed.
The suggested rotation method is the "forward-cross”
tire rotation method. This method takes advantage of
current tire industry practice which now allows rota­
tion of radial-ply tires. Other rotation methods may
be used, but may not have all the benefits of the
recommended method.
For proper tire rotation, refer to the "Operating
Instructions Manual,” usually found in the storage
bin, under the front passenger's seat.
TREAD W E IR INDICATORS
Tread wear indicators are molded into the bottom of
the tread grooves. When tread is 1.6 mm (1/16 in.),
the tread wear indicators will appear as a 13 mm (1/2
in.) band.
Tire replacement is necessary when indicators ap­
pear in two or more grooves, or if localized balding
occurs (Fig. 3).
Fig. 3 Tread Wear Indicators
REPAIRING LEAKS
For proper repairing, a radial tire must be removed
from the wheel and repairs should only be made if the
defect, or puncture, is in the tread area, otherwise the
tire should be replaced.
Deflate tire completely before dismounting tire from
the wheel. Use lubrication such as a mild soap solu­
tion when dismounting or mounting tire. Use tools
free of burrs or sharp edges which could damage the
tire or wheel rim.
Before mounting tire on wheel, make sure all rust
scale is removed from the rim and repaint if neces­
sary.
Install wheels on vehicle, progressively tightening
wheel nuts to 129 N*m (95 ft. Ibs.) torque(See "Wheels”).
TIRE NOISE OR VIBRATION
The radial-ply tire on your vehicle is sensitive to
force impulses caused by improper mounting, wheel
irregularities, or imbalance, than the bias-ply tire.
To determine if the tires are causing the noise or
vibration, drive the vehicle over a smooth portion of
highway at different speeds and note the effect of
acceleration and deceleration on noise level. Differen­
tial and exhaust noise will change in intensity as
speed varies, while tire noise will usually remain
constant.
TIRE WEAR PATTERNS
Underinflation results in faster wear on shoulders
of tire. Overinflation causes faster wear at center of
tread.
Excessive camber causes the tire to run at an angle
to the road. One side of tread is worn more than the
other.
Excessive toe-in or toe-out causes wear on the tread
edges of the tire, from dragging of tire. There is a
feathered effect across the tread (Fig. 4).

UNPER- OVER-INFLATION EXCESSIVE um M m m

1NFLATION CAMlEi INCORRECT TOE WHEEL
Oft LACK LACK Of
OR LACK Of ROTATION
OF ROTATION ROTATION
Of TIRES
CAUSE Oi
WORN O i OUT-
OF ALIGNMENT
SUSPENSION
O i TIRE DEFECT*
ADJUST PRESSURE TO iOTATE TIRES
SPECIFICATIONS WHEN ADJUST CAMBER ADJUST TOE-IN DYNAMIC O i AND INSPECT
CORRECTION TIRES ARE COOL TO TO STATIC SUSPENSION
ROTATE TIRES SPECIFICATIONS SPECIFICATIONS BALANCE WHEELS SEE GROUP 2

f lf . 4 Tim Wear Patterns

 LEAD CORRECTION CHART

ADJUST TIRE PRESSURE OK

TO REDUCED LOAD ON
PRESSURE PLACARD

I
CAR LEADS
CROSS SWITCH FRONT
TIRE & WHEEL ASSEMBLIES

I
ROAD TEST OK

I
I 1
CAR LEADS CAR LEADS
SAME DIRECTION IEC1
PROBABLE CAUSE - TIRES
SWITCH TIRES FRONT TO REAR
PROBABLE CAUSE • VEHICLE LEFT FR<
CHECK FRONT ALIGNMENT LEFT REAR TO LEFT FR<
TOE-CASTER-CAMBER RIGHT FRONT TO Rl<
RIGHT REAR TO RIGHT FRONT

i
ALIGNMENT NOT OK ROAD TEST OK

ADJUST ALIGNMENT TO z
PREFERRED SETTINGS.
CAR STILL LEADS

CROSS SWITCH FRONT TIRES

I
ROAD TEST - ► OK

I
CAR STILL LEADS

SWITCH RIGHT FRONT

I
ROAD TEST OK

I
CAR STILL LEADS
LEAD CAUSED BY
LEFT FRONT
TIRE - REPLACE
 WHEELS
INDEX
Page
General Information .......................................................
Tire and Wheel Balance .................................................
Tire and Wheel R u n o u t........................................... ........ 7
GENERAL INFORMATION
Original equipment wheels are designed for satis­
factory operation at all loads up to the specified maxi­
mum vehicle capacity.
All models use steel or cast aluminum drop center
wheels. The safety rim wheel (Fig. 1) has raised sec­
tions between the rim flanges and the rim well "A”.
Initial inflation of the tires forces the bead over
these raised sections. In case of tire failure, the raised
sections help hold the tire in position on the wheel
until the vehicle can be brought to a safe stop.
Cast aluminum wheels require special balance
weights and alignment equipment.
WHEEL INSTALLATION
The wheel studs and nuts are designed for specific
applications and must be replaced with equivalent
parts. Do not use replacement parts of lessor quality
or a substitute design. All aluminum and some steel
wheels have wheel stud nuts which feature an en­
larged nose. This enlarged nose is necessary to ensure
proper retention of the aluminum wheels.
Before installing the wheel, be sure to remove any
build up of corrosion on the wheel mounting surfaces
with scraping and wire brushing. Installing wheels
without good metal-to-metal contact could cause later
loosening of wheel nuts which could adversely affect
the safety and handling of your vehicle.
Page
6 Wheel Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
6 Wheel Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
To install the wheel, first position it properly on the
mounting surface using the hub pilot as a guide. All
wheel nuts should then be tightened just snug before
progressively tightening them in sequence (Fig. 3) to
129 N-m (95 ft. lbs.) Newer yse oil or grease on studs
or nuts.
WHEEL REPLACEMENT
Wheels must be replaced if they have excessive run­
out, are bent or dented, leak air through welds, or
have damaged bolt holes. Wheel repairs employing
hammering, heating, or welding are not allowed.
Original equipment replacement wheels are avail­
able through your dealer. When obtaining wheels from
any other source, the replacement wheels should be
equivalent in load carrying capacity and physical di­
mensions (diameter, width, offset, .and mounting con­
figuration) to the original equipment wheels. Failure
to use equivalent replacement wheels may adversely
affect the safety and handling of your vehicle. Re­
placement with “used” wheels Is not recommended
as their service history may have Included severe
treatment or very high mileage and they could fill
without warning.
TIRE AND WHEEL BALANCE ■
Balancing need is indicated by vibration of seats,
floor pan, or steering wheel when driving over 64
km/h (40 mph) on a smooth road.
It is recommended that a two plane dynamic bal­
ancer be used when a wheel and tire assembly require
balancing. Static should be used only when a two
plane balancer is not available.
For static imbalance, find location of heavy spot
causing imbalance and counter balance wheel directly
opposite the heavy spot. Determine weight required to
counterbalance the area of imbalance and place half
of this weight on thelnner rim flange and the other
half on the outerrim flange (Fig. 2).
 Use runout gauge D-128-TR to determine runout
(Fig. 4).

Off-vehicle balancing is preferred.

TIRE AND WHEEL RUNOUT

Radial runout is the difference between the high

and low points on the tire or wheel periphery.
Lateral runout is the "wobble” of the tire or wheel.
Radial runout of more than 1.5 mm (.060 inch)
measured at the center line of the tread may cause
the vehicle to shake.
Lateral runout of more than 2.0 mm (.080 inch)
measured near the shoulder of the tire may cause the
vehicle to shake.
Sometimes radial runout can be reduced by relocat­
ing the wheel and tire assembly on the mounting
Relocate wheel on the mounting, two studs over
studs (See Method 1). If this does not reduce runout to
from the original position.
an acceptable level, the tire can be rotated on the
Retighten wheel nuts (Fig. 3) until all are properly
wheel. (See Method 2).
torqued, to eliminate brake distortion.
Check radial runout. If still excessive, mark tire
METHOD 1 (RELOCATE WHEEL ON HUB)
sidewall, wheel, and stud at point of maximum runout
Check accuracy of the wheel mounting surface; ad­
and proceed to Method 2.
just wheel bearings.
Drive vehicle a short distance to eliminate tire flat
METHOD 2 (RELO C ATE TIRE ON WHEEL)
spotting from a parked position.
Rotating tire on wheel is particularly effective when
Make sure all wheel nuts are properly torqued (Fig.
there is runout in both tire and wheel.
3).
Remove tire from wheel and remount wheel on hub
in former position.
Check wheel radial runout (Fig. 5). It should be no
more than O.i mm (.035 inch).
 Lateral runout (Fig. 5) should be no more than 1.1
mm (.§45 inch).
If point of greatest wheel radial runout is near orig­
inal chalk mark, remount tire degrees from its origi­
nal position. Eecheck runout.

SPECIFICATIONS

The following guide should help you understand the tire designations: ’-
P . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Passenger car tire (or "T" for temporary-use tire).
185 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Nominal width of tire in miHimeters.
70 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Tire height-to-width ratio.
R ........................................................................................ Radial-ply tire (qr "D " for bias-ply tire).
14 ......................... ......................................................... Nominal rim diameter in inches.
Do not install smaller than minimum size tires shown on the fir© inflation placard on the vehicle.

9122-75

TIGHTENING REFERENCE

Stud Size . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .M12 x 1.5mm

Nut Size . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19mm
Torque Wheel Nuts (4 or 5 Stud).......... ................................................ ............................. .............. 129 N*m (95 ft. lbs)
 BODY
CONTENTS
Page
BODY COMPONENT SERVICE ...................... 7 PAINT ......................................................
BODY DIAGNOSTIC PROCEDURES ............... 2 WINDSHIELD ...........................................
GENERAL SERVICE INFORMATION ............... 1
GENERAL SERVICE INFORMATION
INDEX
Page
Safety Precautions and Warnings ................................. 1
VEHICLE IDENTIFICATION
Throughout this group, references to the Chrysler
Motors vehicle family identification code is used when
describing a procedure that is unique to that vehicle.
Refer to Introduction Group of this manual for de­
tailed information on vehicle identification. If a proce­
dure is common to all vehicles covered in this manual,
no reference will be made to a vehicle family code.
SAFETY PRECAUTIONS AND WARNINGS
WARNING: EYE PROTECTION SHOULD BE USED
WHEN SERVICING GLASS COMPONENTS. PERSON­
AL INJURY CAN RESULT.
USE A BREATHING FILTER WHEN SPRAYING
PAINT OR SOLVENTS IN A CONFINED AREA. PER­
SONAL INJURY CAN RESULT.
AVOID PROLONGED SKIN CONTACT WITH PETRO­
LEUM OR ALCOHOL BASED CLEANING SOLVENTS.
PERSONAL INJURY CAN RESULT.
DO NOT VENTURE UNDER A HOISTED VEHICLE
THAT IS NOT PROPERLY SUPPORTED ON SAFETY
STANDS. PERSONAL INJURY CAN RESULT.
CAUTION When holes must be drilled or punched in
a inner body panel, verify depth of space to the outer
body panel, electrical wiring, or other components.
Damage to vehicle can result.
Page
3
4
Page
Vehicle Identification ...................................................... 1
Do not use abrasive chemicals or compounds on
painted surfaces. Damage to finish can result.
Do not use harsh alkaline based cleaning solvents
on painted or upholstered surfaces. Damage to fin­
ish or color can result.
Do not hammer or pound on plastic trim panel
attaching fasteners when servicing interior trim. Plas­
tic panel can break.
Chrysler Motors uses many different types of push-in
fasteners to secure the interior and exterior trim to
the body . Most of these fasteners can be reused to
assemble the trim during various repair procedures.
At times a push-in fastener cannot be removed with­
out damaging the fastener or the component it is
holding. If it is not possible to remove a fastener
without damaging a component or body, cut or brake
the fastener and use a new one when installing the
component. Never pry or pound on a plastic or press-
board trim component. Using a suitable fork-type
prying device, pry the fastener from the retaining
hole behind the component being removed. When in­
stalling, verify that fastener is aligned with the re­
taining hole, by hand, push directly on or over the
fastener until it seats. Apply a low force pull to the
panel to verify that it is secure.
When it is necessary to remove components to ser­
vice another, it should not be necessary to apply ex­
cessive force or bend a component to remove it. Before
damaging a component to be reused, verify there is no
hidden fasteners or captured edges holding the compo­
nent in. Often a fastener is hidden by carpeting nap or
trim plugs.
 BODY DIAGNOSTIC PROCEDURES
INDEX
Page
Water Leaks . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
WATER LEAKS
Water leaks can be caused by poor sealing, im­
proper body component alignment, body seam poros­
ity, missing plugs, or blocked drain holes. Centrifugal
and gravitational force can cause water to drip from
an area somewhat distant from the actual leak point,
making leak detection difficult. All body sealing points
should be water tight in normal wet driving condi­
tions. Water flowing downward from the front of the
vehicle should not enter the passenger or luggage
compartment. Moving sealing surfaces will not al­
ways seal water tight under all conditions. At times,
side glass or door seals will allow water to enter the
passenger compartment during high pressure wash­
ing or hard driving rain (severe) conditions. Over com­
pensating on door or glass adjustments to stop a water
leak that occurs'under severe conditions, can cause
premature seal wear and excessive closing or latching
effort. After a repair procedure has been performed,
water test vehicle to verify leak has stopped before
returning vehicle to use.
VISUAL IN SP E C T IO N BEFORE
W ATER LEAK T E S T S
Verify that floor and body plugs are in place, body
drains are clear and body components are aligned and
sealed. If component alignment or sealing is neces­
sary, refer to the appropriate section of this group for
proper procedures.
W ATER LEAK T E S T S
WARNING: DO NOT USE ELECTRIC SHOP LIGHTS
OR TOOLS IN WATER TEST AREA, PERSONAL IN­
JURY CAN RESULT.
When a determination has been made on the condi­
tions that a water leak occurs, simulate the conditions
as closely as possible.
• If a leak occurs when the car is parked in a steady
light rain, flood the leak area with a open ended
garden hose.
• If a leak occurs while driving at highway speeds in
a steady rain, test the leak area with a reasonable
velocity stream or fan spray of water from a garden
hose with an adjustable nozzle. Direct the spray in the
direction comparable to actual conditions.
• If a leak seems to occur only when the vehicle is
parked on an incline, hoist the end or side of the
vehicle to simulate this condition before water test-
Page
2 Wind Noise . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
ing. This method can also be used when the leak
occurs when the vehicle accelerates, stops, or turns. If
the leak occurs on acceleration, hoist the front of the
vehicle. If the leak occurs when braking, hoist the
back of the vehicle. If the leak occurs on left turns,
hoist the left side of the vehicle. If the leak occurs on
right turns, hoist the right side of the vehicle. For
hoisting recommendations refer to Group 0, Lubrica­
tion and Maintenance, General Information section.
W ATER LEAK DETECTION
To detect a water leak point of entry, perform a
water test and watch for water tracks or droplets
forming on the inside if the vehicle. If necessary re­
move interior trim covers or panels to gain visual
access to the leak area. If the hose can not be posi­
tioned without being held, have someone help perform
the water test.
Some water leaks must be tested for a considerable
length of time to become apparent. When a leak ap­
pears, determine the highest point of the water track
or drop. The highest point usually will indicate the
point of entry. After leak point has been determined,
repair the leak and water test to verify that leak has
stopped.
Locating the entry point of water that is leaking
into a cavity between panels can be difficult. The
trapped water splashes or runs from the cavity it is
dammed up in, often at a distance from the entry
point. Most water leaks of this type become apparent
after accelerating, stopping, turning, or when on a
incline.
M IRROR IN SP E C TIO N METHOD
When a leak point area is visually obstructed, use a
suitable mirror to gain visual access. A mirror can
also be used to deflect light to a limited access area to
assist in locating a leak point.
BRIGHT LIGHT LEAK T E S T METHOD
Some water leaks in the luggage compartment can
be detected without water testing. Position the vehicle
in a brightly light area. From inside the darkened
luggage compartment inspect around seals and body
seams. If necessary, have a helper direct a drop light
over the suspected leak areas around the luggage com­
partment. If light is visible through a normally sealed
location, water could enter through the opening.
P R E S S U R IZ E D LEAK T E S T METHOD
When a water leak into the passenger compartment
can not be detected by water testing, pressurize the
passenger compartment and soap test exterior of the
vehicle. To pressurize the passenger compartment, close
all doors and windows, start engine, and set heater
control to high blower in HEAT position. If engine can
not be started, connect a charger to the battery to
assure adequate voltage to the blower. With interior
pressurized, apply dish detergent solution to suspected
leak area on the exterior of the vehicle. Apply deter­
gent solution with spray device or soft bristle brush. If
soap bubbles occur at a body seam, joint, seal or gas­
ket the leak entry point could be at that location.
WIND NOISE
Wind noise is the result of most air leaks. Air leaks
can be caused by poor sealing, improper body compo­
nent alignment, body seam porosity, or missing plugs
in the engine compartment or door hinge pillar areas.
All body sealing points should be air tight in normal
driving conditions. Moving sealing surfaces will not
always seal air tight under all conditions. At times,
side glass or door seals will allow wind noise to be
noticed in the passenger compartment during high
cross-winds. Over compensating on door or glass ad­
justments to stop wind noise that occurs under severe
conditions, can cause premature seal wear and exces­
sive closing or latching effort. After a repair proce­
dure has been performed, test vehicle to verify noise
has stopped before returning vehicle to use.
INT10DUCT10N
A paint code is provided on the body code plate
located in the engine compartment. Refer to the Intro­
duction section at the front of this manual for body
code plate description.
BASE COAT/CIEAR COAT FINISH
On most vehicles a two part paint application (base
coat/clear coat) is used. Color paint that is applied to
primer is called base coat. The clear coat protects the
base coat from ultra violet light and provides a dura­
ble high gloss finish.
WET SANDING,BUFFING AND POLISHING
Minor acid etching, orange peel or smudging in
clear coat can be reduced with light wet sanding,
hand buffing and polishing. If the finish has been wet
sanded in the past, it can not be repeated. Wet sand­
ing operation should be performed by a trained auto­
motive painter.
Wind noise can also be caused by improperly fitted
exterior moldings or body ornamentation. Loose mold­
ings can flutter, creating a buzzing or chattering noise.
An open cavity or protruding edge can create whis­
tling or howling noise. Inspect the exterior of the
vehicle to verify that these conditions do not exist.
VISU AL IN S P E C T ION BEFORE T E S T S
Verify that floor and body plugs are in place and
body components are aligned and sealed. If component
alignment or sealing is necessary, refer to the appro­
priate section of this group for proper procedures.
ROAD TE ST IN G WIND NO ISE
(1) Drive the vehicle to verify the general location
of the wind noise.
(2) Apply 50 mm (2 in.) masking tape in 150 mm (6
in.) lengths along weatherstrips, weld seams or mold­
ings. After each length is applied drive vehicle. If
noise goes away after a piece of tape is applied, re­
move tape, locate and repair defect.
POSSIBLE CAUSE OF WIND NOISE
• Moldings standing away from body surface can catch
wind and whistle.
• Gaps in sealed areas behind overhanging body flanges
can cause wind rushing sounds.
• Misaligned movable components.
• Missing or improperly installed plugs in pillars.
• Weld burn through holes.
CAUTION: Do not remove clear coat finish, if equipped.
Base coat paint must retain clear coat to shine.
PAINTED SUiPACE TOUCH-UP
When a painted metal surface has been scratched or
chipped, it should be touched-up as soon as possible to
avoid corrosion. For best results, use Mopar® Scratch
Filler/Primer, Touch-Up Paints and Clear Top Coat.
Refer to Introduction group of this manual for Body
Code Plate information.
TOUCH-UP PROCEDURE
(1) Scrape loose paint and corrosion from inside
scratch or chip.
(2) Clean affected area with Mopar® Tar/Road Oil
Remover and allow to dry.
(3) Fill the inside of the scratch or chip with- a coat
of filler/primer. Do not overlap primer onto good sur­
face finish. The applicator brush should be wet enough
to puddle fill the defect without running. Do not stroke
brush applicator on body surface. Allow the filler/
primer to dry hard.
(4) Cover the filler/primer with color touch-up paint.
Do not overlap touch-up color onto the original color
coat around the scratch or chip. Butt the new color to
the original color if possible. Do not stroke applicator
brush on body surface. Allow touch-up paint to dry
hard.
(5) On vehicles without clear coat, the touch-up
color can be lightly (600 grit) wet sanded and polished
with rubbing compound.
(6) On vehicles with clear coat, Apply clear top coat
to touch-up paint with the same technique as de­
scribed in step 4. Allow clear top coat to dry hard. If
desired, step 5 can be performed on clear top coat.

PAINT AND TRIM CODE DESCRIPTIONS

PAINT COLOR NAME PEARL CLEAR

CODE METALLIC COAT COAT

GM4 Clare X
FM9 Black Cherry X
KV4 Light Champagne X X
KTA Safari Brown Satin GI*
EC7 Twilight B'
HCI Diamond Blue X X
DX8 E X
HD8 Dark Quartz Gray X X
HD1 Platinum Silver X X
GW7 Bright White X
TRIM COLOR NAME
CODE

D5 Medium Quartz
C5 Twilight B1
R8 Bordeaux
V4 Champagne
9123-134

WINDSHIELD
SAFETY PRECAUTIONS AND WARNINGS
WARNING: DO NOT USE URETHANE ADHESIVE OR
PRIMER IN CLOSED WORK AREA, PERSONAL IN­
JURY CAN RESULT.
PROTECT SKIN FROM COMING IN CONTACT WITH
URETHANE, PERSONAL INJURY CAN RESULT.
WEAR EYE AND HAND PROTECTION WHEN WORK­
ING WITH GLASS, PERSONAL INJURY CAN RESULT.
CAUTION Protect all painted or trimmed surfaces
from coming in contact with urethane or primers,
damage will result.
Do not damage painted surfaces when removing mold­
ings or cutting urethane around windshield.
It is difficult to salvage a windshield during the
removal operation. The windshield is part of the struc­
tural support for the roof. The urethane bonding used
to secure the windshield to the fence is difficult to cut
or clean from any surface. If the moldings are set in
urethane, it would also be unlikely they could be
salvaged. Before removing the windshield, check the
availability of the windshield and moldings from the
parts supplier.
WINDSHIELD REPLACEMENT
WINDSHIELD REMOVAL
(1) Remove inside rear view mirror.
(2) Remove cowl cover. Refer to Cowl Cover Re­
moval paragraph in this group.
 (3) Remove windshield moldings. Pull outward on
molding at the bottom of A-pillars using pliers.
(4) Cut urethane bonding from around windshield
using a suitable sharp cold knife. A pneumatic cutting
device can be used if available (Fig. 2).
(5) Separate windshield'from vehicle..
Fig. I Windshield Moldings
WINDSHIELD INSTALLATION
CAUTION Open the left front door glass before in­
stalling windshield to avoid pressurizing the passen­
ger compartment if a door or the trynk lid is slammed
before urethane bonding is cured. Water leaks can
result.
Allow the urethane at least 4 hoyrs to cure before
returning the vehicle to use.
The windshield fence should be cleaned of old ure­
thane bonding material. Support spacers should be
cleaned and properly installed on weld studs or repair
screws at bottom of windshield opening.
(1) Place replacement windshield into windshield
opening and position glass in the center of the open­
ing against the support spacers. Mark the glass at the
support spacers with a grease pencil or pieces of mask­
ing tape and ink pen to use as a reference for installa­
tion. Remove replacement windshield from windshield
opening (Fig. 8).
(2) 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
parallel 75 cm (2.5 ft.) apart (Fig. 4).
(8) Clean inside of windshield with Mopar Glass
Cleaner and lint-free cloth.
(4) Apply clear glass primer 25 mm (1 in.) wide
around perimeter of windshield and wipe with clean/
dry lint-free cloth.
(5) Apply black-out primer 15 mm (.75 in.) wide on
top and sides of windshield and 25 mm (1 in.) on
bottom of windshield. Allow at least three minutes
drying time.
(8) Position windshield bonding compression spac­
ers on lower fence above the support spacers at the
edge of the windshield opening (Fig. 5).
(7) Apply a 10 mm (0.4 in.) bead of urethane around
perimeter of windshield along the inside of the moldings.
(8) With the aid of a helper, position the windshield
over the windshield opening. Align the reference marks
at the bottom of the windshield to the support spacers.
(9) Slowly lower windshield' glass to windshield open­
ing fence. Guide the top molding into.proper position
if necessary. Push windshield inward to fence spacers
at bottom and until top molding is flush to roof line
(Fig. 8).
(10) Clean access urethane from exteripr with Mopar,
Super Clean or equivalent.
(11) Install windshield molding. Apply 150 mm (6
in.) lengths of 50 mm (2 in.) masking tape spaced 250
mm (10 in.) apart to hold molding in place until ure­
thane cures. . '
(12) Install cowl cover and wipers.
(13) Install inside rear view mirror.
(14) After urethane has cured, remove tape strips
and water test windshield to verify repair.
WINDSHIELD
 Flg. 6 Lower Windshield Into Position

Fig. 4 Work Surface Set up and Molding Installation

A-PILLAR ROOF

Fig. 5 Position Urethane Compression Spacers

 BODY COMPONENT SERVICE
INDEX
Page Page
A-Pillar and Roof Rail Moldings 25 Left Quarter Trim Panel ................................................ 26
Body Side Applique ................ 23 Left Quarter Trim Panel— With Rear A /C ................... 27
Cowl Cover ................................. 11 Left Front Seat Track and Riser ................................. 30
Cowl Trim and Scuff Plates . . . - Lift Gate .......................................................................... 36
Door Opening Weatherstrips .. 21 Lift Gate Latch ........ ..................................................... 36
Exterior Moldings .................... 21 Lift Gate Trim Panel ...................................................... 36
First Rear Seat Risers ............ 32 Low Line Front Bumper ................................................ 7
Floor Carpet ............................... 35 Outside Front Door Latch Release Handle .............. 13
Front Bumper Support Bracket 8 Overhead Console ................................... . .................... 35
Front Center Consoles ............ 34 Rear Bumper .................................................................. 38
Front Door and H in g e ........ ...... 13 Rear Engine Compartment Splash Shield ................ 12
Front Door Belt Molding and Rear Seat Belts .............................................................. 29
Weatherstrip— Van .............. 15 Rear Window Glass ........................................................ 39
Front Door Belt Molding and Right B-Pillar Trim C o ve r............................................. 25
Weatherstrip— Wagon .......... 15 Right Front Seat Riser and Storage Box ................... 31
Front Door Frame Rear Molding— Van ....................... 15 Right Quarter Trim Panel ............................................. 25
Front Door Glass ............................................................ 14 Right Side Grab Handle ................................................ 24
Front Door Glass Channel and Run Weatherstrip . . . 15 Roof Top Luggage Rack ................................................ 37
Front Door Glass Lower C h an nel................................. 16 Second Rear Seat T ra c k ................................................ 33
Front Door Latch ............................................................ 14 Sight Shield .................................................................... 11
Front Door Side View Mirror ....................................... 14 Sliding D o o r.......... ......................................................... 17
Front Door Trim Panel .......... ....................................... 12 Sliding Door Center Hinge ........................................... 18
Front Door Window Regulator— Manual ..................... 16 Sliding Door Center Hinge Track Cover ..................... 17
Front Door Window Regulator— Power ....................... 16 Sliding Door Frame Upper Molding ........................... 17
Front End Splash Shields ............................................ 11 Sliding Door Inside Latch/Lock Control ..................... 19
Front Fender .................................................................. 12 Sliding Door Latch/Lock Linkage ............................... 19
Front Seat Belts ............................................................ 28 Sliding Door Lower Hinge ........................................... 19
Front S e a ts ...................................................................... 30 Sliding Door Outside Latch Release Handle ............ 20
Fuel Fill Door Release Cable ....................................... 37 Sliding Door Power Lock Actuator ............................. 20
Grille ................................................................................ 8 Sliding Door Pull Handle ............................................. 1/
Head Lining .................................................................... 35 Sliding Door Rear L a tc h ................................................ 20
High Line Front Bumper and Fascia ......................... 7 Sliding Door Trim Panel ............................................... 17
High Line Rear Bumper and Fascia ........................... 39 Sliding Door Upper Hinge ............................................ 18
Hood and Hinges .......................................................... 9 Stick-On Body Side Molding ....................................... 21
Hood Latch .................................................................... 10 Vent Window .......... .............. ......................................... 20
Hood Ornament .............................................................. 9 Vent Window W eatherstrip........................................... 21
Hood Release Cable ..................................................... 10 Wood Grain Overlay ...................................................... 23
Hood Safety Catch ....................................................... 10
LOW LINE FRONT BUMPER HIGH LINE FRONT BUMPER AND FASCIA

LOW LINE FRONT BUMPER REMOVAL (FIG. 1) HIGH LINE FRONT BUMPER AtlD
(1) Remove nut holding front bumper end caps to FASCIA REMOVAL (FIG. 2)
front fenders. (1) Remove retainers holding front bumper fascia to
(2) Remove nut holding front bumper end caps to bottom of radiator closure panel.
bumper support. (2) Remove retainers holding fascia to forward edge
(3) Remove push-in fastener holding front bumper of front wheel openings.
end caps to bumper. (3) Remove nuts holding fascia to front fenders.
(4) Support front bumper on a suitable liftin g device. (4) Disconnect fog lamp wire connector, if equipped.
(5) Remove nuts holding front bumper to support (5) Support front bumper on a suitable lifting device.
bracket. (6) Remove bolts holding front bumper reinforce­
ment to bumper support bracket.
LOW LINE FRONT BUMPER INSTALLATION (7) Separate bumper assembly from vehicle.
Reverse the preceding operation. Align front bumper
to 15 mm (0.6 in.) from bottom of grille. To move HIGH LINE FRONT BUMPER AND
bumper up or down, loosen nuts holding support bracket FASCIA INSTALLATION
to radiator closure panel. Reverse the preceding operation. Align front bumper
to 15 mm (0.6 in.) from bottom of grille. To move
bumper up or down, loosen nuts holding support bracket
to radiator closure panel.

Pig. 2 High Line Front Bumper
HIGH LINE FRONT BUMPER OVERHAUL (PIG. 3J
(1) Remove high line front bumper and fascia
assembly.
(2) Position front bumper and fascia on a suitable
padded work surface to protect painted finish.
(3) Remove fog lamp assemblies.
(4) Remove push-in fasteners holding fascia to
bumper reinforcement.
(5) Separate reinforcement from fascia.
HIGH LINE FRO NT BUM PER A S S E M B L Y
Reverse the preceding operation.
F lf. 3 High line Front Bumper'Owerhaui
FRONT BOiPIR SUPPORT BRACKET
m o m BU M PER S U P P O R T .
B R A C K E T REMOVAL:
(1) Remove front bumper as necessary to' clear re­
moval path of support bracket..
'(2) Remove nuts holding bumper support bracket to
radiator closure panel.
(3) Separate bumper support bracket from vehicle.
FRONT BU M PER S U P P O R T B R A C K E T
IN ST A L L A T IO N
Reverse the preceding operation.
GRILLE
GRILLE REM OVAL (FIG. 4 or SJ ' '’
CD Remove bolt holding grille to bracket in front of
radiator. , . .
(2) Remove headlamp bezel and park/turn signal
lamp on low line models. Refer "to Group 8L, -Lamps
for proper procedures.
(3) Remove" screws 'holding grille to ’front'headlamp
assemblies.
(4) Separate grille from vehicle.
GRILLE IN S T A L L A T IO N " ■
Reverse the preceding operation.

Fig. 4 Grille—Low Line
Fig. 5 Grille—High Line
HOOD ORNAMENT
HOOD ORNAMENT REMOVAL (FIG. S)
(1) Raise hood to the full up position.
(2) Remove nut holding hood ornament to hood.
(3) Separate ornament from hood.
HOOD ORNAMENT INSTALLATION
Reverse the preceding operation.
HOOD
ORNAMENT
9123-127
Fig. 5 Hood Ornament
HOOD AND HINGES
HOOD REMOVAL (FIG. 6)
(1) Raise hood to full up position.
(2) Remove cowl cover as necessary to gain access to
under hood lamp connector. Disconnect under hood
lamp wire connector.
(3) Mark all bolt and hinge attachment locations
with a grease pencil or other suitable device to pro­
vide reference marks for installation. When installing
hood, align all marks and secure bolts. The hood should
be aligned to 4 mm (0.160 in.) gap to the front fenders
and flush across the top surfaces along fenders.
(4) Remove the top hood to hinge attaching bolts
and loosen the bottom bolts until they can be removed
by hand.
(5) With assistance of a helper at the opposite side
of the vehicle to support the hood, remove the bottom
hood to hinge attaching bolts. Separate the hood from
the vehicle.
HOOD INSTALLATION
Reverse the preceding operation.
HOOD HINGE REMOVAL (FIG. 6)
(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. When installing
hood hinge, align all marks and secure bolts. The
hood should be aligned to 4 mm (0.160 in.) gap to the
front fenders and flush across the top surfaces along
fenders. Shims can be added or removed between the
hood and hinge to achieve proper hood height.
(3) Remove cowl cover as necessary to gain access to
hood hinge pin.
(3) Remove hood to hinge attaching bolts.
(4) Remove push-on retainer holding hood hinge
arm to hinge pin through access hole in cowl.
HOOD HINGE INSTALLATION HOOD LATCH INSTALLATION
Reverse the preceding operation. If necessary, paint Reverse the preceding operation.
new hinge before installation.

F lf. 8 H m d Latch

HOOD RELEASE CABLE

HOOD SAFETY CATCH
HOOD S A F E T Y CATCH REMOVAL (FIG. 7)
(1) Raise hood and support with prop rod.
(2) Remove bolts holding safety catch to hood.
(3) Separate safety catch from hood.
HOOD SAFETY CATCH INSTALLATION
Reverse the preceding operation.
HOOD RELEASE CABLE REMOVAL (FIG. 9)
(1) Raise hood and support with prop rod.
(2) Remove grille and radiator closure sight shield.
(3) Disconnect hood release cable casing and cable
end from hood latch assembly.
(4) Remove hood latch release cable handle attach­
ing bolts from under left lower edge of instrument panel.
(5) Disengage release cable rubber grommet from
engine compartment dash panel behind instrument
panel.
(6) Rout cable assembly through engine compart­
ment around battery, under fender lip, around relay
bank, and under wiring harnesses, toward dash panel.
Push cable through access hole in dash panel under
the brake master cylinder, into passenger compartment.
HOOD RELEASE CABLE INSTALLATION
Reverse the preceding operation.

f l f . 7 Hood Safety Catch

HOOD LATCH
HOOD LATCH REMOVAL (FIG. 8 J
(1) Raise hood and remove grille and radiator clo­
sure panel sight shield.
(2) Remove bolts holding latch to radiator closure
panel.
(3) Separate latch from closure panel. Pry latch
cable casing from slot retainer on latch.
(4) Disengage cable end from latch release arm.
SIGHT SHIELD
SIG H T SHIELD REMOVAL (FIG. 10)
(1) Raise hood and -support with prop rod.
(2) Remove grille as necessary to gain clearance for
sight shield removal.
(3) Remove push-in fasteners holding sight shield to
radiator closure panel.
(4) Separate sight shield from vehicle.
S IG H T SHIELD IN S T A L L A T IO N
Reverse the preceding operation.
COWL COVER IN S T A L L A T IO N ■ ,
Reverse the preceding operation.
FRONT END SPLASH SHIELDS
FRO NT WHEELHOUSE S P L A S H SHIELD
REM OVAL (FIG. 12)
(1) Remove rear engine compartment splash shield.
(2) Remove bolts holding wheelhouse splash shield
to front frame member.
(3) Remove push-in fasteners holding wheelhouse
splash shield to front fender wheel lip and upper sus­
pension tower. •■
(4) Separate wheelhouse splash shield from vehicle.

FRO NT WHEELHOUSE S P L A S H SHIELD

IN ST A L L A T IO N
Reverse the preceding operation.

ENGINE DRIVE B E L T S P L A S H SHIELD

REM OVAL (FIG. 12)
(1) Remove wheelhouse splash shield as necessary
to gain access to engine drive belt splash shield. '
( 2 ) Remove screws holding engine drive belt splash
shield to front frame member.
(3) Separate splash shield from vehicle.

ENGINE DRIVE B E L T S P L A S H SHIELD

I N ST A L L A T IO N
Fig. 10 Sight Shield Reverse the preceding operation.
COWL COVER FRONT
FENDER
COWL COVER REMOVAL (FIG. 11)
(1) Raise hood and support with prop rod.
(2) Remove windshield wiper arms. Refer to Group
8K, Electrical/Windshield Wipers and Washers for
proper procedures.
(3) Remove screws holding cowl cover to cowl panel
below windshield.
(4) Separate cowl cover from vehicle.

REAR ENGINE
COMPARTMENT
SPLASH SHIELD
LOWER
DRIVE BELT
SPLASH SHIELD

PLUG 9123-140
REAR ENGINE COMPARTMENT SPLASH SHIELD FRO NT PENDER I N S T A L L A T IO N
Reverse the preceding operation. Align front fender
R E A R ENGINE C O M P A R TM E N T S P L A S H to 6 mm (0.240 in.) to forward edge of door and 4 min
SHIELD REM O VAL (PIG. 12) (0.180) to edge of hood. All surfaces across gaps should
(1) Remove bolt holding rear engine compartment be flush.
splash shield to frame side member.
(2) Remove push-in fastener holding rear engine
compartment splash shield to wheelhouse splash shield.
(8 separate splash shield from vehicle.

R E A R ENGINE C O M P A R TM E N T S P L A S H
SHIELD IN S T A L L A T IO N
Reverse the preceding operation.

TRANSAXLE S P L A S H SHIELD
REM OVAL (FIO. 13)
(1) Remove front wheelhouse splash shield as neces­
sary to gain access to transaxle splash shield,
(2) Remove screws holding transaxle splash shield
to front frame member.
(3) Separate splash shield from vehicle.

T R A N S A X L E S P L A S H SHIELD IN S T A L L A T IO N f l f . 14 Front Fender

Reverse the preceding operation.
FRONT DOOR T R ii PANEL
DOOR TRIM P A N E L WITH PO W ER WINDOWS
REM OVAL (PIG. I S )
(1) Lower door glass.
(2) Disconnect battery negative cable if equipped
with power windows.
(3) Remove screw holding door latch handle bezel to
door trim panel. Separate bezel from door.
(4) Remove screw holding upper door trim to side
view mirror frame.
(5) Remove plugs and screws holding trim to door
from above map pocket.
(6) Remove plug and screw holding bottom rear­
ward edge of trim to door.
(7) Remove plugs and screws holding arm rest' to
door panel.
(8) Remove screw holding window crank to regula­
tor and separate crank from door, if equipped.
FRONT FENDER (3) Disengage trim clips holding trim panel to pe­
rimeter door inner panel.
FRONT FENDER REMOVAL (FIG. 14)
(10) Lift trim panel upward to disengage barb clips
(1) Remove grille and headlamp assembly.
at top of trim panel.
(2) Remove wheelhouse splash shield.
(11) Disconnect courtesy lamp, power lock switch
(8) Remove bolts holding jack hoisting pad to under
and power window switch wire connectors, if equipped.
body and separate pad from vehicle.
(12) Separate trim panel from door.
(4) Remove bolts holding fender to hinge pillar from
inside wheel opening.
(5) Remove bolt holding fender to rocker panel.
(6) Remove bolts holding fender to lower radiator
closure panel.
(7) Remove bolts holding fender to cowl side panel.
(8) Cut adhesive holding support brace to fender
near upper door hinge, if equipped
(9) Separate fender from vehicle.
 Fig. 15 Front Door Trim Panel
FRONT DOOR AND HINGE
The front door hinge is welded to the door and
bolted to the hinge pillar. The door half of the hinge
pivots on a removable hinge pin. The hinge pin is
driven in from the bottom on the top hinge and from
the top on the bottom hinge. All adjustments to the
hinge are performed on the hinge pillar half of the
hinge. If the welded half of the hinge must be bent to
align door, consult an authorized body repair facility.
m o m m o m r e m o v a l ( f ig . i s j
(1) Remove door trim panel, silencer pad, and water
shield.
(2) Disconnect all wire connectors and wire harness
hold doWns inside door and push wire harness through
access hole in front of door into hinge pillar opening.
(3) Open door and support door on a suitable lifting
device.
(4) Dtive bottom hinge pin upward and remove pin
from hinge.
(5) Drive top hinge pin downward and remove pin
from hinge.
(6) Separate door from vehicle.
FRONT DOOR INSTALLATION
Reverse the preceding operation. The door should
not require re-alignment. If door does need alignment,
refer to Front Door Hinge Installation paragraph in
this section.
f l f . 18 Front Doofr-TyplcaL . ■
PMONTMOOR HINGE REMOVAL (PIG. f6 J
(1) Remove front fender wheelhouse splash shield.
Refer to Front Wheelhouse Splash Shield Removal
paragraph in this section.
(2) Support door on a suitable lifting device.
(3) Drive out hinge pin on the effected hinge.
(4) Remove bolts holding hinge to hinge pillar and
separate hinge form vehicle.
FRONT DOOR HINGE INSTALLATION
Reverse the preceding operation. ■ Align door to
achieve 6 mm (§.240 in.) gap to all surrounding pan­
els and flush across gaps.
OUTSIDE FRONT 0 0 0 1 LATCH RELEASE HANDLE
o u t s id e m o m d o o r l a t c h
RELEASE HANDLE REMOVAL f F IG . f 7J .
(1). Remove door trim panel and water shield as
necessary to gain access to outside door handle.
(2) Disconnect lock cylinder linkage from door latch.
(3) Disconnect latch release linkage from door latch.
(4) Disconnect illuminated entry switch wire con­
nector.
(5) Remove nut holding outside handle retaining
bracket to door panel and separate bracket from door.
(8) 'Lift lock cylinder linkage upward to parallel
back of outside handle. .
(7) Separate outside handle from door.
 (4) Separate mirror from door.
OUTSIDE HANDLE ASSEMBLY

LOCK CYLINDER . FRONT DOOR SIDE VIEW MIRROR

INSTALLATION
LOCK CYLINDER Reverse the preceding operation.
RETAINER
2 N*m (17 IN. LBS.)

LOCK CYLINDER
TO LAT CH LINK

7 N *m
DOOR PANEL (65 IN. LBS.)

RH1320

f l f . 17 Outside Door Latch Ralaaaa Handle

FRONT 0001 LATCH

m O N T DOOR LATCH REMOVAL (PIG. 18)

(1) Remove door trim panel and water shield as
necessary to gain access to door latch.
(2) Disconnect all linkage rods from latch.
(3) Disconnect power door lock actuator wire connector.
(4) Remove screws holding latch to door end frame.
(5) Separate door latch from door.
FRONT DOOR LATCH INSTALLATION
Reverse the preceding operation.
LOCK INSIDE
BUTTON HANDLE
f l f . 19 Side View Mirror
FRONT DOOR OLASS
FRONT DOOR GLASS REMOVAL (FIG. 20)
(1) Remove front door trim panel and water shield.
(2) Raise glass to align attaching nuts to access
holes in inner door panel.
(3) Remove nuts holding door glass to window regu­
lator lift plate.
(4) Separate glass from lift plate.
(5) Lift glass upward through opening at top of door.

FRONT DOOR GLASS INSTALLATION

LOCK Reverse the preceding operation. To align glass, in­
CYLINDER
LINK stall attaching nuts hand tight allowing glass to slide
i-P ILLA i on lift plate. Raise glass to full up position. Secure
glass attaching nuts.
DOOR END POWER.
FRAME DOOR LOCK STUD AND GASKET
ACTUATOI WASHER
7 N»m
(60 IN. LBS.)
STilKEi 9123-144
FRONT W IN D O W
f l f . 18 Front Door Latch REGULATOR ASSEMBLY

FRONT DOOR SIDE VIEW MIRROR

FRONT DOOR SIDE .VIEW MIRROR

REMOVAL (FIG. 19) 10 N«m
(1) Remove door trim panel and water shield as (85 IN. LBS.)
necessary to gain access to side view mirror.
(2) Disconnect power side view mirror wire connec­
tor, if equipped.
(3) Remove nuts holding side view mirror to door
frame.
FRONT DOOR BELT MOLDING AND (4) Disengage clips holding door frame molding to
WEATHERSTRIP— VAN door frame.
(5) Remove screws holding belt molding and weath­
BELT MOLDING AND WEATHERSTRIP erstrip to door panel.
REMOVAL (FIG. 21) (6) Separate belt molding and weatherstrip from
(1) Remove door glass. door.
(2) Remove side view mirror.
(3) Remove screws holding belt molding and weath­
B E L T MOLDING AND W E A T H E R S T R IP
erstrip to door panel.
IN S T A L L A T IO N
(4) Separate belt molding and weatherstrip from
Reverse the preceding operation.
door.

BELT MOLDING AND WEATHERSTRIP

INSTALLATION
Reverse the preceding operation.

Flf. 22 Belt Molding and Weatherstrip—Wagon Onfy

FRONT DOOR GLASS CHANNEL AND

RUN WEATHERSTRIP
Fig. 21 Belt Molding and Weatherstrip—Van Only GLASS CHANNEL AND RUN WEATHERSTRIP
REMOVAL (FIG. 23)
FRONT DOOR FRAME REAR MOLDING— 'VAN
(1) Lower door glass to down position.
(2) Remove side view mirror as necessary to gain
FRO NT DOOR FRAME R E A R MOLDING
clearance for weatherstrip removal.
REM OVAL (FIG. 21)
(3) Pull glass run weatherstrip from door frame
(1) Remove belt molding and weatherstrip as neces­
channel.
sary to clear door frame molding removal path.
(2) Remove glass run weatherstrip to gain access to
GLASS CHANNEL AND RUN WEATHERSTRIP
molding clips.
INSTALLATION
(3) Disengage clips holding door frame molding to
Reverse the preceding operation.
door frame.
(4) Separate molding from door.

FRONT DOOR FRAME REAR MOLDING

INSTALLATION
Reverse the preceding operation.

FRONT DOOR BELT MOLDING AND

WEATHERSTRIP—WAGON

BELT MOLDING AND WEATHERSTRIP REMOVAL

(FIG. 22)
(1) Remove door glass.
(2) Remove side view mirror.
(3) Remove door glass run weatherstrip.

fig. 23 Glass Channel and Run Weatherstrip
FRONT DOOR GLASS LOWER CHANNEL
FRONT LOWER CHANNEL REMOVAL (PIG. 24)
(1) Remove door trim panel and water shield.
(2) Raise glass to up position.
(3) Remove bolts holding channel to inner door panel.
(4) Separate channel from door.
FRONT LOWER CHANNEL INSTALLATION
■ Reverse the preceding operation.
FRONT DOOR WINDOW REGULATOR—MANUAL
MANUAL WINDOW R E G U L A T O R REMOVAL
(PIG. 24)
(1) Remove door trim panel and water shield.
(2) Remove bolts holding door glass to window lift
plate.
(3) Allow glass to rest on bottom of door.
(4) Remove bolts holding regulator to door inner
panel.
(5) Disengage push-in fastener holding regulator
cables to inner door panel.
(8) Separate regulator from door.
MANUAL WINDOW REGULATOR INSTALLATION
Reverse the preceding operation.
FRONT DOOR WINDOW REGULATOR— POWER
POWER WINDOW REGULATOR REMOVAL
(FIG. 24)
(1) Remove door trim panel and water shield.
(2) Remove bolts holding door glass to window lift
plate.
(3) Disconnect battery negative cable.
(4) Allow glass to rest on bottom of door.
(5) Disconnect power window regulator motor wire
connector. Disengage push-in fastener holding wire
harness to inner door panel.
(6) Remove bolts holding regulator to door inner
panel.
(7) Disengage push-in fastener holding regulator
cables to inner door panel.
(8) Separate regulator from door.
POWER WINDOW REGULATOR INSTALLATION
Reverse the preceding operation.
SLIDING DOOR TRIM PANEL
SLIDING TRIM PANEL REMOVAL (FIG. 1)
(1) Close sliding door. From inside vehicle perform
the following.
(2) Remove screw plug at rearward center of door
trim and remove screw.
(3) Remove hidden screw from upper rearward cor­
ner of carpet insert.
(4) Remove screws holding trim to door from along
bottom of trim panel.
(5) Disengage trim clips holding trim to door from
around perimeter of trim panel.
(6) Lift trim panel upward to disengage barbed re­
tainers holding top of trim to door flange.
(7) Separate trim panel from sliding door.
SLIDING TRIM P A N E L IN ST A L L A T IO N
Reverse the preceding operation. ' When removing the sliding door as an assembly it
DOOR FRAME
UPPER M O LD IN G
PUSH-IN SLIDING
FASTENER DOOR TRIM
9123-150 CARPET PANEL
f lf . I Sliding Door Trim and Pull Hanil§
SLIDING DOOR FRAME UPPER MOLDING
SLIDING DOOR FRAME UPPER MOLDING
REMOW AL (FIG. f j
(1) Remove sliding door trim panel.
(2) Remove screw plugs from upper door frame
molding.
(8) Remove screws holding upper molding to door
frame.
(4) Separate molding from door frame.
SLIDING DOOR F R A ^ E U PPER MOLDING
IN ST A L L A T IO N
Reverse the preceding operation.
SLIDING DOOR PULL HANDLE
SLIDING DOOR PULL HANDLE REMOWAL
(FIG. f J
(1) Remove sliding door trim panel.
(2) Remove upper door frame molding.
(3) Remove screw holding top of pull handle to door
frame. '
(4) Remove bolts holding pull handle to inner door
panel. -
(5) Separate pull handle from door.
SLIDING DOOR PULL HANDLE IN S T A L L A T IO N
Reverse the preceding operation.
SLIDING DOOR
SLIDING DOOR REM OVAL
is not necessary to loosen bolts that would alter the
alignment.
(1) Remove sliding door upper track cover.
(2) Remove upper track over travel stop.
(3) Remove sliding door sill plate.
(4) Remove lower track over travel stop.
(5) Remove sliding door center track cover.
(6) Remove center track over travel stop.
(7) With assistance, roll the door rearward and dis­
engage hinge rollers from tracks.
(8) Separate sliding door from vehicle.
SLIDING DOOR IN S T A L L A T IO N ■ ' . " ■'
Reverse the preceding operation.
SLIDING DOOR CENTER HINGE TRACK COVER
SLIDING DOOR CENTER HINGE
TRACK COVER REMOVAL (FIG. 2 )
(1) Open lift gate.
(2) Remove screws holding center track cover to
quarter panel from above right tail lamp.
(3) Open sliding door.
(4) Remove screws holding center track cover to
quarter panel from above sliding door rear latch striker.
(5) Disengage clips holding track cover to quarter
panel.
(6) Separate track cover from vehicle.
 SLIDING
DOOR

CENTER
HINGE

center
HINGE f l f . 3 Sliding Door Center Hinge
GUIDE
HACK
SLIDING 000R UPPER HINGE
TRACK
COVER SLIDING DOOR UPPER HINGE REMOVAL
(FIG. 4)
QUARTER (1) Remove sliding door upper frame molding and
PANEL pull handle.
= CLEAN TRACK WITH (2) Remove sliding door upper track cover.
SUITABLE SOLVENT (3) Remove upper track over travel stop.
AND LUBRICATE WITH
MULTI-PURPOSE GREASE 9123-151 (4) Mark hinge location on sliding door for reference
points when installing.
Pig. 2 Sliding Do#r Center Tract Cover (5) Support Sliding door on a suitable lifting device.
and Over Travel Stop (8) Remove bolts holding hinge to sliding door.
(7) Separate hinge from sliding door.
SLIDING DOOR CENTER HINGE (8) Slide hinge from open end of track at rear of
door opening.
SLIDING DOOM C E N TER HINGE REM OVAL
(PIG. 3) SLIDING DOOM UPPER HINGE INSTALLATION
(1) Remove sliding door center hinge track cover. Reverse the preceding operation. Align sliding door
(2) Remove screw holding over travel stop to center to 6 min (0.240 in.) gap to edge of quarter panel and
hinge track (Fig. 2). B-pillar, 7 mm (0.280 in.) gap to rocker and flush
(3) Remove sliding door trim panel. across gaps.
(4) Mark hinge location on sliding door for reference
points when installing.
(8) Support Sliding door on a suitable lifting device.
(8) Remove bolts holding center hinge to sliding
door. .
(7) Separate hinge from door.
( 8 ) Slide hinge rollers from open end of channel at
rear of quarter panel.

SLIDING DOOM HINGE IN ST A L L A T IO N

Reverse the preceding operation. Clean center track
with suitable solvent and wipe or blow dry with com­
pressed air. Lubricate track and rollers with Mopar®
Multi-purpose Grease. Align sliding door to 8 mjn
(0.240 in.) gap to edge of quarter panel and B-pillar, 7
mm (0.280 in.) gap to rocker and flush across gaps.
SLIDING DOOR LOWER HINGE SLIDING DOOR INSIDE LATCH/LOCK
CONTROL INSTALLATION
SLIDING DOOR LOWER, HINGE REM OVAL Reverse the preceding operation.
(PIG. 5)
(1) Remove sliding door trim panel.
(2) Remove sliding door lower hinge cover.
(3) Remove sliding door sill plate.
(4) Remove lower track over travel stop.
(5) Mark hinge location on sliding door for reference
points when installing.
(8) Support sliding door on a suitable lifting device.
Do not allow door to contact quarter panel.
(7) Remove bolts holding hinge to mounting bracket.
If mounting bracket must be replaced, remove bolts
holding mounting bracket to sliding door.
(8) Separate hinge from sliding door.
(9) Slide hinge from open end of track at rear of
door opening.

SLIDING DOOR LOWER HINGE IN ST A L L A T IO N

Reverse the preceding operation. Align sliding door
to 6 'mm (0.240 in.) gap to edge of quarter panel and
B-pillar, 7 mm (0.280 in.) gap to rocker and flush
across gaps.

Fig. 6 Inside Latch/Lock Control

SLIDING DOOR LATCH/LOCK LINKAGE

SLIDING DOOR LATCH/LOCK LINKAGE
REMOVAL (FIG. 7)
(1) Remove sliding door trim panel and water shield.
(2) Remove latch/lock control.
(3) Disconnect ends of linkage rod to be replaced.
(4) Separate linkage rod from door.

SLIDING DOOR LATCH/LOCK

LINKAGE INSTALLATION
Reverse the preceding operation.

Pig. 5 Sliding Door Lower Hinge

SLIDING DOOR INSIDE LATGH/LOCK CONTROL

SLIDING DOOR INSIDE LATCH/LOCK
CONTROL REMOVAL (FIG. 6)
(1) Remove sliding door trim panel and water shield.
(2) Remove screws holding inside door handle bezel
to latch/lock control assembly.
(3) Separate bezel from control.
(4) Remove bolts holding latch/lock control to inner
door panel.
(5) Pull control away from inner door panel and
disconnect linkage rods and power door lock wire con­
nector, if equipped.
(6) Separate control from door.
SLIDING DOOR OUTSIDE LATCH RELEASE HANDLE
SLIDING DOOR OUTSIDE LATCH
RELEASE HANDLE REMOVAL (FIG. 8)
(1) Remove sliding door trim panel and water shield.
(2) Remove screws holding inside latch/lock control
assembly to door inner panel.
(3) Disconnect linkage rods and wire connectors as
necessary to gain access to outside handle mounting.
(4) Disconnect lock rod from lock cylinder arm.
(5) Remove nuts holding mounting plate to inner
door panel and separate plate from door.
(6) Separate outside handle from door.

SLIDING DOOR OUTSIDE LATCH

RELEASE HANDLE INSTALLATION
Reverse the preceding operation.

9123-158

Fig. 9 Sliding Door Rear Latch

SLIDING DOOR POWER LOCK ACTUATOR

Fig. 8 Sliding Door Outside Release Handle
SLIDING DOOR REAR LATCH
SLIDING DOOR REAR LATCH REMOVAL
(FIG. 9)
(1) Remove sliding door trim panel and water shield
as necessary.
(2) Unlatch door and allow to swing outward, do not
open.
(3) Disconnect linkage rods from rear latch.
(4) Remove screws holding latch to door end frame.
(5) Separate latch from door end frame and remove
through access hole in inner door panel.
SLIDING DOOR POWER LOCK ACTUATOR
REMOVAL (FIG. 7)
(1) Remove sliding door latch/lock control assembly.
(2) Disconnect linkage rod from power door lock
actuator.
(3) Remove screws holding actuator to control.
(4) Separate actuator from control.
SLIDING DOOR POWER LOCK
ACTUATOR INSTALLATION
Reverse the preceding operation.
VENT WINDOW
VENT WINDOW REMOVAL (FIG. 10)
The sliding door, body side and quarter glass vent
windows are serviced using same procedure.
(1) Remove upper trim molding from around glass.
(2) Remove screw holding latch to glass.
(3) Separate glass from latch.
(4) Remove nut covers and nuts holding glass hinge
to window opening flange.
(5) Separate glass from vehicle.

VENT WINDOW INSTALLATION

Reverse the preceding operation.

Fig. 10 Vent Window—Sliding Door,
Body Side or Quarter
VENT WINDOW WEATHERSTRIP
VENT WINDOW WEATHERSTRIP REMOVAL
(FIG. 11)
(1) Remove interior trim as necessary to gain clear­
ance for weatherstrip removal.
(2) Remove screw holding latch to glass.
(3) Hinge vent glass away from weatherstrip.
(4) Pull vent glass weatherstrip from pinch flange.
VENT WINDOW WEATHERSTRIP INSTALLATION
Reverse the preceding operation.
WEATHERSTRIP ----- ------V
Fig. 11 Vent Window Weatherstrip
DOOR OPENING WEATHERSTRIPS
FRONT DOOR OPENING
WEATHERSTRIP REMOVAL
(1) Remove interior trim as necessary to gain clear­
ance for weatherstrip removal.
(2) Pull weatherstrip from pinch flange around door
opening.
DOOR OPENING WEATHERSTRIP
INSTALLATION
(1) Locate the middle to the weatherstrip at the
center of the upper pinch flange. Push weatherstrip
onto pinch flange at the top corner.
(2) When the weatherstrip has been installed down
the door opening to the sill pinch flange, mate the
ends of the weatherstrip together and finish installing.
STICK-ON BODY SIDE MOLDING
REMOVAL AND INSTALLATION
(1) Warm the effected stick-on molding and body
metal to approximately 38°C (100°F) using a suitable
heat lamp or heat gun.
(2) Pull stick-on molding from painted surface.
(3) Remove adhesive tape residue from painted sur­
face of vehicle.
(4) If molding is to be reused, Remove tape residue
from molding. Clean back of molding with Mopar®,
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.
(5) Clean body surface with Super Kleen solvent or
equivalent. Wipe surface dry with lint free cloth.
(6) Apply a length of masking tape on the body,
parallel to the top edge of the molding to use as a
guide, if necessary.
(7) Remove protective cover from tape on back of
molding. Apply molding to body below the masking
tape guide.
(8) Remove masking tape guide and heat body and
molding, see step one. Firmly press molding to body
surface to assure adhesion.
EXTERIOR MOLDINGS (FIG.12)
UPPER MOLDINGS
LIFT GATE
(1) Open lift gate and remove nuts holding upper
molding to lift gate.
(2) Disengage clips holding upper molding to lift
gate.
(3) Separate molding from lift gate.
To install, reverse the preceding operation.
SLIDING DOOR TRACK COVER
(1) Disengage barrel clip fastener holding rear end
of upper molding to sliding door center track cover.
(2) Disengage clips holding upper molding to center
track cover.
(3) Separate molding from track cover.
To install, reverse the preceding operation.
DOORS ■• ' ' ■ • " ; ■:'
(1) Disengage clips holding upper Molding to door.
(2) Separate upper molding from door.
To install, reverse the preceding operation.
FENDERS
(1) Remove headlamp bezel as necessary to gain
access to molding fastener,
(2) Remove screw holding upper molding to fender
at front of molding.
(3) Disengage clips holding upper molding to fender.
(4) Separate molding from' fender.
To install, reverse the preceding operation.
WHEEL LIP MOLDINGS
(1) Remove screws holding wheel lip moldings to
wheel opening flange.
(2) Separate wheel lip molding from vehicle.
To install, reverse the preceding operation.
SILL MOLDINGS
RIGHT QUARTER
(1) Remove screws holding right quarter panel sill
molding to wheel opening flange.
(2) Disengage clips holding sill molding to sill panel.
To install, reverse the preceding operation.

LEFT QUARTER PAU L LIFT QUARTER

(1) Disengage clips holding upper molding to quar­ (1) Disengage clips holding sill molding to sill.
ter panel. (2) Separate sill molding from vehicle.
(2) Separate molding from quarter panel. To install, reverse th e preceding operation.
To install, reverse the preceding operation.
DOORS
(1) Disengage clips holding sill molding to door.
LOWER MOLDINGS
(2) Separate sill molding from, door.
DOORS To install, reverse the preceding operation.
(1) Disengage clips holding lower molding to door.
(2) Separate lower molding from door. FENDERS ’
To install, reverse the preceding operation. (1) Remove screws .holding sill molding to wheel
opening flange.
LIFT QUARTER PANEL (2) Disengage clips holding sill molding to fender.
(1) Disengage clips holding lower molding to left (3) Separate sill molding from front fender.
quarter panel. To install, reweme the preceding operation.
(2) Separate lower molding from quarter panel.
To install, reverse the preceding operation.
UPPER .UPPER MOLDING
LIFT GATE
MOLDINGS *LOWER MOLDING

UPPER
QUARTER
MOLDING

REAR WHEEL REAR WHEEL

LIP MOLDING LIP MOLDING

LEFT QUARTER
RIGHT QUARTER SILL SILL MOLDING
MOLDING

FRONT FENDER
SLIDING DOOR FRONT DOOR SILL MOLDING
SILL MOLDING SILL MOLDING
SLIDING DOOR
APPLIQUE

RIGHT QUARTER LIFT QUARTER

SILL APPLIQUE APPLIQUE
RIGHT FRONT
SILL APPLIQUE LEFT FRONT ' LEFT UPPER
RIGHT QUARTER SILL APPLIQUE QUARTER RETAINER
RETAINER

LEFT SILL RETAINER

RIGHT SILL iETAINER
9123-162

Pig. 13 Body Side Applique

BODY SIDE APPLIQUE (FIG. 13)
DOOR APPLIQUE
(1) Remove screws holding applique to bottom edge
of door.
(2) Lift applique upward to disengage from retain­
ing channel.
(3) Separate applique from door.
To install, reverse the preceding operation.
FRONT SILL APPLIQUE
(1) Remove screws holding front sill applique to
front wheel opening flange.
(2) Remove screws holding applique to under side of
rocker panel.
(3) Lift applique upward to disengage from retain­
ing channel.
(4) Separate applique from sill.
To install, reverse the preceding operation.
RIGHT REAR SILL APPLIQUE
(1) Remove screws holding rear sill applique to rear
wheel opening flange.
(2) Remove screws holding applique to under side of
rocker panel.
(3) Lift applique upward to disengage from retain­
ing channel.
(4) Separate applique from sill.
To install, reverse the preceding operation.
LEFT QUARTER APPLIQUE
(1) Remove screws holding left quarter applique to
rear wheel opening flange.
(2) Remove screws holding applique to under side of
rocker panel.
(3) Lift applique upward to disengage from retain­
ing channel.
(4) Separate applique from quarter panel.
To install, reverse the preceding operation.
WOOD GRAIN OVERLAY
WOOD GRAIN OVERLAY REMOVAL
(1) Remove exterior trim as necessary to clear cap­
tured edges of wood grain overlay for removal.
(2) Remove wood grain overlay using a suitable
heat gun or sun lamp to soften the adhesive backing.
Start removal in most accessible corner of panel to be
serviced.
(3) Clean adhesive residue from body finish using a
suitable adhesive remover.
23-24 BODY- . . . — — — ———— —— —

POOD GRAIN OVERLAY INSTALLATION RIGHT S iil GRAB HANDLE

INSTALLATION EQUIPMENT
• Pail filled with, mild dish soap solution. MIGHT S i m GRAB HANDLE REmOWAL (PIG. 14)
(1) Remove screw covers from grab handle.
• Lint free applicator cloth or sponge.
(2) Remove screws holding grab handle to roof rail
• Body putty applicator squeegee. - above right front door.
• Heat gun or sun lamp. (3) Separate grab handle from roof rail.
• Razor knife. (4) Remove A-piliar/roof rail molding.
The painted surface of the body panel to be covered ; (5) Remove bolts holding grab handle reinforcement
by a wood grain overlay must be smooth and com-, to roof rail/
pletely cured before-overlay can be applied. If painted (6) Separate reinforcement from roof rail.
surface is not smooth, wet sand with 800 grit wet/dry
sand paper until surface is smooth. Ripples and feather MIGHT-SIDE G RAB HANDLE IN ST A L L A T IO N
edging will read through overlay if surface is not Reverse the preceding* operation.
properly prepared.
(1) With backing still in place, position overlay across
panel to .receive overlay. Apply masking at top of
overlay to hold it in position.
(2) Mark outside edge of panel on overlay with a
grease pencil.
(3) Trim overlay to within 17 min (0.750 in.) of
outline marks.
(4) Spread overlay across a smooth flat work surface
wood grain side down. '
(5) Peel paper backing away from overlay exposiiig
adhesive back of overlay.
(6) Apply soap solution liberally to adhesive back of
overlay.
(7) Apply soap solution liberally to body panel surface.
(8) Place overlay into position on body panel. Smooth
out wrinkles by pulling lightly.--on-edges of overlay
until it lays flat on painted surface.
(3) Push air pockets from under overlay to the perim­ COWL TRIM AID SCUFF PLATES ■ ■"
eter of the panel from the center-of the overlay out.
(10) Squeegee soap solution and air bubbles'from COWL m i M AND SCUFF PLA TE REM OVAL ‘ ■
behind overlay from the center of the .panel out using (PIG. 151
a body putty app!i<';.ttor ^squeegee. . (1) Remove plug and screw holding windshield side
CAPTION: Do not cut into painted surface of body garnish molding to cowl trim cover.
panel when trimming overlay to size.' (2) Remove screws-holding scuff plate to door sill.
(3) Separate cowl trim/scuff plate from vehicle.
(11) Trim overlay to size using a razor knife. Leave
at least 18 mm (0.5 in.) for edges of doors and openings. COWL TRIM AND SCUFF PLATE 'INSTALLATION
CAUTION: Do not overheat overlay when performing Reverse the preceding operation. '
step 12.
SLIDING DOOR SCUFF P LA TE REM OVAL
(12) Apply heat to overlay••toevaporate .residual (FIG. 15) ' ‘ ■ '
moisture from edges of overlay and to allow overlay to (1) Remove screws holding sliding door scuff plate
be stretched into concave surfaces. . to sill. : :
<13) Edge turn overlay-around doors or fenders. (2) Separate scuff plate'from'vehicle.
(14) Install exterior trim if necessary.
.Small air or water bubbles under overlay can be
pierced with-a pin and smoothed out.
A-PILLAR AND ROOF RAIL MOLDINGS
A-PILLAR MOLDING REMOVAL (FIG. 15)
(1) Remove grab handle, if equipped.
(2) Remove windshield side garnish molding.
(3) Remove plug and screw holding A-pillar trim to
roof rail.
(4) Disengage fasteners holding A-pillar trim to
A-pillar.
(5) Separate A-pillar trim from vehicle.
A-PILLAR MOLDING INSTALLATION
Reverse the preceding operation.
RIGHT B-PILLAR TRIM COVER
RIGHT B-PILLAR TRIM COVER REMOVAL
(FIG. 15)
(1) Remove cover and bolt holding shoulder harness
turning loop to B-pillar.
(2) Remove bolt holding outboard seat belt anchor
to floor.
(3) Remove A-pillar trim as necessary to gain clear­
ance for removal of B-pillar trim.
(4) Remove door sill scuff plates to gain clearance
for removal of B-pillar trim.
(5) Remove screws holding B-pillar trim to B-pillar.
(6) Separate B-pillar trim from vehicle
RIGHT B-PILLAR TRIM COVER INSTALLATION
Reverse the preceding operation.
UPPER TRACK COVER REMOVAL (FIG. 15)
(1) Remove plugs and screws holding upper track
cover to sliding door track.
(2) Separate track cover from vehicle.
UPPER TRACK COVER INSTALLATION
Reverse the preceding operation.
RIGHT QUARTER TRIM PANEL
RIGHT QUARTER TRIM PANEL REMOVAL
(FIG. 15)
(1) Remove lift gate and sliding door sill scuff plate.
(2) Remove sliding door upper track cover.
(3) Pull outward at bottom of quarter trim insert to
disengage fasteners holding insert to trim panel.
(4) Lift upward on quarter trim insert and separate
insert from quarter trim panel.
(5) Remove screw holding coat hook to roof rail and
separate hook from vehicle.
(6) Remove covers and bolts holding shoulder har­
ness turning lops to roof rail and separate belts from
trim panel.
(7) Remove bolts holding outboard seat belt to floor
and separate belt from floor.
(8) Remove plugs and screws holding quarter trim
to inner quarter panel.
(9) Separate quarter trim panel from vehicle.
RIGHT QUARTER TRIM PANEL INSTALLATION
Reverse the preceding operation.
A-PILLAR/ROOF RAIL
TRIM

QUARTER TRIM
PANEL

COWL TRIM *B-PILLAR

SCUFF PLATE TRIM 9123-164

f lf . 15 Interim Trim

LIFT QUARTER TRIM PANEL
LEFT Q U A R TE R TRIM PAN EL REM OVAL
(FIG. 16)
(1) Remove ash tray.
(2) Remove screw holding quarter trim insert to
quarter trim from inside ash tray opening.
(3) Pull outward at bottom of trim insert to disen­
gage clips holding insert to quarter trim.
(4) Lift insert upward and separate quarter trim
insert from vehicle.
(8) Remove screws holding lower quarter trim panel LEFT QU ARTE R TRIM PAN EL IN S T A L L A T IO N
to inner quarter panel.
(8) Separate lower quarter trim from vehicle.
(7) Remove covers and bolts holding shoulder har­
ness turning loops to upper quarter panel.
( 8 ) Remove bolts holding outboard seat belt anchor
to floor.
(9) Remove seat belt retractor covers.
(10) Remove screw holding coat hook to quarter
panel.
(11) Remove screws holding upper quarter trim panel
to inner quarter panel.
(12) Separate upper quarter trim panel from vehicle.
Reverse the preceding operation.

LOWER
QUARTER TRIM
PANEL
9123-165
Flf. 16 Quarter Trim Panel
LEFT QUARTER T R ii PANEL—WITH REAR A/C
LEFT Q U ARTE R TRIM PAN EL REMOVAL
(PI G. 17)
(1) Remove ash tray.
(2) Remove screw holding quarter trim insert to
quarter trim from inside ash tray opening.
(3) Pull outward at bottom of trim insert to disen­
gage clips holding insert to quarter trim.
(4) Lift insert upward and separate quarter trim
insert from vehicle.
(5) Remove screws holding lower quarter trim panel
to inner quarter panel.
(6) Separate lower quarter trim from vehicle.
UPPER QUARTER
TRIM PANEL
COAT
HOOK
(7) Remove covers and bolts holding shoulder har­
ness turning loops to upper quarter panel.
(8) Remove bolts holding outboard seat belt anchor
to floor.
(9) Remove seat belt retractor covers.
(10) Remove screws holding coat hook to quarter
panel.
(11) Remove screws holding upper quarter trim panel
to inner quarter panel.
(12) Separate upper quarter trim panel from vehicle.
left QU Amrem t r im p a n e l i n s t a l l a t i o n ,
Reverse the preceding operation.
 UPPER QUARTER
TRIM PANEL

COAT
HOOK

FRONT
Q U A tlii TRIM
INSERT

ASH
:-HEAT TRAY
LOWER QUARTER REAR QUARTER LOUVERS
9123-166 TRIM PANEL TRIM INSERT

fig . 17 Quarter Trim Panel—With Hear A/C

FRONT SE1T BELTS 1 iit»l "LEFT

COVER
B-PILLAR
OUTBOARD SHOULDER HARNESS/LAP BELT
REMOWAL (FIG. 18 or IS ] TURNING
(1) Remove shoulder harness turning loop. LOOP
(2) Remove B-pillar or quarter trim panels as neces­
sary to gain access to belt retractor.
(8) Remove bolt holding retractor and lower lap belt
anchor to B-pillar.
(4) Separate belt from vehicle.

OUTBOARD SHOULDER HARNESS/LAP BELT

INSTALLATION
SILT
Reverse the preceding operation.

RETRACTOR 9123-167
f l f . 18 Front Outboard Seat Belt—Lett Side
 HIGH!
REAR SEAT BELTS .
COVER
B-PILLAR
OUTBOARD SHOULDER H A R N E S S /L A P B E L T
REM OVAL (FIG. 21 or 2 2 )
TURNING (1) Remove interior trim as necessary to gain access
LOOP to belt retractor.
(2) Remove bolt holding lower lap belt anchor to
floor bracket.
(3) Remove bolt holding belt retractor to inner quar­
ter panel.
(4) Separate belt from vehicle.

OU TBOARD SHOULDER H A R N E S S /
BELT LA P B E L T IN S T A L L A T IO N
Jieverse the preceding operation.

SECOND SEAT .TURNING.

SHOULDER
HARNESS

RETRACTOR / ' 9123-168

f l f . 19 Front Outboard Seat Belt—Right Side

INBO ARD BU CKLE REM OVAL (FIG. 2 0 )

(1) Upmove bolt'holding seat belt buckle t o seat 7 PASSENGER
riser. WAGON
FRONT SEAT
(2) separate buckle from seat riser. SHOULDER
(3) Disconnect seat belt sensor wire connector, if HARNESS
equipped.
BELT
GUIDE
INBO ARD BU CKLE IN ST A L L A T IO N OF*-
Reverse the preceding operation. LIFT GATE
OPENING LEFT
QUARTER
PANEL

9123-170
SEAT
'‘Fig. 21 Rear Shoulder/lap Belts—Left Side

LEFT SIDE
SEAT BELT
SEAT
SENSOR CONNECTOR
BELT
BUCKLE
 - SECOND
SEAT
SHOULDER
-y/w

RIGHT QUARTER
PANEL
LIFT GATE
OPENING
9123-171

Fig. 22 Rear Shoulder/lap Belts—Right Side

FRONT-SEATS
FRONT S E A T REM OVAL (FIG. 23)
(1) Remove fuel fill door release handle and discon­
nect seat belt sensor wire connector if left seat is
being serviced.
(2) Remove nuts holding seat riser to floor.
(3) Separate seat and riser from vehicle,
Flf. 23 Front Seat and Riser—Typical
LEFT FRONT SEAT TRACI ANi RISER ■
LEFT FRONT S E A T T R A C K AND R IS E R
REM OVAL (FIG. 24)
(1) Remove seat and riser from vehicle.
(2) Remove screws holding riser covers to riser.
(3) Separate riser covers from riser.
(4) Remove nuts holding seat track to riser.
(5) Separate track from riser.
(6) Remove screws holding rear track cover to track.
Separate cover from track, if equipped.
(7) Remove bolts holding track to bottom of seat.
Separate track from seat.

LEFT FRONT S E A T T R A C K AND R IS E R

IN ST A L L A T IO N
Reverse the preceding operation.
 FRONT SEAT
24 IN.

UPPER ADJUST ER COVER ELECTRIC SEAT

ADJUSTER

24 IN. Li.
(3 N*m)

200 IN. LB.

(23 N«m)

LATCH CONNECTOR
WIRE 70 FT. Li. (95 N*m)
200 IN. Li.
(23 N*m) SEAT RISER
RH1087

F lf. 24 Left Front Seat Track and Riser—typical

RIGHT FRONT SEAT RISER AND STORAGE BOX (4) Remove nuts holding seat to riser.
(5) Separate seat from riser.
RIGHT FRONT SEAT RISER AND
STORAGE BOX REMOVAL (FIG. 25 )
(1) Remove right front seat and riser from vehicle.
(2) Open storage box and release retainer clips at
ends of roller channels.
(3) Pull storage box from riser.
 350 IN. LB. (39 N»m) STOWAGE BOX LOCK CYLINDER RH1086

Fig. 25 Right Front Seat Riser and Storage Box—Typical

FIRST REAR SEAT RISERS (3) Remove bolts holding riser to seat fr a m e /5
(4) Separate riser from seat.
Refer to Owner’s Manual for proper rear seat re- - ^ . :
moval procedures. ' ' ■: ■ ■ ■ : FIRST REAR S E A T R IS E R IN S T A L L A T IO N ' ‘
■ ■" ■ Reverse the preceding operation.
FIRST HEAR S E A T RISER REM OVAL (PIG. 2 6 J
(1) Remove seat from vehicle.
(2) Remove screws holding riser covers to risers.
250 IN. LB. ARMREST COVER
(28 N*m) ARMREST
SUPPORT

RISER
105 IN. LB.
(12 N*m)

VIEW IN DIRECTION
OF ARROW X
(2 PASS. SEAT)

24 IN. LB.
(3 N«m)

24 IN. LB.
(3 N*m)

VIEW IN DIRECTION
OF ARROW Z
(RT. SIDE 2 PASS. SEAT) RH1089

Fig. 26 First Rear Seat Riser—Typical

SECOND REAR SEAT TRACK (3) Disconnect adjuster link cable from adjuster
handle.
Refer to Owner’s Manual for proper rear seat re­ (4) Remove bolts holding track to seat frame.
moval procedures. (5) Separate track from seat.

SECOND REAR SEAT TRACK REMOVAL

(FIG. 27)
(1) Remove seat from vehicle.
(2) Remove screws holding seat track covers to tracks.
Separate covers from tracks.
 24 IN. LBS. -SEAT BACK RELEASE HANDLE SECOND REAR SEAT
(3 N*m) - BACK FRAME-
.REAR SEAT BACK SHIELD
SEAT BACK
RELEASE LINK'

LATCH PIN

24 IN.
(3 N*m)

HINGE
AiM COVER

24 IN, IB S .
<3 N*m)
SECOND’ REAR--SEAT CUSHION
SPRING ASSEMBLY

SEAT RISER COVER ^ FRONT ADJUSTER COVER RH1112

f lf . 27 Second Rear S m t Track—Typlcsl

FRONT CUTER-CONSOL! INSTRUMENT

PANEL
FRONT C E N T E R CO N SO LE REMOVAL (FIG. 28 )
(1) Remove center instrument panel bezel Refer to FULL
FORWARD
Group 8E, Instrument Panel for proper procedure. CONSOLE
(2) Remove screws holding top of console to instru­ (IF -EQUIPPED)
ment panel.
(3) Remove ash tray or open sun glass bin. Remove UPPER TRIM
screws holding console to instrument panel. CONSOLE FILLER
(4) Separate upper console module from instrument MODULE
panel, if equipped.
(5) Disconnect ash tray lamp wire connector.
(8) Remove screws holding bottom of full forward
console to floor bracket.
(?) separate froward console from vehicle.

FR O N T 0 E N T E R C O N SO LE I N S 1 now ASH TRAY

Reverse the preceding operation.
FLOOR PAN

SUN GLASS ^
BIN
FLOOR CARPET
FLOOR CARPET REMOVAL (FIG. 29)
(1) Remove full forward console, if equipped.
(2) Remove Seats.
(3) Remove door sill scuff plates.
(4) Remove rear seat anchor well bezels, if equipped.
(5) Fold carpet to center of vehicle and remove
through sliding door.

FLOOR CARPET INSTALLATION

Reverse the preceding operation.

HEAD LINING
HEAD LINING REMOVAL (FIG. 30)
(1) Remove overhead console, if equipped.
(2) Remove inboard sun visor clips, if equipped.
(3) Remove roof rail moldings as necessary to gain
clearance for head lining removal.
(4) Remove sliding door upper track cover.
(5) Remove right quarter trim panel.
(6) Remove dome lamp, if equipped.
(7) Separate head lining from vehicle.
Fig 29 Floor Carpet and Silencers
HEAD LINING INSTALLATION
OVERHEAD CONSOLE Reverse the preceding operation.
OVERHEAD CONSOLE REMOVAL (FIG. 29)
(1) Disengage sun visor ends from overhead console
(2) Remove screws holding overhead console to roof
at front of console.
(3) Slide overhead console forward to disengage clips
holding rear of console to roof.
(4) Disconnect wire connectors from back of console.
(5) Separate overhead console from vehicle.

OVERHEAD CONSOLE INSTALLATION

Reverse the preceding operation.
LIFT GATE
LIFT GATE REMOVAL (FIG. 31)
(1) Raise and support lift gate in open position.
(2) Mark hinge to lift gate attaching locations to
assist installation.
(2) Disconnect lift prop rods from lift -gate.
(3) Remove bolts holding body half of hinge closed.
Lift gate will rotate away from roof panel.
(4) With assistance of a helper at the opposite side
of the vehicle to support the lift gate, remove the
hinge to lift gate attaching bolts.
(5) Separate the lift gate from the vehicle,
LIFT GATE INSTALLATION
Reverse the preceding operation. Align lift gate to 7
mm (0.280 in.) gap to roof panel and 6 mm (0.240 in.)
gap to quarter panels. Surfaces should be flush across
gaps.
LIFT GATE T i l l PAIEl
LIFT GATE TRIM PANEL REMOVAL (FIG. 32)
(1) Raise lift gate and remove courtesy lamp lenses.
(2) Remove courtesy lamp assemblies. Insert cour­
tesy lamps through openings in the trim panel into
lift gate, if equipped.
(3) Remove speaker -grilles, if equipped.
(4) Remove plugs at the ends of the assist handle,
and remove screws. Separate handle from trim panel,
if equipped.
(5) Remove push-in fasteners from above the rear
window.
(8) Remove two trim plugs at lower corners of trim
panel and remove screws.
(7) Disengage frog-leg fasteners around perimeter of
trim panel. Separate trim panel from lift gate.
LIFT GATE TRIM PANEL INSTALLATION
(1) Position trim panel under lift gate between the
prop-rod cylinders. Insert courtesy lamp assemblies
through trim cover openings.
(2) Position frog-leg fasteners below holes in lift
gate, one at a time, push (do not pound) fasteners into
locked position.
(3) Install assist handle, courtesy lamps, outer cor­
ner attaching screws, speaker grilles and push-in fas­
teners above rear window.
Pig. 32 Lift Gate Trim Panel
LIFT GATE LATCH
LIFT GATE LATCH REMOVAL (FIG. 33)
(1) Raise lift gate to open position.
(2) Remove lift gate trim panel.
(3) Disconnect linkage rods from latch.
(4) Remove screws holding latch to lift gate.
(5) Separate latch from lift gate.
LIFT GATE LATCH INSTALLATION
Reverse the preceding operation.

Fig. 34 Roof Top Luggage Rack

FUEL FILL DOOR RELEASE CABLE

FUEL FILL DOOR CABLE REMOVAL (FIG. 35)
(1) Remove interior trim as necessary to gain access
to cable.
(2) Remove screw holding hood release handle to
mechanism. Separate handle from mechanism.
(3) Remove screws holding release mechanism to
seat riser. Separate mechanism from riser.
(4) Disengage cable casing from slot on mechanism.
Fig. 33 Lift Gate Latch (5) Remove nut holding cable end to fuel fill opening.
(6) Remove cable from vehicle.
ROOF TOP LUGGAGE RACK
FUEL FILL DOOR CABLE INSTALLATION
ROOF TOP LUGGAGE RACK REMOVAL (FIG. 34)
Reverse the preceding operation.
The luggage rack skid strips are attached to the
roof panel with adhesive strips using the same meth­
ods as stick-on body side moldings. Refer to Stick-on
Body Moldings paragraph for procedures.
(1) Slide side rail end covers from ends of side rails.
(2) Remove screws holding rails to roof panel.
(3) Separate luggage rack from vehicle.

ROOF TOP LUGGAGE RACK INSTALLATION

Reverse the preceding operation.
 Fig. 35 Fuel Fill Door Release Cable

REAR BUMPER
REAR BUMPER REMOVAL (FIG. 36}
(1) Remove nuts holding front bumper end caps to
quarter panels.
(2) Remove nut holding front bumper end caps to
bumper support.
(3) Remove push-in fastener holding front bumper
end caps to bumper.
(4) Support front bumper on a suitable lifting device.
(5) Remove nuts holding front bumper to support
bracket.

REAR BUMPER INSTALLATION

Reverse the preceding operation.

Fig. 36 Rear Bumper

HIGH LINE REAR BUMPER AND FASCIA
HIGH LINE REAR BUMPER AND FASCIA
REMOVAL (FIG. 37)
(1) Remove push-in fasteners holding fascia to wheel
openings.
(2) Remove nuts holding fascia to quarter panels.
(3) Support front bumper on a suitable lifting device.
(4) Remove bolts holding bumper reinforcement to
bumper support brackets.
(5) Separate bumper assembly from vehicle.

HIGH LINE REAR BUMPER AND

WRAP-AROUND FASCIA INSTALLATION
Reverse the preceding operation.

Fig. 37 High Line Rear Bumper and Fascia

REAR WINDOW GLASS

The rear window glass is serviced using the same
method as servicing the windshield. Refer to Wind­
shield section of this group for proper service procedures.
 HEATING AND AIR CONDITIONING
CONTENTS
Page Page
AUXILIARY REAR HEATING OR DIAGNOSTIC SERVICING PROCEDURES....... 4
HEATING-AIR/CONDITIONING 61 GENERAL INFORMATION .......................... 1
COMPONENT REMOVAL/INSTALLATION REFRIGERANT .......................................... 25
AND OVERHAUL 31
GENERAL INFORMATION
INDEX
Page Page
A/C System Identification............................................... 2 Engine Cooling System Requirements ......................... 2
Body Identification ................................. ........................ 1 Handling Tubing and Fittings ....................................... 2
Description and Operation ............................................. 1 Safety Precautions and Warnings ................................. 2

BODY IDENTIFICATION AIRFLOW

The system pulls outside (ambient) air through the
Throughout this group, code references are made to cowl opening at the base of the windshield and into
various body lines. Example: AS/H, AH/K. To deter­ the plenum chamber above the A/C-heater unit hous­
mine the vehicle model by it’s code, refer to the Model ing. On air-conditioned vehicles, the air passes through
Chart in the INTRODUCTION SECTION at the front the evaporator (Fig. 1). At this point the air flow can
of this manual. be directed either through or di-bund the heater core
by adjusting the blend-air door with the TEMP con­
DESCRIPTION AND OPERATION trol on the instrument panel. The air flow can then be
directed from the PANEL, BI-LEVEL (panel and floor),
Both the heater and the heater/air conditioning sys­ and FLOOR-DEFROST outlets. Air flow velocity can
tems share many of the same functioning components. be adjusted with the blower speed selector switch on
This group will deal with both systems together when the instrument panel (Fig. 2).
component function is common, and separately when
they are not.
For proper operation of the instrument panel con­
trols, refer to the Owner’s Manual provided with the
vehicle.
All vehicles are equipped with a common A/C-heater
unit housing assembly. When the vehicle has only a
heater system, the evaporator and recirculating air
door are omitted from the heater unit housing assem­
bly (Fig. 1).

HEATER MIY
TEMP CONTROL OUTSIDE AIR INTAKE
DOOR
A/C ONLY L

^ \M O D E RECIRE AIR INTAKE*

I -Vjiruy— ^ — SL
DQQR ly RN411
9124-1
 On air-conditioned vehicles, ambient air intake can
be shut off by closing the recirculating air door (Fig.
1) to recirculate the air that is already inside the
vehicle. This is done by moving the TEMP control into
the RECIRC position. Depressing the DEFROST or
A/C button will engage the compressor. This will send
refrigerant through the evaporator, and will remove
heat and humidity from the air before it is directed
through or around the heater core (Fig. 1).
OUTSIDE AIR VENTILATION
For proper operation of the outside air ventilation
systems, refer to the Owner’s Manual. Forced-Venti-
lation is directed from the instrument panel and/or
floor outlets when the heater-A/C control mode selec­
tor is on panel or bi-level setting. The temperature of
the forced-vent air can be regulated with the TEMP
control.
SIDE WINDOW DEMISTERS
The side window demisters direct air from the heater
assembly. The outlets are located on the top outboard
corners of the instrument panel. The Demisters oper­
ate when the A/C control mode selector is on FLOOR
or DEFROST setting.
A/C SYSTEM IDENTIFICATION
The terms FIXED DISPLACEMENT COMPRES­
SOR SYSTEM and VARIABLE DISPLACEMENT
COMPRESSOR SYSTEM will be used to describe the
two types of A/C systems used throughout this group.
Refer to COMPRESSOR IDENTIFICATION in the DI­
AGNOSTIC SERVICING PROCEDURES section.
The Variable Displacement Compressor can be iden­
tified by the location of the high pressure line mounted
to the end of the compressor case.
ENGINE COOLING SYSTEM REQUIREMENTS
To maintain adequate temperature levels from the
heating/air-conditioning system, the engine cooling sys­
tem must be prepared as described in Group 0, LU­
BRICATION AND MAINTENANCE, or Group 7,
COOLING SYSTEM of this manual.
The use of a bug screen is not recommended. Any
obstructions forward of the radiator or condenser can
reduce the effectiveness of the air-conditioning or en­
gine cooling system.
SAFETY PRECAUTIONS AND WARNINGS
WARNING: WEAR EYE PROTECTION WHEN SERV­
ICING THE AIR-CONDITIONING REFRIGERANT SYS­
TEM, AS SERIOUS EYE INJURY CAN RESULT FROM
EYE CONTACT WITH REFRIGERANT. IF EYE CONTACT
IS MADE, SEEK MEDICAL ATTENTION IMMEDIATELY.
DO NOT EXPOSE REFRIGERANT TO OPEN FLAME.
POISONOUS GAS IS CREATED WHEN REFRIGER­
ANT IS BURNED. AN ELECTRONIC TYPE LEAK DE­
TECTOR IS RECOMMENDED.
LARGE AMOUNTS OF REFRIGERANT RELEASED
IN A CLOSED WORK AREA WILL DISPLACE THE
OXYGEN AND CAUSE SUFFOCATION.
THE EVAPORATION RATE OF (R-12) REFRIGER­
ANT AT AVERAGE <L.W.HtHATURE AND ALTITUDE
IS EXTREMELY HIGH. AS A RESULT, ANYTHING
THAT COMES IN CONTACT WITH THE REFRIGER­
ANT WILL FREEZE. ALWAYS PROTECT SKIN OR
DELICATE OBJECTS FROM DIRECT CONTACT WITH
REFRIGERANT.
CAUTION: Liquid refrigerant is corrosive to metal
surfaces. Follow the operating instructions and pre­
cautions supplied with equipment being used when
servicing refrigerant system.
COOLING SYSTEM PRECAUTIONS
WARNING: ANTIFREEZE IS AN ETHYLENE GLYCOL
BASE COOLANT AND IS HARMFUL IF SWALLOWED
OR INHALED. IF SWALLOWED, DRINK TWO GLASSES
OF WATER AND INDUCE VOMITING. IF INHALED,
MOVE TO FRESH AIR AREA. SEEK MEDICAL AT­
TENTION IMMEDIATELY.
DO NOT STORE IN OPEN OR UNMARKED CON­
TAINERS.
WASH SKIN AND CLOTHING THOROUGHLY AF­
TER COMING IN CONTACT WITH ETHYLENE GLYCOL.
KEEP OUT OF REACH OF CHILDREN AND PETS.
DO NOT OPEN A COOLING SYSTEM WHEN THE
ENGINE IS AT RUNNING TEMPERATURE. PERSONAL
INJURY CAN RESULT.
The engine cooling system is designed to develop
internal pressure of 97 to 123 kPa (14 to 18 psi) under
normal operating conditions. Allow the vehicle ap­
proximately 15 minutes (or until a safe temperature
and pressure are attained) before opening the cooling
system. Refer to Group 7, COOLING SYSTEM.
HANDLING TUBING AND FITTINGS
Kinks in the refrigerant tubing or sharp bends in
the refrigerant hose lines will greatly reduce the ca­
pacity of the entire system. High pressures are pro­
duced in the system when it is operating. Extreme
care must be exercised to make sure that all connec­
tions are pressure tight. Dirt and moisture can enter
the system when it is opened for repair or replace­
ment of lines or components. The refrigerant oil will
absorb moisture readily out of the air. This moisture
will convert into acids within a closed system.
 The following precautions must be observed:'
The system must be completely discharged before
opening any fitting or connection in the refrigeration
system. Open fittings with caution even after the sys­
tem has been discharged. If any pressure is noticed as
a fitting is loosened, allow trapped pressure to bleed
off very slowly.
A good rule for the flexible hose lines i s to keep the
radius of all bends at least 10 times the diameter of
the hose. Sharper bends will reduce the flow of refrig­
erant. The flexible hose lines should be routed so they
are at least 3 inches (80 mm) from the exhaust mani­
fold. Inspect all flexible hose lines to make sure they
are in good condition and properly routed.
Unified plumbing connections with aluminum gas­
kets cannot be serviced with O-rings. These gaskets
are not reusable and do not require lubrication before
installing.
The u se.of correct wrenches when making connec­
tions is very important. Improper,.,; wrenches or im­
proper use of wrenches can damage the fittings.
The internal parts of the refrigeration system will
remain in a state of chemical stability as long as
pure-moisture-free Refrigerant 12 and refrigerant oil
is used. Abnormal amounts of dirt, moisture or air can
upset the chemical stability and cause operational
troubles or even serious damage if present in more
than very small quantities. .
When it is necessary to open the refrigeration.sys­
tem, have everything you will need to service the
system ready, so the system will not be left open any
longer than necessary. Cap or plug all lines and fit­
tings as soon as they are opened to prevent the en­
trance or dirt and moisture. All lines and components
in parts stock should be capped or sealed-until they
are ready to be used.
All tools, including the refrigerant dispensing man­
ifold, the manifold gauge, set, and- test hoses should be
kept clean and dry.
 DIAGNOSTIC SERVICING PROCEDURES
INDEX
Page Page
A/C Overall Performance Test ..................................... 22 Expansion Valve Tests— With Variable
Ambient Switch Diagnosis........................................... 15 Displacement Compressor ....................................... 21
Blower Motor Operation and Diagnosis .................... 10 Fixed Displacement Compressor
Clutch Coil T e s ts ............................................................ 14 Refrigerant System .................................................... 17
Compressor Clutch Inoperative ................................... 11 Heater Output ................................................................ 5
Compressor Drive Belt Adjustm ent............................. 5 High Pressure Cut-Out Switch Diagnosis .................. 16
Compressor identification ........................................... 10 High Pressure Relief Valve (HPR) Diagnosis............ 23
Compressor Noise ...................................................... 11 Low-Pressure Cut-Off Switch Diagnosis..................... 14
Condensate Water D rainage......................................... 24 Sight Glass Refrigerant Level Inspection................... 4
Condenser Fan Control Switch Diagnosis ................ 15 Vacuum Control System Diagnosis ............................. 5
Differential Pressure Cut-Off Switch Diagnosis ___ 14 Variable Displacement Compressor
Electronic Cycling Clutch Switch ............................... 16 Refrigerant System .................................................... 17
Expansion Valve Tests— With Fixed
Displacement Compressors ..................................... 21

SIGHT GLASS REFRIGERANT LEVEL INSPECTION

The filter-drier is equipped with a sight glass (Fig.
3) that is used as a refrigerant level indicator only .This
sight glass is not to be used for A/C performance
testing.
To check the refrigerant level, remove the vehicle
jack, clean the sight glass, start and warm up engine,
and hold idle at 1100 rpm. Place the air-conditioning
control on A/C, RECIRC and high blower. The work
area temperature should be at least 21°C (70°F). If a
Fixed Displacement type compressor does not engage,
the refrigerant level is probably too low for the Low
Pressure Cut-Off switch to detect. Or, with a Variable
Displacement compressor, for the Differential Pres­
sure Cut-off switch to detect. If compressor clutch does
not engage, refer to TESTING REFRIGERANT SYS­
TEM FOR LEAKS in the REFRIGERANT section of
this group. If compressor clutch engages, allow ap­
proximately one minute for refrigerant to stabilize.
View refrigerant through sight glass. The suction line
should be cold to the touch and the sight glass should
be clear.
Fig. 3 Filter Drier and Sight glass

If foam or bubbles are visible in sight glass, the

refrigerant level is probably low. Occasional foam or
bubbles are normal when the work area temperature
is above 43°C (110°F) or below 21°C (70°F). If suction
line is cold and occasional bubbles are visible in the
sight glass, block the condenser air flow to increase
the compressor discharge pressure (Do not allow en­
gine to over heat). Bubbles should dissipate. If not,
the refrigerant level is low. For proper charging pro­
cedures refer to CORRECTING LOW REFRIGERANT
LEVEL in the REFRIGERANT section.
WARNING: (R-12) REFRIGERANT IS DETRIMENTAL
TO THE ENVIRONMENT WHEN RELEASED TO THE
ATMOSPHERE. DO NOT RECHARGE AN A/C SYS­
TEM BY ADDING (R-12) REFRIGERANT TO A SYS­
TEM THAT HAS A KNOWN LEAK.
COMPRESSOR DRIVE BELT ADJUSTMENT
' If. p ro p e r a ir-c o n d itio n in g co m p resso r d riv e belt ten­
sion or condition is not maintained, the belt could slip,
and reduce air-conditioning system effectiveness. The
drive belts should be' inspected when other under hood
service is performed. For proper service intervals refer
to Group 0, LUBRICATION AND MAINTENANCE.
For proper Drive Belt service procedures refer to Group
7, COOLING SYSTEM.
HEATER OUTPUT
PRE-DI A G N O ST IC P R E P A R A T IO N S
Review SAFETY PRECAUTIONS AND WARNINGS
in the GENERAL INFORMATION section of this group
before performing the following procedures.
3ck the radiator coolant level, drive belt tension,
engine vacuum line connections, radiator air flow and
radiator fan operation. Start engine and allow to warm
up to normal running temperature.
WARNING; DO NOT REMOVE RADIATOR CAP WHEN
ENGINE IS HOT, PERSONAL INJURY CAN RESULT.
If vehicle has been run recently, wait 15 minutes
before removing cap. Place a rag over the cap and
turn it to the first safety stop. Allow pressure to es­
cape through the overflow tube. When the system,
stabilizes, remove the cap completely.
MAXIMUM HEATER OUTPUT:TEST AMD ACTION-
Engine coolant is provided to the heater system by
two 18 mm (5/8 inch inside diameter) heater hoses.
With engine idling at normal running temperature,
set the control to maximum heat, floor, and high blower
setting. Using a test thermometer, check the air tem­
perature coming from the floor outlets, refer to TEM­
PERATURE REFERENCE chart.
TEMPERATURE REFERENCE CHART
Minimum H eater System
Am bient Tem perature Floor O u tle t Tem perature
Celsius Fahrenheit Celsius
15.5° 60° 62.2° ■ 144°
21.1° 70° 63.8°
26.6° 80° 65.5°
32.2° 9CI° 67.2°
If the floor outlet air temperature is insufficient,
refer to Group 7, COOLING SYSTEMS for normal
engine coolant temperature specifications. Both heater
hoses should be HOT to the touch (coolant return hose
should be slightly cooler than the supply hose). If
coolant return hose is. much cooler than the supply
hose, locate and repair, engine .coolant flow obstruction
in heater system.
POSSIBLE LOCATIONS OR CAUSE O f ■
OBSTRUCTED COOLANT FLOW . ■
(a) Pinched or kinked heater hoses.
(b) Improper heater hose routing.- *■
(c) Plugged heater hoses or supply'- and return
ports at cooling system connections, refer to Group' 7,
COOLING SYSTEM.
(d) Plugged heater core.
(e) Water valve sticking or inoperative.
If proper engine coolant flow through heater system
is verified and floor outlet air temperature is still
insufficient, a mechanical problem can exist in the
heater system.
POSSIBLE LOCATION'OR CAUSE Of INSUFFICIENT HEAT
(a) Obstructed cowl air intake.
(b) Obstructed heater system outlets.
(c) Blend-air door not functioning properly.
TEMPERATURE CONTROL
If temperature cannot be adjusted with the TEMP
lever on the control panel, or TEMP lever is difficult
to move, the''following could require service:
(a) Blend-air door binding. '
(b) Control cables miss-routed, pinched, kinked,
or disconnected.
(c) Improper engine coolant temperature, see PRE­
DIAGNOSTIC PREPARATIONS in this section. '■
VACUUM CONTROL SYSTEM DIAGNOSIS
Use' an adjustable Vacuum Test Gauge (C-3707)
and a suitable vacuum pump to test heater A/C con­
trol vacuum. With a finger placed over the end of test
hose (Fig. 4), calibrate vacuum control valve on the
test gauge to obtain -27 kPa (8 in. Hg.). Release and
block the end of the test hose' several times to verify
vacuum setting.
Fahrenheit
'
147°
150°
153°
 connector (Fig. 5). The brown, bi-level, vacuum circuit
has a metal fiber restrictive device located in the line.
More reaction time is required for the test gauge to
return to calibrated setting. After each connection is
made, the test gauge should return to calibrated set­
ting. If all circuits function properly, replace control
mode vacuum switch. If not, determine the color of the
vacuum circuit that is leaking. To determine vacuum
line colors, see the VACUUM CIRCUITS^HEATER
OR HEATER A/C CONTROL chart in this section.
Disconnect the vacuum actuator at the other end of
the circuit. (Instrument panel removal may be neces­
sary to gain access to some components). Block the
end of the disconnected vacuum line. The test gauge
should return to calibrated setting. If not, that circuit
has a leak and must be repaired or replaced. If test
Fig. 4 Adjust Vacuum Test Bleed Valwe gauge returns to calibrated setting, the vacuum actu­
ator must be replaced.
VACUUM TESTING THE ONE-WAY
CHECK VALVE
(1) In the engine compartment, disconnect the
Heater-A/C vacuum supply (black) hose. This hose
passes through an opening in the dash panel used for
th e a ir co n d itio n in g e x p a n sio n valve.
(2) Remove the vacuum check valve. This valve is
located on the (black) vacuum supply hose at the brake
power booster.
(3) Connect test vacuum supply hose to the HEATER
side of the valve. In this direction the gauge should
return to calibrated setting. If valve leaks vacuum in
this direction, valve replacement is necessary.
(4) Connect test vacuum supply hose to the EN­
GINE VACUUM side of the valve. Vacuum should
flow through valve.

VACUUM TESTING THE HEATER-A/C

CONTROLS
(1) Connect the test vacuum prod (Fig. 4) to the
vehicles (black) vacuum supply hose. Position vacuum
test gauge so it can be viewed from the passenger
compartment.
(2) Position the heater A/C control mode selector to ® Vacuum Circuit Test
DEFROST, FLOOR, BI-LEVEL, PANEL, and RECIRC
(with A/C). Pause after each selection. The test gauge
should return to the calibrated setting of -2? kPa (8
in. Hg.) after each selection is made. If the gauge
cannot achieve the calibrated setting, a vacuum cir­
cuit or component has a leak.

LOCATING VACUUM LEAKS

To locate a vacuum leak, disconnect 7-way vacuum
connector behind the instrument panel at the heater
A/C control. For removal and installation of heater
A/C control panel, refer to the SWITCH AND PANEL
COMPONENT SERVICE section of Group 8E, IN­
STRUMENT PANEL. Connect the calibrated vacuum
hose prod (Fig. 4) to each port in the vacuum harness
 VACUUM CIRCUIT&-HEATER OR HEMTER M/C CONTROL

OUTSIDE A /C
PANEL RECIRCULATING
LIGHT GREEN*
LIGHT GREEN*
YELLOW
YELLOW
PE f^w ftO O R ( PEF-t^FLOOR b r 0 WN
OUTSIDE
AIR FLOOR VACUUM SWITCH
FLOOR r VACUUM SWITCH
OUTSIDE
AW t
PANEL

CHECK VALVE ENGINE BI-LEVEL

VACUUM
BLACK
0 >RECIRCULATING
DARK GREEN'
SOLID LINE INDICATES
SOLID LINE INDICATES
ENGINE VACUUM
ENGINE VACUUM
DARK GREEN DARK GREEN
GRAY

BI-LEVEL w WATER VALVE

ACTUATOR
WATER VALVE LIGHT GREEN*
ACTUATOR

VACUUM ACTUATORS VACUUM SWITCH

>
(7) FLOOR-DEFROST © *A /C ONLY
CHECK VALVE "RESTRICTOR IS PART
{ 7 ) PANEL-FLOOR-il-IEVEl
O f VACUUM LINE
BLACK
RECIRCULATING A lt* AND IS NOT VISIBLE
ENGINE
VACUUM

SOLID LINE INDICATES

' ENGINE VACUUM
DARK GREEN
FLOOR DEFROST

LIGHT GREEN* WATER VALVE LIGHT GREEN*

ACTUATOR
BI-LEVEL YELLOW
DEF FLOOR broW N
FLOOR VACUUM SWITCH
VACUUM SWITCH OUTSIDE
- A ii
t
PANEL

CHECK VALVE
BI-LEVEL
J*LACK ENGINE
VACUUM © RECIRCULATING
*AIR ENGINE
DARK GREEN* VACUUM
SOLID LINE INDICATES 1
ENGINE VACUUM TJ
DARK G il SOLID LINE INDICATES
DARK GREEN ENGINE VACUUM
GRAY GRAY

WATER VALVE WATER VALVE

ACTUATOi' ACTUATOR
 -BLOWER-MOTOR NOISE/VIBRATION DIAGNOSIS

BLOWER MOTOR NOISE

OR VIBRATION

NCUSE ■ VlStATiON

ENGINE ON CHECK MOTOR

MOUNTING
CHECK BLOWER '
' MOTOR IN ALI
SPEED MODES
“nzz
MOUNTING
OK
LOOSE
NOISE PiESEIm
A/C BUT Ai / i
NOT HTi. A m > TIGHTEN

LEAVE ENGINE ON RE-CHECK

RADiATOt SHUT BLOWER
FAN OR MOTOR OFF
COMPRESSOR
NOISE OK

NOISE STILL PRESENT NOISE GONE VIBRATION

STILL PiiSI

PROBLEM NOT CHECK BLOWER

IN BLOWER SCROLL AREA
SYSTEM
REMOVE BLOWER
WHEEL AND
OPERATE BLOWER
MOTOR AT
FOREIGN MATERIAL IN FAN VIBRATION
LOW SPEED
FAN OR SClOLl RUBBING GONE
HOUSING

YES 'NO REPLACE SLOWER VIBRATION

REMOVE REPLACE YES WHEEL STILL
FOREIGN MOTOR ■ ADJUST PRESENT
MATERIAL ' TO iCORRE(

RE-CHECK REPLACE
RE-CHECK RE-CHECK MOTOR

RE-CHECK

NOISE STILL NOISE

PRESENT GONE

REPLACE — RE-CHECK
MOTOR
BLOWER MOTOR ELECTRICAL SYSTEM DIAGNOSIS
BLOWER MOTOR OPERATION AND DIAGNOSIS
BLOWER MOTOR OPERATION
The heater control blower speed selector switch, in
conjunction with a resistor block (Fig. 6), supplies the
blower motor with varied voltage (low and middle
speeds) or battery voltage (high speed).

Fig. 7 Fixed D’splacement Compressor-

Model C171IA590
Fig. 6 Blower Motor Resistor Block—Typical

CAUTION: Stay clear of the blower motor and resis­

tor block (Hot). Do not operate the blower motor with
the resistor block removed from the heater-A/C
housing.

BLOWER MOTOR VIBRATION AND/OR

NOISE DIAGNOSIS
Refer to the BLOWER MOTOR VIBRATION/NOISE
chart in this section for diagnosis.

BLOWER MOTOR ELECTRICAL DIAGNOSIS

Refer to the BLOWER MOTOR ELECTRICAL SYS­
TEM DIAGNOSIS chart in this section. Also see Group
8, WIRING DIAGRAMS for more information.

COMPRESSOR IDENTIFICATION
The terms FIXED DISPLACEMENT COMPRES­
SOR and VARIABLE DISPLACEMENT COMPRES­
SOR will be used to describe the two types of A/C PORT 9124-11
systems used throughout this group. Refer to (Figs. 7,
8, and 9).
The Variable Displacement Compressor can be iden­
tified by the location of the high pressure line mounted
to the end of the compressor case (Fig. 9).

Fig. 9 Variable Displacement Compressor—Model 6Cl 7
COMPRESSOR NOISE
Excessive noise that occurs when the air-conditioning
is being used, can be caused by loose bolts, mounting
brackets, loose clutch, or excessive high refrigerant
system operating pressure. Verify compressor drive
belt condition, proper refrigerant charge ahd head pres­
sure before compressor repair is performed.
For noise diagnostic procedures, refer to the COM­
PRESSOR NOISE AND COMPRESSOR CLUTCH DI­
AGNOSIS chart in this section.
COMPRESSOR CLUTCH INOPERATIVE
The air-conditioning compressor clutch electHcal cir­
cuit is controlled by the engine controller computer
located in the engine compartment outboard of the
battery.
If the compressor clutch does not engage:
Verify refrigerant charge. See SIGHT GLASS RE­
FRIGERANT LEVEL INSPECTION in this section.
If the compressor clutch still does not engage:
Check for battery voltage at the low pressure or
differential pressure cut-off switch located on the ex­
pansion valve. If voltage is not detected, refer to:
(1) Group 8, WIRING DIAGRAMS.
(2) The appropriate POWERTRAIN DIAGNOSTIC
PROCEDURES MANUAL for diagnostic information.
(3) The COMPRESSOR CLUTCH D IA G N O SIS-
VARIABLE DISPLACEMENT COMPRESSOR chart
in this section.
If voltage is detected at the cut-off switch, connect
switch and check for battery voltage between the com­
pressor clutch connector terminals.
If voltage is detected, perform A/C Clutch Coil Tests.
Refer to CLUTCH COIL TESTS in this section.
COMPRESSOR NOISE AND COMPRESSOR CLUTCH DIAGNOSIS
COMPRESSOR CLUTCH DIAGNOSIS—VARIABLE DISPLACEMENT COMPRESSOR-MODEL 6C17
CLUTCH COIL TESTS
(1) Verify battery state of charge. (Test indicator in
battery should be green).
(2) Connect an ammeter (0-10 ampere scale) in se­
ries with the clutch coil terminal. Use a volt meter
(0-20 volt scale) with clip leads measuring voltage
across the battery and A/C clutch.
(3) With A/C control in A/C mode and blower at low
speed, start the engine and run at normal idle.
(4) The A/C clutch should engage immediately and
the clutch voltage should be within two volts of the
battery voltage. If the A/C clutch does not engage, test
the fusible link.
(5) The A/C clutch coil is acceptable if the current
draw is 2.0 to 3.7 amperes at 11.5-12.5 volts at clutch
coil. This is with the work area temperature at 21°C
(70°F). If voltage is more than 12.5 volts, add electri­
cal loads by turning on electrical accessories until
voltage reads below 12.5 volts.
If coil current reads zero, the coil is open and should
be replaced. If the ammeter reading is 4 amperes or
more, the coil is shorted and should be replaced. If the
coil voltage is not within two volts of the battery
voltage, test clutch coil feed circuit for excessive volt­
age drop.
LOW-PRESSURE CUT-OFF SWITCH DIAGNOSIS
FIXED D ISPLA CEM ENT C O M P R E S S O R S
The Low Pressure Cut-Off (LPCO) Switch (Fig. 1)
monitors the refrigerant gas pressure on the suction
side of the system. The LPCO is located on the expan­
sion valve, and the expansion valve is silver in color
when a fixed displacement compressor is used. The
LPCO turns off voltage to the compressor clutch coil
when refrigerant gas pressure drops to levels that
could damage the compressor. The LPCO is a sealed
factory calibrated unit. It must be replaced if defective.
EXPANSION
LPCO SW ITC H T E S T
The work area temperature must not be below 10°C
(50°F) to test the compressor clutch circuit. .
(1) With gear selector in park or neutral and park
brake set, start engine and allow to idle.
(2) Raise hood and disconnect LPCO switch connec­
tor boot.
(3) Using a suitable jumper wire, jump across the
terminals inside wire connector boot.
(4) If the compressor clutch does not engage, the
cycling clutch switch, wiring, relay, or fuse can be
defective, see Group 8W, WIRING DIAGRAMS.
(5) If clutch engages, connect manifold gauge set.
See MANIFOLD GAUGE SET CONNECTIONS in
the REFRIGERANT section. Read low pressure gauge.
At pressure above 97 kPa (14 psi) and above, LPCO
switch will complete the clutch circuit. If the low
pressure gauge reads below 172 kPa (25 psi), the sys­
tem is low on refrigerant charge or empty due to a
leak. Refer to TESTING FOR REFRIGERANT LEAKS
in this section.
(6) Install connector boot on switch and repeat step
number 3. If the clutch does not engage, replace the
LPCO switch. See COMPONENT REMOVAL/IN­
STALLATION in this group.
DIFFERENTIAL PRESSURE CUT-OFF
SWITCH DIAGNOSIS
V AR IAB LE D ISPLA CEM ENT C O M P R E S S O R
The Differential Pressure Cut-Off (DPCO) Switch
(Fig. 2) monitors the liquid refrigerant pressure on
the liquid side of the system. The DPCO is located on
the expansion valve. The expansion valve is black in
color when a variable displacement compressor is used.
The DPCO turns off voltage to the compressor clutch
coil when liquid refrigerant pressure drops to levels
that could damage the compressor. The DPCO is a
sealed factory calibrated unit. It must be replaced if
defective.
EXPANSION VALVE DIFFERENTIAL PRESSURE
DPCO SW ITCH T E S T
The work area temperature must not be below 10°C
(50°F) to test the compressor clutch circuit.
(1) With gear selector in park or neutral, and park
brake set, start engine and allow to idle.
(2) Raise hood and disconnect DPCO switch connec­
tor boot.
(3) U sin g a su ita b le ju m p e r w ire, ju m p across th e
terminals inside wire connector boot.
(4) If clutch does not engage, the wiring, fuse, relay,
ambient switch, or high pressure cut-off switch can be
defective. Refer to Group SW, WIRING DIAGRAMS.
(5) If clutch engages, connect a suitable manifold
gauge set. See MANIFOLD GAUGE SET CONNER
TIONS in the REFRIGERANT section. Read low pres­
sure gauge. At pressure 288 kPa (41 psi) and above,
DPCO switch will complete the clutch circuit. If the
low pressure gauge reads below 317 kPa (46 psi), the
system is low on refrigerant charge or empty due to a
leak. Refer to TESTING FOR REFRIGERANT LEAKS
in the REFRIGERANT section.
(6) Install connector boot on switch and repeat step
number 3. If the clutch does not engage, replace the
DPCO switch. See COMPONENT REMOVAL/IN­
STALLATION in this group.
AillENT SWITCH DIAGNOSIS
VARIABLE DISPLACEMENT -
C O M P R E SSO R S Y S T E M
The ambient switch is a temperature sensor located
in front of the condenser behind the grille. The ambi­
ent switch prevents the .compressor from engaging in
cold temperatures. The ambient switch is a sealed
factory calibrated unit. It must be replaced if defective.
AM BIENT SW ITCH T E S T
(1) Disconnect ambient switch wire connector.
(2) Using a suitable ohm meter or continuity tester,
test for continuity across the ambient switch terminals.
(a) At temperature above 10°C (50°F), the switch
circuit should be complete.
(b) Chill the switch with ice to below 10°C (50°F)
and test for continuity. The switch circuit should be
open, with continuity not detected.
Replace ambient switch if defective.
cycle the radiator/condenser fan on and off depending
on the engine temperature. . ■
FAN CONTROL SWITCH TEST
Review SAFETY PRECAUTIONS AND WARNINGS
in the GENERAL INFORMATION section of this group
before proceeding with this operation. Connect a suit­
able manifold gauge set to the refrigerant system ser­
vice ports. See MANIFOLD GAUGE SET. CONNEC­
TIONS in the REFRIGERANT section for informa­
tion. Work area temperature can not be below 21°C
(70°F). . ‘
WARNING: AVOID RADIATOR/CONDENSER FAN
BLADES WHEN WORKING IN THE RADIATOR AREA.
FAN IS CONTROLLED BY TEMPERATURE AND CAN
START ANY TIME IGNITION IS ON. PERSONAL IN­
JURY CAN RESULT.
(1) Disconnect fan control switch wire connector.
(2) Using a suitable jumper wire, jump across termi­
nals in wire connector.
(3) Connect a suitable continuity tester across fan
control switch terminals.
(4) Start engine and set idle at 1300 rpm. The radia­
tor fan should run constantly.
(5) Set the A/C controls to A/C and high blower.
(6) If the high pressure gauge reads below 1102 kPa
(160 psi) there should be no continuity across the
switch terminals.
CAUTION: Do not allow engine, to overheat when
radiator air flow is blocked.
(7) Block radiator air flow with a suitable cover to
increase the high side pressure to at least 1585 kPa
(230 psi). Electrical continuity should be detected across
the fan control switch terminals.
(8) Remove cover from front of vehicle to allow high
side pressure to decrease. When pressure drops below
1102 kPa (160 psi), continuity should cease. -

CONDENSER FAN CONTROL SWITCH'DIAGNOSIS

VARIABLE D ISPLACEM ENT

C O M P R E SSO R S Y S T E M
The Fan Control Switch is located on the plumbing
discharge line at the A/C compressor (Fig. 3). The fan
control switch cycles the radiator/condenser fan on
and off by monitoring the compressor discharge pres­
sure. The radiator top tank temperature sensor can
over ride the function of the fan control switch and
 If fan control switch is defective, replace it. See
COMPONENT REMOVAL /INSTALLATION in this
group.
HIGH PRESSURE CUT-OUT SWITCH DIAGNOSIS
VAR/ABLE DISPLACEMENT
COMPRESSOR ONLY
The High Pressure Cut Out (HPCO) switch is lo­
cated on the rear cover of the Variable Displacement
Compressor (Fig. 4). The function of the switch is to
disengage the compressor clutch by monitoring the
compressor discharge (high) pressure. The HPCO
Switch is in the same circuit as the Differential Pres­
sure Cut Out (DPCO) switch and Ambient Switch.
Fig. 4 Variable Displacement Compressor—Model 6C17
HIGH PRESSURE CUT-OUT SWITCH TESTS
Review SAFETY PRECAUTIONS AND WARNINGS
in the GENERAL INFORMATION section before pro­
ceeding with this operation.
Connect a suitable manifold gauge set to the refrig­
erant system service ports. See MANIFOLD GAUGE
SET CONNECTIONS in the REFRIGERANT section
for information. Work area temperature can not be
below 21°C (70°F).
(1) Raise hood of vehicle.
(2) With gear selector in park or neutral, and park
brake set, start engine and allow to idle at 1300 rpm.
(3) Set the A/C controls to A/C and High blower.
(6) If the high pressure gauge reads below 2963 kPa
(430 psi) ± 138 kPa (20 psi) the compressor clutch should
be engaged.
CAUTION: Do not allow engine to overheat when
radiator air flow is blocked.
(7) Block radiator air flow with a suitable cover to
increase the high side pressure to at least 3100 kPa
(450 psi). Compressor clutch should disengage.
(8) Remove cover from front of vehicle to allow high
side pressure to decrease. When pressure drops below
1826 kPa (265 psi), compressor clutch should engage.
If High Pressure Cut-Out Switch is defective, re­
place it. See COMPONENT REMOVAL/INSTALLA­
TION in this group.
ELECTRONIC CYCLING CLUTCH SWITCH
FIXED DISPLACEMENT COMPRESSORS
The Electronic Cycling Clutch Switch (ECCS) is
located on the A/C refrigerant line at the expansion
valve (Fig. 5). The ECCS prevents evaporator freeze-up
by signaling the Engine Controller Computer to cycle
the compressor ON and OFF by monitoring the tem­
perature of the suction line.
The ECCS uses a thermistor probe in a capillary
tube. This is inserted into a capillary tube well on the
suction line. The well must be filled with conductive
grease to prevent corrosion and allow thermal trans­
fer to the probe. The ECCS is a sealed unit and cannot
be adjusted or repaired. It must be replaced if found
defective.
Fig. 5 Electronic Cycling Clutch Switch—
With Fixed Displacement Compressor
TEST PROCEDURE
With the ambient temperature in the test area
around 21°C (70°F), supply 12 ( ± 1) volts to pin 2 and
ground pin 4 (Fig. 6). Test for continuity from pin 1 to
pin 3. If the test shows continuity, see COMPRESSOR
CLUTCH INOPERATIVE tests in this group. If conti­
nuity is detected, replace the ECCS.

Fig. 6 ECCS Connector
FIXED DISPLACEMENT COMPRESSOR
REFRIGERANT SYSTEM
FIXED DISPLACEMENT
COMPRESSOR DIAGNOSIS
Refer to the REFRIGERANT SYSTEM DIAGNOSIS-
FIXED DISPLACEMENT COMPRESSOR chart in this
section.
VARIABLE DISPLACEMENT COMPRESSOR
REFRIGERANT SYSTEM
GENERAL INFORMATION
The Variable Displacement Compressor (VDC) pro­
vides maximum air-conditioning performance in most
ambient conditions. It is designed to operate continu­
ously without any cycling of the compressor clutch.
The basic compressor mechanism is a variable angle
wobble plate with six axially oriented cylinders.
The compressor will change displacement to match
the vehicle air conditioning demand. The pumping
stroke is governed by the pressure differential of the
suction and the crankcase pressures. When the suc­
tion pressure is higher than the crankcase pressure,
the wobble plate angle in the compressor will increase.
This will cause the compressor pumping stroke to
increase. When the suction pressure is lower than the
crankcase pressure, the wobble plate angle will de­
crease and so will the compressor pumping stroke.
When the heat load at the evaporator decreases, or
when RPM increases, the suction pressure increases
which causes the main control valve to close off dis­
charge pressure to the crankcase. As the crankcase
pressure reduces, the wobble plate angle increases
and lengthens the piston stroke, increasing the refrig­
erant flow to the evaporator during high load periods.
When quick cooling is needed, the sub-control valve
allows for quicker release of crankcase pressure to the
suction side.
VARIABLE DISPLACEMENT
COMPRESSOR DIAGNOSIS
(1) Verify that refrigerant system is at full charge.
Refer to the REFRIGERANT section in this group.
(2) Perform A/C Overall Performance Test. See A/C
OVERALL PERFORMANCE TEST in this group.
(3) If performance is not acceptable, perform expan­
sion valve tests. See EXPANSION VALVE TESTS in
this section.
(4) If expansion valve test is correct, see the VARI­
ABLE DISPLACEMENT COMPRESSOR test charts.
 VARIABLE DISPLACEMENT COMPRESSOR DIAGNOSIS

ELECTRICALLY BYPASS RADIATOR FAN CONTROL SWITCH •IN THE ACCEPTABLE RANGE ABOVE 180 PSI
THE COMPRESSOR IS AT 100% OUTPUT AND
WILL FUNCTION LIKE A FIXED DISPLACEMENT
COMPRESSOR

PRESSURE RANGE GRAPH

LOW
PRESSURE
READING

160

HIGH PRESSURE READING

 REFRIGERANT SYSTEM DIAGNOSIS— VARIABLE DISPLACEMENT COMPRESSOR

TEMPERATURE IN TEST AREA 21-29°C (70-85°F)

VERIFY R-12 CHARGE-CONNECT MANIFOLD GAUGES
SEE REFRIGERANT SECTION IN THIS GROUP
IF R-12 CHARGE IS LOW, CORRECT LEAK, EVACUATE,
AND CHARGE SYSTEM

LOCATE AND REMOVE BOTH

VACUUM LINES AT RECIRC
DOOR ACTUATOR INSTALL
LT-GN LINE WHERE DK-GN
LINE HAD BEEN
START ENGINE ADJUST IDLE TO
1000 rpm IN PARK OR NEUTRAL
W I TH PARK BRAKE SET

—* PRESSURES OK
CLOSE PASSENGER COMPARTMENT
SET CONTROL TO A 1 C . PANEL. HIGH
BLOWER, FULL HEAT

SYSTEM IS
NORMAL

CORRECT CORRECT
EVAPORATOR COMPRESSOF
SUCTION GAUGE DISCHARGE GAUGE
PRESSURE= PRESSURE= PRESSURES
20-35 PSI 140-240 PSI ABNORMAL
(152-240 kPa) (966 TO 1656 kPa)

C •FREEZE 15% OR MORE REDUCTION

OF COMPRESSOR
H-VALVE 1
DISCHARGE PRESSURE?
H-VALVE
STUCK OPEN IF
CONDITIONS
CANNOT BE MET
38 PSI (262 kPa) OR MORE
THEN DROPS TO 22-35 PSI
J152-240 kPa). DISCHARGE
PRESSURE SHOULD STABILIZE H-VALVE
TO 140-240 PSI (965-1655 kPa) STUCK CLOSED IF
CONDITIONS
CANNOT BE MET

D ’ THAW
H-VALVE
RESTRICTED
CONDENSOR-
RESTRICTED
DI SCHARGE LINE
-RADIATOR
RETURN RECIRC DOOR VACUUM LINES TO NORMAL OVERHEATING-
AIR IN SYSTEM-
OVERCHARGED
SYSTEM-COOLING
‘ SEE EXPANSION 22-35 PSI 240 PSI OR HIGHER FAN INOP.
(152-240 kPa) — (1656 kPa)
VALVE TESTS

DEFECTIVE
22-35 PSI a) COMPRESSOR
(152-240 kPa) OR LESS
REFRIGERANT SYSTEM DIAGNOSIS-FIXED DISPLACEMENT COMPRESSOR
EXPANSION VALVE TESTS— WITH
FIXED DISPLACEMENT COMPRESSORS
(SILVER COLORED EXPANSION VALVE)
Expansion valve tests should be performed after
compressor tests.
Review SAFETY PRECAUTIONS AND WARNINGS
in the GENERAL INFORMATION section of this
group. The work area and vehicle temperature must
be 21°C to 27°C (70°F to 85°F) when testing expansion
valve. To test the expansion valve:
(1) Connect a charging station or manifold gauge
set to the refrigerant system service ports. See MANI­
FOLD GAUGE SET CONNECTIONS in the REFRIG­
ERANT section. Verify the refrigerant charge level
using the sight glass method. See SIGHT GLASS RE­
FRIGERANT LEVEL INSPECTION.
(2) Disconnect and plug the vacuum line at the
water control valve.
(3) Disconnect wire connector at low pressure cut-off
switch (Fig. 7). Using a jumper wire, jump terminals
inside wire connector boot.
EXPANSION
Fig. 7Low Pressure Cut-OffSwitch
(4) Close all doors, windows and vents to the pas­
senger compartment.
(5) Set heater-A/C control to A/C, full heat, FLOOR,
and high blower.
(6) Start the engine and hold the idle speed at 1000
rpm. After the engine has reached running tempera­
ture, allow the passenger compartment to heat up to
create the need for maximum refrigerant flow into the
evaporator.
(7) If the refrigerant charge is sufficient, discharge
(high pressure) gauge should read 965 to 1655 kPa
(140 to 240 psi). Suction (low pressure) gauge should
read 140 kPa to 207 kpa (20 psi to 30 psi). If system
cannot achieve proper pressure readings, replace the
expansion valve. For proper service procedures, refer
to COMPONENT REMOVAL/INSTALLATION in this
group. If pressure is correct, proceed with test.
WARNING: PROTECT SKIN AND EYES FROM CON­
TACTING C 02 PERSONAL INJURY CAN RESULT.
(8) If suction side low pressure is within specified
range, freeze the expansion valve control head (Fig.8)
for 30 seconds. Use a super cold substance (liquid
C 02).Do not spray R-12 Refrigerant on the expansion
valve for this test. See REFRIGERANT RECYCLING
in the REFRIGERANT section. Suction side low pres­
sure should drop to -50 kPa (-15 in. Hg) If not, replace
expansion valve.
Fig. 8 Expansion Valve
(9) Allow expansion valve to thaw. The low pressure
gauge reading should stabilize at 140 kPa to 240 kPa
(20 psi to 30 psi). If not, replace expansion valve.
Refer to COMPONENT REMOVAL/INSTALLATION
in this group.
When expansion valve test is complete, test A/C
overall performance. See A/C OVERALL PERFOR­
MANCE TEST in this section. Remove all test equip­
ment before returning vehicle to use.
EXPANSION VALVE TESTS— WITH
VARIABLE DISPLACEMENT COMPRESSOR
(BLACK COLORED EXPANSION VALVE)
Review SAFETY PRECAUTIONS AND WARNINGS
in GENERAL INFORMATION section of this group.
The work area temperature must be 21°C to 27°C
(70°F to 85°F) when testing expansion valve. To test
the expansion valve:
(1) Connect a charging station or manifold gauge
set to the refrigerant system service ports. See MANI­
FOLD GAUGE SET CONNECTIONS in the REFRIG­
ERANT section. Verify the refrigerant charge level
using the sight glass method.
(2) Disconnect and plug the vacuum line at the
water control valve.
(3) Disconnect the wire connector at the differential
pressure cut-off switch. Using a jumper wire, jump
across the terminals inside the connector boot (Fig.9).
EXPANSION VALVE : DIFFERENTIAL PRESSURE
F lf- § Differential Pressure Cut-Out Switch
(4) C lose a ll doors, w indow s a n d vents to th e p a s ­
se n g e r c o m p a rtm e n t.
(8) S e t h ea te r-A /C con trol to A/C, full h e a t, FLO O R,
a n d h ig h blow er.
(6) S ta r t th e e n g in e a n d hold th e id le speed a t 1000
rpm . A fte r th e e n g in e h a s re a c h e d running te m p e ra ­
tu re , allow th e p a s se n g e r c o m p a rtm e n t to h e a t up to
c re a te th e n e e d for m a x im u m r e frig e ra n t flow in to th e
ev ap o rato r.
(7) D isc h a rg e (h ig h p re ssu re ) g a u g e sh o u ld re a d 965
to 1855 kPa (140 to 240 psi) w h en th e re frig e ra n t
ch a rg e is su fficien t. If sy ste m c a n n o t ach iev e p ro p er
p re ssu re , re p la c e th e ex p an sio n valv e. F o r p ro p e r s e r­
vice p roced ures, re fe r to C O M PO N E N T REM O V A L/
IN ST A L L A T IO N in th is group. I f p re s su re is correct,
record re a d in g a n d proceed w ith te st.
WARNING: PROTECT SKIN AND EYES FROM CON­
TACTING C 0 2'PERSONAL INJURY CAN RESULT.
(8) I f d isc h a rg e p re s su re is within specified ra n g e ,
freeze th e ex p a n sio n v alv e control h e a d (Fig. 8) for 30
seconds. U se a su p e r cold su b sta n c e (liq u id C 02).Do
not spray R-12 Refrigerant on the expansion valve
for this test. See REFRIGERANT RECYCLING in the
REFRIGERANT section J f com pressor d isc h a rg e (high)
p re ssu re does n o t drop by 15% or m ore of th e p re ssu re
recorded in ste p 7, re p la c e th e e x p an sio n valve. A llow
th e e x p a n sio n v a lv e to th a w . T h e d isc h a rg e p re ssu re
sh ou ld sta b iliz e to th e p re s su re record ed in step 7. If
th e p re ssu re does n o t sta b iliz e , rep lace th e e x p an sio n
valve. See C O M PO N E N T REM O V A L/IN STA LLA TIO N
in th is group.
W hen e x p a n sio n v alv e te s ts a re com plete, re fe r to
A/C O V ER A LL PE R F O R M A N C E T E S T a n d rem ove
all te s t e q u ip m e n t before r e tu r n in g veh icle to use.
A/C OVERALL PEiFOillNCE TEST'
The air-conditioning system is designed to remove
heat and humidity from the air entering the passen­
ger compartment. The evaporator, located in the heater
A/C unit behind the instrument panel, is cooled to
temperatures near the freezing point. As warm damp
air passes over the fins in the evaporator, moisture in
the air condenses to water, dehumidifying the air.
Condensation on the evaporator fins reduces the evap­
orators ability to absorb heat. During periods of high
heat and humidity an air-conditioning system (within
specifications) will be less effective than during peri­
ods of high heat and low humidity. With the instrument
control set to RECIRC, only air from the passenger
compartment passes through the evaporator. As the
passenger compartment air dehumidifies, A/C perfor­
mance levels rise.
PERFORMANCE TEST PROCEDURE
Review SAFETY PRECAUTIONS AND WARNINGS
in the GENERAL INFORMATION section of this group
before proceeding with this procedure. Air tempera­
ture in test room and on vehicle must be 70°F (21°C)
minimum for this test.
(1) Connect a tachometer and manifold gauge set.
Refer to MANIFOLD GAUGE SET CONNECTIONS
in the REFRIGERANT section.
(2) Set control to A/C, RECIRC, PANEL, or MAX
A/C, temperature lever on full cool and blower on
high.
(3) Start engine and hold at 1000 rpm with A/C
clutch engaged.
(4) Engine should be warmed up with doors and
windows closed.
(5) Insert a thermometer in the left center A/C out­
let and operate the engine for five minutes. The A/C
clutch may cycle depending on ambient conditions.
(6) With the A/C clutch engaged, compare the dis­
charge air temperature to the A/C PERFORMANCE
TEMPERATURES chart in this section.
 A/C PERFORMANCE TEMPERATURES

Ambient Temperature 21 °C 26.5 °C 32 °C 37.5°C 43 °C

(70 °F) (80°F) (90°F) (100°F) F)

Air Temperature at Center 2-8°C 4-10°C 7-13°C 10-17°C 13-21 °C

Panel Outlet (35-46°F) (39-50°F) (44-55 °F) (50-62 °F) (56-70°F)

965- 1240- 1448- 1655- 1930-

Compressor Discharge Pressure 1448 kPa 1620 kPa 1860 kPa 2137 kPa 2413 kPa
(140-210 PSI) (180-235 PSI) (210-270 PSI) (240-310 PSI) (280-350 PSI)

69- • 138- 172- 207-

Evaporator Suction Pressure 241 kPa 262 kPa 290 kPa 331 kPa 379 kPa
(10-35 PSI) (16-38 PSI) (20-42 PSI) (25-48 PSI) 30-55 PSI)

9124-26

(7) O p e ra te th e A/C for tw o m o re m in u te s a n d ta k e a m o u n t o f re f rig e r a n t n e c e ssa ry to re d u c e sy ste m p re s ­

th e d isc h a rg e a ir te m p e ra tu re re a d in g a g a in . If th e
te m p e ra tu re in c re a se d by m ore th a n 51°F (21°C), check
th e b le n d a ir door for co rrect o p e ra tio n . If th e te m p e r­
a tu r e does n o t in c re a se m ore th a n 51°F (21°C), com ­
p a r e th e d is c h a rg e a ir te m p e r a tu r e , s u c tio n a n d
d isc h a rg e p re ssu re s. T hese ca n be found in th e A/C
P E R F O R M A N C E T E M P E R A T U R E S c h a r t in th is
section.
(8) I f th e d isc h a rg e a ir te m p e ra tu re fa ils to m e e t th e
sp ecificatio ns in th e p erfo rm an ce te m p e ra tu re c h a rt,
re fe r to th e diag n o stic a n a ly sis c h a rts in th is gro up for
f u rth e r te s t in fo rm a tio n .
su re a n d th e n re s e a ts itself. T h e m a jo rity of th e r e ­
frig e ra n t is con served in th e sy stem . T he v alv e is
c a lib ra te d to v e n t a t a p re s s u re o f 3100 to 4140 K p a
(450 to 600 psi). I f a v a lv e h a s v e n te d a sm a ll a m o u n t
of re frig e ra n t, i t does n o t n e c e ssa rily m e a n th e v alv e
is defective.
F or (HPR) valve replacement, refer to COM PRESSO R
H IG H PR E S S U R E R E L IE F V A LV E, REM O V A L A N D

HIGH PRESSURE RELIEF VALVE (HPR) DIAGNOSIS

T he H P R v a lv e p re v e n ts d a m a g e to th e a ir-co n d i­
tio n in g sy ste m if excessive p re s su re develops d u e to
condenser air flow blockage, refrigerant overcharge,
or a ir a n d m o istu re in th e sy stem .

(HPR) WALWE LOCATION

W ith fixed d isp la c e m e n t com pressors: O n th e d is­
c h a rg e lin e a t th e A/C co m pressor (Fig. 10).
W ith v a ria b le d isp lacem ent com pressors: O n th e com­
p re sso r e n d p la te . (Fig. 11).
T h e h ig h p re s su re re lie f v a lv e v e n ts only a sm all
INSTALLATION, in the COMPONENT REMOVAL/
INSTALLATION AND OVERHAUL section.
Fig. 11 High Pressure Relief V a lv e -
Variable Displacement Compressor
CONDENSATE WATER DRAINAGE
Condensation that accumulates on the bottom of the
evaporator housing is drained from a rubber tube
through the dash panel and on to the ground. This
tube must be kept open to prevent condensate water
from collecting in the bottom of the heater A/C unit
housing (Fig. 12).
The tapered end of the drain tube is designed to keep
contaminants from entering the heater A/C unit hous­
ing. If the tube is pinched or blocked, condensate can­
not drain, causing water to back up and spill into the
passenger compartment. It is normal to see conden­
sate drainage below the vehicle. If the tube is dam­
aged, it should be replaced. Refer to CONDENSATE
DRAIN TUBE, REMOVAL AND INSTALLATION in
the COMPONENT REMOVAL/INSTALLATION AND
OVERHAUL section.
 REFRIGERANT
INDEX
Page Page
Correcting Low Refrigerant Level .... 28 Oil Level ................................................. 30
Discharging Refrigerant System __ 29 Refrigerant Recycling ............................ 25
Charging Refrigerant System . . . .... 29 Refrigerant (R-12) Equipment ............. 26
Evacuating Refrigerant System . .... 29 Sight Glass Refrigerant Level Inspection 25
Manifold Gauge Set Connections __ 26 Testing for Refrigerant Leaks ............... 27

REFRIGERANT RECYCLING
(R-12) refrigerant is a chlorofluorocarbon (CFC) that
can contribute to the depletion of the ozone layer in
the upper atmosphere. Ozone filters out harmful radi­
ation from the sun. To assist in protecting the ozone
layer, an (R-12) refrigerant recycling device that meets
SAE standard J1991 should be used. Contact an auto­
motive service equipment supplier for refrigerant re­
cycling equipment that is available in your area. Refer
to the operating instructions provided with the recycl­
ing equipment for proper operation. Also see SAFETY
PRECAUTIONS AND WARNINGS in the GENERAL
INFORMATION SECTION.

SIGHT GLASS REFRIGERANT LEVEL INSPECTION

The filter-drier is equipped with a sight glass (Fig.
13) that is used as a refrigerant level indicator only.
This sight glass is not to be used for A/C perfor­
mance testing. To check the refrigerant level, remove
the vehicle jack, clean the sight glass, start and warm
up engine, and hold idle at 1100 rpm. Place the air-
conditioning control on A/C, RECIRC and high blower.
The work area temperature should be at least 21°C
(70°F). If a Fixed Displacement type compressor does
not engage, the refrigerant level is probably too low
for the Low Pressure Cut-Off switch to detect. Or,
with a Variable Displacement compressor, for the Dif­
ferential Pressure Cut-off to detect. If compressor clutch
does not engage, refer to TESTING REFRIGERANT
SYSTEM FOR LEAKS in the DIAGNOSTIC SER­
VICING PROCEDURES section of this group. If com­
pressor clutch engages, allow approximately one minute
for refrigerant to stabilize. View refrigerant through
sight glass. The suction line should be cold to the
touch and the sight glass should be clear.
Fig. 13 Filter Drier and Sight Glass
If foam or bubbles are visible in sight glass, the
refrigerant level is probably low. Occasional foam or
bubbles are normal when the work area temperature
is above 43°C (110°F) or below 21°C (70°F). If suction
line is cold and occasional bubbles are visible in the
sight glass, block the condenser air flow to increase
the compressor discharge pressure (Do not allow en­
gine to over heat). Bubbles should dissipate. If not,
the refrigerant level is low. For proper charging pro­
cedures refer to CORRECTING LOW REFRIGERANT
LEVEL in this section.
WARNING: (R-12) REFRIGERANT IS DETRIMENTAL
TO THE ENVIRONMENT WHEN RELEASED TO THE
ATMOSPHERE. DO NOT RECHARGE AN A/C SYS­
TEM BY ADDING (R-12) REFRIGERANT TO A SYS­
TEM THAT HAS A KNOWN LEAK.
 T he re f r ig e r a n t sy ste m w ill n o t be low on (R-12)'
u n le ss th e re is a le a k . F in d a n d re p a ir th e le a k before
c h a rg in g . R e fe r to T E S T IN G A/C S Y S T E M F O R
L E A K S in th e D IA G N O ST IC S E R V IC IN G PROCE^
DURES sectio n of th is group.

REFRIGERANT (R-12) EQUIPMENT

WARNING; EYE PROTECTION MUST BE USED WHEN

SERVICING AN AIR-CONDITIONING REFRIGERANT
SYSTEM. .
TURN OFF (ROTATE CLOCKWISE) ALL VALVES ON
THE EQUIPMENT BEING USED BEFORE PROCEED­
ING WITH THIS OPERATION. PERSONNEL INJURY
CAN RESULT.
- When servicing an air-conditioning system, it is
reco m m end ed t h a t a s u ita b le a ir-c o n d itio n in g c h a rg ­
in g s ta tio n (Fig. 14) be u sed. A n (R-12) r e frig e ra n t
reco v ery /recy clin g device (Fig. 15) sh o u ld also be used.
T h is device sh o u ld m e e t SA E s ta n d a rd J1991. C o n ta c t 9124-3
an automotive service equipment supplier for refriger­
ant recycling/recovering equipment that is available Fig. 15 Refrigerant-Recovery I'Recycling S ta tio n -
in your area. Refer to the operating instructions pro­ Typical
vided with the equipment for proper operation. SUCTION GAUGE DISCHARGE GAUGE
A manifold gauge set (Fig. 16) must also be used in (LOW PRESSURE) (HIGH PRESSURE)
conjunction with the charging and/or recovery/recycling
device. The service hoses on the gauge set being used
should have manual (turn wheel) or automatic back
flow valves at the service port connector ends, to pre­
vent refrigerant release into the atmosphere.
CHAIGfNG
STATION

VALVE VALVE
REFRIGERANT
CHARGING
CYLINDER

YELLOW VACUUM
REFRIGERANT
'm an ifo ld HOSE
■GAUGE SET BLUE LOW MED HIGH
SIDE HOSE SIDE HOSE

9024-5

Fig. IS Manifold Gauge Set—Typical

11IIF0L0 GAUGE SET CONNECTIONS

GENERAL INFORMATION
VACUUM The high pressure (discharge) (RED) hose should be
PUMP 9024-4
attached to the 1/4 in. discharge service port. This
p o rt w ill be lo cated (d ep en d in g on th e veh icle m odel),
on either the discharge line between the air condition­
ing compressor and the condenser, or on the high
pressure (liquid) line.
 T h e low p re ss u re (suction) (B L U E ) hose sh o u ld be
a tta c h e d to th e 3/8 in. su c tio n serv ice p o rt. T h is p o rt
is located (d ep en d in g on v eh icle m odel), on e ith e r th e
a ir c o n d itio n in g co m pressor, o r th e su c tio n lin e b e­
tw e e n th e e x p a n sio n v a lv e a n d th e com pressor.
SUCTION (LOW PiESSUiE) GAUGE COIIECTiOl
(1) Remove th e serv ice p o rt cap from 3/8 in . su ctio n
serv ice p o rt.
(2) C heck a ll v a lv e s on th e e q u ip m e n t b e in g u se d to
verify th e y a re closed.
(3) In sp e c t th e ho se g a s k e t in th e serv ice p o rt con­
n e c to r a t th e en d of th e (B L U E ) hose. I f th e g a s k e t is
flaw ed, re p la c e it.
(4) T h re a d th e ho se co n nector on to th e serv ice p o rt
u n til th e v a lv e core d e p re sso r in th e hose e n d m a k e s
c o n tact w ith th e v a lv e core in th e serv ice p o rt. Q u ickly
secu re hose co n n ecto r to th e serv ice p o rt to avoid
loosing re frig e ra n t.
To d isco n n ect su c tio n g a u g e (B LU E) hose:
(a) W ra p th e e n d o f hose w ith a shop tow el.
(b) Loosen th e ho se connector.
(c) P u s h a n d h o ld th e e n d o f hose to w a rd th e
service p o rt to k eep th e g a s k e t in c o n ta c t w ith service
po rt.
(d) Q u ick ly r o ta te th e co n n ecto r co u nterclockw ise.
W hen th e h ose co n n ecto r is co m p letely b a c k e d off,
im m e d ia te ly p o in t th e e n d o f h o se to w a rd floor, as
possibly tra p p e d re frig e ra n t in th e hose w ill be released.
(e) I n s ta ll serv ice p o rt cap.
DISCHARGE (HIGH PRESSURE) GAUGE CONNECTION
(1) R em ove th e serv ice p o rt cap from th e 1/4 in.
service p o rt.
(2) C heck a ll v a lv e s on th e e q u ip m e n t b e in g u se d to
verify th e y a re closed.
(3) In sp e c t th e ho se g a sk e t in th e serv ice p o rt con­
n e c to r a t th e /end of the (RED ) hose. I f th e g a s k e t is
flaw ed, re p la c e it.
(4) U se a s u ita b le (3/8 in. m a le to 1/4 in . fem ale)
a d a p te r (Fig. 17), th re a d e d se c u re ly in to th e e n d of
th e (RED) hose connector.
(5) S ta r t th re a d in g th e 1/4 in . h o se a d a p te r connec­
to r onto th e serv ice p o rt u n til th e v a lv e core d ep resso r
in th e a d a p te r m a k e s c o n ta c t w ith th e v alv e core in
th e service p o rt. Q u ick ly se c u re a d a p te r co nn ecto r to
serv ice p o rt to avoid lo osing re frig e ra n t.
To d isco n n ect th e d isc h a rg e g a u g e (RED) hose: ■ *-
(a) W ra p th e en d o f hose w ith a shop tow el. 5 - '■
(b) Loosen th e hose connector.
(c) P u s h a n d h old th e e n d o f ho se to w a rd th e
service p o rt to k eep th e g a s k e t i n c o n ta c t w ith service
po rt.
(d) Q u ick ly r o ta te th e co n n ecto r co un terclockw ise.
W h en th e hose c o n n e c to r, is co m p letely b a c k e d off,
im m e d ia te ly p o in t th e e n d o f ho se to w a rd flo o r,' a s
possibly tra p p e d re frig e ra n t in th e hose w ill be released.
(e) In s ta ll serv ice p o rt cap.
EVACUATION/RECOVERY/RECYCLING/CHARGING . ,
LINE CONNECTION :
T h e c e n te r m an ifo ld (Y ELLO W ) o r (W H ITE ) hose is
u sed to discharge, recycle, recover, ev acu ate, a n d charge
th e r e frig e ra n t sy stem . W h en th e d isc h a rg e or su ctio n
v a lv e s on th e m an ifo ld g a u g e se t a re opened, th e r e ­
f rig e ra n t in th e sy ste m w ill escape th ro u g h th is hose.
It is recommended that this hose be attached to a
coriitTierciaiif awaiiabie refrigerant (R-12) Recovery/
Recycling device. Refer to the operators manual for
procedures. ' ; < ■
F o r disco n n ectio n o f th is hose, re fe r to D isco n n ect­
in g th e D isc h a rg e G au g e (RED ) hose in th e p reced in g
p a ra g ra p h s .
TESTING FOR REFRIGERANT LEAKS
I f th e a ir-c o n d itio n in g sy ste m is n o t cooling th e
p a sse n g e r c o m p a rtm e n t p ro p erly , d e te rm in e if th e r e ­
f rig e ra n t sy ste m is fu lly c h a rg e d w ith (R-12) re frig e r­
a n t. Follow th e p ro c e d u re s in th e P E R F O R M A N C E
T E S T PR O C E D U R E S sectio n o f th is group. I f th e
r e f r ig e r a n t sy ste m is e m p ty or low in r e f r ig e r a n t
c h arg e, a le a k a t a n y lin e fittin g o r co m p o nen t se a l is
lik ely . To d e te c t a le a k in th e re f r ig e r a n t sy stem ,
perfo rm one of th e follow ing p ro c e d u re s a s in d ic a te d
by th e sym ptom s.
EMPTY REFRIGERANT SYSTEM LEAK TEST
CAUTION: Review Safety Precautions an Warnings
in General Information section of this group.
(1) E v a c u a te th e r e f r ig e r a n t sy ste m to th e lo w est
d eg ree o f v a c u u m possible. See D ISC H A R G IN G R E ­
F R IG E R A N T SY ST E M in th is section.
(2) P re p a re a 10 oz. r e f r ig e r a n t (R-12) c h a rg e to be
injected into the system. See CHARGING REFRIG­
E R A N T SY ST E M for in stru c tio n s.
(3) C on n ect a n d d isp e n se 10 ozs. of r e frig e ra n t in to
th e e v a c u a te d re f r ig e ra n t sy stem . See C H A R G IN G
R E F R IG E R A N T SY ST E M for in stru c tio n s.
 (4) Proceed to step two of LOW REFRIGERANT
LEVEL LEAK TEST.

LOW REFRIGERANT LEVEL LEAK TEST

Caution: Review SAFETY PRECAUTIONS AND WARN­
INGS in the GENERAL INFORMATION section of this
group.
(1) Using the refrigerant level sight glass, deter­
mine if there is any (R-12) refrigerant in the system.
Refer to SIGHT GLASS REFRIGERANT LEVEL IN­
SPECTION in this section.
(2) Position the vehicle in a wind free work area to
make it less difficult to detect a small leak.
(3) Bring the refrigerant system up to operating
temperature and pressure by allowing the engine to
warm up.
(4) With the engine not running, use an Electronic
Leak Detector (or equivalent) and search for leaks in
the most accessible areas first (Fig.18).
(a) Fittings, lines, or components that appear oily
usually will indicate a refrigerant leak.
(b) To inspect the evaporator core for leaks, it is
possible to insert the leak detector probe into the
recirculating air door opening. This opening is located
near the right side cowl trim behind the instrument
panel. Or, insert the probe into the defroster outlet
with the blower set on low speed and the control panel
set to DEFROST.
(5) For component; replacement, refer to COMPO­
NENT REMOVAL/INSTALLATION AND OVER­
HAUL in this group.

8924-24

Fig. 18 Testing forA/C Leaks—

TypicalFront/RearA/C System
CORRECTING LOW REFRIGERANT LEVEL
REFRIGERANT LEAK DETECTION
If the air-conditioner does not blow cooled air from
the instrument panel outlets, refer to TESTING FOR
REFRIGERANT LEAKS.

ADDING PARTIAL REFRIGERANT CHARGE

After all leaks have been corrected and if it was not
necessary to completely discharge the refrigerant sys­
tem, a partial refrigerant charge can be added to the
system.
CAUTION :Review all SAFETY PRECAUTIONS AND
WARNINGS in the GENERAL INFORMATION section
before attempting to add refrigerant to the system.
Do not add refrigerant to a system that is known to
have a leak.
 (1) A tta c h m an ifo ld g a u g e set. R efer to M A N IFO L D
G A U G E S E T C O N N E C T IO N S.
(2) O pen th e w indow s of th e p a s se n g e r c o m p a rt­
m e n t a n d se t th e a ir-c o n d itio n in g c o n tro ls to A/C,
REC IR C , a n d Low b low er speed.
(3) S ta r t th e e n g in e a n d allo w it to w a rm u p to
n o rm a l running te m p e ra tu re .
(4) I f th e a ir-c o n d itio n in g com p ressor does n o t e n ­
gage, disco n n ect th e low p re ss u re cut-off sw itch. P lace
a ju m p e r w ire across th e te rm in a ls in th e con nector
boot. I f th e com p ressor s till does n o t en g ag e, a p rob ­
lem e x ists in th e com p resso r c lu tc h feed c irc u it. See
D IA G N O STIC SE R V IC IN G P R O C E D U R E S in th is
group.
(8) H old th e e n g in e speed a t 1400 rp m .
(7) W h ile follow ing th e in s tru c tio n s p rov ided w ith
th e c h a rg in g e q u ip m e n t b e in g u sed , c h a rg e th ro u g h
th e su c tio n side o f th e sy stem , eno ug h' re frig e ra n t to
c le a r th e s ig h t g la ss in th e filte r d rie r.
(8) A t th e p o in t w h e n th e s ig h t g la ss c le a rs, n o te
th e w e ig h t of th e re f r ig e r a n t su p p ly d ru m or th e level
in th e c h a rg in g c y lin d e r a n d a d d a n a d d itio n a l 340 g
(12 oz) of re frig e ra n t. R em ove th e ju m p e r w ire' from
th e low p re ss u re cu t-o ff sw itch co n n ecto r a n d co nn ect
th e cu t-off sw itch.
(9) T est th e o ver a ll p erform ance of th e air-con ditio ner
as described in A/C O V ERA LL PE R FO R M A N C E T E ST
in th is group. C lose a ll v a lv e s on th e c h a rg in g e q u ip ­
m e n t a n d d isco n n ect th e h oses from th e serv ice p o rts
as d escribed in - th e M A N IFO L D G A U G E SET''" C O N ­
N E C T IO N S sectio n of th is group. In s ta ll th e service
p o rt caps.
DISCHARGING REFRIGERANT SYSTEM
REFRIGERANT RECYCLING
(R-12) re f rig e r a n t is a ch lorofluo rocarb o n (CFG) t h a t
ca n c o n trib u te to th e d ep le tio n o f th e ozone la y e r in
th e u p p e r a tm o sp h e re . O zone filte rs o u t h a rm fu l ra d i­
a tio n from th e su n . To a s s is t in p ro te c tin g th e ozone
lay er, C h ry sle r C o rp o ratio n recom m ends t h a t a n (R-12)
r e frig e ra n t re c y c lin g device t h a t m e e ts SA E s ta n d a rd
J1 9 9 1 be used. U se th is device w h e n i t is n e c e ssa ry to
d isc h a rg e th e re f r ig e r a n t sy stem . C o n ta c t a n au to m o ­
tiv e serv ice e q u ip m e n t su p p lie r for re f r ig e r a n t recycl­
in g e q u ip m e n t t h a t is a v a ila b le in y o u r a re a . R efer to
th e o p e ra tin g in s tru c tio n s p rov ided w ith th e recy clin g
e q u ip m e n t for p ro p e r o p e ra tio n .
EVACUATING REFRIGERANT SYSTEM
I f th e a ir-c o n d itio n in g re f r ig e r a n t sy ste m h a s b een
open to th e atm o sp h e re , it m u s t be e v a c u a te d before th e
sy stem c a n be c h a rg e d w ith re frig e ra n t. M o istu re a n d
a ir m ix ed w ith th e re f r ig e r a n t w ill ra is e th e com pres­
sor h e a d p re ss u re above acc e p ta b le o p e ra tin g lev els
■and w ill red u ce th e p erfo rm an ce o f th e a ir-c o n d itio n e r
a n d d a m a g e th e com pressor. M o istu re w ill boil a t n e a r
room te m p e ra tu re w h e n ex p o sed 'to v acu u m . To e v a c u ­
a te th e re f r ig e r a n t system :
(1) C o nn ect a s u ita b le c h a rg in g s ta tio n , re frig e ra n t
reco very m a c h in e , a n d a m an ifo ld g a u g e se t w ith v ac­
u u m pum p.
(2) O pen th e su c tio n a n d d isc h a rg e v a lv e s a n d s ta r t
th e v a c u u m p u m p . W h en th e su c tio n g a u g e reads. -88
kPa (-26 in . Hg) v a c u u m or g re a te r, close a ll v alv es
a n d t u r n off v a c u u m pu m p . I f th e sy ste m fa ils to re a c h
specified v a c u u m , th e re f r ig e r a n t sy ste m lik e ly h a s a
le a k t h a t m u s t be co rrected . I f th e re f r ig e r a n t sy stem
m a in ta in s specified v a c u u m for a t le a s t 30 m in u te s,
s t a r t th e v a c u u m p u m p , open th e su c tio n a n d d is­
c h a rg e v alv es, a n d allow th e sy ste m to e v a c u a te a n
a d d itio n a l 10 m in u te s.
(3) C lose a ll v alv es. T u rn off a n d d isco n n ect th e
v a c u u m pum p .
T he r e frig e ra n t sy ste m is p re p a re d to be c h a rg e d
w ith re frig e ra n t.
CHARGING REFRIGERANT SYSTEM
CAUTION: Do not over charge refrigerant system, as
excessive compressor head pressure can cause noise
and system failure.
WARNING: Review SAFETY PRECAUTIONS AND
WARNINGS in GENERAL INFORMATION section of
this group before charging the refrigerant system.
After the refrigerant system has been tested for
leaks and evacuated, a refrigerant (R-12) charge can
be injected into the refrigerant system.
(1) Connect manifold gauge set. See MANIFOLD
GAUGE SET CONNECTIONS in this group.
(2) Measure refrigerant (see capacities) and heat to
52°C (125°F) with the charging station. Refer to the
instructions provided with the equipment being used.
REFRIGERANT CAPACITIES:
• Without Rear A/C = 907 g (32 oz.)
• With Rear A/C = 1219 g (43 oz.)
(3) Open the suction and discharge valves. Open the
charge valve to allow the heated refrigerant to flow
into the system. When the transfer of refrigerant has
stopped, close the suction and discharge valve.
(4) If all of the refrigerant charge did not transfer
from the dispensing device, start the engine and hold
idle at 1400 rpm. Set the A/C control to A/C, low
blower speed, and open windows. If the A/C compres­
sor does not engage, test the compressor clutch control
circuit and correct any failure. Refer to DIAGNOSTIC
SERVICING PROCEDURES in this group, and Group
8W, WIRING DIAGRAMS.
(5) Open the suction valve to allow the remaining
refrigerant to transfer to the system.
WARNING: TAKE CARE NOT TO OPEN THE DIS­ erant oil must be added. When the compressor is re­
CHARGE (HiGH-PRESSURE) VALVE AT THIS TIME. placed, the amount of oil that is retained in the rest of
the system must be drained from the replacement
(8) C lose a ll valves a n d te s t th e A/C sy ste m o v erall
compressor. When a refrigerant line or component has
p erfo rm ance. See A/C O V ER A LL PE R FO R M A N C E
ruptured and has released an unknown amount of oil,
T E ST in th is group.
the A/C compressor should be removed and drained
(7) Disconnect the charging station or manifold gauge
th ro u g h th e su c tio n p o rt. T h e filte r-d rie r m u s t be r e ­
set. See M A N IFO L D G A U G E S E T C O N N E C T IO N S
placed along with the ruptured part, and the oil ca­
in this group. Install the service port caps.
pacity of the system minus the amount of oil still in
the remaining components can be measured and poured
OIL LEVEL
into the suction port of the compressor.
Example: The evaporator retains 60 ml (2 oz). The
It is important to have the correct amount of oil in
condenser retains 30 ml (1 oz) of oil, and system ca­
the A/C system to ensure proper lubrication of the
pacity may be 214 ml (7.25 oz) of oil.
compressor. Too little oil will result in damage to the
214 m l m in u s 90 m l = 124 m l (4.25 oz).
compressor, while too much oil will reduce the cooling
capacity of the system and consequently result in higher
REFRIGERANT OIL CAPACITIES
discharge air temperatures.
The oil used in the compressor is a 500 SUS viscos­ A/C Component Refrigerant O il CapacWes
ity, wax-free refrigerant oil. Only refrigerant oil of
C om ponent mi oz
the same type should be used to service the system.
Do not use any other oil. The oil container should be Fixed Di splacement Compressor System 214 ml 7.25 oz
kept tightly capped until it is ready for use, and then Variable Displacement Compressor System 257 ml 8.7 oz
tightly capped after use to prevent contamination from Fi lter-drier 30 ml 1 oz
dirt and moisture. Refrigerant oil will quickly absorb Condenser 30 ml 1 oz
any moisture it comes in contact with. Evaporator 60 ml 2 oz
It will not be necessary to check oil level in the Rear Evaporator 60 ml 2 oz.
compressor or to add oil unless there has been an oil
9124-61
loss. This may be due to a ruptured line, shaft seal
leakage, leakage from the evaporator, condenser leak,
VERIFY REFRIGERANT OIL LEVEL
filter drier or loss of refrigerant due to a collision. Oil
(1) Slowly discharge refrigerant system. See DIS­
loss at a the leak point will be evident by the presence
CHARGING R E F R IG E R A N T SY STEM .
of a wet, shiny surface around the leak.
(2) Remove refrigerant lines from A/C compressor.
(3) Remove compressor from vehicle.
REFRIGERANT OIL LEVEL CHECK
(4) From suction port on top of compressor, drain
When an air-conditioning system is first assembled
refrigerant oil from compressor.
at the factory, all of the components (except the com­
(5) A dd sy ste m c a p a c ity m in u s th e c a p a c ity o f com ­
pressor) are refrigerant oil free. After the system has
p o n e n ts that have not been replaced (see REFRIGER­
been charged with (R12) refrigerant and operated, the
ANT O IL C A PA C IT Y c h a rt), th ro u g h su c tio n p o rt on
oil in the compressor is dispersed through the lines
compressor.
and components. The evaporator, condenser, and filter-
(6) Install compressor, connect refrigerant lines, evac­
drier will retain a significant amount of oil. (See the
uate, and charge refrigerant system. See CHARGING
R E F R IG E R A N T O IL C A PA C IT IE S c h a rt). W hen a
R E F R IG E R A N T SY ST EM .
component is replaced, the specified amount of refrig­
 COMPONENT REMOVAL/INSTALLATION AND OVERHAUL
INDEX
Page Page
Air Distribution Duct ............................................... 33 Compressor High-Pressure Relief Valve ................... 59
Blower Motor and Wheel Assembly ........................ 37 Compressor Identification ......................................... 40
Blower Motor Wheel ................................................. 37 Compressor Main or Sub Control Valves—
Blower Resistor Block ............................................. 31 Variable Displacement Compressor—
Compressor Clutch/Coil Assembly— Model 6C17 ............................................................ 59
Fixed Displacement Compressor— Compressor Removal and Installation ..................... 41
Model C171/A590 ............................................... 42 Compressors—General Information ......................... 40
Compressor Clutch/Coil Assembly— Condensate Drain Tube ............................................. 40
Fixed Displacement Compressor— Condenser Assembly................................................... 36
Model 10PA17 .................................................... 46 Condenser Fan Control Switch—
Compressor Clutch/Coil Assembly— Variable Displacement Compressor System ........ 34
Variable Displacement Compressor— Defroster Ducts/Demister Ducts and Hoses ............ 33
Model 6C17 ......................................... ................ 44 Electronic Cycling Clutch Switch (ECCS) ............... 34
Compressor Front Shaft S< Evaporator Coil .......................................................... 37
Fixed Displacement Compressor— Expansion Valve ........................................................ 35
Model C171/A590 ............................................... 48 Filter-Drier Assembly ................................................. 36
Compressor Front Shaft Seal— Heater—A/C Unit Housing......................................... 37
Fixed Displacement Compressor— Heater A/C Unit Overhaul ......................................... 38
Model 10PA17 .................................................... 53 Heater Core ................................................................ 37
Compressor Front Shaft Seal— Heater Hoses .............................................................. 33
Variable Displacement Compressor— Low or Differential Pressure Cut-Off Switch ............ 35
Model 6 C 1 7 .......................................................... 57 Temperature Control Cable ............................. ........ 31
Compressor High Pressure Cut-Out Switch— Vacuum Actuator—Fresh/Recirc Door ................... . 32
Variable Displacement Compressor— Vacuum Actuators—Mode Doors ............................. 32
Model 6C17 .......................................................... 58 Water Control Valve ................................................... 34

TEMPERATURE CONTROL CABLE access hole and rotate the clip from the cable.
To install, reverse the preceding operation.
REMOVAL AND INSTALLATION To adjust temperature cable, position the TEMP
(1) Disconnect the attaching flag from heater A/C lever on the control to the cool side of its travel.
control. See SWITCH AND PANEL COMPONENT Allowing the self-adjusting clip to slide on the cable,
SERVICE in Group 8E, INSTRUMENT PANEL. Re­ rotate the blend-air door crank counterclockwise by
move cable from the control. hand until it stops.
(2) Locate and disconnect the attaching flag on the
heater A/C housing (Fig. 1). BLOWER RESISTOR BLOCK
(3) Slip cable self-adjusting clip downward from the
blend-air door crank. REMOVAL AND INSTALLATION
(4) Insert a 3/16 diameter tool (drill bit or phillips (1) Open hood.
screwdriver shank, Fig. 1-Inset) into the crank pin (2) Locate and remove the wire connector from the
blower resistor block. Block is located at the back of
the engine compartment on the passenger side of the
vehicle (Fig. 2).
(3) Remove resistor block attaching screws and pull
BLACK the resistor block from the vehicle.
SELF
ATTACHING
ADJUSTING
CABLE FU G CAUTION: The resistor block may be hot and could
CLIP
ASSEMBLY cause burns.
To install, reverse the preceding operation. The coils
on the Resistor Block should not be contacting one
another. Before installation, gently separate the coils
(with fingers only) if one coil is contacting another.
PUSH TAB HEATER A/C v
TO UNLOCK UNIT H O U S IN G ^ ( )
FLAG
RECEIVER RP162
FIREWALL FORWARD REMOVAL
(1) R em ove th e in s tr u m e n t p a n e l cover u n d e r th e
'■ steerin g colum n. See G roup 8E, M S T R U M E N T PA N E L
A N D G A U G ES.
H e a t/D e fro st A c tu a to r:
R em ove tw o screw s from b ra c k e t. L ift a c tu a to r u p ­
w a rd a n d p u ll o u t (Fig. 4).
M ode D oor A c tu a to r:
R em ove tw o screw s from b ra c k e t (Fig. 5). Rotate
CONDENSATE a c tu a to r cou nter-clock w ise to u n h o o k from door a n d
RH1145 DRAIN TUBE p u ll to rem ove.

Fig.I Resistor Block Removal or Installation INSTALLATION '

H e a t/D e fro st A c tu a to r; ..
VACUUM ACTUATOR— FRESH/RECIRC DOOR Install a c tu a to r lin k th ro u g h h o u sin g and insert in
h e a t d e fro st door slot.. P u s h dow n to hook lin k to door.
T h e V a c u u m A c tu a to r for th e Fresh/Recirc D oor is
L ocate th e b ra c k e t to th e h o u sin g a n d in s ta ll tw o
located on th e p a sse n g e r side of th e h eater/A C h ousing.
screw s.
M ode D oor A c tu a to r:
REMOVAL AND INSTALLATION
I n s e rt th e a c tu a to r s h a ft th ro u g h th e ho le in th e
(1) R em ove in s tr u m e n t p a n e l. See G roup 8E , IN ­
h o u sin g a n d h e a t/d e fro st door. A tta c h th ro u g h m o u n t­
ST R U M E N T P A N E L A N D G A U G ES.
in g hole in th e m ode door. In s ta ll tw o screw s in b rack et.
(2) D isco nn ect a c tu a to r lin k a g e from recirculation
I n s ta ll th e instrument panel cover under the s te e r­
door, a n d vacuum lin e s from a c tu a to r. Loosen tw o
in g column.
n u ts a tta c h in g a c tu a to r to h o u s in g a n d rem o v e a c tu a ­
to r (Fig. 3).
To in s ta ll, re v e rse th e p reced in g o p eratio n .

‘ACTUATOR LINKAGE
ACTUATOR

BLOWER
'MOTOR WIRING F lf. 4 Removing or InstallingHeat/Defrost
RH1137 Vacuum Actuator Assembly
f lf . 3 Removing or Installing
Fresh/Recirc Vaeuum Actm tor
VACUUM ACTUATORS— MODE DOORS
The Vacuum Actuators for the Mode Doors are lo­
cated on the drivers side of heater/AC housing above
the accelerator pedal.
 DEFROSTER DUCTS/DEMISTER DUCTS AND HOSES
REMOVAL AND INSTALLATION
(1) Instrument panel assembly must be removed.
Refer to Group 8E, INSTRUMENT PANEL AND
GAUGES.
(2) After instrument panel has been removed, sepa­
rate the defroster/demister ducts from the air distri­
bution duct.
(3) Remove the demister tubes and hoses (Fig. 7).

Fig.5 Mode Door Vacuum Actuators

AIR DISTRIBUTION DUCT
REMOVAL AND INSTALLATION
(1) Instrument panel assembly must be removed.
Refer to Group 8E, INSTRUMENT PANEL AND
GAUGES.
(2) After instrument panel has been removed, sepa­
rate the defroster/demister ducts from the air distri­
bution duct.
(3) Remove the air distribution duct-to-instrument Fig. 7 DefrosterDucts/Demister Ducts and Hoses
panel mounting screws (Fig. 6).
HEATER HOSES
^^--^JNSTRU M EN T PANEL—..____
REMOVAL AND INSTALLATION
Review Safety Precautions and Warnings the in
General Information section before proceeding with
this operation.
(1) Drain engine cooling system. See Group 7, Cool­
ing System.
(2) Loosen clamps at each end of hose to be removed
(Figs. 8 or 9).
(3) Carefully rotate hose back and forth while tug­
ging slightly away from connector nipple.
CAUTION: When removing hoses from heater core
inlet or outlet nipples, do not use excessive force.
Heater core may become damaged and leak engine
coolant into heater A/C unit.
 from water control valve (mark the heater hoses to
assure correct valve installation).
To install, reverse the preceding operation.

ELECTRONIC CYCLING CLUTCH SWITCH (ECCS)

REMOVAL AND INSTALLATION
(1) Disconnect the 4 pin connector at the ECCS.
(2) Remove the tie strap securing the capillary tube
splice to the suction line (Fig. 11).
(3) Remove two attaching screws securing the switch
to the refrigerant line manifold plate at the expansion
valve (Fig. 11).
(4) Separate the switch from the manifold plate and
slip the capillary tube from the well on the suction
line. The capillary-tube-well Is filled with a special
temperature conductive grease. Save this special
grease and re-use it when installing the switch.
To install, reverse the preceding operation.

Fig. 9 2.5L Engine Heater Hose Routing

WATER CONTROL VALVE Fig. 11 Remove or InstallElectronic
Cycling Clutch Switch
REMOVAL AND INSTALLATION
(1) Drain engine cooling system. See Group 7, Cool­ CONDENSER FAN CONTROL SW ITC H -
ing System. VARIABLE DISPLACEMENT COMPRESSOR SYSTEM
(2) Locate and loosen clamps at water control valve
(Fig. 10). The Fan Control Switch is located on the plumbing
(3) Disconnect the vacuum line and heater hoses discharge line at the A/C compressor (Fig. 12).

2.51 ENGINE CAUTION: Refrigerant discharge is not necessary

when removing the CONDENSER FAN CONTROL
SWITCH. However, a small amount of refrigerant will
vent from the switch port. Review the refrigerant
handling section of SAFETY PRECAUTIONS AND
WARNINGS in the GENERAL INFORMATION section
of this group.

REMOVAL AND INSTALLATION

(1) Disconnect wire connector from condenser fan
control switch (Fig. 12).
(2) Loosen and quickly rotate the switch counter­
clockwise and separate from the high pressure line
switch port.
 To install, reverse the preceding operation.
Fig. 12 Condenser Fan Control Switch
LOW OR DIFFERENTIAL PRESSURE
CUT-OFF SWITCH
REMOVAL AND INSTALLATION
WARNING: THE REFRIGERATION SYSTEM MUST BE
COMPLETELY DISCHARGED BEFORE PROCEEDING
WITH THIS OPERATION. SEE DISCHARGING REFRIG­
ERATION SYSTEM IN THIS GROUP.
(1) Disconnect the boot like wire connector at the
cut-off switch.
(2) Using a sender unit type socket, remove the
switch from the expansion valve (Fig. 13 or 14).
EXPANSION
Fig. 13 Low Pressure Cut-OffSwitch and
Expansion Valve— Typical
EXPANS ION VALVE DIFFERENTIAL PRESSURE
Fig. 14 DifferentialPressure Cut-Off
Switch and Expansion Valve— Typical
To install, assure an adequate seal by using a small
amount of thread sealing tape on the replacement
switch and reverse the preceding steps.
Evacuate and charge the system. See CHARGING
REFRIGERANT SYSTEM in the REFRIGERANT
section.
EXPANSION VALVE
rem o val
WARNING: THE REFRIGERATION SYSTEM MUSI BE
COMPLETELY DISCHARGED BEFORE PROCEEDING
WITH THIS OPERATION. SEE DISCHARGING REFRIG­
ERATION SYSTEM IN THIS GROUP.
(1) Remove th e boo t-typ e w ire co nn ecto r from th e
p re s s u re cu t-o ff sw itch.
(2) R em ove th e a tta c h in g bolt' in c e n te r o f re frig e r­
a n t lin e -p lu m b in g s e a lin g p la te (F ig .'15).
(3) C a re fu lly p u ll th e re f rig e r a n t lin e -se a lin g p la te
assem b ly from th e e x p a n sio n v a lv e to w a rd s fro n t of
v ehicle (DO N O T sc ra tc h th e e x p a n sio n v alv e se a lin g
su rfa c e s w ith p ilo t tu b es).
(4) C over th e op en in g s on re frig e ra tio n lin e -se a lin g
p la te a ssem b ly to p re v e n t d ir t or m o istu re' c o n ta m in ­
atio n . . . t
 Fig. 15 Expansion Valve
(5) Remove two screws securing the expansion valve
to the evaporator sealing plate.
(6) Carefully remove valve.
INSTALLATION
(1) Remove and replace the aluminum gasket (Fig.
15) on the evaporator sealing plate.
(2) Carefully hold the expansion valve to the evapo­
rator sealing plate (do not scratch sealing surface).
Install two attaching screws and tighten to 11 ± 3 N-m
(100 ± 30 inch lbs.).
(3) Remove and replace the aluminum gasket (Fig.
15) on the refrigerant line-sealing plate assembly.
(4) Carefully hold the refrigerant line-sealing plate
assembly to the expansion valve, install bolt and
tighten to 23 ± 3 N-m (200 ± 30 inch lbs.).
(5) Connect wires to low pressure cut-off switch.
(6) Evacuate and recharge system. See CHARGING
REFRIGERANT SYSTEM in the REFRIGERANT
section.
(7) After expansion valve is installed, system is
charged, and leaks have been checked, repeat A/C
performance check.
FILTER-DRIER ASSEMBLY
REMOVAL AND INSTALLATION
WARNING: THE REFRIGERATION SYSTEM MUST BE
COMPLETELY DISCHARGED BEFORE PROCEEDING
WITH THIS OPERATION. SEE DISCHARGING REFRIG­
ERATION SYSTEM IN THIS GROUP.
(1) Remove the vehicle jack.
(2) Remove the two high pressure refrigerant lines
from the sides of the filter-drier assembly (Fig. 16),
and carefully separate lines from filter-drier. Discard
old gaskets.
(3) Cover the open ends of the refrigerant lines to
minimize refrigerant system contamination.
Fig. 16 Filter-Drier— Typical
(4) Remove two mounting strap bolts and lift the
filter-drier from vehicle. If replacing the filter-drier
assembly, transfer the mounting strap to replacement
part.
To install, replace both refrigerant line-to-filter-
drier gaskets, and reverse the preceding operation.
Evacuate and recharge system. See CHARGING RE­
FRIGERANT SYSTEM in the REFRIGERANT section.
CONDENSER ASSEMBLY
WARNING: THE REFRIGERATION SYSTEM MUST BE
COMPLETELY DISCHARGED BEFORE PROCEEDING
WITH THIS OPERATION. SEE DISCHARGING REFRIG­
ERATION SYSTEM IN THIS GROUP.
REMOVAL AND INSTALLATION
(1) Remove grill assembly. See Group 23, BODY.
(2) Remove refrigerant line attaching nut (Fig. 17)
and separate refrigerant line assembly from condenser
sealing plate.
(3) Cover the open ends of the refrigerant lines and
condenser to minimize refrigeration system contam­
ination.
(4) Remove bolts (Fig. 17) securing the condenser
assembly to the radiator core support, and lift the
condenser assembly from vehicle.
To install, replace all O-rings and gaskets, coat all
sealing surfaces with approved wax-free refrigerant
oil and reverse the preceding operation. When install­
ing NEW condenser, refer to OIL LEVEL in the RE­
FRIGERANT section.
 Evacuate and recharge system. See CHARGING RE­
FRIGERATION SYSTEM in this group.
REFRIGERANT CONDENSER
CONDENSER GASKET 9124-62
Fig. 17 A/C Condenser Removal and Installation-
Typical
BLOWER MOTOR AND WHEEL ASSEMBLY
REMOVAL AND INSTALLATION
(1) To remove the blower motor, the lower right
instrument panel assembly must be removed. Refer to
Group 8E, INSTRUMENT PANEL AND GAUGES.
(2) Remove blower assembly-to-heater housing
mounting screws.
(3) Allow the blower assembly to drop down, and
remove assembly from vehicle.
To install, reverse the preceding operation.
BLOWER MOTOR WHEEL
REMOVAL AND INSTALLATION
(1) Blower motor must be removed from vehicle
before performing this operation. See BLOWER MO­
TOR AND WHEEL ASSEMBLY—REMOVAL AND
INSTALLATION.
(1) Remove the spring type retaining ring from the FRIGERANT section.
center of the blower wheel (Fig. 18). Note the location
of the blower wheel on the blower motor shaft.
PR458
Fig. 18 Blower Wheel Retaining Ring
Removal and Installation
(2) Remove blower wheel from blower motor shaft.
To install, reverse the preceding operation. To pre­
vent noise or vibration, rotate the blower wheel by
hand to check for rubbing.
HEATER CORE
REMOVAL AND INSTALLATION
See HEATER A/C UNIT OVERHAUL in this Group.
EVAPORATOR COIL
REMOVAL AND INSTALLATION
See HEATER A/C UNIT OVERHAUL in this Group.
HEATER-A/C UNIT HOUSING
REMOVAL AND INSTALLATION
WARNING: IF EQUIPPED WITH AIR CONDITIONING,
THE REFRIGERATION SYSTEM MUST BE COM­
PLETELY DISCHARGED BEFORE PROCEEDING WITH
THIS OPERATION. SEE DISCHARGING REFRIGERA­
TION SYSTEM IN THIS GROUP.
(1) Set parking brake.
(2) Disconnect negative battery cable.
(3) Discharge refrigerant system. Refer to DIS­
CHARGING REFRIGERANT SYSTEM in the RE­
(4) Disconnect all engine compartment lines and
vacuum hoses.
(5) Drain engine coolant. Plug coolant lines.
(6) Remove the steering column cover.
(7) Remove the left underpanel silencer.
(8) Remove the right underpanel silencer.
(9) Remove the center bezel (clips to instrument
panel).
 (10) Remove th e accessory sw itc h c a rrie r. (4) R em ove screw from h e a te r core tu b e r e ta in in g
(11) R em ove H eat-A /C co ntrols. S ee th e SW IT C H b ra c k e t a n d lift h e a te r core o u t o f u n it (Fig. 20).
A N D P A N E L C O M P O N E N T S E R V IC E se c tio n of
G roup 8E , IN S T R U M E N T P A N E L A N D G A U G E S. HEATER CORE
(12) Remove s ta n d a rd sto ra g e m odule. ASSEMBLY
(13) R em ove th e r ig h t lo w er in s tru m e n t p a n e l.
(14) R em ove th e r ig h t 40-w ay w irin g b ra c k e t.
(15) R em ove th e low er r ig h t re in fo rc e m e n t, body
co m p u te r b ra c k e t, a n d mid-to-lower re in fo rc e m e n t a s
one assem b ly.
(18) D isco n n ect a ll n e c e ssa ry in s tr u m e n t p a n e l w ir­
in g a n d te m p o ra rily ro u te w irin g o u t o f th e w ay.
■ (17) D iscon nect th e A/C u n it h a n g e r s tr a p from th e
u n it a n d te m p o ra rily re-p o sitio n .
(18) R em ove th e ru b b e r c o n d e n sa te d ra in tu b e (in
e n g in e c o m p a rtm e n t).
■ (IS) R em ove th e fo u r n u ts (in th e e n g in e c o m p a rt­
m e n t) se c u rin g th e u n it to th e d a s h p a n e l.
(20) P u ll th e e n tir e u n it re a rw a rd u n til th e s tu d s on
th e u n it c le a r th e d a s h p a n e l. D rop th e u n it dow n a n d
p u ll it r e a rw a rd to rem o v e i t from v ehicle,
To in s ta ll th e a ssem b ly , re v e rse th e p re c e d in g o p er­
a tio n . R efer to C H A R G IN G R E F R IG E R A N T SY STE M
in th e R E F R IG E R A N T section. RH1135

HEATER A/C UNIT OVERHAUL F lf. 2# Hemming or Installing Heater C o re Assembly

(5) R em ove A/C e v a p o ra to r coil o u t of u n it (Fig. 21).

H eater-A /C H o u sin g m u s t be rem o v ed from veh icle
b efore p e rfo rm in g th is o p e ra tio n . S ee H E A T E R -A /C
U N IT H O U SIN G —REM O V A L A N D IN STA LLA TIO N .
DISASSEMBLY
(1) P la c e h e a te r/A /C u n it asse m b ly (Fig. 19) on
w orkbench.
(2) R em ove one screw re ta in in g th e v a c u u m h a r ­
n ess. F eed h a rn e s s th ro u g h h ole in cover.
(3) R em ove th ir te e n screw s from to p cover a n d r e ­
m ove cover. T e m p e ra tu re c o n tro l door w ill com e o u t
w ith th e cover. R em ove th e n u t a n d le v e r from th e
door s h a ft to rem o v e th e te m p e ra tu re door from th e
cover.

CHECK VALVE ACTUATOR ASSEMBLY

RH1136

A ii DISTRIBUTION DUCT BLOWER MOTOR RH1134

 ASSEMBLY
(1) P lace e v a p o ra to r coil in to u n it.
(2) P lace h e a te r core in to u n it a n d fa ste n w ith screw s.
(3) R e in s ta ll blow er w h eel on to b lo w er m o to r s h a ft
a n d secu re w ith r e ta in in g clam p.
(4) F eed blow er m o to r w ire s th ro u g h h ole in h o u s­
ing. L ow er b low er a sse m b ly (ru b b e r se a l in place) in to
h o u sin g . P u ll w irin g g ro m m e t in to place a n d in s ta ll
th re e m o u n tin g screw s.
(5) I n s ta ll blow er m o to r a sse m b ly (five screw s) to
h ou sin g .
(6) I n s ta ll fre s h /re c irc u la tin g door in to h o u sin g . In ­
s ta ll fre sh /re c irc u la tin g cover (four screw s). R o ta te ac­
tu a to r s h a ft in to door a n d slide a c tu a to r in to b ra c k e t
a n d tig h te n tw o n u ts.

Fig. 22 Remowing or Installing FreahlReclrc

Vacuum Actuator and Linkage

(8) D iscon nect a c tu a to r lin k a g e from fresh/recircu­

lation door a n d v a c u u m lin e s from a c tu a to r. L oosen
tw o n u ts a tta c h in g a c tu a to r to h o u sin g a n d rem ove
a c tu a to r (Fig. 22).
(7) Remove fo u r screw s a tta c h in g fresh/recirculation
cover to u n it a n d lift off cover.
(8) F re sh /re c irc u la tin g door m a y now be rem oved
from its h o u sin g .
(9) To rem ov e h e a t d efro st door, rem ov e re ta in in g
clip from s h a ft in sid e th e h o u sin g . P u ll s h a ft from
h o u sin g a n d rem o v e door.
(10) To rem o ve m ode door, rem ov e r e ta in in g clip RH1141
from s h a ft in sid e th e h o u sin g . P u ll th e s h a ft from th e
h o u sin g a n d rem o v e door. f lf . 24 Removing or Installing Mode Door Shaft

(7). To in s ta ll m ode door to h o u sin g , in s e r t door

HEATER CORE EVAPORATOR sh a ft th ro u g h h o u sin g a n d door p ivo t. P u s h on sh a ft
r e ta in e r (Fig. 24).
(8) To in s ta ll demister door, co n n ect w ire rod to
m ode door. I n s e r t p iv o t e n d o f door in to h ole in h o u s­
ing. P o sitio n opposite in to slot.
(9) To in s ta ll h e a t/d e fro st door, in s e r t door sh a ft
th ro u g h h o u sin g a n d door pivot. P u s h on s h a ft re ta in e r.
(10) I n s ta ll h e a t d is trib u tio n d u c t to b o tto m o f h o u s­
in g w ith th r e e screw s.
BLOWER MOTOR WIRING-^ RH1140 (11) To in s ta ll te m p e ra tu re co n tro l door, in s ta ll door
shaft- in to low er p iv o t in th e case h o u sin g . P la c e u n it
cover over h o u sin g w h ile feed in g te m p e ra tu re door
s h a ft th ro u g h cover. I f th e te m p e ra tu re co n tro l door is
a tta c h e d to th e cover, feed th e door in to th e h o u sin g
w ith th e cover. D ire c t the b o tto m p iv o t o f th e door
w ith y o u r h a n d th ro u g h th e m ode door open in g.
 (12) To in s ta ll h o u sin g cover, lin e u p cover to h o u s­
in g u sin g p ilo t p in s, th e te m p e ra tu re door, a n d screw
h oles for alignment. I n s ta ll th ir te e n screw s.
(13) R o u te v a c u u m h a rtie s s th ro u g h h o les in cover.
In s ta ll screw to r e ta in v a c u u m h a rn e ss . M ak e a ll v ac­
u u m hose attachments to vacuum actuators.
CONDENSATE DRAIN TU&E
7.25 fl. oz.) of re f r ig e ra n t oil. W h e n re p la c in g a com ­
p resso r, d ra in old re f rig e r a n t oil, m e a s u re th e a m o u n t
a n d d isc a rd old oil. F o r th e re p la c e m e n t co m pressor
u se th e sa m e a m o u n t o f r e f r ig e r a n t oil a s recovered
from fa ile d com pressor. F o r f u r th e r d e ta ils , see O IL
L E ¥ E L in th e R E F R IG E R A N T sectio n . T h is adjust-
ment is n o t n eed ed if th e sy ste m h a s b e e n flu sh ed ,
removing re ta in e d oil.

REMOVAL AND INSTALLATION COMPRESSOR IDENTIFICATION

(1) R aise vehicle.
(2) L ocate r u b b e r D ra in T ub e on r ig h t sid e o f d a sh The terms FIXED DISPLACEMENT COMPRES­
p a n e l (Pig. 25), ■ SOR and VARIABLE DISPLACEMENT COMPRES­
SOR will be used to describe the two types of A/C
systems used throughout this group. Refer to (Figs. 1,
2, and 3).
The VARIABLE DISPLACEMENT COMPRESSOR
can be identified by the location of the high pressure
line mounted to the end of the compressor case (Fig.
3).
REFRIGERANT

Fig. 25 Condensate Water Drain Tube—typical

(3) S queeze clam p a n d rem ov e d ra in tu b e .

To in s ta ll, re v e rse th e p reced in g o p e ra tio n . C h eck
th e d ra in tu b e n ip p le on th e h eater-A /C h o u sin g (Fig.
25) for a n y o b stru c tio n s.

COMPRESSORS— GENERAL INFORMATION

CAUTION: Cleanliness is extremely important when

disassembly of the compressor is necessary. The
surfaces aroyrti the suction and discharge ports of
the compressor Should be cleaned thoroughly be­
fore opening the system at these points. If compres­ Fig. 1Fixed Displacement Compressor—
sor is retrtowed frowt' vehicle, apply tape to the opened Model C171IA590
ports to prewent any contamination.
F a c to ry in s ta lle d com presso rs c o n ta in .207 to 214 m l
(7 to 7.25 fl. oz.) of a special w ax -free (500 SU S)
viscosity re frig e ra n t oil. W h ile th e a ir co n d itio n in g
sy stem is in o p e ra tio n , th e oil is c a rrie d th ro u g h th e
e n tire sy ste m a n d r e tu r n s to th e .c o m p re sso r by w ay of
th e su ctio n p o rt. Som e of th is oil w ill m ove from th e
com pressor and be re ta in e d in v a rio u s p a r ts o f th e
system . C o n seq u en tly , once th e sy ste m h a s b e e n in
o p eratio n , th e a m o u n t of oil le ft in th e com p ressor w ill
alw ay s be less th a n the. o rig in a l a m o u n t. R e p la c e m e n t
com pressors a re also c h a rg e d w ith 207 to 214 m l ( 7 to
 WARNING: Refrigerant pressures remain high even
though the engine may be turned off. Before remov­
ing a fully charged compressor, review the SAFETY
PRECAUTIONS AND WARNINGS section in this group.
Do not twist or kink the refrigerant lines when re­
moving a fully charged compressor. Safety glasses
must be worn.
If the A/C compressor refrigerant lines will be re­
moved for compressor removal, refer to DISCHARG­
ING REFRIGERANT SYSTEM in the REFRIGERANT
section before proceeding with the following steps.
(1) Disconnect NEGATIVE battery cable.
(2) Loosen and remove drive belts (refer to Group 7,
COOLING SYSTEM) and disconnect compressor clutch
wire lead.
(3) Remove refrigerant lines from compressor (if
necessary).
(4) Remove compressor attaching nuts and bolts (Fig.
4, 5 or 6).
SUCTIO N DJS>CHARGE (5) Remove compressor. If refrigerant lines were not
PORT 9124-11 removed, lift compressor/clutch assembly and tie it to
a suitable component.
Fig.2 Fixed Displacement Compressor- To install, reverse the preceding operation. If neces­
Model 10PA17 sary, refer to CHARGING REFRIGERANT SYSTEM
in the REFRIGERANT SECTION.

COMPRESSOR REMOVAL AND INSTALLATION

The A/C compressor may be removed and posi­
tioned without discharging the refrigerant system. Dis­
charging is not necessary if removing the A/C com­
pressor clutch/coil assembly, engine, cylinder head, or
alternator.
 (2) Screw c lu tc h F R O N T P L A T E P U L L E R (0^4771)
in to h u b . T ig h te n c e n te r screw a n d rem o v e fro n t p la te
a n d sh im s (Fig. 8).
CAUTION: Do not use screwdrivers between the front
piate assembly and pulley to rentowe front plat© as
this may damage the front plate assembly.
(3) Remove p u lle y r e ta in in g sn a p rin g w ith SN A P
R IN G P L IE R S (C-4574), a n d slid e p u lle y a ssem b ly off
of com p resso r (Fig. 9).
(4) R em ove sn a p r in g r e ta in in g field coil o nto com ­
p re sso r h o u sin g . A fte r rem o v in g screw a n d w ire clip,
slide field coil off o f h o u sin g (Fig. 10)i
(5) E x a m in e fric tio n a l faces of th e c lu tc h p u lle y a n d
fro n t p la te for w ear. T h e p u lle y a n d fro n t p la te sh o uld
be rep la c e d if th e r e is ex cessive w e a r or scoring. I f th e
fric tio n su rfa c e s a re oily, in sp e c t th e sh a ft nose a re a
o f th e co m p resso r for oil a n d rem o v e t i e fe lt from th e
front cover. If the compressor felt is saturated with
oil, the shaft seal is leaking and will have to be
replaced.
(6) Check bearing for roughness or excessive leak­
Fig.5 A/C Compressor Removal and age or grease. If grease from bearing has contami­
Installation— 3.3L Engines nated the faces of the pulley or front plate or if the
bearing is rough, the clutch pulley and front plate
sh o u ld be replaced . " •.
CAUTION; The clutch pulley and the front plate were
mated at the factory by'a burnishing operation. No
attempt sftoyid be made to separately replace either
part. This n i l result in clutch slippage due to insuffi­
cient contact area.

Fig. 6 A/C Compressor Removal and

Installation— 3.0L Engine
COMPRESSOR CLUTCH/COIL ASSEMBLY—
FIXED DISPLACEMENT COMPRESSOR-
MODEL C171/A590

REMOVAL
C om p ressor a sse m b ly m u s t be rem o v ed from m o u n t­
ing. A lth o u g h , re f r ig e r a n t d isc h a rg e is n o t n ecessary .
R efer to C O M PR E SSO R REM O V A L A N D IN S T A L ­
LA TIO N .
(1) U sin g a 13 m m so cket a n d S P A N N E R W R E N C H
(C-4563), rem ove th e s h a ft n u t a n d lock w a s h e r (Fig.
7).
F lf. 8 Removing Clutch Front Plate F lf. l i Remowing Clutch Coil

INSTALLATION . ‘ *
(1) A lig n ho le in b a c k of field coil w ith p in in com­
pressor e n d h o u sin g a n d ’p o sitio n field coil in to p lace
(Fig. 11). M ake su re th a t le a d w ires' a re pro perly routed,
a n d fa ste n w ith th e 'w ir e clip r e ta in in g screw .
(2) In s ta ll field coil re ta in in g snap ring (bevel side
o u tw a rd a n d b o th e y e le ts to th e r ig h t or left of th e pih
on th e com pressor) w ith S N A P R IN G F L IE R S (0-4874).
P re ss sn a p r in g to m a k e s u re it is p ro p e rly s e a te d in
the''groove.
CAUTION: If snap ring-Is''not fully seated It will vi­
brate out, resulting in a clutch failure and severe
damage to the front face of the compressor.
(3) In s ta ll p u lle y a sse m b ly o nto com pressor. I f nec­
essa ry , ta p g e n tly w ith a block'of wood on th e frictio n
su rface (Fig. 12).
CAUTION: Do not mar the pulley frictional surface.
(4) In s ta ll p u lle y assem b ly re ta in in g sn a p rin g (bevel
PU153 side o u tw a rd ) w ith S N A P R IN G P L IE R S (C-4574).
P re s s th e sn a p rin g to m a k e su re i t is p ro p e rly s e a te d
in th e groove.
(5) If th e o rig in a l fro n t p la te asse m b ly a n d p u lle y
a ssem b ly a re to be re u se d , th e old sh im s ca n b e used.
I f n o t, p lace a tr ia l s ta c k o f sh im s, 2.54 m m (0.10 in.)
th ic k , on th e s h a ft a g a in s t th e sh o u ld e r.
(6) In s ta ll fro n t p la te asse m b ly o nto s h a ft m a k in g
su re th e k ey e n te rs k e y w ay in fro n t p la te a ssem b ly
hu b.
 (7) With the front plate assembly tight against the
shims, measure the air gap between front plate and
pulley face with feeler gauges (Fig. 13). The air gap
should be between 0.5 and 0.9 mm (.020 and .035
inch). If proper air gap is not obtained, add or subtract
shims until desired air gap is obtained.
(8) Install lock washer and shaft nut. Tighten to
17.5 ± 2 N’m (155 ± 20 in. lbs.) using torque wrench and
SPANNER WRENCH TOOL (C-4563).
Shims may compress after tightening shaft nut.
Check air gap in four or more places to verify if air
gap is still correct. Spin pulley for final check.

CLUTCH BREAK-IN
After a new clutch has been installed, and the volt­
age and amperage are determined to be satisfactory,
cycle the A/C clutch approximately 20 times (5 sec. on
and 5 sec. off)- For this procedure, set the system to
the A/C mode, using high blower, and engine rpm at
1500-2000. This procedure (burnishing) will seat the
opposing friction surfaces and provide a higher clutch
torque capability.

Fig. 11 InstallingClutch Coil

Fig. 13 Measuring AirGap
COMPRESSOR CLUTCH/COIL ASSEMBLY-
VARIABLE DISPLACEMENT COMPRESSOR-
MODEL 6C17
REMOVAL AND INSTALLATION
Compressor assembly must be removed from mount­
ing. Although, refrigerant discharge is not necessary.
Refer to COMPRESSOR REMOVAL AND INSTAL­
LATION.

3.0 L ENGINE
Remove the front lower splash shield and front en­
gine mount through-bolt. Allow the engine to swing
down to provide access to the front of the compressor.
3.3 L ENGINE
Remove the coolant recovery bottle to provide ac­
CLUTCH PLATE AIR A/C COMPRESSOR
cess the front of the compressor. SPACER SHIMS CLUTCH PULLEY
(1) Remove clutch retaining center nut by using
CLUTCH PLATE HOLDER (6355) (Fig. 14).
(2) Using a CLUTCH PLATE REMOVER (6354),
remove the clutch front plate from the compressor
(Fig. 15). When installing the front plate, select the
proper shims to achieve .5 to .9 mm (.020 to .035 inch)
air gap to the pulley surface (Fig. 16). To install front
plate, align shaft key to groove in front plate hub.
Push on until it seats, and measure the air gap (Fig.
17).

8924-14
A/C COMPRESSOR CLUTCH PLATE
CLUTCH PLATE HOLDER (6355) Fig. 16 InstallFrontPlateand Shims

,9MM (.035 IN)

FEELER GAUGE'
COMPRESSOR CLUTCH
FRONT PLATE

COMPRESSOR
ASSEMBLY
8V24-21

Fig. 14 Remove or InstallFront Plate Retaining Nut AIR GAP

DRIVE
PULLEY 8924-11
^ CLUTCH PLATE
, REMOVER (6354)
Fig. 17 Measure FrontPlateAirGap

A/C COMPRESSOR
CLUTCH PLATE

Fig. 15 Remove FrontPlate

(3) Remove clutch pulley retaining snap ring (Fig 8924-15
18) and pull the pulley from the assembly (Fig. 19).
(4) Remove the clutch coil wire lead strap screw.
 (5) R em ove c lu tc h coil re ta in in g sn a p rin g (Fig. 20) COMPRESSOR CLUTCH/COIL ASSEMBLY—
a n d p u ll th e coil from th e assem b ly (Fig. 21). 'W hen FIXED DISPLACEMENT COMPRESSOR-
in s ta llin g th e c lu tc h coil, a lig n th e p in on th e fro n t of MODEL 10PA17
the compressor to the middle hole in the hub of the
coil. P o sitio n th e p in in th e sn a p rin g gap. REMOVAL
To in s ta ll, re v e rse th e p re c e d in g o p e ra tio n . Compressor assembly must be removed from mount­
ing. Although, refrigerant discharge is not necessary.
Refer to COMPRESSOR REMOVAL AND INSTAL­
LATION.
(1) Remove the compressor shaft bolt (Fig. 1). A
band type oil filter removal tool can be placed around
the clutch plate to aid in bolt removal.

flf. 19 Fiemme or Install Pulley

Fig. 1 Compressor Shaft Bolt and Clutch Plate

(2) Tap the clutch plate with a plastic hammer and

remove clutch plate and shim (Fig. 2).

Fig. 20 Fiemme or Install Clutch Coil Snap Ring

CAUTION: Do not use screwdrivers between the clutch
plate assembly and pulley to remove front plate as pressor housing (Fig. 4). Slide field coil off of compres­
this may damage the front plate assembly.
(3) Remove pulley retaining snap ring with SNAP
RING PLIERS (C-4574), and slide pulley assembly off
of compressor (Fig. 3).
PU153
Fig. 3 Removing Pulley Snap Ring
(4) Remove coil wire clip screw and wire harness
(Fig. 1).
(5) Remove snap ring retaining field coil onto com­
sor housing.
(6) Examine frictional faces of the clutch pulley and
front plate for wear. The pulley and front plate should
be replaced if there is excessive wear or scoring. If the
friction surfaces are oily, inspect the shaft nose area
of the compressor for oil and remove the felt from the
front cover. If the compressor felt is saturated with
oil, the shaft seal is leaking and will have to be
replaced.
(7) Check bearing for roughness, excessive leakage
or grease. If grease from bearing has contaminated
the faces of the pulley or front plate, or if the bearing
is rough, the clutch pulley and front plate should be
replaced.
CAUTION: The clutch pulley and the front plate were
mated at the factory by a burnishing operation. No
attempt should be made to separately replace either
part. This will result in clutch slippage due to insuffi­
cient contact area.
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 with the wire clip retaining screw (Fig. 1).
(2) Install field coil retaining snap ring (bevel side
outward and both eyelets to the right or left of the pin
on the compressor) with SNAP RING PLIERS (C-4574)
(Fig. 4). Press snap ring to make sure it is properly
seated in the groove.
CAUTION: If snap ring is not fully seated it will vi­
brate out, resulting in a clutch failure and severe
damage to the front face of the compressor.
(3) Install pulley assembly to compressor. If neces­
sary, tap gently with a block of wood on the friction
surface (Fig. 5).
CAUTION: Do not mar the pulley frictional surface.
 (8) Install compressor shaft bolt. Tighten to 17.5 ±2
N-m (155 ±20 in. lbs.).
Shims may compress after tightening shaft nut.
Check air gap in four or more places to werify If air
gap is still correct Spin pulley for final check. .

CLUTCH BREAK-IN
After a new clutch has been installed, and the volt­
age and amperage are determined to be satisfactory,
cycle the A/C clutch approximately 20 times (5 sec. on
and 5 sec. off). For this procedure, set the system to
the A/C mode, using high blower, and engine rpm at
1500-2000. This procedure (burnishing) will seat the
opposing friction surfaces and provide a higher clutch
torque capability.

COMPRESSOR -FRONT SHIFT SEAL—

FIXED DISPLACEMENT COMPRESSOR
MODEL C171/A590

REMOVAL . ■ ■
(1) Discharge the refrigerant system. See DIS­
Fig. 5 installing Pulley Assembly ■ CHARGING REFRIGERANT SYSTEM in th e RE­
FRIGERANT section.
(4) In sta ll p u lle y a ssem b ly re ta in in g sn a p rin g (bevel (2 ) Remove A/C compressor. See COMPRESSOR RE­
side o u tw a rd ) w ith S N A P R IN G P L IE R S (€- 4574 ). MOVAL AND INSTALLATION.
P re ss th e sn a p rin g to m a k e s u re it is p ro p e rly se a te d (3) Remove compressor clutch/coil assembly. See
in th e groove. COMPRESSOR CLUTCH/COIL ASSEMBLY RE­
(5) I f th e o rig in a l fro n t p la te a sse m b ly a n d p u lle y MOVAL AND INSTALLATION.
assem b ly a re to b e re u se d , th e old shim(s) c a n be used. (4) Remove key from crankshaft of compressor (Fig.
If n o t, place a tr ia l sta c k o f sh im s, 2.54 m m (0.10 in.) 7).
th ic k , on th e s h a ft a g a in s t th e sh o u ld er. (5) Remove six compressor through-bolts (Fig. 8).
(6) In s ta ll fro n t p la te assem b ly onto sh a ft.
(7) W ith th e fro n t p la te a ssem b ly tig h t a g a in s t th e
shim(s), m e a su re th e a ir g a p b e tw e e n fro n t p la te a n d
p u lle y face w ith fe e le r g a u g e s (Fig. 6). T h e a ir g ap
sh ou ld be b etw een §.5 a n d §.9 m m (.020 a n d .035
inch) I f p ro p e r a ir g a p is n o t o b ta in e d , a d d o r s u b tra c t
sh im s u n til d e sire d a ir g a p is o b tain ed .
 Fig. 8 Removing Compressor Through-Bolts Fig. 10 Removing O-Ring

(6) Remove front cover by tapping on the outside

diameter of the cover with a plastic hammer (Fig. 9).

RB307A

Fig. 11 Removing Felt

RB305
(8) Remove felt from front cover (Fig. 11).
Fig. 9 Removing Front Cover (9) Place compressor front cover on a flat surface
with neck of cover facing up. Using a brass drift, press
(7) Remove O-ring seal from front cover and discard out gas seal plate (Fig. 12).
(Fig. 10).
Never reuse cover O-rings or the steel valve plate
gaskets.
 Fig. 12 Removing Gas Seal Plate
(10) Remove shaft seal cartridge from crankshaft
(Fig. 13).
(11) Remove dowel pins, valve plate, suction reed
valve, and steel valve plate gasket. Discard steel gas­
ket (Fig. 14).
(12) Remove rear cover by tapping the outside di­
ameter of the cover with a plastic hammer (Fig. 15).
Fig. 14 Disassembling Compressor Front End
(13) Remove O-ring from rear cover and discard
(Fig. 16).
(14) Remove the dowel pins, valve plate, suction
reed valve, and steel valve plate gasket. Discard steel
gasket (Fig. 17).
 REAR "O" RING

REAR COVER

COMPRESSOR
BODY

RB312 BODY LUGS

RB314

f l f . 16 Removing Rear O-RIng f l f . 18 Separating Body Halves

REAR COVER

DOWEL PINS
REAR
STEEL-N-GASKET VALVE PLATE

REAR "O" FRONT

RB313 BODY HALF R|NG BODY HALF RB315

Fig. 17 Disassembling Compressor Rear End F lf. 19 Compressor Body Half Separation .

REPLACING CENTER O-RING 01 COMPRESSOR BODY INSTALLATION

(15) C a re fu lly s e p a ra te fro n t a n d r e a r com pressor
h o u sin g s by ta p p in g th e body lu g s w ith a p la stic h a m ­
m e r (Fig. 18).Do not separate front and rear hous­
ings more than one inch (Fig. 19).
(18) R em ove O -rin g (Fig. 19) a n d discard.
(17) In sp e c t O -rin g se a lin g su rfa c e for sc ra tc h e s,
d irt, or p orosity. I f a sc ra tc h or p o ro sity is found,
com pressor sh o u ld be rep laced .
(1) In s ta ll O -rin g by c a re fu lly s tre tc h in g a n d p a ss­
in g a new , d ry O -rin g over th e r e a r h o u sin g to c e n te r
of co m presso r body.
(2) O il new O -rin g w ith re f r ig e r a n t oil (500 SUS)
a n d p o sitio n in to se a l groove.
(3) M a te tw o body h a lv e s by c a re fu lly p u sh in g th e m
to g e th e r m a k in g su re O -rin g a n d h o u sin g s a re p ro p ­
e rly positio ned .
 (4) In s ta ll dow el p in s in r e a r com pressor body.
(5) In s ta ll su c tio n re e d valv e.
(8) In s ta ll r e a r v a lv e p la te assem bly,
(7) I n s ta ll ste e l v a lv e p la te g a sk e t.
(8) A pply lig h t c o a tin g of re frig e ra tio n oil to n ew
O -ring a n d c a re fu lly place in to se a lin g groove of r e a r
cover.
(9) In s ta ll r e a r cover to r e a r co m pression h o u sin g .
(10) H old fro n t com pressor body a n d r e a r cover firm ly
to g e th e r. P o sitio n co m presso r a ssem b ly on r e a r cover
w ith c ra n k s h a ft facin g u p w ard .
(11) In s ta ll dow el p in s in fro n t com pressor body.
(12) In s ta ll su c tio n re e d v alve.
(13) Install front valve plate assembly.
(14) In s ta ll ste e l g a sk e t.
(15) C le a n c ra n k s h a ft a n d co at lig h tly w ith re frig e r­
a n t oil.
(16) L ig h tly lu b ric a te c ra n k s h a ft g a s se a l c a rtrid g e
w ith re frig e ra tio n oil a n d in s ta ll on c ra n k s h a ft. C a r­
trid g e m u st be prop erly positioned on slot of c ra n k sh a ft.
(17) L u b ric a te c ra n k s h a ft se a l s e a t ca v ity o f fro n t
h o u sin g w ith re frig e ra tio n oil.
(18) L u b ric a te c ra n k s h a ft se a l s e a t a n d se a l s e a t
O -ring w ith re frig e ra tio n oil. In s ta ll O -rin g on seal
se a t a n d in s ta ll seal se a t in fro n t cover u sin g a socket
th a t co n ta c ts th e o u te r d ia m e te r o f th e se a l s e a t p la te
(Figs. 20 a n d 21).
(19) L u b ric a te fro n t cover O -rin g w ith re frig e ra tio n
oil a n d c arefu lly place it in se a l groove o f fro n t ho using .
(20) I n s ta ll fro n t cover to fro n t co m presso r body. I f
cover does n o t v is u a lly a lig n w ith dow el p in s on in ­
sta lla tio n , completely remove cover and make certain
the carbon seal of the crankshaft seal cartridge is
properly positioned in the seal cartridge and not stick­
ing to the seal seat plate.
(21) Install six compressor through-bolts and finger
tighten only. After bolts have been finger tightened,
torque to 29N*m (260 in. lbs.).
(22) Install key in crankshaft.
(23) Install felt shaft seal into front housing and
position at base of housing neck.
Caution: See OIL LEVEL in the REFRIGERANT sec­
tion for further details.
(24) Install refrigeration oil (500 SUS) into the com­
pressor through the suction port.
(25) Check compressor operation for smoothness by
rotating crankshaft at least five full revolutions.
(26) Check front housing clutch coil alignment pin
for proper installation.
(27) In s ta ll c lu tc h assem bly . See C O M PR E SSO R
C L U T C H /C O IL in s ta lla tio n in th is group.
COMPRESSOR FRONT SHAFT S E A L-
FIXED DISPLACEMENT COMPRESSOR
MODEL 10PA17
REMOVAL
(1) Discharge the refrigerant system. See DIS­
CHARGING REFRIGERANT SYSTEM in the RE­
FRIGERANT section.
(2) Remove A/C compressor. See COMPRESSOR RE­
MOVAL AND INSTALLATION.
(3) Remove compressor clutch/coil assembly. See
COMPRESSOR CLUTCH/COIL ASSEMBLY RE­
MOVAL AND INSTALLATION.
(4) Remove compressor through-bolts (Fig. 1).
COMPRESSOR
THROUGH-BOLTS

(6) Remove O-ring seal from front cover and discard

(Fig. 3).
Never reuse cover O-rings or the steel valve plate
gaskets.

Fig. 1Compressor Through-Bolts

(5) Remove front cover by tapping on the outside
diameter of the cover with a plastic hammer (Fig. 2).

Fig.3 Removing O-Ring

(7) Pry out the felt retainer and remove felt from
front cover (Fig. 4).
 FELT FELT

f lf . 4 Hemming Felt Retainer and Felt

(8) Remove se a l s n a p r in g (Fig. 5).

f lf . § Flemming Seal

(10) R em ove dow el p in s, v a lv e p la te s, a n d ste e l v alv e

p la te g a sk e t. D iscard ste e l g a s k e t (Fig. 7).

f lf , 5 Sm l Snap Ring
(9) P la c e co m p resso r fro n t cover on a f la t su rface
w ith n eck of cover facin g up. U sin g a b ra s s d rift, p re ss
o u t se a l a sse m b ly (Fig. 6).

Fig. 7 Disassembling Compressor fro n t End

(11) R em ove r e a r cover by ta p p in g th e o u tsid e d i­
a m e te r o f th e cover w ith a p la stic h a m m e r (Fig. 8).
(12) R em ove O -rin g from r e a r cover a n d d iscard
(Fig. 9).
(13) R em ove th e dow el p in s, v a lv e p la te s, a n d steel
v a lv e p la te g a sk e t. D iscard ste e l g a sk e t.
 Fig. 8 Removing Rear Cover
Fig. 9 Removing Rear O-Ring
REPLACING CENTER O-RING ON COMPRESSOR BODY
(14) Carefully separate front and rear compressor
housings by tapping the body lugs with a plastic ham-
mer (Fig. 10).Do not separate front and rear hous-
ings more than one inch (Fig. 11).
(15) Remove O-ring (Fig. 11) and discard.
(16) Inspect O-ring sealing surface for scratches,
dirt, or porosity. If a scratch or porosity is found,
compressor should be replaced.
Fig. 10 Separating Body Halves
Fig. 11 Compressor Body Half Separation
IN S T A L L A T IO N
(i) Install O-ring by carefully stretching and pass-
ing a new, dry O-ring over the rear housing to center
Gf compressor body.
(2) Oil new O-ring with refrigerant oil (500 SUS)
and position into seal groove.
(3) Mate two body halves by carefully pushing them
together making sure O-ring and housings are prop-
erly positioned.
 14) In s ta ll dow el p in s in r e a r com presso r body.
(5) Install cleaned valve plates.
(6) In s ta ll ste e l v a lv e p la te g a sk e t.
(7) A pply lig h t c o a tin g o f re frig e ra tio n oil to new
O -rin g a n d c a re fu lly p lace in to se a lin g groove o f re a r
cover.
(8) In s ta ll r e a r cover to r e a r com p ression h o u sin g .
(9) H old fro n t com presso r body a n d r e a r cover firm ly
to g e th e r. P o sitio n co m p ressor asse m b ly on r e a r cover
w ith c ra n k s h a ft fa c in g u p w a rd .
(10) I n s ta ll dow el p in s in fro n t com p resso r body.
(11) I n s ta ll c le a n e d v a lv e p la te s.
(12) Install steel gasket.
(13) C le a n c r a n k s h a ft a n d co at lig h tly w ith re frig e r­
a n t oil.
(14) L u b ric a te c ra n k s h a ft se a l s e a t c a v ity of fro n t
housing with refrigeration oil.
(15) Lubricate crankshaft seal seat and seal seat
O-ring with refrigeration oil. Install O-ring on seal
se a t a n d in s ta ll se a l s e a t in fro n t cover u s in g a sock et
t h a t c o n ta c ts th e o u te r d ia m e te r of th e se a l s e a t p la te
(Figs. 12 a n d 13).

(16) Install seal snap ring (Fig. 14).

Fig. 14 Seal Snap flin g

(17) Lubricate front cover O-ring with refrigeration

oil and carefully place it in seal groove of front housing.
(18) I n s ta ll fro n t cover to fro n t com presso r body.
(IS ) I n s ta ll co m p resso r th ro u g h -b o lts a n d fin g e r
tighten only. After bolts have been finger tightened,
to rq u e to 29N -in (260 in. lbs.). ' ■
(20) I n s ta ll fe lt s h a ft se a l a n d retainer'(Fig. 15) in to
front housing.
 9124-23

Fig. 15 FeltRetainerand Felt Fig. 1FeltContaminant Absorber

Caution: See OIL LEVEL in the REFRIGERANT sec­
tion for further details.
(21) Install refrigeration oil (500 SUS) into the com­
pressor through the suction port.
(22) Check compressor operation for smoothness by
rotating crankshaft at least five full revolutions.
(23) Check front housing clutch coil alignment pin
for proper installation.
(24) Install clutch assembly. See COMPRESSOR
CLUTCH/COIL installation in this group.
(25) Install compressor.
(26) Evacuate and charge refrigerant system. See
REFRIGERANT section.

COMPRESSOR FRONT SHAFT SEAL—

VARIABLE DISPLACEMENT COMPRESSOR
MODEL 6C17
(7) Using SEAL REMOVER/INSTALLER (6429), re­
REMOVAL move the shaft seal (Fig. 3).
(1) Discharge the refrigerant system. See DIS­
CHARGING REFRIGERANT SYSTEM in the RE­ INSTALLATION
FRIGERANT section. (1) Lubricate the new shaft seal with refrigerant oil.
(2) Remove A/C compressor. See COMPRESSOR RE­ (2) Place SEAL PROTECTOR (6231) over the end of
MOVAL AND INSTALLATION. compressor shaft (Fig. 4). Use the larger flat end of
(3) Remove the compressor clutch assembly and the remover/installer and push the seal in until it
shaft key. See COMPRESSOR CLUTCH/COIL ASSEM­ seats and the snap ring groove is visible above the
BLY—REMOVAL AND INSTALLATION. seal (Fig. 5).
(4) Remove the felt contaminant absorber and re­
tainer (Fig. 1).
(5) Using a mineral spirits based solvent, thoroughly
clean and dry the seal end of the compressor to avoid
refrigerant system contamination.
(6) Remove the snap ring shaft seal retainer (Fig.
2). Do not use the old snap ring to assemble.
 COMPRESSOR HIGH PRESSURE CUT-OUT SW ITCH-
VARIABLE DISPLACEMENT COMPRESSOR
MODEL 6C17
REMOVAL AND INSTALLATION
(1) Discharge the refrigerant system. See DIS­
CHARGING REFRIGERANT SYSTEM in the RE­
FRIGERANT section.
(2) Disconnect wire connector from the high pres­
sure cut-out switch (Fig. 6).
(3) Remove snap ring securing the switch in the
compressor end cover (Fig. 7).

Fig.3 Remove Shaft Seal

Fig.4 Shaft Seal Protector Fig. 6 High Pressure Cut-out Switch

Fig. 5 InstallShaftSeal
(4) Pull switch straight out from end cover. Remove
(3) Install clutch/coil assembly.
and discard used O-ring seal (Fig. 8).
(4) Install compressor.
To install, reverse the preceding operation using a
(5) Evacuate and charge the refrigerant system. Re­
new O-ring seal. Evacuate and charge the refrigerant
fer to CHARGING REFRIGERANT SYSTEM in the
system, refer to CHARGING REFRIGERANT SYS­
REFRIGERANT section. If oil loss of 3 ml (1 oz) or
TEM in the REFRIGERANT section.
greater is suspected, refer to OIL LEVEL in the RE­
FRIGERANT section.
 Fig.8 Remove or InstallHigh Pressure
Cut-outSwitch
COMPRESSOR HIGH-PRESSURE RELIEF VALVE
REMOVAL AND INSTALLATION
(1) Discharge the refrigerant system. See DIS­
CHARGING REFRIGERANT SYSTEM in the RE­
FRIGERANT section.
(2) Rotate the high pressure relief valve counter­
clockwise and separate relief valve from the vehicle
(Fig. 9 or 10).
Fig.9 Variable Displacement Compressor-
Model 6C17
To install, reverse the preceding operation using a
new O-ring seal. Evacuate and charge the refrigerant
system. Refer CHARGING REFRIGERANT SYSTEM
in the REFRIGERANT section.
Fig. 10 High Pressure ReliefValve—Typical
COMPRESSOR MAIN OR SUB CONTROL VALVES—
VARIABLE DISPLACEMENT COMPRESSOR
MODEL 6C17
If the main or sub control valve is leaking refriger­
ant to the atmosphere, replace the main or sub control
valve. If a functional problem is suspected with the
main or sub control valve, the compressor should be
replaced.
REMOVAL AND INSTALLATION
(1) Discharge the refrigerant system. See DIS­
CHARGING REFRIGERANT SYSTEM in the RE­
FRIGERANT section.
(2) Remove the compressor assembly. See COMPRES­
SOR REMOVAL/INSTALLATION AND OVERHAUL
in this group. Position it to gain access to the control
valves. It is not necessary to disconnect the suction or
discharge lines from the compressor.
(3) Remove the snap ring retaining either the main
or sub control valve to the compressor (Fig. 11).
(4) Pull the main or sub control valve from the
compressor end cover (Fig. 12).
To install, reverse the preceding operation using
new O-ring seals. Evacuate and charge the refriger­
ant system. Refer to CHARGING REFRIGERANT SYS­
TEM in the REFRIGERANT SECTION.
SUB CONTROL SUB CONTROL
VALVE VALVE

MAIN CONTROL
VALVE 9024-24 9024-25

Fig. 11 Main m Sub Control Waive Sm p Ring f lf . 12 Remove or Install Main or Sub Control ¥Bim
 AUXILIARY REAR HEATING OR HEATING-AIR/CONDITIONING
INDEX
Page Page
62 Rear Blower Resistor Block . . . . . ...................... 62
63 Rear Heater A/C Air Outlets . . . . . . . . . . . . . . . . . 62
63 Rear Heater A/C Blower Motor . . . . . . . . . . . . . . 62
61 Rear Heater A/C Control . . . . . . . . . . . . . . . . . . . . 61
. 63 Rear Heater A/C Control Illumination Bulb 62
61 Rear Heater—A/C'Unit . . . . . . . . . . . . . . . . . . . . . 62
63

GENERAL INFORMATION When the HEAT mode is selected, the airflow is di­
rected from the heat outlets at the floor. When the
For proper operation of the rear heating-air/condi- FAN or A/C mode is selected, the airflow is directed
tioning system, refer to the Owner’s Manual supplied from the upper air outlets (Fig. 2).
with the vehicle.
, AIR OUTLETS.
The auxiliary rear heater functions the same as the
heater-A/C system. The rear heater utilizes the same I ... X J 9
components as the rear heater-A/C system. Only the
refrigerant components have been omitted. " 1
The auxiliary rear heating-air/conditioning system \____ 1_____ -i___ J
is located in the left rear quarter panel. It is a man­
CONTROL
ually operated device, controlled by the rear-seat oc­ SWITCHES
cupant. The rear heater A/C control (Fig.l) operates
in conjunction with the front heater A/C control. A
AIR
four position blower (override) switch is located on the INTAKE
instrument panel (Fig. 1). The operator of the vehicle
can use the rear heater-A/C blower instrument panel
switch to operate the blower at HI or LO speed re­
gardless of the setting of the rear control. In the OFF HEATER
position, the rear control will not function. In the ON 'OUTLETS' 9124-66

position, the rear control will function properly.

Fig.2 LeftRear Quarter Trim Panel
DIAGNOSTIC PROCEDURES
When diagnosing electrical problems in the auxil­
iary rear heater or rear A/C system, refer to Group
8W, Wiring Diagrams.
When diagnosing mechanical problems in the auxil­
REAR HEAT CONTROL— REAR HEAT-A/C CONTROL
CANADIAN MODELS ONLY
iary rear heater or rear A/C systems, refer to the
DIAGNOSTIC and TEST procedures sections for (front)
heater-A/C.

REAR HEATER A/C CONTROL

INSTRUMENT PANEL
SWITCH FOR REAR HEAT-A/C 9124-65
Fig. 1Rear Heater, Rear Heater-A/C Controls
Air from inside the vehicle is drawn into the air
intake grille in the left rear quarter trim panel (Fig.
2). The air enters the blower and is pushed through
the heater core and A/C evaporator coil (if equipped).
REMOVE AND INSTALL
(1) Pry outward on the outside upper and lower
comers of the control.
(2) Separate the control from the trim panel and
disconnect the wire connectors.
To install, push the control into the opening until it
locks into place.
REAR HEATER A/C CONTROL ILLUMINATION BULB ■ REAR HEATER A/C BLOWER.MOTOR

REMOVE AND INSTALL ■ HEMOVE AND INSTALL

(1) R em ove r e a r h e a te r A/C con tro l from trim p an el. (1) R em ove th e le ft low er q u a r te r tr im p a n e l. See
(2) O n th e b a c k o f co n tro l opposite from th e w ire :G roup 28, Body.
connectors, lo cate th e b u lb so ck et lug. (2) R em ove one b lo w er cover to floor a tta c h in g screw
(3) R o ta te th e so ck et co un terclo ckw ise a n d p u ll th e a n d sev en blow er cover to u n it a tta c h in g screw s. ■
socket from th e control. (3) R o ta te b lo w er cover from u n d e r h ea te r-A /C u n it
■ To in s ta ll, reverse th e p re c e d in g o p e ra tio n . R efer to cover.
th e b a c k of G roup 8L, L am ps, for b u lb u sag e. (4) C om press th e clam p a t th e c e n te r o f th e b lo w er
w h eel a n d p u ll th e w h eel from th e b lo w er sh a ft. -
REAR HEATER A/C AIR OUTLETS (5) Remove three blower motor attaching screws.
(6) S e p a ra te th e blower motor from, th e M u s in g
REMOVAL AND INSTALL unit.
(1) P ry o u tw a rd on the outside u p p e r a n d low er -To in s ta ll, re v e rse th e p re c e d in g operation..'
co rn ers of th e o u tle ts.
(2) S e p a ra te th e a ir o u tle t from th e tr im p a n e l. REAR HEATER—A/C UNIT
To in s ta ll, p u s h th e o u tle t firm ly in to th e o p en in g
u n til it locks in to place. ■R E M O V E AND INSTALL ■ ■ .
Warning; On vehicles equipped with rear A/C, the
REAR BLOWER RESISTOR BLOCK refrigerant system must be discharged before per­
forming the following operation. See DISCHARGING
REMOVE AND INSTALL REFRIGERANT SYSTEM in the REFRIGERANT.sec­
(1) Remove th e le ft low er q u a r te r tr im p a n e l. See tion of this Group. The engine cooling system must
G roup 23, Body. also be relieved of all pressure.-. ■ -
(2) D isco nn ect w ire co nn ecto rs from re s is to r block.
(1) Drain engine cooling system, see Group 7, Cool­
(3) R em ove tw o a tta c h in g screw s from re s is to r block
ing System. Disconnect heater hoses at rear heater-A/C
a n d s e p a ra te from th e heater-A/C u n it.
u n it.
To in s ta ll, re v e rse th e p re c e d in g o p e ra tio n .
(2) Discharge refrigerant system. Disconnect A/C
AIR DISTRIBUTION CONTROL LEFT QUARTER plumbing from rear heater-A/C unit.
DUCT SWITCHES TRIM PANEL ,(3) Rem ove le ft lo w er q u a r te r tr im p a n e l. See G roup
23, Body.
(4) Remove the attaching screws securing the air
distribution duct to the rear wheel housing.
- (5) Remove the attaching screws securing the heater
unit to the floor pan.
(6) Remove attaching screw securing the unit to the
quarter panel support. • .:. .
(7) Lift the unit enough to clear the floor pan and
remove the unit from the vehicle.
To install, reverse the preceding operation. Install
new gaskets at refrigerant lines and expansion valve.
Evacuate and charge the refrigerant system (See the
R E F R IG E R A N T section, o f th is group). R efill th e cool­
in g system. Test for leaks and overall performance.

AIR DISTRIBUTION DUCT

REMOVE AND INSTALL
(1) Remove left quarter trim panel. See Group 23,
Body.
(2) Remove the screws se c u rin g the A/C duct to the
h eater-A /C u n it a n d th e body. • ' ■ ■ ■
( 3) Pull the distribution duct straight up to remove.
To install, reverse the preceding operation.
HEATER CORE (4) D e te rm in e th e a m o u n t o f old re frig e ra n t oil
d ra in e d from th e e v ap o rato r. A dd th is a m o u n t (of clean
REMOVE AND INSTALL r e f rig e ra n t oil) b a c k in to th e sy stem .
(1) D ra in th e e n g in e co olan t sy stem . (5) C a re fu lly a lig n th e e x p a n sio n v a lv e onto th e
(2) D iscon n ect h e a te r tu b in g from th e underbody p ilo t tu b e of th e p lu m b in g se a lin g p la te (do n o t sc ra tc h
h e a te r lin e s to th e r e a r u n it. th e se a lin g surface). In s ta ll th e b o lt th ro u g h th e p lu m b ­
(3) R em ove th e low er le ft q u a r te r tr im p an el. See in g p la te in to th e u n it se a lin g p la te a n d tig h te n to
G roup 23, Body. 200 ± 30 in c h po u n d s (23 ± 3 N-m).
(4) R em ove FA N -A /C d is trib u tio n d uct. (6) In s ta ll u n it cover a n d a ir d is trib u tio n du ct.
(5) R em ove heater-unit cover. (7) In s ta ll q u a r te r trim ' p a n e l, e v a c u a te /c h a rg e sy s­
(8) C a re fu lly p u ll th e h e a te r core a n d h e a te r tu b e s te m , a n d te s t p erfo rm an ce.
s tr a ig h t o u t of th e u n it.
(7) R aise th e h e a te r core to d ra in re sid u a l co o lant AUXILIARY UNilRBOiY HEATER P L U iiIN i
from th e core.
(8) D isco nn ect tw o h e a te r hose clam p s t h a t a tta c h REMOVAL AND INSTALLATION
p lu m b in g to th e h e a te r core tu b e . Warning: The engine cooling system m yst be re­
(9) To in s ta ll, re v e rse th e p re c e d in g o p e ra tio n . lieved of ali pressure.
(1) D ra in th e e n g in e cooling sy ste m , see G roup 7,
EVAPORATOR! A l i EXPANSION VALVE
C ooling S ystem .
(2) In th e e n g in e c o m p a rtm e n t, a n d d isco n n ect tw o
REMOVE
a u x ilia ry r e a r h e a te r h oses from th e (front) h e a te r
Warning; The refrigerant system myst be discharged
hose te e fittin g s.
before performing the following operation. See DIS­
(3) H o ist th e vehicle.Diseonnect tw o p u sh -to g e th e r
CHARGING REFRIGERANT SYSTEM in the REFRIG­
cou p lin gs from th e a u x ilia ry r e a r h e a te r core tu b e s
ERANT section of this Groyp. The engine cooling
p ro tru d in g th ro u g h th e floor p an .
system must also be relieved of ail pressure.
(4) Rem ove fo ur b o lts a n d one n u t h o ld in g th e p lu m b ­
(1) R em ove le ft q u a r te r tr im p a n e l. See G rou p 23, in g to th e floor p a n a n d low er th e p lu m b in g from th e
Body. v ehicle.
(2) R em ove FA N -A /C d is trib u tio n du ct. To in s ta ll, re v e rse th e p re c e d in g o p e ra tio n .
(3) R em ove u n it cover.
(4) R em ove th e b o lt t h a t m o u n ts th e u n ifie d re frig ­
e r a n t p lu m b in g block to th e ex p a n sio n v alv e.
(5) C arefu lly p u ll th e e v a p o ra to r a n d exp an sio n v alve
s tr a ig h t o u t of u n it (ta k e c a re N O T to sc ra tc h th e
se a lin g su rfaces w ith th e p lu m b in g e x te n sio n tu b e
pilots).
(6) Remove a n d d isc a rd th e a lu m in u m g a s k e t b e­
tw een th e p lu m b in g e x te n sio n a n d th e ex p an sio n v alve.
(7) C over th e p lu m b in g e x te n sio n se a lin g su rfa c e to
p re v e n t c o n ta m in a tio n .
(8) B rin g e v a p o ra to r a n d e x p a n sio n v alv e to a cle a n
w ork space.
(9) R em ove tw o 1/4-20 T orx H e a d screw s.
(10) R em ove e x p a n sio n valve.
(11) M e a su re a n d record th e a m o u n t of re s id u a l oil
from th e rem ov ed ev a p o ra to r.
f lf . 5 Wear Heater Underbodf Plumbing
INSTALL
(1) R eplace th e a lu m in u m g a sk e ts (one on e v a p o ra ­
AUXILIARY UNDERBODY REFRIGERANT PLUMBING
to r p la te a n d one on p lu m b in g p la te ).
REMOVAL
(2) H old ex p a n sio n v a lv e a g a in s t e v a p o ra to r se a lin g
Warning: The refrigerant system must be discharged
p la te (do n o t sc ra tc h th e se a lin g surface). I n s ta ll tw o
before performing the following operation. See DIS­
screw s a n d tig h te n to 200 ± 30 in c h p o u n d s (23 ± 3N*m).
CHARGING REFRIGERANT SYSTEM in the REFRIG­
(3) C a re fu lly in s ta ll th e e v a p o ra to r a n d e x p a n sio n
ERANT section of this Group.
v alv e s tr a ig h t in to th e u n it (ta k e c a re N O T to sc ra tc h
th e se a lin g su rfa c e s w ith th e p lu m b in g e x te n sio n tu b e
pilots).
 (1) Hoist the vehicle. Disconnect two tube-fittings
from the engine compartment plumbing.
(2) Remove the bolt from the unified plumbing block
(left side of car, outboard of rail, forward of fuel tank).
(3) Carefully pull refrigerant line assembly down
(take care NOT to scratch the sealing surface with
the tube pilots). Remove and discard the aluminum
gasket and cover unit sealing surface to prevent
contamination.
(4) Remove two screws holding plumbing to the fuel
tank support and left-side support rail (near muffler
support bracket).
(5) Remove two screws holding the plumbing to the
floor pan.
(6) Disconnect the parking brake system at hook
above muffler and the cable connection near the sup­
port rails. f lf . i Wear M/C Underbody Plumbing
(7) Fish the nylon tubing and unified plumbing block
above the muffler support member.
(8) Lower the plumbing from the vehicle.
(9) Measure the residual oil in the underbody plumb­
ing out of each end of the plumbing. The low-side
(larger diameter line) has a check valve that can re­
strict oil flow from the tube-fitting to the unified plumb­
ing end of the hose. Measure clean 500 SUS viscosity
wax-free refrigerant oil to be returned to the refriger­
ant system.

INSTALL
(1) Protect the plumbing ends from scratches. If
plumbing is new, do not remove the shipping caps
until joining together.
(2) Reverse the preceding steps from the REMOVAL
procedure.
(3) New gaskets and O-rings are required for instal­
lation. The O-rings must be covered with clean refrig­
erant oil prior to installation.
14) Connect the tube-fittings to the engine compart-
ment-underbody plumbing. Avoid misalignment of the
threads (cross threading) and tighten to 200 in-lbs.
(5) Remove the shipping cap from the plumbing side
sealing surface and verify that the aluminum gasket
is present.
(6) Carefully a l i g n the pilot tubes of the plumbing
line block into the unit (take care not to scratch the
sealing surface).
(7) Install the bolt through the plumbing plate into
the unit sealing plate and tighten to 200 ± 30 inch
pounds (23 ± 3 N-m).
 EMISSION CONTROL SYSTEMS
CONTENTS
p^gg
EVAPORATIVE EMISSION CONTROLS............
EVAPORATIVE EMISSION CONTROLS
Page
Canister Purge Solenoid ............................................. 3
Emission Maintenance Reminder (EMR) System __
Evaporation Control System ....................................... 3
GENERAL INFORMATION
Throughout this group, references may be made to a
particular vehicle by letter or number designation. A
chart showing the breakdown of these designations is
included in the Introduction Section at the front of
this service manual.
EMISSION MAINTENANCE REMINDER
(EMR) SYSTEM
There are some systems and components that need
periodic maintenance; such as the PCV valve, EGR
system, the heated oxygen sensor, and some vacuum
operated components.
The Emissions Maintenance Reminder System (EMR)
is incorporated into the engine controller. The engine
controller records the vehicles mileage and stores it
into memory every 8 miles. At that time, the engine
controller checks for the 60,000, 82,500, and 120,000
mileage trip points. When the current mileage matches
one of the above mentioned trip points, the EMR light
is activated.
The following parts are to be replaced at the indi­
cated mileage, or when the emissions maintenance
reminder light remains on continuously with the key
in the on position, whichever occurs first. After per­
forming the required maintenance, the EMR light must
be reset to turn the light off.
60.000 miles:
(a) Replace EGR Valve.
(b) Replace EGR Tube (if equipped).
(c) Clean EGR passage.
(d) Replace PCV Valve.
82,500 miles:
(a) Replace Oxygen Sensor.
120.000 miles:
(a) Replace EGR Valve.
(b) Replace EGR Tube (if equipped).
(c) Clean EGR passage.
(d) Replace PCV Valve.
pagg
1 EXHAUST EMISSION CONTROLS ............... . 5
INDEX
Page
General Information ................................................... 1
1 Vehicle Emission Control Information
(VECI) Label . . ........................................................ 1
Failure to perform the required maintenance and
only reset the EMR light may be a violation of federal
law. Only after performing the required maintenance
should the EMR light be reset.
RESETTING EMR LAMP
(1) Connect DRBII tool to the diagnostic connector.
(2) Turn the ignition switch to the run position,
access Select Systems on the DRBII.
(3) Select the applicable engine.
(4) Select with or without air conditioning.
(5) Select Fuel and Ignition.
(6) Select Adjustments
(7) Select Reset EMR Light.
(8) Reset the EMR Light.
VEHICLE EMISSION CONTROL INFORMATION
(VECI) LABEL
All vehicles are equipped with a Vehicle Control
Information (VECI) Label (Figs. 2 through 6) which is
located in the engine compartment (Fig. 1). This label
is permanently attached and cannot be removed with­
out defacing information and destroying the label.
The label contains emission specifications and vac­
uum hose routings for the vehicle the label is mounted
on. All hoses must be connected and routed as shown
on the label.
If any difference exists between the specifications or
vacuum hose routing shown on the vehicle label and
those shown in the Service Manual, those shown on
the vehicle label should be used. The labels shown
are for vacuum hose routing Information only.
 IMPORTANT VEHICLE INFORMATION
THIS VEHICLE CONFORMS TO U.S. EPA AND STATE O f
CALIFORNIA REGULATIONS APPLICABLE 10 1191 MODEL
VEHICLE YEAR NEW LI6HT-DUTY TRUCKS PROVIDED THAT THIS
EMISSION VEHICLE IS O ILY INTRODUCED INTO COMMERCE FOR SALE
CONTROL IN THE STATE OF CALIFORNIA.
INFORMATION » BASIC IGNITION T IM ING AND I DLE FUEL/AIR MIXTURE 2.5 LITER SPARK PLUGS
MCR 2.5T5FCF2 -
(VECI) LABEL HAVE BEEN PRESET AT THE FACTORY. SEE THE SERVICE
MANUAL FOR PROPER PROCEDURES AND OTHER MCRTA
03 5 in. GAP
RN12YC
ADDITIONAL INFORMATION
• ADJUSTM ENTS MADE BY OTHER THAN APPROVED IDLE •
TI MING BTC
mm.
12°
SERVICE M ANUAL PROCEDURES MAY VIOLATE
FEDERAL AND STATE LAWS.
NO OTHER ADJUSTM ENTS NEEDED
CAUTION: APPLY PARKING BRAKE WHEN SERVI CING VEHICLE
RHC/CO/NOx STDS .39/9.0/0.7

un
CM
in
o
3
DC*
9025-31 1
zg
Oo £9 iorvr v
Pig. 1 Underhood Label Location
i m p o r t a n t v e h i c l e in fo r m at io n
m m m 9125-21

THIS VEHICLE CONFORMS TO U.S. EPA

Fig.3 Hose Routing Label 2.5L
REGULATIONS APPLICABLE TO 1991 MODEL YEAR California Fuel InjectedEngines
NEW LIGHT-DUTY TRUCKS AT ALL ALTITUDES.
IMPORTANT VEHICLE INFORMATION

* BASIC IGNITION T IM ING AND IDLE FUEL/AIR M IXTURE

2.5 LITER SPARK PLUGS
M CR2.5T5FDAX
HAVE BEEN PRESET AT THE FACTORY. SEE THE SERVICE MCRTA
0 3 5 in GAP THIS VEHICLE CONFORMS TO U.S. EPA
RN12YC
M ANUAL FOR PROPER PROCEDURES AND OTHER
ADDITIONAL INFORMATION.
REGULATIONS APPLICABLE TO 1991MODEL YEAR
IDLE • AUTO NEW LJ6H TPU IY TRUCKS AT ALL ALTITUDES.
* ADJUSTM ENTS M ADE BY OTHER THAN APPROVED T IM I NG BTC 12°
SERVICE M ANUAL PROCEDURES MAY VIOLATE
FEDERAL AND STATE LAWS. NO OTHER ADJUSTM ENTS NEEDED
. BASIC IGNITION TIM ING AND IDLE FUEL/AIR MIXTURE 3.3 LITER SPARK PLUGS
CAUTION: APPLY PARKING BRAKE W HEN SERVICING VEHICLE HAVE BEEN PRESET AT THE FACTORY. SEE THE SERVICE MCR3.0T5FBL8
FAMILY NOx E M ISSION L IM IT 1.7 1.1 m m GAP
M ANUAL FOR PROPER PROCEDURES AND OTHER MCRTH
ADDITIONAL INFORMATION. RN11YC4

• ADJUSTM ENTS MADE BY OTHER THAN APPROVED

SERVICE MANUAL PROCEDURES MAY VIOLATE IDLE* AUTO
FEDERAL AND STATE LAWS. T IM ING BTC 12°
/ CAUTION: APPLY PARKING BRAKE W HEN SERVICING VEHICLE NO OTHER ADJUSTMENTS NEEDED

x * § FAMILY NO* EMISSION L IM IT 1.7

--- O --

IO -... ...____________________ __ tOAli CO

Kg CO
Sg
in
OCZ
O 9125-20
21

Fig.2 Hose Routing Label 2.5L Federal and

Canadian Fuel InjectedEngines
9125-22

Fig.4 Hose Routing Label 3.0L Federal, California,

and Canadian FuelInjectedEngines
 I MPORTANT VEHICLE INFORMATION
THIS VEHICLE CONFORMS ID U.S. EPA
REGULATIONS APPLICABLE TO 1991 MODEL YEAR
NEW LiGHT-DUTY TRUCKS AT ALL ALTITUDES,
. BASIC IGNIT I ON T IM ING AND IDLE FUEL/AIR MIXTURE 3.3 LITER
HAVE BEEN PRESET AT THE FACTORY. SEE THE SERVICE
MANUAL FOR PROPER PROCEDURES AND OTHER
MCR 33T5FCZI
mm
ADDITIONAL INFORMATION.
EVAPORATION CONTROL SYSTEM
The function of the evaporation control system is to
prevent the emissions of gasoline vapors from the fuel
SPARK PLIJC
tank into the atmosphere. When fuel evaporates in
.050 in. GAP
RN16YC5
the fuel tank, the vapors pass through vent hoses or

• ADJUSTMENTS MADE BY OTHER THAN APPROVED

SERVICE MANUAL PROCEDURES MAY VIOLATE
FEDERAL AND STATE LAWS.
CAUTION: APPLY PARKING BRAKE W HEN SERVICING VEHICLE
CCZ
yjg
05
Fig.5 Hose Routing Label 3.3L Federal, California,
and Canadian FuelInjectedEngines—
Front Wheel Drive
IMPORTANT ¥EH1CLE INFORMATION
THIS VEHICLE CONFORMS TO U.S. EPA
REGULATIONS APPLICABLE TO 1991 MODEL YEAR
NEW U 6 W D U IY TRUCKS AT ALL ALTITUDES.
• BASIC IGNITION TIM ING AND IDLE FUEL/AIR M IXTURE
HAVE BEEN PRESET AT THE FACTORY. SEE THE SERVICE
M ANUAL FOR PROPER PROCEDURES AND OTHER
ADDITIO NAL INFORMATION.
• ADJUSTM ENTS MADE BY OTHER THAN APPROVED
SERVICE MANUAL PROCEDURES MAY VIOLATE
FEDERAL AND STATE LAWS.
CAUTION. APPLY PARKING BRAKE W HEN SERVICING VEHICLE
tubes to a charcoal canister where they are temporar­
NO ADJUSTMENTS NEEDED
ily held until they can be drawn into the intake mani­
FAMILY NOx EM ISSIO N L IM IT 1.7 fold when the engine is running.
The vapors are drawn into the engine at idle as well
as off idle. This system is called bi-level purge, where
there is a dual source of vacuum to remove fuel vapor
from the canister.
The charcoal canister is a feature on all models for
the storage of fuel vapors from the fuel tank.
The hoses used in this system are specially manu­
factured and .if replacement becomes necessary it is
important to use only fuel resistant hose.
PRESSURE RELIEF/ROLLOVER VALVE
All vehicles pass a full 360° rollover without fuel
leakage. To accomplish this, fuel and vapor flow con­
trols are required for all fuel tank connections. A
rollover valve is mounted in the top of the fuel tank to
9125-23
prevent fuel leakage if vehicle is accidentally rolled
over.
All fuel injected vehicles will be equipped with a
combination pressure relief and rollover valve. The
valve provides a path for fuel vapors to travel from
the fuel tank to the canister and also provides fuel
leakage protection if a vehicle rollover occurs. This
valve also incorporates a pressure relief mechanism
3.3 LITER SPARK PLUGS which is designed to release pressure to the canister
M CR3.3T5FCZI
MCfffG
.050 in. GAP
RN16YC5
when the fuel tank pressure increases above the cali­
brated sealing valve.
NO ADJUSTM ENTS NEEOED
Refer to Group 14 Fuel Tank Section For Service.
FAMILY NOx EM ISSIO N L IM IT 1.7

CHARCOAL CANISTER
§ A sealed, maintenance free, charcoal canister is used

i on all engines and is located in the wheel well area of

the engine compartment. The fuel tank vents into the
canister. Fuel vapors are temporarily held in the can­
ister until they can be drawn into the intake manifold.
The hoses used in this system are specially manu­
factured and if replacement becomes necessary it is
important to use only fuel resistant hose.

Kg
3o CANISTER PURGE SOLENOID
*21
T h e ' p u rg e solen oid is c o n tro lle d by th e E n g in e
Controller.(Fig. 7) D u rin g w a rm -u p a n d for a specified
tim e period a fte r h o t s ta r ts th e E n g in e C o n tro lle r
$ 9125-24 grounds th e P urge Solenoid causing it to energize.
Fig.6 Hose Routing Label3.3L Federal, California, T h is p re v e n ts vacuum from re a c h in g th e ch arco al c a n ­
and Canadian FuelInfectedEngines—AllWheel Drive is te r valv e. W h en th e ’e n g in e re a c h e s a specified o p er­
a tin g te m p e ra tu re a n d th e tim e d e la y in te rv a l h a s
o ccurred th e solenoid is d e-en erg ized by tu r n in g off
the ground. Once this occurs vacuum will flow to the
canister purge valve and purge fuel vapors through
the throttle body. The Purge Solenoid will also be
energized during certain idle conditions, this is to
update the fuel delivery calibration. See On Board
Diagnostics in the General Diagnosis section of Group
14, for further test procedures.
9114-154
Fig. 7 CanisterPurge Solenoid
PRESSURE-VACUUM FILLER CAP
The fuel tank is sealed with a specially engineered
pressure-vacuum relief filler cap. (Fig. 8) The relief
valves in the cap are a safety feature, and operate
only to prevent excessive pressure or vacuum in the
tank caused by a malfunction in the system or dam­
age to the vent lines.
The cap has a threaded configuration which allows
the seal to be broken and pressure to be relieved with
separation of the cap from the filler tube. Approxi­
mately two and a half turns are required to remove
the cap.
PLASTIC
CUT-AWAY
If replacement of the filler cap is necessary, a sim­
ilar unit must be used in order for the system to
remain effective.
CAUTION: Remove filler cap prior to removing or
repairing fuel lines.
POSITIVE CRANKCASE VENTILATION
(PCV) SYSTEMS
Crankcase vapors and piston blow-by are removed
from the engine by manifold vacuum. These emissions
pass through the PCV valve into the intake manifold
where they become part of the calibrated air-fuel mix­
ture, are burned and expelled with the exhaust gases.
When there is not enough vapor or blow-by present in
the engine, make up air is drawn from the air cleaner.
No fresh air enters the crankcase with this system.
(Fig. 9)
PCV VALVE AIR
CLEANER
CRANKCASE VENT VALVE
HOSE ASSEMBLY
INTAKE
AAANIFOLD
CRANKCASE VENT VALVE
HOSE CRANKCASE VENT
TO AIR CLEANER
RR25G5
Fig.9 PCV System 2.5L Engines
WARNING: BE SURE TO APPLY PARKING BRAKE
AND/OR BLOCK WHEELS BEFORE PERFORMING
IDLE CHECK OR ADJUSTMENT, OR ANY ENGINE
RUNNING TESTS OR ADJUSTMENTS.
PCV VALVE TEST
With the engine idling, remove the PCV valve from
its attaching point. If the valve is operating properly,
a hissing noise will be heard and a strong vacuum felt
when a finger is placed over the valve inlet. (Fig. 10)
With the engine off, the valve should rattle when it is
shaken. If the valve is not operating properly it must
be replaced. Do not attempt to clean the old PCV
valve.
 CRANKCASE VENT FILTER
All engines are equipped with a crankcase vent
filter. The filter is used to filter outside air before it
CRANKCASE VENT enters the PCV system. On throttle body fuel injected
engines, the filter is in the upper shell assembly of the
air cleaner. On 3.0L engines,the filter is located on
the inside of the filter element box under the filter
element. On the 3.3L engines, the filter is located in
the bottom of the filter element box. (See Group 0 for
mileage intervals and service procedures.)

RP268

Fig.10 TypicalPCV Test

EXHAUST EMISSION CONTROLS
INDEX
Page Page
EGR System Service 11 Heated Inlet Air System ............... .. 5
Exhaust Gas Recirculation (EGR) System 7 Heated Oxygen Sensor (02 Sensor)

HEATED INLET AIR SYSTEM WIRING HARNESS AIR CLEANER

GROUND ASSEMBLY
2.5L TBI engines are equipped with air preheaters. HEATED AIR /
ASSEMBLY
This device is a part of the air cleaner and controls
the temperature of the air entering the throttle body
when ambient temperatures are low. By maintaining
the temperature, the throttle body can be calibrated
much leaner to reduce hydrocarbon emissions, engine
warm-up characteristics are improved and icing is
minimized (Fig. 1).
The heated air system is basically a two circuit air
flow system.
When the ambient air temperature is 8°C (15°F) or
more degrees above the control temperature the air
flow will be through the outside air inlet.
When the ambient air temperature is below the
control temperatures there will be air flow through
both circuits after the engine has been started and the
exhaust manifold starts to give off heat. The colder
the ambient air the greater the flow of air through the
AIR HEATER
stove, and the warmer the air the greater the flow CONNECTOR 9025-32
through the snorkel. The quantity of air through each
circuit is controlled by a heat control door in the
snorkel to maintain a predetermined temperature at
the temperature sensor mounted inside the air cleaner
housing (Fig. 2).
 The modulation of the induction air temperature is not lift off the bottom of the snorkel at less than 2
performed by intake manifold vacuum, a temperature inches Hg. The door should be in the full up position
sensor and a vacuum diaphragm which operates the with no more than 4 inches Hg.
heat control door in the snorkel. (6) Should the vacuum diaphragm not perform ade-
VACUUM PUMP
HEATED AIR INLET CRANK CASE VENT TO DIAPHRAGM VACUUM

AIR
ASSEMBLY RR25G13

Fig.3 Testing Vacuum Diaphragm on

The vacuum diaphragm is opposed by a spring. Tem­
perature modulation occurs only at road load throttle
positions or when the intake manifold vacuum is above
the operating vacuum of the vacuum diaphragm.
There is no heated air system on the multi-point
fuel injection systems.
Heateo AirInletSystems
(7) Should the vacuum diaphragm perform adequately
but proper temperature is not maintained, replace the
sensor and repeat the temperature checks in steps 2
and 3.

HEATED INLET AIR SYSTEM SERVICE HEATED AIR TEMPERATURE SENSOR SERVICE
A malfunction of this system will affect driveability REMOVAL
as well as the vehicle exhaust emissions.
To determine whether the system is functioning With air cleaner housing removed from vehicle:
properly, the following procedure should be used: (1) Disconnect vacuum hoses from sensor, remove
(1) Make sure all vacuum hoses and the stove to air retainer clips (Fig. 4), and discard (new clips are sup­
cleaner flexible connector are properly attached and plied with a new sensor).
are in good condition. (2) Remove sensor with gasket and discard.
(2) With a cold engine and ambient temperature
less than 46°C (115°F.), the heat control door (valve
plate) should be in the up or heat on position.
(3) With the engine warmed up and running,check
the air temperature entering the snorkel or at the
sensor. When the air temperature entering the outer
end of snorkel is 60°C (140°F.) for fuel injected engines
or higher the door should be in the down position
(heat off).
(4) Remove the air cleaner from the engine and
allow it to cool down to 46°C (115°F). With 20 in.
vacuum applied to the sensor the door should be in
the up or (heat on position). Should the door not rise
to the heat on position, check the vacuum diaphragm
for proper operation.
(5) To test the diaphragm, apply 20 inches of vac­
uum with vacuum pump tool number C-4207 or equiv­
alent (Fig. 3). The diaphragm should not bleed down
more than 10 inches in 5 minutes. The door should
INSTALLATION
(1) Position gasket on the sensor and install sensor
(Fig. 5).
(2) Supporting sensor on outer diameter, install new
retainer clips securely being sure gasket is compressed
to form an air seal. No attempt should be made to
adjust sensor.
Fig. 5 InstallingGasket and Sensor
HEATED OXYGEN SENSOR (02 SENSOR)
The Oxygen Sensor (02 Sensor) is a device which
produces an electrical voltage when exposed to the
oxygen present in the exhaust gasses. (Fig. 6) The
sensor is electrically heated internally for faster switch­
ing when engine is running. When there is a large
amount of oxygen present (lean mixture), the sensor
produces a low voltage. When there is a lesser amount
present (rich mixture) it produces a higher voltage.
By monitoring the oxygen content and converting it to
electrical voltage, the sensor acts as a rich-lean switch.
The voltage is supplied to the Engine Controller, which
adjusts the fuel delivery accordingly.
SENSOR OUTPUT
(BLACK WIRE) **
A t
POWER AND
4-WAY
GROUND RR14G133
ELECTRICAL CONNECTOR
REMOVAL
CAUTION: Care should be exercised so that no pull­
ing force is put on sensor wire. Use care in working
around sensor as the exhaust manifold may be ex­
tremely hot.
(1) Disconnect engine harness lead from Sensor.
(2) Remove sensor using Oxygen Sensor Socket
C-4907.(Fig. 7)
SPECIAL TO OL C-4907
9114-106
Fig. 7 Oxygen Sensor Socket
(3) When the sensor is removed, the exhaust mani­
fold threads must be cleaned with an 18 mm X 1.5 X
6E tap.
INSTALLATION
(1) If the same sensor is to be reinstalled, the sensor
threads must be coated with an anti-seize compound
such as Loctite 771-64 or equivalent. New sensors are
packaged with compound on the threads and no addi­
tional compound is required.
(2) Torque sensor to 27 N*m (20 ft. lbs.).
(3) Connect oxygen sensor electrical connector.
EXHAUST GAS RECIRCULATION (EGR) SYSTEM
The EGR system reduces oxides of nitrogen (Nox) in
engine exhaust and helps prevent spark knock. This
is accomplished by allowing a predetermined amount
of hot exhaust gas to recirculate and dilute the incom­
ing fuel/air mixture. This dilution reduces peak flame
temperature during combustion.
The EGR system for the 2.5L engines is a back­
pressure type. (Figs 8 and 9) A backpressure trans­
ducer measures the amount of exhaust gas backpressure
on the exhaust side of the EGR valve and varies the
strength of the vacuum signal applied to the EGR
valve. The transducer uses this backpressure signal to
provide the correct amount of Exhaust Gas Recircula­
tion under all conditions.
The EGR systems for the 2.5L engines utilize an in­
take manifold-mounted EGR valve and Electric EGR
Transducer (EET). An EGR tube carries the exhaust
gasses from the intake manifold to the exhaust manifold.
The EGR systems are solenoid controlled, using a
m an ifo ld vacuum signal fro m th e th r o ttle body. T h e
E G R solenoid is p a r t o f the. E le c tric E G E T ra n sd u c e r
(EET).
T h ese sy ste m s do n o t allow E G R a t idle. E G R sy s­
te m s o p e ra te a t a ll te m p e ra tu re s above 60°F.
f lf . S EGf? System
■ Pig. i EGR Mounting
e l e c t r ic e x h a u s t q m s n e g in g u la tio n
TRANSDUCER (EETI
T h e elec tric e x h a u s t g a s recirculation tra n s d u c e r
(EET) is a b a c k p re ss u re tra n s d u c e r a n d a n e lectric
v a c u u m solenoid com bined in to a sin g le u n it. (Fig. 10)
T h e v a c u u m solenoid p o rtio n of th e E E T receiv es its
e le c tric a l s ig n a l from th e e n g in e c o n tro ller. U s in g th is
sig n a l, th e so leno id re g u la te s th e v a c u u m flow ing
th ro u g h to th e tra n s d u c e r p o rtio n o f th e E E T . T h e
back-pressure tra n s d u c e r m e a su re s th e a m o u n t of e x ­
h a u s t g a s b a c k p re ss u re o n th e e x h a u s t sid e o f th e
E G R v a lv e a n d v a rie s th e s tre n g th of th e v acu u m
sig n a l a p p lie d to th e EGR valve. T he tra n s d u c e r u ses
th is b a c k p re ssu re sig n a l to pro vid e th e co rrect a m o u n t
of e x h a u s t g as re c irc u la tio n u n d e r a ll conditions.
ELECTRIC
BACK PRESSURE
TRANSDUCER ' . 9114-30
f lf . 10 ElectricEGR Transducer (EET) Assembly
e m SY§rem o n b o a r d d ia g n o s t ic s
(CALIFORNIA VEHICLES)
T he ■e n g in e c o n tro lle r p erfo rm s a n o n -b o ard d ia g ­
no stic check o f th e E G R sy ste m on a ll C a lifo rn ia v e h i­
cles w ith E G R sy stem s. T h e d ia g n o stic sy ste m u ses
th e E le c tric E G R T ra n sd u c e r (E E T ) for th e sy ste m
te sts.
T he d iag n o stic check is a c tiv a te d only d u rin g se­
lected e n g in e /d riv in g co n ditio ns to avoid mis-diagnosis,
a n d checks th e e n tir e EGR system for fa ilu re s. O nce
a ll o f th e above co n d itio n s a re m e t, th e E G R solenoid
is en erg ized , d isa b lin g EG R . T h e O xy gen 0 2 feed back
sy stem is m o n ito re d to see a m in im u m a m o u n t of
ch an ge. T h e m ix tu re sh o u ld go le a n a n d th e sy ste m
w ill tr y to richen. The engine controller monitors EGR
system performance and registers a fault code if the
system h a s failed o r d eg rad ed , a n d th e CHECK ENGINE
light is turned on indicating immediate service is
required.
If a malfunction is indicated by a CHECK ENGINE
light and a fault code for EGR system, proper opera­
tion of the EGR system should be checked using the
service procedures. If the EGR system is found to be
functioning correctly, the on-board diagnostics system
should then be checked. Refer to Group 14, On-Board
Diagnosis. If the EGR system is not functioning cor­
rectly, refer to EGR diagnosis in this section for sys­
tem correction.
WARNING: BE SURE TO APPLY PARKING BRAKE
AND/OR BLOCK WHEELS BEFORE PERFORMING
IDLE CHECK OR ADJUSTMENT, OR ANY ENGINE
RUNNING TESTS OR ADJUSTMENTS.
EXHAUST GAS RECIRCULATION (EON)
SYSTEM TEST
A failed or malfunctioning EGR system can cause
e n g in e s p a rk kn ock, sa g s or h e s ita tio n , ro u g h idle,
and/or engine stalling. To assure proper operation of
the EGR system all passages and moving parts must
be free from plugging or sticking as a result of depos­
its. It is also important for the entire system to be free
from leaks. Any hoses or components found to be leak­
ing should be replaced.
Inspect all hose connections between throttle body,
intake manifold, and EGR control valve. Replace any
hoses that are hardened, cracked, or melted, and any
faulty connectors.
Operation of the EGR control system and valve
should be checked with the engine fully warmed up
and running (engine coolant temperature over 150°F).
Allow the engine to idle, in neutral, for 70 seconds
with the throttle closed. Abruptly accelerate the en­
gine to approximately 2000 rpm, but not over 3000
rpm. Visible movement of the EGR valve stem should
occur during this operation. This can be determined
by change in the relative position of the groove on the
EGR valve stem. This operation may be repeated sev­
eral times to confirm movement. Movement of the
stem indicates that the control system is functioning
correctly. If faulty operation is indicated by the above
check, use the service diagnosis procedures to deter­
mine the problem area.
EGR GAS FLOW TEST
The following procedure should be used to deter­
mine if EGR gas is flowing through the system:
Connect a hand vacuum pump to the EGR valve
vacuum motor. With engine running at idle speed,
slowly apply vacuum. Engine speed should begin to
drop when applied vacuum reaches 2.0 to 3.5 inches
Hg vacuum. Engine speed may drop quickly or engine
may even stall. This indicates that EGR gas is flowing
through the system.
If both this EGR gas flow check and the control
system check are completed satisfactorily, then the
EGR system is functioning as intended.
If engine speed does not drop off when above test is
performed, remove both the EGR valve and EGR tube
and check for plugged passages.Also, check the intake
manifold inlet passage. Clean or replace these compo­
nents for restoration of proper flow.
 EGR DIAGNOSIS CHART

NOT 1: ALL TESTS MUST I I MAD! WITH FULLY WARM ENGINE RUNNING
CONTINUOUSLY FO I AT LEAST TWO MINUTES.
WARNINGS IE S U i l TO APPLY PARKING MAKE ANDIOl UlOCiC WHEELS i l f O t l PERFORMING
IDLE CHECK O i ADJUSTMENT, O i ANY ENGINE RUNNING TESTS O i ADJUSTMENTS.

C ondition . P o s s i b l e Co us# Correction

EGR WALWi STEM (a) Cracked, leaking, disconnected or (a) Verify correct hose connections and leak check
DOES NOT MOW! plugged hoses. and confirm that all hoses are open. If defective
ON SYSTEM TEST. hoses are found, replace hose harness.
(b) Disconnect hose harness from EGR vacuum
transducer and connect auxiliary vacuum
supply. Raise engine rpm to 2000 rpm and
hold. Apply 10" Hg vacuum while checking
valve movement. If no valve movement occurs,
replace valve/transducer assy. If valve opens
(approx. 3 mm or 1/8" travel), hold supply
vacuum to check for diaphragm leakage.
Valve should remain open 30 seconds or
longer. If leakage occurs, replace valve/
transducer assy. If valve is satisfactory, check
control system. .
EGR VALWi STEM (a) Defective control system — (a) Remove throttle body and inspect port (slot
DOES NOT MOWI plugged passages. type) in throttle bore and associated passage
ON SYSTEM TEST. in throttle body. Use suitable solvent to remove
OPERATES deposits and check for flow with light air
NORMALLY pressure. Normal operation should be
ON EXTERNAL restored to EGR system.
VACUUM SOURCE. (b) Defective control system — (b) Refer to Group 14. General Diagnosis
solenoid or solenoid control circuit. "On Board Diagnostics" to check solenoid.
ENGINE WILL NOT (a) High EGR valve leakage in closed (a) If removal of vacuum hose from EGR valve
IDLE. DIES OUT ON position. does not correct rough idle,
RETURN TO IDLE O i (a1) Turn engine off. Remove the air cleaner
IDLE IS WHY ROUGH exposing the inlet to the throttle body.
OR SLOW. (a2) Disconnect the backpressure hose from the
EGR valve.
(a3) Using a nozzle with a rubber grommet connec­
tion, direct compressed air (50 to 60 psi) down
through the steel backpressure tube on the
EGR valve while opening and closing the
throttle blade.
(a4) If the sound from the compressed air changes
distinctly in step a3, the poppet is leaking and
air is entering the intake manifold. Replace the
EGR valve.
(b) EGR tube to intake manifold leak. (b) Remove tube and visually inspect tube seal
on gasket. Tube end should be uniformly
indented on gasket with no signs of leak.
If signs of exhaust gas leakage are present,
replace gaskets and tighten flange nuts to
23 N-m (200 in. lbs.). If an intake plenum leak
persists, replace EGR tube and gaskets,
following installation instructions.
(c) Solenoid or control signal to solenoid (c) Verify correct hose connections and leak
failure. check and confirm that all hoses are open.
If defective hoses are found, replace hose
harness.
(d ) Refer to Group 14, General Diagnosis
“ On Board Diagnostics” to check solenoid.

NOTEs DO NOT ATTEMPT TO CLEAN BACKPRESSURE EGR WALWEf REPLACE

ENTIRE WALWIfTRANSPUCElt ASSEMBLY If NECESSARY.
EGR SYSTEM SERVICE
EGR VALVE REMOVAL
(1) Disconnect vacuum line between the throttle
body and the electric EGR transducer (EET). (Fig. 11)
Inspect for damage.
(2) Remove EGR valve bolts (2) from intake manifold.
(3) Remove EGR valve from intake manifold.
(4) Clean gasket surface and discard old gasket.
Check for any signs of leakage or cracked surfaces.
INSTALLATION
(1) Assemble EGR valve with new gasket onto the
intake manifold.
(2) Install attaching bolts (2) and torque to 22 N-m
(200 in. lbs.).
(3) Reconnect vacuum line between the throttle body
and electric EGR transducer (EET).
EGR TUBE REMOVAL
(1) Remove EGR tube attaching bolts (4) from in­
take and exhaust manifolds.(Fig. 12)
(2) Remove EQR tube.
(3) Clean intake and exhaust manifold gasket sur­
faces and EGR tube flange gasket surfaces. Discard
old gaskets.
(4) Check for signs of leakage or cracked surfaces on
either manifolds or tube.
INSTALLATION
(1) Loose assemble EGR tube, with new gaskets into
place on intake and exhaust manifolds with attaching
bolts.
(2) Torque attaching bolts (4) to 22 N*m (200 in.lbs.).
Fig. 12 EGR Mounting TBI Engines
 SAFETY NOTICE
CAUTION
ALL SERVICE AND REBUILDING INSTRUCTIONS CONTAINED HEREIN ARE
APPLICABLE TO, AND FOR THE CONVENIENCE OF, THE AUTOMOTIVE
TRADE ONLY. All test and repair procedures on components or assemblies in
non-automotive applications should be repaired in accordance with instructions
supplied by the manufacturer of the total product.

Proper service and repair is important to the safe, reliable, operation of all motor vehicles.
The service procedures recommended and described in this publication were developed
for professional service personnel and are effective methods for performing vehicle
repair. Following these procedures will help assure efficient economical vehicle
performance and service reliability. Some of these service procedures require the use of
special tools designed for specific procedures. These special tools should be used when
recommended throughout this publication.

Special attention should be exercised when working with spring or tension loaded
fasteners and devices such as E-Clips, Circlips, Snap rings, etc., as careless removal
may cause personal injury. Always wear safety goggles whenever working on
vehicles or vehicle components.

It is important to note that this publication contains various Cautions and Warnings.
These should be carefully read in order to minimize the risk of personal injury, or the
possibility that improper service methods may damage the vehicle or render it unsafe.
It is important to note that these Cautions and Warnings cover only the situations and
procedures Chrysler Corporation has encountered and recommended. Chrysler
Corporation could not possibly know, evaluate, and advise the service trade of all
conceivable ways that service may be performed, or of the possible hazards of each.
Consequently, Chrysler Corporation has not undertaken any such broad service review.
Accordingly, anyone who uses a service procedure, or tool, that is not recommended in
this publication must assure oneself thoroughly that neither personal safety, nor vehicle
safety, be jeopardized by the service methods they select.

WE SUPPORT
VOLUNTARY MECHANIC
CERTIFICATION
THROUGH

SERVICE
 CHRYSLER
CORPORATION

WIRING DIAGRAMS
SERVICE MANUAL
SUPPLEMENT

1991 FRONT WHEEL DRIVE

ALL WHEEL DRIVE
VAN/WAGON

CHRYSLER
W CORPORATION

NO PART OF THIS PUBLICATION MAY BE

REPRODUCED, STORED IN A RETRIEVAL
SYSTEM, OR TRANSMITTED, IN ANY FORM
OR BY ANY MEANS, ELECTRONIC, ME­
CHANICAL, PHOTOCOPYING, RECORDING,
OR OTHERWISE, WITHOUT THE PRIOR
WRITTEN PERMISSION OF CHRYSLER
CORPORATION.

Chrysler Corporation reserves the right to make changes in design or to make

additions to or improvements in its products without imposing any obliga­
tions upon itself to install them on its products previously manufactured.

Litho In U.S.A. Copyright © 1991 Chrysler Corporation 20M291

 FOREWORD
This supplement contains revised wiring diagrams for
the Front Wheel Drive-All Wheel Drive Van/Wagon.
These diagrams supercede all diagrams found in Ser­
vice Manual 81-370-1105.
The information contained in this Service Manual has
been prepared for the professional automotive techni­
cian involved in daily repair operations.
This supplement contains the latest information at the
time of publication and incorporates the wiring sche­
matics for the basic vehicle and optional equipment.
An alphabetical index is provided to help you in locat­
ing a system or component. All diagrams are identified
by SHEET NUMBER which is found in the lower right
or lefthand corner of the page.
Chrysler Corporation reserves the right to change test­
ing procedures, specifications, diagnosis, repair meth­
ods, or vehicle wiring at any time without prior notice
or incurring obligation.
Information describing the operation and use of stan­
dard and optional equipment is included in the Own­
er’s Manual provided with the vehicle.
 — ------------------- — —------------------ ---------- WIRING DIAGRAMS
WIRING DIAGRAMS S-BODY H-K
ALPHABETICAL INDEX
Wiring Diagram Name____________________ Sheet Number
ABS Pump Motor Connector ............................................ 123
ABS Pump Motor R e la y ......................................................35
ABS Warning Lamp R elay................................................... 3 7 -
A/C Heater System 2.5L Engine ................................... 27, 28
A/C Clutch Relay ............................................................ 28
A/C Damped Pressure S w itc h .......................................... 27
A/C Fan Motor ...............................................................28
A/C Fan Motor Relay ......................................................27
A/C High Pressure Cut-Out S w itc h ................................... 27
Blower Motor ................................................................. 27
C lu tc h .............................................................................28
Compressor ................................................................... 28
Control Switch ...............................................................27
Diode .............................................................................28
Electronic A/C Cycling S w itc h ..........................................27
Fuse ............................................................................... 27
Lamp-Switch Illum ination.................................................27
Radiator Fan Motor ........................................................28
Radiator Fan R e la y.......................................................... 28
R esistor.......................................................................... 27
S w itc h .............................................................................27
A/C Heater System 3.0L & 3.3L E ngine....................... 29, 30
A/C Clutch Relay ............................................................ 30
Control Switch ...............................................................29
A/C Damped Pressure S w itc h ..........................................29
A/C Fan Cut-Out Switch .................................................29
A/C Fan Motor ...............................................................30
A/C Fan Motor Relay ..................................................... 29
A/C High Pressure Cut-Out ............................................ 29
Ambient Air Temperature S ensor..................................... 29
Blower Motor ................................................................. 29
Clutch ............................................................................ 30
Compressor ................................................................... 30
Diode ............................................................................ 30
High Pressure Cut-Out Switch ........................................ 29
Radiator Fan Motor ........................................................30
Radiator Fan R e la y..........................................................30
R esistor.......................................................................... 29
S w itc h ............................................................................ 29
Alternator .................................................................. . . 6 , 8
Ambient Switch-Overhead Console ..................................... 84
Anti-Lock Brake S ystem ................................... 34, 35, 36, 37
ABS Pump Motor Relay .................................................35
ABS Warning Lamp Relay .............................................. 35
Connector 60 Way ....................................................... 124
Controller ...................................................34, 35, 36, 37
Diagnostic Connector ..................................................... 37
Left Front Wheel Sensor .................................................34
Left Rear Wheel Sensor ................................................ 34
M o d u la to r..........................................................35, 36, 37
Pump M o to r................................................................... 35
Right Front Wheel Sensor .............................................. 34
8W-1
Wiring Diagram Name____________________ Sheet Number
Right Rear Wheel Sensor ............................ .................. 34
System Relay ................................................................. 36
Anti-Lock Brake System Controller Connector .................. 124
Automatic Idle Speed Motor 2.5L E n g in e ............................ 12
Automatic Idle Speed Motor 3.0L E ngine............................ 20
Automatic Idle Speed Motor 3.3L E ngine............................ 22
Automatic Shutdown Relay 2.5L Engine.............................. 14
Automatic Shutdown Relay 3.0L E ngine.............................. 19
Automatic Shutdown Relay 3.3L Engine.............................. 24
Automatic Transmission Switch ............................................ 9
Back-Up Lamp Switch 2.5L Engine ..................................... 8
Back-Up Lamp R elay............................................ 33, 92, 100
Battery ................................................................. 1, 5, 7, 22
Brake Warning Indicator L a m p ............................................ 72
Body Computer .............................. 101, 102, 103, 104, 105
C lu ste r.......................................................................... 104
F u se ......................................................................101, 102
Left Pod ...............................................................103, 104
Park Brake Switch ........................................................105
Right P o d ..................................................................... 103
Warning Lamp Center .......................................... 102, 104
Body Computer Connectors ..................................... 115, 116
Body to Instrument Panel Connector (16 way) ......... 121, 122
Bulkhead Disconnect Connector (50 way) . . . . .106, 107, 108
Cam S ensor........................................................................26
Cargo L a m p ........................................................................ 82
Charge Temperature Sensor .............................................. 24
Charging System 2 . 5 L ..................................................... 5, 6
Alternator..................................................... .................... 6
Battery ............................................................................ 5
Ignition-Off Draw Connector.............................................. 5
Charging System 3.0L, 3 .3 L ............................................ 7, 8
Alternator.......................................................................... 8
Battery ....................... ..................................................... 7
Ignition-Off Draw Connector.............................................. 7
Choke Filter (R adio)............................................ ................62
Cigar Lighter ..................................................................... 44
Circuit Breaker Electric Door Locks ..........................2, 78, 87
Circuit Breaker Electric Windows ...................................3, 79
Circuit Breaker Headlamps....................................... 2, 44, 50
C lock..................................................................... 58, 60, 62
Cluster Illumination L a m p ................................................... 52
Combo F lasher................................................................... 50
Console-Overhead................................................... 84, 85, 86
Ambient S w itc h ...............................................................85
Connector ..................................................................... 84
Fuse ...............................................................................85
Ground .......................................................................... 84
Left Vent Switch ............................................................ 86
Right Vent Switch .......................................................... 86
Twin Map L a m p s ..................................................... 84, 85
Control-Rear H eater............................................................ 65
Wiring Diagram Name Sheet Number
Control-Rear Heater Lamp . . . . . . . . . . . . . . . . . . . . . . . . . 6 5
Coolant Sensor 2.5L Engine . ............ ................................15
Coolant Sensor 3.0L Engine ....................... .. ................... 21
Coolant Sensor 3.3L Engine .............................................. 26
Courtesy Lamp S yste m ....................................... .. .81, 82
Crank S e n s o r......................................................................25
Cut-Out Switch-A/C ..................................................... 27, 29
Cycling Switch-A/C Electronic ............................................ 27
Daytime Running Light Module W irin g .................................92
Detonation Sensor 3.3L Engine .......................................... 25
Diagnostic Connector 2.5L EFI E n g in e .............................. .14
Diagnostic Connector 3.0L EFI E n g in e ................................ 19
Diagnostic Connector 3.3L EFI E n g in e .................................23
Diagnostic Connector Electronic Transm ission..................... 56
Diagnostic Solenoid-Exhaust Gas ....................................... 13
Dimmer Switch-Headlamp ..................................... 4 1 , 5 0 , 9 3
Dimming Module ............................................ 50, 51, 55, 84
Diode Courtesy L a m p s ........................................................81
Direct Ignition System ........................................................26
Distance Sensor 2.5L Engine EFI ....................................... 15
Distance Sensor 3.0L E ngine.............................................. 21
Distance Sensor 3.3L Engine............ .................................. 25
Dome and Courtesy Lamps .......................................... 81, 82
Door and Liftgate Ajar Warning S y ste m .............................. 73
Door Sw itches................................................................. 73
Liftgate Switch ...............................................................73
Left and Right Front Switches ....................................... 73
Sliding Door Switch ........................................................ 73
Electronic Automatic Transaxle Solenoid C onnector............126
Electronic Automatic Transaxle .............................. 31, 32, 33
Back-Up Lamp Relay ..................................................... 33
C onnector...................................................................... 119
Control Module .................................................31, 32, 33
Neutral Safety Switch ......................................................31
PRNDL Switch ...............................................................32
Safety Shutdown Mini R elay............................................ 32
Transaxle Solenoids ........................................................32
Turbine Input Speed S ensor............................................ 31
Turbine Output Speed S e n so r.......................................... 31
Electronic C luster................................... .......................55, 56
Connector 14 Way ........................................................118
Diagnostic Connector ......................................................56
Fuse ................................................................................55
Ground .......................................................................... 55
Electronic Fuel Injection System 2.5L
EFI Engine ........................................12, 13, 14, 15, 16
Automatic Idle Speed M o to r............................................ 12
Automatic Shutdown Relay ............................................ 14
Connector 60 Way-SBEC ...............................................109
Diagnostic Connector ..................................................... 14
Distance Sensor ............................................................ 15
Distributor ......................................................................15
Engine Coolant Sensor ................................................... 15
Exhaust Gas Recirculation Solenoid .................................13
Ground ................ .. .. . ................................................. 12
Heated Oxygen Sensor ................................................... 12
Ignition Coil ................................................................... 14
Injector ...........................................................................16
Wiring Diagram Name ______ Sheet Number
MAP S e n s o r....................... ................ .. .13
Part Throttle Unlock Solenoid .......................................... 16
Purge Solenoid ......... .. ................................... . . .13
Single Board Engine C o n tro lle r.............. 12, 13, 14, 15, 16
Throttle Position Sensor .................................................12
Electronic Fuel Injection System
3.0L Engine ..................................... 17, 18, 19, 20, 21
Automatic Idle Speed M o to r............................................ 20
Automatic Shutdown Relay ............................................ 18
Connector 60 Way-SBEC .............................................. 110
Diagnostic Connector ..................................................... 18
Distance Sensor ............................................................ 21
Distributor ..................................................................... 21
Engine Coolant Sensor ................................................... 21
Heated Oxygen Sensor ................................ .................. 17
Ignition Coil ................................................................... 18
Injectors ........................................................................ 19
MAP S e n s o r................................................................... 20
Purge Solenoid ...............................................................17
Single Board Engine C on tro ller.............. 17, 18, 19, 20, 21
Throttle Position Sensor ................................... ............. 20
Electronic Fuel Injection System
3.3L Engine ..................................... 22, 23, 24, 25, 26
Automatic idle Speed M o to r............................................ 22
Automatic Shutdown Relay ............................................ 24
Cam Sensor ................................................................... 26
Charge Temperature S e n s o r............................................ 22
Connector 60 Way-SBEC .............................................. 111
Crank Sensor ................................................................. 25
Detonation Sensor .......................................................... 25
Diagnostic Connector ..................................................... 24
Distance Sensor ............................................................ 25
Direct Ignition System ................................................... 26
Engine Coolant Sensor ................................................... 26
Heated Oxygen Sensor ................................................... 22
Injectors ........................................................................ 26
MAP S e n s o r................................................................... 22
Purge Solenoid ................................................... ........... 23
Single Board Engine C o n tro lle r.............. 22, 23, 24, 25, 26
Temperature Sending Unit .............................................. 26
Throttle Position Sensor .................................................22
Electronic Transaxle Control Module ................................ 117
Flasher-Hazard Warning ..................................................... 50
Flasher-Turn Signal ......................... .................................. 50
Fog Lamp S yste m ...............................................................70
Four Wheel Drive Vacuum Solenoid System .............. 99, 100
Front Door Ajar Switches ................................................... 73
Front Door Courtesy Lamps .............................................. 81
Front Door Jamb Switch Left ............................................ 81
Front Door Jamb Switch R ig h t............................................ 82
Front End L ig h tin g ........................................................41, 42
Front End Lighting w/Daytime Running L ig h ts .............. 93, 94
Fuel Pump Motor and Gauge System .............................. .88
Fuel Pump Motor and Gauge System (AWD) ..................... 98
Fuel Tank Sending U n it.................................................88, 98
Fuse Application C h a rt.................................................1, 2, 3
Fuse B lo c k ........................................................................112
Wiring Diagram Name Sheet Number
Fuses
Fuse 1 ......... .................................... .. ............ 1, 5, 7, 53
Fuse 2 ................................... ....................... .3, 64, 76
Fuse 3 . . . . .2, 5 ,7 , 55, 57, 59, 61, 70, 71, 76, 78, 81
Fuse 5 . .......................... . .3, 4, 46, 49, 53, 57, 61, 101
Fuse 6 .............. ........................... 3, 4, 46, 49, 53, 57, 61
Fuse 7 ................................... 3, 4, 46, 49, 53, 57, 59, 61
Fuse 9 ................................................... 1, 50, 54, 55, 64
Fuse 13 ............................3, 4, 5, 11, 13, 67, 72, 74, 91
Fuse 14 ............................ 3, 4, 5, 11, 13, 43, 66, 72, 74
Fuse 15 ..........................3, 4, 5, 11, 13, 55, 72, 74, 102
Fuse 1 7 ......................................................................2, 50
Fuse 18 ........................................................ 2, 41, 70, 93
Fuse 19 .......................................................... . .1, 43, 65
Fuse 2 0 ......................................................................1, 65
Fuse 21 ................................................. 1 , 4 4 , 5 0 , 6 1 , 7 0
Fuse 22 ........................................................ 1 , 4 4 , 5 0 , 6 1
Fuse 23 ........................................................ 1, 44, 50, 61
Fuse 24 ..........................3, 9, 11, 28, 30, 64, 65, 89, 92
Fuse 26 ................................................... 3, 4, 27, 29, 57
Fusible Links .................................1, 2, 3, 4, 5, 6, 7, 8, 11
Ground S tra p s........................................................58, 60, 62
Hazard Warning System .............................................. 53, 54
Flasher ........................................................................ .50
Fuse ............................................................................... 53
S w itc h .............................................................................53
Headlamp Dimmer S w itc h ............................................ 41, 50
Headlamp Switch System ................................................... 49
Headlamp Switch Controlled Interior Lamps ................ 51, 52
Combo Flasher ...............................................................50
Dimmer Switch ......... .....................................................50
Low Beam Relay ............................................................ 49
Park Lamp R e la y ............................................................ 50
Heated Oxygen Sensor 2.5L EFI E n g in e .............................. 12
Heated Oxygen Sensor 3.0L Engine ...................................17
Heated Oxygen Sensor 3.3L Engine .............. .................... 22
Heated Rear Window Defogger System .............................. 64
Indicator Lamp ...............................................................64
L.E.D................................................................................64
S w itc h .............................................................................64
Switch Illumination L a m p s.............................................. 64
Heater System 2.5L, 3.0L and 3.3L Engine ....................... 63
Blower Motor ................................................................. 63
Fuse ............................................................ .................. 63
R e sisto r.......................................................................... 63
S w itc h ............................................................................ 63
High Beam Indicator Lamp .................................................72
Horn System ......................................................................44
Horns ............................................................................ 44
Horn R e la y..................................................................... 44
Horn Switch ................................................................... 44
Ignition Coil 2.5L EFI Engine..................................... .. .14
Ignition Coil 3.0L Engine ................................................... 18
ignition Off Disconnect ................................................... 5, 7
Ignition S w itc h ..................................................................... 4
Illuminated Entry System ................................................... 85
Instrument Panel Ground System ................................ 47, 48
Instrument Panel Illumination L a m p s.............................. .. .52
Wiring Diagram Name Sheet Number
Instrument Panel to Body Wiring Connector 16-Way . . . . .121
Instrument Panel to Steering Column Wiring
Connector-24 Way ..................................... ...113
Lamps
A/C and Heater Control ............................................ 27, 52
Anti-Lock Warning In d ic a to r............................................ 72
Ash Receiver Lamp ....................................................... 51
Back-Up Lamps ........................................................89, 90
Brake Warning Indicator Lamp ....................... ................72
Cargo Lamp .......................................................... .. .82
Center High Mount Stop L a m p ....................................... 90
Cigar Lighter Lamp ....................................................... 51
Cluster Illumination Lam ps.............................................. 52
Courtesy L a m p s ........................................................81, 82
Dome Lamps ................................................................. 82
F o g ............................................................ .................... 70
Front Door Courtesy L a m p s ............................................ 81
Glove Box Lamp ............................................................ 82
HALO ............................................................................ 81
Headlamp-Left.......................................................... 42, 94
Headlamp-Right ....................................................... 41, 93
Headlamp Switch L a m p ...................................................49
Heated Rear Window Defogger Indicator L am p................ 64
Heated Rear Window Defogger Switch L a m p .................. 52
High Beam Indicator Lamp ............................................ 72
Instrument Panel Illumination Lamps .............................. 52
Left Front Turn Signal L a m p ..................................... 42, 94
Left Pod Lamp ........................................................52, 81
Left Turn Signal Indicator Lamp .............................53, 72
License Lamps .............................................................. 90
Liftgate Courtesy L a m p ................................................... 82
Liftgate Release Switch L a m p ..........................................52
Low Beam Relay L a m p ....................... ........................... 49
Maintenance Required L am p............................................ 72
Map Lamp ................................... ........................... 83, 84
Overhead Console Illumination L a m p s ................ 52, 83, 84
Parking Brake Warning L a m p ..........................................72
Parking Lamp-Left ................................................... 42, 94
Parking Lamp-Right ................................................ 41, 93
Rear Dome Lamp ..........................................................82
Rear Cargo Lamp .......................................................... 82
Rear Courtesy L a m p ....................................................... 82
Rear End Lighting System ....................................... 89, 90
Rear Heater A/C Control Lamp ....................................... 65
Rear Heater Control L a m p .............................................. 65
Right Front Turn Signal L a m p......... .. . ! ................ 41, 93
Right Pod Lamp ............................................................ 51
Right Turn Signal Indicator Lamp ............................53, 72
Seat Belt Warning Lamp ................................................ 72
Side Marker Lamp-Left Front ...................................42, 94
Side Marker Lamp-Left Rear ......................................... 89
Side Marker Lamp-Right Front ................................ 41, 93
Side Marker Lamp-Right R ear......................................... 90
Stop Lamp-Left R e a r................................................ 54, 89
Stop Lamp-Right R e a r.............................................. 54, 90
Tail Lamp-Left Rear ....................................................... 89
Tail Lamp-Right Rear ..................................................... 90
Turn Signal Indicator Lamps ................................... .72
Wiring Diaflram N a m e ______ Sheet Number
Turn Signal Lamp-Left Front . . . ......... .. . .42, 94
Turn Signal Lamp-Left Rear ................................ . .54, 89
Turn Signal Lamp-Right Front ................................... 41, 93-
Turn Signal Lamp-Right Rear ................................... 54, 90
Twin Map L a m p s ..................................................... 84, 85
Underhood L a m p ................................... ............. ........... 95
Underseat Storage .......................................................... 82
Visor L a m p s ................................................................... 82
Liftgate Courtesy Lamp ..................................................... 82
Liftgate Latch S w itc h .......................................................... 82
Liftgate Release Switch Lamp ............................................ 71
Liftgate Release System ..................................................... 71
Fuse ............................................................................... 71
Indicator Lamp ...............................................................71
Solenoid ........................................................................ 71
S w itc h ................................... ......................................... 71
Liftgate Wiper and Washer System .............................. 67, 68
M otor-W asher................................................................. 68
M otor-W iper............................ .......................................68
S w itc h ............................................................................. 67
Timer ............................................................................. 67
Low Washer Fluid Switch ............................ .......................45
Map L a m p ................ .............................................. .. .84
Map Lamp S w itc h ............................................ ..................84
Map Sensor 2.5L EFI E ngine.............................................. 13
Map Sensor 3.0L Engine ................................................... 20
Map Sensor 3.3L Engine ................................................... 22
Modules
Daytime Running Light ................................................... 94
Intermittent W ip e ............................................................ 45
Overhead Console .......................................................... 84
Single Board Engine Controller
2.5L EFI E n g in e ............................ .. .12, 13, 14, 15, 16
Single Board Engine Controller
3.0L Engine ..................................... 17, 18, 19, 20, 21
Single Board Engine Controller
3.3L Engine ...................................... 22, 23, 24, 25, 26
Motors
A/C Fan ....................................................................28, 30
Blower-A/C .......................................................... .. .27, 29
Blower-Heater ................................................................. 57
Fuel Pump ............................................ .................. 88, 98
Idle S peed.......................................................... 12, 20, 22
Intermittent Wipe Washer .............................................. 45
Intermittent Wipe Windshield W ip e r................................ 46
Liftgate W a s h e r...............................................................68
Liftgate W ip e r ................................................................. 68
Power Door Locks ................................................... 77, 78
Power M irro r................................................. .. .75, 76
Power S e a t...................................................................... 87
Power Vent ................................................................... 86
Power Window ........................................................79, 80
Pump (ABS) ................................................................... 35
Radiator Fan Motor ..................................... 28, 30, 96, 97
Starter 2.5L Engine ........................................................11
Starter 3.0L Engine ................................................... 9, 10
Starter 3.3L Engine ........................................................10
Multi-Function Switch Connector....................... ................ 119
Wiring Diagram Name ________ Sheet Number
Name Brand Speaker R e la y ....................................... .. .61
Neutral Safety Switch 2.5L E n g in e ....................................... 8
Neutral Safely Switch EATX................ ................................31
Oil Pressure Switch .............. ................................38, 39, 40
Oil Pressure and Temperature Warning System 2.5L ......... 38
Oil Pressure and Temperature Warning System 3.0L . . . . .39
Oil Pressure and Temperature Warning System 3.3L ......... 40
Overhead Console .................................................83, 84, 86
Ambient S w itc h ...............................................................84
Fuse ............................................................................ .84
Twin Map Lam ps............................ ............................... 83
Overhead Console Connector ............................................ 117
Parking Brake Warning Lamp ............................................ 72
Parking Brake Warning Lamp S w itc h .................................105
Park Lamp Relay ...............................................................50
Part Throttle Unlock Solenoid ............................................ 16
Power Door Lock System ............................................ 77, 78
Circuit Breaker ............................................................... 78
Left Front Door Motor .............. .....................................77
Left Front Door Switch . ................................................. 77
Lock R e la y ......................................................................78
Right Front Door Motor .................................................77
Right Front Door Switch ................................................ 77
Sliding Door C ontacts..................................................... 78
Sliding Door Motor ........................................................78
Switch Functions ............................................................ 77
Unlock Relay................................................................... 78
Power Rear Quarter Windows ............. . ......................... .86
Motors .......................................................................... 86
S w itc h ............................................................................ 86
Power Remote Mirrors ....................................... .. .75, 76
Left Motors ................................................................... 75
Right Motors ................................................................. 76
S w itc h ................................ ............................................75
Switch F un ctio ns............................................ .. .75
Power Seat S y s te m ............................................................ 87
Circuit Breaker ..................................... ........................ 87
Front Vertical M o to r ........................................................87
Horizontal Motor ............................................................ 87
Rear Vertical Motor ........................................................87
S w itc h ............................................................................ 87
Switch F unctions............................................................ 87
Power Window Lift System .......................................... 79, 80
Circuit Breaker ...............................................................79
Left Front Master S w itc h .................................................79
Left Front Motor ............................................................ 79
Left Front S w itc h ............................................................ 79
Right Front Motor .......................................................... 80
Right Front S w itc h .......................................................... 80
Power Window Connector and Switch Functions .................79
Purge Solenoid 2.5L EFI Engine.......................................... 13
Purge Solenoid 3.0L Engine .............................................. 17
Purge Solenoid 3.3L Engine .............................................. 23
Radiator Fan Motor ..................................................... 96, 97
Radiator Fan Relay ..................................................... 96, 97
Radiator Fan System w/Heater ..................................... 96, 97
Radio Choke .....................................................................62
Radio-2 Speaker .................................. ...................... 57, 58
Wiring Diagram Name Sheet Number
Radio w/Name Brand Speakers . . . . . . . . . . . . . . . . .61, 62
Radio w/o Name Brand Speakers .......................... .59, 60
Radio-AM/FM Stereo Cassette ................................ .. .60, 62
Radio Speakers , . ................... .57, 58, 59, 61, 62
Rear Heater A/C System ............................................... 65, 66
Blower Motor ................................................................. 66
Blower S w itch-F ront................................... .................... 65
Blower Switch-Rear ................................................... . .66
Fuses .............................................................................65
Heater A/C Assembly ..................................................... 66
Lamp-Switch illumination F ro n t....................................... 65
Lamp-Switch Illumination Rear ....................................... 66
Microtemp Sensor .......................................................... 66
Mode Servo M o to r.......................................................... 66
Mode Servo Switch . ...................................................... 66
Relay .............................................................................65
Rear Liftgate Wiper and Washer System ..................... 67, 68
Fuse ............................................................................... 67
Motors .......................................................................... 68
Timer ............................................................................ 67
S w itc h .............................................................................67
Rear Lighting System/Trailer Tow ................................ 89, 90
Back-Up Lamp Relay ..................................................... 89
CHMSL Lamps .............................................................. 90
Left Back-Up Lamp ........................................................89
Left License Lamp ......................................... ............... 90
Left Side Marker L a m p ................................................... 89
Left Turn Signal Lamp ................................................... 89
Left Tail Lamp ...............................................................89
Right Back-Up Lamp ....................................... ............. 90
Right License Lamp ........................................................90
Right Side Marker Lamp .............................. .................. 90
Right Stop L a m p .................. .................... .................... 90
Right Turn Signal Lamp .................................................90
Right Tail L a m p.............................................................. 90
Reiays
ABS Pump Motor Relay .................................................35
ABS Warning Relay ....................................................... 37
A/C Clutch Relay .............................................. 28, 30, 65
A/C Fan Motor R elay................................................ 27, 29
Automatic Shutdown Relay ................................ 14, 18, 24
Back-Up Lamp R elay.................................................33, 89
Combo-Flasher Relay ..................................................... 50
Horn Relay . ....................................................................44
Low Beam Relay ............................................................ 49
Name Brand Speaker Relay ............................................ 61
Park Lamp R e la y ............................................................ 50
Power Lock Relay ..........................................................78
Power Unlock R e la y ....................................................... 78
Radiator Fan Relay ............................................ 30, 96, 97
Rear A/C and Fog Lights R e la y....................................... 64
Safety Shutdown R e la y ................................................... 32
Starter R e la y ..................................................... .9, 10, 11
System Relay (ABS) ........................................................ 36
Van Conversion R e la y..................................................... 91
Relay B ank........................................................................114
Seat Belt Warning System ' ........................................... , .74
Wiring Diagram Name _______ Sheet Number
Sensors
A/C Ambient Temp................ .................................. .29, 84
Camshaft .............................. ......................... .. .26
Charge Temp ......................................... ........... .. .22
Crankshaft ..................................................................... 25
Detonation ....................................... ..............................25
Distance 2.5L Engine ......................... ........................... 15
Distance 3.0L Engine ..................................................... 21
Distance 3.3L Engine ................................................ .. .25
Engine Coolant 2.5L E ngine............................................ 15
Engine Coolant 3.0L E n g in e ............................................ 21
Engine Coolant 3.3L E n g in e ............................................ 26
Heated Oxygen 2.5L E ngine..................................... .12
Heated Oxygen 3.0L E n g in e ............................................ 17
Heated Oxygen 3.3L E ngine............................................ 22
Left Front Wheel . . . s .............................. .................... 34
Left Rear Wheel ............................................................ 34
Low Windshield Washer F lu id ..........................................45
Map 2.5L E ng in e............................................................ 13
Map 3.0L E n g in e ............................................................ 20
Map 3.3L E ngine............................................................ 22
Output Speed .................................................................31
Right Front Wheel ..........................................................34
Right Rear Wheel ......................................................... 34
Throttle Position 2.5L E n g in e ..........................................12
Throttle Position 3.0L E n g in e ....................... .................. 20
Throttle Position 3.3L E ngine ..........................................22
Turbine S peed.................................................................31
Single Board Engine Controller-SBEC 60 Way Connector
2.5L Engine .................................................................109
Single Board Engine Controller-SBEC 60 Way Connector
3.0L Engine .................................................................110
Single Board Engine Controller-SBEC 60 Way Connector
3.3L Engine .................................................................111
Solenoids
Exhaust Gas Recirculation 2.5L EFI Engine ..................... 13
Liftgate Release.............................................................. 71
Part Throttle Unlock ........................................................ 16
Purge 2.5L E.F.I. Engine................................................ 13
Purge 3.0L E ngine..........................................................17
Purge 3.3L E ngine..........................................................23
Vacuum (AWD) ..................................................... 99, 100
Speed Control System ........................................................ 43
Control Switch .............................................................. 43
Fuse ............................................................................... 43
Servo ............................................................................ 43
Stop Lamp Switch ..................................................... .. .43
Splices
Splice A 0 ..................................................................... 6, 8
Splice A 1 ..................................................................... 6, 8
Splice A 2 ..................................................................... 6, 8
Splice A 3 .............................................................. 6, 8, 65
Splice A3-1 ...................................................................44
Splice A 4 ..........................................................................7
Splice A4-1 ................................................................ 5, 7
Splice A4-2 .................................................................5, 7
Splice A 6 ....................... ..............................................6, 8
Splice A 1 0 ..................................................................... 35
Splice A11 .............................. .................................... 6 ,8
Wiring Diagram Name Sheet Number
Splice A14 , . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6, 8
Splice A14-1 ................ ......... .................... ............. 6, 8
Splice A 1 4 -2 .................. .................................. .. .6, 8, 18
Splice A15 ................... . .............. .5, 7, 10, 11, 54
Splice A16 ......... .. ..........................................28, 30
Splice A16-1 ................ ................................ ........... 6, 8
Splice A18 ..................... .............................................. 91
Splice A20 ..................... .............................. ................35
Splice A 2 1 ..................... .................................17, 23, 100
Splice A21-1 ................ ...................................13, 18, 23
Splice A21-2 ................ .............................. 5, 13, 18, 23
Splice A21-3 ................ ................................ 4, 5, 13, 67
Splice A 2 1 -4 .................. .............................................. 13
Splice A22 ................... .............................. 4, 65 , 79 , 92
Splice A61 ................... ................................... 16, 19, 25
Splice A61-1 .................. ......................................... 19, 26
Splice A 6 1 -2 .................. ..........................................19, 26
Splice A 6 1 -3 ................... . ............................................ 19
Splice B47 ..................... .............................................. 37
Splice C7 ..................... ...................................27, 29, 63
Splice C15 ..................... .............................................. 64
Splice C20 ............................ .................................. 28, 30
Splice C23 .............................................................. 28, 30
Splice D1 ..................... .................................33, 56, 101
Splice D1-1 ................... ....................................... 56, 101
Splice D2 ..................... ................................ 33, 56, 101
Splice D2-1 ................... ....................................... 56, 101
Splice E 2 ....................... .............................................. 51
Splice E 2 -1 ..................... . . . ....................................... 52
Splice E 1 7 ..................... ........................................51, 103
Splice E 9 2 ..................... ....................................... 51, 103
Splice F20 ..........................................................9, 11, 65
Splice F20-1 ................... .............................................. 66
Splice F 2 0 -2 ................... .............................................. 66
Splice F 2 0 -4 .............. .............................................. 11
Splice F21 ..................... .............................................. 79
Splice F21-1 .................. .............................................. 79
Splice F21-2 .................. ....................................... 83, 86
Splice F 2 1 -3 ................... ......................... .................... 86
Splice F35 ..................... ....................................... 44, 78
Splice F62 ..................... .............................................. 44
Splice G5 ..................... ....................................... 74, 102
Splice G 6 ....................... ...................38, 39, 40, 55, 104
Splice G7 ....................... ....................................... 25, 92
Splice G9 ..................... ....................................... 35, 104
Splice G 9 -1 ..................... ....................................... 4, 104
Splice G19 ..................... .............................................. 37
Splice K4 ..................... ................................... 15, 21, 25
Splice K4-1 ................... ............................ 15, 18, 21, 22
Splice K 4 -2 ..................... ....................................... 15, 26
Splice K4-3 .................. .............................................. 25
Spiice K6 ..................... ................................... 13, 20, 22
Splice K 7 ....................... .............................................. 25
Splice K11 ..................... ....................................... 19, 26
Splice K12 ..................... ....................................... 19, 26
Splice K13 ..................... ......................................... 19, 26
Splice K22 ................... ...................................20, 22, 31
Spiice K24 ................... ................................... 21, 25, 31
Wiring Diagram Name Sheet Number
Splice L1 ....................... ....................................... .89
Splice L 1 -1 ................ .. . . . .......................... .. .99
Splice L2 ............................ ................ .. . .50, 104
Splice L3 ............................ ............................ 41, 50, 93
Splice L7 . ............................ ..........................................50
Splice L7-1 ......................... ...................................54, 90
Splice L 7 -2 ......................... ..........................................90
Splice L20 ........................... ......................................... 50
Splice L39 ........................... ......................................... 70
SpliGe L44 ......................... ...................................70, 93
Splice L50 ........................... ......................................... 89
Splice L50-1 ......................... ..........................................90
Splice L 6 0 ............................ ................................ 53, 104
Splice L 6 1 ............................ ................................ 53, 104
Splice L62 ........................... ......................................... 90
Splice L62-1 ......................... ......................................... 90
Splice L63 ..................................................................... 89
Splice L94 ......................... ....................................... 104
Splice M1 ..................................................................... 81
Splice M1-1 ......................... ........................................ 77
Splice M1-2 ....................... ...................................82, 83
Splice M 2 ............................ . ...............................81, 102
Splice M2-1 ......................... ......................................... 81
Splice M2-2 ....................... .............. .................... 81, 83
Splice M2-3 ......................... ......................................... 82
Splice M11 ......................... ...................................81, 83
Splice M11-1 ....................... ......... ............................. 82
Splice M l 1-2 ....................... ....................... ,............... 82
Splice P33 ............................ ....................................... 78
Splice P 3 3 -1 ......................... ....................................... 77
Splice P34 ............................ ....................................... 78
Splice P 3 4 -1 ......................... ....................................... 77
Splice T16 ............................ . ..................................... 32
Splice T 4 1 ........................... ......................... 10, 31, 100
Splice V 3 .............................. ....................................... 45
Spiice V7 ............................ ................................ 45, 103
Splice V10 .......................... ................................ 45, 101
Splice V23 ............................ ....................................... 67
Splice X13 ........................... ....................................... 62
Splice X 1 3 -1 .......................... ................ ...................... 62
Splice X 1 3 -2 ......................... ....................................... 62
Splice X15 ............................ ....................................... 62
Splice X 1 5 -2 ......................... ....................................... 62
Splice X53 ......................... ............................58, 60, 61
Splice X54 ......................... ............................58, 60, 61
Splice X55 ......................... ............................58, 60, 61
Splice X56 ......................... ............................58, 60, 61
Splice Z0-1 ......................... ....................... ; .14, 17, 32
Splice ZO-2 ......................... ..........................................5
Splice Z1 ................................................................ 70, 93
Splice Z1 - 1 ............................ ......... ..............................35
Splice Z 1 - 2 ........................... .................................. 42, 94
Splice Z 1 -3 ............................ ....................................... 48
Splice Z 1 -4 ............................ ....................................... 48
Splice Z 1 -5 ............................ ................................. , . .47
Splice Z1-6 ......................... ............................54, 80, 81
Splice Z 1 - 7 ........................... ................................. 54, 89
Splice Z 1 - 8 ........................... .................................. 54, 90
Wiring ‘ Diagram Name Sheet Number
Splice Z1-9 . . . . . _____ _ . . . . . . . . . . , . . . . . .47, 82
Spiice Z1-10 . ....................................................... .. .90
Splice Z1-11 . ............ .................... ........... .....................90
Splice Z 1 - 1 2 ........................... .................... .. .52, 89
Splice Z1-13 ............................................................ 88, 98
Splice Z 1 -1 4 ................................................................... 86
Splice Z 1 -1 5 ................................................................... 76
Splice Z 1 -1 6 ................................................................... 70
Splice Z 1 -1 7 ................................................................... 28
Splice Z 1 -1 8 ................................................................... 99
Splice Z 1 -1 9 ................................................................... 66
Splice Z2 .............................................................. 47, 101
Splice Z 3 ................................ ....................................... 48
Splice Z 1 1 ..........................................................12, 17, 23
Spiice Z 1 2 .............................. .................... 14, 18, 86, 89
Splice Z13 ..................................................................... 32
Splice Z14 ..................................................................... 32
Starter System 2.5L TBi E ngine..........................................11
Motor .......................................................................... .11
Neutral Start/Back-Up lam p Switch ................................ 11
Relay ............................................................................ 11
Starter System 3.0L Engine .................................................9
M o to r ..................................................................... .. .9
Neutral Start/Back-Up Lamp S w itc h ................................... 9
Relay ...............................................................................9
Starter System 3.0L and 3.3L Engine with Electronic
Transmission ................................................................. 10
Motor ............................................................................ 10
Neutral Start/Back-Up Lamp Switch ................................ 10
Relay ............................................................................ 10
Steering Column to Instrument Panel Wiring
Connector 25 Way ....................................................... 120
Stop Lamp Switch ..........................................................43
Switches
A/C Clutch 2.5L EFI Engine ............................................28
A/C Clutch 3.0L & 3.3L Engine ..................................... 30
A/C Cycling Clutch ...................................................27, 29
A/C Damped P ressure.............................................. 27, 29
A/C Fan Cut Out ............................................................ 29
A/C Heater Blower ................................ .................. 27, 29
A/C High Pressure C ut-O ut....................................... 27, 29
Ambient-Overhead Console.............................................. 85
Automatic Transaxle Neutral Safety ................................ 31
Back-Up Lamp 2.5L Engine ............................................11
Brake Stop L a m p ............................................................ 43
Brake Warning Lamp . ............................................ 4, 105
Cargo Lamp .................................. ................................ 82
Courtesy Lamp ....................................................... 81, 82
Dimmer-Headlamp.............................................. 41, 50, 93
Dome Lamp-Rear............................................................ 82
Door A ja r-L e ft................ ................................................73
Door A ja r-R ig h t....................................... ...................... 73
Door Ja m b-Left.............................................................. 81
Door Jam b-R ight........................................................... 82
Door Lock-Electric ............................................ ............. 77
Fog Lamp ..................................................................... 70
Glove Box ..................................................................... 82
Hazard W arning.............................................................. 53
Wiring Diagram Name Sheet Number
Headlamp......... ......................................................... .. .49
Headlamp Dimmer .......................................................... 50
Heater B lo w e r......................... .......................................63
Heated Rear Window D efogg er................................... . .64
H o rn ................................ .............................................44
Ignition ............................................................................ 4
Intermittent W ip e ............................................................ 45
Key-in 81
Left Front Door J a m b ..................................................... 81
Left Front illuminated Entry ............................................ 85
Left Vent ........................................................................86
Liftgate Ajar ......... ..........................................................73
Liftgate Latch Switch ..................................................... 82
Liftgate Release................ .............................................. 71
Liftgate Wiper and W asher.............................................. 67
Map Lamp .......................................... .................... 84, 85
Neutral S afety..................................... .. .9, 11, 31, 100
Oil-Low Pressure ............................................... 38, 39, 40
Optical Horn ............................................................ 50, 93
Park Brake Warning ......... , ......................................... 104
Power Door L o c k s .......................................................... 77
Power Rear Quarter W indow s.......................................... 86
Power S e a ts ................................................................... 87
Power W in dow s....................................................... 79, 80
Power Remote Mirrors ................................................... 75
PRNDL .............. ........................................................... 32
Rear Heater A /C ....................................................... 65, 66
Right Front Door J a m b ...................................................82
Right Front Door Illuminated Entry ................................ 85
Right Vent ......... ............................................................86
Seat Belt Warning ..........................................................74
Seats-Electric .................................................................87
Sliding Door . . ........................................................ 73, 82.
Speed C o n tro l.................................................................43
Speed Control B rake....................................................... 43
Stop L a m p ..................................................................... 43
Temperature Sending..........................................38, 39, 40
Turn Signal ...................................................................53
Underhood L a m p ............................................................ 95
Underseat Storage ..........................................................82
Vent ............................................................................... 86
Window Lift ................................................................... 79
Windshield Washer Low F lu id ..........................................45
Windshield W iper-Interm ittent................................ .. .45
Temperature Sending Unit .............................. 26, 38, 39, 40
Throttle Position Sensor 2.5L EFI E ng in e............................ 12
Throttle Position Sensor 3.0L Engine ................................ 20
Throttle Position Sensor 3.3L Engine ................................ 22
Trailer Tow Connector ................................................ 89, 90
Turn Signal System ..................................................... 53, 54
Flasher ....................................................... .................. 50
Fuses ............................................................................ 53
Lamps-Front................................................ 41, 42, 92, 93
Lamps-Rear ...................................................................54
Switch Control .............................................................. 53
Underhood Lamp .............................................. ............... 95
.Underhood Lamp Switch ................................................... 95
Vacuum Solenoids.............................................................. 99
Wiring Diagram Name Sheet Number Wiring Diagram Name Sheet Number
Van Conversion Wiring . , , . . . . . . , . . ....................... . .91 Windshield Wiper-Intermittent . . . . . . . . ......... .. .45, 46
Fuse ............................................ ......... . ................ ..91 ...................... . .46
Van Conversion R e la y......... .. . . . . . . . . . . . . . . .91 Low Washer Fluid Lamp ................... ......................... .45
Visor Courtesy Lamp .................. . ...............................82 Low Washer Fluid Lamp Sensor . . . . ......... .................. 45
Warning Lamp Center System ........... ................................ 72 Washer M o to r................................... ..............45
Warning Lamp Connector ................ .............................. 125 Washer Switch ................................ ............................45
Wiper M o to r..................................... ............................46
NOTES
 FUSIBLE LINK
1S GAUGE
| GRAY)
BATTERY
GROUND A11 FUSIBLE LINK
6BK10 GAUGE
FUSIBLE LINK GY* (PARK GREEN)
FUSIBLE
20 GAUGE (ORANGE) LINK CHARGING
REAR OF BATTERY FUSIBLE LINK SYSTEM
18 GAUGE
20 GAUGE SH §f 8
A15 14PK (GRAY) A3
(ORANGE) 12RD/WT*
FUSE #1
20 AMP
(YELLOW)
21 1
A /C SYSTEM
A6
t A3>1J
A3 12RD/WT*

V
L9
SH 28, SO
10RD
WT*
A3
12RD/WT
A3 12RD/WT*

18BK
WT# I
i
HAZARD
SWITCH
SH 49 21 FUSE #21
20 AMP
FUSE #22 (YELLOW)
20 AMP FUSE #19 — 1 FUSE #20
(YELLOW) F? 20 AMP
20
r 20 AMP

F63
F61
18WT
OR*
’J
(YELLOW)
sf? (YELLOW)

18FK F32 F36

RD* 18PK 16WT/BK*
FOG LAMP SWITCH
DB*
PARK LAMP
RELAY
SH 70

CHMSL LAMPS
i
REAR HEATER
LOCATION #2 SH 90 AND A/C SYSTEM
STOP LAMP SH 65
REAR
LIGHTING SWITCH
SH 43
SH 89.90
23 □ FUSE #23
20 AMP
(YELLOW)
L7 18BK/YL*
" X
FRONT
f?
F62
END iSRD
L7 LIGHTING
FUSE #9 18BK SH 41,42
7.5 AMP YL* HORN RELAY
(BROWN) SH 44
CIGAR
DIGITAL CLOCK LIGHTER
22TN DISPLAY SH 44
X
DIMMER
SH 51, 59, 61
RADIO DISPLAY
SH 57, 59, 61
NBS RADIO
SPEAKERS
SH 61
MODULE
SH 50
 FUSIBLE LINK
r 20 GAUGE
(RED)
FUSIBLE LINK
■ A3 12RD/WT' 1B GAUGE
A10 (GRAY)
- A3 12RD/WT* 20RD

+
A10
A4
18GY
12RD
DG*
ABSSYSTEM
SH 34, 35, 36,
37
2 7 ^ - Z j 30 AMP CIRCUIT
BREAKER {PLUGS
INTO CAVITY #27
OF FUSEBLOCK)

F35 25 AMP
12RD CIRCUIT BREAKER (PLUGS
INTO LOCATION 11 OF FUSE #3
vk
RELAY BANK) 20 AMP
HORN RELAY
SH 44 (YELLOW)
POWER SEATS
SH 87 L20 14LG/WT*
POWER DOOR
LOCK MOTOR 1
HEADLAMP
SH 78
SWITCH COURTESY
SH 50 LAMPS
*L2Q 14LG/WT
DRL SH 81, 82
_ L20 MODULE
14LG/WT RADIO MEMORY
SH 92 SH 57, 59, 61
HEADLAMP *fl­ ELECTRONIC
LOW BEAM DIMMER SWITCH ee CLUSTER
RELAY SH 50 SH 55
(LOCATION 1) OVERHEAD
SH 49 CONSOLE
L4
14VT
L HIGH BEAM
16RD— f HEADLAMP
SH 41, 42
SH 83
BODY
COMPUTER
WT*
SH 102
POWER
- k - LEFT POD MIRRORS
SWITCH SH 76
FUSE #17 FUSE #18 SH 49 UNDERSEAT
10 AMP 10 AMP j STORAGE LAMP
(RED) (RED) M11 SH 82
18PWLB* GLOVEBOX LAMP
J -, SH 82
LIFTGATE VANITY LAMPS
LAMPS SH 82
SH 82
OVERHEAD
CONSOLE COURTESY
LT LOW BEAM RT LOW BEAM LAMPS
HEADLAMP HEADLAMP SH 84
SH 42 SH 41 REAR DOME
AND CARGO LAMP
 FUSIBLE LINK
18 GAUGE (GRAY)

CHARGING SYSTEM
n AO 10RD

(SEE SH 6, 8)

t A1 200R
A2
FUSIBLE LINK 12PK/BK*
20 GAUGE (ORANGE)
IGNITION STARTER
A21 14DB — SWITCH SYSTEM
SH 4 SH 9, 10, 11

• A31 14BK/WT*
15 = 1 FUSE #15
10 AMP A22 12BK/OR*
(RED)

?
G5
20DB/WT*
J .
WARNING LAMP
14 3 FUSE #14
2 AMP
FUSE #24
20 AMP
zs FUSE #26
30 AMP
30 AMP
CIRCUIT
BREAKER
CENTER SH 72 (GRAY) (YELLOW) (LIGHT
(PLUGS
BODY COMPUTER GREEN)
SH 102 INTO
V34 F21 CAVITY
ELECTRONIC F20 C1
20WT 12TN #25 OF
CLUSTER 18WT 12DG
RD*
SH 55
X
SPEED CONTROL
1
BACK-UP LAMPS
i
HEATER OR AIR
i FUSEBLOCK)

POWER WINDOWS
SH 43 SH 89 CONDITIONING SH 79, 80
HEATED REAR BLOWER MOTOR POWER REAR
WINDOW SWITCH SH 27, 29, 63 QUARTER VENTS
SH 64 SH 86
REAR OVERHEAD
CONSOLE
A/C FAN RELAY
SH 84
SH 27, 29
MANUAL TRANSMISSION
SH 11

FUSE #2
10 AMP
13 FUSE #13
20 AMP
FUSE #5
20 AMP
FUSE m
20 AMP
S FUSE #7
10 AMP
(RED) ) — u (YELLOW) (YELLOW) (YELLOW) (RED)

VV23 L5
k
X12
16BR 18BK 20RD/WT*
PK* PK*
J- vU J .
LIFTGATE TURN SIGNAL RADIO FEED
WIPER/WASHER FLASHER SH 57, 59, 61
SH 67 SH 49s 53
VAN CONVERSION RELAY HEADLAMP
SH 91 SWITCH
SH 49, 53
 FUSE #13
(20 AMP) V — V23 -------A TO SPLICE
IGNITION 16BR/PK* (SEE SH 67) V
, TO CHARGING SWITCH F U S i #14
4 SYSTEM (2 AMP) > - V34 20WT/RD*
(SEE SH 6, 8) ACC*
A1
12RD
OFF RUN
FUSE #15
(10 AMP) i 1
TO SPEED
A21 14DB G5
#49 20DB/ CONTROL
A21 WT* ( S i i SH 43)
-----)> - A1 12RD 14DB
J-% TO
TO EATX CONTROL­
LER (SEE SH 10) TO IGNITION
EATX ONLY SYSTEM TO POWER
(SEE SH 13, WINDOWS
17, 23) SPLICE (SEE SH 79)
(SEE SH 72)
TO AIR CONDITIONING
AND HEATER FEED
□ {SEE SH 27, 29, 57)

— ) ) —A212PK/BK* - «
A2
12PK/BK*
TO CHARGING
-s SYSTEM FUSE CAVITY
{SEE SH 6, 8) #25(30 AMP)
FUSE #24 CIRCUIT
(20 AMP) BREAKER
F20 16WT
GROUND THRU
STEERING COLUMN
ATTACHMENT

G9
BLUE 20GY/BK*
A31
14BK
V - j r t ___ , G9
TO STARTER r u -i
K
A41 14YL fo oooooo 20GY/BK’'
SYSTEM A21 14DB 1 2 3 4 5 6 7
0=4 8 9 10 11 12 13 14
(SEE SH 9, 11) G9 20GY/BK*
D=j
A2 12PK/BK*
io o p o o o o J
D=j TO WARNING LAMP
A22 12BK/OR*
a - CENTER
m
A31 14BK/WT* ABS ONLY
(SEE SH 72)
TO RADIO
(SEE SH 57,
H
It l .
A1 12RD ---- --------- G9 20GY/BK* TO
PARK
59, 61) WITHOUT
ABS BRAKE
SWITCH
TO ANTI-LOCK
(SEE SH 104)
BRAKE SYSTEM
(SEE SH 35)
■ X12 20RD/WT* - ( ( ■
FUSE #5
TO (20 AMP)
Y L5 18BK/PK* GRAY
HEADLAMP FUSE #6
SWITCH (20 AMP)
(SEE SH 49) FUSE #7
(10 AMP) BRAKE
WARNING

— V6 18DB 4 TO WIPER
SYSTEM
LAMP
SWITCH
(SEE SH 48) (LEFT
FRAME
RAIL)
IGNITION SWITCH
 TO RADIATOR
S FAN MOTOR
(SEE SH 28, 96)

ENGINE
GROUND •
=" (UPPER LEFT OF
r to ENGINE) TO A/C
4 STARTER SYSTEM
(SEE SH 11) 5 CLUTCH
(SEE SH 28)

A21 14DB

SPLICE
j ------ M l 18PK
(SEE SH 81)
TO
IGNITION TO WARNING
(FRONT OF CAR SWITCH LAMP
(SEE SH 4) FUSE #3
LEFT SIDE) MODULE
(20 AMP)
+ RED (SEE SH 72)
#47 TO SPEED
A21 A21
14DB 14DB FUSE #13 CONTROL
(20 AMP) (SEE SH 43)
AO 6BK
FUSE #14
TO
STARTER SYSTEM
(SEE SH 11)
A (2 AMP)
FUSE ,#1§
TO REAR
WIPER
(SEE SH 67)
T (10 AMP)
T40
14BR A4
12BK
RD#
(REAR OF
BLACK
BATTERY)
V23 18BR/PK*
T40
14BR

TO TO HEATED
STARTER RELAY REAR WINDOW
(SEE SH 11) A4 SWITCH
(REAR OF 12BK (SEE SH 64)
BATTERY) RD*
FUSIBLE LINK AO 6BK
(HYPALON WIRE)
(REAR OF A18 14RD/PK*
BATTERY) A15
14PK SPLICE #48
(SEE SH 91)

TO
#23 UNDERHOOD
LAMP )---- A4 12BK/RD
(SEE SH 95)
A15 IGNITION
14PK FUSE #1
(20 AMP) OFF
TO LEFT DISCONNECT
'L 9 18BK/WT* POD SWITCH
(SEE SH 49)

CHARGING SYSTEM (2.5L ENGINE)

 BOSCH 40/90 ALTERNATOR
A11 (RIGHT SIDE FORWARD OF ENGINE)

TO SPLICE
(SEE SH 28)

TO IGNITION
SWITCH
(SEE SH 4)

TO STARTER
RELAY
(SEE SH 11)

FUSIBLE LINK TO SINGLE

(HYPALON WIRE) BOARD ENGINE
(REAR OF BATTERY) ^ CONTROLLER
CAVITY 3
(SEE SH 14)

TO SHUTDOWN
$ RELAY
(SEE SH 14)
CHARGING SYSTEM (2.5L ENGINE)
 TO
STARTER SYSTEM
(SEE SH 9,10)
ENGINE GROUND
(AIR PUMP BRACKET
MOUNTING BOLT)

T40
14BR
J .
TO
A15 AO 6BK AO 6BK
STARTER RELAY
20 OR
(SEE SH 9,10) TO VAN A
CONVERSION) 14RD /PK* ------ A18 12RD/BK*
(SEE SH 91) #3 TO <A1£2
FUSIBLE LINK
A14 16RD/WT* spucE
(HYPALON WIRE)
(REAR OF (SEE SH 8)
TO UNDERHOOD (REAR OF NATURAL
BATTERY)
LAMP BATTERY) ^
(SEE SH 95)
A4 12BK/RD*
A4 12BK/RD A14 16RDAATP
#23

A15 IGNITION
14 PK FUSE #1 OFF-DRAW
(20 AMP) DISCONNECT TO SAFETY
TO HEADLAMP SHUTDOWN
- % y j7 + - L9 18BK/WT* SWITCH RELAY
--------------- (SEE SH 49) (SEE SH 32)

CHARGING SYSTEM
(3.0L & 3.3L ENGINE)
 ENGINE BOSCH 40/90 ALTERNATOR
GROUND (RIGHT SIDE FORWARD OF ENGINE)
(UPPER RIGHT
OF ENGINE) =

TO
PARK AND
FOG LAMPS
(SEE SH SO, 70) A6

TO SPLICE

(SEE SH 30)

TO IGNITION
SWITCH
(SEE SH 4)

, TO SBEC CAVITY 3
A14 16RD/WT* (SEE SH 18, 24)

AUTO
A14 16RD/W T*4 T0SHUTD0WN
' RELAY
(SEE SH 18, 24)
TO I.O.D.
-A14 16RD/WT* 4 (SEE SH 7)
EATX
ONLY TO < A 3; SPLICE
A3 12RD/WT* — ) ) - A 3 12RD/WT*-^
(SEE SH 44)
CHARGING SYSTEM
(3.0L & 3.3L ENGINE)
TO CHARGING €
SYSTEM > A0 6RD
(SEE SH 7)
TO SINGLE TO CHARGING
BOARD ENGINE SYSTEM
^ CONTROLLER (SEE SH 8)

TO BACK-UP
LAMPS
(SEE SH 89)

TO A /C
FAN RELAY
(SEE SH 27)

L1 18VT/BK*

STARTER SYSTEM (3.0L ENGINE)

WITH 3 SPEED AUTOMATIC
 TO
CHARGING y -------------------- '------------------ --------- :----------;--------- A1 12RD
SYSTEM
{SEE SH 8)

TO
BATTERY V ao m o
(SEE SH 7) A1
12RD

T40 14BR

V-
I
A15
14BK { AO SRD---- [ £
vU X
TO CHARGING | T40 14BR—C
SYSTEM STARTER MOTOR \ — ! 3.0 LITRE ONLY
{SEE SH 7)
{REAR OF ENGINE) \
BLACK

(REAR OF
BATTERY) N a ° 6RD- m
I NATURAL
FUSIBLE
LINK T40 14BR-
TO
CHARGING I 3,3 LITRE ONLY
A15 200R A15 14PK -----) ) ----- A15 14PK “4 SYSTEM
■ (SEE SH 7)
#23

TO NEUTRAL
A1 12RD
SAFETY SWITCH t T41 18BR/YU
(SEE SH 3 !)

TO TRANSAXLE C. T41 18BR/YL

CONTROLLER ?
CAVITY 41 ~ T41 20BR/YL*
T40 (SEE SH 31) - BLACK
__ 11,1. Ui_ £
14BR T40 14BR
TO SINGLE T41 20BR/YL A41 18YL
BOARD ENGINE A1 12RD
CONTROLLER
CAVITY 30 - T41 18BR/YL*
(SEE SH 20, 22)
STARTER RELAY
(LEFT SHOCK HOUSING)

TO TRANSAXLE ---- A41 18YL

\
CONTROLLER
CAVITY 8
{SEE SH 31)

TO IGNITION ^— A41 18YL - 4 ^ A41 18YL

SWITCH
{SEE SH 4) #31 | j j j

— T40 14BR

STARTER SYSTEM WITH ELECTRONIC

918W-10 TRANSAXLE (3.0L & 3,3L ENGINE) AS-HK 10
 {CENTER REAR
K39 18GY/RD* OF ENGINE)
K41 18BK* r 212 16BK/TN*
BLACK

KSO 18YL/BK*
(TOP REAR
K40 18BR/WT* OF ENGINE)
K59 18VT/BK*

HEATED
OXYGEN SENSOR
{CENTER OF
n r w w n ENGINE ON GROUND
EXHAUST
nnnn MANIFOLD)
AUTOMATIC IDLE
K40 K39 K60 K59 SPEED MOTOR
{ON THROTTLE
MX ’ BODY)
x :

K40 18BR/WT*
K39 18GY/RD*

BLACK
K620VT/W T* BLACK
K22 1SOR/DB* (RIGHT REAR L- K4 18BK/LB* - 1
OF ENGINE)
^ ^ f - * ~ K 4 18BK/LB*

THROTTLE POSITION TO ^ 8 J > SPLICE

SENSOR
(RIGHT SIDE OF (SEE SH 16) TO TO
THROTTLE BODY) DIAGNOSTIC
fi> 1 | CONNECTOR
(SEE SH 14)
BLACK SPLICE SPLICE
(RIGHT REAR (SEE SH 56) (SEE SH 58)
OF ENGINE)
TD2
SPLICE
(SEE SH 14)

Z11
[ _^TO<K6> SPLICE 16BK
WT*
(SEE SH 13)

K4 18BK/LB*
SPLICE
{SEE SH 15)

22
 TO SPLICE

$ V23 18BR/PK* <^>

(SEE SH 67)
A21 14DB — ) ) - V34 20WT/RD*
TO SPEED
CONTROL
) ) - G5 20DB/WT* (SEE SH 43)
A21
14DB FUSE #13 TO
X (20 AMP)
TO IGNITION FUSE #14
SWITCH (2 AMP)
FUSE #15 SPLICE
(FRONT OF A21 (SEE SH 4) (SEE SH 72)
RIGHT SIDE 14DB (10 AMP)
SHIELD) TO PTU
A21 14DB SOLENOID
TO CHARGING (SEE SH 16)
SYSTEM
(SEE SH 5) .TO DIAGNOSITC
A21 A21 14DB 4 CONNECTOR
14DS (SEE SH 14)
TO AUTO
A21 14DB 4 SHUTDOWN RELAY
EXHAUST GAS (SEE SH 14)
RECIRCULATION
/ DIAGNOSTIC SOLENOID TO THROTTLE
f ----- ------------------------------ ^ A21 K6 20VT/WT* POSITION
I 14DB SENSOR
A21 14DB 12 )
K35 20GY/YL* vL
TO RADIATOR
FAN RELAY
BLACK
(SEE SH 28, 96)

K6
20VT
WT*
PURGE SOLENOID
(FRONT OF RIGHT
SIDE SHIELD) (RIGHT BLACK
SHOCK , K i 20VT/WT*
K52 20PK/BK* TOWER)
A21 14DB ! K1 20DG/RD*
MAP
SENSOR K4 18BK/LB*
BLACK

G24
20GY
PK*
K6 L K4 18BK/LB* T O < K ^ | ] SPLICE
K52 #15
20VT
20PK (SEE SH 15)
WT*
BK*
TO WARNING
LAMP
CENTER
t1
G24
20GY
K35
20GY
KI
20DG
RD*
(SEE SH 72) PK* YL*
X
52
T56 35 1
 (RIGHT FENDER
SIDE SHIELD)

TO DIRECT
NEGATIVE CONNECTION
BATTERY ZO 10BK
TERMINAL
{SEE SH 5)

LT GRAY
{REAR OF
BATTERY)

11 12 27 31 34 19 51 25 45 3
SINGLE BOARD ENGINE CONTROLLER FOR 60 WAY SINGLE BOARD
(SBEC) ENGINE CONTROLLER CONNECTOR
(LEFT FENDER SIDE SHIELD) {SEE SH 109)
 TO HEATED
TO A UTO SH UT-
f s t ! SH
(SEE I h 12) D (SEE
O W N SB
R E L14}
A Y I
K11 18WT/DB* |
A61 14DG/BK* |
|— BLACK |

(TOP OF
THROTTLE BODY)

K54 1SOR/BK*
PARK
THROTTLE A21 14DB
UNLOCK /
SOLENOID /
/
fHRP# v

A61 14DG/BK

A21 K54
14DB 180R

TO IGNI­
r1
A61
BK*

TION COIL 14DG r? Ivl

(SEE SH 14) BK* (f O o i ( o•*>
x
TO FUEL
TANK ELEC­ DK GRAY
TRICAL FUEL TO (REAR OF
PUMP MOTOR CHARGING BATTERY)
(SEE SH 88) SYSTEM
(SEE SH 6)
TO SPLICE

(SEE SH 11)

T
F20
18WT
K20
18DG
K11
18WT
DB*
(SEE SH 13)
J
s s,
s.
sN
1
... ± .......... .............. .......... _ .............. ... 1 " .....................................
8 20 18 54

SINGLE BOARD ENGINE CON­ FOR 60 WAY SINGLE BOARD

TROLLER (SBEC) (LEFT ENGINE CONTROLLER CON­
FENDER SIDE SHIELD) NECTOR (SEE SH 109)
TO CHARGING
SYSTEM
(SEE SH 8)
 ■O.D. A14 16R D /W T*--------1

FUSIBLE
LINK

11 12 27 31 34 19 51 25 45 3

SINGLE BOARD ENGINE CONTROLLER FOR SINGLE BOARD ENGINE CONTROLLER

(SBEC) CONNECTOR
(LEFT FENDER SIDE SHIELD) (SEE SH 110)

918W-10 AS-HK 18
 TO FUEL TANK
ELECTRICAL
FUEL PUMP MOTOR
(SEE SH 86)

TO AUTO
SHUTDOWN
RELAY
(SEE SH 18)
TO TO

TO CHARGING
SYSTEM
(SEE SH 8)
8
< >
SPLICE
3
< >
SPLICE
{SEE SH 33) (SEE SH 33)

TK20
A61
16DG K12
18TN
K11
18WT
T
D2
T
D1
BK* DB* 20WT 20VT
16DG
I BK* BR#
l A A
T
20
T8 14 15
T
16
T
46 26
 AUTOMATIC
IDLE SPEED MOTOR

30 40 39 59 60 22 6

SINGLE BOARD ENGINE CONTOLLER FOR SINGLE BOARD ENGINE CONTROLLER

(SBEC) CONNECTOR
(LEFT FENDER SIDE SHIELD) (SEE SH 110)
 DISTRIBUTOR
(RIGHT FRONT
OF ENGINE)
K7 180R
BLACK
K44 18TN/YL*
K24 18GY/BK*

L- K4 18BK/LB*

K4 18BK/LB’

G7 2QWT/OR

G7 20WT/QR*
ELECTRONIC
TRANSAXLE ONLY
ENGINE COOLANT
SENSOR
(TOP LEFT I
OF ENGINE) K4 18BK/LB*
K4 18BK/LB*
DISTANCE SENSOR
K4 18BK/LB* (ON REAR OF
a
TO HEATED
j<4 TRANSMISSION)
18BK
LB* TO
OXYGEN SENSOR ELECTRONIC
{SEE SH 17) J TRANSAXLE
LA CONTROLLER
CAVITY 51
(SEE SH 31)

K4 ELECTRONIC
18BK TRANSAXLE ONLY
TO LB*
ELECTRONIC (SEE SH 92)
TRANSAXLE
CONTROL MODULE
K7 CAVITY 45 G7
18DR (SEE SH 31) 20WT
GRAY
(NEAR OR*
THROTTLE
BODY) K24 18GY/BK* J
K2
20TN ELECTRONIC
BK* TRANSAXLE ONLY

A 4 47
 AUTOMATIC IDLE
SPEED MOTOR

TO ELECTRONIC
TRANSAXLE C
CONTROLLER >
CAVITY 12 (SEE
SH 31)

TO
STARTER
SYSTEM
(SEE SH
10)

K5S mo K22 K6 SPLICE

18VT 18YL 180R 20VT (SEE SH 25)
BK* BK* DB* WT*
X X X X
r
59
T
60
T
22
T
6
SINGLE BOARD ENGINE CONTROLLER FOR SINGLE BOARD ENGINE
(SBEC) CONTROLLER CONNECTOR
(LEFT FENDER SIDE SHIELD) (SEE SH 111)

918W-1Q AS-HK 22
 TO ANTI-LOCK TO TO
BRAKE DIAGNOSTIC RADIATOR
SYSTEM CONNECTOR FAN RELAY
(SEE SH 35, 37) (SEE SH 24) (SEE SH 30)
TO
CHARGING wv w- |
SYSTEM ABS SYSTEM
(SEE SH 8) ONLY
14DB 14DB

* A21 14DB

TO CHARGING
SYSTEM
(SEE SH 7)

TO (LEFT FRONT
AUTO OF ENGINE) BA t TERY
SHUTDOWN
RELAY
(SEE SH 24)

TO SPLICE
213 18BK/RD* (SEE SH 32)
TO SPLICE
Z14 18BK/YL* (SEE SH 32)’
Z12 12BK/TN*

211 16BK/WT* 211 18BK/WT*

BLACK j
A21 14DB |
K52 20PK/BK* 1

PURGE / TO AIR
SOLENOID / CONDITIONING
A21 14DB SYSTEM
(SEE SH 30)
A21 A21 Z11
14DB 14DB 16BK/
WT*
Jx vk
TO ELECTRONIC TO ELECTRONIC
TRANSAXLE TRANSAXLE
TO IGNITION NEUTRAL SAFETY CONTROL MODULE
SWITCH SWITCH CAVITY 11
(SEE SH 4) (SEE SH 31, 100) (SEE SH 31)

52 i
SINGLE BOARD ENGINE CONTROLLER
(SBEC)
LEFT FENDER SIDE SHIELD)
TO FUEL RAIL
(SEE SH 26)

TO ELECTRONIC
TRANSAXLE
CONTROLLER
CAVITY 45
{SEE SH 31)

TO FUEL TANK
ELECTRICAL FUEL
PUMP MOTOR
(SEE SH 88, 98)
T
A61
14DG
BK*

TO AUTO
SHUTDOWN
RELAY
(SEE SH 24)

8 47 42 7 24 4 20 46 26

SINGLE BOARD ENGINE CONTROLLER FOR SINGLE BOARD ENGINE

(SBEC) (LEFT FENDER SIDE SHIELD) CONTROLLER CONNECTOR
(SEE SH 111)
j~ r _K11 18W T/DB' "j [" ],r r K 1 3 18YL/WT *"j j " _ E K 1 1 18VTODB* _ r £ t 3 18YL/W T*]| K12 18TN

| BLACK j j jC g jjH ^ BLACK J j j j c g j j B BLACK [ J |j—y l ] ^ BLACK | { — BLACK j [ — BLACKj

|_3_A61 16DGffil^J|_ JVA6116DG/BK;J 16DG/BK; J j_ ^ A 6 1 16DG/BK_* J !_ ^ A 6 1 16DGBK*J J^A61 16DG/BK* J

m~7'
/
INJECTOR #1 INJECTOR #3 INJECTOR #5 INJECTOR #6 INJECTOR #4 INJECTOR #2

r Y
K11
Y
A61
Y
K12 A61
Y Y
K13
Y
A61
Y Y
A61
YK13
A61 K11
16DG 1SWT 16DG 18TN 16DG 18YL 16DG 18WT 16DG 18YL
BK* DB* BK* BK* WT* BK* DB* BK* WT*
AIR CONDITIONING SYSTEM
 AIR CONDITIONING
COMPRESSOR

AIR CONDITIONING
918W-10 SYSTEM (2.5L ENGINE) AS-HK 28
 AIR CONDITIONING
DAMPED PRESSURE r C19 !
SWITCH 4QQO
18BR 1
A22 (ON H VALVE
DASH PANEL
1OR* FUSE #26 RIGHT SIDE)
(30 AMP)
C19 18BR
TO IGNITION I C19 18BR
SWITCH (RUN) GRAY
(SEE SH 4) C23 12DQI I / C FAN! CUTOUT^
C1 12DG F20 18WT SWITCH
F20 18WT | FRONT OF VEHICLE
A16 12GY 21
18BK
(LEFT FENDER
AIR CONDITIONING SIDE SHIELD)
FAN MOTOR RELAY C23
12DG X F20 18WT - ) } - F20 18WT
-i rC2018BR/W T*~i

l r BLACK
A A A / C
~ AMBIENT p i p
TEMP
&
J
B
K^jJ
F20 18WT - 4
TO BACK
yp LA M P
RELAY
-C20 18BR/WT! (FRONT OF
VEHICLE) SENSOR (SEE SH 89)
C2018BR* I (FRONT A16 12GY
ra A /C HIGH PRESS OP C23 12DG
CUT-OUT SWITCH VEHICLE)/'
C1 12DG C20 18BR
C21 18DB/OR* r ^ -BLACK *!
C20 18BR TO SINGLE BOARD ILLUMINATION
A /C BLOWER
MOTOR (UNDER ct i ®U§JJ • ENGINE CONTROLLER LAMPS
INSTRUMENT 12DG I ^ 1 ^ 0 2 0 18BR/WT CAVITY 27
(SEE SH 18, 24) / DEFROST A /C
O J O O - 23
12DG

A16
12GY

AIR CONDITIONING SYSTEM

 AIR CONDITIONING
COMPRESSOR

A16 12GY
x TO CHARGING
A1B 12GY — { SYSTEM TO <A2t> SPLICE ^------ ^21 14DB
(SEE SH 1,8)
C23 12DG {SEE SH 17, 23)
AIR CONDITIONING
918W-10 SYSTEM (3.0L & 3.3L ENGINE) AS-HK 30
 BLACK TO THROTTLE
POSITION
□3 A21 14DB
SENSOR
€F T41 18BR/YL* (SEE SH 20, 22)
T3 18VT T
K22
NEUTRAL SAFETY 180R
SWITCH (FRONT OF DB*
TO SINGLE
TRANSMISSION)
BOARD ENGINE

TURBINE INPUT
SPEED SENSOR
(FRONT OF
TRANSMISSION)

TURBINE OUTPUT
SPEED SENSOR
(FRONT OF
TO STARTER
RELAY TRANSMISSION)
(SEE SH 10)

41 11 45 51 12 8 13 52 14

ELECTRONIC AUTOMATIC TRANSAXLE FOR CONTROL

CONTROL MODULE MODULE CONNECTOR
(RIGHT FENDER SIDE SHIELD) (SEE SH 117)
 SAFETY
SHUTDOWN
MINI-RELAY
{RIGHT SIDE FENDER
* ^ S ID E SHIELD)
 ELECTRONIC AUTOMATIC TRANSAXLE FOR CONTROL
CONTROL MODULE (EATX) MODULE CONNECTOR
(RIGHT COWL PANEL) (SEE SH 117)
4 43 3 2

TO NEUTRAL
SAFETY SWITCH t
(SEE SH 31) *

L1 18VT/BK*
■T314VT
-T3 18VT
■ BLACK

F20 18WT

T2 14TN/BK

i____ ________ _ . ___ __ ________l

BACK-UP LAMP RELAY
(RIGHT REAR SIDE FENDER)

TO AIR
CONDITIONIN
SYSTEM
(SEE SH 29)
SPLICE
TWISTED (SEE SH 65)
PAIR
WIRE

TO TO

0>1\ <0H]
SPLICE iPLie
SPLICE
(SEE SH 38, 56) (SEE SH 3
38, 56)

T
D2
TD1
18WT 18VT
BK* BR*
TWISTED #11
PAIR
WIRE D2 20WT/BK*
- D2 20WT/BK*------
FOR FOR MANUAL
MANUAL ONLY
ONLY D1 20VT/BR* ------
D1 20VT/BR*---------

26 46

SINGLE BOARD ENGINE CONTROLLER FOR 60 WAY SINGLE BOARD ENGINE

(SBEC) CONTROLLER CONNECTOR
(LEFT FENDER SIDE SHIELD) (SEE SH 109f 110. 111)
 RIGHT
FRONT
WHEEL
SENSOR

LEFT
FRONT
WHEEL
SENSOR

RIGHT
REAR
WHEEL
SENSOR

LEFT
REAR
WHEEL
SENSOR

1-9 1-8 1-7 1-6

(UNDER BATTERY TRAY)

FOR 60 WAY ANTI-LOCK

ANTI-LOCK BRAKE SYSTEM BRAKE SYSTEM CONTROLLER
CONTROLLER CONNECTOR (SEE SH 124)

918W-10 ANTI-LOCK BRAKE SYSTEM AS-HK 34

 (ON DASH PANEL) FOR ANTI-LOCK
ANTI-LOCK BRAKE BRAKE SYSTEM
SYSTEM HYDRAULIC CONNECTOR
MODULATOR (SEE SH 124)
 (ON DASH PANEL) FOR ANTI-LOOK
ANTI-LOCK BRAKE BRAKE SYSTEM
SYSTEM HYDRAULIC CONNECTOR
MODULATOR (SEE SH 124)

1-52 1-46 1-48 1-49

ANTI-LOGK BRAKE FOR 60-WAY ANTI-LOCK

BRAKE SYSTEM CONTROLLER
SYSTEM CONTROLLER CONNECTOR
(SEE SH 124)

ANTI-LOCK BRAKE SYSTEM

 TO SYSTEM
RELAY B47 14 RD/LB*
(SEE SH 36 )

B47 14RD/LB*

G19 20LG/OR*

G19 B47 B47

20LG 16RD 16RD
✓K 4 OR* LB* LB*
ABS WARNING
LAMP RELAY BLUE

TO WARNING
LAMP MODULE DIAGNOSTIC
(SEE SH 72 ) CONNECTOR
(LOCATED ON
T
G19
LEFT LOWER
REIN FORCEM ENT)
20LG
BK*
21 21 D12
20BK 20BK

#4
<€h 200R

S/OR* — m
G19 2DLG/OR
D12
20OR
TO

^ i i
SPLICE
(SEE SH 35 )

TO
#43
El El #44

21 20BK D11 D12

L_J <^>23 20WT 2QOR
JLa _ ^ -B L A C K
VT*
G19 20LG/OR* SPLICE
(SEE SH 23)
B47 14RD/LB*
21 20BK

G19 B47 B47 A21 D11 D12

20LG 16RD 16RD 14DB 20WT 20OR
OIR* LI3* LI3* I V T*

k Jk s s, xk / s. > X,
y"S. X s, X s / N

(UNDER BATTERY TRAY) 1-15 1-50

L T
1-47 1-60
1
1-11 1-12
FOR 60-WAY ANTI-
ANTI-LOCK BRAKE SYSTEM lo c k b ra k e s y s te m
m m t d a i ICD c o n t r o lle r co n n e c-
OUN I HULLtH t o r (SEE SH 124)

ANTI-LOCK BRAKE SYSTEM

 TO MECHANICAL
{SEE SH 115) OR ELECTRONIC
CLUSTER
r G60 22GY/YL* - i TO BODY
NATURAL

SPLICE
(SEE SH 33)

SWITCH
(FRONT OF
ENGINE)

918W-10 AS-HK 38
 TO MECHANICAL
(SEE SH 115) OR ELECTRONIC
CLUSTER
r G60 22GY/YL* TO BODY
NATURAL

OIL
PRESSURE
SWITCH
=■ (FRONT OF
ENGINE)
 TO MECHANICAL
OR ELECTRONIC -
(SEE SH 115) CLUSTER
TO BODY
NATURAL

SPLICE
(SEE SH 33)

OIL
PRESSURE
SWITCH
(FRONT OF
ENGINE)
 TO
HEADLAMP
DIMMER SWITCH
(SEE SH SO)

TO WARNING
LAMP MODULE
(SEE SH 72)
'T
034
16RD
BK*
 LEFT
HEADLAMP
GROUND
{LEFT SIDE
CLOSURE
PANEL-FRONT
OF BATTERY)

TO TURN TO FUSE #17

SIGNAL HEADLAMP
SWITCH SWITCH
(SEE SH 49,104) SYSTEM

T (SEE SH 50)

L61
18LG
T
L43
#21 20VT
LEFT
BLACK HEADLAMP
(AERO)

L3 16RD
PARKLAMP RELAY L43 20VT
(SEE SH 50)
Z1 16BK 201 20BK

Z1
21 20BK TO WINDSHIELD
22BK WASHER PUMP
#28 MOTOR
1 TO SPEED (SEE SH 45)
CONTROL
(SEE SH 43)

L61 18TN
L7 18BK/YL
Z1 18BK

L7 18BK/YL* 18TN
18BK/YL*

18BK

L7 18BK/YL* LEFT
SIDE
MARKER
Z1 18BK LAMP-

FRONT END LIGHTING

 TO
IGNITION A21 14DB \ FUSE #14
SWITCH 7 (2 AMP)
(SEE SH 4)
V34 20WT/RD*

SINGLE BOARD 60 WAY

ENGINE CONTROLLER SINGLE MODULE
(SBEC) ENGINE CONTROLLER
(LEFT FENDER CONNECTOR
SIDE SHIELD) (SEE SH 109, 110, 111)
29 49 53 33 50 48

Y 5
Y " Y
six
Y
six sP
Y Y
TO HORN
RELAY X3 20BK/RD*
K29 V32 V35 V36 V33 V31 (SEE SH 44) >
18WT 20YL 20LG 20TN 20WT 20BR
PK* RD* RD* RD* LG* RD*

l e a ' s
20WT/
PK* NATURAL

STOP LAMP AND SPEED

CONTROL SWITCH
(MOUNTED ON STEERING SPEED CON-
COLUMN SUPPORT) TROL SWITCH
SPEED CONTROL AND STOP LAMP SWITCH (ON STEERING
 HORN 1 0 1 #2
(LO-NOTE) ' TO I ----- A610RD-
CHARGING SYSTEM
(SEE SH 6. 8)
}— A3 12RD/WT*
vNI 3 #1 A3
f ) -------------- 12RD
WT*
TO OPTICAL HORN) ____ -A3
(SEE SH 50) < 12RD/WT
X02 18DG/RD ____ A3
“71 JU 12RD*
TO STOP LAMP
21 18BK (SEE SH 43)
FUSE CAVITY #27
(30 AMP CIRCUIT
BREAKER)
HORN TO POWER LOCK
(Hl-NOTE) UNLOCK RELAY
(LOCATION 10)
(SEE SH 78)
TL-
F35 12RD
TO POWER LOCK
LOCK RELAY
X2 18DG/RD* (LOCATION 9) F35
(SEE SH 78) 12RD

Z1 18BK X
HORN RELAY IN
RELAY MODULE
X2 18DG/RD* I (LOCATION 3)
21 18BK I (SEE SH 114) F3S
I___X._________ _ ____ I 12RD

BLACK
X3 20BK/RD*
NATURAL
TO NBS RELAY TO POWER SEAT
im m^__ mm
r (LOCATION 6)
(SEE SH 61)
(SEE SH 87)

CLOCKSPRING T ___ FS2 16RD

18BK TO DIAGNOSTIC,
CONNECTOR \ ------ F62 18RD
(SEE SH 56)

18BK F62 16RD

HORN SWITCH TO
(ON STEERING
COLUMN) <8^3
SPLICE
(SEE SH 47)
2T
£ — ^ D ~ » v 21 16BK

CIGAR I
LIGHTER Z1 16BK |
BLACK1
FUSE #23
(20 AMP)
 BLACK LEFT
Z116BK
V10 20BR HEADLAMP
Z01 20BK GROUND
Z01 20BK Z1 K g S I]
20BK (SEE SH 42} G29 20BK/TN*
\ WINDSHIELD WASHER
\ PUMP MOTOR ^ BROWN

r i r
• im
Z1 20BK
$ m
WINDSHIELD WASHER
LOW FLUID LEVEL SENSOR
(TOP OF WINDSHIELD
WASHER RESERVOIR)

V10 18BR
V10
18BR
V9 18DG/YL*

V10
18BR
(ON-OFF)
FRONT WASH

INTERMITTENT- d
WIPER SWITCH
■o
-^>— V3 18BRAATP
Vi
18DG
YL* - V7 18DG/WT*

r - V7 18DG/WT*

H* V4 18RD/YL*
L- - ) ) -----V3 18BR/WT*
"< f

l_QFF
i V6 18DB

V6 18DB

0
V9 18DG/YL* TO
co OOOR DIMMING
UiMMINU
V4 18RD/YL* E2 2QOR MODULE
• -
(SEE SH 51, 55)
V3 18BR/WT* RIGHT POD LAMP
V3 18BR/WT* REAR WASH (SEE SH 51)
TO LIFTGATE
V7 18DG/WT* V22 18BR/YL* WIPER AND
V7 18DG/WT* RR WIPE DELAY
WASHER SYSTEM
--------------------- - ) ) - V21 18DB/RD* (SEE SH 67)
BLACK

E2 20OR
Z3 20BK/OR*
V10 18BR
V618DB
V6 18DB
V21 18DB/RD*
V22 tBBR/YL GREEN
GRAY (RIGHT LOWER
m rm m m
SIDE OF I.P.)
BODY GROUND i f y u Of--------
---------- u k ^
(LEFT SIDE
KICK PANEL) <s>- Z1 18BK
G29 20BK/TN* - < f- G29 20BK/TN*

El #30

TO BODY
COMPUTER
¥10 18BR (SEE SH 101, 103)

— V618DB -
V9 18DG/YL*

V7 18DG/WT*

V5 18DG -

¥7 18DG/WT*

¥4 18RD/YL* V4 18RD/YL*

-V 3 18BR/WT V3 18BR/WT*

¥3 V6
18BR/WT* 18DB
¥6 18DB
P2 P1
#36

s ✓ S, x s, P2 PI
FUSE #5
11 ii i1 (20 AMP)
c PARK
SWITCH
d ? 1
Y INTERMITTENT WIND­
A31 SHIELD WIPER MOTOR
14BK/WT* V3 18BR/WT* (PLENUM LEFT SIDE)
J*
TO IGNITION Pol — V6 18DB
SWITCH E U ~ - ¥5 18DG
(SEE SH 4)

INTERMITTENT WIPER SYSTEM

 Z3 18BK/OR*

- Z1 18BK
* Z2 18BK/LG

Z3 n £ X I
18BK
OR*
A A fliW ¥ ¥ l
U U l iU U U U U
GREEN
(LOWER RIGHT ■ <
....r\ ................................n .. r
Z1
□ a a C □ c□ a a a
SIDE OF I.P.) 18BK
a ca o qp cp o a a
fll_.....& vk
TO RT
DOOR JAMB
SWITCH GROUND
(LEFT
Z3 18BK/OR* (SEE SH 82) SIDE
I r 70 KICK
W UNDERSEAT PANEL)
' STORAGE
LAMP
TO BODY (SEE SH 82) TO ELECTRONIC
COMPUTER Z2 18BK/LG* Z2 18BK/LG* CLUSTER
(SEE SH 101} (SEE SH 55)

TO DIAGNOSTIC
CONNECTOR
(SEE SH 101 )

TO A/C AND TO HEADLAMP

HEATER SWITCH
CONTROLS (SEE SH 49)
(SEE SH 27, 29)

TO ASH
RECEIVER
LAMP
(SEE SH 51)

TO CIGAR
TO RIGHT LIGHTER
COWL LAMP
WIRING (SEE SH 51 )
(SEE SH 76)
TO CIGAR
LIGHTER
GROUND
(SEE SH 44 )

INSTRUMENT PANEL GROUND SYSTEM

 23 18 BK/OR*
23
18 BK
TO GLOVE > TO WIPER
BOX LAMP JT \ SWITCH
(SEE SH 82) (SEE SH 45)

TO ELECTRONIC
CLUSTER y
(SEE SH 55)

TO WARNING TO REAR WINDOW

LAMP CENTER Y DEFOGGER SWITCH
(SEE SH 72) (SEE SH 64)

TO COMBO TO VAN TO NAME

FLASHER CONVERSION TO POWER TO POWER BRAND SPEAKER
RELAY RELAY LOCK RELAY UNLOCK RELAY RELAY
(SEE SH 60) (SEE SH 91) (SEE SH 78) (SEE SH 78) (SEE SH 61)

TO LEFT
^ SILL WIRING
{SEE SH 65, 87)

— BLACK
{LOWER LEFT
TO KEY SIDE OF I.P.)
LIGHT SWITCH 21 20BK
(SEE SH 81) .0...,CTT~ TO SPLICE
m m r n m
TO MULTI , < 8 ^3
FUNCTION ) n 18BK
SWITCH (SEE SH 80)
21 21
(SEE SH 119) 20BK 20BK
rL 4 . 21 18BK
TO DIMMING TO STOP LAMP BODY
MODULE AND SPEED GROUND
(SEE SH 51) CONTROL SWITCH (LEFT
(SEE SH 43) KICK PANEL)

INSTRUMENT PANEL GROUND SYSTEM

 TO IGNITION
L32 18PK
SWITCH
(SEE SH 4) LOW SEAM
RELAY
T
A31
L32
18PK TO TURN SIGNAL
14BK
A
FUSE #6
(20 AMP)

TO BATTERY
POSITIVE
TERMINAL
(SEE SH 1, 5, 7,
T
A15
14PK

FUSE #1
(20 AMP)
 TO <A3>Tj SPLICE

(SEE SH 44)

.T

OPTICAL
HORN

TO
FRONT
END
LIGHT­
ING
(SEE SH
41, 42)

TO BATTERY
(SEESH 1,6,8, 44)

FUSE #9 TO BODY COMPUTER

(7.5 AMP) (SEE SH 103}
 TO FUSE #9 ON
(REAR OF HEADLAMP SWITCH SYSTEM
4>- E1 22TN -
I.P. LEFT (SEE SH 50, 55)
SIDE) E2 200R - 52 200R
-fr-
DIMMER y ■ E92 200R/BK*
MODULE
-» ■ - E17 18YL/BK*

— 21 20BK -

E22 200R/W T*
E2 200R

E92
RED 200R
E17 18YL/BK* BK*
E92 200R/BK’ E92

E22 200R/W T* 21 20BK

200R
BK* i
TO BODY
E2 200R

E1 22TN E2 200R
iTO
COMPUTER
(SEE SH 103)

TO STEREO LEFT POD E2 200R

DISPLAY J— DIMMER
(SEE SH 58, 60, 62) SLIDE
r ^ L TO CONTROL
(o ) - (SEE SH 49)
BODY
GROUND SPLICE
(LEFT
SIDE $ *C 22
Z2 GREEN(SEE
GREEl SH 4?) iSEE SH 48)
KICK Z1 18BK
PANEL) 18PK LG* TO BODY , E17
COMPUTER / tr * L
(SEE SH 103)

TO DIMMER E17
SLIDE 20YL E2 200R
f\............................. n ...
o a a c□ o a a q CONTROL BK*
(SEE SH 49)
a a o qp o a a a
w.:s=3z;::..:|r .....m.— x a H J
(LOWER
RIGHT TO WARNING
SIDE OF Z3 LAMP CENTER
l.p.) 18BK (SEE SH 72)

Z3 20BK/OR*
' TO CLUSTER
Z3 2QBK/OR*
> (SEE SH 55) CIGAR “ 7 /
LIGHTER
LAMP
E2 200R
(SEE SH 47)

21 20BK

ASH E2 200R
RECEIVER
LAMP

_____________ HEADLAMP SWITCH CONTROLLED INTERIOR LAMPS

AS-HK 51 918W-10
 EBL SWITCH
ILLUMINATION
---- E2 20OR //
\\
TO CIGAR LIGHTER LAMP (__ C#J LIFTGATE
(SEESH51) E2 20OR RELEASE
SWITCH
TO ASH RECEIVER LAMP C__ - ILLUMINATION
(SEE SH 51) ~

E2 200R 203 20BK/OR*

CLUSTER ILLUMINATION
LAMP

E02 20OR

21
GROUND 18BK
(ABOVE OVER­
HEAD CONSOLE)
TO POWER
QUARTER VENT
SWITCH
(SEE SH 86) j__E2 180R_____
 FUSE #6
(20 AMP)

TO TURN L5 18BK/PK*
SIGNAL & , TO IGNITION
HAZARD SWITCH L9 18BK/WT* A31 14BK/WT* *1 SWITCH
(LEFT POD) (SEE SH 84)
L55 18PK/BK*
(SEE SH 49)
L9 18BK/WT* fv /M h -) )— A15 14PK

TO COMBO FUSE #1
FLASHER (20 AMP)
^T- L91.18DB/PK (SEE SH 50)
TO
HEADLAMP L32 18PK
SWITCH
(LOCATED J— L80 18TN L60 18TN
IN LEFT POD)
(SEE SH 49)

L61 18LG LS1 18LG

L60 LSO L62 L63

18TN 18LG 20BK 18BR 18DG
RD* RD*

I
-T*
TURN SIGNAL
SWITCH
(LOCATED IN
STEERING COLUMN
MULTIFUNCTION
SWITCH)
(SEE SH 119)

#11, 12, 14, 15 /

x NATURAL STRG V
0 (SH 118) COLUMN

L61 18LG

ii (REAR CEN­
LSO 18TN TER OF I.P .)

STOP/TURN AND HAZARD

FLASHER SYSTEM
 POSITIVE
BATTERY
TERMINAL

A1514PK ~ < f-

0 #23

TO RIGHT
^ PARK LAMP
)
(SEE SH 41

STOP/TURN AND HAZARD

FLASHER SYSTEM
 TO SPLICE
L7 18BK/YL •-4 < §>
(SEE SH 50)

TO BODY
COMPUTER
(SEE SH 104)

A Sac
□□□□□□□□□□□□a

NATURAL

D13 D14 G6
1SOR 18LB 20GY
DB*
/% >
m - G6 20GY
20
- n .— \ n
R iir ir i/ W l
U U U U liU l/ U
G6
20GY
.... n ....... ....... n..
a a a a c3 a a a
a a a a c3 a a a
-- ess-sjjy,

22
18BK
IB K
LG
■ r y ®
1 ^ (SEE SH 47)

22 G5 23 E2 M1 D13 D14 G6
18BK 20DB 20BK 200R 18PK 1SOR 18LB 20 GY
LG* WT* OR* I I DB* I I
A X A A A A
T T .1 \ T
i 11 14 6 2 3 5 8
 ELECTRONIC TRANSMISSION CONTROLLER SINGLE BOARD ENGINE CONTROLLER
(SEE SH 117) (SEE SH 109, 110, 111)

TO OIL
PRESSURE
SWITCH
(SEE SH
38, 30, 40)

T
DK GRAY _ ilieiTPn
20GY TWISTED
PAIR —

• v i i

IP-

#12
G6
20^3Y
TO OVERHEAD
— JI 4 CONSOLE t-
#18
3 ir (SEE SH 85)

DIAGNOSTIC
G6 20GY —
CONNECTOR TO

BLUE F&2 18RD

SPLICE
=i
(SEE SH 44)
,fu u i
Ln-nJ D2
TO BODY COMPUTER
(SEE SH 102)

M1 18PK
(LEFT SIDE
REINFORCEMENT
OF I.P,)

*D1 & D2
CIRCUIT FAMILY
MUST BE
TWISTED PAIR
WIRE
 TO IGNITION
SWITCH t-
(SEE SH 4)
A31
14BWWT*

SPLICE
(SEE SH 5, 7) 2 SPEAKER STEREO RADIOS
 LEFT FRONT SPEAKER RIGHT FRONT SPEAKER
(LEFT INSTRUMENT PANEL) (RIGHT INSTRUMENT PANEL)
2 SPEAKER STEREO RADIOS
 TO IGNITION
SWITCH U
(SEE SH 4) *
A31
14BK/WT*

TO DIMMING
MODULE 20RD/WT* TO

SPLICE
(SEE SH 5, 7)
 RT -X51 20BR/YL*
BODY #4
X57 18BR/LB* X57 2QBR/LB* —j
BLACK
RT
BODY #11
- ,X52 18DB/WT* X52 20DB/WT*

X51 18BR/YL* -
RT
BODY #9
— X58 18DB/OR* X58 2QDB/OR*
RT
BODY #6

LEFT REAR SPEAKER RIGHT REAR SPEAKER flAARRAAR

(IN TAILGATE STANDARD) (IN TAILGATE STANDARD) U U l J l i W J U
(NOT USED)
GRAY
IS d u uIj

X55 22BR/RD*

X5§ 20DB/RD1

X51 20BR/YL*
X52 20DB/WT*
— XS3 20DG
— X54 20VT
X57 20BR/L3*
X58 20DB/QR*

JBL-5T, rs L -s a
T O

LEFT FRONT SPEAKER

(LEFT INSTRUMENT PANEL)
zm RIGHT FRONT SPEAKER
] (RIGHT INSTRUMENT PANEL).
 LEFT FRONT SPEAKER RIGHT FRONT SPEAKER
(LEFT INSTRUMENT PANEL) (RIGHT I NSTRUMENT PANEL)
TO IGNITION
SWITCH £
(SEE SH 4) ' I TO CHARGING
A31 SYSTEM
14BK* •nr* • m i 1 (SEE SH 5r 7)

FUSE #7
(10 AMP)

X55 FUSE #23

20BR (20 AMP)
X12 RD*
20RD/WT*
i
TO SPUCE X if X53 X54
20DB/ 20DG 20VT
/&
vh DIMMING RD*
MODULE
(SEE SH
c o n SO) (SEE SH 50, 51, 55} X55 20BR/RD*
T
E22
TL7
200R
W T*
X55
20BR
X56 20DB/RD*
RD*
18BK
YL* X55 20BR/RD* —
(SEE SH 44) F62
X56 20DB/RD*
16RD
X15 16BK/DG*
X51 20SR/YL*
X15 - X52 20DB/WT*
r< $ > 18BK — X53 20DG
i (SEE SH 81) DG*
— X54 20VT
M1 18PK

M1
i X57 20BR/LB*
X58 2QDB/OR
18 GRAY
PK
A
FUSE #3 ^ X80 20DG/RD* 1
(20 AMP) BLACK

IGNITION
NAME J FEED RELAY
CONNECTOR REAR CONNECTOR REAR BRAND (LOCATION 7)
OF RADIO OF RADIO SPEAKER (SEE SH 114)
ELECTRONIC TUNE RELAY
STEREO (LOCATION 6)
TO SPUCE (SEE SH 114) T*
RADIO WITH CLOCK Z1
18BK

(SEE SH 48)
SPLICE zix:x: x x:x :x x :x m X1 1©RD/LG*

SPUCE GROUND STRAP

Z1 18BK
(SEE SH 5, 7)
 ILLUMINATION LAMP

TO DIMMING
MODULE
(SEE SH 51)

FUSE #26
(30 AMP)
TO SPLICE

HEATER BLOWER
(SEE SH 65) MOTOR RESISTOR
 - f TO DOOR

TO
/ BATTERY
1 FEED
(SEE SH 1» 6f 8)

TO HEADLAMP
SWITCH
(LEFT POD)
(SEE SH 49)

NBS % L E U 8BK— ( i f -----

(LEpr i
RELAY > I ] S w A Y ) 2° ?
(LOCATION 6) 21
(SEE SH 114) w m E2 200R ™ /CCC
(SEE CU
SH 52)

F20
16WT ■ F21 14TN-----------
E2 180R ---------
ELECTRONIC A ------- F 2016W T ----------
TRANSAXLE ------- Z1 16BK/WT*-------
ONLY I A jW h H iv i I------ GRAY
TO BACK- U U U U IA J U U
UP LAMP F20
18WT
F20
18WT
C24 (LEFT SIDE OF UP.)
RELAY
------- C50 16BK/LG* —
(SEE SH 33)
i
TO
Y
A22
------ C80 18BK/LB* —
TO BACKUP ------ CTO 16DG ----------
LIFTGATE/ LAMPS 12BK
EBL OR*
(SEE SH 4» 89)
(SEE SH 64)
TO
IGNITION f
SWITCH F
(SEE SH 4 )
A22 12BK/OR* Je 12BK/OR*
A22 1
/ TO HEATER
"1 SYSTEM
FUSE #25
(SEE SH 63)

REAR HEATER AND A/C SYSTEM

 REAR HEATER AND A/C ASSEMBLY (BLACK BOX)

MODE
REAR BLOWER SLIDE SWITCH
SLIDE SWITCH
MODE
OFF SERVO
MOTOR
LO
LiJ
MED

HI

. . MICRO ,
I I TEMP » Z1
I L SENSOR i 16BK
L J 2 __________ I REAR
SWITCH
BLOWER MOTOR ILLUM

Zt 16BK

C50 C70 CSO Z1 F2Q

© n E2
18BK 16DG 18BK 16BK 16WT 180R
LG* LB*

Z1 F20 E2
16BK 16WT 180R
C7Q
18DG

(FOR POWER
WINDOW) jQ E i n
(SEE SH 79) i n J li
o ts tat w o na a o- BLACK
q o a a a g ,a n

GRAY Z1
F21 14TN 14BK

E2 180R
F20 16WT
Z1 16BK

BLACK
CSO 18BK/LQ*
CSO 18BK/LB*
— C70 16DG —

REAR HEATER AND A/C SYSTEM

TO RIGHT POD SWITCH
(SEE SH 45) TO IGNITION
SWITCH
(SEE SH 4) J

TT
V21 V22
TO IGNITION
SYSTEM
(SEE SH 13)
18DB/ 18BR/ (2.5L)>
RD* YL*

S.

FUSE #1*3
.rpfU iili—
i
(20 AMP)
3i □ i □ □
o d □ ■
a c□ a o a in a a
u u <1
n h4i 1
i
5

15 14 13

> BLACK si/ N/ s/

Y
V23
fm s m r m m TO VAN CON- s 16BR/PK
V23
m s u u m s m VERSION RELAY y V23 18BR/PK*
(SEE SH 91)
V23 18BR/PK*

V23 16BR/WT*
V23 16BR/WT* ~)>— V23 16BR/WT*

#8
(SEE SH 122)

(SEE SH 122)
WIPE INPUT

GROUND *

WASHER MOTOR GND V23

16BR/WT*
V23
IGNITION FEED'
16BR/WT*
WIPER MOTOR FEED- 21
"» ■ 18BK
V20

WASHER SWITCH INPUT -

16BK
WT* l
TO <21>10
V13 GROUND SPLICE
16BR (SEE SH 90)
¥20 16BK/WT* LG*
Z1 18BK — V22 18BR/YL*
V13 16BR/LG*
l3 fL
BLACK-
¥23 16BR/WT
¥21 18DB/RD*

LIFTGATE WIPER AND WASHER SYSTEM

LIFTGATE WIPER MOTOR
(CENTER OF LIFTGATE)

LIFTGATE WIPER AND WASHER SYSTEM

LEFT REAR RIGHT REAR
FOG LAMP FOG LAMP

(SEE SH 52)

FOG LAMPS
 FOG LAMPS SWITCH
■ F61 18WT/OR*
j— L39 18LB k

L44 20VT/RD* iT
BLACK

TO A /C
FAN
CUT-OUT
SWITCH
(SEE SH 29)

F81 1SWT/OR

L44
TO DRL
20VT
FUSE #21 MODULE RD*
Z1 (20 AMP) (SEE SH 92)
18BK
TO
RIGHT
HEADLAMP
(SEE SH 41)
TO SPLICE

A6 12RD/WT* -4 <A^> FUSE #18

(10 AMP)
Z1 18BK
Z1 16BK

Z1 14BK
Z1 Y
12BK Z1 L4
RIGHT I A/C 22BK BLACK 14VT/WT*

■
HEADLAMP
O } GROUND J -*
CLUTCH
(SEE SH 30) TO X
TO A/C RIGHT TO DIMMER
FAN park SWITCH
m oto r lam p HEADLAMP TO HORN (SEE SH 50, 55)
(SEE SH 28. 30) {SEE SH 41) (SEE SH 41) {SEE SH 44)
•• L38 16 BR/WT* - ■ BUX
ONLY

RIGHT
FOG
LAMP
 14LG COMPUTER
BK* (SEE SH 102)
#a
LT
LIFTGATE RELEASE. BODY
SOLENOID
Q2 (SEE SH 122)
14LG r
BK* I
* - j T n r '—~ < t

(CENTER REAR
OF LIFTGATE)

f
/ GROUND THRU LIFT
t----- GATE PANEL FOR
LIFTGATE GROUND
CIRCUIT

LIFTGATE RELEASE
 BLUE
GRAY
looonooaopDocr!&
Doaaooaoooaoo□ ]
G13 18DB/RD* TO MECHANICAL (OOOOOOO
J TO BODY Q5 OR ELECTRONIC
TO COMPUTER 20DB
IGNITION CLUSTER
(SEE SH 102) WT*
SWITCH
(SEE SH 4) G5 20DB/WT*
T FUSE #15
A21 (10 AMP)
14DB

A21 14DB G5 20DB/WT

G13 TO
18DB
RD* (SEE SH 13, 67, 102) BRAKE
^ G9 20GY/BK* — WARNING
SPLICE
(SEE SH 4, 104)
TO

G19 20LG/BK* G19 20LG/BK* -<4 ANTI-LOCK

SPLICE
{SEE SH 37)
#4

G13 18DB/RD* # SEATBELT

—
WARNING LAMP CENTER
FOR WARNING LAMP
CENTER CONNECTOR
#15 (SEE SH 125)
TO SINGLE
BOARD ENGINE
CONTROLLER
CAVITY 56
r G24 20GY/PK* G24 22GY/PK* MAINT REQD

(SEE SH 13, 17, 24)

TO DAYTIME
RUNNING LIGHT TO SPLICE ^
MODULE LEFT TURN
L61 18LG SIGNAL
(SEE SH 92) TO TURN (SEE SH 53, 104) '
- r & HAZARD
i FLASHER
G34 SYSTEM TO <±.m> SPUCE
FOR 16RD RIGHT TURN
L60 18TN \SULA SIGNAL
DAYTIME GY*
(SEE SH 53, 104)
RUNNING I #16
LIGHTS k
ONLY —-------
J3
L33 16RD - ^ ) — G34 16RD/BK* HI BEAM
« :

I L33 16RD
TO

L3
m #6 L3
<Q > 23 20BK/OR*

16RD 14RD SPLICE

OR* OR* (SEE SH 48, 51)

TO
FRONT END TO
Di'MMER
LIGHTING
SWITCH
(SEE SH 41) (SEE SH 50, 55)
WARNING LAMP CENTER
RD BODY —
GROUND
(RIGHT SIDE
KICK PANEL)

L - G74 18TN/RD* G74 1STN/RD*

(TERMINAL
& SLEEVE)

GREEN
(RIGHT SIDE RIGHT FRONT
OF I.P .} DOOR AJAR
(RIGHT DOME SWITCH
16-WAY)
 r— A21 14DB
TO MECHANICAL
OR ELECTRONIC
CLUSTER GRAY

TO
IGNITION
boooooo
SWITCH opooooo,
(SEE SH 4)
G5 20DB/WT*

BLUE
TO INSTRUMENT
TO WARNING PANEL WIRING
LAMP CENTER (SEE SH 48)
(SEE SH 72)
TZ1
12BK (LEFT SIDE KICK
PANEL)
BODY GROUND

21 16BK

18BK

r
fti SEAT BELT
SWITCH
(IN BUCKLE)
21
G10 18BK
20LG X 18BK-
RD* TO (RIGHT SIDE OF
SEAT RISER
LEFT REINFORCEMENT)
FRONT
DOOR
JAMB
SWITCH
(SEE SH 81
m m n m n
Sa a a M j u u
1-CT
GREEN
(LEFT SIDE
. r—
i.... it UL .._JT-1.. ■ OF I,P .)
ru
0
0

fl

ba a a a
BLUE
n
0
0

3 a a o a
□

v ■" .............u
□□□□□□□□□□□□ G10
□ □ □aaaooooDooa
□□□o a o a o p o 20LG
T" i G13 18DB/RD*
RD*
TO BODY
COMPUTER
(SEE SH 102)

SEAT BELT WARNING SYSTEM

BUTTON CIR SEL (LEFT) CIR SEL (RIGHT) MIRROR
DIRECT

A AE, BCDF, HL, GJ AE, BCDF, HK, Gl RIGHT

B BE, ACDF, HL, GJ BE, ACDF, HK, Gl UP

C CE, ABDF, HL, GJ CE, ABDF, HK, Gl DOWN

D DE* ABCF, HL, GJ DE, ABCF, HK, Gl LEFT

~ PANEL)
 P33 1SOR/BK* f
I
LEFT FRONT
I
DOOR LOCK MOTOR P34 16PK/BK*
—— BLACK

P33 160R/BK* -------

P33 1SOR/BK*
P34 16PK/BK*

I
RIGHT FRONT ! I
DOOR LOCK MOTOR j - P34 16PK/BK *
• BLACK
GRAY— '
----------- P33 160R/BK* (RIGHT SIDE
OF IP.)

P34 16PK/BK*

■))----------- P34 1SPK/BK*

TO POWER
REMOTE - M t 18PK
Ml MIQDACC
MIRRORS t
18PK {SEE SH ?6)

LOCK
P36 18PK/VT* P35 180R/VT*

P36 18PK/VT P36 18PK/VT*

*---- GRAY *-----GRAY
l& O - f - M i 1SPK
- °h» 18PK
P35 1BOR/VT* P35 1SOR/VT*

LOCK ____ _ _____ - _______ — J

LEFT FRONT RIGHT FRONT

DOOR LOCK SWITCH DOOR LOCK SWITCH

LEFT DOOR CONNECTOR RIGHT DOOR CONNECTOR

AND DOOR LOCK SWITCH FUNCTION AND DOOR LOCK SWITCH FUNCTION

BI­ BI­ DOOR LOCK BI­ B~ DOOR LOCK

POLARITY POLARITY FUNCTION POLARITY POLARITY FUNCTION
OR/VT* PK/VT* LOCK OR/VT* PK/VT* LOCK
PK/VT* OR/VT* UNLOCK PK/VT* OR/VT* UNLOCK
PK — FEED PK — FEED
 (CENTER
OF DOOR)

LEFT FRONT
DOOR WINDOW
LIFT MOTOR

G16 14BR/WT*

Q20 14VT/WT* Q26 14VT/WT*

F21 12TN F21 12TN

LEFT WINDOW
LIFTMASTER
SWITCH
CONNECTOR m r W v t t l
r n im
T -.•D- c m
u u
GRAY
F21 12TN (LEFT SILL
Z1 12BK 16-WAY)
021 14WT
VIEW LOOKING THRU
TOP OF SWITCH F21 12TN

TO Z1 14BK
MASTER SWITCH OVERHEAD

B+
PWR WINDOWS

B- WINDOW/
MOVEMENT
CONSOLE
(SEE SH 84)
r
TO FUSE #24
BACKUP LAMP
A22
12BK
LB WT LEFT UP (SEE SH 89) OR
WT LB LEFT DOWN
BR/WT* VT/WT* RIGHT UP
F21 12TN *—( A22 12BK/OR*
VT/W T* BR/WT* RIGHT DOWN
TN FUSE CAVITY #25 A22
FEED 12BK
(30 AMP) CIRCUIT
— BK GROUND BREAKER OR*
TO IGNITION
SWITCH
(SEE SH 4)
 RIGHT FRONT
DOOR WINDOW
LIFT MOTOR

TO FUEL TANK
(SEE SH 88)

T21
14BK

BODY
GROUND
(LEFT
KICK
PANEL) TO LIFTGATE
(SEE SH 90)

.. uir-t TO <.Z1>8| SPLICE

o a o a a oa o
spa a a a a a a (SEE SH 90)
J L * -.:.
Z1 14BK ------- -JB ----- - Z1 12BK

RIGHT DOOR
(SEE SH 48)
BI­ B- WINDOW AND
POLARITY POLARITY MOVEMENT
VT BR DOWN-FROM DOOR SWITCH
BR VT UP-FROM DOOR SWITCH
VT/W T* BR/WT* DOWN-FROM MASTER SWITCH
BR/WT* VT/WT* UP-FROM MASTER SWITCH
TN — FEED
 LEFT
LEFT FRONT RIGHT FRONT POD SWITCH
DOOR' DOOR BLACK
{SEE SH 49},
COURTESY COURTESY
LAMP LAMP
u p in

{IN ARM
REST)
r©i (IN ARM
REST)
I
M2
18YL
i
M11
18PK
SPUCE
(SEE SH 48)

18BK 18BK 18BK

BODY
GROUND
(LEFT
KICK
PANEL)

fm m n n m

(LEFT SIDE
GREEN OF L P ' !
(SEE SH 8°} ^

BLACK LEFT FRONT . TO BODY

COMPUTER DIODE ASS’ Y
TO SEATBELT DOOR JAMB SWITCH LT. RR. OTR.
(SEE SH 102)
SWITCH 21 18BK ------
(SEE SH 74)
M11
18PK
BK*

o S S S er Lmp
iSEE m W
(SEE SH l 103)
102, W3\ REAR
(LOCATED ON
Q f DRAWER) Z1 18BK"

M2 18YL/RD* --------------- « ------- M2 18YL M2 18YL

LT [3<M 2 M2 18YL
#11t - BODY -

M11 18PK/L6* M11 18PK/LB

M11 18PK/LB* —
LT
" BODY

M tt
18PK BLACK-
LB*

18BK

REAR DOME AND

CARGO LIGHT

LEFT : RIGHT
LIFTGATE LIFTGATE
COURTESY COURTESY
LAMP LAMP
OVERHEAD CONSOLE LAMPS
 X02 18GY TWIN MAP
COURTESY LAMP
TOUCH SWITCH UNIT
(IN ROOF CONSOLE)

X2 18GY
M1 18PK
M2 18YL
M11 18PK/LB*
M11
f >18R D
M11 18PK/LB*
V J TWIN MAP
^ ^ - ^ C O U R T E S Y LAMPS
(IN ROOF CONSOLE)
SPLICE
RR, LAMPS
(COURTESY SW GND)
(SEE SH 81)
• TO < SPLICE
M11 18PK/LB* ------------------------
(COURTESY LAMP FEED)
^ TO <f^21> SPLICE (SEE SH 81)
GREEN F21 12TN
(LEFT SIDE (POWER WINDOW)
OF I.P .) (SEE SH 79)

— G32 18BK/LB* * a\ / t tt rs+

— G31 18VT/LG*

D2 18WT/BK*

D1 18VT/BR*

E2 180R

AMBIENT SWITCH
- ) ) h- L7 18BK/YL* -
(RADIATOR FAN MOTOR FRAME)

OVERHEAD CONSOLE LAMPS

 TO BODY
COMPUTER
(SEE SH 103)
— _________ CL
□□□□□□□□□□□□
□□□□□□□□□□□□□
[&
BLUE*
t TO REAR
Z1 16BK 4 LIGHTING
(SEE SH 90)
[O Z1 12BK

— BODY
GROUND
(LEFT KICK
PANEL)
flflflflfW lA
UUUUUUUU
BLACK 'rzcrr..ir x x r _
(LEFT SIDE
IDE \
M22
18WT
OF LP
•’ \ . r-n lir’'IIMbtP=i.......
a a a a □ □DO
sp a a ca o o a o
..lid...._ .....

a db a a a a a a
GRAY cp c3 a O Q Cl o o
(RIGHT SIDE Iu ■ V■
OF I.P .)
(RIGHT
COWL TOP
16-WAY)
p u li™

Z1 18BK

M22 Z1>15
18WT
(SEE SH 76)

LEFT FRONT RIGHT FRONT ^

DOOR ILLUMINATED DOOR ILLUMINATION
ENTRY SWITCH ENTRY SWITCH
--- -------------
Z1 18BK Z1 18BK

C fM — M22 18WT
iS a S C
& M22 18WT

1 BLACK i F V - “ BLACK
i_______________ . _ _____i i~_____________________— .J

ILLUMINATED ENTRY SYSTEM

 RED
Q11 18LB Q2S 14YL/DQ*
(AT MOTOR) p 0 W E R R E A R Q U A R T E R W IN D O W
 MOTOR INSULATOR POLARITY
+POLARITY -POLARITY SEAT MOVEMENT
YL/LB* RD/LB* FORWARD
P21 14RD/LG*
RD/LB* YL/LB* REARWARD
P19 14YL/LG*
YL/WT* RD/WT* REAR UP
P15 14YL/LB* m /m * YL/WT* REAR DOWN
P11 14YL/WT* YL/LG* RD/LG* FRONT UP
RD/LG* YL/LG* FRONT DOWN
S E M ? '—
RD FEED
s s — BK GROUND
S B e -BLACK
8

F35 14RD/WT* P13 14RD/WT*

F35 14RD/LG* P21 14RD/LG*
Z1 14BK/LG*
BL JE2L P19 14YL/LG*
P13 14RD/WT*
F35 14RD Z1 14BK/WT* P11 14YL/WT*
P17 14RD/LB* P15 14YL/LB*
F35 14RD/LB*
Z1 14BK Z1 14BK/LB* BLACK P17 14RD/LB*

/ (UNDER SEAT) /
FRONT CENTER / REAR /
SWITCH SWITCH / SWITCH /
/
/
/
/
F35 /
12RD /
/
/
/
/
/
/
/
T T T /
P19 P21 P15 P17 P11 P13
14YL 14RD 14YL 14RD 14YL 14RD
LG* LG* LB* LB* WT* WT*
-(f P21 14RD/LG*
FRONT
RED VERTICAL

-((- P19 14YL/LG*

Z t 14BK -(£• P17 14RD/LB*
HORIZONTAL

GRAY -<£- P15 14YL/LB*

tm n n a r t S
*-({- P13 14RD/WT*
u y u i^ ju u u . (LEFT SIDE
OF I.P .) TO REAR
a a a a a a a
17' “ Z1 14BK .< 0 5 3
VERTICAL
-(£ P11 14YL/WT*
□ □a □a □a O
a Io a a
(LEFT SILL SPLICE POWER SEAT
16-WAY) (SEE SH 48) MOTORS
CAVITY #27
(30 AMP CIRCUT BREAKER)
(SEE SH 44, 78) TO IGNITION
-) SWITCH
(SEE SH 4)
 TO INSTRUMENT
CLUSTER
(SEE SH 50) _ g ray BODY
GROUND

.. n
i^fobooaootiaaools
(aoooocpooooaoaj

TO BODY
COMPUTER
(SEE SH 101)

ELECTRIC FUEL PUMP AND GAUGE SYSTEM _____________

918W-10 AS-HK 88
 TO
PARK LAMP
RELAY
(SEE SH 50)

TO
IGNITION WIRES
SWITCH LEFT BACKUP LAMP CAPPED
(SEE SH 4) FOR
TRAILER
REAR LIGHTING & TRAILER TOW WIRING
 -W IB IN fi-;D fA .G R A jM S , 8 W -S 9

— L1 18VT/BK

WIRES
CAPPED
FOR
TRAILER
TOW WIRING

----- Z1 18BK

TO SLIDING i
DOOR AJAR
(SEE SH 73)

RIGHT TAIL, STOP,

TURN AND SIDE
RIGHT BACKUP LAMP MARKER LAMP
 TO
IGNITION Y A21 14DB
SWITCH
(SEE SH 4)

FUSE #13
(20 AMP}
(*13 (114 £15
SPLICE
T 11 i1
(SEE SH 6, 8)

W %S N

TO
LIFTGATE
V23 16BR/PK* WIPER/
WASHER
(SEE SH 67)

VAN
CONVERSION
RELAY
(LOCATION i )
(SEE SH 114)

18BK / - < Z lJ ? ]

U r (SEE SH 48)
— A18 14RD/PK*

Z1
12BK
TO

□ □ □ □ □ □ □ □ SPLICE
ZjsJI f l- ..flferC
P = = £ _ _ -^ r (SEE SH 80)
BLACK
I£T l,.,n -..fra :
R A iw m n n ffSLr

Z1
16BK

YELLOW BODY
MOLD O j GROUND
(LEFT
BATTERY KICK PANEL)
FEED
(LOCATED NEAR
BULKHEAD CONNECTOR)

VAN CONVERSION WIRING

★ V -.- ..?.r .•.- ......................■— — rer-T'-".............r '... WIRiNG DIAGRAMS 8W-1Q1

TO HEADLAMP
DIMMER SWITCH
(SEE SH 50)

L20
14LG

DAYTIME RUNNING LIGHT MODULE WIRING

 TO
HEADLAMP SWITCH
(SEE SH 50)

OPTICAL HORN
HEADLAMP
DIMMER SWITCH
(SEE SH 113)

1 TURN SIGNAL SWITCH

' (SEE SH 53, 49)

TO DAYTIME
RUNNING
16BK LIGHTS WIRING
(SEE SH 92)

----- L7 18BK/YL*
L7 18BK/YL*
RIGHT SIDE
MARKER LAMP

FRONT END LIGHTING WITH

DAYTIME RUNNING LIGHTS
 TO TURN
--------- LSI 18LG ----------- k SIGNAL SWITCH
* {SEE SH 49, 53)

TO FUSE #17
HEADLAMP DIMMER
SWITCH SYSTEM
(SEE SH 50)
LEFT
HEADLAMP
(AERO)

TO WINDSHIELD WASHER
PUMP MOTOR (SEE SH 45)

LEFT PARK
AND TURN
SIGNAL LAMP

LEFT SIDE
MARKER LAMP

FRONT END LIGHTING

WITH DAYTIME RUNNING LIGHTS
 TO I.O’.D.
A4 12BK/RD*
(SEE SH 5, 6)

(SEE SH 5, 7) A4
12BK
RD*

TO
CHARGING
A4 SYSTEM
12BK (SEE SH 5, 7)
RD*

16BK
RD*

UNDERHOOD
LAMP
(RIGHT SIDE
HOOD INNER
PANEL)

UNDERHOOD LAMP
 RADIATOR TO IGNITION
FAN MOTOR SWITCH
----- C25 14LG (SEE SH 4)
iiln lljW ----- Z1 12BK

o /
A
/ L.
^ — BLACK

A21
14DB

21 C25
12BK 14LG
#47

-N>
—O eo «o

O o o o o
^ .
J1. C27 20DB/PK* C25 12LG

SLACK
(REAR OF
BATTERY)
A21 14DB

GRAY A16 12GY

ENGINE GROUND
(UPPER LEFT
OF ENGINE)
A21 14DB (SEE SH 13)

RADIATOR FAN
MOTOR RELAY
(LEFT SHOCK
TOWER)

TO SINGLE BOARD
f ENGINE CONTROLLER
C27 20DB/PK* “7 CAVITY 31
(SEE SH 14)

TO BATTERY
A16 12GY A16 20OR (SEE SH 6)

RADIATOR FAN SYSTEM WITH HEATER

(2.5L ENGINE ONLY)
 RADIATOR TO IGNITION
FAN MOTOR SWITCH
(SEE SH 4)

RADIATOR
FAN GROUND
CUPPER LEFT
OF ENGINE) 4 T (SEE SH 18. 23}

RADIATOR FAN
MOTOR RELAY
(LEFT SHOCK
- TOWER)

TO SINGLE BOARD
K ENGINE CONTROLLER
■ C27 20DB/PK* “1 CAVITY 31
(SEE SH 18, 24)

TO BATTERY
A16 20GY (SEE SH 8)
 TO SPLICE

TO INSTRUMENT BODY
CLUSTER GROUND
(SEE SH 56)

TO BODY
COMPUTER
(SEE SH 101, 102)
 ( TO BACK
~1 UP LAMPS
(SEE SH 89)

L1 18VT/BK*

L1 18VT/BK*
L1
16VT (CONNECTOR LOCATED
BK* UNDER VEHICLE
NEAR FUEL TANK)

BLACK

- GREEN
(LEFT SIDE
OF I.P .)

VACUUM VACUUM
SOLENOID SOLENOID
A B

4 WHEEL DRIVE VACUUM SOLENOID SYSTEM

 — L1 18VT/BK* t--------
r _____ T3 14VT ■"feU BLACK

j& io llB lA C K T
y* m ,
v...........>
A21 14DB
T41 18BR/YL*
T2 14TN T3 18VT
BK* NEUTRAL SAFETY SWITCH
F20 13WT (FRONT OF /
BACK-UP LAMP RELAY TRANSMISSION) /

4 WHEEL DRIVE VACUUM SOLENOID SYSTEM

 TO SINGLE BOARD
ENGINE CONTROLLER TO EATX MODULE
CAVITY #26s 48 CAVITY #4, 43
TO tO W LEVEL
(SEE SH 12,19, 25). (SEE SH 33)
FLUID SENSOR
(SEE SH 46)

M1 18PK
 TO RIGHT DOOR
JAM SWITCH
TO SEATBELT (SEE SH 82)
SWITCH
(SEE SH 74) M2
(RIGHT
TO WARNING rfo o' TO LEFT DOOR SIDE
18YL

LAMP CENTER to o AJAR SWITCH OF l.P .)

(SEE SH 72) to o (SEE SH 73) GREEN
r ih iW tn r ih
u u u u u u u u
(o o u L -i
(o o TO FUEL TANK ■ .m . Ill ut........r=
i....*
BLUE o o WIRING
(SEE SH 88)
a a a a c□ a a a
so Cl a a a a cp □
'V
□ □
G10
M1 18BK 20LG TO LEFT DOOR
RD* JAM SWITCH
(SEE SH 81) TO
T
G75 G4 G ie
18TN 18DB 18BK SPLICE
G13 LB* (SEESH 81)
18DB
RD* VfS
M2
18YL

n n n n n n n rt
u u u u w j u
IT r > GREEN
- G5 20DB/WT* G5 20DB/WT* {LEFT
FUSE #15
(10 AMP)
i BE
a a a o c s c a o a
a o a o a a a a
SIDE
OF I.P .)

M1
Z2 18BK
18BK (RIGHT SIDE
LG* M2 OF l.P.)
1BYL GRAY

a a o o a a o o m ^ L ,
□ a n
a a a a c s a a a

fliW liW lR
A21
14DB
(SEE SH 67) i a a a a a a a

sum
j f u ..c J . m n n n n m
TO IGNITION
SWITCH
UUIRAJUUU
Z1 GREEN'— G13
(SEE SH 4) 18DB
18BK
GROUND LG* RD*
___i M2 M2
TO M1 G5 18YL 18YL
(LEFT G10 G16
18BK 20DB 20LG vk sX I
SIDE ---- Z1 18BK { ^ Z l T i l G?5 G4 20BK
WT* RD*
KICK 18TN 20DB 18*
TO C/LAMP M2
PANEL) SPLICE
WIRING 18YL
(SEE SH 47 )

16
i12 21
_ T Jl 2 10
A 1
(SEE SH 11)

25
FOR CONNECTOR
BODY COMPUTER (BLUE) (SEE SH 115) 25 PIN CONNECTOR
 TO LEFT TO RIGHT
ILLUMINATION ILLUMINATION
ENTRY ENTRY
TO (SEE SH 85) (SEE SH 85)
LEFT ROD
(SEE SH 49) TO POWER DOOR LOCK
RELAY
(LO CAfiON 9)
(SEE SH 78) W
3 F

BLACK
VI
M22 M22
BLACK
18WT 18WT
TO
RIGHT ROD
BLACK (SEE SH 45)

P38 a r m n iw m
200R
WT* m s w ju iM j
M2 18YL G R A Y -< f
(RIGHT
RIGHT S ID E ^ k f ts...................... -...n
OF I.P.) aa
a o d n a n qp C 3
•-------------lit.- -H
i. •

KEYLIGHT SWITCH M22

(SEE SH 81) 18WT

|n o a g |
r E92 200R /B K *H i

BLACK

G26
r M51
20LB 18YL
RD*

TO
DIMMING
MODULE
(SEE SH 51)

P38 G26 M51 M22

200R 20LB 18YL 18WT
WT* RD*

BODY COMPUTER (BLUE) 25 PIN CONNECTOR

 TO ABS PUMP MOTOR
TO TEMPERATURE (SEE SH 35) '
GAUGE SENDING UNIT
(SEE SH 26, 38, 39, 40}

TO LOW BEAM RELAY

(LOCATION 1)
(SEE SH 49)
TO LEFT DOOR TO RIGHT DOOR
LOCK SWITCH LOCK SWITCH
(SEE SH 77) (SEE SH 77)
TO SLIDING DOOR
AJAR SWITCH
j \
A o f o l
(SEE SH 73)

^ gray#H0 Q
id r

P3S P35
180R 1SOR
VT* VT*

(RIGHT (LEFT
COWL TOP BODY
16-WAY) u u u u u u u u 16-WAY)

GRAY BLACK
(RIGHT a a c□ a a a a a
CENTER
OF I.P) a a e;p a a a a a
—
TO RIGHT FRONT
DOOR AJAR
P35 SWITCH
180R (SEE SH 73)
BLACK
VT*

GREEN

ip ¥ ¥ in n m

TO LIFTGATE
RELEASE SWITCH
(SEE SH 71) a a o a a a a a
o o a a n a a a
iiT lr L

T T
GREEN
(REAR
CENTER
OF I.P)
r «
a a a db a a a a
o a a a a a
^ 4 - --- PL.—fli - .o
GRAY
Q33 P35 G74 G76 G78 G42
20BR 180R 18TN 18TN 18TN 20DB
LB* VT* RD* YL* BK* YL*

* A X X X
T T .T..__..._._.. t T
19 20 2 3 4 5
BODY COMPUTER (NATURAL) FOR CONNECTOR 25 PIN CONNECTOR
(SEE SH 116)
CAV WIRE CODE INSTRUMENT PANEL CIRCUITS SHEET
1 A3 12RD/WT* IGNITION SWITCH FEED (BATTERY FEED) 6,8
2 A6 12RD/BK* BATTERY FEED - PARK LAMPS 6,8
3 A18 14RD/PK* VAN CONVERSION (BATTERY SUPPLY) 91
4 G19 20LG/BK* ABS WARNING LAMP • 72
5 — — _
6 L3 14RD/OR* HEADLAMP HIGH BEAM 41
7 V30 22DB/RD* SPEED CONTROL 43
8 V31 20BR/RD* SPEED CONTROL 43
9 V33 20WT/LG* SPEED CONTROL 43
10 V32 20YL/RD* SPEED CONTROL 43
V32 20YL/RD* SPEED CONTROL 43
11 D2 18WT/BK* CCD BUS (-) 56
12 D1 18VT/BR* CCD BUS (+) 56
13 L43 20VT FUSE 10 LT HEADLAMP 42
14 L44 20VT/RD* FUSE TO RT HEADLAMP 41
15 G24 22GY/PK* EMISS MAINT REMINDER LAMP 72 TERMINAL END
16 G34 16RD/BK* DAYTIME RUNNING LIGHT MODULE TO 72 OF DISCONNECT
HI-BM IND
17 G20 22VT/YL* TEMPERATURE SEND 38* 39,40
18 G6 20GY OIL PRESSURE LAMP 38, 39,40
19 G60 22GY/YL* OIL PRESSURE SEND 1 38, 39,40
20 L39 18LB FUSED FOG LAMP FEED 70
21 L61 18LG LEFT TURN SIGNAL LAMP 54
22 L60 18TN RIGHT TURN SIGNAL LAMP 54
23 A15 14PK HA2ARD FLASHER 54
24 V4 18RD/YL* WIPER MOTOR HIGH SPEED 46
25 V318BR/W T* WIPER MOTOR LO¥/ SPEED 46
26 L7 18BK/YL* PARKING LAMPS 42
27 F20 18WT BACK-UP LAMP SWITCH FEED 89
28 L1 18VT/BK* BACK-UP LAMP 89
29 V10 18BR WINDSHIELD-WASHER MOTOR 45
30 G2S 22BK/TN* LOW WASHER FLUID 46
31 A41 14YL IGNITION START 4
32 X2 14DG/RD* HORNS 44
33 C21 18DB/OR* AIR CONDITIONING 27, 29
34 G9 20GY/BK* BRAKE WARNING LAMP 104 INDEX
35 V5 18DG WINDSHIELD WIPER SWITCH 46
36 V6 18DB WINDSHIELD WIPER MOTOR 46
V6 18DB WINDSHIELD WIPER MOTOR 46
37 B3 20LG/DB* LEFT RR WHEEL SENSOR 34
38 B4 20LG LEFT RR WHEEL SENSOR 34
39 B1 20YL/DB* ' RIGHT RR WHEEL SENSOR 34
40 82 20YL RIGHT RR WHEEL SENSOR 34
41 K29 20WT/PK* BRAKE SENSE 43
42 L50 18WT/TN* SPEED SENSOR 89
43 D11 20WT/VT* DIAG. ANTI-LOCK BRAKES 37
44 D12 200R D!AG» ANTI-LOCK BRAKES 37
45 A61 14DG/BK* FUEL PUMP FEED 88, 98
46 L20 14LG/WT* BATTERY FEED 50
47 A21 14DB IGNITION RUN/START 5
48 A4 12BK/RD* HEATED REAR WINDOW 5,7
49 A1 12RD IGNITION SWITCH FEED 8
50 A2 12PK/BK* IGNITION SWITCH FEED 6,8

50 WAY BULKHEAD DISCONNECT

 CAV WIRE CODE ENGINE COMPARTMENT CIRCUITS SHEET ■
1 A3 12RD/WT* IGNITION SWITCH FEED 6, 8
2 A6 1QRD [BATTERY FEED 6,8
3 A18 12RD/BK* VAN CON¥ERS!ON 91
4 — — —
5 — — —
6 L33 15RD LEFT HEADLAMP 41
6 L3 16RD/OR* DRL ONLY 41
7 V30 20DB/RD* SPEED CONTROL 43
8 V31 20BR/RD* SPEED CONTROL 43
9 ¥33 20WT/LG* SPEED CONTROL 43
10 ¥32 20YL/RD* I SPEED CONTROL 43
' 11 D2 20WT/BK* CCD BUS {-) 56
12 D1 20VT/BR* CCD BUS M 56
I 13 L43 20¥T FUSE TO LT HEADLAMP 42
14 L44 20VT/RD* FUSE TO RT HEADLAMP 41
15 <324 20GY/PK* EMISS MAINT REMINDER LAMP 72
18 L33 16RD DRL 72
17 <320 20VT/YL* WATER TEMPERATURE SENDING UNIT 38,39,40
18 06 20GY OIL PRESSURE SWITCH 38,39,40
19 G80 20GY/YL* OIL PRESSURE SENDING UNIT 38,39,40
20 L39 18LB FUSED FOG LAMP FEED 70
21 L61 18LG LEFT TURN SIGNAL LAMP 54
22 L60 18TN RIGHT TURN SIGNAL LAMP 54
23 A15 14PK BATTERY-HAZARD FLASHER 54
24 ¥4 18RD/YL* WIPER MOTOR-HIGH SPEED 46
25 ¥3 18BR/WT* r WIPER MOTOR-LOW SPEED *16
SMALL LARGE 28 L7 18BK/YL* SPLICE-SIDEMARKER AND PARK 42
L7 18BK/YL* AND TURN SIGNAL LAMPS
27 F20 18WT BACK-UP LAMP SWITCH 89
28 ^ LI 18VT/BK* BACK-UP LAMP SWITCH 89
29 ¥10 20BR WINDSHIELD WASHER MOTOR > 45
30 G29 2QSK/TN* LOW WASHER FLUID INDICATOR LE¥EL SENSOR 46
31 A41 18YL STARTER RELAY-IGNITION 4
32 X2 18DG/RD* HORN 44
33 C21 18DS/OR* AIR CONDITIONING 27,29
34 G9 20GY/BK* BRAKE WARNING LAMP SWITCH I 104
35 ¥5 18DG WINDSHIELD WIPER MOTOR 46
38 ¥6 18DB WINDSHIELD WIPER MOTOR 4f
37 — — —
38 —. — —
39 — — —
40 —, —. —
41 K29 16WT/PK* 60-WAY BRAKE SENSE 43
42 — — —
TERMINAL END
OF DISCONNECT 43 — .
— —
44^ — —
45 A61 14DG/BK* FUEL PUMP FEED 88
45 L20 14LG/WT* BATTERY FEED 50
47 A21 14DB SPLICE-IGNITION RUN CIRCUIT 5
48 A4 12BK/RD* ELECTRICALLY HEATED REAR WINDOW 5,7
49 A1 12RD IGNITION SWITCH 8
50 A2 12PK/BK* IGNITION SWITCH 6, 8

50 WAY BULKHEAD DISCONNECT

(2.5L ENGINE)
 CAV WIRE CODE ENGINE COMPARTMENT CIRCUITS SHEET
1 A3 12RD/WT* IGNITION SWITCH FEED 6 ,8
2 AS 10RD> BATTERY FEED 6.8
3 A18 I2RD/BK* VAN CONVERSION 91
4 G19 20LG/QR* ABS WARNING (3.3L ONLY) 72
5 — — —
6 L33 16RD LEFT HEADLAMP 41
6 L3 1SRD/OR* DRL ONLY 41

El 7
8
V30 20DB/RD*
V31 20BR/RD*
SPEED CONTROL
SPEED CONTROL
43
43
9 V33 20WT/LG* SPEED CONTROL 43
10 V32 20YL/RD* SPEED CONTROL 43
11 D2 20WT/BK* CCD BUS M 56
12 D1 20VT/BR* CCD BUS {+) 56
13 L43 20VT FUSE TO LT HEADLAMP 42
14 L44 20VT/RD* FUSE TO RT HEADLAMP 41
15 Q24 20GY/PK* EMISS MAINT REMINDER LAMP 72
16 L33 16RD DRL 72
17 G20 20VT/YL* WATER TEMPERATURE SENDING UNIT 38,39,40
18 G6 20GY OIL PRESSURE SWITCH 38,39,40
19 G60 20GY/YL* OIL PRESSURE SENDING UNIT 38,39,40
20 L39 18LB FUSED FOG LAMP FEED 70
21 L61 1SLG LEFT TURN SIGNAL LAMP 54
22 L60 18TN RIGHT TURN SIGNAL LAMP 54
23 A15 I4PK BATTERY-HAZARD FLASHER 54
24 V4 18RD/YL* WIPER MOTOR-HIGH SPEED 4b
25 V3 18BR/WT* 1 WIPER MOTOR-LOW SPEED 4t
26 L7 18BK/YL* SPLICE-SIDEMARKER AND PARK 42
L7 18BK/YL* AND TURN SIGNAL LAMPS 42
SMALL LARGE 27 F20 18WT BACK-UP LAMP SWITCH 89
F20 18WT 89
28 L1 18VT/BK* BACK-UP LAMP SWITCH 89
29 V10 20BR WINDSHIELD WASHER MOTOR 46
30 G29 20BK/TN* LOW WASHER FLUID INDICATOR LEVEL SENSOR 46
31 A41 18YL STARTER RELAY-IGNITION 4
A41 18YL STARTER RELAY-IGNITION 4
32 X2 18DG/RD* HORN 44
33 C21 18DB/OR* AIR CONDITIONING 27,29
34 G9 20GY/BK* BRAKE WARMING LAMP SWITCH 104
35 V5 18DG I WINDSHIELD WIPER MOTOR 46
36 V6 18DB WINDSHIELD WIPER MOTOR 46
37 B3 20LG/DB* LEFT RR WHEEL SENSOR (&3L ONLY) 34
38 B4 20LG LEFT RR WHEEL SENSOR (3.3L ONLY) 34
39 B1 20YL/DB* RIGHT RR WHEEL SENSOR (3.3L ONLY) 34
40 B2 20YL RIGHT RR WHEEL SENSOR (3.3L ONLY) 34
41 K29 18WT/PK* 60-WAY BRAKE SENSE 43
TERMINAL END 42 L50 18WT/TN* SPEED INDICATOR (3.3L ONLY) 89
OF DISCONNECT 43 D11 20WT/VT* DIAG, ANTI-LOCK BRAKES (3.3L ONLY) 37
44 D12 200R DIAG, ANTI-LOCK BRAKES (3.3L ONLY) 37
45 A61 14DG/BK* FUEL PUMP FEED 88,98
46 L20 14LG/WT* BATTERY FEED 50
47 A21 14DB SPLICE-IGNITION RUN CIRCUIT 5
48 A4 12BK/RD* ELECTRICALLY HEATED REAR WINDOW 5, 7
49 A t 12RD IGNITION SWITCH 5
50 A2 12PK/BK* IGNITION SWITCH 6 8

50 WAY BULKHEAD DISCONNECT

(3.0L & 3.3L)
CAV WIRE CODE IGNITION SYSTEM CIRCUITS SHEET NO,
t K1 20DG/RD* MAP SENSOR SIGNAL 13
2 K2 20TN/BK* TEMPERATURE SENSOR SIGNAL 15
3 A14 16RD/WT* DIRECT BATTERY FEED 14
4 K4 18BK/LB* SIGNAL GROUND 15
5 211 16BK/WT* SIGNAL GROUND 12
6 K6 20VT/WT* MAP SENSOR SIGNAL 13
7 K7 180R 8 VOLT OUTPUT 15
8 F20 16WT IGNITION FEED 16
9 A21 14DB IGNITION START/RUN 13
10 — — ,—

11 212 16BK/TN* •POWER GROUND 14

12 212 16BK/TN* POWER GROUND 14
13 — — —

14 — — —

15 — — —

16 K11 18WT/DB* INJECTOR 16 1 21 41

17 — — — .

18 —

19 K19 18GY IGNITION COIL 14

20 K20 18DG ALTERNATOR 16
21 — — —

22 K22 180R/DB* THROTTLE POSITION SENSOR 12

23 ____ ___

24 K24 18GY/BK* DISTRIBUTOR PICKUP SIGNAL 15

25 D21 20PK SCI (TRANSMIT) 14
26 D1 20VT/BR* CCD BUS M 12
27 C20 18BR A/C CLUTCH INPUT 14
28 — __

29 K29 18WT/PK* BRAKE SWITCH SIGNAL 43

30 T41 20BR/YL* PARK/NEUTRAL SWITCH SIGNAL 15
31 C27 20DB/PK* RADIATOR FAN RELAY 14
32 — — —

33 V36 20TN/RD* SPEED CONTROL {VACUUM) 43

34 C13 2QDB/OR* A /C CLUTCH RELAY SIGNAL 14
35 K35 20GY/YL* EGR SOLENOID SIGNAL {CALIF) 13
36 — — —

37 —

38 ,— —

39 K39 18GY/RD* AUTOMATIC IDLE SPEED MOTOR (AIS-3) 12

40 K40 18BR/WT* AUTOMATIC IDLE SPEED MOTOR (AIS-1) 12 VIEWED FROM WIRE END
41 K41 18BK/DG* OXYGEN SENSOR SIGNAL 12 OF CONNECTOR
42 — —

43 — — —

44 ___ — > —

45 D20 20LG SCI (RECEIVE) 14

46 D2 20WT/BK* CCD BUS M 12
47 G7 20WT/DR* DISTANCE SENSOR SIGNAL 15
48 V31 20BR/RD* SPEED CONTROL SET 43
49 V32 20YL/RD* SPEED CONTROL ON/OFF 43
50 V33 20WT/LG* SPEED CONTROL RESUME W
51 K51 20DB/YL* AUTO SHUTDOWN SIGNAL 14
52 K52 20PK/BK* PURGE SOLENOID SIGNAL 13
53 V35 20LG/RD* SPEED CONTROL (VENT) 43
54 K54 200R/BK* PARK THROTTLE UNLOCK SOLENOID 16
55 — —

56 G24 20GY/PK* EMISS MAINT REMINDER LAMP 13

57 — —

___ ___
m
59 K59 18VT/BK* AUTOMATIC IDLE SPEED MOTOR (AIS-4) 12
60 K60 18YL/BK* AUTOMATIC IDLE SPEED MOTOR (AIS-3) 12
CAV WIRE CODE IGNITION SYSTEM CIRCUITS SHEET NO.
1 K1 20DG/RD* MAP SENSOR SIGNAL 17
2 K2 20TN/BK* TEMPERATURE SENSOR SIGNAL
3 A14 16RD/WT* . DIRECT..BATTERY. FEED.............................. 18
4 K4 18BK/LB* SIGNAL GROUND 21
5 211 16BK/WT* SIGNAL GROUND 17
6 K6 20VT/WT* MAP SENSOR SIGNAL 20
7 K7 18DR 8 VOLT OUTPUT 21
8 A61 16DG/BK* INJECTOR 19
9 A21 14DB IGNITION START/RUN 17
10 __ — —
11 Z12 16BK/TN* POWER GROUND 18
12 212 16BK/TN* POWER GROUND 18
13 _ —
14 K13 18YL/WT* INJECTOR 19
15 K12 18TN INJECTOR 19
16 K11 18WT/DB* INJECTOR 19
17 —
18 — _. —
19 K19 18GY IGNITION COIL 18
20 K20 18DG ALTERNATOR 19
21 — *— —
22 K22 1SOR/DB* THROTTLE POSITION SENSOR 20
23 —
?4 _K24 18J3Y/BK* _ DISTRIBUTOR PICKUP SIGNAL 21
25 D21 20PK SCI (TRANSMIT! 18
26 D1 20VT/BR* CCD BUS M 19
SHORT TAB
27 C20 18BR A/C CLUTCH INPUT 18
28 — —
29 K29 18WT/PK* BRAKE SWITCH SIGNAL 43
♦ H"H I I I i I ♦ 1
30 T41 2QBR/YL* n PARK/NEUTRAL SWITCH SIGNAL 20
♦ ~H I I I I I I +21
31 C27 20DB/PK* RADIATOR FAN RELAY | 18
♦+ + + + + + + + ♦4 1
—
32
33 V36 20TN/RD* SPEED CONTROL fVACUUM} 43 Ef
34 C13 2QDB/OR* A/C CLUTCH RELAY SIGNAL 18
LONG TAB
35 — — ___

36 — —
—. — V'EWED FROM WIRE
37
— END OF CONNECTOR
38 ____ —
39 K39 18GY/RD* AUTOMATIC IDLE SPEED MOTOR (AIS-3) 20
m K40 18BR/WT* AUTOMATIC IDLE SPEED MOTOR 20
41 K41 18BK/DG* OXYGEN SENSOR SIGNAL 17
42 — — —
43 — — ___

44 K44 18TN/YL* DISTRIBUTOR

45 D20 20LG SCI (RECEIVE) 18
46 D2 20WT/BK* CCD BUS ( - } 19
47 G7 20WT/OR* DISTANCE SENSOR SIGNAL 21
48 V31 20BR/RD* SPEED CONTROL SET 43
49 V32 20YL/RD* SPEED CONTROL ON-OFF 43
50 V33 20WT/LG* SPEED CONTROL RESUME 43
51 K51 20DB/YL* AUTO SHUTDOWN SIGNAL 18
52 K52 20PK/BK* PURGE SOLENOID SIGNAL 17
$3 V35 20LG/RD* SPEED CONTROL IVENTI 43
54 — —
■ 55 — _ —

$6 G24 20GY/PK* EMISS MAINT REMINDER LAMP 17

57 —

58 — — —

59 K59 18VT/BK* AUTOMATIC IDLE SPEED MOTOR fAIS-41 20

60 K60 18YL/BK* AUTOMATIC IDLE SPEED MOTOR (AIS-2) 20
 CAV WIRE CODE IGNITION SYSTEM CIRCUITS SHEET NO.
1 K1 20DG/RD* MAP SENSOR SIGNAL 24
2 K2 20TN/BK* TEMPERATURE SENSOR SIGNAL 26
3 A14 16RD/WT* DIRECT BATTERY FEED 23
4 K4 18BK/LB* SIGNAL GROUND 25
5 Z11 16BK/WT* SIGNAL GROUND 22
. ..S. KB 20VT/WT* MAP SENSOR SIGNAL 24
7 K7 18DR 8 VOLT OUTPUT 25
8 A61 16DG/BK* INJECTOR 25
9 A21 14DB I IGNITION START/RUN 22
10 _ — .—
11 Z12 16BK/TN* POWER GROUND 23
12 Z12 16BK/TN* POWER GROUND 23
13 — —
14 K13 18YL/WT* INJECTOR
15 K12 18TN INJECTOR
16 K11 18WT/DB* INJECTOR
17 K17 18DB/YL* IGNITION COIL
18 K18 18RD/YL* IGNITION COIL
19 K19 18GY IGNITION COIL
20 K2018DG ALTERNATOR 25
21 K21 18BK/RD* CHARGE TEMP SENSOR 24
22 ! K22 180R/DB* THROTTLE POSITION SENSOR 24
23 —
24 ^K M JJG Y/BK * DISTRIBUTOR PICKUP SIGNAL 25
25 D21 20PK SCI (TRANSMITi 23
26 D1 20VT/BR* CCD BUS (+) 25~
JLCL
SHORT TAB
27 C20 18BR A/C CLUTCH INPUT r ... -.. 23.... ..
28
29 K29 lIW T /P K * BRAKE SWITCH SIGNAL 43
30 T41 2GBR/YL*
2 0 *4 + F+Tl
PARK/NEUTRAL SWITCH SIGNAL 24
<4444 4 444+- 4421)
31 C27 20DB/PK* RADIATOR FAN RELAY 23 h+411
— ♦+ + -
32 — —
33 V36 20TN/RD* SPEED CONTROL (VACUUMI 43
34 C13 20DB/OR* A/C CLUTCH RELAY SIGNAL 23 LONG TAB
35 — - —
36 — — —
— — — VIEWED FROM WIRE
37 END OF CONNECTOR
38 _ _ —
39 K39 18GY/RD* AUTOMATIC IDLE SPEED MOTOR (AIS-3) 24
40 K40 18BR/WT* AUTOMATIC IDLE SPEED MOTOR fAIS-1) 24
41 K41 18BK/DG* OXYGEN SENSOR SIGNAL 24
42 K42 18BK/LG* DETONATION SENSOR SIGNAL 25
43 — —
44 K44 18TN/YL* DISTRIBUTOR 26
45 D20 20LG SCI (RECEIVE) 23
46 D2 20WT/BK* CCD BUS (—) 25
47 G7 20WT/OR* DISTANCE SENSOR SIGNAL 25
48 V31 20BR/RD* SPEED CONTROL SET 43
49 V32 20YL/RD* SPEED CONTROL ON-OFF 43
50 V33 20WT/LG* SPEED CONTROL RESUME 43
51 K51 20DB/YL* AUTO SHUTDOWN SIGNAL 23
52 K52 20PK/BK* PURGE SOLENOID SIGNAL 22
53 V35 20LG/RD* SPEED CONTROL (VENT) 43
54 — — —
55 .— — —
56 G24 20GY/PK* EMISS MAINT REMINDER LAMP _ . 2C
57
58 — —. . —
59 K59 18VT/BK* AUTOMATIC IDLE SPEED MOTOR (AIS-4) 24
60 K60 18YUBK* AUTOMATIC IDLE SPEED MOTOR (AlS-2) 24
 HEADLAMP A3 12RD/WT
IGNITION START/RUN A21 14DB BLOWER MOTOR C1 12DG
DIMMED ILLUMINATION FEED E1 22TN POWER WINDOWS F21 12TN
LAMP FEED L7 18BK/YL’ iGNITiON ACCESSORY/RUN A22 12BK/OR* -
RADIO FEED X12 20RD/WT* POWER SEATS, LOCK & HORN F35 12RD -----
TURN SIGNAL FEED L5 18BK/PK* — r HEADLAMP (LO) L4 14VT/WT*
WIPER MOTOR V6 18DB — LEFT HEADLAMP L43 20VT
IGNITION ACCESSORY FEED A31 14BK/WT* RIGHT HEADLAMP L44 2QVT/RD*
- PARK LAMPS AS 12RD/BK*
HAZARD FEED L9 18BKJWT
BATTERY FEED A15 14PK
r
m — .
r iin •i • • • ii* i l+ i-g d
HEATED MIRROR 13 H7 ,21 ts
FEED C18 20LB/YL* -
EBL SWITCH C15 12BK/WT* LJ# I ± h
I 16 10 18 f 22 26
BODY M1 18PK
LAMPS [ A4 12BK/RD* In <3 \m * rUfiS E 3 -]
ffi.
■p t .T l
11 15 I 119 23 I 27
• • \® m\ m\ # m i s ri i IS
E tE jtk
12 16 2d 24 28
SEE *
FOG LAMPS
OWNERS F61 18WT/OR*
o MANUAL
527075 o - PARK LAMPS
F63 18PK/RD*
IGNITION START/RUN G5 20DB/WT* ---- - - FEED F62 16RD
LAMPS/WIPER F20 16WT
SPEED CONTROL V34 20WT/RD* -
— IGN ACCESSORY/RUN
REAR WIPER ¥23 16BR/PK* A22 12BK/OR*
“ STOP LAMP F32 18PK/DB*
A/C F36 T3WT/BK*
BATT FEED A3 12RD/WT*

FUSE# AMPS COLOR SHEET #

1 , 20 YELLOW1 53
2 10 RED 64, 76
3 20 1 YELLOW 76, 81
4 — NOT USED —
5 20 YELLOW 46
6 20 YELLOW 53
.7 10 RED 68, 60, 61
8 _ NOT USED __
9 7,5 BROWN 50
10 — NOT USED
11 — NOT USED --
12 ,
— NOT USED 1
13 20 YELLOW 67
14 2 GRAY *3
15 10 RED 72
16 — NOT USED —
17 1 10 RED 50
18 10 RED 4*
19 20 YELLOW 43
20 20 YELLOW 65
21 20 YELLOW 70
22 20 YELLOW 50
23 20 YELLOW ^4, 61
24 20 YELLOW 89
25 30 CIRCUIT BREAKER 79
28 1 30 ' LT GREEN r 27, 29, 63
27 30 CIRCUIT BREAKER 44
28 — NOT USED —
CAV CIRCUIT DESCRIPTION
1 E2 1SOR DIMMABLE LAMP FEED
2 D1 18VT/BR* SERIAL BUSS B+
3 D2 18WT/BK* SERIAL BUSS B-
4 G32 18BK/LB* EXT TEMP SENSOR RETURN
5 G31 18VT/LG* EXT TEMP SENSOR SIGNAL
6 M2 18YL DOOR JAMB SWITCHES
7 F21 16TN IGNITION FEED
8 — NOT USED
9 72 18BK/LG* GROUND
10 — NOT USED
11 Z1 18BK GROUND
12 M11 18PK/LB* SWITCHED COURTESY LAMP FEED
13 M1 18PK READING AND VISOR LAMP FEED
 F20 18WT ----- *
IGNITION F3S 16WT/BK* —
FEED
(LOCATION 7} C40 16BR/YL* —
21 18BK -----

MULTI-FUNCTION L20 14LG/WT* L94 20OR/WT* LOW

SWITCH CIRCUIT
BREAKER [ A3 12RD/WT* L20 14LG/WT*
L20 14LG/WT*
BEAM
RELAY
(LOCATION 1)
— L2 14LG .
- 0
P36 18PK/VT* L97 18BR/OR*
POWER F35 12RD CZ3 PARK
UNLOCK F63 18BK/RD* LAMPS
21 18BK F63 18PK/RD* RELAY
RELAY Z1 18BK t I t It F63 18PK/RD*
(LOGATION 10) (LOCATION 2)
21 18BK
P34 14PK/BK* V L7 18BK/YL*

X3 20BK/RD*
" P38 200R/WT* o
- F3514RD HORN
F35 12RD
POWER RELAY
Z1 18BK - F62‘18RD
LOCK (LOCATION 3)
21 18BK
RELAY X2 14D G /R D \
{LOCATION 9) 21 18BK
P33 140R/BK* L55 18PK/BK*"
COMBO-
Q3 14TN L91 18DB/PK* FLASHER
VAN RELAY
CONVERSION 21 18BK — 21 18BK
RELAY
{LOCATION 8) V23 18BR/PK* I — L32 18PK -
(LOCATION 4)

A18 14RD/PK*

X1 16RD/LG*
NAME
X60 20DG/RD* BRAND
F62 16RD SPEAKER
RELAY '
Z1 18BK (LOCATION 6)
Z1 18BK

{WIRE END VIEW)

RELAY BLOCK
 T 24 22 20 18 16 14 12 10 8 6
n
4 2

□ □ □ □ □ □ □ □ □ □ □ □

□□□□□□□□□□□□a
25 23 21 19 17 15 13 11 9 7 5 3 1

BLUE

CAV CIRCUIT DESCRIPTION SHEET

2 G75 18TN DOOR AJAR SWITCH LEFT FRONT DOOR 102
4 G26 20LB KEY-fN BUZZER CHIME 103
6 E17 20YL/BK* ELEC DISPLAY 103
8 E92 20OR/BK* SW POD TO ILLUM MOD DIMMING CONTROL 103
to G4 20DB FUEL TANK SENDING UNIT 102
12 G5 20DB/WT* IGN RUN/START FEED 102
14 D1 18VT/BR* SERIAL BUSS B+ 101
16 M1 18PK COURTESY, DOME, VISOR LAMPS 102
18 — NOT USED —
20 V5 18DG WIPER MOTOR FEED 101
22 V6 18DB WIPER MOTOR 101
24 V7 18DG/WT* PULSE WIPE PARK (B-) DWELL 103
1 Q16 20BK/LB* CHIME GROUND 102
3 G10 20LG/RD* SEAT BELT WARNING 102
5 G29 22BK/TN* LOW WASH FLUID INDICATOR 101
7 M22 18WT ILLUMINATED ENTRY RELAY GROUND 103
9 V9 18DG/YL* PULSE WIPE INTERMITTENT 103
11 V10 18BR WASH PUMP MOTOR 101
13 Z2 18BK/LG* GROUND 101
15 D2 18WT/BK* SERIAL BUSS B- 101
17 P38 2O0R/V/T* AUTO DOOR LOCK RELAY COIL B+ 103
19 M51 18YL/RD* KEY IN LIGHT GROUND 103
21 G13 18DB/RD* SEAT BELT LAMP 102
23 _ NOT USED —
25 M2 18YL GROUND FOR COURTESY LAMPS 102
 n
24 22 20 18 16 14 12 10 8 6 4 2

□ □ □ □ □ □ □ □ □ □ □ □

□ □ □ □ □ □ □ □ □ □ □ □ a
25 23 21 19 17 15 13 11

NATURAL

CAV CIRCUIT DESCRIPTION SHEET

2 G?4 18TN/RD* DOOR AJAR SWITCH RT FRONT DOOR 105
4 G78 18TN/BK* LIFTGATE/DECK LID AJAR SWITCH 105
1 — NOT USED —.
4 — NOT USED -
7 NOT USED
6 .— NOT USED ,—
14 L60 18TN RT FRONT TURN SIGNAL 104
6 — NOT USED _
18 D14 18LB DECODE - HIGH INST CLUSTER 104
20 P35 18 OR/VT* POWER DOOR LOCK B+ LOCK 105
22 G60 22GY/YL* OIL PRESSURE SENDING UNIT - GAUGE 104
24 D13 180R/DB* DECODE - LOW INST CLUSTER 104
9 —■ NOT USED
3 G76 18TN/YL* DOOR AJAR SWITCH REAR DOOR 105
5 G42 20DB/YL* SIGNAL GROUND FOR 4WD 105
10 — NOT USED —
11 — NOT USED —
12 — NOT USED —.
13 LSI 18LG LT FRONT TURN SIGNAL 104
15 L94 200R/WT* LO BEAM RELAY COIL 104
17 L2 16LG HEADLAMP DIMMER SWITCH FEED 104
19 Q33 20BR/LB* SP - SENSE - GND FROM LIFT GATE 105
21 G6 20GY LOW OIL PRESSURE WARNING 104
16 — NOT USED _
25 G20 20VT/YL* COOLANT TEMP SENDING UNIT 104
 CAV WIRE CODE IGNITION SYSTEM CIRCUITS SHEET
1 T1 16LG/BK* * FRNDL SWITCH 32
2 T2 14TN/BK* BACK UP LIGHT RELAY 33
3 T3 14VT BACK UP LIGHT RELAY 33
4 D2 20WT/BK* CCD B U S H 33
5 — — —
6 — —
7 — — __
8 A41 18YL STARTER RELAY 31
9 T9 1SOR/BK* OVERDRIVE PRESSURE SWITCH 32
10 — — —
11 A21 14DB NEUTRAL SAFETY SWITCH 31
12 K22 180R/DB* (SMEC) SINGLE MODULE CONTROLLER 31
13 T13 18DB/BK* SPEED SENSOR GROUND 31
14 T14 18LG/WT* OUTPUT SPEED SENSOR 31
15 T15 18LG SAFETY SHUTDOWN RELAY 32
16 T16 16RD TRANS, SOLENOIDS & PRESSURE SWITCH 32
17 T16 16RD SAFETY SHUTDOWN RELAY 32
18 — _ —
19 I T19 18WT TRANS. SOLENOIDS & PRESSURE SWITCH 32
20 T20 18LB TRANS. SOLENOIDS & PRESSURE SWITCH 32
21 — —
22 — — —
23 — —
24 — —
25 _
26 — —
27
28 — — —
29 —. —
30 _ — —.
31 — —,
32 — —
33 — — —
34 — —, —
35 — — —
36 —
37 — — —
VIEWED FROM WIRE 38 — — —
END OF CONNECTOR 39 . —
40 — — —
41 T41 18BR/YL* NEUTRAL SAFETY SWITCH 31
42 T42 18VT/WT* PRNDL SWITCH 32
43 D1 20VT/BR* CCD BUS H 33
44
45 K24 18GY/BK* DISTRIBUTOR 31
46 — —. ' —
47 T47 18YL/BK* TRANS. SOLENOIDS & PRESSURE SWITCH 32
48 — — —
49 — — —
50 T50 18DG TRANS. SOLENOIDS & PRESSURE SWITCH1 32
51 K4 183K/LB* SIGNAL GROUND 31
52 T52 18RD/BK* 1 TURBINE SPEED SENSOR 31
53 214 18BK/YL* SIGNAL GROUND 32
54 214 18BK/YL* SIGNAL GROUND 32
55 —. — —
56 A14 16RD/WT* DIRECT BATTERY GROUND 32
57 213 18BK/RD* SIGNAL GROUND 32
58 Z13 18BK/RD* SIGNAL GROUND 32
59 T59 18PK TRANS. SOLENOIDS & PRESSURE SWITCH 32
60 T60 18BR TRANS. SOLENOIDS & PRESSURE SWITCH 32
CAV CIRCUIT DESCRIPTION
1 — NOT USED
2 M1 18PK ILLUMINATION
3 D13 180R/DB* DECODE-LOW INST CLUST TO BCOMP
4 '— NOT USED
5 014 18LB DECODE-HIGH INST CLUST TO BCOMP
6 E2 200R I/P DIMMABLE ILLUMINATION
7 Z2 18BK/LG* GROUND
8 G6 20GY LOW OIL PRESSURE
9 D2 18WT/BK* SERIAL BUSS B -
10 D1 18VT/BR* SERIAL BUSS B+
11 G§ 20DB/WT* IGN FEED
12 — NOT USED
13 _ NOT USED
14 Z3 20BK/OR* GROUND
 BLACK

0 0 0 0 0 0 0 0 0

17 16 15 14 13 12 10
0

n m\m 1211r~2o11is11isi
STRQ
COLUMN

CAV WIRE CODE IGNITION SYSTEM CIRCUITS

1 — NOT USED
2 — NOT USED
3 — NOT USED
4 NOT USED
5 — NOT USED
...6 — NOT USED
7 — NOT USED
8 — NOT USED
9 — NOT USED
10 _ NOT USED
11 L60 18TN RT FT TURN SIGNAL
12 L62 18BR/RD* RT RR STOP & TURN SIG LP
13 , L59 18TN/LG* FLASHER FEED
14 L63 18DG/RD* LT RR STOP Si TURN SIG LP
15 L61 18LG LT FT TURN SIGNAL
16 L53 18BR STOP LAMP FEED
17 Z1 18BK GROUND
18 L4 14VT/WT* HEADLAMP (LO-BEAM!
19 L2 14LG HEADLAMP DIMMER SWITCH
20 L3 14RD/OR* HEADLAMP fHl-BEAMI
21 L20 14LG/WT* OPTICAL HORN
22 — NOT USED
23 —. NOT USED
24 NOT USED

MULTI-FUNCTION SWITCH CONNECTOR

 GRAY
CAV CIRCUIT DESCRIPTION SHEET NO.
21 18BK GROUND 49
1 LEFT POD
21 18BK GROUND 49
2 CONNECTOR
E2 200R l/P ILLUMINATION 49
3 L59 18TN/LG* FLASHER FEED 49
4 L53 18BR STOP LAMP FEED 49
5 L50 18WT/TN* STOP LAMP SW 49
6 L55 18PK/BK* SW FEED FROM HAZARD UNIT 49
7 L i 18BK/WT* FUSED HAZARD FLASHER FEED 49
8 L5 18BK/PK* TURN SIGNAL FLASHER UNIT 49

GRAY
CAV CIRCUIT DESCRIPTION SHEET NO,
1 V22 18BR/YL* WASH DELAY - RR WIPER 45
ON/OFF SW - RR WIPER 45 RIGHT POD
2 V21 18DB/RD*
WINDSHIELD WIPER MOTOR 45 CONNECTOR
V8 18DB
V6 18DB WINDSHIELD WIPER MOTOR 45
4 V10 18BR WASH PUMP MOTOR 45
5 Z3 208K/OR* GROUND 45
6 E2 200R l/P ILLUMINATION 45
7 — NOT USED _
8 — NOT USED —

STEERING COLUMN SWITCH

TO PANEL WIRING
 _ n r u
8 7 —6___ 5 4 3 2 1
□ □ □ c r a a a a
1

t _ t i _ r

GREEN

CAV CIRCUIT DESCRIPTION SHEET NO.

1 — NOT USED —
2 L50 18WT/TN* STOP LAMP SWITCH 89
3 G75 18TN LEFT FRONT DOOR AJAR SWITCH 73
4 M11 18PK/LB* SWITCHED COURTESY LAMP FEED 81
5 G78 18TN/BK* LIFTGATE AJAR SWITCH 73
fi M2 18YL GROUND FOR COURTESY LAMPS ........ 81......._..
7 CM 20DB FUEL TANK SENDING UNIT 88, 98
8 — NOT USED —
9 L I 18VT/BK* BACK UP LAMP FEED 89
L1 18VT/BK* BACK UP LAMP FEED 89
10
L I tiV T /B K * .... BACK UP LAMP FEED .......... _ _ .... 89..........
11 L62 18BR/RD* RT RR TURN AND STOP LAMP 89
12 G10 20LG/RD* SEAT BELT WARNING SWITCH 74
13 G16 20BK/LB* CHIME GROUND 102
14 L63 18DG/RD* LT RR TURN AND STOP LAMP 89
15 G42 20DB/YL* SIGNAL GROUND 98
18 NOT USED

LEFT BODY CONNECTOR

 BLACK

CAV CIRCUIT DESCRIPTION SHEET - LT

1 L7 18BK/YL* LICENSE LAMP FEED 90 BODY
2 Z1 12BK GROUND 90
3 C15 12BK/WT* EBL 64
4 G78 18TN/BK* DECK LID AJAR SWITCH 73
5 — NOT USED —
6 M11 18PK/LB* SWITCHED COURTESY LAMP FEED 82
7 V20 16BK/WT* WASH PUMP GROUND 68
8 Q2 14LG/BK* LIFTGATE RELEASE 71
9 — NOT USED —
10 L50 18WT/TN * CHMSL FEED i 90
11 M2 18YL LIFTGATE JAMB SWITCH ’ = 82

CAV CIRCUIT DESCRIPTION SHEET _ RT

1 V21 18DB/RD* RR WIPER ON/OFF SIGNAL 67 BODY
2 X15 14BK/DG* SPEAKER AMP B - 62
3 X13 14BK/RD* SPEAKER AMP B + 62
4 XS7 18BR/LB* LEFT REAR SPEAKER B - 60, 62
5 — NOT USED —
6 X58 18DB/OR* RIGHT REAR SPEAKER B- 60, 62
7 V22 18BR/YL* RR WIPER DELAY 67
8 F20 16WT REAR WIPER PARK 67
9 X51 18BR/YL* LEFT REAR SPEAKER B+ 60, 62
10 — NOT USED —
11 X52 18DB/WT* RIGHT REAR SPEAKER B+ 60, 62

BODY CONNECTORS
CAV CIRCUIT DESCRIPTION SHEET
1 B82 12BR/WT* ABS PUMP MOTOR FEED 35
2 Z1 14BK GROUND 35

BLACK

CAV CIRCUIT DESCRIPTION SHEET

1 Z1 16BK GROUND 35
2 B210 20RD/BK* TRANSDUCER RETURN (-) 35 5 4 3 2 1
3 •— ' NOT USED _
z—
4 G9 20GY/BK* BRAKE WARNING LAMP 35
5 B21 14GY ABS PUMP MOTOR CONTROL 35
O O o
i Z1 14BK STARTER RELAY CONTACT 35
7 B258 20GY/LB* TRANSDUCER FEED {+) 35 10 9 8 7 6
8 B219 20DB (ABS) 35 \
BLACK
9 B218 20WT/OR* PRIMARY PRESSURE/DPA 35
10 B217 14RD LOW ACCUMULATOR 35

CAV CIRCUIT DESCRIPTION SHEET

1 B245 20WT/LG* LEFT FRONT ISOLATE VALVE 36
2 B243 20DG/BK* LEFT FRONT DECAY VALVE 36 5 4 3 2 1
3 B242 20BR/WT* LEFT FRONT BUILD VALVE 36
4 B254 20DG/OR* RIGHT AND LEFT REAR DECAY VALVE 36
5 B255 20WT/PK* RIGHT AND LEFT REAR ISOLATOR VALVE 36
O ono o O
6 B249 20WT/TN* RIGHT FRONT ISOLATE VALVE 36
7 B24S 20DG/WT* RIGHT FRONT DECAY VALVE 36 10 9 8 7 6
a
9
B246 20BR/RD*
B252 20BR/TN*
RIGHT FRONT BUILD VALVE
RIGHT AND LEFT REAR BUILD VALVE
36
36
\
DARK GRAY
10 B251 20WT/BK* LEFT REAR ISOLATE VALVE 36

ABS PUMP MOTOR

CONNECTORS
 CAV WIRE CODE IGNITION SYSTEM CIRCUITS SHEET
1 81 20YL/DB* RIGHT REAR WHEEL SENSORH 34
2 B2 20YL RIGHT REAR WHEEL SENSOR{+> 34
3 S3 20LG/DB* LEFT REAR WHEEL SENSORH 34 j
4 84 20LG LEFT REAR WHEEL SENSORI+) 34
5 Z1 16BK GROUND 35
6 86 20WT/DB* RIGHT FRONT WHEEL SENSOR{-) 34
7 87 20WT RIGHT FRONT WHEEL SENS0RM 34
8 88 20RD/DB* LEFT FRONT WHEEL SENSORH 34
9 89 20RD LEFT FRONT WHEEL SENSORI+) 34
10 8210 20RD/BK* ABS TRANSDUCER RETURN f-) 35
11 D11 20WT/VT* DIAGNOSTICS 37
12 D12 200R DIAGNOSTICS 37
13 L50 18WT/TN* STOP LAMP SWITCH 36
14 G9 20GY/BK* BRAKE WARNING LAMP SWITCH 35
15 G19 20LG/OR* ABS WARNING LAMP 37
15 — NOT USED —

17 8217 14RD LOW ACCUMULATOR 35

18 8218 20WT/CR* PRIMARY PRESSURE /DPA 35
19 8219 20DB (ABS) 35
20 — _
—

21 — NOT USED —

22 — ' NOT USED —

23 — NOT USED —

24 _ NOT USED —

25 — NOT USED —

26 — NOT USED . —

27 NOT USED —

28 — NOT USED —

29 — NOT USED .—

30 — NOT USED —

31 — NOT USED —

32 — NOT USED —

33 — NOT USED —

34 — NOT USED —

35 NOT USED —

36 — . NOT USED —

37 — NOT USED —

38 — NOT USED —

VIEWED FROM WIRE 39 — NOT USED .

END OF CONNECTOR 40 NOT USED —

41 — NOT USED —

42 B242 20BR/WT* LEFT FRONT BUILD VALVE 36

43 B243 20DG/BK* LEFT FRONT DELAY VALVE 36
44 — NOT USED
45 8245 20WT/LG* LEFT FRONT ISOLATE VALVE 36
46 B246 20BR/RD* RIGHT FRONT BUILD VALVE 36
47 847 16RD/LB* MODULE FEED 37
48 B248 20DG/WT* RIGHT FRONT DELAY VALVE 36
49 B249 20WT/TN* RIGHT FRONT ISOLATE VALVE 36
50 B47 16RD/LB* MODULE FEED 37
51 B251 20WT/BK* LEFT REAR ISOLATE VALVE 36
52 B252 20BR/TN* RIGHT AND NLEFT REAR BUILD VALVE 36
53 — NOT USED —

54 B254 2QDG/OR* RIGHT AND LEFT REAR DELAY VALVE 36

55 B255 20WT/PK* RIGHT AND LEFT REAR ISOLATOR VALVE 36
56 — . NOT USED
57 857 20BR/BK* ABS SYSTEM RELAY COIL FEED 36
58 B258 20GY/LB* TRANSDUCER FEEDf+l 35
59 — NOT USED —

60 A21 14D8 IGNITION START RUN 37

CAV CIRCUIT DESCRIPTION
1 — NOT USED
2 NOT USED
3 L60 18 TN RT FT TURN SIGNAL
4 — NOT USED
§ L61 18 LG LT FT TURN SIGNAL
6 G19 20LG/BK* ANTI-LOCK BRAKE WARNING
7 G5 20DB/WT* IGN RUN/START FEED
8 G13 18DB/RD* SEAT BELT LAMP
9 G34 16RD/BK* HI BEAM INDICATOR
10 G24 22GY/PK* EMISSION MAINTENANCE LAMP
11 Z3 2DBK/OR* GROUND
12 — NOT USED
13 — NOT USED
14 G9 20GY/BK* BRAKE WARNING LAMP
CAV CIRCUIT DESCRIPTION
1 T47 18YL/6K* KICK-DOWN PRESSURE SWITCH
2 T5G 18DG LOW REV PRESSURE SWITCH
3 T9 180R/BK* OVERDRIVE PRESSURE SWITCH
4 T1818RD SWITCHED BATTERY FEED
5 T59 18PK UD SOLENOID
6 T60 188R OD SOLENOID
7 T20 18LB LR/LU SOLENOID
8 T19 18WT KD/LR SOLENOID

TRANSAXLE SOLENOID CONNECTOR

 S A F E T Y N O T IC E
C A U T IO N
A L L S E R V IC E A N D R E B U IL D IN G IN S T R U C T IO N S C O N T A IN E D H E R E IN A R E
A P P L IC A B L E TO , AND FO R THE C O N V E N IE N C E O F, TH E A U T O M O T IV E
TRADE O N L Y . A ll te s t a n d r e p a ir p ro c e d u re s o n c o m p o n e n ts o r a s s e m b lie s in
n o n -a u to m o tiv e a p p lic a tio n s s h o u ld b e re p a ire d in a c c o rd a n c e w it h in s tru c tio n s
s u p p lie d b y th e m a n u fa c tu re r o f th e to ta l p ro d u c t.

P ro p e r s erv ice a n d re p a ir is im p o rta n t to th e s afe, re lia b le , o p e ra tio n o f a ll m o to r v e h ic le s .

T h e s erv ice p ro c e d u re s re c o m m e n d e d a n d d e s c rib e d in th is p u b lic a tio n w e re d e v e lo p e d
fo r p ro fe s s io n a l s erv ice p e rs o n n e l a n d a re e ffe c tiv e m e th o d s fo r p e rfo rm in g v e h ic le
re p a ir. F o llo w in g th ese p ro c e d u re s w ill h e lp assure e ffic ie n t e c o n o m ic a l v e h ic le
p e rfo rm a n c e an d s erv ice r e lia b ility . S o m e o f th ese s erv ice p ro c e d u re s re q u ire th e use o f
s p e cial to o ls d e s ig n e d fo r s p e c ific p ro c e d u re s . T h e s e s p e cial to o ls s h o u ld be u sed w h e n
re c o m m e n d e d th ro u g h o u t th is p u b lic a tio n .

S p e c ia l a tte n tio n s h o u ld b e e x e rc is e d w h e n w o r k in g w it h s p rin g o r te n s io n lo a d e d

fa s te n e rs a n d d e v ic e s s u c h as E -C lip s , C ir c lip s , S n a p rin g s , e tc ., as c a re le s s re m o v a l
m a y cau se p e rs o n a l in ju r y . A lw a y s w e a r s a fe ty g o g g le s w h e n e v e r w o r k in g on
v e h ic le s o r v e h ic le c o m p o n e n ts .

I t is im p o rta n t to n o te th a t th is p u b lic a tio n c o n ta in s v a rio u s C a u tio n s a n d W a rn in g s .

T h e s e s h o u ld b e c a re fu lly re a d in o rd e r to m in im iz e th e ris k o f p e rs o n a l in ju r y , o r th e
p o s s ib ility th a t im p ro p e r s e rv ic e m e th o d s m a y d am ag e th e v e h ic le o r re n d e r it u n s a fe .
I t is im p o rta n t to n o te th a t th e s e C a u tio n s a n d W a rn in g s c o v e r o n ly th e s itu a tio n s a n d
p ro c e d u re s C h ry s le r M o to rs has e n c o u n te re d a n d re c o m m e n d e d . C h ry s le r M o to rs c o u ld
n o t p o s s ib ly k n o w , e v a lu a te , a n d a d v is e th e s ervice tra d e o f a ll c o n c e iv a b le w a y s th a t
s e rv ic e m a y be p e rfo rm e d , o r o f th e p o s s ib le h a za rd s o f each . C o n s e q u e n tly , C h ry s le r
M o to rs has n o t u n d e rta k e n a n y such b ro a d service re v ie w . A c c o rd in g ly , a n y o n e w h o
uses a s erv ice p ro c e d u re , o r to o l, th a t is n o t re c o m m e n d e d in th is p u b lic a tio n , m u s t assure
o n e s e lf th o ro u g h ly th a t n e ith e r p e rs o n a l s a fe ty , n o r v e h ic le s a fe ty , be je o p a rd iz e d b y
th e s e rv ic e m e th o d s th e y s ele ct.

WE SUPPORT
VOLUNTARY MECHANIC
CERTIFICATION S E R V IC E I_ _______ i
THROUGH P R O F E S S IO N A L S w

S E R V IC E
 CHRYSLER
MOTORS
DRIVER AIR BAG
SERVICE MANUAL
SUPPLEMENT
1991V2 FRONT WHEEL DRIVE
ALL WHEEL DRIVE
VAN/WAGON

^ CHRYSLER
W MOTORS

NO PART OF THIS PUBLICATION MAY BE

REPRODUCED, STORED IN A RETRIEVAL
SYSTEM, OR TRANSMITTED, IN ANY FORM
OR BY ANY MEANS, ELECTRONIC, ME­
CHANICAL, PHOTOCOPYING, RECORDING,
OR OTHERWISE, WITHOUT THE PRIOR
WRITTEN PERMISSION OF CHRYSLER
MOTORS.

Chrysler Motors reserves the right to make changes in design or to make

additions to or improvements in its products without imposing any obliga­
tions upon itself to install them on its products previously manufactured.

Litho in U.S.A. Copyright © 1991 Chrysler Motors 20M191

 FOREWORD
The information contained in this service manual has been prepared for the profes­
sional automotive technician involved in daily repair operations. This manual does not
cover theory of operation, which is addressed in service training material.
Information in this manual is divided into groups. These groups contain general
information, diagnosis, testing, adjustments, removal, installation, disassembly, and
assembly procedures for the components.
Chrysler Motors reserves the right to change testing procedures, specifications,
diagnosis, repair methods, or vehicle wiring at any time without prior notice or
incurring obligation.
Information describing the operation and use of standard and optional equipment is
included in the Owner’s Manual provided with the vehicle.
 CONTENTS
Page Page
Air Bag Module ...................... ................................ 3 General Information ................................ ................ 1
A ir Bag Service and Test P rocedures...................... 1 Key Left In Ignition ............................................. .. 9
Air Bag System Check ............................................. 3 Left Front im pact S e n s o r......................................... 4
Air Bag System Diagnostic Module (ASDM) ........... 5 Right Front Im pact Sensor ................................. .. 4
Chime System Diagnosis ......................................... 9 Seat Belt Buckle Replacement ............................... 11
Chime Warning/Reminder System .......................... 8 Service Procedures ................................................. 10
Clockspring .............................................................. 6 Steering ............................................................ .... 14
Clockspring Centering Procedure ............................ 6 Steering Column S w itc h e s ....................................... 7
Exterior Lamps Left On ........................................... 8 Steering Wheel ........................................................ 7
Fasten Seat Belts .............................................— 8 Turn Signal W a rn in g ............................................. .. 8
W iring Diagram s ..................................................... 11

RESTRAINT SYSTEMS
AIR BAG SERVICE AND TEST PROCEDURES supporting components. The air bag module contains
a housing to which the cushion and inflator are at­
WARNING: THIS SYSTEM IS A SENSITIVE, COMPLEX
tached and sealed.
ELECTRO-MECHANICAL UNIT. BEFORE ATTEMPT­
ING TO DIAGNOSE, REMOVE OR INSTALL THE AIR CLOCKSPRING AIR BAG
BAG SYSTEM COMPONENTS, YOU MUST FIRST DIS­
CONNECT AND ISOLATE THE NEGATIVE (GROUND)
BATTERY CABLE. FAILURE TO DO SO COULD RE­
SULT IN ACCIDENTAL DEPLOYMENT AND POSSI­
BLE PERSONAL INJURY.
WHEN AN UNDEPLOYED AIR BAG ASSEMBLY IS
TO BE REMOVED FROM THE STEERING WHEEL,
DISCONNECT BATTERY GROUND CABLE AND ISO­
LATE. ALLOW SYSTEM CAPACITOR TO DISCHARGE
FOR 2 MINUTES THEN BEGIN AIR BAG REMOVAL.
Vehicles equipped with a Minivan Driver Air Bag
System must be inspected every 3 years or 30,000
miles / 48,000 Km. To inspect system use Passive W/INTERNAL
Restraint System Diagnostic Procedures Manual. CRASH SENSOR 918M-6
If the Air Bag Module Assembly is defective and
non-deployed, refer to Chrysler Motors current return Fig. 1 M inivan D rive r A ir Bag System
list for proper handling procedures.
The inflator assembly is mounted to the back of the
WARNING: REPLACE AIR BAG SYSTEM COMPO­ module housing. It seals the hole so it can discharge
NENTS WITH CHRYSLER MOPAR® SPECIFIED the gas it is designed to produce, directly into the
REPLACEMENT PARTS. SUBSTITUTE PARTS MAY cushion, when supplied with the proper electrical sig­
VISUALLY APPEAR INTERCHANGEABLE, BUT IN­ nal. A protective cover is fitted to the front of the air
TERNAL DIFFERENCES MAY RESULT IN INFERIOR bag module and forms a decorative cover in the center
OCCUPANT PROTECTION. of the steering wheel. The air bag module is mounted
THE FASTENERS, SCREWS, AND BOLTS, ORIGI­ directly to the steering wheel.
NALLY USED FOR THE AIR BAG COMPONENTS,
HAVE SPECIAL COATINGS AND ARE SPECIFICALLY FRONT IMPACT SENSORS
DESIGNED FOR THE AIR BAG SYSTEM. THEY MUST The driver air bag system is a safety device de­
NEVER BE REPLACED WITH ANY SUBSTITUTES. signed to protect the driver from serious injury, caused
ANYTIME A NEW FASTENER IS NEEDED, REPLACE by a frontal impact of the vehicle.
WITH THE CORRECT FASTENERS PROVIDED IN THE The impact sensors provide verification of the direc­
SERVICE PACKAGE OR FASTENERS LISTED IN THE tion and severity of the impact. Three impact sensors
PARTS BOOKS. are used. One is called a safing sensor. It is located
inside the diagnostic module which is mounted on the
GENERAL INFORMATION floor pan, just forward of the center console. The other
AIR BAG MODULE two sensors are mounted on the upper crossmember of
The air bag module is the most visible part of the the radiator closure panel on the left and right side of
the vehicle under the hood.
system (Fig 1). It contains the air bag cushion and its
 The impact sensors are threshold sensitive switches
that complete an electrical circuit when an impact
provides a sufficient G force to close the switch. The
sensors are calibrated for the specific vehicle and react
to the severity and direction of the impact.

cLomspmm
The clockspring is mounted on the steering column
behind the steering wheel, and is used to maintain a
continuous electrical circuit between the wiring har­
ness and the driver’s air bag module. This assembly
consists of a flat ribbon-like electrically conductive
tape which winds and unwinds with the steering wheel
rotation.

DIAGNOSTIC MODULE
The Air Bag System Diagnostic Module (ASDM) Fig. 2 Wear Safety Glasses a n d R u b b e r G loves
contains the safing sensor and energy reserve capaci­
tor. The ASDM monitors the unit to determine the If you find that the clean up is irritating your skin,
readiness of the system. The ASDM will have suffi­ run cool water over the affected area. Also, if you
cient energy stored to deploy the air bag up to 9.5 experience nasal or throat irritation, exit the vehicle
minutes after the battery is disconnected, if both front for fresh air until the irritation ceases. If irritation
sensors are open. The ASDM contains on-board diag­ continues, see a physician.
nostics, and will illuminate the AIR BAG warning
light in the cluster when a fault occurs. CLEAN UP PROCEDURE
Begin the clean up by putting tape over the air bag
STORAGE exhaust vent (Fig. 3) so that no additional powder will
The air bag module must be stored in its original find its way into the vehicle interior. Then remove the
special container until used for service. Additionally, air bag and air bag module from the vehicle.
it must be stored in a clean, dry environment, away
from sources of extreme heat, sparks, and sources of
high electrical energy. Always place or store the mod­
ule on a surface with the trim cover facing up to
minimize movement in case of accidental deployment.

HANDLING LIVE MODULE

At no time should any source of electricity be per­
mitted near the inflator on the back of the module.
When carrying a live module, the trim cover should
be pointed away from the body to minimize iiyury in
the event of accidental deployment. In addition, if the
module is placed on a bench or other surface, the
plastic trim cover should be face up to minimize move­
ment in case of accidental deployment.
When handling a steering column with an air bag
module attached, never place the column on the floor
or other surface with the steering wheel or module
face down. Use a vacuum cleaner to remove any residual pow­
der from the vehicle interior. Work from the outside
DEPLOYED MODULE in as you do, so that you avoid kneeling or sitting on
The vehicle interior may contain a very small amount
uncleaned area.
of sodium hydroxide powder, a byproduct of air bag Be sure to vacuum the heater and A/C outlets as
deployment. Since this powder can irritate the skin, well (Fig. 4). In fact it's a good idea to run the blower
eyes, nose or throat, be sure to wear safety glasses, on low and to vacuum up any powder expelled from
rubber gloves and long sleeves during clean up (Fig. the plenum. You may need to vacuum the interior of
2).
the car a second time to recover all of the powder.

Fig, 4 Vacuum Heater and A!C Outlets
Place the deployed bag and module in your automo­
tive scrap.
SERVICE OF DEPLOYED AIR BAG MODULE
After an air bag has been deployed, the air bag
module and clockspring must be replaced because they
cannot be reused. Other air bag system components
are replaced if damaged.
AIR BAG SYSTEM CHECK
WARNING: BEFORE BEGINNING ANY AIR BAG SYS­
TEM CHECK PROCEDURES, REMOVE AND ISOLATE
THE BATTERY NEGATIVE (-) CABLE (GROUND)
FROM THE VEHICLE BATTERY. THIS IS THE ONLY
SURE WAY TO DISABLE THE AIR BAG SYSTEM.
FAILURE TO DO THIS COULD RESULT IN ACCIDEN­
TAL AIR BAG DEPLOYMENT AND POSSIBLE PER­
SONAL INJURY.
WHEN AN UNDEPLOYED AIR BAG ASSEMBLY IS
TO BE REMOVED FROM THE STEERING WHEEL,
DISCONNECT BATTERY GROUND CABLE AND ISO­
LATE. ALLOW SYSTEM CAPACITOR TO DISCHARGE
FOR 2 MINUTES, THEN BEGIN AIR BAG REMOVAL
(1) Disconnect the battery negative cable and isolate.
(2) Remove forward console or cover as necessary.
(3) Connect DRB II to ASDM diagnostic 6-way con­
nector, located at right side of module.
(4) Turn the ignition key to ON position. Exit vehi­
cle with DRB II. Use the latest version of the proper
cartridge.
; (5) After checking that no one is inside the vehicle,
connect the negative battery cable.
(6) Using the DRB II, read and record active fault
data.
(7) Read and record any. stored faults.
(8) Refer to the Passive Restraint Diagnostic Test
Manual if any faults are found in steps 6.
(9) Erase stored faults if there are no active fault
codes. If problems remain, fault codes will not erase.
(10) With the ignition key in the ON position, make
sure no one is in the vehicle.
(11) From the passenger side of vehicle, turn the
ignition key to OFF then ON and observe the instru­
ment cluster air bag light. It should go on for 6 to 8
seconds, then go out; indicating system is functioning
normally.
If air bag warning light either fails to light, or goes
on and stays on, there is a system malfunction. Re­
fer to the Passive Restraint Diagnostic Test Manual
to diagnose the problem.
AIR BAS MODULE
WARNING: BEFORE BEGINNING ANY AIR BAG SYS­
TEM REMOVAL OR INSTALLATION PROCEDURES,
REMOVE AND ISOLATE THE BATTERY NEGATIVE
(-) CABLE (GROUND) FROM THE VEHICLE BATTERY.
THIS IS THE ONLY SURE WAY TO DISABLE THE AIR
BAG SYSTEM. FAILURE TO DO THIS COULD RE­
SULT IN ACCIDENTAL AIR BAG DEPLOYMENT AND
POSSIBLE PERSONAL INJURY.
UNDEPLOYED AIR BAG REMOVAL FROM THE
STEERING WHEEL DISCONNECT BATTERY GROUND
CABLE AND ISOLATE. ALLOW SYSTEM CAPACI­
TOR TO DISCHARGE FOR 2 MINUTES. BEGIN AIR
BAG REMOVAL
REMOVAL
When removing a deployed module, rubber gloves,
eye protection and long sleeve shirt should be worn,
as there may be deposits on the surface which could
irritate the skin and eyes,
(1) Disconnect battery negative cable and isolate.
(2) Wait 2 minutes for the reserve capacitor to dis­
charge before removing undeployed module.
(3) Remove 4 nuts attaching air bag module to steer­
ing wheel (Fig. 5).
 CLOCKSPRING
Fig. 5 Air Bag Module
(4) Lift module, and disconnect electrical connector
by spreading apart the external latching arms and
prying upward on the connector.
(5) Remove module,
(6) When replacing a deployed module, the clock­
spring must also be replaced. Refer to clockspring
Removal and Installation for proper procedure.
INSTALLATION
(1) Connect clockspring wiring connector to the mod­
ule, by pressing straight in on the connector. The
connector should latch securely beneath module lock­
ing clip to assure positive connection.
(2) Install 4 nuts and torque to 9 to 11 N*m (80 to
100 in. lbs.).
(3) Do not connect battery negative cable. Refer to
Air Bag System Check for proper procedure.
LEFT FRONT IMPACT SENSOR
REMOVAL
WARNING: BEFORE BEGINNING ANY AIR BAG SYS­
TEM REMOVAL OR INSTALLATION PROCEDURES,
REMOVE AND ISOLATE THE BATTERY NEGATIVE
(-) CABLE (GROUND) FROM THE VEHICLE BATTERY.
THIS IS THE ONLY SURE WAY TO DISABLE THE AIR
BAG SYSTEM. FAILURE TO DO THIS COULD RE­
SULT IN ACCIDENTAL AIR BAG DEPLOYMENT AND
POSSIBLE PERSONAL INJURY.
(1) Disconnect battery negative cable and isolate.
(2) Remove 3 nuts holding sensor to upper cross-
member of radiator closure panel and remove sensor
(Fig. 6).
918M-15
Fig. 6 Left impact Sensor
(3) Disconnect impact sensor electrical connector,
INSTALLATION
(1) Connect sensor wiring lead from harness to con­
nector on body of sensor.
(2) Install left sensor and torque nuts to 4.5 to 7 N*m
( 40 to 60 in. lbs.) using nuts provided with the new
sensor.
(3) Do not connect battery negative cable. Refer to
Air Bag Systems Check for proper procedure.
RIGHT FRONT IMPACT SENSOR
rem oval
(1) Disconnect battery negative cable and isolate.
(2) Remove 3 nuts holding sensor to upper cross­
member of radiator closure panel. Remove right sensor.
(3) Disconnect impact sensor electrical connector
(Fig. 7).
 RADIATOR CLOSURE PANEL

Fig. 8 A ir Bag System D ia g no stic M odule

CENTER CONSOLE

Fig. 7 Right impact Sensor

INSTALLATION
(1) Connect sensor wiring lead from harness to con­
nector on body of sensor.
(2) Install right sensor and torque nuts to 4.5 to 7
N-m ( 40 to 60 in. lbs.) using nuts provided with the
new sensor.
(3) Do not connect battery negative cable. Refer to
Air Bag Systems Check for proper procedure.

AIR BAG SYSTEM DIAGNOSTIC MODULE (ASDM)

WARNING: THE ASDM CONTAINS ONE OF THE IM­
PACT SENSORS WHICH ENABLE THE SYSTEM TO
FIRE THE AIR BAG. TO AVOID ACCIDENTAL DE­
PLOYMENT, NEVER CONNECT ASDM ELECTRICALLY 918M-17
TO THE SYSTEM WHILE VEHICLE BATTERY IS CON­
NECTED. BEFORE BEGINNING ANY AIR BAG SYS­ Fig. 9 A ir Bag System D ia g no stic M odule w ith
TEM REMOVAL OR INSTALLATION PROCEDURES, C enter C onsole
REMOVE AND ISOLATE THE BATTERY NEGATIVE
(-) CABLE (GROUND) FROM THE VEHICLE BATTERY. (3) Remove 5 module and bracket mounting screws,
THIS IS THE ONLY SURE WAY TO DISABLE THE AIR and lift module carefully up and rearward.
BAG SYSTEM. FAILURE TO DO THIS COULD RE­ (4) Disconnect wiring at ASDM and remove module.
SULT IN ACCIDENTAL AIR BAG DEPLOYMENT, AND
POSSIBLE PERSONAL INJURY. INSTALLATION
(1) Position module and bracket facing forward. Con­
REMOVAL nect wiring connectors and ensure they are locked
(1) Disconnect battery negative cable, and isolate into position.
cable.
(2) Remove forward console or cover as necessary
(Fig. 8 and 9).
 (2) Place the module and bracket on the lower mount­
ing bracket, using locating tab to position module.
(3) Attach module and bracket with screws and torque
to 4 N-n (35 in. lbs.).
CAUTION:USE SUPPLIED SCREWS
(4) Install forward console.
(5) Do not connect battery negative cable. Refer to
Air Bag System Check for proper procedure.
CLOCKSPRING
WARNING: BEFORE BEGINNING ANY AIR BAG SYS­
TEM REMOVAL OR INSTALLATION PROCEDURES,
REMOVE AND ISOLATE THE BATTERY NEGATIVE
B CABLE (GROUND) FROM THE VEHICLE BATTERY.
THIS IS THE ONLY SURE WAY TO DISABLE THE AIR
BAG SYSTEM. FAILURE TO DO SO COULD RESULT
IN ACCIDENTAL AIR BAG DEPLOYMENT, AND POS­
SIBLE INJURY.
WHEN AN UNDEPLOYED AIR BAG ASSEMBLY IS
TO BE REMOVED FROM THE STEERING WHEEL,
DISCONNECT BATTERY GROUND CABLE AND ISO­
LATE. ALLOW SYSTEM CAPACITOR TO DISCHARGE
FOR 2 MINUTES, THEN BEGIN AIR BAG REMOVAL
REMOVAL
(1) Place the front wheels in the straight ahead
position before starting the repair.
(2) Disconnect battery negative cable and isolate.
(3) Wait 2 minutes for the reserve capacitor to dis­
charge before removing undeployed module.
(4) Remove the air bag module.
(5) Remove Speed Control switch and connector if so
equipped or cover.
(6) Disconnect horn terminals.
(7) Remove the steering wheel.
(8) Remove upper and lower steering column shrouds
to gain access to clockspring wiring.
(9) Disconnect the 2-way connector between the
clockspring and the instrument panel wiring harness
on top of the fuse block.
(10) To remove, pull clockspring assembly from the
steering column by lifting locating fingers as neces­
sary. The clockspring cannot be repaired, and must be
replaced if faulty.
INSTALLATION
(1) Snap clockspring onto the steering column. If
the clockspring is not properly positioned, follow the
clockspring centering procedure before installing steer­
ing wheel.
(2) Connect the clockspring to the instrument panel
harness, ensure wiring locator clips are properly seated
on wiring trough. Ensure harness locking tabs are
properly engaged.
(3) Install steering column shrouds. Be sure air bag
wire is inside of shrouds.
(4) Front wheels should still be in the straight­
ahead position. Install steering wheel, ensure the flats
on hub align with clockspring. Pull the horn lead
through the smaller upper hole. Pull the air bag and
speed control leads through the larger bottom hole.
Ensure leads are not pinched tinder the steering wheel.
(5) Connect the horn lead wire, then the air bag
lead wire to the air bag module. To assure complete
connection, latching arms must be visible on top of
connector housing.
(6) Install the air bag module and torque nuts to 9
to 11 N*m (80 to 100 in. lb.).
(7) Install speed control switch and connector or
cover.
(8) Do not connect battery negative cable. Refer to
Air Bag Systems Check for proper procedure.
CLOCKSPRING CENTERING PROCEDURE
If the rotating tape within the clockspring is not
positioned properly with the steering wheel and the
front wheels, the clockspring may fail during use. The
following procedure MUST p i USED to center the
clockspring if it is not known to be properly posi­
tioned, or if the front wheels were moved from the
straight ahead position.
WARNING: BEFORE BEGINNING ANY AIR BAG SYS­
TEM REMOVAL OR INSTALLATION PROCEDURES,
REMOVE AND ISOLATE THE BATTERY NEGATIVE
B CABLE (GROUND) FROM THE VEHICLE BATTERY.
THIS IS THE ONLY SURE WAY TO DISABLE THE AIR
BAG SYSTEM. FAILURE TO DO THIS COULD RE­
SULT IN ACCIDENTAL AIR BAG DEPLOYMENT AND
D A O O IE ti P IM 18IR V
WHEN AN UNDEPLOYED AIR BAG ASSEMBLY IS
TO BE REMOVED FROM THE STEERING WHEEL,
DISCONNECT BATTERY GROUND CABLE AND ISO­
LATE. ALLOW SYSTEM CAPACITOR TO DISCHARGE
FOR 2 MINUTES, THEN BEGIN AIR BAG REMOVAL.
(1) Place front wheels in the straight ahead position.
(2) Wait 2 minutes for the reserve capacitor to dis­
charge before removing und^ployed module.
(3) Refer to Steering Wheel procedures for removal
of air bag module and steering wheel.
(4) Depress the 2 plastic locking pins to disengage
locking mechanism (Fig. 10).

(5) Keeping locking mechanism disengaged, rotate
the clockspring rotor in the CLOCKWISE DIREC­
TION to the end of travel Do not apply excessive
torque.
(6) From the end of travel, rotate the rotor 2 full
turns and a half in the counterclockwise direction.
The horn wire should end up at the top and the squib
wire at the bottom.
(7) Refer to Steering Wheel procedures for installa­
tion of steering wheel and air bag module.
(8) Do not connect battery negative cable. Refer to
Air Bag System Check for proper procedure.
STEERING WHEEL
WARNING; BEFORE BEGINNING ANY AIR BAG SYS­
TEM REMOVAL OR INSTALLATION PROCEDURES,
REMOVE AND ISOLATE THE BATTERY NEGATIVE
(-) CABLE (GROUND) FROM THE VEHICLE BATTERY.
THIS IS THE ONLY SURE WAY TO DISABLE THE AIR
BAG SYSTEM. FAILURE TO DO THIS COULD RE­
SULT IN ACCIDENTAL AIR BAG DEPLOYMENT AND
POSSIBLE PERSONAL INJURY,
WHEN AN UNDEPLOYED AIR BAG ASSEMBLY IS
TO BE REMOVED FROM THE STEERING WHEEL,
DISCONNECT BATTERY GROUND CABLE AND ISO­
LATE. ALLOW SYSTEM CAPACITOR TO DISCHARGE
FOR 2 MINUTES. BEGIN AIR BAG REMOVAL.
REMOVAL
(1) Make sure front wheels are straight, and steer­
ing column is locked in place.
(2) Disconnect battery negative cable and isolate.
(3) Wait 2 minutes for the reserve capacitor to dis­
charge before removing undeployed module.
(4) Remove 4 nuts attaching air bag module from
the back side of steering wheel.
(5) Lift module, and disconnect connector by spread­
ing apart the external latching arms and prying up­
ward on the connector.
(6) Remove speed control switch and connector if so
equipped or cover.
(7) Remove steering wheel retaining nut.
(8) Remove steering wheel with steering wheel puller
Tool C-3428B.
INSTALLATION
(1) If the clockspring is not properly positioned or if
front wheels were moved, follow the clockspring cen­
tering procedure before installing steering wheel. With
the front wheels in the straight ahead position. Posi­
tion the steering wheel on the steering column. Mak­
ing sure to fit the flats on the hub of the steering
wheel with the formations on the inside of the clock­
spring. Pull the air bag and speed control wires through
the lower, larger hole in the steering wheel and the
horn wire through smaller hole at the top. Make sure
not to pinch wires (Fig. 11).
AIR BAG MODULE HORN WIRE CLOCKSPRING
Fig. 11 Steering Wheel W iring
(2) Install retaining nut, and torque it to 61 N*m (45
ft. lbs.).
(3) Connect horn wiring lead.
(4) Connect 4-way connector to speed control switch
and attach switch to steering wheel.
(5) Connect air bag lead wire to air bag module, and
secure module to steering wheel.
(6) Do not connect negative battery cable. Refer to
Air Bag System Check for proper procedure.
STEERING COLUMN SWITCHES
This procedure covers the removal and installation
of the steering wheel and clockspring. Once the steer­
ing wheel and clockspring have been removed, refer to
the appropriate section of this service manual for switch
replacement. .
WARNING: BEFORE BEGINNING ANY AIR BAG SYS­
TEM REMOVAL OR INSTALLATION PROCEDURES,
REMOVE AND ISOLATE THE BATTERY NEGATIVE
(«) CABLE (GROUND) FROM THE VEHICLE BATTERY.
THIS IS THE ONLY SURE WAY TO DISABLE THE AIR
BAG SYSTEM. FAILURE TO DO THIS COULD RE­
SULT IN ACCIDENTAL AIR BAG DEPLOYMENT AND
POSSIBLE INJURY.
WHEN AN UNDEPLOYED AIR BAG ASSEMBLY IS
TO BE REMOVED FROM THE STEERING WHEEL,
DISCONNECT BATTERY GROUND CABLE AND ISO­
LATE. ALLOW SYSTEM CAPACITOR TO DISCHARGE
FOR 2 MINUTES. BEGIN AIR BAG REMOVAL.
REMOVAL
(1) Disconnect battery negative cable, and isolate.
(2) Wait 2 minutes for the reserve capacitor to dis­
charge before removing undeployed module.
(3) Remove 4 nuts attaching air bag module from
the back side of steering wheel.
(4) Lift module, and disconnect connector by spread­
ing apart the external latching arms and prying up­
ward on the connector.
(5) Remove speed control switch and connector if so
equipped or cover.
(6) Remove steering wheel.
(7) Unsnap clockspring, and remove it.
(8) Refer to the appropriate section for switch
replacement.
INSTALLATION
(1) Snap clockspring on to steering column. Assure
the 4 way connector is still seated.
(2) Install steering wheel.
(3) Install speed control switch and connector or
cover.
(4) Connect clockspring wiring connector to the mod­
ule. To assure complete connection, latching arms must
be visible on top of the connector housing.
(5) Install 4 nuts to module, and torque to 9 to 11
N*m (80 to 100 in. lbs.).
(6) Do not connect negative battery cable. Refer to
Air Bag System Check for proper procedure.
CHIME WARNING/REMINDER SYSTEM
WARNING: ON VEHICLES EQUIPPED WITH AN AIR
BAG, REFER TO THE AIR BAG PORTION OF THIS
SECTION FOR STEERING WHEEL OR SWITCH RE­
MOVAL AND INSTALLATION PROCEDURES.
The chime warning/reminder system includes sig­
nals for fasten seat belts, turn signal warning, exte­
rior lamps left on and key left in ignition.
When using the DRB II refer to the Body Chassis
Diagnostic Manual for the procedure.
FASTEN SEAT BELTS
A warning lamp on the instrument panel, and an
audible chime tone are used as the fasten seat belt
warning/reminder.
TURN SIGNAL WARNING
An audible chime tone indicates turn signal has
been on for .5 mi. (.8 km) at a speed above 15 mph (24
km/h).
EXTERIOR LAMPS LEFT ON
An audible chime tone that indicates the exterior
lamps were left on.
HEY LEFT IN IGNITION
An audible chime tone that indicates the key was
left in ignition.
FASTEN SEAT BELTS
To test the ignition switch must be in the off posi­
tion for several minutes before testing the fasten seat
belts. Turn the ignition switch to the ON position
with the driver’s seat belt unbuckled. The seat belt
warning lamp should light for 4 to 8 seconds and the
tone should sound 3 to 5 times.
TURN SIGNAL WARNING
To test turn signal warning system it must have:
• The input from either the right or left turn signal
lamps creates a voltage change between 0 and battery
voltage.
• The distance sensor message from the engine con­
troller, must exceed 15 mph (24 km/h) for .6 mi. (.8
km).
• When the two conditions above are met, the chime
will sound. The chime will stop when no further volt­
age change or a drop in speed is detected.
• If hazard warning signals are pulsing, then no chime
shall sound.
• If turn signal lamps are not working properly no
chime shall sound.
• Wheii using DRB II refer to the Body Chassis Diag­
nostic Manual for the procedure.
EXTERIOR LAMPS LEFT ON
To test the headlamps left on function, turn ignition
off, turn exterior lamps on with drivers door open.
Chime should sound until headlamps are turned off or
drivers door is closed.
KEY LEFT IN IGNITION :PROCEDURE
(1) Check driver’s seat belt buckle switch for a ground
To test the key left in ignition function, insert key
when unbuckled.
into the ignition and open drivers door. Chime should (2) Check for battery feed at terminal B-16 and
sound until key is removed from ignition or drivers ignition feed at terminal B-12 of body controller (Fig.
door is closed. 1 and 2).
(3) Check for tone in any other function.
CHIME SYSTEM DIAGNOSIS
CONDITION CONDITION
No tone when ignition switch is turned on and driv­ No fasten seat belt lamp when ignition switch is
ers seat belt is unbuckled. turned on.

918M-19
Fig. 1 Chime Warning/Reminder Wiring

25-WAY 25-WAY 25-WAY CONNECTOR PROCEDURE

PIN NUMBERS
CONNECTOR CONNECTOR (1) Check for burned out bulb.
(BLUE) (NATURAL) NATURAL BLUE(B)
TaW oT=n
(2) Check for battery feed at terminal B-16 and
lamp output at terminal B-21 of body controller.
(3) Check for ignition feed at terminal B-12 of body
controller.

CONDITION
Fasten seat belt lamp or tone continue for more
than 10 seconds after seat belts are fastened and driv­
ers door is closed.

PROCEDURE
BODY VIEWED FROM WIRE END (1) Check left door jamb switch.
CONTROLLER 918M-20 (2) Inspect body controller connectors and wires for
proper connection.
Fig. 2 Body Controller 25-Way Connectors
common
No tone when headlamps are on and drivers door is
open.

PROCEDURE
(1) Check left door jamb switch for good ground
when drivers door is open.
(2) Inspect body controller connectors and wires for
proper connection.
(3) Check for battery feed at terminal B-16 of body
controller.
(4) Check headlamp switch.

CONDITION
No tone when key is left in ignition and drivers
door is open.

PROCEDURE
(1) Check left door jamb switch for good ground
when drivers door is open.
(2) Inspect body controller connectors and wires for
proper connection.
(3) Check for battery feed at terminal B-16 of body
controller (Fig. 1).
(4) Check key-in switch.

CONDITION HEADLAMP SWITCH REPLACEMENT

Chimes continue when headlamps are turned off Refer to Group 8E, Instrument Panel and Gauges.
and/or key is removed from ignition.

PROCEDURE
SEAT BELT BUCKLE REPLACEMENT
(1) Check wiring for a grounded condition between Refer to Group 23, Body for service procedures.
headlamp switch, key-in switch and chime module.
(2) Inspect body controller connectors and wires for KEY-IN SWITCH
proper connection. The Key-in switch is built into the ignition switch
assembly. Should the Key-in switch require service,
SERVICE PROCEDURES the ignition switch assembly must be replaced. Refer
to Group 8D, Ignition System for service procedures.
BODY CONTROLLER REPLACEMENT
(1) Remove steering column cover to gain access to
the body controller (Fig. 3).
(2) Disconnect the two 25-way connectors from body
controller.
(3) Remove mounting screws from body controller.
(4) Pull to the left to release body controller of
S-clips and remove unit.
(5) For installation reverse above procedures. En­
sure body controller is locked into the S-clips.
 WIRING DIAGRAMS
INDEX
Wiring Diagram
Name______________ ____________ Sheet Number
Airbag System.................... ■....................... ....................1,2
Clock Spring .................................................................1
Cluster Connector ................................................... ; . .1
F20 Splice ..................................................................... 1
F62 Splice .............................................................. .. . .2
G5 Splice ..................................................................... 1
Ground ......................................................................... 1
Wiring Diagram
Name_______________________________ Sheet Number
ignition Switch Connector.............................................. 2
Impact Sensor-Left ................................... ................... 2
Impact Sensor-Right ..................................................... 2
Interface Grom m et......................................................... 2
Module ASDM .............................................................. 1
Squib ........................................................................... 1
Warning Lamp Center Connector ................................... 1
 (BELO W STEERING COLUMN)
JV-,
R43 18BK/LB* • R43 18BK/LB* GRAY
R45 18DG/LB* -a R45 18DG/LB*
XT'

• YELLOW
CLUSTER
CONNECTOR

R45
PART OF 18DG
R43 R45
STEERING LB*
20BK20DG
COLUMN BLUE-
G5
201
R43 wr
18BK
LB* WARNING LAMP
CENTER
CONNECTOR
R47
G5
(FUSE #15} T8DB
20DB
TO FUSE BLOCK LB*
WT*
CAVITY 43
1 TO BODY COMPUTER R46
* BLUE CONNECTOR 18BR
CAVITY 12 LB*

R49
R41 18LB
“18BK/TN*"

F6218RD -
R48
18TN

R43 18BK/LB*
AIR BAG SYSTEM *R47 18DB/LB*
■ R45 18DG/LB*
DIAGNOSTIC *R46 18BR/LB*-
MODULE R49 18LB-
{CENTER SUPPORT
BRACKET) •RfS 18TN-
> TO BACK UP
F20 18WT- •F 2 0 1 8 W T ------1 LAMP RELAY
CAVITY #8

YELLOW F20 16WT- > TO FUSE BLOCK {FUSE #24)

1 CAVITY 52
JL
R43 18BK/LB*4 q D f " m 18DG/LB" F20 I8W T--------- f TO RELAY B A ^ L O C A T IO N #7)
m I8RD
BLACK Z6 18BK/PK* F20 18WT- TO UFTGATE/
HEATED REAR
R47 18DB/LB* W INDO W SWITCH
R46 18BR/LB*
R48 18TN
G5 R49 18LB AIR BAG GROUND
18D B /W P (LOWER RIGHT COWL)
R41 18BK/TN*
F20 18WT
• 16 18BK/PK
 F62 16RD- TO FUSEBLOCK (FUSE#23|
< CAVITY 51
J TO RELAY BANK (KXATION #7j
< CAVITY 21
F62 18RD J TO RELAYBANK (LOCATION #3)
< CAVITY 44
TO CIGAR
C UGHTEi
, TO BODY DIAGNOSTIC
F62 18RD- " f CONNECTOR
CAVITY 2
 STEERING
SERVICING ACUSTAR STANDARD AND TILT STEERING COLUMN WITH AIR BAG
GENERAL INFORMATION MODULE (FIG. 1) MUST BE REMOVED FROM THE
This group of the service manual supplement will STEERING WHEEL.
highlight the safety measures that must be observed If the vehicle to be serviced is equipped with an Air
when servicing the steering wheel or steering column. Bag system, refer to the appropriate section of this
On Air Bag equipped vehicles, there will be a warn­ service maiiual, for proper removal of the Air Bag
ing statement about seat belt usage on the steering Module.
wheel (Fig. 1). On speed control equipped vehicles it is For detailed repair procedures of the steering wheel,
on the speed control switch. On non speed control steering column and its components, refer to the ap­
equipped vehicles it is on the trim bar which replaces propriate group in the 1991 Front Wheel Drive-All
the speed control switch (Fig. 1). If this warning state­ Wheel Drive Van/Wagon service manual.
ment is not on the steering wheel, the vehicle is not Be sure to read and follow all applicable warnings
equipped with an Air Bag system. prior to performing any type of service on an Air Bag
equipped steering wheel or steering column,
WARNING; PRIOR TO PERFORMING ANY SERVICE
PROCEDURES ON THE STEERING WHEEL, STEER­ WARNING; SAFETY GOGGLES SHOULD BE WORN
ING COLUMN, OR THE REMOVAL OF THE STEER­ AT ALL TIMES WHEN WORKING ON STEERING
ING COLUMN FROM THE VEHICLE, THE AIR BAG COLUMNS.
T
IL
TLE
VER U
PPE
RSH
ROU
D L
OWE
RUP
PER B
RAK
EPE
DALB
RAC
KET
STEERING
WHEEL NUT

SH
IM(IFR
EQU
IR
ED)

COUW SIOU
RETAINING BN

D
VERA
ND
mm
SfEfUNG SHAFT
seal

DASH
PANEL

H
ORNSW
IT
CH 9119-40X

Fig. 1 A cu sta r S tandard a nd T ilt Steering Colum n With A n d W ithout A ir Bag