Jeep Compass 4wd Workshop Manual l4 2 4l Vin W 2007

Factory Workshop Manual
Make
Jeep
Model
Compass 4wd
Engine and year
L4-2.4L VIN W (2007)
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This manual was submitted by

Anonymous
Date
1st January 2018
Jeep Compass 4wd Workshop Manual (L4-2.4L VIN W (2007))
Jeep Workshop Manuals > Relays and Modules > Relays and Modules - Accessories and Optional Equipment > Alarm
Module, (Vehicle Antitheft) > Component Information > Locations
Alarm Module: Locations
Component ID: 161
Component : MODULE-INTRUSION TRANSCEIVER
Connector:
Name : MODULE-INTRUSION TRANSCEIVER C1
Color : BLACK
# of pins : 6
Pin Description Circuit
1 FUSED B(+) (I.O.D.) A415 20RD/TN
2--
3 CAN B BUS (+) D55 20WT/OR
4 CAN B BUS (-) D54 20WT/PK
5 SIREN SIGNAL CONTROL D96 20WT/BR
6 GROUND Z941 20BK/WT
Component Location - 40
Module, (Vehicle Antitheft) > Component Information > Locations > Page 7
Connector:
Color : BLACK
# of pins : 3
1--
2 COURTESY LAMPS DRIVER M24 20YL/WT
Alarm Module: Diagrams
Component ID: 161
Component : MODULE-INTRUSION TRANSCEIVER
Connector:
Color : BLACK
# of pins : 6
2--
5 SIREN SIGNAL CONTROL D96 20WT/BR
Connector:
Color : BLACK
# of pins : 3
1--
2 COURTESY LAMPS DRIVER M24 20YL/WT
Module, (Vehicle Antitheft) > Component Information > Description and Operation > Description
Alarm Module: Description and Operation Description
DESCRIPTION
An Intrusion Transceiver Module (ITM) is part of the export premium version of the Vehicle Theft
Alarm (VTA) in the Vehicle Theft Security System (VTSS). The export premium version of the VTA
is only available in vehicles built for certain markets, where the additional features offered by this
system are required. The ITM is integral to the rear dome lamp housing (1) located in the
passenger compartment, on the lower surface of the headliner near the center of the vehicle. The
ITM is designed to provide interior motion detection, and serve as an interface between the
ElectroMechanical Instrument Cluster (EMIC) (also known as the Cab Compartment Node/CCN)
and the alarm siren module.
The ITM is concealed within the dome lamp housing. Only the black grilled openings (4) for the ITM
ultrasonic transmitter and receiver are visible on the outside of the housing, one each ahead and
behind the dome lamp lens (3). The entire module is secured to the headliner by a fixed retainer (5)
integral to the left side of the housing and a hinged retainer (2) on the right side that is integral to
the dome lamp lens. A notch (6) in the housing at the left edge of the lens affords access for
service removal.
Concealed within the housing is the electronic circuitry of the ITM which includes a microprocessor,
and the ultrasonic transmit and receive transducers. A molded plastic connector receptacle on the
circuit board is connected to the vehicle electrical system by a dedicated take out and connector of
the headliner wire harness that is integral to the headliner.
The ITM unit cannot be adjusted or repaired and, if ineffective or damaged, it must be replaced.
The dome lamp lens and bulb are available for separate service replacement.
Module, (Vehicle Antitheft) > Component Information > Description and Operation > Description > Page 18
Alarm Module: Description and Operation Operation
OPERATION
The microprocessor in the Intrusion Transceiver Module (ITM) contains the motion sensor logic
circuits and controls all of the features of the export premium version of the Vehicle Theft Alarm
(VTA). The ITM uses On-Board Diagnostics (OBD) and can communicate with other electronic
modules in the vehicle as well as with a diagnostic scan tool using the Controller Area Network
(CAN) data bus. This method of communication is used by the ITM to communicate with the
and for diagnosis and testing through the 16-way data link connector located on the driver side
lower edge of the instrument panel. The ITM also communicates with the alarm siren module over
a dedicated serial bus circuit.
The ITM microprocessor continuously monitors inputs from its on-board motion sensor circuitry as
well as inputs from the EMIC and the alarm siren module. The on-board ITM motion sensor
circuitry transmits ultrasonic signals into the vehicle cabin through a transmit transducer, then
listens to the returning signals through a receive transducer as they bounce off of objects in the
vehicle interior. If an object is moving in the interior, a detection circuit in the ITM senses this
movement through the modulation of the returning ultrasonic signals that occurs due to the Doppler
effect. The motion detect function of the ITM can be disabled by depressing the LOCK button on
the Remote Keyless Entry (RKE) transmitter three times within 15 seconds while the VTA is arming
(security indicator is flashing rapidly). The ITM will signal the alarm siren module to provide a single
siren chirp as an audible confirmation that the motion sensor function has been disabled.
If movement is detected while the VTA is armed, the ITM sends an electronic status message to
the EMIC over the CAN data bus and sends an electronic message to the alarm siren module over
a dedicated serial bus line to sound the siren. Then the EMIC relays an electronic request message
to the Totally Integrated Power Module (TIPM) to flash the exterior lighting. When the EMIC detects
a breach in the perimeter protection through a hard wired door or liftgate ajar switch input or
receives a hood ajar switch input from the TIPM, it sends an electronic message to the ITM and the
ITM sends an electronic message to the alarm siren module over a dedicated serial bus line to
sound the siren.
The ITM also monitors inputs from the alarm siren module for siren battery or siren input/output
circuit tamper alerts, and for siren battery condition alerts, then sets active and stored Diagnostic
Trouble Codes (DTC) for any monitored system faults it detects. An active fault only remains for the
current ignition switch cycle, while a stored fault causes a DTC to be stored in memory by the ITM.
If a fault does not recur for 50 ignition cycles, the ITM will automatically erase the stored DTC.
The ITM is connected to the vehicle electrical system through the headliner wire harness. The ITM
receives battery current through a fuse in the TIPM, and receives ground through the body wire
harness. These connections allow the ITM to remain operational, regardless of the ignition switch
position.
The hard wired circuits of the ITM may be diagnosed using conventional diagnostic tools and
procedures. Refer to the appropriate wiring information. However, conventional diagnostic methods
will not prove conclusive in the diagnosis of the ITM or the electronic controls or communication
between modules and other devices that provide some features of the VTA. The most reliable,
efficient, and accurate means to diagnose the ITM or the electronic controls and communication
related to ITM operation requires the use of a diagnostic scan tool. Refer to the appropriate
diagnostic information.
Module, (Vehicle Antitheft) > Component Information > Service and Repair > Removal
Alarm Module: Service and Repair Removal
REMOVAL
1. Disconnect and isolate the battery negative cable.
2. Insert the tip of a small flat bladed screwdriver into the notch (4) between the rear dome lamp
lens (2) and the housing (1) on the left end of the
lens.
3. Gently pry the end of the lens outward until it unsnaps from the housing.
4. Swing the lens outward until it is perpendicular to the housing.
5. Pull the lens hinge/retainer end of the housing downward slightly from the headliner, then slide
the exposed end of the housing away from the
mounting hole far enough to disengage the fixed retainer on the notched end from the headliner.
6. Pull the lamp away from the headliner mounting hole far enough to access and disconnect the
wire harness connections from the back of the lamp
and from the Intrusion Transceiver Module (ITM).
7. Remove the ITM from the vehicle.

Module, (Vehicle Antitheft) > Component Information > Service and Repair > Removal > Page 21
Alarm Module: Service and Repair Installation
INSTALLATION
1. Position the Intrusion Transceiver Module (ITM) (1) to the mounting hole in the headliner.
2. Reconnect the wire harness connectors to the ITM and rear dome lamp connector receptacles
on the back of the ITM.
3. Insert the fixed retainer on the left side of the ITM housing up into the left side of the mounting
hole in the headliner.
4. Slide the notched end (4) of the housing into the mounting hole far enough to engage the rear
dome lamp lens hinge/retainer into the opposite side
of the hole in the headliner.
5. Gently and evenly press the lens hinge/retainer end of the lamp into the mounting hole until the
bezel of the ITM housing is flush with the
headliner.
6. Swing the notched end of the lamp lens (2) into position against the lamp housing, then press
upward on the lens firmly and evenly until it snaps
into the housing.
7. Reconnect the battery negative cable.

Jeep Workshop Manuals > Relays and Modules > Relays and Modules - Accessories and Optional Equipment > Keyless
Entry Module > Component Information > Locations
Keyless Entry Module: Locations
Component ID: 166
Component : MODULE-SENTRY KEY REMOTE ENTRY/WCM
Connector:
Name : MODULE-SENTRY KEY REMOTE ENTRY/WCM
Color : BLACK
# of pins : 8
1 IGNITION SWITCH SENSE G20 20VT/BR
2 COM-LIN TIRE PRESSURE MONITOR LAN D508 20WT/GY
3 IGNITION SWITCH OUTPUT (RUN-START) F20 20PK/WT
4 GROUND Z937 20BK/YL
5 FUSED B(+) (I.O.D.) A411 20RD/LG

8--
Entry Module > Component Information > Locations > Page 25
Keyless Entry Module: Diagrams
Component ID: 166
Connector:
Color : BLACK
# of pins : 8

8--
Entry Module > Component Information > Description and Operation > Description
Keyless Entry Module: Description and Operation Description
DESCRIPTION
The Sentry Key REmote Entry Module (SKREEM) (3) is sometimes referred to as the Wireless
Control Module (WCM). The SKREEM is the primary component of the Sentry Key Immobilizer
System (SKIS). It is also the receiver for the Remote Keyless Entry (RKE) system and the Tire
Pressure Monitor (TPM) system. The SKREEM is located on the right side of the steering column
near the ignition lock cylinder housing and is concealed beneath the column shrouds. The molded
black plastic housing for the SKREEM has an integral molded plastic halo-like antenna ring (1) that
extends from one side. When the SKREEM is properly installed, the antenna ring is oriented
around the circumference of the ignition lock cylinder housing.
A single integral connector receptacle (4) is located adjacent to the antenna ring on the SKREEM
housing. An integral molded plastic mounting tab (2) on the SKREEM housing has a hole in the
center through which a screw passes to secure the unit to the steering column lock housing. The
SKREEM is connected to the vehicle electrical system through a single take out and connector of
the instrument panel wire harness.
The SKREEM cannot be adjusted or repaired. If ineffective or damaged, the entire SKREEM unit
must be replaced.
Entry Module > Component Information > Description and Operation > Description > Page 34
Keyless Entry Module: Description and Operation Operation
OPERATION
The Sentry Key REmote Entry Module (SKREEM) (also known as the Wireless Control
Module/WCM) contains a Radio Frequency (RF) transceiver and a microprocessor. The SKREEM
transmits RF signals to, and receives RF signals from the Sentry Key transponder through a tuned
antenna enclosed within the molded plastic antenna ring integral to the SKREEM housing. If this
antenna ring is not mounted properly around the ignition lock cylinder housing, communication
problems between the SKREEM and the transponder may arise. These communication problems
will result in Sentry Key transponder-related faults.
The SKREEM also serves as the Remote Keyless Entry (RKE) RF receiver and, if the vehicle is so
equipped, the receiver for the Tire Pressure Monitoring (TPM) system. The SKREEM
communicates over the Controller Area Network (CAN) data bus with the ElectroMechanical
Instrument Cluster (EMIC) (also known as the Cab Compartment Node/CCN), the Powertrain
Control Module (PCM) or the diagnostic scan tool.
The SKREEM and the PCM both use software that includes a rolling code algorithm strategy,
which helps to reduce the possibility of unauthorized Sentry Key Immobilizer System (SKIS)
disarming. The rolling code algorithm ensures security by preventing an override of the SKIS
through the unauthorized substitution of the SKREEM or the PCM. However, the use of this
strategy also means that replacement of either the SKREEM or the PCM units will require a system
initialization procedure to restore system operation.
The SKREEM retains in memory the ID numbers of any Sentry Key transponder that is
programmed into it. A maximum of eight Sentry Key transponders can be programmed into the
SKREEM. For added system security, each SKREEM is programmed with a unique Secret Key
code. This code is stored in memory, sent over the CAN data bus to the PCM, and is encoded to
the transponder of every Sentry Key that is programmed into the SKREEM. Therefore, the Secret
Key code is a common element that is found in every component of the SKIS.
Another security code, called a PIN, is used to gain access to the SKREEM Secured Access Mode.
The Secured Access Mode is required during service to perform the SKIS initialization and Sentry
Key transponder programming procedures. The SKREEM also stores the Vehicle Identification
Number (VIN) in its memory, which it learns through a CAN data bus message from the PCM
during SKIS initialization.
In the event that a SKREEM replacement is required, the Secret Key code can be transferred to
the new SKREEM from the PCM using the diagnostic scan tool and the SKIS initialization
procedure. Proper completion of the SKIS initialization will allow the existing Sentry Keys to be
programmed into the new SKREEM so that new keys will not be required. In the event that the
original Secret Key code cannot be recovered, SKREEM replacement will also require new Sentry
Keys. The diagnostic scan tool will alert the technician during the SKIS initialization procedure if
new Sentry Keys are required.
When the key is inserted into the ignition switch and when the ignition switch is turned to the ON
position, the SKREEM transmits an RF signal to excite the transponder in the ignition key. The
SKREEM then waits for an RF signal response from the transponder. If the response received
identifies the key as valid, the SKREEM sends an electronic valid key message over the CAN data
bus. If the response received identifies the key as invalid or if no response is received from the key
transponder, the SKREEM sends an invalid key message. The PCM will enable or disable engine
operation based upon the status of the SKREEM messages. It is important to note that the default
condition in the PCM is an invalid key; therefore, if no message is received from the SKREEM by
the PCM, the engine will be disabled and the vehicle immobilized after two seconds of running.
The SKREEM also sends electronic security indicator request messages to the EMIC over the CAN
data bus to tell the EMIC how to operate the security indicator. The security indicator request
message from the SKREEM tells the EMIC to turn the indicator ON for about three seconds each
time the ignition switch is turned to the ON position as a bulb test. After completion of the bulb test,
the SKREEM sends security indicator request messages to the EMIC to turn the indicator OFF,
turn the indicator ON, or to flash the indicator ON and OFF. If the security indicator flashes or stays
ON solid after the bulb test, it signifies a SKIS fault. If the SKREEM detects a system malfunction
or the SKIS has become ineffective, the security indicator will stay ON solid. If the SKREEM
detects an invalid key or if a key transponder-related fault exists, the security indicator will flash. If
the vehicle is equipped with the Customer Learn transponder programming feature, the SKREEM
will also send messages to the EMIC to flash the security indicator whenever the Customer Learn
programming mode is being utilized.
The SKIS performs a self-test each time the ignition switch is turned to the ON position, and will
store fault information in the form of a Diagnostic Trouble Code (DTC) in SKREEM memory if a
system malfunction is detected. The hard wired circuits of the SKREEM may be diagnosed using
conventional diagnostic tools and procedures. Refer to the appropriate wiring information.
However, conventional diagnostic methods will not prove conclusive in the diagnosis of the
SKREEM or the electronic controls or communication between other modules and devices that
provide some features of the SKIS. The most reliable, efficient, and accurate means to diagnose
the SKREEM or the electronic controls and communication related to SKREEM operation requires
the use of a diagnostic scan tool. Refer to the appropriate diagnostic information.
Entry Module > Component Information > Description and Operation > Page 35
Keyless Entry Module: Testing and Inspection
REMOTE KEYLESS ENTRY MODULE
The most reliable, efficient, and accurate means to diagnose the power lock system requires the
use of a scan tool and the proper Diagnostic information.
Refer to the appropriate wiring information.

Entry Module > Component Information > Service and Repair > Removal
Keyless Entry Module: Service and Repair Removal
REMOVAL
WARNING: To avoid serious or fatal injury on vehicles equipped with airbags, disable the
supplemental restraint system before attempting any steering wheel, steering column, airbag,
occupant classification system, seat belt tensioner, impact sensor, or instrument panel component
diagnosis or service. Disconnect and isolate the battery negative (ground) cable, then wait two
minutes for the system capacitor to discharge before performing further diagnosis or service. This
is the only sure way to disable the supplemental restraint system. Failure to take the proper
precautions could result in accidental airbag deployment.
2. Remove but do not disconnect the right multi-function switch from the integral mounting bracket
(1) on the right side of the clockspring and
position it so that the Sentry Key REmote Entry Module (SKREEM) mounting screw (2) may be
accessed.
3. Disconnect the instrument panel wire harness connector (4) from the SKREEM (3) connector
receptacle.
4. Remove the screw that secures the SKREEM to the boss on the top of the ignition lock cylinder
housing (5).
5. Disengage the SKREEM antenna ring from around the ignition lock housing and remove the
SKREEM from the steering column.
Entry Module > Component Information > Service and Repair > Removal > Page 38
Keyless Entry Module: Service and Repair Installation
INSTALLATION
WARNING: To avoid serious or fatal injury, on vehicles equipped with airbags, disable the
1. Position the Sentry Key REmote Entry Module (SKREEM) (3) onto the steering column ignition
lock housing with the antenna ring oriented
around the lock cylinder (5).
2. Install and tighten the screw (2) that secures the SKREEM mounting bracket to the boss on the
top of the ignition lock housing. Tighten the screw
to 2 Nm (20 in. lbs.).
3. Reconnect the instrument panel wire harness connector (4) to the SKREEM connector
receptacle.
4. Reinstall the right multi-function switch onto the integral mounting bracket (1) on the right side of
the clockspring.

NOTE: On vehicles equipped with the optional Sentry Key Immobilizer System (SKIS), when the
SKREEM is replaced with a new unit, a diagnostic scan tool MUST be used to initialize the new
SKREEM and to program at least two Sentry Key transponders before the vehicle can be operated.
Jeep Workshop Manuals > Relays and Modules > Relays and Modules - Accessories and Optional Equipment > Navigation
Module > Component Information > Locations
Navigation Module: Locations
Component ID: 169
Component : MODULE-TRAFFIC INFORMATION RECEIVER
Connector:
Name : MODULE-TRAFFIC INFORMATION RECEIVER
Color : # of pins :
12
1 FUSED B(+) (I.O.D.) A413 20RD/LB
3--
4--
7 GROUND Z909 20BK

9--
10 - -
12 GROUND Z909 20BK
Module > Component Information > Locations > Page 42
Navigation Module: Diagrams
Component ID: 169
Component : MODULE-TRAFFIC INFORMATION RECEIVER
Connector:
Name : MODULE-TRAFFIC INFORMATION RECEIVER
Color : # of pins :
12
3--
4--
7 GROUND Z909 20BK

9--
10 - -
12 GROUND Z909 20BK
Jeep Workshop Manuals > Relays and Modules > Relays and Modules - Accessories and Optional Equipment > Voice
Activation Module > Component Information > Locations
Voice Activation Module: Locations
Component ID: 157
Component : MODULE-HANDS FREE
Connector:
Name : MODULE-HANDS FREE
Color : DK. GRAY
# of pins : 22
1 FUSED B(+) (I.O.D.) A417 18RD/DG
2--
3--
5 MICROPHONE 2 IN(+) X722 20LB/DG
6--
7--
8 LEFT AUDIO OUTPUT X703 22DG/OR
9 RIGHT AUDIO OUTPUT X704 22DG/PK
10 COMMON AUDIO OUTPUT X795 22DG/BK
11 - -
12 - -
13 - -
15 VOICE RECOGNITION/PHONE SWITCH SIGNAL X730 20GY/YL
16 MICROPHONE 1 IN(+) X712 20DG/LB
17 MICROPHONE IN(-) X792 20LB/TN
18 - -
19 - -
20 MICROPHONE FEED X793 20DG/YL
21 SENSOR GROUND X835 20OR/BK
Activation Module > Component Information > Locations > Page 48
Voice Activation Module: Diagrams
Component ID: 157
Component : MODULE-HANDS FREE
Connector:
Name : MODULE-HANDS FREE
Color : DK. GRAY
# of pins : 22
2--
3--
5 MICROPHONE 2 IN(+) X722 20LB/DG
6--
7--
8 LEFT AUDIO OUTPUT X703 22DG/OR
9 RIGHT AUDIO OUTPUT X704 22DG/PK
10 COMMON AUDIO OUTPUT X795 22DG/BK
11 - -
12 - -
13 - -
15 VOICE RECOGNITION/PHONE SWITCH SIGNAL X730 20GY/YL
16 MICROPHONE 1 IN(+) X712 20DG/LB
17 MICROPHONE IN(-) X792 20LB/TN
18 - -
19 - -
20 MICROPHONE FEED X793 20DG/YL
21 SENSOR GROUND X835 20OR/BK
Jeep Workshop Manuals > Relays and Modules > Relays and Modules - Body and Frame > Keyless Entry Module >
Component Information > Locations
Keyless Entry Module: Locations
Component ID: 166
Connector:
Color : BLACK
# of pins : 8

8--
Component Information > Locations > Page 55
Keyless Entry Module: Diagrams
Component ID: 166
Connector:
Color : BLACK
# of pins : 8

8--
Component Information > Description and Operation > Description
Keyless Entry Module: Description and Operation Description
DESCRIPTION
The Sentry Key REmote Entry Module (SKREEM) (3) is sometimes referred to as the Wireless
Control Module (WCM). The SKREEM is the primary component of the Sentry Key Immobilizer
System (SKIS). It is also the receiver for the Remote Keyless Entry (RKE) system and the Tire
Pressure Monitor (TPM) system. The SKREEM is located on the right side of the steering column
near the ignition lock cylinder housing and is concealed beneath the column shrouds. The molded
black plastic housing for the SKREEM has an integral molded plastic halo-like antenna ring (1) that
extends from one side. When the SKREEM is properly installed, the antenna ring is oriented
around the circumference of the ignition lock cylinder housing.
A single integral connector receptacle (4) is located adjacent to the antenna ring on the SKREEM
housing. An integral molded plastic mounting tab (2) on the SKREEM housing has a hole in the
center through which a screw passes to secure the unit to the steering column lock housing. The
SKREEM is connected to the vehicle electrical system through a single take out and connector of
the instrument panel wire harness.
The SKREEM cannot be adjusted or repaired. If ineffective or damaged, the entire SKREEM unit
must be replaced.
Component Information > Description and Operation > Description > Page 64
Keyless Entry Module: Description and Operation Operation
OPERATION
The Sentry Key REmote Entry Module (SKREEM) (also known as the Wireless Control
Module/WCM) contains a Radio Frequency (RF) transceiver and a microprocessor. The SKREEM
transmits RF signals to, and receives RF signals from the Sentry Key transponder through a tuned
antenna enclosed within the molded plastic antenna ring integral to the SKREEM housing. If this
antenna ring is not mounted properly around the ignition lock cylinder housing, communication
problems between the SKREEM and the transponder may arise. These communication problems
will result in Sentry Key transponder-related faults.
The SKREEM also serves as the Remote Keyless Entry (RKE) RF receiver and, if the vehicle is so
equipped, the receiver for the Tire Pressure Monitoring (TPM) system. The SKREEM
communicates over the Controller Area Network (CAN) data bus with the ElectroMechanical
Instrument Cluster (EMIC) (also known as the Cab Compartment Node/CCN), the Powertrain
Control Module (PCM) or the diagnostic scan tool.
The SKREEM and the PCM both use software that includes a rolling code algorithm strategy,
which helps to reduce the possibility of unauthorized Sentry Key Immobilizer System (SKIS)
disarming. The rolling code algorithm ensures security by preventing an override of the SKIS
through the unauthorized substitution of the SKREEM or the PCM. However, the use of this
strategy also means that replacement of either the SKREEM or the PCM units will require a system
initialization procedure to restore system operation.
The SKREEM retains in memory the ID numbers of any Sentry Key transponder that is
programmed into it. A maximum of eight Sentry Key transponders can be programmed into the
SKREEM. For added system security, each SKREEM is programmed with a unique Secret Key
code. This code is stored in memory, sent over the CAN data bus to the PCM, and is encoded to
the transponder of every Sentry Key that is programmed into the SKREEM. Therefore, the Secret
Key code is a common element that is found in every component of the SKIS.
Another security code, called a PIN, is used to gain access to the SKREEM Secured Access Mode.
The Secured Access Mode is required during service to perform the SKIS initialization and Sentry
Key transponder programming procedures. The SKREEM also stores the Vehicle Identification
Number (VIN) in its memory, which it learns through a CAN data bus message from the PCM
during SKIS initialization.
In the event that a SKREEM replacement is required, the Secret Key code can be transferred to
the new SKREEM from the PCM using the diagnostic scan tool and the SKIS initialization
procedure. Proper completion of the SKIS initialization will allow the existing Sentry Keys to be
programmed into the new SKREEM so that new keys will not be required. In the event that the
original Secret Key code cannot be recovered, SKREEM replacement will also require new Sentry
Keys. The diagnostic scan tool will alert the technician during the SKIS initialization procedure if
new Sentry Keys are required.
When the key is inserted into the ignition switch and when the ignition switch is turned to the ON
position, the SKREEM transmits an RF signal to excite the transponder in the ignition key. The
SKREEM then waits for an RF signal response from the transponder. If the response received
identifies the key as valid, the SKREEM sends an electronic valid key message over the CAN data
bus. If the response received identifies the key as invalid or if no response is received from the key
transponder, the SKREEM sends an invalid key message. The PCM will enable or disable engine
operation based upon the status of the SKREEM messages. It is important to note that the default
condition in the PCM is an invalid key; therefore, if no message is received from the SKREEM by
the PCM, the engine will be disabled and the vehicle immobilized after two seconds of running.
The SKREEM also sends electronic security indicator request messages to the EMIC over the CAN
data bus to tell the EMIC how to operate the security indicator. The security indicator request
message from the SKREEM tells the EMIC to turn the indicator ON for about three seconds each
time the ignition switch is turned to the ON position as a bulb test. After completion of the bulb test,
the SKREEM sends security indicator request messages to the EMIC to turn the indicator OFF,
turn the indicator ON, or to flash the indicator ON and OFF. If the security indicator flashes or stays
ON solid after the bulb test, it signifies a SKIS fault. If the SKREEM detects a system malfunction
or the SKIS has become ineffective, the security indicator will stay ON solid. If the SKREEM
detects an invalid key or if a key transponder-related fault exists, the security indicator will flash. If
the vehicle is equipped with the Customer Learn transponder programming feature, the SKREEM
will also send messages to the EMIC to flash the security indicator whenever the Customer Learn
programming mode is being utilized.
The SKIS performs a self-test each time the ignition switch is turned to the ON position, and will
store fault information in the form of a Diagnostic Trouble Code (DTC) in SKREEM memory if a
system malfunction is detected. The hard wired circuits of the SKREEM may be diagnosed using
SKREEM or the electronic controls or communication between other modules and devices that
provide some features of the SKIS. The most reliable, efficient, and accurate means to diagnose
the SKREEM or the electronic controls and communication related to SKREEM operation requires
the use of a diagnostic scan tool. Refer to the appropriate diagnostic information.
Component Information > Description and Operation > Page 65
Keyless Entry Module: Testing and Inspection
REMOTE KEYLESS ENTRY MODULE
The most reliable, efficient, and accurate means to diagnose the power lock system requires the
use of a scan tool and the proper Diagnostic information.
Refer to the appropriate wiring information.

Component Information > Service and Repair > Removal
Keyless Entry Module: Service and Repair Removal
REMOVAL
2. Remove but do not disconnect the right multi-function switch from the integral mounting bracket
(1) on the right side of the clockspring and
position it so that the Sentry Key REmote Entry Module (SKREEM) mounting screw (2) may be
accessed.
3. Disconnect the instrument panel wire harness connector (4) from the SKREEM (3) connector
receptacle.
4. Remove the screw that secures the SKREEM to the boss on the top of the ignition lock cylinder
housing (5).
5. Disengage the SKREEM antenna ring from around the ignition lock housing and remove the
SKREEM from the steering column.
Component Information > Service and Repair > Removal > Page 68
Keyless Entry Module: Service and Repair Installation
INSTALLATION
WARNING: To avoid serious or fatal injury, on vehicles equipped with airbags, disable the
1. Position the Sentry Key REmote Entry Module (SKREEM) (3) onto the steering column ignition
lock housing with the antenna ring oriented
around the lock cylinder (5).
2. Install and tighten the screw (2) that secures the SKREEM mounting bracket to the boss on the
top of the ignition lock housing. Tighten the screw
3. Reconnect the instrument panel wire harness connector (4) to the SKREEM connector
receptacle.
4. Reinstall the right multi-function switch onto the integral mounting bracket (1) on the right side of
the clockspring.

NOTE: On vehicles equipped with the optional Sentry Key Immobilizer System (SKIS), when the
SKREEM is replaced with a new unit, a diagnostic scan tool MUST be used to initialize the new
SKREEM and to program at least two Sentry Key transponders before the vehicle can be operated.
Jeep Workshop Manuals > Relays and Modules > Relays and Modules - Body and Frame > Seat Heater Control Module >
Seat Heater Control Module: Locations
Component ID: 160
Component : MODULE-HEATED SEATS
Connector:
Name : MODULE-HEATED SEATS
Color : BLACK
# of pins : 10
A--
B--
C--
D LEFT SEAT HEATER B(+) DRIVER P187 16LG/BR
E FUSED IGNITION SWITCH OUTPUT (RUN) F937 14PK/YL
F GROUND Z960 18BK

F GROUND Z960 18BK/LB
G--
H--
J LIN BUS D506 20WT/DG
K RIGHT SEAT HEATER B(+) DRIVER P188 16LG/VT
Seat Heater Control Module: Diagrams
Component ID: 160
Component : MODULE-HEATED SEATS
Connector:
Name : MODULE-HEATED SEATS
Color : BLACK
# of pins : 10
A--
B--
C--
F GROUND Z960 18BK

F GROUND Z960 18BK/LB
G--
H--
J LIN BUS D506 20WT/DG
Seat Heater Control Module: Description and Operation Description
DESCRIPTION
The heated seat module (2) is located under the left front seat. It has a single electrical connector
(1) and a push pin style retainer that secures it to the seat pan. The module can be accessed from
under the front left seat with the seat in the full back position.
The heated seat module is a microprocessor designed to use the Local Interface Network (LIN)
data bus messages from the instrument cluster also known as the Cabin Compartment Node
(CCN). The CCN receives inputs from the heated seat switches and in turn signals the heated seat
module to operate the heated seat elements for both front seats.
Seat Heater Control Module: Description and Operation Operation
OPERATION
The heated seat module operates on fused battery current received from the ignition switch. The
module is grounded to the body at all times through the electrical connector. Inputs to the module
include Local Interface Network (LIN) data bus messages and standard hardwired 12 volt power
and ground. In response to the LIN inputs the heated seat module will control the battery current to
the appropriate heated seat elements.
When a heated seat switch LIN data bus signal is received by the heated seat module, the module
energizes the selected heated seat element. The Low heat set point is about 38° C (100.4° F), and
the High heat set point is about 42° C (107.6° F).
In addition to operating the heated seat elements, the heated seat module sends LED illumination
messages to the CCN via the LIN data bus. The CCN then sends the LED illumination message to
the accessory switch bank so that the appropriate LEDs are illuminated for any given heating level.
Pressing the switch once will select high-level heating. Pressing the switch a second time will
select low-level heating. Pressing the switch a third time will shut the heating elements off.
If the heated seat module detects a heated seat element OPEN or SHORT circuit, it will record and
store the appropriate diagnostic trouble code (DTC).
Seat Heater Control Module: Testing and Inspection
HEATED SEAT MODULE
In order to obtain conclusive testing, the heated seat system and the Local Interface Network (LIN)
data bus circuit must be checked. Any diagnosis of the heated seat system should begin with, the
use of a scan tool and the appropriate diagnostic service information.
Refer to the appropriate wiring information for complete circuit schematic or connector pin-out
information.
NOTE: Vehicles equipped with the heated seat option utilize a low voltage cut-off feature. This
feature turns off power to the heated seat system anytime vehicle voltage is below 11.7 V or above
15.5 V. Be certain to check the vehicle electrical system for proper voltage anytime the power seat
system appears inoperative.
Before any testing of the heated seat system is attempted, the battery should be fully-charged.
Seat Heater Control Module: Service and Repair Removal
REMOVAL
CAUTION: The Heated Seat Module mounting tab can be damaged during module removal and
installation. Use care to properly align tab to prevent binding that could result in tab breakage.
1. Position the right front seat to the full rearward position.
3. Disconnect the wire harness connector (4) from the heated seat module (3).
4. Unsnap the heated seat module retaining tab (2) from the seat pan (1).
5. Remove the heated seat module (3) from the vehicle.

Seat Heater Control Module: Service and Repair Installation
INSTALLATION
CAUTION: The Heated Seat Module mounting tab can be damaged during module removal and
installation. Use care to properly align tab to prevent binding that could result in tab breakage.
1. Install the heated seat module (3) into the vehicle.
2. Position the retaining tab (2) with the mounting hole in the seat pan (1). Firmly apply even
pressure to the module (3) until the mounting tab is
fully seated.
3. Connect the wire harness connector (4) to the heated seat module (3).
4. Connect the battery negative cable.
5. Check for proper heated seat system operation.

Jeep Workshop Manuals > Relays and Modules > Relays and Modules - Brakes and Traction Control > Electronic Brake
Control Module > Component Information > Technical Service Bulletins > Recalls for Electronic Brake Control Module: >
F50 > Feb > 07 > Recall - ABS Module Reprogramming
Technical Service Bulletin # F50 Date: 070212
Recall - ABS Module Reprogramming
February 2007
Dealer Service Instructions for: Safety Recall F50 Reprogram ABS Control Module
Models
2007 (LX) Chrysler 300, Dodge Charger and Magnum - built from September 7, 2006 through
November 18, 2006 (MDH 090701 - 111801).
2007 (JS) Chrysler Sebring - built from October 10, 2006 through November 15, 2006 (MDH
101019 - 111509).
2007 (PM) Dodge Caliber - built from September 7, 2006 through November 18, 2006 (MDH
090707 - 111801).
2007 (MK49) Jeep(R) Compass - built from September 7, 2006 through November 18, 2006 (MDH
090707 - 111801).
2007 (MK74) Jeep Patriot - built from September 7, 2006 through November 18, 2006 (MDH
090707 - 111801).
2007 (WK) Jeep Grand Cherokee - built from October 18, 2006 through December 6, 2006 (MDH
101813 - 120606).
2007 (XK) Jeep Commander - built from October 18, 2006 through December 6, 2006 (MDH
101813 - 120606).
2007 (KJ) Jeep Liberty - built from September 18, 2006 through November 30, 2006 (MDH 091807
- 113018).
2007 (KA) Dodge Nitro - built from September 18, 2006 through November 30, 2006 (MDH 091807
- 113018).
2007 (JK) Jeep Wrangler - built from November 9, 2006 through December 8, 2006 (MDH 110914 -
120811).
NOTE:
This recall applies only to the above vehicles equipped with an ESP/ABS system (sales code BNB,
BRF, BRY, BR1 or BR3).
IMPORTANT:
Some of the involved vehicles may be in dealer new vehicle
inventory. Federal law requires you to complete this recall service on these vehicles before retail
delivery. Dealers should also consider this requirement to apply to used vehicle inventory and
should perform this recall on vehicles in for service. Involved vehicles can be determined by using
the VIP inquiry process.
Subject
The software programmed into the Anti-Lock Brake System (ABS) control module on about 50,600
of the above vehicles may cause the rear brakes to lock up during certain braking conditions. This
could result in a loss of vehicle control and cause a crash without warning.
Repair
The ABS control module must be reprogrammed (flashed).
Parts Information
No parts are required to perform this service procedure.
Special Tools
F50 > Feb > 07 > Recall - ABS Module Reprogramming > Page 91
The existing special tools may be required to perform this repair.
NOTE:
The StarSCAN and the Star Mobile scan tools must be at version 7.03
or higher before this procedure can be performed.

Completion Reporting and Reimbursement
Claims for vehicles that have been serviced must be submitted on the DealerCONNECT Claim
Entry Screen located on the Service tab. Claims submitted will be used by DaimlerChrysler to
record recall service completions and provide dealer payments.
Use one of the labor operation numbers and time allowances shown.
Dealer Notification
All dealers will receive three copies of this dealer recall notification letter by mail.
To view this notification on DealerCONNECT, select "Global Recall System" on the Service tab,
then click on the description of this notification.
Owner Notification and Service Scheduling
All involved vehicle owners known to DaimlerChrysler are being notified of the service requirement
by first class mail. They are requested to schedule appointments for this service with their dealers.
A generic copy of the owner letter is shown.
Enclosed with each owner letter is an Owner Notification postcard to allow owners to update our
records if applicable.
Vehicle Lists, Global Recall System, VIP and Dealer Follow Up
All involved vehicles have been entered into the DealerCONNECT Global Recall System (GRS)
and Vehicle Information Plus (VIP) for dealer inquiry as needed.
GRS provides involved dealers with an updated VIN list of their incomplete vehicles.
The owner's name, address and phone number are listed if known. Completed vehicles are
removed from GRS within several days of repair claim submission.
To use this system, click on the "Service" tab and then click on "Global Recall System." Your
dealer's VIN list for each recall displayed can be sorted by: those vehicles that were unsold at
recall launch, those with a phone number, city, zip code, or VIN sequence.
Dealers must perform this repair on all unsold vehicles before retail delivery.
Dealers should also use the VIN list to follow up with all owners to schedule appointments for this
repair.
Recall VIN lists may contain confidential, restricted owner name and address information that was
obtained from the Department of Motor Vehicles of various states. Use of this information is
permitted for this recall only and is strictly prohibited from all other use.
Additional Information
If you have any questions or need assistance in completing this action, please contact your Service
and Parts District Manager.
Customer Services Field Operations DaimlerChrysler Corporation
Service Procedure
NOTE:
Reprogramming of the ABS Control Module can be performed using the StarSCAN scan tool or the
StarMOBILE scan tool.
A. Reprogram the ABS Control Module Using StarSCAN
NOTE:
The StarSCAN tool must be at version 7.03 or higher before this
procedure can be performed. The software release level is visible in the blue header at the top of
the StarSCAN screen.
1. Open the hood and install a battery charger. Verify that the charging rate provides approximately
13.5 volts.
2. Use the following procedure to determine the ABS Control Module software part number:
a. Connect the StarSCAN to the vehicle data link connector located under the steering column and
turn the ignition key to the "RUN" position.
b. Power ON the StarSCAN.
c. From the StarSCAN Home Screen, select "ECU View".
d. From the StarSCAN ECU View Screen, select "ABS" from the list of modules.
e. Select "More Options" and then select "ECU Flash".
f. Record the part number displayed at the top of the "Flash ABS" screen for later reference.
3. Connect the CH9410 ethernet cable to the StarSCAN and the dealer's network drop.
4. Select "Browse for New File" and follow the on screen instructions.
5. Highlight the calibration and then select "Download to Scantool".

6. Select "Close" after the download is complete, disconnect the ethernet cable from the scan tool
and then select "Back".
7. Highlight the listed calibration.
8. Select "Update Controller" and follow the screen instructions.
9. When the ABS control module update is complete, select "OK".
10. Verify the part number (resident flash file) at the top of the screen has updated to the new part
number.
11. After completing the ABS control module reprogramming, clear all Diagnostic Trouble Codes
(DTC's) using the following procedure:
a. Return to the "Main Menu" (Home Page).
b. Select "System View".
c. Select "All DTC's".
d. Select "Clear All Stored DTC's" and follow the screen prompts.
12. Disconnect and remove the StarSCAN and battery charger from the vehicle.
B. Reprogram the ABS Control Module Using StarMOBILE
NOTE:
The StarMOBILE scan tool must be at version 7.03 or higher before this procedure can be
performed.
13.5 volts.
2. Connect the StarMOBILE scan tool to the vehicle data link connector located under the steering
column and turn the ignition key to the "RUN" position.
3. Power ON the StarMOBILE scan tool.
4. Connect the CH9410 ethernet cable to the StarMOBILE and the dealer's network drop.
5. From the desktop, launch the "StarMOBILE Desktop Client" software.
6. From the main menu on the StarMOBILE, select "System Status".
7. Establish a connection with the StarMOBILE scan tool.
8. Select "Flash Download".
9. Select "Next" and then enter your ID and password.
10. Enter the vehicle information (manually or use the automatic function).
11. Highlight the required flash file and select "Download to Client".
12. Select "BACK" then select "ECU View".
13. Select "ABS Antilock Brakes".
14. Select "More Options".
15. Select "ECU Flash".
16. Select "Manage Files".
17. Highlight downloaded flash file.
18. Select "Copy to SM Devise" and then follow the screen prompts.
19. Disconnect the ethernet cable from the StarMOBILE scan tool.
20. Turn off the StarMOBILE scan tool and then restart the scan tool.
NOTE:
The StarMOBILE scan tool must be shut down and restarted to unlock the flash.
21. From the "System Status" screen press the "Exit" button.
22. From the "Main Menu" select "Enter Standalone Diagnostic Mode".
23. Select "ECU View" and press the select button.

24. Highlight "ABS" and press the select button.
25. Select "Flash ECU" and press the select button.
26. Verify the file number on the screen. If correct, press the select button and follow the screen
prompts.
27. When the flash is complete, press the "OK" button.
28. Clear all Diagnostic Trouble Codes (DTC's) using the following procedure:
b. From the "Home" screen, select "System View" and then select "All DTC's".
c. Select the "Clear All Stored DTC's" and follow screen prompts.
29. Disconnect the StarMOBILE scan tool and battery charger from the vehicle.
NHTSA06V493000 > Dec > 06 > Recall 06V493000: ABS Control Module Software Update
Electronic Brake Control Module: Recalls Recall 06V493000: ABS Control Module Software
Update
MAKE/MODELS: MODEL/BUILD YEARS: Chrysler/300 2007 Chrysler/Sebring 2007
Dodge/Caliber 2007 Dodge/Charger 2007 Dodge/Magnum 2007 Dodge/Nitro 2007
Jeep/Commander 2007 Jeep/Compass 2007 Jeep/Grand Cherokee 2007 Jeep/Liberty 2007
Jeep/Wrangler 2007 MANUFACTURER: DaimlerChrysler Corporation NHTSA CAMPAIGN ID
NUMBER: 06V493000 MFG'S REPORT DATE: December 22, 2006
COMPONENT: Service Brakes, Hydraulic: Antilock: Control Unit/Module
POTENTIAL NUMBER OF UNITS AFFECTED: 62369
SUMMARY: On certain vehicles, the Antilock Brake System (ABS) control module software may
cause the rear brakes to lock up during certain braking conditions.
CONSEQUENCE: This could result in a loss of vehicle control and cause a crash without warning.
REMEDY: Dealers will reprogram the ABS electronic control unit. The recall is expected to begin
during February 2007. Owners may contact DaimlerChrysler at 1-800-853-1403.
NOTES: DaimlerChrysler recall No. F50. Customers may also contact The National Highway
Traffic Safety Administration's Vehicle Safety Hotline at 1-888-327-4236 (TTY 1-800-424-9153), or
go to http://www.safercar.gov.
Control Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Electronic
Brake Control Module: > F50 > Feb > 07 > Recall - ABS Module Reprogramming
February 2007
Models
November 18, 2006 (MDH 090701 - 111801).
101019 - 111509).
090707 - 111801).
090707 - 111801).
090707 - 111801).
101813 - 120606).
101813 - 120606).
- 113018).
- 113018).
120811).
NOTE:
IMPORTANT:
Subject
Repair
Parts Information
Special Tools
Brake Control Module: > F50 > Feb > 07 > Recall - ABS Module Reprogramming > Page 105
NOTE:

Dealer Notification
repair.
Service Procedure
NOTE:
NOTE:
13.5 volts.

number.
NOTE:
performed.
13.5 volts.
NOTE:

prompts.
Brake Control Module: > NHTSA06V493000 > Dec > 06 > Recall 06V493000: ABS Control Module Software Update
Electronic Brake Control Module: All Technical Service Bulletins Recall 06V493000: ABS Control
Module Software Update
Control Module > Component Information > Technical Service Bulletins > Page 114
Electronic Brake Control Module: Locations
Component ID: 151
Component : MODULE-ANTI-LOCK BRAKES
Connector:
Name : MODULE-ANTI-LOCK BRAKES
Color : BLACK
# of pins : 47
Gender : FEMALE
1 FUSED B(+) (PUMP) A921 12RD/DB
2--
3--
4--
5--
6--
7--
8 IGNITION SWITCH OUTPUT (RUN-START) F202 18PK/GY
9--
10 - -
11 - -
12 CAN C BUS (+) D65 20WT/BK
13 CAN C BUS (-) D64 20WT/LB
14 - -
15 - -
17 - -
18 DYNAMICS SENSOR HIGH DATA LINK D465 20WT/DB
19 DYNAMICS SENSOR LOW DATA LINK D464 20WT/YL
20 - -
21 - -
22 DYNAMICS SENSOR SUPPLY G4 18VT/LB
23 - -
24 - -
25 - -
26 - -
27 - -
28 - -
29 DYNAMICS SENSOR GROUND G94 18VT/DB
30 - -
31 - -
32 FUSED B(+) (VALVE) A922 14RD/BK
33 RIGHT FRONT WHEEL SPEED SENSOR SIGNAL B6 20WT/DB
34 RIGHT FRONT WHEEL SPEED SENSOR 12 VOLT SUPPLY B7 20WT

35 HILL DESCENT RELAY CONTROL B122 20DG/LG
36 LEFT REAR WHEEL SPEED SENSOR 12 VOLT SUPPLY B4 20LG/BK
37 LEFT REAR WHEEL SPEED SENSOR SIGNAL B3 20LG/DB
38 - -
39 - -
40 - -
41 - -
42 RIGHT REAR WHEEL SPEED SENSOR SIGNAL B1 20YL/DB
43 RIGHT REAR WHEEL SPEED SENSOR 12 VOLT SUPPLY B2 20DG/LB
44 - -
45 LEFT FRONT WHEEL SPEED SENSOR 12 VOLT SUPPLY B9 20DG/LG

46 LEFT FRONT WHEEL SPEED SENSOR SIGNAL B8 20DG/TN
Electronic Brake Control Module: Diagrams
Component ID: 151
Connector:
Color : BLACK
# of pins : 47
Gender : FEMALE
2--
3--
4--
5--
6--
7--
9--
10 - -
11 - -
14 - -
15 - -
17 - -
20 - -
21 - -
23 - -
24 - -
25 - -
26 - -
27 - -
28 - -
30 - -
31 - -

38 - -
39 - -
40 - -
41 - -
44 - -

Control Module > Component Information > Description and Operation > Description
Electronic Brake Control Module: Description and Operation Description
DESCRIPTION
The Antilock Brake Module (ABM) is a microprocessor-based device which monitors the antilock
brake system (ABS) during normal braking and controls it when the vehicle is in an ABS stop or
when in a traction control or Electronic Stability Program (ESP) situation. The ABM utilizes a
47-way electrical connector on the vehicle wiring harness. The power source for the ABM is
through the ignition switch in the RUN or ON position.
The ABM (1) is mounted to the HCU (2) as part of the Integrated Control Unit (ICU). The ICU is
located in the engine compartment on the inboard side of the right body frame rail behind the strut
tower. For information on the ICU.
Control Module > Component Information > Description and Operation > Description > Page 122
Electronic Brake Control Module: Description and Operation Operation
OPERATION
The primary functions of the Antilock Brake Module (ABM) are to:
- Monitor the Antilock Brake System (ABS) and Electronic Stability Program (ESP) for proper
operation.
- Detect wheel locking or wheel slipping tendencies by monitoring the speed of all four wheels of
the vehicle.
- Control fluid modulation to the wheel brakes while the system is in ABS or traction control mode.
- Modulates fluid pressure to the wheel brakes to control vehicle yaw rate in ESP mode.
- Store diagnostic information.
- Provide communication to the scan tool while in diagnostic mode.
- Illuminate the amber ABS indicator in the instrument cluster.
- Illuminate the yellow ESP/BAS indicator in the instrument cluster (if equipped).
The ABM constantly monitors the ABS and ESP (if equipped) for proper operation. If the ABM
detects a fault, it will turn on the amber ABS and yellow ESP/BAS indicators and disable the ABS
or ESP if so equipped. The normal base braking system will remain operational at that time.
The ABM continuously monitors the speed of each wheel through the signals generated by the
wheel speed sensors to determine if any wheel is beginning to lock. When a wheel locking
tendency is detected, the ABM commands the ABM solenoid coils to actuate. The coils then open
and close the valves in the HCU that modulate brake fluid pressure in some or all of the hydraulic
circuits. The ABM continues to control pressure in individual hydraulic circuits until a locking
tendency is no longer present.
Control Module > Component Information > Service and Repair > Removal
Electronic Brake Control Module: Service and Repair Removal
REMOVAL
Due to packaging and limited space it is necessary to remove and disassemble the Integrated
Control Unit (ICU) to service the Antilock Brake Module (ABM) on this vehicle.
Control Module > Component Information > Service and Repair > Removal > Page 125
Electronic Brake Control Module: Service and Repair Installation
INSTALLATION
Due to packaging and limited space it is necessary to install the Antilock Brake Module (ABM) on
the Hydraulic Control Unit (HCU), then install the Integrated Control Unit (ICU) on the vehicle as an
assembly.
Jeep Workshop Manuals > Relays and Modules > Relays and Modules - Brakes and Traction Control > Traction Control
Relay > Component Information > Diagrams
Traction Control Relay: Diagrams
Component ID: 186
Component : RELAY-HILL DESCENT
Connector:
Name : RELAY-HILL DESCENT
Color : # of pins :
C6 FUSED B(+) A924 20DG/WT
C7 STOP LAMP SWITCH OUTPUT L53 20DG/WT
C8 - -
C10 HILL DESCENT RELAY CONTROL B122 20DG/LG

Jeep Workshop Manuals > Relays and Modules > Relays and Modules - Cooling System > Radiator Cooling Fan Motor
Relay > Component Information > Locations
Radiator Cooling Fan Motor Relay: Locations
Radiator Fan Relays are located in the Fuse/Relay Block.

Relay > Component Information > Diagrams > Radiator Fan High/Low Relay (In F/RB)
Radiator Cooling Fan Motor Relay: Diagrams Radiator Fan High/Low Relay (In F/RB)
Radiator Fan-Low/High Relay

Relay > Component Information > Diagrams > Radiator Fan High/Low Relay (In F/RB) > Page 135
Radiator Cooling Fan Motor Relay: Diagrams Radiator Fan High/Medium Relay (In F/RB)
Radiator Fan-Medium/High Relay

Relay > Component Information > Diagrams > Radiator Fan High/Low Relay (In F/RB) > Page 136
Radiator Cooling Fan Motor Relay: Diagrams Radiator Fan Series/Parallel Relay (In F/RB)
Radiator Fan-Series/Parallel Relay

Jeep Workshop Manuals > Relays and Modules > Relays and Modules - Instrument Panel > Instrument Panel Control
Module > Component Information > Technical Service Bulletins > Customer Interest for Instrument Panel Control Module: >
08-039-06 > Aug > 06 > Instruments - Odometer/Trip Switch Not Responsive
Instrument Panel Control Module: Customer Interest Instruments - Odometer/Trip Switch Not
Responsive
NUMBER: 08-039-06
GROUP: Electrical
DATE: August 29, 2006
SUBJECT: Flash - Odometer/Trip Switch Not Responsive
OVERVIEW:
This bulletin involves Flash Reprogramming the Instrument Cluster, Cabin Compartment Node
(CCN).
NOTE:
The StarMOBILE(TM) in standalone mode cannot be used for the flash.
MODELS:
2007 (MK-49) Compass
NOTE:
This bulletin applies to vehicles built before August 1, 2006 (MDH 0801XX).
SYMPTOM/CONDITION:
The CCN will not respond to the odometer/trip switch when pressed. This condition will temporarily
clear itself if a new warning message is displayed in the odometer.
DIAGNOSIS:
Using a Scan Tool (StarSCAN(R)) with TechCONNECT and the appropriate Diagnostic
Procedures, verify all systems are functioning as designed. If DTC's are present, record them on
the repair order and repair as necessary before proceeding further with this bulletin.
If the customer describes the Symptom/Condition, perform the Repair Procedure.

SPECIAL TOOLS/EQUIPMENT REQUIRED:
REPAIR PROCEDURE - USING THE INTERNET TO RETRIEVE THE FLASH FILE:
NOTE:
NOTE:
USE THE StarSCAN(R) TO PERFORM THIS PROCEDURE.
NOTE:
Before performing this Repair Procedure, the operating software in the StarSCAN(R); must be
programmed with software release level 7.01 or higher.
08-039-06 > Aug > 06 > Instruments - Odometer/Trip Switch Not Responsive > Page 146
The software release level is visible in the blue header at the top of the StarSCAN(R) screen.
NOTE:
The StarSCAN(R) diagnostic scan tool fully supports Internet connectivity. However, to take
advantage of this feature you must first configure the StarSCAN(R) for your dealership's network.
Make sure the StarSCAN(R) is configured to the dealership's network before proceeding. For
instruction on setting up your StarSCAN(R) for the dealer's network refer to either:
"DealerCONNECT > Service > StarSCAN and StarMOBILE tools > Online Documentation", or refer
to the StarSCAN(R) Quick Start Networking Guide. The StarSCAN(R) Quick Start Networking
Guide is also available on the website under the "Download Center".
NOTE:
If this flash process is interrupted/aborted, the flash should be restarted.
1. Install a battery charger and verify that the charging rate provides approximately 13.5 volts. Set
the battery charger to continuous charge. Do not allow the charger to time out during the flash
process. Remove the charger from the battery when the flash process is complete.
2. Connect the CH9410 StarSCAN(R) ethernet cable to the StarSCAN(R) and the dealer's network
drop.
3. Connect the CH9404 StarSCAN(R) vehicle cable to the StarSCAN(R) and the vehicle data link
connector (DLC).
4. Power ON the StarSCAN(R).
5. Select "ECU View"
6. Touch the screen to highlight the CCN in the list of modules.
7. Select "More Options"
9. Record the "Part Number", displayed on the "Flash CCN" screen, for later reference.
10. Select "Browse for New File". Follow the on screen instructions.
11. Highlight the listed CCN calibration.
12. Select "Download to Scantool".
13. Select "Close" after the download is complete, then select "Back".
14. Select "Update Controller". Follow the on screen instructions.

15. When the CCN update is complete, select "OK". update is complete, select "OK".
16. Verify that the part number changed at the top of the "Flash CCN" screen.
NOTE:
Due to the CCN programming procedure, a DTC may be set in other modules (TCM, BCM,
SKREEM, etc.) within the vehicle, if so equipped. Some DTC's may cause the MIL to illuminate.
From the "Home" screen select "System View". Then select "All DTCs". Press "Clear All Stored
DTCs" if there are any DTCs shown on the list.
POLICY: Reimbursable within the provisions of the warranty.
TIME ALLOWANCE:
FAILURE CODE:
Disclaimer:
This bulletin is supplied as technical information only and is not an authorization for repair.
Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Instrument Panel
Control Module: > 08-039-06 > Aug > 06 > Instruments - Odometer/Trip Switch Not Responsive
Instrument Panel Control Module: All Technical Service Bulletins Instruments - Odometer/Trip
Switch Not Responsive
NUMBER: 08-039-06
GROUP: Electrical
OVERVIEW:
(CCN).
NOTE:
MODELS:
NOTE:
SYMPTOM/CONDITION:
DIAGNOSIS:

NOTE:
NOTE:
NOTE:
Control Module: > 08-039-06 > Aug > 06 > Instruments - Odometer/Trip Switch Not Responsive > Page 153
NOTE:
NOTE:
drop.
connector (DLC).

NOTE:
TIME ALLOWANCE:
Control Module: > 08-039-06 > Aug > 06 > Instruments - Odometer/Trip Switch Not Responsive > Page 154
FAILURE CODE:
Disclaimer:
Jeep Workshop Manuals > Relays and Modules > Relays and Modules - Lighting and Horns > Horn Relay > Component
Information > Service and Repair > Removal
Horn Relay: Service and Repair Removal
REMOVAL
2. Remove cover from Totally Integrated Power Module (TIPM).
3. Using special tool C-4817 (1), grip the relay (2) by the sides and pull upward with an even effort.
Jeep Workshop Manuals > Relays and Modules > Relays and Modules - Lighting and Horns > Horn Relay > Component
Information > Service and Repair > Removal > Page 160
Horn Relay: Service and Repair Installation
INSTALLATION
1. Align relay (2) with Totally Integrated Power Module (TIPM) and press into position.
2. Install cover to TIPM.
3. Connect battery negative cable.

Jeep Workshop Manuals > Relays and Modules > Relays and Modules - Power and Ground Distribution > Power
Distribution Module > Component Information > Technical Service Bulletins > Recalls: > G42 > Jan > 08 > Campaign -
TIPM Software Update for Antitheft System
Technical Service Bulletin # G42 Date: 080101
Campaign - TIPM Software Update for Antitheft System
January 2008
Distributor/Dealer Service Instructions for: Customer Satisfaction Notice G42 TIPM Re-Configure,
Anti-Theft System
Models
2007 2008 (JS/PM/MK) Sebring, Avenger, Caliber, Compass and Patriot vehicles (International
Markets Only)
NOTE:
This customer satisfaction notice applies only to the above vehicles built at the Sterling Heights
Assembly Plant through July 25, 2007 (MDH 0725XX) and the Belvidere Assembly Plant through
July 23, 2007 (MDH 0723XX).
IMPORTANT:
Many of the vehicles within the above build period have already been inspected or repaired and,
therefore, have been excluded from this customer satisfaction notice.
IMPORTANT:
Some of the involved vehicles may be in distributor/dealer used vehicle inventory.

Distributors/Dealers should complete this recall service on these vehicles before retail delivery.
Distributors/Dealers should also perform this repair on vehicles in for service. Involved vehicles can
be determined by using the VIP inquiry process.
Subject
The Totally Integrated Power Module (TIPM) vehicles may be configured incorrectly preventing the
Anti-Theft Security System from operating properly.
Repair
The Totally Integrated Power Module (TIPM) must be Re-Configured.
Special Tools
These existing special tools are required to perform this repair.
Entry Screen located on the Service tab. Claims submitted will be used by Chrysler to record recall
service completions and provide dealer payments.
TIPM Software Update for Antitheft System > Page 170
Use the labor operation number and time allowance shown.
Distributor/ Dealer Notification and Vehicle List
Regional offices will receive an electronic list of involved vehicles. The Vehicle List is arranged by
Distributor/Dealer code and in Vehicle Identification Number (VIN) sequence. The lists are for
Distributor/Dealer reference in arranging for service of involved vehicles.
All involved vehicle owners should be notified of the service requirement by their Distributor/Dealer.
Owners are requested to schedule appointments for this service. A sample copy of the owner
notification letter is included.
Vehicle Lists, Global Recall System, VIP and Distributor/Dealer Follow up
All involved vehicles have been entered into the Global Recall System (GRS) and Vehicle
Information Plus (VIP) for Distributor/Dealer inquiry as needed.
GRS provides involved Distributors/Dealers with an updated VIN list of their incomplete vehicles.
Completed vehicles are removed from GRS within several days of repair claim submission.
Distributors/Dealers must perform this repair on all unsold vehicles before retail delivery.
Distributors/Dealers should also use the VIN list to follow up with all owners to schedule
appointments for this repair.
If you have any questions or need assistance in completing this action, please contact your
International Service and Parts Manager.
Global Service & Parts - International Chrysler LLC
Service Procedure
NOTE:
Use StarSCAN(R) to perform this Customer Satisfaction Notice. This procedure must be performed
using software release 8.02 or higher.
Re-Configure the TIPM using StarSCAN(R)

1. Open the hood. Install a battery charger and verify that the charging rate provides 13.0 to 13.5
volts. Do not allow the charger to time out during the process. Set the battery charger timer (if so
equipped) to continuous charge.
NOTE:
Use an accurate stand alone voltmeter. The battery charger voltmeter may not be sufficiently
accurate. Voltages outside of the specified range will cause an unsuccessful flash. If voltage
reading is too high, apply an electrical load by activating the park or headlamps and/or HVAC
blower motor to lower the voltage.
2. Connect the CH9410 StarSCAN(R) Ethernet cable to the StarSCAN(R) and the dealer's network
drop.
3. Connect the CH9404 StarSCAN® vehicle cable to the StarSCAN(R) and the vehicle.
4. Place the Ignition in the "RUN" position, then Power "ON" the StarSCAN(R).
5. Re-Configure the TIPM as Follows:
a. With the StarSCAN(R) on the "Home" screen, select "ECU View".
b. Select "TIPMCGW Central Gateway" in the list of modules.
c. Select "Misc Functions".

d. Select "Restore Vehicle Configuration".
e. Press "Start".
f. Follow the prompts listed on the StarSCAN(R).
g. When prompted, Enter the full 17 digit VIN found on the VIN plate.
NOTE:
Assure the correct VIN is input into the StarSCAN(R).
h. Select "Next".
NOTE:
The StarSCAN(R) must be connected to the dealer network drop.
i. Follow the prompts listed on the StarSCAN(R).
6. Check and clear any Diagnostic Trouble Codes (DTC's) that may have been set.
7. Turn the ignition key to the "OFF" position and remove the StarSCAN(R) unit, StarSCAN(R)
cable, and battery charger from the vehicle.
Distribution Module > Component Information > Technical Service Bulletins > Recalls: > G19 > Jun > 07 > Recall - Daytime
Running Lamp Reconfiguration
Recall - Daytime Running Lamp Reconfiguration
Revised G19
2007-05-15
To: All Dealers of DaimlerChrysler Canada Inc.
SUBJECT: SAFETY RECALL G19 RECONFIGURE TIPM DAYTIME RUNNING LAMPS
MODELS: 2007 (MK) Jeep(R) Compass and Patriot
NOTE:
This notification applies only to the above vehicles equipped with the trail rated option (sales code
DAW) built from January 23, 2007 through March 23, 2007 (MDH: 01-23-00 through 03-23-18).
Recall information for Canadian Dealers is now available on DealerCONNECT See Group 30
CANADIAN RECALLS DealerCONNECT > Service > Repair > TechCONNECT > Group 30
CANADIAN RECALLS
^ The Daytime Running Lamp option on about 120 of the above vehicles was inadvertently
deactivated when they were manufactured and is inoperative.
^ To correct this condition, the TIPM configuration must be reset.
Details of this service action are explained in the following section.
IMPORTANT:
Some of the involved vehicles may be in your new/used vehicle dealer inventory. Be sure to
complete the recall service on these vehicles before retail delivery.
Vehicle List
Involved Dealers
Each dealer to whom involved vehicles in this recall were invoiced (or current dealer at the same
location) has available through DealerCONNECT a Dealer Vehicle Listing arranged in Vehicle
Identification Number (VIN) sequence. Available names and addresses known to DaimlerChrysler
Canada are also listed. These lists are for use by dealers to arrange for service of involved
vehicles.
DealerCONNECT > Service > Reports & Information > Global Recall System > Recall & Selection
Criteria
Non-Involved Dealers
If no VIN list is available in DealerCONNECT for your dealer code, then this letter is for your
information and to assist you in providing the recall service to transient owners or other involved
vehicles, which you may encounter. THE SUCCESS OF RECALL COMPLETION WILL BE
GREATLY HELPED BY GOOD DEALER FOLLOW-UP.
All owners of involved vehicles known to DaimlerChrysler Canada are being notified of the service
requirement by first class mail. They are requested to schedule service appointments with their
dealers at the earliest possible date. A copy of the notification letter is included. A Service
Authorization Card is enclosed with each customer letter. Owners are instructed to present the card
to their dealer at the time of recall service.
Service Authorization Cards for each vehicle whose owner is not known to DaimlerChrysler
Canada will be mailed to the dealer to whom the vehicle was invoiced (or the current dealer at the
same location) for dealer follow-up.
NOTE:
Every dealer is responsible for scheduling of campaign service for all involved vehicles upon
request. At the time of ANY SERVICE, enter the vehicle VIN into DealerCONNECT VIP for
outstanding recalls. Advise the customer of any recalls which are still outstanding and offer to do
the repairs (schedule a future service appointment if parts are not available). This action will help
toward our common goal of completing the recalls, and will contribute to overall customer
satisfaction.
DealerCONNECT > Service > Writeup > VIP > Single VIN Inquiry > Recall Tab Vehicle Lists,
Global Recall System, VIP and Dealer Follow up
Running Lamp Reconfiguration > Page 176
and Vehicle Information Plus (VIP) at the time of recall implementation for dealer inquiry as
needed.
GRS provides involved dealers with an updated VIN list of their incomplete vehicles. The owner's
name, address and phone number are listed if known. Any incorrect owner information should be
updated using the owner update application in DealerCONNECT
DealerCONNECT > Sales > Sales Reporting > Time of Sales Reporting > Used Sales > Owner
Update
recall launch, those with a phone number, city, postal code, or VIN sequence.
Dealers must perform this repair on all unsold vehicles before retail delivery. Dealers should also
use the VIN list to follow up with all owners to schedule appointments for this repair.
NOTE:
Recall VIN lists may contain confidential owner name and address information that was obtained
from the Provincial Registrars Offices as well as other sources. Use of this information is permitted
for recall purposes only and is strictly prohibited from all other use.
Completion Status Reporting
When a vehicle has been serviced, submit your claim through DealerCONNECT. Your completion
will automatically be recorded in Windsor and in a few days, the VIN will be removed from the
GRS.
Check the name and address on the Service Authorization Card and if there are any changes,
complete customer name and address update in DealerCONNECT.
PARTS INFORMATION
No parts are required for this repair.
SPECIAL TOOLS
The special tools are required to perform this repair:
REIMBURSEMENT
When the campaign service is completed, submit your claim using DealerCONNECT. The recall
number can be identified from the Customer's Service Authorization Card or from
DealerCONNECT.
Use the Labour Operation Number and Time Allowance for reimbursement and add the cost of the
campaign part(s) to your claim.
Please follow the above reimbursement procedure. Failure to do so will result in a delay in
processing your claim.
and Parts District Manager (SPDM) or Business Centre.
Service Procedure
NOTE:
The StarSCAN tool software must be at version 7.04 or higher before this procedure can be
performed.
A. Program the TIPM
1. Open the hood and remove the inlet air duct over the battery.
2. Install a battery charger. Verify that the charging rate provides approximately 13.5 volts. Do not
allow the charger to time out during the reconfiguration process. Set the battery charger timer (if so
3. Connect the CH9410 StarSCAN ethernet cable to the StarSCAN and the dealer's network drop.
4. Connect the CH9404 StarSCAN vehicle cable to the StarSCAN and the vehicle.
5. Place the Ignition in the "RUN" position, then Power "ON" the StarSCAN.
6. Select "ECU View".
7. Select "TIPM/CGW".
8. Select "MISC".
9. Select "Restore Vehicle Configuration".
10. Press "START"
11. Press "Next".
12. A selection box will appear on the StarSCAN screen. Scroll down and select "07 MK".
13. Press "Next".
14. When prompted, enter the full 17 digit VIN.
15. Press "Next".
16. Press "Next" again.
17. Press "OK".
18. When prompted, enter your User ID and Password.
19. Press "OK".
20. Press "Next" to configure the vehicle.
21. Press "Next".
22. Press "Finish".
23. Wait one minute and turn the ignition key to the "OFF" position.
24. Remove the StarSCAN unit, StarSCAN cable and charger from the vehicle.
25. Install the inlet air duct.
26. Check DRL for proper operation. Start the engine and fully release the park brake. Apply the
service brakes and place the transmission selector into "Drive" (D). The DRL should illuminate.
Distribution Module > Component Information > Technical Service Bulletins > Customer Interest: > 08-007-08A > Jul > 08 >
Antitheft System - Engine No Crank/No Start Condition
Power Distribution Module: Customer Interest Antitheft System - Engine No Crank/No Start
Condition
NUMBER: 08-007-08 REV. A
GROUP: Electrical
DATE: July 04,2008
THIS BULLETIN SUPERSEDES TECHNICAL SERVICE BULLETIN 08-007-08, DATED MARCH

04, 2008. THIS IS A COMPLETE REVISION AND NO ASTERISKS HAVE BEEN USED TO
HIGHLIGHT REVISIONS.
DO NOT ORDER PART NUMBER 05026070AP UNTIL JULY 21, 2008. ALL OTHER PART
NUMBERS ARE AVAILABLE NOW.
SUBJECT: No Engine Crank Or No Engine Start Due To Electronic Lockup Of The WCM /
SKREEM
OVERVIEW: This bulletin involves the replacement of the Wireless Control Module (WCM), and if
equipped, the replacement of the Electric Steering Column Lock (ELV). The WCM is also referred
to as the Sentry Key Remote Entry Module (SKREEM).
MODELS:
2007 - 2008 (DR/DH/D1/DC/DM) Ram Truck (1500/2500/3500/4500/5500)
2007 - 2008 (JK) Wrangler
2007 - 2008 (J1) Sebring (China)
2007 - 2008 (JS) Avenger/Sebring
2007 - 2008 (KA) Nitro
2008 (KK) Liberty/Cherokee
2007 - 2008 (MK) Compass/Patriot
2007 - 2008 (PM) Caliber
2006 - 2008 (PT) Chrysler PT Cruiser
NOTE:
This bulletin applies to vehicles built on or before May 05, 2008 (MDH 0505XX).
SYMPTOM/CONDITION: The customer will experience a no engine crank AND a no engine start
condition. Also, the remote keyless entry (RKE) system will not operate. This condition may be due
to an electrostatic discharge (ESD) from the ignition key into the Wireless Control Module (WCM),
causing the WCM to electronically lockup. This condition may occur more frequently in dry and/or
cold weather conditions where a sufficient electrostatic charge is more easily produced. This
condition is corrected by the replacement of the WCM.
DIAGNOSIS:
1. With the condition present (i.e. the vehicle in the no crank / no start condition), connect the
StarSCAN(R) scan tool to the vehicle.
2. Turn the ignition switch to the "ON position, and power up the StarSCAN(R).
3. If the WCM is electronically locked up, the StarSCAN(R) will display the WCM as being "off bus".
4. If the no crank / no start condition is present, and the WCM is "off bus", then reset the WCM by
temporarily removing the IOD fuse (with the key out of the ignition switch), wait for 10 seconds and
then reinstall the IOD fuse.
5. With the IOD fuse reset having been performed, verify that the vehicle will now crank, start, and
run.
6. If the condition is temporarily corrected by performing the above steps, and if the part number of
the WCM is earlier than the part number of the WCM listed in the part reference table in the
Service Bulletin Parts Required Section below, then perform the Repair Procedure.
Antitheft System - Engine No Crank/No Start Condition > Page 185
PARTS REQUIRED:
NOTE:
The part numbers listed in the following part reference table are to be used as A GUIDE to help
determine if the WCM, that is currently in the vehicle, may require replacement. If it is determined
that the WCM requires replacement, then ALWAYS REFER TO THE PARTS MANUAL to
determine the correct WCM for the specific vehicle in question. In some earlier model years, the
WCM may rule (supersede) to one of the part numbers listed in the table. ALWAYS REFER TO
THE PARTS MANUAL (not the part reference table) to determine the correct part number ruling
(supercedence / substitution). MAKE CERTAIN THAT THE CORRECT WCM IS ORDERED THE
FIRST TIME FOR THE SPECIFIC VEHICLE IN QUESTION.
REPAIR PROCEDURE:
NOTE:
If the vehicle (a JS model vehicle in certain International markets) is equipped with an Electric
Steering Column Lock (ELV), then the WCM and the ELV must be replaced. Replace the WCM
and then the ELV. Next program the WCM and at least one (1) ignition key BEFORE programming
the ELV. IMPORTANT: Not following this repair process correctly will cause the new ELV to fail.
NOTE:
Insert the ignition key into the ignition lock cylinder. This will move the shaft lock module locking
bolt to the unlocked position. LEAVE the key in the lock cylinder while the shaft lock module is
being removed.
1. If vehicle is equipped with a Steering Shaft Lock Module (JS - Avenger I Stratus - some
International Markets), then the Shaft Lock Module will require replacement. From the Service Info
tab select: 8 - Electrical > Vehicle Theft Security - Security Information > Module, Shaft Lock >
Removal and Installation.
NOTE:
The shaft lock module cannot be removed from the steering column while the locking bolt is in the
locked position without irreversibly damaging the column. Before attempting service, the ignition
key must have been inserted into the ignition lock cylinder. Then rotate the steering wheel from
side to side. If the steering wheel can be rotated, the locking bolt is in the unlocked position. Leave
the key in the ignition lock cylinder until shaft lock module removal has been completed. If the
steering wheel cannot be rotated, test and repair the wiring circuits between the module and the
ignition switch as required. If no problem is found in these circuits, the module has failed with the
locking bolt in the locked position and both the module and the steering column must be replaced
with new units.
2. Replace the WCM/SKREEM. Refer to TechCONNECT for detailed service information. From the
Service Info tab select: 8 - Electrical > Vehicle Theft Security - Service Information > Module,
Sentry Key Remote Entry > Removal and Installation.
NOTE:
Obtain the vehicle PIN number prior to programming WCM/SKREEM or ELV.
NOTE:
If during the following steps the PIN number is properly entered but is rejected, then reenter the
PIN number again until it is accepted.
3. After both the WCM/SKREEM and the ELV (if equipped) have been replaced, Program the
WCM/SKREEM as follows:
a. Turn the ignition key to the ON position, (Engine Off)
b. Connect the scan tool (StarSCAN(R)) to the data link connector and turn the ignition to the RUN
position, (engine off).
c. Select "ECU View."
d. Scroll down and select "WCM" in the list of modules.
e. Select "Misc. Functions."
f. Scroll to "WCM Replaced."
g. Press "Start".
h. Press "Next".
i. Select "Show Keyboard".
j. Enter the vehicle PIN number.
k. Select "Next".
l. Verify PIN is correct.
m. Select "Next".
n. Follow on-screen prompts to complete WCM function programing for Tire Pressure Monitoring
(TPM) and so on.
0. Turn the ignition key to the OFF position. Wait 30 seconds.
p. Turn the ignition key to the ON position, (Engine Off)

q. Select "ECU View".
r. Scroll down and select "WCM" in the list of modules.
s. Select "Misc. Functions."
t. Select "Program Ign. Keys" and follow on-screen prompts.
u. Select "Complete".
v. Verify ignition key will start vehicle and the Remote Keyless Entry (RKE) functions operate.
CAUTION:
If the vehicle is equipped with a Shaft Lock Module (used in some International Markets on JS
model vehicles), then at least one (1 ignition key must have been programmed to the new WCM
BEFORE the new Shaft Lock Module is "married" to the new WCM.
4. Is the vehicle equipped with Steering Shaft Lock Module (ELV)?
a. Yes >> Proceed to Step # 5.
b. No >>Repair is complete.
5. Program the ELV as follows;
a. Select "ECU View".
b. Scroll down and select "WCM" in the list of modules.
c. Select "Misc. Functions".
d. Scroll to "ELV Replaced."
e. Press "Start".
f. When complete, verify steering shaft lock mechanism is operating. Remove and insert key from
the ignition lock cylinder and listen for solenoid "click at lower end of column.
TIME ALLOWANCE:
FAILURE CODE:
Disclaimer:
Distribution Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Power
Distribution Module: > 08-007-08A > Jul > 08 > Antitheft System - Engine No Crank/No Start Condition
Power Distribution Module: All Technical Service Bulletins Antitheft System - Engine No Crank/No
Start Condition
GROUP: Electrical
DATE: July 04,2008

SKREEM
MODELS:
2007 - 2008 (KA) Nitro
2007 - 2008 (PM) Caliber
NOTE:
DIAGNOSIS:
run.
Distribution Module: > 08-007-08A > Jul > 08 > Antitheft System - Engine No Crank/No Start Condition > Page 194
PARTS REQUIRED:
NOTE:
REPAIR PROCEDURE:
NOTE:
NOTE:
being removed.
NOTE:
with new units.
NOTE:
NOTE:
g. Press "Start".
h. Press "Next".
k. Select "Next".
m. Select "Next".
(TPM) and so on.

CAUTION:
e. Press "Start".
TIME ALLOWANCE:
FAILURE CODE:
Disclaimer:
Distribution Module: > G42 > Jan > 08 > Campaign - TIPM Software Update for Antitheft System
January 2008
Anti-Theft System
Models
Markets Only)
NOTE:
July 23, 2007 (MDH 0723XX).
IMPORTANT:
IMPORTANT:

Subject
Repair
Special Tools
Distribution Module: > G42 > Jan > 08 > Campaign - TIPM Software Update for Antitheft System > Page 202
Service Procedure
NOTE:

NOTE:
drop.

e. Press "Start".
NOTE:
h. Select "Next".
NOTE:
Distribution Module: > G19 > Jun > 07 > Recall - Daytime Running Lamp Reconfiguration
Revised G19
2007-05-15
NOTE:
CANADIAN RECALLS
IMPORTANT:
Vehicle List
Involved Dealers
vehicles.
Criteria
NOTE:
satisfaction.
Distribution Module: > G19 > Jun > 07 > Recall - Daytime Running Lamp Reconfiguration > Page 208
needed.
Update
NOTE:
GRS.
PARTS INFORMATION
SPECIAL TOOLS
REIMBURSEMENT
DealerCONNECT.
Service Procedure
NOTE:
performed.
A. Program the TIPM
8. Select "MISC".
10. Press "START"
11. Press "Next".
13. Press "Next".
15. Press "Next".
17. Press "OK".
19. Press "OK".
21. Press "Next".
22. Press "Finish".
Distribution Module > Component Information > Technical Service Bulletins > All Other Service Bulletins for Power
Start Condition
GROUP: Electrical
DATE: July 04,2008

SKREEM
MODELS:
2007 - 2008 (KA) Nitro
2007 - 2008 (PM) Caliber
NOTE:
DIAGNOSIS:
run.
PARTS REQUIRED:
NOTE:
REPAIR PROCEDURE:
NOTE:
NOTE:
being removed.
NOTE:
with new units.
NOTE:
NOTE:
g. Press "Start".
h. Press "Next".
k. Select "Next".
m. Select "Next".
(TPM) and so on.

CAUTION:
e. Press "Start".
TIME ALLOWANCE:
FAILURE CODE:
Disclaimer:
January 2008
Anti-Theft System
Models
Markets Only)
NOTE:
July 23, 2007 (MDH 0723XX).
IMPORTANT:
IMPORTANT:

Subject
Repair
Special Tools
Service Procedure
NOTE:

NOTE:
drop.

e. Press "Start".
NOTE:
h. Select "Next".
NOTE:
Revised G19
2007-05-15
NOTE:
CANADIAN RECALLS
IMPORTANT:
Vehicle List
Involved Dealers
vehicles.
Criteria
NOTE:
satisfaction.
needed.
Update
NOTE:
GRS.
PARTS INFORMATION
SPECIAL TOOLS
REIMBURSEMENT
DealerCONNECT.
Service Procedure
NOTE:
performed.
A. Program the TIPM
8. Select "MISC".
10. Press "START"
11. Press "Next".
13. Press "Next".
15. Press "Next".
17. Press "OK".
19. Press "OK".
21. Press "Next".
22. Press "Finish".
Distribution Module > Component Information > Locations > Module-Inverter
Power Distribution Module: Locations Module-Inverter
Component ID: 162
Component : MODULE-INVERTER
Connector:
Name : MODULE-INVERTER
Color : # of pins :
Qualifier : (EXCEPT EXPORT)
1 FUSED B(+) A999 16RD/PK
2--
3 110 VOLT AC LINE 1 P801 18LG/PK
4 GROUND Z940 14BK/LG
5 INVERTER ENABLE SWITCH SIGNAL P805 18LG/DB
6--
7--
8 110 VOLT AC COMMON P809 18LG/LB
9--
Distribution Module > Component Information > Locations > Module-Inverter > Page 238
Power Distribution Module: Locations Totally Integrated Power Module
Totally Integrated Power Module (TIPM)

Distribution Module > Component Information > Diagrams > Module-Totally Integrated Power
Power Distribution Module: Diagrams Module-Totally Integrated Power
Component ID: 168
Component : MODULE-TOTALLY INTEGRATED POWER
Connector:
Name : MODULE-TOTALLY INTEGRATED POWER C1
Color : BLACK
# of pins : 13
1 REAR WASHER PUMP MOTOR CONTROL W20 20BR/YL
2 FRONT WASHER PUMP MOTOR CONTROL W10 20BR/TN
4--
5--
6 CABIN HEATER RELAY 2 CONTROL K232 20BR/LB
7 CABIN HEATER RELAY 1 CONTROL K132 20DB/LB

8--
9--
10 - -
11 - -
12 BRAKE FLUID LEVEL SWITCH SENSE B20 20DG/RD
13 GROUND Z924 20BK/LB
Distribution Module > Component Information > Diagrams > Module-Totally Integrated Power > Page 243
Connector:
Color : LT. GRAY
# of pins : 8
1--
2--
3 TRANSMISSION CONTROL OUTPUT T16 16YL/OR
4--
5 FUSED MAIN RELAY OUTPUT F343 18DB/LG

6 FUSED MAIN RELAY OUTPUT F344 18DB/LB
7--
8 STARTER CONTROL OUTPUT T750 16YL/GY
Connector:
Color : GREEN
# of pins : 22
1 FUSED MAIN RELAY OUTPUT F342 14BR/DG
1 FUSED MAIN RELAY OUTPUT F342 14BR/WT
2--
3--
5 FRONT FOG LAMP CONTROL OUTPUT L89 20WT/YL
6 FRONT FOG LAMP CONTROL OUTPUT L90 20WT/OR
7 LOW/HIGH RAD FAN RELAY CONTROL N201 20DB/LG
8 HORN CONTROL OUTPUT X22 20GY/LB
9 HORN CONTROL OUTPUT X21 20GY/YL
10 FRONT WIPER HIGH SPEED CONTROL OUTPUT W4 16BR/LB
11 FUSED B(+) A935 20RD/LB
12 FRONT WIPER LOW SPEED CONTROL OUTPUT W3 16BR/WT
13 FUSED IGNITION SWITCH OUTPUT (RUN) F936 20PK/YL

15 - -
16 - -
18 - -
19 FUSED B(+) A931 20RD/WT
20 - -
21 GROUND Z971 16BK
22 RAD FAN RELAY CONTROL N112 20DB/OR
Connector:
Color : LT. GRAY
# of pins : 14
1 IGNITION SWITCH OUTPUT (UNLOCK-RUN-START) F901 20PK/RD
2 STARTER CONTROL T752 20DG/OR
3--
4 FUEL PUMP CONTROL K31 20DB/BK
4 FUEL PUMP CONTROL K31 20BR

5 FRONT WIPER PARK SWITCH SENSE W7 20BR/DB
7 CAN C BUS (+) D265 20DB/LB
8--
9--
11 HOOD AJAR SWITCH SENSE G70 20VT/LB
12 - -
14 CAN C BUS (-) D264 20DB/WT

Connector:
Color : BROWN
# of pins : 16
2 DIAGNOSTIC CAN C (+) D72 20WT/TN
4 LEFT REAR TURN SIGNAL L63 18DG/RD

5--
6 RIGHT REAR TURN SIGNAL L62 18WT/YL
7 STOP LAMP SWITCH OUTPUT L53 20DG/WT
8 PARK LAMP CONTROL OUTPUT L217 20WT/VT
10 DIAGNOSTIC CAN C (-) D71 20WT/DB
12 - -
13 STOP LAMP CONTROL OUTPUT L55 20WT/OR
14 - -
Connector:
Color : BLACK
# of pins : 10
1 LEFT TURN SIGNAL L61 20WT/LG
1 LEFT TURN SIGNAL L61 20WT/RD
2 RIGHT TURN SIGNAL L60 20WT/TN

3 RIGHT HIGH BEAM OUTPUT L34 20WT/GY
4 LEFT LOW BEAM OUTPUT L43 20WT/DB
5--
6--
7--
8 AAT SIGNAL G31 20VT/LG
9 AAT RETURN G931 20VT/DB
10 - -
Connector:
Color : BLUE
# of pins : 14
1 HEADLAMP SWITCH OUTPUT L70 20WT/GY
2 RIGHT TURN SIGNAL (OUT) L160 20WT/TN
3 RIGHT LOW BEAM OUTPUT L44 20VT/RD
4 LEFT HIGH BEAM OUTPUT L33 20WT/PK
5 LEFT TURN SIGNAL (OUT) L161 20WT/LG

6 HEADLAMP SWITCH OUTPUT L7 20WT/VT
6 HEADLAMP SWITCH OUTPUT L7 20WT/YL
7 A/C PRESSURE SENSOR SUPPLY C818 20LB/TN
8 BACKUP LAMP SWITCH SIGNAL T22 20YL/VT
9 HEADLAMP LEVEL SENSOR SIGNAL L131 20WT/LG
10 HEADLAMP LEVEL SENSOR SIGNAL L132 20LG/WT
11 - -
12 A/C PRESSURE SENSOR SIGNAL C18 20LB/BR
13 A/C PRESSURE SENSOR GROUND C918 20BK/LB
14 IGNITION SWITCH OUTPUT (START) F962 20PK/BK
Connector:
Color : LT. GRAY
# of pins : 13
1--
2--
3--
4--
5 REAR WIPER MOTOR CONTROL W13 20BR/LG

6--
7--
8--
9--
10 - -
11 - -
12 REAR FOG LAMP CONTROL OUTPUT L239 18WT/DG
13 - -
Connector:
Color : LT. GRAY
# of pins : 22
1--
3 FUSED B(+) A924 20DG/WT
4 FUSED B(+) A952 20RD/OR
5 FUSED IGNITION SWITCH OUTPUT (RUN-START) F200 18PK/LB

6 FUSED B(+) A100 18RD/VT
7 FUSED IGNITION SWITCH OUTPUT (RUN) F100 20DG/YL
8--
9 FUSED B(+) A933 20RD/LG
10 - -
11 FUEL PUMP CONTROL OUTPUT N1 16DB/OR
12 - -
14 - -
15 FUSED B(+) (I.O.D.) A418 20RD/BK

16 FUSED B(+) (I.O.D.) A412 20RD/DB
17 FUSED B(+) A16 12RD/BR
18 FUSED B(+) (I.O.D.) A932 18RD/BR
19 FUSED IGNITION SWITCH OUTPUT (RUN-ACC) F996 20PK/YL
20 - -
21 IGNITION SWITCH OUTPUT (RUN-ACC) F981 14PK/BR
Connector:
Color : BLACK
# of pins : 22
1 BLOWER MOTOR CONTROL C7 12DB/PK
2 FUSED B(+) A927 20RD/GY
5 FUSED B(+) (I.O.D.) A416 18RD

6 FUSED B(+) (I.O.D.) A420 18WT/RD
7 FUSED B(+) A14 12RD/YL
9 FUSED REAR WINDOW DEFOGGER CONTROL OUTPUT C16 20DB/GY
10 - -
11 BACKUP LAMP SWITCH OUTPUT L1 20WT/LG
11 BACKUP LAMP SWITCH OUTPUT L1 20WT/DG
12 FUSED IGNITION SWITCH OUTPUT (RUN) F929 20PK/RD
15 - -
16 - -
17 REAR WINDOW DEFOGGER CONTROL OUTPUT C515 12LB/OR
21 FUSED IGNITION SWITCH OUTPUT (RUN-ACC) F986 20PK/BK
22 MAIN RELAY OUTPUT K542 12BR/WT
Connector:
Color : # of pins :
1 B(+) A0 6RD
Power Distribution Module: Diagrams Module-Inverter
Component ID: 162
Connector:
Color : # of pins :
2--
6--
7--
9--
Distribution Module > Component Information > Description and Operation > Totally Integrated Power Module
Power Distribution Module: Description and Operation Totally Integrated Power Module
Description
DESCRIPTION
All of the electrical current distributed throughout this vehicle is directed through the standard
equipment Totally Integrated Power Module (TIPM). The molded plastic TIPM housing is located in
the left front corner of the engine compartment, just behind the air cleaner housing and the battery.
The TIPM housing has a molded plastic cover. The TIPM cover is easily removed for service
access and has a convenient fuse layout label affixed to the inside surface of the cover to ensure
proper component identification.
The TIPM housing is secured to the TIPM mounting bracket by three clips integral to the TIPM
housing. All of the TIPM outputs are through the integral engine compartment wire harness.
Operation
OPERATION
All of the current to the Totally Integrated Power Module (TIPM) comes directly from the positive
battery cable to a stud located on the bottom of the TIPM. The cable is secured to the TIPM stud
with a nut. Internal connection of all the Totally Integrated Power Module (TIPM) circuits is
accomplished by an intricate network of hard wiring and bus bars. Refer to Wiring Diagrams for
complete circuit diagrams.
The fuses and TIPM housing assembly are available for service replacement.
Distribution Module > Component Information > Description and Operation > Totally Integrated Power Module > Page 270
Power Distribution Module: Description and Operation Module-Inverter
Description
DESCRIPTION
The inverter module is located in the instrument panel. The A/C outlet is mounted in the center
console. The inverter module provides A/C power for user accessories. The inverter converts the
12 Volt DC from the battery system to a 110 Volt AC output.
Operation
OPERATION
The AC power outlet receives 12 volts from the Totally Integrated Power Module (TIPM) and
passes it as an enable signal to the inverter module. The inverter module also receives 12 volts via
the TIPM and inverts this to a 110 volt AC output. The enable signal received from the power outlet
enables the inverter to convert the received voltage and pass it to the power outlet to power
external devices.
Distribution Module > Component Information > Description and Operation > Page 271
Power Distribution Module: Testing and Inspection
Inverter Module
For complete circuit diagrams, refer to the appropriate wiring information.
WARNING: Disable the airbag system before attempting any steering wheel, steering column, seat
belt tensioner, side airbag, or instrument panel component diagnosis or service. Disconnect and
isolate the battery negative (ground) cable, then wait two minutes for the airbag system capacitor to
discharge before performing further diagnosis or service. This is the only sure way to disable the
airbag system. Failure to take the proper precautions could result in accidental airbag deployment
and possible personal injury.
Distribution Module > Component Information > Service and Repair > Totally Integrated Power Module
Power Distribution Module: Service and Repair Totally Integrated Power Module
Removal
REMOVAL
1. Open hood.
3. Disconnect each of the Totally Integrated Power Module (TIPM) wire harness connectors.
4. Remove the TIPM positive cable retaining nut and remove the cable from the stud.
5. Depress the three mounting clips to disengage and remove the TIPM housing from its mounting
bracket.
6. Remove the TIPM from the vehicle.
Installation
INSTALLATION
CAUTION: The original Cab Compartment Node (CCN) and Powertrain Control Module (PCM)
must be installed and functioning properly prior to powering up the new Totally Integrated Power
Module (TIPM). The TIPM receives vehicle configuration data from the CCN and Vehicle
Identification Number information from the PCM. If configuration information becomes lost or
corrupted, the data can be obtained from DealerCONNECT
1. Position the TIPM onto the mounting bracket and push down until the mounting clips are fully
seated.
Distribution Module > Component Information > Service and Repair > Totally Integrated Power Module > Page 274
2. Position the TIPM positive cable onto the mounting stud and install the retaining nut. Torque nut
9 - 11 Nm (80 - 100 in. lbs.).
3. Connect each of the TIPM wire harness connectors.
4. Remove TIPM cover and fully seat the Airbag fuse holder (two fuses in one yellow carrier). Fully
seat the Ignition Off Draw (IOD) fuses (two
fuses in a white/natural carrier).
6. Close hood.
7. Insert the ignition key and turn it to the "RUN" position and wait twelve seconds. The TIPM will
collect the necessary vehicle configuration and
VIN data from the CCN and PCM at this time. After twelve seconds turn the ignition key to the
"OFF" position and then back to the "ON" position and verify proper vehicle systems operation.
Power Distribution Module: Service and Repair Module-Inverter
Removal
REMOVAL
WARNING: Disable the airbag system before attempting any steering wheel, steering column, or
instrument panel component diagnosis or service. Disconnect and isolate the negative battery
(ground) cable, then wait two minutes for the airbag system capacitor to discharge before
performing further diagnosis or service. This is the only sure way to disable the airbag system.
Failure to take the proper precautions could result in accidental airbag deployment and possible
personal injury or death.
1. Disconnect and isolate the negative battery cable.
2. Remove the shift bezel.
3. Remove the center bezel from the instrument panel.
4. Remove the fasteners from the mounting brackets of the inverter module.
5. Disconnect the electrical connectors and remove the inverter module.
Installation
INSTALLATION
1. Connect the electrical connectors to the inverter module.
2. Install the fasteners to the mounting brackets.

3. Install the center bezel to the instrument panel.
4. Install the shift bezel.

Jeep Workshop Manuals > Relays and Modules > Relays and Modules - Power and Ground Distribution > Relay Box >
Component Information > Locations > Fuse/Relay Block
Relay Box: Locations Fuse/Relay Block
Fuse/Relay Block
Engine Compartment-Front Left
Frame Rail-Left Front (Gas)

Component Information > Locations > Fuse/Relay Block > Page 281
Relay Box: Locations Integrated Power Module (IPM)

Component Information > Application and ID > Fuse/Relay Block
Relay Box: Application and ID Fuse/Relay Block

Component Information > Application and ID > Fuse/Relay Block > Page 284
Relay Box: Application and ID Integrated Power Module (IPM)
Jeep Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules -
Computers and Control Systems > Engine Control Module > Component Information > Technical Service Bulletins >
Engine, A/T Controls - PCM/TCM Replacement Requirements
Engine Control Module: Technical Service Bulletins Engine, A/T Controls - PCM/TCM Replacement
Requirements
GROUP: Vehicle Performance
DATE: February 19, 2007
THIS BULLETIN SUPERSEDES SERVICE BULLETIN 18-006-07, DATED JANUARY 26, 2007,
WHICH SHOULD BE REMOVED FROM YOUR FILES. ALL REVISIONS ARE HIGHLIGHTED
WITH **ASTERISKS** AND INCLUDE ADDITIONAL YEARS AND MODELS.
THE StarSCAN(R) FLASH FILES FOR THIS BULLETIN MUST BE RETRIEVED FROM THE
INTERNET.
StarSCAN(R) SOFTWARE LEVEL MUST BE AT RELEASE 7.03 OR HIGHER FOR THIS

BULLETIN.
StarMOBILE(R) DOES NOT SUPPORT THIS SERVICE BULLETIN.
SUBJECT: Generic PCM (GPEC) or TCM (CVI Controller) Replacement Requirements
OVERVIEW: This bulletin describes the requirements that must occur when replacing a (CPEG)
PCM or (CVI) TCM for the models listed below.
MODELS:
**2007 (JS) Sebring**
**2008 (JS) Avenger**
2007 (MK49) Compass
2007 (MK74) Patriot
2007 (PM) Caliber
NOTE:
This Bulletin applies to **JS Models with a 2.0L or 2.4L engine (Sales Codes ECN, ED3, ED4, or
EDG) and PM/MK Models with a 1.8L, 2.O0 or 2.4L engine (Sales Codes EBA, ECN, ED3 or ED4)
and/or CVT transmission, (sales code DAV or DAW)**.
DISCUSSION:
This bulletin describes the requirements that must occur when replacing a (GPEC) PCM or (CVI)
TCM for the models listed above. This bulletin involves selecting the proper PCM or TCM software
application for the vehicle, and programming the module. Additionally it is extremely important **on
vehicles with a CVI transmission ** that the software level between the PCM and TCM be
coordinated at the latest levels available whenever one or the other module is replaced.
The steps involved in replacing, (FLASHING) a (GPEC) PCM are different from previous modules.
If the PCM is replaced, use the StarSCAN® to flash the new module with appropriate software,
perform the PCM replace function to transfer the immobilizer secret key and VIN to the PCM,
perform Learn ETC function, write odometer mileage to the PCM and ** if CVI ~ check the 1CM for
the latest software. If an update for the 1CM exists, flash the 1CM to the latest level.
If the TCM is replaced, use the StarSCAN(R) to flash the new module with appropriate software,
Initialize the TCM module and check the PCM for the latest software. If an update for the PCM
exists, flash the PCM to the latest level.
^ **If the vehicle is a PM/MK with a CVT transmission, follow PCM AND TCM Repair Procedures
below.
^ If the vehicle is a JS with a 2.0L or 2.4L engine or PM/MK with manual transmission, follow PCM
Repair Procedures below**.
The following steps must be followed whenever a Powertrain Control Module (PCM) or
Transmission Control Module (TCM) is replaced. Failure to maintain the latest software levels
between the PCM and TCM **on vehicles with a CVI transmission ** may cause MIL illumination or
poor vehicle performance.
CAUTION:
WHENEVER A PCM OR TCM MODULE IS REPLACED THE SOFTWARE FLASHED INTO THE
PCM OR TCM MODULES MUST BE
Engine, A/T Controls - PCM/TCM Replacement Requirements > Page 291
COORDINATED TO THE LATEST LEVELS. ALWAYS CHECK THE CONTROLLER THAT WAS
NOT REPLACED FOR THE LATEST UPDATE AND IF A LATER (NEWER) VERSION OF
SOFTWARE IS AVAILABLE UPDATE THE MODULE TO THE LATEST LEVEL.
PARTS REQUIRED:
SPECIAL TOOLS / EQUIPMENT REQUIRED:
PCM REPAIR PROCEDURE - USING THE INTERNET TO RETRIEVE THE FLASH FILE:
CAUTION:
EXTREME CARE MUST BE TAKEN WHEN PROGRAMMING A CALIBRATION INTO A

GENERIC PCM OR TCM. DO NOT RANDOMLY SELECT A CALIBRATION. ONCE A
CALIBRATION IS SELECTED AND PROGRAMMED, THE CONTROLLER CANNOT BE
REPROGRAMMED TO A DIFFERENT APPLICATION. THE MODULE CAN ONLY BE
REPROGRAMMED TO A MORE RECENT VERSION OF THAT SAME CALIBRATION.
1. Using the StarSCAN(R) attempt to read/record the part number of the existing controller before
removing it from the vehicle. This part number can be used to identify the correct calibration for
down load.
2. Replace the controller using the steps outlined in DealerCONNECT / TechCONNECT.
CAUTION:
DO NOT START THE ENGINE PRIOR TO COMPLETING STEP 7n. IF THE PROCEDURE IS
NOT ADHERED TO THE CONTROLLERS MAY NOT COMPLETE THE PROGRAMMING
PROCESS.
NOTE:
When performing this Repair Procedure, the software release level in the StarSCAN®; must be
programmed with 7.03 software or higher. The software release level is visible in the blue header at
the top of the StarSCAN(R) screen.
NOTE:
"DealerCONNECT > Service> StarSCAN and StarMOBILE tools > Online Documentation", or refer
NOTE:
drop.
5. Connect the CH9404 StarSCAN(R) vehicle cable to the StarSCAN(R) and the vehicle.
7. Using the StarSCAN(R) at the "Home" screen:
a. Select "ECU View"
b. Touch the screen to highlight the PCM in the list of modules.
c. Select "More Options"
d. Select "ECU Flash"
e. Select "Browse for New File". Follow the on screen instructions.
f. Select the correct flash file either from the part number recorded in step 1 or by using
Year/Model/Engine and appropriate emissions selection for the vehicle being worked on..
g. Select "Download to Scantool".
h. Select "Close" after the download is complete, then select "Back".
i. Highlight the listed calibration.
j. Select "Update Controller". Follow on screen instructions.
k. When the update is complete, select "OK".
l. Verify the part number at the top of the "Flash PCM" screen has updated to the new part number
that was selected in step f.
m. Turn the ignition switch to the OFF position for no less than 15 seconds.
n. Turn the ignition switch to the RUN position (DO NOT CRANK THE ENGINE) for no less than 20
seconds.
CAUTION:
DO NOT START THE ENGINE PRIOR TO COMPLETING 7n. IF THE PROCEDURE IS NOT
ADHERED TO THE CONTROLLER MAY NOT COMPLETE THE PROGRAMMING PROCESS.
NOTE:
Steps 8, 9 and 10 are only required if the PCM was replaced.
8. Using the StarSCAN(R) perform the PCM replace function. This is located in the WCM
miscellaneous function menu. Follow all instructions/prompts provided on the StarSCAN(R) screen.
This function transfers the secret key for immobilizer operation and transfers the VIN to the new
PCM.
NOTE:
The vehicle pin (Personal Identification Number) will be required to complete step 8.
9. Using the StarSCAN(R) write the odometer mileage to the new PCM. Use check PCM odometer
located in the PCM miscellaneous function menu. Follow all instructions/prompts provided on the
StarSCAN(R) screen.
10. Using the StarSCAN(R) perform the Learn ETC function. This is located in the PCM
This operation must be completed or the engine will not operate above idle rpm.
NOTE:
Due to the PCM/TCM programming procedure, a DTC may be set in other modules within the
vehicle. Some DTC's may cause the MIL to illuminate. From the "Home" screen select "System
View". Then select "All DTCs". Press "Clear All Stored DTCs" if there are any DTCs shown on the
list.

b. Touch the screen to highlight the TCM in the list of modules.
e. Record the part number at the top of the "Flash TCM" screen for later reference.
f. Select "Browse for New File". Follow the on screen instructions.
12. Is the part number recorded in step lie above, the same as the new pin shown on the "Flash
File List" screen?
a. Yes >> TCM controller reprogramming is not necessary. Proceed to step 13.
b. No >> TCM controller will require flash reprogramming, proceed to TCM Repair Procedure. Start
with step 9.
NOTE:
The following step is required by law when reprogramming a PCM and/or TCM.
13. Type the necessary information on the "Authorized Modification Label" p/n 04275086AB and
attach near the VECI label (Fig. 1).
TCM REPAIR PROCEDURE - USING THE INTERNET TO RETRIEVE THE FLASH FILE:
CAUTION:

down load.
NOTE:
When performing this Repair Procedure, the software release level in the StarSCAN(R); must be
NOTE:
to the StarSCAN® Quick Start Networking Guide. The StarSCAN(R) Quick Start Networking Guide
is also available on the website under the "Download Center".
NOTE:
down load.
drop.
9. Retrieve the old TCM part number. Using the StarSCAN(R) at the "Home" screen:
g. Select the correct File for the vehicle.
h. Select "Download to Scantool".
i.Select "Close" after the download is complete, then select "Back".
j. Highlight the listed calibration.
k. Select "Update Controller". Follow on screen instructions.
l. When the update is complete, select "OK".
m. Verify the part number at the top of the "Flash TCM" screen has updated to the new part
number.
10. Select Miscellaneous Function and perform Initialize CVI. Follow all on screen instructions.
NOTE:
Due to the TCM/PCM programming procedure, a DTC may be set in other modules (BCM, MIC,
From the "Home" screen select "System View". Then select "All DTC's". Press "Clear All Stored
DTC's" if there are any DTC's shown on the list.

e. Record the part number at the top of the "Flash PCM" screen for later reference.

12. Is the part number recorded in step 10e above, the same as the new pin shown on the "Flash
File List" screen?
a. Yes >> PCM controller reprogramming is not necessary. Proceed to step 13.
b. No >> PCM controller will require flash reprogramming, proceed to PCM repair procedure. Start
with step 7.
NOTE:
TIME ALLOWANCE:
NOTE:The following Labor Operations are standard LOP's associated with Generic Module
Replacement and Programming.
FAILURE CODE:
Disclaimer:
Engine Control Module: Technical Service Bulletins Engine Controls - MIL On/DTC P0116/ECT
Sensor
NUMBER: 18-039-06
DATE: December 6, 2006
INTERNET.
UPDATE CD 6.05 WAS THE LAST CD TO CONTAIN FLASH FILES FOR StarSCAN.
StarSCAN(R) SOFTWARE LEVEL MUST BE AT RELEASE 7.02 SP2 OR HIGHER FOR THIS
BULLETIN.
SUBJECT:
Flash: MIL Illumination DTC P0116 - Engine Coolant Temperature Sensor Performance
OVERVIEW: This bulletin involves selectively erasing and reprogramming the Powertrain Control
Module (PCM) and the Transmission Control Module (1CM) with new software.
CAUTION:
VEHICLES EQUIPPED WITH A CVT TRANSMISSION MUST HAVE THE TRANSMISSION

CONTROL MODULE (TCM) CHECKED FOR THE LATEST SOFTWARE LEVEL WHENEVER
THE PCM SOFTWARE IS UPGRADED. IF NEWER TCM SOFTWARE IS AVAILABLE, IT MUST
BE INSTALLED.
MODELS:
2007 (PM) Caliber
2007 (MK49) Compass
NOTE:
This bulletin applies to PM/MK models equipped with a 1.8L, 2.0L or 2.4L gasoline engine (Sales
Code EBA, ECN or ED3) and block heater (Sales Code NHK) built before November 20, 2006
(MDH 1120XX).
NOTE:
If an aftermarket or MOPAR accessory block heater is installed, the same conditions may apply.
SYMPTOM/CONDITION: Some customers may experience MIL illumination after using the block
heater. No other symptoms will be experienced.
The technician may find the following DTC's:
^ P0116 - ENGINE COOLANT TEMPERATURE SENSOR PERFORMANCE
DIAGNOSIS:
Using a Scan Tool (StarSCAN(R)) with the appropriate Diagnostic Procedures available in
TechCONNECT, verify all engine systems are functioning as designed. If DTC's are present record
them on the repair order and repair as necessary before proceeding further with this bulletin.
If MIL illumination with DTC P0116 is present, perform the Repair Procedure.
PARTS REQUIRED:
CAUTION:
DO NOT START THE ENGINE PRIOR TO COMPLETING **STEP 5n and/or 8h**. IF THE
PROCEDURE IS NOT ADHERED TO THE CONTROLLERS MAY NOT COMPLETE THE
PROGRAMMING PROCESS.
NOTE:
programmed with 7.02 SP2 software or higher. The software release level is visible in the blue
header at the top of the StarSCAN(R) screen.
PM/MK Models equipped with a CVT must have the TCM reprogrammed as follows:
7. Is the TCM part number recorded in step 6e above, the same as the new p/n shown on the
"Flash File List" screen?
a. Yes >> No further action is necessary. Proceed to Step 9.
b. No >> the TCM will require flash reprogramming, proceed to Step 8.
8. Flash reprogram the TCM as follows:

a. From the "Flash File List" screen, select "Download to Scantool".
b. Select "Close" after the download is complete, then select "Back".
c. Highlight the listed calibration.
d. Select "Update Controller". Follow on screen instructions.
e. When the update is complete, select "OK".
f. Verify the part number at the top of the "Flash TCM" screen has updated to the new part number.
g. Turn the ignition switch to the OFF position for no less than 15 seconds.
h. Turn the ignition switch to the RUN position (DO NOT CRANK THE ENGINE) for no less than 20
seconds.
CAUTION:
DO NOT START THE ENGINE PRIOR TO COMPLETING STEP 5n and 8h. IF THE PROCEDURE
IS NOT ADHERED TO THE CONTROLLER MAY NOT COMPLETE THE PROGRAMMING
PROCESS.
NOTE:
Due to the TCM programming procedure, a DTC may be set in other modules within the vehicle.
Some DTC's may cause the MIL to illuminate. From the "Home" screen select "System View".
Then select "All DTCs". Press "Clear All Stored DTCs" if there are any DTCs shown on the list. **
NOTE:
TIME ALLOWANCE:
FAILURE CODE:
Disclaimer:
Engine Control Module: Technical Service Bulletins Engine Control - PCM Initialization Procedure
GROUP: Electrical
THIS BULLETIN SUPERSEDES SERVICE BULLETINS 08-030-06, DATED JULY 12, 2006,
WITH **ASTERISKS** AND INCLUDES REVISED CROSSFIRE AND SPRINTER INITIALIZATION
PROCEDURES.
SUBJECT: Powertrain Control Module Initialization
MODELS:
2001-2004 (AN) Dakota
2004 - 2007 (CS) Pacifica
2007 (DC) Ram Cab & Chassis
2001 - 2003 (DN) Durango
2002 - 2007 (DR/DH/D1) Ram Truck
2004 - 2007 (HB) Durango
2007 (HG) Aspen
1999 - 2000 (JA) Breeze/Cirrus/Stratus
2007 (JK) Wrangler
2001 - 2006 (JR) Sebring Convertible/Sebring Sedan/Stratus Sedan
2007 (JS) Sebring
1998 - 2000 (JX) Sebring Convertible
2007 (KA) Nitro
2002 - 2007 (KJ) Liberty
1999 - 2004 (LH) 300M/Concorde/Intrepid/LHS
2005 - 2007 (LX) 300/Charger/Magnum
2007 (MK49) Compass
2007 (MK74) Patriot
2005-2007 (ND) Dakota
2000 - 2005 (PL) Neon/SX2.0
2007 (PM) Caliber
2001 - 2007 (PT) Chrysler PT Cruiser/Chrysler PT Cruiser Convertible
2001 - 2007 (RS) Town & Country/Caravan/Voyager

2001 - 2005 (ST) Sebring Coupe/Stratus Coupe
1998 - 2006 (TJ) Wrangler
2004 - 2006 (VA) Sprinter
1999 -2004 (WJ) Grand Cherokee
2005 - 2007 (WK) Grand Cherokee
1999 - 2001 (XJ) Cherokee
2006 - 2007 (XK) Commander
2005 - 2006 (ZB) Viper
2004 - 2006 (ZH) Crossfire Coupe/Crossfire Roadster
NOTE:
The model years and vehicles above must be equipped (optional) with Sentry Key Theft Deterrent
System (sales code GXX) for this bulletin to apply.
DISCUSSION:
ALL LISTED VEHICLES EXCEPT SEBRING COUPE/STRATUS COUPE (ST), CROSSFIRE, AND
SPRINTER.
When a Powertrain Control Module (PCM) is replaced on vehicles equipped with the Sentry
Key(TM) Theft Deterrent System, it must be initialized to properly function with the anti-theft
module. This is accomplished at a Chrysler Group Dealer by using the DRBIII(R) or StarSCAN(TM)
Scan Tool to enter a PIN number.
When the PIN number is not available from the vehicle owner or a Chrysler Group Scan Tool(s) is
not available this can be accomplished by writing the Vehicle Identification Number (VIN) into the
PCM using an after-market scan tool with a "VIN Write Function".
More information is available from the scan tool manufacturer or the Equipment & Tool Institute.
NOTE:
After performing this procedure with an after-market scan tool on vehicles equipped with Chrysler
Group's Next Generation Controller (NGC), Diagnostic Trouble Code (DTC) "P0633 - SKIM
SECRET KEY DATA NOT STORED IN PCM" will be set. This DTC will not effect vehicle or system
performance and cannot be erased.
SEBRING COUPE/STRATUS COUPE (ST)
Initializing the PCM on these vehicles requires the use of a DaimlerChrysler scan tool (DRBIII(R)),
J1962 MMC Cable (Special Tool CH7010), and the BLUE 5T22 PCMCIA
Diagnostic Card (Special Tool CH8425). This equipment is available for lease from
DaimlerChrysler for short periods of time. A credit card deposit will be required.
CROSSFIRE AND SPRINTER.
Multiplexer cable box (Special Tool CH 9043), and the ORANGE Crossfire PCMCIA card (Special
Tool CH9044) or the GREEN Sprinter PCMCIA card (Special Tool CH9087). This equipment is
available for lease from DaimlerChrysler for short periods of time. A credit card deposit will be
required.
The DRBIII(R) will be shipped within 24 hours to your location by an overnight delivery service.
When the DRBIII(R) is returned, your credit card will be charged the lease price.
2007 GRAND CHEROKEE W/ 3.0L TD/2005 - 2007 LIBERTY w/2.8L TD/2007 RAM TRUCK/RAM
CAB CHASSIS w 6.7L TD AND 2004-2006 SPRINTER w 2.7L TD ENGINES.
For the above models equipped with Turbo Diesel Engines, the fuel injector "Quantity Values" must
be physically read from each injector and the values written to the ECU with an appropriate scan
tool.
**PCM INITIALIZATION PROCEDURE CROSSFIRE/SPRINTER**:
NOTE:
Depending on the situation, there are two methods for initializing the PCM/ECM. Either Automatic
Replacement or Service Replacement must be performed. Automatic Replacement uploads the
data from the old controller and downloads data to the new controller when the part numbers are
identical between the replacement and replaced controller. Service Replacement is used when part
numbers are not identical or when the part number is not recognized by the DRBIII(R).
Automatic Replacement
1. **Using the DRBIII(R) select: "1. DRBIII(R) Standalone"
2. "1.1998 - 2007 Diagnostics"
3. Make the appropriate selection: "5. 2004 - 2006 Crossfire" or "6. 2002 - 2006 Sprinter"
4. "1. System Select"
5. "1. Engine"
6. "9. Miscellaneous Functions"
NOTE:
For Sprinter only, injector classification must be recorded. Under Miscellaneous Functions, select
"5. Injector Classification" then "2. Injector Modification" on the DRBIII(R) and record the
information for all 5 cylinders.
7. "1. Module Auto Replacement"
8. Follow the DRBIII(R) "On Screen" prompts until "Module Replacement Successful" message is
displayed.
Module Service Replacement
2. "1.1998 - 2007 Diagnostics"
5. "1. Engine"
7. "7. Read PCM Coding for Crossfire" OR "6 Read ECM Coding for Sprinter" and record all data.
NOTE:
Record all information shown on the PCM/ECM screen for future use.
Additionally, for Sprinter only, injector classification must be recorded.
Under Miscellaneous Functions, select "5. Injector Classification" then "2.
Injector Modification" on the DRBIII(R) and record the information for all 5 cylinders.
8. Install new controller using the procedures found in TechCONNECT.
9. Using the DRBIII(R), repeat above steps 1 through 6 and select "2. Module Service
Replacement".
displayed.
11. Was the message "Module Replacement Successful" received?
a. Yes >> No Further Action is Required, Module has been successfully replaced.
b. No >> proceed to the next Step # 12.
12. Open TechAUTHORITY. TechAUTHORITY is available on the internet.

13. At the "Home" page, open the "Powertrain Control Module Initialization" link.
14. Open the "Coding String Calculator for Sprinter & Crossfire Vehicles" link.
15. Open the "Select Module" pull down menu and select "PCM".
16. Select the appropriate "Transmission Type" button (Manual or Automatic).
17. Carefully enter the 17 character VIN.
18. Carefully enter the PCM pin located on the new PCM.
19. Select the "Calculate" button at the bottom of the window.
NOTE:
TechAUTHORITY will automatically populate the "Coding String", "SCN", and "CheckSum"
information.
20. Print the information from the technician's PC or accurately record the information.
21. Using the DRBIII(R) select: "1. DRBIII(R) Standalone"
22. "1.1998 - 2007 Diagnostics"
25. "1. Engine"
27. "2. Module Service Replacement"
28. Follow the on screen instructions and carefully enter the "Coding String", "SCN" "CheckSum"
and VIN information into the DRBIII(R)**
NOTE:
If one or more errors were made entering the data in step 28, the DRBIII(R) will display an error
and ask that the data be checked and re-input as necessary.
29. Follow the DRBIII(R) "On Screen" prompts until 'Module Replacement Successful" message is
displayed.
PCM INITIALIZATION PROCEDURE SEBRING COUPE/STRAUS COUPE (ST):
1. Perform the "Registration Procedure" described in service bulletin 08-036-04. This service
bulletin, including the password, is available on the internet under the "Powertrain Control Module
Initialization" link.
POLICY: Information Only
Disclaimer:
Computers and Control Systems > Engine Control Module > Component Information > Technical Service Bulletins > Page
303
Engine Control Module: Locations
Component ID: 165
Component : MODULE-POWERTRAIN CONTROL
Connector:
Name : MODULE-POWERTRAIN CONTROL C1
Color : BLACK
# of pins : 58
Qualifier : (GAS)

5--
6--
7 O2 1/2 HEATER CONTROL K299 20BR/RD
8--
9--
10 - -
11 - -
12 - -
13 S/C SWITCH GROUND V937 20VT/LG
14 - -
17 - -
18 - -
20 O2 1/2 RETURN K904 20DB/DG
21 O2 1/2 SIGNAL K141 20DB/YL
22 5 VOLT SUPPLY K858 20BR/GY
23 5 VOLT SUPPLY F856 20YL/PK
24 - -
26 S/C SIGNAL 2 V72 20OR/VT
27 S/C SIGNAL 1 V71 20VT/OR
28 - -
29 - -
30 SENSOR GROUND K914 20DB/PK

304
31 - -
32 BRAKE SIGNAL 1 B15 20DG/WT
33 - -
34 APP SENSOR GROUND 2 K400 20BR/VT
35 EVAP PURGE RETURN K70 20DB/BR
36 APP SENSOR GROUND 1 K167 20BR/YL
37 START ENABLE F963 20PK/DB
38 VEHICLE SPEED SIGNAL K75 20DB/OR
39 EVAP PURGE CONTROL K52 20DB/WT
40 - -
42 - -
43 - -
44 - -
45 - -
46 - -
47 ESM SIGNAL K107 20VT/WT
48 APP SIGNAL 2 K29 20WT/BR
49 APP SIGNAL 1 K23 20BR/OR
50 CLUTCH INTERLOCK SIGNAL T141 20YL/RD
51 - -
52 BRAKE SIGNAL 2 B16 20LB/DG
53 GEN SENSE A804 20RD/GY
55 - -
56 - -
57 - -
58 MAIN RELAY CONTROL K51 20BR/LG
58 MAIN RELAY CONTROL K51 20BR/WT
305
306
307
Connector:
Color : BLACK
# of pins : 96
Qualifier : (GAS)
1 ETC MOTOR (+) K124 20DB/GY
2--
3--
4--
308
5--
6 A/C COMPRESSOR CONTROL C27 20LB/WT
7--
8 IAT SIGNAL K21 20BK/RD
9--
10 - -
11 ECT 2 SIGNAL K222 20BR/YL
12 - -
13 - -
14 - -
15 - -
16 - -
17 - -
18 - -
19 - -
20 - -
21 INJECTOR 3 CONTROL K13 20BR/LB
22 INJECTOR 4 CONTROL K14 20BR/TN
23 INJECTOR 1 CONTROL K11 20YL/BR
24 INJECTOR 2 CONTROL K12 20BR/DB
25 ETC MOTOR (-) K126 20DB/LG
26 - -
27 MFV CONTROL K601 20BR/VT
28 - -
29 - -
30 - -
31 - -
32 - -
33 O2 1/1 SIGNAL K41 20BK/DG
34 - -
35 - -
36 O2 1/1 RETURN K902 20BR/DG

37 EOT SIGNAL G24 20VT/BR
38 CMP 1/2 SIGNAL K441 20DB/BR
39 - -
40 - -
41 5 VOLT SUPPLY F855 20PK/YL
42 5 VOLT SUPPLY K857 20BR/LG
43 - -
44 - -
45 - -
46 - -
47 - -
48 - -
49 O2 1/1 HEATER CONTROL K99 20BR/OR
50 - -
51 GEN FIELD CONTROL K20 20BR/GY
52 - -
53 - -
54 - -
55 - -
56 - -
57 CMP 1/1 SIGNAL K44 20DB
58 SENSOR GROUND K915 20BR/WT
59 - -
60 - -
61 - -
62 TP SENSOR GROUND K922 20BR
63 TP SIGNAL 2 K122 20DG/BR
64 TP SIGNAL 1 K22 20OR/BR
65 KS RETURN K942 20WT/BR
66 - -
67 - -
68 - -
69 - -
70 CMP 1/1 CONTROL K76 20LB/WT

309
71 - -
72 CMP 1/2 CONTROL K276 20DB/WT
73 COIL 4 CONTROL K15 18GY/DB
74 COIL 3 CONTROL K18 18DB/OR
75 COIL 2 CONTROL K17 18DB/TN
76 COIL 1 CONTROL K19 18DB/LB
77 - -
78 - -
79 CKP SIGNAL K24 20BR/LB
80 - -
81 - -
82 SENSOR GROUND K900 20DB/DG
83 ECT 1 SIGNAL K2 20VT/OR
84 MFV SIGNAL K602 20YL/DB
85 MAP SIGNAL K1 20VT/LB
86 EOP SIGNAL G6 20VT/GY
87 - -
88 KS SIGNAL K42 20LG/DB
89 - -
90 - -
91 - -
92 - -
93 - -
94 - -
95 - -
96 - -
310
311
Computers and Control Systems > Engine Control Module > Component Information > Diagrams > Diagram Information
and Instructions
Engine Control Module: Diagram Information and Instructions
Warnings
WARNINGS - GENERAL
WARNINGS: provide information to prevent personal injury and vehicle damage. Below is a list of
general warnings that should be followed any time a vehicle is being serviced.
WARNING: Always wear safety glasses for eye protection.
WARNING: Use safety stands anytime a procedure requires being under a vehicle.
WARNING: Be sure that the ignition switch always is in the off position, unless the procedure
requires it to be on.
WARNING: Set the parking brake when working on any vehicle. An automatic transmission should
be in park. A manual transmission should be in neutral.
WARNING: Operate the engine only in a well-ventilated area.
WARNING: Keep away from moving parts when the engine is running, especially the fan and belts.
WARNING: To prevent serious burns, avoid contact with hot parts such as the radiator, exhaust
manifold(s), tail pipe, catalytic converter and muffler.
WARNING: Do not allow flame or sparks near the battery. Gases are always present in and around
the battery.
WARNING: Always remove rings, watches, loose hanging jewelry and avoid loose clothing.
How to Use Wiring Diagrams
DESCRIPTION - HOW TO USE WIRING DIAGRAMS
DaimlerChrysler Corporation wiring diagrams are designed to provide information regarding the
vehicles wiring content. In order to effectively use the wiring diagrams to diagnose and repair
DaimlerChrysler Corporation vehicles, it is important to understand all of their features and
characteristics.
Diagrams are arranged such that the power (B+) side of the circuit is placed near the top of the
page, and the ground (B-) side of the circuit is placed near the bottom of the page.
All switches, components, and modules are shown in the at rest position with the doors closed and
the key removed from the ignition.
Components are shown two ways. A solid line around a component indicates that the component is
complete. A dashed line around the component indicates that the component is being shown is not
complete. Incomplete components have a reference number to indicate the page where the
component is shown complete.
It is important to realize that no attempt is made on the diagrams to represent components and
wiring as they appear on the vehicle. For example, a short piece of wire is treated the same as a
long one. In addition, switches and other components are shown as simply as possible, with regard
to function only.
and Instructions > Page 314
SYMBOLS
International symbols are used throughout the wiring diagrams. These symbols are consistent with
those being used around the world.
TERMINOLOGY
This is a list of terms and definitions used in the wiring diagrams.
LHD -Left Hand Drive Vehicles RHD -Right Hand Drive Vehicles ATX -Automatic
Transmissions-Front Wheel Drive
MTX -Manual Transmissions-Front Wheel Drive AT -Automatic Transmissions-Rear Wheel Drive
MT -Manual Transmissions-Rear Wheel Drive SOHC -Single Over Head Cam Engine DOHC
-Double Over Head Cam Engine Export -Vehicles Built For Sale In Markets Other Than North
America Except Export -Vehicles Built For Sale In North America
Circuit Functions
DESCRIPTION - CIRCUIT FUNCTIONS
All circuits in the diagrams use an alpha/numeric code to identify the wire and it's function. To
identify which circuit code applies to a system, refer to the Circuit Identification Code Chart. This
chart shows the main circuits only and does not show the secondary codes that may apply to some
models.
Circuit Information
DESCRIPTION - CIRCUIT INFORMATION
Each wire shown in the diagrams contains a code which identifies the main circuit, a specific part of
the main circuit, gage of wire, and color. An example would be A 2 18 LB/YL. This is a Battery
Feed circuit, level two, eighteen gauge, light blue with a yellow tracer.
Connector, Ground and Splice Information
DESCRIPTION - CONNECTOR, GROUND AND SPLICE INFORMATION
CAUTION: Not all connectors are serviced. Some connectors are serviced only with a harness. A
typical example might be the Supplemental Restraint System connectors. Always check parts
availability before attempting a repair.
IDENTIFICATION
In-line connectors are identified by a number, as follows:
- In-line connectors located in the engine compartment are C100 series numbers.
- In-line connectors located in the instrument panel area are C200 series numbers.
- In-line connectors located in the body are C300 series numbers.
- Jumper harness connectors are C400 series numbers.
- Grounds and ground connectors are identified with a "G" and follow the same series numbering
as the in-line connectors.
- Splices are identified with an "S" and follow the same series numbering as the in-line connectors.
In addition, S001-S099 numbers are located in the engine compartment.
- Component connectors are identified by the component name instead of a number. Multiple
connectors on a component use a C1, C2, etc. identifier.
LOCATIONS
The abbreviation T/O is used in the component location section to indicate a point in which the
wiring harness branches out to a component. The abbreviation N/S means Not Shown in the
illustrations.
Section Identification and Information
DESCRIPTION - SECTION IDENTIFICATION AND INFORMATION
The wiring diagrams are grouped into individual sections. If a component is most likely found in a
particular group, it will be shown complete (all wires, connectors, and pins) within that group. For
example, the Auto Shutdown Relay is most likely to be found in Powertrain Management, so it is
shown there complete. It can, however, be shown partially in another group if it contains some
associated wiring.
Splice diagrams show the entire splice and provide references to other sections the splices serves.
Splice information contains splice diagrams that are not shown in their entirety somewhere else in
the wiring diagrams.
Connector Pin-outs shows each connector and the circuits involved with that connector. The
connectors are identified using the name/number on the diagram pages.
Removal
REMOVAL
1. Disconnect battery.
2. Release Connector Lock (2).
3. Disconnect the connector (3) being repaired from its mating half/component.
4. Remove the dress cover (if applicable) (1).

5. Release the Secondary Terminal Lock, if required (1).
6. Position the connector locking finger away from the terminal using the proper special tool. Pull
on the wire to remove the terminal from the
connector.
Installation
INSTALLATION
1. Insert the removed terminal in the same cavity on the repair connector.
2. Repeat steps for each terminal in the connector, being sure that all wires are inserted into the
proper cavities. For additional connector pin-out
identification, refer to the wiring diagrams.

3. When the connector is re-assembled, the secondary terminal lock must be placed in the locked
position to prevent terminal push out.
4. Replace dress cover (if applicable).
5. Connect connector to its mating half/component.
6. Connect battery and test all affected systems.
Removal
REMOVAL
1. Disconnect the battery.
2. Locate the diode in the harness, and remove the protective covering.
3. Remove the diode from the harness, pay attention to the current flow direction (1) (2) (3).
Installation
INSTALLATION
1. Remove the insulation from the wires in the harness. Only remove enough insulation to solder in
the new diode.
2. Install the new diode in the harness, making sure current flow is correct. If necessary, refer to the
appropriate wiring diagram for current flow.
3. Solder the connection together using rosin core type solder only. Do not use acid core solder.
4. Tape the diode to the harness using electrical tape. Make sure the diode is completely sealed
from the elements.
5. Re-connect the battery and test affected systems.
Removal
REMOVAL
1. Follow steps for removing terminals described in the connector removal section.
2. Cut the wire 6 inches from the back of the connector.
Installation
INSTALLATION
1. Select a wire from the terminal repair kit that best matches the color and gage of the wire being
repaired.
2. Cut the repair wire to the proper length and remove one-half (1/2) inch of insulation.
3. Splice the repair wire to the wire harness (see wire splicing procedure).
4. Insert the repaired wire into the connector.
5. Install the connector locking wedge, if required, and reconnect the connector to its mating
half/component.
6. Re-tape the wire harness starting at 1-1/2 inches behind the connector and 2 inches past the
repair.
Wire Splicing
STANDARD PROCEDURE - WIRE SPLICING
When splicing a wire, it is important that the correct gage be used as shown in the wiring diagrams.
1. Remove one-half (1/2) inch of insulation from each wire that needs to be spliced.
2. Place a piece of adhesive lined heat shrink tubing on one side of the wire. Make sure the tubing
will be long enough to cover and seal the entire
repair area.
3. Place the strands of wire overlapping each other inside of the splice clip (1).
4. Using crimping tool (1), Mopar p/n 05019912AA, crimp the splice clip and wires together.
5. Solder (3) the connection (2) together using rosin core type solder (1) only.
CAUTION: DO NOT USE ACID CORE SOLDER.

6. Center the heat shrink tubing (2) over the joint and heat using a heat gun. Heat the joint until the
tubing is tightly sealed and sealant (1) comes out
of both ends of the tubing.
Special Tools
WIRING/TERMINAL
PROBING TOOL PACKAGE 6807
TERMINAL PICK TOOL SET 6680

TERMINAL REMOVING TOOLS 6932 AND 8638
TERMINAL REMOVING TOOL 6934

Engine Control Module: Diagnostic Aids
Electrostatic Discharge (ESD) Sensitive Devices
STANDARD PROCEDURE - ELECTROSTATIC DISCHARGE (ESD) SENSITIVE DEVICES
All ESD sensitive components are solid state and a symbol is used to indicate this. When handling
any component with this symbol, comply with the following procedures to reduce the possibility of
electrostatic charge build up on the body and inadvertent discharge into the component. If it is not
known whether the part is ESD sensitive, assume that it is.
1. Always touch a known good ground before handling the part. This should be repeated while
handling the part and more frequently after sliding
across a seat, sitting down from a standing position, or walking a distance.
2. Avoid touching electrical terminals of the part, unless instructed to do so by a written procedure.
3. When using a voltmeter, be sure to connect the ground lead first.
4. Do not remove the part from it's protective packing until it is time to install the part.
5. Before removing the part from it's package, ground the package to a known good ground on the
vehicle.
Testing Of Voltage Potential
STANDARD PROCEDURE - TESTING OF VOLTAGE POTENTIAL

1. Connect the ground lead of a voltmeter to a known good ground.
2. Connect the other lead of the voltmeter to the selected test point. The vehicle ignition may need
to be turned ON to check voltage. Refer to the
appropriate test procedure.
Testing For Continuity
STANDARD PROCEDURE - TESTING FOR CONTINUITY
1. Remove the fuse (1) for the circuit being checked or, disconnect the battery.
2. Connect one lead of the ohmmeter to one side of the circuit being tested.
3. Connect the other lead to the other end of the circuit being tested. Low or no resistance means
good continuity.
Testing For A Short To Ground
STANDARD PROCEDURE - TESTING FOR A SHORT TO GROUND
1. Remove the fuse and disconnect all items involved with the fuse.
2. Connect a test light or a voltmeter across the terminals of the fuse.
3. Starting at the fuse block, wiggle the wiring harness about six to eight inches apart and watch
the voltmeter/test lamp.
4. If the voltmeter registers voltage or the test lamp glows, there is a short to ground in that general
area of the wiring harness.
Testing For A Short To Ground On Fuses Powering Several Loads
STANDARD PROCEDURE - TESTING FOR A SHORT TO GROUND ON FUSES POWERING

SEVERAL LOADS
1. Refer to the wiring diagrams and disconnect or isolate all items on the suspected fused circuits.
2. Replace the blown fuse.
3. Supply power to the fuse by turning ON the ignition switch or re-connecting the battery.
4. Start connecting or energizing the items in the fuse circuit one at a time. When the fuse blows
the circuit with the short to ground has been isolated.
Testing For A Voltage Drop

STANDARD PROCEDURE - TESTING FOR A VOLTAGE DROP
1. Connect the positive lead of the voltmeter to the side of the circuit closest to the battery.
2. Connect the other lead of the voltmeter to the other side of the switch, component or circuit.
3. Operate the item.
4. The voltmeter will show the difference in voltage between the two points.
Troubleshooting Wiring Problems
DIAGNOSIS AND TESTING - WIRING HARNESS

TROUBLESHOOTING TOOLS
When diagnosing a problem in an electrical circuit there are several common tools necessary.
These tools are listed and explained below.
- Jumper Wire - This is a test wire used to connect two points of a circuit. It can be used to bypass
an open in a circuit.
WARNING: Never use a jumper wire across a load, such as a motor, connected between a battery
feed and ground.
- Voltmeter - Used to check for voltage on a circuit. Always connect the black lead to a known good
ground and the red lead to the positive side of the circuit.
CAUTION: Most of the electrical components used in today's vehicles are Solid State. When
checking voltages in these circuits, use a meter with a 10 - megohm or greater impedance rating.
- Ohmmeter - Used to check the resistance between two points of a circuit. Low or no resistance in
a circuit means good continuity.
checking resistance in these circuits use a meter with a 10 - megohm or greater impedance rating.
In addition, make sure the power is disconnected from the circuit. Circuits that are powered up by
the vehicle's electrical system can cause damage to the equipment and provide false readings.
- Probing Tools - These tools are used for probing terminals in connectors. Select the proper size
tool from Special Tool Package 6807, and insert the probing end (2) into the terminal being tested.
Use the other end of the tool (1) to insert the meter probe.
INTERMITTENT AND POOR CONNECTIONS
Most intermittent electrical problems are caused by faulty electrical connections or wiring. It is also
possible for a sticking component or relay to cause a problem. Before condemning a component or
wiring assembly, check the following items.
- Connectors are fully seated
- Spread terminals, or terminal push out
- Terminals in the wiring assembly are fully seated into the connector/component and locked into
position
- Dirt or corrosion on the terminals. Any amount of corrosion or dirt could cause an intermittent
problem
- Damaged connector/component casing exposing the item to dirt or moisture
- Wire insulation that has rubbed through causing a short to ground
- Some or all of the wiring strands broken inside of the insulation
- Wiring broken inside of the insulation
TROUBLESHOOTING WIRING PROBLEMS
When troubleshooting wiring problems there are six steps which can aid in the procedure. The
steps are listed and explained below. Always check for non-factory items added to the vehicle
before doing any diagnosis. If the vehicle is equipped with these items, disconnect them to verify
these add-on items are not the cause of the problem.
1. Verify the problem.
2. Verify any related symptoms. Do this by performing operational checks on components that are
in the same circuit. Refer to the wiring diagrams.
3. Analyze the symptoms. Use the wiring diagrams to determine what the circuit is doing, where the
problem most likely is occurring and where the
diagnosis will continue.
4. Isolate the problem area.
5. Repair the problem area.
6. Verify the proper operation. For this step, check for proper operation of all items on the repaired
circuit. Refer to the wiring diagrams.
Engine Control Module: Connector Views
Component ID: 165
Connector:
Color : BLACK
# of pins : 58
Qualifier : (GAS)

5--
6--
8--
9--
10 - -
11 - -
12 - -
14 - -
17 - -
18 - -
24 - -
28 - -
29 - -

31 - -
33 - -
40 - -
42 - -
43 - -
44 - -
45 - -
46 - -
51 - -
55 - -
56 - -
57 - -
Connector:
Color : BLACK
# of pins : 96
Qualifier : (GAS)
2--
3--
4--
5--
7--
9--
10 - -
12 - -
13 - -
14 - -
15 - -
16 - -
17 - -
18 - -
19 - -
20 - -
26 - -
28 - -
29 - -
30 - -
31 - -
32 - -
34 - -
35 - -

39 - -
40 - -
43 - -
44 - -
45 - -
46 - -
47 - -
48 - -
50 - -
52 - -
53 - -
54 - -
55 - -
56 - -
59 - -
60 - -
61 - -
66 - -
67 - -
68 - -
69 - -

71 - -
77 - -
78 - -
80 - -
81 - -
87 - -
89 - -
90 - -
91 - -
92 - -
93 - -
94 - -
95 - -
96 - -
Computers and Control Systems > Engine Control Module > Component Information > Description and Operation >
Powertrain Control Module (PCM)
Engine Control Module: Description and Operation Powertrain Control Module (PCM)
PCM Ground
PCM GROUND
Ground is provided through multiple pins of the PCM connector. Depending on the vehicle there
may be as many as two different ground pins. There are power grounds and sensor grounds.
The power grounds are used to control the ground side relays, solenoids, ignition coil or injectors.
The signal ground is used for any input that uses sensor return for ground, and the ground side of
any internal processing component.
The PCM case is shielded to prevent RFI and EMI. The PCM case is grounded and must be firmly
attached to a good, clean body ground.
Internally all grounds are connected together, however there is noise suppression on the sensor
ground. For EMI and RFI protection the housing and cover are also grounded separately from the
ground pins.
Sensor Return - PCM Input
SENSOR RETURN - PCM INPUT
The sensor return circuit provides a low electrical noise ground reference for all of the systems
sensors. The sensor return circuit connects to internal ground circuits within the Powertrain Control
Module (PCM).
Operation
5 VOLT SUPPLY - PCM OUTPUT
The PCM supplies 5 volts to the following sensors:
- A/C pressure transducer
- Ambient Temperature sensor
- Battery temperature
- Camshaft Position Sensor (NGC)
- Crankshaft Position Sensor (NGC)
- Engine coolant temperature sensor
- Inlet Air Temperature Sensor
- Knock sensor
- Linear EGR solenoid (if equipped)
- Manifold absolute pressure sensor
- Oil Pressure Switch

Powertrain Control Module (PCM) > Page 342
Engine Control Module: Description and Operation Module-Powertrain Control
POWERTRAIN CONTROL MODULE
The PCM receives input signals from various switches and sensors that are referred to as PCM
Inputs. Based on these inputs, the PCM adjusts various engine and vehicle operations through
devices that are referred to as PCM Outputs.
NOTE: PCM Inputs:
- Air Conditioning Controls
- Battery Voltage
- Brake Switch
- Camshaft Position Sensor
- Clutch Upstop Switch
- Clutch Interlock
- Crankshaft Position Sensor
- Engine Coolant Temperature Sensor
- Fuel Level Sensor (Bus message)
- Ignition Switch
- Intake Air Temperature Sensor
- Knock Sensor
- Evaporative System Integrity Monitor
- Manifold Absolute Pressure (MAP) Sensor
- Oxygen Sensors
- Power Steering Pressure Switch
- Speed Control Switches
- Vehicle Speed Sensor (MTX-equipped models)
NOTE: PCM Outputs:
- Air Conditioning Clutch Relay
- Charging Indicator Lamp (Bus Message)
- Proportional Purge Solenoid
- Fuel Injectors
- Generator Field
- Ignition Coils
- Malfunction Indicator (Check Engine) Lamp (Bus Message)
- Manifold Flow Valve
- Oxygen Sensors Heater Controls
- Variable Valve Timing
- Vehicle Speed (Manual Transmission)
Based on inputs it receives, the PCM adjusts fuel injector pulse width, idle speed, ignition spark
advance, ignition coil dwell and EVAP canister purge operation. The PCM also determines the
appropriate transmission shift schedule and shift points, depending on the present operating
conditions and driver demand. The PCM regulates the cooling fan, air conditioning and speed
control systems. The PCM changes generator charge rate by adjusting the
Powertrain Control Module (PCM) > Page 343
generator field. The PCM also performs diagnostics.
The PCM adjusts injector pulse width (air-fuel ratio) based on the following inputs.
- Battery voltage
- Coolant temperature
- Exhaust gas content (oxygen sensor)
- Engine speed (crankshaft position sensor)
- Intake air temperature
- Manifold absolute pressure
- Throttle position
The PCM adjusts ignition timing based on the following inputs.
- Knock sensor
- Throttle position
- Transmission gear selection (park/neutral switch)
The PCM also adjusts engine idle speed through the idle air control motor based on the following
inputs.
- Air conditioning sense
- Battery voltage
- Brake switch
- Engine run time
- Power steering pressure switch
- Throttle position
- Vehicle distance (speed)
The camshaft position sensor and crankshaft position sensor signals are sent to the PCM. If the
PCM does not receive the signal within approximately 1 second of engine cranking, it deactivates
the fuel pump. When these are deactivated, power is shut off to the fuel injectors, ignition coils,
oxygen sensor heating elements and fuel pump.
The PCM contains a voltage converter that changes battery voltage to a regulated 5 volts direct
current to power the camshaft position sensor, crankshaft position sensor, manifold absolute
pressure sensor, throttle position sensor, A/C pressure switch, A/C pressure transducer, and
vehicle speed sensor.
Computers and Control Systems > Engine Control Module > Component Information > Description and Operation > Page
344
Engine Control Module: Testing and Inspection
SKREEM PROGRAMMING
When a Powertrain Control Module (PCM) for a gasoline engine, or an Engine Control Module
(ECM) for a diesel engine and the Sentry Key REmote Entry Module (SKREEM) (also known as
the Wireless Control Module/WCM) on vehicles equipped with the Sentry Key Immobilizer System
(SKIS) are replaced at the same time, perform the following steps in order:
1. Program the new PCM/ECM.
2. Program the new SKREEM/WCM.
3. Replace all ignition keys and program them into the new SKREEM/WCM.
PROGRAMMING THE SKREEM
The SKIS Secret Key is an ID code that is unique to each SKREEM/WCM. This code is
programmed and stored in the SKREEM/WCM, the PCM/ECM, and each ignition key transponder
chip. When the PCM/ECM or SKREEM/WCM is replaced, it is necessary to program the Secret
Key into the new module using a diagnostic scan tool. Follow the programming steps outlined in
the diagnostic scan tool for PCM REPLACED, ECM REPLACED, WCM REPLACED, or
GATEWAY REPLACED under MISCELLANEOUS FUNCTIONS for the WIRELESS CONTROL
MODULE/WCM menu item as appropriate.
NOTE: Be certain to enter the correct country code for the SKREEM/WCM. If the incorrect country
code is programmed into the SKREEM, it cannot be changed and the SKREEM must be replaced.
NOTE: In addition, the SKREEM/WCM must be configured for certain optional equipment in the
vehicle, including Tire Pressure Monitor (TPM), Remote Keyless Entry (RKE) and Remote Start.
Follow the programming steps outlined in the diagnostic scan tool under MISCELLANEOUS
FUNCTIONS for the WCM/WIRELESS CONTROL MODULE menu item as appropriate.
NOTE: A replacement SKREEM/WCM is supplied with TPM enabled by default; therefore, if the
vehicle is not equipped with TPM, the ElectroMechanical Instrument Cluster (EMIC) will incorrectly
learn that the vehicle has TPM after the replacement SKREEM is installed. The TPM indicator in
the EMIC will illuminate to show a TPM fault condition after TPM has been disabled in the
SKREEM. The EMIC must unlearn TPM to correct this false TPM indication. Follow the
programming steps outlined in the diagnostic scan tool for CLEAR LEARNED FEATURES under
MISCELLANEOUS FUNCTIONS for the INSTRUMENT CLUSTER menu item as appropriate.
NOTE: If the PCM/ECM and the SKREEM/WCM are replaced at the same time, all vehicle ignition
keys will need to be replaced and new keys programmed into the new SKREEM/WCM.
NOTE: Programming the PCM/ECM or SKREEM is done using a diagnostic scan tool and a PIN to
enter secure access mode. If three attempts are made to enter secure access mode using an
incorrect PIN, secure access mode will be locked out for one hour. To exit this lockout mode, turn
the ignition to the RUN position for one hour then enter the correct PIN. Be certain that all
accessories are turned OFF. Also monitor the battery state and connect a battery charger if
necessary.
PROGRAMMING IGNITION KEYS TO THE SKREEM
Each ignition key transponder also has a unique ID code that is assigned at the time the key is
manufactured. When a key is programmed into the SKREEM/WCM, the transponder ID code is
learned by the module and the transponder acquires the unique Secret Key ID code from the
SKREEM/WCM. To program ignition keys into the SKREEM/WCM, follow the programming steps
outlined in the diagnostic scan tool for PROGRAM IGNITION KEYS OR KEY FOBS under
MISCELLANEOUS FUNCTIONS for the WIRELESS CONTROL MODULE/WCM menu item.
NOTE: A maximum of eight keys can be learned to each SKREEM. Once a key is learned to a
SKREEM, that key has acquired the Secret Key for that SKREEM and cannot be transferred to any
other SKREEM or vehicle.
If ignition key programming is unsuccessful, the scan tool will display one of the following error
messages:
PROGRAMMING NOT ATTEMPTED - The scan tool attempts to read the programmed key status
and there are no keys programmed into SKREEM memory.
- PROGRAMMING KEY FAILED (POSSIBLE USED KEY FROM WRONG VEHICLE) - SKREEM is
unable to program an ignition key transponder due to one of the following:
- The ignition key transponder is ineffective.
- The ignition key transponder is or has been already programmed to another vehicle.
- 8 KEYS ALREADY LEARNED, PROGRAMMING NOT DONE - The SKREEM transponder ID

memory is full.
- LEARNED KEY IN IGNITION - The ID for the ignition key transponder currently in the ignition lock
cylinder is already programmed into SKREEM memory.
Computers and Control Systems > Engine Control Module > Component Information > Service and Repair > Procedures
Engine Control Module: Procedures
PINION FACTOR SETTING
NOTE: This procedure must be performed if the PCM has been replaced with a NEW or
replacement unit. Failure to perform this procedure will result in an inoperative or improperly
calibrated speedometer.
The vehicle speed readings for the speedometer are taken from the output speed sensor. The
PCM must be calibrated to the different combinations of equipment (final drive and tires) available.
Pinion Factor allows the technician to set the Powertrain Control Module initial setting so that the
speedometer readings will be correct. To properly read and/or reset the Pinion Factor, it is
necessary to use a scan tool.
1. Plug the scan tool into the diagnostic connector located under the instrument panel.
2. Select the Transmission menu.
3. Select the Miscellaneous menu.
4. Select Pinion Factor. Then follow the instructions on the scan tool screen.
Computers and Control Systems > Engine Control Module > Component Information > Service and Repair > Procedures >
Page 347
Engine Control Module: Removal and Replacement

Removal
REMOVAL
USE THE SCAN TOOL TO REPROGRAM THE NEW POWERTRAIN CONTROL MODULE (PCM)
WITH THE VEHICLES ORIGINAL IDENTIFICATION NUMBER (VIN) AND THE VEHICLES
ORIGINAL MILEAGE. IF THIS STEP IS NOT DONE, A DIAGNOSTIC TROUBLE CODE (DTC)
MAY BE SET.
To avoid possible voltage spike damage to PCM, ignition key must be off, and negative battery
cable must be disconnected before unplugging PCM connectors.
1. Disconnect negative battery cable.
2. Unlock and disconnect the electrical connectors from PCM.
3. Remove the air cleaner box.
4. Remove the three mounting bolts.

Page 348
5. Tip module out and remove from bracket.
Installation
INSTALLATION
MAY BE SET.
1. Tip module into bracket.
2. Install three mounting bolts and tighten to 9 Nm (80 in. lbs.) torque.
Page 349
3. Check pins in electrical connectors for damage. Repair as necessary.
4. Connect electrical connectors and lock.
5. Install air cleaner box.
6. Connect negative battery cable.
7. Use the scan tool to reprogram new PCM with vehicles original Identification Number (VIN) and
original vehicle mileage.
Computers and Control Systems > Main Relay (Computer/Fuel System) > Component Information > Locations
Main Relay (Computer/Fuel System): Locations
Main Relay is located in the Fuse/Relay Block.

Computers and Control Systems > Main Relay (Computer/Fuel System) > Component Information > Locations > Page 353
Main Relay (Computer/Fuel System): Diagrams
Main Relay
Fuel Delivery and Air Induction > Main Relay (Computer/Fuel System) > Component Information > Locations

Fuel Delivery and Air Induction > Main Relay (Computer/Fuel System) > Component Information > Locations > Page 358
Main Relay
Jeep Workshop Manuals > Relays and Modules > Relays and Modules - Restraint Systems > Air Bag Control Module >
Component Information > Locations > Module-Occupant Classification
Air Bag Control Module: Locations Module-Occupant Classification
Component ID: 163
Component : MODULE-OCCUPANT CLASSIFICATION
Connector:
Name : MODULE-OCCUPANT CLASSIFICATION C1
Color : BLACK
# of pins : 10
2--
3--
6--
7 DRIVER SEAT POSITION SENSOR VOLTAGER263 20LB/BK
8--
9 DRIVER SEAT POSITION SENSOR DATA R261 20LB/TN
Component Information > Locations > Module-Occupant Classification > Page 364
Connector:
Color : BLACK
# of pins : 12
1 SEAT WEIGHT SENSOR 5 VOLT R701 20LG
2 PASSENGER SEAT POSITION SENSOR VOLTAGE R264 20VT/LB
3 SEAT WEIGHT LEFT FRONT SENSOR SIGNAL R717 20LG/DG
4--
5 SEAT WEIGHT RIGHT FRONT SENSOR SIGNAL R718 20LB/DG
6--
7 SEAT WEIGHT RIGHT REAR SENSOR SIGNAL R706 20LB/OR
8--
9 SEAT WEIGHT LEFT REAR SENSOR SIGNALR705 20LG/OR
10 - -
11 PASSENGER SEAT POSITION SENSOR DATAR262 20WT/LB
12 SEAT WEIGHT SENSOR GROUND R728 20LB/YL
Air Bag Control Module: Locations Module-Occupant Restraint Controller
Component ID: 164
Component : MODULE-OCCUPANT RESTRAINT CONTROLLER
Connector:
Name : MODULE-OCCUPANT RESTRAINT CONTROLLER C1 (ORC)
Color : YELLOW
# of pins : 24
1--
2--
5--
6--
7--
8--
9 LEFT FRONT IMPACT SENSOR GROUND R81 20LB/WT
9 LEFT FRONT IMPACT SENSOR GROUND R81 20DG/YL
10 LEFT FRONT IMPACT SENSOR SIGNAL R79 20LB/VT
11 RIGHT FRONT IMPACT SENSOR GROUND R82 20WT/OR
12 RIGHT FRONT IMPACT SENSOR SIGNAL R80 20VT/LB
13 - -
14 - -
15 - -
16 - -
17 DRIVER SQUIB 1 LINE 2 R43 18LG/BR
18 DRIVER SQUIB 1 LINE 1 R45 18LG/RD
19 PASSENGER SQUIB 1 LINE 1 R44 18LB/OR
20 PASSENGER SQUIB 1 LINE 2 R42 18LB/BR
21 DRIVER SQUIB 2 LINE 2 R61 18LG/VT
22 DRIVER SQUIB 2 LINE 1 R63 18LG/BK
23 PASSENGER SQUIB 2 LINE 1 R64 18LB/WT
24 PASSENGER SQUIB 2 LINE 2 R62 18LB/VT
Connector:
Color : YELLOW
# of pins : 32
1--
2--
3--
4--
5 LEFT CURTAIN SQUIB 1 LINE 2 R1 18LB/WT

6 LEFT CURTAIN SQUIB 1 LINE 1 R3 18LB/OR
7 RIGHT CURTAIN SQUIB 1 LINE 1 R4 18OR/LB
8 RIGHT CURTAIN SQUIB 1 LINE 2 R2 18WT/LB
9 DRIVER SEAT BELT TENSIONER LINE 2 R53 18LG/YL
10 DRIVER SEAT BELT TENSIONER LINE 1 R55 18LG/DG
11 PASSENGER SEAT BELT TENSIONER LINE 1R56 18LB/DG
12 PASSENGER SEAT BELT TENSIONER LINE 2R54 18LB/YL
13 RIGHT SEAT SQUIB 1 LINE 2 R6 18VT/LB
14 RIGHT SEAT SQUIB 1 LINE 1 R8 18GY/LG
15 LEFT SEAT SQUIB 1 LINE 1 R7 18LG/GY
16 LEFT SEAT SQUIB 1 LINE 2 R5 18LB/VT
19 - -
21 - -
22 - -
23 - -
24 - -
27 RIGHT SIDE IMPACT SENSOR 1 SIGNAL R14 20TN/LG
28 RIGHT SIDE IMPACT SENSOR 1 GROUND R16 20BR/LG
29 LEFT SIDE IMPACT SENSOR 1 GROUND R15 20LG/BR
30 LEFT SIDE IMPACT SENSOR 1 SIGNAL R13 20LG/TN
Component Information > Diagrams > Module-Occupant Classification
Air Bag Control Module: Diagrams Module-Occupant Classification
Component ID: 163
Component : MODULE-OCCUPANT CLASSIFICATION
Connector:
Color : BLACK
# of pins : 10
2--
3--
6--
8--
Component Information > Diagrams > Module-Occupant Classification > Page 374
Connector:
Color : BLACK
# of pins : 12
4--
6--
8--
10 - -
Air Bag Control Module: Diagrams Module-Occupant Restraint Controller
Component ID: 164
Component : MODULE-OCCUPANT RESTRAINT CONTROLLER
Connector:
Color : YELLOW
# of pins : 24
1--
2--
5--
6--
7--
8--
13 - -
14 - -
15 - -
16 - -
Connector:
Color : YELLOW
# of pins : 32
1--
2--
3--
4--
5 LEFT CURTAIN SQUIB 1 LINE 2 R1 18LB/WT

6 LEFT CURTAIN SQUIB 1 LINE 1 R3 18LB/OR
9 DRIVER SEAT BELT TENSIONER LINE 2 R53 18LG/YL
10 DRIVER SEAT BELT TENSIONER LINE 1 R55 18LG/DG
11 PASSENGER SEAT BELT TENSIONER LINE 1R56 18LB/DG
12 PASSENGER SEAT BELT TENSIONER LINE 2R54 18LB/YL
13 RIGHT SEAT SQUIB 1 LINE 2 R6 18VT/LB
14 RIGHT SEAT SQUIB 1 LINE 1 R8 18GY/LG
15 LEFT SEAT SQUIB 1 LINE 1 R7 18LG/GY
16 LEFT SEAT SQUIB 1 LINE 2 R5 18LB/VT
19 - -
21 - -
22 - -
23 - -
24 - -
Air Bag Control Module: Description and Operation Description
DESCRIPTION
The Occupant Restraint Controller (ORC) (1) is secured with three nuts to three studs on a
stamped steel mounting bracket welded onto the top of the floor panel transmission tunnel near the
dash panel. The ORC is located beneath the console shifter housing forward of the transmission
gearshift mechanism and center floor console in the passenger compartment of the vehicle.
Concealed within a hollow in the center of the die cast aluminum ORC housing is the electronic
circuitry of the ORC which includes a microprocessor, an electronic impact sensor, an electronic
safing sensor, and an energy storage capacitor. A stamped metal cover plate is secured to the
bottom of the ORC housing with four screws to enclose and protect the internal electronic circuitry
and components.
An arrow (2) printed on the label (3) on the top of the ORC housing provides a visual verification of
the proper orientation of the unit, and should always be pointed toward the front of the vehicle. The
ORC housing has integral mounting flanges (5) on the left front and rear corners and near the
center of the right side. A molded plastic electrical connector receptacle (4) exits the rearward
facing side of the ORC housing. This receptacle connects the ORC to the vehicle electrical system
through two dedicated take outs and connectors from the instrument panel wire harness.
The impact sensor and safing sensor internal to the ORC are calibrated for the specific vehicle, and
are only serviced as a unit with the ORC. In addition, there are unique versions of the ORC for
vehicles with or without side curtain airbags. The ORC cannot be repaired or adjusted and, if
damaged or ineffective, it must be replaced.
Air Bag Control Module: Description and Operation Operation
OPERATION
The microprocessor in the Occupant Restraint Controller (ORC) contains the supplemental
restraint system logic circuits and controls all of the supplemental restraint system components.
The ORC uses On-Board Diagnostics (OBD) and can communicate with other electronic modules
in the vehicle as well as with the diagnostic scan tool using the Controller Area Network (CAN) data
bus. This method of communication is used for control of the airbag indicator in the
and for supplemental restraint system diagnosis and testing through the 16-way data link connector
located on the driver side lower edge of the instrument panel.
The ORC microprocessor continuously monitors all of the supplemental restraint system electrical
circuits to determine the system readiness. If the ORC detects a monitored system fault, it sets an
active and stored Diagnostic Trouble Code (DTC) and sends electronic messages to the EMIC
over the CAN data bus to turn ON the airbag indicator. An active fault only remains for the duration
of the fault, or in some cases for the duration of the current ignition switch cycle, while a stored fault
causes a DTC to be stored in memory by the ORC. For some DTCs, if a fault does not recur for a
number of ignition cycles, the ORC will automatically erase the stored DTC. For other internal
faults, the stored DTC is latched forever.
On vehicles equipped with the Occupant Classification System (OCS), the ORC communicates
with the Occupant Classification Module (OCM) over the CAN data bus. The ORC will internally
disable the passenger airbag and seat belt tensioner deployment circuits if the OCM detects that
the passenger side front seat is unoccupied or that it is occupied by a load that is inappropriate for
an airbag deployment. The ORC also provides a control output to the passenger airbag on/off
indicator through the passenger airbag indicator driver circuit. The OCM notifies the ORC when it
has detected a monitored system fault and stored a DTC in its memory for any ineffective OCS
component or circuit, then the ORC sets a DTC and controls the airbag indicator operation
accordingly.
The ORC receives battery current through two circuits; a fused ignition switch output (run) circuit
through a fuse in the Totally Integrated Power Module (TIPM), and a fused ignition switch output
(run-start) circuit through a second fuse in the TIPM. The ORC receives ground through a ground
circuit and take out of the instrument panel wire harness. These connections allow the ORC to be
operational whenever the ignition switch is in the START or ON positions. Refer to the appropriate
wiring information for additional details.
The ORC also contains an energy-storage capacitor. When the ignition switch is in the START or
ON positions, this capacitor is continually being charged with enough electrical energy to deploy
the supplemental restraint components for up to one second following a battery disconnect or
failure. The purpose of the capacitor is to provide backup supplemental restraint system protection
in case there is a loss of battery current supply to the ORC during an impact.
Two sensors are contained within the ORC, an electronic impact sensor and a safing sensor. The
ORC also monitors inputs from two remote front impact sensors located on the back of the right
and left vertical members of the radiator support near the front of the vehicle. The electronic impact
sensors are accelerometers that sense the rate of vehicle deceleration, which provides verification
of the direction and severity of an impact. On vehicles equipped with optional side curtain airbags
or seat airbags the ORC also monitors inputs from an internal rollover sensor and four additional
remote impact sensors located on the left and right inner B-pillars and C-pillars to control
deployment of the side curtain airbag and seat airbag units.
The safing sensor is an electronic accelerometer sensor within the ORC that provides an additional
logic input to the ORC microprocessor. The safing sensor is used to verify the need for a
supplemental restraint deployment by detecting impact energy of a lesser magnitude than that of
the primary electronic impact sensors, and must exceed a safing threshold in order for the airbags
to deploy. Vehicles equipped with optional side curtain airbags or seat airbags feature a second
safing sensor within the ORC to provide confirmation to the ORC microprocessor of side impact
forces. This second safing sensor is a bi-directional unit that detects impact forces from either side
of the vehicle.
Pre-programmed decision algorithms in the ORC microprocessor determine when the deceleration
rate as signaled by the impact sensors and the safing sensors indicate an impact that is severe
enough to require supplemental restraint system protection and, based upon the severity of the
monitored impact, determines the level of front airbag deployment force required for each front
seating position. When the programmed conditions are met, the ORC sends the proper electrical
signals to deploy the dual multistage front airbags at the programmed force levels, the front seat
belt tensioners and, if the vehicle is so equipped, either side curtain and seat airbag unit. For
vehicles equipped with the OCS, the passenger front airbag and seat belt tensioner will be
deployed by the ORC only if enabled by the OCM messages (passenger airbag on/off indicator
OFF) at the time of the impact.
The hard wired inputs and outputs for the ORC may be diagnosed using conventional diagnostic
tools and procedures. Refer to the appropriate wiring information. However, conventional
diagnostic methods will not prove conclusive in the diagnosis of the ORC or the electronic controls
or communication between other modules and devices that provide features of the supplemental
restraint system. The most reliable, efficient, and accurate means to diagnose the ORC or the
electronic controls and communication related to ORC operation requires the use of a diagnostic
scan tool. Refer to the appropriate diagnostic information.
Air Bag Control Module: Service and Repair Removal
REMOVAL
WARNING: To avoid serious or fatal injury on vehicles equipped with side curtain or seat airbags,
disable the supplemental restraint system before attempting any occupant restraint controller
diagnosis or service. The occupant restraint controller contains a rollover sensor, which enables
the system to deploy the side curtain and seat airbags in the event of a vehicle rollover event. If an
occupant restraint controller is accidentally rolled during service while still connected to battery
power, the side curtain and seat airbags will deploy. Disconnect and isolate the battery negative
(ground) cable, then wait two minutes for the system capacitor to discharge before performing
further diagnosis or service. This is the only sure way to disable the supplemental restraint system.
Failure to take the proper precautions could result in accidental airbag deployment.
WARNING: To avoid serious or fatal injury, never strike or drop the occupant restraint controller, as
it can damage the impact sensor or affect its calibration. The occupant restraint controller contains
the impact sensor, which enables the system to deploy the supplemental restraints. If an occupant
restraint controller is accidentally dropped during service, the module must be scrapped and
replaced with a new unit. Failure to observe this warning could result in accidental, incomplete, or
improper supplemental restraint deployment.
CAUTION: On vehicles equipped with the Occupant Classification System (OCS), never replace
both the Occupant Restraint Controller (ORC) and the Occupant Classification Module (OCM) at
the same time. If both require replacement, replace one. Then perform the supplemental restraint
verification test before replacing the other. Both the ORC and the OCM store OCS calibration data,
which they transfer to one another when one of them is replaced. If both are replaced at the same
time, an irreversible fault will be set in both modules.
NOTE: Several different Occupant Restraint Controllers (ORC) are available for this vehicle. For
vehicles equipped with the optional side curtain or seat airbags the ORC contains a second
bi-directional safing sensor.
1. Disconnect and isolate the battery negative cable. Wait two minutes for the system capacitor to
discharge before further service.
2. Remove the center console shifter housing from the top of the floor panel transmission tunnel..
3. Lift, but do not remove, the jute covered panel (1) over the Occupant Restraint Controller (ORC)
(2) between the dash panel and the gearshift
mechanism as necessary to access the ORC connections and fasteners.

4. Remove the three nuts (2) that secure the ORC (3) to the three studs (1) on the ORC mount
welded onto the top of the floor panel transmission
tunnel (5).
5. Unlatch and disconnect the two instrument panel wire harness connectors (4) from the ORC
connector receptacles located on the rearward facing
side of the module. To disconnect the wire harness connectors from the ORC, depress the release
tab and lift the lever arm on each connector.
6. Remove the ORC from the ORC mount.

Air Bag Control Module: Service and Repair Installation
INSTALLATION
WARNING: To avoid serious or fatal injury on vehicles equipped with side curtain or seat airbags,
disable the supplemental restraint system before attempting any occupant restraint controller
diagnosis or service. The occupant restraint controller contains a rollover sensor, which enables
the system to deploy the side curtain and seat airbags in the event of a vehicle rollover event. If an
occupant restraint controller is accidentally rolled during service while still connected to battery
power, the side curtain and seat airbags will deploy. Disconnect and isolate the battery negative
(ground) cable, then wait two minutes for the system capacitor to discharge before performing
further diagnosis or service. This is the only sure way to disable the supplemental restraint system.
Failure to take the proper precautions could result in accidental airbag deployment.
WARNING: To avoid serious or fatal injury, never strike or drop the occupant restraint controller, as
it can damage the impact sensor or affect its calibration. The occupant restraint controller contains
the impact sensor, which enables the system to deploy the supplemental restraints. If an occupant
restraint controller is accidentally dropped during service, the module must be scrapped and
replaced with a new unit. Failure to observe this warning could result in accidental, incomplete, or
improper supplemental restraint deployment.
CAUTION: On vehicles equipped with the Occupant Classification System (OCS), never replace
both the Occupant Restraint Controller (ORC) and the Occupant Classification Module (OCM) at
the same time. If both require replacement, replace one. Then perform the supplemental restraint
verification test before replacing the other. Both the ORC and the OCM store OCS calibration data,
which they transfer to one another when one of them is replaced. If both are replaced at the same
time, an irreversible fault will be set in both modules.
NOTE: Several different Occupant Restraint Controllers (ORC) are available for this vehicle. For
vehicles equipped with the optional side curtain or seat airbags the ORC contains a second
bi-directional safing sensor.
1. Lift, but do not remove, the jute covered panel (1) over the Occupant Restraint Controller (ORC)
(2) mount between the dash panel and the
gearshift mechanism as necessary to reinstall the ORC, its connections and fasteners.
CAUTION: Be certain that the jute covered panel over the ORC is restored to its original installed
position following ORC service. Failure to do so may result in the setting of a false Diagnostic
Trouble Code (DTC) and illumination of the airbag indicator. This cover protects the ORC from the
gearshift selector cables vibrating against or striking the top of the ORC housing, which could be
falsely interpreted as a vehicle impact pulse by the sensors within the ORC.
2. Carefully position the Occupant Restraint Controller (ORC) (3) onto the three studs (1) of the
ORC mount on the floor panel transmission tunnel
(5). The bottom of the ORC housing is keyed. When the ORC is correctly positioned, the bottom of
the housing will fit flush with the mount and the orientation arrow on the label on top of the housing
will be pointed forward in the vehicle.
3. Reconnect the two instrument panel wire harness connectors (4) to the ORC connector
receptacles located on the rearward facing side of the
module. Be certain that the latches on the connectors are each fully engaged.
4. Install and tighten the three nuts (2) that secure the ORC to the studs of the ORC mount. Tighten
the nuts to 9 Nm (80 in. lbs.).
5. Restore the jute covered panel to its proper position over the ORC between the dash panel and
the gearshift mechanism.
6. Reinstall the center console shifter housing onto the top of the floor panel transmission tunnel.
7. Do not reconnect the battery negative cable at this time. The supplemental restraint system
verification test procedure should be performed
following service of any supplemental restraint system component.

Jeep Workshop Manuals > Relays and Modules > Relays and Modules - Restraint Systems > Seat Occupant Classification
Module - Air Bag > Component Information > Description and Operation > Description
Seat Occupant Classification Module - Air Bag: Description and Operation Description
DESCRIPTION
The Occupant Classification Module (OCM) (1) is secured with one screw and one tab to the
passenger side front seat cushion pan under the front edge of the seat cushion. Concealed within a
hollow in the center of the molded plastic OCM housing is a microprocessor and the other
electronic circuitry of the module. The module housing is sealed to enclose and protect the internal
electronic circuitry.
Four mounting tabs (2) and two connector receptacles (3) are integral to the OCM housing. One
mounting tab is inserted into a slot in a dimpled pocket formation of the seat cushion pan, while a
screw secures another tab to the seat pan. The remaining two mounting tabs are unused in this
application. The connector receptacles contain terminal pins that connect the OCM to the vehicle
electrical system through dedicated take outs and connectors of the passenger side front seat wire
harness.
The OCM and all of the other components of the Occupant Classification System (OCS) including
the passenger side front seat, the seat weight sensors, and the seat adjusters, cushion, back,
frame, foam, springs, and wiring harness are a factory-calibrated and assembled unit. Any time any
one of these components is removed or replaced for any reason, the OCM must be re-calibrated
using a diagnostic scan tool, the Occupant Classification Seat Weight special tool, and the
Occupant Classification System Verification Test. Refer to the appropriate diagnostic procedures.
The OCM cannot be adjusted or repaired and, if damaged or ineffective, it must be replaced. The
OCM software is flash programmable. A non-calibrated OCM is available for separate service
replacement.
Module - Air Bag > Component Information > Description and Operation > Description > Page 394
Seat Occupant Classification Module - Air Bag: Description and Operation Operation
OPERATION
The microprocessor in the Occupant Classification Module (OCM) contains the Occupant
Classification System (OCS) logic circuits. The OCM uses On-Board Diagnostics (OBD) and can
communicate with other electronic modules in the vehicle as well as with the diagnostic scan tool
using the Controller Area Network (CAN) data bus. This method of communication is also used for
OCS diagnosis and testing through the 16-way data link connector located on the driver side lower
edge of the instrument panel.
The OCM provides voltage to the four seat weight sensors located on the corners of the passenger
side front seat, and to the seat track position sensors on the outboard passenger and driver side
front seat upper seat tracks. The OCM then monitors return inputs from each of the sensors on
dedicated hard wired data communication circuits. The seat weight sensor inputs allow the OCM to
determine whether the passenger side front seat is occupied and the relative size of the occupant
by providing a weight-sensing reference to the load on the seat. The seat track position sensors
provide additional logic inputs to the OCM microprocessor that allow it to determine the position of
the front seat passenger and the driver relative to the front airbags.
Pre-programmed decision algorithms and OCS calibration allow the OCM microprocessor to
determine when passenger airbag protection is appropriate based upon the seat load as signaled
by the seat weight sensors. When the programmed conditions are met, the OCM sends the proper
electronic occupant classification messages over the CAN data bus to the Occupant Restraint
Controller (ORC), and the ORC controls the deployment circuits for the passenger front
supplemental restraints. On vehicles so equipped, the ORC also provides a control output for the
passenger airbag on/off indicator in the instrument panel based upon the electronic occupant
classification messages it receives from the OCM.
The OCM also sends electronic driver and passenger seat track position messages to the ORC
over the CAN data bus. The ORC uses the seat track position data as an additional logic input for
determining the force level with which to deploy the multistage front airbags.
The OCM microprocessor continuously monitors all of the OCS electrical circuits and components
to determine the system readiness. If the OCM detects a monitored system fault, it sets an active
and stored Diagnostic Trouble Code (DTC) and sends the appropriate electronic messages to the
ORC over the CAN data bus. Then the ORC sets a DTC and sends messages to control the airbag
indicator operation accordingly. An active fault only remains for the duration of the fault, or in some
cases for the duration of the current ignition switch cycle, while a stored fault causes a DTC to be
stored in memory by the OCM and the ORC. For some DTCs, if a fault does not recur for a number
of ignition cycles, the OCM will automatically erase the stored DTC. For other internal faults, the
stored DTC is latched forever.
The OCM receives battery current on a fused B(+) circuit through a fuse in the Totally Integrated
Power Module (TIPM) and receives electronic ignition switch status messages indicating the
ignition switch position over the CAN data bus. The OCM receives ground through a ground circuit
and take out of the body wire harness. These connections allow the OCM to be operational
whenever the ignition switch is in the ON or START positions.
The hard wired inputs and outputs for the OCM may be diagnosed using conventional diagnostic
tools and procedures. Refer to the appropriate wiring information. However, conventional
diagnostic methods will not prove conclusive in the diagnosis of the OCM or the electronic controls
and communication between other modules and devices that provide features of the OCS. The
most reliable, efficient, and accurate means to diagnose the OCM or the electronic controls and
communication related to OCM operation requires the use of a diagnostic scan tool. Refer to the
appropriate diagnostic information.
Module - Air Bag > Component Information > Service and Repair > Removal
Seat Occupant Classification Module - Air Bag: Service and Repair Removal
REMOVAL
NOTE: A non-calibrated Occupant Classification Module (OCM) is available for separate service
replacement. The OCM and all of the other components of the Occupant Classification System
(OCS) including the passenger side front seat, the seat weight sensors, and the passenger seat
adjusters, cushion, back, frame, foam, springs, and wiring harness are a factory-calibrated and
assembled unit. Any time any one of these components is removed or replaced for any reason, the
OCM must be re-calibrated using a diagnostic scan tool, the Occupant Classification Seat Weight
special tool, and the Occupant Classification System Verification Test. Refer to the appropriate
diagnostic procedures.
2. Reach under the front edge of the passenger side front seat cushion to access and disconnect
the two seat wire harness connectors (3) from the
Occupant Classification Module (OCM) (1) connector receptacles located on the left end of the
module.
3. Remove the screw (2) that secures the OCM to the underside of the passenger side front seat
cushion pan.
4. Slide the OCM forward far enough to disengage the mounting tab from the slot in the dimpled
pocket formation (4) in the seat cushion pan.
5. Remove the OCM from under the passenger side front seat.
Module - Air Bag > Component Information > Service and Repair > Removal > Page 397
Seat Occupant Classification Module - Air Bag: Service and Repair Installation
INSTALLATION
NOTE: A non-calibrated Occupant Classification Module (OCM) is available for separate service
replacement. The OCM and all of the other components of the Occupant Classification System
(OCS) including the passenger side front seat, the seat weight sensors, and the passenger seat
adjusters, cushion, back, frame, foam, springs, and wiring harness are a factory-calibrated and
assembled unit. Any time any one of these components is removed or replaced for any reason, the
OCM must be re-calibrated using a diagnostic scan tool, the Occupant Classification Seat Weight
special tool, and the Occupant Classification System Verification Test. Refer to the appropriate
diagnostic procedures.
1. Reach under the front edge of the passenger side front seat cushion to carefully position the
Occupant Classification Module (OCM) (1) to the
underside of the seat cushion pan. When the OCM is correctly positioned, the connector
receptacles on the module will be pointed toward the left side of the seat.
2. Slide the OCM rearward far enough to engage the mounting tab into the slot in the dimpled
pocket formation (4) in the seat cushion pan.
3. Install and tighten the screw (2) that secures the OCM to the seat cushion pan. Tighten the
screw to 2 Nm (20 in. lbs.).
4. Reconnect the two seat wire harness connectors (3) to the OCM connector receptacles located
on the left end of the module. Be certain that the
latches on each connector are fully engaged.
6. Following successful completion of the supplemental restraint system verification test procedure,
perform the Occupant Classification System
Verification Test using a diagnostic scan tool. Refer to the appropriate diagnostic procedures.
Jeep Workshop Manuals > Relays and Modules > Relays and Modules - Steering and Suspension > Relays and Modules -
Steering > Steering Column Control Module > Component Information > Description and Operation > Description
Steering Column Control Module: Description and Operation Description
DESCRIPTION
This vehicle is equipped with a Steering Control Module (SCM) that is internal to the left
multi-function switch housing (2). The left (lighting) multi-function switch is located on the left side
of the steering column, just below the steering wheel. This switch is the primary control for the
interior and exterior lighting systems. The only visible components of the switch are the control
stalk (1), control knob and control sleeve that extend through the steering column shrouds on the
left side of the column. The remainder of the switch including its mounting provisions and electrical
connections are concealed beneath the shrouds.
The switch housing and controls are constructed of molded black plastic. A single screw (7)
through a mounting tab integral to the back of the switch housing, and a slide tab integral to the
bottom of the switch housing secure the switch to the mounting bracket integral to the clockspring
(3). A connector receptacle containing seven terminal pins is integral to the inboard end of the
switch housing and connects the SCM through a jumper wire harness (5) directly to the right
(wiper) multi-function switch (6). A second connector receptacle containing four terminal pins is
integral to the back of the switch housing and connects the SCM to the vehicle electrical system
through a dedicated takeout and connector of the instrument panel wire harness.
The SCM cannot be adjusted or repaired. If ineffective or damaged the entire left multi-function
switch must be replaced. The clockspring (with the multi-function switch mounting bracket), the left
multi-function switch (with the SCM), the right multi-function switch and the jumper wire harness
are each available for separate service replacement.
Steering > Steering Column Control Module > Component Information > Description and Operation > Description > Page
404
Steering Column Control Module: Description and Operation Operation
OPERATION
The microprocessor-based Steering Control Module (SCM) utilizes integrated circuitry to monitor
hard wired analog and multiplexed inputs from both the right and left multi-function switches. In
response to those inputs, the internal circuitry of the SCM allow it to transmit electronic message
outputs to the Electromechanical Instrument Cluster (EMIC) (also known as the Cab Compartment
Node/CCN) over the Local Interface Network (LIN) data bus.
In response to those inputs the internal circuitry and programming of the EMIC, which is also the
LIN master module in the vehicle, allow it to control and integrate many electronic functions and
features of the vehicle through both hard wired outputs and the transmission of electronic message
outputs to other electronic modules in the vehicle over the Controller Area Network (CAN) data
bus.
The SCM is connected to both a fused B(+) circuit and a fused ignition switch output (run-start)
circuit. It receives a path to ground at all times. These connections allow it to remain functional
regardless of the ignition switch position. Any input to the SCM that controls a vehicle system
function that does not require that the ignition switch be in the ON position such as turning on the
lights, prompts the SCM to wake up and transmit on the LIN data bus.
The hard wired circuits between components related to the SCM may be diagnosed using
conventional diagnostic tools and procedures. Refer to the appropriate wiring information. The
wiring information includes wiring diagrams, proper wire and connector repair procedures, details of
wire harness routing and retention, connector pin-out information and location views for the various
wire harness connectors, splices and grounds.
However, conventional diagnostic methods will not prove conclusive in the diagnosis of the SCM or
the electronic controls or communication between modules and other devices that provide some
features of the SCM. The most reliable, efficient, and accurate means to diagnose the SCM or the
electronic controls and communication related to SCM operation requires the use of a diagnostic
Steering > Steering Column Control Module > Component Information > Service and Repair > Removal
Steering Column Control Module: Service and Repair Removal
REMOVAL
SCCM
1. Place the front road wheels in the STRAIGHT-AHEAD position. 2. Open hood. 3. Disconnect
and isolate the battery negative cable.
WARNING: Wait two minutes for the airbag system reserve capacitor to discharge before
beginning any airbag system or component service. Failure to do so may result in accidental airbag
deployment, personal injury or death.
4. Remove steering wheel. 5. Remove upper and lower steering column shrouds to gain access to
the Steering Column Control Module (SCCM). 6. Lock the clockspring rotor in the center position
as follows: Insert a grenade pin through the hole in the rotor at the 10 o'clock position. 7. Remove
the three screws (1) to the Steering Column Control Module (SCCM) (3).
Steering > Steering Column Control Module > Component Information > Service and Repair > Removal > Page 407
8. Disconnect the electrical connectors (2) between the SCCM (1) and the instrument panel wiring
harness at the base of the SCCM and remove from
column.
NOTE: If only removing the SCCM from column, there is no need to continue to next step.
DISASSEMBLY
1. Remove the left multi-function switch stalk retaining screw (2). 2. Pull the left stalk out of the
SCCM.
3. Disconnect the left stalk electrical connector. 4. Separate the left switch from the SCCM.
5. Remove the one right multi-function switch retaining screw. 6. Pull right switch out of SCCM.
7. Disconnect the right switch electrical connector.
Steering Column Control Module: Service and Repair Installation
INSTALLATION
NOTE: If SCCM is already assembled and needs to be installed, bypass ASSEMBLY and proceed
with SCCM STEP 1.
ASSEMBLY
1. Connect the right stalk electrical connector.
2. Slide the right stalk into the groove and install the one retaining screw.
3. Connect the left stalk switch electrical connector.
4. Install the left stalk switch retaining screw.
SCCM
1. Position the SCCM (3) over the steering column shaft (2). 2. Install the three screws (1).
3. Connect the electrical connectors (2) to the instrument panel harness, ensure wiring is properly
routed. Then check that the connectors, locking
tabs are properly engaged.
4. Install steering column shrouds. Be sure all wires are inside of shrouds. 5. Install steering wheel
ensuring the flats on hub align with the clockspring. Pull the airbag leads through the larger slot.
Ensure leads do not get
pinched under the steering wheel.
NOTE: There is a small wire harness in the steering wheel and it contains the horn circuits and
speed control circuits.
6. Connect the speed control and horn wire connector into the clockspring. 7. Pull the grenade pin
out of the clockspring. 8. Install the driver airbag.
WARNING: Do not connect the battery negative cable. Personal injury or death may result if the
system test is not performed first.
Steering > Steering Control Module > Component Information > Description and Operation > Description
Steering Control Module: Description and Operation Description
DESCRIPTION
Steering > Steering Control Module > Component Information > Description and Operation > Description > Page 417
Steering Control Module: Description and Operation Operation
OPERATION
outputs to the ElectroMechanical Instrument Cluster (EMIC) (also known as the Cab Compartment
bus.
Steering > Steering Control Module > Component Information > Description and Operation > Page 418
Steering Control Module: Testing and Inspection
STEERING CONTROL MODULE
Steering > Steering Mounted Controls Communication Module > Component Information > Locations
Steering Mounted Controls Communication Module: Locations
Component ID: 167
Component : MODULE-STEERING CONTROL
Connector:
Name : MODULE-STEERING CONTROL C1
Color : WHITE
# of pins : 4
3 LIN BUS D506 20WT/DG
Steering > Steering Mounted Controls Communication Module > Component Information > Locations > Page 422
Connector:
Color : WHITE
# of pins : 6
1 RADIO CONTROL MUX X20 20GY/WT
2 RADIO CONTROL RETURN Y13 20DG/RD
3 HORN SWITCH SENSE X3 20DG/VT

Connector:
Color : WHITE
# of pins : 4

Connector:
Color : WHITE
# of pins : 6
1 RADIO CONTROL MUX X20 20GY
2 RADIO CONTROL RETURN Y13 20BK

3 HORN SWITCH SENSE X3 20DB
4 S/C SIGNAL 2 V72 20PK
5 S/C SIGNAL 1 V71 20VT
6 S/C SWITCH GROUND V937 20YL
Steering Mounted Controls Communication Module: Diagrams
Component ID: 167
Connector:
Color : WHITE
# of pins : 4
Connector:
Color : WHITE
# of pins : 6

Connector:
Color : WHITE
# of pins : 4

Connector:
Color : WHITE
# of pins : 6

Wheels and Tires > Tire Pressure Monitor Receiver / Transponder > Component Information > Locations >
Transponder-Tire Pressure-Left Front
Tire Pressure Monitor Receiver / Transponder: Locations Transponder-Tire Pressure-Left Front
Component ID: 369
Component : TRANSPONDER-TIRE PRESSURE-LEFT FRONT
Connector:
Name : TRANSPONDER-TIRE PRESSURE-LEFT FRONT
Color : YELLOW
# of pins : 6
Qualifier : (TIRE PRESSURE MONITOR)
3 GROUND Z904 20BK/OR
5--
6--
Transponder-Tire Pressure-Left Front > Page 460
Tire Pressure Monitor Receiver / Transponder: Locations Transponder-Tire Pressure-Left Rear
Component ID: 370
Component : TRANSPONDER-TIRE PRESSURE-LEFT REAR
Connector:
Name : TRANSPONDER-TIRE PRESSURE-LEFT REAR
Color : BLACK
# of pins : 6
4--
5--
6--
Tire Pressure Monitor Receiver / Transponder: Locations Transponder-Tire Pressure-Right Rear
Component ID: 371
Component : TRANSPONDER-TIRE PRESSURE-RIGHT REAR
Connector:
Name : TRANSPONDER-TIRE PRESSURE-RIGHT REAR
Color : BLACK
# of pins : 6
3 GROUND Z965 20BK/GY
4--
5--

Wheels and Tires > Tire Pressure Monitor Receiver / Transponder > Component Information > Diagrams >
Tire Pressure Monitor Receiver / Transponder: Diagrams Transponder-Tire Pressure-Left Front
Component ID: 369
Connector:
Color : YELLOW
# of pins : 6
5--
6--
Tire Pressure Monitor Receiver / Transponder: Diagrams Transponder-Tire Pressure-Left Rear
Component ID: 370
Connector:
Color : BLACK
# of pins : 6
4--
5--
6--
Tire Pressure Monitor Receiver / Transponder: Diagrams Transponder-Tire Pressure-Right Rear
Component ID: 371
Connector:
Color : BLACK
# of pins : 6
4--
5--

Wheels and Tires > Tire Pressure Monitor Receiver / Transponder > Component Information > Description and Operation >
Description
Tire Pressure Monitor Receiver / Transponder: Description and Operation Description
DESCRIPTION
A transponder, sometimes referred to as a trigger module, is located in three of the four wheel
wells (behind the wheelhouse splash shields) of a vehicle equipped with Premium TPM. These
transponders are used to provide the Wireless Control Module (WCM), commonly referred to as
the Sentry Key Remote Entry Module (SKREEM), with the location of the tire pressure sensors on
the vehicle. A fourth transponder is not necessary in the remaining wheel well due to the
process-of-elimination theory. Once the system knows the location of the first three sensors it
assumes the location of the fourth tire pressure sensor. On this vehicle, there is a transponder
located in the left front, left rear, and right rear wheelhouse. There is not a transponder located in
the right front wheelhouse.
Wheels and Tires > Tire Pressure Monitor Receiver / Transponder > Component Information > Description and Operation >
Description > Page 474
Tire Pressure Monitor Receiver / Transponder: Description and Operation Operation
OPERATION
On vehicles equipped with the premium TPM system, the Wireless Control Module (WCM),
commonly referred to as the Sentry Key Remote Entry Module (SKREEM), uses transponders
(trigger modules) located in three of the four wheel wells on the vehicle to provide it with the
location of the tire pressure sensors on the vehicle. Like the base system, the WCM receives RF
signals from all four rotating wheel speed sensors. When the WCM needs to know which sensor is
located at a particular location on the vehicle, it directs the transponder at that location to send out
a low frequency signal to excite the nearby sensor. The WCM then receives that excited signal and
knows where that sensor is located. This auto-locating process only happens in the first 10 minutes
of any WCM cycle while traveling at speeds above 20 mph (32 km/h). (The auto-locating process
will start again only if the vehicle has been shut off for approximately 20 minutes or longer). Once
the WCM has performed this to the three locations that have transponders, it uses the
process-of-elimination theory to know that the fourth sensor ID signal is coming from.
Wheels and Tires > Tire Pressure Monitor Receiver / Transponder > Component Information > Service and Repair >
Removal
Tire Pressure Monitor Receiver / Transponder: Service and Repair Removal
Front
FRONT
1. Remove the wheelhouse splash shield at the transponder requiring service.
2. Disconnect the wiring harness connector (2) at the transponder (1). 3. Remove the mounting
nuts (3), then remove the transponder (1).
Rear
REAR
Wheels and Tires > Tire Pressure Monitor Receiver / Transponder > Component Information > Service and Repair >
Removal > Page 477
Tire Pressure Monitor Receiver / Transponder: Service and Repair Installation
Front
FRONT
1. Position the transponder (1) and install the mounting nuts (3). 2. Connect the wiring harness
connector (2) to the transponder (1). 3. Install the wheelhouse splash shield and all components
removed to access it. 4. Perform the TPM Diagnostic Verification Test. See: Powertrain
Management/Computers and Control Systems/Testing and Inspection/Diagnostic
Trouble Code Tests and Associated Procedures/Verification Tests
Rear
REAR
connector (3) to the transponder (1). 3. Install the rear wheelhouse splash shield and all
components removed to access it. 4. Perform the TPM Diagnostic Verification Test. See:
Powertrain Management/Computers and Control Systems/Testing and Inspection/Diagnostic

Jeep Workshop Manuals > Relays and Modules > Relays and Modules - Transmission and Drivetrain > Relays and
Modules - A/T > Control Module, A/T > Component Information > Technical Service Bulletins > Engine, A/T Controls -
PCM/TCM Replacement Requirements
Control Module: Technical Service Bulletins Engine, A/T Controls - PCM/TCM Replacement
Requirements
INTERNET.

BULLETIN.
MODELS:
2007 (MK49) Compass
2007 (MK74) Patriot
2007 (PM) Caliber
NOTE:
DISCUSSION:
below.
CAUTION:
PCM/TCM Replacement Requirements > Page 484
PARTS REQUIRED:
CAUTION:

down load.
CAUTION:
PROCESS.
NOTE:
NOTE:
NOTE:
drop.
seconds.
CAUTION:
NOTE:
PCM.
NOTE:
StarSCAN(R) screen.
NOTE:
list.

File List" screen?
with step 9.
NOTE:
CAUTION:

down load.
NOTE:
NOTE:
NOTE:
down load.
drop.
number.
NOTE:


File List" screen?
with step 7.
NOTE:
TIME ALLOWANCE:
FAILURE CODE:
Disclaimer:
Control Module: Technical Service Bulletins Engine Controls - MIL On/DTC P0116/ECT Sensor
NUMBER: 18-039-06
INTERNET.
BULLETIN.
SUBJECT:
CAUTION:

BE INSTALLED.
MODELS:
2007 (PM) Caliber
2007 (MK49) Compass
NOTE:
(MDH 1120XX).
NOTE:
DIAGNOSIS:
PARTS REQUIRED:
CAUTION:
NOTE:

seconds.
CAUTION:
PROCESS.
NOTE:
NOTE:
TIME ALLOWANCE:
FAILURE CODE:
Disclaimer:
Modules - CVT > Control Module, CVT > Component Information > Technical Service Bulletins > Customer Interest for
Control Module: > 18-032-07 > May > 07 > A/T - MIL ON Possible DTC P2004
Control Module: Customer Interest A/T - MIL ON Possible DTC P2004
NUMBER: 18-032-07
DATE: May 16, 2007
INTERNET.
StarSCAN(R) SOFTWARE LEVEL MUST BE AT RELEASE 7.04 SPI OR HIGHER FOR THIS
BULLETIN.
SUBJECT: Flash: MIL Illumination with DIG P2004
OVERVIEW: This bulletin involves selectively erasing and reprogramming the GPEC Powertrain
Control Module (PCM) with new software and replacing the intake manifold as required.
CAUTION:

BE INSTALLED.
MODELS:
2007-2008 (JS) Avenger
2007 (JS) Sebring
2008 (J527) Sebring Convertible
2007 (MK49) Compass
2007 (MK74) Patriot
2007 (PM) Caliber
NOTE:
This bulletin applies to models equipped with a 1.8L, 2.0L or 2.4L gasoline engine (Sales Code
EBA, ECN or ED3) as follows: Flash portion applies to PM/MK models built through April 21, 2007
(MDH 0421 XX) and JS models built through May 15, 2007 (0515XX). The Intake Manifold
Replacement portion applies to models built through March 22, 2007 (MDHO322XX).
SYMPTOM/CONDITION:
Some customers may experience MIL Illumination with no other symptoms. The condition may
occur intermittently. Further investigation by the technician may find DTC P2004 - Intake Manifold
Runner Control Stuck Open as the cause for MIL Illumination.
DIAGNOSIS:
TechCONNECT, verify all engine Systems are functioning as designed. If DTC's other than those
listed above are present record them on the repair order and repair as necessary before
proceeding further with this bulletin.
Perform the standard diagnostic procedures for DIG P2004. If the diagnostics do not lead to the
failure, perform the Repair Procedure.
PARTS REQUIRED:
Control Module: > 18-032-07 > May > 07 > A/T - MIL ON Possible DTC P2004 > Page 501
CAUTION:
DO NOT START THE ENGINE PRIOR TO COMPLETING STEP 5n and/or 8h. IF THE
NOTE:
programmed with 7.04 SPI software or higher. The software release level is visible in the blue
NOTE:
NOTE:
drop.
c. Select "More Options
d. Select "ECU Flash

l. Verify the part number at the top of the "Flash PCM" screen has updated to the new part number.
seconds.
CAUTION:
DO NOT START THE ENGINE PRIOR TO COMPLETING 5n OR 8h. IF THE PROCEDURE IS

NOT ADHERED TO THE CONTROLLER MAY NOT COMPLETE THE PROGRAMMING
PROCESS.
NOTE:
Due to the PCM programming procedure, a DTC may be set in other modules within the vehicle.
Then select "All DTCs". Press "Clear All Stored DTCs" if there are any DTCs shown on the list.
6. Using the StarSCAN(R) at the "Home screen":
7. Is the TCM part number recorded in step 6e above, the same as the new pin shown on the
a. Yes > No further action is necessary. Proceed to Step 9.
b. No > the TCM will require flash reprogramming, proceed to Step 8.
a. From the "Flash File List screen, select "Download to Scantool".
seconds.
CAUTION:
DO NOT START THE ENGINE PRIOR TO COMPLETING STEP Sn and 8h. IF THE
PROCEDURE IS NOT ADHERED TO THE CONTROLLER MAY NOT COMPLETE THE
NOTE:
Then select "All DTCs". Press "Clear All Stored DTCs" if there are any DTCs shown on the list.**
NOTE:
9. Type the necessary information on the "Authorized Modification Label p/n 04275086AB and
attach near the VECI label (Fig.1).
1. Vehicles built through March 22, 2007 will require a new Intake Manifold pn 04884495AF.
Following the procedures listed in DealerCONNECT > TechCONNECT replace the intake manifold.
TIME ALLOWANCE:
FAILURE CODE:
Disclaimer:
Modules - CVT > Control Module, CVT > Component Information > Technical Service Bulletins > All Technical Service
Bulletins for Control Module: > 18-032-07 > May > 07 > A/T - MIL ON Possible DTC P2004
Control Module: All Technical Service Bulletins A/T - MIL ON Possible DTC P2004
NUMBER: 18-032-07
DATE: May 16, 2007
INTERNET.
BULLETIN.
CAUTION:

BE INSTALLED.
MODELS:
2007 (JS) Sebring
2007 (MK49) Compass
2007 (MK74) Patriot
2007 (PM) Caliber
NOTE:
SYMPTOM/CONDITION:
DIAGNOSIS:
PARTS REQUIRED:
Bulletins for Control Module: > 18-032-07 > May > 07 > A/T - MIL ON Possible DTC P2004 > Page 509
CAUTION:
NOTE:
NOTE:
NOTE:
drop.

seconds.
CAUTION:

PROCESS.
NOTE:
seconds.
CAUTION:
NOTE:
NOTE:
TIME ALLOWANCE:
FAILURE CODE:
Disclaimer:
Modules - CVT > Control Module, CVT > Component Information > Technical Service Bulletins > Page 512
Control Module: Locations
Component ID: 170
Component : MODULE-TRANSMISSION CONTROL
Connector:
Name : MODULE-TRANSMISSION CONTROL C1
Color : WHITE
# of pins : 24
Qualifier : (CVT)
1 LINE PRESSURE CONTROL T20 18DG/LB
2 SECONDARY PRESSURE CONTROL T19 18YL/DB
3 TCC CONTROL T59 18YL/LB
4 TCC ON/OFF CONTROL T60 18YL/GY

7--
8--
9--
11 STEP MOTOR CONTROL A T314 18LB/YL
12 STEP MOTOR CONTROL B T315 18YL/OR
13 CLOCK SELECT T302 18DG/BR
14 CHIP SELECT T313 18YL/LG
15 DATA IN/OUT SELECT T327 18GY/YL
16 - -
17 - -
18 TRS T41 SIGNAL T41 20YL/BK
20 STEP MOTOR CONTROL C T316 18YL/WT
21 STEP MOTOR CONTROL D T317 18TN/YL
22 TRS T42 SIGNAL T42 20DG/PK
23 - -
24 - -
Connector:
Color : LT. GRAY
# of pins : 24
Qualifier : (CVT)
1 GROUND Z967 18BK
2 TRS T4 SIGNAL T4 20DG/LB
3--
4 FUSED B(+) (I.O.D.) A416 18RD

4 FUSED B(+) (I.O.D.) A952 20RD/OR
5 OUTPUT SPEED SIGNAL T52 18DG/WT
6--
7--
8--
9--
10 AUTOSTICK UPSHIFT SWITCH SIGNAL T5 20DG/LG
11 - -
12 AUTOSTICK DOWNSHIFT SWITCH SIGNAL T44 20YL/DG
13 SECONDARY PRESSURE SIGNAL T50 18PK/LB
14 INPUT SPEED SIGNAL T14 18DG/BK

15 - -
16 - -
17 PRIMARY PRESSURE SENSOR SIGNAL T21 18DG/YL
18 SENSOR GROUND T13 18DG/TN
19 TRS T3 SIGNAL T3 20DG/DB
20 TRS T1 SIGNAL T1 20DG/GY
21 OUTPUT SPEED SENSOR GROUND T130 18TN/DG
22 5 VOLT SUPPLY T72 18PK/LB
23 TRANSMISSION TEMPERATURE SIGNAL T54 18RD/WT
24 GROUND Z967 18BK
Control Module: Diagrams
Component ID: 170
Connector:
Color : WHITE
# of pins : 24
Qualifier : (CVT)

7--
8--
9--
16 - -
17 - -
23 - -
24 - -
Connector:
Color : LT. GRAY
# of pins : 24
Qualifier : (CVT)
1 GROUND Z967 18BK
3--
4 FUSED B(+) (I.O.D.) A416 18RD

6--
7--
8--
9--
11 - -

15 - -
16 - -
24 GROUND Z967 18BK
Modules - CVT > Control Module, CVT > Component Information > Description and Operation > Description
Control Module: Description and Operation Description
DESCRIPTION
The transmission control module (TCM) is inside the car, behind the instrument panel where the
clutch pedal would be located. New controllers are shipped with generic software but need to be
initialized for the vehicle into which it is installed.
Modules - CVT > Control Module, CVT > Component Information > Description and Operation > Description > Page 524
Control Module: Description and Operation Operation
OPERATION
Shift Control
In order to select the gear ratio which can obtain the driving force in accordance with driver's
intention and the vehicle condition, TCM monitors the driving conditions, such as the vehicle speed
and the throttle position and selects the optimum gear ratio, and determines the gear change steps
to the gear ratio. Then it sends the command to the stepping motor, and controls the
flow-in/flow-out of line pressure to/from the primary pulley to determine the position of the
moving-pulley and control the gear ratio.
Selection of the gear ratio is set for every position separately.
"Drive" Position
Shifting is available over all the ranges of gear ratios from the lowest to the highest.
When using the Manual Mode (Vehicles with the manual mode)
When the manual mode switch is turned ON, the fixed changing gear line is set. By moving the
switch to + side or - side, shift change is like a M/T and selects from a range of 6 pre-programmed
gear ranges.
By limiting the shift to the area nearest the low side of the gear ratio, a larger driving force and
engine brake are secured.
Downhill Engine Brake Control
When a downhill condition is detected while the accelerator pedal is released, the engine brake will
be increased by downshifting so as to limit acceleration of the vehicle. Also, if uphill is detected,
acceleration performance is improved by limiting the shift area on the highest side of the gear ratio.
Acceleration Control
According to vehicle speed and a increase of accelerator pedal angle, driver's request for
acceleration as well as driving conditions are measured. At the time of starting or acceleration while
moving, this function improves in acceleration feeling by making the engine speed proportionate to
the vehicle speed. Even at the time of slower acceleration, a shift map which can gain a larger
driving force is chosen for compatibility of mileage with drivability.
Line Pressure and Secondary Pressure Control
Control of line pressure and secondary pressure with a high degree of accuracy has reduced
friction and improved fuel economy.
Normal Fluid Pressure Control
The line pressure and the secondary pressure are optimized depending on driving conditions, on
the basis of the throttle position, the engine speed, the primary pulley (input) revolution speed, the
secondary pulley (output) revolution speed, the stop lamp SW signal, the PNP switch signal, the
lock-up signal, the voltage, the target gear ratio, the fluid temperature, and the fluid pressure.
Secondary Pressure Feedback Control
When controlling the normal fluid pressure or the fluid pressure at the time of selection, the
secondary pressure can be set more accurately by using the fluid pressure sensor to detect the
secondary pressure and performing the feedback control.
Lock-up Control
The lock-up applied gear range has been expanded by locking up the torque converter at a lower
vehicle speed than conventional A/T models.
Selection Control
When selecting between N (P) and D(R) position, the optimum operating pressure is set on the
basis of the throttle position, the engine speed, and the secondary pulley (output) revolution speed
to lessen the select shock.
CAN Communication
Real-time communications (signal exchanges) are maintained among the control units such as the
CVT, C/U, ECM, combination meter etc. Each unit is controlled optimally depending on vehicle
driving conditions while sharing information and in cooperating with the other control units.
In CAN (Controller Area Network) communication, control units are connected with two
communication lines (CAN-H line, CAN-L line) allowing a high rate of information to be transmitted
by fewer wirings. Each control unit transmits/receives data but selectively reads required data only.
Inputs and Outputs

Engine/CVT Integration Control (CAN Communication Control)
In order to improve gearshift feeling and to perform controls such as prevention of engine
slowdown, engine power control signals are intercommunicated between the engine ECM and the
TCM, and real-time cooperative controls depending on vehicle driving conditions are performed.
TCM sends information such as fast slowdown signals, lock-up signals, torque down request
signals to ECM, while receiving information such as torque down permission/prohibition signals,
lock-up permission/prohibition signals, throttle position from ECM.
Fail-safe Function
If an unexpected signal is sent from any sensor, switch, solenoid etc., this function controls the
CVT to make driving as smooth as possible.
Secondary Speed Sensor
The shift pattern is changed in accordance with throttle position when an unexpected signal is sent
from the output speed sensor (secondary speed sensor) to the TCM. The manual mode position or
the sports mode position is inhibited, and the transaxle is put in "D".
Primary Speed Sensor
The shift pattern is changed in accordance with throttle position and secondary speed (vehicle
speed) when an unexpected signal is sent from the primary speed sensor to the TCM. The manual
mode function or the sports mode function is inhibited, and the transaxle is put in "D".
PNP Switch
If an unexpected signal is sent from the PNP switch to the TCM, the transaxle is put in "D".
Fluid Temperature Sensor
If an unexpected signal is sent from the fluid temperature sensor to the TCM, the gear ratio
obtained immediately before receiving the unexpected signal is maintained and the gear ratio is
controlled to keep engine speed under 5,000 rpm (approximately), depending on driving conditions.
Secondary Pressure Sensor
If an unexpected signal is sent from the secondary pressure sensor to the TCM, the secondary
pressure feedback control is stopped and the offset value obtained immediately before the
non-standard condition occurs is used to control line pressure.
Line Pressure Solenoid
If an unexpected condition of the solenoid is detected by the TCM, the line pressure solenoid is
turned OFF to achieve the maximum fluid pressure.
Secondary Pressure Solenoid
If an unexpected condition of the secondary solenoid is detected by the TCM, the secondary
pressure solenoid is turned OFF to achieve the maximum fluid pressure.
Lock-up solenoid
If an unexpected condition of the lock-up solenoid is detected by the TCM, the lock-up solenoid is
turned OFF to cancel the lock-up.
Stepping Motor
If an unexpected condition of the stepping motor is detected by the TCM, the stepping motor coil
phases "A" through "D" are all turned OFF to hold the gear ratio used immediately before the
unexpected condition occurred.
Lock-up/Selection Switching Solenoid
If an unexpected condition of the solenoid is detected by the TCM, the lock-up/selection switching
solenoid is turned OFF to cancel the lock-up.
Backup Power Supply
Transaxle assembly is protected by limiting the engine torque when the memory back-up power
supply for controlling from the battery is not supplied to the TCM. Normal status is restored when
turning the ignition switch OFF to ON after power is normally supplied
TCM
1. Shift control 2. Line pressure control 3. Selection control 4. Lock-up control 5. Engine/CVT
integration control [CAN communication control] 6. Self-diagnosis function 7. Fail-safe function
Primary Speed Sensor, Secondary Speed Sensor
Primary Speed Sensor It is installed near the CVT fluid cooler in the transaxle case. It sends
rotating speed of the primary pulley (input shaft) to the TCM as a pulse signal.
Secondary Speed Sensor It is installed near the output gear part in the transaxle case. It sends
rotating speed of the secondary pulley (output shaft) to the TCM as a pulse signal. TCM converts
the pulse signal to vehicle speed.
Modules - CVT > Control Module, CVT > Component Information > Service and Repair > Removal
Control Module: Service and Repair Removal
REMOVAL
1. The TCM (2) is located between the brake pedal bracket (1) and the left kick panel (3).
2. Unplug the two electrical connectors (2) at the TCM.
3. Remove the two nuts (1) that hold the TCM to the bulkhead.
Modules - CVT > Control Module, CVT > Component Information > Service and Repair > Removal > Page 531
4. Remove the TCM.

Control Module: Service and Repair Installation
INSTALLATION
1. Install TCM mounting bracket holes (1) over the two studs on the bulkhead.
2. Install the two nuts to mounting studs (1) on the bulkhead and tighten to 15 Nm (130 in. lbs.).
3. Plug in electrical connectors (2) to TCM (3).
NOTE: If a new TCM is installed a learn procedure must be performed.

Modules - Transfer Case > Control Module, Transfer Case > Component Information > Locations
Component ID: 150
Component : MODULE-ALL WHEEL DRIVE CONTROL
Connector:
Name : MODULE-ALL WHEEL DRIVE CONTROL
Color : # of pins :
16
Qualifier : (AWD)
1--
2--
3--

7--
8 REAR DIFFERENTIAL SOLENOID CONTROLT312 20YL/VT
9--
10 - -
11 - -
13 - -
14 - -
15 GROUND Z967 20BK
16 SOLENOID SUPPLY VOLTAGE T78 20YL/BK
Modules - Transfer Case > Control Module, Transfer Case > Component Information > Locations > Page 537
Component ID: 150
Connector:
Color : # of pins :
16
Qualifier : (AWD)
1--
2--
3--

7--
9--
10 - -
11 - -
13 - -
14 - -
15 GROUND Z967 20BK
Modules - Transfer Case > Control Module, Transfer Case > Component Information > Description and Operation >
Description
DESCRIPTION
The All Wheel Drive (AWD) Control Module controls the Electronically Controlled Coupling (ECC)
mounted on the rear axle. It is located in the left kick panel area and gets signals over the vehicle
bus.
OPERATION
The all-wheel-drive system requires no driver input or control. Under most driving conditions, it is
passive and power is transmitted to the front wheels alone. Unlike all-wheel drive systems that rely
on pumps or viscous fluids to transfer torque, this system requires no front-to-rear slippage for
activation. This allows the system to transfer torque solely in response to accelerator pedal
position. If the driver is asking for a lot of power, the system immediately starts clamping the
electronically controlled coupling (ECC), transferring a high percentage of power to the rear
wheels. This avoids front wheel slippage, as power to propel the car is transmitted through all four
tires. This mode of operation is called open-loop operation in that there is no feedback to affect the
torque transfer.
A second, closed loop, operating mode uses feedback from the wheel-speed sensors to determine
the appropriate torque transfer. When the front wheels slip, the All Wheel Drive (AWD) Control
Module tells the ECC to start clamping, sending power to the rear wheels. Attempting the same
aggressive launch described above with the front wheels on ice and the rear wheels on dry
pavement, the ECC sends even more torque to the rear wheels to minimize slippage and launch
the vehicle. Both modes are always active with the closed loop mode layered on top of open loop
mode to increase torque to the rear wheels when needed to maintain traction in extreme cases.
Power to the rear wheels is modulated under the following conditions:
- Slipping on ice while backing up will send a lot of power to the rear axle
- Loss of traction while traveling at freeway speeds, for example hydroplaning on a puddle of water,
will send very little power to the rear wheels because the controller knows at those speeds a lot of
power is not needed at the rear wheels
- A third condition, which is independent of the others, uses wheel speed differences to determine
when the vehicle is turning in a tight circle. This condition, which is indicated by a large discrepancy
in side-to-side wheel speeds, causes the electronic control module to reduce torque to the rear
wheels to prevent binding in the driveline. The electronic control module is always checking for this
condition as well.
- A fourth condition that is unique to this system is to influence vehicle dynamics. Other systems
limit AWD to aiding traction or providing off-road capability. The primary focus is on launching the
vehicle or going off road at speeds up to about 25 mph (40 km/hr). Above that speed range, they
use it to limit wheel slip for traction. On this system, additional ECM calibration controls torque to
the rear wheels for improved handling in the 25-65 mph (40-105 km/hr) range. In this speed range,
the system increases torque to the rear wheels during cornering with the throttle open to make the
car turn more easily - make the handling more neutral. This is more readily accomplished with an
electronically controlled system, than with viscous-coupling or generator systems that require some
degree of front-to-rear slip to transfer torque to the rear wheels. Above 70 mph (113 km/hr), the
control strategy provides minimal torque to the rear wheels under normal driving conditions to aid
fuel economy.
The control module also interfaces with the Electronic Stability Program (ESP) and traction control
systems. The interface allows the ESP system to use the ECC to help gain control of the vehicle.
For this purpose, torque transmitted to the rear wheels by the ECC can be reduced. This system is
not traction control. It only works on situations where front-to-rear traction varies, for instance, front
wheels on ice, rear wheels on dry pavement or climbing steep grades. AWD does not aid
side-to-side traction. ESP does that through brake intervention on this system.
Modules - Transfer Case > Control Module, Transfer Case > Component Information > Service and Repair > Removal
REMOVAL
1. Remove the left front kick panel.
2. Remove module retaining bolts (2).
3. Remove electrical connector (3).
4. Remove ECC module (1).

Modules - Transfer Case > Control Module, Transfer Case > Component Information > Service and Repair > Removal >
Page 545
INSTALLATION
1. Plug ECC module in (3).
2. Move into place, install bolts (2) and tighten to 11 Nm (97 in. lbs.).
3. Install the left front kick panel.

Jeep Workshop Manuals > Relays and Modules > Relays and Modules - Windows and Glass > Power Window Control
Module > Component Information > Description and Operation > Description
Power Window Control Module: Description and Operation Description
DESCRIPTION
The window regulator modules are directly connected to each of the front door window regulator
motors. The window switches are hard wired by a mux circuit to the respective window regulator
module. The respective rear window motor is hard wired to the module. The front window motor is
directly attached to the module. Both front door window switches have the express down feature.
The module will cease lowering the front glass when a fully down position is sensed through the
hall effect sensor.
When a module must be replaced, it is necessary to replace the entire regulator assembly.
Jeep Workshop Manuals > Relays and Modules > Relays and Modules - Windows and Glass > Power Window Control
Module > Component Information > Description and Operation > Description > Page 551
Power Window Control Module: Description and Operation Operation
OPERATION
When a door is opened, the respective module will receive a signal from the door ajar switch or the
window drop switch. The window drop switch is directly controlled by both the interior and the
exterior door handle switches. The drop switch is part of the door latch. This switch is faster than
the door ajar switch to signal an open door operation. At that point the module will drop the front
door glass 10 mm (0.5 in). However, if the window drop switch should fail, the door ajar sense
would also drop the window 10 mm (0.5 in) and the module would set a trouble code. When the
module then receives a door ajar switch open (door closed) it would raise the window 10 mm (0.5
in). The module knows the position of the window by counting the motor rotation through the hall
effect sensor in the module. If a door window is raised while that door is open, the module will raise
the glass up, but when the door is closed it will raise the glass an additional 10 mm (0.5 in). When
the convertible top down switch is pressed to the first detent, input is received by the driver window
regulator module and passenger window regulator module, which will lower the front windows
approximately 40 mm (1.6 in), and lower the rear windows approximately 55 mm (2.0 in). After a
200 ms delay, it energizes the power top down relay to lower the convertible top.
Jeep Workshop Manuals > Sensors and Switches > Sensors and Switches - Accessories and Optional Equipment > Hood
Sensor/Switch (For Alarm) > Component Information > Description and Operation > Description
Hood Sensor/Switch (For Alarm): Description and Operation Description
DESCRIPTION
The hood ajar switch is a normally closed, single pole, spring-loaded plunger actuated switch. This
switch has two unique versions that are used in two different applications. One switch is used only
on vehicles equipped with the Vehicle Theft Alarm (VTA) system for sale in certain export markets
where protection of the underhood area is required equipment. The second switch is used only on
domestic vehicles equipped with an optional remote starter system.
The molded plastic switch body (5) has an integral molded connector receptacle (1) on the lower
end containing two terminal pins. The switch is connected to the vehicle electrical system through a
dedicated take out of the engine compartment wire harness. Two integral latches (2) lock the
switch into a keyed mounting hole in the stamped steel switch mounting bracket. The mounting
bracket is secured with screws to the left side of the cowl plenum panel in the engine compartment.
A molded plastic striker cap secured in the underside of the hood panel inner reinforcement
actuates the switch plunger as the hood panel is closed.
The switch plunger (3) extends through a mounting collar (4) and a sleeve-like retainer ring on the
upper end of the switch body. The retainer ring has a one time, self-adjustment feature that is
activated after the switch is installed by closing the hood. The retainer ring is also color-coded to
aid in identifying the switch application. A dark brown retainer ring identifies the underhood security
switch application, while a white retainer ring identifies the remote starter system application.
An installed hood ajar switch cannot be readjusted or repaired. If the switch is damaged,
ineffective, or requires readjustment, it must be replaced with a new unit. The hood ajar switch
striker cap is not intended for reuse. If the striker is removed from the hood inner reinforcement for
any reason, it must be replaced with a new unit.
Sensor/Switch (For Alarm) > Component Information > Description and Operation > Description > Page 558
Hood Sensor/Switch (For Alarm): Description and Operation Operation
OPERATION
The hood ajar switches are interchangeable physically, but not functionally. In each case, the hood
ajar switch is a normally closed switch that is held open as the spring-loaded switch plunger is
depressed by the striker cap on the inner hood panel reinforcement when the hood panel is closed
and latched. When the hood is opened, the spring-loaded switch plunger extends from the switch
body and the switch contacts are closed.
In the underhood security application (export vehicles only - dark brown retainer ring), the switch is
connected in series between ground and the hood ajar switch sense input of the Totally Integrated
Power Module (TIPM). The TIPM uses an internal resistor pull up to monitor the state of the hood
ajar switch contacts.
In the remote starter system application (domestic vehicles only - white retainer ring) the switch has
a 1 kiloohm diagnostic resistor connected in parallel to the switch contacts between the two switch
terminals. The switch is connected in series between an output of the TIPM and the hood ajar
switch sense input of the TIPM. The TIPM continually monitors this circuit and will store a
Diagnostic Trouble Code (DTC) for any fault that it detects.
The components of the switch self-adjustment feature include an integral stop on the shaft of the
plunger and a ribbed, ratcheting sleeve-like retainer ring at the top of the switch body from which
the plunger extends. With the switch mounting collar secured in its mounting bracket, the plunger is
depressed by the striker cap on the hood inner reinforcement as the hood is closed. As the plunger
is depressed, the plunger stop contacts the top of the retainer ring and it is driven downward,
ratcheting through the switch mounting collar until the hood is fully closed and latched. The ribs on
the retainer ring are engaged within the mounting collar to maintain this adjusted position.
The hood ajar switch as well as the hard wired circuits between the switch and the TIPM may be
diagnosed using conventional diagnostic tools and procedures. Refer to the appropriate wiring
information. However, conventional diagnostic methods will not prove conclusive in the diagnosis of
the electronic controls or communication between modules and other devices related to hood ajar
switch operation that provide some features of the export vehicle theft or domestic remote starter
systems. The most reliable, efficient, and accurate means to diagnose the electronic controls and
communication related to hood ajar switch operation requires the use of a diagnostic scan tool.
Refer to the appropriate diagnostic information.
Sensor/Switch (For Alarm) > Component Information > Service and Repair > Removal
Hood Sensor/Switch (For Alarm): Service and Repair Removal
Bracket
BRACKET
1. Remove the hood ajar switch (2) from the mounting bracket (3).
2. Remove the two screws (4) that secure the hood ajar switch bracket to the left side of the cowl
plenum panel (1).
3. Remove the hood ajar switch bracket from the cowl plenum panel.
Striker Cap
STRIKER CAP
NOTE: The hood ajar switch striker cap is not intended for reuse. If the striker is removed from the
hood inner reinforcement for any reason, it must be replaced.
1. Unlatch and open the hood.
2. Pry the hood ajar switch (3) striker cap (1) away from the mounting hole (2) in the inner hood
panel reinforcement far enough to disengage the cap
from its mounting hole.
3. Remove the striker cap from the inner hood panel reinforcement and discard.
Switch
SWITCH
Sensor/Switch (For Alarm) > Component Information > Service and Repair > Removal > Page 561
3. From the top of the mounting bracket (3) on the left side of the cowl plenum panel (1), squeeze
the two hood ajar switch (2) latch tabs together and
pull the switch upward.
4. Pull the hood ajar switch up through the hole in the mounting bracket far enough to access and
disconnect the wire harness connector (5) from the
switch connector receptacle.
5. Remove the hood ajar switch from the mounting bracket.

Hood Sensor/Switch (For Alarm): Service and Repair Installation
Bracket
BRACKET
1. Position the hood ajar switch bracket (3) onto the left side of the cowl plenum panel (1).
2. Install and tighten the two screws (4) that secure the hood ajar switch bracket to the cowl plenum
panel. Tighten the screws to 4 Nm (35 in. lbs.).
3. Reinstall the hood ajar switch (2) into the mounting bracket.
Striker Cap
STRIKER CAP
NOTE: The hood ajar switch striker cap is not intended for reuse. If the striker cap is removed from
the hood inner reinforcement for any reason, it must be replaced.
1. Position the new hood ajar switch striker cap (1) to the mounting hole (2) in the inner hood panel
reinforcement over the hood ajar switch (3).
2. Using hand pressure, press the hood ajar switch striker cap upward into the mounting hole in the
inner hood panel reinforcement until it is fully
engaged in the mounting hole.
3. Close and latch the hood.
Switch
SWITCH
1. Position the hood ajar switch (2) near the hole in the mounting bracket (3) on the left side of the
cowl plenum panel (1).
2. Route the wire harness connector (5) through the switch mounting bracket and reconnect it to
the switch connector receptacle.
3. From the top of the mounting bracket, press the switch downward into the mounting hole until
the integral switch latch tabs lock it into place.

Jeep Workshop Manuals > Sensors and Switches > Sensors and Switches - Accessories and Optional Equipment >
Integrated Accessory Switch Assembly > Component Information > Description and Operation > Description
Integrated Accessory Switch Assembly: Description and Operation Description
DESCRIPTION
The instrument panel switch pod (1) is located just below the heater and air conditioner controls in
the center stack area of the instrument panel. This switch is available in multiple configurations,
which varies from two single push button switches to as many as five push button switches, or four
switches and an indicator lamp, depending upon the optional equipment in the vehicle. The pod
may include the following switches or indicators:
- Heated Seat Switch (2)
- Electronic Stability Program (ESP) Switch (5)
- Hazard Warning Switch (4)
- Headlamp Leveling Switch (Not Shown)
- Passenger Airbag On/Off Indicator (3)
The switch housing and the push buttons are constructed of molded plastic. Each push button has
a smooth finish and is clearly identified with the appropriate text and International Control and
Display Symbol icons. Several of the push buttons feature Light Emitting Diode (LED) units to give
the vehicle operator an indication when the function of that switch is currently active. Only the
hazard warning switch push button latches, while the remaining switches feature momentary
operation.
Four screws secure the switch to the back of the instrument panel center bezel through integral
mounting tabs that are molded into each corner of the switch housing. The back of the switch
housing has an integral connector receptacle containing terminal pins that connect the switch to the
vehicle electrical system through a dedicated take out and connector of the instrument panel wire
harness.
Panel lamps dimmer controlled illumination lamps integral to the circuit board within the switch
provide back lighting for visibility at night, but these lamps are not serviceable. The individual
switches in the lower instrument panel switch pod cannot be repaired and are not serviced
individually. If any component within the switch pod is ineffective or damaged, the entire switch pod
must be replaced.
Integrated Accessory Switch Assembly > Component Information > Description and Operation > Description > Page 568
Integrated Accessory Switch Assembly: Description and Operation Operation
OPERATION
For information covering details of operation for the individual switches or indicator contained within
the instrument panel switch pod, refer to the specific covering the system to which that switch or
indicator belongs.
Integrated Accessory Switch Assembly > Component Information > Service and Repair > Removal
Integrated Accessory Switch Assembly: Service and Repair Removal
REMOVAL
3. Disconnect the wire harness connector from the back of the instrument panel switch pod (4).
4. Remove the screws that secure the switch pod to the back of the center bezel.
5. Remove the switch pod from the center bezel.

Integrated Accessory Switch Assembly > Component Information > Service and Repair > Removal > Page 571
Integrated Accessory Switch Assembly: Service and Repair Installation
INSTALLATION
NOTE: There are several different instrument panel switch pods available, depending upon the
optional equipment content of the vehicle. Be certain that a replacement switch pod matches the
optional equipment of the vehicle into which it is being installed.
1. Position the instrument panel switch pod (4) to the back of the center bezel.
2. Install and tighten the screws that secure the switch pod to the center bezel. Tighten the screws
3. Reconnect the wire harness connector to the back of the switch pod.
4. Reinstall the center bezel onto the instrument panel.

Remote Switch, Audio - Stereo > Component Information > Locations > Switch-Remote Radio-Left
Remote Switch: Locations Switch-Remote Radio-Left
Component ID: 361
Component : SWITCH-REMOTE RADIO-LEFT
Connector:
Name : SWITCH-REMOTE RADIO-LEFT
Color : BLACK
# of pins : 2
Remote Switch, Audio - Stereo > Component Information > Locations > Switch-Remote Radio-Left > Page 576
Remote Switch: Locations Switch-Remote Radio-Right
Component ID: 362
Component : SWITCH-REMOTE RADIO-RIGHT
Connector:
Name : SWITCH-REMOTE RADIO-RIGHT
Color : BLACK
# of pins : 2
Remote Switch, Audio - Stereo > Component Information > Diagrams > Switch-Remote Radio-Left
Remote Switch: Diagrams Switch-Remote Radio-Left
Component ID: 361
Component : SWITCH-REMOTE RADIO-LEFT
Connector:
Name : SWITCH-REMOTE RADIO-LEFT
Color : BLACK
# of pins : 2
Remote Switch, Audio - Stereo > Component Information > Diagrams > Switch-Remote Radio-Left > Page 581
Remote Switch: Diagrams Switch-Remote Radio-Right
Component ID: 362
Component : SWITCH-REMOTE RADIO-RIGHT
Connector:
Name : SWITCH-REMOTE RADIO-RIGHT
Color : BLACK
# of pins : 2
Remote Switch, Audio - Stereo > Component Information > Description and Operation > Description
Remote Switch: Description and Operation Description
DESCRIPTION
Two rocker-type switches (if equipped) are mounted on the back (instrument panel side) of the
steering wheel spokes. The switch on the left spoke is the seek switch and has seek up, seek
down, and preset station advance functions. The switch on the right spoke is the volume control
switch and has volume up, and volume down functions. The switch on the right spoke also includes
a "mode" control that allows the driver to sequentially select AM radio, FM radio, cassette player,
CD player or CD changer (if equipped).
Remote Switch, Audio - Stereo > Component Information > Description and Operation > Description > Page 586
Remote Switch: Description and Operation Operation
OPERATION
These switches are resistor multiplexed units that are hard-wired to the Cab Compartment Node
(CCN) through the clockspring. The CCN sends the proper messages on the Controller Area
Network (CAN) data bus network to the radio receiver. For diagnosis of the CCN or the CAN data
bus, the use of a scan tool and the proper Diagnostic Procedures manual are recommended. For
more information on the operation of the remote radio switch controls, refer to the owner's manual
in the vehicle glove box.
Remote Switch, Audio - Stereo > Component Information > Description and Operation > Page 587
Remote Switch: Testing and Inspection
REMOTE SWITCHES
WARNING: On vehicles equipped with airbags, refer to electrical, restraints before attempting any
steering wheel, steering column, or instrument panel component diagnosis or service. Failure to
take the proper precautions could result in accidental airbag deployment and possible personal
injury.
Any diagnosis of the Audio system should begin with the use of the scan tool. For information on
the use of the scan tool, refer to the appropriate Diagnostic Procedure.
2. Remove the remote radio switch(es) from the steering wheel.
3. Use an ohmmeter to check the switch resistance as shown in the Remote Radio Switch Test
table
NOTE: The right remote radio switch back is white in color. The left switch back is black in color.
The right/left remote radio switch orientation is with the steering wheel installed, and driver in
driver's seat.
4. If the switch resistance checks OK, go to STEP 5. If not OK, replace the faulty switch.
5. Check for continuity between the ground circuit cavity of the switch wire harness connector and
a good ground. There should be continuity. If OK,
go to STEP 6. If not OK, repair the open circuit as required.
6. Unplug the connector from the Cab Compartment Node (CCN). Check for continuity between the
radio control circuit cavity of the remote radio
switch wire harness connector and a good ground. There should be no continuity. If OK, go to
STEP 7. If not OK, repair the short circuit as required.
7. Check for continuity between the radio control circuit cavities of the remote radio switch wire
harness connector and the CCN wire harness
connector. There should be continuity. If OK, refer to the proper Diagnostic Procedures manual to
test the CCN and the CAN data bus. If not OK, repair the open circuit as required.
Remote Switch, Audio - Stereo > Component Information > Service and Repair > Removal
Remote Switch: Service and Repair Removal
REMOVAL
injury.
2. Remove the driver side airbag.
3. Remove the steering wheel.
4. Unplug the wire harness connector from the remote radio switch.
5. Remove steering wheel rear cover.
6. Remove the remote radio switch from the steering wheel by depressing tabs on each side of
each switch.
NOTE: The right remote radio switch back is white in color. The left switch back is black in color.
The right/left remote radio switch orientation is with the steering wheel installed, and driver in
driver's seat.
Remote Switch, Audio - Stereo > Component Information > Service and Repair > Removal > Page 590
Remote Switch: Service and Repair Installation
INSTALLATION
injury.
1. Install remote radio switch to the steering wheel.
2. Install steering wheel rear cover.
3. Connect the wire harness to the remote radio switch.
4. Install the steering wheel.
5. Install the driver side airbag.

Jeep Workshop Manuals > Sensors and Switches > Sensors and Switches - Body and Frame > Hood Switch / Sensor >
Hood Sensor/Switch (For Alarm) > Component Information > Description and Operation > Description
Hood Sensor/Switch (For Alarm): Description and Operation Description
DESCRIPTION
The hood ajar switch is a normally closed, single pole, spring-loaded plunger actuated switch. This
switch has two unique versions that are used in two different applications. One switch is used only
on vehicles equipped with the Vehicle Theft Alarm (VTA) system for sale in certain export markets
where protection of the underhood area is required equipment. The second switch is used only on
domestic vehicles equipped with an optional remote starter system.
The molded plastic switch body (5) has an integral molded connector receptacle (1) on the lower
end containing two terminal pins. The switch is connected to the vehicle electrical system through a
dedicated take out of the engine compartment wire harness. Two integral latches (2) lock the
switch into a keyed mounting hole in the stamped steel switch mounting bracket. The mounting
bracket is secured with screws to the left side of the cowl plenum panel in the engine compartment.
A molded plastic striker cap secured in the underside of the hood panel inner reinforcement
actuates the switch plunger as the hood panel is closed.
The switch plunger (3) extends through a mounting collar (4) and a sleeve-like retainer ring on the
upper end of the switch body. The retainer ring has a one time, self-adjustment feature that is
activated after the switch is installed by closing the hood. The retainer ring is also color-coded to
aid in identifying the switch application. A dark brown retainer ring identifies the underhood security
switch application, while a white retainer ring identifies the remote starter system application.
An installed hood ajar switch cannot be readjusted or repaired. If the switch is damaged,
ineffective, or requires readjustment, it must be replaced with a new unit. The hood ajar switch
striker cap is not intended for reuse. If the striker is removed from the hood inner reinforcement for
any reason, it must be replaced with a new unit.
Hood Sensor/Switch (For Alarm) > Component Information > Description and Operation > Description > Page 597
Hood Sensor/Switch (For Alarm): Description and Operation Operation
OPERATION
The hood ajar switches are interchangeable physically, but not functionally. In each case, the hood
ajar switch is a normally closed switch that is held open as the spring-loaded switch plunger is
depressed by the striker cap on the inner hood panel reinforcement when the hood panel is closed
and latched. When the hood is opened, the spring-loaded switch plunger extends from the switch
body and the switch contacts are closed.
In the underhood security application (export vehicles only - dark brown retainer ring), the switch is
connected in series between ground and the hood ajar switch sense input of the Totally Integrated
Power Module (TIPM). The TIPM uses an internal resistor pull up to monitor the state of the hood
ajar switch contacts.
In the remote starter system application (domestic vehicles only - white retainer ring) the switch has
a 1 kiloohm diagnostic resistor connected in parallel to the switch contacts between the two switch
terminals. The switch is connected in series between an output of the TIPM and the hood ajar
switch sense input of the TIPM. The TIPM continually monitors this circuit and will store a
Diagnostic Trouble Code (DTC) for any fault that it detects.
The components of the switch self-adjustment feature include an integral stop on the shaft of the
plunger and a ribbed, ratcheting sleeve-like retainer ring at the top of the switch body from which
the plunger extends. With the switch mounting collar secured in its mounting bracket, the plunger is
depressed by the striker cap on the hood inner reinforcement as the hood is closed. As the plunger
is depressed, the plunger stop contacts the top of the retainer ring and it is driven downward,
ratcheting through the switch mounting collar until the hood is fully closed and latched. The ribs on
the retainer ring are engaged within the mounting collar to maintain this adjusted position.
The hood ajar switch as well as the hard wired circuits between the switch and the TIPM may be
information. However, conventional diagnostic methods will not prove conclusive in the diagnosis of
the electronic controls or communication between modules and other devices related to hood ajar
switch operation that provide some features of the export vehicle theft or domestic remote starter
systems. The most reliable, efficient, and accurate means to diagnose the electronic controls and
communication related to hood ajar switch operation requires the use of a diagnostic scan tool.
Hood Sensor/Switch (For Alarm) > Component Information > Service and Repair > Removal
Hood Sensor/Switch (For Alarm): Service and Repair Removal
Bracket
BRACKET
1. Remove the hood ajar switch (2) from the mounting bracket (3).
2. Remove the two screws (4) that secure the hood ajar switch bracket to the left side of the cowl
plenum panel (1).
3. Remove the hood ajar switch bracket from the cowl plenum panel.
Striker Cap
STRIKER CAP
NOTE: The hood ajar switch striker cap is not intended for reuse. If the striker is removed from the
hood inner reinforcement for any reason, it must be replaced.
2. Pry the hood ajar switch (3) striker cap (1) away from the mounting hole (2) in the inner hood
panel reinforcement far enough to disengage the cap
from its mounting hole.
3. Remove the striker cap from the inner hood panel reinforcement and discard.
Switch
SWITCH
Hood Sensor/Switch (For Alarm) > Component Information > Service and Repair > Removal > Page 600
3. From the top of the mounting bracket (3) on the left side of the cowl plenum panel (1), squeeze
the two hood ajar switch (2) latch tabs together and
pull the switch upward.
4. Pull the hood ajar switch up through the hole in the mounting bracket far enough to access and
disconnect the wire harness connector (5) from the
switch connector receptacle.
5. Remove the hood ajar switch from the mounting bracket.

Hood Sensor/Switch (For Alarm): Service and Repair Installation
Bracket
BRACKET
1. Position the hood ajar switch bracket (3) onto the left side of the cowl plenum panel (1).
2. Install and tighten the two screws (4) that secure the hood ajar switch bracket to the cowl plenum
panel. Tighten the screws to 4 Nm (35 in. lbs.).
3. Reinstall the hood ajar switch (2) into the mounting bracket.
Striker Cap
STRIKER CAP
NOTE: The hood ajar switch striker cap is not intended for reuse. If the striker cap is removed from
the hood inner reinforcement for any reason, it must be replaced.
1. Position the new hood ajar switch striker cap (1) to the mounting hole (2) in the inner hood panel
reinforcement over the hood ajar switch (3).
2. Using hand pressure, press the hood ajar switch striker cap upward into the mounting hole in the
inner hood panel reinforcement until it is fully
engaged in the mounting hole.
Switch
SWITCH
1. Position the hood ajar switch (2) near the hole in the mounting bracket (3) on the left side of the
cowl plenum panel (1).
2. Route the wire harness connector (5) through the switch mounting bracket and reconnect it to
the switch connector receptacle.
3. From the top of the mounting bracket, press the switch downward into the mounting hole until
the integral switch latch tabs lock it into place.

Jeep Workshop Manuals > Sensors and Switches > Sensors and Switches - Body and Frame > Power Door Lock Switch >
Component Information > Testing and Inspection
Power Door Lock Switch: Testing and Inspection
DOOR LOCK SWITCH
1. Remove the switch.
2. Using an ohmmeter, refer to Door Lock Switch Test table to determine if switch resistance is
correct in the Lock and Unlock switch positions.
Refer to Wiring Diagrams for harness connector pin-outs.

Power Door Lock Switch: Service and Repair Removal
REMOVAL
2. Remove the front door bolster.
3. Disconnect the electrical harness connectors.
4. With the bolster on the bench, gently pry in on the tabs of the mirror switch and push through the
front of the cover and remove.
Power Door Lock Switch: Service and Repair Installation
INSTALLATION
1. Place the mirror switch in bolster opening and firmly snap into place.
2. Connect the electrical harness connectors.
3. Install the front door bolster.

Jeep Workshop Manuals > Sensors and Switches > Sensors and Switches - Body and Frame > Power Mirror Switch >
Power Mirror Switch: Locations
Component ID: 354
Component : SWITCH-MIRROR
Connector:
Name : SWITCH-MIRROR
Color : BLACK
# of pins : 10
Qualifier : (LHD)
1--
2--
3 MIRROR COMMON DRIVER P76 20YL/PK
6 RIGHT MIRROR VERTICAL DRIVER P72 20TN/GY

7 LEFT MIRROR VERTICAL DRIVER P71 20TN/DG
8 RIGHT MIRROR HORIZONTAL DRIVER P74 20TN/OR
9 LEFT MIRROR HORIZONTAL DRIVER P75 20TN/OR
10 - -
Connector:
Color : # of pins :
10
Qualifier : (RHD)
1 FOLDING MIRROR RETURN P110 20LG/WT
2--

10 MIRROR-POWER FOLDING/UNFOLDING P699 20LG/DG
Power Mirror Switch: Diagrams
Component ID: 354
Component : SWITCH-MIRROR
Connector:
Color : BLACK
# of pins : 10
Qualifier : (LHD)
1--
2--

10 - -
Connector:
Color : # of pins :
10
Qualifier : (RHD)
1 FOLDING MIRROR RETURN P110 20LG/WT
2--

10 MIRROR-POWER FOLDING/UNFOLDING P699 20LG/DG
Component Information > Testing and Inspection > Power Mirror Switch - LHD
Power Mirror Switch: Testing and Inspection Power Mirror Switch - LHD
POWER MIRROR SWITCH - LHD
2. Remove power mirror switch.
3. Using an ohmmeter, test for continuity between the terminals of the switch as shown in the
Mirror Switch Test table.
4. If test results are not obtained as shown in the Mirror Switch Test table, replace the switch.
SWITCH POSITION
MOVE BUTTON
Component Information > Testing and Inspection > Power Mirror Switch - LHD > Page 619
Power Mirror Switch: Testing and Inspection Power Foldaway Mirror Switch - Rhd
POWER FOLDAWAY MIRROR SWITCH - RHD
The following test is designed to be used only on vehicles equipped with power foldaway side view
mirrors.
1. Remove power mirror switch from mounting position.
2. Using an ohmmeter, test for continuity between the terminals of the switch as shown in the
tables below.
NOTE: When testing using the chart below be certain to read the chart correctly. Example - When
testing left mirror "DOWN", pins 1, 9, 10 will show continuity to each other but not with 3, 4, 5.
3. If test results are not obtained as shown in the tables below, replace the switch.
EXTENDED MIRROR SWITCH CIRCUIT TEST
NOTE: Mirror position switch must be in the "extended" position to use chart below.
RETRACTED MIRROR SWITCH CIRCUIT TEST
NOTE: Mirror position switch must be in the "retracted" position to use chart below.
Component Information > Service and Repair > Power Mirror Switch - Lhd
Power Mirror Switch: Service and Repair Power Mirror Switch - Lhd
Removal
REMOVAL
Installation
INSTALLATION

Component Information > Service and Repair > Power Mirror Switch - Lhd > Page 624
Power Mirror Switch: Service and Repair Power Foldaway Mirror Switch - Rhd
Removal
REMOVAL
Installation
INSTALLATION

Jeep Workshop Manuals > Sensors and Switches > Sensors and Switches - Body and Frame > Seat Heater Switch >
Seat Heater Switch: Description and Operation Description
DESCRIPTION
The heated seat switches are located in the center stack (1) of the instrument panel. The switches
are located on the outer edges of the accessory switch bank (2). If either of the switches is
damaged or inoperative the complete accessory switch bank assembly must be replaced.
When either of the heated seat switches are depressed a switch status message is sent to the Cab
Compartment Node (CCN) or instrument cluster via the Local Interface Network (LIN) data bus.
The CCN then sends a message via the LIN data bus to the heated seat module, signaling the
module to energize the heating element for the selected seat. Amber Light Emitting Diodes (LEDs)
in the top portion of each switch indicate the level of heat in use: Two LEDs are illuminated for high,
one for low, and none for off. The heated seat module sends the LED illumination message to the
CNN via the LIN data bus. The CNN then sends the LED illumination message to the accessory
switch bank so that the appropriate LEDs are illuminated for any given heating level. Pressing the
switch once will select high-level heating. Pressing the switch a second time will select low-level
heating. Pressing the switch a third time will shut the heating elements off.
The LED indicator lamps in each heated seat switch cannot be repaired. If the LED lamps are
inoperative or damaged, or the switch is inoperative or damaged the complete accessory switch
bank assembly must be replaced.
Seat Heater Switch: Description and Operation Operation
OPERATION
The heated seat switches are active any time the Local Interface Network (LIN) data bus is active.
Depressing the heated seat switch provides a switch status message to the Cabin Compartment
Node (CCN) via the LIN data bus. The CCN is responsible for supplying the LIN data bus message
to the heated seat module, signaling the module to power the heated seat element of the selected
seat and maintain the temperature setting. If the heated seat switch is depressed to a different
position (Low or High) than the currently selected state, the CCN will go through the process again
to change the temperature setting.
Seat Heater Switch: Testing and Inspection
HEATED SEAT SWITCH
In order to obtain conclusive testing, the heated seat system and the Local Interface Network (LIN)
data bus circuit must be checked. Any diagnosis of the heated seat system should begin with, the
use of a scan tool and the appropriate diagnostic service information.
Refer to the appropriate wiring information for complete circuit schematic or connector pin-out
information.
NOTE: Vehicles equipped with the heated seat option utilize a low voltage cut-off feature. This
feature turns off power to the heated seat system anytime vehicle voltage is below 11.7v or above
15.5v. Be certain to check the vehicle electrical system for proper voltage anytime the power seat
system appears inoperative.
Before any testing of the heated seat system is attempted, the battery should be fully-charged.
Seat Heater Switch: Service and Repair Removal
REMOVAL
WARNING: On vehicles equipped with airbags, disable the airbag system before attempting any
steering wheel, steering column, or instrument panel component diagnosis or service. Disconnect
and isolate the negative battery (ground) cable, then wait two minutes for the airbag system
capacitor to discharge before performing further diagnosis or service. This is the only sure way to
disable the airbag system. Failure to take the proper precautions could result in accidental airbag
deployment and possible personal injury or death.
NOTE: The heated seat switches are integral to the accessory switch bezel and cannot be serviced
separately.
2. Remove the center bezel from the instrument panel and place it on a work bench.
3. Remove the screws that secure the accessory switch bank (4) to the back of the center bezel
and remove the accessory switch bank.
Seat Heater Switch: Service and Repair Installation
INSTALLATION
NOTE: There are different instrument panel accessory switch banks available based on the option
content of the vehicle. Ensure the accessory switch bank being installed matches the vehicle
options.
1. Position the accessory switch bank (4) onto the back of the instrument panel center bezel.
2. Install the screws that secure the accessory switch bank to the center bezel. Tighten the screws
3. Install the center bezel onto the instrument panel.
4. Reconnect the negative battery cable.
5. Verify heated seat system operation.

Jeep Workshop Manuals > Sensors and Switches > Sensors and Switches - Body and Frame > Trunk / Liftgate Ajar Switch
> Component Information > Description and Operation > Description
Trunk / Liftgate Ajar Switch: Description and Operation Description
LIFTGATE
A liftgate ajar switch is standard equipment on this vehicle. The switch is concealed within and
integral to the liftgate latch unit. The switch is a momentary leaf contact-type unit that is actuated by
the liftgate latch mechanism. An integral connector receptacle on the liftgate latch connects the
liftgate ajar switch to the vehicle electrical system through the liftgate wire harness.
The liftgate ajar switch cannot be adjusted or repaired and, if ineffective or damaged, the liftgate
latch unit must be replaced.
Jeep Workshop Manuals > Sensors and Switches > Sensors and Switches - Body and Frame > Trunk / Liftgate Ajar Switch
> Component Information > Description and Operation > Description > Page 638
Trunk / Liftgate Ajar Switch: Description and Operation Operation
LIFTGATE
The liftgate ajar switch is actuated by the liftgate latch mechanism. When the liftgate is closed and
properly latched, its liftgate ajar switch is an open circuit. When the liftgate is open or only partially
latched, the liftgate ajar switch is a closed circuit. The liftgate ajar switch is hard wired in series
between a body ground and the ElectroMechanical Instrument Cluster (EMIC) (also known as the
Cab Compartment Node/CCN). The EMIC reads the hard wired liftgate ajar switch input through an
internal pull-up, then uses this input to control many electronic functions and features of the
vehicle.
The liftgate ajar switch as well as the hard wired inputs and outputs of the switch may be
information.
Jeep Workshop Manuals > Sensors and Switches > Sensors and Switches - Brakes and Traction Control > Brake Fluid
Level Sensor/Switch > Component Information > Locations
Brake Fluid Level Sensor/Switch: Locations
Component ID: 292
Component : SENSOR-BRAKE FLUID LEVEL
Connector:
Name : SENSOR-BRAKE FLUID LEVEL
Color : BLACK
# of pins : 2
Level Sensor/Switch > Component Information > Locations > Page 643
Brake Fluid Level Sensor/Switch: Diagrams
Component ID: 292
Connector:
Color : BLACK
# of pins : 2
Brake Fluid Level Sensor/Switch: Description and Operation
DESCRIPTION
The brake fluid level switch (2) is mounted through the center of the fluid reservoir (1). The switch
can be serviced separately from the master cylinder fluid reservoir.
Level Sensor/Switch > Component Information > Service and Repair > Removal
Brake Fluid Level Sensor/Switch: Service and Repair Removal
REMOVAL
NOTE: Refer to Warnings and Cautions.
1. Remove the wiring harness connector (1) from the brake fluid level switch (2) in the master
cylinder brake fluid reservoir.
2. Push together the retaining tabs (1) holding the brake fluid level switch in place in the brake fluid
reservoir (2). 3. Pull the brake fluid level switch out the right side of the reservoir.
Level Sensor/Switch > Component Information > Service and Repair > Removal > Page 651
Brake Fluid Level Sensor/Switch: Service and Repair Installation
INSTALLATION
1. Align the brake fluid level switch with its mounting hole on the right side of the master cylinder
brake fluid reservoir. Push the switch into the fluid
reservoir until the switch retaining tabs (1) are expanded on the opposite side of the reservoir (2),
locking it in place.
2. Connect the wiring harness connector (1) to the switch (2).

Jeep Workshop Manuals > Sensors and Switches > Sensors and Switches - Brakes and Traction Control > Lateral
Accelerometer > Component Information > Locations
Lateral Accelerometer: Locations
Component ID: 297
Component : SENSOR-DYNAMICS
Connector:
Name : SENSOR-DYNAMICS
Color : BLACK
# of pins : 6
Qualifier : (ESP)
4--
6--
Accelerometer > Component Information > Locations > Page 655
Lateral Accelerometer: Diagrams
Component ID: 297
Connector:
Color : BLACK
# of pins : 6
Qualifier : (ESP)
4--
6--
Lateral Accelerometer: Description and Operation
DESCRIPTION
The Yaw Rate and Lateral Acceleration Sensors are housed into one unit known as the Dynamics
Sensor (1). The sensor is used to measure side-to-side (Lateral) motion and vehicle rotational
sensing (how fast the vehicle is turning - Yaw).
Yaw and Lateral Acceleration Sensors cannot be serviced separately. The entire Dynamics Sensor
must be replaced when necessary.
Accelerometer > Component Information > Service and Repair > Removal
Lateral Accelerometer: Service and Repair Removal
REMOVAL
1. Disconnect and isolate the battery negative cable from the battery post. 2. Remove the shifter
housing center console.
3. Disconnect the wiring harness connector (3) at the dynamics sensor (1). 4. Remove the nuts (2)
mounting the dynamics sensor to the floor pan tunnel (4). 5. Remove the dynamics sensor (1).
Accelerometer > Component Information > Service and Repair > Removal > Page 663
Lateral Accelerometer: Service and Repair Installation
INSTALLATION
1. Install the dynamics sensor (1) over the studs mounted to the floor pan tunnel (4). 2. Install the
two mounting nuts (2). Tighten the nuts to 9 Nm (80 in. lbs.). 3. Connect the wiring harness
connector (3) to the dynamics sensor (1). 4. Install the shifter housing center console. 5. Connect
the battery negative cable to the battery post. It is important that this be performed properly. 6.
Perform the Verification Test and clear any faults. See: Powertrain Management/Computers and
Control Systems/Testing and
Inspection/Diagnostic Trouble Code Tests and Associated Procedures/Verification Tests

Jeep Workshop Manuals > Sensors and Switches > Sensors and Switches - Brakes and Traction Control > Parking Brake
Warning Switch > Component Information > Locations
Parking Brake Warning Switch: Locations
Component ID: 356
Component : SWITCH-PARKING BRAKE
Connector:
Name : SWITCH-PARKING BRAKE
Color : NATURAL
# of pins : 1
1 PARK BRAKE SWITCH SENSE B25 20DG/WT
Warning Switch > Component Information > Locations > Page 667
Parking Brake Warning Switch: Diagrams
Component ID: 356
Connector:
Color : NATURAL
# of pins : 1
Warning Switch > Component Information > Description and Operation > Description
Parking Brake Warning Switch: Description and Operation Description
DESCRIPTION
The park brake switch (1) is located on the park brake lever mechanism on the floor panel
transmission tunnel below the center floor console. This switch includes a spade-type output
terminal (2) that connects the switch to the vehicle electrical system through a dedicated take out
and connector of the body wire harness. The output terminal is integral to the stationary contact
within a molded plastic insulator. A locating tab (4) on the insulator engages a slot in the park brake
lever mechanism for positive switch location. External to the insulator is a movable leaf contact (3)
with an integral grounding lug on one end and an integral actuating lever and follower on the
opposite end. The switch is secured to and grounded by a single screw to the park brake lever
mechanism.
The park brake switch cannot be adjusted or repaired and, if ineffective or damaged, it must be
replaced.
Warning Switch > Component Information > Description and Operation > Description > Page 672
Parking Brake Warning Switch: Description and Operation Operation
OPERATION
The park brake switch is a normally closed, mechanically actuated leaf contact switch that is
operated by the park brake lever mechanism. The switch is grounded through its mounting to the
park brake lever mechanism and provides a ground input to the ElectroMechanical Instrument
Cluster (EMIC) (also known as the Cab Compartment Node/CCN) on a park brake switch sense
circuit whenever the park brake is applied, and opens this circuit whenever the park brake is
released. The park brake switch sense input to the EMIC is used for control of the brake indicator
and may also be used as a logic input for other electronic features in the vehicle.
The park brake switch as well as the hard wired inputs and outputs of the switch may be diagnosed
using conventional diagnostic tools and procedures. Refer to the appropriate wiring information.
Warning Switch > Component Information > Description and Operation > Page 673
Parking Brake Warning Switch: Testing and Inspection
PARK BRAKE SWITCH
NOTE: If the brake indicator stays ON with the ignition switch in the ON position and the park brake
released, or comes ON while driving, the brake system must be diagnosed and repaired prior to
performing the following tests. If no brake system problem is found, the following procedures will
help to locate a shorted or open park brake switch sense circuit, or an ineffective park brake switch.
INDICATOR ILLUMINATES DURING BULB TEST, BUT DOES NOT WHEN PARK BRAKE
APPLIED
1. Disconnect and isolate the battery negative cable. Disconnect the instrument panel wire harness
connector for the park brake switch from the
switch terminal. Apply the parking brake. Check for continuity between the park brake switch
terminal and a good ground. There should be continuity. If OK, go to STEP 2. If not OK, replace the
ineffective park brake switch.
2. Disconnect the instrument panel wire harness connector (Connector C2) for the instrument
cluster from the cluster connector receptacle. Check for
continuity between the park brake switch sense circuit cavities of the instrument panel wire harness
connectors for the park brake switch and the instrument cluster. There should be continuity. If not
OK, repair the open park brake switch sense circuit between the park brake switch and the
instrument cluster as required.
INDICATOR REMAINS ILLUMINATED - BRAKE SYSTEM CHECKS OK
switch terminal. Check for continuity between the terminal of the park brake switch and a good
ground. There should be no continuity with the park brake released, and continuity with the park
brake applied. If OK, go to STEP 2. If not OK, replace the ineffective park brake switch.
continuity between the park brake switch sense circuit cavity of the connector for the park brake
switch and a good ground. There should be no continuity. If not OK, repair the shorted park brake
switch sense circuit between the park brake switch and the instrument cluster as required.
Warning Switch > Component Information > Service and Repair > Removal
Parking Brake Warning Switch: Service and Repair Removal
REMOVAL
2. Remove the console from the floor panel transmission tunnel (3).
3. Pull the parking brake lever (1) upward to apply the parking brake.
4. Disconnect the instrument panel wire harness connector from the terminal of the park brake
switch (4) located on the inboard side of the park
brake lever mechanism.
5. Remove the screw (5) that secures the switch to the park brake lever bracket.
6. Remove the switch from the park brake lever bracket.

Warning Switch > Component Information > Service and Repair > Removal > Page 676
Parking Brake Warning Switch: Service and Repair Installation
INSTALLATION
1. Position park brake switch (4) onto the inboard side of the park brake lever (1) bracket. Be
certain to engage the locating pin on the back of the
switch insulator into the locating slot in the lever bracket.
2. Install and tighten the screw (5) that secures the switch to the lever bracket. Tighten the screw to
2.5 Nm (24 in. lbs.).
3. Reconnect the instrument panel wire harness connector (2) to the terminal of the switch.
4. Reinstall the console onto the floor panel transmission tunnel (3).
6. Turn the ignition switch to the ON position and check for proper brake indicator operation with
the parking brake applied, then release the parking
brake and check that the brake indicator extinguishes.

Jeep Workshop Manuals > Sensors and Switches > Sensors and Switches - Brakes and Traction Control > Steering Angle
Sensor, Traction Control > Component Information > Locations
Steering Angle Sensor: Locations
Component ID: 325
Component : SENSOR-STEERING ANGLE
Connector:
Name : SENSOR-STEERING ANGLE
Color : WHITE
# of pins : 4

Sensor, Traction Control > Component Information > Locations > Page 680
Steering Angle Sensor: Diagrams
Component ID: 325
Connector:
Color : WHITE
# of pins : 4

Steering Angle Sensor: Description and Operation
DESCRIPTION
The steering angle sensor is an integral part of the clockspring (3) mounted on the steering column.
Refer to CLOCKSPRING - DESCRIPTION
Jeep Workshop Manuals > Sensors and Switches > Sensors and Switches - Brakes and Traction Control > Traction Control
Switch > Component Information > Description and Operation
Traction Control Switch: Description and Operation
DESCRIPTION
The ESP Off Switch is part of the accessory switch bank module located in the center bezel on the
instrument panel above the transmission gear shifter.
The ESP Off switch turns the Electronic Stability Program off and back on. The ESP has three
modes: Full-On, Partial and Full-Off. The ESP default mode is Full-On with every key-on. Pressing
the ESP Off switch button in the center stack once activates the Partial mode. In Partial mode,
Traction Control is deactivated and ESP operates at a higher threshold, therefore, it will not come
on as aggressively as in the Full-On mode. Pressing and holding the ESP button for five seconds
or longer turns the system completely off. This condition is confirmed by a single warning chime
and a text message in the odometer display "ESP FULL OFF." The system can be returned to
"normal" Full-On mode by briefly pressing and releasing the ESP Off switch. The switch resets
itself each time the ignition is cycled.
The ESP Off switch is serviced as part of the accessory switch bank. There are different accessory
switch banks available based on the option content of the vehicle. Ensure the accessory switch
bank being installed matches the vehicle options.
Switch > Component Information > Service and Repair > Removal
Traction Control Switch: Service and Repair Removal
REMOVAL
NOTE: The ESP Off switch is integral to the accessory switch bank and cannot be serviced
separately.
1. Disconnect and isolate the negative battery cable. 2. Remove the center bezel from the
instrument panel and place it on a work bench. 3. Remove the screws that secure the accessory
switch bank to the back of the center bezel and remove the accessory switch bank.
Switch > Component Information > Service and Repair > Removal > Page 693
Traction Control Switch: Service and Repair Installation
INSTALLATION
NOTE: The ESP Off switch is serviced as part of the accessory switch bank.
options.
1. Position the accessory switch bank onto the back of the instrument panel center bezel. 2. Install
the screws that secure the accessory switch bank to the center bezel. Tighten the screws to 2 Nm
(17 in. lbs.). 3. Install the center bezel onto the instrument panel. 4. Reconnect the negative battery
cable. 5. Perform the ABS Verification Test and make sure the ESP Off switch operates properly.
See: Powertrain Management/Computers and Control
Systems/Testing and Inspection/Diagnostic Trouble Code Tests and Associated

Procedures/Verification Tests/ABS Verification Test
6. Verify proper operation of all components controlled by the switch bank.

Jeep Workshop Manuals > Sensors and Switches > Sensors and Switches - Brakes and Traction Control > Wheel Speed
Sensor > Component Information > Locations > Sensor-Wheel Speed-ABS-Left Front
Wheel Speed Sensor: Locations Sensor-Wheel Speed-ABS-Left Front
Component ID: 327
Component : SENSOR-WHEEL SPEED-ABS-LEFT FRONT
Connector:
Name : SENSOR-WHEEL SPEED-ABS-LEFT FRONT
Color : BLACK
# of pins : 2
Sensor > Component Information > Locations > Sensor-Wheel Speed-ABS-Left Front > Page 698
Connector:
Color : # of pins :
Qualifier : (SENSOR SIDE)
1 LEFT FRONT WHEEL SPEED SENSOR 12 VOLT SUPPLY DG/LG
2 LEFT FRONT WHEEL SPEED SENSOR SIGNAL DG/TN
Wheel Speed Sensor: Locations Sensor-Wheel Speed-ABS-Left Rear
Component ID: 328
Component : SENSOR-WHEEL SPEED-ABS-LEFT REAR
Connector:
Name : SENSOR-WHEEL SPEED-ABS-LEFT REAR
Color : BLACK
# of pins : 2
Connector:
Color : # of pins :
1 LEFT REAR WHEEL SPEED SENSOR 12 VOLT SUPPLY LG
2 LEFT REAR WHEEL SPEED SENSOR SIGNAL LG/DB
Wheel Speed Sensor: Locations Sensor-Wheel Speed-ABS-Right Front
Component ID: 329
Component : SENSOR-WHEEL SPEED-ABS-RIGHT FRONT
Connector:
Name : SENSOR-WHEEL SPEED-ABS-RIGHT FRONT
Color : BLACK
# of pins : 2
Connector:
Color : # of pins :
1 RIGHT FRONT WHEEL SPEED SENSOR 12 VOLT SUPPLY WT
2 RIGHT FRONT WHEEL SPEED SENSOR SIGNAL WT/DB
Wheel Speed Sensor: Locations Sensor-Wheel Speed-ABS-Right Rear
Component ID: 330
Component : SENSOR-WHEEL SPEED-ABS-RIGHT REAR
Connector:
Name : SENSOR-WHEEL SPEED-ABS-RIGHT REAR
Color : BLACK
# of pins : 2
Connector:
Color : # of pins :
1 RIGHT REAR WHEEL SPEED SENSOR 12 VOLT SUPPLY DG/LB
2 RIGHT REAR WHEEL SPEED SENSOR SIGNAL DG/OR
Sensor > Component Information > Diagrams > Sensor-Wheel Speed-ABS-Left Front
Wheel Speed Sensor: Diagrams Sensor-Wheel Speed-ABS-Left Front
Component ID: 327
Connector:
Color : BLACK
# of pins : 2
Sensor > Component Information > Diagrams > Sensor-Wheel Speed-ABS-Left Front > Page 713
Connector:
Color : # of pins :
Wheel Speed Sensor: Diagrams Sensor-Wheel Speed-ABS-Left Rear
Component ID: 328
Connector:
Color : BLACK
# of pins : 2
Connector:
Color : # of pins :
Wheel Speed Sensor: Diagrams Sensor-Wheel Speed-ABS-Right Front
Component ID: 329
Connector:
Color : BLACK
# of pins : 2
Connector:
Color : # of pins :
Wheel Speed Sensor: Diagrams Sensor-Wheel Speed-ABS-Right Rear
Component ID: 330
Connector:
Color : BLACK
# of pins : 2
Connector:
Color : # of pins :
Sensor > Component Information > Description and Operation > Front Wheel Speed
Wheel Speed Sensor: Description and Operation Front Wheel Speed
Description
DESCRIPTION
The antilock brake system uses two-wire wheel speed sensors, known as active wheel speed
sensors. The sensors use an electronic principle known as magnetoresistive to help increase
performance and durability. The sensors convert wheel speed into a small digital signal. A Wheel
Speed Sensor (WSS) is used at each wheel. A magnetic pole encoder serves as the trigger
mechanism for each sensor. At each wheel of the vehicle there is one wheel speed sensor and one
encoder.
A front wheel speed sensor (3) is attached to a mounting boss on each front knuckle (4). The
encoder is an integral part of the hub and bearing.
WSS air gaps are not adjustable.
Operation
OPERATION
The ABM sends 12 volts to power an Integrated Circuit (IC) in the sensor. The IC supplies a
constant 7 mA power supply to the ABM. The relationship of the magnetic pole encoder to the
permanent magnet in the sensor, signals the IC to enable a second 7 mA power supply. The output
of the sensor, sent to the ABM, is a DC voltage signal with changing voltage and current levels.
The ground for the IC and the current sense circuit is provided by the ABM.
When a pole is properly aligned with the sensor, the voltage signal is approximately 0.8 volts and a
constant 7 mA current is sent to the ABM. As the magnetic pole encoder rotates, the encoder shifts
the magnetic field and the IC enables a second 7 mA current source. The ABM senses a voltage
signal of approximately 1.6 volts and 14 mA. The ABM measures the amperage of the digital signal
for each wheel. The resulting signal is interpreted by the ABM as the wheel speed.
Sensor > Component Information > Description and Operation > Front Wheel Speed > Page 728
Wheel Speed Sensor: Description and Operation Rear Wheel Speed
Description
DESCRIPTION
encoder.
On all-wheel-drive vehicles, the rear wheel speed sensor head (1) is secured to the rear hub and
bearing (2) by a spring-loaded clip on the rear of the assembly. The encoder is integral to the hub
and bearing assembly. The encoder is serviced as part of the rear hub and bearing.
On front-wheel-drive vehicles, the rear wheel speed sensor head (3) is mounted to the rear of the
hub and bearing by a screw. The encoder is integral to the hub and bearing assembly. The
encoder is are serviced as part of the rear hub and bearing.
The WSS air gaps are not adjustable.
Operation
OPERATION
Sensor > Component Information > Service and Repair > Front Wheel Speed
Wheel Speed Sensor: Service and Repair Front Wheel Speed
Removal
REMOVAL
1. Open the hood. 2. Disconnect the wheel speed sensor cable connector (2) from the wiring
harness connector (3) on top of the frame rail (1) to the inside of the strut
tower.
3. Raise and support the vehicle.
4. Remove the grommet (1) from the hole in the body (7) and pull the wheel speed sensor cable
out of the hole. 5. Remove the speed sensor cable routing clip (2) from the outside frame rail (6). 6.
Remove the screw fastening the cable routing clamp (3) to the outside frame rail (6).
Sensor > Component Information > Service and Repair > Front Wheel Speed > Page 732
7. Remove the screw (1) securing the wheel speed sensor routing bracket (2) to the brake flex
hose bracket (5).
8. Remove the mounting screw (2) fastening the wheel speed sensor head (3) to the knuckle (4).
Pull the sensor head out of the knuckle.
NOTE: In the following step, the routing clip can be easily removed without damaging it by rotating
it (with entire sensor) counterclockwise.
9. Remove the routing clip (1) securing wheel speed sensor cable to the knuckle (4). Remove the
sensor from the vehicle.
Installation
INSTALLATION
CAUTION: Failure to install speed sensor cables properly may result in contact with moving parts
or an over extension of cables causing an open circuit. Be sure that cables are installed, routed,
and clipped properly.
1. Install the wheel speed sensor head (3) into the knuckle (4). Install the mounting screw (2) and
tighten it to 12 Nm (106 in. lbs.). 2. Install the routing clip (1) securing the wheel speed sensor
cable to the knuckle (4).
3. Position the wheel speed sensor routing bracket (2) on the brake flex hose bracket (5) and install
the mounting screw (1). Tighten the mounting
screw to 18 Nm (13 ft. lbs.).

4. Position the wheel speed sensor cable routing clamp (4) on the outside frame rail (6) and install
5. Install the speed sensor cable routing clip (2) on the outside frame rail (6). 6. Insert the wheel
speed sensor cable through the hole in the body (7) and install the grommet (1) in the hole.
7. Lower the vehicle. 8. Connect the wheel speed sensor cable connector (2) to the wiring harness
connector (3) on top of the frame rail (1). 9. Perform the Diagnostic Verification Test and clear any
faults. (Refer to 5 - BRAKES - STANDARD PROCEDURE)
Wheel Speed Sensor: Service and Repair Sensor-Rear Wheel Speed

Removal
ALL-WHEEL-DRIVE
1. Remove the cargo floor cover. 2. Remove the rear floor pan silencer (1).
3. If equipped, remove the nuts mounting the satellite receiver (1) or amplifier (2) to rear floor pan.
Move the component aside to allow access to the
wheel speed sensor wiring connector through the opening in bottom of the quarter trim panel.
4. Through the opening in the bottom of the quarter trim panel, disconnect the wheel speed sensor
cable connector (2) at the body wiring harness
connector (3).
6. Remove the wheel mounting nuts (3), then the rear tire and wheel assembly (1).
out through the hole. 8. Remove the speed sensor cable routing clip (3) from the outside frame rail
(4).
9. Remove the screw (1) fastening the cable routing clamp (3) to the rear suspension crossmember
(4).
10. Remove the speed sensor cable routing clip (1) from the trailing link (2). 11. Remove the screw
(4) fastening the cable routing clamp to the trailing link.
12. Unclip the wheel speed sensor head (1) from the spring-loaded retainer on the rear of the hub
and bearing (2). Remove the sensor from the vehicle.
Installation
ALL-WHEEL-DRIVE
NOTE: When installing the sensor head to the spring-loaded retainer on the hub and bearing, make
sure the head is held snug in the retainer. If there is any play, the clip is deformed and the hub and
bearing must be replaced. The retainer is not serviced separately.
1. Clip the wheel speed sensor head (1) (flat side to bearing rear face) into the spring-loaded
retainer on the rear of the hub and bearing (2).
2. Position the wheel speed sensor (3) on the trailing link (2) and install the screw (4) securing it in
place. Tighten the mounting screw to 18 Nm (13
ft. lbs.).
3. Position the wheel speed sensor (3) and install the routing clip (1) fastening the sensor to the
trailing link (2).
4. Position the wheel speed sensor cable routing clamp (3) on the rear suspension crossmember
(4) and install the mounting screw (1). Tighten the
mounting screw to 18 Nm (13 ft. lbs.).

5. Install the speed sensor cable routing clip (3) on the outside frame rail (4).
NOTE: When inserting the wheel speed sensor cable through the hole in the body, route the cable
toward the shock tower to make it easier to grasp the cable to connect it to the body wiring harness
connector in a later step.
6. Insert the wheel speed sensor cable (5) through the hole in the body (1) and install the grommet
(2) in the hole.
7. Install the tire and wheel assembly (1). Install and tighten the wheel mounting nuts (3) to 135 Nm
(100 ft. lbs.). 8. Lower the vehicle.
9. Through the opening in the bottom of the quarter trim panel, connect the wheel speed sensor
cable connector (2) to the body wiring harness
connector (3).
10. If equipped, install the satellite receiver (1) or amplifier (2) to rear floor pan.
11. Install the rear floor pan silencer (1). 12. Install the cargo floor cover. 13. Perform the
Diagnostic Verification Test and clear any faults. See: Powertrain Management/Computers and

Jeep Workshop Manuals > Sensors and Switches > Sensors and Switches - Brakes and Traction Control > Yaw Rate
Sensor > Component Information > Locations
Yaw Rate Sensor: Locations
Component ID: 297
Connector:
Color : BLACK
# of pins : 6
Qualifier : (ESP)
4--
6--
Sensor > Component Information > Locations > Page 744
Yaw Rate Sensor: Diagrams
Component ID: 297
Connector:
Color : BLACK
# of pins : 6
Qualifier : (ESP)
4--
6--
Yaw Rate Sensor: Description and Operation
DESCRIPTION
Sensor > Component Information > Service and Repair > Removal
Yaw Rate Sensor: Service and Repair Removal
REMOVAL
Sensor > Component Information > Service and Repair > Removal > Page 752
Yaw Rate Sensor: Service and Repair Installation
INSTALLATION

Jeep Workshop Manuals > Sensors and Switches > Sensors and Switches - Cooling System > Engine - Coolant
Temperature Sensor/Switch > Coolant Temperature Sensor/Switch (For Computer) > Component Information > Technical
Service Bulletins > Engine Controls - MIL On/DTC P0116/ECT Sensor
Coolant Temperature Sensor/Switch (For Computer): Technical Service Bulletins Engine Controls -
MIL On/DTC P0116/ECT Sensor
NUMBER: 18-039-06
INTERNET.
BULLETIN.
SUBJECT:
CAUTION:

BE INSTALLED.
MODELS:
2007 (PM) Caliber
2007 (MK49) Compass
NOTE:
(MDH 1120XX).
NOTE:
DIAGNOSIS:
PARTS REQUIRED:
Service Bulletins > Engine Controls - MIL On/DTC P0116/ECT Sensor > Page 759
CAUTION:
NOTE:

seconds.
Service Bulletins > Engine Controls - MIL On/DTC P0116/ECT Sensor > Page 760
CAUTION:
PROCESS.
NOTE:
NOTE:
TIME ALLOWANCE:
FAILURE CODE:
Disclaimer:
Temperature Sensor/Switch > Coolant Temperature Sensor/Switch (For Computer) > Component Information > Locations >
Sensor-Engine Coolant Temperature 1
Coolant Temperature Sensor/Switch (For Computer): Locations Sensor-Engine Coolant

Temperature 1
Component ID: 299
Component : SENSOR-ENGINE COOLANT TEMPERATURE 1
Connector:
Name : SENSOR-ENGINE COOLANT TEMPERATURE 1
Color : DK. GRAY
# of pins : 2
Qualifier : (GAS)
Sensor-Engine Coolant Temperature 1 > Page 763

Temperature 2
Component ID: 300
Connector:
Color : BLACK
# of pins : 2
Qualifier : (GAS)
Temperature Sensor/Switch > Coolant Temperature Sensor/Switch (For Computer) > Component Information > Diagrams >
Sensor-Engine Coolant Temperature 1
Coolant Temperature Sensor/Switch (For Computer): Diagrams Sensor-Engine Coolant

Temperature 1
Component ID: 299
Connector:
Color : DK. GRAY
# of pins : 2
Qualifier : (GAS)

Temperature 2
Component ID: 300
Connector:
Color : BLACK
# of pins : 2
Qualifier : (GAS)
Jeep Workshop Manuals > Sensors and Switches > Sensors and Switches - Cruise Control > Cruise Control Switch >
Cruise Control Switch: Locations
Component ID: 364
Component : SWITCH-SPEED CONTROL
Connector:
Name : SWITCH-SPEED CONTROL
Color : BLACK
# of pins : 3
Cruise Control Switch: Diagrams
Component ID: 364
Component : SWITCH-SPEED CONTROL
Connector:
Name : SWITCH-SPEED CONTROL
Color : BLACK
# of pins : 3
Cruise Control Switch: Service and Repair Removal
REMOVAL
WARNING:
- Do not place a non-deployed airbag face down on a hard surface, the airbag will propel into the
air if accidentally deployed, and could result in serious or fatal injury.
- Disconnect and isolate the battery negative (ground) cable before beginning steering wheel
removal or installation. This will disable the front airbag system. Failure to disconnect the battery
could result in accidental front airbag module deployment and possible personal injury.
- Allow the front airbag system capacitor to discharge for two minutes before removing the steering
wheel or any front airbag system component.
The speed control switches is mounted in the steering wheel and wired through the clock spring
device under the airbag module.
1. Adjust the steering wheel so that the tires are in the STRAIGHT-AHEAD position.
2. Remove the negative battery cable.
3. Turn off ignition.
4. Remove air bag, refer to the Restraint systems.

5. Disconnect the connector from the clockspring.
6. Remove the three mounting fasteners.
7. Remove the horn switch.
8. Remove 2 speed control switch mounting screws.
9. Disconnect the electrical connector.
10. Remove switch.

Cruise Control Switch: Service and Repair Installation
INSTALLATION
The speed control switch is mounted in the steering wheel and wired through the clock spring
device under the airbag module.
1. Connect the electrical connector to speed control switch.
2. Install the 2 speed control screw.
3. Tighten the screws (1) to 1.6 Nm (15 in. lbs.). Make sure rubber seal is in place around switch.
4. Install the horn switch.
5. Install the three mounting fasteners.
6. Connect the electrical connector to the clockspring.
7. Install the driver airbag (3).
WARNING: Do not connect battery negative cable yet. Refer first to airbag system test.
8. Reconnect battery using Airbag System Test procedure in Restraints.
9. Close hood.
10. Verify vehicle and system operation.

Jeep Workshop Manuals > Sensors and Switches > Sensors and Switches - Engine > Oil Pressure Sender > Component
Information > Locations
Oil Pressure Sender: Locations
Component ID: 349
Component : SWITCH-ENGINE OIL PRESSURE
Connector:
Name : SWITCH-ENGINE OIL PRESSURE
Color : LT. GREEN
# of pins : 2
Qualifier : (GAS)
2--
Information > Locations > Page 791
Oil Pressure Sender: Diagrams
Component ID: 349
Connector:
Color : LT. GREEN
# of pins : 2
Qualifier : (GAS)
2--
Information > Description and Operation > Description
Oil Pressure Sender: Description and Operation Description
DESCRIPTION
The oil pressure switch is located on the left front side of the engine block. The oil pressure switch
is a pressure sensitive switch that is activated by the engine's oil pressure (in the main oil gallery).
The switch is a two terminal device (one terminal is provided to the wiring harness and the other
terminal is the switch's metal housing that screws into the engine block).
Information > Description and Operation > Description > Page 798
Oil Pressure Sender: Description and Operation Operation
OPERATION
The oil pressure switch is normally "Closed." The switch changes from a "Closed" circuit to an
"Open" circuit, on increasing pressure of 7 psig. The oil pressure switch changes from an "Open"
circuit to a "Closed" circuit, on decreasing pressure, between 2 psig and 4 psig.
Oil Pressure Sender: Service and Repair Removal
REMOVAL
1. Raise vehicle. 2. Disconnect electrical connector. 3. Remove oil pressure sensor using oil
pressure socket C-4597 (1) and discard sensor.
Oil Pressure Sender: Service and Repair Installation
INSTALLATION
NOTE: If the oil pressure sensor is removed, it must be replaced with a new sensor.
CAUTION: The oil pressure sensor has tapered threads, over tightening could crack the engine
block.
1. Install oil pressure sensor using oil pressure socket C-4597 (1) and tighten to 8 Nm (71 in. lbs.).
2. Connect electrical connector.
Jeep Workshop Manuals > Sensors and Switches > Sensors and Switches - Engine > Oil Temperature Sensor/Switch,
Engine > Component Information > Locations
Oil Temperature Sensor/Switch: Locations
Component ID: 311
Component : SENSOR-OIL TEMPERATURE
Connector:
Name : SENSOR-OIL TEMPERATURE
Color : BLACK
# of pins : 2
Qualifier : (GAS)
Engine > Component Information > Locations > Page 805
Oil Temperature Sensor/Switch: Diagrams
Component ID: 311
Connector:
Color : BLACK
# of pins : 2
Qualifier : (GAS)
Engine > Component Information > Service and Repair > Removal
Oil Temperature Sensor/Switch: Service and Repair Removal
REMOVAL
1. Disconnect oil temperature sensor (1) electrical connector. 2. Remove sensor (1).
Engine > Component Information > Service and Repair > Removal > Page 810
Oil Temperature Sensor/Switch: Service and Repair Installation
INSTALLATION
1. If re-using the oil temperature sensor, coat the threads with Mopar(R) thread sealant. 2. Install oil
temperature sensor (1). Tighten to 18 Nm (160 in. lbs.). 3. Connect electrical connector.
Jeep Workshop Manuals > Sensors and Switches > Sensors and Switches - HVAC > Ambient Temperature Sensor / Switch
HVAC > Component Information > Locations
Ambient Temperature Sensor / Switch HVAC: Locations
Component ID: 291
Component : SENSOR-AMBIENT AIR TEMPERATURE
Connector:
Name : SENSOR-AMBIENT AIR TEMPERATURE
Color : BLACK
# of pins : 2
HVAC > Component Information > Locations > Page 815
Ambient Temperature Sensor / Switch HVAC: Diagrams
Component ID: 291
Connector:
Color : BLACK
# of pins : 2
Jeep Workshop Manuals > Sensors and Switches > Sensors and Switches - HVAC > Evaporator Temperature Sensor /
Switch > Component Information > Locations
Evaporator Temperature Sensor / Switch: Locations
Component ID: 301
Component : SENSOR-EVAPORATOR TEMPERATURE
Connector:
Name : SENSOR-EVAPORATOR TEMPERATURE
Color : NATURAL
# of pins : 2
1 EVAPORATOR TEMPERATURE SENSOR SIGNAL C21 20DB/LG
2 SENSOR GROUND C121 20DB/DG
Switch > Component Information > Locations > Page 821
Evaporator Temperature Sensor / Switch: Diagrams
Component ID: 301
Connector:
Color : NATURAL
# of pins : 2
Switch > Component Information > Description and Operation > Description
Evaporator Temperature Sensor / Switch: Description and Operation Description
DESCRIPTION
The evaporator temperature sensor measures the temperature of the conditioned air downstream
of the A/C evaporator. The evaporator temperature sensor is an electrical thermistor (1) mounted
on the end of a molded plastic housing (2) that is inserted into the driver side of the HVAC housing
near the coldest point of the A/C evaporator. The evaporator temperature sensor is retained in the
HVAC housing by two integral retaining tabs (3) and is connected to the vehicle electrical system
by use of a wire lead and connector (4) with two terminals.
Switch > Component Information > Description and Operation > Description > Page 832
Evaporator Temperature Sensor / Switch: Description and Operation Operation
OPERATION
The evaporator temperature sensor monitors the surface temperature of A/C evaporator and
supplies an input signal to the A/C-heater control. The A/C-heater control uses the evaporator
temperature sensor input signal to optimize A/C system performance and to protect the A/C system
from evaporator freezing. The evaporator temperature sensor will change its internal resistance in
response to the temperatures it monitors and is connected to the A/C-heater control through sensor
ground circuit and a 5-volt reference signal circuit. As the temperature of the A/C evaporator
decreases, the internal resistance of the evaporator temperature sensor decreases.
The A/C-heater control uses the monitored voltage reading as an indication of evaporator
temperature. The A/C-heater control is programmed to respond to this input by requesting the
powertrain control module (PCM) or the engine control module (ECM) (depending on engine
application) to adjust the compressor swash plate angle as necessary to optimize A/C system
performance and to protect the A/C system from evaporator freezing.
The evaporator temperature sensor is diagnosed using a scan tool.
The evaporator temperature sensor cannot be adjusted or repaired and it must be replaced if found
inoperative or damaged.
Evaporator Temperature Sensor / Switch: Service and Repair Removal
REMOVAL
NOTE: Illustration shown with air distribution housing removed for clarity.
NOTE: It is not necessary to remove and disassemble the HVAC housing to service the evaporator
temperature sensor. The evaporator temperature sensor can be removed for service from
underneath the instrument panel.
2. Reach up under the driver side of the instrument panel and disconnect the electrical connector
for the evaporator temperature sensor (1) from the
instrument panel wire harness.
3. Using needle nose pliers, disengage the two retaining tabs (3) that secure the evaporator
temperature sensor to the HVAC housing (2) by carefully
pulling the sensor straight out of the side of the HVAC housing.
4. Route the electrical connector and wire lead of the evaporator temperature sensor out from
under the heater core tubes and remove the sensor from
the vehicle.
Evaporator Temperature Sensor / Switch: Service and Repair Installation
INSTALLATION
1. Route the electrical connector and wire lead of the evaporator temperature sensor (1) under the
heater core tubes located on the driver side of the
HVAC housing (2).
2. Install the evaporator temperature sensor into the driver side of the HVAC housing. Make sure
the retaining tabs (3) are fully engaged to the
housing.
3. Connect the electrical connector for the evaporator temperature sensor to the instrument panel
wire harness.

Jeep Workshop Manuals > Sensors and Switches > Sensors and Switches - HVAC > Refrigerant Pressure Sensor / Switch,
HVAC > Component Information > Locations
Refrigerant Pressure Sensor / Switch: Locations
Component ID: 368
Component : TRANSDUCER-A/C PRESSURE
Connector:
Name : TRANSDUCER-A/C PRESSURE
Color : GRAY
# of pins : 4
4--
Refrigerant Pressure Sensor / Switch: Diagrams
Component ID: 368
Connector:
Color : GRAY
# of pins : 4
4--
HVAC > Component Information > Description and Operation > Description
Refrigerant Pressure Sensor / Switch: Description and Operation Description
DESCRIPTION
The A/C pressure transducer (1) is a switch that is installed on a fitting located on the A/C
discharge line. An internally threaded fitting on the A/C pressure transducer connects it to the
externally threaded Schrader-type fitting on the A/C discharge line. A rubber O-ring seals the
connection between the A/C pressure transducer and the discharge line fitting. The A/C pressure
transducer is connected to the vehicle electrical system by a molded plastic connector with three
terminals.
HVAC > Component Information > Description and Operation > Description > Page 844
Refrigerant Pressure Sensor / Switch: Description and Operation Operation
OPERATION
The A/C pressure transducer monitors the pressures in the high side of the refrigerant system
through its connection to a fitting on the A/C discharge line. The internal resistance of the A/C
pressure transducer changes in response to the pressures it monitors. The totally integrated power
module (TIPM) provides a five volt reference signal and a sensor ground to the A/C pressure
transducer. The TIPM then monitors the output voltage of the transducer on a sensor return circuit
to determine refrigerant pressure and sends a message to the powertrain control module (PCM) or
the engine control module (ECM) (depending on engine application) over the CAN C BUS. The
PCM/ECM is programmed to respond to this and other sensor inputs by controlling the operation of
the swashplate within the A/C compressor and the radiator cooling fan to help optimize A/C system
performance and to protect the system components from damage. The PCM adjusts the
swashplate to nearly a zero degree angle (low compressor displacement) when high side pressure
rises above 3130 kPa (454 psi) and re-adjusts the swashplate to a greater angle (higher
compressor displacement) when high side pressure drops below 1999 kPa (290 psi). The A/C
pressure transducer also reduces the swashplate angle if the high side pressure drops below 200
kPa (29 psi) and will increase the swashplate angle when the high side pressure rises above 234 -
262 kPa (34 - 38 psi). When the refrigerant pressure rises above 1655 kPa (240 psi), the PCM will
actuate the cooling fan.
A Schrader-type valve in the A/C discharge line fitting permits the A/C pressure transducer to be
removed or installed without disturbing the refrigerant in the A/C system.
The A/C pressure transducer is diagnosed using a scan tool.
The A/C pressure transducer cannot be adjusted or repaired and must be replaced if found
HVAC > Component Information > Service and Repair > Removal
Refrigerant Pressure Sensor / Switch: Service and Repair Removal
REMOVAL
NOTE: It is not necessary to discharge the refrigerant system to replace the A/C pressure
transducer.
NOTE: Typical A/C pressure transducer shown.
2. Carefully pull the top of the fascia forward to gain access to the A/C pressure transducer (2).
3. Reach down through the opening between the A/C condenser and the front fascia and
disconnect the wire harness connector (1) from the A/C
pressure transducer located on the A/C discharge line (3).
4. Remove the A/C pressure transducer from the A/C discharge line and remove and discard the
O-ring seal (4).
HVAC > Component Information > Service and Repair > Removal > Page 847
Refrigerant Pressure Sensor / Switch: Service and Repair Installation
INSTALLATION
NOTE: Use only the specified O-ring as it is made of special material for R-134a. Use only
refrigerant oil of the type required for the A/C compressor.
1. Lubricate a new rubber O-ring seal (4) with clean refrigerant oil and install it onto the A/C
discharge line (3).
2. Install the A/C pressure transducer (2) onto the A/C discharge line. Tighten the A/C pressure
transducer securely.
3. Connect the wire harness connector (1) to the A/C pressure transducer.
4. Reinstall the top of the front fascia.

Jeep Workshop Manuals > Sensors and Switches > Sensors and Switches - Instrument Panel > Door Switch > Component
Door Switch: Description and Operation Description
DOOR
This vehicle has four door ajar switches, one for each door. Each switch is concealed within and
integral to its respective door latch unit. The switches are momentary leaf contact-type units that
are actuated by the mechanisms internal to the door latch. A short pigtail wire and connector on
each door latch connects the door ajar switch to the vehicle electrical system through its respective
door wire harness.
The door ajar switches cannot be adjusted or repaired and, if ineffective or damaged, the door latch
unit must be replaced.
Jeep Workshop Manuals > Sensors and Switches > Sensors and Switches - Instrument Panel > Door Switch > Component
Door Switch: Description and Operation Operation
DOOR
The door ajar switches are actuated by the mechanisms internal to the door latch. When a door is
closed and properly latched, its door ajar switch is an open circuit. When a door is open or only
partially latched, the door ajar switch is a closed circuit. The door ajar switches are hard wired in
series between a body ground and the ElectroMechanical Instrument Cluster (EMIC) (also known
as the Cab Compartment Node/CCN). The EMIC reads the hard wired door ajar switch inputs
through internal pull-ups, then uses these inputs to control many electronic functions and features
of the vehicle. The EMIC also sends electronic door ajar switch status messages over the
Controller Area Network (CAN) data bus.
The door ajar switches as well as the hard wired inputs and outputs of the switches may be
information.
Jeep Workshop Manuals > Sensors and Switches > Sensors and Switches - Instrument Panel > Fuel Gauge Sender >
Fuel Gauge Sender: Locations
The fuel pump module is installed in the top of the fuel tank.
The fuel pump module contains the following:
- Electric fuel pump
- Fuel pump reservoir
- Inlet strainer
- Fuel pressure regulator
- Fuel gauge sending unit
- Fuel supply line connection
- Fuel Filter
Jeep Workshop Manuals > Sensors and Switches > Sensors and Switches - Instrument Panel > Outside Temperature
Display Sensor > Component Information > Description and Operation > Description
Outside Temperature Display Sensor: Description and Operation Description
DESCRIPTION
The ambient temperature sensor is a variable resistor type sensor. It is mounted to the lower front
fascia behind the radiator grille and in front of the engine compartment.
The ambient temperature sensor cannot be adjusted or repaired and, if inoperative or damaged, it
must be replaced.
Display Sensor > Component Information > Description and Operation > Description > Page 861
Outside Temperature Display Sensor: Description and Operation Operation
OPERATION
The ambient temperature sensor is a variable resistor that operates on a five-volt reference signal.
The resistance in the sensor changes as temperature changes, changing the temperature sensor
signal circuit voltage to the Totally Integrated Power Module (TIPM). Based upon the resistance in
the sensor, the instrument cluster or Cab Compartment Node (CCN) display senses a specific
voltage on the Controller Area Network (CAN) data bus circuit, which corresponds to a specific
temperature. The compass/temperature display unit then displays the proper ambient temperature.
Display Sensor > Component Information > Description and Operation > Page 862
Outside Temperature Display Sensor: Testing and Inspection
AMBIENT TEMPERATURE SENSOR
The thermometer function is supported by the ambient temperature sensor, the Totally Integrated
Power Module (TIPM), the Controller Area Network (CAN) data bus circuit, and the instrument
cluster or Cab Compartment Node (CCN) compass/temperature display unit.
If the display shows "OC" (-45° C (-49° F)) or "SC" (60° C (140° F)), there is an OPEN or SHORT
CIRCUIT that must be repaired.
The ambient temperature sensor circuit can also be diagnosed using the following Sensor Test,
and Sensor Circuit Test. If the temperature sensor and circuit are confirmed to be OK, but the
temperature display is inoperative or incorrect, replace the instrument cluster or CCN assembly.
SENSOR TESTING
1. Turn the ignition switch to the OFF position. Disconnect and isolate the battery negative cable.
2. Disconnect the ambient temperature sensor wire harness connector.
3. Measure the resistance of the ambient temperature sensor. At room temperature (approx. 20° C
(68° F)), the sensor resistance should be between
9-11 Kiloohms (9000-11000 ohms). The sensor resistance should read between these two values.
If OK, refer to the appropriate diagnostic information to continue diagnosis of the Totally Integrated
Power Module (TIPM), the Controller Area Network (CAN) data bus circuit, and the instrument
cluster or CCN. If not OK, replace the inoperative ambient temperature sensor.
Display Sensor > Component Information > Service and Repair > Removal
Outside Temperature Display Sensor: Service and Repair Removal
REMOVAL
2. Remove the belly pan.
3. Disconnect the wire harness connector (1) from the ambient temperature sensor (2).
4. Remove the fastener that secures the ambient temperature sensor bracket to the front fascia.
5. Remove the ambient temperature sensor from the vehicle.
Display Sensor > Component Information > Service and Repair > Removal > Page 865
Outside Temperature Display Sensor: Service and Repair Installation
INSTALLATION
1. Position the ambient temperature sensor in the vehicle.
2. Install the fastener that secures the ambient temperature sensor to the front fascia.
3. Connect the wire harness connector (1) to the ambient temperature sensor (2).
4. Install the belly pan.

Jeep Workshop Manuals > Sensors and Switches > Sensors and Switches - Instrument Panel > Parking Brake Warning
Switch > Component Information > Locations
Component ID: 356
Connector:
Color : NATURAL
# of pins : 1
Component ID: 356
Connector:
Color : NATURAL
# of pins : 1
DESCRIPTION
mechanism.
replaced.
OPERATION
Switch > Component Information > Description and Operation > Page 875
PARK BRAKE SWITCH
APPLIED
REMOVAL

INSTALLATION
2.5 Nm (24 in. lbs.).

Jeep Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Backup Lamp Switch >
Backup Lamp Switch: Locations
Component ID: 346
Component : SWITCH-BACKUP LAMP
Connector:
Name : SWITCH-BACKUP LAMP
Color : LT. GRAY
# of pins : 2
Qualifier : (DIESEL)
1 GROUND Z967 18BK/VT
Connector:
Color : GRAY
# of pins : 2
Qualifier : (GAS)
A GROUND Z967 18BK/VT
B BACKUP LAMP SWITCH SIGNAL T22 20YL/VT
Backup Lamp Switch: Diagrams
Component ID: 346
Component : SWITCH-BACKUP LAMP
Connector:
Color : LT. GRAY
# of pins : 2
Connector:
Color : GRAY
# of pins : 2
Qualifier : (GAS)
A GROUND Z967 18BK/VT
B BACKUP LAMP SWITCH SIGNAL T22 20YL/VT
Backup Lamp Switch: Description and Operation Description
DESCRIPTION
Vehicles equipped with a manual transmission (2) have a normally open, spring-loaded plunger
type backup lamp switch (1). Vehicles with an optional electronic automatic transmission have a
Transmission Range Sensor (TRS) that is used to perform several functions, including that of the
backup lamp switch. The TRS is described in further detail elsewhere in this service information.
Refer to the service and diagnostic information for the automatic transmission type installed in the
vehicle.
The backup lamp switch is located in a threaded hole on the forward-facing surface of the manual
transmission housing. The switch has a threaded body and a hex formation near the plunger end of
the switch. An integral connector receptacle at the end of the switch opposite the plunger connects
the switch to the vehicle electrical system through a take out and connector of the engine wire
harness. When installed, only the switch connector and the hex formation are visible on the outside
of the transmission housing.
The backup lamp switch cannot be adjusted or repaired and, if ineffective or damaged, the entire
switch unit must be replaced.
Backup Lamp Switch: Description and Operation Operation
OPERATION
The backup lamp switch controls a path to ground for the Totally Integrated Power Module (TIPM)
on the reverse switch signal circuit. The TIPM reads this input through an internal pull-up, then
controls an output through a high side driver that regulates the flow of battery voltage to the backup
lamp bulbs as appropriate on the backup lamp feed circuit. The switch plunger is mechanically
actuated by the gearshift mechanism within the transmission, which will depress the switch plunger
and close the switch contacts whenever the REVERSE gear has been selected. The switch
receives ground at all times through a take out and eyelet terminal of the unibody wire harness that
is secured by a nut to a ground stud on the body sheet metal within the passenger compartment of
the vehicle.
The backup lamp switch as well as the hard wired inputs and outputs of the switch may be
information.
Backup Lamp Switch: Testing and Inspection
BACKUP LAMP SWITCH
2. Locate and disconnect the engine wire harness connector from the backup lamp switch
connector receptacle.
3. Check for continuity between the two terminal pins in the backup lamp switch connector
receptacle.
a. With the gear selector lever in the REVERSE position, there should be continuity. b. With the
gear selector lever in any position other than REVERSE, there should be no continuity.
4. If the switch fails either of these two continuity tests, replace the ineffective backup lamp switch.
Component Information > Service and Repair > BG6 Manual Transaxle
Backup Lamp Switch: Service and Repair BG6 Manual Transaxle
Removal
REMOVAL
1. Disconnect battery negative cable. 2. Raise vehicle on hoist. 3. Disconnect backup lamp switch
connector. 4. Remove backup lamp switch (1).
Installation
INSTALLATION
Component Information > Service and Repair > BG6 Manual Transaxle > Page 894
1. Install the backup lamp switch (1) with anew washer and tighten to 40 Nm (29 ft. lbs.). 2.
Connect backup lamp switch connector. 3. Lower vehicle. 4. Connect battery negative cable.
Backup Lamp Switch: Service and Repair T355 Manual Transaxle
Removal
REMOVAL
1. Lift vehicle on hoist. 2. From bottom side of vehicle, disconnect back-up lamp switch connector
(2).
3. Unscrew switch (2) from transaxle.
Installation
INSTALLATION
Install back-up lamp switch (2). Teflon tape or equivalent must be used on switch threads. Tighten
switch to 24 Nm (18 ft. lbs.).
CAUTION: Do not overtighten switch.

1. Connect back-up lamp switch connector (2). 2. Lower vehicle. 3. Verify back-up lamp operation.
Jeep Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Brake Light Switch >
Brake Light Switch: Locations
Component ID: 365
Component : SWITCH-STOP LAMP
Connector:
Name : SWITCH-STOP LAMP
Color : BLACK
# of pins : 6
Brake Light Switch: Diagrams
Component ID: 365
Component : SWITCH-STOP LAMP
Connector:
Name : SWITCH-STOP LAMP
Color : BLACK
# of pins : 6
Brake Light Switch: Description and Operation Description
DESCRIPTION
The brake lamp switch (2) is a three circuit, spring-loaded plunger actuated switch that is secured
to the brake pedal support bracket on the dash panel under the instrument panel on the driver side
of the vehicle. The molded plastic switch housing has an integral connector receptacle (1)
containing six terminal pins and featuring a Connector Position Assurance (CPA) lock. The switch
is connected to the vehicle electrical system through a dedicated take out of the unibody wire
harness.
The switch plunger (3) extends through a mounting collar (4) on one end of the switch housing. The
plunger has a one time telescoping self-adjustment feature that is activated after the switch is
installed by moving an adjustment release lever (5) on the opposite end of the switch housing
clockwise, until it locks into a position that is horizontal and parallel to the connector receptacle.
An installed brake lamp switch cannot be readjusted or repaired. If the switch is damaged,
ineffective, or removed from its mounting position for any reason, it must be replaced with a new
unit.
Brake Light Switch: Description and Operation Operation
OPERATION
The brake lamp switch controls three independent circuits. These circuits are described as follows:
- Brake Lamp Switch Circuit - A normally open brake lamp switch circuit receives a battery voltage
input, and supplies this battery voltage to the Center High Mounted Stop Lamp (CHMSL), the
Totally Integrated Power Module (TIPM) and the ElectroMechanical Instrument Cluster (EMIC)
(also known as the Cab Compartment Node/CCN) on a brake lamp switch output circuit only when
the brake pedal is depressed (brake lamp switch plunger released). Then the TIPM regulates the
appropriate battery voltage output to the brake lamps in the rear lamp units through a high side
driver on the tail/stop lamp rear feed circuit.
- Brake Lamp Switch Signal Circuit - A normally closed brake lamp switch signal circuit receives a
direct path to ground, and supplies this ground input to the Powertrain Control Module (PCM) on a
brake lamp switch sense circuit only when the brake pedal is released (brake lamp switch plunger
is depressed).
- Speed Control Circuit - A normally closed speed control circuit receives a battery voltage input
from the Powertrain Control Module on a speed control supply circuit, and supplies this battery
voltage to the speed control servo solenoids (dump, vacuum, and vent) on a speed control brake
switch output circuit only when the speed control system is turned ON and the brake pedal is
released (brake lamp switch plunger is depressed).
The components of the self-adjusting brake switch plunger consist of a two-piece telescoping
plunger, a split plunger locking collar, and a release wedge. The release lever has a shaft with a
wedge that spreads the plunger locking collar to an open or released position. After the switch is
installed and the brake pedal is released, the plunger telescopes to the correct adjustment position.
When the release lever is moved to the release position, the wedge is disengaged from the locking
collar causing the collar to apply a clamping pressure to the two plunger halves, fixing the plunger
length.
The brake lamp switch as well as the hard wired inputs and outputs of the switch may be
information.
Brake Light Switch: Testing and Inspection
BRAKE LAMP SWITCH
CAUTION: Do not remove the brake lamp switch from the mounting bracket. The self-adjusting
switch plunger is a one time only feature. If the switch is removed from the mounting bracket, it
MUST be replaced with a new switch.
2. Disconnect the wire harness connector from the brake lamp switch.
3. Using an ohmmeter, perform the continuity tests at the terminal pins (1) in the brake lamp switch
connector receptacle as shown in the Brake Lamp
Switch Tests table.
4. If the switch fails any of the continuity tests, replace the ineffective brake lamp switch as
required.
Brake Light Switch: Service and Repair Removal
REMOVAL
2. Locate the brake lamp switch (4) on the brake pedal support bracket (2) on the dash panel.
3. Disengage the wire harness retainer (1) from the brake pedal support bracket.
4. Disconnect the unibody wire harness take out and connector (5) from the brake lamp switch.
5. Rotate the brake lamp switch housing (3) clockwise about 30 degrees to align the tabs on the
switch locking collar with the keyed hole in the
brake pedal support bracket (1).
6. Pull the switch straight back from the keyed hole to remove it from the bracket.
CAUTION: The brake lamp switch self-adjusting switch plunger is a one time only feature. If the
switch is removed from the mounting bracket, it MUST be replaced with a new switch.
7. Discard the removed brake lamp switch.

Brake Light Switch: Service and Repair Installation
INSTALLATION
CAUTION: The brake lamp switch self-adjusting switch plunger is a one time only feature. If the
switch is removed from the mounting bracket, it MUST be replaced with a new switch.
1. Depress and hold the brake pedal (2) in the depressed position.
2. Align the tabs on the brake lamp switch (3) locking collar with the keyed hole in the brake pedal
mounting bracket (1) on the dash panel.
3. Insert the tabs on the brake lamp switch locking collar through the keyed hole in the brake pedal
mounting bracket until the switch housing is
firmly seated against the bracket.
4. Rotate the switch housing counterclockwise about 30 degrees to engage the tabs on the locking
collar with the pedal mounting bracket.
CAUTION: Do not release or pull up on the brake pedal before the switch plunger adjustment has
been completed.
5. Release the brake pedal, but do not pull it upward.
6. Reconnect the unibody wire harness connector (5) to the brake lamp switch (4).
7. Engage the wire harness retainer (1) in the locator hole in the brake pedal support bracket (2).
8. Rotate the plunger adjustment release lever (3) clockwise until it locks into place. The lever
should be parallel to the brake lamp switch connector
receptacle. This action will set the switch plunger length to a final adjustment position and cannot
be undone. If not performed properly the first time, a new brake lamp switch must be installed.

Jeep Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Combination Switch >
Combination Switch: Description and Operation Description
DESCRIPTION
The left (lighting) multi-function switch is located on the left side of the steering column, just below
the steering wheel. This switch is the primary control for the interior and exterior lighting systems.
The only visible components of the switch are the control stalk (2), control knob (1) and control
sleeve (3) that extend through the steering column shrouds on the left side of the column. The
remainder of the switch including its mounting provisions, its electrical connection, and the turn
signal cancel actuator are concealed beneath the shrouds.
The switch housing (2) and controls (1) are constructed of molded black plastic. Each of the switch
controls has white International Control and Display Symbol graphics applied to it, which clearly
identify its many functions. A single screw (7) through a mounting tab integral to the back of the
switch housing, and a slide tab integral to the bottom of the switch housing secure the switch to the
mounting bracket integral to the clockspring (3).
The Steering Control Module (SCM) is internal to the switch housing. The switch outputs are
internally connected directly to the SCM. A single connector receptacle containing seven terminal
pins is integral to the inboard end of the switch housing and connects the right multi-function switch
(6) through a jumper wire harness (5) directly to the SCM. An integral connector receptacle on the
back of the switch housing connects the SCM to the vehicle electrical system through a dedicated
take out and connector of the instrument panel wire harness.
The left multi-function switch provides the vehicle operator with a control interface for the following
exterior lighting system functions:
- Front Fog Lamps - For vehicles so equipped, the left multi-function switch control knob provides
detent switching for the optional front fog lamps.
- Headlamps - The left multi-function switch control knob provides detent switching for the
headlamps.
- Headlamp Beam Selection - The left multi-function switch control stalk provides detent switching
for selection of the headlamp high or low beams.
Headlamp Optical Horn - The left multi-function switch control stalk includes momentary switching
of the headlamp high beam circuits to provide an optical horn feature (sometimes referred to as
flash-to-pass), which allows the vehicle operator to momentarily flash the headlamp high beams as
an optical signalling device.
- Park Lamps - The left multi-function switch control knob provides detent switching for the park
lamps.
- Rear Fog Lamps - For vehicles so equipped, the left multi-function switch control knob provides
detent switching for the optional rear fog lamps. Rear fog lamps are optional only for vehicles
manufactured for certain markets, where they are required.
- Turn Signal Control - The left multi-function switch control stalk provides both momentary
non-detent switching and detent switching with automatic cancellation for both the left and right turn
signal lamps.
The left multi-function switch also provides the vehicle operator with a control interface for the
following interior lighting functions:
- Interior Lamps Defeat - The left multi-function switch control ring provides detent switching to
DEFEAT the illumination of all interior courtesy lamps when a door, the rear flip-up glass, or the
liftgate are opened.
- Interior Lamps On - The left multi-function switch control ring provides detent switching to
simultaneously illuminate all interior courtesy lamps.
- Panel Lamps Dimming - The left multi-function switch control ring provides simultaneous
adjustable control of the illumination intensity of all instrument panel lighting at one of five available
illumination intensity levels.
- Parade Mode - The left multi-function switch control ring provides detent switching for a PARADE
mode that maximizes the illumination intensity of all instrument panel lighting for visibility when
driving in daylight with the exterior lamps turned ON.
The left multi-function switch cannot be adjusted or repaired. If any function of the switch is
ineffective, or if the switch is damaged, the entire switch unit must be replaced. The clockspring
(with the multi-function switch mounting bracket), the left multi-function switch (with the SCM), the
right multi-function switch and the jumper wire harness are each available for separate service
replacement.
Combination Switch: Description and Operation Operation
OPERATION
The left (lighting) multi-function switch uses resistor multiplexing to control the many functions and
features it provides using a minimal number of hard wired circuits. The switch receives clean
grounds from the Steering Control Module (SCM), then provides resistor multiplexed return outputs
to the SCM to indicate the selected switch positions. The SCM then sends electronic switch status
messages over a Local Interface Network (LIN) data bus to the ElectroMechanical Instrument
Cluster (EMIC) (also known as the Cab Compartment Node/CCN), and the EMIC relays electronic
switch request messages over the Controller Area Network (CAN) data bus to other electronic
modules in the vehicle.
If the SCM detects no inputs from the left multi-function switch, it transmits an electronic Signal Not
Available (SNA) status message over the LIN data bus. The SNA status signals the EMIC to
request other electronic modules to implement a failsafe mode of operation for the exterior lighting
systems. The failsafe mode automatically turns the exterior lighting ON when the ignition switch is
in the ON position, and OFF when the ignition switch is in the OFF position.
The hard wired inputs and outputs of the left multi-function switch and SCM may be diagnosed
However, the most reliable, efficient and accurate means to diagnose this component requires the
use of a diagnostic scan tool. Refer to the appropriate diagnostic information.
EXTERIOR LIGHTING
Following are descriptions of how the left multi-function switch is operated to control the many
exterior lighting functions and features it provides:
- Front Fog Lamps - The optional front fog lamps are requested when the left multi-function switch
control knob is pulled outward to the front fog lamps detent position. The SCM reads the resistor
multiplexed input from the left multi-function switch and sends an electronic exterior lighting switch
status message over the LIN data bus to the EMIC, which relays an electronic exterior lighting
switch request message over the CAN data bus to other electronic modules in the vehicle. The
switch control knob incorporates an internal cam mechanism that will only allow the front fog lamps
to be selected while the headlamp ON position is also selected, and will automatically move the
control knob to the front fog lamps OFF position when the control knob is rotated to deselect the
headlamps.
- Headlamps - The headlamps are requested when the left multi-function switch control knob is
rotated to the headlamps ON detent position. The SCM reads the resistor multiplexed input from
the left multi-function switch and sends an electronic exterior lighting switch status message over
the LIN data bus to the EMIC, which relays an electronic exterior lighting switch request message
over the CAN data bus to other electronic modules in the vehicle.
- Headlamp Beam Selection - The headlamp high beams are selected when the left multi-function
switch control stalk is pushed forward to the high beam selection detent position. The low beams
are selected when the control stalk is pulled rearward to the low beam selection detent position.
The SCM reads the resistor multiplexed input from the left multi-function switch and sends an
electronic beam select switch status message over the LIN data bus to the EMIC, which relays an
electronic beam select switch request message over the CAN data bus to other electronic modules
in the vehicle.
- Headlamp Optical Horn - The headlamp optical horn is selected each time the left multi-function
switch control stalk is pulled fully rearward to a momentary position. The headlamp high beams will
remain illuminated for as long as the control stalk is held in this momentary position and the low
beams will be restored when the control stalk is released. The SCM reads the resistor multiplexed
input from the left multi-function switch and sends an electronic beam select switch status message
over the LIN data bus to the EMIC, which relays an electronic beam select switch request message
- Park Lamps - The headlamps are requested when the left multi-function switch control knob is
rotated to the park lamps ON detent position. The SCM reads the resistor multiplexed input from
the left multi-function switch and sends an electronic exterior lighting switch status message over
the LIN data bus to the EMIC, which relays an electronic exterior lighting switch request message
- Rear Fog Lamps - The optional rear fog lamps are requested when the left multi-function switch
control knob is pulled outward to the front fog lamps detent position and then rotated to the rear fog
lamps detent position. The SCM reads the resistor multiplexed input from the left multi-function
switch and sends an electronic exterior lighting switch status message over the LIN data bus to the
EMIC, which relays an electronic exterior lighting switch request message over the CAN data bus
to other electronic modules in the vehicle. The switch control knob incorporates an internal cam
mechanism that will only allow the rear fog lamps to be selected while the front fog lamps ON
position is also selected, and will automatically move the control knob to the rear fog lamp OFF
position when the control knob is pushed in to deselect the front fog lamps.
- Turn Signal Control - The turn signals are requested when the left multi-function switch control
stalk is moved downward (left signal) or upward (right signal). The control stalk has a detent
position in each direction that provides turn signals with automatic cancellation, and an
intermediate, momentary position in each direction that automatically provides three turn signal
blinks as a LANE CHANGE feature when the control stalk is tapped or will energize the turn signals
for as long as the control stalk is held in the momentary position. When the control stalk is moved
to a detent turn signal switch position, a cancel actuator extends through an opening in the side of
the clockspring case toward the center of the steering column. A turn signal cancel cam that is
integral to the clockspring rotor rotates with the steering wheel and the cam lobes contact the
cancel actuator when it is extended from the left multi-function switch. When the steering wheel is
rotated during a turning maneuver, one of the turn signal cancel cam lobes will contact the turn
signal cancel actuator. The cancel actuator latches against the cancel cam rotation in the direction
opposite that which is signaled. If the left turn signal detent is selected, the lobes of the cancel cam
will ratchet past the cancel actuator when the steering wheel is rotated to the left, but will unlatch
the cancel actuator as the steering wheel rotates to the right and returns to center, which will
cancel the turn signal event and release the control stalk from the detent so it returns to the neutral
OFF position. The SCM reads the resistor multiplexed input from the left multi-function switch and
sends an electronic exterior lighting switch status message over the LIN data bus to the EMIC,
which relays an electronic exterior lighting switch request message over the CAN data bus to other
electronic modules in the vehicle.
INTERIOR LIGHTING
Following are descriptions of the how the left multi-function switch is operated to control the many
interior lighting functions and features it provides:
- Interior Lamps Defeat - The interior lamps defeat feature is requested when the left multi-function
switch control sleeve is rotated to the interior lamps DEFEAT detent position. The SCM reads the
resistor multiplexed input from the left multi-function switch and sends an electronic interior lighting
switch status message over the LIN data bus to the EMIC, which relays an electronic interior
lighting switch request message over the CAN data bus to other electronic modules in the vehicle.
- Interior Lamps On - The interior lamps ON feature is requested when the left multi-function switch
control sleeve is rotated to the interior lamps ON detent position. The SCM reads the resistor
multiplexed input from the left multi-function switch and sends an electronic interior lighting switch
status message over the LIN data bus to the EMIC, which relays an electronic interior lighting
switch request message over the CAN data bus to other electronic modules in the vehicle.
- Panel Lamps Dimming - The panel lamps dimming function is active only when the left
multi-function switch control knob is in any exterior lighting ON position. With the exterior lighting
ON, the panel lamps dimming level is requested when the left multi-function switch control sleeve is
rotated to any one of five minor detent positions. The SCM reads the resistor multiplexed input from
the left multi-function switch and sends an electronic interior lighting switch status message over
the LIN data bus to the EMIC, which relays an electronic interior lighting switch request message
- Parade Mode - The PARADE (or funeral) mode is active only when the left multi-function switch
control knob is in any exterior lighting ON position. With the exterior lighting ON, the PARADE
mode is requested when the left multi-function switch control sleeve is rotated to the PARADE
mode detent position. The SCM reads the resistor multiplexed input from the left multi-function
switch and sends an electronic interior lighting switch status message over the LIN data bus to the
EMIC, which relays an electronic interior lighting switch request message over the CAN data bus to
other electronic modules in the vehicle.
Combination Switch: Service and Repair Removal
REMOVAL
2. Remove both the upper and lower shrouds from the steering column.
3. Disconnect the instrument panel wire harness connector from the connector receptacle on the
back of the left multi-function switch.
4. Remove the screw (2) that secures the left multi-function switch (1) to the mounting bracket
integral to the left side of the clockspring (3) on the
steering column.
5. Slide the switch away from the clockspring far enough to disengage the slide tabs on the switch
housing from the channel formations in the
mounting bracket.
6. Disconnect the jumper wire harness connector from the connector receptacle on the inboard end
of the left multi-function switch.
7. Remove the switch from the clockspring.

Combination Switch: Service and Repair Installation
INSTALLATION
1. Position the left multi-function switch (1) close enough to the mounting bracket (3) integral to the
left side of the clockspring to reconnect the
jumper wire harness connector to the connector receptacle on the inboard side of the switch
housing.
2. Align the slide tabs on the switch housing with the channel formations integral to the clockspring
mounting bracket, then slide the switch into the
bracket until it is firmly seated.
3. Install and tighten the screw (2) that secures the mounting tab on the front of the left
multi-function switch to the mounting bracket on the
clockspring. Tighten the screw to 1 Nm (10 in. lbs.).
4. Reconnect the instrument panel wire harness connector to the connector receptacle on the back
of the switch housing.
5. Reinstall the upper and lower shrouds onto the steering column.

Jeep Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Door Switch >
Door Switch: Description and Operation Description
DOOR
This vehicle has four door ajar switches, one for each door. Each switch is concealed within and
integral to its respective door latch unit. The switches are momentary leaf contact-type units that
are actuated by the mechanisms internal to the door latch. A short pigtail wire and connector on
each door latch connects the door ajar switch to the vehicle electrical system through its respective
door wire harness.
The door ajar switches cannot be adjusted or repaired and, if ineffective or damaged, the door latch
unit must be replaced.
Jeep Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Door Switch >
Door Switch: Description and Operation Operation
DOOR
The door ajar switches are actuated by the mechanisms internal to the door latch. When a door is
closed and properly latched, its door ajar switch is an open circuit. When a door is open or only
partially latched, the door ajar switch is a closed circuit. The door ajar switches are hard wired in
series between a body ground and the ElectroMechanical Instrument Cluster (EMIC) (also known
as the Cab Compartment Node/CCN). The EMIC reads the hard wired door ajar switch inputs
through internal pull-ups, then uses these inputs to control many electronic functions and features
of the vehicle. The EMIC also sends electronic door ajar switch status messages over the
The door ajar switches as well as the hard wired inputs and outputs of the switches may be
information.
Jeep Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Hazard Warning Switch >
Hazard Warning Switch: Description and Operation Description
DESCRIPTION
The hazard switch (4) is integral to the instrument panel switch pod (1), which is secured to the
instrument panel center bezel just below the heater and air conditioner controls. A red, stencil-like
International Control and Display Symbol icon for Hazard Warning identifies the hazard switch
button. The remainder of the hazard switch circuitry is concealed within the instrument panel switch
pod.
The hazard switch button has panel lamps dimmer controlled illumination for night visibility. The
switch button unlatches to a slightly raised position when the hazard warning system is activated
and the icon on the switch button will illuminate at an increased intensity while the turn signals and
turn signal indicators are flashing. The switch button latches to a lowered position flush with the
other push buttons in the switch pod when the hazard warning is deactivated.
All of the circuitry and components of the hazard switch are contained within a molded black plastic
instrument panel switch pod housing. A single connector receptacle is integral to the back of the
switch pod housing. The switch is connected to the vehicle electrical system through a dedicated
take out and connector of the instrument panel wire harness.
The hazard switch cannot be adjusted or repaired and, if ineffective or damaged, the entire
instrument panel switch pod unit must be replaced.
Jeep Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Hazard Warning Switch >
Hazard Warning Switch: Description and Operation Operation
OPERATION
The status of the hazard switch is continually monitored by the circuitry within the instrument panel
switch pod. The switch pod receives battery voltage at all times on a fused battery feed circuit, and
a path to ground at all times through the instrument panel wire harness. The only other inputs to
and outputs from the switch pod consist of electronic communication with the ElectroMechanical
Instrument Cluster (EMIC) (also known as the Cab Compartment Node/CCN) over the single wire
Local Interface Network (LIN) data bus.
Whenever the hazard switch is in its unlatched and raised position, the hazard warning system is
selected and the switch pod circuitry sends an electronic hazard switch status message to the
EMIC over the LIN data bus and the EMIC responds to this input by sending the appropriate
electronic hazard system request messages to the Totally Integrated Power Module over the CAN
data bus.
When the TIPM receives a hazard system request message it then controls hazard warning system
operation and flash rate by controlling battery voltage outputs through high side drivers on the right
and left turn signal feed circuits. The TIPM also sends the appropriate electronic messages back to
the EMIC to control the illumination and flash rate of the right and left turn signal indicators, as well
as to control the click rate of an electromechanical relay soldered onto the EMIC electronic circuit
board that emulates the sound emitted by a conventional hazard warning flasher. The EMIC then
sends messages back to the switch pod to control the illumination of the hazard switch push
button.
The hard wired circuits for the instrument panel switch pod may be diagnosed using conventional
diagnostic tools and procedures. Refer to the appropriate wiring information. However,
conventional diagnostic methods will not prove conclusive in the diagnosis of the hazard warning
switch or the electronic controls and communication between other modules and devices that
provide some features of the hazard warning system. The most reliable, efficient, and accurate
means to diagnose the hazard switch or the electronic controls and communication related to
hazard warning system operation requires the use of a diagnostic scan tool. Refer to the
Jeep Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Horn Switch >
Horn Switch: Locations
Component ID: 352
Component : SWITCH-HORN
Connector:
Name : SWITCH-HORN
Color : BLACK
# of pins : 2
Horn Switch: Diagrams
Component ID: 352
Component : SWITCH-HORN
Connector:
Name : SWITCH-HORN
Color : BLACK
# of pins : 2
Horn Switch: Description and Operation Description
DESCRIPTION
WARNING: On vehicles equipped with an airbag, refer to restraint systems for warnings and
cautions before servicing the horn switch.
The horn switch is mounted under the driver airbag. The horn switch has three contacts that are
grounded when the driver airbag is depressed.
Horn Switch: Description and Operation Operation
OPERATION
When the Driver Airbag Cover is pressed, the horn switch grounds through the clockspring. The
ground signal is carried to the horn relay and the horn sounds. The horn switch grounds to the
airbag housing.
Horn Switch: Service and Repair Removal
REMOVAL
WARNING: On vehicles equipped with an airbag, refer to restraint systems for warnings and
cautions before servicing the horn switch.
2. Remove the driver airbag.
3. Disconnect the horn plate connector.
4. Remove the three mounting fasteners.
5. Remove the horn switch.

Horn Switch: Service and Repair Installation
INSTALLATION
1. Install the horn switch.
2. Install the three mounting fasteners.
3. Connect the horn plate connector.
4. Install the driver airbag.

Jeep Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and
Switches - Computers and Control Systems > Accelerator Pedal Position Sensor > Component Information > Locations
Accelerator Pedal Position Sensor: Locations
Component ID: 290
Component : SENSOR-ACCELERATOR PEDAL POSITION
Connector:
Name : SENSOR-ACCELERATOR PEDAL POSITION
Color : BLACK
# of pins : 6
3 5 VOLT SUPPLY K854 20VT/BR
6 5 VOLT SUPPLY K852 20BR/VT

Switches - Computers and Control Systems > Accelerator Pedal Position Sensor > Component Information > Locations >
Page 951
Page 952
Page 953
Accelerator Pedal Position Sensor: Diagrams
Component ID: 290
Connector:
Color : BLACK
# of pins : 6

Page 954
Page 955
Page 956
Accelerator Pedal Position Sensor: Description and Operation
DESCRIPTION
The Accelerator Pedal Position Sensor (APPS) is a variable resistor that provides the PCM with an
input signal (voltage). The signal represents pedal angle position. As the position of the accelerator
pedal changes, the resistance of the APPS changes.
Switches - Computers and Control Systems > Accelerator Pedal Position Sensor > Component Information > Service and
Repair > Removal
Accelerator Pedal Position Sensor: Service and Repair Removal
REMOVAL
2. Disconnect the electrical connector from the module.
3. Remove the mounting nuts.
4. Remove assembly from the mounting studs.

Repair > Removal > Page 959
Accelerator Pedal Position Sensor: Service and Repair Installation
INSTALLATION
1. Install APPS module.
2. Tighten the mounting nuts.

Switches - Computers and Control Systems > Camshaft Position Sensor > Component Information > Locations >
Sensor-Camshaft 1/1 Position
Camshaft Position Sensor: Locations Sensor-Camshaft 1/1 Position
Component ID: 293
Component : SENSOR-CAMSHAFT 1/1 POSITION
Connector:
Name : SENSOR-CAMSHAFT 1/1 POSITION
Color : BLACK
# of pins : 3
Qualifier : (GAS)
Sensor-Camshaft 1/1 Position > Page 964
Component ID: 294
Connector:
Color : BLACK
# of pins : 3
Qualifier : (GAS)
Switches - Computers and Control Systems > Camshaft Position Sensor > Component Information > Diagrams >
Camshaft Position Sensor: Diagrams Sensor-Camshaft 1/1 Position
Component ID: 293
Connector:
Color : BLACK
# of pins : 3
Qualifier : (GAS)
Component ID: 294
Connector:
Color : BLACK
# of pins : 3
Qualifier : (GAS)
Switches - Computers and Control Systems > Camshaft Position Sensor > Component Information > Description and
Operation > Description
Camshaft Position Sensor: Description and Operation Description
DESCRIPTION
The camshaft position sensors are mounted to the front and rear of the cylinder head.
Operation > Description > Page 976
Camshaft Position Sensor: Description and Operation Operation
OPERATION
The PCM sends approximately 5 volts to the Hall-effect sensor. This voltage is required to operate
the Hall-effect chip and the electronics inside the sensor. The input to the PCM occurs on a 5 volt
output reference circuit. A ground for the sensor is provided through the sensor return circuit. The
PCM identifies camshaft position by registering the change from 5 to 0 volts, as signaled from the
camshaft position sensor.
The PCM determines fuel injection synchronization and cylinder identification from inputs provided
by the camshaft position sensor and crankshaft position sensor. From the two inputs, the PCM
determines crankshaft position.
Switches - Computers and Control Systems > Camshaft Position Sensor > Component Information > Service and Repair >
Removal
Camshaft Position Sensor: Service and Repair Removal
Front Camshaft Position Sensor
FRONT CAMSHAFT POSITION SENSOR
1. Remove the air cleaner hose to throttle body, disconnect the inlet air temperature sensor
electrical connector.
3. Disconnect electrical connector from camshaft position sensor.
4. Remove camshaft position sensor mounting screws.
5. Remove sensor.
Rear Camshaft Position Sensor

Removal > Page 979
REAR CAMSHAFT POSITION SENSOR
2. Disconnect electrical connector at sensor.
3. Remove nut retaining heat shield.
4. Pull heat shield out to uncover sensor.
5. Remove mounting bolt.

Removal > Page 980
6. Remove sensor.
Removal > Page 981
Camshaft Position Sensor: Service and Repair Installation
1. Lubricate sensor O-ring.
2. Install camshaft position sensor utilizing twisting motion. Make sure sensor is fully seated. Do not
drive sensor into the bore with screw. This can
cause sensor to be incorrectly seated causing engine to fail. Tighten sensor mounting screws to 9
Nm (79.5 in. lbs.).
3. Carefully attach electrical connector to camshaft position sensor. Installation at an angle may
damage the sensor pins.
4. Install the negative battery cable.
5. Install the air cleaner to throttle body hose, connect the inlet air temperature sensor electrical
connector.
Removal > Page 982
2. Install sensor utilizing twisting motion. Make sure sensor is fully seated. Do not drive sensor into
the bore with screw. This can cause sensor to be
incorrectly seated causing engine to fail.
3. Install mounting bolt and tighten to 9 Nm (79.5 in. lbs.).
4. Carefully attach electrical connector to camshaft position sensor. Fill for positive lock (click).
Installation at angle may damage the sensor pins.
5. Install heat shield onto mounting stud.
6. Install heat shield retaining nut and tighten.

Removal > Page 983
7. Connect the electrical connector.

Switches - Computers and Control Systems > Coolant Temperature Sensor/Switch (For Computer) > Component
Information > Technical Service Bulletins > Engine Controls - MIL On/DTC P0116/ECT Sensor
NUMBER: 18-039-06
INTERNET.
BULLETIN.
SUBJECT:
CAUTION:

BE INSTALLED.
MODELS:
2007 (PM) Caliber
2007 (MK49) Compass
NOTE:
(MDH 1120XX).
NOTE:
DIAGNOSIS:
PARTS REQUIRED:
Information > Technical Service Bulletins > Engine Controls - MIL On/DTC P0116/ECT Sensor > Page 988
CAUTION:
NOTE:

seconds.
CAUTION:
PROCESS.
NOTE:
NOTE:
TIME ALLOWANCE:
FAILURE CODE:
Disclaimer:
Information > Locations > Sensor-Engine Coolant Temperature 1

Temperature 1
Component ID: 299
Connector:
Color : DK. GRAY
# of pins : 2
Qualifier : (GAS)
Information > Locations > Sensor-Engine Coolant Temperature 1 > Page 992

Temperature 2
Component ID: 300
Connector:
Color : BLACK
# of pins : 2
Qualifier : (GAS)
Information > Diagrams > Sensor-Engine Coolant Temperature 1

Temperature 1
Component ID: 299
Connector:
Color : DK. GRAY
# of pins : 2
Qualifier : (GAS)
Information > Diagrams > Sensor-Engine Coolant Temperature 1 > Page 999

Temperature 2
Component ID: 300
Connector:
Color : BLACK
# of pins : 2
Qualifier : (GAS)
Switches - Computers and Control Systems > Crankshaft Position Sensor > Component Information > Locations
Crankshaft Position Sensor: Locations
The Crankshaft Position Sensor is in the rear of the engine block near the transmission.
Switches - Computers and Control Systems > Crankshaft Position Sensor > Component Information > Locations > Page
1007
Crankshaft Position Sensor: Diagrams
Component ID: 296
Component : SENSOR-CRANKSHAFT POSITION
Connector:
Name : SENSOR-CRANKSHAFT POSITION
Color : BLACK
# of pins : 3
1 CKP SENSOR 5 VOLT SUPPLY K853 20DB/BR
2 CKP SENSOR SIGNAL K24 20BR/LB
3 CKP SENSOR GROUND K925 20DB/WT
1008
1009
1010
Connector:
Color : # of pins :
Qualifier : (GAS)
3 CKP SIGNAL K24 20LB/BR

1011
1012
1013
Switches - Computers and Control Systems > Crankshaft Position Sensor > Component Information > Description and
Crankshaft Position Sensor: Description and Operation Description
DESCRIPTION
The crankshaft position sensor mounts to the rear of the engine block near the transmission.
The PCM uses the Crankshaft Position sensor to calculate the following:
- Engine RPM
- TDC number 1 and 4
- Ignition coil synchronization
- Injector synchronization
- Camshaft-to-crankshaft misalignment (Timing belt skipped 1 tooth or more diagnostic trouble

code).
Crankshaft Position Sensor: Description and Operation Operation
OPERATION
the Hall-effect chip and the electronics inside the sensor. A ground for the sensor is provided
through the sensor return circuit. The input to the PCM occurs on a 5 Volt output reference circuit
that operates as follows: The Hall-effect sensor contains a powerful magnet. As the magnetic field
passes over the dense portion of the counterweight, the 5-volt signal is pulled to ground (0.3 volts)
through a transistor in the sensor. When the magnetic field passes over the notches in the
crankshaft counterweight, the magnetic field turns off the transistor in the sensor, causing the PCM
to register the 5-volt signal. The PCM identifies crankshaft position by registering the change from
5 to 0 volts, as signaled from the Crankshaft Position sensor (2).
The PCM determines which cylinder to fire from the crankshaft position sensor input and the
camshaft position sensor input. The #8 crankshaft counterweight has a target ring with 32 teeth
and notches (1), including one long reference tooth and notch. From the crankshaft position sensor
input the PCM determines engine speed and crankshaft angle (position).
Switches - Computers and Control Systems > Crankshaft Position Sensor > Component Information > Service and Repair >
Removal
Crankshaft Position Sensor: Service and Repair Removal
2.0/2.4L
If vehicle is All Wheel Drive the Power Transfer Unit must be removed.
1. Disconnect the negative battery cable.
2. Raise vehicle and support.
3. Remove heat shield retaining bolt.
4. Remove heat shield.
5. Unlock and disconnect the electrical connector to the crankshaft position sensor.
Removal > Page 1019
6. Remove the crankshaft position sensor bolt.
7. Remove the sensor.

Removal > Page 1020
Crankshaft Position Sensor: Service and Repair Installation
2.0/2.4L
1. Check O-ring for damage and lubricate the O-ring with engine oil before installing sensor.
2. Use a twisting motion when installing the sensor.
3. Install and tighten the crankshaft position sensor bolt and tighten to 9 Nm (79.5 in. lbs.).
4. Connect and lock the electrical connector to the crankshaft position sensor.
5. Install heat shield and retaining bolt.

Removal > Page 1021
If vehicle is All Wheel Drive the Power Transfer Unit must be installed.
6. Lower vehicle.
7. Connect the negative battery cable.

Switches - Computers and Control Systems > Fuel Level Sensor > Component Information > Locations
Fuel Level Sensor: Locations
- Inlet strainer
- Fuel Filter
Switches - Computers and Control Systems > Intake Air Temperature Sensor > Component Information > Locations
Intake Air Temperature Sensor: Locations
The sensor is located in the clean air duct.

Switches - Computers and Control Systems > Intake Air Temperature Sensor > Component Information > Locations > Page
1028
Intake Air Temperature Sensor: Diagrams
Component ID: 306
Component : SENSOR-INTAKE AIR TEMPERATURE
Connector:
Name : SENSOR-INTAKE AIR TEMPERATURE
Color : BLACK
# of pins : 2
Qualifier : (GAS)
1029
1030
Intake Air Temperature Sensor: Description and Operation
DESCRIPTION
The IAT Sensor is a Negative Temperature Coefficient (NTC) Sensor that provides information to
the PCM regarding the temperature of the air entering the intake manifold.
Switches - Computers and Control Systems > Intake Air Temperature Sensor > Component Information > Service and
Repair > Removal
Intake Air Temperature Sensor: Service and Repair Removal
2.0/2.4L
2. Disconnect electrical connector from the sensor.

Intake Air Temperature Sensor: Service and Repair Installation
2.0/2.4L
The sensor is in the clean air duct.
1. Install sensor. Make sure of sensor orientation.
2. Attach electrical connector to sensor.

Switches - Computers and Control Systems > Knock Sensor > Component Information > Locations
Knock Sensor: Locations
Component ID: 308
Component : SENSOR-KNOCK
Connector:
Name : SENSOR-KNOCK
Color : BLACK
# of pins : 2
Qualifier : (GAS)
Switches - Computers and Control Systems > Knock Sensor > Component Information > Locations > Page 1037
Knock Sensor: Diagrams
Component ID: 308
Connector:
Name : SENSOR-KNOCK
Color : BLACK
# of pins : 2
Qualifier : (GAS)
Switches - Computers and Control Systems > Knock Sensor > Component Information > Description and Operation >
Description
Knock Sensor: Description and Operation Description
DESCRIPTION
The knock sensor is bolted to the cylinder block. The knock sensor is designed to detect engine
vibration that is caused by detonation or preignition.
Knock Sensor: Description and Operation Operation
OPERATION
When the knock sensor detects a knock in one of the cylinders, it sends an input signal to the
PCM. In response, the PCM retards ignition timing for all cylinders by a scheduled amount.
Knock sensors contain a piezoelectric material which constantly vibrates and sends an input
voltage (signal) to the PCM while the engine operates. As the intensity of the crystal's vibration
increases, the knock sensor output voltage also increases.
The voltage signal produced by the knock sensor increases with the amplitude of vibration. The
PCM receives as an input the knock sensor voltage signal. If the signal rises above a
predetermined level, the PCM will store that value in memory and retard ignition timing to reduce
engine knock. If the knock sensor voltage exceeds a preset value, the PCM retards ignition timing
for all cylinders. It is not a selective cylinder retard.
The PCM ignores knock sensor input during engine idle conditions. Once the engine speed
exceeds a specified value, ignition timing retard is allowed.
Ignition timing is retarded uses its own short term and long term memory program.
Long term memory stores previous detonation information in its battery-backed RAM. The
maximum authority that long term memory has over timing retard can be calibrated.
Short term memory is allowed to retard ignition timing up to a preset amount under all operating
conditions (as long as rpm is above the minimum rpm) except WOT. The PCM, using short term
memory, can respond quickly to retard timing when engine knock is detected. Short term memory
is lost any time the ignition key is turned off.
NOTE: Over or under tightening affects knock sensor performance, possibly causing improper
spark control.
Switches - Computers and Control Systems > Knock Sensor > Component Information > Service and Repair > Removal
Knock Sensor: Service and Repair Removal
2.0/2.4L
The knock sensor bolts into the side of the cylinder block in front of the starter under the intake
manifold.
2. Remove the bolt holding the knock sensor.
3. Remove sensor with electrical connector attached.
4. Disconnect electrical connector from knock sensor.

Switches - Computers and Control Systems > Knock Sensor > Component Information > Service and Repair > Removal >
Page 1047
5. Remove the knock sensor.

Page 1048
Knock Sensor: Service and Repair Installation
2.0/2.4L
manifold.
1. Attach electrical connector to knock sensor.
2. Install knock sensor. Tighten knock sensor bolt to 22 Nm (195 in. lbs.). Over or under tightening
effects knock sensor performance, possibly
causing improper spark control.

Switches - Computers and Control Systems > Manifold Pressure/Vacuum Sensor > Component Information > Locations
Manifold Pressure/Vacuum Sensor: Locations
Component ID: 309
Component : SENSOR-MAP
Connector:
Name : SENSOR-MAP
Color : BLACK
# of pins : 3
Qualifier : (GAS)
Switches - Computers and Control Systems > Manifold Pressure/Vacuum Sensor > Component Information > Locations >
Page 1052
Page 1053
Manifold Pressure/Vacuum Sensor: Diagrams
Component ID: 309
Connector:
Name : SENSOR-MAP
Color : BLACK
# of pins : 3
Qualifier : (GAS)
Page 1054
Switches - Computers and Control Systems > Manifold Pressure/Vacuum Sensor > Component Information > Description
and Operation > Description
Manifold Pressure/Vacuum Sensor: Description and Operation Description
DESCRIPTION
The MAP sensor mounts to the intake manifold.

and Operation > Description > Page 1057
Manifold Pressure/Vacuum Sensor: Description and Operation Operation
OPERATION
The MAP serves as a PCM input, using a silicon based sensing unit, to provide data on the
manifold vacuum that draws the air/fuel mixture into the combustion chamber. The PCM requires
this information to determine injector pulse width and spark advance. When MAP equals
Barometric pressure, the pulse width will be at maximum.
Also like the cam and crank sensors, a 5 Volt reference is supplied from the PCM and returns a
voltage signal to the PCM that reflects manifold pressure. The zero pressure reading is 0.5 volt and
full scale is 4.5 volt. For a pressure swing of 0 - 15 psi the voltage changes 4.0 volt. The sensor is
supplied a regulated 4.8 to 5.1 volts to operate the sensor. Like the cam and crank sensors ground
is provided through the sensor return circuit.
The MAP sensor input is the number one contributor to pulse width. The most important function of
the MAP sensor is to determine barometric pressure. The PCM needs to know if the vehicle is at
sea level or is it in Denver at 5000 feet above sea level, because the air density changes with
altitude. It will also help to correct for varying weather conditions. If a hurricane was coming through
the pressure would be very, very low or there could be a real fair weather, high pressure area. This
is important because as air pressure changes the barometric pressure changes. Barometric
pressure and altitude have a direct inverse correlation, as altitude goes up barometric goes down.
The first thing that happens as the key is rolled on, before reaching the crank position, the PCM
powers up, comes around and looks at the MAP voltage, and based upon the voltage it sees, it
knows the current barometric pressure relative to altitude. Once the engine starts, the PCM looks
at the voltage again, continuously every 12 milliseconds, and compares the current voltage to what
it was at key on. The difference between current and what it was at key on is manifold vacuum.
During key On (engine not running) the sensor reads (updates) barometric pressure. A normal
range can be obtained by monitoring known good sensor in your work area.
As the altitude increases the air becomes thinner (less oxygen). If a vehicle is started and driven to
a very different altitude than where it was at key On the barometric pressure needs to be updated.
Any time the PCM sees Wide Open throttle, based upon TPS angle and RPM it will update
barometric pressure in the MAP memory cell. With periodic updates, the PCM can make its
calculations more effectively.
The PCM uses the MAP sensor to aid in calculating the following:
- Barometric pressure
- Engine load
- Manifold pressure
- Injector pulse-width
- Spark-advance programs
- Shift-point strategies (F4AC1 transmissions only, via the PCI bus)
- Idle speed
- Decel fuel shutoff
The PCM recognizes a decrease in manifold pressure by monitoring a decrease in voltage from the
reading stored in the barometric pressure memory cell. The MAP sensor is a linear sensor; as
pressure changes, voltage changes proportionately. The range of voltage output from the sensor is
usually between 4.6 volts at sea level to as low as 0.3 volts at 88 kPa (26 in. Hg). Barometric
pressure is the pressure exerted by the atmosphere upon an object. At sea level on a standard
day, no storm, barometric pressure is 101 kPa (29.92 in. Hg). For every 30.5 meters (100 feet) of
altitude barometric pressure drops 0.33 kPa (0.10 in. Hg). If a storm goes through it can either add,
high pressure, or decrease, low pressure, from what should be present for that altitude. You should
make a habit of knowing what the average pressure and corresponding barometric pressure is for
your area.
Switches - Computers and Control Systems > Manifold Pressure/Vacuum Sensor > Component Information > Service and
Repair > Removal
Manifold Pressure/Vacuum Sensor: Service and Repair Removal
2.0/2.4L
1. Remove the air cleaner cover.
3. Disconnect the electrical connector from the MAP sensor.
4. Remove the screws from the MAP sensor.
5. Remove the MAP sensor.

Manifold Pressure/Vacuum Sensor: Service and Repair Installation
2.0/2.4L
1. Make sure that the manifold is clean.
2. Install sensor to manifold.
3. Tighten screw.
4. Connect the electrical connector to the sensor.
6. Install the air cleaner cover.

Switches - Computers and Control Systems > Mileage Calibration Switch > Component Information > Technical Service
Bulletins > Customer Interest for Mileage Calibration Switch: > 08-039-06 > Aug > 06 > Instruments - Odometer/Trip Switch
Not Responsive
Mileage Calibration Switch: Customer Interest Instruments - Odometer/Trip Switch Not Responsive
NUMBER: 08-039-06
GROUP: Electrical
OVERVIEW:
(CCN).
NOTE:
MODELS:
NOTE:
SYMPTOM/CONDITION:
DIAGNOSIS:

NOTE:
NOTE:
NOTE:
Not Responsive > Page 1069
NOTE:
NOTE:
drop.
connector (DLC).

NOTE:
TIME ALLOWANCE:
FAILURE CODE:
Disclaimer:
Bulletins > All Technical Service Bulletins for Mileage Calibration Switch: > 08-039-06 > Aug > 06 > Instruments -
Odometer/Trip Switch Not Responsive
Mileage Calibration Switch: All Technical Service Bulletins Instruments - Odometer/Trip Switch Not
Responsive
NUMBER: 08-039-06
GROUP: Electrical
OVERVIEW:
(CCN).
NOTE:
MODELS:
NOTE:
SYMPTOM/CONDITION:
DIAGNOSIS:
NOTE:
NOTE:
NOTE:
Odometer/Trip Switch Not Responsive > Page 1076
NOTE:
NOTE:
drop.
connector (DLC).

NOTE:
TIME ALLOWANCE:
FAILURE CODE:
Disclaimer:
Switches - Computers and Control Systems > Oxygen Sensor > Component Information > Locations > Sensor - Oxygen 1/1
Oxygen Sensor: Locations Sensor - Oxygen 1/1
Component ID: 313
Component : SENSOR-OXYGEN 1/1
Connector:
Name : SENSOR-OXYGEN 1/1
Color : GRAY
# of pins : 4
Qualifier : (GAS)
1 GROUND Z916 18BK
> Page 1082
> Page 1083
> Page 1084
> Page 1085
Component ID: 314
Connector:
Color : BLACK
# of pins : 4
Qualifier : (GAS)
> Page 1086
> Page 1087
Oxygen Sensor: Locations 1/1 Upstream - 2.0/2.4L
The upstream oxygen sensor threads into the outlet flange of the exhaust manifold.
> Page 1088
Oxygen Sensor: Locations 1/2 Downstream - 2.0/2.4L
The downstream heated oxygen sensor threads into the catalytic converter.
Switches - Computers and Control Systems > Oxygen Sensor > Component Information > Diagrams > Sensor-Oxygen 1/1
Oxygen Sensor: Diagrams Sensor-Oxygen 1/1
Component ID: 313
Connector:
Color : GRAY
# of pins : 4
Qualifier : (GAS)
1 GROUND Z916 18BK
> Page 1091
> Page 1092
> Page 1093
> Page 1094
Component ID: 314
Connector:
Color : BLACK
# of pins : 4
Qualifier : (GAS)
> Page 1095
Switches - Computers and Control Systems > Oxygen Sensor > Component Information > Diagrams > Page 1096
Oxygen Sensor: Application and ID
- Cylinder bank number one is the bank that contains number one cylinder.
See: Engine, Cooling and Exhaust/Engine/Tune-up and Engine Performance Checks/Firing Order
Cylinder #1 on left side.
Cylinder #1 on right side.
- The first oxygen sensor in cylinder bank # 1 is numbered O2 Sensor 1/1.
- The second oxygen sensor in cylinder bank # 1 is numbered O2 Sensor 1/2.
- A third oxygen sensor in cylinder bank # 1 would be numbered O2 Sensor 1/3.

- If a V-6 or V-8 vehicle only uses one downstream Heated Oxygen Sensor (HO2S) it is numbered
O2 Sensor 1/2, even if it uses two upstream
HO2S.
Switches - Computers and Control Systems > Oxygen Sensor > Component Information > Description and Operation >
Description
Oxygen Sensor: Description and Operation Description
DESCRIPTION
The downstream heated oxygen sensor threads into the system depending on emission package.
Oxygen Sensor: Description and Operation Operation
OPERATION
Separate upstream and downstream grounds are used on the NGC vehicles (4 Cyl.).
As vehicles accumulate mileage, the catalytic convertor deteriorates. The deterioration results in a
less efficient catalyst. To monitor catalytic convertor deterioration, the fuel injection system uses
two heated oxygen sensors. One sensor upstream of the catalytic convertor, one downstream of
the convertor. The PCM compares the reading from the sensors to calculate the catalytic convertor
oxygen storage capacity and converter efficiency. Also, the PCM uses the upstream heated oxygen
sensor input when adjusting injector pulse width.
When the catalytic converter efficiency drops below emission standards, the PCM stores a
diagnostic trouble code and illuminates the malfunction indicator lamp (MIL).
The O2 sensors produce a constant 2.5 volts on NGC vehicles, depending upon the oxygen
content of the exhaust gas. When a large amount of oxygen is present (caused by a lean air/fuel
mixture, can be caused by misfire and exhaust leaks), the sensors produce a low voltage. When
there is a lesser amount of oxygen present (caused by a rich air/fuel mixture, which can be caused
by internal engine problems) it produces a higher voltage. By monitoring the oxygen content and
converting it to electrical voltage, the sensors act as a rich-lean switch.
The oxygen sensors are equipped with a heating element that keeps the sensors at proper
operating temperature during all operating modes. Maintaining correct sensor temperature at all
times allows the system to enter into closed loop operation sooner. Also, it allows the system to
remain in closed loop operation during periods of extended idle.
In Closed Loop operation the PCM monitors the O2 sensor's input (along with other inputs) and
adjusts the injector pulse width accordingly. During Open Loop operation the PCM ignores the O2
sensor input. The PCM adjusts injector pulse width based on preprogrammed (fixed) values and
inputs from other sensors.
The NGC Controller has a common ground for the heater in the O2S. 12 volts is supplied to the
heater in the O2S by the NGC controller. Both the upstream and downstream O2 sensors for NGC
are pulse width modulation (PWM). NOTE: When replacing an O2 Sensor, the PCM RAM memory
must be cleared, either by disconnecting the PCM C-1 connector or momentarily disconnecting the
Battery negative terminal. The NGC learns the characteristics of each O2 heater element and
these old values should be cleared when installing a new O2 sensor. The customer may
experience driveability issues if this is not performed.
UPSTREAM OXYGEN SENSOR
The input from the upstream heated oxygen sensor tells the PCM the oxygen content of the
exhaust gas. Based on this input, the PCM fine tunes the air-fuel ratio by adjusting injector pulse
width.
The sensor input switches from 2.5 to 3.5 volt, depending upon the oxygen content of the exhaust
gas in the exhaust manifold. When a large amount of oxygen is present (caused by a lean air-fuel
mixture), the sensor produces voltage as low as 2.5 volt. When there is a lesser amount of oxygen
present (rich air-fuel mixture) the sensor produces a voltage as high as 3.5 volt. By monitoring the
oxygen content and converting it to electrical voltage, the sensor acts as a rich-lean switch.
The heating element in the sensor provides heat to the sensor ceramic element. Heating the
sensor allows the system to enter into closed loop operation sooner. Also, it allows the system to
In Closed Loop, the PCM adjusts injector pulse width based on the upstream heated oxygen
sensor input along with other inputs. In Open Loop, the PCM adjusts injector pulse width based on
preprogrammed (fixed) values and inputs from other sensors.
DOWNSTREAM OXYGEN SENSOR
The downstream heated oxygen sensor input is used to detect catalytic convertor deterioration. As
the convertor deteriorates, the input from the downstream sensor begins to match the upstream
sensor input except for a slight time delay. By comparing the downstream heated oxygen sensor
input to the input from the upstream sensor, the PCM calculates catalytic convertor efficiency. This
is also used to establish the upstream O2 goal voltage (switching point).
Switches - Computers and Control Systems > Oxygen Sensor > Component Information > Service and Repair > Removal
Oxygen Sensor: Service and Repair Removal
1/1 Upstream - 2.0/2.4L
1/1 UPSTREAM - 2.0/2.4L
1. Remove the engine cover.
3. Disconnect electrical connector from O2 sensor.

Switches - Computers and Control Systems > Oxygen Sensor > Component Information > Service and Repair > Removal >
Page 1102
4. Remove sensor using an oxygen sensor crow foot wrench such as Snap-On tool YA8875 or
equivalent.
1/2 Downstream - 2.0/2.4L
1/2 DOWNSTREAM - 2.0/2.4L

Page 1103
3. Disconnect electrical connector from sensor.
4. Disconnect sensor electrical harness from clips along body.
equivalent.
Page 1104
Oxygen Sensor: Service and Repair Installation
1/1 Upstream - 2.0/2.4L
1/1 UPSTREAM - 2.0/2.4L
1. After removing the sensor, the exhaust manifold threads must be cleaned with an 18 mm X 1.5 +
6E tap. If reusing the original sensor, coat the
sensor threads with an anti-seize compound such as Loctite(R) 771-64 or equivalent. New sensors
have compound on the threads and do not require an additional coating. Tighten the sensor to 41
Nm (30 ft. lbs.).
2. Install sensor using an oxygen sensor crow foot wrench such as Snap-On tool YA8875 or
equivalent.
Page 1105
3. Connect electrical connector to sensor.
5. Install the engine cover.

Page 1106
The downstream heated oxygen sensor threads into the exhaust pipe behind the catalytic
converter.
Nm (30 ft. lbs.).
equivalent.
3. Connect sensor electrical harness to clips along body.
5. Lower vehicle.

Switches - Computers and Control Systems > Oxygen Sensor > Component Information > Service and Repair > Page 1107
Oxygen Sensor: Tools and Equipment
O2S (Oxygen Sensor) Remover/Installer-C-4907
O2S (Oxygen Sensor) Remover/Installer - 8439

Switches - Computers and Control Systems > Vehicle Speed Sensor > Component Information > Diagrams > Diagram
Information and Instructions
Vehicle Speed Sensor: Diagram Information and Instructions
Warnings
WARNINGS - GENERAL
the battery.
characteristics.
to function only.
Information and Instructions > Page 1112
SYMBOLS
TERMINOLOGY
Circuit Functions
models.
Circuit Information
IDENTIFICATION
LOCATIONS
illustrations.
associated wiring.
Removal
REMOVAL

connector.
Installation
INSTALLATION

Removal
REMOVAL
Installation
INSTALLATION
the new diode.
from the elements.
Removal
REMOVAL
Installation
INSTALLATION
repaired.
half/component.
repair.
Wire Splicing
repair area.

Special Tools
WIRING/TERMINAL


Vehicle Speed Sensor: Diagnostic Aids
vehicle.

good continuity.

SEVERAL LOADS


feed and ground.
position
problem
Switches - Fuel Delivery and Air Induction > Accelerator Pedal Position Sensor > Component Information > Locations
Component ID: 290
Connector:
Color : BLACK
# of pins : 6

Switches - Fuel Delivery and Air Induction > Accelerator Pedal Position Sensor > Component Information > Locations >
Page 1133
Page 1134
Page 1135
Component ID: 290
Connector:
Color : BLACK
# of pins : 6

Page 1136
Page 1137
Page 1138
DESCRIPTION
Switches - Fuel Delivery and Air Induction > Accelerator Pedal Position Sensor > Component Information > Service and
Repair > Removal
REMOVAL

INSTALLATION

Switches - Ignition System > Camshaft Position Sensor > Component Information > Locations > Sensor-Camshaft 1/1
Position
Component ID: 293
Connector:
Color : BLACK
# of pins : 3
Qualifier : (GAS)
Position > Page 1147
Component ID: 294
Connector:
Color : BLACK
# of pins : 3
Qualifier : (GAS)
Switches - Ignition System > Camshaft Position Sensor > Component Information > Diagrams > Sensor-Camshaft 1/1
Position
Component ID: 293
Connector:
Color : BLACK
# of pins : 3
Qualifier : (GAS)
Component ID: 294
Connector:
Color : BLACK
# of pins : 3
Qualifier : (GAS)
Switches - Ignition System > Camshaft Position Sensor > Component Information > Description and Operation >
Description
DESCRIPTION
OPERATION
Switches - Ignition System > Camshaft Position Sensor > Component Information > Service and Repair > Removal
5. Remove sensor.

Switches - Ignition System > Camshaft Position Sensor > Component Information > Service and Repair > Removal > Page
1162

1163
6. Remove sensor.
1164
Nm (79.5 in. lbs.).
connector.
1165

1166

Switches - Ignition System > Crankshaft Position Sensor > Component Information > Locations
Switches - Ignition System > Crankshaft Position Sensor > Component Information > Locations > Page 1170
Component ID: 296
Connector:
Color : BLACK
# of pins : 3
Connector:
Color : # of pins :
Qualifier : (GAS)

Switches - Ignition System > Crankshaft Position Sensor > Component Information > Description and Operation >
Description
DESCRIPTION
- Engine RPM

code).
OPERATION
Switches - Ignition System > Crankshaft Position Sensor > Component Information > Service and Repair > Removal
2.0/2.4L
Switches - Ignition System > Crankshaft Position Sensor > Component Information > Service and Repair > Removal > Page
1182

1183
2.0/2.4L

1184
6. Lower vehicle.

Switches - Ignition System > Ignition Switch > Ignition Switch Lock Cylinder > Component Information > Service and Repair
> Key/Lock Cylinder
Ignition Switch Lock Cylinder: Service and Repair Key/Lock Cylinder
Removal
REMOVAL
1. Access and remove the Steering Column Control Module (SCCM) (3) from the steering column
(2).
2. If equipped with That cham security (Export), remove the screws securing the cup (1) over the
key cylinder. Remove the cup.
> Key/Lock Cylinder > Page 1190
3. Remove the screw (1) fastening the SKREEM/WCM (2) to the lock cylinder housing (3).
4. Unhook the SKREEM/WCM (2) retainer fingers from the lock cylinder housing (3) and remove it.
5. Insert the key (2) and turn the key cylinder (3) to the RUN position.
6. Insert an appropriate tool into the slot (1) formed into the lock cylinder housing depressing the
key cylinder retaining tab.
7. Pull the key cylinder and key straight out of the lock cylinder housing as one unit.
8. Using a Tamper-Proof Torx(R) Plus (five point) 30 bit, remove the two screws (1) fastening the
lock cylinder housing (2) to the column.
9. Remove the lock cylinder housing from the steering column.

10. Remove the ignition module (2) mounting screw (1).
11. Pull the module (1) straight out and off the retaining tabs (2) located on the lock cylinder
housing.
Installation
INSTALLATION
NOTE: Ignition module must be installed prior to lock housing installation on column. Otherwise,
the tilt lever will obstruct installation of ignition switch.
1. Ensure the ignition module is in the RUN position and the actuator shaft in the lock housing is in
the RUN position.
2. Align the ignition module with the pin (3), actuator shaft and retaining tabs (2) located on the lock
cylinder housing. Carefully install the module,
snapping it into place over the retaining tabs.
3. Install the ignition module (2) mounting screw (1). Tighten the screw to 2 Nm (18 in. lbs.).
NOTE: Ignition module needs to be installed on lock cylinder housing before housing installation to
clear tilt lever.
4. Position the lock cylinder housing in the RUN position.
5. Align the lock cylinder housing (2) with the steering column.
6. Install the two screws (1) fastening the lock cylinder housing (2) to the column. Tighten the
screws to 12 Nm (110 in. lbs.).
7. Place the actuator in the lock cylinder housing to the RUN position (if not already there).
8. Insert the key into the key cylinder and turn the key cylinder to the RUN position.
9. Align the retaining tab on the key cylinder with the slot in the top of the lock cylinder housing.
10. Slide the key cylinder into the lock cylinder housing until the key cylinder retaining tab locks the
cylinder into place.
11. Rotate the key back and forth (OFF to START), then remove and reinstall it, making sure the
key cylinder and lock cylinder housing operate
properly.
12. Slide the ring of the SKREEM/WCM (2) over the lock cylinder housing (3) and engage the
retainer fingers in the recesses formed on the lock
cylinder housing.
13. Install the screw (1) fastening the SKREEM/WCM (2) to the lock cylinder housing (3). Tighten
the screw to 2.5 Nm (22 in. lbs.).
14. If equipped with Thatcham security (Export), install the cup (1) over the key cylinder and install
the two mounting screws.
15. Install the Steering Column Control Module (SCCM) (3) and all components removed to access
it.
16. Check operation of all steering column mounted components.

Ignition Switch Lock Cylinder: Service and Repair Housing-Lock Cylinder
Removal
REMOVAL
(2).
2. If equipped with Thatcham security (Export), remove the screws securing the cup (1) over the
3. Remove the screw (1) fastening the SKREEM/WCM (2) to the lock cylinder housing (3). 4.
Unhook the SKREEM/WCM (2) retainer fingers from the lock cylinder housing (3) and remove it.
5. Insert the key (2) and turn the key cylinder (3) to the RUN position. 6. Insert an appropriate tool
into the slot (1) formed into the lock cylinder housing depressing the key cylinder retaining tab. 7.
Pull the key cylinder and key straight out of the lock cylinder housing as one unit.
lock cylinder housing (2) to the column. 9. Remove the lock cylinder housing from the steering
column.
housing.
Installation
INSTALLATION
the RUN position. 2. Align the ignition module with the pin (3), actuator shaft and retaining tabs (2)
located on the lock cylinder housing. Carefully install the module,

clear tilt lever.
4. Position the lock cylinder housing in the RUN position. 5. Align the lock cylinder housing (2) with
the steering column. 6. Install the two screws (1) fastening the lock cylinder housing (2) to the
column. Tighten the screws to 12 Nm (110 in. lbs.).
7. Place the actuator in the lock cylinder housing to the RUN position (if not already there). 8. Insert
the key into the key cylinder and turn the key cylinder to the RUN position. 9. Align the retaining tab
on the key cylinder with the slot in the top of the lock cylinder housing.
cylinder into place. 11. Rotate the key back and forth (OFF to START), then remove and reinstall it,
making sure the key cylinder and lock cylinder housing operate
properly.
cylinder housing.
it. 16. Check operation of all steering column mounted components.
Switches - Ignition System > Knock Sensor > Component Information > Locations
Component ID: 308
Connector:
Name : SENSOR-KNOCK
Color : BLACK
# of pins : 2
Qualifier : (GAS)
Switches - Ignition System > Knock Sensor > Component Information > Locations > Page 1204
Component ID: 308
Connector:
Name : SENSOR-KNOCK
Color : BLACK
# of pins : 2
Qualifier : (GAS)
Switches - Ignition System > Knock Sensor > Component Information > Description and Operation > Description
DESCRIPTION
Switches - Ignition System > Knock Sensor > Component Information > Description and Operation > Description > Page
1211
OPERATION
spark control.
Switches - Ignition System > Knock Sensor > Component Information > Service and Repair > Removal
2.0/2.4L
manifold.

Switches - Ignition System > Knock Sensor > Component Information > Service and Repair > Removal > Page 1214

2.0/2.4L
manifold.

Jeep Workshop Manuals > Sensors and Switches > Sensors and Switches - Restraint Systems > Impact Sensor >
Component Information > Locations > Sensor-Front Impact-Left
Impact Sensor: Locations Sensor-Front Impact-Left
Component ID: 302
Component : SENSOR-FRONT IMPACT-LEFT
Connector:
Name : SENSOR-FRONT IMPACT-LEFT
Color : YELLOW
# of pins : 2
Component Information > Locations > Sensor-Front Impact-Left > Page 1221
Impact Sensor: Locations Sensor-Front Impact-Right
Component ID: 303
Component : SENSOR-FRONT IMPACT-RIGHT
Connector:
Name : SENSOR-FRONT IMPACT-RIGHT
Color : YELLOW
# of pins : 2
Impact Sensor: Locations Sensor-Side Impact-Left 1
Component ID: 321
Component : SENSOR-SIDE IMPACT-LEFT 1
Connector:
Name : SENSOR-SIDE IMPACT-LEFT 1
Color : YELLOW
# of pins : 4
3 LEFT SIDE IMPACT SENSOR 2 GROUND R19 20LG/WT
4 LEFT SIDE IMPACT SENSOR 2 SIGNAL R17 20LG/LB
Impact Sensor: Locations Sensor-Side Impact-Left 2
Component ID: 322
Connector:
Color : YELLOW
# of pins : 2
Impact Sensor: Locations
Sensor-Front Impact-Left
Component ID: 302
Connector:
Color : YELLOW
# of pins : 2
Sensor-Front Impact-Right
Component ID: 303
Connector:
Color : YELLOW
# of pins : 2

Sensor-Side Impact-Left 1
Component ID: 321
Connector:
Color : YELLOW
# of pins : 4

Component ID: 322
Connector:
Color : YELLOW
# of pins : 2
Sensor-Side Impact-Right 1
Component ID: 323
Component : SENSOR-SIDE IMPACT-RIGHT 1

Connector:
Name : SENSOR-SIDE IMPACT-RIGHT 1
Color : YELLOW
# of pins : 4
3 RIGHT SIDE IMPACT SENSOR 2 GROUND R20 20WT/LG
4 RIGHT SIDE IMPACT SENSOR 2 SIGNAL R18 20LB/LG
Component ID: 324
Connector:
Color : YELLOW
# of pins : 2

Component Information > Diagrams > Sensor-Front Impact-Left
Impact Sensor: Diagrams Sensor-Front Impact-Left
Component ID: 302
Connector:
Color : YELLOW
# of pins : 2
Component Information > Diagrams > Sensor-Front Impact-Left > Page 1240
Impact Sensor: Diagrams Sensor-Front Impact-Right
Component ID: 303
Connector:
Color : YELLOW
# of pins : 2
Impact Sensor: Diagrams Sensor-Side Impact-Left 1
Component ID: 321
Connector:
Color : YELLOW
# of pins : 4
Impact Sensor: Diagrams Sensor-Side Impact-Left 2
Component ID: 322
Connector:
Color : YELLOW
# of pins : 2
Impact Sensor: Diagrams
Sensor-Front Impact-Left
Component ID: 302
Connector:
Color : YELLOW
# of pins : 2
Sensor-Front Impact-Right
Component ID: 303
Connector:
Color : YELLOW
# of pins : 2

Component ID: 321
Connector:
Color : YELLOW
# of pins : 4

Component ID: 322
Connector:
Color : YELLOW
# of pins : 2
Component ID: 323

Connector:
Color : YELLOW
# of pins : 4
Component ID: 324
Connector:
Color : YELLOW
# of pins : 2

Impact Sensor: Description and Operation Description
Front
FRONT
Two front impact sensors (1) are used on this vehicle, one each for the left and right sides of the
vehicle. These sensors are mounted remotely from the impact sensor that is internal to the
Occupant Restraint Controller (ORC). Each front sensor is secured with a screw to the backs of the
right and left vertical headlamp bars on either side of the radiator within the engine compartment.
The sensor housing has an integral connector receptacle (4), an integral anti-rotation pin (3), and
an integral mounting hole (2) with a metal sleeve to provide crush protection.
The right and left front impact sensors are identical in construction and calibration. A cavity in the
center of the molded black plastic impact sensor housing contains the electronic circuitry of the
sensor which includes an electronic communication chip and an electronic impact sensor. Potting
material fills the cavity to seal and protect the internal electronic circuitry and components. The
front impact sensors are each connected to the vehicle electrical system through a dedicated take
out and connector of the engine compartment wire harness.
The impact sensors cannot be repaired or adjusted and, if damaged or ineffective, they must be
replaced.
Side
SIDE
Four side impact sensors (1) are used with the side curtain airbags, two each for the left and right
sides of the vehicle. These sensors are mounted remotely from the impact sensor that is internal to
the Occupant Restraint Controller (ORC). Each side sensor is secured with a screw to the inner
right or left B-pillar ahead of the front seat belt retractor, and the inner quarter panel near the
C-pillar beneath the trim within the passenger compartment. The sensor housing has an integral
connector receptacle (4), an integral anti-rotation pin (3), and an integral mounting hole (2) with a
metal sleeve to provide crush protection.
The right and left side impact sensors are identical in construction and calibration. A cavity in the
center of the molded black plastic impact sensor housing contains the electronic circuitry of the
sensor which includes an electronic communication chip and an electronic impact sensor. Potting
material fills the cavity to seal and protect the internal electronic circuitry and components. The side
impact sensors are each connected to the vehicle electrical system through a dedicated take out
and connector of the body wire harness.
The impact sensors cannot be repaired or adjusted and, if damaged or ineffective, they must be
replaced.
Impact Sensor: Description and Operation Operation
Front
FRONT
The front impact sensors are electronic accelerometers that sense the rate of vehicle deceleration,
which provides verification of the direction and severity of an impact. Each sensor also contains an
electronic communication chip that allows the unit to communicate the sensor status as well as
sensor fault information to the microprocessor in the Occupant Restraint Controller (ORC).
The ORC microprocessor continuously monitors all of the passive restraint system electrical
circuits to determine the system readiness. If the ORC detects a monitored system fault, it sets a
Diagnostic Trouble Code (DTC) and controls the airbag indicator operation accordingly. The impact
sensors each receive battery current and ground through dedicated left and right sensor plus and
minus circuits from the ORC. The impact sensors and the ORC communicate by modulating the
voltage in the sensor plus circuit.
The hard wired circuits between the front impact sensors and the ORC may be diagnosed using
However, conventional diagnostic methods will not prove conclusive in the diagnosis of the impact
sensors or the electronic controls or communication between other modules and devices that
provide features of the supplemental restraint system. The most reliable, efficient, and accurate
means to diagnose the impact sensors or the electronic controls and communication related to
front impact sensor operation requires the use of a diagnostic scan tool. Refer to the appropriate
Side
SIDE
The side impact sensors are electronic accelerometers that sense the rate of vehicle deceleration,
which provides verification of the direction and severity of an impact. Each sensor also contains an
electronic communication chip that allows the unit to communicate the sensor status as well as
sensor fault information to the microprocessor in the Occupant Restraint Controller (ORC).
The ORC microprocessor continuously monitors all of the side passive restraint system electrical
circuits to determine the system readiness. If the ORC detects a monitored system fault, it sets a
Diagnostic Trouble Code (DTC) and controls the airbag indicator operation accordingly. The impact
sensors each receive battery current and ground through the same left or right sensor plus and
minus circuits in a series arrangement from the ORC. The impact sensors and the ORC
communicate by modulating the voltage in the sensor plus circuit.
The hard wired circuits between the side impact sensors and the ORC may be diagnosed using
However, conventional diagnostic methods will not prove conclusive in the diagnosis of the impact
sensors or the electronic controls or communication between other modules and devices that
provide features of the supplemental restraint system. The most reliable, efficient, and accurate
means to diagnose the impact sensors or the electronic controls and communication related to side
impact sensor operation requires the use of a diagnostic scan tool. Refer to the appropriate
Impact Sensor: Service and Repair Removal
Front
FRONT
WARNING: To avoid serious or fatal injury, never strike or drop the front impact sensor, as it can
damage the impact sensor or affect its calibration. The front impact sensor enables the system to
deploy the front supplemental restraints. If an impact sensor is accidentally dropped during service,
the sensor must be scrapped and replaced with a new unit. Failure to observe this warning could
result in accidental, incomplete, or improper front supplemental restraint deployment.
NOTE: The front and side impact sensors are interchangeable.
2. Remove the screw (4) that secures the impact sensor (3) to the of the right or left radiator
support vertical member (2).
3. Disconnect the engine compartment wire harness connector (1) from the right or left front impact
sensor connector receptacle.
4. Remove the right or left front impact sensor from the engine compartment.
Side - B-Pillar
SIDE - B-PILLAR
WARNING: To avoid serious or fatal injury, never strike or drop the side impact sensor, as it can
damage the impact sensor or affect its calibration. The side impact sensor enables the system to
deploy the side curtain supplemental restraints. If an impact sensor is accidentally dropped during
service, the sensor must be scrapped and replaced with a new unit. Failure to observe this warning
could result in accidental, incomplete, or improper front supplemental restraint deployment.
1. Adjust the driver or passenger side front seat to its most forward position for easiest access to
the B-pillar trim.
3. Remove the trim from the inside of the lower right or left B-pillar (3).
4. Remove the screw (1) that secures the side impact sensor (2) to the lower B-pillar.
5. Disconnect the body wire harness connector (4) from the sensor connector receptacle.
6. Remove the sensor from the B-pillar.
Side - C-Pillar
SIDE - C-PILLAR

2. Remove the quarter trim panel from the inside of the lower C-pillar (1).
3. Remove the screw (4) that secures the side impact sensor (3) to the C-pillar.
4. Disconnect the body wire harness connector (2) from the sensor (3) connector receptacle.
5. Remove the sensor from the C-pillar.

Impact Sensor: Service and Repair Installation
Front
FRONT
WARNING: To avoid serious or fatal injury, never strike or drop the front impact sensor, as it can
damage the impact sensor or affect its calibration. The front impact sensor enables the system to
deploy the front supplemental restraints. If an impact sensor is accidentally dropped during service,
the sensor must be scrapped and replaced with a new unit. Failure to observe this warning could
result in accidental, incomplete, or improper front supplemental restraint deployment.
1. Position the right or left front impact sensor (3) into the engine compartment.
2. Reconnect the engine compartment wire harness connector (1) to the sensor connector
receptacle.
3. Carefully position the sensor onto the back of the right or left radiator support vertical member
(2). Be certain that the anti-rotation pin on the back
of the sensor is engaged in the clearance hole of the radiator support.
4. Install and tighten the screw (4) that secures the sensor to the back of the support vertical
member. Tighten the screw to 8 Nm (70 in. lbs.).
Side - B-Pillar
SIDE - B-PILLAR
supplemental restraint system before attempting
any steering wheel, steering column, airbag, occupant classification system, seat belt tensioner,
impact sensor, or instrument panel component diagnosis or service. Disconnect and isolate the
battery negative (ground) cable, then wait two minutes for the system capacitor to discharge before
performing further diagnosis or service. This is the only sure way to disable the supplemental
restraint system. Failure to take the proper precautions could result in accidental airbag
deployment.
1. Reconnect the body wire harness connector (4) to the side impact sensor (2) connector
receptacle.
2. Position the sensor onto the inner B-pillar (3). Be certain that the anti-rotation pin on the back of
the sensor is engaged in the clearance hole of the
B-pillar.
3. Install and tighten the screw (1) that secures the sensor to the inner B-pillar. Tighten the screw to
8 Nm (70 in. lbs.).
4. Reinstall the lower trim onto the inside of the B-pillar.
Side - C-Pillar
SIDE - C-PILLAR

1. Reconnect the body wire harness connector (2) to the side impact sensor (3) connector
receptacle.
2. Position the sensor onto the lower inner C-pillar (1). Be certain that the anti-rotation pin on the
back of the sensor is engaged in the clearance hole
of the C-pillar.
3. Install and tighten the screw (4) that secures the sensor to the inner C-pillar. Tighten the screw
4. Reinstall the quarter trim panel onto the inner lower C-pillar.

Jeep Workshop Manuals > Sensors and Switches > Sensors and Switches - Restraint Systems > Seat Belt Buckle Switch >
Seat Belt Buckle Switch: Locations
Component ID: 363
Component : SWITCH-SEAT BELT-DRIVER
Connector:
Name : SWITCH-SEAT BELT-DRIVER
Color : BLACK
# of pins : 2
1 DRIVER SEAT BELT SWITCH SENSE R57 20LG/GY
Seat Belt Buckle Switch: Diagrams
Component ID: 363
Component : SWITCH-SEAT BELT-DRIVER
Connector:
Name : SWITCH-SEAT BELT-DRIVER
Color : BLACK
# of pins : 2
1 DRIVER SEAT BELT SWITCH SENSE R57 20LG/GY
Jeep Workshop Manuals > Sensors and Switches > Sensors and Switches - Restraint Systems > Seat Position Sensor >
Seat Position Sensor: Description and Operation Description
DESCRIPTION
The seat track position sensor (2) is a Hall Effect-type sensor used on some vehicles. This sensor
consists of a Hall Effect Integrated Circuit (IC) chip encased in potting material within a cavity of the
molded plastic sensor housing.
The sensor housing has a mounting slot containing an integral latch feature (1) and slides and
latches onto a stamped metal blade-type bracket located on the inboard side of the upper outboard
seat adjuster track near the rear of both the passenger and driver front seats. A molded connector
receptacle (3) integral to the sensor housing is connected to the vehicle electrical system through a
connector and take out of the seat wire harness beneath the front seat cushion frame.
The seat track position sensor cannot be adjusted or repaired and, if ineffective or damaged, the
entire sensor must be replaced.
Seat Position Sensor: Description and Operation Operation
OPERATION
The seat track position sensor is designed to provide a seat position data input to the Occupant
Restraint Controller (ORC) indicating whether the driver or passenger front seat is in a full forward
or a not full forward position. The ORC uses this data as an additional logic input for use in
determining the appropriate deployment force to be used when deploying the multistage driver side
front airbag.
The seat track position sensor receives a nominal five volt supply from the ORC. The sensor
communicates the seat position by modulating the voltage returned to the ORC on a sensor data
circuit. The ORC also monitors the condition of the sensor circuits and will store a Diagnostic
Trouble Code (DTC) for any fault that is detected, and sends messages over the CAN data bus to
illuminate the airbag indicator in the ElectroMechanical Instrument Cluster (EMIC) (also known as
the Cab Compartment Node/CCN).
The hard wired circuits between the seat track position sensor and the OCM may be diagnosed
However, conventional diagnostic methods will not prove conclusive in the diagnosis of the seat
track position sensor or the electronic controls and communication between other modules and
devices that provide features of the supplemental restraint system. The most reliable, efficient, and
accurate means to diagnose the seat track position sensor or the electronic controls and
communication related to seat track position sensor operation requires the use of a diagnostic scan
tool. Refer to the appropriate diagnostic information.
Seat Position Sensor: Service and Repair Removal
REMOVAL
2. Reach under the front seat cushion to access the seat track position sensor (2) on a bracket
located on the outboard side near the rear of the upper
outboard seat track (3).
3. Using a small screwdriver, hold the latch feature (4) depressed while sliding the connector end of
the sensor off of the bracket.
4. Disconnect the seat wire harness connector (1) from the sensor connector receptacle.
5. Remove the sensor from under the front seat.

Seat Position Sensor: Service and Repair Installation
INSTALLATION
1. Reach under the front seat cushion to reconnect the seat wire harness connector (1) to the seat
track position sensor (2) connector receptacle. Be
certain that the latch on the connector is fully engaged.
2. Align the open end of the sensor to the slide tab of the sensor bracket located on the outboard
side near the rear of the upper outboard seat track
(3).
3. Push the sensor firmly onto the bracket until the latch feature (4) snaps into place with an
audible click.

Jeep Workshop Manuals > Sensors and Switches > Sensors and Switches - Restraint Systems > Seat Sensor/Switch >
Component Information > Locations > Sensor-Seat Track Position-Driver
Seat Sensor/Switch: Locations Sensor-Seat Track Position-Driver
Component ID: 315
Component : SENSOR-SEAT TRACK POSITION-DRIVER
Connector:
Name : SENSOR-SEAT TRACK POSITION-DRIVER
Color : DK. GRAY
# of pins : 2
Component Information > Locations > Sensor-Seat Track Position-Driver > Page 1285
Seat Sensor/Switch: Locations Sensor-Seat Track Position-Passenger
Component ID: 316
Component : SENSOR-SEAT TRACK POSITION-PASSENGER
Connector:
Name : SENSOR-SEAT TRACK POSITION-PASSENGER
Color : DK. GRAY
# of pins : 2
Seat Sensor/Switch: Locations Sensor-Seat Weight-Left Front
Component ID: 317
Component : SENSOR-SEAT WEIGHT-LEFT FRONT
Connector:
Name : SENSOR-SEAT WEIGHT-LEFT FRONT
Color : BLACK
# of pins : 3
Seat Sensor/Switch: Locations Sensor-Seat Weight-Left Rear
Component ID: 318
Component : SENSOR-SEAT WEIGHT-LEFT REAR
Connector:
Name : SENSOR-SEAT WEIGHT-LEFT REAR
Color : BLACK
# of pins : 3
Seat Sensor/Switch: Locations
Sensor-Seat Track Position-Driver
Component ID: 315
Connector:
Color : DK. GRAY
# of pins : 2
Sensor-Seat Track Position-Passenger
Component ID: 316
Connector:
Color : DK. GRAY
# of pins : 2

Sensor-Seat Weight-Left Front
Component ID: 317
Connector:
Color : BLACK
# of pins : 3
Sensor-Seat Weight-Left Rear
Component ID: 318

Connector:
Color : BLACK
# of pins : 3
Sensor-Seat Weight-Right Front
Component ID: 319
Component : SENSOR-SEAT WEIGHT-RIGHT FRONT
Connector:
Name : SENSOR-SEAT WEIGHT-RIGHT FRONT
Color : BLACK
# of pins : 3

Sensor-Seat Weight-Right Rear
Component ID: 320
Component : SENSOR-SEAT WEIGHT-RIGHT REAR
Connector:
Name : SENSOR-SEAT WEIGHT-RIGHT REAR
Color : BLACK
# of pins : 3
Component Information > Diagrams > Sensor-Seat Track Position-Driver
Seat Sensor/Switch: Diagrams Sensor-Seat Track Position-Driver
Component ID: 315
Connector:
Color : DK. GRAY
# of pins : 2
Component Information > Diagrams > Sensor-Seat Track Position-Driver > Page 1302
Seat Sensor/Switch: Diagrams Sensor-Seat Track Position-Passenger
Component ID: 316
Connector:
Color : DK. GRAY
# of pins : 2
Seat Sensor/Switch: Diagrams Sensor-Seat Weight-Left Front
Component ID: 317
Connector:
Color : BLACK
# of pins : 3
Seat Sensor/Switch: Diagrams Sensor-Seat Weight-Left Rear
Component ID: 318
Connector:
Color : BLACK
# of pins : 3
Seat Sensor/Switch: Diagrams
Sensor-Seat Track Position-Driver
Component ID: 315
Connector:
Color : DK. GRAY
# of pins : 2
Sensor-Seat Track Position-Passenger
Component ID: 316
Connector:
Color : DK. GRAY
# of pins : 2

Sensor-Seat Weight-Left Front
Component ID: 317
Connector:
Color : BLACK
# of pins : 3
Sensor-Seat Weight-Left Rear
Component ID: 318

Connector:
Color : BLACK
# of pins : 3
Sensor-Seat Weight-Right Front
Component ID: 319
Component : SENSOR-SEAT WEIGHT-RIGHT FRONT
Connector:
Name : SENSOR-SEAT WEIGHT-RIGHT FRONT
Color : BLACK
# of pins : 3

Sensor-Seat Weight-Right Rear
Component ID: 320
Component : SENSOR-SEAT WEIGHT-RIGHT REAR
Connector:
Name : SENSOR-SEAT WEIGHT-RIGHT REAR
Color : BLACK
# of pins : 3
Component Information > Description and Operation > Seat Belt Switch
Seat Sensor/Switch: Description and Operation Seat Belt Switch
Description
DESCRIPTION
The seat belt switch (4) is a small, normally open, single pole, single throw, plunger (3) actuated,
momentary switch. One seat belt switch is installed on the driver front seat belt retractor frame (2)
over the retractor spool (1). The seat belt switch includes an integral connector that is connected to
the vehicle electrical system through a take out and connector of the body wire harness.
The seat belt switch cannot be adjusted or repaired and, if ineffective or damaged, the entire front
seat belt and retractor unit must be replaced.
Operation
OPERATION
The seat belt switch is designed to control a path to ground for the seat belt switch sense input of
the ElectroMechanical Instrument Cluster (EMIC) (also known as the Cab Compartment
Node/CCN). The seat belt switch plunger is actuated by the seat belt webbing wound onto the seat
belt retractor spool. When the seat belt tip-half webbing is pulled out of the retractor far enough to
engage the seat belt buckle-half, the switch plunger is extended and closes the seat belt switch
sense circuit to ground. Conversely, when the seat belt tip-half webbing is wound onto the retractor
spool the switch plunger is depressed, opening the ground path.
The EMIC monitors the seat belt switch status, then controls the illumination of the seatbelt
indicator and the generation of audible electronic chime tones based upon that input. The seat belt
switch receives ground through its connection to the body wire harness from another take out of
the body wire harness. An eyelet terminal connector on that ground take out is secured under a
ground screw. The seat belt switch is connected in series between ground and the seat belt switch
sense input of the EMIC.
The seat belt switch as well as the hard wired inputs and outputs of the switch may be diagnosed
Component Information > Description and Operation > Seat Belt Switch > Page 1319
Seat Sensor/Switch: Description and Operation Sensor-Seat Weight
Description
DESCRIPTION
The seat weight sensors are strain gauge-type units. The electronic elements of the sensor are
encased within the sensor body (5) and the sensor body is located within a stamped metal cage
(3). Four sensors are used in the Occupant Classification System (OCS). The sensors are located
below the seat cushion between the seat adjuster track and the seat cushion frame at each corner
of the passenger side front seat.
A threaded mounting stud (2) on each sensor body is secured by a nut to the seat cushion frame,
and two nuts secure each sensor mounting flange (1) to two studs integral to the front and rear of
the inboard and outboard passenger side upper seat adjuster tracks. A molded connector
receptacle (4) integral to each sensor body is oriented towards the center of the seat and is
connected to the vehicle electrical system through a dedicated connector and take out of the
passenger seat wire harness beneath the seat cushion.
The seat weight sensors cannot be adjusted or repaired and, if ineffective or damaged, the entire
sensor must be replaced.
Operation
OPERATION
The seat weight sensor units are designed to sense the relative weight of a load applied to the
passenger side front seat, which provides a logic input to the microprocessor of the Occupant
Classification Module (OCM). When any load is applied to the seat the load is transmitted through
the sensor mounting stud to the sensor body (strain gauge) of each sensor, causing a change of
electrical resistance through the strain gauge. These changes in resistance within the internal
sensor circuitry change the sensor output voltage.
Each weight sensor receives a nominal five volts and a ground through parallel hard wired circuits
from the OCM. The OCM then monitors the output voltage of each sensor on dedicated hard wired
data communication circuits. The OCM also monitors the condition of the sensor circuits and will
store a Diagnostic Trouble Code (DTC) for any fault that is detected, then send messages to the
Occupant Restraint Controller (ORC) to illuminate the airbag indicator in the ElectroMechanical
Instrument Cluster (EMIC) (also known as the Cab Compartment Node/CCN).
The hard wired circuits between the seat weight sensor and the OCM may be diagnosed using
However, conventional diagnostic methods will not prove conclusive in the diagnosis of the seat
weight sensors or the electronic controls and communication between other modules and devices
that provide features of the Occupant Classification System (OCS). The most reliable, efficient, and
accurate means to diagnose the seat weight sensors or the electronic controls and communication
related to seat weight sensor operation requires the use of a diagnostic scan tool. Refer to the
Seat Sensor/Switch: Service and Repair Removal
REMOVAL
WARNING: To avoid serious or fatal injury on vehicles equipped with the Occupant Classification
System (OCS), do not modify the front passenger seat assembly or center floor console in any
way. Do not use any prior year, subsequent year, secondary or aftermarket seat trim covers. At no
time should any Supplemental Restraint System (SRS) or OCS component be modified or replaced
with any part except those which are specified for the particular vehicle application in the
DaimlerChrysler Mopar(R) Parts Catalog. Failure to observe these precautions could cause an
OCS miscalibration condition, which may result in the passenger airbag failing to deploy when
required or deploying when not required.
WARNING: To avoid serious or fatal injury, never strike or drop a seat weight sensor or the
passenger side front seat assembly to which the sensors are secured as it can damage the
sensors or affect their calibration. The seat weight sensors and the passenger side front seat
assembly must be handled with care to avoid damage to the sensors. Do not sit upon or place any
loads upon a passenger side front seat while it is removed from its mounts in or outside of the
vehicle. If an individual sensor is dropped or damaged, replace the sensor with a new and unused
unit. If a seat has been dropped during removal or loaded while removed from its mounts, replace
each of the seat weight sensors with new and unused units. Failure to observe this warning could
result in an accidental, incomplete, or improper passenger side front supplemental restraint
deployment.
2. Remove the passenger side front seat from the vehicle.

3. From the underside of the seat, disconnect the seat wire harness from the connector receptacles
of each of the four weight sensors.
4. Disconnect the seat wire harness from the connector receptacle of the seat track position sensor
located on the inboard side of the outboard seat
adjuster upper track near the rear of the seat track.
5. Remove the seat cushion from the passenger side front seat.
CAUTION: A strain gauge alignment tool (Special Tool No. 9689) (2) must be used to secure the
body of the seat weight sensor (1) from any rotation during removal or installation of the nut that
secures the sensor stud to the seat cushion frame. In addition, the sensor fasteners should always
be serviced using hand tools ONLY, and not electric or pneumatic power tools. Failure to observe
these cautions may result in irreversible sensor damage requiring sensor replacement.
6. Install the strain gauge alignment tool (Special Tool 9689) on the sensors by inserting the center
fork (1) of the tool between the flats on each side
of the sensor body and inside of the cage, then seating the tool support yoke (2) firmly against the
outside of the sensor cage.
7. With the alignment tool securing the body of the seat weight sensor (2), remove the nut (1) that
secures the sensor stud to the seat cushion frame
(3).
8. Transfer the special tool to each weight sensor, one at a time, and remove the nuts that secure
the sensor studs to the seat cushion frame until all
four nuts have been removed.
9. Carefully separate the seat cushion frame from the seat weight sensor studs.
10. Remove the two nuts that secure the sensor to the studs on the upper track of the seat adjuster
(4).
11. Remove the seat weight sensor from the seat adjuster.
Seat Sensor/Switch: Service and Repair Installation
INSTALLATION
System (OCS), do not modify the front passenger seat assembly or center floor console in any
way. Do not use any prior year, subsequent year, secondary or aftermarket seat trim covers. At no
time should any Supplemental Restraint System (SRS) or OCS component be modified or replaced
with any part except those which are specified for the particular vehicle application in the
DaimlerChrysler Mopar(R) Parts Catalog. Failure to observe these precautions could cause an
OCS miscalibration condition, which may result in the passenger airbag failing to deploy when
required or deploying when not required.
WARNING: To avoid serious or fatal injury, never strike or drop a seat weight sensor or the
passenger side front seat assembly to which the sensors are secured as it can damage the
sensors or affect their calibration. The seat weight sensors and the passenger side front seat
assembly must be handled with care to avoid damage to the sensors. Do not sit upon or place any
loads upon a passenger side front seat while it is removed from its mounts in or outside of the
vehicle. If an individual sensor is dropped or damaged, replace the sensor with a new and unused
unit. If a seat has been dropped during removal or loaded while removed from its mounts, replace
each of the seat weight sensors with new and unused units. Failure to observe this warning could
result in an accidental, incomplete, or improper passenger side front supplemental restraint
deployment.
System (OCS), any time the passenger side front seat assembly has been removed or loosened
from the vehicle for service of any vehicle component or system the Occupant Classification
System Verification Test must be performed using a diagnostic scan tool and the Occupant
Classification Seat Weight special tool following reinstallation. Refer to the appropriate diagnostic
procedures. Failure to observe this warning could result in an accidental, incomplete, or improper
passenger side front supplemental restraint deployment.
1. Position the seat weight sensor (2) over the studs on the upper track of the passenger side front
seat adjuster (4).
2. Install and tighten the two nuts that secure the sensor to the studs. Tighten the nuts to 28 Nm
(21 ft. lbs.).
3. Carefully position the seat cushion frame (3) over all four seat weight sensor studs.
CAUTION: A strain gauge alignment tool (Special Tool No. 9689) (2) must be used to secure the
body of the seat weight sensor (1) from any rotation during removal or installation of the nut that
secures the sensor stud to the seat cushion frame. In addition, the sensor fasteners should always
be serviced using hand tools ONLY, and not electric or pneumatic power tools. Failure to observe
these cautions may result in irreversible sensor damage requiring sensor replacement.
4. Install the strain gauge alignment tool (Special Tool 9689) on the sensors by inserting the center
fork (1) of the tool between the flats on each side
of the sensor body and inside of the cage, then seating the tool support yoke (2) firmly against the
outside of the sensor cage.
5. With the alignment tool securing the body of the seat weight sensor, install and tighten the nut
that secures the sensor stud to the seat cushion
frame. Tighten the nut to 45 Nm (33 ft. lbs.).
6. Transfer the special tool to each weight sensor, one at a time, then install and tighten the nuts
that secure each of the four sensor studs to the seat
cushion frame until all four nuts have been installed and tightened.
7. Reinstall the seat cushion onto the passenger side front seat.
8. From the underside of the seat, reconnect the seat wire harness to the connector receptacle of
the seat track position sensor located on the inboard
side of the outboard seat adjuster upper track near the rear of the seat track.
9. Reconnect the seat wire harness to the connector receptacles of each of the four weight
sensors.
10. Reinstall the passenger side front seat into the vehicle.
12. Following successful completion of the supplemental restraint system verification test
procedure, perform the Occupant Classification System
Verification Test using a diagnostic scan tool and the Occupant Classification Seat Weight special
tool. Refer to the appropriate diagnostic procedures.
Jeep Workshop Manuals > Sensors and Switches > Sensors and Switches - Starting and Charging > Ignition Switch >
Ignition Switch Lock Cylinder > Component Information > Service and Repair > Key/Lock Cylinder
Removal
REMOVAL
(2).
Ignition Switch Lock Cylinder > Component Information > Service and Repair > Key/Lock Cylinder > Page 1331

housing.
Installation
INSTALLATION
the RUN position.
clear tilt lever.
properly.
cylinder housing.
it.

Removal
REMOVAL
(2).
column.
housing.
Installation
INSTALLATION

clear tilt lever.
properly.
cylinder housing.
Jeep Workshop Manuals > Sensors and Switches > Sensors and Switches - Starting and Charging > Neutral Safety Switch
> Component Information > Locations
Neutral Safety Switch: Locations
Component ID: 348
Component : SWITCH-CLUTCH INTERLOCK
Connector:
Name : SWITCH-CLUTCH INTERLOCK
Color : BLACK
# of pins : 3
Qualifier : (MTX)
1 CLUTCH UPSTOP SWITCH SIGNAL T26 20DG/OR
> Component Information > Locations > Page 1345
Neutral Safety Switch: Diagrams
Component ID: 348
Connector:
Color : BLACK
# of pins : 3
Qualifier : (MTX)
Jeep Workshop Manuals > Sensors and Switches > Sensors and Switches - Steering and Suspension > Sensors and
Switches - Steering > Steering Angle Sensor > Component Information > Technical Service Bulletins > Steering - ESP
Lamp On Possible DTC C121A/C2205
Steering Angle Sensor: Technical Service Bulletins Steering - ESP Lamp On Possible DTC
C121A/C2205
NUMBER: 08-010-07
DATE: May 17, 2007
THE StarSCAN(R) FLASH FILES FOR THIS BULLETIN ARE AVAILABLE VIA THE INTERNET.
SUBJECT: FLASH: DTC's C121A / C2205 - Steering Angle Sensor - Not Initialized / Internal
OVERVIEW:
This bulletin involves selectively erasing and reprogramming the Steering Angle Sensor (SAS) with
new software.
MODELS:
2007 (JK) Wrangler
2007 (JS) Sebring
2007 (KA) Nitro
2007 (MK49) Compass
2007 (MK74) Patriot
2007 (PM) Caliber
NOTE:
This bulletin applies to vehicles built on or before April 12, 2007 (MDH 0412XX).
SYMPTOM/CONDITION:
The vehicle operator may experience an illumination of the Electronic Stability Program (ESP) lamp
on the vehicle instrument cluster. The ESP lamp illumination may be due to the following
Diagnostic Trouble Codes (DTC's):
C121A - Steering Angle Sensor Not Initialized C2205 - Steering Angle Sensor Internal
This condition, and DTC's, may be intermittent. If the above DTC's occur during a drive cycle, then
the ESP lamp will remain illuminated until the end of that drive cycle (key off).
DIAGNOSIS:
Using a StarSCAN(R) with the appropriate Diagnostic Procedures available in TechCONNECT,

verify all engine systems are functioning as designed. If DTCs are present record them on the
repair order and repair as necessary before proceeding further with this bulletin.
If the vehicle operator describes or experiences the Symptom/Condition, perform the Repair
Procedure.
Lamp On Possible DTC C121A/C2205 > Page 1356
REPAIR PROCEDURE - USING StarSCAN AND THE INTERNET TO RETRIEVE THE FLASH
FILE:
NOTE:
programmed with software release level 7.04 SPI or higher. The software release level is visible in
the blue header at the top of the StarSCAN® screen.
NOTE:
The StarSCAN(R) diagnostic scan tool fully supports Internet connectivity. However, in order to
take advantage of this feature you must first configure the StarSCAN(R) for your dealership's
network. For instruction on setting up your StarSCAN® for the dealer's network; refer to the
StarSCAN(R) Quick Start Networking Guide available on the website under the "download center".
NOTE:
1. Open the hood and install a battery charger. Using a voltmeter, verify that the charging rate
provides 13.2 - 13.5 volts. Set the battery charger to continuous charge. Do not allow the charger
to time out during the flash process. Remove the charger from the battery when the flash process
is complete.
NOTE:
Do not allow the charging voltage to climb above 13.5 volts during the flash process.
drop.
5. Retrieve the old ECU (SAS) part number. Using the StarSCAN(R) at the "Home screen:
b. Touch the screen to highlight the ECU (SAS) in the list of modules.
d. Select "ECU Flash".
e. Record the part number at the top of the "Flash PCM screen for later reference.
h. Select "Close after the download is complete, then select "Back".
j. Select "Update Controller".

NOTE:
Due to the ECU (SAS) programming procedure, a DTC may be set in other electronic modules
within the vehicle, if so equipped. Some DTC's may cause the MIL to illuminate. From the "Home"
screen select "System View". Then select "All DTCs". Press "Clear All Stored DTCs" if there are
any DTCs shown on the list.
TIME ALLOWANCE:
FAILURE CODE:
Disclaimer:
Switches - Suspension > Steering Angle Sensor > Component Information > Technical Service Bulletins > Steering - ESP
C121A/C2205
NUMBER: 08-010-07
DATE: May 17, 2007
OVERVIEW:
new software.
MODELS:
2007 (JK) Wrangler
2007 (JS) Sebring
2007 (KA) Nitro
2007 (MK49) Compass
2007 (MK74) Patriot
2007 (PM) Caliber
NOTE:
SYMPTOM/CONDITION:
DIAGNOSIS:

Procedure.
FILE:
NOTE:
NOTE:
NOTE:
is complete.
NOTE:
drop.

NOTE:
TIME ALLOWANCE:
FAILURE CODE:
Disclaimer:
Switches - Wheels and Tires > Tire Pressure Sensor > Component Information > Service Precautions
Tire Pressure Sensor: Service Precautions
CAUTION
CAUTION: The use of some tire sealants is prohibited for vehicles equipped with the Tire Pressure
Monitoring system. Some tire sealants can clog tire pressure sensors.
CAUTION: Any time a sensor is to be installed in a wheel, it is necessary to install a new

sensor-to-wheel seal, metal washer and valve stem nut, to ensure air tight sealing.
CAUTION: Tire pressure sensor valve stem caps and cores are specially designed for the sensors.
Due to risk of corrosion, do not use a standard valve stem cap or core in a tire pressure sensor in
place of the original equipment style sensor cap and core.
CAUTION: When installing the valve core, be sure to tighten the core to specifications.
Overtightening by a little as three or four inch pounds can damage the sensor.
CAUTION: Do not attempt to install a tire pressure sensor in an aftermarket wheel. Use tire
pressure sensors in original style factory wheels only. If aftermarket wheels are installed, and
therefore do not contain tire pressure sensors, the system will not function properly and the driver
will be continuously notified of a system malfunction.
NOTE: TPM thresholds have been established for the original tire size equipped on the vehicle.
Use original size tires only to maintain system accuracy.
Switches - Wheels and Tires > Tire Pressure Sensor > Component Information > Description and Operation > Description
Tire Pressure Sensor: Description and Operation Description
DESCRIPTION
On vehicles equipped with Tire Pressure Monitoring (TPM), one tire pressure sensor (6) is
mounted to each wheel (5) in place of the traditional tire valve stem. Each sensor has an internal
battery that lasts up to 10 years. The battery is not serviceable. At the time of battery failure, the
The TPM system operates on a 315 MHz radio frequency. The 315 MHz sensors can be easily
identified by a white outline oval (black center) insignia (3) on the sensor body.
Switches - Wheels and Tires > Tire Pressure Sensor > Component Information > Description and Operation > Description >
Page 1371
The Export TPM system operates on a 433 MHz radio frequency. The 433 MHz sensors can be
easily identified by either a solid white oval insignia (3) on the body or...
...a solid white oval insignia (3) with 433 printed in the center. The sensors are identical except for
the oval insignia. The 433 MHz sensors can either have a black or grey sensor body.
CAUTION: Although 315 MHz and 433 MHz sensors are identical in size and shape, they are not
interchangeable. Always make sure the correct sensor is being used.
NOTE: Sensors may be identified by valve stem cap color. From the factory, 315 MHz sensors
have a gray valve stem cap while 433 MHz sensors have a black valve stem cap. Otherwise, once
mounted inside a tire and wheel assembly you are not able to visually tell the difference between a
315 MHz and 433 MHz sensor. At that point, the TPM-RKE Analyzer, Special Tool 9936, with the
Scan Tool may be used to identify the sensor frequency or the tire can be dismounted allowing
visual inspection of the sensor body.
The TPM sensors are designed for original style factory wheels. It is not recommended to install a
tire pressure sensor in an aftermarket wheel (This could cause sealing and system performance
issues). Do not attempt to install a tire pressure sensor in an aftermarket wheel. If aftermarket
wheels are installed and do not contain tire pressure sensors, the system will not function properly
and the driver will be continuously notified of a system malfunction.
Page 1372
The serviceable components of the tire pressure sensor are:
- Sensor-To-Wheel Seal (2) and Metal Washer (1)
- Valve Stem Cap (4)
- Valve Stem Core
- Valve Stem Nut (with pressed-in washer) (3)
NOTE: Any time a sensor is installed on a wheel, a new Sensor-To-Wheel Seal (2), Metal Washer
(1) and Valve Stem Nut (3) must be installed to ensure air tight sealing. A service kit is available.
The valve stem caps and cores are specifically designed for the tire pressure monitoring sensors.
Although similar to standard valve stem caps and cores, they are different. The valve stem cap has
a special seal inside to keep moisture and corrosion out. The valve stem core has a special nickel
coating to protect from corrosion.
Page 1373
Tire Pressure Sensor: Description and Operation Operation
OPERATION
The battery operated tire pressure sensor is both a transmitter and a receiver. The TPM sensor can
be forced to transmit by using a special tool such as a TPM-RKE Analyzer, or from a transponder.
The TPM-RKE Analyzer has the ability to change the sensor's operating mode to PARK MODE
and to help diagnose a faulty TPM sensor. Using a TPM-RKE Analyzer can take up to a minute to
force a transmission from a sensor.
The TPM sensor can be in one of the following operating modes:
- SLEEP MODE - This is the operating mode of a new TPM sensor. If placed on the vehicle as a
road tire, the sensor will transmit once every 20 seconds when the vehicle is driven at speeds over
15 mph (24 km/h). Driving the vehicle continuously at this speed for more then 4 minutes will
change the sensor state to DRIVE MODE. Stopping the vehicle for 20 minutes will change the
sensor state to PARK MODE. If the vehicle is not moving, the sensor will only transmit on a
pressure change greater then 1 psi (6.9 kPa).
- PARK MODE - This is the correct operating mode when the vehicle is not moving. The sensor will
transmit once every 13 hours to update the WCM, or will transmit on a 1 psi (6.9 kPa) delta
change. The sensors will internally take a measurement of the tire pressure every minute to
determine a change in tire pressure.
- 30 BLOCK MODE - If the vehicle has been stopped for more then 20 minutes, or if the sensor's
operating mode was forced to PARK MODE using a TPM-RKE Analyzer, the sensor's operating
mode will transition from PARK MODE to 30 BLOCK MODE once the vehicle is driven over 15
mph. In this mode, the sensor will transmit once every 15 seconds when the vehicle is driven at
speeds over 15 mph (24 km/h) for the first 30 transmissions. After about 8 minutes of continuous
driving above 15 mph (24 km/h), the sensor's mode will change to DRIVE MODE.
- DRIVE MODE - In this mode, the sensor will transmit once every minute when the vehicle is
driven at speeds over 15 mph (24 km/h). At any time the vehicle speed drops below 15 mph, the
sensor will not transmit. The sensor mode will still be in drive mode when the sensor reaches
speeds over 15 mph (24 km/h), unless the vehicle has been stationary for more then 20 minutes.
Each sensor's (transmitter) broadcast is uniquely coded so that the wireless control module (WCM)
can monitor the state of each of the sensors on the four rotating road wheels. The WCM can
automatically learn and store the sensor's ID while driving "within 10 minutes continuously above
15 mph (24 Km/h)" after a sensor has been replaced. The vehicle must be stationary for more then
20 minutes in order to initiate the learning sequence. The WCM can also learn the sensor's ID
using the TPM-RKE Analyzer, Special Tool 9936, with the Scan Tool following the procedure listed
in the appropriate diagnostic information.
Switches - Wheels and Tires > Tire Pressure Sensor > Component Information > Service and Repair > Removal
Tire Pressure Sensor: Service and Repair Removal
REMOVAL
1. Raise and support vehicle.
2. Remove wheel mounting nuts (3), then tire and wheel assembly (1).
CAUTION: The cap used on this valve stem contains an O-ring seal to prevent contamination and
moisture from entering the valve stem. Retain this valve stem cap for reuse. Do not substitute a
regular valve stem cap in its place.
CAUTION: The valve stem used on this vehicle is made of aluminum and the core is nickel plated
brass. The original valve stem core must be reinstalled and not substituted with a valve stem core
made of a different material. This is required to prevent corrosion in the valve stem caused by the
different metals.
3. Dismount tire from wheel following tire changer manufacturers instructions while paying special
attention to the following to avoid damaging the
pressure sensor: a. When breaking the tire bead loose from the wheel rim, avoid using the Bead
Breaker in the area of the sensor. That includes both front and
rear beads of the tire.

Switches - Wheels and Tires > Tire Pressure Sensor > Component Information > Service and Repair > Removal > Page
1376
b. When preparing to dismount the tire from the wheel, carefully insert the mounting/dismounting
tool at the valve stem ±10°, then proceed to
dismount the tire from the wheel. Use this process on both the upper and lower tire beads.
4. Remove sensor nut (3) retaining sensor to wheel. While removing nut, hold pressure against
rear of metal valve stem to keep valve stem from
pushing rearward, damaging antenna strap.
5. Remove sensor (1) from wheel (2).

1377
Tire Pressure Sensor: Service and Repair Installation
INSTALLATION
NOTE: Anytime a TPM sensor is reused on a wheel, it is necessary to install a new

sensor-to-wheel seal (2), metal washer (1) and valve stem nut (3), to ensure proper sealing around
the sensor valve stem (6).
1. Wipe the area clean around the sensor/valve stem mounting hole in the wheel (5). Make sure
the surface of the wheel is not damaged.
CAUTION: To avoid damaging the sensor antenna strap (1), hold pressure against the rear of the
metal valve stem (2) while the sensor is inserted through the wheel mounting hole and the nut is
installed.
1378
2. Insert the sensor (1) through the wheel (2) as shown keeping pressure against the rear of the
metal valve stem (See Arrow). The potted side of the
sensor is to be positioned toward the wheel. Do not attempt to mount the sensor otherwise,
damage may occur.
3. Install the sensor nut (with pressed-in washer) (3) by hand.
NOTE: Before tightening the sensor nut, push downward on the sensor housing (2) in an attempt to
make it flush with the interior contour of the wheel (1).
4. While holding the sensor in position, tighten the sensor nut to 6.5 Nm (58 in. lbs.).
CAUTION: Over-torquing the sensor nut by as little as 12 Nm (106 in. lbs.) may result in sensor
separation from the valve stem. Under this condition, the sensor may still function. However, the
condition should be corrected immediately.
5. Mount the tire on the wheel following the tire changer manufacturers instructions, paying special
attention to the following to avoid damaging tire
pressure sensor: a.
1379
Rotating Wheel Tire Changers - Once the wheel is mounted to the changer, position the sensor
valve stem (2) approximately 210° from the head of the changer (located at 1) in a clockwise
direction before rotating the wheel (also in a clockwise direction) to mount the tire. Use this
procedure on both the upper and lower tire beads.
b.
Rotating Tool Tire Changers - Position the wheel on the changer so that the sensor valve stem (1)
is located approximately 210° clockwise from the installation end of the mounting/dismounting tool
(2) once the tool is mounted for tire installation. Make sure the sensor is clear of the lower bead
breaker area (3) to avoid damaging the sensor when the breaker rises. Rotate the tool (2) in a
counterclockwise direction to mount the tire. Use this procedure on both the upper and lower tire
beads.
1380
6. Adjust air pressure to that listed on the Tire Inflation Pressure Label (Placard) provided with the
vehicle (applied to driver's side B-pillar). Make
sure the original style and color valve stem cap is securely installed to keep moisture out of the
sensor.
7. Install the tire and wheel assembly (1) on the vehicle. Tighten wheel mounting nuts (3) to 135
Nm (100 ft. lbs.). 8. Lower vehicle. 9. Perform one of the following to make the system learn the
new sensor ID.
a. Use the TPM-RKE Analyzer, Special Tool 9936, with the Scan Tool to program the
WCM/SKREEM with the tire pressure sensor ID. This is
part of the TPM Diagnostic Verification Test.
b. Once the vehicle has remained stationary for more than 20 minutes, drive vehicle for a minimum
of 10 minutes while maintaining a
continuous speed above 15 mph (24 km/h). During this time, the system will learn the new sensor
ID. This is part of the TPM Diagnostic Verification Test.
NOTE: If a sensor cannot be trained, refer to appropriate diagnostic information.

Jeep Workshop Manuals > Sensors and Switches > Sensors and Switches - Transmission and Drivetrain > Sensors and
Switches - CVT > Fluid Pressure Sensor/Switch, CVT > Component Information > Locations
Fluid Pressure Sensor/Switch: Locations
Component ID: 15
Component : ASSEMBLY-TRANSMISSION SOLENOID/PRESSURE SWITCH
Connector:
Name : ASSEMBLY-TRANSMISSION SOLENOID/PRESSURE SWITCH
Color : BLACK
# of pins : 22
6 GROUND Z967 18BK

12 - -
13 - -
14 - -
15 - -
20 - -
Switches - CVT > Fluid Pressure Sensor/Switch, CVT > Component Information > Locations > Page 1386
Fluid Pressure Sensor/Switch: Diagrams
Component ID: 15
Connector:
Color : BLACK
# of pins : 22
6 GROUND Z967 18BK

12 - -
13 - -
14 - -
15 - -
20 - -
Switches - CVT > Transmission Position Switch/Sensor, CVT > Component Information > Locations
Transmission Position Switch/Sensor: Locations
Component ID: 15
Connector:
Color : BLACK
# of pins : 22
6 GROUND Z967 18BK

12 - -
13 - -
14 - -
15 - -
20 - -
Switches - CVT > Transmission Position Switch/Sensor, CVT > Component Information > Locations > Page 1392
Switches - CVT > Transmission Speed Sensor, CVT > Component Information > Locations
Transmission Speed Sensor: Locations
Component ID: 15
Connector:
Color : BLACK
# of pins : 22
6 GROUND Z967 18BK

12 - -
13 - -
14 - -
15 - -
20 - -
Switches - CVT > Transmission Speed Sensor, CVT > Component Information > Locations > Page 1396
Switches - CVT > Transmission Temperature Sensor/Switch, CVT > Component Information > Description and Operation >
Description
Transmission Temperature Sensor/Switch: Description and Operation Description
DESCRIPTION
A transmission over-temperature indicator is standard equipment on all instrument clusters.

However, on vehicles not equipped with an optional automatic transmission, this indicator is
electronically disabled. This indicator is located above the coolant temperature gauge on the
cluster overlay, to the right of the tachometer.
The transmission over-temperature indicator consists of a stencil-like cutout of the International

Control and Display Symbol icon for Transmission Temperature in the opaque layer of the
instrument cluster overlay. The dark outer layer of the overlay prevents the indicator from being
clearly visible when it is not illuminated. A red Light Emitting Diode (LED) behind the cutout in the
opaque layer of the overlay causes the indicator to appear in red through the translucent outer
layer of the overlay when it is illuminated from behind by the LED, which is soldered onto the
instrument cluster electronic circuit board.
The transmission over-temperature indicator is serviced as a unit with the instrument cluster.
Switches - CVT > Transmission Temperature Sensor/Switch, CVT > Component Information > Description and Operation >
Transmission Temperature Sensor/Switch: Description and Operation Operation
OPERATION
The transmission over-temperature indicator gives an indication to the vehicle operator when the
transmission fluid temperature is excessive, which may lead to accelerated transmission
component wear or failure. This indicator is controlled by a transistor on the instrument cluster
circuit board based upon cluster programming and electronic messages received by the cluster
from the Powertrain Control Module (PCM) over the Controller Area Network (CAN) data bus.
The transmission over-temperature indicator Light Emitting Diode (LED) is completely controlled by
the instrument cluster logic circuit, and that logic will only allow this indicator to operate when the
instrument cluster receives a battery current input on the fused ignition switch output (run-start)
circuit. Therefore, the LED will always be OFF when the ignition switch is in any position except ON
or START. The LED only illuminates when it is provided a path to ground by the instrument cluster
transistor. The instrument cluster will turn ON the transmission over-temperature indicator for the
following reasons:
- Bulb Test - Each time the ignition switch is turned to the ON position the transmission
over-temperature indicator is illuminated for about two seconds as a bulb test.
- Trans Over-Temp Indicator Lamp-On Message - Each time the cluster receives an electronic
trans over-temp indicator lamp-ON message from the PCM indicating that the transmission fluid
temperature is 135° C (275° F) or higher, the indicator will be illuminated and a single chime tone is
sounded. The indicator remains illuminated until the cluster receives a lamp-OFF message from
the PCM, or until the ignition switch is turned to the OFF position, whichever occurs first. The chime
tone feature will only repeat during the same ignition cycle if the indicator is cycled OFF and then
ON again by the appropriate lamp-ON and lamp-OFF messages from the PCM.
- Actuator Test - Each time the cluster is put through the actuator test, the transmission
over-temperature indicator will be turned ON, then OFF again during the bulb check portion of the
test to confirm the functionality of the LED and the cluster control circuitry.
The PCM continually monitors the transmission temperature sensor to determine the transmission
operating condition. The PCM then sends the proper lamp-ON or lamp-OFF message to the
ElectroMechanical Instrument Cluster (EMIC). If the instrument cluster illuminates the transmission
over-temperature indicator due to a high transmission oil temperature condition, it may indicate that
the transmission or the transmission cooling system are being overloaded, or that they require
service.
For proper diagnosis of the transmission temperature sensor, the PCM, the EMIC, the CAN data
bus or the electronic communication related to transmission over-temperature indicator operation a
diagnostic scan tool is required.
Switches - M/T > Transmission Speed Sensor, M/T > Component Information > Description and Operation
Transmission Speed Sensor: Description and Operation
VEHICLE SPEED SENSOR
The Vehicle Speed Sensor (VSS) is a hall effect sensor mounted above the transaxle differential.
The sensor is triggered by the ring gear teeth passing below it. The VSS pulse signal to the
speedometer/odometer is monitored by the PCM speed control circuitry to determine vehicle speed
and to maintain speed control set speed.
Switches - M/T > Transmission Speed Sensor, M/T > Component Information > Service and Repair > Removal
Transmission Speed Sensor: Service and Repair Removal
REMOVAL
1. Open hood. 2. Remove the air cleaner housing. 3. Disconnect the speed sensor connector.
CAUTION: Clean area around speed sensor before removing to prevent dirt from entering the
transaxle during speed sensor removal.
4. Remove speed sensor retaining bolt. 5. Remove speed sensor from transaxle.
Switches - M/T > Transmission Speed Sensor, M/T > Component Information > Service and Repair > Removal > Page 1408
Transmission Speed Sensor: Service and Repair Installation
INSTALLATION
1. Using a NEW O-ring, install the speed sensor to the transaxle. 2. Install the bolt and tighten to 7
Nm (60 in. lbs.). 3. Connect speed sensor connector. 4. Install the air cleaner housing.
Switches - Transfer Case > Four Wheel Drive Selector Switch > Component Information > Locations
Four Wheel Drive Selector Switch: Locations
Component ID: 366
Component : SWITCH-TRANSFER CASE SELECTOR
Connector:
Name : SWITCH-TRANSFER CASE SELECTOR
Color : BLACK
# of pins : 6
Gender : FEMALE
2 TRANSFER CASE POSITION SENSOR INPUT K77 20BR/WT
3--
4--
5 PANEL LAMPS DRIVER E12 20OR/GY

Switches - Transfer Case > Four Wheel Drive Selector Switch > Component Information > Locations > Page 1413
Four Wheel Drive Selector Switch: Diagrams
Component ID: 366
Connector:
Color : BLACK
# of pins : 6
Gender : FEMALE
3--
4--

Jeep Workshop Manuals > Sensors and Switches > Sensors and Switches - Windows and Glass > Heated Glass Element
Heated Glass Element Switch: Description and Operation Description
DESCRIPTION
The switch for the rear window defogger (EBL) system (1) is located in the A/C-heater control (2) in
the instrument panel center bezel (3). When the rear window defogger switch is pressed to the On
position a request signal is sent to the cabin compartment node (CCN), which sends a message to
the totally integrated power module (TIPM) to operate the EBL system.
When the high side driver in the TIPM is energized, current is directed to the rear defogger grid
lines and to the heated side view mirrors (when equipped). The grid lines heat the glass to help
clear the surface of fog or frost.
Jeep Workshop Manuals > Sensors and Switches > Sensors and Switches - Windows and Glass > Heated Glass Element
Heated Glass Element Switch: Description and Operation Operation
OPERATION
An amber indicator will illuminate when the rear window defogger switch is activated. When
activated, the switch sends a request signal to the cabin compartment node (CCN), which sends a
message to the totally integrated power module (TIPM) to energize the internal EBL high side
driver to provide battery current to the rear window defogger grid lines and to the heated side view
mirrors, when equipped.
NOTE: The EBL system turns off automatically after 10 minutes of initial operation. Each following
activation cycle of the EBL system will last 5 minutes.
The EBL system will automatically turn off after an initial programmed time interval of about 10
minutes as long as the ignition switch is in RUN. After the initial time interval has expired, if the rear
window defogger switch is pressed to ON again during the same ignition cycle, the EBL system will
automatically turn off after about 5 minutes. The EBL system will also turn off if the ignition switch is
turned to any position other than RUN or by manually pressing the rear window defogger switch a
second time.
The rear window defogger switch is diagnosed using a scan tool.
The rear window defogger switch and indicator cannot be adjusted or repaired. The A/C-heater
control must be replaced if the rear window defogger switch or indicator is found inoperative or
damaged.
Jeep Workshop Manuals > Sensors and Switches > Sensors and Switches - Windows and Glass > Power Window Switch >
Component Information > Locations > Switch-Power Window-Driver
Power Window Switch: Locations Switch-Power Window-Driver
Component ID: 357
Component : SWITCH-POWER WINDOW-DRIVER
Connector:
Name : SWITCH-POWER WINDOW-DRIVER C1
Color : LT. GRAY
# of pins : 6
1 MASTER WINDOW SWITCH LEFT REAR (UP)Q411 14OR/WT
2 MASTER WINDOW SWITCH RIGHT REAR (UP) Q412 14OR/LB
3 MASTER WINDOW SWITCH RIGHT REAR (DOWN) Q612 14OR/DB
4 MASTER WINDOW SWITCH LEFT REAR (DOWN) Q611 14OR/GY
5 MASTER WINDOW SWITCH PASSENGER (DOWN) Q26 14OR/GY
5 RIGHT FRONT WINDOW DRIVER (DOWN) Q22 14OR/VT
6 MASTER WINDOW SWITCH PASSENGER (UP) Q16 14OR/TN

6 RIGHT FRONT WINDOW DRIVER (UP) Q12 14OR/BR
Component Information > Locations > Switch-Power Window-Driver > Page 1426
Connector:
Color : LT. GRAY
# of pins : 8
1--
3 GROUND Z929 20BK/PK

5 WINDOW LOCK OUT SWITCH OUTPUT Q15 14OR/RD
6 LEFT FRONT WINDOW DRIVER (DOWN) Q21 14OR/WT
7 LEFT FRONT WINDOW DRIVER (UP) Q11 14OR/LG
8 DOOR LOCK SWITCH MUX P697 20LG/DG
Power Window Switch: Locations Switch-Power Window-Left Rear
Component ID: 358
Component : SWITCH-POWER WINDOW-LEFT REAR
Connector:
Name : SWITCH-POWER WINDOW-LEFT REAR
Color : LT. GRAY
# of pins : 6
2 LEFT REAR WINDOW DRIVER (DOWN) Q211 14TN/LB
3 LEFT REAR WINDOW DRIVER (UP) Q111 14TN/YL
5--
Power Window Switch: Locations Switch-Power Window-Passenger
Component ID: 359
Component : SWITCH-POWER WINDOW-PASSENGER
Connector:
Name : SWITCH-POWER WINDOW-PASSENGER
Color : LT. GRAY
# of pins : 6
5--
Power Window Switch: Locations Switch-Power Window-Right Rear
Component ID: 360
Component : SWITCH-POWER WINDOW-RIGHT REAR
Connector:
Name : SWITCH-POWER WINDOW-RIGHT REAR
Color : LT. GRAY
# of pins : 6
2 RIGHT REAR WINDOW DRIVER (DOWN) Q212 14OR/VT
3 RIGHT REAR WINDOW DRIVER (UP) Q112 14OR/BR
5--
Component Information > Diagrams > Switch-Power Window-Driver
Power Window Switch: Diagrams Switch-Power Window-Driver
Component ID: 357
Component : SWITCH-POWER WINDOW-DRIVER
Connector:
Color : LT. GRAY
# of pins : 6

Component Information > Diagrams > Switch-Power Window-Driver > Page 1436
Connector:
Color : LT. GRAY
# of pins : 8
1--
3 GROUND Z929 20BK/PK

8 DOOR LOCK SWITCH MUX P697 20LG/DG
Power Window Switch: Diagrams Switch-Power Window-Left Rear
Component ID: 358
Component : SWITCH-POWER WINDOW-LEFT REAR
Connector:
Name : SWITCH-POWER WINDOW-LEFT REAR
Color : LT. GRAY
# of pins : 6
2 LEFT REAR WINDOW DRIVER (DOWN) Q211 14TN/LB
3 LEFT REAR WINDOW DRIVER (UP) Q111 14TN/YL
5--
Power Window Switch: Diagrams Switch-Power Window-Passenger
Component ID: 359
Component : SWITCH-POWER WINDOW-PASSENGER
Connector:
Name : SWITCH-POWER WINDOW-PASSENGER
Color : LT. GRAY
# of pins : 6
5--
Power Window Switch: Diagrams Switch-Power Window-Right Rear
Component ID: 360
Component : SWITCH-POWER WINDOW-RIGHT REAR
Connector:
Name : SWITCH-POWER WINDOW-RIGHT REAR
Color : LT. GRAY
# of pins : 6
2 RIGHT REAR WINDOW DRIVER (DOWN) Q212 14OR/VT
3 RIGHT REAR WINDOW DRIVER (UP) Q112 14OR/BR
5--
Jeep Workshop Manuals > Sensors and Switches > Sensors and Switches - Wiper and Washer Systems > Wiper Switch >
Wiper Switch: Description and Operation Description
DESCRIPTION
The right (wiper) multi-function switch is located on the right side of the steering column, just below
the steering wheel. This switch is the primary control for the front and rear wiper and washer
systems. The only visible components of the switch are the control stalk (1), control knob (2) and
control sleeve (3) that extend through the steering column shrouds on the right side of the column.
The remainder of the switch including its mounting provisions and electrical connection are
concealed beneath the shrouds.
The switch housing and controls (6) are constructed of molded black plastic. Each of the switch
controls has white International Control and Display Symbol graphics applied to it, which clearly
identify its many functions. A single screw (7) through a mounting tab integral to the back of the
switch housing, and a slide tab integral to the bottom of the switch housing secure the switch to the
mounting bracket integral to the clockspring (3). A single connector receptacle containing seven
terminal pins is integral to the inboard end of the switch housing and is connected by a jumper wire
harness (5) directly to the Steering Control Module (SCM), which is internal to the housing (2) of
the left multi-function switch (1).
The right (wiper) multi-function switch provides the vehicle operator with a control interface for the
following wiper and washer system functions:
- Continuous Front Wipers - The right multi-function switch control knob provides detent switching
for two continuous front wipe modes, low speed or high speed.
Intermittent Front Wipers - The right multi-function switch control knob provides detent switching for
the intermittent front wipe mode with five minor detent delay interval positions.
- Front Wiper Mist Mode - The right multi-function switch control stalk includes momentary
switching of the front wiper motor low speed circuit to provide a mist mode features (sometimes
referred to as pulse wipe), which allows the vehicle operator to momentarily operate the front
wipers for one or more complete cycles.
- Front Washer Mode - The right multi-function switch control stalk provides momentary switching
for control of the front washer system operation.
- Intermittent Rear Wipe Mode - The right multi-function switch control sleeve provides detent
switching for a single fixed interval intermittent rear wiper mode.
- Rear Washer Mode - The right multi-function switch control sleeve provides two momentary
switch positions for control of rear washer system operation.
The right multi-function switch cannot be adjusted or repaired. If any function of the switch is
ineffective, or if the switch is damaged, the entire switch unit must be replaced. The clockspring
(with the multi-function switch mounting bracket), the left multi-function switch (with the SCM), the
right multi-function switch and the jumper wire harness are each available for separate service
replacement.
Wiper Switch: Description and Operation Operation
OPERATION
The right (wiper) multi-function switch uses a combination of resistor multiplexing and conventional
switching to control the many functions and features it provides. The switch receives a clean
ground from the Steering Control Module (SCM), then provides resistor multiplexed and
conventional analog return outputs to the SCM to indicate the selected switch positions. The SCM
then sends electronic switch status messages over a Local Interface Network (LIN) data bus to the
ElectroMechanical Instrument Cluster (EMIC) (also known as the Cab Compartment Node/CCN),
and the EMIC relays electronic wiper and washer switch request messages over the Controller
Area Network (CAN) data bus to other electronic modules in the vehicle.
If the SCM detects no inputs from the right multi-function switch, it transmits an electronic Signal
Not Available (SNA) status message over the LIN data bus. The SNA status signals the EMIC to
request other electronic modules to implement a failsafe mode of operation for the front and rear
wiper systems. The failsafe mode will maintain the last selected front and rear wiper system
operation for the remainder of the current ignition cycle, after which both wiper systems will default
to OFF.
The right multi-function switch as well as the hard wired inputs and outputs of the switch may be
information. However, the most reliable, efficient and accurate means to diagnose this component
requires the use of a diagnostic scan tool. Refer to the appropriate diagnostic information.
Following are descriptions of how the right multi-function switch is operated to control the many
front and rear wiper and washer system functions and features it provides:
- Front Wiper Control - The control knob on the end of the right multi-function switch control stalk is
rotated to one of the two continuous wiper detents, to one of five intermittent wiper detents, or to
the OFF position to select the front wiper mode. The SCM reads the input from the right
multi-function switch and sends electronic wiper switch status messages over the LIN data bus to
the EMIC, which relays an electronic wiper switch request message over the CAN data bus to other
- Front Wiper Mist Mode - The front wiper mist mode is requested when the right multi-function
switch control stalk is depressed downward towards the floor to a momentary MIST position. The
front wiper motor will continue to operate, one complete cycle at a time, for as long as the control
stalk is held in this position. The SCM reads the resistor multiplexed input from the right
multi-function switch and sends an electronic wiper switch status message over the LIN data bus to
the EMIC, which relays an electronic wiper switch request message over the CAN data bus to other
- Front Washer Control - The right multi-function switch control stalk is pulled rearward towards the
steering wheel to a momentary WASH position to activate the washer pump/motor in the front
washer mode. The washer pump/motor will continue to operate for as long as the control stalk is
held in this position. The SCM reads the resistor multiplexed input from the right multi-function
switch and sends an electronic washer switch status message over the LIN data bus to the EMIC,
which relays an electronic washer switch request message over the CAN data bus to other
- Rear Wiper Control - The rear wiper mode is selected when the right multi-function switch control
sleeve is rotated to the fixed interval intermittent rear wipe detent position, or the OFF detent
position. The SCM reads the input from the right multi-function switch and sends an electronic
wiper switch status message over the LIN data bus to the EMIC, which relays an electronic wiper
switch request message over the CAN data bus to other electronic modules in the vehicle.
- Rear Washer Control - The right multi-function switch control sleeve is rotated to one of two
momentary WASH positions, either fully forward or fully rearward, to activate the washer
pump/motor in the rear washer mode. The washer pump/motor will continue to operate in the rear
washer mode until the control sleeve is released. The SCM reads the input from the right
multi-function switch and sends an electronic washer switch status message over the LIN data bus
to the EMIC, which relays an electronic washer switch request message over the CAN data bus to
other electronic modules in the vehicle.
Wiper Switch: Testing and Inspection
RIGHT MULTI-FUNCTION SWITCH

The right multi-function switch as well as the hard wired inputs and outputs of the switch may be
information.
Steering Control Module (SCM) or the electronic controls or communication between other
modules and devices that provide some features of the front and rear wiper and washer systems.
The most reliable, efficient and accurate means to diagnose the SCM or the electronic controls and
communication related to SCM operation requires the use of a diagnostic scan tool. Refer to the
1. Remove the right multi-function switch from the integral mounting bracket on the right side of the
clockspring.
2. Using an ohmmeter, test the resistance between the terminals of the switch as shown in the
three Function Tests tables. For all functions except
those of the control stalk the values should be either less than 100 ohms (switch CLOSED) or
greater than 1 megohm (switch OPEN).
3. If the switch fails any of the tests, replace the ineffective right multi-function switch as required. If
the switch tests okay, but the switch input to the
Steering Control Module (SCM) remains incorrect, be certain to check for a short or open in the
jumper harness between the right multi-function switch and the SCM.
Wiper Switch: Service and Repair Removal
REMOVAL
2. Remove both the upper and lower shrouds from the steering column.
3. Remove the screw (2) that secures the right multi-function switch (1) to the mounting bracket
integral to the right side of the clockspring (3) on the
steering column.
4. Slide the switch away from the clockspring far enough to disengage the slide tabs on the switch
housing from the channel formations in the
mounting bracket.
5. Disconnect the jumper wire harness connector (1) from the connector receptacle on the inboard
end of the right multi-function switch (2).
6. Remove the switch from the clockspring (3).
Wiper Switch: Service and Repair Installation
INSTALLATION
1. Position the right multi-function switch (2) close enough to the mounting bracket (3) integral to
the right side of the clockspring to reconnect the
jumper wire harness connector (1) to the connector receptacle on the inboard side of the switch
housing.
2. Align the slide tabs on the switch housing with the channel formations integral to the clockspring
mounting bracket, then slide the switch into the
bracket until it is firmly seated.
3. Install and tighten the screw (2) that secures the mounting tab on the back of the right
multi-function switch (1) to the mounting bracket on the
clockspring (3). Tighten the screw to 1 Nm (10 in. lbs.).
4. Reinstall the upper and lower shrouds onto the steering column.
Jeep Workshop Manuals > Maintenance > Alignment > System Information > Specifications > Wheel Alignment
Specifications
Alignment: Specifications Wheel Alignment Specifications
Specifications > Page 1463
Alignment: Specifications Curb Height Specifications
CURB HEIGHT SPECIFICATIONS
Curb Height Specifications

Jeep Workshop Manuals > Maintenance > Alignment > System Information > Specifications > Page 1467
Alignment: Description and Operation
DESCRIPTION
Vehicle wheel alignment is the positioning of all interrelated front and rear suspension angles.
These angles affect the handling and steering of the vehicle when it is in motion. Proper wheel
alignment is essential for efficient steering, good directional stability, and proper tire wear.
The method of checking a vehicle's front and rear wheel alignment varies depending on the
manufacturer and type of equipment used. The manufacturer's instructions should always be
followed to ensure accuracy of the alignment, except when DaimlerChrysler Corporation's wheel
alignment specifications differ.
On this vehicle, the suspension angles that can be adjusted are as follows:
Front
- Camber (with cradle shift or service adjustment bolt package)
- Caster (limited adjustment with cradle shift)
- Toe
Rear
- Toe
Check the wheel alignment and make all wheel alignment adjustments with the vehicle standing at
its proper curb height specification. Curb height is the normal riding height of the vehicle. It is
measured from a certain point on the vehicle to the ground or a designated area while the vehicle
is sitting on a flat, level surface. Refer to Curb Height Measurement.
Typical wheel alignment angles and measurements are described in the following paragraphs.
CAMBER
Camber is the inward or outward tilt of the top of the tire and wheel assembly. Inward tilt (2) is
known as negative camber. Outward tilt (1) is known as positive camber. Camber is measured in
degrees of angle relative to a true vertical line. Camber is a tire wearing angle.
- Excessive negative camber will cause tread wear at the inside of the tire.
- Excessive positive camber will cause tread wear on the outside of the tire.
CROSS CAMBER
Cross camber is the difference between left and right camber. To achieve the cross camber
reading, subtract the right side camber reading from the left. For example, if the left camber is -0.7°
and the right camber is -0.5°, the cross camber would be -0.2° (-0.7 - (-0.5) = -0.7 + 0.5 = -0.2).
CASTER
Caster is the forward or rearward tilt of the steering knuckle in reference to the position of the upper
and lower ball joints. Caster is measured in degrees of angle relative to a true vertical center line.
This line is viewed from the side of the tire and wheel assembly.
- Forward tilt (upper ball joint ahead of lower) results in a negative caster angle.
- Rearward tilt (upper ball joint trailing lower) results in a positive caster angle.
Although caster does not affect tire wear, a caster imbalance between the two front wheels may
cause the vehicle to lead to the side with the least positive caster.
CROSS CASTER
Cross caster is the difference between left and right caster. To achieve the cross caster reading,
subtract the right side caster reading from the left. For example, if the left caster is 2.5° and the
right caster is 2.7°, the cross caster would be -0.2° (2.5 - 2.7 = -0.2).
TOE
Toe is the inward or outward angle of the wheels as viewed from above the vehicle.
- Toe-in (1) is produced when the front edges of the wheels on the same axle are closer together
than the rear edges.
- Toe-out (2) is produced when the front edges of the wheels on the same axle are farther apart
Toe-in and toe-out can occur at the front wheels and the rear wheels.
Toe is measured in degrees or inches. The measurement identifies the amount that the front of the
wheels point inward (toe-in) or outward (toe-out). Toe is measured at the spindle height. Zero toe
means the front and rear edges of the wheels on the same axle are equal distant.
TOE-OUT ON TURNS
Toe-out on turns (1), sometimes referred to as Ackerman Steering, is the relative positioning of the
front wheels while steering through a turn. This compensates for each front wheel's turning radius.
As the vehicle encounters a turn, the outboard wheel must travel in a larger radius circle than the
inboard wheel. The steering system is designed to make each wheel follow its particular radius
circle. To accomplish this, the front wheels must progressively toe outward as the steering is turned
from center. This eliminates tire scrubbing and undue tire wear when steering a vehicle through a
turn.
DYNAMIC TOE PATTERN
Dynamic toe pattern is the inward and outward toe movement of the front and rear tires through the
suspension's jounce and rebound travel. As the vehicle's suspension moves up and down, the toe
pattern varies. Toe pattern is critical in controlling the directional stability of the vehicle while in
motion. Front and rear dynamic toe pattern is preset by the factory at the time the vehicle is
assembled.
It is not necessary to check or adjust front or rear dynamic toe pattern when doing a normal wheel
alignment. The only time dynamic toe pattern needs to be checked or adjusted is if the frame of the
vehicle has been damaged.
STEERING AXIS INCLINATION (S.A.I.)

Steering axis inclination (1) is the angle between a true vertical line starting at the center of the tire
at the road contact point and a line drawn through the center of the upper ball joint (or strut) and
the lower ball joint. S.A.I. is built into the vehicle and is not an adjustable angle. If S.A.I. is not
within specifications, a bent or damaged suspension component may be the cause.
INCLUDED ANGLE (I.A.)

Included angle (3) is the sum of the S.A.I. angle (1) plus or minus the camber angle (2), depending
on whether or not the wheel has positive or negative camber. If camber is positive, add the camber
angle to the S.A.I angle. If camber is negative, subtract the camber angle from the S.A.I. angle.
Included angle is not adjustable, but can be used to diagnose a frame misalignment or bent
suspension component (spindle, strut).
THRUST ANGLE
Thrust angle is the averaged direction the rear wheels are pointing in relation to the vehicle's center
line. The presence of negative or positive thrust angle causes the rear tires to track improperly to
the left or right of the front tires (dog tracking).
- Negative thrust angle means the rear tires are tracking to the left of the front tires.
- Positive thrust angle means the rear tires are tracking to the right of the front tires.
Improper tracking can cause undue tire wear, a lead or pull and a crooked steering wheel.
Excessive thrust angle can usually be corrected by adjusting the rear wheel toe so that each wheel
has one-half of the total toe measurement.
Alignment: Testing and Inspection
SUSPENSION AND STEERING

Suspension And Steering (Part 1)


Jeep Workshop Manuals > Maintenance > Alignment > System Information > Service and Repair > Wheel Alignment
Alignment: Service and Repair Wheel Alignment
WHEEL ALIGNMENT
PRE-WHEEL ALIGNMENT INSPECTION
Before any attempt is made to change or correct the wheel alignment, the following inspection and
necessary corrections must be made to the vehicle to ensure proper alignment.
1. Verify the fuel tank is full of fuel. If the fuel tank is not full, the reduction in weight will affect the
curb height of the vehicle and the alignment
specifications.
2. The passenger and luggage compartments of the vehicle should be free of any load that is not
factory equipment. 3. Check the tires on the vehicle. The tires are to be inflated to the
recommended air pressure. All tires must be the same size and in good condition
with approximately the same tread wear.
4. Check the front tire and wheel assemblies for excessive radial runout. 5. Inspect all suspension
component fasteners for looseness and proper torque. 6. Inspect the lower front ball joints and all
steering linkage for looseness and any sign of wear or damage. 7. Inspect the rubber bushings on
all the suspension components for signs of wear or deterioration. If any bushings show signs of
wear or
deterioration, they should be replaced prior to aligning the vehicle.
8. Check vehicle curb height to verify it is within specifications.
WHEEL ALIGNMENT SETUP
1. Position the vehicle on an alignment rack. 2. Install all required alignment equipment on the
vehicle, per the alignment equipment manufacturer's instructions. On this vehicle, a four-wheel
alignment is recommended.
NOTE: Prior to reading the vehicle's alignment readouts, the front and rear of vehicle should be
jounced. Induce jounce (rear first, then front) by grasping the center of the bumper and jouncing
each end of vehicle an equal number of times. The bumper should always be released when
vehicle is at the bottom of the jounce cycle.
3. Read the vehicle's current front and rear alignment settings. Compare the vehicle's current
alignment settings to the vehicle specifications for
camber, caster and toe-in.
REAR CAMBER
Rear camber settings on this vehicle are determined at the time the vehicle is designed, by the
location of the vehicle's suspension components. This is referred to as Net Build. The result is no
required adjustment of camber after the vehicle is built or when servicing the suspension
components. Thus, when performing a wheel alignment, rear camber is not considered an
adjustable angle.
CAUTION: Do not attempt to adjust the vehicle's wheel alignment by heating or bending any of the
suspension components.
FRONT CAMBER AND CASTER

Front camber and caster settings on this vehicle are determined at the time the vehicle is designed,
by the location of the vehicle's suspension components. This is referred to as Net Build. The result
is no required adjustment of camber and caster after the vehicle is built or when servicing the
suspension components. Thus, when performing a wheel alignment, caster and camber are not
normally considered adjustable angles but some adjustment can be made. Camber and caster
should be checked to ensure they meet vehicle specifications.
If individual front camber or caster is found not to meet alignment specifications, each can be
adjusted by shifting the crossmember or by using an available service adjustment bolt package. If
an adjustment bolt package installation is necessary, inspect the suspension components for any
signs of damage or bending first.
ADJUSTMENT BY SHIFTING CROSSMEMBER
CAUTION: Always use care when shifting crossmember to avoid damaging other components on
the vehicle.
1. Loosen the four bolts fastening the front crossmember to the frame just enough to allow
movement of the crossmember. 2. Loosen the bolts fastening the fore/aft crossmember to the
frame just enough to allow movement of the crossmember.
CAUTION: When shifting the front crossmember, keep in mind that the front and rear engine
mounts are attached to the front crossmember and fore/aft crossmember and should be inspected
following the crossmember shift to make sure they are properly aligned.
Jeep Workshop Manuals > Maintenance > Alignment > System Information > Service and Repair > Wheel Alignment >
Page 1479
3. Shift front crossmember as necessary to bring camber or caster into specifications. When
shifting crossmember, use care not to move other angles
(camber or caster) that are within specifications, out of specifications.
4. Tighten all previously loosened fasteners (bolts) securing the crossmember to the vehicle to
specifications. 5. Jounce the rear, then front of the vehicle an equal amount of times. 6. Measure
camber and caster. If camber and caster are within specifications, proceed to TOE. If camber
cannot be brought into specifications,
perform the CAMBER ADJUSTMENT BOLT PACKAGE INSTALLATION below.
CAMBER ADJUSTMENT BOLT PACKAGE INSTALLATION
The camber adjustment bolt package contains new bolts and nuts for attaching the strut clevis
bracket to the steering knuckle. The bolts contained in the package are slightly undersize allowing
for movement between the strut clevis bracket and the steering knuckle. The movement allowed by
the undersize bolts provide approximately two degrees of camber adjustment per side of the
vehicle. To install and adjust the camber adjustment bolt package, follow the procedure below.
7. Raise the vehicle until its tires are not supporting the weight of the vehicle.
8. Remove the wheel mounting nuts (3), then the front tire and wheel assembly (1).
CAUTION: The strut clevis-to-knuckle attaching bolt shanks are serrated and must not be turned
during removal. Remove the nuts while holding the bolts stationary, then tap the bolts out using a
punch.
9. Remove the original upper bolt (1) and nut (3) attaching the strut clevis bracket (2) to the knuckle
(5).
10. Install a bolt from the adjustment package into the hole where the original bolt was removed.
Install the bolt as indicated. 11. Install a nut provided in adjustment package on the replacement
bolt. Tighten the nut until it's snug, but still allows the knuckle to slide in the
Page 1480
clevis bracket.
12. Remove the original lower bolt (6) and nut (4) attaching the strut clevis bracket (2) to the
knuckle (5). 13. Install a bolt from the adjustment package into the bottom hole of the strut clevis
bracket. Install the bolt as indicated. 14. Install a nut provided in adjustment package on the
replacement bolt. Tighten the nut until it's snug, but still allows the knuckle to slide in the
clevis bracket.
15. Install the tire and wheel assembly (1). Install and tighten the wheel mounting nuts (3) to 135
Nm (100 ft. lbs.). 16. Perform the above procedure to opposite strut as required. 17. Lower the
vehicle and jounce the front and rear of the vehicle.
Page 1481
18. Adjust the front camber to the preferred setting by pushing or pulling on the top of the tire.
When camber is set to specifications, tighten the upper
and lower strut clevis-to-knuckle attaching bolt nuts (3, 4) enough to hold the adjustment. Again
jounce the front and rear of the vehicle, then verify the camber settings.
19. Tighten the front strut clevis-to-knuckle attaching bolt nuts (3, 4) to 84 Nm (62 ft. lbs.). 20. Once
camber is within specifications, adjust toe to meet the preferred specification setting. Refer to
FRONT TOE within this wheel alignment
service procedure.
TOE
1. Center the steering wheel and lock it in place using a steering wheel clamp.
NOTE: When setting toe, make sure to set rear toe to the preferred specifications before setting
front toe to the preferred specifications
REAR TOE
NOTE: Perform the following at each rear wheel as necessary.

Page 1482
2. While holding the cam bolt head (3) stationary, loosen the toe link mounting cam bolt nut (1). 3.
Rotate the cam bolt head (3) left or right until the rear wheel toe for that rear wheel is set to the
preferred specification. 4. While holding the cam bolt head (3) stationary, tighten the toe link
mounting cam bolt nut (1) to 35 Nm (26 ft. lbs.).
FRONT TOE
CAUTION: Do not twist the inner tie rod-to-steering gear rubber boots while turning the inner tie
rods during the front toe adjustment.
NOTE: Perform the following at each front wheel as necessary.
5. Loosen the tie rod adjusting jam nut (1). Grasp the inner tie rod (3) and rotate it one way or the
other until the front wheel toe is set to the preferred
specification.
6. Tighten the tie rod adjusting jam nut to of 75 Nm (55 ft. lbs.). 7. Make sure the inner tie
rod-to-steering gear rubber boot is not twisted.
Page 1483
8. Remove the steering wheel clamp. 9. Remove the alignment equipment.
10. Road test the vehicle to verify the steering wheel is straight and the vehicle does not pull or
wander.
Page 1484
Alignment: Service and Repair Curb Height Measurement
CURB HEIGHT MEASUREMENT
The wheel alignment is to be checked and all alignment adjustments made with the vehicle at its
required curb height specification.
Vehicle height is to be checked with the vehicle on a flat, level surface, preferably a vehicle
alignment rack. The tires are to be inflated to the recommended pressure. All tires are to be the
same size as standard equipment. Vehicle height is checked with the fuel tank full of fuel, and no
passenger or luggage compartment load.
Vehicle height is not adjustable. If the measurement is not within specifications, inspect the vehicle
for bent or weak suspension components. Compare the parts tag on the suspect coil spring(s) to
the parts book and the vehicle sales code, checking for a match. Once removed from the vehicle,
compare the coil spring height to a correct new or known good coil spring. The heights should vary
if the suspect spring is weak.
NOTE: Prior to reading the curb height measurement, the front and rear of the vehicle must be
jounced to settle the suspension. Induce jounce by pushing down on the center of the bumper
(fascia), using care not to damage the vehicle, moving the vehicle up and down, gradually
increasing the suspension travel with each stroke. Release the bumper at the bottom of each
stroke, repeating this action several times. Perform this to both front and rear suspensions an equal
amount of times.
Measure curb height as follows:
1. Jounce the vehicle. Refer to above note.
NOTE: On some vehicles it may be necessary to remove an engine belly pan in order to gain
access to the lower control arm pivot bolt.
2. FRONT - On each side of the vehicle, measure the distance (2) from the center of the lower
control arm rear (vertical) pivot bolt head (1) to the
floor or alignment rack/lift runway surface. It may be necessary to measure to the bottom of a
straight edge (3) placed from lift runway to runway to get an accurate measurement.
3. REAR - On each side of the vehicle, measure the distance (2) from the center of the outboard
trailing arm-to-body mounting bolt (1) to the floor or
Page 1485
alignment rack/lift runway surface.
4. Compare the measurements to specifications listed in the following CURB HEIGHT

SPECIFICATIONS chart. Maximum left-to-right
differential is not to exceed 12.5 mm (0.5 in.).
5. If curb height is found to be out of specification and there is no sign of excessive body damage,
curb height can be changed by replacing the
applicable spring with a spring offering a different check load.

Jeep Workshop Manuals > Maintenance > Tune-up and Engine Performance Checks > Fuel Pressure > System Information
> Specifications
Fuel Pressure: Specifications
FUEL SYSTEM PRESSURE

> Specifications > Page 1490
Fuel Pressure: Testing and Inspection
*CHECKING THE FUEL DELIVERY SYSTEM
For a complete wiring diagram refer to Diagrams/Electrical.
Diagnostic Test
1. CHECKING THE FUEL PUMP OPERATION
Turn the ignition on.
NOTE: Diagnose and repair any fuel pump control circuit or relay DTCs before continuing with this
test.
With a scan tool, actuate the fuel pump control to ON (100%).
NOTE: It may be necessary to use a mechanics stethoscope in the next step.
Listen for fuel pump operation at the fuel tank. The fuel pump should operate smoothly, without
excessive noise. If necessary, compare to a known good vehicle of similar year, make, and model.
NOTE: If the pump has excessive noise or grinding, the pump should be replaced.
CAUTION: Stop all actuation tests before continuing.
Is the fuel pump operating when actuated?
Yes
- Go to 2
No
- Go to 7
2. CHECKING THE FUEL PRESSURE
Turn the ignition off.
WARNING: The fuel system is under a constant pressure even with the engine off. Before testing
or servicing any fuel system hose, fitting or line, the fuel system pressure must be released. Failure
to follow these instructions can result in personal injury or death.
Install a fuel pressure gauge on the fuel rail.
With the scan tool, actuate the fuel pump relay control. Observe the fuel pressure gauge.
NOTE: The fuel pressure specification is 407 KPa ± 34 KPa (59 psi ± 5 psi).
Select the conclusion that best matches the result of the test:
Fuel pressure is within the stated specification
- Test complete.
Fuel pressure is below the stated specification

- Go to 3
Fuel pressure is above the stated specification
- Replace the fuel filter/pressure regulator.

- Perform the PCM Verification Test. See: Powertrain Management/Computers and Control
Procedures/Verification Tests/PCM Verification Test
3. RESTRICTED FUEL SUPPLY LINE
WARNING: The fuel system is under a constant pressure, even with the engine off. Before testing
Raise vehicle on hoist, and disconnect the fuel pressure line at the fuel pump module.
Install special 5/16 fuel line adapter tool #6539 between disconnected fuel line and the fuel pump
module.
Attach a fuel pressure test gauge to the T fitting on tool #6539.
NOTE: Fuel pressure specification is 407 KPa ± 34 KPa (59 psi ± 5 psi).
CAUTION: Stop all actuation tests before proceeding.
Is the fuel pressure within specification?
Yes
- Repair or replace fuel supply line as necessary.
No
- Go to 4
4. SADDLE FUEL TANK
Is the vehicle equipped with a saddle type fuel tank?
Yes
- Go to 5
No
- Go to 6
5. FUEL TANK SIPHON HOSE OR FUEL LINE RESTRICTED OR DAMAGED
Gain access to the fuel pump module and the fuel tank module.
Inspect the fuel line and siphon hose between the fuel pump module and the fuel tank module.
Look for disconnected or damaged lines and hoses.
Inspect the fuel pressure regulator for damage or a condition that might cause a fuel flow problem.
Make sure that it is seated in the module properly.
Were any problems found?
Yes
- Repair as necessary.
No
- Go to 6
6. FUEL PUMP INLET STRAINER
Remove the fuel pump module and inspect the fuel inlet strainer for damage or a condition that
might cause a fuel flow problem.
Yes
- Replace the Fuel Pump Inlet Strainer.
No
- Replace the Fuel Pump Module.
7. FUEL PUMP GROUND CIRCUIT OPEN OR HIGH RESISTANCE
Disconnect the Fuel Pump Module harness connector.
Using a 12 volt test light connected to 12 volts, check the Fuel Pump Motor Ground circuit at the
Fuel Pump Module harness connector.
NOTE: The test light should be illuminated and bright. Compare the brightness to that of a direct
connection to the battery.
Is the test light illuminated and bright?
Yes
No
- Repair the Fuel Pump Ground circuit for an open circuit or high resistance.
Jeep Workshop Manuals > Maintenance > Tune-up and Engine Performance Checks > Idle Speed > System Information >
Specifications
Idle Speed: Specifications
Information not supplied by manufacturer.

Jeep Workshop Manuals > Maintenance > Tune-up and Engine Performance Checks > Air Cleaner Housing > Air Filter
Element > Component Information > Service and Repair > Removal
Air Filter Element: Service and Repair Removal
REMOVAL
1. Turn lock retainers (5) and remove fresh air inlet (2) from air cleaner housing (1).
2. Disconnect intake air temperature sensor connector (4). 3. Remove air inlet tube (5) from air
cleaner housing (1). 4. Unfasten clasps (2) on sides of air cleaner housing cover.
5. Pull air cleaner cover (1) aside. 6. Remove filter element (3).
Element > Component Information > Service and Repair > Removal > Page 1501
7. If necessary, clean the inside of the air cleaner housing (2).
Air Filter Element: Service and Repair Installation
INSTALLATION
1. Install new filter element.
2. Place cover over air cleaner housing. Snap clasps (2) in place. 3. Install air inlet tube (5). 4.
Connect intake air temperature sensor connector (4).
5. Install fresh air inlet (2) on air cleaner housing (1) and lock retainers (5).
Jeep Workshop Manuals > Maintenance > Tune-up and Engine Performance Checks > Fuel Filter > Fuel Pressure Release
> System Information > Service and Repair
Fuel Pressure Release: Service and Repair
STANDARD PROCEDURE - FUEL SYSTEM PRESSURE RELEASE PROCEDURE
1. Remove lower rear seat cushion.
2. Remove the fuel pump module cover.
3. Disconnect the electrical connector for fuel pump module.
4. Start and run engine until it stalls.
5. Attempt restarting engine until it will no longer run.

Jeep Workshop Manuals > Maintenance > Tune-up and Engine Performance Checks > Fuel Filter > Fuel Pressure Release
> System Information > Service and Repair > Page 1507
6. Turn ignition key to OFF position.
8. One or more Diagnostic Trouble Codes (DTC's) may have been stored in PCM memory. The
scan tool must be used to erase a DTC.
Jeep Workshop Manuals > Maintenance > Tune-up and Engine Performance Checks > Firing Order > Component
Information > Specifications
Firing Order: Specifications
DESCRIPTION
The 2.4 Liter (148 cu. in.) in-line four cylinder engine is a double over head camshaft design with
mechanical lash tappets and four valves per cylinder design. This engine is NOT free-wheeling;
meaning that the pistons will contact the valves in the event of a timing chain failure.
The cylinders are numbered from front of the engine to the rear. The firing order is 1-3-4-2.
Jeep Workshop Manuals > Maintenance > Tune-up and Engine Performance Checks > Spark Plug > Component
Spark Plug: Specifications
SPARK PLUGS
Spark Plug: Service and Repair Removal
2.0/2.4L
2. Disconnect the electrical connectors from ignition coils.
3. Remove the ignition coil mounting bolt.

4. Twist the ignition coil then pull straight up.
5. Remove the spark plug using a quality socket with a rubber or foam insert.
6. Inspect the spark plug condition.

Spark Plug: Service and Repair Installation
2.0/2.4L
Special care should be used when installing spark plugs in the cylinder head spark plug wells. Be
sure the plugs do not drop into the wells, damage to the electrodes can occur.
Always tighten spark plugs to the specified torque. Over tightening can cause distortion resulting in
a change in the spark plug gap. Overtightening can also damage the cylinder head.
1. To avoid cross threading, start the spark plug into the cylinder head by hand.
2. Tighten spark plugs to 17.5 ± 2 Nm (13 ± 2 ft. lbs.).
3. Install ignition coil on to spark plug.

4. Tighten coil mounting bolt. Tighten to 9 Nm (79.5 in. lbs.).

Jeep Workshop Manuals > Maintenance > Tune-up and Engine Performance Checks > Compression Check > System
Compression Check: Specifications
Compression Pressure
..............................................................................................................................................................
1172-1551 kpa (170-225 psi)
Jeep Workshop Manuals > Maintenance > Tune-up and Engine Performance Checks > Compression Check > System
Information > Specifications > Page 1522
Compression Check: Testing and Inspection
CYLINDER COMPRESSION PRESSURE TEST
The results of a cylinder compression pressure test can be utilized to diagnose several engine
malfunctions.
Ensure the battery is completely charged and the engine starter motor is in good operating
condition. Otherwise the indicated compression pressures may not be valid for diagnosis purposes.
1. Check engine oil level and add oil if necessary. 2. Drive the vehicle until engine reaches normal
operating temperature. Select a route free from traffic and other forms of congestion, observe all
traffic laws, and accelerate through the gears several times briskly.
3. Remove engine cover. 4. Disconnect coil electrical connectors and remove coils. 5. Remove all
spark plugs from engine. As spark plugs are being removed, check electrodes for abnormal firing
indicators fouled, hot, oily, etc.
Record cylinder number of spark plug for future reference.
6. Disconnect injector electrical connectors. 7. Be sure throttle blade is fully open during the
compression check. 8. Insert compression gauge adaptor 8116 or the equivalent, into the #1 spark
plug hole in cylinder head. Connect the 0-500 psi (Blue) pressure
transducer CH7059 with cable adaptors to the DRBIII(R).
9. Crank engine until maximum pressure is reached on gauge. Record this pressure as #1 cylinder
pressure.
10. Repeat the previous step for all remaining cylinders. 11. Compression should not be less than
1034 kPa (150 psi) and not vary more than 25 percent from cylinder to cylinder. 12. If one or more
cylinders have abnormally low compression pressures, repeat the compression test. 13. 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 problems. An engine should not be disassembled to determine the cause of
low compression unless some malfunction is present.
Jeep Workshop Manuals > Maintenance > Timing Component Alignment Marks > Component Information > Locations
Timing Component Alignment Marks: Locations
- Verify that the crankshaft sprocket keyway is at the 9 o'clock position.
- Align camshaft timing marks (3) so they are parallel to the cylinder head and aligned each other
as shown.
- Install timing chain guide (4) and tighten bolts to 12 Nm (105 in. lbs.).
Jeep Workshop Manuals > Maintenance > Timing Component Alignment Marks > Component Information > Locations >
Page 1526
- Install timing chain so plated links on chain align with timing marks on camshaft sprockets (1).
- Align timing mark on the crankshaft sprocket (2) with the plated link (3) on the timing chain.
Position chain so slack will be on the tensioner side.
- Rotate the crankshaft CLOCKWISE two complete revolutions until the crankshaft is repositioned
at the TDC position with the key way at the 9 o'clock position.
Jeep Workshop Manuals > Maintenance > Timing Component Alignment Marks > Component Information > Locations >
Page 1527
- Verify that the camshafts timing marks (3) are in the proper position.
Jeep Workshop Manuals > Maintenance > Drive Belt > Component Information > Description and Operation
Drive Belt: Description and Operation
GAS ENGINE
The accessory drive belt (2) is a serpentine type belt that is driven by the crankshaft pulley (6).
The belt drives the A/C compressor, generator (3), power steering pump (1) and water pump (7).
Belt tension is maintained by an automatic belt tensioner (8).
Jeep Workshop Manuals > Maintenance > Drive Belt > Component Information > Description and Operation > Page 1531
Drive Belt: Testing and Inspection
ACCESSORY DRIVE BELT
VISUAL DIAGNOSIS
When diagnosing serpentine accessory drive belts, small cracks that run across the ribbed surface
of the belt from rib to rib (1), are considered normal. These are not a reason to replace the belt.
However, cracks running along a rib (not across) (2) are not normal. Any belt with cracks running
along a rib must be replaced. Also replace the belt if it has excessive wear, frayed cords or severe
glazing.
Refer to ACCESSORY DRIVE BELT DIAGNOSIS CHART for further belt diagnosis.
NOISE DIAGNOSIS
Noises generated by the accessory drive belt are most noticeable at idle. Before replacing a belt to
resolve a noise condition, inspect all of the accessory drive pulleys for contamination, alignment,
glazing, or excessive end play.
Accessory Drive Belt Diagnosis Chart (Part 1)


Jeep Workshop Manuals > Maintenance > Drive Belt > Component Information > Service and Repair > Procedures
Drive Belt: Procedures
CLEANING
Clean all foreign debris from belt pulley grooves. The belt pulleys must be free of oil, grease, and
coolants before installing the drive belt.
Jeep Workshop Manuals > Maintenance > Drive Belt > Component Information > Service and Repair > Procedures > Page
1536
Drive Belt: Removal and Replacement
Removal
GAS ENGINE
1. Using a wrench, rotate accessory drive belt tensioner (8) counterclockwise until accessory drive
belt (2) can be removed from pulleys (5 and 9). 2. Remove accessory drive belt (2).
Installation
GAS ENGINE
NOTE: When installing drive belt on the pulleys, make sure that belt is properly routed and all
V-grooves make proper contact with pulley grooves.
1. Install the accessory drive belt (2) around all the pulleys except for the generator pulley (3).
Jeep Workshop Manuals > Maintenance > Drive Belt > Component Information > Service and Repair > Procedures > Page
1537
belt (2) can be installed on the generator pulley
(3). Release spring tension onto accessory drive belt (2).

Jeep Workshop Manuals > Maintenance > Filters > Air Cleaner Housing > Air Filter Element > Component Information >
Service and Repair > Removal
REMOVAL
Service and Repair > Removal > Page 1544
INSTALLATION
Jeep Workshop Manuals > Maintenance > Filters > Cabin Air Filter > Component Information > Description and Operation
Cabin Air Filter: Description and Operation
DESCRIPTION
Some models are equipped with a particulate air filter (1) that helps purify the outside air entering
the HVAC housing. The filter is mounted in the passenger compartment, behind the glove box bin.
The filter should be replaced at least once a year or every 24,000 km (15,000 miles) and checked if
heating-A/C system performance seems lower than expected. The particulate air filter is labeled
with an arrow (2) to indicate the direction of air flow through the filter.
Jeep Workshop Manuals > Maintenance > Filters > Cabin Air Filter > Component Information > Service and Repair >
Procedures
Cabin Air Filter: Procedures
Air Filtration System - If Equipped
An air filter is included in the optional Security Group. Chrysler provides no information on removal
and replacement. See your authorized dealer for service.
Procedures > Page 1551
Cabin Air Filter: Removal and Replacement
Removal
REMOVAL
NOTE: LHD model shown in illustrations. RHD model similar.
NOTE: Illustration shown with instrument panel removed for clarity.
1. Remove the glove box bin.
2. Disengage the two retaining tabs (1) that secure the particulate air filter cover (2) to the
passenger side of the HVAC housing (3) and remove the
cover.
3. Remove the particulate air filter (1) from the HVAC housing (2) by pulling the filter element
straight out of the housing.
Installation
INSTALLATION
NOTE: The particulate air filter is labeled with an arrow to indicate air flow direction through the
filter. Make sure to properly install the particulate air filter. Failure to properly install the filter will
result in the need to replace the filter sooner than required by design.
1. Install the particulate air filter (1) into the filter opening in the HVAC housing (2). Insert the
particulate air filter directly into the housing with the
arrow on the filter pointing to the floor.
2. Position the particulate air filter cover (2) to the HVAC housing (3) and engage the two retaining
tabs (1) that secure the cover to the housing.
Make sure the retaining tabs are fully engaged.
3. Install the glove box bin.

Jeep Workshop Manuals > Maintenance > Filters > Fluid Filter - CVT > Component Information > Service and Repair >
Removal
Fluid Filter - CVT: Service and Repair Removal
REMOVAL
1. Raise the vehicle on a hoist. 2. Remove the left front tire. 3. Remove the left front splash shield.
4. Drain the coolant. 5. Remove the transmission lines (2) at the cooler (3). 6. Remove the coolant
lines (1) at the cooler. 7. Remove the mounting bolts at the cooler. 8. Remove the cooler from the
transmission.
9. Remove the fluid filter (1).

Removal > Page 1557
Fluid Filter - CVT: Service and Repair Installation
INSTALLATION
CAUTION: Apply CVT fluid on the seal part when installing the CVT fluid filter.
1. Install the CVT fluid filter (1) into the transaxle case.
CAUTION: Do not re-use the O-ring. Apply CVT fluid when installing the O-ring.
2. Install the new O-ring (1) onto the CVT fluid filter.
Removal > Page 1558
3. Install the CVT fluid cooler onto the transaxle case. 4. Install and tighten the mounting bolts to 4
Nm (37 in.lbs.). 5. Install the coolant lines (1) at the cooler. 6. Install the transmission lines (2) at
the cooler (3). 7. Install the left front splash shield. 8. Install the left front tire. 9. Lower the hoist.
10. Top off coolant. 11. Top off transmission fluid.

Jeep Workshop Manuals > Maintenance > Filters > Fuel Filter > Fuel Pressure Release > System Information > Service and
Repair

Jeep Workshop Manuals > Maintenance > Filters > Fuel Filter > Fuel Pressure Release > System Information > Service and
Repair > Page 1563
Jeep Workshop Manuals > Maintenance > Filters > Fuel Pump Pickup Filter > Component Information > Description and
Operation
Fuel Pump Pickup Filter: Description and Operation
DESCRIPTION
The fuel pump inlet strainer is a non-serviceable part.

Jeep Workshop Manuals > Maintenance > Filters > Oil Filter, Engine > Component Information > Service and Repair >
Engine Oil and Filter Change
Oil Filter: Service and Repair Engine Oil and Filter Change
ENGINE OIL AND FILTER CHANGE
WARNING: New or used engine oil can be irritating to the skin. Avoid prolonged or repeated skin
contact with engine oil. Contaminants in used engine oil, caused by internal combustion, can be
hazardous to your health. Thoroughly wash exposed skin with soap and water. Do not wash skin
with gasoline, diesel fuel, thinner, or solvents, health problems can result. Do not pollute, dispose
of used engine oil properly. Contact your dealer or government agency for location of collection
center in your area.
Change engine oil at mileage and time intervals described in the Maintenance Schedule.
1. Run engine until achieving normal operating temperature. 2. Position the vehicle on a level
surface and turn engine off. 3. Remove oil fill cap. 4. Raise vehicle on hoist. 5. Place a suitable oil
collecting container under oil pan drain plug (2). 6. Remove oil pan drain plug (2) or and allow oil to
drain into collecting container. Inspect drain plug threads for stretching or other damage.
Replace drain plug and gasket if damaged.
7. Remove oil filter (1).

Engine Oil and Filter Change > Page 1571
8. Install oil pan drain plug (2) and tighten drain plug to 40 Nm (30 ft. lbs.).
9. Install new oil filter (1), tighten to 14 Nm (10 ft. lbs.).
10. Lower vehicle and fill crankcase with specified type and amount of engine oil. 11. Install oil fill
cap. 12. Start engine and inspect for leaks. 13. Stop engine and inspect oil level.
OIL FILTER SPECIFICATION
All engines are equipped with a high quality full-flow, disposable type oil filter. Replace oil filter with
a Mopar(R) or the equivalent.
USED ENGINE OIL DISPOSAL
Care should be exercised when disposing used engine oil after it has been drained from a vehicle
engine. Refer to the WARNING listed above.
Oil Filter: Service and Repair Removal
REMOVAL
CAUTION: When servicing the oil filter, avoid deforming the filter can by installing the
remove/install tool band strap against the can to base lock seam. The lock seam joining the can to
the base is reinforced by the base plate.
1. Using a suitable filter wrench, turn oil filter (1) counterclockwise to remove.
Oil Filter: Service and Repair Installation
INSTALLATION
1. Clean and check filter mounting surface. The surface must be smooth, flat and free of debris or
pieces of gasket. 2. Lubricate new oil filter gasket. 3. Screw oil filter (1) on until the gasket contacts
base. Tighten to 14 Nm (10 ft. lbs.).
Jeep Workshop Manuals > Maintenance > Hoses > Coolant Line/Hose > Component Information > Service and Repair >
Removal
Coolant Line/Hose: Service and Repair Removal
REMOVAL
The water pump inlet tube (2) connects the water pump to the coolant adapter. This tube is sealed
by an O-ring and held in place by fasteners to the water pump housing.
1. Drain cooling system. 2. Remove the coolant adapter and secondary thermostat. 3. Raise and
support vehicle. 4. Remove inlet tube mounting nuts (1). 5. Remove inlet tube (2).
Jeep Workshop Manuals > Maintenance > Hoses > Coolant Line/Hose > Component Information > Service and Repair >
Removal > Page 1579
Coolant Line/Hose: Service and Repair Installation
INSTALLATION
1. Inspect the O-ring for damage before installing the tube. Replace O-ring as necessary. 2.
Lubricate O-rings with soapy water. 3. Install new water inlet gasket between tube and water pump
housing (2). 4. Position water pump inlet tube (3) on water pump housing (2). Hand tighten nuts to
aide in tube alignment. 5. Install secondary thermostat and coolant adapter. 6. Tighten coolant tube
nuts (1) to 24 Nm (212 in. lbs.). 7. Fill cooling system.
Jeep Workshop Manuals > Maintenance > Hoses > Hose/Line HVAC > Component Information > Service Precautions >
Warning
Hose/Line HVAC: Service Precautions Warning
WARNING
WARNING: The A/C system contains refrigerant under high pressure. Repairs should only be
performed by qualified service personnel. Serious or fatal injury may result from improper service
procedures.
WARNING: Avoid breathing the refrigerant and refrigerant oil vapor or mist. Exposure may irritate
the eyes, nose, and/or throat. Wear eye protection when servicing the A/C refrigerant system.
Serious eye injury can result from direct contact with the refrigerant. If eye contact occurs, seek
medical attention immediately.
WARNING: Do not expose the refrigerant to open flame. Poisonous gas is created when refrigerant
is burned. An electronic leak detector is recommended. Serious or fatal injury may result from
improper service procedures.
WARNING: If accidental A/C system discharge occurs, ventilate the work area before resuming
service. Large amounts of refrigerant released in a closed work area will displace the oxygen and
cause suffocation and serious or fatal injury.
WARNING: The evaporation rate of R-134a refrigerant at average temperature and altitude is
extremely high. As a result, anything that comes in contact with the refrigerant will freeze. Always
protect the skin or delicate objects from direct contact with the refrigerant.
WARNING: The R-134a service equipment or the vehicle refrigerant system should not be
pressure tested or leak tested with compressed air. Some mixtures of air and R-134a have been
shown to be combustible at elevated pressures. These mixtures are potentially dangerous, and
may result in fire or explosion causing property damage and serious or fatal injury.
WARNING: The engine cooling system is designed to develop internal pressures up to 145
kilopascals (21 pounds per square inch). Do not remove or loosen the coolant pressure cap,
cylinder block drain plugs, radiator drain, radiator hoses, heater hoses, or hose clamps while the
engine cooling system is hot and under pressure. Allow the vehicle to cool for a minimum of 15
minutes before opening the cooling system for service. Failure to observe this warning can result in
serious burns from the heated engine coolant.
Jeep Workshop Manuals > Maintenance > Hoses > Hose/Line HVAC > Component Information > Service Precautions >
Warning > Page 1584
Hose/Line HVAC: Service Precautions Caution
CAUTION
CAUTION: Never add R-12 to a refrigerant system designed to use R-134a. Do not use R-12
equipment or parts on an R-134a A/C system. These refrigerants are not compatible and damage
to the A/C system will result.
CAUTION: Never use R-12 refrigerant oil in an A/C system designed to use R-134a refrigerant oil.
These refrigerant oils are not compatible and damage to the A/C system will result.
CAUTION: The use of A/C system sealers may result in damage to A/C refrigerant
recovery/evacuation/recharging equipment and/or A/C system. Many federal, state/provincial and
local regulations prohibit the recharge of A/C systems with known leaks. DaimlerChrysler
recommends the detection of A/C system leaks through the use of approved leak detectors and
fluorescent leak detection dyes. Vehicles found with A/C system sealers should be treated as
contaminated and replacement of the entire A/C refrigerant system is recommended. A/C systems
found to be contaminated with A/C system sealers, A/C stop-leak products or seal conditioners
voids the warranty for the A/C system.
CAUTION: Recover the refrigerant before opening any fitting or connection. Open the fittings with
caution, even after the system has been discharged. Never open or loosen a connection before
recovering the refrigerant.
CAUTION: The internal parts of the A/C system will remain stable as long as moisture-free
refrigerant and refrigerant oil is used. Abnormal amounts of dirt, moisture or air can upset the
chemical stability. This may cause operational troubles or even serious damage if present in more
than very small quantities. Before disconnecting a component, clean the outside of the fittings
thoroughly to prevent contamination from entering the refrigerant system. Keep service tools and
the work area clean. Do not open the refrigerant system or uncap a replacement component until
you are ready to service the system. Immediately after disconnecting a component from the
refrigerant system, seal the open fittings with a cap or plug. This will prevent contamination from
entering the A/C system.
CAUTION: Refrigerant oil will absorb moisture from the atmosphere if left uncapped. Do not open a
container of refrigerant oil until you are ready to use it. Replace the cap on the oil container
immediately after using. Store refrigerant oil only in a clean, airtight, and moisture-free container.
CAUTION: Do NOT run the engine with a vacuum pump in operation or with a vacuum present
within the A/C system. Failure to follow this caution will result in serious A/C compressor damage.
CAUTION: Do not overcharge the refrigerant system. Overcharging will cause excessive
compressor head pressure and can cause compressor noise and A/C system failure.
Jeep Workshop Manuals > Maintenance > Hoses > Hose/Line HVAC > Component Information > Description and Operation
> A/C Discharge Line
Hose/Line HVAC: Description and Operation A/C Discharge Line
DESCRIPTION
NOTE: Typical A/C discharge line shown.
The A/C discharge line (1) is the refrigerant line that carries refrigerant from the A/C compressor to
the A/C condenser and includes the high side service port (2) and a fitting (3) for the A/C pressure
transducer (4).
NOTE: Replacement of the refrigerant line O-ring seals and gaskets is required anytime a
refrigerant line is opened. Failure to replace the rubber O-ring seals and metal gaskets could result
in a refrigerant system leak.
The A/C discharge line has no serviceable parts except for the metal gaskets (5) and rubber O-ring
seals (6) and the high side service port valve core. The O-ring seals used on the connections are
made from a special type of rubber not affected by R-134a refrigerant. The O-ring seals and
gaskets must be replaced whenever the A/C discharge line is removed.
The A/C discharge line cannot be repaired and must be replaced if found to be leaking or
damaged.
> A/C Discharge Line > Page 1587
Hose/Line HVAC: Description and Operation A/C Liquid Line
DESCRIPTION
The A/C liquid line (1) is the refrigerant line that carries refrigerant from the A/C condenser to the
A/C evaporator. The A/C liquid line contains the low side service port (2) and the variable A/C
orifice tube. The A/C liquid line is only serviced as an assembly with the upper A/C suction line (3).
The A/C liquid/suction line assembly has no serviceable parts except for the metal gaskets (4),
rubber O-ring seals (5) and the low side service port valve core. The O-ring seals used on the
connections are made from a special type of rubber not affected by R-134a refrigerant. The O-ring
seals and gaskets must be replaced whenever the A/C liquid/suction line assembly is removed.
The A/C liquid/suction line assembly cannot be repaired and must be replaced if found to be
leaking or damaged, or if an internal failure of the A/C compressor has occurred.
Hose/Line HVAC: Description and Operation A/C Suction Line
DESCRIPTION
The A/C suction line is serviced in two sections. The upper section of the A/C suction line (1) is the
refrigerant line that carries refrigerant from the A/C evaporator to the A/C accumulator. The lower
section of the A/C suction line (2) carries refrigerant from the A/C accumulator to the A/C
compressor. The upper portion of the A/C suction line is only serviced as an assembly with the A/C
liquid line (5).
The lower A/C suction line and the A/C liquid/suction line assembly has no serviceable parts except
for the rubber O-ring seals (3), metal gaskets (4) and the low side service port valve core. The
O-ring seals used on the connections are made from a special type of rubber not affected by
R-134a refrigerant. The O-ring seals and gaskets must be replaced whenever the lower A/C
suction line and/or the A/C liquid/suction line assembly is removed.
The lower A/C suction line and the A/C liquid/suction line assembly cannot be repaired and must
be replaced if found to be leaking or damaged.
Hose/Line HVAC: Description and Operation Plumbing
Description
DESCRIPTION
The A/C refrigerant lines and hoses are used to carry the refrigerant between the various A/C
system components. The refrigerant lines and hoses for the R-134a A/C system consist of a
barrier-hose design with a nylon tube sandwiched between rubber layers. The nylon tube helps to
contain the R-134a refrigerant, which has a small molecular structure. The ends of the refrigerant
lines are made from lightweight aluminum and braze-less fittings.
Any kinks or sharp bends in the refrigerant lines and hoses will reduce the capacity of the entire
A/C system and can reduce the flow of refrigerant within the system.
Operation
OPERATION
High pressures are produced in the refrigerant system when the A/C compressor is operating.
Extreme care must be exercised to make sure that each of the refrigerant system connections is
pressure-tight and leak free. It is a good practice to inspect all flexible hose refrigerant lines at least
once a year to make sure they are in good condition and properly routed.
Depending on vehicle, model and market application, refrigerant lines are connected to each other
or other A/C system components with block-type or quick-connect type fittings. To ensure the
integrity of the refrigerant system, flat gaskets and O-rings are used to seal the refrigerant system
connections.
The refrigerant lines and hoses cannot be repaired and must be replaced if leaking or damaged.
Jeep Workshop Manuals > Maintenance > Hoses > Hose/Line HVAC > Component Information > Service and Repair > A/C
Discharge Line
Hose/Line HVAC: Service and Repair A/C Discharge Line
Removal
REMOVAL
WARNING: Review safety precautions and warnings before performing this procedure. Failure to
follow the warnings and cautions could result in possible personal injury or death.
NOTE: It is not necessary to completely remove the front fascia for A/C discharge line service.
2. Recover the refrigerant from the refrigerant system.
4. Remove the splash shield from the right side frame rail.
5. Remove the nut (1) that secures the A/C discharge line (2) to the A/C compressor (3).
6. Disconnect the A/C discharge line from the A/C compressor and remove and discard the O-ring
seal and gasket.
7. Install plugs in, or tape over the opened discharge line fitting and the compressor port.
8. Lower the vehicle.

Discharge Line > Page 1592
9. Remove the upper radiator closure panel and carefully pull the top of the fascia forward to gain
access to the A/C discharge line (3).
10. Reach down through the opening between the radiator and the front fascia and disconnect the
wire harness connector (1) from the A/C pressure
transducer (2).
11. Remove the nut (5) that secures the A/C discharge line to the right side of the A/C condenser
(4).
12. Disconnect the A/C discharge line from the A/C condenser and remove and discard the O-ring
seal and gasket.
13. Install plugs in, or tape over the discharge line fitting and the condenser port.
14. If necessary, remove the A/C pressure transducer from the A/C discharge line.
Installation
INSTALLATION
CAUTION: Be certain to adjust the refrigerant oil level when servicing the A/C refrigerant system.
Failure to properly adjust the refrigerant oil level will prevent the A/C system from operating as
designed and can cause serious A/C compressor damage.
NOTE: When replacing multiple A/C system components, refer to the Refrigerant Oil Capacities
chart to determine how much oil should be added to the refrigerant system.
1. If removed, install the A/C pressure transducer (2) onto the A/C discharge line (3). Tighten the
A/C pressure transducer securely.
2. Position the A/C discharge line into the engine compartment.
3. Remove the tape or plugs from the discharge line fitting and the condenser port.
4. Lubricate a new rubber O-ring seal with clean refrigerant oil and install it and a new gasket onto
the discharge line fitting. Use only the specified
O-ring as it is made of a special material for the R-134a system. Use only refrigerant oil of the type
recommended for the A/C compressor in the vehicle.
5. Reach down through the opening between the radiator and the front fascia and connect the A/C
discharge line to the A/C condenser (4).
6. Install the nut (5) that secures the A/C discharge line to the A/C condenser. Tighten the nut to 5
Nm (44 in. lbs.).
8. Install the upper radiator closure panel.

10. Remove the tape or plugs from the discharge line fitting and the compressor port.
12. Connect the A/C discharge line (2) to the A/C compressor (3).
13. Install the nut (1) that secures the A/C discharge line to the A/C compressor. Tighten the nut to
20 Nm (15 ft. lbs.).
14. Install the splash shield onto the right side frame rail.
17. Evacuate the refrigerant system.
18. Adjust the refrigerant oil level.
19. Charge the refrigerant system.

Hose/Line HVAC: Service and Repair A/C Liquid Line
Removal
REMOVAL
NOTE: The A/C liquid line is only serviced as an assembly with the upper A/C suction line.
NOTE: Illustration shown with front fascia removed for clarity.
4. Remove the A/C accumulator.

5. Reach up through the opening in the bottom of the front fascia located in the right front corner of
the vehicle and remove the nut (3) that secures
the A/C liquid line (1) to the A/C condenser (2).
6. Disconnect the A/C liquid line from the A/C condenser and remove and discard the O-ring seal
and gasket.
7. Install plugs in, or tape over the opened refrigerant line fittings and the condenser and
accumulator ports.
9. Remove the three nuts (1) that secure the heat shield (3) to the studs (2) located on the dash
panel in the engine compartment and remove the heat
shield.
NOTE: It is only necessary to position the engine coolant reservoir and the power steering fluid
reservoir out of the way. Draining of the coolant and brake fluid is not required when servicing the
washer bottle.
10. Remove the windshield washer reservoir.

11. Remove the nut (1) that secures the refrigerant line retaining bracket (2) to the right front strut
tower (5).
12. On RHD models, disengage the retainers that secure the power brake booster vacuum supply
hose to the dash panel and position the vacuum line
out of the way.
13. Remove the bolt (3) that secures the A/C liquid and suction line assembly (4) to the A/C
evaporator (6).
14. Disconnect the A/C liquid and suction line assembly from the A/C evaporator and remove and
discard the dual-plane seals.
15. Install plugs in, or tape over the opened refrigerant line fittings and the evaporator ports.
16. Remove the A/C liquid and suction line assembly from the engine compartment.
Installation
INSTALLATION
CAUTION: The A/C liquid line must be replaced if an internal failure of the A/C compressor has
occurred. Failure to replace the A/C liquid line can prevent the A/C system from operating as
1. Position the A/C liquid and suction line assembly (4) into the engine compartment.
2. Remove the tape or plugs from the refrigerant line fittings and the evaporator ports.
3. Lubricate the rubber O-rings on new dual-plane seals with clean refrigerant oil and install the
seals onto the liquid and suction line fittings. Use
only the specified seals as they are made of special materials compatible to the R-134a system.
Use only refrigerant oil of the type recommended for the A/C compressor in the vehicle.
4. Connect the A/C liquid and suction line assembly to the A/C evaporator (6).
5. Install the bolt (3) that secures the A/C liquid and suction line assembly to the A/C evaporator.
Tighten the bolt to 12 Nm (105 in. lbs.).
6. On RHD models, engage the retainers that secure the power brake booster vacuum supply hose
to the dash panel.
7. Install the nut (1) that secures the refrigerant line bracket (2) to the right front strut tower (5).
Tighten the nut to 4.5 Nm (40 in. lbs.).
8. Install the windshield washer reservoir, power steering reservoir and the engine coolant
reservoir.
9. Position the heat shield (3) onto the studs (2) located on the dash panel in the engine
compartment.
10. Install the three nuts (1) that secure the heat shield to the dash panel. Tighten the nuts to 1 Nm
(10 in. lbs.).
12. Remove the tape or plugs from the liquid line fitting and the condenser port.
the liquid line fitting. Use only the specified
14. Reach up through the opening in the bottom of the front fascia and connect the A/C liquid line
(1) to the A/C condenser (2) and install the
retaining nut (3). Tighten the nut to 5 Nm (44 in. lbs.).
15. Install the A/C accumulator.

20. Charge the A/C system.

Hose/Line HVAC: Service and Repair A/C Suction Line
Removal
REMOVAL
NOTE: The A/C suction line is serviced in two sections. The upper section of the A/C suction line is
the refrigerant line that carries refrigerant from the A/C evaporator to the A/C accumulator. The
lower section of the A/C suction line carries refrigerant from the A/C accumulator to the A/C
compressor.
Upper A/C Suction Line
NOTE: The upper portion of the A/C suction line is only serviced as an assembly with the A/C liquid
line.

and gasket.
accumulator ports.
shield.
washer bottle.

tower (5).
out of the way.
evaporator (6).
Lower A/C Suction Line

20. Remove the right front wheel.
21. Remove the three push-pin retainers (1) and three screws (2) that secure the front portion of
the right front wheelhouse splash shield (3) to body
(4) and position the front of the wheelhouse splash shield out of the way to gain access to the A/C
accumulator.
22. Remove the nut (2) that secures the lower A/C suction line (3) to the A/C accumulator (1).
23. Disconnect the lower A/C suction line from the A/C accumulator and remove and discard the
O-ring seal and gasket.
24. Install plugs in, or tape over the opened suction line fitting and the accumulator port.
25. Remove the nut (1) that secures the lower A/C suction line (2) to the A/C compressor (3).
26. Disconnect the lower A/C suction line from the A/C compressor and remove and discard the
27. Install plugs in, or tape over the opened suction line fitting and the compressor port.
28. Remove the lower A/C suction line from the engine compartment.
Installation
INSTALLATION
Failure to properly adjust the refrigerant
oil level will prevent the A/C system from operating as designed and can cause serious A/C
compressor damage.
to the dash panel.
reservoir.
compartment.
(10 in. lbs.).

19. Be certain to adjust the refrigerant oil level when servicing the A/C refrigerant system. Use only
refrigerant oil of the type recommended for the
A/C compressor in the vehicle.
21. Position the lower A/C suction line (2) into the engine compartment.
22. Remove the tape or plugs from the suction line fitting and the compressor port.
23. Lubricate a new rubber O-ring seal with clean refrigerant oil and install it and new gasket onto
the suction line fitting. Use only the specified
24. Connect the lower A/C suction line to the A/C compressor (3).
25. Install the nut (1) that secures the A/C suction line to the A/C compressor. Tighten the nut to 20
Nm (15 ft. lbs.).
26. Remove the tape or plugs from the suction line fitting and the accumulator port.
28. Connect the lower A/C suction line (3) to the A/C accumulator (1).
29. Install the nut (2) that secures the lower A/C suction line to the A/C accumulator. Tighten the
nut to 5 Nm (44 in. lbs.).
30. Reposition the front of the right front wheel house splash shield (3) to the body (4) and install
the three push-pin retainers (1) and the three screws
(2). Tighten the screws securely.
31. Install the right front wheel.


Jeep Workshop Manuals > Maintenance > Hoses > Power Steering Line/Hose > Component Information > Service and
Repair > Fluid Cooler
Power Steering Line/Hose: Service and Repair Fluid Cooler
Removal
REMOVAL
NOTE: Before proceeding, refer to STEERING WARNING.
1. Siphon as much fluid as possible from the power steering fluid reservoir. 2. Raise and support
the vehicle. 3. Remove the front fascia.
4. Remove the hose clamps (6) attaching the fluid return hose (7) to the power steering fluid cooler
line. Separate the return hose from the cooler line
(5).
5. Remove the two cooler mounting screws (4). 6. Remove the cooler tubes from the clips on the
side of the frame rail. 7. Remove the cooler lines (5) from the vehicle.
Installation
INSTALLATION
1. Install the cooler tubes in the clips on the side of the frame rail. 2. Install the fluid cooler
mounting screws (4) to the support. Tighten the screws to 8 Nm (71 in. lbs.). 3. Install the fluid
return hose (7) on the power steering fluid cooler lines (5). Install the hose clamp (6) on the hose
past the bead formed into the end
of the cooler tube and secure in place.
4. Install the front fascia. 5. Lower the vehicle.

Repair > Fluid Cooler > Page 1613
6. Fill and bleed the power steering system. 7. Check for leaks.
Power Steering Line/Hose: Service and Repair Hose-Pressure
Removal
GAS ENGINE
1. Siphon as much fluid as possible from the power steering fluid reservoir. 2. Remove the engine
appearance cover. 3. Remove the pressure Hose (3) at the pump pressure port (5). 4. Remove the
pressure hose routing bracket bolt (2) at the upper mount (8).
5. All except 2.4L Engine with All-Wheel-Drive - Remove the pressure hose routing clamp bolt (1)
at the exhaust manifold.
6. 2.4L Engine with All-Wheel-Drive - Remove the pressure hose routing clamp bolt (1) at the
exhaust manifold. 7. Raise and support the vehicle.
8. Remove the return hose (1) at the return tube (2).
9. Remove the return tube (1) at the steering gear (3).
10. Remove the pressure hose (2) at the steering gear (3).
11. Remove the fasteners (1) securing the power steering hose routing clamps (2) to the
crossmember. 12. Remove the power steering pressure hose from the vehicle.
Installation
GAS ENGINE
CAUTION: Power steering fluid hoses must remain away from the exhaust system, driveshafts,
vehicle components and any unfriendly surface that can possibly damage the hoses.
1. Using a lint free towel, wipe clean the open power steering hose end and the power steering
pump port. Replace any used O-rings with new.
Lubricate the O-ring with power steering fluid.
2. Install the power steering pressure hose into the engine compartment from below. 3. Install the
fasteners (1) securing the power steering hose routing clamps (2) to the crossmember. Use a NEW
push clip on the left and tighten the
screw on the right to 8 Nm (71 in. lbs.).

4. Install the pressure hose (2) at the gear (3). Tighten the tube nut to 32 Nm (24 ft. lbs.). 5. Install
the return tube (1) at the gear (3). Tighten the tube nut to 20 Nm (15 ft. lbs.).
6. Install the return hose (1) at the return tube (2). 7. Lower the vehicle.
8. Install the pressure hose (3) at the pump pressure port (5). Tighten the tube nut to 32 Nm (24 ft.
lbs.). 9. Install the pressure hose routing bracket bolt (2) to the upper mount (8).
10. All except 2.4L Engine with All-Wheel-Drive - Position the pressure hose routing clamp (2) at
the exhaust manifold and install the mounting bolt
(1). Tighten the bolt to 9 Nm (80 in. lbs.).
11. 2.4L Engine with All-Wheel-Drive - Position the pressure hose routing clamp (2) at the exhaust
manifold and install the mounting bolt (1). Tighten
the bolt to 9 Nm (80 in. lbs.).

12. Fill and bleed the power steering system. 13. Check for leaks. 14. Install the engine
appearance cover.
Power Steering Line/Hose: Service and Repair Return Hose
Removal
REMOVAL
1. Remove the engine appearance cover. 2. Remove the coolant recovery bottle. 3. Siphon as
much fluid as possible from the power steering fluid reservoir. 4. Remove the power steering fluid
reservoir. 5. Remove the windshield washer reservoir. 6. Remove the front fascia. 7. Raise and
support the vehicle.
9. Remove the return hose routing clamp screw (2) securing the return hose (7) to the frame rail.
10. Lower the vehicle. 11. Remove the return hose routing clamp screw (1) securing the return
hose (7) to the strut tower. 12. Remove the hose clamps (6) securing the return hose to the power
steering reservoir and cooler. Slide the hose off the end of the cooler tube.
13. Remove the return hose from the vehicle.
Installation
INSTALLATION
1. Install the power steering return hose (7) into the engine compartment. 2. Install the return hose
routing clamp screw (1) securing the return hose (7) to the strut tower. 3. Install the return hose
onto the cooler tubes (5) and install the hose clamps (6). 4. Raise and support the vehicle. 5. Install
the screw (2) securing the return hose to the frame rail. Tighten the screw to 19 Nm (14 ft. lbs.).
6. Install the return hose (1) at the return tube (2). 7. Lower the vehicle. 8. Install the front fascia. 9.
Install the windshield washer reservoir.
10. Install the power steering fluid reservoir. 11. Install the coolant recovery bottle. 12. Fill and
bleed the power steering system. 13. Check for leaks. 14. Install the engine appearance cover.
Power Steering Line/Hose: Service and Repair Hose-Supply
Removal
GAS ENGINE
1. Siphon as much fluid as possible from the power steering fluid reservoir.
2. Remove the clamp (2) securing the supply hose to the power steering pump (3) supply fitting,
then remove the hose from the supply fitting.
3. Remove the hose clamp securing the supply hose (4) to the power steering fluid reservoir (5).
Slide the hose off the end of the reservoir fitting and
remove from vehicle.
Installation
GAS ENGINE
1. Slide hose clamps (2) onto both ends of the power steering fluid supply hose (1) far enough to
clear the fittings on the reservoir and pump once the
hose is installed.
2. Place the pump end of the supply hose (1) onto the pump (3) supply fitting. Expand the hose
clamp (2) and slide it over the hose and pump supply
fitting. Secure the clamp once it is past the bead formed into the fluid supply fitting.
3. Expand the hose clamp (4) at the fluid reservoir (5) and slide it over the hose and fitting. Secure
the clamp once it is past the bead formed into the
fluid reservoir fitting.
4. Perform the POWER STEERING PUMP BLEED PROCEDURE. 5. Check for leaks at all hose
connections.
Jeep Workshop Manuals > Maintenance > Fluids > Brake Fluid > Component Information > Technical Service Bulletins >
Maintenance - Fluid Flushing Information
Brake Fluid: Technical Service Bulletins Maintenance - Fluid Flushing Information
NUMBER: 26-001-09
GROUP: Miscellaneous
DATE: September 24, 2009

30, 2007, WHICH SHOULD BE REMOVED FROM YOUR FILES. THIS IS A COMPLETE
REVISION AND NO ASTERISKS HAVE BEEN USED TO HIGHLIGHT REVISIONS.
SUBJECT: Fluid Flushing Requirements
MODELS:
2006 - 2009 (D1) Ram Truck (3500 Pick Up)
2010 (D2) Ram Truck (3500 Pick Up)
2007 - 2010 (DC) Ram Truck (3500 Chassis Cab)
2005 - 2009 (DH) Ram Truck (1500/2500 Pick Up)
2010 (DJ) Ram Truck (2500 Pick Up)
2005 - 2008 (DR) Ram Truck (1500/2500 Pick Up)
2009 - 2010 (DS) Ram Truck (1500)
2005 - 2009 (HB) Durango
2007 - 2009 (HG) Aspen
2009 - 2010 (JC) Journey
2005 - 2006 (JR) Sebring Sedan & Convertible/Stratus Sedan
2008 - 2010 (KK) Liberty
2007 - 2010 (KA) Nitro
2005 - 2007 (KJ) Liberty
2009 - 2010 (LC) Challenger
2005 - 2010 (LE) 300C/300C Touring (International Markets)
2005 - 2010 (LX) 300/Magnum/Charger
2005 - 2010 (ND) Dakota
2005 - 2006 (PL) Neon

2007 - 2010 (PM) Caliber

Maintenance - Fluid Flushing Information > Page 1629
2005 - 2007 (RG) Chrysler Voyager (International Markets)
2009 - 2010 (RT) Town & Country/Grand Caravan
2007 - 2010 (VB) Sprinter
2005 - 2010 (WH) Grand Cherokee (International Markets)
2006 - 2010 (XH) Commander (International Markets)
2005 - 2010 (ZB) Viper
2005 - 2007 (ZH) Crossfire
DISCUSSION:
Chrysler Group vehicle fluid systems do NOT require regular flushing. These systems include:
engine oil, transmission oil, axle lube, brake fluid, power steering fluid, and refrigerant. The only
exception to this requirement are published in the vehicle maintenance schedules, e.g. engine
coolant.
Exceptions to this recommendation include only those instances where a failure has occurred
and/or the system has become compromised, contaminated or overheated beyond the normal
operating range.
Chrysler Group does NOT recommend aftermarket chemicals to flush the engine, transmission,
brake or steering systems. Chemicals contained in these products can damage the system
elastomeric components, and contaminate the component fluid, leading to loss of
system/component durability and service life. When necessary, only the original approved system
fluid should be used to flush these components using teamPSE(R) approved equipment.
If the engine coolant contains a considerable amount of sediment, clean and flush with Mopar
Cooling System Flush, p/n 04856977, or equivalent. Follow with a thorough rinsing to remove all
deposits and chemicals. Refill with a minimum of a 50% mixture of the specified coolant and
distilled water.
Disclaimer:
Page 1630
Brake Fluid: Specifications
Brake Fluid Type
Mopar DOT 3, SAE J1703 should be used. If DOT 3, SAE J1703 brake fluid is not available, the
DOT 4 is acceptable. Use only recommended brake fluids or equivalent.
Page 1631
Brake Fluid: Testing and Inspection
BRAKE FLUID CONTAMINATION
Indications of fluid contamination are swollen or deteriorated rubber parts. Swelling indicates the
presence of petroleum in the brake fluid.
To test for contamination, put a small amount of drained brake fluid in clear glass jar. If the fluid
separates into layers, there is mineral oil or other fluid contamination of the brake fluid.
If the brake fluid is contaminated, drain and thoroughly flush the brake system. Replace all the
rubber parts or components containing rubber coming into contact with the brake fluid including:
the master cylinder and reservoir; proportioning valves (non-ABS); caliper seals; wheel cylinder
seals; ABS hydraulic control unit; and all hydraulic fluid hoses.
Page 1632
Brake Fluid: Service and Repair
BRAKE FLUID LEVEL CHECKING
NOTE: Brake fluid level should be checked a minimum of twice a year.
Master cylinder reservoirs (2) are marked, FULL and ADD, indicating the allowable brake fluid level
range in the master cylinder fluid reservoir.
CAUTION: Use only Mopar(R) Brake Fluid DOT 3 Motor Vehicle or equivalent from a tightly sealed
container. Do not use petroleum-based fluid because seal damage in the brake system will result.
NOTE: Although there is a range, the preferred level is FULL.
1. Remove the cap (1). 2. Adjust the brake fluid level to the FULL mark listed on the side of the
master cylinder fluid reservoir (2) as necessary. Do not overfill the system. 3. Install the cap (1).
Jeep Workshop Manuals > Maintenance > Fluids > Clutch Fluid > Component Information > Technical Service Bulletins >
Clutch Fluid: Technical Service Bulletins Maintenance - Fluid Flushing Information
NUMBER: 26-001-09

MODELS:
2009 - 2010 (DS) Ram Truck (1500)
2005 - 2009 (HB) Durango
2007 - 2009 (HG) Aspen
2009 - 2010 (JC) Journey
2008 - 2010 (KK) Liberty
2007 - 2010 (KA) Nitro
2005 - 2007 (KJ) Liberty
2005 - 2010 (ND) Dakota
2005 - 2006 (PL) Neon

2007 - 2010 (PM) Caliber

2005 - 2010 (ZB) Viper
DISCUSSION:
coolant.
operating range.
distilled water.
Disclaimer:
Page 1638
Clutch Fluid: Specifications
Clutch Fluid Type
Jeep Workshop Manuals > Maintenance > Fluids > Coolant > Component Information > Technical Service Bulletins >
Coolant: Technical Service Bulletins Maintenance - Fluid Flushing Information
NUMBER: 26-001-09

MODELS:
2009 - 2010 (DS) Ram Truck (1500)
2005 - 2009 (HB) Durango
2007 - 2009 (HG) Aspen
2009 - 2010 (JC) Journey
2008 - 2010 (KK) Liberty
2007 - 2010 (KA) Nitro
2005 - 2007 (KJ) Liberty
2005 - 2010 (ND) Dakota
2005 - 2006 (PL) Neon

2007 - 2010 (PM) Caliber

Jeep Workshop Manuals > Maintenance > Fluids > Coolant > Component Information > Technical Service Bulletins >
2005 - 2010 (ZB) Viper
DISCUSSION:
coolant.
operating range.
distilled water.
Disclaimer:
Jeep Workshop Manuals > Maintenance > Fluids > Coolant > Component Information > Specifications > Capacity
Specifications
Coolant: Capacity Specifications
Engine Coolant Capacity
Engine Coolant ....................................................................................................................................

....................................... 7.2 Quarts ( 6.8 Liters )
Note: Includes heater and coolant recovery bottle filled to MAX level.
Jeep Workshop Manuals > Maintenance > Fluids > Coolant > Component Information > Specifications > Capacity
Coolant: Fluid Type Specifications
Engine Coolant Type
Mopar Antifreeze/Coolant 5 Year/100,000 mile formula HOAT (Hybrid Organic Additive

Technology) or equivalent.
Jeep Workshop Manuals > Maintenance > Fluids > Coolant > Component Information > Description and Operation >
Coolant
Coolant: Description and Operation Coolant
ENGINE COOLANT
WARNING: Antifreeze is an ethylene glycol base coolant and is harmful if swallowed or inhaled. If
swallowed, drink two glasses of water and induce vomiting. If inhaled, move to fresh air area, seek
medical attention immediately. Do not store in open or unmarked containers. Wash skin and
clothing thoroughly after coming in contact with ethylene glycol. Keep out of reach of children.
Dispose of glycol base coolant properly, contact your dealer or government agency for location of
collection center in your area. Do not open a cooling system when the engine is at operating
temperature or hot under pressure, personal injury can result. Avoid radiator cooling fan when
engine compartment related service is performed, personal injury can result.
ETHYLENE-GLYCOL MIXTURES
CAUTION: Richer antifreeze mixtures cannot be measured with normal field equipment and can
cause problems associated with 100 percent ethylene-glycol.
The use of aluminum cylinder blocks, cylinder heads and water pumps requires special corrosion
protection. Only Mopar(R) Antifreeze/Coolant, 5 year/100,000 Mile Formula (ethylene-glycol base
coolant with corrosion inhibitors called HOAT, (Hybrid Additive Technology) is recommended. This
coolant offers the best engine cooling without corrosion when mixed with 50% distilled water to
obtain a freeze point of -37° C (-35° F).
The required ethylene-glycol (antifreeze) and water mixture depends upon the climate and vehicle
operating conditions. The antifreeze concentration must always be a minimum of 44 percent,
year-round in all climates. If percentage is lower than 44 percent, engine parts may be eroded by
cavitation, and cooling system components may be severely damaged by corrosion. Maximum
protection against freezing is provided with a 68% antifreeze concentration, which prevents
freezing down to -67.7° C (-90° F). A higher percentage will freeze at a warmer temperature. Also,
a higher percentage of antifreeze can cause the engine to overheat because the specific heat of
antifreeze is lower than that of water.
Use of 100 percent ethylene-glycol will cause formation of additive deposits in the system, as the
corrosion inhibitive additives in ethylene-glycol require the presence of water to dissolve. The
deposits act as insulation, causing temperatures to rise to as high as 149° C (300° F). This
temperature is hot enough to melt plastic and soften solder. The increased temperature can result
in engine detonation. In addition, 100 percent ethylene-glycol freezes at 22° C (-8° F ).
PROPYLENE-GLYCOL MIXTURES
It's overall effective temperature range is smaller than that of ethylene-glycol. The freeze point of
50/50 propylene-glycol and water is -32° C (-26° F). 5° C higher than ethylene-glycol's freeze point.
The boiling point (protection against summer boil-over) of propylene-glycol is 125° C (257 °F ) at
96.5 kPa (14 psi), compared to 128° C (263° F) for ethylene-glycol. Use of propylene-glycol can
result in boil-over or freeze-up on a cooling system designed for ethylene-glycol. Propylene glycol
also has poorer heat transfer characteristics than ethylene glycol. This can increase cylinder head
temperatures under certain conditions.
Propylene-glycol/ethylene-glycol Mixtures can cause the destabilization of various corrosion

inhibitors, causing damage to the various cooling system components. Also, once ethylene-glycol
and propylene-glycol based coolants are mixed in the vehicle, conventional methods of determining
freeze point will not be accurate. Both the refractive index and specific gravity differ between
ethylene glycol and propylene glycol.
Coolant > Page 1649
Coolant: Description and Operation Description
HOAT COOLANT
WARNING: Antifreeze is an ethylene-glycol base coolant and is harmful if swallowed or inhaled. If

swallowed, drink two glasses of water and induce vomiting. If inhaled, move to fresh air area. Seek
clothing thoroughly after coming in contact with ethylene-glycol. Keep out of reach of children.
CAUTION: Use of Propylene-Glycol based coolants is not recommended, as they provide less
freeze protection and less corrosion protection.
The cooling system is designed around the coolant. The coolant must accept heat from engine
metal, in the cylinder head area near the exhaust valves and engine block. Then coolant carries the
heat to the radiator where the tube/fin radiator can transfer the heat to the air.
The use of aluminum cylinder blocks, cylinder heads, and water pumps requires special corrosion
protection. Mopar(R) Antifreeze/Coolant, 5 Year/160.00 km, (100,000 Mile) Formula (MS-9769), or
the equivalent ethylene-glycol base coolant with organic corrosion inhibitors (called HOAT, for
Hybrid Organic Additive Technology) is recommended. This coolant offers the best engine cooling
without corrosion when mixed with 50% ethylene-glycol and 50% distilled water to obtain a freeze
point of -37° C (-35° F). If it loses color or becomes contaminated, drain, flush, and replace with
fresh properly mixed coolant solution.
CAUTION: Mopar(R) Antifreeze/Coolant, 5 Year/160.00 km (100,000) Mile Formula (MS-9769)

may not be mixed with any other type of antifreeze. Mixing of coolants other than specified
(non-HOAT or other HOAT), may result in engine damage that may not be covered under the new
vehicle warranty, and decreased corrosion protection.
COOLANT PERFORMANCE
The required ethylene-glycol (antifreeze) and water mixture depends upon climate and vehicle
operating conditions. The coolant performance of various mixtures follows:
Pure Water - Water can absorb more heat than a mixture of water and ethylene-glycol. This is for
purpose of heat transfer only. Water also freezes at a higher temperature and allows corrosion.
100 percent Ethylene-Glycol - The corrosion inhibiting additives in ethylene-glycol need the
presence of water to dissolve. Without water, additives form deposits in system. These act as
insulation causing temperature to rise to as high as 149° C (300° F). This temperature is hot
enough to melt plastic and soften solder. The increased temperature can result in engine
detonation. In addition, 100 percent ethylene-glycol freezes at -22° C (-8° F).
50/50 Ethylene-Glycol and Water - Is the recommended mixture, it provides protection against
freezing to -37° C (-34° F). The antifreeze concentration must always be a minimum of 44 percent,
year-round in all climates. If percentage is lower, engine parts may be eroded by cavitation.
Maximum protection against freezing is provided with a 68 percent antifreeze concentration, which
prevents freezing down to -67.7° C (-90° F). A higher percentage will freeze at a warmer
temperature. Also, a higher percentage of antifreeze can cause the engine to overheat because
specific heat of antifreeze is lower than that of water.
COOLANT SELECTION AND ADDITIVES

protection. Only Mopar(R) Antifreeze/Coolant, 5 Year/160.000 km (100,000 Mile) Formula (glycol
base coolant with corrosion inhibitors called HOAT, for Hybrid Organic Additive Technology) is
recommended. This coolant offers the best engine cooling without corrosion when mixed with 50%
distilled water to obtain a freeze point of -37° C (-35° F). If it loses color or becomes contaminated,
drain, flush, and replace with fresh properly mixed coolant solution.
CAUTION: Do not use coolant additives that are claimed to improve engine cooling.
Coolant > Page 1650
Coolant: Description and Operation Operation
OPERATION
Coolant flows through the engine block absorbing the heat from the engine, then flows to the
radiator where the cooling fins in the radiator transfers the heat from the coolant to the atmosphere.
During cold weather the ethylene-glycol or propylene-glycol coolant prevents water present in the
cooling system from freezing within temperatures indicated by mixture ratio of coolant to water.
Jeep Workshop Manuals > Maintenance > Fluids > Coolant > Component Information > Testing and Inspection > Coolant
Concentration Testing
Coolant: Testing and Inspection Coolant Concentration Testing
COOLANT CONCENTRATION TESTING
Coolant concentration should be checked when any additional coolant was added to system or
after a coolant drain, flush and refill. The coolant mixture offers optimum engine cooling and
protection against corrosion when mixed to a freeze point of -37° C (-34° F) to -46° C (-50° F). The
use of a hydrometer or a refractometer can be used to test coolant concentration.
A hydrometer will test the amount of glycol in a mixture by measuring the specific gravity of the
mixture. The higher the concentration of ethylene glycol, the larger the number of balls that will
float, and higher the freeze protection (up to a maximum of 60% by volume glycol).
A refractometer Tool 8286 will test the amount of glycol in a coolant mixture by measuring the
amount a beam of light bends as it passes through the fluid.
Some coolant manufactures use other types of glycols into their coolant formulations. Propylene
glycol is the most common new coolant. However, propylene glycol based coolants do not provide
the same freezing protection and corrosion protection and is not recommended.
CAUTION: Do not mix types of coolant corrosion protection will be severely reduced.
Jeep Workshop Manuals > Maintenance > Fluids > Coolant > Component Information > Testing and Inspection > Coolant
Concentration Testing > Page 1653
Coolant: Testing and Inspection Coolant Level Check
COOLANT LEVEL CHECK
NOTE: Do not remove pressure cap for routine coolant level inspections.
The coolant recovery/reserve system provides a quick visual method for determining the coolant
level without removing the pressure cap. Simply observe, with the engine idling and warmed up to
normal operating temperature, that the level of the coolant in the recovery/reserve bottle is between
the FULL HOT and ADD marks.
Jeep Workshop Manuals > Maintenance > Fluids > Differential Fluid - A/T > Component Information > Technical Service
Bulletins > Maintenance - Fluid Flushing Information
Differential Fluid - A/T: Technical Service Bulletins Maintenance - Fluid Flushing Information
NUMBER: 26-001-09

MODELS:
2009 - 2010 (DS) Ram Truck (1500)
2005 - 2009 (HB) Durango
2007 - 2009 (HG) Aspen
2009 - 2010 (JC) Journey
2008 - 2010 (KK) Liberty
2007 - 2010 (KA) Nitro
2005 - 2007 (KJ) Liberty
2005 - 2010 (ND) Dakota
2005 - 2006 (PL) Neon

2007 - 2010 (PM) Caliber

Jeep Workshop Manuals > Maintenance > Fluids > Differential Fluid - A/T > Component Information > Technical Service
Bulletins > Maintenance - Fluid Flushing Information > Page 1658
2005 - 2010 (ZB) Viper
DISCUSSION:
coolant.
operating range.
distilled water.
Disclaimer:
Jeep Workshop Manuals > Maintenance > Fluids > Differential Fluid - CVT > Component Information > Technical Service
Differential Fluid - CVT: Technical Service Bulletins Maintenance - Fluid Flushing Information
NUMBER: 26-001-09

MODELS:
2009 - 2010 (DS) Ram Truck (1500)
2005 - 2009 (HB) Durango
2007 - 2009 (HG) Aspen
2009 - 2010 (JC) Journey
2008 - 2010 (KK) Liberty
2007 - 2010 (KA) Nitro
2005 - 2007 (KJ) Liberty
2005 - 2010 (ND) Dakota
2005 - 2006 (PL) Neon

2007 - 2010 (PM) Caliber

Jeep Workshop Manuals > Maintenance > Fluids > Differential Fluid - CVT > Component Information > Technical Service
2005 - 2010 (ZB) Viper
DISCUSSION:
coolant.
operating range.
distilled water.
Disclaimer:
Jeep Workshop Manuals > Maintenance > Fluids > Differential Fluid - M/T > Component Information > Technical Service
Differential Fluid - M/T: Technical Service Bulletins Maintenance - Fluid Flushing Information
NUMBER: 26-001-09

MODELS:
2009 - 2010 (DS) Ram Truck (1500)
2005 - 2009 (HB) Durango
2007 - 2009 (HG) Aspen
2009 - 2010 (JC) Journey
2008 - 2010 (KK) Liberty
2007 - 2010 (KA) Nitro
2005 - 2007 (KJ) Liberty
2005 - 2010 (ND) Dakota
2005 - 2006 (PL) Neon

2007 - 2010 (PM) Caliber

Jeep Workshop Manuals > Maintenance > Fluids > Differential Fluid - M/T > Component Information > Technical Service
2005 - 2010 (ZB) Viper
DISCUSSION:
coolant.
operating range.
distilled water.
Disclaimer:
Jeep Workshop Manuals > Maintenance > Fluids > Differential Fluid - Transfer Case > Component Information > Technical
Service Bulletins > Maintenance - Fluid Flushing Information
Differential Fluid - Transfer Case: Technical Service Bulletins Maintenance - Fluid Flushing
Information
NUMBER: 26-001-09

MODELS:
2009 - 2010 (DS) Ram Truck (1500)
2005 - 2009 (HB) Durango
2007 - 2009 (HG) Aspen
2009 - 2010 (JC) Journey
2008 - 2010 (KK) Liberty
2007 - 2010 (KA) Nitro
2005 - 2007 (KJ) Liberty
2005 - 2010 (ND) Dakota

2005 - 2006 (PL) Neon
2007 - 2010 (PM) Caliber

Jeep Workshop Manuals > Maintenance > Fluids > Differential Fluid - Transfer Case > Component Information > Technical
Service Bulletins > Maintenance - Fluid Flushing Information > Page 1673
2005 - 2010 (ZB) Viper
DISCUSSION:
coolant.
operating range.
distilled water.
Disclaimer:
Jeep Workshop Manuals > Maintenance > Fluids > Fluid - A/T > Component Information > Technical Service Bulletins >
Fluid - A/T: Technical Service Bulletins Maintenance - Fluid Flushing Information
NUMBER: 26-001-09

MODELS:
2009 - 2010 (DS) Ram Truck (1500)
2005 - 2009 (HB) Durango
2007 - 2009 (HG) Aspen
2009 - 2010 (JC) Journey
2008 - 2010 (KK) Liberty
2007 - 2010 (KA) Nitro
2005 - 2007 (KJ) Liberty
2005 - 2010 (ND) Dakota
2005 - 2006 (PL) Neon

2007 - 2010 (PM) Caliber

Jeep Workshop Manuals > Maintenance > Fluids > Fluid - A/T > Component Information > Technical Service Bulletins >
2005 - 2010 (ZB) Viper
DISCUSSION:
coolant.
operating range.
distilled water.
Disclaimer:
Jeep Workshop Manuals > Maintenance > Fluids > Fluid - CVT > Component Information > Technical Service Bulletins >
Fluid - CVT: Technical Service Bulletins Maintenance - Fluid Flushing Information
NUMBER: 26-001-09

MODELS:
2009 - 2010 (DS) Ram Truck (1500)
2005 - 2009 (HB) Durango
2007 - 2009 (HG) Aspen
2009 - 2010 (JC) Journey
2008 - 2010 (KK) Liberty
2007 - 2010 (KA) Nitro
2005 - 2007 (KJ) Liberty
2005 - 2010 (ND) Dakota
2005 - 2006 (PL) Neon

2007 - 2010 (PM) Caliber

Jeep Workshop Manuals > Maintenance > Fluids > Fluid - CVT > Component Information > Technical Service Bulletins >
2005 - 2010 (ZB) Viper
DISCUSSION:
coolant.
operating range.
distilled water.
Disclaimer:
Jeep Workshop Manuals > Maintenance > Fluids > Fluid - CVT > Component Information > Specifications > Capacity
Specifications
Fluid - CVT: Capacity Specifications
CVT Transmission Service Fill ............................................................................................................

.............................................................................. 14.8 pints (7.0 liters) Overhaul Fill ........................
.............................................................................................................................................................
17.1 pints (8.1 liters)*
*Note: Dry fill capacity. Depending on type and size of internal cooler, length and inside diameter of
cooler lines, or use of an auxiliary cooler, these figures may vary.
Jeep Workshop Manuals > Maintenance > Fluids > Fluid - CVT > Component Information > Specifications > Capacity
Fluid - CVT: Fluid Type Specifications
Automatic Transmission Fluid Type Transmission Fluid .....................................................................

................................................................................................................ Mopar CVTF + 4
Jeep Workshop Manuals > Maintenance > Fluids > Fluid - CVT > Component Information > Testing and Inspection >
Causes Of Burnt Fluid
Fluid - CVT: Testing and Inspection Causes Of Burnt Fluid
CAUSES OF BURNT FLUID
Burnt, discolored fluid is a result of overheating which has three primary causes.
- Internal clutch slippage, usually caused by low line pressure, inadequate clutch apply pressure, or
clutch seal failure.
- A result of restricted fluid flow through the main and/or auxiliary cooler. This condition is usually
the result of a faulty or damaged oil cooler, or severe restrictions in the coolers and lines caused by
debris or kinked lines.
- Heavy duty operation with a vehicle not properly equipped for this type of operation. Trailer towing
or similar high load operation will overheat the transmission fluid if the vehicle is improperly
equipped. Such vehicles should have an auxiliary transmission fluid cooler, a heavy duty cooling
system, and the engine/axle ratio combination needed to handle heavy loads.
Causes Of Burnt Fluid > Page 1689
Fluid - CVT: Testing and Inspection Effects Of Incorrect Fluid Level
EFFECTS OF INCORRECT FLUID LEVEL
A low fluid level allows the pump to take in air along with the fluid. Air in the fluid will cause fluid
pressures to be low and develop slower than normal. If the transmission is overfilled, the gears
churn the fluid into foam. This aerates the fluid and causing the same conditions occurring with a
low level. In either case, air bubbles cause fluid overheating, oxidation, and varnish buildup which
interferes with valve and clutch operation. Foaming also causes fluid expansion which can result in
fluid overflow from the transmission vent or fill tube. Fluid overflow can easily be mistaken for a
leak if inspection is not careful.
Causes Of Burnt Fluid > Page 1690
Fluid - CVT: Testing and Inspection Fluid Contamination
FLUID CONTAMINATION
Transmission fluid contamination is generally a result of:
- adding incorrect fluid
- failure to clean dipstick and fill tube when checking level
- engine coolant entering the fluid
- internal failure that generates debris
- overheat that generates sludge (fluid breakdown)
- failure to replace contaminated converter after repair
The use of non-recommended fluids can result in transmission failure. The usual results are erratic
shifts, slippage, abnormal wear and eventual failure due to fluid breakdown and sludge formation.
Avoid this condition by using recommended fluids only.
The dipstick cap and fill tube should be wiped clean before checking fluid level. Dirt, grease and
other foreign material on the cap and tube could fall into the tube if not removed beforehand. Take
the time to wipe the cap and tube clean before withdrawing the dipstick.
Engine coolant in the transmission fluid is generally caused by a cooler malfunction. The only
remedy is to replace the radiator as the cooler in the radiator is not a serviceable part. If coolant
has circulated through the transmission, an overhaul is necessary.
The torque converter should be replaced whenever a failure generates sludge and debris. This is
necessary because normal converter flushing procedures will not remove all contaminants.
Jeep Workshop Manuals > Maintenance > Fluids > Fluid - CVT > Component Information > Service and Repair > Check Oil
Level
Fluid - CVT: Service and Repair Check Oil Level
CHECK OIL LEVEL
1. Verify that the vehicle is parked on a level surface. 2. Remove the dipstick tube cap.
WARNING: There is a risk of accident from vehicle starting off by itself when engine is running.
There is a risk of injury from contusions and burns if you insert your hands into the engine when it
is started or when it is running. Secure vehicle to prevent it from moving off by itself. Wear properly
fastened and close-fitting work clothes. Do not touch hot or rotating parts.
3. Actuate the service brake. Start engine and let it run at idle speed in selector lever position "P".
4. Shift through the transmission modes several times with the vehicle stationary and the engine
idling. 5. Warm up the transmission, wait at least 2 minutes and check the oil level with the engine
running. Push the Oil Dipstick 9336 into transmission
fill tube until the dipstick tip contacts the oil pan and pull out again, read off oil level, repeat if
necessary.
NOTE: The dipstick will protrude from the fill tube when installed.
CVT TRANSMISSION FILL GRAPH
6. Check transmission oil temperature using the appropriate scan tool. 7. The transmission Oil
Dipstick 9336 has indicator marks every 10 mm. Determine the height of the oil level on the dipstick
and using the height,
the transmission temperature, and the Transmission Fluid Graph, determine if the transmission oil
level is correct.
8. Add or remove oil as necessary and recheck the oil level. 9. Once the oil level is correct, install
the dipstick tube cap.
Level > Page 1693
Fluid - CVT: Service and Repair Fluid And Strainer Service
FLUID AND STRAINER SERVICE
1. Remove the bolts holding the oil pan (1) to the transaxle case. 2. Remove the oil pan from the
transaxle case.
3. Remove the oil pan gasket (1) from the transaxle case.
Level > Page 1694
4. Remove the bolts holding the oil strainer (1) to the valve body. 5. Remove the oil strainer. 6.
Remove and discard the oil strainer O-ring.
7. Install the new O-ring (1) onto the new oil strainer.
Level > Page 1695
8. Install the new oil strainer (1) onto the control valve assembly. Install and tighten the mounting
bolts to 8 Nm (70 in. lbs.).
CAUTION: Do not re-use the oil pan gasket. Remove any moisture, oil, and used gasket material
from the surface where the new gasket is to be installed. When installing the oil pan gasket, align
the dowel pin with the dowel pin hole in the oil pan gasket.
9. Install the oil pan gasket (1) onto the transaxle case.
Level > Page 1696
CAUTION: When installing the oil pan, align the dowel pin of the transaxle case with the dowel pin
hole of the oil pan.
10. Install the oil pan on the transaxle case (1). Install and tighten the mounting bolts to 8 Nm (70
in.lbs.).
NOTE: Only transmission fluid of the type labeled Mopar(R) CVTF+4 (Automatic Transmission
Fluid) should be used in this transaxle.
11. Check the oil level.

Level > Page 1697
Fluid - CVT: Service and Repair Transmission Cooler Filter
Removal
REMOVAL
transmission.
Installation
INSTALLATION
Level > Page 1698
Level > Page 1699

Level > Page 1700
Fluid - CVT: Service and Repair Transmission Fill
TRANSMISSION FILL
To avoid overfilling transmission after a fluid change or overhaul, perform the following procedure:
1. Verify that the vehicle is parked on a level surface. 2. Remove the dipstick tube cap. 3. Add
following initial quantity of MOPAR(R) CVTF+4, Automatic Transmission Fluid, to the transmission:
a. If only fluid and filter were changed, add 7.0 L (14.8 pts.) of transmission fluid to transmission. b.
If the transmission was completely overhauled or the torque converter was replaced or drained,
add 8.1 L (17.1 pts.) of transmission fluid to
transmission.
4. Check the transmission fluid and adjust as required.

Jeep Workshop Manuals > Maintenance > Fluids > Fluid - M/T > Component Information > Technical Service Bulletins >
Fluid - M/T: Technical Service Bulletins Maintenance - Fluid Flushing Information
NUMBER: 26-001-09

MODELS:
2009 - 2010 (DS) Ram Truck (1500)
2005 - 2009 (HB) Durango
2007 - 2009 (HG) Aspen
2009 - 2010 (JC) Journey
2008 - 2010 (KK) Liberty
2007 - 2010 (KA) Nitro
2005 - 2007 (KJ) Liberty
2005 - 2010 (ND) Dakota
2005 - 2006 (PL) Neon

2007 - 2010 (PM) Caliber

Jeep Workshop Manuals > Maintenance > Fluids > Fluid - M/T > Component Information > Technical Service Bulletins >
2005 - 2010 (ZB) Viper
DISCUSSION:
coolant.
operating range.
distilled water.
Disclaimer:
Jeep Workshop Manuals > Maintenance > Fluids > Fluid - M/T > Component Information > Specifications > Capacity
Specifications
Fluid - M/T: Capacity Specifications
Manual Transmission Fluid Capacity
NV T355 ..............................................................................................................................................
.......................................... 2.4 - 2.7 L ( 2.5 - 2.8 Qt )
BG6 .....................................................................................................................................................
........................................................... 2.0 L ( 2.1 Qt )
Jeep Workshop Manuals > Maintenance > Fluids > Fluid - M/T > Component Information > Specifications > Capacity
Fluid - M/T: Fluid Type Specifications
Manual Transmission Fluid Type Transmission Fluid .........................................................................

................................................................................................ Mopar ATF + 4 MS9602
Jeep Workshop Manuals > Maintenance > Fluids > Fluid - M/T > Component Information > Service and Repair > BG6
Manual Transaxle
Fluid - M/T: Service and Repair BG6 Manual Transaxle
Fluid Level Checking
FLUID LEVEL CHECKING
The fluid required for this transaxle is Mopar(R) ATF+4 (Automatic Transmission Fluid). Use of
improper or substitute fluids can cause shift problems and/or transaxle failure.
1. Insure the vehicle is level, remove the fill plug and add fluid until the fluid just starts to trickle out.
Fluid Drain And Fill
FLUID DRAIN AND FILL
NOTE: The fluid required for this transaxle is Mopar(R) ATF+4 (Automatic Transmission Fluid).
Use of improper or substitute fluids can cause shift problems and/or transaxle failure.
1. Raise vehicle on hoist. 2. Obtain suitable fluid collection container and place under transaxle. 3.
Remove transaxle drain plug (2). Allow fluid to drain into container until empty. 4. Install the drain
plug (1) with a new gasket and tighten to 39 Nm (29 ft. lbs.). 5. Remove transaxle fill plug (1). 6.
Add the appropriate amount of transaxle fluid to the transaxle.
Jeep Workshop Manuals > Maintenance > Fluids > Fluid - M/T > Component Information > Service and Repair > BG6
Manual Transaxle > Page 1711
Fluid - M/T: Service and Repair T355 Manual Transaxle
STANDARD PROCEDURE - FLUID DRAIN AND FILL
NOTE: All T355 Manual Transaxles require the use of ATF+4 (Automatic Transmission Fluid).
The transaxle fill plug (1) is located on the left side of the transaxle differential area. The fluid level
should be within 3/16 inch from the bottom of the transaxle fill hole (vehicle must be level when
checking).
The transaxle drain plug (2) is located on the lower right side of the transaxle differential housing.
Tighten drain plug to 14 Nm (120 in. lbs.).
Jeep Workshop Manuals > Maintenance > Fluids > Fluid - Differential > Component Information > Technical Service
Fluid - Differential: Technical Service Bulletins Maintenance - Fluid Flushing Information
NUMBER: 26-001-09

MODELS:
2009 - 2010 (DS) Ram Truck (1500)
2005 - 2009 (HB) Durango
2007 - 2009 (HG) Aspen
2009 - 2010 (JC) Journey
2008 - 2010 (KK) Liberty
2007 - 2010 (KA) Nitro
2005 - 2007 (KJ) Liberty
2005 - 2010 (ND) Dakota
2005 - 2006 (PL) Neon

2007 - 2010 (PM) Caliber

Jeep Workshop Manuals > Maintenance > Fluids > Fluid - Differential > Component Information > Technical Service
2005 - 2010 (ZB) Viper
DISCUSSION:
coolant.
operating range.
distilled water.
Disclaimer:
Jeep Workshop Manuals > Maintenance > Fluids > Fluid - Differential > Component Information > Specifications > Capacity
Specifications
Fluid - Differential: Capacity Specifications
Rear Drive Assembly ( RDA ) Fluid Capacity Rear Differential ...........................................................

......................................................................................................................... 500 ml ( 1 - 1.1 pts )
Jeep Workshop Manuals > Maintenance > Fluids > Fluid - Differential > Component Information > Specifications > Capacity
Fluid - Differential: Fluid Type Specifications
Rear Drive Assembly ( RDA ) Fluid Type Mopar Gear & Axle Lubricant SAE 80W-90 API GL 5 or
equivalent non-synthetic product.
Jeep Workshop Manuals > Maintenance > Fluids > Fluid - Differential > Component Information > Specifications > Page
1720
Fluid - Differential: Service and Repair
STANDARD PROCEDURE - DRAIN AND FILL
1. Remove fill plug (1) and drain plug (2). Drain fluid. 2. Install drain plug (2) and tighten to 32 Nm
(24 ft.lb.). 3. Fill with MOPAR(R) MS9020 SAE 80W90 Gear Lube to bottom of fill plug. 4. Install fill
plug (1) and tighten to 32 Nm (24 ft.lb.).
Jeep Workshop Manuals > Maintenance > Fluids > Fluid - Transfer Case > Component Information > Technical Service
Fluid - Transfer Case: Technical Service Bulletins Maintenance - Fluid Flushing Information
NUMBER: 26-001-09

MODELS:
2009 - 2010 (DS) Ram Truck (1500)
2005 - 2009 (HB) Durango
2007 - 2009 (HG) Aspen
2009 - 2010 (JC) Journey
2008 - 2010 (KK) Liberty
2007 - 2010 (KA) Nitro
2005 - 2007 (KJ) Liberty
2005 - 2010 (ND) Dakota
2005 - 2006 (PL) Neon

2007 - 2010 (PM) Caliber

Jeep Workshop Manuals > Maintenance > Fluids > Fluid - Transfer Case > Component Information > Technical Service
2005 - 2010 (ZB) Viper
DISCUSSION:
coolant.
operating range.
distilled water.
Disclaimer:
Jeep Workshop Manuals > Maintenance > Fluids > Fluid - Transfer Case > Component Information > Specifications >
Capacity Specifications
Fluid - Transfer Case: Capacity Specifications
Power Transfer Unit ( PTU ) Fluid Capacity Transfer Case ................................................................

............................................................................................................................... 540 ml ( 1.1 Pt )
Jeep Workshop Manuals > Maintenance > Fluids > Fluid - Transfer Case > Component Information > Specifications >
Capacity Specifications > Page 1728
Fluid - Transfer Case: Fluid Type Specifications
Power Transfer Unit ( PTU ) Fluid Type Mopar Gear & Axle Lubricant SAE 80W-90 API GL 5 or
Jeep Workshop Manuals > Maintenance > Fluids > Engine Oil > Component Information > Technical Service Bulletins >
Engine Oil: Technical Service Bulletins Maintenance - Fluid Flushing Information
NUMBER: 26-001-09

MODELS:
2009 - 2010 (DS) Ram Truck (1500)
2005 - 2009 (HB) Durango
2007 - 2009 (HG) Aspen
2009 - 2010 (JC) Journey
2008 - 2010 (KK) Liberty
2007 - 2010 (KA) Nitro
2005 - 2007 (KJ) Liberty
2005 - 2010 (ND) Dakota
2005 - 2006 (PL) Neon

2007 - 2010 (PM) Caliber

Jeep Workshop Manuals > Maintenance > Fluids > Engine Oil > Component Information > Technical Service Bulletins >
2005 - 2010 (ZB) Viper
DISCUSSION:
coolant.
operating range.
distilled water.
Disclaimer:
Jeep Workshop Manuals > Maintenance > Fluids > Engine Oil > Component Information > Specifications > Capacity
Specifications
Engine Oil: Capacity Specifications
Engine Oil ............................................................................................................................................

.................................................... 4.26Liters (4.5 Qt)
Jeep Workshop Manuals > Maintenance > Fluids > Engine Oil > Component Information > Specifications > Capacity
Engine Oil: Fluid Type Specifications
Engine Oil ............................................................................................................................................

........................................ API SAE Certified 5W-20
Jeep Workshop Manuals > Maintenance > Fluids > Engine Oil > Component Information > Specifications > Page 1737
Engine Oil: Testing and Inspection
ENGINE OIL LEVEL CHECK
NOTE: The engine must be HOT when checking oil level.
The best time to check engine oil level is after the engine is at operating temperature. Allow the
engine to be shut off for at least 5 minutes before checking oil level.
Checking the oil while the vehicle is on level ground will improve the accuracy of the oil level
reading. Remove dipstick (1), and observe oil level. Add oil only when the level is at or below the
SAFE mark. If the oil level is in the safe (2) range, do not add oil.
CAUTION: Do not operate engine if the oil level is above the MAX mark on the dipstick. Excessive
oil volume can cause oil aeration which can lead to engine failure due to loss of oil pressure or
increase in oil temperature.
Engine Oil: Service and Repair


Jeep Workshop Manuals > Maintenance > Fluids > Power Steering Fluid > Component Information > Technical Service
Power Steering Fluid: Technical Service Bulletins Maintenance - Fluid Flushing Information
NUMBER: 26-001-09

MODELS:
2009 - 2010 (DS) Ram Truck (1500)
2005 - 2009 (HB) Durango
2007 - 2009 (HG) Aspen
2009 - 2010 (JC) Journey
2008 - 2010 (KK) Liberty
2007 - 2010 (KA) Nitro
2005 - 2007 (KJ) Liberty
2005 - 2010 (ND) Dakota
2005 - 2006 (PL) Neon

2007 - 2010 (PM) Caliber

2005 - 2010 (ZB) Viper
DISCUSSION:
coolant.
operating range.
distilled water.
Disclaimer:
Bulletins > Page 1745
Power Steering Fluid: Specifications
Power Steering Fluid Type
Mopar Power Steering Fluid +4 or Mopar ATF+4 Automatic Transmission Fluid.

Power Steering Fluid: Description and Operation
DESCRIPTION
The recommended fluid for the power steering system is Mopar(R) Power Steering fluid + 4 or
Mopar(R) ATF+4 Automatic Transmission Fluid. Both fluids have the same material standard
specifications (MS-9602).
Mopar(R) ATF+4 (and Mopar(R) Power Steering fluid + 4), when new, is red in color. ATF+4 is
dyed red so it can be identified from other fluids used in the vehicle such as engine oil or
antifreeze. The red color is not permanent and is not an indicator of fluid condition. As the vehicle is
driven, ATF+4 will begin to look darker in color and may eventually become brown. THIS IS
NORMAL. ATF+4 also has a unique odor that may change with age. Consequently, odor and color
cannot be used to indicate the fluid condition or the need for a fluid change.
Power Steering Fluid: Testing and Inspection
POWER STEERING FLUID LEVEL CHECKING
WARNING: Fluid level should be checked with the engine OFF to prevent personal injury from
moving parts and to assure an accurate fluid level reading.
CAUTION: Mopar(R) Power Steering Fluid + 4 or Mopar(R) ATF+4 Automatic Transmission Fluid is
to be used in the power steering system. Both fluids have the same material standard
specifications (MS-9602). No other power steering or automatic transmission fluid is to be used in
the system. Damage may result to the power steering pump and system if another fluid is used. Do
not overfill the system.
NOTE: Although not required at specific intervals, the fluid level may be checked periodically.
Check the fluid level anytime there is a system noise or fluid leak suspected.
The power steering fluid level can be viewed through the side of the power steering fluid reservoir.
Compare the fluid level to the markings on the side of the reservoir. When the fluid is at normal
ambient temperature, approximately 21° C to 27° C (70° F to 80° F), the fluid level should read
between the MAX. and MIN. markings. When the fluid is hot, fluid level is allowed to read up to the
MAX. line.
Power Steering Fluid: Service and Repair
POWER STEERING SYSTEM BLEEDING
WARNING: The fluid level should be checked with engine off to prevent injury from moving
components.
to be used in the power steering system. Both Fluids have the same material standard
CAUTION: If the air is not purged from the power steering system correctly, pump failure could
result.
NOTE: Be sure the vacuum tool used in the following procedure is clean and free of any fluids.
1. Check the fluid level. As measured on the side of the reservoir, the level should indicate between
MAX and MIN when the fluid is at normal
ambient temperature. Adjust the fluid level as necessary.

2. Tightly insert Power Steering Cap Adapter (4), Special Tool 9688, into the mouth of the reservoir
(3).
CAUTION: Failure to use a vacuum pump reservoir (1) may allow power steering fluid to be sucked
into the hand vacuum pump.
3. Attach Hand Vacuum Pump (2), Special Tool C-4207 or equivalent, with reservoir (1) attached,
to the Power Steering Cap Adapter (4).
CAUTION: Do not run the engine while vacuum is applied to the power steering system. Damage
to the power steering pump can occur.
NOTE: When performing the following step make sure the vacuum level is maintained during the
entire time period.
4. Using Hand Vacuum Pump (2), apply 68-85 kPa (20-25 in. Hg) of vacuum to the system for a
minimum of three minutes. 5. Slowly release the vacuum and remove the special tools. 6. Adjust
the fluid level as necessary. Refer to STEP 1. 7. Repeat STEP 1 through STEP 6 until the fluid no
longer drops when vacuum is applied. 8. Start the engine and cycle the steering wheel lock-to-lock
three times.
NOTE: Do not hold the steering wheel at the stops.
9. Stop the engine and check for leaks at all connections.
10. Check for any signs of air in the reservoir and check the fluid level. If air is present, repeat the
procedure as necessary.
Jeep Workshop Manuals > Maintenance > Fluids > Refrigerant > Component Information > Specifications
Refrigerant: Specifications
REFRIGERANT CHARGE LEVEL

Jeep Workshop Manuals > Maintenance > Fluids > Refrigerant > Component Information > Description and Operation >
Description
Refrigerant: Description and Operation Description
DESCRIPTION
The refrigerant used in this air conditioning system is a HydroFluoroCarbon (HFC), type R-134a.
Unlike R-12, which is a ChloroFluoroCarbon (CFC), R-134a refrigerant does not contain
ozone-depleting chlorine. R-134a refrigerant is a non-toxic, non-flammable, clear, and colorless
liquefied gas.
Even though R-134a does not contain chlorine, it must be reclaimed and recycled just like
CFC-type refrigerants. This is because R-134a is a greenhouse gas and can contribute to global
warming.
Refrigerant: Description and Operation Operation
OPERATION
R-134a refrigerant is not compatible with R-12 refrigerant in an A/C system. Even a small amount
of R-12 refrigerant added to an R-134a refrigerant system will cause A/C compressor failure,
refrigerant oil sludge or poor A/C system performance. In addition, the polyalkylene glycol (PAG)
synthetic refrigerant oils used in an R-134a refrigerant system are not compatible with the
mineral-based refrigerant oils used in an R-12 refrigerant system.
R-134a refrigerant system service ports, service tool couplers and refrigerant dispensing bottles
have all been designed with unique fittings to ensure that an R-134a refrigerant system is not
accidentally contaminated with the wrong refrigerant (R-12). There are also labels posted in the
engine compartment of the vehicle and on the A/C compressor to identify that the A/C system is
equipped with R-134a refrigerant.
Page 1755
Refrigerant: Tools and Equipment
REFRIGERANT SYSTEM SERVICE EQUIPMENT
WARNING: Refer to the applicable warnings and cautions for this system before performing the
following operation. Failure to follow the warnings and cautions could result in possible personal
injury or death.
WARNING: Eye protection must be worn when servicing an air conditioning refrigerant system.
Turn off (rotate clockwise) all valves on the equipment being used, before connecting to or
disconnecting from the refrigerant system. Failure to observe these warnings may result in
When servicing the A/C system, an R-134a refrigerant recovery/recycling/charging station that
meets SAE standard J2210 must be used (1). Contact an automotive service equipment supplier
for refrigerant recovery/recycling/charging equipment. Refer to the operating instructions supplied
by the equipment manufacturer for proper care and use of this equipment.
A manifold gauge set (1) may be needed with some recovery/recycling/charging equipment. The
manifold gauge set should have manual shut-off valves (2 and 6), or automatic back-flow valves
located at the service port connector end of the manifold gauge set hoses (4 and 5). This will
prevent refrigerant
Page 1756
from being released into the atmosphere.
MANIFOLD GAUGE SET CONNECTIONS
CAUTION: Do not use an R-12 manifold gauge set on an R-134a system. The refrigerants are not
compatible and system damage will result.
- LOW PRESSURE GAUGE HOSE - The low pressure hose (Blue with Black stripe) attaches to
the low side service port. This port is located on the A/C liquid line near the right front strut tower.
- HIGH PRESSURE GAUGE HOSE - The high pressure hose (Red with Black stripe) attaches to
the high side service port. This port is located on the A/C discharge line near the A/C condenser.
- RECOVERY/RECYCLING/EVACUATION/CHARGING HOSE - The center manifold hose (Yellow,

or White, with Black stripe) is used to recover, evacuate, and charge the refrigerant system. When
the low or high pressure valves on the manifold gauge set are opened, the refrigerant in the system
will escape through this hose.
Jeep Workshop Manuals > Maintenance > Fluids > Refrigerant Oil > Component Information > Description and Operation >
Description
Refrigerant Oil: Description and Operation Description
DESCRIPTION
The refrigerant oil used in R-134a refrigerant systems is a synthetic-based, polyalkylene glycol
(PAG), wax-free lubricant. Mineral-based R-12 refrigerant oils are not compatible with PAG oils and
should never be introduced to an R-134a refrigerant system.
There are different PAG oils available and each contain a different additive package. Always use
only the type of refrigerant oil recommended for the A/C compressor in the vehicle.
CAUTION: Be certain to adjust the refrigerant system oil level when replacing an A/C compressor.
Failure to properly adjust the refrigerant oil level can prevent the A/C system from operating as
The Denso 5SE12C A/C compressor used in this vehicle is designed to use ND-8 PAG refrigerant
oil. Use only this type of refrigerant oil in the refrigerant system.
Refrigerant Oil: Description and Operation Operation
OPERATION
After performing any refrigerant recovery or recycling operation, always replenish the refrigerant
system with the same amount of the recommended refrigerant oil as was removed. Too little
refrigerant oil can cause A/C compressor damage, and too much can reduce A/C system
performance.
PAG refrigerant oil is more hygroscopic than mineral oil, and will absorb any moisture it comes into
contact with, even moisture in the air. The PAG oil container should always be kept tightly capped
until it is ready to be used. After use, recap the oil container immediately to prevent moisture
contamination.
Page 1762
Refrigerant Oil: Service and Repair
REFRIGERANT OIL LEVEL
When an A/C system is assembled at the factory, all components except the A/C compressor are
refrigerant oil free. After the refrigerant system has been charged and operated, the refrigerant oil
in the A/C compressor is dispersed throughout the refrigerant system. The A/C accumulator, A/C
evaporator, A/C condenser and the A/C compressor will each retain a significant amount of the
needed refrigerant oil.
It is important to have the correct amount of refrigerant oil in the A/C system. This ensures proper
lubrication of the A/C compressor. Too little oil will result in damage to the A/C compressor, while
too much oil will reduce the cooling capacity of the A/C system and consequently result in higher
discharge air temperatures.
CAUTION: ND-8 PAG refrigerant oil is used in the Denso 5SE12C A/C compressor. Only
refrigerant oil of the same type should be used to service this R-134a A/C system. Do not use any
other refrigerant oil. The refrigerant oil container should be kept tightly capped until it is ready for
use and then tightly capped after use to prevent contamination from moisture and dirt. Refrigerant
oil will quickly absorb any moisture it comes in contact with, therefore, special effort must be used
to keep all R-134a system components moisture-free. Moisture in the refrigerant oil is very difficult
to remove and will cause a reliability problem with the A/C compressor.
NOTE: Most reclaim/recycling equipment will measure the amount of refrigerant oil being removed
during the recovery process. This amount of refrigerant oil should always be added back into the
refrigerant system. Refer to the reclaim/recycling equipment manufacturers instructions.
It will not be necessary to check the oil level within the A/C refrigerant system or to add oil, unless
there has been an oil loss. A refrigerant oil loss may occur due to component replacement or a
rupture or leak from a refrigerant line, connector fitting, component or component seal. If a leak
does occurs, add 30 milliliters (1 fluid ounce) of the recommended refrigerant oil to the refrigerant
system after the repair has been made. Refrigerant oil loss will be evident at the leak point by the
presence of a wet, shiny surface around the leak.
Refrigerant oil must be added when an A/C accumulator, A/C evaporator or A/C condenser is
replaced. Refer to the Refrigerant Oil Capacities chart.
The refrigerant oil level in a new A/C compressor must first be adjusted prior to compressor
installation. Refer to the following COMPRESSOR OIL DRAIN PROCEDURE.
COMPRESSOR OIL DRAIN PROCEDURE
The refrigerant oil in the Denso 5SE12C A/C compressor can only be drained using the procedure
described below. Failure to properly drain the refrigerant oil from the A/C compressor can prevent
the A/C system from operating as designed and cause serious compressor damage.
chart to determine how much oil should be removed from the new A/C compressor (example: new
compressor and accumulator requires 80 ml. (2.7 oz.) of oil to be added to the system. 120 ml. (4.1
oz.) of oil is in new compressor. 120 ml. (4.1 oz.) minus 80 ml. (2.7 oz.) equals 40 ml. (1.4 oz.) oil
to be drained from new compressor).
The Denso 5SE12C A/C compressor is filled with 120 milliliters (4.1 oz.) from the factory. When
only the A/C compressor is being replaced, 70 milliliters (2.4 oz.) of refrigerant oil must first be
drained from the new compressor prior to installation. Use the following procedure to drain and
measure refrigerant oil from the Denso 5SE12C A/C compressor.
Page 1763
1. Place the new A/C compressor (1) on a workbench,
2. Position the A/C compressor so that the refrigerant oil can drain out of the suction port (2) into a
suitable clean measured container. Hold the A/C
compressor in this position until no more oil comes out of the compressor port.
3. Reposition the A/C compressor (1) so that the pulley (2) is facing upward and slowly rotate the
compressor pulley clockwise one full turn.
4. Repeat steps 2 and 3 at least seven times or until 70 milliliters (2.4 oz.) of refrigerant oil is
drained from the new A/C compressor.
CAUTION: Failure to properly adjust the refrigerant oil level prior to installation of a new
compressor can prevent the A/C system from operating as designed and cause serious
compressor damage.
5. Install the new A/C compressor onto the engine.

Jeep Workshop Manuals > Maintenance > Brake Bleeding > System Information > Service and Repair > Master Cylinder
Bleeding
Brake Bleeding: Service and Repair Master Cylinder Bleeding
MASTER CYLINDER BLEEDING
NOTE: On vehicles without ABS this procedure is designed to be performed with the proportioning
valves installed in the master cylinder.
1. Clamp the master cylinder in a vise with soft-jaw caps.
2. Attach the special tools for bleeding the master cylinder in the following fashion:
a. Thread Bleeder Tube Adapters (3), Special Tool 8822-2, into the primary and secondary outlet
ports of the master cylinder. Tighten Adapters
to 17 Nm (150 in. lbs.).
b. Thread a Bleeder Tube (2), Special Tool 8358-1, into each Adapter. Tighten tube nuts to 17 Nm
(150 in. lbs.). c. Flex each Bleeder Tube and place the open ends into the neck of the master
cylinder reservoir. Position the open ends of the tubes into the
reservoir so their outlets are below the surface of the brake fluid in the reservoir when filled.
NOTE: Make sure the ends of the Bleeder Tubes stay below the surface of the brake fluid in the
reservoir at all times during the bleeding procedure.
3. Fill the brake fluid reservoir with fresh Mopar(R) Brake Fluid DOT 3 Motor Vehicle, or equivalent.
4. Using an appropriately sized wooden dowel as a pushrod, slowly press the pistons inward
discharging brake fluid through the Bleeder Tubes, then
release the pressure, allowing the pistons to return to the released position. Repeat this several
times until all air bubbles are expelled from the master cylinder bore and Bleeder Tubes.
5. Remove the Bleeder Tubes and Adapters from the master cylinder and plug the master cylinder
outlet ports. 6. Install the fill cap on the reservoir. 7. Remove the master cylinder from the vise. 8.
Install the master cylinder on the vehicle.
Bleeding > Page 1768
Brake Bleeding: Service and Repair Base Brake Bleeding
BASE BRAKE BLEEDING
NOTE: For bleeding the ABS hydraulic system, refer to Antilock Brake System Bleeding in the
Antilock Brake System.
CAUTION: Before removing the master cylinder cap, wipe it clean to prevent dirt and other foreign
matter from dropping into the master cylinder reservoir.
CAUTION: Use only Mopar(R) brake fluid or an equivalent from a fresh, tightly sealed container.
Brake fluid must conform to DOT 3 specifications.
NOTE: For bleeding of the Antilock Brake System, Refer to BRAKES ABS STANDARD
PROCEDURE).
Do not pump the brake pedal at any time while having a bleeder screw open during the bleeding
process. This will only increase the amount of air in the system and make additional bleeding
necessary.
Do not allow the master cylinder reservoir to run out of brake fluid while bleeding the system. An
empty reservoir will allow additional air into the brake system. Check the fluid level frequently and
add fluid as needed.
The following wheel circuit sequence for bleeding the brake hydraulic system should be used to
ensure adequate removal of all trapped air from the hydraulic system.
- Left rear wheel
- Right front wheel
- Right rear wheel
- Left front wheel
MANUAL BLEEDING
NOTE: To bleed the brakes manually, the aid of a helper will be required.
1. Attach a clear plastic hose (1) to the bleeder screw and feed the hose into a clear jar (2)
containing enough fresh brake fluid to submerge the end of
the hose.
2. Have a helper pump the brake pedal three or four times and hold it in the down position. 3. With
the pedal in the down position, open the bleeder screw at least one full turn. 4. Once the brake
pedal has dropped, close the bleeder screw. After the bleeder screw is closed, release the brake
pedal. 5. Repeat the above steps until all trapped air is removed from that wheel circuit (usually
four or five times).
6. Bleed the remaining wheel circuits in the same manner until all air is removed from the brake
system. Monitor the fluid level in the master cylinder
reservoir (2) to make sure it does not go dry.
7. Check and adjust brake fluid level to the FULL mark. 8. Check the brake pedal travel. If pedal
travel is excessive or has not been improved, some air may still be trapped in the system. Re-bleed
the
brakes as necessary.
9. Test drive the vehicle to verify the brakes are operating properly and pedal feel is correct.
PRESSURE BLEEDING
NOTE: Follow pressure bleeder manufacturer's instructions for use of pressure bleeding
equipment.
1. Attach Master Cylinder Cap (2), Special Tool 6921, in place of the filler cap on the master
cylinder reservoir (3). 2. Attach Bleeder Tank (1), Special Tool C-3496-B, or an equivalent, to the
Master Cylinder Cap 6921.
the hose.
4. Open the bleeder screw at least one full turn or more to obtain a steady stream of brake fluid. 5.
After approximately 120 - 240 ml (4 - 8 ounces) of fluid have been bled through the brake circuit
and an air-free flow is maintained in the clear
plastic hose and jar, close the bleeder screw.
6. Repeat this procedure at all the remaining bleeder screws.
7. Check and adjust brake fluid level to the FULL mark on the reservoir (2). 8. Check the brake
pedal travel. If pedal travel is excessive or has not been improved, some air may still be trapped in
the system. Re-bleed the
Brake Bleeding: Service and Repair Antilock Brake System Bleeding
ANTILOCK BRAKE SYSTEM BLEEDING
The base brake's hydraulic system must be bled anytime air enters the hydraulic system. The ABS
must always be bled anytime it is suspected that the HCU has ingested air.
Brake systems with ABS must be bled as two independent braking systems. The non-ABS portion
of the brake system with ABS is to be bled the same as any non-ABS system.
The ABS portion of the brake system must be bled separately. Use the following procedure to
properly bleed the brake hydraulic system including the ABS.
NOTE: During the brake bleeding procedure, be sure the brake fluid level remains close to the
FULL level in the master cylinder fluid reservoir. Check the fluid level periodically during the
bleeding procedure and add Mopar(R) DOT 3 brake fluid as required.
BLEEDING
When bleeding the ABS system, the following bleeding sequence must be followed to insure
complete and adequate bleeding.
1. Make sure all hydraulic fluid lines are installed and properly torqued. 2. Connect the scan tool to
the diagnostics connector. The diagnostic connector is located under the lower steering column
cover to the left of the
steering column.
3. Using the scan tool, check to make sure the ABM does not have any fault codes stored. If it
does, clear them.
WARNING: When bleeding the brake system wear safety glasses. A clear bleed tube (1) must be
attached to the bleeder screws and submerged in a clear container filled part way with clean brake
fluid (2). Direct the flow of brake fluid away from yourself and the painted surfaces of the vehicle.
Brake fluid at high pressure may come out of the bleeder screws when opened.
NOTE: Pressure bleeding is recommended to bleed the base brake system to ensure all air is
removed from system. Manual bleeding may also be used, but additional time is needed to remove
all air from system.
4. Bleed the base brake system. 5. Using the scan tool, select ECU VIEW, followed by ABS
MISCELLANEOUS FUNCTIONS to access bleeding. Follow the instructions
displayed. When finished, disconnect the scan tool and proceed.
6. Bleed the base brake system a second time. Check brake fluid level in the reservoir periodically
to prevent emptying, causing air to enter the
hydraulic system.
7. Fill the master cylinder fluid reservoir (1) to the FULL level. 8. Test drive the vehicle to be sure
the brakes are operating correctly and that the brake pedal does not feel spongy.
Jeep Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse > Component Information > Technical
Service Bulletins > Customer Interest for Fuse: > 08-016-06A > Jul > 06 > Electrical Systems - Intermittent Component
Operation
Fuse: Customer Interest Electrical Systems - Intermittent Component Operation
NUMBER:08-016-06 REV. A
GROUP: Electrical
DATE: July 18, 2006

22, 2006, WHICH SHOULD BE REMOVED FROM YOUR FILES. ALL REVISIONS ARE
HIGHLIGHTED WITH **ASTERISKS** AND INCLUDE THE ADDITION OF A VEHICLE BODY
STYLE.
SUBJECT: Intermittent Operation Of Electrical Components Due To Ignition Off Draw (IOD) Fuse
Not Being Fully Seated
MODELS:
2007 (PM) Caliber
**2007 (MK-49) Compass**
2006 - 2007 (DHIDRID1) Ram Truck
DISCUSSION:
The Ignition Off Draw (IOD) fuse is used to prevent battery discharge during shipping and long term
storage of the vehicles. The IOD fuse is located in the Total Integrated Power Module (TI PM). If
the fuse is not completely inserted partial contact of the fuse terminals could occur. When the
vehicle is prepped for customer delivery, ensure that the fuse is fully engaged (Fig. 1). The IOD
fuse must also be fully released to prevent battery drain from occurring when the vehicle is stored.
When the IOD fuse holder is depressed into the carrier, an initial distinct detent will be felt to
overcome the "pre-hold position". You must then continue to push straight down on the IOD
pre-holder until no further downward movement is encountered.
NOTE:
If the fuse is not pushed down symmetrically, two detents MAY be felt as each side snaps past the
pre-hold position. Push down until no further downward movement is encountered.
On 2006 and 2007 PT and PM vehicles the circuits fed by the IOD fuse are: Radio, Security module
& siren (BUX), Wireless Control Module (RKE & SKREEM), Hands Free Module, Satellite Radio,
Power Mirrors, Clock, Memory Seat, Amplifier, CCN wake-up with ignition off and Homelink.
On 2006 and 2007 DR, DH or D1 vehicles the circuits fed by the IOD fuse are: Radio, EVIC,
Wireless Control Module (RKE & SKREEM), Hands Free Module, Satellite Radio, Video Screen,
CCN wake-up with ignition off, Underhood Lamp, CCN Interior Lighting
Service Bulletins > Customer Interest for Fuse: > 08-016-06A > Jul > 06 > Electrical Systems - Intermittent Component
Operation > Page 1782
Disclaimer:
Service Bulletins > All Technical Service Bulletins for Fuse: > 08-016-06A > Jul > 06 > Electrical Systems - Intermittent
Component Operation
Fuse: All Technical Service Bulletins Electrical Systems - Intermittent Component Operation
GROUP: Electrical
DATE: July 18, 2006

STYLE.
MODELS:
2007 (PM) Caliber
**2007 (MK-49) Compass**
DISCUSSION:
NOTE:
Service Bulletins > All Technical Service Bulletins for Fuse: > 08-016-06A > Jul > 06 > Electrical Systems - Intermittent
Component Operation > Page 1788
Disclaimer:
Jeep Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse > Component Information > Locations >
Fuse/Relay Block
Fuse: Locations Fuse/Relay Block
Fuse/Relay Block

Jeep Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse > Component Information > Locations >
Fuse/Relay Block > Page 1791
Fuse: Locations Integrated Power Module (IPM)

Jeep Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse > Component Information > Diagrams >
Diagram Information and Instructions
Fuse: Diagram Information and Instructions
Warnings
WARNINGS - GENERAL
the battery.
characteristics.
to function only.
Diagram Information and Instructions > Page 1794
SYMBOLS
TERMINOLOGY
Circuit Functions
models.
Circuit Information
IDENTIFICATION
LOCATIONS
illustrations.
associated wiring.
Removal
REMOVAL

connector.
Installation
INSTALLATION

Removal
REMOVAL
Installation
INSTALLATION
the new diode.
from the elements.
Removal
REMOVAL
Installation
INSTALLATION
repaired.
half/component.
repair.
Wire Splicing
repair area.

Special Tools
WIRING/TERMINAL


Fuse: Diagnostic Aids
vehicle.

good continuity.

SEVERAL LOADS


feed and ground.
position
problem
Jeep Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse > Component Information > Application and
ID > Fuse/Relay Block
Fuse: Application and ID Fuse/Relay Block

Jeep Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse > Component Information > Application and
ID > Fuse/Relay Block > Page 1813
Fuse: Application and ID Integrated Power Module (IPM)
Jeep Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse Block > Component Information > Locations
> Fuse/Relay Block
Fuse Block: Locations Fuse/Relay Block
Fuse/Relay Block

Jeep Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse Block > Component Information > Locations
> Fuse/Relay Block > Page 1818
Fuse Block: Locations Integrated Power Module (IPM)

Jeep Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse Block > Component Information > Diagrams
> Diagram Information and Instructions
Fuse Block: Diagram Information and Instructions
Warnings
WARNINGS - GENERAL
the battery.
characteristics.
to function only.
> Diagram Information and Instructions > Page 1821
SYMBOLS
TERMINOLOGY
Circuit Functions
models.
Circuit Information
IDENTIFICATION
LOCATIONS
illustrations.
associated wiring.
Removal
REMOVAL

connector.
Installation
INSTALLATION

Removal
REMOVAL
Installation
INSTALLATION
the new diode.
from the elements.
Removal
REMOVAL
Installation
INSTALLATION
repaired.
half/component.
repair.
Wire Splicing
repair area.

Special Tools
WIRING/TERMINAL


Fuse Block: Diagnostic Aids
vehicle.

good continuity.

SEVERAL LOADS


feed and ground.
position
problem
Jeep Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse Block > Component Information > Application
and ID > Fuse/Relay Block
Fuse Block: Application and ID Fuse/Relay Block

Jeep Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse Block > Component Information > Application
and ID > Fuse/Relay Block > Page 1840
Fuse Block: Application and ID Integrated Power Module (IPM)
Jeep Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse Block > Component Information > Description
Fuse Block: Description and Operation Description
DESCRIPTION
An electrical Fuse Block is located in the left front bumper fascia. It serves to simplify and centralize
numerous electrical components, as well as to distribute electrical current to many of the accessory
systems in the vehicle.
There are two clips that retain the fuse block cover to the fuse block. The cover can be removed to
service the fuses and relays by depressing the clips and lifting off the cover. If fuse block wire
terminal or insulator service is required the complete fuse block assembly must be removed.
Jeep Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse Block > Component Information > Description
Fuse Block: Description and Operation Operation
OPERATION
The fuse block houses relays and blade-type fuses. The fuses, relays and fuse block unit are
available for service replacement. Refer to Wiring Diagrams for complete circuit diagrams.
Jeep Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse Block > Component Information > Service
and Repair > Removal
Fuse Block: Service and Repair Removal
REMOVAL
WARNING: ON VEHICLES EQUIPPED WITH AIRBAGS, REFER TO RESTRAINT SYSTEMS

BEFORE ATTEMPTING ANY STEERING COLUMN OR INSTRUMENT PANEL COMPONENT
DIAGNOSIS OR SERVICE. FAILURE TO TAKE THE PROPER PRECAUTIONS COULD RESULT
IN ACCIDENTAL AIRBAG DEPLOYMENT AND POSSIBLE PERSONAL INJURY.
2. Remove the front bumper fascia.
3. Depress mounting clips and lift the fuse block off the bracket.
4. Remove the wire harness and fuse block.

Jeep Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse Block > Component Information > Service
and Repair > Removal > Page 1846
Fuse Block: Service and Repair Installation
INSTALLATION

1. Install the new wire harness and fuse block into the vehicle.
2. Position the fuse block onto the mounting bracket and push down until the mounting clips are
fully seated.
3. Install the front bumper fascia.

Jeep Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Relay Box > Component Information > Locations >
Fuse/Relay Block
Fuse/Relay Block

Jeep Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Relay Box > Component Information > Locations >

Jeep Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Relay Box > Component Information > Application
and ID > Fuse/Relay Block

Jeep Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Relay Box > Component Information > Application
and ID > Fuse/Relay Block > Page 1854
Jeep Workshop Manuals > Maintenance > Service Reminder Indicators > Low Tire Pressure Indicator > Component
Low Tire Pressure Indicator: Description and Operation Description
DESCRIPTION
A Tire Pressure Monitor (TPM) indicator is standard equipment on all instrument clusters. However,
on vehicles not equipped with the TPM system, this indicator is electronically disabled. This
indicator is located within the odometer Vacuum Fluorescent Display (VFD) unit. On vehicles
equipped with an optional reconfigurable VFD unit, a vehicle icon with tire pressure data for all four
tires may be displayed in the reconfigurable VFD. The reconfigurable VFD is also capable of
displaying textual messages identifying the location of a tire with low pressure as well as diagnostic
messages for certain faults in the TPM system.
The TPM indicator consists of a stencil-like cutout of an icon that represents a cross-section of a
tire with a centered exclamation point in the VFD unit. The odometer VFD unit is soldered onto the
instrument cluster electronic circuit board, and is visible through a window with a smoked clear lens
located on the lower edge of the tachometer gauge dial face of the cluster overlay. The dark lens
over the VFD prevents it from being clearly visible when it is not illuminated. The TPM indicator
appears in an amber color and at the same lighting level as the odometer information when it is
illuminated by the instrument cluster electronic circuit board.
The TPM indicator is serviced as a unit with the odometer VFD unit in the instrument cluster.
Jeep Workshop Manuals > Maintenance > Service Reminder Indicators > Low Tire Pressure Indicator > Component
Low Tire Pressure Indicator: Description and Operation Operation
OPERATION
The Tire Pressure Monitor (TPM) indicator gives an indication to the vehicle operator of the status
of the TPM system. The TPM indicator is controlled by the instrument cluster circuit board based
upon cluster programming and electronic messages received by the cluster from the Sentry Key
REmote Entry Module (SKREEM) (also known as the Wireless Control Module/WCM) over the
The TPM indicator is completely controlled by the instrument cluster logic circuit, and that logic will
only allow this indicator to operate when the instrument cluster receives a battery current input on
the fused ignition switch output (run-start) circuit. Therefore, the indicator will always be OFF when
the ignition switch is in any position except ON or START. The indicator only illuminates when it is
energized by the instrument cluster logic circuit. The instrument cluster will turn ON the TPM
indicator for the following reasons:
- Bulb Test - Each time the ignition switch is turned to the ON position, the SKREEM sends an
electronic TPM indicator lamp-ON message to the cluster to illuminate the TPM indicator for about
three seconds as a bulb test.
- TPM Indicator Lamp-On Message - Each time the cluster receives an electronic TPM indicator
lamp-ON message from the SKREEM, the indicator will be illuminated. The indicator can be
flashed ON and OFF, or illuminated solid, as dictated by the SKREEM message. The indicator
remains illuminated until the cluster receives a lamp-OFF message from the SKREEM, or until the
ignition switch is turned to the OFF position, whichever occurs first.
- Premium Cluster TPM Pressure Indication - On vehicles equipped with the optional premium
cluster with a reconfigurable VFD, an icon representing an overhead view of the vehicle is
displayed in the reconfigurable VFD with the actual monitored pressure of each tire.
- Communication Error - If the cluster receives no TPM lamp-ON or lamp-OFF messages from the
SKREEM for six consecutive seconds, the TPM indicator is illuminated by the instrument cluster.
The indicator remains controlled and illuminated by the cluster until a valid lamp-ON or lamp-OFF
message is received from the SKREEM.
- Actuator Test - Each time the cluster is put through the actuator test, the TPM indicator will be
turned ON, then OFF again during the odometer VFD portion of the test in order to confirm the
functionality of the VFD and the cluster control circuitry.
The SKREEM performs a self-test each time the ignition switch is turned to the ON position to
decide whether the TPM system is in good operating condition and whether the tire inflation
pressures are too high or too low. The SKREEM then sends the proper lamp-ON or lamp-OFF
message to the ElectroMechanical Instrument Cluster (EMIC). If the instrument cluster turns ON
the TPM indicator after the bulb test, it indicates that the inflation pressure of a tire is too low or that
a malfunction has occurred and the TPM system is ineffective.
For proper diagnosis of the TPM system, the SKREEM, the EMIC, the CAN data bus or the
electronic communication related to TPM indicator operation a diagnostic scan tool is required.
Jeep Workshop Manuals > Maintenance > Service Reminder Indicators > Maintenance Required Lamp/Indicator >
Component Information > Service and Repair
Maintenance Required Lamp/Indicator: Service and Repair
Chrysler provides no information regarding a Maintenance Required Lamp/Indicator.

Jeep Workshop Manuals > Maintenance > Service Reminder Indicators > Malfunction Indicator Lamp > Component
Malfunction Indicator Lamp: Description and Operation Description
DESCRIPTION
A Malfunction Indicator Lamp (MIL) is standard equipment on all instrument clusters. The MIL
information is displayed in the upper portion of the odometer Vacuum Fluorescent Display (VFD)
unit. This VFD unit is soldered onto the cluster electronic circuit board, and is visible through a
window with a smoked clear lens located on the lower edge of the tachometer dial face of the
cluster overlay. The dark lens over the VFD unit prevents the indicator from being clearly visible
when it is not illuminated.
The MIL consists of a stencil-like cutout of the International Control and Display Symbol icon for
Engine in the opaque layer of the instrument cluster overlay. The dark outer layer of the overlay
prevents the indicator from being clearly visible when it is not illuminated. The indicator appears in
an amber color and at the same lighting level as the odometer information.
The MIL is serviced as a unit with the VFD unit in the instrument cluster.
Jeep Workshop Manuals > Maintenance > Service Reminder Indicators > Malfunction Indicator Lamp > Component
Malfunction Indicator Lamp: Description and Operation Operation
OPERATION
The Malfunction Indicator Lamp (MIL) gives an indication to the vehicle operator when the
Powertrain Control Module (PCM) has recorded a Diagnostic Trouble Code (DTC) for an On-Board
Diagnostics II (OBDII) emissions-related circuit or component malfunction. The MIL is controlled by
the instrument cluster circuit board based upon cluster programming and electronic messages
received by the cluster from the PCM over the Controller Area Network (CAN) data bus.
The MIL is completely controlled by the instrument cluster logic circuit, and that logic will only allow
this indicator to operate when the instrument cluster receives a battery current input on the fused
ignition switch output (run-start) circuit. Therefore, the indicator will always be OFF when the
ignition switch is in any position except ON or START. The indicator only illuminates when it is
energized by the instrument cluster logic circuit. The instrument cluster will turn ON the MIL for the
following reasons:
- Bulb Test - Each time the ignition switch is turned to the ON position the indicator is illuminated
for about 15 seconds as a bulb test. The entire bulb test is a function of the PCM.
- MIL Lamp-On Message - Each time the cluster receives an electronic MIL lamp-ON message
from the PCM, the indicator will be illuminated. The indicator can be flashed ON and OFF, or
illuminated solid, as dictated by the PCM message. For some DTCs, if a problem does not recur,
the PCM will send a lamp-OFF message automatically. Other DTCs may require that a fault be
repaired and the PCM be reset before a lamp-OFF message will be sent. For more information on
the PCM, and the DTC set and reset parameters.
- Communication Error - If the cluster receives no lamp-ON or lamp-OFF messages from the PCM
for 10 consecutive message cycles, the MIL is illuminated by the instrument cluster to indicate a
loss of bus communication. The indicator remains controlled and illuminated by the cluster until a
valid message is received from the PCM.
- Actuator Test - Each time the cluster is put through the actuator test, the MIL indicator will be
The PCM continually monitors the fuel and emissions system circuits and sensors to decide
whether the system is in good operating condition. The PCM then sends the proper lamp-ON or
lamp-OFF message to the ElectroMechanical Instrument Cluster (EMIC). If the EMIC turns ON the
MIL after the bulb test, it may indicate that a malfunction has occurred and that the fuel and
emissions systems require service.
For proper diagnosis of the fuel and emissions systems, the PCM, the EMIC, the CAN data bus or
the electronic communication related to MIL operation a diagnostic scan tool is required. Refer to
the appropriate diagnostic information.
Jeep Workshop Manuals > Maintenance > Service Reminder Indicators > Oil Change Reminder Lamp > Component
Information > Service and Repair
Oil Change Reminder Lamp: Service and Repair
This Vehicle does not come equipped with an Oil Change Reminder Lamp.
Jeep Workshop Manuals > Maintenance > Wheels and Tires > Relays and Modules - Wheels and Tires > Tire Pressure
Monitor Receiver / Transponder > Component Information > Locations > Transponder-Tire Pressure-Left Front
Component ID: 369
Connector:
Color : YELLOW
# of pins : 6
5--
6--
Monitor Receiver / Transponder > Component Information > Locations > Transponder-Tire Pressure-Left Front > Page 1878
Component ID: 370
Connector:
Color : BLACK
# of pins : 6
4--
5--
6--
Component ID: 371
Connector:
Color : BLACK
# of pins : 6
4--
5--

Monitor Receiver / Transponder > Component Information > Diagrams > Transponder-Tire Pressure-Left Front
Component ID: 369
Connector:
Color : YELLOW
# of pins : 6
5--
6--
Monitor Receiver / Transponder > Component Information > Diagrams > Transponder-Tire Pressure-Left Front > Page 1885
Component ID: 370
Connector:
Color : BLACK
# of pins : 6
4--
5--
6--
Component ID: 371
Connector:
Color : BLACK
# of pins : 6
4--
5--

Monitor Receiver / Transponder > Component Information > Description and Operation > Description
DESCRIPTION
Monitor Receiver / Transponder > Component Information > Description and Operation > Description > Page 1892
OPERATION
Monitor Receiver / Transponder > Component Information > Service and Repair > Removal
Front
FRONT
Rear
REAR
Monitor Receiver / Transponder > Component Information > Service and Repair > Removal > Page 1895
Front
FRONT
Rear
REAR

Jeep Workshop Manuals > Maintenance > Wheels and Tires > Sensors and Switches - Wheels and Tires > Tire Pressure
Sensor > Component Information > Service Precautions
CAUTION

Sensor > Component Information > Description and Operation > Description
DESCRIPTION
Sensor > Component Information > Description and Operation > Description > Page 1902
- Valve Stem Core
OPERATION
REMOVAL
different metals.


INSTALLATION

installed.
damage may occur.
pressure sensor: a.
b.
beads.
sensor.
new sensor ID.

Jeep Workshop Manuals > Maintenance > Wheels and Tires > Tire Monitoring System > Low Tire Pressure Indicator >
DESCRIPTION
Jeep Workshop Manuals > Maintenance > Wheels and Tires > Tire Monitoring System > Low Tire Pressure Indicator >
OPERATION
Jeep Workshop Manuals > Maintenance > Wheels and Tires > Tire Monitoring System > Tire Pressure Monitor Receiver /
Transponder > Component Information > Locations > Transponder-Tire Pressure-Left Front
Component ID: 369
Connector:
Color : YELLOW
# of pins : 6
5--
6--
Transponder > Component Information > Locations > Transponder-Tire Pressure-Left Front > Page 1922
Component ID: 370
Connector:
Color : BLACK
# of pins : 6
4--
5--
6--
Component ID: 371
Connector:
Color : BLACK
# of pins : 6
4--
5--

Transponder > Component Information > Diagrams > Transponder-Tire Pressure-Left Front
Component ID: 369
Connector:
Color : YELLOW
# of pins : 6
5--
6--
Transponder > Component Information > Diagrams > Transponder-Tire Pressure-Left Front > Page 1929
Component ID: 370
Connector:
Color : BLACK
# of pins : 6
4--
5--
6--
Component ID: 371
Connector:
Color : BLACK
# of pins : 6
4--
5--

Transponder > Component Information > Description and Operation > Description
DESCRIPTION
Transponder > Component Information > Description and Operation > Description > Page 1936
OPERATION
Transponder > Component Information > Service and Repair > Removal
Front
FRONT
Rear
REAR
Transponder > Component Information > Service and Repair > Removal > Page 1939
Front
FRONT
Rear
REAR

Jeep Workshop Manuals > Maintenance > Wheels and Tires > Tire Monitoring System > Tire Pressure Sensor >
Component Information > Service Precautions
CAUTION

DESCRIPTION
- Valve Stem Core
OPERATION
REMOVAL
different metals.


INSTALLATION

installed.
damage may occur.
pressure sensor: a.
b.
beads.
sensor.
new sensor ID.

Jeep Workshop Manuals > Maintenance > Wheels and Tires > Tires > Spare Tire > Component Information > Technical
Service Bulletins > Tire Monitor System - Dashes Displayed Using Spare Tire
Spare Tire: Technical Service Bulletins Tire Monitor System - Dashes Displayed Using Spare Tire
NUMBER: 22-001-06 REV. B
GROUP: Tires & Wheels
THIS BULLETIN SUPERSEDES SERVICE BULLETIN 22-001-06 REV. A, DATED JUNE 29, 2006,
WITH **ASTERISKS** AND INCLUDES ADDITIONAL MODELS.
SUBJECT: Tire Pressure Monitoring System (1PM) Displays Dashes "--" When The Spare Tire Is
Used
MODELS:
2007 (PM) Caliber
**2007 (JS)
**2007 (KA) Nitro**
DISCUSSION:
If the TPM system detects a low tire, it will set a low tire DTC (C0077 - Low Tire Pressure), notify
the customer by illuminating the TPM telltale, and display the low tire pressure values in the EVIC
display. Once the low road tire is replaced by the spare tire and the vehicle is driven above 25 MPH
(40 KPH) for more than 10 minutes; the TPM system will set an additional DTC (C151C - Tire
Pressure Sensor Missing), notify the customer by displaying "CHECK TPM SYSTEM" for 3
seconds, and replaces the low tire pressure value with dashes
If:
^ The original tire with pressure sensor remains inside the vehicle or within a valid Radio
Frequency range with the WCM (TPM receiver).
And:
^ The pressure changes in the low tire by more than 1 PSI or 13 hours expire from the time the low
tire event occurred.
Then:
^ The dashes will be replaced by the actual low tire pressure value.
This low tire / dash "--" cycle will repeat until the pressure is restored in the original tire.
NOTE:
The spare tire is not equipped with a tire pressure monitoring (TPM) sensor.
Do not replace any TPM sensors for this condition. Correct the low tire condition first and then
verify that the C151C - Tire Pressure Sensor Missing and the C0077 - Low Tire Pressure DTC
change to a stored code.
POLICY: Information Only.
Disclaimer:
Jeep Workshop Manuals > Maintenance > Wheels and Tires > Wheels > Component Information > Technical Service
Bulletins > Wheels/Tires - Chrome Clad Wheel Balancing Information
Wheels: Technical Service Bulletins Wheels/Tires - Chrome Clad Wheel Balancing Information
NUMBER: 22-002-09
GROUP: Wheels/Tires
DATE: July 29, 2009
SUBJECT: Chrome Clad Wheel Adapters For Proper Balancing
OVERVIEW: This bulletin describes the use of proper wheel adapters when mounting Chrome
Clad wheels to wheel balancing equipment.
MODELS:
2004-2008 (CS) Pacifica
2007 - 2010 DC) Ram Truck (3500 Chassis Cab)
2009 - 2010 (DS) Ram Truck (1500)
2004 - 2009 (HB) Durango
2007-2009 (HG) Aspen
2009-2010 (JC) Journey
2008 - 2010 (JS27) Sebring Convertible
2007 - 2010 (JS41) Sebring/Avenger
2007-2010 (KA) Nitro
2002-2007 (KJ) Liberty
2002 - 2007 (KJ) Cherokee (International Markets)
2008 - 2010 (KK) Liberty
2005-2010 (ND) Dakota
2007 - 2001 (PM) Caliber

2008 - 2010 (RI) Town & Country/Grand Caravan
Bulletins > Wheels/Tires - Chrome Clad Wheel Balancing Information > Page 1964
2008 - 2010 (RI) Town & Country/Grand Voyager (International Markets)
2005-2010 (WK) Grand Cherokee
NOTE:
This information applies to any model equipped with Chrome Clad Wheels.
DISCUSSION:
Models equipped with Chrome Clad wheels require specific piloting on balance equipment to
properly center the wheel and prevent damage to the chrome clad surface. The chrome cladding is
not removable or replaceable and has cladding tabs that extend into the wheel bore. Traditional
high-taper cones will come into contact with the cladding tabs rather than properly seat on the hub
bore chamfer. Many modern aluminum wheel designs cannot be mounted with traditional cones.
Direct-Fit Collets should be used to properly mount clad wheels on balance equipment (Fig 1).
NOTE:
This kit includes the adapters for all Dodge, Chrysler & Jeep models with clad wheels. Individual
adapters for specific wheel sizes can be ordered separately. To order a kit or individual adapters,
contact Pentastar Service Equipment @ 1-800-223-5623.
Disclaimer:
Wheels: Specifications
WHEEL
Torque Specifcations
Torque Specifications
Wheels: Description and Operation
WHEEL
All vehicles use either steel or cast aluminum drop center wheels. The original equipment wheels
are designed for proper operation at all loads up to the specified maximum vehicle capacity.
Every wheel has raised sections between the rim flanges (1) and drop well (3) called safety humps
(2). In case of air loss, these raised sections help hold the tire in position on the wheel until the
vehicle can be brought to a safe stop. When being installed on the wheel, initial inflation of the tire
forces the tire bead over these raised sections into place.
The wheel studs and nuts are designed for specific wheel applications and must be replaced with
equivalent parts. Do not use replacement parts of lesser quality or of a substitute design. All
aluminum and steel wheels have wheel stud nuts with an enlarged nose. This enlarged nose is
necessary to ensure proper retention of the wheels.
Wheels: Testing and Inspection
WHEEL INSPECTION
Inspect wheels for:
- Excessive runout
- Dents, cracks or irregular bends
- Damaged wheel stud (lug) holes
- Air Leaks
NOTE: Do not attempt to repair a wheel by hammering, heating or welding.
If a wheel is damaged, an original equipment replacement wheel should be used. When obtaining
replacement wheels, they must be equivalent in load carrying capacity. The diameter, width, offset,
pilot hole and bolt circle of the wheel should be the same as the original wheel.
WARNING: Failure to use equivalent replacement wheels may adversely affect the safety and
handling of the vehicle.
WARNING: Replacement with used wheels is not recommended. The service history of the wheel
may have included severe treatment or very high mileage. The rim could fail without warning.
WARNING: DaimlerChrysler Corporation does not recommend that customers use "reconditioned"
wheels (wheels that have been damaged and repaired) because they can result in a sudden
catastrophic wheel failure which could cause loss of control and result in injury or death. For
clarification:
- Cosmetic refinishing for the purpose of repairing a superficial flaw is an acceptable procedure
providing it is limited to paint or clear coat only, the wheel is not modified in any way, and there is
no exposure to paint curing heat over 200 degrees Fahrenheit.
- Damaged wheels are those which have been bent, broken, cracked or sustained some other
physical damage which may have compromised the wheel structure.
- Repaired indicates that the wheel has been modified through bending, welding, heating,
straightening, or material removal to rectify damage.
- Re-plating of chrome plated wheels is not an acceptable procedure nor is chrome plating of
original equipment painted or polished wheels, as this may alter mechanical properties and affect
fatigue life.
Wheels: Service and Repair
WHEEL AND WHEEL TRIM CARE
All wheels and wheel trim, especially aluminum and chrome plated, should be cleaned regularly
using mild soap and water to maintain their luster and to prevent corrosion. Wash them with the
same soap solution recommended for the body of the vehicle.
When cleaning extremely dirty wheels, care must be taken in the selection of tire and wheel
cleaning chemicals and equipment to prevent damage to the wheels. Mopar(R) Tire & Wheel
Cleaner, Mopar(R) Wheel Treatment or Mopar(R) Chrome Cleaner is recommended. Any of the
"DO NOT USE" items listed below can damage wheels and wheel trim.
DO NOT USE:
- Any abrasive cleaner
- Any abrasive cleaning pad (such as steel wool) or abrasive brush
- Any cleaner that contains an acid which can react with and discolor the chrome surface. Many
wheel cleaners contain acids that can harm the wheel surface.
- Oven cleaner
- A car wash that uses carbide-tipped wheel cleaning brushes or acidic solutions.
Jeep Workshop Manuals > Maintenance > Wheels and Tires > Wheel Bearing > Component Information > Specifications
Wheel Bearing: Specifications
Wheel Bearing Grease Fluid Type
Mopar Multi-Purpose Grease NLGI Grade 2 EP, GC-LB or equivalent.

Jeep Workshop Manuals > Maintenance > Wheels and Tires > Wheel Bearing > Component Information > Description and
Operation > Front Suspension
Wheel Bearing: Description and Operation Front Suspension

DESCRIPTION
The wheel bearing (5) and hub (3) are pressed into the knuckle (1). The wheel bearing is secured
in place using a snap ring.
One side of the wheel bearing has an integrated magnetic encoder ring for wheel speed sensor
usage as equipped. It is important that the wheel speed sensor magnetic encoder ring (dark band)
(3) be positioned to the inside of the knuckle or the wheel speed sensor will not operate correctly.
The wheel bearing is a Unit 1 type cartridge bearing that requires no maintenance. The wheel
bearing can be serviced separately from the hub.
The hub supports the driveline halfshaft outer constant velocity (C/V) joint. Each is splined and
meshes in the center of the hub. The outer C/V joint is retained to the hub using a nut. The nut is
locked to the outer C/V stub shaft using a cotter pin.
The hub has five studs pressed into its flange.

Jeep Workshop Manuals > Maintenance > Wheels and Tires > Wheel Bearing > Component Information > Description and
Operation > Front Suspension > Page 1974
Wheel Bearing: Description and Operation Rear Suspension
DESCRIPTION
The rear wheel bearing and wheel mounting hub used on this vehicle are a one-piece sealed unit
or hub and bearing assembly. It is permanently lubricated when assembled and is sealed for life.
There is no periodic lubrication or maintenance recommended for these units.
The hub and bearing (5) is mounted to the trailing link (1).
All vehicles have a magnetic encoder integrated into the right rear hub and bearing for speed
sense. Vehicles equipped with antilock brakes have a magnetic encoder integrated into both rear
hub and bearings. The encoder works with the rear wheel speed sensors to provide wheel speed
signal. The sensor mounts by screw to the rear of the front-wheel-drive hub and bearing while the
sensor clips to the rear of the all-wheel-drive hub and bearing.
The only serviceable components of the hub and bearing are the wheel mounting studs pressed
into the hub.
Jeep Workshop Manuals > Maintenance > Wheels and Tires > Wheel Bearing > Component Information > Testing and
Inspection > Front Suspension
Wheel Bearing: Testing and Inspection Front Suspension
WHEEL BEARING AND HUB
NOTE: The wheel bearing is designed to last for the life of the vehicle and requires no type of
periodic maintenance.
The following procedure may be used for diagnosing the condition of the wheel bearing and hub.
1. Remove the wheel and tire assembly, disc brake caliper and brake rotor. 2. Rotate the wheel
hub checking for resistance or roughness.
Any roughness or resistance to rotation may indicate dirt intrusion or a failed hub bearing. If the
bearing exhibits any of these conditions, the hub bearing will require replacement. Do not attempt
to disassemble the bearing for repair. If the wheel bearing is disassembled for any reason, it must
be replaced.
Damaged bearing seals and the resulting excessive grease loss may also require bearing
replacement. Moderate grease weeping from the bearing is considered normal and should not
require replacement of the wheel bearing.
To diagnose a bent hub, measure hub runout. Refer to Brakes and Traction Control/Testing and
Inspection.
Jeep Workshop Manuals > Maintenance > Wheels and Tires > Wheel Bearing > Component Information > Testing and
Inspection > Front Suspension > Page 1977
Wheel Bearing: Testing and Inspection Rear Suspension
HUB AND BEARING
bearing exhibits any of these conditions, the hub and bearing will require replacement. Do not
attempt to disassemble the bearing for repair. If the wheel bearing is disassembled for any reason,
it must be replaced.
replacement. Moderate grease seapage from the bearing is considered normal and should not
Inspection.
Jeep Workshop Manuals > Maintenance > Wheels and Tires > Wheel Bearing > Component Information > Service and
Repair > Front Suspension
Wheel Bearing: Service and Repair Front Suspension
Removal
REMOVAL
NOTE: The removal and installation of the wheel bearing and hub from the knuckle is only to be
done with the knuckle removed from the vehicle.
1. Remove the steering knuckle from the vehicle.
2. Position the locator block (2) for Fixture, Special Tool 9712, as follows:
a. For left side knuckles, place the locator block (2) to the left side (4) on the Fixture. The side of
the locator block with the angle cut goes
downward, toward the Fixture. Install the mounting screws and tighten them to approximately 54
Nm (40 ft. lbs.).
b. For right side knuckles, place the locator block (2) to the right side (3) on the Fixture. The side of
Nm (40 ft. lbs.).
3. Install the knuckle in the Fixture as shown, guiding the steering arm (1) to rest on the locator
block (3) and the brake caliper mounting bosses on
the two Fixture pins (2).

Repair > Front Suspension > Page 1980
4. Place the Fixture (3) with knuckle in an arbor press. 5. Position Remover/Installer, Special Tool
9712-2 (2), in the small end of the hub. Lower the arbor press ram (1) and remove the hub from the
wheel bearing and knuckle. The bearing race will normally come out of the wheel bearing with the
hub as it is pressed out of the bearing.
6. Remove the knuckle from the Fixture and turn it over. 7. Remove the snap ring (2) from the
knuckle using an appropriate pair of snap ring pliers (1).
8. Place the knuckle back in the Fixture (3) in the arbor press ram. 9. Place Installer (2), Special
Tool MD-998334, on the outer race of the wheel bearing. Lower the arbor press ram (1) and
remove the wheel bearing
from the knuckle.
10. Remove the knuckle and tools from arbor press.

11. If the bearing race is still pressed onto the hub, install the Bearing Splitter (5), Special Tool
1130, between the hub flange and the bearing inner
race (4).
12. Place the hub, bearing race and Bearing Splitter in an arbor press. The press support blocks
must not obstruct the wheel hub while it is being
pressed out of the bearing race.
13. Place Remover/Installer (2), Special Tool 9712-2, in the end of the hub (3). Lower the arbor
press ram (1) and remove the hub from the bearing
race.
Installation
INSTALLATION
CAUTION: When installing the wheel bearing (1) in the knuckle (2) it is important to place the side
of bearing with the wheel speed sensor magnetic encoder ring (dark band) (3) in the knuckle first.
Otherwise, the wheel speed sensor will not operate correctly.
1. Wipe the bearing bore of the knuckle clean of any grease or dirt with a clean, dry shop towel.
2. Place the knuckle in an arbor press supporting the knuckle from underneath using Cup (4),
Special Tool 6310-1. 3. Place the NEW wheel bearing (5) magnetic encoder ring side down (see
above Caution) into the bore of the knuckle. Be sure the wheel bearing is
placed squarely into the bore.
4. Place Receiver (3), Special Tool 8498, larger inside diameter end down over the outer race of
the wheel bearing. 5. Place Disc (2), Special Tool 6310-2, into top of Receiver 8498. Lower the
arbor press ram (1) and press the wheel bearing into the knuckle until it
is bottomed in the bore of the knuckle.
6. Remove the knuckle and tools from the arbor press.
7. Install a NEW snap ring (2) in the knuckle using an appropriate pair of snap ring pliers (1). Make
sure the snap ring is fully seated.
8. Place the knuckle in an arbor press. Support the knuckle from underneath using
Remover/Installer (3), Special Tool MB-990799, smaller end up
against the wheel bearing inner race.
9. Place the hub (4) in the wheel bearing making sure it is square with the bearing inner race.
10. Position Remover/Installer, Special Tool 9712-2 (2), in the end of the hub. Lower the arbor
press ram (1) and press the hub into the wheel bearing
until it bottoms.
11. Remove the knuckle and tools from the press. 12. Verify the hub turns smoothly without
rubbing or binding. 13. Install the knuckle on the vehicle.
Wheel Bearing: Service and Repair Rear Suspension
Removal
ALL-WHEEL-DRIVE
NOTE: Before proceeding, refer to Rear Suspension WARNING.
2. Remove the wheel mounting nuts (3), then the tire and wheel assembly (1).
3. Remove the cotter pin (2) from the hub nut (3) on the end of the axle half shaft. 4. While a helper
applies the brakes to keep the hub (1) from rotating, remove the hub nut (3) and washer (4) from
the axle half shaft. 5. Tap the end of the half shaft inward, loosening it from the hub and bearing.
6. Remove the disc brake caliper (2) lower guide pin bolt (1).
CAUTION: When moving rear brake caliper upward, use extreme care not to damage or
overextend the flex hose. Damage may occur.
7. Rotate the caliper upward hinging off the upper guide pin bolt. Rotate the caliper upward just
enough to allow brake rotor removal. Hang the
caliper assembly in this position using wire or a bungee cord.

8. Remove any clips (2) retaining the brake rotor (3) to the wheel mounting studs. 9. Slide the
brake rotor (3) off the hub and bearing (1).
10. Unclip the wheel speed sensor head (1) from the retainer on the rear of the hub and bearing
(2).
11. Remove the four bolts (1) securing the hub and bearing (2) to the trailing link. 12. Remove the
hub and bearing.
Installation
ALL-WHEEL-DRIVE
1. Slide the hub and bearing over the axle half shaft and position it on the brake support plate and
trailing link. 2. Install the four bolts (1) securing the hub and bearing (2) to the trailing link. Tighten
the bolts to 105 Nm (77 ft. lbs.).
3. Clip the wheel speed sensor head (1) (flat side to bearing rear) into the retainer on the rear of
the hub and bearing (2).
4. Slide the brake rotor (3) over the parking brake shoes and onto the hub and bearing (1).
5. Rotate the disc brake caliper downward over the brake rotor and lower part of caliper adapter. 6.
Install the disc brake caliper (2) lower guide pin bolt (1). Tighten the guide pin bolt to 60 Nm (44 ft.
lbs.).
7. Clean all foreign matter from the threads of the half shaft outer C/V joint. 8. Install the washer (4)
and hub nut (3) on the end of the half shaft and snug it. 9. While a helper applies the brakes to
keep the hub (1) from rotating, tighten the hub nut (3) to 245 Nm (181 ft. lbs.).
10. Insert the cotter pin (2) through the notches in the nut and the hole in half shaft. If the notches
in the nut do not line up with the hole in the half
shaft, continue to tighten the nut until they do. Do not loosen the nut.
11. Wrap the cotter pin (2) ends tightly around the lock nut.
Nm (100 ft. lbs.). 13. Lower the vehicle. 14. Pump the brake pedal several times to ensure the
vehicle has a firm brake pedal before moving it.
Jeep Workshop Manuals > Maintenance > Wheels and Tires > Wheel Hub > Axle Nut > Component Information >
Specifications
Axle Nut: Specifications
Front and Rear Axle Nut ......................................................................................................................

................................................. 244 Nm (180 ft. lbs.)
Jeep Workshop Manuals > Maintenance > Wheels and Tires > Wheel Fastener > Component Information > Specifications
Wheel Fastener: Specifications
WHEEL LUG NUTS
Aluminum Wheel
Steel Wheel
Progressively tighten all wheel mounting nuts in the proper sequence shown. Tighten nuts to a final
torque of 135 Nm (100 ft. lbs.).
Jeep Workshop Manuals > Maintenance > Wheels and Tires > Wheel Fastener > Component Information > Service and
Repair > Front
Wheel Fastener: Service and Repair Front
Removal
REMOVAL
NOTE: Use the following procedure to remove one of five studs on one wheel hub.
1. Access and remove front brake rotor.
CAUTION: Do not hammer wheel mounting studs out of the hub. Damage to the wheel bearing will
occur, leading to premature bearing failure.
2. Install Remover (3), Special Tool 8677, on the hub flange (1) and wheel stud (2). 3. Tighten the
Remover, pushing the wheel mounting stud out the rear of the hub flange. When the shoulder of
the stud is past the flange, remove the
Remover from the hub.
4. Remove the stud from the hub flange.

Installation
INSTALLATION
NOTE: Use the following procedure to install one of five studs on one wheel hub.
Repair > Front > Page 1999
1. Install the NEW wheel mounting stud in the flange of the hub (2) from the rear. 2. Install several
washers (1) and a standard wheel mounting (lug) nut (3) on the stud (4). Install the mounting nut so
that the flat side of the nut is
against the washers to eliminate any binding.
3. Tighten the wheel mounting nut. This will pull the wheel mounting stud into the hub flange. When
the head of the stud is fully seated against the
rear of the hub flange, remove the wheel mounting nut and washers.
4. Install the brake rotor and all components previously removed to access it.
Wheel Fastener: Service and Repair Rear
Removal
REMOVAL
1. Access and remove rear brake rotor.
2. Install Remover (1), Special Tool 8677, on the hub flange (2) and wheel stud (3). 3. Rotate the
hub around until an open spot is found directly behind the wheel stud. 4. Tighten the Remover,
pushing the wheel mounting stud out the rear of the hub flange. When the shoulder of the stud is
past the flange, remove the
Installation
INSTALLATION
4. Install the rear brake rotor and all components previously removed to access it.
Jeep Workshop Manuals > Engine, Cooling and Exhaust > Engine > Actuators and Solenoids - Engine > Variable Valve
Timing Solenoid > Component Information > Locations > Solenoid-Camshaft 1/1 Position
Variable Valve Timing Solenoid: Locations Solenoid-Camshaft 1/1 Position
Component ID: 333
Component : SOLENOID-CAMSHAFT 1/1 POSITION
Connector:
Name : SOLENOID-CAMSHAFT 1/1 POSITION
Color : BLACK
# of pins : 2
Qualifier : (GAS)
2 FUSED MAIN RELAY OUTPUT K343 16BR/YL
Timing Solenoid > Component Information > Locations > Solenoid-Camshaft 1/1 Position > Page 2009
Component ID: 334
Connector:
Color : BLACK
# of pins : 2
Qualifier : (GAS)
Timing Solenoid > Component Information > Diagrams > Solenoid-Camshaft 1/1 Position
Variable Valve Timing Solenoid: Diagrams Solenoid-Camshaft 1/1 Position
Component ID: 333
Connector:
Color : BLACK
# of pins : 2
Qualifier : (GAS)
Timing Solenoid > Component Information > Diagrams > Solenoid-Camshaft 1/1 Position > Page 2015
Component ID: 334
Connector:
Color : BLACK
# of pins : 2
Qualifier : (GAS)
Timing Solenoid > Component Information > Description and Operation > Description
Variable Valve Timing Solenoid: Description and Operation Description
DESCRIPTION
Variable valve timing solenoid assembly. The solenoid receives pulse width modulation signal and
the current is controlled within 0 ma to 1000 ma. The spool position is controllable at any position to
control supply of oil between the advance and retard ports.
Timing Solenoid > Component Information > Description and Operation > Description > Page 2021
Variable Valve Timing Solenoid: Description and Operation Operation
OPERATION
There is both an Intake and an exhaust camshaft sensor on vehicles equipped with a World
Engine. The variable valve timing system used on World Engines requires the exact position of
both the intake and exhaust camshaft. The GPEC1 uses camshaft sensor data along with
crankshaft data to determine the actual position of the camshafts. Intake and exhaust phaser oil
control valves are required on World Engine vehicles using variable valve timing. The oil valves
direct oil to the Intake and exhaust phasers. Oil pressure in the phasers moves the camshafts to an
advanced or retarded position.
To resolve this inherent conflict between optimum high and low speed valve timing, the GPEC1
controlled engine uses a variable valve timing system. The variable valve timing system advances
and retards valve timing by rotating the position of both the intake and exhaust camshafts. With this
system, the intake valve opening can range from 80 to 120 crankshaft degrees after Top Dead
Center. Likewise, the exhaust valve opening can range from 85 to 120 crankshaft degrees before
Top Dead Center. This degree of flexibility provides many benefits, including: Improved Engine
Performance, Increased Fuel Economy, Improved Idle Stability and Decreased Engine Emissions.
In non operating condition, the camshaft stays in lockpin position of cam phases. This is 120
degrees ATDC for intake camshaft and 120 degrees BTDC for exhaust camshaft.
The variable valve timing system is electronically controlled and hydraulically operated. The
GPEC1 receives information from many sensors to determine the optimum valve timing. It then
pulse-width modulates oil control valves which direct oil to the cam phasers. The cam phasers use
oil pressure to rotate the intake and exhaust camshafts. The rotation of the camshafts is referred to
as cam phasing. Before the GPEC1 can begin commanding the camshaft phasing, several
enabling conditions must be met:
- The engine oil temperature must be at least -6.6° C (20° F)
- The oil control valve coil temperature must be less than 140° C (284° F)
- Engine speed must be at least 600 to 1000 rpm to achieve minimum oil pressure.
- Battery voltage must be at least 10 volts
- And there must be no camshaft or crankshaft sensor faults, engine timing faults, or oil control
valve faults
First we will examine variable valve timing enabling conditions, and then we will take a closer look
at the inputs and outputs of the system:
- Accelerator pedal position sensor
- Oil temperature sensor
- Map sensor
- Intake cam sensor
- Exhaust cam sensor
- Crankshaft sensor
- GPEC1
- Exhaust phaser oil control valve
- Intake phaser oil control valve

- Inputs
- Engine control module
- Outputs
- Sensed battery voltage
A minimum oil temperature is required to enable variable valve timing operation. Oil temperature
and viscosity also have an impact on the operation of variable valve timing after start-up. Oil is
used to control the movement of the camshafts. An incorrect oil viscosity could adversely affect the
operation of the system or even render the system inoperative. It may even set a fault code.
The accelerator pedal position sensor indicates how far the driver wants to open the throttle plate.
The GPEC1 calculates an initial camshaft set point based on whether the accelerator pedal is at
part throttle or wide open throttle.
The MAP sensor provides information regarding engine load.
Sensed battery voltage provides information regarding current system voltage. Sensed battery
voltage must be at least 10 volts in order for the oil control valves to function properly.
This information allows the GPEC1 to adjust camshaft timing to achieve the best fuel economy, the
best engine performance or a combination of both. The hall-effect crankshaft sensor provides RPM
information and determines when the number one piston is approaching Top Dead Center. The
sensor generates a signal as the tone wheel, attached to the crankshaft, rotates. The tone wheel
has 60 teeth minus two. When the gap, created by the missing teeth passes by the sensor, a signal
is produced that indicates the number one piston is at Top Dead Center. The GPEC1 uses
crankshaft sensor data along with camshaft data to determine the actual position of the camshaft.
There are two hall-effect camshaft sensors on engines equipped with variable valve timing. The
GPEC1 uses camshaft sensor data along with crankshaft data to determine the actual position of
the camshaft.
The GPEC1 individually controls each valve. It sends a pulse width modulated signal to move a
spool within the outer casing of the valve. Depending upon spool movement, oil is directed through
the passages to advance or retard cam timing. The oil control valve also has a special cleaning
strategy at
key-on. The cleaning strategy is known as "debris crush mode". At key-on the GPEC1 cycles the
oil control valve on and off several (5) times to crush any debris in the oil control valve and prevent
the spool valve from sticking. In non operating condition, the camshaft stays in lockpin position of
cam phases. This is 120 degrees ATDC for intake camshaft and 120 degrees BTDC for exhaust
camshaft.
There are two oil control valves. One valve directs oil to the intake cam phaser, the other valve
directs oil to the exhaust cam phaser. The valves are designed and function in the same manner.
The outer casing of each oil valve has five oil passages. A passage for pressurized supply oil. A
passage to the advance chamber of the cam phaser. A passage to the retard chamber of the cam
phaser. A passage for oil return from the advance chamber of the cam phaser. A passage for oil
return from the retard chamber of the cam phaser. Oil flows through the passages and applies
pressure to the cam phasers to change cam timing.
There are two cam phasers. One phaser controls the position of the intake camshaft. The other
phaser controls the position of the exhaust camshaft. The phasers consist of a sprocket, a rotor
vane, and a housing or stator. The exhaust cam phaser also consists of a front bushing and spring.
We will discuss the purpose and function of the bushing and spring later. The housing is bolted and
permanently fixed to the camshaft sprocket, while the rotor vane is bolted and permanently fixed to
the camshaft. With this design, any movement of the rotor vane in relation to the housing will also
move the camshaft. The phaser and sprocket are serviced as an assembly.
Camshaft and crankshaft sensors provide feedback to the GPEC1 regarding the actual position of
the camshafts. The GPEC1 then compares the actual camshaft positioning with desired
positioning. If the desired positioning is not achieved within a specified time, during the second key
cycle a trouble code is set.
There are six new diagnostic trouble codes available to help you determine if the control circuit
from the GPEC1 to the oil control valve is intact and operating properly. The codes identify whether
the control circuit is open, shorted to ground, or shorted to power. Three trouble codes are related
to intake camshaft positioning, the other three codes are specific to exhaust camshaft positioning.
The oil control valve contains both electrical and mechanical components. It is electrically
controlled by the GPEC1. The electrical current that energizes the coil results in mechanical motion
of the spool valve. It is possible to verify both the electrical and mechanical operation of the valve.
The oil control valve consists of a coil that is energized to move a spool within an outer casing. The
condition of the coil can be tested with a Digital Volt Ohmmeter or DVOM. With the DVOM set to
measure resistance, check the coil for an open, a short to ground, or excessive resistance. The
correct resistance value of the coil is between 6 and 8 ohms. The mechanical operation of the oil
control valve can be tested using actuator commands on the scan tool. Remove the oil control
valve, then navigate to the actuator menu and select the oil control valve. Use commands to
activate the valve and watch as the spool valve moves back and forth inside the casing.
Because the cam phasers are hydraulically operated by engine oil, the condition of the oil is very
important. The oil must be of the correct viscosity, not obstructed by debris, to maintain correct
pressure. Maintaining the correct oil viscosity is critical to the operation of the variable valve timing
system. The wrong oil viscosity may cause the variable valve timing to malfunction and trouble
codes to set. The correct oil viscosity for this system is 5W20. Oil must be clean, unobstructed and
free to flow through the variable valve timing system. Oil could become obstructed in oil passages
located in the cylinder head, cylinder block, or even in the oil screen. In the event oil flow is
obstructed, further diagnosis or disassembly may be required to pin point the source of the
obstruction. The variable valve timing system relies on oil pressure to advance or retard the
position of the camshaft. Insufficient oil pressure will adversely affect the operation of variable valve
timing. The minimum oil pressure for this system is 15 psi at normal operating temperature.
Though not directly used to change camshaft positioning, the oil screen is an important component
of the variable valve timing system. It helps to remove debris going to the variable valve timing
components. The oil screen is located in the cylinder block, immediately below the cylinder head.
Oil must pass through the oil screen before entering the oil control valve. The cylinder head must
be removed to service the oil screen. The intention is not to service the oil screen during vehicle
life.
How the cam phaser works. The cam phaser assembly has eight separate chambers; four advance
chambers and four retard chambers. When camshaft advance is requested, oil enters all four
advance chambers and exerts force on the rotor vane. Because the rotor vane is bolted to the
camshaft, the entire camshaft profile moves along with the rotor vane. At the same time, oil is
forced out of the retard chambers. When camshaft retard is requested oil enters the retard
chambers to move the camshaft in the opposite direction. There is a lock pin on one side of the
rotor vane that fits inside a recessed area in the housing. The lock pin ensures that the default
position of the intake cam phaser is 120 crankshaft degrees full retard and the default position of
the exhaust cam phaser is 120 crankshaft degrees full advance. When the engine is turned off,
rotational force and inertia move the intake camshaft and rotor vane toward the retard position. The
exhaust cam phaser includes a spring and bushing to work against the rotational force of the
engine, allowing the exhaust cam phaser to lock in the fully advanced position. Under most
conditions the cam phasers are returned to lock pin position when the engine is turned off. In the
unique condition of an engine stall, which abruptly shuts off the engine, the cam phasers may not
return to the lock pin position. In this case, the phasers will return to the lock pin position at the next
start-up. Lock pin position is the most ideal cam timing for idle stability. When engine rpm exceeds
approximately 600 to 1000 rpm, oil pressure unlocks the pins and variable valve timing resumes.
Once enabling conditions are met, the GPEC1 uses input from sensors to calculate optimum valve
timing.
There are four preprogrammed modes from which the GPEC1 bases initial valve timing.
- Starting
- Idle or Part throttle
- Wide open throttle
- Limp-in or Default
From each preprogrammed mode, the GPEC1 adjusts valve timing based on operating conditions.
GPEC1 has calculated optimum intake valve timing of 112 degrees after Top Dead Center and
optimum exhaust valve timing of 97 degrees before Top Dead Center. The GPEC1 pulse width
modulates the oil control valves to advance or retard the camshaft to their desired location. The
spool valve inside the intake oil control valve is energized and moves to allow pressurized oil into
the advance chambers of the intake cam phaser. At the same time, the spool valve inside the
exhaust oil control valve is energized and moves to allow pressurized oil into the retard chambers
of the exhaust cam phaser. Oil enters the advance chambers of the intake phaser and the retard
chambers of the exhaust phaser. Oil pressure releases the lock pin from its locked position and
pushes against the rotor vane. Both the rotor vanes are moved, advancing the intake camshaft and
retarding the exhaust camshaft.
Timing Solenoid > Component Information > Service and Repair > Variable Valve Timing Solenoid - Removal
Variable Valve Timing Solenoid: Service and Repair Variable Valve Timing Solenoid - Removal
Front Solenoid 1/1
FRONT SOLENOID 1/1
2. Remove engine cover.
3. Rotate hose clamp out of way.
4. Disconnect oil pressure sensor electrical connector.
5. Remove oil pressure sensor.
6. Disconnect variable valve timing solenoid electrical connector.

Timing Solenoid > Component Information > Service and Repair > Variable Valve Timing Solenoid - Removal > Page 2026
7. Remove variable valve timing solenoid mounting bolt.
8. Pull solenoid straight out of cylinder head.
Rear Solenoid 1/2
REAR SOLENOID 1/2


Variable Valve Timing Solenoid: Service and Repair Variable Valve Timing Solenoid - Installation
Front Solenoid 1/1
FRONT SOLENOID 1/1
1. Solenoid for front location 1/1. Note mounting tab location is different between front and rear
solenoids.
2. Install solenoid into cylinder head.
3. Install mounting bolt and tighten to 12 Nm (9 ft. lbs.).

4. Install oil pressure sensor.
5. Connect electrical connector to oil pressure sensor.
6. Connect electrical connector to Variable valve timing solenoid.
8. Install engine cover.
Rear Solenoid 1/2
REAR SOLENOID 1/2
1. Rear variable valve timing solenoid. Note mounting tab location is different between front and
rear solenoids.


Jeep Workshop Manuals > Engine, Cooling and Exhaust > Engine > Compression Check > System Information >
Specifications
..............................................................................................................................................................
1172-1551 kpa (170-225 psi)
Jeep Workshop Manuals > Engine, Cooling and Exhaust > Engine > Compression Check > System Information >
malfunctions.
pressure.
Jeep Workshop Manuals > Engine, Cooling and Exhaust > Engine > Camshaft, Lifters and Push Rods > Camshaft Bearing
> Component Information > Technical Service Bulletins > Recalls for Camshaft Bearing: > F38 > Oct > 06 > Campaign -
Engine Camshaft Cap Bolt Torque
Campaign - Engine Camshaft Cap Bolt Torque
October 2006
Dealer Service Instructions for: Customer Satisfaction Notification F38 Engine Camshaft Cap Bolts
Effective immediately, all repairs on involved vehicles are to be performed according to this
notification. Rapid Response Transmittal (RRT) # 06-026 has been cancelled.
Models
2007 (PM) Dodge Caliber 2007 (MK) Jeep(R) Compass
NOTE:
This notification applies only to the above vehicles with an engine build date code through
TxxP11596 (Txx=traceability identifier [ignore], P1 = plant code, 159=Julian date for June 8, and,
6=2006). The date code is on the bar code label affixed to the front of the cylinder head cover.
IMPORTANT: Those vehicles that have already had this repair performed, as determined by our
warranty records, have been excluded from this notification.
IMPORTANT:
Some of the involved vehicles may be in dealer vehicle inventory. Dealers should complete this
repair on these vehicles before retail delivery. Dealers should also perform this repair on vehicles in
for service. Involved vehicles can be determined by using the VIP inquiry process.
Subject
The engine camshaft cap bolts on about 250 of the above vehicles may not have been adequately
tightened. This can cause damage to the camshaft bearing and/or the camshaft.
Repair
The # 1 engine exhaust camshaft bearing position must be inspected and the # 1 camshaft cap
bolts must be tightened to specification.
Parts Information
IMPORTANT:
Due to the likelihood that the required Mopar Engine Sealant RTV is already in your parts
inventory, no Engine Sealant RTV will be distributed to involved dealers initially. Parts may be
ordered as needed to support scheduled repairs. Each tube of sealant is sufficient to complete
about 30 vehicles.
record Customer Satisfaction Notification service completions and provide dealer payments.
Engine Camshaft Cap Bolt Torque > Page 2044
Dealer Notification
All dealers will receive three copies of this dealer notification letter by mail. To view this notification
on DealerCONNECT, select "Global Recall System" on the Service tab, then click on the
description of this notification.
by mail. They are requested to schedule appointments for this service with their dealers. A generic
copy of the owner letter is included.
name, address and phone number are listed if known. Completed vehicles are removed from GRS
within several days of repair claim submission.
Dealers should perform this repair on all unsold vehicles before retail delivery. Dealers should also
VIN lists may contain confidential, restricted owner name and address information that was
permitted for this notification only and is strictly prohibited from all other use.
Service Procedure
Engine Camshaft Cap Inspection and Bolt Tightening:
1. Discharge the fuel system pressure as follows:
a. Remove the lower rear seat cushion.
b. Remove the fuel pump module cover.
c. Disconnect the electrical connector to the fuel pump module.
d. Start and run engine until it stalls.

e. Attempt restarting engine until it will no longer run.
f. Turn ignition key to OFF position.
2. Remove air inlet duct over the battery.
NOTE:
To enhance customer satisfaction, remember to reset the clock when you have completed the
service procedure.
4. Remove the engine cover and the plastic retainers on the valve cover studs.
5. Disconnect the electrical connectors on the ignition coils.
6. Disconnect the PCV and make-up air hoses from cylinder head cover.
7. Unfasten the electrical harness and its retainer clips from the cylinder head cover studs.
8. Disconnect the fuel line at the engine fuel rail.
9. Use compressed air to blow dirt and debris off the cylinder head cover.
10. Remove the cylinder head cover, ignition coils, bolts and studs as a complete assembly.
CAUTION:
Do not remove the coils from the cylinder head cover at this time to minimize dirt from entering the
engine during disassembly.
11. On the bench, remove the four ignition coils from the cylinder head cover.
12. Inspect the rear of the # 1 camshaft bearing cap at the exhaust camshaft (Figure 1):
If the split line of the bearings and the split line of the bearing cap-to-cylinder head are parallel to
each other, continue with Step 13.
If the split line of the bearings and the split line of the bearing cap-to-cylinder head are NOT parallel
to each other, (the bearing has rotated) contact the STAR Center for further assistance.
13. Tighten each of the front camshaft bearing cap bolts to 20 ft.lbs. (27 N.m) in the following order
(Figure 2):
a. Exhaust side outside bolt (1).
b. Intake side outside bolt (2).

c. Exhaust side middle bolt (3).
d. Intake side middle bolt (4).
14. Clean all RTV from the cylinder head surface and wipe the surface with a clean cloth.
15. With a clean cloth, wipe the cylinder head cover gasket and inspect for damage (cuts, tears or
voids). If damaged, replace with PN 04884765AA center gasket and/or PN 04884762AA perimeter
gasket.
16. Apply a 1/8" (3mm) bead of Mopar Engine Sealant RTV to cylinder head/front cover T-joint
(Figure 3).
17. Position the cylinder head cover on the engine and install cylinder head cover studs as shown.
(Figure 4).
18. Position the cylinder head cover on the cylinder head and install all bolts.
19. Tighten the cylinder head cover fasteners in two steps following the sequence as shown in
Figure 5:
a. Tighten all fasteners to 44 in. lbs. (5 N.m).
b. Tighten all bolts to 90 in. lbs. (10 N.m).
20. Install the four ignition coils. Tighten fasteners to 70 in. lbs. (8 N.m).
21. Connect the fuel line to the engine fuel rail.
22. Install the harness and its retainer clips onto the cylinder head cover studs.
23. Remove the plastic retainers (if any) from the engine cover and install the four retainers onto
the appropriate studs of the cylinder head cover.
24. Connect the PCV and make-up air hoses to the cylinder head cover.
25. Install the engine cover. Check all four mounting grommets for proper engagement to the
plastic retainers.
26. Connect the fuel pump harness connector to the fuel pump.
27. Install the fuel pump access cover and tighten the screw.
28. Install the rear seat lower cushion.
29. Connect the battery.
30. Install the air inlet duct over the battery.
NOTE:
Due to the fuel line pressure discharge procedure, a Diagnostic Trouble Code (DTC) may be set in
some modules (PCM, TCV, ABS, BCM, MIC, WCM, etc.) within the vehicle, if so equipped. Some
DTC's may cause the MIL to illuminate. Connect the StarSCAN tool to the vehicle. From the
"Home" screen select "System View". Then select "All DTCs". Press "Clear All Stored DTCs" if
there are any DTCs shown on the list.
> Component Information > Technical Service Bulletins > All Technical Service Bulletins for Camshaft Bearing: > F38 > Oct
> 06 > Campaign - Engine Camshaft Cap Bolt Torque
October 2006
Models
NOTE:
IMPORTANT:
Subject
Repair
Parts Information
IMPORTANT:
about 30 vehicles.
> 06 > Campaign - Engine Camshaft Cap Bolt Torque > Page 2055
Dealer Notification
Service Procedure

NOTE:
service procedure.
CAUTION:
(Figure 2):

gasket.
(Figure 3).
(Figure 4).
Figure 5:
plastic retainers.
NOTE:
> Component Information > Technical Service Bulletins > Page 2061
Camshaft Bearing: Specifications
Camshaft Bearing Cap-Bolts
M6 Bolts ...............................................................................................................................................
............................................. 11 Nm (100 in. lbs.) M8 Bolts ................................................................
............................................................................................................ 25 Nm (18 ft. lbs.) 220 in. lbs.
Jeep Workshop Manuals > Engine, Cooling and Exhaust > Engine > Camshaft, Lifters and Push Rods > Camshaft
Gear/Sprocket > Component Information > Description and Operation > Variable Valve Timing Assembly - Description
Camshaft Gear/Sprocket: Description and Operation Variable Valve Timing Assembly - Description
DESCRIPTION
The world engine is equipped with Variable Valve Timing (VVT). This system advances and/or
retards intake and/or exhaust camshaft timing to improve engine performance, mid-range torque,
idle quality, fuel economy, and reduce emissions. The camshaft sprockets are integrated with the
VVT assemblies and are serviced as an assembly. VVT assemblies are sometimes referred to as
camshaft phasers.
Gear/Sprocket > Component Information > Description and Operation > Variable Valve Timing Assembly - Description >
Page 2066
Camshaft Gear/Sprocket: Description and Operation Variable Valve Timing Assembly - Operation
OPERATION
The Variable Valve Timing (VVT) assemblies are actuated with engine oil pressure. The oil flow to
the VVT assemblies are controlled by two Oil Control Valves (OCV). There is an OCV and
Camshaft Position Sensor (CMP) for each camshaft. The OCV's consist of a Pulse Width
Modulated (PWM) solenoid and a spool valve. The PCM actuates the OCV to control oil flow
through the spool valve into the VVT assemblies. The VVT assembly consists of a rotor, stator, and
sprocket. The stator is connected to the timing chain through the sprocket. The rotor is connected
to the camshaft. Oil flow in to the VVT assembly rotates the rotor with respect to the stator, thus
rotating the camshaft with respect to the timing chain. Thus, the VVT assemblies change valve
timing by changing the relationship between the camshaft and the timing chain. An integral oil
pressure activated pin is used to lock base camshaft timing for engine start up. Oil pressure
releases the pin and allows the PCM to control cam timing once the engine is running. An infinitely
variable valve timing position can be achieved within the limits of the hardware. The CMP monitors
the position of the camshaft with respect to the crankshaft and provides feedback to the PCM.
Gear/Sprocket > Component Information > Service and Repair > Camshaft Sprockets - Removal
Camshaft Gear/Sprocket: Service and Repair Camshaft Sprockets - Removal
REMOVAL
NOTE: Camshaft phaser and camshaft sprocket are supplied as an assembly, do not attempt to
disassemble.
1. Remove camshafts. 2. Remove camshaft phaser (2) retaining bolt while holding the camshaft in
place with a wrench (1) on the camshaft flats. 3. Remove phaser (2) assembly from camshaft.
Gear/Sprocket > Component Information > Service and Repair > Camshaft Sprockets - Removal > Page 2069
Camshaft Gear/Sprocket: Service and Repair Camshaft Sprockets - Installation
INSTALLATION
CAUTION: Do not use an impact wrench to tighten camshaft sprocket bolts. Damage to the
camshaft-to-sprocket locating dowel pin and camshaft phaser may occur.
1. Install phaser (2) assembly on camshaft.
NOTE: Make sure the dowel is seated in the dowel hole and not in a oil feed hole. The dowel hole
is larger than the 4 oil feed holes.
2. Install phaser retaining bolt and torque while holding camshaft in place with a wrench (1). 3.
Install camshafts.
Jeep Workshop Manuals > Engine, Cooling and Exhaust > Engine > Camshaft, Lifters and Push Rods > Camshaft, Engine
> Component Information > Technical Service Bulletins > Recalls for Camshaft: > F38 > Oct > 06 > Campaign - Engine
Camshaft Cap Bolt Torque
October 2006
Models
NOTE:
IMPORTANT:
Subject
Repair
Parts Information
IMPORTANT:
about 30 vehicles.
Camshaft Cap Bolt Torque > Page 2078
Dealer Notification
Service Procedure

NOTE:
service procedure.
CAUTION:
(Figure 2):

gasket.
(Figure 3).
(Figure 4).
Figure 5:
plastic retainers.
NOTE:
> Component Information > Technical Service Bulletins > All Technical Service Bulletins for Camshaft: > F38 > Oct > 06 >
October 2006
Models
NOTE:
IMPORTANT:
Subject
Repair
Parts Information
IMPORTANT:
about 30 vehicles.
Campaign - Engine Camshaft Cap Bolt Torque > Page 2089
Dealer Notification
Service Procedure

NOTE:
service procedure.
CAUTION:
(Figure 2):

gasket.
(Figure 3).
(Figure 4).
Figure 5:
plastic retainers.
NOTE:
> Component Information > Description and Operation > Camshaft - Description
Camshaft: Description and Operation Camshaft - Description
CAMSHAFTS
Both camshafts have five bearing journal surfaces and two cam lobes per cylinder. The two front
journals are larger to allow for feeding oil to the variable valve timing (VVT) camshaft phasers.
Flanges on the third smaller journal control camshaft end play. At the rear of each camshaft is an
integral cam sensor target.
CAMSHAFT BEARING CAPS
The front cam bearing cap spans both camshafts, and includes dowels for precise alignment. The
front exhaust journal has a select fit bearing insert. This bearing is required to seal the oil passage
to the camshaft phaser, because a portion of the lower bearing saddle is machined away for head
bolt access. The select fit is required to minimize bearing clearance and oil leakage. An exhaust
bearing grade (1,2 or 3) is stamped into the front bearing cap adjacent to the exhaust cam journal.
The bearings are also marked with the corresponding grade markings. If the bearing is replaced,
the same grade must be used. Due to unique purpose of this bearing, it may appear to have
uneven wear patterns. Unless the wear is excessive it is no cause for concern.
The front intake journal has a full lower bearing saddle, and therefore, no bearing insert is required.
All small bearing caps have a formed in arrow to assist in assembly. All small bearing cap arrows
must point towards the center of the cylinder head. The small bearing caps are marked for position
during the manufacturing process, and must be reinstalled in their original position.
The #1 small cap includes a passage to direct oil from the cylinder head oil gallery to the #1 small
bearing journal, and into the camshaft as well. The hollow camshaft then distributes oil to the
remainder of the small journals. Oil flowing out of each cam journal lubricates the valve tappets.
The #3 small cap is machined at the front and rear face to control camshaft end-play. This cap has
dowels for precise alignment.
> Component Information > Description and Operation > Camshaft - Description > Page 2097
Camshaft: Description and Operation Camshaft - Operation
OPERATION
The camshaft is driven by the crankshaft via drive sprockets and a chain. The camshaft has
precisely machined lobes to provide accurate valve timing and duration.
> Component Information > Service and Repair > Procedures
Camshaft: Procedures
Measuring Camshaft End Play
MEASURING CAMSHAFT END PLAY
1. Using a suitable tool, move camshaft as far rearward as it will go. 2. Zero dial indicator. 3. Move
camshaft as far forward as it will go. 4. Record reading on dial indicator. 5. If end play is excessive,
check cylinder head and camshaft for wear; replace as necessary.
Camshaft - Cleaning
CLEANING
Clean camshafts with a suitable solvent.
Camshaft - Inspection
INSPECTION
1. Inspect camshaft bearing journals for damage. If journals are damaged, check the cylinder head
for damage. Also check cylinder head oil holes for
clogging.
2. Check the cam lobe and bearing surfaces for abnormal wear and damage. Replace camshaft if
defective.
NOTE: If camshaft is replaced due to lobe wear or damage, always replace the lash buckets.
> Component Information > Service and Repair > Procedures > Page 2100
Camshaft: Removal and Replacement
Camshaft - Removal
REMOVAL
1. Remove engine cover (1) by pulling upward.
2. Disconnect negative cable from battery (3).
3. Disconnect coil electrical connectors (1). 4. Remove cylinder head cover.

5. Raise vehicle. 6. Remove right splash shield. 7. Rotate engine to TDC (1).
8. Make sure camshaft timing marks (3) are aligned. 9. Mark the chain link corresponding to timing
marks (1) with a paint marker.
10. Remove timing tensioner plug (1) from front cover.

11. Insert small allen wrench through timing tensioner plug hole and lift ratchet (2) upward to
release the tensioner and push allen wrench inward.
Leave the allen wrench installed during the remainder of this procedure.
12. Verify that camshaft timing marks (3) are facing each other as shown. 13. Mark the camshaft
sprocket timing marks and the corresponding chain links (1) with a paint marker.
14. Insert wedge 9701 (1) between camshaft phasers.
15. Lightly tap Wedge 9701(2) into place until it will no longer sink down.
16. Remove the front camshaft bearing cap. 17. Slowly remove the remaining intake and exhaust
camshaft bearing cap bolts one turn at a time.
18. Remove intake camshaft (1) by lifting the rear of the camshaft upward.
19. Rotate the camshaft while lifting out of the front bearing cradle.
20. Lift the timing chain (2) off the sprocket (1). 21. Remove exhaust camshaft. 22. Secure timing
chain with wire so that it does fall into the timing chain cover.
Camshaft - Installation
INSTALLATION
1. The cam cap (1) is numbered (2) either one, two, or three, this corresponds to the select fit
bearing to use.
2. Install the corresponding select fit bearing (1). 3. Oil all of the camshaft journals with clean
engine oil. 4. Install camshaft phasers on camshafts if removed.
a. Install camshaft phaser making sure that the dowel is in the correct hole. b. Install camshaft
phaser bolt and hand tighten.
5. Install timing chain onto exhaust cam sprocket making sure that the timing marks (1) on the
sprocket and the painted chain link are aligned.
6. Position exhaust camshaft and on bearing journals in the cylinder head. 7. Align exhaust cam
timing mark (3) so it is parallel to the cylinder head as shown.
8. Install intake camshaft by raising the rear of the camshaft upward and roll the sprocket into the
chain.
9. Align the timing marks (1) on the intake cam sprocket with the painted chain link.
10. Position the intake camshaft into the bearing journals in the cylinder head. 11. Verify that the
timing marks (1) are aligned on both camshafts and that the timing marks (3) are parallel with the
cylinder head.
CAUTION: Install the front intake and exhaust camshaft bearing cap last. Ensure that the dowels
are seated and follow torque sequence or damage to engine could result.
NOTE: If the front camshaft bearing cap is broken, the cylinder head MUST be replaced.
12. Install intake and exhaust camshaft bearing caps and slowly tighten bolts to 11 Nm (100 in.
lbs.) in the sequence shown.
NOTE: Verify that the exhaust bearing shells are correctly installed, and the dowels are seated in
the head, prior to torquing bolts.
13. Install the front intake and exhaust bearing cap and tighten bolts to 25 Nm (18 ft. lbs.) in the
sequence shown.
14. Verify that all timing marks (1, 3) are aligned. 15. Remove allen wrench from timing chain
tensioner.
16. Remove locking wedge 9701 by pulling straight upward on pull rope.
17. Apply MOPAR(R) thread sealant to timing tensioner plug (1) and Install. 18. Install right splash
shield.
19. Remove RTV from gasket (1). 20. Inspect cylinder head cover gaskets (1, 2) for damage. If no
damage is present, gaskets can be re-installed.
21. Install cylinder head cover.
22. Connect negative cable at battery (3). 23. Fill cooling system. 24. Fill with oil.
25. Start engine and check for leaks. 26. Install engine cover (1).
Jeep Workshop Manuals > Engine, Cooling and Exhaust > Engine > Camshaft, Lifters and Push Rods > Lifter / Lash
Adjuster, Valve > Component Information > Testing and Inspection
Lifter / Lash Adjuster: Testing and Inspection
MECHANICAL VALVE TAPPET NOISE DIAGNOSIS
A tappet-like noise may be produced from incorrect valve lash Refer to - CYLINDER
HEAD/HYDRAULIC LIFTERS - STANDARD PROCEDURE).
Adjuster, Valve > Component Information > Service and Repair > Procedures
Lifter / Lash Adjuster: Procedures
STANDARD PROCEDURE - MEASURING VALVE LASH

1. Remove engine cover. 2. Remove cylinder head cover.
3. Rotate camshaft so lobes are vertical (1). 4. Check clearance using feeler gauges. 5. Repeat for
all tappets and record readings. 6. If clearance was too small, go to the clearance to small
procedure Clearance to Small. 7. If clearance was too large, go to the clearance to large procedure
Clearance to Large.
Clearance to Small
Adjuster, Valve > Component Information > Service and Repair > Procedures > Page 2116
1. Remove camshafts. 2. Specification - clearance = change. 3. Decrease tappet thickness by
change figure. 4. Install camshafts. 5. Verify that valve lash is correct.
Clearance to Large
1. Remove camshafts. 2. Clearance - specification = change. 3. Increase tappet thickness by

change figure. 4. Install camshafts. 5. Verify that valve lash is correct.
Lifter / Lash Adjuster: Removal and Replacement
Removal
REMOVAL
NOTE: This procedure is for in-vehicle service with camshafts installed.
NOTE: Camshaft tappets must be replaced if cylinder head or camshafts are replaced.
1. Remove cylinder head cover. 2. Remove camshafts.
3. Remove camshaft tappets (1). 4. Repeat removal procedure for each camshaft tappet (1). 5. If
reusing, mark each tappet for reassembly in original position.
Installation
INSTALLATION
NOTE: If reinstalling original tappets they must go back in their original location or engine damage
could result.
1. Apply a light coat of clean engine oil to camshafts tappets (1) prior to assembly. 2. Install
camshaft tappets (1) into cylinder head. 3. Repeat installation procedure for each camshaft tappet.
4. Install camshafts.
NOTE: If installing new tappets, the valve lash procedure must be performed.

Jeep Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Block Assembly > Connecting Rod Bearing >
Component Information > Specifications
Connecting Rod Bearing: Specifications
Connecting Rod
Connecting Rod
Component Information > Service and Repair > Connecting Rod Bearing Fitting
Connecting Rod Bearing: Service and Repair Connecting Rod Bearing Fitting
CONNECTING ROD - FITTING
There are three different sizes of rod bearings available. Connecting rod bearing identification (4)
can be found on the nose of the crankshaft (3). Use the table below for proper bearing selection.
Connecting Rod Bearing Selection
1. For measuring connecting rod bearing clearance procedure and use of Plastigage. For bearing
clearance refer to Engine Specifications.
NOTE: The rod bolts should not be reused.
2. Before installing the NEW rod bolts the threads and under the bolt head should be oiled with
clean engine oil.
Component Information > Service and Repair > Connecting Rod Bearing Fitting > Page 2125
3. Install each bolt finger tight then alternately torque each bolt to assemble the cap properly. 4.
Tighten the connecting rod bolts using the 2 step torque-turn method. Tighten according to the
following values:
CAUTION: Do not use a torque wrench for the second step.
- Tighten the bolts to 20 Nm (15 ft. lbs.).
- Tighten the connecting rod bolts an additional 90°.
5. Using a feeler gauge, check connecting rod side clearance. Refer to clearance specifications.
Component Information > Service and Repair > Connecting Rod Bearing Fitting > Page 2126
Connecting Rod Bearing: Service and Repair Measuring Bearing Clearance Using Plastigage
MEASURING BEARING CLEARANCE USING PLASTIGAGE
Engine crankshaft bearing clearances can be determined by use of Plastigage or equivalent. The
following is the recommended procedure for the use of Plastigage:
1. Remove oil film from surface to be checked. Plastigage is soluble in oil. 2. Place a piece of
Plastigage (1) across the entire width of the journal. (In addition, suspected areas can be checked
by placing the Plastigage in the
suspected area). Torque the bearing cap bolts of the bearing being checked to the proper
specifications.
3. Remove the bearing cap and compare the width of the flattened Plastigage with the scale
provided on the package. Locate the band closest to the
same width. This band shows the amount of clearance. Differences in readings between the ends
indicate the amount of taper present. Record all readings taken. Compare clearance
measurements to specs found in engine specifications Refer to ENGINE - SPECIFICATIONS.
Plastigage generally is accompanied by two scales. One scale is in inches, the other is a metric
scale.
NOTE: Plastigage is available in a variety of clearance ranges. Use the most appropriate range for
the specifications you are checking.
4. Install the proper crankshaft bearings to achieve the specified bearing clearances.
Jeep Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Block Assembly > Connecting Rod, Engine >
Connecting Rod: Specifications
Connecting Rod
Connecting Rod
Connecting Rod Cap-Bolts

................................................................................................................................................... 20
Nm + 90° (15 ft. lbs. + 90°)
Component Information > Specifications > Page 2130
Connecting Rod: Description and Operation
DESCRIPTION
The pistons are made of a cast aluminum alloy. The pistons have pressed-in pins attached to
forged connecting rods. The pistons pin is offset 0.8 mm (0.0314 in.) towards the thrust side of the
piston. The connecting rods are a cracked cap design and are not repairable. The piston with rings,
connecting rod and piston pin are serviced as an assembly.
Component Information > Service and Repair > Piston and Connecting Rod - Removal
Connecting Rod: Service and Repair Piston and Connecting Rod - Removal
REMOVAL
NOTE: Pistons, rings, and rods are serviced as an assembly.
CAUTION: To maintain engine balance, 1, 3, or 4 pistons can be replaced. If 2 pistons are

replaced, engine will be out of balance.
1. Remove engine. 2. Remove engine from lift chain (1) and place on a suitable engine stand. 3.
Remove cylinder head.
4. Drain engine oil (2). 5. Remove oil pan (1).

Component Information > Service and Repair > Piston and Connecting Rod - Removal > Page 2133
6. Remove oil filter (1). 7. Remove balance shaft assembly. 8. Remove ladder frame.
NOTE: Remove any carbon build up and clean debris from cylinder prior to piston removal to avoid
scratching piston skirts.
9. Remove top ridge of cylinder bores with a reliable ridge reamer before removing pistons from
cylinder block. Be sure to keep tops of pistons
covered during this operation.
10. Rotate crankshaft so that each connecting rod is centered in cylinder bore. 11. Using a
permanent ink or paint marker, identify cylinder number on each connecting rod cap.
CAUTION: DO NOT use a number stamp or a punch to mark connecting rods, as damage to
connecting rod could occur.
CAUTION: Care must be taken not to damage the fractured rod and cap joint surfaces, as engine
damage many occur.
12. Remove connecting rod bolts and cap.
NOTE: Do not reuse connecting rod bolts.
13. Carefully push each piston and rod assembly out of cylinder bore. Re-install bearing cap on the
mating rod. 14. Repeat procedure for each piston and connecting rod assembly.
Connecting Rod: Service and Repair Piston and Connecting Rod - Installation
INSTALLATION
1. Install piston rings on piston. 2. Before installing pistons and connecting rod assemblies into the
bore, be sure that top compression ring gap (1) and the second compression ring
gap (3) are staggered so that neither is in line with oil ring rail gap.
3. Before installing the ring compressor, make sure the oil ring expander ends are butted (1) and
the rail gaps (2, 4) located as shown above. As
viewed from the top of the piston.
4. Immerse the piston head and rings in clean engine oil, slide the ring compressor, over the piston.
Be sure position of rings does not change
during this operation.
5. The directional arrow stamped on the piston should face toward the front of the engine. 6. Rotate
crankshaft so that the connecting rod journal is on the center of the cylinder bore. Lubricate
connecting rod journal with clean engine oil.
NOTE: There are three different size rod bearings, perform rod bearing selection procedure.
NOTE: The rod bearing sizes are indicated on the nose of the crankshaft.
7. Install connecting rod upper bearing half into connecting rod. 8. Install ring compressor (3). 9.
Tap the piston (1) down in cylinder bore, using a hammer handle (2). At the same time, guide
connecting rod into position on connecting rod
journal.
NOTE: The connecting rod cap bolts should NOT be reused.
10. Before installing the NEW bolts, the threads should be coated with clean engine oil. 11. Install
connecting rod lower bearing half into connecting rod cap. Install connecting rod cap. 12. Install
each bolt finger tight then alternately torque each bolt to assemble the cap properly. 13. Tighten the
connecting rod bolts using the 2 step torque-turn method. Tighten according to the following
values:
14. Using a feeler gauge, check connecting rod side clearance. 15. Install the ladder frame. 16.
Install oil pump/balance shaft carrier assembly. 17. Install oil pan. 18. Install cylinder head.
19. Install engine on lift chain (1). 20. Install engine.

Jeep Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Block Assembly > Crankshaft Main Bearing >
Crankshaft Main Bearing: Specifications
Crankshaft
Crankshaft
Crankshaft Main Bearing Cap-Bolts

................................................................................................................................... 27 Nm + 45°
(20 ft. lbs. + 45°)
Component Information > Service and Repair > Crankshaft Main Bearing Selection
Crankshaft Main Bearing: Service and Repair Crankshaft Main Bearing Selection
STANDARD PROCEDURE - MAIN BEARING SELECTION
NOTE: There are three different possibilities for the upper main bearings and five different lower
main bearings. The upper and lower bearing shells are not interchangeable.
The lower main bearing identification (2) is stamped in the nose of the crankshaft (3). There are 5
different bearing sizes available 0 through 4.
Component Information > Service and Repair > Crankshaft Main Bearing Selection > Page 2143
The upper main bearing shell identification (1) is located in the middle of cylinder block on the right
side of the engine. There are three different size bearings available. The bearing class is read
downward from top and corresponds to the front journal to the rear journal on the bottom.
Upper Main Bearing Selection

Component Information > Service and Repair > Crankshaft Main Bearing Selection > Page 2144
Crankshaft Main Bearing: Service and Repair Measuring Bearing Clearance Using Plastigage
MEASURING BEARING CLEARANCE USING PLASTIGAGE
Engine crankshaft bearing clearances can be determined by use of Plastigage or equivalent. The
following is the recommended procedure for the use of Plastigage:
1. Remove oil film from surface to be checked. Plastigage is soluble in oil. 2. Place a piece of
Plastigage (1) across the entire width of the journal. (In addition, suspected areas can be checked
by placing the Plastigage in the
suspected area). Torque the bearing cap bolts of the bearing being checked to the proper
specifications.
3. Remove the bearing cap and compare the width of the flattened Plastigage with the scale
provided on the package. Locate the band closest to the
same width. This band shows the amount of clearance. Differences in readings between the ends
indicate the amount of taper present. Record all readings taken. Compare clearance
measurements to specs found in engine specifications Refer to ENGINE - SPECIFICATIONS.
Plastigage generally is accompanied by two scales. One scale is in inches, the other is a metric
scale.
NOTE: Plastigage is available in a variety of clearance ranges. Use the most appropriate range for
the specifications you are checking.
4. Install the proper crankshaft bearings to achieve the specified bearing clearances.
Jeep Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Block Assembly > Crankshaft, Engine >
Crankshaft: Specifications
Crankshaft
Crankshaft
Component Information > Service and Repair > Procedures
Crankshaft: Procedures
Crankshaft - Inspection
INSPECTION
The crankshaft main journals should be checked for excessive wear, taper and scoring. Limits of
taper on any crankshaft main journals should be held to 0.006 mm (0.00024 in.). Limits of taper on
any crankshaft rod journals should be held to 0.005 mm (0.0002 in.). DO NOT nick crank pin or
bearing fillets. Limits of out of round on any crankshaft journals should be held to 0.005 mm
(0.0002 in). DO NOT nick crank pin or bearing fillets.
Measuring Crankshaft End Play
MEASURING CRANKSHAFT END PLAY
1. Mount a dial indicator (2) to front of engine with the locating probe on nose of crankshaft (1). 2.
Move crankshaft all the way to the rear of its travel. 3. Zero the dial indicator. 4. Move crankshaft all
the way to the front and read the dial indicator.
Component Information > Service and Repair > Procedures > Page 2150
Crankshaft: Removal and Replacement
Crankshaft - Removal
REMOVAL
NOTE: Crankshaft can not be removed when engine is in vehicle.
1. Remove engine assembly from vehicle. 2. Separate transaxle from engine. 3. Remove flex
plate/flywheel (1). 4. Remove crankshaft rear oil seal.
5. Remove engine from lift chain (1) and mount engine on a suitable repair stand.
6. Drain engine oil (2).
8. Remove crankshaft vibration damper (2). 9. Remove water pump pulley (3).
10. Remove engine mount support bracket (1).

11. Remove the oil pan (2). 12. Remove timing chain cover. 13. Remove the timing chain. 14.
Remove balance shaft module.
15. Remove the crankshaft sprocket (1).
16. Remove crankshaft position sensor retaining bolt (1) and remove sensor (2). 17. Remove
ladder frame.
NOTE: If piston/connecting rod replacement is necessary, remove cylinder head.
CAUTION: DO NOT use a number stamp or a punch to mark connecting rods. Damage to
18. Using a permanent ink or paint marker, identify cylinder number on each connecting rod and
cap. 19. Remove all connecting rod bolts and caps. Care should be taken not to damage the
fracture rod and cap surfaces.
20. Remove main bearing caps.
CAUTION: Use extreme care when handling crankshaft. Tone wheel damage can occur if
crankshaft is mis-handled.
21. Lift out crankshaft from cylinder block. Do not damage the main bearings or journals when
removing the crankshaft.
Crankshaft - Installation
INSTALLATION
The crankshaft is supported in five main bearings. All upper bearing shells (2) in the crankcase
have oil grooves and holes. All lower bearing shells (1) are smooth. Crankshaft end play is
controlled by a two piece thrust bearing (3) on the number three main bearing journal.
1. Clean main bearing cap bolt holes with Mopar(R) brake parts cleaner or equivalent and blow out
with compressed air. 2. Install the main bearing upper (2) shells with the lubrication groove and oil
hole in the engine block. 3. Make certain oil holes in block line up with oil hole in bearings and
bearing tabs seat in the block tab slots.
NOTE: If the crankshaft is sent out for machine work, it must be balanced as an assembly with the
target ring installed.
4. Clean crankshaft and target ring with MOPAR(R) Brake Parts cleaner and dry with compressed
air to ensure that the crankshaft mating surface and
target ring mounting holes are free from oil and lock patch debris.
NOTE: Always use NEW mounting screws whether installing original or new target ring.
5. Install NEW mounting screws finger tight starting with the #1 location. Make sure engagement
occurs with the shoulder of the screws and
mounting hole before starting all other screws.
6. Tighten all mounting screws with T30 torx bit to 13 Nm (110 in-lbs) in the sequence shown.
NOTE: Lightly apply trans gel to thrust bearings to hold bearings in block.
NOTE: The thrust bearings must be installed the notches facing the crankshaft.
7. Install thrust bearings (2) in block (1).
CAUTION: Do not get oil on the ladder frame mating surface. It will affect the ability of the RTV to
seal the ladder frame to cylinder block.
8. Oil the bearings and journals. Install crankshaft in engine block.

9. Install lower main bearings (1) into main bearing cap. Make certain the bearing tabs are seated
into the bearing cap slots.
NOTE: Main bearing caps are stamped 1 - 5 front to rear. Arrows on the caps must point towards
the front of the engine.
10. Install main bearing caps to engine block. 11. Before installing the bolts the threads should be
clean and dry.
12. To ensure correct thrust bearing alignment, perform the following steps:
- Step 1: Rotate crankshaft until number 4 piston is at TDC.
- Step 2: Move crankshaft rearward to limits of travel.
- Step 3: Then, move crankshaft forward to limits of travel.
- Step 4: Wedge an appropriate tool between the rear of the cylinder block and the rear crankshaft
counterweight. This will hold the crankshaft in its furthest forward position.
13. Tighten bolts (1-10) to 27 Nm + 45° (20 ft. lbs. + 45°) in the sequence shown above. 14.
Remove wedge tool used to hold crankshaft. 15. Check the crankshaft turning torque, it should not
exceed 5.6 Nm (50 in. lbs.). 16. Check crankshaft end play. 17. Install connecting rod bearings and
caps. Do Not Reuse Connecting Rod Bolts. Tighten connecting rod bolts to 20 Nm + 90° (15 ft. lbs.
+ 90°). 18. Install the ladder frame assembly. 19. Install the balance shaft module.
20. Install crankshaft position sensor (2) and tighten bolt (1). 21. Install cylinder head if it was
removed.
22. Install front crankshaft sprocket (1). 23. Install the timing chain. 24. Install the timing chain front
cover. 25. Install the oil pan. 26. Install rear crankshaft oil seal. 27. Install front crankshaft oil seal.
28. Install engine mount support bracket (1). 29. Install crankshaft vibration damper (2). 30. Install
water pump pulley (3).
31. Install engine lift chain (1). 32. Install crankshaft rear oil seal. 33. Install drive plate/flex plate
using new bolts. Tighten bolts to 95 Nm (70 ft. lbs.). 34. Attach transaxle to engine. Tighten
bellhousing bolts to 101 Nm (75 ft. lbs.). 35. Install the engine assembly.
36. Install new oil filter (1) and fill with oil. 37. Fill with coolant. 38. Start engine and check for leaks.
Jeep Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Block Assembly > Engine Block Heater >
Component Information > Description and Operation > Engine Block Heater - Description
Engine Block Heater: Description and Operation Engine Block Heater - Description
DESCRIPTION
The cartridge type block heater is mounted in a bore at the rear of the block under the coolant
adapter. The block heater does not directly contact coolant. It heads the aluminum block.
The heater is powered by 110 Volt AC through a power cord and connector.
Component Information > Description and Operation > Engine Block Heater - Description > Page 2162
Engine Block Heater: Description and Operation Engine Block Heater - Operation
OPERATION
The block heater element is inserted into a bore in the engine block. When electrical power (110
volt A.C.) is applied to the element, it creates heat. This heat is transferred to the aluminum engine
block. This provides easier engine starting and faster warm-up when vehicle is operated in areas
having extremely low temperatures.
Engine Block Heater: Testing and Inspection
ENGINE BLOCK HEATER TESTING
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 ohmmeter or 12-volt test light.
Component Information > Service and Repair > Engine Block Heater - Removal
Engine Block Heater: Service and Repair Engine Block Heater - Removal
REMOVAL
1. Remove engine cover. 2. Remove air cleaner inlet. 3. Detach power cord plug from heater. 4.
Remove retaining clip (1). Remove block heater assembly (2).
Component Information > Service and Repair > Engine Block Heater - Removal > Page 2166
Engine Block Heater: Service and Repair Engine Block Heater - Installation
INSTALLATION
1. Thoroughly clean bore hole. 2. Insert block heater assembly into bore. 3. Install retaining clip. 4.
Connect power cord to block heater.
5. Install air intake inlet. 6. Install engine cover.

Jeep Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Block Assembly > Harmonic Balancer -
Crankshaft Pulley > Component Information > Specifications
Harmonic Balancer - Crankshaft Pulley: Specifications
Crankshaft Damper-Bolt ......................................................................................................................

................................................. 210 Nm (155 ft. lbs.)
Crankshaft Pulley > Component Information > Service and Repair > Vibration Damper - Removal
Harmonic Balancer - Crankshaft Pulley: Service and Repair Vibration Damper - Removal
REMOVAL
1. Remove accessory drive belts. 2. Install Damper holder 9707 (1). 3. Remove crankshaft damper
bolt. 4. Pull damper off crankshaft.
Crankshaft Pulley > Component Information > Service and Repair > Vibration Damper - Removal > Page 2172
Harmonic Balancer - Crankshaft Pulley: Service and Repair Vibration Damper - Installation
INSTALLATION
1. Install crankshaft damper. 2. Apply clean engine oil crankshaft damper bolt threads and between
bolt head and washer. Tighten bolt to 210 Nm (155 ft. lbs.). 3. Install accessory drive belts.
Jeep Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Block Assembly > Piston, Engine >
Piston: Specifications
Pistons
Pistons
Piston: Description and Operation
DESCRIPTION
The pistons are made of a cast aluminum alloy. The pistons have pressed-in pins attached to
forged connecting rods. The pistons pin is offset 0.8 mm (0.0314 in.) towards the thrust side of the
piston. The connecting rods are a cracked cap design and are not repairable. The piston with rings,
connecting rod and piston pin are serviced as an assembly.
Piston: Procedures
Piston and Bore Measurement
PISTON and BORE MEASUREMENT
NOTE: Pistons and cylinder bores should be measured at normal room temperature, 21° C (70° F).
Piston and cylinder wall must be clean and dry. Piston diameter should be measured 90 degrees to
piston pin (1).
1. Measurement should be taken approximately 17 mm (0.669 in.) from the bottom of the skirt (2)
as shown.
NOTE: Correct piston to bore clearance must be established in order to assure quiet and
economical operation.
2. Cylinder bores should be measured halfway down the cylinder bore and transverse
(measurement location B) to the engine crankshaft center line
shown. Refer to for Engine Specifications.
Piston Selection
STANDARD PROCEDURE - PISTON SELECTION

The pistons are select fit to each bore. There are three different grades of pistons available; A, B,
and C. The piston identification (2) is located in the middle of the block on the right side of the
engine. The bore identification starts at the top and reads downward. Bore #1 is at the top and bore
#4 is at the bottom.
The piston, rings and rod are serviced as an assembly, after determining what size piston is
needed, Refer to CONNECTING ROD BEARINGS - STANDARD PROCEDURE to determine
correct rod bearing size.
Piston: Removal and Replacement
Piston and Connecting Rod - Removal
REMOVAL
NOTE: Pistons, rings, and rods are serviced as an assembly.
CAUTION: To maintain engine balance, 1, 3, or 4 pistons can be replaced. If 2 pistons are

replaced, engine will be out of balance.
1. Remove engine. 2. Remove engine from lift chain (1) and place on a suitable engine stand. 3.
Remove cylinder head.
4. Drain engine oil (2). 5. Remove oil pan (1).

6. Remove oil filter (1). 7. Remove balance shaft assembly. 8. Remove ladder frame.
NOTE: Remove any carbon build up and clean debris from cylinder prior to piston removal to avoid
scratching piston skirts.
9. Remove top ridge of cylinder bores with a reliable ridge reamer before removing pistons from
cylinder block. Be sure to keep tops of pistons
covered during this operation.
10. Rotate crankshaft so that each connecting rod is centered in cylinder bore. 11. Using a
permanent ink or paint marker, identify cylinder number on each connecting rod cap.
CAUTION: DO NOT use a number stamp or a punch to mark connecting rods, as damage to
CAUTION: Care must be taken not to damage the fractured rod and cap joint surfaces, as engine
damage many occur.
12. Remove connecting rod bolts and cap.
13. Carefully push each piston and rod assembly out of cylinder bore. Re-install bearing cap on the
mating rod. 14. Repeat procedure for each piston and connecting rod assembly.
Piston and Connecting Rod - Installation
INSTALLATION
1. Install piston rings on piston. 2. Before installing pistons and connecting rod assemblies into the
bore, be sure that top compression ring gap (1) and the second compression ring
gap (3) are staggered so that neither is in line with oil ring rail gap.
3. Before installing the ring compressor, make sure the oil ring expander ends are butted (1) and
the rail gaps (2, 4) located as shown above. As
viewed from the top of the piston.
4. Immerse the piston head and rings in clean engine oil, slide the ring compressor, over the piston.
Be sure position of rings does not change
during this operation.
5. The directional arrow stamped on the piston should face toward the front of the engine. 6. Rotate
crankshaft so that the connecting rod journal is on the center of the cylinder bore. Lubricate
connecting rod journal with clean engine oil.
NOTE: There are three different size rod bearings, perform rod bearing selection procedure.
NOTE: The rod bearing sizes are indicated on the nose of the crankshaft.
7. Install connecting rod upper bearing half into connecting rod. 8. Install ring compressor (3). 9.
Tap the piston (1) down in cylinder bore, using a hammer handle (2). At the same time, guide
connecting rod into position on connecting rod
journal.
NOTE: The connecting rod cap bolts should NOT be reused.
10. Before installing the NEW bolts, the threads should be coated with clean engine oil. 11. Install
connecting rod lower bearing half into connecting rod cap. Install connecting rod cap. 12. Install
each bolt finger tight then alternately torque each bolt to assemble the cap properly. 13. Tighten the
connecting rod bolts using the 2 step torque-turn method. Tighten according to the following
values:
14. Using a feeler gauge, check connecting rod side clearance. 15. Install the ladder frame. 16.
Install oil pump/balance shaft carrier assembly. 17. Install oil pan. 18. Install cylinder head.
19. Install engine on lift chain (1). 20. Install engine.

Jeep Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Block Assembly > Piston Ring, Engine >
Piston Ring: Specifications
Piston Rings
Piston Rings
Piston Ring: Procedures
PISTON RING - FITTING
1. Wipe cylinder bore clean. Insert ring and push down with piston to ensure it is square in bore.
The ring gap measurement must be made with the
ring positioning at least 13 mm (0.50 inch) from bottom of cylinder bore and below the bottom of the
oil ring travel where cylinder bore has minimal wear. Check gap with feeler gauge. Refer to Engine
Specifications.
NOTE: Ring end gap measurements are sensitive to the ring being square in the bore. Care must
be used to avoid tilting the rings in cylinder bores when taking measurements.
2. Check piston ring to groove side clearance. Refer to Engine Specifications.
CAUTION: Exercise care when using tools on piston. Do not scratch or gouge piston surface or
ring grooves as this may cause engine damage.
Piston Ring: Removal and Replacement
Piston Ring(s) - Removal
REMOVAL
1. Using a suitable ring expander, remove upper and intermediate piston rings. 2. Remove the
upper oil ring side rail, lower oil ring side rail and then oil ring expander from piston. 3. Clean ring
grooves of any carbon deposits.
Piston Ring(s) - Installation
INSTALLATION
NOTE: The identification mark on face of upper and intermediate piston rings must point toward top
of piston.
CAUTION: Install piston rings in the following order:
- Oil ring expander.
- Upper oil ring side rail.
- Lower oil ring side rail.
- No. 2 Intermediate piston ring.
- No. 1 Upper piston ring.
1. Install oil ring expander. 2. Install upper side rail first and then the lower side rail. Install the side
rails by placing one end between the piston ring groove and the oil ring
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.
NOTE: The compression rings are marked Y1 for the upper compression ring and Y2 for the
second compression ring. These markings must face upward.
3. Install No. 2 piston ring and then No. 1 piston ring.

4. Position piston ring end gaps as shown. 5. 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
important for oil control.

Jeep Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Head Assembly > Fuel Pressure Release >
System Information > Service and Repair

Jeep Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Head Assembly > Fuel Pressure Release >
System Information > Service and Repair > Page 2196
Jeep Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Head Assembly > Camshaft Housing >
Component Information > Technical Service Bulletins > Recalls for Camshaft Housing: > F38 > Oct > 06 > Campaign -
Engine Camshaft Cap Bolt Torque
October 2006
Models
NOTE:
IMPORTANT:
Subject
Repair
Parts Information
IMPORTANT:
about 30 vehicles.
Dealer Notification
Service Procedure

NOTE:
service procedure.
CAUTION:
(Figure 2):

gasket.
(Figure 3).
(Figure 4).
Figure 5:
plastic retainers.
NOTE:
Component Information > Technical Service Bulletins > All Technical Service Bulletins for Camshaft Housing: > F38 > Oct >
06 > Campaign - Engine Camshaft Cap Bolt Torque
October 2006
Models
NOTE:
IMPORTANT:
Subject
Repair
Parts Information
IMPORTANT:
about 30 vehicles.
06 > Campaign - Engine Camshaft Cap Bolt Torque > Page 2216
Dealer Notification
Service Procedure

NOTE:
service procedure.
CAUTION:
(Figure 2):

gasket.
(Figure 3).
(Figure 4).
Figure 5:
plastic retainers.
NOTE:
Jeep Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Head Assembly > Valve Cover > Component
Valve Cover: Service and Repair Removal
REMOVAL
1. Remove engine cover. 2. Disconnect ignition coil electrical connectors. 3. Disconnect PCV and
make-up air hoses from cylinder head cover. 4. Use compressed air to blow dirt and debris off the
cylinder head cover prior to removal. 5. Remove cylinder head cover bolts. 6. Remove cylinder
head cover from cylinder head.
Valve Cover: Service and Repair Installation
INSTALLATION
1. Install new cylinder head cover gaskets (1,2).
2. Install studs in cover as shown.
3. Clean all RTV from cylinder head.
NOTE: When using RTV, the sealing surfaces must be clean and free from grease and oil.
NOTE: When using RTV, parts should be assembled in 10 minutes and tighten to final torque
within 45 minutes.
4. Apply a dot of Mopar(R) engine sealant RTV or equivalent to cylinder head/front cover T-joint
(1).
5. Install cylinder head cover assembly to cylinder head and install all bolts, ensuring the studs are
located as shown. 6. Tighten bolts in sequence shown using a 2 step torque method as follows:
a. Tighten all bolts to 5 Nm (44 in. lbs.) b. Tighten all bolts to 10 Nm (90 in. lbs.).
7. Install ignition coils. Tighten fasteners to 8 Nm (70 in. lbs.). 8. If the PCV valve was removed,
tighten PCV valve to 5 Nm (44 in. lbs.). 9. Connect PCV and make-up air hoses to cylinder head
cover.

Jeep Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Head Assembly > Valve Spring > Component
Information > Service and Repair > Procedures
Valve Spring: Procedures
Cylinder Head On
INSPECTION
1. Whenever valves have been removed for inspection, reconditioning or replacement, valve
springs should be tested for correct load. Discard the
springs that do not meet specifications. The following specifications apply to both intake and
exhaust valves springs: -
Valve closed nominal load - 75 lbs. @ 38.0 mm (1.50 in.)
- Valve open nominal load - 134 lbs. @ 29.75 mm (1.17 in.)
2. Inspect each valve spring for squareness with a steel square and surface plate, test springs from
both ends. If the spring is more than 1.5 mm (1/16
inch) out of square, install a new spring.
Cylinder Head Off
INSPECTION
1. Whenever valves have been removed for inspection, reconditioning or replacement, valve
springs should be tested for correct load. Discard the
springs that do not meet specifications. The following specifications apply to both intake and
exhaust valves springs: -
Valve closed nominal load - 75 lbs. @ 38.0 mm (1.50 in.)
- Valve open nominal load - 134 lbs. @ 29.75 mm (1.17 in.)
2. Inspect each valve spring for squareness with a steel square and surface plate, test springs from
both ends. If the spring is more than 1.5 mm (1/16
inch) out of square, install a new spring.

Information > Service and Repair > Procedures > Page 2232
Valve Spring: Removal and Replacement
Removal
CYLINDER HEAD ON
1. Remove cylinder head cover. 2. Remove camshafts. 3. Mark valve tappet location for assembly.
4. Remove valve tappets. 5. Rotate crankshaft until piston is at TDC on compression. 6. With air
hose attached to adapter tool installed in spark plug hole, apply 90-120 psi air pressure.
CAUTION: Care must be taken not to damage the tappet bore or engine damage may result.
7. Using metric valve keeper tool (1) such as Snap-on(R) GA317 (or equivalent), and remove valve
spring keepers and retainer. 8. Remove valve spring(s). 9. Remove valve stem seal(s) by a using
valve stem seal tool.
Installation
CYLINDER HEAD ON
1. Install valve seal/valve spring seat (3) assembly. Push the assembly down with appropriate size
socket to seat it onto the valve guide. 2. Install valve spring (2) and retainer (4) with keepers (1).
3. Place the valve keepers in the retainer. Using metric valve keeper tool such as Snap-on(R)
GA317 (or equivalent) installer (2) and remover (1) as a
handle, install valve keepers with a downward push.
4. Remove air hose and install spark plugs. 5. Install valve tappets. 6. Install camshafts. 7. Install
cylinder head cover.
Removal
CYLINDER HEAD OFF
1. With cylinder head removed from cylinder block, place a ball of rags in the combustion chamber.
2. Mark valve tappet location for assembly. 3. Remove valve tappets. 4. Using metric valve keeper
tool such as Snap-on(R) GA317 (or equivalent) remover (1), remove valve keepers with a
downward push. 5. Remove retainer and springs. 6. Before removing valves, remove any burrs
from valve stem lock grooves to prevent damage to the valve guides. Identify valves, locks and
retainers to insure installation in original location.
7. Inspect the valves.
Installation
CYLINDER HEAD OFF
1. Coat valve stems with clean engine oil and insert in cylinder head. 2. Install new valve stem
seals (3) on all valves using an appropriate sized socket to seat the seal/spring seat. The valve
stem seals should be pushed
firmly and squarely over valve guide.
3. Install valve springs (2). 4. Install keepers in retainer and place on valve spring.
5. Using metric valve keeper tool such as Snap-on(R) GA317 (or equivalent) installer (2) and
remover (1) as a handle, push downward to install
keepers.
6. Check the valve spring installed height B after refacing the valve and seat. Make sure
measurements are taken from top of spring seat to the
bottom surface of spring retainer. If height is greater than 38.75 mm (1.525 in.), install a 0.762 mm
(0.030 in.) spacer under the valve spring seat to bring spring height back within specification.
7. Install valve tappets.

Jeep Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Head Assembly > Valve, Intake/Exhaust >
Valve: Description and Operation Description
DESCRIPTION
The valves are made of heat resistant steel. They have nitrided stems to prevent scuffing. Viton
rubber valve stem seals are integral with the spring seats. The valves have a single bead lock
keepers to retain the springs.
Valve: Description and Operation Operation
OPERATION
The four valves per cylinder (two intake and two exhaust) are opened by using direct acting tappets
which are actuated by the camshaft.
Valve: Service and Repair
CLEANING
Clean all valves thoroughly and discard burned, warped and cracked valves.
CAUTION: Due to the small margin on the valves, grinding is not recommended.
Jeep Workshop Manuals > Engine, Cooling and Exhaust > Engine > Drive Belts, Mounts, Brackets and Accessories > Drive
Belt > Component Information > Description and Operation
Drive Belt: Description and Operation
GAS ENGINE
The accessory drive belt (2) is a serpentine type belt that is driven by the crankshaft pulley (6).
The belt drives the A/C compressor, generator (3), power steering pump (1) and water pump (7).
Belt tension is maintained by an automatic belt tensioner (8).
Belt > Component Information > Description and Operation > Page 2245
Drive Belt: Testing and Inspection
ACCESSORY DRIVE BELT
VISUAL DIAGNOSIS
When diagnosing serpentine accessory drive belts, small cracks that run across the ribbed surface
of the belt from rib to rib (1), are considered normal. These are not a reason to replace the belt.
However, cracks running along a rib (not across) (2) are not normal. Any belt with cracks running
along a rib must be replaced. Also replace the belt if it has excessive wear, frayed cords or severe
glazing.
Refer to ACCESSORY DRIVE BELT DIAGNOSIS CHART for further belt diagnosis.
NOISE DIAGNOSIS
Noises generated by the accessory drive belt are most noticeable at idle. Before replacing a belt to
resolve a noise condition, inspect all of the accessory drive pulleys for contamination, alignment,
glazing, or excessive end play.


Belt > Component Information > Service and Repair > Procedures
Drive Belt: Procedures
CLEANING
Clean all foreign debris from belt pulley grooves. The belt pulleys must be free of oil, grease, and
coolants before installing the drive belt.
Belt > Component Information > Service and Repair > Procedures > Page 2250
Drive Belt: Removal and Replacement
Removal
GAS ENGINE
belt (2) can be removed from pulleys (5 and 9). 2. Remove accessory drive belt (2).
Installation
GAS ENGINE
NOTE: When installing drive belt on the pulleys, make sure that belt is properly routed and all
V-grooves make proper contact with pulley grooves.
1. Install the accessory drive belt (2) around all the pulleys except for the generator pulley (3).
Belt > Component Information > Service and Repair > Procedures > Page 2251
belt (2) can be installed on the generator pulley
(3). Release spring tension onto accessory drive belt (2).

Belt Tensioner > Component Information > Description and Operation
Drive Belt Tensioner: Description and Operation
DESCRIPTION
The automatic belt tensioner maintains proper tension on the accessory drive belt. The tensioner
pulley can be serviced separately.
Belt Tensioner > Component Information > Service and Repair > Removal
Drive Belt Tensioner: Service and Repair Removal
GAS ENGINE
1. Raise vehicle on hoist. 2. Remove belt splash shield (3).
3. Remove accessory drive belt. 4. Remove accessory drive belt tensioner mounting bolt. Remove
accessory drive belt tensioner (8).
Belt Tensioner > Component Information > Service and Repair > Removal > Page 2257
Drive Belt Tensioner: Service and Repair Installation
GAS ENGINE
1. Position accessory drive belt tensioner (8) and install mounting bolt (1). Tighten bolt (1) to 24 Nm
(212 in. lbs.). 2. Install accessory drive belt.
3. Install belt splash shield (3). 4. Lower vehicle.

Jeep Workshop Manuals > Engine, Cooling and Exhaust > Engine > Drive Belts, Mounts, Brackets and Accessories >
Engine Mount > Component Information > Description and Operation > Description
Engine Mount: Description and Operation Description
DESCRIPTION
The engine mounting system consists of a four-point system utilizing two load-carrying mounts and
two torque controlling mounts. The load-carrying mounts are located on each frame rail. The right
and left mounts are hydro-elastic mounts. The two torque controlling mounts are attached to a
fore/aft member and the front and rear of the engine.
Engine Mount > Component Information > Description and Operation > Description > Page 2262
Engine Mount: Description and Operation Operation
OPERATION
The four-point engine mounting system minimizes the transmission of structure-borne engine noise
to the passenger compartment. The load-carrying right and left mounts dampen and isolate vertical
motion and vibration. The front and rear mount absorb torque reaction forces and torsional
vibrations.
Engine Mount > Component Information > Service and Repair > Front Mount
Engine Mount: Service and Repair Front Mount
Removal
REMOVAL
1. Raise vehicle. 2. Remove fore aft member (3) to mount (4) bolts. 3. Remove mount through bolt
(1). 4. Remove fore aft member (3) mounting bolts and remove. 5. Remove front mount (4).
Installation
INSTALLATION
1. Position mount (4) and torque bolts to 47 Nm (35 ft. lbs.). 2. Install fore aft member (3) and
torque bolts to 100 Nm (74 ft. lbs.). 3. Install mount through bolt (1) and torque to 47 Nm (35 ft.
lbs.). 4. Lower vehicle.
Engine Mount > Component Information > Service and Repair > Front Mount > Page 2265
Engine Mount: Service and Repair Left Mount

Removal
REMOVAL
1. Remove air cleaner inlet (2) and air cleaner housing (1).
2. Remove PCM (1). 3. Remove PCM mounting bracket. 4. Disconnect negative cable from battery
(3). 5. Support transaxle with a suitable jack.
6. Remove left mount through bolt (3). 7. Remove left mount bracket to body frame rail fasteners
(1). 8. Remove mount.
Installation
INSTALLATION
1. Position mount (2) in place. 2. Install left mount to frame rail bolts (1) and torque to 75 Nm (55 ft.
lbs.). 3. Install mount through bolt (3) and torque to 100 Nm (74 ft.lbs.). 4. Remove jack.
5. Install PCM mounting bracket.

6. Install PCM (1). 7. Connect negative cable to battery (3).
8. Install air cleaner housing (1) and air cleaner inlet (2).
Engine Mount: Service and Repair Right Mount
Removal
REMOVAL
1. Remove coolant reservoir (3) and set aside. 2. Remove power steering reservoir (2) and set
aside. 3. Remove windshield washer bottle (1).
4. Remove power steering line support bracket (1) from engine mount.
5. Support transaxle with a block of wood and a suitable jack. 6. Remove engine mount through
bolt (4). 7. Remove engine mount bracket bolts (3). 8. Remove engine mount retaining bolts. 9.
Remove engine mount.
Installation
INSTALLATION
1. Position right engine mount (1). 2. Install engine mount retaining bolts and tighten to 75 Nm (55
ft. lbs.). 3. Install engine mount adapter (2) and tighten bolts (3) to 68 Nm (50 ft. lbs.). 4. Install
engine mount through bolt (4) and tighten to 88 Nm (65 ft. lbs.).
5. Remove jack. 6. Install power steering line support bracket (1) at engine mount.
7. Install windshield washer bottle (1). 8. Install power steering reservoir (2). 9. Install coolant
reservoir (3).

Engine Mount: Service and Repair Rear Mount
Removal
REMOVAL
1. Remove rear mount retaining bolts (4). 2. Remove rear mount through bolt (1). 3. Remove
oxygen sensor connector (2) from mount. 4. Remove rear mount (3).
Installation
INSTALLATION
1. Position rear mount (3). 2. Install rear mount retaining bolts (4) and torque to 50 Nm (37 ft. lbs.).
3. Install rear mount through bolt (1) and torque to 75 Nm (55 ft. lbs.). 4. Install oxygen sensor
connector (2) retainer to mount (3).
Jeep Workshop Manuals > Engine, Cooling and Exhaust > Engine > Drive Belts, Mounts, Brackets and Accessories > Idler
Pulley > Component Information > Service and Repair > Removal
Idler Pulley: Service and Repair Removal
REMOVAL
1. Raise vehicle on hoist. 2. Remove belt splash shield. 3. Remove accessory drive belt. 4.
Remove idler pulley mounting bolt. Remove idler pulley (5 or 9).
Jeep Workshop Manuals > Engine, Cooling and Exhaust > Engine > Drive Belts, Mounts, Brackets and Accessories > Idler
Pulley > Component Information > Service and Repair > Removal > Page 2276
Idler Pulley: Service and Repair Installation
INSTALLATION
1. Position pulley (5 or 9) in mounting position. Install idler pulley mounting bolt. Tighten bolt to 48
Nm (35 ft. lbs.). 2. Install accessory drive belt. 3. Install belt splash shield. 4. Lower vehicle.
Jeep Workshop Manuals > Engine, Cooling and Exhaust > Engine > Engine Lubrication > Engine Oil Pressure >
Engine Oil Pressure: Specifications
Oil Pressure
Oil Pressure
Component Information > Testing and Inspection > Checking Engine Oil Pressure
Engine Oil Pressure: Testing and Inspection Checking Engine Oil Pressure
CHECKING ENGINE OIL PRESSURE
NOTE: Anytime the oil temperature sensor is removed, it should be replaced with a new sensor.
1. Disconnect and remove oil temperature sensor (1).
CAUTION: Threads in cylinder head are British Standard Pipe (BSP). Do not install a NPT
threaded adapter, this could crack the cylinder head.
2. Install threaded adapter 9879 (1). 3. Install oil pressure gauge (2).
Component Information > Testing and Inspection > Checking Engine Oil Pressure > Page 2283
4. Start engine and record reading on oil pressure gauge (1).
CAUTION: If oil pressure is 0 at idle, do not perform the 3000 RPM test
5. If oil pressure is 0 at idle, shut off engine. Check for pressure relief valve stuck open, a clogged
oil pick-up screen. 6. Remove oil pan and inspect for debris. 7. Remove oil pressure relief valve. 8.
Inspect oil pressure relief valve. 9. If pressure relief valve is ok, replace balance shaft module
assembly.
10. After test is complete, remove oil pressure gauge (2) and adapter 9879 (1).
11. Install a new oil pressure temperature sensor (1) and connect electrical connector.
Engine Oil Pressure: Testing and Inspection Checking VVT Oil Pressure
CHECKING VVT OIL PRESSURE
This test can be used to help diagnose VVT faults.
1. Disconnect and remove oil pressure sensor (1).
CAUTION: Threads in block are 1/8"-28 British Standard Pipe (BSP). Do not install a National Pipe
Thread (NPT) threaded adapter, this could crack the cylinder block.
2. Install an 1/8-28 BSP male to 1/8-27 female threaded adapter (2). 3. Install oil pressure gauge
(1). 4. Start engine and record oil pressure.
5. If oil pressure is 0 at idle, shut off engine. check for pressure relief valve stuck open, a clogged
oil pick-up screen. 6. Remove oil pan and inspect for debris. 7. Remove oil pressure relief valve
and inspect, if damaged replace pressure relief valve. 8. If pressure relief valve is ok, replace
balance shaft module assembly.
9. After test is complete, remove test gauge (1) and fitting (2).
10. Install oil pressure sensor and electrical connector.
Jeep Workshop Manuals > Engine, Cooling and Exhaust > Engine > Engine Lubrication > Engine Oil > Component
Information > Technical Service Bulletins > Maintenance - Fluid Flushing Information
Engine Oil: Technical Service Bulletins Maintenance - Fluid Flushing Information
NUMBER: 26-001-09

MODELS:
2009 - 2010 (DS) Ram Truck (1500)
2005 - 2009 (HB) Durango
2007 - 2009 (HG) Aspen
2009 - 2010 (JC) Journey
2008 - 2010 (KK) Liberty
2007 - 2010 (KA) Nitro
2005 - 2007 (KJ) Liberty
2005 - 2010 (ND) Dakota
2005 - 2006 (PL) Neon

2007 - 2010 (PM) Caliber

Information > Technical Service Bulletins > Maintenance - Fluid Flushing Information > Page 2290
2005 - 2010 (ZB) Viper
DISCUSSION:
coolant.
operating range.
distilled water.
Disclaimer:
Information > Specifications > Capacity Specifications
Engine Oil: Capacity Specifications
Engine Oil ............................................................................................................................................

.................................................... 4.26Liters (4.5 Qt)
Information > Specifications > Capacity Specifications > Page 2293
Engine Oil: Fluid Type Specifications
Engine Oil ............................................................................................................................................

........................................ API SAE Certified 5W-20
Engine Oil: Testing and Inspection
ENGINE OIL LEVEL CHECK
NOTE: The engine must be HOT when checking oil level.
The best time to check engine oil level is after the engine is at operating temperature. Allow the
engine to be shut off for at least 5 minutes before checking oil level.
Checking the oil while the vehicle is on level ground will improve the accuracy of the oil level
reading. Remove dipstick (1), and observe oil level. Add oil only when the level is at or below the
SAFE mark. If the oil level is in the safe (2) range, do not add oil.
CAUTION: Do not operate engine if the oil level is above the MAX mark on the dipstick. Excessive
oil volume can cause oil aeration which can lead to engine failure due to loss of oil pressure or
increase in oil temperature.
Engine Oil: Service and Repair

Jeep Workshop Manuals > Engine, Cooling and Exhaust > Engine > Engine Lubrication > Oil Cooler, Engine > Component
Information > Description and Operation
Oil Cooler: Description and Operation
DESCRIPTION
An engine oil cooler is used on some engine packages. The cooler is a coolant-to-oil type and
mounted between the oil filter and oil filter adapter.
Oil Cooler: Service and Repair Removal
REMOVAL
NOTE: The oil cooler can not be cleaned out. In the event that the engine requires rebuilding or
replacement, the oil cooler should be replaced.
1. Raise vehicle on hoist. 2. Drain cooling system (Refer to 7 - COOLING - STANDARD

PROCEDURE). 3. Disconnect oil cooler coolant hoses. 4. Remove oil filter (3).
5. Remove oil cooler connector bolt (2). 6. Remove oil cooler (1).
Oil Cooler: Service and Repair Installation
INSTALLATION
1. Replace oil cooler seal (1). 2. Lubricate seal and position oil cooler to oil filter adapter, aligning
notch to tab. 3. Install oil cooler connector bolt (2). Tighten connector bolt to 49 Nm (36 ft. lbs.).
4. Install oil filter (3). 5. Connect oil cooler coolant hose. 6. Lower vehicle. 7. Fill cooling system.
Jeep Workshop Manuals > Engine, Cooling and Exhaust > Engine > Engine Lubrication > Oil Filter, Engine > Component
Information > Service and Repair > Engine Oil and Filter Change
Oil Filter: Service and Repair Engine Oil and Filter Change

Information > Service and Repair > Engine Oil and Filter Change > Page 2307
Oil Filter: Service and Repair Removal
REMOVAL
CAUTION: When servicing the oil filter, avoid deforming the filter can by installing the
remove/install tool band strap against the can to base lock seam. The lock seam joining the can to
the base is reinforced by the base plate.
1. Using a suitable filter wrench, turn oil filter (1) counterclockwise to remove.
Oil Filter: Service and Repair Installation
INSTALLATION
1. Clean and check filter mounting surface. The surface must be smooth, flat and free of debris or
pieces of gasket. 2. Lubricate new oil filter gasket. 3. Screw oil filter (1) on until the gasket contacts
base. Tighten to 14 Nm (10 ft. lbs.).
Jeep Workshop Manuals > Engine, Cooling and Exhaust > Engine > Engine Lubrication > Oil Pan, Engine > Component
Oil Pan: Specifications
Oil Pan-Bolts
M6 Bolts ...............................................................................................................................................
............................................. 12 Nm (105 in. lbs.) M8 Bolts ................................................................
............................................................................................................................... 24 Nm (18 ft. lbs.)
Oil Pan: Service and Repair Removal
REMOVAL
1. Raise vehicle on hoist. 2. Remove oil drain plug (2) and drain the engine oil. 3. Remove
accessory drive belt splash shield.
4. Remove lower A/C compressor mounting bolt (if equipped). 5. Remove A/C mounting bracket
(2).
NOTE: Do not use pry points in block to remove oil pan.

6. Remove oil pan retaining bolts. 7. Using a putty knife (1), loosen seal around oil pan (2). 8.
Remove oil pan (2).
Oil Pan: Service and Repair Installation
INSTALLATION
NOTE: Oil pan sealing surfaces must be free of grease or oil.
NOTE: Parts must be assembled within 10 minutes of applying RTV.
1. Apply Mopar(R) Engine RTV GEN II at the front cover to engine block parting lines (1).
2. Apply a 2 mm bead of Mopar(R) Engine RTV GEN II around the oil pan as shown. 3. Position oil
pan and install bolts. Tighten bolts to 12 Nm (105 in. lbs.).
NOTE: The 2 long bolts must be tightened to 22 Nm (195 in.lbs.).

4. Install oil drain plug (2). 5. Lower vehicle and fill engine crankcase with proper oil to correct level.
6. Start engine and check for leaks.
Jeep Workshop Manuals > Engine, Cooling and Exhaust > Engine > Engine Lubrication > Oil Pressure Sender >
Component ID: 349
Connector:
Color : LT. GREEN
# of pins : 2
Qualifier : (GAS)
2--
Component ID: 349
Connector:
Color : LT. GREEN
# of pins : 2
Qualifier : (GAS)
2--
DESCRIPTION
OPERATION
REMOVAL
INSTALLATION
block.
Jeep Workshop Manuals > Engine, Cooling and Exhaust > Engine > Engine Lubrication > Oil Pressure Warning
Lamp/Indicator > Component Information > Description and Operation > Description
Oil Pressure Warning Lamp/Indicator: Description and Operation Description
DESCRIPTION
A low oil pressure indicator is standard equipment on all instrument clusters. This indicator is
located above the fuel gauge on the cluster overlay, to the left of the speedometer.
The low oil pressure indicator consists of a stencil-like cutout of the International Control and
Display Symbol icon for Engine Oil in the opaque layer of the instrument cluster overlay. The dark
outer layer of the overlay prevents the indicator from being clearly visible when it is not illuminated.
A red Light Emitting Diode (LED) behind the cutout in the opaque layer of the overlay causes the
indicator to appear in red through the translucent outer layer of the overlay when it is illuminated
from behind by the LED, which is soldered onto the instrument cluster electronic circuit board.
The low oil pressure indicator is serviced as a unit with the instrument cluster.
Jeep Workshop Manuals > Engine, Cooling and Exhaust > Engine > Engine Lubrication > Oil Pressure Warning
Lamp/Indicator > Component Information > Description and Operation > Description > Page 2336
Oil Pressure Warning Lamp/Indicator: Description and Operation Operation
OPERATION
The low oil pressure indicator gives an indication to the vehicle operator when the engine oil
pressure reading reflects a condition requiring immediate attention. This indicator is controlled by a
transistor on the instrument cluster circuit board based upon cluster programming and electronic
messages received by the cluster from the Powertrain Control Module (PCM) over the Controller
Area Network (CAN) data bus.
The low oil pressure indicator Light Emitting Diode (LED) is completely controlled by the instrument
cluster logic circuit, and that logic will only allow this indicator to operate when the instrument
cluster receives a battery current input on the fused ignition switch output (run-start) circuit.
Therefore, the LED will always be OFF when the ignition switch is in any position except ON or
START. The LED only illuminates when it is provided a path to ground by the instrument cluster
transistor. The instrument cluster will turn ON the low oil pressure indicator for the following
reasons:
- Engine Oil Pressure Low Message - Each time the cluster receives an electronic engine oil
pressure message from the PCM indicating the pressure is about 6.9 kPa (1 psi) or lower, the low
oil pressure indicator will be illuminated. The indicator can be flashed ON and OFF, or illuminated
solid, as dictated by the PCM message. The indicator remains illuminated solid or flashing until the
cluster receives a message from the PCM indicating that the pressure is above about 6.9 kPa (1
psi), or until the ignition switch is turned to the OFF position, whichever occurs first. The cluster will
only turn the indicator ON in response to low engine oil pressure if the engine speed is greater than
zero.
- Actuator Test - Each time the cluster is put through the actuator test, the low oil pressure indicator
will be turned ON, then OFF again during the bulb check portion of the test to confirm the
functionality of the LED and the cluster control circuitry.
The PCM continually monitors the engine oil pressure sensor to determine the engine oil pressure.
The PCM then sends the proper messages to the ElectroMechanical Instrument Cluster (EMIC). If
the EMIC turns ON the indicator after the bulb test, it may indicate that the engine or the engine
oiling system requires service.
For proper diagnosis of the engine oil pressure sensor, the PCM, the EMIC, the CAN data bus or
the electronic communication related to low oil pressure indicator operation a diagnostic scan tool
is required.
Jeep Workshop Manuals > Engine, Cooling and Exhaust > Engine > Engine Lubrication > Oil Pump, Engine > Engine Oil
Pressure > Component Information > Specifications
Engine Oil Pressure: Specifications
Oil Pressure
Oil Pressure
Pressure > Component Information > Testing and Inspection > Checking Engine Oil Pressure
Engine Oil Pressure: Testing and Inspection Checking Engine Oil Pressure
CHECKING ENGINE OIL PRESSURE
NOTE: Anytime the oil temperature sensor is removed, it should be replaced with a new sensor.
1. Disconnect and remove oil temperature sensor (1).
CAUTION: Threads in cylinder head are British Standard Pipe (BSP). Do not install a NPT
threaded adapter, this could crack the cylinder head.
2. Install threaded adapter 9879 (1). 3. Install oil pressure gauge (2).
Pressure > Component Information > Testing and Inspection > Checking Engine Oil Pressure > Page 2343
4. Start engine and record reading on oil pressure gauge (1).
5. If oil pressure is 0 at idle, shut off engine. Check for pressure relief valve stuck open, a clogged
oil pick-up screen. 6. Remove oil pan and inspect for debris. 7. Remove oil pressure relief valve. 8.
Inspect oil pressure relief valve. 9. If pressure relief valve is ok, replace balance shaft module
assembly.
10. After test is complete, remove oil pressure gauge (2) and adapter 9879 (1).
11. Install a new oil pressure temperature sensor (1) and connect electrical connector.
Engine Oil Pressure: Testing and Inspection Checking VVT Oil Pressure
CHECKING VVT OIL PRESSURE
This test can be used to help diagnose VVT faults.
1. Disconnect and remove oil pressure sensor (1).
CAUTION: Threads in block are 1/8"-28 British Standard Pipe (BSP). Do not install a National Pipe
Thread (NPT) threaded adapter, this could crack the cylinder block.
2. Install an 1/8-28 BSP male to 1/8-27 female threaded adapter (2). 3. Install oil pressure gauge
(1). 4. Start engine and record oil pressure.
5. If oil pressure is 0 at idle, shut off engine. check for pressure relief valve stuck open, a clogged
oil pick-up screen. 6. Remove oil pan and inspect for debris. 7. Remove oil pressure relief valve
and inspect, if damaged replace pressure relief valve. 8. If pressure relief valve is ok, replace
balance shaft module assembly.
9. After test is complete, remove test gauge (1) and fitting (2).
10. Install oil pressure sensor and electrical connector.
Jeep Workshop Manuals > Engine, Cooling and Exhaust > Engine > Engine Lubrication > Oil Pump, Engine > Oil Pressure
Regulator Valve > Component Information > Description and Operation > Description
Oil Pressure Regulator Valve: Description and Operation Description
DESCRIPTION
Regulator Valve > Component Information > Description and Operation > Description > Page 2350
Oil Pressure Regulator Valve: Description and Operation Operation
OPERATION
- Battery voltage must be at least 10 volts.
valve faults
- Map sensor
- Intake cam sensor
- Crankshaft sensor
- GPEC1

- Inputs
- Outputs
the camshaft.
strategy at
camshaft.
life.
timing.
- Starting
Regulator Valve > Component Information > Service and Repair > Procedures
Oil Pressure Regulator Valve: Procedures
INSPECTION
NOTE: Pressure regulating valve (4) can be service separately from the oil pump assembly.
1. Inspect pressure relief valve (4) scoring, gouging, or debris. Replace as needed. 2. Inspect the
pressure relief valve bore in the pump for scoring, gouging, or debris. 3. If pump bore is damaged,
replace balance shaft module.
Regulator Valve > Component Information > Service and Repair > Procedures > Page 2355
Oil Pressure Regulator Valve: Removal and Replacement
Removal
FRONT SOLENOID 1/1
1. Disconnect negative battery cable. 2. Remove engine cover. 3. Rotate hose clamp out of way. 4.
Disconnect oil pressure sensor electrical connector. 5. Remove oil pressure sensor. 6. Disconnect
variable valve timing solenoid electrical connector.

Installation
FRONT SOLENOID 1/1
solenoids.
2. Install solenoid into cylinder head. 3. Install mounting bolt and tighten to 12 Nm (9 ft. lbs.).
4. Install oil pressure sensor. 5. Connect electrical connector to oil pressure sensor. 6. Connect
electrical connector to Variable valve timing solenoid. 7. Connect negative battery cable. 8. Install
engine cover.
Removal
REAR SOLENOID 1/2
1. Disconnect negative battery cable. 2. Remove engine cover. 3. Disconnect variable valve timing
solenoid electrical connector. 4. Remove variable valve timing solenoid mounting bolt.
Installation
REAR SOLENOID 1/2
rear solenoids. 2. Install solenoid into cylinder head. 3. Install mounting bolt and tighten to 12 Nm
(9 ft. lbs.). 4. Connect electrical connector to Variable valve timing solenoid.
5. Connect negative battery cable. 6. Install engine cover.

Removal
REMOVAL
1. Remove oil pan 2. Remove pressure regulating valve cap (2). 3. Remove pressure regulating
valve spring (3) and valve (4).
Installation
INSTALLATION
1. Lightly coat pressure regulating valve with clean engine oil and install valve (4). 2. Install spring
(3) and cap (2). 3. Tighten cap to 44 Nm (32 lbs.ft.).
Jeep Workshop Manuals > Engine, Cooling and Exhaust > Engine > Engine Lubrication > Oil Temperature Sensor/Switch,
Engine > Component Information > Locations
Component ID: 311
Connector:
Color : BLACK
# of pins : 2
Qualifier : (GAS)
Component ID: 311
Connector:
Color : BLACK
# of pins : 2
Qualifier : (GAS)
Engine > Component Information > Service and Repair > Removal
REMOVAL
Engine > Component Information > Service and Repair > Removal > Page 2368
INSTALLATION
Jeep Workshop Manuals > Engine, Cooling and Exhaust > Engine > Intake Manifold > Component Information > Technical
Service Bulletins > Customer Interest for Intake Manifold: > 18-032-07 > May > 07 > A/T - MIL ON Possible DTC P2004
Intake Manifold: Customer Interest A/T - MIL ON Possible DTC P2004
NUMBER: 18-032-07
DATE: May 16, 2007
INTERNET.
BULLETIN.
CAUTION:

BE INSTALLED.
MODELS:
2007 (JS) Sebring
2007 (MK49) Compass
2007 (MK74) Patriot
2007 (PM) Caliber
NOTE:
SYMPTOM/CONDITION:
DIAGNOSIS:
PARTS REQUIRED:
Service Bulletins > Customer Interest for Intake Manifold: > 18-032-07 > May > 07 > A/T - MIL ON Possible DTC P2004 >
Page 2377
CAUTION:
NOTE:
NOTE:
NOTE:
drop.

Page 2378
seconds.
CAUTION:

PROCESS.
NOTE:
seconds.
CAUTION:
NOTE:
Page 2379
NOTE:
TIME ALLOWANCE:
FAILURE CODE:
Disclaimer:
Service Bulletins > All Technical Service Bulletins for Intake Manifold: > 18-032-07 > May > 07 > A/T - MIL ON Possible
DTC P2004
Intake Manifold: All Technical Service Bulletins A/T - MIL ON Possible DTC P2004
NUMBER: 18-032-07
DATE: May 16, 2007
INTERNET.
BULLETIN.
CAUTION:

BE INSTALLED.
MODELS:
2007 (JS) Sebring
2007 (MK49) Compass
2007 (MK74) Patriot
2007 (PM) Caliber
NOTE:
SYMPTOM/CONDITION:
DIAGNOSIS:
PARTS REQUIRED:
DTC P2004 > Page 2385
CAUTION:
NOTE:
NOTE:
NOTE:
drop.

DTC P2004 > Page 2386
seconds.
CAUTION:

PROCESS.
NOTE:
seconds.
CAUTION:
NOTE:
DTC P2004 > Page 2387
NOTE:
TIME ALLOWANCE:
FAILURE CODE:
Disclaimer:
Service Bulletins > Page 2388
Intake Manifold: Specifications
Intake Manifold ....................................................................................................................................

.................................................... 24 Nm (18 ft. lbs.)
Intake Manifold: Testing and Inspection
INTAKE MANIFOLD LEAKS
An intake manifold air leak is characterized by lower than normal manifold vacuum. Also, one or
more cylinders may not be functioning.
WARNING: Use extreme caution when the engine is operating. Do not stand in a direct line with
the fan. Do not put your hands near the pulleys, belts or the fan. Do not wear loose clothing.
1. Start the engine. 2. Spray a small stream of water (Spray Bottle) at the suspected leak area. 3. If
engine RPM'S change, the area of the suspected leak has been found. 4. Repair as required.
Jeep Workshop Manuals > Engine, Cooling and Exhaust > Engine > Intake Manifold > Component Information > Service
and Repair > Procedures
Intake Manifold: Procedures
Cleaning
CLEANING
1. Discard gasket(s). 2. Clean all sealing surfaces.
Inspection
INSPECTION
1. Inspect manifold for cracks, distortion, or mounting surface warpage. Replace manifold if
necessary. 2. Inspect manifold gasket for surface damage or excessive swelling. Replace gaskets
as necessary.
and Repair > Procedures > Page 2392
Intake Manifold: Removal and Replacement
Removal
INTAKE MANIFOLD
WARNING: Release fuel system pressure before servicing system components. Service vehicles in
well ventilated areas and avoid ignition sources. Never smoke while servicing the vehicle.
1. Remove engine cover (1). 2. Perform fuel system pressure release procedure before attempting
any repairs
3. Remove air cleaner inlet (2).

4. Remove air cleaner housing (1). 5. Disconnect negative cable at battery (3).
6. Disconnect fuel line at rail (3). 7. Remove fuel injector electrical connectors (4). 8. Remove fuel
rail retaining bolts and remove fuel rail.
9. Disconnect oil temperature sensor (1).
10. Disconnect variable valve timing solenoid electrical connector. 11. Disconnect intake camshaft
position sensor electrical connector. 12. Position harness out of the way.
13. Remove throttle body support bracket (1). 14. Disconnect electronic throttle control electrical
connector. 15. Remove wiring harness retainer from the intake manifold (2). 16. Disconnect MAP
sensor electrical connector. 17. Disconnect vacuum lines at intake.
18. Remove upper radiator hose retaining bracket (1).
19. Remove intake manifold retaining bolts. 20. Remove intake manifold.
Installation
INTAKE MANIFOLD
1. Clean all gasket surfaces. 2. Replace intake manifold gasket. 3. Install intake manifold, tighten
bolts to 25 Nm (220 in. lbs.). 4. Install the fuel rail assembly to intake manifold. Tighten bolts to 23
Nm (200 in. lbs.). 5. Connect fuel injector electrical connectors.
6. Inspect quick connect fittings for damage, replace if necessary. Connect fuel supply hose to fuel
rail assembly. Check connection by pulling on
connector to insure it locked into position.
7. Connect negative cable to battery (3). 8. Fill the cooling system.
9. Install air cleaner housing (1).


Jeep Workshop Manuals > Engine, Cooling and Exhaust > Engine > Lamps and Indicators - Engine > Oil Pressure Warning
Lamp/Indicator > Component Information > Description and Operation > Description
Oil Pressure Warning Lamp/Indicator: Description and Operation Description
DESCRIPTION
A low oil pressure indicator is standard equipment on all instrument clusters. This indicator is
located above the fuel gauge on the cluster overlay, to the left of the speedometer.
The low oil pressure indicator consists of a stencil-like cutout of the International Control and
Display Symbol icon for Engine Oil in the opaque layer of the instrument cluster overlay. The dark
The low oil pressure indicator is serviced as a unit with the instrument cluster.
Jeep Workshop Manuals > Engine, Cooling and Exhaust > Engine > Lamps and Indicators - Engine > Oil Pressure Warning
Lamp/Indicator > Component Information > Description and Operation > Description > Page 2402
Oil Pressure Warning Lamp/Indicator: Description and Operation Operation
OPERATION
The low oil pressure indicator gives an indication to the vehicle operator when the engine oil
pressure reading reflects a condition requiring immediate attention. This indicator is controlled by a
messages received by the cluster from the Powertrain Control Module (PCM) over the Controller
Area Network (CAN) data bus.
The low oil pressure indicator Light Emitting Diode (LED) is completely controlled by the instrument
transistor. The instrument cluster will turn ON the low oil pressure indicator for the following
reasons:
- Engine Oil Pressure Low Message - Each time the cluster receives an electronic engine oil
pressure message from the PCM indicating the pressure is about 6.9 kPa (1 psi) or lower, the low
oil pressure indicator will be illuminated. The indicator can be flashed ON and OFF, or illuminated
solid, as dictated by the PCM message. The indicator remains illuminated solid or flashing until the
cluster receives a message from the PCM indicating that the pressure is above about 6.9 kPa (1
psi), or until the ignition switch is turned to the OFF position, whichever occurs first. The cluster will
only turn the indicator ON in response to low engine oil pressure if the engine speed is greater than
zero.
- Actuator Test - Each time the cluster is put through the actuator test, the low oil pressure indicator
The PCM continually monitors the engine oil pressure sensor to determine the engine oil pressure.
The PCM then sends the proper messages to the ElectroMechanical Instrument Cluster (EMIC). If
the EMIC turns ON the indicator after the bulb test, it may indicate that the engine or the engine
oiling system requires service.
For proper diagnosis of the engine oil pressure sensor, the PCM, the EMIC, the CAN data bus or
the electronic communication related to low oil pressure indicator operation a diagnostic scan tool
is required.
Jeep Workshop Manuals > Engine, Cooling and Exhaust > Engine > Seals and Gaskets, Engine > Crankshaft Main Bearing
Seal > Component Information > Service and Repair > Removal
Crankshaft Main Bearing Seal: Service and Repair Removal
REMOVAL
1. Remove transaxle 2. Remove flex plate bolts and discard. 3. Remove flex plate (1).
4. Insert a 3/16 flat bladed screwdriver (7) between the dust lip (8) and the metal case (4) of the
crankshaft seal (1). Angle the screwdriver through
the dust lip against metal case of the seal. Pry out seal.
CAUTION: Do not permit the screwdriver blade to contact crankshaft seal surface. Contact of the
screwdriver blade against crankshaft edge (chamfer) is permitted.
5. Check to make sure the seals garter spring is not on the crankshaft.
Jeep Workshop Manuals > Engine, Cooling and Exhaust > Engine > Seals and Gaskets, Engine > Crankshaft Main Bearing
Seal > Component Information > Service and Repair > Removal > Page 2408
Crankshaft Main Bearing Seal: Service and Repair Installation
INSTALLATION
CAUTION: If a burr or scratch is present on the crankshaft edge (chamfer), cleanup with 800 emery
cloth to prevent seal damage during installation of new seal. If emery cloth is used, the crankshaft
must be cleaned off Mopar(R) brake parts cleaner.
NOTE: When installing seal, lubricate Seal Guide 9509 with clean engine oil.
1. Place Seal Guide 9509 (3) on crankshaft. 2. Position seal (2) over guide tool. Guide tool should
remain on crankshaft during installation of seal. Ensure that the lip of the seal is facing towards
the crankcase during installation.
3. Drive the seal into the block using Seal Driver 9706 (1) and Driver Handle C-4171 (4) until Seal
Driver 9706 bottoms out against the block.
4. Install flex plate (1). 5. Install washer (2). 6. Install new flex plate bolts (3) and tighten to 95 Nm
(70 ft. lbs.). 7. Install transaxle.
Jeep Workshop Manuals > Engine, Cooling and Exhaust > Engine > Seals and Gaskets, Engine > Front Crankshaft Seal >
Front Crankshaft Seal: Service and Repair Removal
REMOVAL
1. Remove accessory drive belt. 2. Install damper holder 9707 (1) and remove damper retaining
bolt. 3. Pull damper off crankshaft.
4. Remove front crankshaft oil seal (1) by prying out with a screw driver (2). Be careful not to
damage the cover seal surface.
Front Crankshaft Seal: Service and Repair Installation
INSTALLATION
1. Place seal (1) onto Seal installer 9506 (2) with seal spring towards the inside of engine.
2. Install new seal (1) by using Seal installer 9506 (2) and crankshaft damper bolt (3).
3. Press seal into front cover until Seal Installer 9506 (1) seats against timing chain cover (3). 4.
Remove seal installer 9506 (1).
5. Install crankshaft vibration damper. 6. Oil the bolt threads and between the bolt head and
washer. 7. Install damper retaining bolt and damper holder 9707 (1). Tighten bolt to 210 Nm (155 ft.
lbs.).
Jeep Workshop Manuals > Engine, Cooling and Exhaust > Engine > Sensors and Switches - Engine > Oil Pressure Sender
Component ID: 349
Connector:
Color : LT. GREEN
# of pins : 2
Qualifier : (GAS)
2--
Component ID: 349
Connector:
Color : LT. GREEN
# of pins : 2
Qualifier : (GAS)
2--
DESCRIPTION
OPERATION
> Component Information > Service and Repair > Removal
REMOVAL
> Component Information > Service and Repair > Removal > Page 2429
INSTALLATION
block.
Jeep Workshop Manuals > Engine, Cooling and Exhaust > Engine > Sensors and Switches - Engine > Oil Temperature
Sensor/Switch, Engine > Component Information > Locations
Component ID: 311
Connector:
Color : BLACK
# of pins : 2
Qualifier : (GAS)
Sensor/Switch, Engine > Component Information > Locations > Page 2433
Component ID: 311
Connector:
Color : BLACK
# of pins : 2
Qualifier : (GAS)
Sensor/Switch, Engine > Component Information > Service and Repair > Removal
REMOVAL
Sensor/Switch, Engine > Component Information > Service and Repair > Removal > Page 2438
INSTALLATION
Jeep Workshop Manuals > Engine, Cooling and Exhaust > Engine > Timing Components > Camshaft Gear/Sprocket >
Component Information > Description and Operation > Variable Valve Timing Assembly - Description
Camshaft Gear/Sprocket: Description and Operation Variable Valve Timing Assembly - Description
DESCRIPTION
The world engine is equipped with Variable Valve Timing (VVT). This system advances and/or
retards intake and/or exhaust camshaft timing to improve engine performance, mid-range torque,
idle quality, fuel economy, and reduce emissions. The camshaft sprockets are integrated with the
VVT assemblies and are serviced as an assembly. VVT assemblies are sometimes referred to as
camshaft phasers.
Component Information > Description and Operation > Variable Valve Timing Assembly - Description > Page 2444
Camshaft Gear/Sprocket: Description and Operation Variable Valve Timing Assembly - Operation
OPERATION
The Variable Valve Timing (VVT) assemblies are actuated with engine oil pressure. The oil flow to
the VVT assemblies are controlled by two Oil Control Valves (OCV). There is an OCV and
Camshaft Position Sensor (CMP) for each camshaft. The OCV's consist of a Pulse Width
Modulated (PWM) solenoid and a spool valve. The PCM actuates the OCV to control oil flow
through the spool valve into the VVT assemblies. The VVT assembly consists of a rotor, stator, and
sprocket. The stator is connected to the timing chain through the sprocket. The rotor is connected
to the camshaft. Oil flow in to the VVT assembly rotates the rotor with respect to the stator, thus
rotating the camshaft with respect to the timing chain. Thus, the VVT assemblies change valve
timing by changing the relationship between the camshaft and the timing chain. An integral oil
pressure activated pin is used to lock base camshaft timing for engine start up. Oil pressure
releases the pin and allows the PCM to control cam timing once the engine is running. An infinitely
variable valve timing position can be achieved within the limits of the hardware. The CMP monitors
the position of the camshaft with respect to the crankshaft and provides feedback to the PCM.
Component Information > Service and Repair > Camshaft Sprockets - Removal
Camshaft Gear/Sprocket: Service and Repair Camshaft Sprockets - Removal
REMOVAL
NOTE: Camshaft phaser and camshaft sprocket are supplied as an assembly, do not attempt to
disassemble.
1. Remove camshafts. 2. Remove camshaft phaser (2) retaining bolt while holding the camshaft in
place with a wrench (1) on the camshaft flats. 3. Remove phaser (2) assembly from camshaft.
Component Information > Service and Repair > Camshaft Sprockets - Removal > Page 2447
Camshaft Gear/Sprocket: Service and Repair Camshaft Sprockets - Installation
INSTALLATION
1. Install phaser (2) assembly on camshaft.
NOTE: Make sure the dowel is seated in the dowel hole and not in a oil feed hole. The dowel hole
is larger than the 4 oil feed holes.
2. Install phaser retaining bolt and torque while holding camshaft in place with a wrench (1). 3.
Install camshafts.
Jeep Workshop Manuals > Engine, Cooling and Exhaust > Engine > Timing Components > Timing Chain > Component
Timing Chain: Procedures
INSPECTION
Inspect timing chain for stretching prior to removal.
1. Rotate engine while watching timing chain tensioner plunger. When the plunger reaches its
maximum travel stop rotating engine. 2. Measure the distance from the tensioner body and the
edge of the chain guide as shown. 3. If the distance is greater than 20.5 mm (0.81 in.) inspect
guide shoes for excessive wear. 4. If guides are okay, replace timing chain.
Timing Chain: Removal and Replacement
Removal
REMOVAL
1. Remove engine cover by pulling upward. 2. Perform fuel pressure bleed procedure. 3.
Disconnect negative cable at battery (3).
4. Remove coolant recovery bottle (3). 5. Remove windshield washer bottle (1). 6. Remove power
steering reservoir (2) and set aside.
7. Remove make up air hose (2). 8. Remove PCV hose (5). 9. Disconnect ignition coil electrical
connectors (1).
10. Remove cylinder head cover.
11. Raise vehicle. 12. Remove right lower splash shield. 13. Set engine to TDC (1). 14. Remove
accessory drive belt.
15. Remove lower A/C compressor (1) retaining bolts. 16. Remove A/C compressor lower bracket
(2).
17. Remove accessory drive belt lower idler pulley. 18. Remove crankshaft damper (2). 19.
Remove front crankshaft oil seal. 20. Remove water pump pulley (4). 21. Remove engine mount
bracket (1) lower bolt.
22. Remove timing chain cover lower bolts (1). 23. Lower vehicle.
24. Remove power steering line support (1). 25. Remove power steering pump and set aside. 26.
Support engine with a suitable jack and a block of wood under the oil pan.
27. Remove right engine mount to mount bracket bolts (3). 28. Remove accessory drive belt upper
idler pulley.
29. Remove right engine mount bracket (1). 30. Remove accessory drive belt tensioner. 31.
Remove timing chain cover retaining bolts.
32. Remove timing chain cover using pry points (1, 2, 3).
33. Remove timing chain cover (1) out through the bottom of the vehicle.
Installation
INSTALLATION
within 45 minutes.
1. Clean all sealing surfaces. 2. Apply Mopar(R) engine sealant RTV or equivalent as shown at the
cylinder head to block parting line (1, 2).
3. Apply Mopar(R) engine sealant RTV or equivalent as shown at the ladder frame to block parting
line (1, 2).
4. Apply Mopar(R) engine sealant RTV or equivalent as shown in the corner of the oil pan and
block. 5. Apply 2 mm bead of Mopar(R) engine sealant RTV or equivalent to the oil pan as shown.
6. Apply 2 mm bead of Mopar(R) engine sealant RTV or equivalent to the engine block (1, 2) as
shown.
7. Install timing chain cover (1) upwards from under the vehicle. 8. Install timing chain cover upper
retaining bolts and tighten M6 bolts to 12 Nm (105 in lbs) and M8 bolts to 23 Nm (204 in lbs). 9.
Install accessory drive belt tensioner.
10. Install right engine mount bracket (1). 11. Install accessory drive belt upper idler pulley.
12. Install right engine mount (1). 13. Remove jack from under engine. 14. Install power steering
pump. 15. Raise vehicle.
16. Install oil pan to timing chain cover lower retaining bolts (1) and tighten bolts. 17. Install timing
chain cover retaining bolts and tighten bolts.
18. Install water pump pulley (4). 19. Install crankshaft pulley (2) and tighten bolt. 20. Install
accessory drive belt lower idler pulley.
21. Install lower A/C compressor mounting bracket (2). 22. Install A/C compressor (1). 23. Install
accessory drive belt. 24. Install right lower splash shield. 25. Lower vehicle.
27. Connect coil electrical connectors (1). 28. Connect PCV hose (5) to PCV valve. 29. Connect
make up air hose (2).
30. Install power steering reservoir (2). 31. Install windshield washer bottle (1). 32. Install coolant
recovery bottle (3). 33. Fill cooling system.
34. Install air cleaner housing inlet (2).
35. Connect negative cable to battery (3). 36. Install engine cover.
Removal - Timing Chain
TIMING CHAIN
1. Set engine to TDC. 2. Remove timing chain cover.
NOTE: If the timing chain plated links can no longer be seen, the timing chain links corresponding
to the timing marks must be marked prior to removal if the chain is to be reused.
3. Mark chain link (1) corresponding to camshaft timing mark.
4. Mark chain link (3) corresponding to crankshaft timing mark (2).

5. Remove timing chain tensioner (5). 6. Remove timing chain (2).
Removal - Camshaft Sprocket(S)
CAMSHAFT SPROCKET(S)
NOTE: Camshaft phasers and camshaft sprockets are supplied as an assembly, do not attempt to
disassemble.
Refer to camshaft phaser removal Refer to CYLINDER HEAD/CAMSHAFT(S) - REMOVAL).
Installation - Camshaft Sprocket(S)
CAMSHAFT SPROCKET(S)
NOTE: The camshaft sprockets and the camshaft phasers are an assembly and cannot be
serviced separately.
1. Refer to Camshaft phaser (2) installation Refer to CYLINDER HEAD/CAMSHAFT(S) -

INSTALLATION).
Installation - Timing Chain
TIMING CHAIN
1. Verify that the crankshaft sprocket keyway is at the 9 o'clock position.
2. Align camshaft timing marks (3) so they are parallel to the cylinder head and aligned each other
as shown.
3. Install timing chain guide (4) and tighten bolts to 12 Nm (105 in. lbs.).
4. Install timing chain so plated links on chain align with timing marks on camshaft sprockets (1).
5. Align timing mark on the crankshaft sprocket (2) with the plated link (3) on the timing chain.
NOTE: Keep the slack in the timing chain on the tensioner side.
6. Install the moveable timing chain pivot guide (6) and tighten bolt to 12 Nm (105 in. lbs.).
7. Reset timing chain tensioner (4) by lifting up on ratchet (2) and pushing plunger (3) inward
towards the tensioner body (4). Insert Tensioner Pin
8514 into slot (1) to hold tensioner plunger in the retracted position.
8. Install timing chain tensioner (1) and tighten bolts to 12 Nm (105 in. lbs.). 9. Remove timing
Tensioner Pin 8514 (2).
10. Rotate the crankshaft CLOCKWISE two complete revolutions until the crankshaft is
repositioned at the TDC position with the key way at the 9
o'clock position.
11. Verify that the camshafts timing marks (3) are in the proper position. 12. Install front timing
chain cover.
13. Install the balancer and verify that balancer mark (2) and cover mark (1) are aligned. 14.
Connect negative battery cable. 15. Fill with oil, start engine and check for leaks.
Removal - Crankshaft Sprocket
CRANKSHAFT SPROCKET
1. Remove timing chain.

2. Remove oil pan. 3. Remove oil pump drive chain tensioner. 4. Remove oil pump drive chain. 5.
Remove crankshaft sprocket (1).
Installation - Crankshaft Sprocket
CRANKSHAFT SPROCKET
1. Install crankshaft sprocket (1) onto crankshaft.
2. Install oil pump drive chain. Verify that Oil pump is correctly timed (1, 2, 5, 6).
3. Reset oil pump drive chain tensioner by pushing plunger inward and install tensioner pin 8514.
4. Install oil pump drive chain tensioner (3) and remove Tensioner Pin 8514 (4). 5. Install timing
chain. 6. Install oil pan. 7. Fill engine with oil. 8. Start engine and check for leaks.
Jeep Workshop Manuals > Engine, Cooling and Exhaust > Engine > Timing Components > Timing Chain Tensioner >
Timing Chain Tensioner: Specifications
Timing Chain Tensioner Assembly-Bolts

.............................................................................................................................................. 12 Nm
(105 in. lbs.)
Timing Chain Tensioner: Service and Repair Removal
REMOVAL
1. Remove timing chain.
NOTE: Tensioner will not come apart during removal.
2. Remove timing chain tensioner retaining bolts and remove tensioner.

Timing Chain Tensioner: Service and Repair Installation
INSTALLATION
1. Reset tensioner. 2. Install timing chain.

Jeep Workshop Manuals > Engine, Cooling and Exhaust > Engine > Timing Components > Timing Component Alignment
Marks > Component Information > Locations
Timing Component Alignment Marks: Locations
- Verify that the crankshaft sprocket keyway is at the 9 o'clock position.
- Align camshaft timing marks (3) so they are parallel to the cylinder head and aligned each other
as shown.
- Install timing chain guide (4) and tighten bolts to 12 Nm (105 in. lbs.).
Marks > Component Information > Locations > Page 2479
- Install timing chain so plated links on chain align with timing marks on camshaft sprockets (1).
- Align timing mark on the crankshaft sprocket (2) with the plated link (3) on the timing chain.
- Rotate the crankshaft CLOCKWISE two complete revolutions until the crankshaft is repositioned
at the TDC position with the key way at the 9 o'clock position.
Marks > Component Information > Locations > Page 2480
- Verify that the camshafts timing marks (3) are in the proper position.
Jeep Workshop Manuals > Engine, Cooling and Exhaust > Engine > Timing Components > Timing Cover > Component
Timing Cover: Specifications
Timing Chain Cover
M6 Bolts ...............................................................................................................................................
............................................. 12 Nm (105 in. lbs.) M8 Bolts ................................................................
............................................................................................................................ 23 Nm (204 in. lbs.)
Timing Cover: Service and Repair Removal
REMOVAL
1. Remove engine cover by pulling upward. 2. Perform fuel pressure bleed procedure. 3.
Disconnect negative cable at battery (3).
4. Remove coolant recovery bottle (3). 5. Remove windshield washer bottle (1). 6. Remove power
steering reservoir (2) and set aside.
7. Remove make up air hose (2). 8. Remove PCV hose (5). 9. Disconnect ignition coil electrical
connectors (1).
10. Remove cylinder head cover.
11. Raise vehicle. 12. Remove right lower splash shield. 13. Set engine to TDC (1). 14. Remove
accessory drive belt.
15. Remove lower A/C compressor (1) retaining bolts. 16. Remove A/C compressor lower bracket
(2).
17. Remove accessory drive belt lower idler pulley.

18. Remove crankshaft damper (2). 19. Remove front crankshaft oil seal. 20. Remove water pump
pulley (4). 21. Remove engine mount bracket (1) lower bolt.
22. Remove timing chain cover lower bolts (1). 23. Lower vehicle.
24. Remove power steering line support (1). 25. Remove power steering pump and set aside. 26.
Support engine with a suitable jack and a block of wood under the oil pan.
27. Remove right engine mount to mount bracket bolts (3). 28. Remove accessory drive belt upper
idler pulley.
29. Remove right engine mount bracket (1). 30. Remove accessory drive belt tensioner. 31.
Remove timing chain cover retaining bolts.
32. Remove timing chain cover using pry points (1, 2, 3).
33. Remove timing chain cover (1) out through the bottom of the vehicle.
Timing Cover: Service and Repair Installation
INSTALLATION
within 45 minutes.
1. Clean all sealing surfaces. 2. Apply Mopar(R) engine sealant RTV or equivalent as shown at the
cylinder head to block parting line (1, 2).
3. Apply Mopar(R) engine sealant RTV or equivalent as shown at the ladder frame to block parting
line (1, 2).
4. Apply Mopar(R) engine sealant RTV or equivalent as shown in the corner of the oil pan and
block. 5. Apply 2 mm bead of Mopar(R) engine sealant RTV or equivalent to the oil pan as shown.
6. Apply 2 mm bead of Mopar(R) engine sealant RTV or equivalent to the engine block (1, 2) as
shown.
7. Install timing chain cover (1) upwards from under the vehicle. 8. Install timing chain cover upper
retaining bolts and tighten M6 bolts to 12 Nm (105 in lbs) and M8 bolts to 23 Nm (204 in lbs). 9.
Install accessory drive belt tensioner.
10. Install right engine mount bracket (1). 11. Install accessory drive belt upper idler pulley.
12. Install right engine mount (1). 13. Remove jack from under engine. 14. Install power steering
pump. 15. Raise vehicle.
16. Install oil pan to timing chain cover lower retaining bolts (1) and tighten bolts. 17. Install timing
chain cover retaining bolts and tighten bolts.
18. Install water pump pulley (4). 19. Install crankshaft pulley (2) and tighten bolt. 20. Install
accessory drive belt lower idler pulley.
21. Install lower A/C compressor mounting bracket (2). 22. Install A/C compressor (1). 23. Install
accessory drive belt. 24. Install right lower splash shield. 25. Lower vehicle.

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STACK:
Jeep Workshop Manuals > Engine, Cooling and Exhaust > Engine > Timing Components > Variable Valve Timing >
Variable Valve Timing Solenoid > Component Information > Locations > Solenoid-Camshaft 1/1 Position
Component ID: 333
Connector:
Color : BLACK
# of pins : 2
Qualifier : (GAS)
Variable Valve Timing Solenoid > Component Information > Locations > Solenoid-Camshaft 1/1 Position > Page 2501
Component ID: 334
Connector:
Color : BLACK
# of pins : 2
Qualifier : (GAS)
Variable Valve Timing Solenoid > Component Information > Diagrams > Solenoid-Camshaft 1/1 Position
Component ID: 333
Connector:
Color : BLACK
# of pins : 2
Qualifier : (GAS)
Variable Valve Timing Solenoid > Component Information > Diagrams > Solenoid-Camshaft 1/1 Position > Page 2507
Component ID: 334
Connector:
Color : BLACK
# of pins : 2
Qualifier : (GAS)
Variable Valve Timing Solenoid > Component Information > Description and Operation > Description
DESCRIPTION
Variable Valve Timing Solenoid > Component Information > Description and Operation > Description > Page 2513
OPERATION
valve faults
- Map sensor
- Intake cam sensor
- Crankshaft sensor
- GPEC1

- Inputs
- Outputs
the camshaft.
strategy at
camshaft.
life.
timing.
- Starting
Variable Valve Timing Solenoid > Component Information > Service and Repair > Variable Valve Timing Solenoid -
Removal
Front Solenoid 1/1
FRONT SOLENOID 1/1

Removal > Page 2518
Rear Solenoid 1/2
REAR SOLENOID 1/2

Removal > Page 2519

Removal > Page 2520
Front Solenoid 1/1
FRONT SOLENOID 1/1
solenoids.

Removal > Page 2521
Rear Solenoid 1/2
REAR SOLENOID 1/2
rear solenoids.

Removal > Page 2522

Jeep Workshop Manuals > Engine, Cooling and Exhaust > Engine > Tune-up and Engine Performance Checks > Fuel
Pressure > System Information > Specifications

Pressure > System Information > Specifications > Page 2527
Diagnostic Test
test.
Yes
- Go to 2
No
- Go to 7
- Test complete.

- Go to 3

module.
Yes
No
- Go to 4
4. SADDLE FUEL TANK
Yes
- Go to 5
No
- Go to 6
Yes
No
- Go to 6
Yes
No
Yes
No
Jeep Workshop Manuals > Engine, Cooling and Exhaust > Engine > Tune-up and Engine Performance Checks > Idle
Speed > System Information > Specifications

Jeep Workshop Manuals > Engine, Cooling and Exhaust > Engine > Tune-up and Engine Performance Checks > Air
Cleaner Housing > Air Filter Element > Component Information > Service and Repair > Removal
REMOVAL
Cleaner Housing > Air Filter Element > Component Information > Service and Repair > Removal > Page 2538
Cleaner Housing > Air Filter Element > Component Information > Service and Repair > Removal > Page 2539
INSTALLATION
Jeep Workshop Manuals > Engine, Cooling and Exhaust > Engine > Tune-up and Engine Performance Checks > Fuel Filter
> Fuel Pressure Release > System Information > Service and Repair

Jeep Workshop Manuals > Engine, Cooling and Exhaust > Engine > Tune-up and Engine Performance Checks > Fuel Filter
> Fuel Pressure Release > System Information > Service and Repair > Page 2544
Jeep Workshop Manuals > Engine, Cooling and Exhaust > Engine > Tune-up and Engine Performance Checks > Firing
Order > Component Information > Specifications
DESCRIPTION
Jeep Workshop Manuals > Engine, Cooling and Exhaust > Engine > Tune-up and Engine Performance Checks > Spark
Plug > Component Information > Specifications
SPARK PLUGS
Plug > Component Information > Service and Repair > Removal
2.0/2.4L

Plug > Component Information > Service and Repair > Removal > Page 2553

2.0/2.4L


Jeep Workshop Manuals > Engine, Cooling and Exhaust > Engine > Tune-up and Engine Performance Checks >
Compression Check > System Information > Specifications
..............................................................................................................................................................
1172-1551 kpa (170-225 psi)
Jeep Workshop Manuals > Engine, Cooling and Exhaust > Engine > Tune-up and Engine Performance Checks >
Compression Check > System Information > Specifications > Page 2559
malfunctions.
pressure.
Jeep Workshop Manuals > Engine, Cooling and Exhaust > Engine > Water Pump > Component Information > Description
and Operation
Water Pump: Description and Operation
GAS ENGINE
The water pump (3) on the world engine is attached to the water pump adapter on the front of the
cylinder block.
The water pump is driven by the accessory drive belt. The water pump is connected to the water
plenum by the return tube.
Jeep Workshop Manuals > Engine, Cooling and Exhaust > Engine > Water Pump > Component Information > Description
and Operation > Page 2563
Water Pump: Testing and Inspection
WATER PUMP
A quick flow test to determine if the water pump is working effectively is to check heater system for
proper operation. A defective pump will not provide an adequate flow of heated coolant through the
system.
WARNING: DO NOT REMOVE THE COOLING SYSTEM PRESSURE CAP WITH THE SYSTEM
HOT AND UNDER PRESSURE BECAUSE SERIOUS BURNS FROM COOLANT CAN OCCUR.
Another flow test to help determine water pump operation is as follows:
1. Remove cooling system pressure cap. 2. Remove a small amount of coolant from the system. 3.
Start the engine and warm up until thermostat opens. 4. With the thermostat open and coolant level
low, visually inspect for coolant flow. If flow is present, the water pump is pumping coolant through
the system.
Jeep Workshop Manuals > Engine, Cooling and Exhaust > Engine > Water Pump > Component Information > Service and
Repair > Procedures
Water Pump: Procedures
INSPECTION
Replace water pump body assembly if it has any of these defects:
- Cracks or damage on the body.
- Coolant leaks from the shaft seal, evident by wet coolant traces on the pump body.
- Loose or rough turning bearing.
- Impeller rubs either the pump body or the engine block.
- Impeller loose or damaged.
- Sprocket or sprocket flange loose or damaged.

Jeep Workshop Manuals > Engine, Cooling and Exhaust > Engine > Water Pump > Component Information > Service and
Repair > Procedures > Page 2566
Water Pump: Removal and Replacement
Removal
GAS ENGINE
1. Remove the accessory drive belt. 2. Drain engine coolant. 3. Raise vehicle. 4. Remove
accessory drive belt splash shield. 5. Drain cooling system. 6. Remove screws attaching water
pump pulley (1). Remove pulley (1). 7. Remove water pump mounting bolts (2). 8. Remove water
pump (3).
Installation
GAS ENGINE
1. Position water pump assembly (3) into water pump housing (4). 2. Install mounting bolts (2).
Tighten bolts to 24 Nm (212 in. lbs.). 3. Install water pump pulley (1). Tighten bolts to 9 Nm ( 80 in
lbs.). 4. Install drive belt splash shield. 5. Lower vehicle. 6. Install accessory drive belt. 7. Connect
battery negative terminal. 8. Fill cooling system.
Jeep Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Coolant > Component Information > Technical
Service Bulletins > Maintenance - Fluid Flushing Information
Coolant: Technical Service Bulletins Maintenance - Fluid Flushing Information
NUMBER: 26-001-09

MODELS:
2009 - 2010 (DS) Ram Truck (1500)
2005 - 2009 (HB) Durango
2007 - 2009 (HG) Aspen
2009 - 2010 (JC) Journey
2008 - 2010 (KK) Liberty
2007 - 2010 (KA) Nitro
2005 - 2007 (KJ) Liberty
2005 - 2010 (ND) Dakota
2005 - 2006 (PL) Neon

2007 - 2010 (PM) Caliber

Jeep Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Coolant > Component Information > Technical
Service Bulletins > Maintenance - Fluid Flushing Information > Page 2572
2005 - 2010 (ZB) Viper
DISCUSSION:
coolant.
operating range.
distilled water.
Disclaimer:
Jeep Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Coolant > Component Information >
Specifications > Capacity Specifications
Coolant: Capacity Specifications
Engine Coolant Capacity
Engine Coolant ....................................................................................................................................

....................................... 7.2 Quarts ( 6.8 Liters )
Note: Includes heater and coolant recovery bottle filled to MAX level.
Specifications > Capacity Specifications > Page 2575
Coolant: Fluid Type Specifications
Engine Coolant Type
Mopar Antifreeze/Coolant 5 Year/100,000 mile formula HOAT (Hybrid Organic Additive

Technology) or equivalent.
Description and Operation > Coolant
Coolant: Description and Operation Coolant
ENGINE COOLANT
WARNING: Antifreeze is an ethylene glycol base coolant and is harmful if swallowed or inhaled. If
swallowed, drink two glasses of water and induce vomiting. If inhaled, move to fresh air area, seek
clothing thoroughly after coming in contact with ethylene glycol. Keep out of reach of children.
ETHYLENE-GLYCOL MIXTURES
protection. Only Mopar(R) Antifreeze/Coolant, 5 year/100,000 Mile Formula (ethylene-glycol base
coolant with corrosion inhibitors called HOAT, (Hybrid Additive Technology) is recommended. This
coolant offers the best engine cooling without corrosion when mixed with 50% distilled water to
obtain a freeze point of -37° C (-35° F).
The required ethylene-glycol (antifreeze) and water mixture depends upon the climate and vehicle
operating conditions. The antifreeze concentration must always be a minimum of 44 percent,
year-round in all climates. If percentage is lower than 44 percent, engine parts may be eroded by
cavitation, and cooling system components may be severely damaged by corrosion. Maximum
protection against freezing is provided with a 68% antifreeze concentration, which prevents
freezing down to -67.7° C (-90° F). A higher percentage will freeze at a warmer temperature. Also,
a higher percentage of antifreeze can cause the engine to overheat because the specific heat of
antifreeze is lower than that of water.
Use of 100 percent ethylene-glycol will cause formation of additive deposits in the system, as the
corrosion inhibitive additives in ethylene-glycol require the presence of water to dissolve. The
deposits act as insulation, causing temperatures to rise to as high as 149° C (300° F). This
temperature is hot enough to melt plastic and soften solder. The increased temperature can result
in engine detonation. In addition, 100 percent ethylene-glycol freezes at 22° C (-8° F ).
PROPYLENE-GLYCOL MIXTURES
It's overall effective temperature range is smaller than that of ethylene-glycol. The freeze point of
50/50 propylene-glycol and water is -32° C (-26° F). 5° C higher than ethylene-glycol's freeze point.
The boiling point (protection against summer boil-over) of propylene-glycol is 125° C (257 °F ) at
96.5 kPa (14 psi), compared to 128° C (263° F) for ethylene-glycol. Use of propylene-glycol can
result in boil-over or freeze-up on a cooling system designed for ethylene-glycol. Propylene glycol
also has poorer heat transfer characteristics than ethylene glycol. This can increase cylinder head
temperatures under certain conditions.
Propylene-glycol/ethylene-glycol Mixtures can cause the destabilization of various corrosion

inhibitors, causing damage to the various cooling system components. Also, once ethylene-glycol
and propylene-glycol based coolants are mixed in the vehicle, conventional methods of determining
freeze point will not be accurate. Both the refractive index and specific gravity differ between
ethylene glycol and propylene glycol.
Description and Operation > Coolant > Page 2578
Coolant: Description and Operation Description
HOAT COOLANT
WARNING: Antifreeze is an ethylene-glycol base coolant and is harmful if swallowed or inhaled. If

swallowed, drink two glasses of water and induce vomiting. If inhaled, move to fresh air area. Seek
clothing thoroughly after coming in contact with ethylene-glycol. Keep out of reach of children.
CAUTION: Use of Propylene-Glycol based coolants is not recommended, as they provide less
freeze protection and less corrosion protection.
The cooling system is designed around the coolant. The coolant must accept heat from engine
metal, in the cylinder head area near the exhaust valves and engine block. Then coolant carries the
heat to the radiator where the tube/fin radiator can transfer the heat to the air.
The use of aluminum cylinder blocks, cylinder heads, and water pumps requires special corrosion
protection. Mopar(R) Antifreeze/Coolant, 5 Year/160.00 km, (100,000 Mile) Formula (MS-9769), or
the equivalent ethylene-glycol base coolant with organic corrosion inhibitors (called HOAT, for
Hybrid Organic Additive Technology) is recommended. This coolant offers the best engine cooling
without corrosion when mixed with 50% ethylene-glycol and 50% distilled water to obtain a freeze
point of -37° C (-35° F). If it loses color or becomes contaminated, drain, flush, and replace with
fresh properly mixed coolant solution.
CAUTION: Mopar(R) Antifreeze/Coolant, 5 Year/160.00 km (100,000) Mile Formula (MS-9769)

may not be mixed with any other type of antifreeze. Mixing of coolants other than specified
(non-HOAT or other HOAT), may result in engine damage that may not be covered under the new
vehicle warranty, and decreased corrosion protection.
COOLANT PERFORMANCE
The required ethylene-glycol (antifreeze) and water mixture depends upon climate and vehicle
operating conditions. The coolant performance of various mixtures follows:
Pure Water - Water can absorb more heat than a mixture of water and ethylene-glycol. This is for
purpose of heat transfer only. Water also freezes at a higher temperature and allows corrosion.
100 percent Ethylene-Glycol - The corrosion inhibiting additives in ethylene-glycol need the
presence of water to dissolve. Without water, additives form deposits in system. These act as
insulation causing temperature to rise to as high as 149° C (300° F). This temperature is hot
enough to melt plastic and soften solder. The increased temperature can result in engine
detonation. In addition, 100 percent ethylene-glycol freezes at -22° C (-8° F).
50/50 Ethylene-Glycol and Water - Is the recommended mixture, it provides protection against
freezing to -37° C (-34° F). The antifreeze concentration must always be a minimum of 44 percent,
year-round in all climates. If percentage is lower, engine parts may be eroded by cavitation.
Maximum protection against freezing is provided with a 68 percent antifreeze concentration, which
prevents freezing down to -67.7° C (-90° F). A higher percentage will freeze at a warmer
temperature. Also, a higher percentage of antifreeze can cause the engine to overheat because
specific heat of antifreeze is lower than that of water.
COOLANT SELECTION AND ADDITIVES

protection. Only Mopar(R) Antifreeze/Coolant, 5 Year/160.000 km (100,000 Mile) Formula (glycol
base coolant with corrosion inhibitors called HOAT, for Hybrid Organic Additive Technology) is
recommended. This coolant offers the best engine cooling without corrosion when mixed with 50%
distilled water to obtain a freeze point of -37° C (-35° F). If it loses color or becomes contaminated,
drain, flush, and replace with fresh properly mixed coolant solution.
CAUTION: Do not use coolant additives that are claimed to improve engine cooling.
Description and Operation > Coolant > Page 2579
Coolant: Description and Operation Operation
OPERATION
Coolant flows through the engine block absorbing the heat from the engine, then flows to the
radiator where the cooling fins in the radiator transfers the heat from the coolant to the atmosphere.
During cold weather the ethylene-glycol or propylene-glycol coolant prevents water present in the
cooling system from freezing within temperatures indicated by mixture ratio of coolant to water.
Jeep Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Coolant > Component Information > Testing
and Inspection > Coolant Concentration Testing
Coolant: Testing and Inspection Coolant Concentration Testing
COOLANT CONCENTRATION TESTING
Coolant concentration should be checked when any additional coolant was added to system or
after a coolant drain, flush and refill. The coolant mixture offers optimum engine cooling and
protection against corrosion when mixed to a freeze point of -37° C (-34° F) to -46° C (-50° F). The
use of a hydrometer or a refractometer can be used to test coolant concentration.
A hydrometer will test the amount of glycol in a mixture by measuring the specific gravity of the
mixture. The higher the concentration of ethylene glycol, the larger the number of balls that will
float, and higher the freeze protection (up to a maximum of 60% by volume glycol).
A refractometer Tool 8286 will test the amount of glycol in a coolant mixture by measuring the
amount a beam of light bends as it passes through the fluid.
Some coolant manufactures use other types of glycols into their coolant formulations. Propylene
glycol is the most common new coolant. However, propylene glycol based coolants do not provide
the same freezing protection and corrosion protection and is not recommended.
CAUTION: Do not mix types of coolant corrosion protection will be severely reduced.
Jeep Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Coolant > Component Information > Testing
and Inspection > Coolant Concentration Testing > Page 2582
Coolant: Testing and Inspection Coolant Level Check
COOLANT LEVEL CHECK
NOTE: Do not remove pressure cap for routine coolant level inspections.
The coolant recovery/reserve system provides a quick visual method for determining the coolant
level without removing the pressure cap. Simply observe, with the engine idling and warmed up to
normal operating temperature, that the level of the coolant in the recovery/reserve bottle is between
the FULL HOT and ADD marks.
Jeep Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Coolant Line/Hose > Component Information
> Service and Repair > Removal
Coolant Line/Hose: Service and Repair Removal
REMOVAL
The water pump inlet tube (2) connects the water pump to the coolant adapter. This tube is sealed
by an O-ring and held in place by fasteners to the water pump housing.
1. Drain cooling system. 2. Remove the coolant adapter and secondary thermostat. 3. Raise and
support vehicle. 4. Remove inlet tube mounting nuts (1). 5. Remove inlet tube (2).
Jeep Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Coolant Line/Hose > Component Information
> Service and Repair > Removal > Page 2587
Coolant Line/Hose: Service and Repair Installation
INSTALLATION
1. Inspect the O-ring for damage before installing the tube. Replace O-ring as necessary. 2.
Lubricate O-rings with soapy water. 3. Install new water inlet gasket between tube and water pump
housing (2). 4. Position water pump inlet tube (3) on water pump housing (2). Hand tighten nuts to
aide in tube alignment. 5. Install secondary thermostat and coolant adapter. 6. Tighten coolant tube
nuts (1) to 24 Nm (212 in. lbs.). 7. Fill cooling system.
Jeep Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Coolant Reservoir > Component Information >
Description and Operation > Description
Coolant Reservoir: Description and Operation Description
GAS ENGINE
The coolant recovery system consists of a coolant recovery container mounted to the RH inner
wheel housing, a vent hose for the coolant recovery container, a hose connecting the container to
the radiator neck, and a pressure cap.
Description and Operation > Description > Page 2592
Coolant Reservoir: Description and Operation Operation
GAS ENGINE
The system works in conjunction with the cooling system pressure cap to utilize thermal expansion
and contraction of the coolant to keep the coolant free of trapped air. The system provides space
for expansion and contraction. Also, the system provides a convenient and safe method for
checking and adjusting the coolant level at atmospheric pressure without removing the pressure
cap. It also provides some reserve coolant to compensate for minor leaks and evaporation or
boiling losses.
Coolant Reservoir: Service and Repair Removal
GAS ENGINE
1. Siphon coolant from coolant recovery container. 2. Remove return hose (5) from upper radiator
hose tee (3). 3. Remove coolant recovery bottle mount bolt (2). 4. Disengage coolant recovery
container (6) from washer reservoir bottle (4). 5. Remove coolant recovery container and drain.
Coolant Reservoir: Service and Repair Installation
GAS ENGINE
1. Engage coolant recovery container (6) into washer fluid reservoir (4). 2. Install coolant recovery
container mounting bolt (2) and tighten to 4 Nm (35 in. lbs.). 3. Connect hose (5) at upper radiator
Tee (3). 4. Fill coolant recovery container to proper level.
Jeep Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Radiator Cooling Fan > Radiator Cooling Fan
Motor > Component Information > Locations
Radiator Cooling Fan Motor: Locations
Component ID: 55
Component : FAN MODULE-RADIATOR COOLING
Connector:
Name : FAN MODULE-RADIATOR COOLING C1
Color : BLACK
# of pins : 2
A SERIES/PARALLEL RAD FAN RELAY FEED N210 12DB/DG
B LOW/HIGH RAD FAN RELAY OUTPUT N23 12DB/GY
Motor > Component Information > Locations > Page 2600
Connector:
Color : BLACK
# of pins : 2
A GROUND Z904 10BK/LG
B RAD FAN RELAY OUTPUT N24 12DG/DB
Motor > Component Information > Locations > Page 2601
Motor > Component Information > Diagrams > Diagram Information and Instructions
Radiator Cooling Fan Motor: Diagram Information and Instructions
Warnings
WARNINGS - GENERAL
the battery.
characteristics.
to function only.
Motor > Component Information > Diagrams > Diagram Information and Instructions > Page 2604
SYMBOLS
TERMINOLOGY
Circuit Functions
models.
Circuit Information
IDENTIFICATION
LOCATIONS
illustrations.
associated wiring.
Removal
REMOVAL

connector.
Installation
INSTALLATION

Removal
REMOVAL
Installation
INSTALLATION
the new diode.
from the elements.
Removal
REMOVAL
Installation
INSTALLATION
repaired.
half/component.
repair.
Wire Splicing
repair area.

Special Tools
WIRING/TERMINAL


Radiator Cooling Fan Motor: Diagnostic Aids
vehicle.

good continuity.

SEVERAL LOADS


feed and ground.
position
problem
Radiator Cooling Fan Motor: Connector Views
Component ID: 55
Component : FAN MODULE-RADIATOR COOLING
Connector:
Color : BLACK
# of pins : 2
A SERIES/PARALLEL RAD FAN RELAY FEED N210 12DB/DG
B LOW/HIGH RAD FAN RELAY OUTPUT N23 12DB/GY
Connector:
Color : BLACK
# of pins : 2
B RAD FAN RELAY OUTPUT N24 12DG/DB
Motor Relay > Component Information > Locations

Motor Relay > Component Information > Diagrams > Radiator Fan High/Low Relay (In F/RB)

Motor Relay > Component Information > Diagrams > Radiator Fan High/Low Relay (In F/RB) > Page 2629

Motor Relay > Component Information > Diagrams > Radiator Fan High/Low Relay (In F/RB) > Page 2630

Jeep Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Engine - Coolant Temperature Sensor/Switch
> Coolant Temperature Sensor/Switch (For Computer) > Component Information > Technical Service Bulletins > Engine
Controls - MIL On/DTC P0116/ECT Sensor
NUMBER: 18-039-06
INTERNET.
BULLETIN.
SUBJECT:
CAUTION:

BE INSTALLED.
MODELS:
2007 (PM) Caliber
2007 (MK49) Compass
NOTE:
(MDH 1120XX).
NOTE:
DIAGNOSIS:
PARTS REQUIRED:
Controls - MIL On/DTC P0116/ECT Sensor > Page 2636
CAUTION:
NOTE:

seconds.
Controls - MIL On/DTC P0116/ECT Sensor > Page 2637
CAUTION:
PROCESS.
NOTE:
NOTE:
TIME ALLOWANCE:
FAILURE CODE:
Disclaimer:
> Coolant Temperature Sensor/Switch (For Computer) > Component Information > Locations > Sensor-Engine Coolant
Temperature 1

Temperature 1
Component ID: 299
Connector:
Color : DK. GRAY
# of pins : 2
Qualifier : (GAS)
Temperature 1 > Page 2640

Temperature 2
Component ID: 300
Connector:
Color : BLACK
# of pins : 2
Qualifier : (GAS)
> Coolant Temperature Sensor/Switch (For Computer) > Component Information > Diagrams > Sensor-Engine Coolant
Temperature 1

Temperature 1
Component ID: 299
Connector:
Color : DK. GRAY
# of pins : 2
Qualifier : (GAS)

Temperature 2
Component ID: 300
Connector:
Color : BLACK
# of pins : 2
Qualifier : (GAS)
Jeep Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Heater Core > Component Information >
Heater Core: Description and Operation Description
DESCRIPTION
NOTE: LHD model shown. RHD model similar.
The heater core (1) for the heating-A/C system is mounted within the HVAC air distribution
housing, which is located behind the instrument panel. The heater core is a heat exchanger made
of rows of tubes with fins and is positioned within the air distribution housing so that only the
selected amount of air entering the housing passes through the heater core before it is distributed
through the heating-A/C system ducts and outlets. One end of the heater core is fitted with a tank
(2) that includes the fittings for the heater core tubes (3).
The heater core can only be serviced by removing the HVAC housing from the vehicle.
Heater Core: Description and Operation Operation
OPERATION
Engine coolant is circulated through the heater hoses to the heater core at all times. As the coolant
flows through the heater core, heat is removed from the engine and is transferred to the heater
core tubes and fins. Air directed through the heater core picks up the heat from the heater core
fins. The blend-air door allows control of the heater output air temperature by regulating the amount
of air flowing through the heater core. The blower motor speed controls the volume of air flowing
through the HVAC housing.
The heater core cannot be repaired and it must be replaced if inoperative, leaking or damaged.
Service and Repair > Installation
Heater Core: Service and Repair Installation
INSTALLATION
NOTE: LHD model with A/C shown. RHD and heater-only models similar.
1. Carefully install the heater core (6) into the left side of the air distribution housing (5).
2. On RHD models, install the air distribution housing (5) onto the HVAC housing (9).
3. Install the retaining bracket (4) and screw (3) that secure the heater core tubes (8). Tighten the
screw to 1.2 Nm (10 in. lbs.).
4. Install the flange (2) that secures the heater core tubes to the front of the HVAC housing.
5. Install the screw (10) that secures the flange to the HVAC housing. Tighten the screw to 1.2 Nm
(10 in. lbs.).
NOTE: If the foam seal for the flange is deformed or damaged, it must be replaced.
6. Install the foam seal (1) onto the flange.

7. Install the left side front floor duct.
NOTE: If the heater core is being replaced, flush the cooling system.
8. Install the HVAC housing assembly.

Service and Repair > Installation > Page 2659
Heater Core: Service and Repair Removal
REMOVAL
NOTE: The HVAC housing assembly must be removed from vehicle for service of the heater core.
1. Remove the HVAC housing assembly and place it on a workbench.
2. Remove the left side front floor duct.
3. Remove the foam seal (1) from the flange (2) located on the front of the HVAC housing (9).
4. Remove the screw (10) that secures the flange to the front of the HVAC housing and remove the
flange.
5. Remove the screw (3) that secures the retaining bracket (4) for the heater core tubes (8) to the
left side of the air distribution housing (5).
6. On RHD models, remove the air distribution housing from the HVAC housing.
7. Carefully pull the heater core (6) out of the driver side of the air distribution housing.
Jeep Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Lamps and Indicators - Cooling System >
Temperature Gauge > Component Information > Description and Operation > Description
Temperature Gauge: Description and Operation Description
DESCRIPTION
An engine coolant temperature gauge is standard equipment on all instrument clusters. This gauge
is located on the right side of the instrument cluster, just right and below the tachometer. The
gauge consists of a movable gauge needle or pointer controlled by the instrument cluster circuitry
and a fixed 90 degree gauge scale on the cluster overlay that reads left-to-right from C (or Cold) to
H (or Hot). An International Control and Display Symbol icon for Engine Coolant Temperature is
located on the cluster overlay, directly above the hub of the gauge needle.
The engine coolant temperature gauge graphics are white against a black field except for a single
red graduation at the high end of the gauge scale, making them clearly visible within the instrument
cluster in daylight. When illuminated from behind by the panel lamps dimmer controlled cluster
illumination lighting with the exterior lamps turned ON, the white text and graphics still appear white
and the red graphics still appear red. The red gauge needle has internal optical illumination. Gauge
illumination is provided by Light Emitting Diode (LED) units soldered onto the instrument cluster
electronic circuit board.
The engine coolant temperature gauge is serviced as a unit with the instrument cluster.
Temperature Gauge > Component Information > Description and Operation > Description > Page 2665
Temperature Gauge: Description and Operation Operation
OPERATION
The engine coolant temperature gauge gives an indication to the vehicle operator of the engine
coolant temperature. This gauge is controlled by the instrument cluster circuit board based upon
cluster programming and electronic messages received by the cluster from the Powertrain Control
Module (PCM) over the Controller Area Network (CAN) data bus.
The engine coolant temperature gauge is driven by an electronic stepper motor unit that receives
battery current on the instrument cluster electronic circuit board through the fused ignition switch
output (run-start) circuit whenever the ignition switch is in the ON or START positions. The cluster
is programmed to move the gauge needle back to the low end of the scale after the ignition switch
is turned to the OFF position. The instrument cluster circuitry controls the gauge needle position
and provides the following features:
- Engine Temperature Message - Each time the cluster receives an electronic engine temperature
message from the PCM indicating the temperature is between the low end of normal [about 41° C
(105° F) for gasoline engines, or about 28° C (82° F) for diesel engines] and the high end of normal
[about 124° C (255° F) for gasoline engines, or about 124° C (256° F) for diesel engines], the
gauge needle is moved to the actual relative temperature position on the gauge scale.
- Engine Temperature Low Message - Each time the cluster receives an electronic engine
temperature message from the PCM indicating the temperature is low [at or below about 40° C
(104° F) for gasoline engines, or about 27° C (81° F) for diesel engines], the gauge needle is held
below the graduation on the far left end of the gauge scale. The gauge needle remains below the
low end of the gauge scale until the cluster receives a message from the PCM indicating that the
temperature is above the low end of normal, or until the ignition switch is turned to the OFF
position, whichever occurs first.
- Engine Temperature High or Critical Message - Each time the cluster receives an electronic
engine temperature message from the PCM indicating the temperature is high [at or above about
127° C (261° F) for gasoline engines, or about 128° C (262° F) for diesel engines], the gauge
needle is moved to the red graduation at the high end of the gauge scale, the engine temperature
indicator is illuminated and a single chime tone is sounded. The gauge needle remains at the red
graduation and the engine temperature indicator remains illuminated until the cluster receives a
message from the PCM indicating that the temperature is below about 124° C (255° F), or until the
ignition switch is turned to the OFF position, whichever occurs first. The chime tone feature will only
repeat during the same ignition cycle if the engine temperature indicator is cycled OFF and then
ON again by the appropriate messages from the PCM.
- Communication Error - If the cluster fails to receive an engine temperature message, it will hold
the gauge needle at the last indication for about five seconds or until the ignition switch is turned to
the OFF position, whichever occurs first. After five seconds, the cluster will move the gauge needle
to the low end of the gauge scale.
- Actuator Test - Each time the cluster is put through the actuator test, the engine coolant
temperature gauge needle will be swept to several calibration points on the gauge scale in a
prescribed sequence in order to confirm the functionality of the gauge and the cluster control
circuitry.
The PCM continually monitors the engine coolant temperature sensor to determine the engine
operating temperature. The PCM then sends the proper messages to the ElectroMechanical
Instrument Cluster (EMIC). If the instrument cluster turns ON the engine temperature indicator due
to a high or critical engine coolant temperature gauge reading, it may indicate that the engine or the
engine cooling system requires service.
For proper diagnosis of the engine coolant temperature sensor, the PCM, the EMIC, the CAN data
bus or the electronic communication related to engine coolant temperature gauge operation a
Temperature Warning Lamp/Indicator, Engine Cooling > Component Information > Description and Operation > Description
Temperature Warning Lamp/Indicator: Description and Operation Description
DESCRIPTION
An engine temperature indicator is standard equipment on all instrument clusters. The engine
temperature indicator is located above the engine coolant temperature gauge in the cluster overlay,
to the right of the tachometer.
The engine temperature indicator consists of a stencil-like cutout of the International Control and
Display Symbol icon for Engine Coolant Temperature in the opaque layer of the instrument cluster
overlay. The dark outer layer of the overlay prevents the indicator from being clearly visible when it
is not illuminated. A red Light Emitting Diode (LED) behind the cutout in the opaque layer of the
overlay causes the indicator to appear in red through the translucent outer layer of the overlay
when it is illuminated from behind by the LED, which is soldered onto the instrument cluster
The engine temperature indicator is serviced as a unit with the instrument cluster.
Temperature Warning Lamp/Indicator, Engine Cooling > Component Information > Description and Operation > Description
> Page 2670
Temperature Warning Lamp/Indicator: Description and Operation Operation
OPERATION
The engine temperature indicator gives an indication to the vehicle operator when the engine
temperature gauge reading reflects a condition requiring immediate attention. This indicator is
controlled by a transistor on the instrument cluster circuit board based upon cluster programming
and electronic messages received by the cluster from the Powertrain Control Module (PCM) over
the Controller Area Network (CAN) data bus.
The engine temperature indicator Light Emitting Diode (LED) is completely controlled by the
instrument cluster logic circuit, and that logic will only allow this indicator to operate when the
transistor. The instrument cluster will turn ON the engine temperature indicator for the following
reasons:
- Bulb Test - Each time the ignition switch is turned to the ON position the engine temperature
indicator is illuminated for about two seconds as a bulb test. The entire bulb test is a function of the
PCM.
127° C (261° F) for gasoline engines, or about 128° C (262° F) for diesel engines], the engine
temperature indicator will be illuminated and a single chime tone is sounded. The indicator remains
illuminated until the cluster receives a message from the PCM indicating that the temperature is
below about 124° C (255° F), or until the ignition switch is turned to the OFF position, whichever
occurs first. The chime tone feature will only repeat during the same ignition cycle if the engine
temperature indicator is cycled OFF, then ON again by the appropriate messages from the PCM.
- Actuator Test - Each time the cluster is put through the actuator test, the engine temperature
indicator will be turned ON, then OFF again during the bulb check portion of the test to confirm the
Instrument Cluster (EMIC). For further diagnosis of the engine temperature indicator or the
instrument cluster circuitry that controls the LED. If the instrument cluster turns ON the engine
temperature indicator due to a high engine temperature gauge reading, it may indicate that the
engine or the engine cooling system requires service.
bus or the electronic communication related to engine temperature indicator operation a diagnostic
scan tool is required.
Jeep Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Radiator > Radiator Drain Plug > Component
Radiator Drain Plug: Service and Repair Removal
REMOVAL
CAUTION: Use of pliers on draincock is not recommended. Damage may occur to radiator or
draincock.
NOTE: It is not necessary to remove draincock during a routine coolant drain.
1. Drain the cooling system. 2. Open the draincock (2) by turning it counterclockwise until it stops.
3. Turn the draincock (2) back (clockwise) 1/8 turn. 4. Pull the draincock (2) from the radiator tank
(1).
Jeep Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Radiator > Radiator Drain Plug > Component
Radiator Drain Plug: Service and Repair Installation
INSTALLATION
1. Align draincock stem to radiator tank opening. 2. Push draincock (2) into the radiator tank
opening. 3. Tighten the draincock (2) by turning clockwise until it stops. 4. Fill the cooling system.
Jeep Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Radiator Cap > Component Information >
Radiator Cap: Description and Operation Description
GAS ENGINES
The cooling system is equipped with a pressure cap that releases built up pressure, maintaining a
range of 97-124 kPa (14 - 18 psi).
There is also a vent valve (6) in the center of the cap. This valve also opens when coolant is
cooling and contracting, allowing coolant to return to radiator from coolant recovery container by
vacuum through connecting hose. If valve is stuck shut, the radiator hoses will be collapsed on cool
down. Clean the vent valve to ensure proper sealing when boiling point is reached.
Radiator Cap: Description and Operation Operation
GAS
The pressure cap allows the cooling system to operate at higher than atmospheric pressure. The
higher pressure raises the coolant boiling point; this allows increased radiator cooling capacity.
The secondary gasket in the cap seals the filler neck and the primary gasket seals the cooling
system so that vacuum can be maintained, allowing coolant to be drawn back into the radiator from
the reserve container.
A vent valve in the center of the cap will remain shut as long as the cooling system is pressurized.
As the coolant cools, it contracts and creates a vacuum in cooling system. This causes the vacuum
valve to open and coolant in reserve/overflow tank to be drawn through connecting hose into
radiator. If the vacuum valve is stuck shut, or overflow hose is kinked, radiator hoses will collapse
on cool-down.
Testing and Inspection > Cap-Radiator Pressure
Radiator Cap: Testing and Inspection Cap-Radiator Pressure
RADIATOR PRESSURE CAP PRESSURE RELIEF TESTING
WARNING: If vehicle has been run recently, wait 15 minutes before removing cap. Place a shop
towel over the cap, and without pushing down, rotate it counterclockwise to the first stop. Allow
fluids to escape through the overflow tube. When the system stops pushing coolant and steam into
the coolant recovery container and pressure drops, push down on the cap and remove it
completely. Squeezing the radiator inlet hose with a shop towel (to check pressure) before and
after turning to the first stop is recommended.
WARNING: The warning words "do not open hot" on the pressure cap is a safety precaution. When
hot, the cooling system builds up pressure. To prevent scalding or other injury, the pressure cap
should not be removed while the system is hot and/or under pressure.
The pressure cap upper gasket to filler neck seal can be checked by removing the overflow hose at
the radiator filler neck overflow nipple. Attach the radiator pressure tester to the filler neck overflow
nipple, and pump air into the system. The pressure cap upper gasket should relieve pressure at 69
- 124 kPa (10 - 18 psi), and hold pressure at 55 kPa (8 psi) minimum.
There is no need to remove the pressure cap at any time except for the following purposes:
- Check and adjust coolant freeze point
- Refill system with new coolant
- Conducting service procedures
- Checking for leaks

Testing and Inspection > Cap-Radiator Pressure > Page 2684
Radiator Cap: Testing and Inspection Radiator Pressure Cap Testing
RADIATOR PRESSURE CAP TESTING
Dip the pressure cap in water. Clean any deposits off the vent valve or its seat and apply cap to
end of the Pressure Cap Test Adaptor that is included with the Cooling System Tester 7700.
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 the pressure cap.
CAUTION: The Cooling System Tester Tool is very sensitive to small air leaks that will not cause
cooling system problems. A pressure cap that does not have a history of coolant loss should not be
replaced just because it leaks slowly when tested with this tool. Add water to the tool. Turn tool
upside down and recheck pressure cap to confirm that cap is bad.
If the pressure cap tests properly while positioned on Cooling System Tester 7700, but will not hold
pressure or vacuum when positioned on the filler neck. Inspect the filler neck and cap top gasket
for irregularities that may prevent the cap from sealing properly.
Service and Repair > Cleaning
Radiator Cap: Service and Repair Cleaning
CLEANING
Use only a mild soap to clean the pressure cap.

Service and Repair > Cleaning > Page 2687
Radiator Cap: Service and Repair Inspection
INSPECTION
Hold the cap in your hand, top side up. The vent valve (6) at the bottom of the cap should not open.
If the valve opens, replace the cap. If the rubber seal (5) has swollen, preventing the valve from
opening, replace the cap.
Hold the cleaned cap in your hand, upside down. If any light can be seen between vent valve (6)
and the rubber seal (5), replace the cap.
A replacement cap must be of the type designed for a full pressure coolant systems. This design
ensures coolant return to the radiator.
Jeep Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Relays and Modules - Cooling System >
Radiator Cooling Fan Motor Relay > Component Information > Locations

Radiator Cooling Fan Motor Relay > Component Information > Diagrams > Radiator Fan High/Low Relay (In F/RB)

Radiator Cooling Fan Motor Relay > Component Information > Diagrams > Radiator Fan High/Low Relay (In F/RB) > Page
2694

Radiator Cooling Fan Motor Relay > Component Information > Diagrams > Radiator Fan High/Low Relay (In F/RB) > Page
2695

Jeep Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Sensors and Switches - Cooling System >
Engine - Coolant Temperature Sensor/Switch > Coolant Temperature Sensor/Switch (For Computer) > Component
NUMBER: 18-039-06
INTERNET.
BULLETIN.
SUBJECT:
CAUTION:

BE INSTALLED.
MODELS:
2007 (PM) Caliber
2007 (MK49) Compass
NOTE:
(MDH 1120XX).
NOTE:
DIAGNOSIS:
PARTS REQUIRED:
CAUTION:
NOTE:

seconds.
CAUTION:
PROCESS.
NOTE:
NOTE:
TIME ALLOWANCE:
FAILURE CODE:
Disclaimer:

Temperature 1
Component ID: 299
Connector:
Color : DK. GRAY
# of pins : 2
Qualifier : (GAS)

Temperature 2
Component ID: 300
Connector:
Color : BLACK
# of pins : 2
Qualifier : (GAS)

Temperature 1
Component ID: 299
Connector:
Color : DK. GRAY
# of pins : 2
Qualifier : (GAS)

Temperature 2
Component ID: 300
Connector:
Color : BLACK
# of pins : 2
Qualifier : (GAS)
Jeep Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Temperature Gauge > Component
Temperature Gauge: Description and Operation Description
DESCRIPTION
An engine coolant temperature gauge is standard equipment on all instrument clusters. This gauge
is located on the right side of the instrument cluster, just right and below the tachometer. The
gauge consists of a movable gauge needle or pointer controlled by the instrument cluster circuitry
and a fixed 90 degree gauge scale on the cluster overlay that reads left-to-right from C (or Cold) to
H (or Hot). An International Control and Display Symbol icon for Engine Coolant Temperature is
located on the cluster overlay, directly above the hub of the gauge needle.
The engine coolant temperature gauge graphics are white against a black field except for a single
red graduation at the high end of the gauge scale, making them clearly visible within the instrument
cluster in daylight. When illuminated from behind by the panel lamps dimmer controlled cluster
illumination lighting with the exterior lamps turned ON, the white text and graphics still appear white
and the red graphics still appear red. The red gauge needle has internal optical illumination. Gauge
illumination is provided by Light Emitting Diode (LED) units soldered onto the instrument cluster
The engine coolant temperature gauge is serviced as a unit with the instrument cluster.
Jeep Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Temperature Gauge > Component
Temperature Gauge: Description and Operation Operation
OPERATION
The engine coolant temperature gauge gives an indication to the vehicle operator of the engine
coolant temperature. This gauge is controlled by the instrument cluster circuit board based upon
cluster programming and electronic messages received by the cluster from the Powertrain Control
Module (PCM) over the Controller Area Network (CAN) data bus.
The engine coolant temperature gauge is driven by an electronic stepper motor unit that receives
battery current on the instrument cluster electronic circuit board through the fused ignition switch
output (run-start) circuit whenever the ignition switch is in the ON or START positions. The cluster
is programmed to move the gauge needle back to the low end of the scale after the ignition switch
is turned to the OFF position. The instrument cluster circuitry controls the gauge needle position
and provides the following features:
- Engine Temperature Message - Each time the cluster receives an electronic engine temperature
message from the PCM indicating the temperature is between the low end of normal [about 41° C
(105° F) for gasoline engines, or about 28° C (82° F) for diesel engines] and the high end of normal
[about 124° C (255° F) for gasoline engines, or about 124° C (256° F) for diesel engines], the
gauge needle is moved to the actual relative temperature position on the gauge scale.
- Engine Temperature Low Message - Each time the cluster receives an electronic engine
temperature message from the PCM indicating the temperature is low [at or below about 40° C
(104° F) for gasoline engines, or about 27° C (81° F) for diesel engines], the gauge needle is held
below the graduation on the far left end of the gauge scale. The gauge needle remains below the
low end of the gauge scale until the cluster receives a message from the PCM indicating that the
temperature is above the low end of normal, or until the ignition switch is turned to the OFF
127° C (261° F) for gasoline engines, or about 128° C (262° F) for diesel engines], the gauge
needle is moved to the red graduation at the high end of the gauge scale, the engine temperature
indicator is illuminated and a single chime tone is sounded. The gauge needle remains at the red
graduation and the engine temperature indicator remains illuminated until the cluster receives a
message from the PCM indicating that the temperature is below about 124° C (255° F), or until the
ignition switch is turned to the OFF position, whichever occurs first. The chime tone feature will only
repeat during the same ignition cycle if the engine temperature indicator is cycled OFF and then
ON again by the appropriate messages from the PCM.
- Communication Error - If the cluster fails to receive an engine temperature message, it will hold
the gauge needle at the last indication for about five seconds or until the ignition switch is turned to
the OFF position, whichever occurs first. After five seconds, the cluster will move the gauge needle
to the low end of the gauge scale.
- Actuator Test - Each time the cluster is put through the actuator test, the engine coolant
temperature gauge needle will be swept to several calibration points on the gauge scale in a
prescribed sequence in order to confirm the functionality of the gauge and the cluster control
circuitry.
Instrument Cluster (EMIC). If the instrument cluster turns ON the engine temperature indicator due
to a high or critical engine coolant temperature gauge reading, it may indicate that the engine or the
engine cooling system requires service.
bus or the electronic communication related to engine coolant temperature gauge operation a
Jeep Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Temperature Warning Lamp/Indicator, Engine
Cooling > Component Information > Description and Operation > Description
Temperature Warning Lamp/Indicator: Description and Operation Description
DESCRIPTION
An engine temperature indicator is standard equipment on all instrument clusters. The engine
temperature indicator is located above the engine coolant temperature gauge in the cluster overlay,
to the right of the tachometer.
The engine temperature indicator consists of a stencil-like cutout of the International Control and
Display Symbol icon for Engine Coolant Temperature in the opaque layer of the instrument cluster
overlay. The dark outer layer of the overlay prevents the indicator from being clearly visible when it
is not illuminated. A red Light Emitting Diode (LED) behind the cutout in the opaque layer of the
overlay causes the indicator to appear in red through the translucent outer layer of the overlay
The engine temperature indicator is serviced as a unit with the instrument cluster.
Jeep Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Temperature Warning Lamp/Indicator, Engine
Cooling > Component Information > Description and Operation > Description > Page 2727
Temperature Warning Lamp/Indicator: Description and Operation Operation
OPERATION
The engine temperature indicator gives an indication to the vehicle operator when the engine
temperature gauge reading reflects a condition requiring immediate attention. This indicator is
and electronic messages received by the cluster from the Powertrain Control Module (PCM) over
the Controller Area Network (CAN) data bus.
The engine temperature indicator Light Emitting Diode (LED) is completely controlled by the
instrument cluster logic circuit, and that logic will only allow this indicator to operate when the
transistor. The instrument cluster will turn ON the engine temperature indicator for the following
reasons:
- Bulb Test - Each time the ignition switch is turned to the ON position the engine temperature
indicator is illuminated for about two seconds as a bulb test. The entire bulb test is a function of the
PCM.
127° C (261° F) for gasoline engines, or about 128° C (262° F) for diesel engines], the engine
temperature indicator will be illuminated and a single chime tone is sounded. The indicator remains
illuminated until the cluster receives a message from the PCM indicating that the temperature is
below about 124° C (255° F), or until the ignition switch is turned to the OFF position, whichever
occurs first. The chime tone feature will only repeat during the same ignition cycle if the engine
temperature indicator is cycled OFF, then ON again by the appropriate messages from the PCM.
- Actuator Test - Each time the cluster is put through the actuator test, the engine temperature
Instrument Cluster (EMIC). For further diagnosis of the engine temperature indicator or the
instrument cluster circuitry that controls the LED. If the instrument cluster turns ON the engine
temperature indicator due to a high engine temperature gauge reading, it may indicate that the
engine or the engine cooling system requires service.
bus or the electronic communication related to engine temperature indicator operation a diagnostic
Jeep Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Thermostat, Engine Cooling > Component
Thermostat: Description and Operation Description
DESCRIPTION
The primary thermostat is located on the front of the water plenum in the thermostat
housing/coolant inlet. The thermostat has an air bleed vent located on its flange. The air bleed vent
(1) and the locator dimple on thermostat seal provide for proper positioning of thermostat in inlet
housing.
The secondary thermostat is located in the cylinder head under the water plenum.
Thermostat: Description and Operation Operation
OPERATION
When the Engine is cold and both the primary and secondary thermostats are closed. The coolant
will circulate through the engine, heater system, and the bypass. The cooling system has no flow
through the radiator
As the engine warms up, the primary thermostat will start to open at 82° C (179° F). Coolant will
start to flow through the radiator oil cooler and transmission cooler. Coolant will flow through the
transmission oil cooler only when the primary thermostat is fully open. The primary thermostat will
fully open at 95° C (203° F).
The secondary thermostat will start to open at 95° C (203° F). This will increase the coolant flow
through the cylinder block and cylinder head and the radiator. The secondary thermostat will fully
open at 110 °C (230° F).
If the thermostat is stuck open or allows coolant leakage through it, the engine will not operate at
the proper temperature for obtaining engine fuel efficiency, performance and emissions levels. If
this condition occurs, a diagnostic trouble code will be set and a MIL light will be turned on. Refer to
the Powertrain Diagnostic Procedures manual for further information and diagnostics provided.
Information > Description and Operation > Page 2733
Thermostat: Testing and Inspection
ENGINE COOLANT THERMOSTAT
The thermostat is operated by a wax filled chamber (pellet) which is sealed.When heated coolant
reaches a predetermined temperature the wax pellet expands enough to overcome the closing
spring and water pump pressure, 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.
Thermostat diagnostics is included in Totally Integrated Power Module's (TIPM) programming for
on-board diagnosis. The malfunction indicator light (MIL) will illuminate and a diagnostic trouble
code (DTC) will be set when an "open too soon" condition occurs. Do not change a thermostat for
lack of heater performance or temperature gauge position, unless a DTC is present. Thermostat
failing shut is the normal long term mode of failure, and normally, only on high mileage vehicles.
The temperature gauge will indicate this.
Thermostat: Service and Repair Removal
Gas - Primary Thermostat
GAS - PRIMARY THERMOSTAT
1. Partially drain cooling system. 2. Remove air filter housing. 3. Disconnect coolant hose (1) from
inlet housing (2). 4. Remove inlet housing bolts (3). 5. Remove thermostat assembly, and clean
sealing surfaces.
Gas - Secondary Thermostat
GAS - SECONDARY THERMOSTAT
1. Partially drain cooling system.. 2. Remove air filter housing. 3. Disconnect coolant hoses (1) from
rear of coolant adapter (2). 4. Remove radiator hose (3). 5. Remove radiator hose (4) from front of
coolant adapter (2). 6. Remove coolant adapter mounting bolts. 7. Carefully slide coolant adapter
off water pump inlet tube and remove coolant adapter (2) and secondary thermostat.
Thermostat: Service and Repair Installation
Gas - Primary Thermostat
GAS - PRIMARY THERMOSTAT
1. Position thermostat into the water plenum, aligning air bleed with the location notch on inlet
housing (2). 2. Install inlet housing (2) onto coolant adapter. Tighten bolts to 9 Nm (79 in. lbs.). 3.
Connect coolant hose (1). 4. Install air filter housing. 5. Fill cooling system.
Gas - Secondary Thermostat
GAS - SECONDARY THERMOSTAT
1. Position thermostat into the cylinder head. 2. Inspect the water pump inlet tube O-rings for
damage before installing the tube in the coolant adapter. Replace O-ring as necessary. 3. Lubricate
O-rings with soapy water. 4. Position coolant adapter on water pump inlet tube and cylinder head.
5. Install coolant adapter mounting bolts. Tighten bolts to 18 Nm (159 in. lbs.). 6. Connect front
coolant hose (1). 7. Connect two rear coolant hoses (1). 8. Connect radiator hose (3). 9. Install air
filter housing.
10. Fill cooling system.

Jeep Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Water Pump > Component Information >
Description and Operation
Water Pump: Description and Operation
GAS ENGINE
The water pump (3) on the world engine is attached to the water pump adapter on the front of the
cylinder block.
The water pump is driven by the accessory drive belt. The water pump is connected to the water
plenum by the return tube.
Description and Operation > Page 2740
Water Pump: Testing and Inspection
WATER PUMP
A quick flow test to determine if the water pump is working effectively is to check heater system for
proper operation. A defective pump will not provide an adequate flow of heated coolant through the
system.
WARNING: DO NOT REMOVE THE COOLING SYSTEM PRESSURE CAP WITH THE SYSTEM
HOT AND UNDER PRESSURE BECAUSE SERIOUS BURNS FROM COOLANT CAN OCCUR.
Another flow test to help determine water pump operation is as follows:
1. Remove cooling system pressure cap. 2. Remove a small amount of coolant from the system. 3.
Start the engine and warm up until thermostat opens. 4. With the thermostat open and coolant level
low, visually inspect for coolant flow. If flow is present, the water pump is pumping coolant through
the system.
Service and Repair > Procedures
Water Pump: Procedures
INSPECTION
Replace water pump body assembly if it has any of these defects:
- Cracks or damage on the body.
- Coolant leaks from the shaft seal, evident by wet coolant traces on the pump body.
- Loose or rough turning bearing.
- Impeller rubs either the pump body or the engine block.
- Impeller loose or damaged.
- Sprocket or sprocket flange loose or damaged.

Service and Repair > Procedures > Page 2743
Water Pump: Removal and Replacement
Removal
GAS ENGINE
1. Remove the accessory drive belt. 2. Drain engine coolant. 3. Raise vehicle. 4. Remove
accessory drive belt splash shield. 5. Drain cooling system. 6. Remove screws attaching water
pump pulley (1). Remove pulley (1). 7. Remove water pump mounting bolts (2). 8. Remove water
pump (3).
Installation
GAS ENGINE
1. Position water pump assembly (3) into water pump housing (4). 2. Install mounting bolts (2).
Tighten bolts to 24 Nm (212 in. lbs.). 3. Install water pump pulley (1). Tighten bolts to 9 Nm ( 80 in
lbs.). 4. Install drive belt splash shield. 5. Lower vehicle. 6. Install accessory drive belt. 7. Connect
battery negative terminal. 8. Fill cooling system.
Jeep Workshop Manuals > Engine, Cooling and Exhaust > Exhaust System > Catalytic Converter > Component Information
> Description and Operation > Catalytic Converter
Catalytic Converter: Description and Operation Catalytic Converter
DESCRIPTION
The combination exhaust manifold/catalytic converter is attached to the intermediate pipe using
fasteners and a gasket for sealing.
WARNING: The normal operating temperature of the exhaust system is very high. Therefore, never
work around or attempt to service any part of the exhaust system until it is cooled. Special care
should be taken when working near the catalytic converter. The temperature of the converter rises
to a high level after a short period of engine operation time.
CAUTION: DO NOT remove spark plug wires from plugs or by any other means short out cylinders.
Failure of the catalytic converter can occur due to a temperature increase caused by unburned fuel
passing through the converter.
The stainless steel catalytic converter body is designed to last the life of the vehicle. Excessive
heat can result in bulging or other distortion, but excessive heat will not be the fault of the
converter. If unburned fuel enters the converter, overheating may occur. If a converter is
heat-damaged, correct the cause of the damage at the same time the converter is replaced. Also,
inspect all other components of the exhaust system for heat damage.
Unleaded gasoline must be used to avoid contaminating the catalyst core.
FWD vehicles use a catalytic converter located after the exhaust manifold and before the
I-Pipe/Muffler assembly.
AWD vehicles use a maniverter and an under floor catalytic converter. The under floor catalytic
converter is located between the maniverter and the I-Pipe/muffler assembly.
Diesel engine vehicles use a catalytic converter located between the turbocharger and the
> Description and Operation > Catalytic Converter > Page 2749
Catalytic Converter: Description and Operation Converter-Catalytic
OPERATION - GAS ENGINE
The three-way catalytic converter simultaneously converts three exhaust emissions into harmless
gases. Specifically, HC and CO emissions are converted into water (H2O) and carbon dioxide
(CO2). Oxides of Nitrogen (NOx) are converted into Nitrogen (N) and Oxygen. The three-way
catalyst is most efficient in converting HC, CO and NOx at the stoichiometric air fuel ratio of 14.7:1.
The oxygen content in a catalyst is important for efficient conversion of exhaust gases. When a
high oxygen content (lean) air/fuel ratio is present for an extended period, oxygen content in a
catalyst can reach a maximum. When a rich air/fuel ratio is present for an extended period, the
oxygen content in the catalyst can become totally depleted. When this occurs, the catalyst fails to
convert the gases. This is known as catalyst "punch through."
Catalyst operation is dependent on its ability to store and release the oxygen needed to complete
the emissions-reducing chemical reactions. As a catalyst deteriorates, its ability to store oxygen is
reduced. Since the catalyst's ability to store oxygen is somewhat related to proper operation,
oxygen storage can be used as an indicator of catalyst performance. Refer to the appropriate
Diagnostic Information for diagnosis of a catalyst related Diagnostic Trouble Code (DTC).
The combustion reaction caused by the catalyst releases additional heat in the exhaust system,
causing temperature increases in the area of the reactor under severe operating conditions. Such
conditions can exist when the engine misfires or otherwise does not operate at peak efficiency. Do
not remove spark plug wires from plugs or by any other means short out cylinders. Failure of the
catalytic converter can occur due to temperature increases caused by unburned fuel passing
through the converter. This deterioration of the catalyst core can result in excessively high emission
levels, noise complaints, and exhaust restrictions.
Unleaded gasoline must be used to avoid ruining the catalyst core. Do not allow engine to operate
above 1200 RPM in neutral for extended periods over 5 minutes. This condition may result in
excessive exhaust system/floor pan temperatures because of no air movement under the vehicle.
The flex joint allows flexing as the engine moves, preventing breakage that could occur from the
back-and-forth motion of a transverse mounted engine.
CAUTION: Due to exterior physical similarities of some catalytic converters with pipe assemblies,
extreme care should be taken with replacement parts. There are internal converter differences
required in some parts of the country (particularly vehicles built for States with strict emission
requirements) and between model years.
Catalytic Converter: Service and Repair Removal
Under Floor Catalytic Converter
UNDER FLOOR CATALYTIC CONVERTER
WARNING: THE NORMAL OPERATING TEMPERATURE OF THE EXHAUST SYSTEM IS VERY

HIGH. THEREFORE, NEVER WORK AROUND OR ATTEMPT TO SERVICE ANY PART OF THE
EXHAUST SYSTEM UNTIL IT IS COOLED. SPECIAL CARE SHOULD BE TAKEN WHEN
WORKING NEAR THE CATALYTIC CONVERTER. THE TEMPERATURE OF THE CONVERTER
RISES TO A HIGH LEVEL AFTER A SHORT PERIOD OF ENGINE OPERATING TIME.
1. Raise vehicle on hoist and apply penetrating oil to band clamp fastener of component being
removed.
NOTE: Do not use petroleum-based lubricants when removing/installing muffler or exhaust pipe
isolators as it may compromise the life of the part. A suitable substitute is a mixture of liquid dish
soap and water.
2. Remove I-Pipe/Muffler assembly. 3. Disconnect oxygen sensor electrical connectors.
NOTE: If spherical gasket is to be reused, mark orientation.
4. Remove flange bolts (3), springs and spherical gasket. 5. Remove under floor catalytic converter
(4) from combination manifold/catalytic converter assembly (1). 6. Clean ends of pipes to assure
mating of all parts. Discard broken or worn isolators, rusted or overused clamps, supports, and
attaching parts.
NOTE: When replacement is required on any component of the exhaust system, you must use
original equipment parts (or their equivalent).
Catalytic Converter - FWD
CATALYTIC CONVERTER - FWD

attempt to service any part of the exhaust system until it is cooled. Special care should be taken
when working near the catalytic converter. The temperature of the converter rises to a high level
after a short period of engine operation time.
NOTE: Before replacing a catalytic converter, determine the root cause of failure. Most catalytic
converter failures are caused by air, fuel or ignition problems. Refer to the appropriate service
diagnostic information for repair procedures.
1. Loosen intermediate pipe-to catalytic converter clamp.
soap and water.
2. Remove catalytic converter to exhaust manifold attaching fasteners and remove converter from
vehicle. 3. Remove I-Pipe/Muffler assembly insulators as necessary to slide I-Pipe/Muffler
assembly out of catalytic converter. 4. Remove and discard flange gasket.
NOTE: When replacement is required on any component of the exhaust system, original equipment
parts (or equivalent) must be used.
Removal - Maniverter
REMOVAL - MANIVERTER

HIGH. THEREFORE, NEVER ATTEMPT TO SERVICE ANY PART OF THE EXHAUST SYSTEM
UNTIL IT IS COOLED. SPECIAL CARE SHOULD BE TAKEN WHEN WORKING NEAR THE
CATALYTIC CONVERTER. THE TEMPERATURE OF THE CONVERTER RISES TO A HIGH
LEVEL AFTER A SHORT PERIOD OF ENGINE OPERATION TIME.
1. Remove under floor catalytic converter.

2. Lower vehicle. 3. Remove secondary thermostat. 4. Remove maniverter mounting bolts. 5.

Remove maniverter and gasket from the engine compartment.
Inspection
INSPECTION
Check catalytic converter for a flow restriction. Refer to EXHAUST SYSTEM TESTING) Exhaust
System Restriction Check for procedure. See: Testing and Inspection/Exhaust System Restriction
Check
Visually inspect the catalytic converter element by using a borescope or equivalent. Remove
oxygen sensor(s) and insert borescope. If borescope is not available, remove converter and
inspect element using a flashlight. Inspect element for cracked or melted substrate.
converter failures are caused by air, fuel or ignition problems. (Refer to Appropriate Diagnostic
Information) for test procedures.
Catalytic Converter: Service and Repair Installation

When assembling exhaust system do not tighten clamps until components are aligned and
clearances are checked.
1. Install under floor catalytic converter and the isolator supports to the underbody. 2. Position
spherical gasket (2) with white side facing rear of vehicle, install springs, and bolts (3). Tighten
bolts to 33 Nm (24 ft. lbs.). 3. Install I-Pipe/muffler assembly. 4. Working from the front of system;
align each component to maintain position and proper clearance with underbody parts.
5. Tighten band clamps to 55 Nm (40 ft. lbs.).
CAUTION: Band clamps should never be tightened such that the two sides of the clamps are
bottomed out against the center hourglass shaped center block. Once this occurs, the clamp band
has been stretched and has lost its clamping force and must be replaced.
NOTE: Maintain proper clamp orientation when replacing with new clamp.
6. Start the engine and inspect for exhaust leaks. Repair exhaust leaks as necessary. 7. Check the
exhaust system for contact with the body panels. Make the necessary adjustments, if needed.
Catalytic Converter - Fwd

1. Position catalytic converter into I-Pipe/muffler assembly. 2. Using new gasket position catalytic
converter against exhaust manifold. 3. Install flange bolts. Tighten to 29 Nm (21 ft. lbs.). 4. Working
from the front of system; align each component to maintain position and proper clearance with
underbody parts. 5. Tighten band clamps to 55 Nm (40 ft. lbs.).
bottomed out against the center hourglass shaped center block. Once this occurs, the clamp has
lost clamping force and must be replaced.
Installation - Maniverter
INSTALLATION - MANIVERTER
NOTE: When assembling exhaust system do not tighten clamps until all components are aligned
and clearances are checked.
1. Position maniverter (1) in vehicle. Use a new flange gasket. 2. Using new gasket, install
maniverter (1) and mounting bolts. Tighten bolts to 28 Nm (250 in. lbs.). 3. Install secondary
thermostat. 4. Install under floor catalytic converter. 5. Working from the front of system; align each
component to maintain position and proper clearance with underbody parts. 6. Start the engine and
inspect for exhaust leaks. Repair exhaust leaks as necessary. 7. Check the exhaust system for
contact with the body panels. Make the necessary adjustments, if needed.
Jeep Workshop Manuals > Engine, Cooling and Exhaust > Exhaust System > Exhaust Manifold > Component Information >
Specifications
Exhaust Manifold: Specifications
Exhaust Manifold-Bolts ........................................................................................................................

.................................................... 34 Nm (25 ft. lbs.)
Exhaust Manifold: Procedures
Cleaning
CLEANING
1. Discard gasket (if equipped) and clean all surfaces of manifold and cylinder head.
Inspection
INSPECTION
1. Inspect manifold gasket surfaces for flatness with straight edge. Surface must be flat within 0.15
mm per 300 mm (0.006 in. per foot) of manifold
length.
2. Inspect manifolds for cracks or distortion. Replace manifold as necessary.

Exhaust Manifold: Removal and Replacement
Removal
FRONT WHEEL DRIVE (FWD)
1. Remove engine cover (1).
2. Disconnect negative cable from battery (3).
3. Remove bolts (2) attaching upper heat shield. 4. Remove upper heat shield (1).
5. Disconnect exhaust pipe (1) from manifold. 6. Disconnect oxygen sensor electrical connector (3).
7. Remove manifold support bracket (2). 8. Remove lower exhaust manifold heat shield.
9. Remove exhaust manifold retaining fasteners.
10. Remove and discard manifold gasket.
Installation
EXHAUST MANIFOLD
1. Install a new exhaust manifold gasketDO NOT APPLY SEALER. 2. Position exhaust manifold in
place. 3. Tighten the exhaust manifold bolts to 34 Nm (25 ft. lbs.).
4. Install exhaust manifold heat shields (1). Tighten bolts (2) to 12 Nm (105 in. lbs.).
5. Install exhaust manifold support bracket (2).

6. Install new catalytic converter gasket. 7. Install exhaust pipe to manifold (1). Tighten fasteners to
28 Nm (250 in. lbs.). 8. Connect oxygen sensor electrical connector (3).
9. Connect negative cable to battery (3).
10. Install engine cover (1).

Jeep Workshop Manuals > Engine, Cooling and Exhaust > Exhaust System > Exhaust Pipe/Muffler Hanger > Component
Exhaust Pipe/Muffler Hanger: Service and Repair Removal
REMOVAL
1. Disconnect isolator from exhaust system component. 2. Remove screws attaching isolator
bracket to underbody. 3. Remove isolator assembly.
Jeep Workshop Manuals > Engine, Cooling and Exhaust > Exhaust System > Exhaust Pipe/Muffler Hanger > Component
Exhaust Pipe/Muffler Hanger: Service and Repair Installation
INSTALLATION
1. Position isolator bracket to underbody and install attaching screws. Tighten bracket screws to
frame rail to 8.5 Nm (75 in. lbs.) and bracket screws
to the rear panel to 3.7 Nm (33 in. lbs.).
2. Connect isolator to exhaust system component. 3. Start the engine and inspect for exhaust
leaks. Repair exhaust leaks as necessary. 4. Check the exhaust system for contact with the body
panels. Make the necessary adjustments, if needed.
Jeep Workshop Manuals > Engine, Cooling and Exhaust > Exhaust System > Heat Shield, Exhaust > Component
Heat Shield: Description and Operation
DESCRIPTION
Heat shields (1), are needed to protect both the vehicle and the environment from the high
temperatures developed in the vicinity of the catalytic converter.
CAUTION: Avoid application of rust prevention compounds or undercoating materials to exhaust

system floor pan heat shield. 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.
Heat Shield: Service and Repair Removal
REMOVAL
1. Raise vehicle on hoist. 2. Remove fasteners attaching heat shield. 3. Remove heat shield(s)
Heat Shield: Service and Repair Installation
INSTALLATION
1. Position heat shield(s) to underbody. 2. Install heat shield fasteners. 3. Inspect heat shield to
exhaust system clearances and adjust as necessary. 4. Lower vehicle. 5. Start the engine and
Jeep Workshop Manuals > Engine, Cooling and Exhaust > Exhaust System > Muffler > Component Information > Service
Muffler: Service and Repair Removal
REMOVAL
to a high level after a short period of engine operating time.
1. Raise vehicle on hoist and apply penetrating oil to band clamp nut and bolt of component being
removed.
isolators (3) as it may compromise the life of the part. A suitable substitute is a mixture of liquid
dish soap and water.
2. Remove exhaust system ground strap (1) at rear of I-Pipe/Muffler assembly (2). 3. Loosen band
clamp and remove support isolators (3) at I-Pipe/Muffler assembly (2). Remove I-Pipe/Muffler
assembly (2) from catalytic converter
4. Clean ends of pipes and muffler to assure mating of all parts. Discard broken or worn isolators,
rusted or overused clamps, supports, and attaching
parts.
Jeep Workshop Manuals > Engine, Cooling and Exhaust > Exhaust System > Muffler > Component Information > Service
Muffler: Service and Repair Installation
INSTALLATION
When assembling exhaust system do not tighten clamp until components are aligned and
1. Install the I-Pipe/Muffler assembly to catalytic converter and the isolator supports to the
underbody.
2. Working from the front of system; align each component to maintain position and proper
clearance with underbody parts. Tighten band clamp to
55 Nm (40 ft. lbs.).
To replace the band clamp; remove the nut and peel back the ends of the clamp until spot weld
breaks. File or grind remaining weld material until pipe surface is smooth.
3. Connect the exhaust system ground strap. 4. Start the engine and inspect for exhaust leaks.
Repair exhaust leaks as necessary. 5. Check the exhaust system for contact with the body panels.
Make the necessary adjustments, if needed.
Jeep Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and
Modules - Computers and Control Systems > Engine Control Module > Component Information > Technical Service
Bulletins > Engine, A/T Controls - PCM/TCM Replacement Requirements
Requirements
INTERNET.

BULLETIN.
MODELS:
2007 (MK49) Compass
2007 (MK74) Patriot
2007 (PM) Caliber
NOTE:
DISCUSSION:
below.
CAUTION:
Bulletins > Engine, A/T Controls - PCM/TCM Replacement Requirements > Page 2788
PARTS REQUIRED:
CAUTION:

down load.
CAUTION:
PROCESS.
NOTE:
NOTE:
NOTE:
drop.
seconds.
CAUTION:
NOTE:
PCM.
NOTE:
StarSCAN(R) screen.
NOTE:
list.

File List" screen?
with step 9.
NOTE:
CAUTION:

down load.
NOTE:
NOTE:
NOTE:
down load.
drop.
number.
NOTE:


File List" screen?
with step 7.
NOTE:
TIME ALLOWANCE:
FAILURE CODE:
Disclaimer:
Sensor
NUMBER: 18-039-06
INTERNET.
BULLETIN.
SUBJECT:
CAUTION:

BE INSTALLED.
MODELS:
2007 (PM) Caliber
2007 (MK49) Compass
NOTE:
(MDH 1120XX).
NOTE:
DIAGNOSIS:
PARTS REQUIRED:
CAUTION:
NOTE:

seconds.
CAUTION:
PROCESS.
NOTE:
NOTE:
TIME ALLOWANCE:
FAILURE CODE:
Disclaimer:
GROUP: Electrical
PROCEDURES.
MODELS:
2001-2004 (AN) Dakota
2001 - 2003 (DN) Durango
2004 - 2007 (HB) Durango
2007 (HG) Aspen
2007 (JK) Wrangler
2007 (JS) Sebring
2007 (KA) Nitro
2002 - 2007 (KJ) Liberty
2007 (MK49) Compass
2007 (MK74) Patriot
2005-2007 (ND) Dakota
2000 - 2005 (PL) Neon/SX2.0
2007 (PM) Caliber

2005 - 2006 (ZB) Viper
NOTE:
DISCUSSION:
SPRINTER.
NOTE:
required.
tool.
NOTE:
2. "1.1998 - 2007 Diagnostics"
5. "1. Engine"
NOTE:
displayed.
2. "1.1998 - 2007 Diagnostics"
5. "1. Engine"
NOTE:
Replacement".
displayed.

NOTE:
information.
22. "1.1998 - 2007 Diagnostics"
25. "1. Engine"
NOTE:
displayed.
Disclaimer:
Component ID: 165
Connector:
Color : BLACK
# of pins : 58
Qualifier : (GAS)

5--
6--
8--
9--
10 - -
11 - -
12 - -
14 - -
17 - -
18 - -
24 - -
28 - -
29 - -

31 - -
33 - -
40 - -
42 - -
43 - -
44 - -
45 - -
46 - -
51 - -
55 - -
56 - -
57 - -
Connector:
Color : BLACK
# of pins : 96
Qualifier : (GAS)
2--
3--
4--
5--
7--
9--
10 - -
12 - -
13 - -
14 - -
15 - -
16 - -
17 - -
18 - -
19 - -
20 - -
26 - -
28 - -
29 - -
30 - -
31 - -
32 - -
34 - -
35 - -

39 - -
40 - -
43 - -
44 - -
45 - -
46 - -
47 - -
48 - -
50 - -
52 - -
53 - -
54 - -
55 - -
56 - -
59 - -
60 - -
61 - -
66 - -
67 - -
68 - -
69 - -

71 - -
77 - -
78 - -
80 - -
81 - -
87 - -
89 - -
90 - -
91 - -
92 - -
93 - -
94 - -
95 - -
96 - -
Modules - Computers and Control Systems > Engine Control Module > Component Information > Diagrams > Diagram
Warnings
WARNINGS - GENERAL
the battery.
characteristics.
to function only.
SYMBOLS
TERMINOLOGY
Circuit Functions
models.
Circuit Information
IDENTIFICATION
LOCATIONS
illustrations.
associated wiring.
Removal
REMOVAL

connector.
Installation
INSTALLATION

Removal
REMOVAL
Installation
INSTALLATION
the new diode.
from the elements.
Removal
REMOVAL
Installation
INSTALLATION
repaired.
half/component.
repair.
Wire Splicing
repair area.

Special Tools
WIRING/TERMINAL


vehicle.

good continuity.

SEVERAL LOADS


feed and ground.
position
problem
Component ID: 165
Connector:
Color : BLACK
# of pins : 58
Qualifier : (GAS)

5--
6--
8--
9--
10 - -
11 - -
12 - -
14 - -
17 - -
18 - -
24 - -
28 - -
29 - -

31 - -
33 - -
40 - -
42 - -
43 - -
44 - -
45 - -
46 - -
51 - -
55 - -
56 - -
57 - -
Connector:
Color : BLACK
# of pins : 96
Qualifier : (GAS)
2--
3--
4--
5--
7--
9--
10 - -
12 - -
13 - -
14 - -
15 - -
16 - -
17 - -
18 - -
19 - -
20 - -
26 - -
28 - -
29 - -
30 - -
31 - -
32 - -
34 - -
35 - -

39 - -
40 - -
43 - -
44 - -
45 - -
46 - -
47 - -
48 - -
50 - -
52 - -
53 - -
54 - -
55 - -
56 - -
59 - -
60 - -
61 - -
66 - -
67 - -
68 - -
69 - -

71 - -
77 - -
78 - -
80 - -
81 - -
87 - -
89 - -
90 - -
91 - -
92 - -
93 - -
94 - -
95 - -
96 - -
Modules - Computers and Control Systems > Engine Control Module > Component Information > Description and Operation
> Powertrain Control Module (PCM)
PCM Ground
PCM GROUND
ground pins.
Module (PCM).
Operation
- Knock sensor

> Powertrain Control Module (PCM) > Page 2839
NOTE: PCM Inputs:
- Battery Voltage
- Brake Switch
- Clutch Interlock
- Ignition Switch
- Knock Sensor
- Oxygen Sensors
NOTE: PCM Outputs:
- Fuel Injectors
- Generator Field
- Ignition Coils
> Powertrain Control Module (PCM) > Page 2840
- Battery voltage
- Throttle position
- Knock sensor
- Throttle position
inputs.
- Battery voltage
- Brake switch
- Engine run time
- Throttle position
> Page 2841
SKREEM PROGRAMMING
necessary.
messages:

memory is full.
Modules - Computers and Control Systems > Engine Control Module > Component Information > Service and Repair >
Procedures

Removal
REMOVAL
MAY BE SET.

Installation
INSTALLATION
MAY BE SET.
Modules - Computers and Control Systems > Main Relay (Computer/Fuel System) > Component Information > Locations

Modules - Computers and Control Systems > Main Relay (Computer/Fuel System) > Component Information > Locations >
Page 2850
Main Relay
Modules - Fuel Delivery and Air Induction > Main Relay (Computer/Fuel System) > Component Information > Locations

Modules - Fuel Delivery and Air Induction > Main Relay (Computer/Fuel System) > Component Information > Locations >
Page 2855
Main Relay
Jeep Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and
Switches - Computers and Control Systems > Accelerator Pedal Position Sensor > Component Information > Locations
Component ID: 290
Connector:
Color : BLACK
# of pins : 6

Page 2861
Page 2862
Page 2863
Component ID: 290
Connector:
Color : BLACK
# of pins : 6

Page 2864
Page 2865
Page 2866
DESCRIPTION
Repair > Removal
REMOVAL

INSTALLATION

Component ID: 293
Connector:
Color : BLACK
# of pins : 3
Qualifier : (GAS)
Component ID: 294
Connector:
Color : BLACK
# of pins : 3
Qualifier : (GAS)
Component ID: 293
Connector:
Color : BLACK
# of pins : 3
Qualifier : (GAS)
Component ID: 294
Connector:
Color : BLACK
# of pins : 3
Qualifier : (GAS)
DESCRIPTION
OPERATION
Removal
5. Remove sensor.

Removal > Page 2889

Removal > Page 2890
6. Remove sensor.
Removal > Page 2891
Nm (79.5 in. lbs.).
connector.
Removal > Page 2892

Removal > Page 2893

NUMBER: 18-039-06
INTERNET.
BULLETIN.
SUBJECT:
CAUTION:

BE INSTALLED.
MODELS:
2007 (PM) Caliber
2007 (MK49) Compass
NOTE:
(MDH 1120XX).
NOTE:
DIAGNOSIS:
PARTS REQUIRED:
CAUTION:
NOTE:

seconds.
CAUTION:
PROCESS.
NOTE:
NOTE:
TIME ALLOWANCE:
FAILURE CODE:
Disclaimer:

Temperature 1
Component ID: 299
Connector:
Color : DK. GRAY
# of pins : 2
Qualifier : (GAS)

Temperature 2
Component ID: 300
Connector:
Color : BLACK
# of pins : 2
Qualifier : (GAS)

Temperature 1
Component ID: 299
Connector:
Color : DK. GRAY
# of pins : 2
Qualifier : (GAS)

Temperature 2
Component ID: 300
Connector:
Color : BLACK
# of pins : 2
Qualifier : (GAS)
Switches - Computers and Control Systems > Crankshaft Position Sensor > Component Information > Locations
2917
Component ID: 296
Connector:
Color : BLACK
# of pins : 3
2918
2919
2920
Connector:
Color : # of pins :
Qualifier : (GAS)

2921
2922
2923
DESCRIPTION
- Engine RPM

code).
OPERATION
Removal
2.0/2.4L
Removal > Page 2929

Removal > Page 2930
2.0/2.4L

Removal > Page 2931
6. Lower vehicle.

Switches - Computers and Control Systems > Fuel Level Sensor > Component Information > Locations
- Inlet strainer
- Fuel Filter
Switches - Computers and Control Systems > Intake Air Temperature Sensor > Component Information > Locations

2938
Component ID: 306
Connector:
Color : BLACK
# of pins : 2
Qualifier : (GAS)
2939
2940
DESCRIPTION
Repair > Removal
2.0/2.4L

2.0/2.4L

Switches - Computers and Control Systems > Knock Sensor > Component Information > Locations
Component ID: 308
Connector:
Name : SENSOR-KNOCK
Color : BLACK
# of pins : 2
Qualifier : (GAS)
Component ID: 308
Connector:
Name : SENSOR-KNOCK
Color : BLACK
# of pins : 2
Qualifier : (GAS)
Description
DESCRIPTION
OPERATION
spark control.
Switches - Computers and Control Systems > Knock Sensor > Component Information > Service and Repair > Removal
2.0/2.4L
manifold.

Page 2957

Page 2958
2.0/2.4L
manifold.

Switches - Computers and Control Systems > Manifold Pressure/Vacuum Sensor > Component Information > Locations
Component ID: 309
Connector:
Name : SENSOR-MAP
Color : BLACK
# of pins : 3
Qualifier : (GAS)
Page 2962
Page 2963
Component ID: 309
Connector:
Name : SENSOR-MAP
Color : BLACK
# of pins : 3
Qualifier : (GAS)
Page 2964
DESCRIPTION

OPERATION
- Engine load
- Manifold pressure
- Idle speed
your area.
Repair > Removal
2.0/2.4L

2.0/2.4L
3. Tighten screw.

Not Responsive
NUMBER: 08-039-06
GROUP: Electrical
OVERVIEW:
(CCN).
NOTE:
MODELS:
NOTE:
SYMPTOM/CONDITION:
DIAGNOSIS:

NOTE:
NOTE:
NOTE:
NOTE:
NOTE:
drop.
connector (DLC).

NOTE:
TIME ALLOWANCE:
FAILURE CODE:
Disclaimer:
Odometer/Trip Switch Not Responsive
Responsive
NUMBER: 08-039-06
GROUP: Electrical
OVERVIEW:
(CCN).
NOTE:
MODELS:
NOTE:
SYMPTOM/CONDITION:
DIAGNOSIS:
NOTE:
NOTE:
NOTE:
NOTE:
NOTE:
drop.
connector (DLC).

NOTE:
TIME ALLOWANCE:
FAILURE CODE:
Disclaimer:
Component ID: 313
Connector:
Color : GRAY
# of pins : 4
Qualifier : (GAS)
1 GROUND Z916 18BK
> Page 2992
> Page 2993
> Page 2994
> Page 2995
Component ID: 314
Connector:
Color : BLACK
# of pins : 4
Qualifier : (GAS)
> Page 2996
> Page 2997
> Page 2998
Component ID: 313
Connector:
Color : GRAY
# of pins : 4
Qualifier : (GAS)
1 GROUND Z916 18BK
> Page 3001
> Page 3002
> Page 3003
> Page 3004
Component ID: 314
Connector:
Color : BLACK
# of pins : 4
Qualifier : (GAS)
> Page 3005
Switches - Computers and Control Systems > Oxygen Sensor > Component Information > Diagrams > Page 3006
See: Ignition System/Firing Order

HO2S.
Description
DESCRIPTION
OPERATION
width.
Switches - Computers and Control Systems > Oxygen Sensor > Component Information > Service and Repair > Removal
1/1 Upstream - 2.0/2.4L
1/1 UPSTREAM - 2.0/2.4L

Page 3012
equivalent.

Page 3013
equivalent.
Page 3014
1/1 Upstream - 2.0/2.4L
1/1 UPSTREAM - 2.0/2.4L
Nm (30 ft. lbs.).
equivalent.
Page 3015

Page 3016
converter.
Nm (30 ft. lbs.).
equivalent.
5. Lower vehicle.

Switches - Computers and Control Systems > Oxygen Sensor > Component Information > Service and Repair > Page 3017

Warnings
WARNINGS - GENERAL
the battery.
characteristics.
to function only.
SYMBOLS
TERMINOLOGY
Circuit Functions
models.
Circuit Information
IDENTIFICATION
LOCATIONS
illustrations.
associated wiring.
Removal
REMOVAL

connector.
Installation
INSTALLATION

Removal
REMOVAL
Installation
INSTALLATION
the new diode.
from the elements.
Removal
REMOVAL
Installation
INSTALLATION
repaired.
half/component.
repair.
Wire Splicing
repair area.

Special Tools
WIRING/TERMINAL


vehicle.

good continuity.

SEVERAL LOADS


feed and ground.
position
problem
Switches - Fuel Delivery and Air Induction > Accelerator Pedal Position Sensor > Component Information > Locations
Component ID: 290
Connector:
Color : BLACK
# of pins : 6

Page 3043
Page 3044
Page 3045
Component ID: 290
Connector:
Color : BLACK
# of pins : 6

Page 3046
Page 3047
Page 3048
DESCRIPTION
Repair > Removal
REMOVAL

INSTALLATION

Position
Component ID: 293
Connector:
Color : BLACK
# of pins : 3
Qualifier : (GAS)
Component ID: 294
Connector:
Color : BLACK
# of pins : 3
Qualifier : (GAS)
Position
Component ID: 293
Connector:
Color : BLACK
# of pins : 3
Qualifier : (GAS)
Component ID: 294
Connector:
Color : BLACK
# of pins : 3
Qualifier : (GAS)
Description
DESCRIPTION
OPERATION
Switches - Ignition System > Camshaft Position Sensor > Component Information > Service and Repair > Removal
5. Remove sensor.

3072

3073
6. Remove sensor.
3074
Nm (79.5 in. lbs.).
connector.
3075

3076

Switches - Ignition System > Crankshaft Position Sensor > Component Information > Locations
Component ID: 296
Connector:
Color : BLACK
# of pins : 3
Connector:
Color : # of pins :
Qualifier : (GAS)

Description
DESCRIPTION
- Engine RPM

code).
OPERATION
Switches - Ignition System > Crankshaft Position Sensor > Component Information > Service and Repair > Removal
2.0/2.4L
3092

3093
2.0/2.4L

3094
6. Lower vehicle.

> Key/Lock Cylinder
Removal
REMOVAL
(2).

housing.
Installation
INSTALLATION
the RUN position.
clear tilt lever.
properly.
cylinder housing.
it.

Removal
REMOVAL
(2).
column.
housing.
Installation
INSTALLATION

clear tilt lever.
properly.
cylinder housing.
Switches - Ignition System > Knock Sensor > Component Information > Locations
Component ID: 308
Connector:
Name : SENSOR-KNOCK
Color : BLACK
# of pins : 2
Qualifier : (GAS)
Component ID: 308
Connector:
Name : SENSOR-KNOCK
Color : BLACK
# of pins : 2
Qualifier : (GAS)
Switches - Ignition System > Knock Sensor > Component Information > Description and Operation > Description
DESCRIPTION
Switches - Ignition System > Knock Sensor > Component Information > Description and Operation > Description > Page
3121
OPERATION
spark control.
Switches - Ignition System > Knock Sensor > Component Information > Service and Repair > Removal
2.0/2.4L
manifold.


2.0/2.4L
manifold.

Jeep Workshop Manuals > Powertrain Management > Tune-up and Engine Performance Checks > Fuel Pressure > System

Diagnostic Test
test.
Yes
- Go to 2
No
- Go to 7
- Test complete.

- Go to 3

- Perform the PCM Verification Test. See: Computers and Control Systems/Testing and
Inspection/Diagnostic Trouble Code Tests and Associated Procedures/Verification Tests/PCM
Verification Test
module.
Yes
Verification Test
No
- Go to 4
4. SADDLE FUEL TANK
Yes
- Go to 5
No
- Go to 6
Yes
Verification Test
No
- Go to 6
Yes
Verification Test
No
Verification Test
Yes
Verification Test
No
Verification Test
Jeep Workshop Manuals > Powertrain Management > Tune-up and Engine Performance Checks > Idle Speed > System

Jeep Workshop Manuals > Powertrain Management > Tune-up and Engine Performance Checks > Air Cleaner Housing >
Air Filter Element > Component Information > Service and Repair > Removal
REMOVAL
Air Filter Element > Component Information > Service and Repair > Removal > Page 3141
Air Filter Element > Component Information > Service and Repair > Removal > Page 3142
INSTALLATION
Jeep Workshop Manuals > Powertrain Management > Tune-up and Engine Performance Checks > Fuel Filter > Fuel
Pressure Release > System Information > Service and Repair

Jeep Workshop Manuals > Powertrain Management > Tune-up and Engine Performance Checks > Fuel Filter > Fuel
Pressure Release > System Information > Service and Repair > Page 3147
Jeep Workshop Manuals > Powertrain Management > Tune-up and Engine Performance Checks > Firing Order >
DESCRIPTION
Jeep Workshop Manuals > Powertrain Management > Tune-up and Engine Performance Checks > Spark Plug >
SPARK PLUGS
2.0/2.4L


2.0/2.4L


Jeep Workshop Manuals > Powertrain Management > Tune-up and Engine Performance Checks > Compression Check >
System Information > Specifications
..............................................................................................................................................................
1172-1551 kpa (170-225 psi)
Jeep Workshop Manuals > Powertrain Management > Tune-up and Engine Performance Checks > Compression Check >
System Information > Specifications > Page 3162
malfunctions.
pressure.
Jeep Workshop Manuals > Powertrain Management > Computers and Control Systems > Accelerator Pedal Position
Component ID: 290
Connector:
Color : BLACK
# of pins : 6

Component ID: 290
Connector:
Color : BLACK
# of pins : 6

DESCRIPTION
REMOVAL

INSTALLATION

Jeep Workshop Manuals > Powertrain Management > Computers and Control Systems > Intake Air Temperature Sensor >

Component ID: 306
Connector:
Color : BLACK
# of pins : 2
Qualifier : (GAS)
DESCRIPTION
2.0/2.4L

2.0/2.4L

Jeep Workshop Manuals > Powertrain Management > Computers and Control Systems > Camshaft Position Sensor >
Component Information > Locations > Sensor-Camshaft 1/1 Position
Component ID: 293
Connector:
Color : BLACK
# of pins : 3
Qualifier : (GAS)
Component Information > Locations > Sensor-Camshaft 1/1 Position > Page 3189
Component ID: 294
Connector:
Color : BLACK
# of pins : 3
Qualifier : (GAS)
Component Information > Diagrams > Sensor-Camshaft 1/1 Position
Component ID: 293
Connector:
Color : BLACK
# of pins : 3
Qualifier : (GAS)
Component Information > Diagrams > Sensor-Camshaft 1/1 Position > Page 3195
Component ID: 294
Connector:
Color : BLACK
# of pins : 3
Qualifier : (GAS)
DESCRIPTION
OPERATION
5. Remove sensor.


6. Remove sensor.
Nm (79.5 in. lbs.).
connector.


Jeep Workshop Manuals > Powertrain Management > Computers and Control Systems > Coolant Temperature
Sensor/Switch (For Computer) > Component Information > Technical Service Bulletins > Engine Controls - MIL On/DTC
P0116/ECT Sensor
NUMBER: 18-039-06
INTERNET.
BULLETIN.
SUBJECT:
CAUTION:

BE INSTALLED.
MODELS:
2007 (PM) Caliber
2007 (MK49) Compass
NOTE:
(MDH 1120XX).
NOTE:
DIAGNOSIS:
PARTS REQUIRED:
P0116/ECT Sensor > Page 3213
CAUTION:
NOTE:

seconds.
P0116/ECT Sensor > Page 3214
CAUTION:
PROCESS.
NOTE:
NOTE:
TIME ALLOWANCE:
FAILURE CODE:
Disclaimer:
Sensor/Switch (For Computer) > Component Information > Locations > Sensor-Engine Coolant Temperature 1

Temperature 1
Component ID: 299
Connector:
Color : DK. GRAY
# of pins : 2
Qualifier : (GAS)
Sensor/Switch (For Computer) > Component Information > Locations > Sensor-Engine Coolant Temperature 1 > Page 3217

Temperature 2
Component ID: 300
Connector:
Color : BLACK
# of pins : 2
Qualifier : (GAS)
Sensor/Switch (For Computer) > Component Information > Diagrams > Sensor-Engine Coolant Temperature 1

Temperature 1
Component ID: 299
Connector:
Color : DK. GRAY
# of pins : 2
Qualifier : (GAS)
Sensor/Switch (For Computer) > Component Information > Diagrams > Sensor-Engine Coolant Temperature 1 > Page 3224

Temperature 2
Component ID: 300
Connector:
Color : BLACK
# of pins : 2
Qualifier : (GAS)
Jeep Workshop Manuals > Powertrain Management > Computers and Control Systems > Crankshaft Position Sensor >
Component ID: 296
Connector:
Color : BLACK
# of pins : 3
Connector:
Color : # of pins :
Qualifier : (GAS)

DESCRIPTION
- Engine RPM

code).
OPERATION
2.0/2.4L

2.0/2.4L

6. Lower vehicle.

Jeep Workshop Manuals > Powertrain Management > Computers and Control Systems > Data Link Connector >
Data Link Connector: Locations
Component ID: 54
Component : DATA LINK CONNECTOR
Connector:
Name : DATA LINK CONNECTOR
Color : BLACK
# of pins : 16
1--
2--
3--
4 GROUND Z11 20BK/BR
7 SCI TRANSMIT D21 20WT/BR

8--
9--
10 - -
11 - -
12 - -
13 - -
15 - -
Component Information > Diagrams > Diagram Information and Instructions
Data Link Connector: Diagram Information and Instructions
Warnings
WARNINGS - GENERAL
the battery.
characteristics.
to function only.
Component Information > Diagrams > Diagram Information and Instructions > Page 3255
SYMBOLS
TERMINOLOGY
Circuit Functions
models.
Circuit Information
IDENTIFICATION
LOCATIONS
illustrations.
associated wiring.
Removal
REMOVAL

connector.
Installation
INSTALLATION

Removal
REMOVAL
Installation
INSTALLATION
the new diode.
from the elements.
Removal
REMOVAL
Installation
INSTALLATION
repaired.
half/component.
repair.
Wire Splicing
repair area.

Special Tools
WIRING/TERMINAL


Data Link Connector: Diagnostic Aids
vehicle.

good continuity.

SEVERAL LOADS


feed and ground.
position
problem
Data Link Connector: Connector Views
Component ID: 54
Component : DATA LINK CONNECTOR
Connector:
Name : DATA LINK CONNECTOR
Color : BLACK
# of pins : 16
1--
2--
3--
7 SCI TRANSMIT D21 20WT/BR

8--
9--
10 - -
11 - -
12 - -
13 - -
15 - -
Data Link Connector: Description and Operation Description
DESCRIPTION
The Data Link Connector (DLC) (2) is a 16-way molded plastic connector insulator on a dedicated
take out of the instrument panel wire harness. This connector is located at the lower edge of the
instrument panel, outboard of the steering column. The connector insulator is retained by integral
snap features within a rectangular cutout in the instrument panel lower structural support (1) just
below the lower instrument panel base trim and just outboard of the instrument panel steering
column opening cover and inboard of the inside hood release (3) on the inner cowl side trim.
Data Link Connector: Description and Operation Operation
OPERATION
The Data Link Connector (DLC) is an industry-standard 16-way connector that permits the
connection of a diagnostic scan tool to the Controller Area Network (CAN) data bus for interfacing
with, configuring, and retrieving Diagnostic Trouble Code (DTC) data from the electronic modules
that reside on the data bus network of the vehicle.
Jeep Workshop Manuals > Powertrain Management > Computers and Control Systems > Electronic Throttle Control
Indicator > Component Information > Description and Operation > Description
Electronic Throttle Control Indicator: Description and Operation Description
DESCRIPTION
An Electronic Throttle Control (ETC) indicator is standard equipment on all instrument clusters.
This indicator is located above the fuel gauge in the cluster overlay, to the left of the speedometer.
The ETC indicator consists of a stencil-like cutout of the International Control and Display Symbol
icon for Electronic Throttle Control in the opaque layer of the instrument cluster overlay. The dark
The ETC indicator is serviced as a unit with the instrument cluster.

Jeep Workshop Manuals > Powertrain Management > Computers and Control Systems > Electronic Throttle Control
Indicator > Component Information > Description and Operation > Description > Page 3283
Electronic Throttle Control Indicator: Description and Operation Operation
OPERATION
The Electronic Throttle Control (ETC) indicator gives an indication to the vehicle operator when the
ETC system, or a circuit or component of the system is ineffective. The ETC indicator is controlled
by a transistor on the instrument cluster circuit board based upon cluster programming and
electronic messages received by the cluster from the Powertrain Control Module (PCM) over the
The ETC indicator Light Emitting Diode (LED) is completely controlled by the instrument cluster
logic circuit, and that logic will only allow this indicator to operate when the instrument cluster
receives a battery current input on the fused ignition switch output (run-start) circuit. Therefore, the
LED will always be OFF when the ignition switch is in any position except ON or START. The LED
only illuminates when it is provided a path to ground by the instrument cluster transistor. The
instrument cluster will turn ON the ETC indicator for the following reasons:
- Bulb Test - Each time the ignition switch is turned to the ON position the ETC indicator is
illuminated for about three seconds. The entire bulb test is a function of the instrument cluster.
- ETC Indicator Lamp-On Message - Each time the cluster receives an electronic ETC indicator
lamp-ON message from the PCM, the ETC indicator will be illuminated. The indicator can be
flashed ON and OFF, or illuminated solid, as dictated by the PCM message. The indicator remains
illuminated solid or continues to flash for about 12 seconds or until the cluster receives a lamp-OFF
message from the PCM, whichever is longer. If the indicator is illuminated solid with the engine
running the vehicle will usually remain drivable. If the indicator is flashing with the engine running
the vehicle may require towing. A flashing indicator means the ETC system requires immediate
service. The indicator will be extinguished when the ignition switch is turned to the OFF position.
- Actuator Test - Each time the cluster is put through the actuator test, the ETC indicator will be
turned ON, then OFF again during the bulb check portion of the test to confirm the functionality of
the LED and the cluster control circuitry. The actuator test illumination of the ETC indicator is a
function of the PCM.
The PCM continually monitors the ETC system circuits and sensors to decide whether the system
is in good operating condition. The PCM then sends the proper lamp-ON or lamp-OFF message to
the ElectroMechanical Instrument Cluster (EMIC). If the PCM sends a lamp-ON message after the
bulb test, it indicates that the PCM has detected an ETC system malfunction or that the ETC
system is ineffective. The PCM will store a Diagnostic Trouble Code (DTC) for any malfunction it
detects. Each time the ETC indicator fails to illuminate due to an open or short in the cluster ETC
indicator circuit, the cluster sends a message notifying the PCM of the condition, then the EMIC
and the PCM will each store a DTC.
For proper diagnosis of the ETC system, the PCM, the EMIC, the CAN data bus or the electronic
communication related to ETC indicator operation a diagnostic scan tool is required.
Jeep Workshop Manuals > Powertrain Management > Computers and Control Systems > Engine Control Module >
Component Information > Technical Service Bulletins > Engine, A/T Controls - PCM/TCM Replacement Requirements
Requirements
INTERNET.

BULLETIN.
MODELS:
2007 (MK49) Compass
2007 (MK74) Patriot
2007 (PM) Caliber
NOTE:
DISCUSSION:
below.
CAUTION:
Component Information > Technical Service Bulletins > Engine, A/T Controls - PCM/TCM Replacement Requirements >
Page 3288
PARTS REQUIRED:
CAUTION:

down load.
CAUTION:
PROCESS.
NOTE:
NOTE:
NOTE:
Page 3289
drop.
seconds.
CAUTION:
NOTE:
PCM.
NOTE:
StarSCAN(R) screen.
NOTE:
list.

Page 3290
File List" screen?
with step 9.
NOTE:
CAUTION:

down load.
NOTE:
NOTE:
Page 3291
NOTE:
down load.
drop.
number.
NOTE:


Page 3292
File List" screen?
with step 7.
NOTE:
TIME ALLOWANCE:
FAILURE CODE:
Disclaimer:
Page 3293
Sensor
NUMBER: 18-039-06
INTERNET.
BULLETIN.
SUBJECT:
CAUTION:

BE INSTALLED.
MODELS:
2007 (PM) Caliber
2007 (MK49) Compass
NOTE:
(MDH 1120XX).
NOTE:
DIAGNOSIS:
PARTS REQUIRED:
Page 3294
CAUTION:
NOTE:

seconds.
Page 3295
CAUTION:
PROCESS.
NOTE:
NOTE:
TIME ALLOWANCE:
FAILURE CODE:
Disclaimer:
Page 3296
GROUP: Electrical
PROCEDURES.
MODELS:
2001-2004 (AN) Dakota
2001 - 2003 (DN) Durango
2004 - 2007 (HB) Durango
2007 (HG) Aspen
2007 (JK) Wrangler
2007 (JS) Sebring
2007 (KA) Nitro
2002 - 2007 (KJ) Liberty
2007 (MK49) Compass
2007 (MK74) Patriot
2005-2007 (ND) Dakota
2000 - 2005 (PL) Neon/SX2.0
2007 (PM) Caliber

Page 3297
2005 - 2006 (ZB) Viper
NOTE:
DISCUSSION:
SPRINTER.
NOTE:
required.
tool.
NOTE:
Page 3298
2. "1.1998 - 2007 Diagnostics"
5. "1. Engine"
NOTE:
displayed.
2. "1.1998 - 2007 Diagnostics"
5. "1. Engine"
NOTE:
Replacement".
displayed.

Page 3299
NOTE:
information.
22. "1.1998 - 2007 Diagnostics"
25. "1. Engine"
NOTE:
displayed.
Disclaimer:
Component Information > Technical Service Bulletins > Page 3300
Component ID: 165
Connector:
Color : BLACK
# of pins : 58
Qualifier : (GAS)

5--
6--
8--
9--
10 - -
11 - -
12 - -
14 - -
17 - -
18 - -
24 - -
28 - -
29 - -

31 - -
33 - -
40 - -
42 - -
43 - -
44 - -
45 - -
46 - -
51 - -
55 - -
56 - -
57 - -
Connector:
Color : BLACK
# of pins : 96
Qualifier : (GAS)
2--
3--
4--
5--
7--
9--
10 - -
12 - -
13 - -
14 - -
15 - -
16 - -
17 - -
18 - -
19 - -
20 - -
26 - -
28 - -
29 - -
30 - -
31 - -
32 - -
34 - -
35 - -
39 - -
40 - -
43 - -
44 - -
45 - -
46 - -
47 - -
48 - -
50 - -
52 - -
53 - -
54 - -
55 - -
56 - -
59 - -
60 - -
61 - -
66 - -
67 - -
68 - -
69 - -

71 - -
77 - -
78 - -
80 - -
81 - -
87 - -
89 - -
90 - -
91 - -
92 - -
93 - -
94 - -
95 - -
96 - -
Warnings
WARNINGS - GENERAL
the battery.
characteristics.
to function only.
SYMBOLS
TERMINOLOGY
Circuit Functions
models.
Circuit Information
IDENTIFICATION
LOCATIONS
illustrations.
associated wiring.
Removal
REMOVAL

connector.
Installation
INSTALLATION

Removal
REMOVAL
Installation
INSTALLATION
the new diode.
from the elements.
Removal
REMOVAL
Installation
INSTALLATION
repaired.
half/component.
repair.
Wire Splicing
repair area.

Special Tools
WIRING/TERMINAL


vehicle.

good continuity.

SEVERAL LOADS


feed and ground.
position
problem
Component ID: 165
Connector:
Color : BLACK
# of pins : 58
Qualifier : (GAS)

5--
6--
8--
9--
10 - -
11 - -
12 - -
14 - -
17 - -
18 - -
24 - -
28 - -
29 - -

31 - -
33 - -
40 - -
42 - -
43 - -
44 - -
45 - -
46 - -
51 - -
55 - -
56 - -
57 - -
Connector:
Color : BLACK
# of pins : 96
Qualifier : (GAS)
2--
3--
4--
5--
7--
9--
10 - -
12 - -
13 - -
14 - -
15 - -
16 - -
17 - -
18 - -
19 - -
20 - -
26 - -
28 - -
29 - -
30 - -
31 - -
32 - -
34 - -
35 - -
39 - -
40 - -
43 - -
44 - -
45 - -
46 - -
47 - -
48 - -
50 - -
52 - -
53 - -
54 - -
55 - -
56 - -
59 - -
60 - -
61 - -
66 - -
67 - -
68 - -
69 - -

71 - -
77 - -
78 - -
80 - -
81 - -
87 - -
89 - -
90 - -
91 - -
92 - -
93 - -
94 - -
95 - -
96 - -
Component Information > Description and Operation > Powertrain Control Module (PCM)
PCM Ground
PCM GROUND
ground pins.
Module (PCM).
Operation
- Knock sensor

Component Information > Description and Operation > Powertrain Control Module (PCM) > Page 3339
NOTE: PCM Inputs:
- Battery Voltage
- Brake Switch
- Clutch Interlock
- Ignition Switch

- Knock Sensor
- Oxygen Sensors
NOTE: PCM Outputs:
- Fuel Injectors
- Generator Field
- Ignition Coils
Component Information > Description and Operation > Powertrain Control Module (PCM) > Page 3340
- Battery voltage
- Throttle position
- Knock sensor
- Throttle position
inputs.
- Battery voltage
- Brake switch
- Engine run time
- Throttle position
SKREEM PROGRAMMING
necessary.
messages:

memory is full.

Removal
REMOVAL
MAY BE SET.

Installation
INSTALLATION
MAY BE SET.
Jeep Workshop Manuals > Powertrain Management > Computers and Control Systems > Fuel Level Sensor > Component
- Inlet strainer
- Fuel Filter
Jeep Workshop Manuals > Powertrain Management > Computers and Control Systems > Information Bus > Component
Information > Diagrams > Diagram Information and Instructions
Information Bus: Diagram Information and Instructions
Warnings
WARNINGS - GENERAL
the battery.
characteristics.
to function only.
Information > Diagrams > Diagram Information and Instructions > Page 3354
SYMBOLS
TERMINOLOGY
Circuit Functions
models.
Circuit Information
IDENTIFICATION
LOCATIONS
illustrations.
associated wiring.
Removal
REMOVAL

connector.
Installation
INSTALLATION

Removal
REMOVAL
Installation
INSTALLATION
the new diode.
from the elements.
Removal
REMOVAL
Installation
INSTALLATION
repaired.
half/component.
repair.
Wire Splicing
repair area.

Special Tools
WIRING/TERMINAL


Information Bus: Diagnostic Aids
vehicle.

good continuity.

SEVERAL LOADS


feed and ground.
position
problem
Information Bus: Electrical Diagrams
PLEASE NOTE: Some diagrams may appear to be missing because of gaps in the number
sequences. These "gaps" are actually for diagrams that do not apply to the vehicle model selected.
8w-18-02
8w-18-03
8w-18-04
8w-18-05
8w-18-06
8w-18-07
Other Diagrams: Other diagrams referred to by number (i.e. 8W-70-2, etc.) within these diagrams
can be found at the vehicle level under Diagrams by Number. See: Diagrams/Electrical
Diagrams/Diagrams By Number
Jeep Workshop Manuals > Powertrain Management > Computers and Control Systems > Knock Sensor > Component
Component ID: 308
Connector:
Name : SENSOR-KNOCK
Color : BLACK
# of pins : 2
Qualifier : (GAS)
Component ID: 308
Connector:
Name : SENSOR-KNOCK
Color : BLACK
# of pins : 2
Qualifier : (GAS)
DESCRIPTION
OPERATION
spark control.
2.0/2.4L
manifold.


2.0/2.4L
manifold.

Jeep Workshop Manuals > Powertrain Management > Computers and Control Systems > Main Relay (Computer/Fuel
System) > Component Information > Locations

Jeep Workshop Manuals > Powertrain Management > Computers and Control Systems > Main Relay (Computer/Fuel
System) > Component Information > Locations > Page 3395
Main Relay
Jeep Workshop Manuals > Powertrain Management > Computers and Control Systems > Malfunction Indicator Lamp >
Malfunction Indicator Lamp: Description and Operation Description
DESCRIPTION
A Malfunction Indicator Lamp (MIL) is standard equipment on all instrument clusters. The MIL
information is displayed in the upper portion of the odometer Vacuum Fluorescent Display (VFD)
unit. This VFD unit is soldered onto the cluster electronic circuit board, and is visible through a
window with a smoked clear lens located on the lower edge of the tachometer dial face of the
cluster overlay. The dark lens over the VFD unit prevents the indicator from being clearly visible
when it is not illuminated.
The MIL consists of a stencil-like cutout of the International Control and Display Symbol icon for
Engine in the opaque layer of the instrument cluster overlay. The dark outer layer of the overlay
prevents the indicator from being clearly visible when it is not illuminated. The indicator appears in
an amber color and at the same lighting level as the odometer information.
The MIL is serviced as a unit with the VFD unit in the instrument cluster.
Jeep Workshop Manuals > Powertrain Management > Computers and Control Systems > Malfunction Indicator Lamp >
Malfunction Indicator Lamp: Description and Operation Operation
OPERATION
The Malfunction Indicator Lamp (MIL) gives an indication to the vehicle operator when the
Powertrain Control Module (PCM) has recorded a Diagnostic Trouble Code (DTC) for an On-Board
Diagnostics II (OBDII) emissions-related circuit or component malfunction. The MIL is controlled by
the instrument cluster circuit board based upon cluster programming and electronic messages
received by the cluster from the PCM over the Controller Area Network (CAN) data bus.
The MIL is completely controlled by the instrument cluster logic circuit, and that logic will only allow
this indicator to operate when the instrument cluster receives a battery current input on the fused
ignition switch output (run-start) circuit. Therefore, the indicator will always be OFF when the
ignition switch is in any position except ON or START. The indicator only illuminates when it is
energized by the instrument cluster logic circuit. The instrument cluster will turn ON the MIL for the
following reasons:
- Bulb Test - Each time the ignition switch is turned to the ON position the indicator is illuminated
for about 15 seconds as a bulb test. The entire bulb test is a function of the PCM.
- MIL Lamp-On Message - Each time the cluster receives an electronic MIL lamp-ON message
from the PCM, the indicator will be illuminated. The indicator can be flashed ON and OFF, or
illuminated solid, as dictated by the PCM message. For some DTCs, if a problem does not recur,
the PCM will send a lamp-OFF message automatically. Other DTCs may require that a fault be
repaired and the PCM be reset before a lamp-OFF message will be sent. For more information on
the PCM, and the DTC set and reset parameters.
- Communication Error - If the cluster receives no lamp-ON or lamp-OFF messages from the PCM
for 10 consecutive message cycles, the MIL is illuminated by the instrument cluster to indicate a
loss of bus communication. The indicator remains controlled and illuminated by the cluster until a
valid message is received from the PCM.
- Actuator Test - Each time the cluster is put through the actuator test, the MIL indicator will be
The PCM continually monitors the fuel and emissions system circuits and sensors to decide
whether the system is in good operating condition. The PCM then sends the proper lamp-ON or
lamp-OFF message to the ElectroMechanical Instrument Cluster (EMIC). If the EMIC turns ON the
MIL after the bulb test, it may indicate that a malfunction has occurred and that the fuel and
emissions systems require service.
For proper diagnosis of the fuel and emissions systems, the PCM, the EMIC, the CAN data bus or
the electronic communication related to MIL operation a diagnostic scan tool is required. Refer to
the appropriate diagnostic information.
Jeep Workshop Manuals > Powertrain Management > Computers and Control Systems > Manifold Pressure/Vacuum
Component ID: 309
Connector:
Name : SENSOR-MAP
Color : BLACK
# of pins : 3
Qualifier : (GAS)
Component ID: 309
Connector:
Name : SENSOR-MAP
Color : BLACK
# of pins : 3
Qualifier : (GAS)
DESCRIPTION

OPERATION
- Engine load
- Manifold pressure
- Idle speed
your area.
2.0/2.4L

2.0/2.4L
3. Tighten screw.

Jeep Workshop Manuals > Powertrain Management > Computers and Control Systems > Mileage Calibration Switch >
Component Information > Technical Service Bulletins > Customer Interest for Mileage Calibration Switch: > 08-039-06 >
Aug > 06 > Instruments - Odometer/Trip Switch Not Responsive
NUMBER: 08-039-06
GROUP: Electrical
OVERVIEW:
(CCN).
NOTE:
MODELS:
NOTE:
SYMPTOM/CONDITION:
DIAGNOSIS:

NOTE:
NOTE:
NOTE:
Aug > 06 > Instruments - Odometer/Trip Switch Not Responsive > Page 3421
NOTE:
NOTE:
drop.
connector (DLC).

NOTE:
TIME ALLOWANCE:
Aug > 06 > Instruments - Odometer/Trip Switch Not Responsive > Page 3422
FAILURE CODE:
Disclaimer:
Component Information > Technical Service Bulletins > All Technical Service Bulletins for Mileage Calibration Switch: >
08-039-06 > Aug > 06 > Instruments - Odometer/Trip Switch Not Responsive
Responsive
NUMBER: 08-039-06
GROUP: Electrical
OVERVIEW:
(CCN).
NOTE:
MODELS:
NOTE:
SYMPTOM/CONDITION:
DIAGNOSIS:

NOTE:
NOTE:
NOTE:
NOTE:
NOTE:
drop.
connector (DLC).

NOTE:
TIME ALLOWANCE:
FAILURE CODE:
Disclaimer:
Jeep Workshop Manuals > Powertrain Management > Computers and Control Systems > Oxygen Sensor > Component
Information > Locations > Sensor - Oxygen 1/1
Component ID: 313
Connector:
Color : GRAY
# of pins : 4
Qualifier : (GAS)
1 GROUND Z916 18BK
Information > Locations > Sensor - Oxygen 1/1 > Page 3434
Component ID: 314
Connector:
Color : BLACK
# of pins : 4
Qualifier : (GAS)
Information > Diagrams > Sensor-Oxygen 1/1
Component ID: 313
Connector:
Color : GRAY
# of pins : 4
Qualifier : (GAS)
1 GROUND Z916 18BK
Information > Diagrams > Sensor-Oxygen 1/1 > Page 3443
Component ID: 314
Connector:
Color : BLACK
# of pins : 4
Qualifier : (GAS)
Information > Diagrams > Page 3448

HO2S.
DESCRIPTION
OPERATION
width.
1/1 Upstream - 2.0/2.4L
1/1 UPSTREAM - 2.0/2.4L

equivalent.

equivalent.
1/1 Upstream - 2.0/2.4L
1/1 UPSTREAM - 2.0/2.4L
Nm (30 ft. lbs.).
equivalent.

converter.
Nm (30 ft. lbs.).
equivalent.
5. Lower vehicle.

Information > Service and Repair > Page 3459

Jeep Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules - Computers
and Control Systems > Engine Control Module > Component Information > Technical Service Bulletins > Engine, A/T
Controls - PCM/TCM Replacement Requirements
Requirements
INTERNET.

BULLETIN.
MODELS:
2007 (MK49) Compass
2007 (MK74) Patriot
2007 (PM) Caliber
NOTE:
DISCUSSION:
below.
CAUTION:
Controls - PCM/TCM Replacement Requirements > Page 3465
PARTS REQUIRED:
CAUTION:

down load.
CAUTION:
PROCESS.
NOTE:
NOTE:
NOTE:
drop.
seconds.
CAUTION:
NOTE:
PCM.
NOTE:
StarSCAN(R) screen.
NOTE:
list.

File List" screen?
with step 9.
NOTE:
CAUTION:

down load.
NOTE:
NOTE:
NOTE:
down load.
drop.
number.
NOTE:


File List" screen?
with step 7.
NOTE:
TIME ALLOWANCE:
FAILURE CODE:
Disclaimer:
Sensor
NUMBER: 18-039-06
INTERNET.
BULLETIN.
SUBJECT:
CAUTION:

BE INSTALLED.
MODELS:
2007 (PM) Caliber
2007 (MK49) Compass
NOTE:
(MDH 1120XX).
NOTE:
DIAGNOSIS:
PARTS REQUIRED:
CAUTION:
NOTE:

seconds.
CAUTION:
PROCESS.
NOTE:
NOTE:
TIME ALLOWANCE:
FAILURE CODE:
Disclaimer:
GROUP: Electrical
PROCEDURES.
MODELS:
2001-2004 (AN) Dakota
2001 - 2003 (DN) Durango
2004 - 2007 (HB) Durango
2007 (HG) Aspen
2007 (JK) Wrangler
2007 (JS) Sebring
2007 (KA) Nitro
2002 - 2007 (KJ) Liberty
2007 (MK49) Compass
2007 (MK74) Patriot
2005-2007 (ND) Dakota
2000 - 2005 (PL) Neon/SX2.0
2007 (PM) Caliber

2005 - 2006 (ZB) Viper
NOTE:
DISCUSSION:
SPRINTER.
NOTE:
required.
tool.
NOTE:
2. "1.1998 - 2007 Diagnostics"
5. "1. Engine"
NOTE:
displayed.
2. "1.1998 - 2007 Diagnostics"
5. "1. Engine"
NOTE:
Replacement".
displayed.

NOTE:
information.
22. "1.1998 - 2007 Diagnostics"
25. "1. Engine"
NOTE:
displayed.
Disclaimer:
and Control Systems > Engine Control Module > Component Information > Technical Service Bulletins > Page 3477
Component ID: 165
Connector:
Color : BLACK
# of pins : 58
Qualifier : (GAS)

5--
6--
8--
9--
10 - -
11 - -
12 - -
14 - -
17 - -
18 - -
24 - -
28 - -
29 - -

31 - -
33 - -
40 - -
42 - -
43 - -
44 - -
45 - -
46 - -
51 - -
55 - -
56 - -
57 - -
Connector:
Color : BLACK
# of pins : 96
Qualifier : (GAS)
2--
3--
4--
5--
7--
9--
10 - -
12 - -
13 - -
14 - -
15 - -
16 - -
17 - -
18 - -
19 - -
20 - -
26 - -
28 - -
29 - -
30 - -
31 - -
32 - -
34 - -
35 - -
39 - -
40 - -
43 - -
44 - -
45 - -
46 - -
47 - -
48 - -
50 - -
52 - -
53 - -
54 - -
55 - -
56 - -
59 - -
60 - -
61 - -
66 - -
67 - -
68 - -
69 - -

71 - -
77 - -
78 - -
80 - -
81 - -
87 - -
89 - -
90 - -
91 - -
92 - -
93 - -
94 - -
95 - -
96 - -
and Control Systems > Engine Control Module > Component Information > Diagrams > Diagram Information and
Instructions
Warnings
WARNINGS - GENERAL
the battery.
characteristics.
to function only.
Instructions > Page 3488
SYMBOLS
TERMINOLOGY
Circuit Functions
models.
Circuit Information
IDENTIFICATION
LOCATIONS
illustrations.
associated wiring.
Removal
REMOVAL

connector.
Installation
INSTALLATION

Removal
REMOVAL
Installation
INSTALLATION
the new diode.
from the elements.
Removal
REMOVAL
Installation
INSTALLATION
repaired.
half/component.
repair.
Wire Splicing
repair area.

Special Tools
WIRING/TERMINAL


vehicle.

good continuity.

SEVERAL LOADS


feed and ground.
position
problem
Component ID: 165
Connector:
Color : BLACK
# of pins : 58
Qualifier : (GAS)

5--
6--
8--
9--
10 - -
11 - -
12 - -
14 - -
17 - -
18 - -
24 - -
28 - -
29 - -

31 - -
33 - -
40 - -
42 - -
43 - -
44 - -
45 - -
46 - -
51 - -
55 - -
56 - -
57 - -
Connector:
Color : BLACK
# of pins : 96
Qualifier : (GAS)
2--
3--
4--
5--
7--
9--
10 - -
12 - -
13 - -
14 - -
15 - -
16 - -
17 - -
18 - -
19 - -
20 - -
26 - -
28 - -
29 - -
30 - -
31 - -
32 - -
34 - -
35 - -

39 - -
40 - -
43 - -
44 - -
45 - -
46 - -
47 - -
48 - -
50 - -
52 - -
53 - -
54 - -
55 - -
56 - -
59 - -
60 - -
61 - -
66 - -
67 - -
68 - -
69 - -

71 - -
77 - -
78 - -
80 - -
81 - -
87 - -
89 - -
90 - -
91 - -
92 - -
93 - -
94 - -
95 - -
96 - -
and Control Systems > Engine Control Module > Component Information > Description and Operation > Powertrain Control
Module (PCM)
PCM Ground
PCM GROUND
ground pins.
Module (PCM).
Operation
- Knock sensor

Module (PCM) > Page 3516
NOTE: PCM Inputs:
- Battery Voltage
- Brake Switch
- Clutch Interlock
- Ignition Switch
- Knock Sensor
- Oxygen Sensors
NOTE: PCM Outputs:
- Fuel Injectors
- Generator Field
- Ignition Coils
Module (PCM) > Page 3517
- Battery voltage
- Throttle position
- Knock sensor
- Throttle position
inputs.
- Battery voltage
- Brake switch
- Engine run time
- Throttle position
and Control Systems > Engine Control Module > Component Information > Description and Operation > Page 3518
SKREEM PROGRAMMING
necessary.
messages:

memory is full.
and Control Systems > Engine Control Module > Component Information > Service and Repair > Procedures
and Control Systems > Engine Control Module > Component Information > Service and Repair > Procedures > Page 3521

Removal
REMOVAL
MAY BE SET.

Installation
INSTALLATION
MAY BE SET.
and Control Systems > Main Relay (Computer/Fuel System) > Component Information > Locations

and Control Systems > Main Relay (Computer/Fuel System) > Component Information > Locations > Page 3527
Main Relay
Jeep Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches -
Computers and Control Systems > Accelerator Pedal Position Sensor > Component Information > Locations
Component ID: 290
Connector:
Color : BLACK
# of pins : 6

Computers and Control Systems > Accelerator Pedal Position Sensor > Component Information > Locations > Page 3532
Component ID: 290
Connector:
Color : BLACK
# of pins : 6

DESCRIPTION
Computers and Control Systems > Accelerator Pedal Position Sensor > Component Information > Service and Repair >
Removal
REMOVAL

Computers and Control Systems > Accelerator Pedal Position Sensor > Component Information > Service and Repair >
Removal > Page 3540
INSTALLATION

Computers and Control Systems > Camshaft Position Sensor > Component Information > Locations > Sensor-Camshaft 1/1
Position
Component ID: 293
Connector:
Color : BLACK
# of pins : 3
Qualifier : (GAS)
Component ID: 294
Connector:
Color : BLACK
# of pins : 3
Qualifier : (GAS)
Computers and Control Systems > Camshaft Position Sensor > Component Information > Diagrams > Sensor-Camshaft 1/1
Position
Component ID: 293
Connector:
Color : BLACK
# of pins : 3
Qualifier : (GAS)
Component ID: 294
Connector:
Color : BLACK
# of pins : 3
Qualifier : (GAS)
Computers and Control Systems > Camshaft Position Sensor > Component Information > Description and Operation >
Description
DESCRIPTION
Computers and Control Systems > Camshaft Position Sensor > Component Information > Description and Operation >
OPERATION
Computers and Control Systems > Camshaft Position Sensor > Component Information > Service and Repair > Removal
5. Remove sensor.

Computers and Control Systems > Camshaft Position Sensor > Component Information > Service and Repair > Removal >
Page 3560

Page 3561
6. Remove sensor.
Page 3562
Nm (79.5 in. lbs.).
connector.
Page 3563

Page 3564

Computers and Control Systems > Coolant Temperature Sensor/Switch (For Computer) > Component Information >
Technical Service Bulletins > Engine Controls - MIL On/DTC P0116/ECT Sensor
NUMBER: 18-039-06
INTERNET.
BULLETIN.
SUBJECT:
CAUTION:

BE INSTALLED.
MODELS:
2007 (PM) Caliber
2007 (MK49) Compass
NOTE:
(MDH 1120XX).
NOTE:
DIAGNOSIS:
PARTS REQUIRED:
Technical Service Bulletins > Engine Controls - MIL On/DTC P0116/ECT Sensor > Page 3569
CAUTION:
NOTE:

seconds.
Technical Service Bulletins > Engine Controls - MIL On/DTC P0116/ECT Sensor > Page 3570
CAUTION:
PROCESS.
NOTE:
NOTE:
TIME ALLOWANCE:
FAILURE CODE:
Disclaimer:
Locations > Sensor-Engine Coolant Temperature 1

Temperature 1
Component ID: 299
Connector:
Color : DK. GRAY
# of pins : 2
Qualifier : (GAS)
Locations > Sensor-Engine Coolant Temperature 1 > Page 3573

Temperature 2
Component ID: 300
Connector:
Color : BLACK
# of pins : 2
Qualifier : (GAS)
Diagrams > Sensor-Engine Coolant Temperature 1

Temperature 1
Component ID: 299
Connector:
Color : DK. GRAY
# of pins : 2
Qualifier : (GAS)
Diagrams > Sensor-Engine Coolant Temperature 1 > Page 3580

Temperature 2
Component ID: 300
Connector:
Color : BLACK
# of pins : 2
Qualifier : (GAS)
Computers and Control Systems > Crankshaft Position Sensor > Component Information > Locations
Computers and Control Systems > Crankshaft Position Sensor > Component Information > Locations > Page 3588
Component ID: 296
Connector:
Color : BLACK
# of pins : 3
Connector:
Color : # of pins :
Qualifier : (GAS)

Computers and Control Systems > Crankshaft Position Sensor > Component Information > Description and Operation >
Description
DESCRIPTION
- Engine RPM

code).
Computers and Control Systems > Crankshaft Position Sensor > Component Information > Description and Operation >
OPERATION
Computers and Control Systems > Crankshaft Position Sensor > Component Information > Service and Repair > Removal
2.0/2.4L
Computers and Control Systems > Crankshaft Position Sensor > Component Information > Service and Repair > Removal >
Page 3600

Page 3601
2.0/2.4L

Page 3602
6. Lower vehicle.

Computers and Control Systems > Fuel Level Sensor > Component Information > Locations
- Inlet strainer
- Fuel Filter
Computers and Control Systems > Intake Air Temperature Sensor > Component Information > Locations

Computers and Control Systems > Intake Air Temperature Sensor > Component Information > Locations > Page 3609
Component ID: 306
Connector:
Color : BLACK
# of pins : 2
Qualifier : (GAS)
DESCRIPTION
Computers and Control Systems > Intake Air Temperature Sensor > Component Information > Service and Repair >
Removal
2.0/2.4L

Computers and Control Systems > Intake Air Temperature Sensor > Component Information > Service and Repair >
Removal > Page 3614
2.0/2.4L

Computers and Control Systems > Knock Sensor > Component Information > Locations
Component ID: 308
Connector:
Name : SENSOR-KNOCK
Color : BLACK
# of pins : 2
Qualifier : (GAS)
Computers and Control Systems > Knock Sensor > Component Information > Locations > Page 3618
Component ID: 308
Connector:
Name : SENSOR-KNOCK
Color : BLACK
# of pins : 2
Qualifier : (GAS)
Computers and Control Systems > Knock Sensor > Component Information > Description and Operation > Description
DESCRIPTION
Computers and Control Systems > Knock Sensor > Component Information > Description and Operation > Description >
Page 3625
OPERATION
spark control.
Computers and Control Systems > Knock Sensor > Component Information > Service and Repair > Removal
2.0/2.4L
manifold.

Computers and Control Systems > Knock Sensor > Component Information > Service and Repair > Removal > Page 3628

Computers and Control Systems > Knock Sensor > Component Information > Service and Repair > Removal > Page 3629
2.0/2.4L
manifold.

Computers and Control Systems > Manifold Pressure/Vacuum Sensor > Component Information > Locations
Component ID: 309
Connector:
Name : SENSOR-MAP
Color : BLACK
# of pins : 3
Qualifier : (GAS)
Computers and Control Systems > Manifold Pressure/Vacuum Sensor > Component Information > Locations > Page 3633
Component ID: 309
Connector:
Name : SENSOR-MAP
Color : BLACK
# of pins : 3
Qualifier : (GAS)
Computers and Control Systems > Manifold Pressure/Vacuum Sensor > Component Information > Description and
DESCRIPTION

Computers and Control Systems > Manifold Pressure/Vacuum Sensor > Component Information > Description and
OPERATION
- Engine load
- Manifold pressure
- Idle speed
your area.
Computers and Control Systems > Manifold Pressure/Vacuum Sensor > Component Information > Service and Repair >
Removal
2.0/2.4L

Computers and Control Systems > Manifold Pressure/Vacuum Sensor > Component Information > Service and Repair >
Removal > Page 3641
2.0/2.4L
3. Tighten screw.

Computers and Control Systems > Mileage Calibration Switch > Component Information > Technical Service Bulletins >
Customer Interest for Mileage Calibration Switch: > 08-039-06 > Aug > 06 > Instruments - Odometer/Trip Switch Not
Responsive
NUMBER: 08-039-06
GROUP: Electrical
OVERVIEW:
(CCN).
NOTE:
MODELS:
NOTE:
SYMPTOM/CONDITION:
DIAGNOSIS:

NOTE:
NOTE:
NOTE:
Responsive > Page 3650
NOTE:
NOTE:
drop.
connector (DLC).

NOTE:
TIME ALLOWANCE:
Responsive > Page 3651
FAILURE CODE:
Disclaimer:
Computers and Control Systems > Mileage Calibration Switch > Component Information > Technical Service Bulletins > All
Technical Service Bulletins for Mileage Calibration Switch: > 08-039-06 > Aug > 06 > Instruments - Odometer/Trip Switch
Not Responsive
Responsive
NUMBER: 08-039-06
GROUP: Electrical
OVERVIEW:
(CCN).
NOTE:
MODELS:
NOTE:
SYMPTOM/CONDITION:
DIAGNOSIS:
NOTE:
NOTE:
NOTE:
NOTE:
NOTE:
drop.
connector (DLC).

NOTE:
TIME ALLOWANCE:
FAILURE CODE:
Disclaimer:
Computers and Control Systems > Oxygen Sensor > Component Information > Locations > Sensor - Oxygen 1/1
Component ID: 313
Connector:
Color : GRAY
# of pins : 4
Qualifier : (GAS)
1 GROUND Z916 18BK
Computers and Control Systems > Oxygen Sensor > Component Information > Locations > Sensor - Oxygen 1/1 > Page
3663
3664
3665
3666
Component ID: 314
Connector:
Color : BLACK
# of pins : 4
Qualifier : (GAS)
3667
3668
3669
Computers and Control Systems > Oxygen Sensor > Component Information > Diagrams > Sensor-Oxygen 1/1
Component ID: 313
Connector:
Color : GRAY
# of pins : 4
Qualifier : (GAS)
1 GROUND Z916 18BK
Computers and Control Systems > Oxygen Sensor > Component Information > Diagrams > Sensor-Oxygen 1/1 > Page
3672
3673
3674
3675
Component ID: 314
Connector:
Color : BLACK
# of pins : 4
Qualifier : (GAS)
3676
Computers and Control Systems > Oxygen Sensor > Component Information > Diagrams > Page 3677

HO2S.
Computers and Control Systems > Oxygen Sensor > Component Information > Description and Operation > Description
DESCRIPTION
Computers and Control Systems > Oxygen Sensor > Component Information > Description and Operation > Description >
Page 3680
OPERATION
width.
Computers and Control Systems > Oxygen Sensor > Component Information > Service and Repair > Removal
1/1 Upstream - 2.0/2.4L
1/1 UPSTREAM - 2.0/2.4L

Computers and Control Systems > Oxygen Sensor > Component Information > Service and Repair > Removal > Page 3683
equivalent.

equivalent.
1/1 Upstream - 2.0/2.4L
1/1 UPSTREAM - 2.0/2.4L
Nm (30 ft. lbs.).
equivalent.

converter.
Nm (30 ft. lbs.).
equivalent.
5. Lower vehicle.

Computers and Control Systems > Oxygen Sensor > Component Information > Service and Repair > Page 3688

Computers and Control Systems > Vehicle Speed Sensor > Component Information > Diagrams > Diagram Information and
Instructions
Warnings
WARNINGS - GENERAL
the battery.
characteristics.
to function only.
SYMBOLS
TERMINOLOGY
Circuit Functions
models.
Circuit Information
IDENTIFICATION
LOCATIONS
illustrations.
associated wiring.
Removal
REMOVAL

connector.
Installation
INSTALLATION

Removal
REMOVAL
Installation
INSTALLATION
the new diode.
from the elements.
Removal
REMOVAL
Installation
INSTALLATION
repaired.
half/component.
repair.
Wire Splicing
repair area.

Special Tools
WIRING/TERMINAL


vehicle.

good continuity.

SEVERAL LOADS


feed and ground.
position
problem
Jeep Workshop Manuals > Powertrain Management > Computers and Control Systems > Variable Valve Timing Solenoid >
Component Information > Locations > Solenoid-Camshaft 1/1 Position
Component ID: 333
Connector:
Color : BLACK
# of pins : 2
Qualifier : (GAS)
Component Information > Locations > Solenoid-Camshaft 1/1 Position > Page 3714
Component ID: 334
Connector:
Color : BLACK
# of pins : 2
Qualifier : (GAS)
Component Information > Diagrams > Solenoid-Camshaft 1/1 Position
Component ID: 333
Connector:
Color : BLACK
# of pins : 2
Qualifier : (GAS)
Component Information > Diagrams > Solenoid-Camshaft 1/1 Position > Page 3720
Component ID: 334
Connector:
Color : BLACK
# of pins : 2
Qualifier : (GAS)
DESCRIPTION
OPERATION
valve faults
- Map sensor
- Intake cam sensor
- Crankshaft sensor
- GPEC1

- Inputs
- Outputs
the camshaft.
strategy at
camshaft.
life.
timing.
- Starting
Component Information > Service and Repair > Variable Valve Timing Solenoid - Removal
Front Solenoid 1/1
FRONT SOLENOID 1/1

Component Information > Service and Repair > Variable Valve Timing Solenoid - Removal > Page 3731
Rear Solenoid 1/2
REAR SOLENOID 1/2


Front Solenoid 1/1
FRONT SOLENOID 1/1
solenoids.

Rear Solenoid 1/2
REAR SOLENOID 1/2
rear solenoids.


Jeep Workshop Manuals > Powertrain Management > Computers and Control Systems > Vehicle Speed Sensor >
Warnings
WARNINGS - GENERAL
the battery.
characteristics.
to function only.
SYMBOLS
TERMINOLOGY
Circuit Functions
models.
Circuit Information
IDENTIFICATION
LOCATIONS
illustrations.
associated wiring.
Removal
REMOVAL

connector.
Installation
INSTALLATION

Removal
REMOVAL
Installation
INSTALLATION
the new diode.
from the elements.
Removal
REMOVAL
Installation
INSTALLATION
repaired.
half/component.
repair.
Wire Splicing
repair area.

Special Tools
WIRING/TERMINAL


vehicle.

good continuity.

SEVERAL LOADS


feed and ground.
position
problem
Jeep Workshop Manuals > Powertrain Management > Emission Control Systems > Catalytic Converter > Component
Information > Description and Operation > Catalytic Converter
Catalytic Converter: Description and Operation Catalytic Converter
DESCRIPTION
The combination exhaust manifold/catalytic converter is attached to the intermediate pipe using
fasteners and a gasket for sealing.
to a high level after a short period of engine operation time.
CAUTION: DO NOT remove spark plug wires from plugs or by any other means short out cylinders.
Failure of the catalytic converter can occur due to a temperature increase caused by unburned fuel
passing through the converter.
The stainless steel catalytic converter body is designed to last the life of the vehicle. Excessive
heat can result in bulging or other distortion, but excessive heat will not be the fault of the
converter. If unburned fuel enters the converter, overheating may occur. If a converter is
heat-damaged, correct the cause of the damage at the same time the converter is replaced. Also,
inspect all other components of the exhaust system for heat damage.
Unleaded gasoline must be used to avoid contaminating the catalyst core.
FWD vehicles use a catalytic converter located after the exhaust manifold and before the
AWD vehicles use a maniverter and an under floor catalytic converter. The under floor catalytic
converter is located between the maniverter and the I-Pipe/muffler assembly.
Diesel engine vehicles use a catalytic converter located between the turbocharger and the
Information > Description and Operation > Catalytic Converter > Page 3762
Catalytic Converter: Description and Operation Converter-Catalytic
OPERATION - GAS ENGINE
The three-way catalytic converter simultaneously converts three exhaust emissions into harmless
gases. Specifically, HC and CO emissions are converted into water (H2O) and carbon dioxide
(CO2). Oxides of Nitrogen (NOx) are converted into Nitrogen (N) and Oxygen. The three-way
catalyst is most efficient in converting HC, CO and NOx at the stoichiometric air fuel ratio of 14.7:1.
The oxygen content in a catalyst is important for efficient conversion of exhaust gases. When a
high oxygen content (lean) air/fuel ratio is present for an extended period, oxygen content in a
catalyst can reach a maximum. When a rich air/fuel ratio is present for an extended period, the
oxygen content in the catalyst can become totally depleted. When this occurs, the catalyst fails to
convert the gases. This is known as catalyst "punch through."
Catalyst operation is dependent on its ability to store and release the oxygen needed to complete
the emissions-reducing chemical reactions. As a catalyst deteriorates, its ability to store oxygen is
reduced. Since the catalyst's ability to store oxygen is somewhat related to proper operation,
oxygen storage can be used as an indicator of catalyst performance. Refer to the appropriate
Diagnostic Information for diagnosis of a catalyst related Diagnostic Trouble Code (DTC).
The combustion reaction caused by the catalyst releases additional heat in the exhaust system,
causing temperature increases in the area of the reactor under severe operating conditions. Such
conditions can exist when the engine misfires or otherwise does not operate at peak efficiency. Do
not remove spark plug wires from plugs or by any other means short out cylinders. Failure of the
catalytic converter can occur due to temperature increases caused by unburned fuel passing
through the converter. This deterioration of the catalyst core can result in excessively high emission
levels, noise complaints, and exhaust restrictions.
Unleaded gasoline must be used to avoid ruining the catalyst core. Do not allow engine to operate
above 1200 RPM in neutral for extended periods over 5 minutes. This condition may result in
excessive exhaust system/floor pan temperatures because of no air movement under the vehicle.
The flex joint allows flexing as the engine moves, preventing breakage that could occur from the
back-and-forth motion of a transverse mounted engine.
CAUTION: Due to exterior physical similarities of some catalytic converters with pipe assemblies,
extreme care should be taken with replacement parts. There are internal converter differences
required in some parts of the country (particularly vehicles built for States with strict emission
requirements) and between model years.
Catalytic Converter: Service and Repair Removal

HIGH. THEREFORE, NEVER WORK AROUND OR ATTEMPT TO SERVICE ANY PART OF THE
EXHAUST SYSTEM UNTIL IT IS COOLED. SPECIAL CARE SHOULD BE TAKEN WHEN
WORKING NEAR THE CATALYTIC CONVERTER. THE TEMPERATURE OF THE CONVERTER
RISES TO A HIGH LEVEL AFTER A SHORT PERIOD OF ENGINE OPERATING TIME.
1. Raise vehicle on hoist and apply penetrating oil to band clamp fastener of component being
removed.
soap and water.
2. Remove I-Pipe/Muffler assembly. 3. Disconnect oxygen sensor electrical connectors.
NOTE: If spherical gasket is to be reused, mark orientation.
4. Remove flange bolts (3), springs and spherical gasket. 5. Remove under floor catalytic converter
(4) from combination manifold/catalytic converter assembly (1). 6. Clean ends of pipes to assure
mating of all parts. Discard broken or worn isolators, rusted or overused clamps, supports, and
attaching parts.
Catalytic Converter - FWD

1. Loosen intermediate pipe-to catalytic converter clamp.
soap and water.
2. Remove catalytic converter to exhaust manifold attaching fasteners and remove converter from
vehicle. 3. Remove I-Pipe/Muffler assembly insulators as necessary to slide I-Pipe/Muffler
assembly out of catalytic converter. 4. Remove and discard flange gasket.
Removal - Maniverter
REMOVAL - MANIVERTER

HIGH. THEREFORE, NEVER ATTEMPT TO SERVICE ANY PART OF THE EXHAUST SYSTEM
UNTIL IT IS COOLED. SPECIAL CARE SHOULD BE TAKEN WHEN WORKING NEAR THE
CATALYTIC CONVERTER. THE TEMPERATURE OF THE CONVERTER RISES TO A HIGH
LEVEL AFTER A SHORT PERIOD OF ENGINE OPERATION TIME.
1. Remove under floor catalytic converter.

2. Lower vehicle. 3. Remove secondary thermostat. 4. Remove maniverter mounting bolts. 5.

Remove maniverter and gasket from the engine compartment.
Inspection
INSPECTION
Check catalytic converter for a flow restriction. Refer to EXHAUST SYSTEM TESTING) Exhaust
System Restriction Check for procedure. See: Engine, Cooling and Exhaust/Exhaust
System/Testing and Inspection/Exhaust System Restriction Check
Visually inspect the catalytic converter element by using a borescope or equivalent. Remove
oxygen sensor(s) and insert borescope. If borescope is not available, remove converter and
inspect element using a flashlight. Inspect element for cracked or melted substrate.
converter failures are caused by air, fuel or ignition problems. (Refer to Appropriate Diagnostic
Information) for test procedures.
Catalytic Converter: Service and Repair Installation

When assembling exhaust system do not tighten clamps until components are aligned and
1. Install under floor catalytic converter and the isolator supports to the underbody. 2. Position
spherical gasket (2) with white side facing rear of vehicle, install springs, and bolts (3). Tighten
bolts to 33 Nm (24 ft. lbs.). 3. Install I-Pipe/muffler assembly. 4. Working from the front of system;
align each component to maintain position and proper clearance with underbody parts.
5. Tighten band clamps to 55 Nm (40 ft. lbs.).
Catalytic Converter - Fwd

1. Position catalytic converter into I-Pipe/muffler assembly. 2. Using new gasket position catalytic
converter against exhaust manifold. 3. Install flange bolts. Tighten to 29 Nm (21 ft. lbs.). 4. Working
from the front of system; align each component to maintain position and proper clearance with
underbody parts. 5. Tighten band clamps to 55 Nm (40 ft. lbs.).
bottomed out against the center hourglass shaped center block. Once this occurs, the clamp has
lost clamping force and must be replaced.
Installation - Maniverter
INSTALLATION - MANIVERTER
NOTE: When assembling exhaust system do not tighten clamps until all components are aligned
and clearances are checked.
1. Position maniverter (1) in vehicle. Use a new flange gasket. 2. Using new gasket, install
maniverter (1) and mounting bolts. Tighten bolts to 28 Nm (250 in. lbs.). 3. Install secondary
thermostat. 4. Install under floor catalytic converter. 5. Working from the front of system; align each
component to maintain position and proper clearance with underbody parts. 6. Start the engine and
Jeep Workshop Manuals > Powertrain Management > Emission Control Systems > Evaporative Emissions System >
Canister Purge Solenoid > Component Information > Locations
Canister Purge Solenoid: Locations
Component ID: 336
Component : SOLENOID-EVAP PURGE
Connector:
Name : SOLENOID-EVAP PURGE
Color : BLACK
# of pins : 2
Qualifier : (GAS)
Canister Purge Solenoid > Component Information > Locations > Page 3773
Canister Purge Solenoid: Diagrams
Component ID: 336
Component : SOLENOID-EVAP PURGE
Connector:
Name : SOLENOID-EVAP PURGE
Color : BLACK
# of pins : 2
Qualifier : (GAS)
Canister Purge Solenoid > Component Information > Description and Operation > Description
Canister Purge Solenoid: Description and Operation Description
DESCRIPTION
All vehicles use a proportional purge solenoid. The solenoid regulates the rate of vapor flow from
the EVAP canister to the intake manifold. The PCM operates the solenoid.
Canister Purge Solenoid > Component Information > Description and Operation > Description > Page 3778
Canister Purge Solenoid: Description and Operation Operation
OPERATION
All vehicles use a proportional purge solenoid. The solenoid regulates the rate of vapor flow from
the EVAP canister to the intake manifold. The PCM operates the solenoid.
During the cold start warm-up period and the hot start time delay, the PCM does not energize the
solenoid. When de-energized, no vapors are purged.
The proportional purge solenoid operates at a frequency of 200 hz and is controlled by an engine
controller circuit that senses the current being applied to the proportional purge solenoid and then
adjusts that current to achieve the desired purge flow. The proportional purge solenoid controls the
purge rate of fuel vapors from the vapor canister and fuel tank to the engine intake manifold.
Canister Purge Solenoid > Component Information > Service and Repair > Removal
Canister Purge Solenoid: Service and Repair Removal
REMOVAL
1. Remove air inlet resonator assembly.
4. Unlock and disconnect electrical connector (1) from solenoid.
5. Disconnect vacuum tubes (2) from solenoid.
6. Remove solenoid (1) from bracket by depressing clip and pulling solenoid from bracket.
Canister Purge Solenoid > Component Information > Service and Repair > Removal > Page 3781
Canister Purge Solenoid: Service and Repair Installation
INSTALLATION
The top of the solenoid has TOP printed on it. The solenoid will not operate unless it is installed
correctly.
1. Connect vacuum tube (2) to solenoid.
2. Connect electrical connector (1) to solenoid and lock.
3. Install solenoid on bracket.
6. Install resonator assembly.

Evaporative Emission Control Canister > Component Information > Locations
Evaporative Emission Control Canister: Locations
The canister mounts to a left rear rail in the rear of the vehicle.
Evaporative Emission Control Canister > Component Information > Description and Operation > Description
Evaporative Emission Control Canister: Description and Operation Description
DESCRIPTION
The canister mounts to a left rear rail in the rear of the vehicle. The vacuum and vapor tube
connect to the top of the canister.
Evaporative Emission Control Canister > Component Information > Description and Operation > Description > Page 3787
Evaporative Emission Control Canister: Description and Operation Operation
OPERATION
All vehicles use a maintenance free, evaporative (EVAP) canister. Fuel tank vapors vent into the
canister. The canister temporarily holds the fuel vapors until intake manifold vacuum draws them
into the combustion chamber. The Powertrain Control Module (PCM) purges the canister through
the proportional purge solenoid. The PCM purges the canister at predetermined intervals and
engine conditions.
Purge Free Cells
Purge-free memory cells are used to identify the fuel vapor content of the evaporative canister.
Since the evaporative canister is not purged 100% of the time, the PCM stores information about
the evaporative canister's vapor content in a memory cell.
The purge-free cells are constructed similar to certain purge-normal cells. The purge-free cells can
be monitored by the scan tool. The only difference between the purge-free cells and normal
adaptive cells is that in purge-free, the purge is completely turned off. This gives the PCM the
ability to compare purge and purge-free operation.
Evaporative Emission Control Canister > Component Information > Service and Repair > Removal
Evaporative Emission Control Canister: Service and Repair Removal
REMOVAL
3. Depress locking tab on vapor hose connector and pull off of canister.
4. Remove hose from ESIM module.

Evaporative Emission Control Canister > Component Information > Service and Repair > Removal > Page 3790
5. Vapor hose removed.
6. Disconnect the electrical connector from ESIM module.

7. Remove two vapor canister mounting bolts.
8. Remove assembly.
Evaporative Emission Control Canister: Service and Repair Installation
INSTALLATION
1. Install canister and bracket.
2. Connect filter hose to ESIM.
3. Connect vapor hose.

4. Make sure locking tab on hose connector locks in place.

5. Connect electrical connector to ESIM module.
6. Lower vehicle.

Jeep Workshop Manuals > Powertrain Management > Emission Control Systems > Evaporative Emissions System > Leak
Detector, Evaporative System > Component Information > Locations
Leak Detector: Locations
Component ID: 350
Component : SWITCH-EVAP SYSTEM MONITOR
Connector:
Name : SWITCH-EVAP SYSTEM MONITOR
Color : BLACK
# of pins : 2
1 GROUND Z965 20BK
2 ESM SIGNAL K107 18VT/LB
Detector, Evaporative System > Component Information > Locations > Page 3796
Leak Detector: Diagrams
Component ID: 350
Component : SWITCH-EVAP SYSTEM MONITOR
Connector:
Name : SWITCH-EVAP SYSTEM MONITOR
Color : BLACK
# of pins : 2
1 GROUND Z965 20BK
Detection Pump, Evaporative System > Component Information > Description and Operation
Leak Detection Pump: Description and Operation
OPERATION
SYSTEM
The ESIM (Evaporative System Integrity Monitor) is very similar to the NVLD. However, the design
of the ESIM has been simplified and unlike the NVLD the ESIM does not require a solenoid. The
ESIM mounts directly to the canister, eliminating the need for a mounting bracket. It is critical that
the ESIM is mounted vertically. On vehicles where the canister is mounted on an angle, the ESIM
requires an adaptor to maintain a vertical position. When the ESIM is installed vertically, the
electrical connector is in the 3 o'clock position.
Detection Pump, Evaporative System > Component Information > Description and Operation > Page 3802
EXPLODED VIEW
The ESIM assembly consists of a housing, a small weight and a large weight that serve as check
valves, a diaphragm, a switch and a cover. There is one large weight and one small weight check
valve in the ESIM assembly. A seal is attached at the end of each weighted check valve. The large
weight check valve seals for pressure. The small weight check valve seals for vacuum. The
weighted check valves are contained within the ESIM housing.
CUT AWAY OF MODULE
The ESIM (Evaporative System Integrity Monitor), while physically different than the NVLD system,
performs the same basic function as the NVLD does - controlling evaporative emissions. The ESIM
has been simplified because the solenoid used on the NVLD is not used on the ESIM.
The ESIM consists of housing, two check valves (sometimes referred to as weights), a diaphragm,
a switch and a cover. The larger check valve seals for pressure and the smaller one seals for
vacuum.
During refueling, pressure is built up in the evaporative system. When pressure reaches
approximately 0.5 inches of water, the large check valve unseats and pressure vents to the fresh
air filter.
Conversely, when the system cools and the resulting vacuum lifts the small check valve from its
seat and allows fresh air to enter the system and relieve the vacuum condition. When a calibrated
amount of vacuum is achieved in the evaporative system, the diaphragm is pulled inward, pushing
on the spring and closing the contacts.
The ESIM conducts test on the evaporative system as follows: An engine off, non-intrusive test for
small leaks and an engine running, intrusive test for medium/large leaks.
The ESIM weights seal the evap. system during engine off conditions. If the evap. system is
sealed, it will be pulled into a vacuum, either due to the cool down from operating temperature or
diurnal ambient temperature cycling. When the vacuum in the system exceeds about 1 inch H20,
the vacuum switch closes. The switch closure sends a signal to the GPEC1. In order to pass the
non-intrusive small leak test, the ESIM switch must close within a calculated amount of time and
within a specified amount of key-off events.
If the ESIM switch does not close as specified, the test is considered inconclusive and the intrusive
engine running test will be run during the next key-on cycle. This intrusive test will run on the next
cold engine running condition.
Conditions for running the intrusive test are:
- After the vehicle is started, the engine coolant temperature must be within 10° C (50° F) of
ambient to indicate a cold start.
- The fuel level must be between 12% and 88%.

- The engine must be in closed loop.
- Manifold vacuum must be greater than a minimum specified value.
- Ambient temperature must be between 4° C and 37° C (39° F and 98° F) and the elevation level
must be below 8500 feet.
The test is accomplished by the GPEC1 activating the purge solenoid to create a vacuum in the
evaporative system. The GPEC1 then measures the amount of time it takes for the vacuum to
dissipate. This is known as the vacuum decay method. If the switch opens quickly a large leak is
recorded. If the switch opens after a predetermined amount of time, then the small leak matures. If
the switch does not close, then a general evaporative failure is recorded. The purge monitor tests
the integrity of the hose attached between the purge valve and throttle body/intake. The purge
monitor is a two stage test and it runs only after the evaporative system passes the small leak test.
Even when all of the thresholds are met, a small leak won't be recorded until after the
medium/large leak monitor has been run. This is accomplished by the GPEC1 activating the purge
solenoid to create a vacuum in the evaporative system. The GPEC1 then measures the amount of
time it takes for the vacuum to dissipate. This is known as the vacuum decay method. If the switch
opens quickly a large leak is recorded. If the switch opens after a predetermined amount of time,
then the small leak matures. If the medium/large leak test runs and the ESIM switch doesn't close,
a general evaporative test is run. The purge solenoid is activated for approximately 10 seconds,
increasing the amount of vacuum in the system. IF the ESIM switch closes after the extended
purge activation, a large leak fault is generated. If the switch doesn't close, a general evaporative
system fault is generated.
The purge monitor tests the integrity of the hose attached between the purge valve and throttle
body/intake. The purge monitor is a two stage test and it runs only after the evaporative system
passes the small leak test.
Stage one of the purge monitor is non-intrusive. GPEC1 monitors the purge vapor ratio. If the ratio
is above a calibrated specification, the monitor passes. Stage two is an intrusive test and it runs
only if stage one fails. During the stage two test, the GPEC commands the purge solenoid to flow
at a specified rate to force the purge vapor ratio to update. The vapor ratio is compared to a
calibrated specification and if it is less than specified, a one-trip failure is recorded.
The ESIM switch stuck closed monitor checks to see if the switch is stuck closed. This is a power
down test that runs at key-off; when the GPEC1 sees 0 rpm's, the purge solenoid is energized for a
maximum of 30 seconds, venting any vacuum trapped in the evaporative system. If the switch
opens or was open before the test began, the monitor passes. If the switch doesn't open, the
monitor fails. This is a two-trip MIL. The star scan tool can be used to force the ESIM switch stick
closed monitor to run.
The GPEC1 also uses the ESIM to detect a loose or missing gas cap. The GPEC1 controller looks
for a change in the fuel level (25% minimum) and then gas cap is loose or missing. If a
medium/large leak is detected, a loose gas cap light illuminates and a pending one-trip fault code is
set. On the GPEC1, this is a three-trip fault before the code matures
Jeep Workshop Manuals > Powertrain Management > Emission Control Systems > Exhaust Gas Recirculation > EGR
Cooler > Component Information > Description and Operation
EGR Cooler: Description and Operation
DESCRIPTION
The EGR cooler (7) cools recirculated exhaust gasses to reduce combustion temperature and a
greater mass of exhaust gases can thus be circulated. There is less nitrogen oxides as a result.
The EGR cooler (7) allows the engine and catalytic converter to reach their operating temperature
quickly.
Cooler > Component Information > Service and Repair > Removal
EGR Cooler: Service and Repair Removal
REMOVAL
1. Remove engine cover. 2. Drain cooling system. 3. Remove EGR cooler coolant hoses (8). 4.
Remove EGR cooler to exhaust manifold tube (11). 5. Remove EGR cooler to EGR valve tube (1).
6. Remove EGR cooler mounting nuts (6). 7. Remove EGR cooler (7). 8. Remove the bypass valve
mounting screws (3). 9. Separate the bypass valve assembly from the EGR cooler body (5).
Cooler > Component Information > Service and Repair > Removal > Page 3811
EGR Cooler: Service and Repair Installation
INSTALLATION
1. Using a new gasket, position the bypass valve assembly to the EGR cooler body (5). Tighten
screws to 10 Nm (88 in. lbs.). 2. Position EGR cooler (7) and install mounting screws. Tighten to 10
Nm (88 in. lbs.). 3. Install EGR cooler to exhaust manifold tube (11). Tighten bolts to 20 Nm (14 ft.
lbs.) and nuts to 20 Nm (14 ft. lbs.). 4. Install EGR cooler to EGR valve tube (1). Tighten bolts to 20
Nm (14 ft. lbs.). 5. Install coolant hoses. 6. Install vacuum line. 7. Fill cooling system. 8. Install
engine cover.
Jeep Workshop Manuals > Powertrain Management > Emission Control Systems > Positive Crankcase Ventilation >
Positive Crankcase Ventilation Valve > Component Information > Locations
Positive Crankcase Ventilation Valve: Locations
It threads into the valve cover.

Positive Crankcase Ventilation Valve > Component Information > Description and Operation > Description
Positive Crankcase Ventilation Valve: Description and Operation Description
DESCRIPTION
It threads into the valve cover.

Positive Crankcase Ventilation Valve > Component Information > Description and Operation > Description > Page 3818
Positive Crankcase Ventilation Valve: Description and Operation Operation
OPERATION
When the engine is not operating or during an engine backfire, the spring forces the plunger back
against the seat. This prevents vapors from flowing through the valve.
When the engine is at idle or cruising, high manifold vacuum is present. At these times manifold
vacuum is able to completely compress the spring and pull the plunger to the top of the valve. In
this position there is minimal vapor flow through the valve.
During periods of moderate intake manifold vacuum the plunger is only pulled part way back from
the inlet. This results in maximum vapor flow through the valve.
Positive Crankcase Ventilation Valve > Component Information > Service and Repair > Removal
Positive Crankcase Ventilation Valve: Service and Repair Removal
REMOVAL
2. Remove the hose from the PCV valve.
3. Unscrew the PCV valve.

Positive Crankcase Ventilation Valve > Component Information > Service and Repair > Removal > Page 3821
Positive Crankcase Ventilation Valve: Service and Repair Installation
INSTALLATION
1. Lubricate the O-ring on the valve.
2. Install the PCV valve and tighten the valve to 8.1 Nm (72 in. lbs.).
3. Install the hose.

Jeep Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Pressure > System

Diagnostic Test
test.
Yes
- Go to 2
No
- Go to 7
- Test complete.

- Go to 3

Verification Test
module.
Yes
Verification Test
No
- Go to 4
4. SADDLE FUEL TANK
Yes
- Go to 5
No
- Go to 6
Yes
Verification Test
No
- Go to 6
Yes
Verification Test
No
Verification Test
Yes
Verification Test
No
Verification Test
Jeep Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Pressure Release > System

Jeep Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Pressure Release > System
Jeep Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Idle Speed > System Information >
Specifications

Jeep Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Accelerator Pedal > Component
Information > Technical Service Bulletins > Recalls for Accelerator Pedal: > K11 > Jun > 10 > Recall - Accelerator Pedal
Inspection/Replacement
Technical Service Bulletin # K11 Date: 100618
Recall - Accelerator Pedal Inspection/Replacement
June 2010
Dealer Service Instructions for: Safety Recall K11 Accelerator Pedal
Effective immediately all repairs on involved vehicles are to be performed according to this recall.
Service Bulletin 14-004-10 is no longer applicable for vehicles involved in this recall. Those
vehicles that have already had this repair performed, as determined by our warranty records, have
been excluded from this recall.
Models
2007 (PM) Dodge Caliber
2007 (MK) Jeep(R) Compass
NOTE:
This recall applies only to the above vehicles equipped with an automatic transmission (sales code
DAV) and built from March 7, 2006 through May 19, 2006 (MDH 030706 through 051921).
IMPORTANT:
Some of the involved vehicles may be in dealer used vehicle inventory. Dealers should complete
this recall service on these vehicles before retail delivery. Dealers should also perform this recall on
vehicles in for service. Involved vehicles can be determined by using the VIP inquiry process.
Subject
The accelerator pedal on about 24,800 of the above vehicles may stick during vehicle operation.
This could cause the vehicle to react differently than the driver anticipated. This could cause a
crash without warning.
SPECIAL NOTE:
All involved vehicles are equipped with an Electronic Throttle Control (ETC) system that utilizes
"Smart Pedal" technology that allows a brake pedal input to override the throttle control system.
Repair
The accelerator pedal cavity number and date code must be inspected. Vehicles found with a
suspect accelerator pedal must have the pedal replaced.
Parts Information
Part Number Description
CAB3K110AA Pedal, Accelerator
Due to the small number of involved vehicles expected to require an accelerator pedal, no parts will
be distributed initially. Accelerator pedals should be ordered only after inspection determines that
replacement is required.
Special Tools
Inspection/Replacement > Page 3844

Add the cost of the recall parts package plus applicable dealer allowance to your claim.
NOTE:
See the Warranty Administration Manual, Recall Claim Processing Section, for complete recall
claim processing instructions.
Dealer Notification
All involved vehicle owners known to Chrysler are being notified of the service requirement by first
class mail. They are requested to schedule appointments for this service with their dealers. A
generic copy of the owner letter is included.
GRS provides involved dealers with an updated VIN list of their incomplete
vehicles. The owner's name, address and phone number are listed if known. Completed vehicles
are removed from GRS within several days of repair claim submission.
Customer Services Field Operations Chrysler Group LLC
Service Procedure
NOTE:
the accelerator pedal must be removed from the vehicle to perform the inspection.

NOTE:
service procedure.
2. Remove the three accelerator pedal mounting nuts (Figure 1).
3. Disconnect the accelerator pedal electrical connector.
4. Remove the accelerator pedal from the vehicle.
5. Inspect the cavity code located on the backside of the accelerator pedal (Figure 2):
> If the cavity code is a number 1, the pedal assembly does not require replacement. Continue to
Step 7 of this procedure.
> If the cavity code is a number 2, the accelerator pedal date code must be inspected. Continue
with Step 6 of this procedure.
6. Inspect the accelerator pedal date code.
UNDERSTANDING THE DATE CODE: The first two digits are the year (06 = 2006). The next three
digits are the day of the year it was built (068 = the 68th day). Disregard the last three digits of the
date code. For example, the date code on the pedal assembly in Figure 3 is 06068828. The first
two digits are 06 (built in 2006), the next three digits are 068 (the 68th day). Ignore the last three
digits.
> If the date code is 06059xxx or lower or it is 06095xxx or higher, the accelerator pedal does not
require replacement. Continue with Step 7 of this procedure.
> If the date code is 06060 through 06094, replace the accelerator pedal.
Continue with Step 7 of this procedure.

> If the date code is not legible, replace the accelerator pedal. Continue with Step 7 of this
procedure.
7. Connect the accelerator pedal electrical connector to the new accelerator pedal or original
accelerator pedal (depending on inspection results).
8. Install the accelerator pedal into the vehicle and tighten the mounting nuts to 22 ft. lbs. (30 N.m)
in the sequence shown in Figure 4.
10. On vehicles that had the original accelerator pedal installed, no further action is required. On
vehicles that had the accelerator pedal replaced,
continue with Step 11.
11. Use one of the following scan tools and related procedure to perform the "Learn ETC"
procedure:
Using wiTECH:
a. Connect the wiPOD to the vehicle data link connector.
b. Place the ignition key in the "RUN" position.
c. Launch the wiTECH diagnostic application.
d. Select "PCM" from the vehicle view screen.
e. Select the "MISC FUNCTION" tab.

f. Select "Learn ETC" from the list.
g. Follow the screen prompts.
h. Clear all DTC's.
NOTE:
Due to the "Learn ETC" procedure, DTC(s) may be set in other modules (PCM, TCM, ABS, BCM,
MIC, WCM, etc.) within the vehicle, if so equipped. Some DTC's may cause the MIL to illuminate.
i. Place the ignition in the "OFF" position, remove the wiPOD from the data link connector
Using StarMOBILE:
a. Connect the StarMOBILE scan tool to the vehicle data link connector located under the steering
column and turn the ignition key to the "RUN"
position.
b. Connect the CH9410 StarMOBILE scan tool ethernet cable to the StarMOBILE and the dealer's
network drop.
c. Power ON the StarMOBILE scan tool.
d. From the desktop, launch the "StarMOBILE Desktop Client" software.

e. Establish a connection with the StarMOBILE scan tool.
f. Starting at the "Home" screen, select "ECU View".
g. Select "Misc Functions".
h. Select "Learn ETC".
i. Follow the screen prompts.
j. Clear any Diagnostic Trouble Codes (DTCs) as follows:)
NOTE:
1. From the "Home" screen select "System View".
2. Select "All DTCs".
3. Press "Clear All Stored DTCs" if there are any DTCs shown on the list.
Information > Technical Service Bulletins > Recalls for Accelerator Pedal: > NHTSA10V234000 > Jun > 10 > Recall
10VC234000: Accelerator Pedal Sticking
Accelerator Pedal: Recalls Recall 10VC234000: Accelerator Pedal Sticking
VEHICLE MAKE/MODEL: MODEL YEAR(S): Dodge/Caliber 2007 Jeep/Compass 2007
MANUFACTURER: Chrysler Group LLC
MFR'S REPORT DATE: June 01, 2010
NHTSA CAMPAIGN ID NUMBER: 10V234000
NHTSA ACTION NUMBER: PE10012 COMPONENT: Vehicle Speed Control: Accelerator Pedal
SUMMARY: Chrysler is recalling certain model year 2007 Dodge Caliber and Jeep Compass
passenger vehicles manufactured from March 7 through May 19, 2006. The pivot bushings in
vehicles with oversized accelerator pedal bearing pockets may become dislodged and potentially
cause the accelerator pedal to bind or stick.
CONSEQUENCE: Should the pedal bind or become stuck, it can be overcome by smart brakes
which override the accelerator pedal in certain conditions.
REMEDY: Chrysler will notify owners and dealers will inspect and replace all affected accelerator
pedal assemblies free of charge. The safety recall is expected to begin During June 2010. Owners
may contact Chrysler toll-free at 1-800-853-1403.
NOTES: Chrysler's recall campaign number is K11. Owners may also contact The National
Highway Traffic Safety Administration's Vehicle Safety Hotline at 1-888-327-4236 (TTY
1-800-424-9153), or go to http://www.safercar.gov.
Information > Technical Service Bulletins > All Technical Service Bulletins for Accelerator Pedal: > K11 > Jun > 10 > Recall
- Accelerator Pedal Inspection/Replacement
Technical Service Bulletin # K11 Date: 100618
Recall - Accelerator Pedal Inspection/Replacement
June 2010
Dealer Service Instructions for: Safety Recall K11 Accelerator Pedal
Effective immediately all repairs on involved vehicles are to be performed according to this recall.
Service Bulletin 14-004-10 is no longer applicable for vehicles involved in this recall. Those
vehicles that have already had this repair performed, as determined by our warranty records, have
been excluded from this recall.
Models
2007 (PM) Dodge Caliber
2007 (MK) Jeep(R) Compass
NOTE:
This recall applies only to the above vehicles equipped with an automatic transmission (sales code
DAV) and built from March 7, 2006 through May 19, 2006 (MDH 030706 through 051921).
IMPORTANT:
Some of the involved vehicles may be in dealer used vehicle inventory. Dealers should complete
this recall service on these vehicles before retail delivery. Dealers should also perform this recall on
vehicles in for service. Involved vehicles can be determined by using the VIP inquiry process.
Subject
The accelerator pedal on about 24,800 of the above vehicles may stick during vehicle operation.
This could cause the vehicle to react differently than the driver anticipated. This could cause a
crash without warning.
SPECIAL NOTE:
All involved vehicles are equipped with an Electronic Throttle Control (ETC) system that utilizes
"Smart Pedal" technology that allows a brake pedal input to override the throttle control system.
Repair
The accelerator pedal cavity number and date code must be inspected. Vehicles found with a
suspect accelerator pedal must have the pedal replaced.
Parts Information
Part Number Description
CAB3K110AA Pedal, Accelerator
Due to the small number of involved vehicles expected to require an accelerator pedal, no parts will
be distributed initially. Accelerator pedals should be ordered only after inspection determines that
replacement is required.
Special Tools
- Accelerator Pedal Inspection/Replacement > Page 3859

Add the cost of the recall parts package plus applicable dealer allowance to your claim.
NOTE:
See the Warranty Administration Manual, Recall Claim Processing Section, for complete recall
claim processing instructions.
Dealer Notification
All involved vehicle owners known to Chrysler are being notified of the service requirement by first
class mail. They are requested to schedule appointments for this service with their dealers. A
generic copy of the owner letter is included.
GRS provides involved dealers with an updated VIN list of their incomplete
vehicles. The owner's name, address and phone number are listed if known. Completed vehicles
are removed from GRS within several days of repair claim submission.
Customer Services Field Operations Chrysler Group LLC
Service Procedure
NOTE:
the accelerator pedal must be removed from the vehicle to perform the inspection.

NOTE:
service procedure.
2. Remove the three accelerator pedal mounting nuts (Figure 1).
3. Disconnect the accelerator pedal electrical connector.
4. Remove the accelerator pedal from the vehicle.
5. Inspect the cavity code located on the backside of the accelerator pedal (Figure 2):
> If the cavity code is a number 1, the pedal assembly does not require replacement. Continue to
Step 7 of this procedure.
> If the cavity code is a number 2, the accelerator pedal date code must be inspected. Continue
with Step 6 of this procedure.
6. Inspect the accelerator pedal date code.
UNDERSTANDING THE DATE CODE: The first two digits are the year (06 = 2006). The next three
digits are the day of the year it was built (068 = the 68th day). Disregard the last three digits of the
date code. For example, the date code on the pedal assembly in Figure 3 is 06068828. The first
two digits are 06 (built in 2006), the next three digits are 068 (the 68th day). Ignore the last three
digits.
> If the date code is 06059xxx or lower or it is 06095xxx or higher, the accelerator pedal does not
require replacement. Continue with Step 7 of this procedure.
> If the date code is 06060 through 06094, replace the accelerator pedal.
Continue with Step 7 of this procedure.

> If the date code is not legible, replace the accelerator pedal. Continue with Step 7 of this
procedure.
7. Connect the accelerator pedal electrical connector to the new accelerator pedal or original
accelerator pedal (depending on inspection results).
8. Install the accelerator pedal into the vehicle and tighten the mounting nuts to 22 ft. lbs. (30 N.m)
in the sequence shown in Figure 4.
10. On vehicles that had the original accelerator pedal installed, no further action is required. On
vehicles that had the accelerator pedal replaced,
continue with Step 11.
11. Use one of the following scan tools and related procedure to perform the "Learn ETC"
procedure:
Using wiTECH:
a. Connect the wiPOD to the vehicle data link connector.
b. Place the ignition key in the "RUN" position.
c. Launch the wiTECH diagnostic application.
d. Select "PCM" from the vehicle view screen.
e. Select the "MISC FUNCTION" tab.

f. Select "Learn ETC" from the list.
g. Follow the screen prompts.
h. Clear all DTC's.
NOTE:
i. Place the ignition in the "OFF" position, remove the wiPOD from the data link connector
Using StarMOBILE:
a. Connect the StarMOBILE scan tool to the vehicle data link connector located under the steering
column and turn the ignition key to the "RUN"
position.
b. Connect the CH9410 StarMOBILE scan tool ethernet cable to the StarMOBILE and the dealer's
network drop.
c. Power ON the StarMOBILE scan tool.
d. From the desktop, launch the "StarMOBILE Desktop Client" software.

e. Establish a connection with the StarMOBILE scan tool.
f. Starting at the "Home" screen, select "ECU View".
g. Select "Misc Functions".
h. Select "Learn ETC".
i. Follow the screen prompts.
j. Clear any Diagnostic Trouble Codes (DTCs) as follows:)
NOTE:
1. From the "Home" screen select "System View".
2. Select "All DTCs".
3. Press "Clear All Stored DTCs" if there are any DTCs shown on the list.
Information > Technical Service Bulletins > All Technical Service Bulletins for Accelerator Pedal: > NHTSA10V234000 > Jun
> 10 > Recall 10VC234000: Accelerator Pedal Sticking
Accelerator Pedal: All Technical Service Bulletins Recall 10VC234000: Accelerator Pedal Sticking
VEHICLE MAKE/MODEL: MODEL YEAR(S): Dodge/Caliber 2007 Jeep/Compass 2007
MANUFACTURER: Chrysler Group LLC
MFR'S REPORT DATE: June 01, 2010
NHTSA CAMPAIGN ID NUMBER: 10V234000
NHTSA ACTION NUMBER: PE10012 COMPONENT: Vehicle Speed Control: Accelerator Pedal
SUMMARY: Chrysler is recalling certain model year 2007 Dodge Caliber and Jeep Compass
passenger vehicles manufactured from March 7 through May 19, 2006. The pivot bushings in
vehicles with oversized accelerator pedal bearing pockets may become dislodged and potentially
cause the accelerator pedal to bind or stick.
CONSEQUENCE: Should the pedal bind or become stuck, it can be overcome by smart brakes
which override the accelerator pedal in certain conditions.
REMEDY: Chrysler will notify owners and dealers will inspect and replace all affected accelerator
pedal assemblies free of charge. The safety recall is expected to begin During June 2010. Owners
may contact Chrysler toll-free at 1-800-853-1403.
NOTES: Chrysler's recall campaign number is K11. Owners may also contact The National
Highway Traffic Safety Administration's Vehicle Safety Hotline at 1-888-327-4236 (TTY
1-800-424-9153), or go to http://www.safercar.gov.
Jeep Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Accelerator Pedal Position Sensor
Component ID: 290
Connector:
Color : BLACK
# of pins : 6

Component ID: 290
Connector:
Color : BLACK
# of pins : 6

DESCRIPTION
REMOVAL

INSTALLATION

Jeep Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Air Cleaner Housing > Air Filter
Element > Component Information > Service and Repair > Removal
REMOVAL
INSTALLATION
Jeep Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Filler Cap > Component
Fuel Filler Cap: Description and Operation Description
DESCRIPTION
The plastic fuel fill cap is threaded/quarter turn onto the end of the fuel filler tube. It's purpose is to
retain vapors and fuel in the fuel tank.
Jeep Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Filler Cap > Component
Fuel Filler Cap: Description and Operation Operation
OPERATION
The fuel filler cap incorporates a two-way relief valve that is closed to atmosphere during normal
operating conditions. The relief valve is calibrated to open when a pressure of 17 kPa (2.5 psi) or
vacuum of 3 kPa (12 in. Hg) occurs in the fuel tank. When the pressure or vacuum is relieved, the
valve returns to the normally closed position.
CAUTION: Remove the fuel filler cap to release fuel tank pressure before disconnecting any fuel
system component.
Jeep Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Filler Cap Warning Indicator >
Fuel Filler Cap Warning Indicator: Description and Operation Description
DESCRIPTION
A gas cap indicator is standard equipment on all instrument clusters. However, on vehicles
equipped with the optional diesel engine, this indicator is electronically disabled. The gas cap
indication appears within the odometer Vacuum Fluorescent Display (VFD) unit. The gas cap
indicator consists of a textual gascap message which appears in place of the odometer information
in the odometer display.
The odometer VFD is soldered onto the cluster electronic circuit board, and is visible through a
window with a smoked clear lens located on the lower edge of the tachometer gauge dial face of
the cluster overlay. The dark lens over the VFD prevents it from being clearly visible when it is not
illuminated. The gas cap textual message appears in the same blue-green color and at the same
lighting level as the odometer information when it is illuminated by the instrument cluster electronic
circuit board.
The gas cap indicator is serviced as a unit with the VFD in the instrument cluster.
Jeep Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Filler Cap Warning Indicator >
Fuel Filler Cap Warning Indicator: Description and Operation Operation
OPERATION
The gas cap indicator gives an indication to the vehicle operator when there is a gross leak
detected in the on-board fuel vapor recovery system. This indicator is controlled by the instrument
cluster logic circuit based upon cluster programming and electronic messages received over the
Controller Area Network (CAN) data bus from the Powertrain Control Module (PCM).
The gas cap indicator function of the odometer Vacuum Fluorescent Display (VFD) unit is
completely controlled by the instrument cluster logic circuit, and that logic will only allow this
indicator to operate when the instrument cluster receives a battery current input on the fused
ignition switch output (run-start) circuit. Therefore, the odometer VFD gas cap indication will always
be OFF when the ignition switch is in any position except ON or START. The instrument cluster will
turn ON the gas cap indicator for the following reasons:
- Gas Cap Indicator Lamp-On Message - Each time the cluster receives an electronic gas cap
indicator lamp-ON message from the PCM indicating there is a gross leak in the vapor recovery
system, the gas cap indicator will be illuminated. The indicator remains illuminated until the cluster
receives a lamp-OFF message from the PCM, or until the ignition switch is turned to the OFF
The PCM continually monitors the on board vapor recovery system to determine whether there are
air leaks in the system. The PCM then sends the proper lamp-ON or lamp-OFF message to the
ElectroMechanical Instrument Cluster (EMIC). If the EMIC turns ON the gas cap indicator due to a
monitored gross leak in the vapor recovery system, it may indicate that the gas cap has been
removed or is improperly installed.
For proper diagnosis of the on board vapor recovery system, the PCM, the EMIC, the CAN data
bus or the electronic communication related to gas cap indicator operation a diagnostic scan tool is
required. Refer to the appropriate diagnostic information.
Jeep Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Filter > Fuel Pressure Release
> System Information > Service and Repair

Jeep Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Filter > Fuel Pressure Release
> System Information > Service and Repair > Page 3902
Jeep Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Injector > Component
Information > Locations > Injector-Fuel 1
Fuel Injector: Locations Injector-Fuel 1
Component ID: 113
Component : INJECTOR-FUEL 1
Connector:
Name : INJECTOR-FUEL 1
Color : BLACK
# of pins : 2
1 FUEL INJECTOR HIGH-SIDE COMMON K663 16BR/YL
2 FUEL INJECTOR 1 LOW-SIDE CONTROL K611 16BR/RD
Information > Locations > Injector-Fuel 1 > Page 3907
Connector:
Color : BLACK
# of pins : 2
Qualifier : (GAS)
Component ID: 114
Connector:
Color : BLACK
# of pins : 2
2 FUEL INJECTOR 2 LOW-SIDE CONTROL K612 16BR/LG
Connector:
Color : BLACK
# of pins : 2
Qualifier : (GAS)
Component ID: 115
Connector:
Color : BLACK
# of pins : 2
2 FUEL INJECTOR 3 LOW-SIDE CONTROL K613 16BR/WT
Connector:
Color : BLACK
# of pins : 2
Qualifier : (GAS)
Component ID: 116
Connector:
Color : BLACK
# of pins : 2
2 FUEL INJECTOR 4 LOW-SIDE CONTROL K614 16BR/LB
Connector:
Color : BLACK
# of pins : 2
Qualifier : (GAS)
Information > Diagrams > Injector-Fuel 1
Fuel Injector: Diagrams Injector-Fuel 1
Component ID: 113
Connector:
Color : BLACK
# of pins : 2
2 FUEL INJECTOR 1 LOW-SIDE CONTROL K611 16BR/RD
Information > Diagrams > Injector-Fuel 1 > Page 3928
Connector:
Color : BLACK
# of pins : 2
Qualifier : (GAS)
Component ID: 114
Connector:
Color : BLACK
# of pins : 2
2 FUEL INJECTOR 2 LOW-SIDE CONTROL K612 16BR/LG
Connector:
Color : BLACK
# of pins : 2
Qualifier : (GAS)
Component ID: 115
Connector:
Color : BLACK
# of pins : 2
2 FUEL INJECTOR 3 LOW-SIDE CONTROL K613 16BR/WT
Connector:
Color : BLACK
# of pins : 2
Qualifier : (GAS)
Component ID: 116
Connector:
Color : BLACK
# of pins : 2
2 FUEL INJECTOR 4 LOW-SIDE CONTROL K614 16BR/LB
Connector:
Color : BLACK
# of pins : 2
Qualifier : (GAS)
Fuel Injector: Description and Operation Description
DESCRIPTION
The injectors are positioned in the intake manifold with the nozzle ends directly above the intake
valve port.
Fuel Injector: Description and Operation Operation
OPERATION
The fuel injectors are 12 volt electrical solenoids. The injector contains a pintle that closes off an
orifice at the nozzle end. When electric current is supplied to the injector, the armature and needle
move a short distance against a spring, allowing fuel to flow out the orifice. Because the fuel is
under high pressure, a fine spray is developed in the shape of a hollow cone or two streams. The
spraying action atomizes the fuel, adding it to the air entering the combustion chamber. Fuel
injectors are not interchangeable between engines.
Injector operation is controlled by a ground path provided for each injector by the PCM. Injector
on-time (pulse-width) is variable, and is determined by the PCM processing all the data previously
discussed to obtain the optimum injector pulse width for each operating condition. The pulse width
is controlled by the duration of the ground path provided.
Information > Service and Repair > Removal - Injector Connector
Fuel Injector: Service and Repair Removal - Injector Connector
REMOVAL - INJECTOR CONNECTOR
1. Disconnect electrical connectors at the fuel injectors.
2. To remove connector pull the red colored slider away from injector (1). While pulling the slider,
depress tab (2) and remove connector (3) from
injector. The factory fuel injection wiring harness is numerically tagged (INJ 1, INJ 2, etc.) for
injector position identification. If harness is not tagged, make note of wiring location before removal.
Information > Service and Repair > Removal - Injector Connector > Page 3952
Fuel Injector: Service and Repair Removal
2.0/2.4L
WARNING: Release fuel system pressure before servicing fuel system components. Service
vehicles in well ventilated areas and avoid ignition sources. Never smoke while servicing the
vehicle. This may result in personal injury or death.
1. Release the fuel pressure.
3. Disconnect the electrical connectors from the fuel injectors.
4. Fuel line connection at fuel rail.

5. Remove the fuel line from the fuel rail.
6. Remove wire harness from fuel rail mounting studs.

7. Remove the 2 bolts to the fuel rail at the lower manifold.
8. Remove the fuel rail.

9. Remove clip holding fuel injector to fuel rail.
10. Remove fuel injector clip and fuel injector from fuel rail.
Fuel Injector: Service and Repair Installation
2.0/2.4L
1. Apply a light coating of clean engine oil to the upper O-ring.
2. Install injector in cup on fuel rail.
3. Install retaining clip.
4. Apply a light coating of clean engine oil to the O-ring on the nozzle end of each injector.
5. Insert fuel injector nozzles into openings in lower intake manifold. Seat the injectors in place.
6. Tighten fuel rail mounting screws to 27 Nm (20 ft. lbs.).
7. Install wiring harness clips to the fuel rail mounting studs.

8. Attach electrical connectors to fuel injectors.
9. Connect fuel supply tube to fuel rail.
11. Use the scan tool to pressurize the fuel system. Check for leaks.
Jeep Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Line Coupler > Component
Fuel Line Coupler: Service and Repair
STANDARD PROCEDURE - QUICK-CONNECT FITTINGS
TWO-TAB IN WINDOW TYPE FITTING
When disconnecting a quick-connect fitting, the retainer will remain on the fuel tube nipple.
WARNING: Release fuel system pressure before disconnecting a quick-connect fittings. This may
result in personal injury or death.
1. Perform Fuel Pressure Release Procedure.
2. Disconnect negative cable from battery or auxiliary jumper terminal.
3. Squeeze retainer tabs (2) together and pull fuel tube/quick-connect fitting assembly off of fuel
tube nipple.
CAUTION: Make sure that the O-ring in installed in fitting. Never install a quick-connect fitting
without the retainer being either on the fuel tube or already in the quick-connect fitting. In either
case, ensure the retainer locks securely into the quick-connect fitting by firmly push-pulling-push on
fuel tube and fitting to ensure it is secured.
4. Using a clean lint free cloth, clean the fuel tube nipple and retainer.
5. Prior to connecting the fitting to the fuel tube, coat the fuel tube nipple with clean engine oil.
6. Push the quick-connect fitting over the fuel tube until the retainer seats and a click is heard.
7. The plastic quick-connect fitting has windows in the sides of the casing. When the fitting
completely attaches to the fuel tube, the retainer locking
ears (2) and the fuel tube shoulder are visible in the windows (1). If they are not visible, the retainer
was not properly installed. Do not rely upon the audible click to confirm a secure connection.
8. Connect negative cable to battery or auxiliary jumper terminal.
9. Use the scan tool Fuel System Test to pressurize the fuel system. Check for leaks.
TWO-TAB TYPE FITTING

This type of fitting is equipped with tabs located on both sides of the fitting. These tabs are supplied
for disconnecting the quick-connect fitting from component being serviced.
CAUTION: The interior components (O-rings, spacers) of this type of quick-connect fitting are not
serviced separately, but new plastic retainers are available. Do not attempt to repair damaged
fittings or fuel lines/tubes. If repair is necessary, replace the complete fuel tube assembly.
WARNING: The fuel system is under a constant pressure (even with the engine off). Before
servicing any fuel system hoses, fittings or lines, the fuel system pressure must be released. Refer
to the fuel pressure release procedure. This may result in personal injury or death.
DISCONNECTION/CONNECTION
1. Perform fuel pressure release procedure.
2. Disconnect negative battery cable from battery or auxiliary jumper terminal.
3. Clean fitting of any foreign material before disassembly.
4. To disconnect quick-connect fitting, squeeze plastic retainer tabs (1) against sides of
quick-connect fitting with your fingers. Tool use is not
required for removal and may damage plastic retainer. Pull fitting from fuel system component
being serviced. The plastic retainer will remain on component being serviced after fitting is
disconnected. The O-rings and spacer will remain in quick-connect fitting connector body.
5. Inspect quick-connect fitting body and component for damage. Replace as necessary.
CAUTION: When the quick-connect fitting was disconnected, the plastic retainer will remain on the
component being serviced. If this retainer must be removed, very carefully release the retainer from
the component with two small screwdrivers. After removal, inspect the retainer for cracks or any
damage.
6. Prior to connecting quick-connect fitting to component being serviced, check condition of fitting
and component. Clean parts with a lint-free cloth.
Lubricate with clean engine oil.
7. Insert quick-connect fitting to component being serviced and into plastic retainer. When a
connection is made, a click will be heard.
8. Verify a locked condition by firmly push-pulling-push on fuel tube and fitting (15-30 lbs.).
9. Connect negative cable to battery or auxiliary jumper terminal.
PLASTIC RETAINER RING TYPE FITTING

This type of fitting can be identified by the use of a full-round plastic retainer ring usually black in
color.
CAUTION: The interior components (O-rings, spacers, retainers) of this type of quick-connect fitting
are not serviced separately. Do not attempt to repair damaged fittings or fuel lines/tubes. If repair is
necessary, replace the complete fuel tube assembly.
to the fuel system pressure release procedure. This may result in personal injury or death.
DISCONNECTION/CONNECTION
1. Perform fuel pressure release procedure.
2. Disconnect negative battery cable from battery or auxiliary jumper terminal.
3. Clean fitting of any foreign material before disassembly.
4. To release fuel system component from quick-connect fitting, firmly push fitting towards
component being serviced while firmly pushing plastic
retainer ring into fitting. With plastic ring depressed, pull fitting from component. The plastic retainer
ring must be pressed squarely into fitting body. If this retainer is cocked during removal, it may be
difficult to disconnect fitting. Use an open-end wrench on shoulder of plastic retainer ring to aid in
disconnection.
5. After disconnection, plastic retainer ring will remain with quick-connect fitting connector body.
6. Inspect fitting connector body, plastic retainer ring and fuel system component for damage.
Replace as necessary.
7. Prior to connecting quick-connect fitting to component being serviced, check condition of fitting
and component. Clean parts with a lint-free cloth.
Lubricate with clean engine oil.
8. Insert quick-connect fitting into component being serviced until a click is felt.
9. Verify a locked condition by firmly push-pulling-push on fuel tube and fitting (15-30 lbs.).
10. Connect negative battery cable to battery or auxiliary jumper terminal.
Jeep Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Pressure Regulator >
Fuel Pressure Regulator: Locations
- Inlet strainer
- Fuel Filter
Jeep Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Pump > Fuel Pressure >
System Information > Specifications

Diagnostic Test
test.
Yes
- Go to 2
No
- Go to 7
- Test complete.

- Go to 3

Verification Test
module.
Yes
Verification Test
No
- Go to 4
4. SADDLE FUEL TANK
Yes
- Go to 5
No
- Go to 6
Yes
Verification Test
No
- Go to 6
Yes
Verification Test
No
Verification Test
Yes
Verification Test
No
Verification Test
Jeep Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Pump Pickup Filter >
Component Information > Description and Operation
Fuel Pump Pickup Filter: Description and Operation
DESCRIPTION
The fuel pump inlet strainer is a non-serviceable part.

Jeep Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Rail > Component Information
> Description and Operation > Description
Fuel Rail: Description and Operation Description
DESCRIPTION
The fuel rail supplies the necessary fuel to each individual fuel injector and is mounted to the intake
manifold.
> Description and Operation > Description > Page 3981
Fuel Rail: Description and Operation Operation
OPERATION
The fuel pressure regulator is no longer mounted to the fuel rail on any engine. It is now located on
the fuel tank mounted fuel pump module. The fuel rail is not repairable.
Fuel Rail: Service and Repair Removal
2.0/2.4L
NOTE: Wrap shop towels around hose to catch any gasoline spillage.
1. Release the fuel system pressure.
3. Disconnect the fuel line from the fuel rail.
4. Fuel line removed from the fuel rail.

5. Unlock and disconnect the electrical connectors from the fuel injectors.
6. Remove the wiring harness from the fuel rail studs.

7. Remove the 2 bolts from the fuel rail.
8. Remove the fuel rail and injectors from the intake manifold.
9. Fuel rail removed from intake manifold.
10. Remove fuel injectors from fuel rail.

Fuel Rail: Service and Repair Installation
2.0/2.4L
1. Apply a light coating of clean engine oil to the O-ring on the nozzle end of each injector.
2. Install the fuel injectors to the fuel rail.
3. Install injector into cup of fuel rail.
4. Install retaining clip and check to ensure injector is properly captured.
Fuel rail assembly.

5. Insert fuel injector nozzles into openings in intake manifold. Seat the injectors in place.
6. Install the 2 bolts to the fuel rail. Tighten fuel rail bolts to 27 Nm (20 ft. lbs.).
7. Install the wiring harness to the fuel rail.
8. Connect and lock the electrical connectors to the fuel injectors.

9. Connect the fuel line to the fuel rail.
11. Use the Scan Tool Fuel System Test to pressurize the fuel system. Check for leaks.
Jeep Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Return Line > Component
Fuel Return Line: Description and Operation
DESCRIPTION - FUEL LINES/HOSES AND CLAMPS
The lines/tubes/hoses used on fuel injected vehicles are of a special construction. This is due to
the higher fuel pressures and the possibility of contaminated fuel in this system. If it is necessary to
replace these lines/tubes/hoses, use new original equipment lines/tubes/hoses.
If equipped: The hose clamps used to secure rubber hoses on vehicles are of a special rolled edge
construction. This construction is used to prevent the edge of the clamp from 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 leaks.
Use new original equipment type hose clamps.

Jeep Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Supply Line > Component
Fuel Supply Line: Description and Operation
DESCRIPTION - FUEL LINES/HOSES AND CLAMPS
The lines/tubes/hoses used on fuel injected vehicles are of a special construction. This is due to
the higher fuel pressures and the possibility of contaminated fuel in this system. If it is necessary to
replace these lines/tubes/hoses, use new original equipment lines/tubes/hoses.
If equipped: The hose clamps used to secure rubber hoses on vehicles are of a special rolled edge
construction. This construction is used to prevent the edge of the clamp from 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 leaks.
Use new original equipment type hose clamps.

Jeep Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Supply Line > Component
Fuel Supply Line: Service and Repair
STANDARD PROCEDURE - HOSES AND CLAMP
Inspect all hose connections (clamps and quick connect fittings) for completeness and leaks.
Replace cracked, scuffed, or swelled hoses. Replace hoses that rub against other vehicle
components or show sign of wear.
Fuel injected vehicles use specially constructed hoses. When replacing hoses, only use hoses
marked EFM/EFI.
When installing hoses, ensure that they are routed away from contact with other vehicle
components that could rub against them and cause failure. Avoid contact with clamps or other
components that cause abrasions or scuffing. Ensure that rubber hoses are properly routed and
avoid heat sources.
The hose clamps have rolled edges to prevent the clamp from cutting into the hose. Only use
clamps that are original equipment or equivalent. Other types of clamps may cut into the hoses and
cause high pressure fuel leaks. Tighten hose clamps to 1 Nm (9 in. lbs.).
Inspect all hose connections such as clamps, couplings and fittings to make sure they are secure
and leaks are not present. The component should be replaced immediately if there is any evidence
of degradation that could result in failure.
Never attempt to repair a plastic fuel line/tube. Replace as necessary.
Avoid contact of any fuel tubes/hoses with other vehicle components that could cause abrasions or
scuffing. Be sure that the plastic fuel lines/tubes are properly routed to prevent pinching and to
avoid heat sources.
Jeep Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Tank > Fuel Filler Neck >
Component Information > Technical Service Bulletins > Customer Interest for Fuel Filler Neck: > 14-003-07 > May > 07 >
Body - Fuel Filler Door Under Flush
Fuel Filler Neck: Customer Interest Body - Fuel Filler Door Under Flush
NUMBER: 14-003-07
GROUP: Fuel System
DATE: May 31, 2007
THIS BULLETIN SUPERSEDES TECHNICAL SERVICE BULLETIN 14-006-06, DATED AUGUST

HIGHLIGHTED WITH **ASTERISKS** AND INCLUDE THE ADDITION OF MODELS, REPAIR
PROCEDURE STEPS AND PARTS.
SUBJECT: Under Flush Fuel Filler Door Splash Shield
OVERVIEW: This bulletin involves installing a Fuel Filler Neck Spacer.
MODELS:
2007 (PM) Caliber
**2007 (MK74) Patriot**
NOTE:
This bulletin applies to PM and MK-49 models built before June 22, 2006 (MDH 0622XX) **and
MK74 models built prior to April 3, 2007 (MDH 0403xx)**.
SYMPTOM/CONDITION:
The condition may present itself as a under-flush fuel filler door or loose fuel filler neck which may
be more noticeable when the vehicle is being fueled up. This condition can also be described as a
loose fuel filler neck housing.
PARTS REQUIRED:
REPAIR PROCEDURE:
1. Open the fuel door.
2. Pull the fuel filler housing back into place. It may be necessary to remove the splash shield to
secure housing. All clips must be engaged.
3. **Refer to proper step based on vehicle being serviced:

a. PM - Caliber or MK49 - Compass, go to > next step.
b. MK74 - Patriot, go to > Step # 5**

Body - Fuel Filler Door Under Flush > Page 4007
4. PM/MK49: Install the fuel filler neck spacer over the lower screw (Fig 1).
NOTE:
Be sure to orient the spacer correctly before installing.
5. **MK74: Install the fuel filler neck spacer over the lower screw on fuel door mount. Push spacer
all the way in until it clicks** (Fig 2)

Body - Fuel Filler Door Under Flush > Page 4008
TIME ALLOWANCE:
FAILURE CODE:
Disclaimer:
Component Information > Technical Service Bulletins > All Technical Service Bulletins for Fuel Filler Neck: > 14-003-07 >
May > 07 > Body - Fuel Filler Door Under Flush
Fuel Filler Neck: All Technical Service Bulletins Body - Fuel Filler Door Under Flush
NUMBER: 14-003-07
GROUP: Fuel System
DATE: May 31, 2007
THIS BULLETIN SUPERSEDES TECHNICAL SERVICE BULLETIN 14-006-06, DATED AUGUST

HIGHLIGHTED WITH **ASTERISKS** AND INCLUDE THE ADDITION OF MODELS, REPAIR
PROCEDURE STEPS AND PARTS.
SUBJECT: Under Flush Fuel Filler Door Splash Shield
OVERVIEW: This bulletin involves installing a Fuel Filler Neck Spacer.
MODELS:
2007 (PM) Caliber
**2007 (MK74) Patriot**
NOTE:
This bulletin applies to PM and MK-49 models built before June 22, 2006 (MDH 0622XX) **and
MK74 models built prior to April 3, 2007 (MDH 0403xx)**.
SYMPTOM/CONDITION:
The condition may present itself as a under-flush fuel filler door or loose fuel filler neck which may
be more noticeable when the vehicle is being fueled up. This condition can also be described as a
loose fuel filler neck housing.
PARTS REQUIRED:
REPAIR PROCEDURE:
1. Open the fuel door.
2. Pull the fuel filler housing back into place. It may be necessary to remove the splash shield to
secure housing. All clips must be engaged.
3. **Refer to proper step based on vehicle being serviced:

a. PM - Caliber or MK49 - Compass, go to > next step.
b. MK74 - Patriot, go to > Step # 5**

May > 07 > Body - Fuel Filler Door Under Flush > Page 4014
4. PM/MK49: Install the fuel filler neck spacer over the lower screw (Fig 1).
NOTE:
Be sure to orient the spacer correctly before installing.
5. **MK74: Install the fuel filler neck spacer over the lower screw on fuel door mount. Push spacer
all the way in until it clicks** (Fig 2)

May > 07 > Body - Fuel Filler Door Under Flush > Page 4015
TIME ALLOWANCE:
FAILURE CODE:
Disclaimer:
Fuel Filler Neck: Service and Repair Removal
REMOVAL
NOTE: Drain fuel tank if it is more than half full.
2. Loosen fuel filler tube cap.
4. Remove the left rear wheel.
5. Remove the inner splash shield.

6. Disconnect filler tube recirculation vent line.
7. Disconnect fuel filler tube hose from fuel tank neck.
8. Remove filler tube mounting screw.
9. Remove fuel filler tube assembly.

Fuel Filler Neck: Service and Repair Installation
INSTALLATION
1. Install fuel filler tube. Connect fuel filler tube hose to fuel tank neck and tighten clamp to 2.8 Nm
(24 in. lbs.).
2. Install fuel filler tube mounting screw and tighten to 9 Nm (79.5 in. lbs.).
3. Connect filler tube vent line.
4. Install the inner splash shield.

5. Install rear tire.
6. Lower vehicle.
7. Install fuel filler tube cap.
9. Install the air cleaner lid and makeup air hose.

Jeep Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Tank > Fuel Gauge Sender >
Fuel Gauge Sender: Locations
- Inlet strainer
- Fuel Filter
Jeep Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Tank Unit > Component
Fuel Tank Unit: Service and Repair Removal
All Wheel Drive
ALL WHEEL DRIVE
1. Perform Fuel System Pressure Release procedure.
2. Remove the air cleaner lid, disconnect the inlet air temperature sensor and makeup air hose.
4. Remove the rear seat cushion.

5. Rear seat cushion loose.
6. Remove plastic cover.
7. Clean top of tank to remove loose dirt and debris.
8. Use special tool Spanner Wrench #9340 to remove left side module lock ring.
9. Note the fuel pump location on the top of the fuel tank.
NOTE: The pump has to be properly located to the tank for the fuel gauge to work properly.
10. Pull module up out of fuel tank, make sure that you do not spill fuel inside of vehicle.
11. Drain fuel from fuel pump module. Do not spill fuel in interior of vehicle.
12. Disconnect internal line from fuel pump module.
13. Tip module on its side to drain remaining fuel from reservoir and remove module from vehicle.
14. Remove module from vehicle.
15. Remove seal from tank. Discard seal.

18. Disconnect electrical line from module.
19. Note the fuel level unit location on the top of the fuel tank (1).
NOTE: The fuel level unit has to be properly located to the tank for the fuel gauge to work properly.
20. Using Special Tool Lock Ring #9318 remove lock ring (2) to release fuel level unit.
21. Note the fuel level unit location on the top of the fuel tank.
NOTE: The fuel level unit has to be properly located to the tank for the fuel gauge to work properly.
22. Remove fuel level unit module and disconnect line.

23. Remove module and seal from tank. Discard seal.
Front Wheel Drive
FRONT WHEEL DRIVE
1. Perform Fuel System Pressure Release procedure.
4. Remove the rear seat cushion.

5. Rear seat cushion loose.
8. Use special tool #9340 to remove left side module lock ring.
9. Note the fuel pump location on the top of the fuel tank.
10. Pull module up out of fuel tank, make sure that you do not spill fuel inside of vehicle.
11. Drain fuel from fuel pump module. Do not spill fuel in interior of vehicle.
Fuel Tank Unit: Service and Repair Installation
All Wheel Drive
ALL WHEEL DRIVE

1. Wipe seal area of tank clean. Place a new seal between the tank threads and the pump module
opening.
2. Connect line to module.

3. Install module.
4. Position fuel pump module in tank. Make sure the alignment tab lines up on the fuel tank and
pump module for Gas or Diesel fuel tanks.
5. While holding the pump module in position, install lock ring and use special tool Lock Ring #9340
to tighten lock ring.
6. Install plastic cover.
opening.
8. Connect line and install venturi module.

9. Position fuel pump module in tank. Make sure the alignment tab line up on the fuel tank and
10. While holding the pump module in position, install lock ring and use special tool Spanner
Wrench #9340 to tighten lock ring.

13. Install rear cushion.
15. Install the air cleaner lid, connect the inlet air temperature sensor and makeup air hose.
16. Fill fuel tank with clean fuel. Use the Scan Tool to pressurize the system and check for leaks.
Front Wheel Drive
FRONT WHEEL DRIVE

opening.
2. Install module.
3. Position fuel pump module in tank. Make sure the alignment tab lines up on the fuel tank and
4. While holding the pump module in position, install lock ring and use special tool Spanner Wrench
#9340 to tighten lock ring.
6. Install rear cushion.

8. Install the air cleaner lid, connect the inlet air temperature sensor and makeup air hose.
9. Fill fuel tank with clean fuel. Use the Scan Tool to pressurize the system and check for leaks.
Jeep Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Main Relay (Computer/Fuel
System) > Component Information > Locations

Jeep Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Main Relay (Computer/Fuel
System) > Component Information > Locations > Page 4047
Main Relay
Jeep Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Relays and Modules - Fuel Delivery
and Air Induction > Main Relay (Computer/Fuel System) > Component Information > Locations

Jeep Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Relays and Modules - Fuel Delivery
and Air Induction > Main Relay (Computer/Fuel System) > Component Information > Locations > Page 4052
Main Relay
Jeep Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Sensors and Switches - Fuel
Delivery and Air Induction > Accelerator Pedal Position Sensor > Component Information > Locations
Component ID: 290
Connector:
Color : BLACK
# of pins : 6

Delivery and Air Induction > Accelerator Pedal Position Sensor > Component Information > Locations > Page 4057
Component ID: 290
Connector:
Color : BLACK
# of pins : 6

DESCRIPTION
Delivery and Air Induction > Accelerator Pedal Position Sensor > Component Information > Service and Repair > Removal
REMOVAL

Delivery and Air Induction > Accelerator Pedal Position Sensor > Component Information > Service and Repair > Removal >
Page 4065
INSTALLATION

Jeep Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Throttle Body > Component
Throttle Body: Locations
Component ID: 367
Component : THROTTLE BODY
Connector:
Name : THROTTLE BODY
Color : BLACK
# of pins : 6
Qualifier : (GAS)
5 TP SIGNAL 1 K22 20BR/OR

Throttle Body: Diagrams
Component ID: 367
Component : THROTTLE BODY
Connector:
Name : THROTTLE BODY
Color : BLACK
# of pins : 6
Qualifier : (GAS)
5 TP SIGNAL 1 K22 20BR/OR

Throttle Body: Description and Operation Description
DESCRIPTION
The throttle body mounts to the intake manifold. The throttle position sensor and throttle actuating
DC motor are integral to the throttle body. The throttle body is a non serviceable item, replace the
throttle body as an assembly.
The throttle blade will not close completely when engine is shut down. This engine off blade
position is for start up. The electric throttle body will adjust the throttle blade for idle control as the
idle air control valve adjusted idle speed previously on cable actuated throttle bodies. The electric
throttle body will also adjust the throttle blade for normal driving operation. The throttle blade will
move to the engine off blade position if throttle body codes are set to provide air for limp-in mode.
Throttle Body: Description and Operation Operation
OPERATION
Filtered air from the air cleaner enters the intake manifold through the throttle body. A throttle valve
(plate) is used to supply air for all conditions from idle to wide open throttle.
Throttle Body: Service and Repair Removal
2.0/2.4L
4. Disconnect inlet hose from throttle body.
5. Remove wire harness clip from air tube.

6. Remove the electrical connector from the throttle body.
7. Remove throttle body support bracket and bolts.

8. Bracket removed and bolts.
9. Remove throttle body mounting bolts.

10. Throttle body O-ring (1) and location pins (2).

Throttle Body: Service and Repair Installation
2.0/2.4L
1. Make sure that the throttle body O-ring (1) is in place in the manifold.
2. Position throttle body on intake manifold alignment pins and install 2 mounting bolts. Do Not
tighten bolts at this time.
3. Install throttle body bracket.
4. Tighten throttle body bolts in a cross pattern to 9 Nm (79.5 in. lbs.).
5. Throttle body bracket installed.

6. Connect electrical connector to throttle body.
7. Install air tube and connect wiring harness to air tube.
9. A Scan Tool may be used to learn electrical parameters. Go to the Miscellaneous menu, and
then select ETC Relearn. If the relearn is not
preformed, a Diagnostic Trouble Code (DTC) will be set. If necessary, use a scan tool to erase any
Diagnostic Trouble Codes (DTC's) from PCM.
Jeep Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Variable Induction System >
Variable Induction Control Valve > Component Information > Locations
Variable Induction Control Valve: Locations
Component ID: 373
Component : VALVE-MANIFOLD FLOW
Connector:
Name : VALVE-MANIFOLD FLOW
Color : BLACK
# of pins : 6
Qualifier : (GAS)
1 GROUND Z916 16BK
2--

Variable Induction Control Valve > Component Information > Locations > Page 4087
Variable Induction Control Valve: Diagrams
Component ID: 373
Component : VALVE-MANIFOLD FLOW
Connector:
Name : VALVE-MANIFOLD FLOW
Color : BLACK
# of pins : 6
Qualifier : (GAS)
1 GROUND Z916 16BK
2--

Variable Induction Control Valve: Description and Operation
OPERATION
The World Engine is equipped with an intake manifold flow control valve to promote maximum
air/fuel atomization. The valve restricts airflow, causing it to tumble or swirl. The tumbling action
helps ensure that the fuel and air mix thoroughly and burn faster. The intake manifold flow control
valve and variable valve timing work together to improve fuel economy, idle stability, and
emissions.
The electrically controlled intake manifold flow control valve is located in the intake manifold at the
cylinder head. The intake manifold is constructed of composite material and divided into equal
length runners. At the end of each runner is an intake manifold flow control valve flap. The intake
manifold flow control valve actuator controls the flaps through a common shaft.
The intake manifold flow control valve actuator is a two-position torque motor that is pulse-width
driven by the GPEC1. The actuator is either energized to move the flaps out of the way to the
wide-open position or de-energized to move the flaps up, to a restricted position.
The intake manifold flow control valve actuator also contains a potentiometer feedback system to
aid in diagnosis. The potentiometer circuit reports the actual position of the intake manifold flow
control valve flaps. The GPEC1 compares the actual position with the desired position to ensure
that the system is functioning correctly. The intake manifold flow control valve flaps are the
mechanical components that restrict airflow to the intake ports. When the valves are moved
upward, airflow is restricted and tumble occurs. When the valves are flat against the manifold, the
full, unrestricted air charge flows to the intake ports.
It is energized under specific operating conditions: At high engine speeds (greater than 3600 rpm
on the 1.8 and 2.0 liter or greater than 4000 rpm on the 2.4 liter) or at wide-open throttle, the intake
manifold flow control valve actuator is energized and the flaps move to the wide-open position, at
lower engine speeds (less than 3600 rpm on the 1.8 and 2.0 liter or less than 4000 rpm on the 2.4
liter), the actuator is de-energized allowing the flaps to remain in the restricted position. The flap is
held at that position by the return spring.
Variable Induction Control Valve > Component Information > Service and Repair > Removal
Variable Induction Control Valve: Service and Repair Removal
REMOVAL
2. Remove air tube.
3. Disconnect electrical connector.
4. Remove 3 mounting screws.

Variable Induction Control Valve > Component Information > Service and Repair > Removal > Page 4093
5. Remove valve.
Variable Induction Control Valve: Service and Repair Installation
INSTALLATION
1. Make sure that slot in shaft is not damaged.
2. Make sure that tab in valve is not damaged.
3. Align tab in valve with slot in intake manifold shaft (2) and rotate valve counterclock wise until
valve drops onto location pin mounting (1).
4. Install mounting screws and tighten to 6 Nm (53 in.lbs.).

6. Install air tube.

Jeep Workshop Manuals > Powertrain Management > Ignition System > Firing Order > Component Information >
Specifications
DESCRIPTION
Jeep Workshop Manuals > Powertrain Management > Ignition System > Camshaft Position Sensor > Component
Information > Locations > Sensor-Camshaft 1/1 Position
Component ID: 293
Connector:
Color : BLACK
# of pins : 3
Qualifier : (GAS)
Information > Locations > Sensor-Camshaft 1/1 Position > Page 4104
Component ID: 294
Connector:
Color : BLACK
# of pins : 3
Qualifier : (GAS)
Information > Diagrams > Sensor-Camshaft 1/1 Position
Component ID: 293
Connector:
Color : BLACK
# of pins : 3
Qualifier : (GAS)
Information > Diagrams > Sensor-Camshaft 1/1 Position > Page 4110
Component ID: 294
Connector:
Color : BLACK
# of pins : 3
Qualifier : (GAS)
DESCRIPTION
OPERATION
5. Remove sensor.


6. Remove sensor.
Nm (79.5 in. lbs.).
connector.


Jeep Workshop Manuals > Powertrain Management > Ignition System > Condenser, Ignition > Component Information >
Condenser: Service and Repair Removal
REMOVAL
2. Remove the electrical connector from the ignition coil capacitor.
3. Remove mounting bolt and remove capacitor.

Jeep Workshop Manuals > Powertrain Management > Ignition System > Condenser, Ignition > Component Information >
Condenser: Service and Repair Installation
INSTALLATION
1. Install coil capacitor (with connector facing rearward) and mounting bolt and tighten to 10 Nm
(88.5 in. lbs.).

Jeep Workshop Manuals > Powertrain Management > Ignition System > Crankshaft Position Sensor > Component
Component ID: 296
Connector:
Color : BLACK
# of pins : 3
Connector:
Color : # of pins :
Qualifier : (GAS)

DESCRIPTION
- Engine RPM

code).
OPERATION
2.0/2.4L

2.0/2.4L

6. Lower vehicle.

Jeep Workshop Manuals > Powertrain Management > Ignition System > Ignition Coil > Component Information > Locations
> Capacitor-Ignition
Ignition Coil: Locations Capacitor-Ignition
Component ID: 46
Component : CAPACITOR-IGNITION
Connector:
Name : CAPACITOR-IGNITION
Color : NATURAL
# of pins : 1
Qualifier : (GAS)
1 FUSED MAIN RELAY OUTPUT K344 16BR/GY
> Capacitor-Ignition > Page 4151
Ignition Coil: Locations Coil-Ignition 1
Component ID: 48
Component : COIL-IGNITION 1
Connector:
Name : COIL-IGNITION 1
Color : DK. GRAY
# of pins : 3
Qualifier : (GAS)
1--
2 COIL 1 CONTROL K19 18DG/LB
Component ID: 49
Connector:
Color : DK. GRAY
# of pins : 3
Qualifier : (GAS)
1--
Component ID: 50
Connector:
Color : DK. GRAY
# of pins : 3
Qualifier : (GAS)
1--
Component ID: 51
Connector:
Color : DK. GRAY
# of pins : 3
Qualifier : (GAS)
1--
Jeep Workshop Manuals > Powertrain Management > Ignition System > Ignition Coil > Component Information > Diagrams
> Capacitor-Ignition
Ignition Coil: Diagrams Capacitor-Ignition
Component ID: 46
Component : CAPACITOR-IGNITION
Connector:
Name : CAPACITOR-IGNITION
Color : NATURAL
# of pins : 1
Qualifier : (GAS)
Ignition Coil: Diagrams Coil-Ignition 1
Component ID: 48
Connector:
Color : DK. GRAY
# of pins : 3
Qualifier : (GAS)
1--
2 COIL 1 CONTROL K19 18DG/LB
Component ID: 49
Connector:
Color : DK. GRAY
# of pins : 3
Qualifier : (GAS)
1--
Component ID: 50
Connector:
Color : DK. GRAY
# of pins : 3
Qualifier : (GAS)
1--
Component ID: 51
Connector:
Color : DK. GRAY
# of pins : 3
Qualifier : (GAS)
1--
> Page 4173
Ignition Coil: Description and Operation
DESCRIPTION
WARNING: The direct ignition system generates approximately 40,000 volts. Personal injury could
result from contact with this system.
The ignition coil is mounted on the valve cover.

Jeep Workshop Manuals > Powertrain Management > Ignition System > Ignition Coil > Component Information > Service
Ignition Coil: Service and Repair Removal
2.0/2.4L
The electronic ignition coil attaches directly to the valve cover.
2. Disconnect electrical connector from ignition coil.
3. Remove ignition coil mounting bolts.

4. Remove ignition coil.

Ignition Coil: Service and Repair Installation
2.0/2.4L
1. Install ignition coil.
2. Tighten bolt to 9 Nm (79.5 in. lbs.).

Jeep Workshop Manuals > Powertrain Management > Ignition System > Knock Sensor > Component Information >
Locations
Component ID: 308
Connector:
Name : SENSOR-KNOCK
Color : BLACK
# of pins : 2
Qualifier : (GAS)
Locations > Page 4181
Component ID: 308
Connector:
Name : SENSOR-KNOCK
Color : BLACK
# of pins : 2
Qualifier : (GAS)
DESCRIPTION
OPERATION
spark control.
Jeep Workshop Manuals > Powertrain Management > Ignition System > Knock Sensor > Component Information > Service
2.0/2.4L
manifold.


2.0/2.4L
manifold.

Jeep Workshop Manuals > Powertrain Management > Ignition System > Sensors and Switches - Ignition System >
Camshaft Position Sensor > Component Information > Locations > Sensor-Camshaft 1/1 Position
Component ID: 293
Connector:
Color : BLACK
# of pins : 3
Qualifier : (GAS)
Camshaft Position Sensor > Component Information > Locations > Sensor-Camshaft 1/1 Position > Page 4198
Component ID: 294
Connector:
Color : BLACK
# of pins : 3
Qualifier : (GAS)
Camshaft Position Sensor > Component Information > Diagrams > Sensor-Camshaft 1/1 Position
Component ID: 293
Connector:
Color : BLACK
# of pins : 3
Qualifier : (GAS)
Camshaft Position Sensor > Component Information > Diagrams > Sensor-Camshaft 1/1 Position > Page 4204
Component ID: 294
Connector:
Color : BLACK
# of pins : 3
Qualifier : (GAS)
Camshaft Position Sensor > Component Information > Description and Operation > Description
DESCRIPTION
Camshaft Position Sensor > Component Information > Description and Operation > Description > Page 4210
OPERATION
Camshaft Position Sensor > Component Information > Service and Repair > Removal
5. Remove sensor.

Camshaft Position Sensor > Component Information > Service and Repair > Removal > Page 4213

6. Remove sensor.
Nm (79.5 in. lbs.).
connector.


Crankshaft Position Sensor > Component Information > Locations
Crankshaft Position Sensor > Component Information > Locations > Page 4221
Component ID: 296
Connector:
Color : BLACK
# of pins : 3
Connector:
Color : # of pins :
Qualifier : (GAS)

Crankshaft Position Sensor > Component Information > Description and Operation > Description
DESCRIPTION
- Engine RPM

code).
Crankshaft Position Sensor > Component Information > Description and Operation > Description > Page 4230
OPERATION
Crankshaft Position Sensor > Component Information > Service and Repair > Removal
2.0/2.4L
Crankshaft Position Sensor > Component Information > Service and Repair > Removal > Page 4233

2.0/2.4L

6. Lower vehicle.

Jeep Workshop Manuals > Powertrain Management > Ignition System > Sensors and Switches - Ignition System > Ignition
Switch > Ignition Switch Lock Cylinder > Component Information > Service and Repair > Key/Lock Cylinder
Removal
REMOVAL
(2).
Switch > Ignition Switch Lock Cylinder > Component Information > Service and Repair > Key/Lock Cylinder > Page 4241

housing.
Installation
INSTALLATION
the RUN position.
clear tilt lever.
properly.
cylinder housing.
it.

Removal
REMOVAL
(2).
column.
housing.
Installation
INSTALLATION

clear tilt lever.
properly.
cylinder housing.
Jeep Workshop Manuals > Powertrain Management > Ignition System > Sensors and Switches - Ignition System > Knock
Component ID: 308
Connector:
Name : SENSOR-KNOCK
Color : BLACK
# of pins : 2
Qualifier : (GAS)
Component ID: 308
Connector:
Name : SENSOR-KNOCK
Color : BLACK
# of pins : 2
Qualifier : (GAS)
DESCRIPTION
OPERATION
spark control.
2.0/2.4L
manifold.


2.0/2.4L
manifold.

Jeep Workshop Manuals > Powertrain Management > Ignition System > Spark Plug > Component Information >
Specifications
SPARK PLUGS
Jeep Workshop Manuals > Powertrain Management > Ignition System > Spark Plug > Component Information > Service
2.0/2.4L


2.0/2.4L


Jeep Workshop Manuals > Powertrain Management > Transmission Control Systems > Actuators and Solenoids -
Transmission and Drivetrain > Actuators and Solenoids - CVT > Pressure Regulating Solenoid, CVT > Component
Pressure Regulating Solenoid: Locations
Component ID: 15
Connector:
Color : BLACK
# of pins : 22
6 GROUND Z967 18BK

12 - -
13 - -
14 - -
15 - -
20 - -
Pressure Regulating Solenoid: Diagrams
Component ID: 15
Connector:
Color : BLACK
# of pins : 22
6 GROUND Z967 18BK

12 - -
13 - -
14 - -
15 - -
20 - -
Transmission and Drivetrain > Actuators and Solenoids - CVT > Shift Solenoid, CVT > Component Information > Locations
Shift Solenoid: Locations
Component ID: 15
Connector:
Color : BLACK
# of pins : 22
6 GROUND Z967 18BK

12 - -
13 - -
14 - -
15 - -
20 - -
> Page 4287
> Page 4288
Shift Solenoid: Diagrams
Component ID: 15
Connector:
Color : BLACK
# of pins : 22
6 GROUND Z967 18BK

12 - -
13 - -
14 - -
15 - -
20 - -
> Page 4289
Transmission and Drivetrain > Actuators and Solenoids - Differential > Solenoid, Differential Lock > Component Information
> Locations
Solenoid: Locations
Component ID: 335
Component : SOLENOID-ELECTRONICALLY CONTROLLED CLUTCH
Connector:
Name : SOLENOID-ELECTRONICALLY CONTROLLED CLUTCH
Color : # of pins :
Qualifier : (ECC)
2 SOLENOID SUPPLY VOLTAGE T78 20YL
> Locations > Page 4294
Solenoid: Diagrams
Component ID: 335
Connector:
Color : # of pins :
Qualifier : (ECC)
Jeep Workshop Manuals > Powertrain Management > Transmission Control Systems > Lamps and Indicators -
Transmission and Drivetrain > Lamps and Indicators - Transfer Case > Four Wheel Drive Indicator Lamp > Component
Information > Description and Operation > Four-Wheel Drive Indicator
Four Wheel Drive Indicator Lamp: Description and Operation Four-Wheel Drive Indicator
Description
DESCRIPTION
A four-wheel drive indicator is standard equipment on all instrument clusters. However, on vehicles
not equipped with the optional Non-Trail Rated four-wheel drive system, this indicator is
electronically disabled. This indicator is located within the odometer Vacuum Fluorescent Display
(VFD) unit.
The four-wheel drive indicator consists of the text 4WD in the VFD display. The odometer VFD unit
is soldered onto the instrument cluster electronic circuit board, and is visible through a window with
a smoked clear lens located on the lower edge of the tachometer gauge dial face of the cluster
overlay. The dark lens over the VFD prevents it from being clearly visible when it is not illuminated.
The four-wheel drive indicator text appears in an amber color and at the same lighting level as the
odometer information when it is illuminated by the instrument cluster electronic circuit board.
During daylight hours (exterior lamps are OFF) the odometer VFD unit is illuminated at full
brightness for clear visibility. At night (exterior lamps are ON), the VFD lighting level is adjusted
with the other cluster illumination lamps using the panel lamps dimmer function of the interior
lighting control sleeve on the left multi-function switch control stalk. However, a PARADE mode
position of the control sleeve allows the VFD unit to be illuminated at full brightness if the exterior
lamps are turned ON during daylight hours.
The four-wheel drive indicator is serviced as a unit with the odometer VFD unit in the instrument
cluster.
Operation
OPERATION
The four-wheel drive indicator gives an indication to the vehicle operator when the Four Wheel
Drive (4WD) Lock mode of the Continuously Variable Transmission (CVT) is activated. This
indicator is controlled by the instrument cluster circuit board based upon cluster programming and
electronic messages received by the cluster from the All Wheel Drive Control Module (AWDCM)
over the Controller Area Network (CAN) data bus.
The four-wheel drive indicator is completely controlled by the instrument cluster logic circuit, and
that logic will only allow this indicator to operate when the instrument cluster receives a battery
current input on the fused ignition switch output (run-start) circuit. Therefore, the indicator will
always be OFF when the ignition switch is in any position except ON or START. The indicator only
illuminates when it is energized by the instrument cluster logic circuit. The instrument cluster will
turn ON the cruise indicator for the following reasons:
- Four-Wheel Drive Indicator Lamp-On Message - Each time the cluster receives an electronic
four-wheel drive indicator lamp-ON message from the AWDCM indicating the Lock mode is
activated, the four-wheel drive indicator is illuminated. The indicator remains illuminated until the
cluster receives a lamp-OFF message from the AWDCM, or until the ignition switch is turned to the
OFF position, whichever occurs first.
- Actuator Test - Each time the cluster is put through the actuator test, the four-wheel drive
indicator will be turned ON, then OFF again during the Vacuum Fluorescent Display (VFD) portion
of the test in order to confirm the functionality of the VFD and the cluster control circuitry.
The AWDCM continually monitors electronic four-wheel drive Lock switch request messages from
Node/CCN) to determine when the Lock mode should be activated. The AWDCM then sends the
proper lamp-ON or lamp-OFF message back to the EMIC after the Lock mode is activated or
deactivated.
Information > Description and Operation > Four-Wheel Drive Indicator > Page 4303
For proper diagnosis of the four-wheel drive Lock switch, the AWDCM, the EMIC, the CAN data
bus or the electronic communication related to four-wheel drive indicator operation a diagnostic
Four Wheel Drive Indicator Lamp: Description and Operation Off Road Indicator
Description
DESCRIPTION
An off road indicator is standard equipment on all instrument clusters. However, on vehicles not
equipped with the Trail Rated four-wheel drive system, this indicator is electronically disabled. This
indicator is located within the odometer Vacuum Fluorescent Display (VFD) unit.
The off road indicator consists of the text OFF ROAD in the VFD unit. The odometer VFD unit is
soldered onto the instrument cluster electronic circuit board, and is visible through a window with a
smoked clear lens located on the lower edge of the tachometer gauge dial face of the cluster
The off road indicator text appears in an amber color and at the same lighting level as the
The off road indicator is serviced as a unit with the odometer VFD unit in the instrument cluster.
Operation
OPERATION
The off road indicator gives an indication to the vehicle operator when the Four Wheel Drive Lock
Mode of the Trail Rated Continuously Variable Transmission (CVT) is activated and the
transmission gear selector is in the Low or Reverse positions. This indicator is controlled by the
instrument cluster circuit board based upon cluster programming and electronic messages received
by the cluster from the All Wheel Drive Control Module (AWDCM) over the Controller Area Network
(CAN) data bus.
The off road indicator is completely controlled by the instrument cluster logic circuit, and that logic
will only allow this indicator to operate when the instrument cluster receives a battery current input
on the fused ignition switch output (run-start) circuit. Therefore, the indicator will always be OFF
when the ignition switch is in any position except ON or START. The indicator only illuminates
when it is energized by the instrument cluster logic circuit. The instrument cluster will turn ON the
Off Road indicator for the following reasons:
- Off Road Indicator Lamp-On Message - Each time the cluster receives an electronic off road
indicator lamp-ON message from the AWDCM indicating the off road mode is activated, the off
road indicator is illuminated. The indicator remains illuminated until the cluster receives a
lamp-OFF message from the AWDCM, or until the ignition switch is turned to the OFF position,
whichever occurs first.
- Actuator Test - Each time the cluster is put through the actuator test, the off road indicator will be
turned ON, then OFF again during the Vacuum Fluorescent Display (VFD) portion of the test in
order to confirm the functionality of the VFD and the cluster control circuitry.
The AWDCM continually monitors the CVT automatic transmission gear selector and the Four
Wheel Drive Lock switch request messages from the ElectroMechanical Instrument Cluster (EMIC)
(also known as the Cab Compartment Node/CCN) to determine when the off road mode should be
activated. The AWDCM then sends the proper lamp-ON or lamp-OFF message to the EMIC.
For proper diagnosis of the Four Wheel Drive Lock switch, the AWDCM, the EMIC, the CAN data
bus or the electronic communication related to off road indicator operation a diagnostic scan tool is
required.
Transmission and Drivetrain > Lamps and Indicators - Transfer Case > Malfunction Indicator Lamp - Transfer Case >
Malfunction Indicator Lamp - Transfer Case: Description and Operation Description
DESCRIPTION
A service 4WD indicator is standard equipment on all instrument clusters. However, on vehicles not
equipped with the optional four-wheel drive system, this indicator is electronically disabled. This
indicator is located near the lower edge of the cluster overlay, between the speedometer and the
tachometer.
The service 4WD indicator consists of a stencil-like cutout of the text 4WD. in the opaque layer of
the instrument cluster overlay. The dark outer layer of the overlay prevents the indicator from being
clearly visible when it is not illuminated. An amber Light Emitting Diode (LED) behind the cutout in
the opaque layer of the overlay causes the indicator to appear in amber through the translucent
outer layer of the overlay when it is illuminated from behind by the LED, which is soldered onto the
The service 4WD indicator is serviced as a unit with the instrument cluster.
Malfunction Indicator Lamp - Transfer Case: Description and Operation Operation
OPERATION
The service 4WD indicator gives an indication to the vehicle operator when the Constantly Variable
Transmission Control Module (CVTCM) has recorded a Diagnostic Trouble Code (DTC) for an
Electronically Controlled Coupling (ECC) circuit or component malfunction. This indicator is
and electronic messages received by the cluster from the CVTCM over the Controller Area
Network (CAN) data bus.
The service 4WD indicator Light Emitting Diode (LED) is completely controlled by the instrument
transistor. The instrument cluster will turn ON the service 4WD indicator for the following reasons:
- Bulb Test - Each time the ignition switch is turned to the ON position the service 4WD indicator is
illuminated for about two seconds as a bulb test.
- Service 4WD Indicator Lamp-On Message - Each time the cluster receives an electronic service
4WD indicator lamp-ON message from the CVTCM, the service 4WD indicator will be illuminated.
The indicator remains illuminated until the cluster receives a lamp-OFF message from the CVTCM,
or until the ignition switch is turned to the OFF position, whichever occurs first.
- Communication Error - If the cluster receives no lamp-ON or lamp-OFF messages from the
CVTCM for 10 seconds, the service 4WD indicator is illuminated by the cluster to indicate a loss of
CVTCM communication. The indicator remains controlled and illuminated by the cluster until a valid
message is received from the CVTCM.
- Actuator Test - Each time the cluster is put through the actuator test, the service 4WD indicator
The CVTCM continually monitors the ECC control circuits and sensors to determine the condition
of the system. The CVTCM then sends the proper lamp-ON or lamp-OFF message to the
ElectroMechanical Instrument Cluster (EMIC). For further diagnosis of the service 4WD indicator or
the instrument cluster circuitry that controls the LED.
For proper diagnosis of the CVTCM, the ECC, the EMIC, the CAN data bus or the electronic
communication related to service 4WD indicator operation a diagnostic scan tool is required.
Jeep Workshop Manuals > Powertrain Management > Transmission Control Systems > Relays and Modules - Transmission
and Drivetrain > Relays and Modules - A/T > Control Module, A/T > Component Information > Technical Service Bulletins >
Engine, A/T Controls - PCM/TCM Replacement Requirements
Requirements
INTERNET.

BULLETIN.
MODELS:
2007 (MK49) Compass
2007 (MK74) Patriot
2007 (PM) Caliber
NOTE:
DISCUSSION:
below.
CAUTION:
PARTS REQUIRED:
CAUTION:

down load.
CAUTION:
PROCESS.
NOTE:
NOTE:
NOTE:
drop.
seconds.
CAUTION:
NOTE:
PCM.
NOTE:
StarSCAN(R) screen.
NOTE:
list.

File List" screen?
with step 9.
NOTE:
CAUTION:

down load.
NOTE:
NOTE:
NOTE:
down load.
drop.
number.
NOTE:


File List" screen?
with step 7.
NOTE:
TIME ALLOWANCE:
FAILURE CODE:
Disclaimer:
NUMBER: 18-039-06
INTERNET.
BULLETIN.
SUBJECT:
CAUTION:

BE INSTALLED.
MODELS:
2007 (PM) Caliber
2007 (MK49) Compass
NOTE:
(MDH 1120XX).
NOTE:
DIAGNOSIS:
PARTS REQUIRED:
CAUTION:
NOTE:

seconds.
CAUTION:
PROCESS.
NOTE:
NOTE:
TIME ALLOWANCE:
FAILURE CODE:
Disclaimer:
and Drivetrain > Relays and Modules - CVT > Control Module, CVT > Component Information > Technical Service Bulletins
> Customer Interest for Control Module: > 18-032-07 > May > 07 > A/T - MIL ON Possible DTC P2004
NUMBER: 18-032-07
DATE: May 16, 2007
INTERNET.
BULLETIN.
CAUTION:

BE INSTALLED.
MODELS:
2007 (JS) Sebring
2007 (MK49) Compass
2007 (MK74) Patriot
2007 (PM) Caliber
NOTE:
SYMPTOM/CONDITION:
DIAGNOSIS:
PARTS REQUIRED:
> Customer Interest for Control Module: > 18-032-07 > May > 07 > A/T - MIL ON Possible DTC P2004 > Page 4334
CAUTION:
NOTE:
NOTE:
NOTE:
drop.

seconds.
CAUTION:

PROCESS.
NOTE:
seconds.
CAUTION:
NOTE:
NOTE:
TIME ALLOWANCE:
FAILURE CODE:
Disclaimer:
> All Technical Service Bulletins for Control Module: > 18-032-07 > May > 07 > A/T - MIL ON Possible DTC P2004
NUMBER: 18-032-07
DATE: May 16, 2007
INTERNET.
BULLETIN.
CAUTION:

BE INSTALLED.
MODELS:
2007 (JS) Sebring
2007 (MK49) Compass
2007 (MK74) Patriot
2007 (PM) Caliber
NOTE:
SYMPTOM/CONDITION:
DIAGNOSIS:
PARTS REQUIRED:
> All Technical Service Bulletins for Control Module: > 18-032-07 > May > 07 > A/T - MIL ON Possible DTC P2004 > Page
4342
CAUTION:
NOTE:
NOTE:
NOTE:
drop.

4343
seconds.
CAUTION:

PROCESS.
NOTE:
seconds.
CAUTION:
NOTE:
4344
NOTE:
TIME ALLOWANCE:
FAILURE CODE:
Disclaimer:
> Page 4345
Component ID: 170
Connector:
Color : WHITE
# of pins : 24
Qualifier : (CVT)

7--
8--
9--
16 - -
17 - -
23 - -
24 - -
> Page 4346
> Page 4347
Connector:
Color : LT. GRAY
# of pins : 24
Qualifier : (CVT)
1 GROUND Z967 18BK
3--
4 FUSED B(+) (I.O.D.) A416 18RD

> Page 4348
6--
7--
8--
9--
11 - -

15 - -
16 - -
24 GROUND Z967 18BK
> Page 4349
> Page 4350
Component ID: 170
Connector:
Color : WHITE
# of pins : 24
Qualifier : (CVT)

7--
8--
9--
16 - -
17 - -
23 - -
24 - -
> Page 4351
> Page 4352
Connector:
Color : LT. GRAY
# of pins : 24
Qualifier : (CVT)
1 GROUND Z967 18BK
3--
4 FUSED B(+) (I.O.D.) A416 18RD

> Page 4353
6--
7--
8--
9--
11 - -

15 - -
16 - -
24 GROUND Z967 18BK
> Page 4354
and Drivetrain > Relays and Modules - CVT > Control Module, CVT > Component Information > Description and Operation
> Description
DESCRIPTION
> Description > Page 4357
OPERATION
Shift Control
"Drive" Position
gear ranges.
Lock-up Control
Selection Control
CAN Communication
Inputs and Outputs

Fail-safe Function
PNP Switch
Lock-up solenoid
Stepping Motor
Backup Power Supply
TCM
and Drivetrain > Relays and Modules - CVT > Control Module, CVT > Component Information > Service and Repair >
Removal
REMOVAL
Removal > Page 4364
4. Remove the TCM.

Removal > Page 4365
INSTALLATION

and Drivetrain > Relays and Modules - Transfer Case > Control Module, Transfer Case > Component Information >
Locations
Component ID: 150
Connector:
Color : # of pins :
16
Qualifier : (AWD)
1--
2--
3--

7--
9--
10 - -
11 - -
13 - -
14 - -
15 GROUND Z967 20BK
Component ID: 150
Connector:
Color : # of pins :
16
Qualifier : (AWD)
1--
2--
3--

7--
9--
10 - -
11 - -
13 - -
14 - -
15 GROUND Z967 20BK
DESCRIPTION
bus.
OPERATION
torque transfer.
condition as well.
fuel economy.
and Drivetrain > Relays and Modules - Transfer Case > Control Module, Transfer Case > Component Information > Service
REMOVAL

and Drivetrain > Relays and Modules - Transfer Case > Control Module, Transfer Case > Component Information > Service
INSTALLATION

Jeep Workshop Manuals > Powertrain Management > Transmission Control Systems > Sensors and Switches -
Transmission and Drivetrain > Sensors and Switches - CVT > Fluid Pressure Sensor/Switch, CVT > Component Information
> Locations
Component ID: 15
Connector:
Color : BLACK
# of pins : 22
6 GROUND Z967 18BK

12 - -
13 - -
14 - -
15 - -
20 - -
Component ID: 15
Connector:
Color : BLACK
# of pins : 22
6 GROUND Z967 18BK

12 - -
13 - -
14 - -
15 - -
20 - -
Transmission and Drivetrain > Sensors and Switches - CVT > Transmission Position Switch/Sensor, CVT > Component
Component ID: 15
Connector:
Color : BLACK
# of pins : 22
6 GROUND Z967 18BK

12 - -
13 - -
14 - -
15 - -
20 - -
Transmission and Drivetrain > Sensors and Switches - CVT > Transmission Speed Sensor, CVT > Component Information
> Locations
Component ID: 15
Connector:
Color : BLACK
# of pins : 22
6 GROUND Z967 18BK

12 - -
13 - -
14 - -
15 - -
20 - -
Transmission and Drivetrain > Sensors and Switches - CVT > Transmission Temperature Sensor/Switch, CVT >
DESCRIPTION


OPERATION
following reasons:
service.
Transmission and Drivetrain > Sensors and Switches - M/T > Transmission Speed Sensor, M/T > Component Information >
REMOVAL
INSTALLATION
Transmission and Drivetrain > Sensors and Switches - Transfer Case > Four Wheel Drive Selector Switch > Component
Component ID: 366
Connector:
Color : BLACK
# of pins : 6
Gender : FEMALE
3--
4--

Component ID: 366
Connector:
Color : BLACK
# of pins : 6
Gender : FEMALE
3--
4--

Jeep Workshop Manuals > Powertrain Management > PROM - Programmable Read Only Memory > Component
Information > Technical Service Bulletins > Customer Interest: > 18-005-09A > Mar > 09 > Engine Controls - MIL ON/DTC
P2610 Stored In Memory
PROM - Programmable Read Only Memory: Customer Interest Engine Controls - MIL ON/DTC
DATE: March 6, 2009
THIS BULLETIN SUPERSEDES TECHNICAL SERVICE BULLETIN 18-005-09, DATED

FEBRUARY 11, 2009, WHICH SHOULD BE REMOVED FROM YOUR FILES. ALL REVISIONS
ARE HIGHLIGHTED WITH **ASTERISKS** AND INCLUDE THE ADDITION OF MODEL YEARS,
VEHICLES BODIES, ENGINES AND A UPDATED SYMPTOM/CONDITION AND DIAGNOSIS
SECTIONS.
INTERNET.
StarSCAN(R) SOFTWARE LEVEL MUST BE AT RELEASE 9.04 OR HIGHER.
StarMOBILE STANDALONE MODE OR StarMOBILE DESKTOP CLIENT MAY ALSO BE USED

TO PERFORM THIS PROCEDURE.
SUBJECT: Flash: MIL Illumination For P2610 - PCM Internal Engine Off Timer Performance
OVERVIEW: This bulletin involves flash reprogramming the Powertrain Control Module (PCM) with
new software.
MODELS:
**2008** - 2009 (PM) Caliber SRT-4
**2007 - 2008 (PM) Caliber**
**2007 - 2008 (MK) Compass/Patriot**
NOTE:
**This bulletin applies to vehicles built with a 1.8L, 2.0L, 2.4L and 2.4L turbo engine (Sales Codes
EBA, ECN, ED3 and ED4) and a engine block heater (sales code NHK) built before February 2,
2009 (MDH 0202xx)**.
NOTE:
**This bulletin does not apply to Japan market vehicles.**
SYMPTOM/CONDITION:
**Some customers may experience a MIL illumination after they have used their engine block
heater. Upon further investigation the Technician may find that P2610 - PCM Internal Engine Off
Timer Performance has been set.
This is caused by the engine block heater (by design) keeping the engine block warm and the logic
in the PCM was expecting a quicker cool down then was actually achieved. The updated software
compensates for the use of the engine block heater. **
DIAGNOSIS: Using a Scan Tool (StarSCAN(R)) with the appropriate Diagnostic Procedures
available in TechCONNECT, verify all engine systems are functioning as designed. If DTC's other
then the one listed above are present record them on the repair order and repair as necessary
before proceeding further with this bulletin.
**If the vehicle operator describes or experiences the Symptom/Condition, perform the Repair
Procedure. If the engine block heater was not in use when the code was set then it will be
necessary to preform the diagnostics available DealerCONNECT/TechCONNECT, Refer To Group
28 - DTC Based Diagnostics > Module - Powertrain Controller > Diagnostic and Testing > P2610 -
PCM Internal Engine Off Timer Performance has been set.**
PARTS REQUIRED:
Information > Technical Service Bulletins > Customer Interest: > 18-005-09A > Mar > 09 > Engine Controls - MIL ON/DTC
P2610 Stored In Memory > Page 4422
REPAIR PROCEDURE:
NOTE:
1. Reprogram the PCM with the latest software. Follow the detailed service procedures available in
DealerCONNECT/TechCONNECT, Refer To Group 8 - Electrical > Electronic Control Modules -
Service Information > Module - Powertrain Control > Standard Procedures > PCM/ECM
Programming - Gas.
2. Type the necessary information on the "Authorized Modification Label and attach it near the
VECI label.
TIME ALLOWANCE:
FAILURE CODE:
Disclaimer:
Information > Technical Service Bulletins > Customer Interest: > 18-016-08A > Sep > 08 > Engine Controls - MIL ON/DTC
THIS BULLETIN SUPERSEDES TECHNICAL SERVICE BULLETIN 18-016-08, DATED APRIL 23,
2008, WHICH SHOULD BE REMOVED FROM YOUR FILES. ALL REVISIONS ARE
HIGHLIGHTED WITH **ASTERISKS** AND INCLUDE THE ADDITION OF 2007 MODEL YEAR.
INTERNET.
StarMOBILE DESKTOP CLIENT -OR- StarMOBILE STANDALONE MODE MAY ALSO BE USED
TO PERFORM THE FLASH.
SUBJECT: Flash: MIL Illumination with DTC P0171
Module (PCM).
NOTE:
Vehicles equipped with a CVT transmission must have the transmission control module (TCM)
checked for the latest software level whenever the PCM software is updated. If newer TCM
software is available, it must be installed. Failure to maintain software coordination may result in
MIL illumination or driveability concerns.
MODELS:
**2007** - 2008 (MK49) Compass
**2007** - 2008 (MK74) Patriot
**2007** - 2008 (PM) Caliber
NOTE:
This Bulletin applies to **2007 and** 2008 models equipped with a 2.4L engine & automatic CVT
transmission (Sales Code ED3 with DAV or DAW) built prior to April 2, 2008 (MDH 0402XX).
SYMPTOM/CONDITION: Some customers may experience intermittent MIL Illumination. This may
be noticed after driving at high speeds, up grades or towing trailers (heavy engine load). No other
symptoms will be noted or experienced. Further investigation by the technician may find DTC
P0171 - Fuel System 1/1 Lean.
than those listed above are present record them on the repair order and repair as necessary before
If the above symptom/condition is experienced and cause for the DIG cannot be determined,
perform the Repair Procedure.
PARTS REQUIRED:

NOTE:
Programming - Gas.
2. Type the necessary information on the "Authorized Modification Label" and attach it near the
VECI label.
TIME ALLOWANCE:
FAILURE CODE:
Disclaimer:
Information > Technical Service Bulletins > Customer Interest: > 18-017-08A > Sep > 08 > Engine Controls - Idle Vibration
With Throttle Closed
PROM - Programmable Read Only Memory: Customer Interest Engine Controls - Idle Vibration
With Throttle Closed
THIS BULLETIN SUPERSEDES TECHNICAL SERVICE BULLETIN, 18-017-08 DATED APRIL 23,
INTERNET.
SUBJECT: Flash: Idle Vibration From a Stop With Closed Throttle
Module (PCM).
NOTE:
MODELS:
**2007** - 2008 (MK49) Compass
**2007** - 2008 (MK74) Patriot
**2007** - 2008 (PM) Caliber
NOTE:
This Bulletin applies to **2007 and** 2008 models equipped with a 2.0L or 2.4L engine & automatic
CVT transmission (Sales Code ECN or ED3 with DAV or DAW) built prior to April 2, 2008 (MDH
0402XX).
SYMPTOM/CONDITION:
Some customers may experience an idle vibration. The condition may occur under the following
parameters:
^ Vehicle in Drive.
^ No throttle input (foot "Off" accelerator pedal).
^ Foot "Off" Brake.
^ Vehicle speed between 0 and 5 miles per hour.
available in TechCONNECT, verify all engine systems are functioning as designed. If DTC's are
present record them on the repair order and repair as necessary before proceeding further with this
bulletin.
If the above symptom/condition is experienced or can be verified by duplicating the conditions

described above, perform the Repair Procedure.
Information > Technical Service Bulletins > Customer Interest: > 18-017-08A > Sep > 08 > Engine Controls - Idle Vibration
With Throttle Closed > Page 4432
PARTS REQUIRED:

NOTE:
Programming - Gas.
VECI label.
TIME ALLOWANCE:
FAILURE CODE:
Disclaimer:
THIS BULLETIN SUPERSEDES TECHNICAL SERVICE BULLETIN 18-019-08, DATED April 25,
INTERNET.
Module (PCM).
NOTE:
MODELS:
**2007** - 2008 (MK49) Compass
**2007** - 2008 (MK74) Patriot
**2007** - 2008 (PM) Caliber
NOTE:
**This Bulletin applies to:
^ 2007 models equipped with a 1.8L, 2.0L or 2.4L (Sales Code EBA, ECN or ED3)
^ **2008 models equipped with a 2.0L or 2.4L engine & automatic CVI2 transmission (Sales Code
ECN or ED3 with DAV or DAW) built prior to April 2, 2008 (MDH 0402XX) or 1.8L/2.4L Engine with
Manual transmission (Sales Code EBA or ED3 with DD7) built prior to February 3, 2008
(MDHO2O3XX).**
SYMPTOM/CONDITION: Some customers may experience intermittent MIL illumination with

electronic throttle control (ETC) lamp Illumination. This may occur during high vehicle speeds or
load conditions. Limp in may occur. If the vehicle ignition is "Keyed off and the vehicle restarted,
the vehicle will operate normally. Further investigation by the technician may find DIG P2173 - High
Airflow/Vacuum Leak Detected (Slow Accumulation).
than P2173 are present record them on the repair order and repair as necessary before proceeding
further with this bulletin.
If the above symptom/condition is experienced and the cause for the condition cannot be
determined, perform the Repair Procedure.
PARTS REQUIRED:

NOTE:
Programming - Gas.
VECI label.
TIME ALLOWANCE:
FAILURE CODE:
Disclaimer:
Information > Technical Service Bulletins > Customer Interest: > 18-011-08C > Jul > 08 > Engine Controls - MIL ON/DTC's
P0139 or P2270
PROM - Programmable Read Only Memory: Customer Interest Engine Controls - MIL ON/DTC's
P0139 or P2270
NUMBER: 18-011-08 REV. C
DATE: July 23, 2008
THIS BULLETIN SUPERSEDES TECHNICAL SERVICE BULLETIN 18-011-08 REV. B DATED

JUNE 18, 2008 WHICH SHOULD BE REMOVED FROM YOUR FILES. IT ALSO INCLUDES THE
NEWEST SOFTWARE TO ADDRESS P0139 REFERENCES IN SERVICE BULLETINS 18-015-06
AND 18-033-06. ALL REVISIONS ARE HIGHLIGHTED WITH **ASTERISKS** AND INCLUDE
THE ADDITION OF 2007 AND EARLY BUILT 2008 JS MODEL AND ENGINE APPLICATION
ADDITIONS.
INTERNET.
SUBJECT: Flash: MIL Illumination with DIG P0139 or P2270
Module (PCM).
NOTE:
MODELS:
**2007 - 2008 (JS) Avenger/Sebring/Sebring Convertible**
2007 - 2008 (MK49) Compass
2007 - 2008 (MK74) Patriot
2007 - 2008 (PM) Caliber
NOTE:
This bulletin applies to:
^ 2007 **PM/MK** models equipped with a 1.8L, 2.0L, or 2.4L engine & any transmission (Sales
Code EBA, ECN or ED3 with DAV, DAW or DD7),
^ **2007 JS vehicles equipped with a 2.4L engine (Sales Code ED3).**
^ 2008 PM/MK models equipped with a 2.0L or 2.4L engine & automatic CVI transmission (Sales
Code ECN or ED3 with DAV or DAW) built prior to January 22, 2008 (MDH 0123XX),
^ 2008 PM/MK models equipped with a 1.8L or 2.4L engine & Manual transmission (Sales Code
EBA or ED3 with DD7) built prior to February 3, 2008 (MDHO2O3XX).
^ **2008 JS vehicles equipped with a 2.4L engine (Sales Code EDG or ED3) built before
January24, 2008 (MDH 0124xx).**
SYMPTOM/CONDITION: Some customers may experience intermittent MIL Illumination. No other
P0139 - 02 Sensor 1/2 Slow Response or DTC P2270 - 02 Sensor 1/2 Signal Biased Lean.
Information > Technical Service Bulletins > Customer Interest: > 18-011-08C > Jul > 08 > Engine Controls - MIL ON/DTC's
P0139 or P2270 > Page 4442
If the above symptom/condition is experienced and cause for DTC's cannot be determined, perform
the Repair Procedure.
PARTS REQUIRED:
NOTE:
Programming - Gas.
VECI label.
TIME ALLOWANCE:
FAILURE CODE:
Disclaimer:
Information > Technical Service Bulletins > Customer Interest: > 18-018-07A > May > 07 > Engine Controls - MIL ON/DTC's
P0016/P0017/P000A/P000B
PROM - Programmable Read Only Memory: Customer Interest Engine Controls - MIL ON/DTC's
P0016/P0017/P000A/P000B
DATE: May 30, 2007

HIGHLIGHTED WITH **ASTERISKS** AND INCLUDE ADDITIONAL DIAGNOSTIC CHECKS FOR
APPROPRIATE OIL PRESSURE.
INTERNET.
BULLETIN.
SUBJECT: Flash: MIL Illumination with DTC's P0016, P0017, P000A, or P000B
Control Module (PCM) with new software, **verifying oil pressure specifications**, replacing the
intake and exhaust oil control valves (OCV), and replacing the engine oil and filter.
CAUTION:

BE INSTALLED.
MODELS:
2007 (JS) Sebring
2007 (MK49) Compass
2007 (MK74) Patriot
2007 (PM) Caliber
NOTE:
EBA, ECN or ED3) on PM/MK models built before February 20, 2007 (MDH 0220XX) and JS
models built before March 5, 2007 (M DH0305XX).
SYMPTOM/CONDITION:
Some customers may experience MIL illumination. Performance issues may or may not be
experienced.
^ P0016-Crankshaft-Camshaft Timing Misalignment-Bank 1 Sensor 1.
^ P000A-Bank 1 Camshaft 1 Position Slow Response.

^ P000B-Bank 1 Camshaft 2 Position Slow Response.
The DTC's may be intermittent and difficult to duplicate.
DIAGNOSIS:
TechCONNECT, verify all engine systems are functioning as designed. If DTC's other than those
P0016/P0017/P000A/P000B > Page 4447
**Verify that the oil pressure meets specifications as listed in DealerCONNECT > TechCONNECT.
If the oil pressure does not meet specifications, the OCV will be unable to function properly. In this
case, further diagnosis will be required to determine the cause of inappropriate oil pressure.**
**If the Oil Pressure meets specifications, DTC's are present and cannot be duplicated, perform the
Repair Procedure**.
PARTS REQUIRED:
FLASH REPAIR PROCEDURE - USING THE INTERNET TO RETRIEVE THE FLASH FILE:
CAUTION:
NOTE:
NOTE:
to the StarSCAN® Quick Start Networking Guide.
The StarSCAN(R) Quick Start Networking Guide is also available on the website under the
"Download Center".
NOTE:
2. Connect the CH9410 StarSCAN® ethernet cable to the StarSCAN(R) and the dealer's network
drop.
P0016/P0017/P000A/P000B > Page 4448
seconds.
CAUTION:

PROCESS.
NOTE:
6. Using the StarSCAN(R) at the "Home screen:
b. Touch the screen to highlight the 1CM in the list of modules.
8. Flash reprogram the 1CM as follows:

P0016/P0017/P000A/P000B > Page 4449
f. Verify the part number at the top of the "Flash TCM screen has updated to the new part number.
seconds.
CAUTION:
PROCESS.
NOTE:
NOTE:
10. Following the procedures listed in DealerCONNECT > TechCONNECT, replace both intake
and exhaust Oil Control Valves pn 04884695AA and 04884483AA.
11. Replace the engine oil and filter.

P0016/P0017/P000A/P000B > Page 4450
TIME ALLOWANCE:
FAILURE CODE:
Disclaimer:
Information > Technical Service Bulletins > Customer Interest: > 18-032-07 > May > 07 > A/T - MIL ON Possible DTC
P2004
PROM - Programmable Read Only Memory: Customer Interest A/T - MIL ON Possible DTC P2004
NUMBER: 18-032-07
DATE: May 16, 2007
INTERNET.
BULLETIN.
CAUTION:

BE INSTALLED.
MODELS:
2007 (JS) Sebring
2007 (MK49) Compass
2007 (MK74) Patriot
2007 (PM) Caliber
NOTE:
SYMPTOM/CONDITION:
DIAGNOSIS:
PARTS REQUIRED:
P2004 > Page 4455
CAUTION:
NOTE:
NOTE:
NOTE:
drop.

P2004 > Page 4456
seconds.
CAUTION:

PROCESS.
NOTE:
seconds.
CAUTION:
NOTE:
P2004 > Page 4457
NOTE:
TIME ALLOWANCE:
FAILURE CODE:
Disclaimer:
Information > Technical Service Bulletins > Customer Interest: > 18-031-07 > Apr > 07 > Engine Controls - Low Accel.
Performance/Ticking Noise
PROM - Programmable Read Only Memory: Customer Interest Engine Controls - Low Accel.
Performance/Ticking Noise
NUMBER: 18-031-07
DATE: April 28, 2007
INTERNET.

BULLETIN.
SUBJECT: Flash: Launch Performance / Driveability Enhancements
OVERVIEW:
This bulletin involves selectively erasing and reprogramming the GPEC Powertrain Control Module
(PCM) with new software.
CAUTION:

BE INSTALLED.
MODELS:
2007 (MK49) Compass
2007 (MK74) Patriot
2007 (PM) Caliber
NOTE:
EBA, ECN or ED3) on PM/MK models built before April 21, 2007 (MDH 0421XX).
SYMPTOM/CONDITION:
Some customers may experience the following:
^ Automatic CVI models - Perceived lack of performance under light to moderate acceleration from
a stop.
^ All Models - Ticking Sound intermittently heard from the engine compartment.
Software changes have been made to improve the above bullet points. In addition, changes to
maximum RPM in neutral have been made to assist A/C compressor function during cold ambient
temperatures to prevent A/C compressor slugging.
DIAGNOSIS:
TechCONNECT, verify all engine Systems are functioning as designed. If DIG's other than those
If the above symptoms are described by the customer, perform the Repair Procedure.
PARTS REQUIRED:
Performance/Ticking Noise > Page 4462
CAUTION:
NOTE:
NOTE:
NOTE:
drop.

seconds.
CAUTION:

PROCESS.
NOTE:
seconds.
CAUTION:
PROCESS.
NOTE:
NOTE:
attach near the VECI label (Fig 1).
TIME ALLOWANCE:
FAILURE CODE:
Disclaimer:
Information > Technical Service Bulletins > Customer Interest: > 18-005-07 > Jan > 07 > Engine Controls - MIL ON/DTC
P0128 Set
P0128 Set
NUMBER: 18-005-07
DATE: January 24, 2007
INTERNET.
BULLETIN.
SUBJECT:
Flash - P0128 Thermostat Rationality
Module (PCM) and the Transmission Control Module (TCM) with new software.
CAUTION:

BE INSTALLED.
MODELS:
2007 (MK49) Compass
NOTE:
This bulletin applies to MK models equipped with a 2.4L gasoline engine (Sales Code ED3) and
CVT transmission (Sales Code DAV) with AWD built before August 16, 2006 (MDH 0816XX).
SYMPTOM/CONDITION:
Some vehicle operators may experience MIL illumination after a cold start with long idle time,
(greater than 20 minutes). This is usually accompanied with minimal accessory loads. No other
symptoms will be experienced.
The technician may find the DTC:
P0128 - THERMOSTAT RATIONALITY
DIAGNOSIS:
Using a Scan Tool (StarSCAN(R) with the appropriate Diagnostic Procedures available in
TechCONNECT, verify all engine systems are functioning as designed. If DTC's other than P0128
are present, record them on the repair order and repair as necessary before proceeding further
with this bulletin.
PARTS REQUIRED:
P0128 Set > Page 4469
CAUTION:
NOTE:
NOTE:
NOTE:
drop.


P0128 Set > Page 4470
seconds.
CAUTION:

PROCESS.
NOTE:
seconds.
CAUTION:
PROCESS.
NOTE:
NOTE:
P0128 Set > Page 4471
TIME ALLOWANCE:
FAILURE CODE:
Disclaimer:
Information > Technical Service Bulletins > Customer Interest: > 18-033-06 > Nov > 06 > Engine Controls - MIL/Charge/Oil
Lamps ON
PROM - Programmable Read Only Memory: Customer Interest Engine Controls - MIL/Charge/Oil
Lamps ON
NUMBER: 18-033-06
DATE:November 2, 2006
INTERNET.
BULLETIN.
SUBJECT: Flash: MIL Illumination/Generator Lamp Illumination/Oil Pressure Lamp

Illumination/Driveability Improvements
Module (PCM) and the Transmission Control Module (TCM) with new software and performing a
memory reset to clear the adaptive memory of the PCM.
CAUTION:
VEHICLES (PM/MK) EQUIPPED WITH A CVT TRANSMISSION MUST HAVE THE

TRANSMISSION CONTROL MODULE (TCM) CHECKED FOR THE LATEST SOFTWARE LEVEL
WHENEVER THE PCM SOFTWARE IS UPGRADED. IF NEWER TCM SOFTWARE IS
AVAILABLE, IT MUST BE INSTALLED.
MODELS:
2007 (JS) Sebring
2007 (PM) Caliber
2007 (MK49) Compass
NOTE:
Code EBA, ECN or ED3) built before October 24, 2006 (MDH 1024XX).
NOTE:
This bulletin applies to JS models equipped with a 2.4L (Sales Code ED3) with the condition of
momentary (1 to 2 second) oil indicator lamp illumination or flicker at idle and was originally
addressed with RRT 06-048 Dated October 17, 2006.
SYMPTOM/CONDITION:
Some customers may experience MIL illumination, Intermittent Generator Lamp Illumination,
Momentary (1 to 2 second) Oil indicator lamp illumination/flicker at idle or momentary delay
returning to idle after clutch actuation.
NOTE:
Momentary oil lamp illumination at idle is due to oil pressure switch venting. This will NOT cause
engine damage. This condition is most noticeable when the oil is hot, engine RPM is returned to
idle and engine load from the power steering system is quickly applied.
The technician may find one or more of the following DTC's or Symptoms:
^ P0139 - 02 Sensor 1/2 Slow Response.
^ P0700 - Transmission Control System (MIL REQUEST). This DTC is logged in PCM and when
TCM is checked, DTC's are not present.
^ P063A - Generator Voltage Sense Circuit (Intermittent Generator Lamp Illumination).
^ Momentary (1 to 2 second) Oil Indicator Lamp Illumination or Flicker at Idle
^ Momentary Delay Returning to Idle when clutch is actuated (Vehicles Equipped with 2.4L Engine
and Manual Transmission (Sales Code ED3 and DD7).
DIAGNOSIS:
Lamps ON > Page 4476
If any of the above Symptom/Conditions are present, perform the Repair Procedure. If P0139 was
present, verify exhaust system integrity after the reprogramming event by performing the drive
cycle listed in TechCONNECT > Engine Electrical Diagnosis > Diagnosis and Testing > P0139,
follow step 10. If P0139 reoccurs exhaust system leak checks and repairs will be required. Follow
procedures listed in TechCONNECT > Engine Electrical Diagnosis > Diagnosis and Testing >
Checking the Exhaust System for Leaks.
PARTS REQUIRED:
CAUTION:
NOTE:
NOTE:
The StarSCAN® diagnostic scan tool fully supports Internet connectivity. However, to take
instruction on setting up your StarSCAN® for the dealer's network refer to either:
NOTE:
drop.

seconds.
CAUTION:

PROCESS.
NOTE:
a. Yes >> No further action is necessary. Proceed to Step # 9.
b. No » the TCM will require flash reprogramming also, proceed to Step # 8.

b. Select 'Close" after the download is complete, then select "Back".

seconds.
CAUTION:
PROCESS.
NOTE:
9. Reset the adaptive memory of the PCM with the StarSCAN(R). Using the StarSCAN(R) at the
"Home Screen":
b. Highlight "PCM" in the list of modules;

d. Select "Reset Memory".
e. Select "All Adaptive Memory".
NOTE:

TIME ALLOWANCE:
FAILURE CODE:
Disclaimer:
Information > Technical Service Bulletins > Customer Interest: > 18-020-06A > Sep > 06 > Engine Controls - Spark Knock
When Warm/DTC P2173/P0452
PROM - Programmable Read Only Memory: Customer Interest Engine Controls - Spark Knock
When Warm/DTC P2173/P0452
THIS BULLETIN SUPERSEDES SERVICE BULLETIN 18-020-06 DATED JUNE 13, 2006, WHICH
SHOULD BE REMOVED FROM YOUR FILES. ALL REVISIONS ARE HIGHLIGHTED WITH
**ASTERISKS** AND INCLUDES AN ADDITIONAL MODEL, REVISED SOFTWARE, CLEAN
DATE, AND REVISED SYMPTOM/CONDITIONS, REPAIR PROCEDURES AND LABOR
OPERATION NUMBERS
INTERNET.
SUBJECT:
Flash: Warm Weather Spark Knock and/or DIG P2173 **and/or P0452**
Module (PCM) **and if necessary, the Transmission Control Module (TCM)** with new software
and performing a memory reset to clear the adaptive memory of the PCM.
MODELS:
2007 (PM) Caliber
**2007 (MK49) Compass**
NOTE:
This bulletin applies to models equipped with a 2.0L or 2.4L gasoline engine and CVT transmission
(sales code ECN or ED3 with DAV) built on or after May 11, 2006 (MDH 0511Xx) through and
including August 16, 2006 (MDH 0816XX).
SYMPTOM/CONDITION:
Some customers may experience Spark Knock in warm ambient conditions (16°C (60°F) or higher).
The technician may find one or more of the following DTC's.
^ P2173 - High Airflow/Vacuum Leak Detected (Slow Accumulation) may be found in the PCM.
This DTC may occur when a vehicle is driven from a higher altitude to a lower altitude (1372 meter
(4500 foot) change).
^ **P0452-Evap Pressure Switch Stuck Closed**
DIAGNOSIS:
If the customer describes a Spark Knock condition, or the technician finds either DTC, perform the
Repair Procedure.
NOTE:
If service bulletin 18-020-06 has been performed and the Symptom/Condition is still present,
PARTS REQUIRED:
When Warm/DTC P2173/P0452 > Page 4484
CAUTION:
DO NOT START THE ENGINE PRIOR TO COMPLETING **STEP 5n and 8h**. IF THE
NOTE:
NOTE:
NOTE:
drop.

seconds.
CAUTION:
DO NOT START THE ENGINE PRIOR TO COMPLETING 5n AND 8h. IF THE PROCEDURE IS
PROCESS.
NOTE:
6. **Using the StarSCAN(R) at the "Home" screen:
b. No >> the TCM will require flash reprogramming also, proceed to Step # 8.
f. Verify the part number at the top of the "Flash PCM" screen has updated to the new part number.
seconds.
CAUTION:
PROCESS.
NOTE:
9. Reset the adaptive memory of the PCM with the StarSCAN®. This function is found under
Miscellaneous Functions and is called Reset Memory.
Select All Adaptive Memory.
NOTE:

TIME ALLOWANCE:
FAILURE CODE:
Disclaimer:
Information > Technical Service Bulletins > All Technical Service Bulletins for PROM - Programmable Read Only Memory: >
18-005-09A > Mar > 09 > Engine Controls - MIL ON/DTC P2610 Stored In Memory
PROM - Programmable Read Only Memory: All Technical Service Bulletins Engine Controls - MIL
ON/DTC P2610 Stored In Memory
DATE: March 6, 2009

FEBRUARY 11, 2009, WHICH SHOULD BE REMOVED FROM YOUR FILES. ALL REVISIONS
ARE HIGHLIGHTED WITH **ASTERISKS** AND INCLUDE THE ADDITION OF MODEL YEARS,
VEHICLES BODIES, ENGINES AND A UPDATED SYMPTOM/CONDITION AND DIAGNOSIS
SECTIONS.
INTERNET.
StarMOBILE STANDALONE MODE OR StarMOBILE DESKTOP CLIENT MAY ALSO BE USED

TO PERFORM THIS PROCEDURE.
SUBJECT: Flash: MIL Illumination For P2610 - PCM Internal Engine Off Timer Performance
OVERVIEW: This bulletin involves flash reprogramming the Powertrain Control Module (PCM) with
new software.
MODELS:
**2008** - 2009 (PM) Caliber SRT-4
**2007 - 2008 (PM) Caliber**
**2007 - 2008 (MK) Compass/Patriot**
NOTE:
**This bulletin applies to vehicles built with a 1.8L, 2.0L, 2.4L and 2.4L turbo engine (Sales Codes
EBA, ECN, ED3 and ED4) and a engine block heater (sales code NHK) built before February 2,
2009 (MDH 0202xx)**.
NOTE:
**This bulletin does not apply to Japan market vehicles.**
SYMPTOM/CONDITION:
**Some customers may experience a MIL illumination after they have used their engine block
heater. Upon further investigation the Technician may find that P2610 - PCM Internal Engine Off
Timer Performance has been set.
This is caused by the engine block heater (by design) keeping the engine block warm and the logic
in the PCM was expecting a quicker cool down then was actually achieved. The updated software
compensates for the use of the engine block heater. **
then the one listed above are present record them on the repair order and repair as necessary
before proceeding further with this bulletin.
**If the vehicle operator describes or experiences the Symptom/Condition, perform the Repair
Procedure. If the engine block heater was not in use when the code was set then it will be
necessary to preform the diagnostics available DealerCONNECT/TechCONNECT, Refer To Group
28 - DTC Based Diagnostics > Module - Powertrain Controller > Diagnostic and Testing > P2610 -
PCM Internal Engine Off Timer Performance has been set.**
PARTS REQUIRED:
18-005-09A > Mar > 09 > Engine Controls - MIL ON/DTC P2610 Stored In Memory > Page 4492
REPAIR PROCEDURE:
NOTE:
Programming - Gas.
VECI label.
TIME ALLOWANCE:
FAILURE CODE:
Disclaimer:
18-016-08A > Sep > 08 > Engine Controls - MIL ON/DTC P0171 Stored In Memory
THIS BULLETIN SUPERSEDES TECHNICAL SERVICE BULLETIN 18-016-08, DATED APRIL 23,
INTERNET.
Module (PCM).
NOTE:
MODELS:
**2007** - 2008 (MK49) Compass
**2007** - 2008 (MK74) Patriot
**2007** - 2008 (PM) Caliber
NOTE:
This Bulletin applies to **2007 and** 2008 models equipped with a 2.4L engine & automatic CVT
transmission (Sales Code ED3 with DAV or DAW) built prior to April 2, 2008 (MDH 0402XX).
SYMPTOM/CONDITION: Some customers may experience intermittent MIL Illumination. This may
be noticed after driving at high speeds, up grades or towing trailers (heavy engine load). No other
P0171 - Fuel System 1/1 Lean.
If the above symptom/condition is experienced and cause for the DIG cannot be determined,
PARTS REQUIRED:
18-016-08A > Sep > 08 > Engine Controls - MIL ON/DTC P0171 Stored In Memory > Page 4497

NOTE:
Programming - Gas.
VECI label.
TIME ALLOWANCE:
FAILURE CODE:
Disclaimer:
18-017-08A > Sep > 08 > Engine Controls - Idle Vibration With Throttle Closed
PROM - Programmable Read Only Memory: All Technical Service Bulletins Engine Controls - Idle
Vibration With Throttle Closed
THIS BULLETIN SUPERSEDES TECHNICAL SERVICE BULLETIN, 18-017-08 DATED APRIL 23,
INTERNET.
SUBJECT: Flash: Idle Vibration From a Stop With Closed Throttle
Module (PCM).
NOTE:
MODELS:
**2007** - 2008 (MK49) Compass
**2007** - 2008 (MK74) Patriot
**2007** - 2008 (PM) Caliber
NOTE:
This Bulletin applies to **2007 and** 2008 models equipped with a 2.0L or 2.4L engine & automatic
CVT transmission (Sales Code ECN or ED3 with DAV or DAW) built prior to April 2, 2008 (MDH
0402XX).
SYMPTOM/CONDITION:
Some customers may experience an idle vibration. The condition may occur under the following
parameters:
^ Vehicle in Drive.
^ No throttle input (foot "Off" accelerator pedal).
^ Foot "Off" Brake.
^ Vehicle speed between 0 and 5 miles per hour.
available in TechCONNECT, verify all engine systems are functioning as designed. If DTC's are
present record them on the repair order and repair as necessary before proceeding further with this
bulletin.
If the above symptom/condition is experienced or can be verified by duplicating the conditions

described above, perform the Repair Procedure.
18-017-08A > Sep > 08 > Engine Controls - Idle Vibration With Throttle Closed > Page 4502
PARTS REQUIRED:

NOTE:
Programming - Gas.
VECI label.
TIME ALLOWANCE:
FAILURE CODE:
Disclaimer:
18-019-08A > Sep > 08 > Engine Controls - MIL ON/DTC P2173 Stored In Memory
THIS BULLETIN SUPERSEDES TECHNICAL SERVICE BULLETIN 18-019-08, DATED April 25,
INTERNET.
Module (PCM).
NOTE:
MODELS:
**2007** - 2008 (MK49) Compass
**2007** - 2008 (MK74) Patriot
**2007** - 2008 (PM) Caliber
NOTE:
**This Bulletin applies to:
^ 2007 models equipped with a 1.8L, 2.0L or 2.4L (Sales Code EBA, ECN or ED3)
^ **2008 models equipped with a 2.0L or 2.4L engine & automatic CVI2 transmission (Sales Code
ECN or ED3 with DAV or DAW) built prior to April 2, 2008 (MDH 0402XX) or 1.8L/2.4L Engine with
Manual transmission (Sales Code EBA or ED3 with DD7) built prior to February 3, 2008
(MDHO2O3XX).**
SYMPTOM/CONDITION: Some customers may experience intermittent MIL illumination with

electronic throttle control (ETC) lamp Illumination. This may occur during high vehicle speeds or
load conditions. Limp in may occur. If the vehicle ignition is "Keyed off and the vehicle restarted,
the vehicle will operate normally. Further investigation by the technician may find DIG P2173 - High
Airflow/Vacuum Leak Detected (Slow Accumulation).
than P2173 are present record them on the repair order and repair as necessary before proceeding
further with this bulletin.
If the above symptom/condition is experienced and the cause for the condition cannot be
determined, perform the Repair Procedure.
PARTS REQUIRED:
18-019-08A > Sep > 08 > Engine Controls - MIL ON/DTC P2173 Stored In Memory > Page 4507

NOTE:
Programming - Gas.
VECI label.
TIME ALLOWANCE:
FAILURE CODE:
Disclaimer:
18-011-08C > Jul > 08 > Engine Controls - MIL ON/DTC's P0139 or P2270
ON/DTC's P0139 or P2270
NUMBER: 18-011-08 REV. C
DATE: July 23, 2008
THIS BULLETIN SUPERSEDES TECHNICAL SERVICE BULLETIN 18-011-08 REV. B DATED

JUNE 18, 2008 WHICH SHOULD BE REMOVED FROM YOUR FILES. IT ALSO INCLUDES THE
NEWEST SOFTWARE TO ADDRESS P0139 REFERENCES IN SERVICE BULLETINS 18-015-06
AND 18-033-06. ALL REVISIONS ARE HIGHLIGHTED WITH **ASTERISKS** AND INCLUDE
THE ADDITION OF 2007 AND EARLY BUILT 2008 JS MODEL AND ENGINE APPLICATION
ADDITIONS.
INTERNET.
SUBJECT: Flash: MIL Illumination with DIG P0139 or P2270
Module (PCM).
NOTE:
MODELS:
**2007 - 2008 (JS) Avenger/Sebring/Sebring Convertible**
2007 - 2008 (MK49) Compass
2007 - 2008 (MK74) Patriot
2007 - 2008 (PM) Caliber
NOTE:
This bulletin applies to:
^ 2007 **PM/MK** models equipped with a 1.8L, 2.0L, or 2.4L engine & any transmission (Sales
Code EBA, ECN or ED3 with DAV, DAW or DD7),
^ **2007 JS vehicles equipped with a 2.4L engine (Sales Code ED3).**
^ 2008 PM/MK models equipped with a 2.0L or 2.4L engine & automatic CVI transmission (Sales
Code ECN or ED3 with DAV or DAW) built prior to January 22, 2008 (MDH 0123XX),
^ 2008 PM/MK models equipped with a 1.8L or 2.4L engine & Manual transmission (Sales Code
EBA or ED3 with DD7) built prior to February 3, 2008 (MDHO2O3XX).
^ **2008 JS vehicles equipped with a 2.4L engine (Sales Code EDG or ED3) built before
January24, 2008 (MDH 0124xx).**
SYMPTOM/CONDITION: Some customers may experience intermittent MIL Illumination. No other
P0139 - 02 Sensor 1/2 Slow Response or DTC P2270 - 02 Sensor 1/2 Signal Biased Lean.
18-011-08C > Jul > 08 > Engine Controls - MIL ON/DTC's P0139 or P2270 > Page 4512
If the above symptom/condition is experienced and cause for DTC's cannot be determined, perform
the Repair Procedure.
PARTS REQUIRED:
NOTE:
Programming - Gas.
VECI label.
TIME ALLOWANCE:
FAILURE CODE:
Disclaimer:
18-018-07A > May > 07 > Engine Controls - MIL ON/DTC's P0016/P0017/P000A/P000B
ON/DTC's P0016/P0017/P000A/P000B
DATE: May 30, 2007

HIGHLIGHTED WITH **ASTERISKS** AND INCLUDE ADDITIONAL DIAGNOSTIC CHECKS FOR
APPROPRIATE OIL PRESSURE.
INTERNET.
BULLETIN.
SUBJECT: Flash: MIL Illumination with DTC's P0016, P0017, P000A, or P000B
Control Module (PCM) with new software, **verifying oil pressure specifications**, replacing the
intake and exhaust oil control valves (OCV), and replacing the engine oil and filter.
CAUTION:

BE INSTALLED.
MODELS:
2007 (JS) Sebring
2007 (MK49) Compass
2007 (MK74) Patriot
2007 (PM) Caliber
NOTE:
EBA, ECN or ED3) on PM/MK models built before February 20, 2007 (MDH 0220XX) and JS
models built before March 5, 2007 (M DH0305XX).
SYMPTOM/CONDITION:
Some customers may experience MIL illumination. Performance issues may or may not be
experienced.
^ P000A-Bank 1 Camshaft 1 Position Slow Response.

^ P000B-Bank 1 Camshaft 2 Position Slow Response.
The DTC's may be intermittent and difficult to duplicate.
DIAGNOSIS:
TechCONNECT, verify all engine systems are functioning as designed. If DTC's other than those
18-018-07A > May > 07 > Engine Controls - MIL ON/DTC's P0016/P0017/P000A/P000B > Page 4517
**Verify that the oil pressure meets specifications as listed in DealerCONNECT > TechCONNECT.
If the oil pressure does not meet specifications, the OCV will be unable to function properly. In this
case, further diagnosis will be required to determine the cause of inappropriate oil pressure.**
**If the Oil Pressure meets specifications, DTC's are present and cannot be duplicated, perform the
Repair Procedure**.
PARTS REQUIRED:
CAUTION:
NOTE:
NOTE:
to the StarSCAN® Quick Start Networking Guide.
The StarSCAN(R) Quick Start Networking Guide is also available on the website under the
"Download Center".
NOTE:
2. Connect the CH9410 StarSCAN® ethernet cable to the StarSCAN(R) and the dealer's network
drop.
seconds.
CAUTION:

PROCESS.
NOTE:
6. Using the StarSCAN(R) at the "Home screen:
8. Flash reprogram the 1CM as follows:

f. Verify the part number at the top of the "Flash TCM screen has updated to the new part number.
seconds.
CAUTION:
PROCESS.
NOTE:
NOTE:
10. Following the procedures listed in DealerCONNECT > TechCONNECT, replace both intake
and exhaust Oil Control Valves pn 04884695AA and 04884483AA.
11. Replace the engine oil and filter.

TIME ALLOWANCE:
FAILURE CODE:
Disclaimer:
18-032-07 > May > 07 > A/T - MIL ON Possible DTC P2004
PROM - Programmable Read Only Memory: All Technical Service Bulletins A/T - MIL ON Possible
DTC P2004
NUMBER: 18-032-07
DATE: May 16, 2007
INTERNET.
BULLETIN.
CAUTION:

BE INSTALLED.
MODELS:
2007 (JS) Sebring
2007 (MK49) Compass
2007 (MK74) Patriot
2007 (PM) Caliber
NOTE:
SYMPTOM/CONDITION:
DIAGNOSIS:
PARTS REQUIRED:
18-032-07 > May > 07 > A/T - MIL ON Possible DTC P2004 > Page 4525
CAUTION:
NOTE:
NOTE:
NOTE:
drop.

seconds.
CAUTION:

PROCESS.
NOTE:
seconds.
CAUTION:
NOTE:
NOTE:
TIME ALLOWANCE:
FAILURE CODE:
Disclaimer:
18-031-07 > Apr > 07 > Engine Controls - Low Accel. Performance/Ticking Noise
PROM - Programmable Read Only Memory: All Technical Service Bulletins Engine Controls - Low
Accel. Performance/Ticking Noise
NUMBER: 18-031-07
DATE: April 28, 2007
INTERNET.

BULLETIN.
SUBJECT: Flash: Launch Performance / Driveability Enhancements
OVERVIEW:
This bulletin involves selectively erasing and reprogramming the GPEC Powertrain Control Module
(PCM) with new software.
CAUTION:

BE INSTALLED.
MODELS:
2007 (MK49) Compass
2007 (MK74) Patriot
2007 (PM) Caliber
NOTE:
EBA, ECN or ED3) on PM/MK models built before April 21, 2007 (MDH 0421XX).
SYMPTOM/CONDITION:
Some customers may experience the following:
^ Automatic CVI models - Perceived lack of performance under light to moderate acceleration from
a stop.
^ All Models - Ticking Sound intermittently heard from the engine compartment.
Software changes have been made to improve the above bullet points. In addition, changes to
maximum RPM in neutral have been made to assist A/C compressor function during cold ambient
temperatures to prevent A/C compressor slugging.
DIAGNOSIS:
TechCONNECT, verify all engine Systems are functioning as designed. If DIG's other than those
If the above symptoms are described by the customer, perform the Repair Procedure.
PARTS REQUIRED:
18-031-07 > Apr > 07 > Engine Controls - Low Accel. Performance/Ticking Noise > Page 4532
CAUTION:
NOTE:
NOTE:
NOTE:
drop.

seconds.
CAUTION:

PROCESS.
NOTE:
seconds.
CAUTION:
PROCESS.
NOTE:
NOTE:
attach near the VECI label (Fig 1).
TIME ALLOWANCE:
FAILURE CODE:
Disclaimer:
18-005-07 > Jan > 07 > Engine Controls - MIL ON/DTC P0128 Set
ON/DTC P0128 Set
NUMBER: 18-005-07
DATE: January 24, 2007
INTERNET.
BULLETIN.
SUBJECT:
Flash - P0128 Thermostat Rationality
Module (PCM) and the Transmission Control Module (TCM) with new software.
CAUTION:

BE INSTALLED.
MODELS:
2007 (MK49) Compass
NOTE:
This bulletin applies to MK models equipped with a 2.4L gasoline engine (Sales Code ED3) and
CVT transmission (Sales Code DAV) with AWD built before August 16, 2006 (MDH 0816XX).
SYMPTOM/CONDITION:
Some vehicle operators may experience MIL illumination after a cold start with long idle time,
(greater than 20 minutes). This is usually accompanied with minimal accessory loads. No other
symptoms will be experienced.
The technician may find the DTC:
P0128 - THERMOSTAT RATIONALITY
DIAGNOSIS:
Using a Scan Tool (StarSCAN(R) with the appropriate Diagnostic Procedures available in
TechCONNECT, verify all engine systems are functioning as designed. If DTC's other than P0128
are present, record them on the repair order and repair as necessary before proceeding further
with this bulletin.
PARTS REQUIRED:
18-005-07 > Jan > 07 > Engine Controls - MIL ON/DTC P0128 Set > Page 4539
CAUTION:
NOTE:
NOTE:
NOTE:
drop.


seconds.
CAUTION:

PROCESS.
NOTE:
seconds.
CAUTION:
PROCESS.
NOTE:
NOTE:
TIME ALLOWANCE:
FAILURE CODE:
Disclaimer:
18-033-06 > Nov > 06 > Engine Controls - MIL/Charge/Oil Lamps ON
PROM - Programmable Read Only Memory: All Technical Service Bulletins Engine Controls -
MIL/Charge/Oil Lamps ON
NUMBER: 18-033-06
DATE:November 2, 2006
INTERNET.
BULLETIN.
SUBJECT: Flash: MIL Illumination/Generator Lamp Illumination/Oil Pressure Lamp

Illumination/Driveability Improvements
Module (PCM) and the Transmission Control Module (TCM) with new software and performing a
memory reset to clear the adaptive memory of the PCM.
CAUTION:
VEHICLES (PM/MK) EQUIPPED WITH A CVT TRANSMISSION MUST HAVE THE

TRANSMISSION CONTROL MODULE (TCM) CHECKED FOR THE LATEST SOFTWARE LEVEL
WHENEVER THE PCM SOFTWARE IS UPGRADED. IF NEWER TCM SOFTWARE IS
AVAILABLE, IT MUST BE INSTALLED.
MODELS:
2007 (JS) Sebring
2007 (PM) Caliber
2007 (MK49) Compass
NOTE:
Code EBA, ECN or ED3) built before October 24, 2006 (MDH 1024XX).
NOTE:
This bulletin applies to JS models equipped with a 2.4L (Sales Code ED3) with the condition of
momentary (1 to 2 second) oil indicator lamp illumination or flicker at idle and was originally
addressed with RRT 06-048 Dated October 17, 2006.
SYMPTOM/CONDITION:
Some customers may experience MIL illumination, Intermittent Generator Lamp Illumination,
Momentary (1 to 2 second) Oil indicator lamp illumination/flicker at idle or momentary delay
returning to idle after clutch actuation.
NOTE:
Momentary oil lamp illumination at idle is due to oil pressure switch venting. This will NOT cause
engine damage. This condition is most noticeable when the oil is hot, engine RPM is returned to
idle and engine load from the power steering system is quickly applied.
The technician may find one or more of the following DTC's or Symptoms:
^ P0139 - 02 Sensor 1/2 Slow Response.
^ P0700 - Transmission Control System (MIL REQUEST). This DTC is logged in PCM and when
TCM is checked, DTC's are not present.
^ P063A - Generator Voltage Sense Circuit (Intermittent Generator Lamp Illumination).
^ Momentary (1 to 2 second) Oil Indicator Lamp Illumination or Flicker at Idle
^ Momentary Delay Returning to Idle when clutch is actuated (Vehicles Equipped with 2.4L Engine
and Manual Transmission (Sales Code ED3 and DD7).
DIAGNOSIS:
18-033-06 > Nov > 06 > Engine Controls - MIL/Charge/Oil Lamps ON > Page 4546
If any of the above Symptom/Conditions are present, perform the Repair Procedure. If P0139 was
present, verify exhaust system integrity after the reprogramming event by performing the drive
cycle listed in TechCONNECT > Engine Electrical Diagnosis > Diagnosis and Testing > P0139,
follow step 10. If P0139 reoccurs exhaust system leak checks and repairs will be required. Follow
procedures listed in TechCONNECT > Engine Electrical Diagnosis > Diagnosis and Testing >
Checking the Exhaust System for Leaks.
PARTS REQUIRED:
CAUTION:
NOTE:
NOTE:
The StarSCAN® diagnostic scan tool fully supports Internet connectivity. However, to take
instruction on setting up your StarSCAN® for the dealer's network refer to either:
NOTE:
drop.

seconds.
CAUTION:

PROCESS.
NOTE:
b. No » the TCM will require flash reprogramming also, proceed to Step # 8.

b. Select 'Close" after the download is complete, then select "Back".

seconds.
CAUTION:
PROCESS.
NOTE:
9. Reset the adaptive memory of the PCM with the StarSCAN(R). Using the StarSCAN(R) at the
"Home Screen":
b. Highlight "PCM" in the list of modules;

d. Select "Reset Memory".
e. Select "All Adaptive Memory".
NOTE:

TIME ALLOWANCE:
FAILURE CODE:
Disclaimer:
18-020-06A > Sep > 06 > Engine Controls - Spark Knock When Warm/DTC P2173/P0452
Spark Knock When Warm/DTC P2173/P0452
THIS BULLETIN SUPERSEDES SERVICE BULLETIN 18-020-06 DATED JUNE 13, 2006, WHICH
SHOULD BE REMOVED FROM YOUR FILES. ALL REVISIONS ARE HIGHLIGHTED WITH
**ASTERISKS** AND INCLUDES AN ADDITIONAL MODEL, REVISED SOFTWARE, CLEAN
DATE, AND REVISED SYMPTOM/CONDITIONS, REPAIR PROCEDURES AND LABOR
OPERATION NUMBERS
INTERNET.
SUBJECT:
Flash: Warm Weather Spark Knock and/or DIG P2173 **and/or P0452**
Module (PCM) **and if necessary, the Transmission Control Module (TCM)** with new software
and performing a memory reset to clear the adaptive memory of the PCM.
MODELS:
2007 (PM) Caliber
**2007 (MK49) Compass**
NOTE:
This bulletin applies to models equipped with a 2.0L or 2.4L gasoline engine and CVT transmission
(sales code ECN or ED3 with DAV) built on or after May 11, 2006 (MDH 0511Xx) through and
including August 16, 2006 (MDH 0816XX).
SYMPTOM/CONDITION:
Some customers may experience Spark Knock in warm ambient conditions (16°C (60°F) or higher).
The technician may find one or more of the following DTC's.
^ P2173 - High Airflow/Vacuum Leak Detected (Slow Accumulation) may be found in the PCM.
This DTC may occur when a vehicle is driven from a higher altitude to a lower altitude (1372 meter
(4500 foot) change).
^ **P0452-Evap Pressure Switch Stuck Closed**
DIAGNOSIS:
If the customer describes a Spark Knock condition, or the technician finds either DTC, perform the
Repair Procedure.
NOTE:
If service bulletin 18-020-06 has been performed and the Symptom/Condition is still present,
PARTS REQUIRED:
18-020-06A > Sep > 06 > Engine Controls - Spark Knock When Warm/DTC P2173/P0452 > Page 4554
CAUTION:
DO NOT START THE ENGINE PRIOR TO COMPLETING **STEP 5n and 8h**. IF THE
NOTE:
NOTE:
NOTE:
drop.

seconds.
CAUTION:
DO NOT START THE ENGINE PRIOR TO COMPLETING 5n AND 8h. IF THE PROCEDURE IS
PROCESS.
NOTE:
6. **Using the StarSCAN(R) at the "Home" screen:
b. No >> the TCM will require flash reprogramming also, proceed to Step # 8.
f. Verify the part number at the top of the "Flash PCM" screen has updated to the new part number.
seconds.
CAUTION:
PROCESS.
NOTE:
9. Reset the adaptive memory of the PCM with the StarSCAN®. This function is found under
Miscellaneous Functions and is called Reset Memory.
Select All Adaptive Memory.
NOTE:

TIME ALLOWANCE:
FAILURE CODE:
Disclaimer:
18-001-06A > Jul > 06 > Engine Controls - Flash Reprogramming Abort Recovery
Flash Reprogramming Abort Recovery
DATE: July 12, 2006
THIS BULLETIN SUPERSEDES TECHNICAL SERVICE BULLETIN 18-001-06, DATED JANUARY

II, 2006, WHICH SHOULD BE REMOVED FROM YOUR FILES. ALL REVISIONS ARE
HIGHLIGHTED WITH **ASTERISKS** AND INCLUDE ADDITIONAL MODELS, YEARS AND A
REVISED DISCUSSION ABOUT ABORTED FLASH REPROGRAMMING RECOVERY.
SUBJECT: StarSCAN(R)/StarMOBILE(TM) Abort Recovery Procedures
OVERVIEW: This Bulletin provides guidelines to minimize flash reprogramming problems and
recovery procedure information for failed flash attempts.
MODELS:
**2007 (DC) Ram Cab & Chassis**
2006 - **2007** (DR/DH/D1) Ram Truck
2004 - **2007** (HB/HG) Durango/Aspen
2007 (JK) Wrangler
**2007 (KA) Nitro**
2006 - **2007** (KJ) Liberty/Cherokee
2005 - **2007** (LX/LE) 300/Magnum/Charger
**2007 (MK) Compass**
2005 - **2007** (ND) Dakota
**2007 (PM) Caliber**
2006 - **2007* (PT) PT Cruiser
2005 - **2007** (WK/WH) Grand Cherokee
2006 - **2007** (XK/XH) Commander
DISCUSSION:
NOTE:
Many of the reasons a flash reprogramming procedure may not complete are documented in this
service bulletin.
Occasionally a flash update procedure may not complete properly and/or the diagnostic equipment
may lock up or become disconnected during the procedure. Flash Reprogramming is a "CRITICAL
PROCESS"; an error may result in a no-start/failed control module. Most modules, encountering an
interruption or failure while reprogramming, are recoverable. Replacing a module that is
recoverable is not covered under the provisions of the warranty.
This service bulletin covers items that may cause this condition, a process to restart the flash
procedure, and miscellaneous information that will help prevent unnecessary replacement of
control modules.
GENERAL: Flash Reprogramming is only authorized when programming a generic module or by a

specific SERVICE ACTION (Service Bulletin/Recall/Rapid Response Transmittal/Advance Service
Information).
CAUTION:
18-001-06A > Jul > 06 > Engine Controls - Flash Reprogramming Abort Recovery > Page 4561
When updating a module because of a Service Action, it is important to follow the steps outlined in
the Repair Procedure section of the Service Action. Procedures may differ depending on the
module that is being reprogrammed.
Review the entire Service Action prior to performing a flash reprogramming update. Often other
parts may need to be serviced, replaced, or tested, prior to flash reprogramming, and ARE
REQUIRED as part of completing the Service Action.
COMMON CAUSES OF FLASH REPROGRAMMING ERRORS
Interruptions, voltage problems, a variety of other outside interactions, and failure to follow the
steps outlined in the Service Action can potentially interfere with the process. This document seeks
to provide information to minimize problems associated with module flash reprogramming.
SOFTWARE VERSIONS MUST BE CURRENT
Before attempting a flash reprogramming session, make sure you have the most current software
installed in the scan tool (StarSCAN(R)/StarMOBILE(TM)). Refer to the current software release
information available in TechCONNECT, under: Service Info > StarSCAN(R) and StarMOBILE(TM)
Tools > Latest News > Select the most recent release number. The technician will be able to see
the applicable version numbers.
Often, because of multiple StarSCAN(R)/StarMOBILE(TM)s in the shop, not all devices will get
updated in a timely manner. The installed StarSCAN(R)/StarMOBILE(TM) software version and
scan tool operating system version, (Fig. 2), can be verified from the "Home" screen as follows:
StarMOBILE Desktop Client
^ Select "Tool Menu".
^ Select "Version Information"

StarSCAN
^ Select "Show Shortcuts"
^ Select "Version Information" Typical Tool Menu (Fig. 1)
NOTE:
The StarSCAN also displays the version number on the right side of the blue header at the top of
each screen.
NOTE:
To read the version on the StarMOBILE(TM), it must be connected and the application running or
the user will receive "N/A" for the "System" value.
GENERAL NOTES FOR CABLES AND VEHICLE CONNECTIONS
Consider ALL cables to be wear items.
It is a good practice to have dedicated cables devoted to "Flash ONLY".
Always have a spare StarSCAN(R) CH9404 (vehicle) cable available.
Always have a spare StarMOBILE(TM) CH9804 (vehicle) cable available (blue cable end).
Diagnosing vehicle cable problems
Inspect vehicle cable connectors for potential problems that might cause communication
interruptions. Use the information available on DealerCONNECT under:
^ eSupport (above the "Marketing" tab)
^ Under "Knowledge Center" - select "Find Answers"
^ In the "Enter link, error message, or topic" area, type "561"
^ In the "Search By" area, select "Answer ID"
^ At the next screen, select the "StarSCAN Flash Lockup.pdf" link to access the information to
diagnose suspect vehicle cable continuity.
FLASH REPROGRAMMING PROBLEM PREVENTION
^ Follow the steps outlined in the Service Action.
^ Pay attention to the screen prompts displayed during the flash process.
^ Replace worn cables.
^ Verify the vehicle is equipped with a known good battery.
^ Ensure the battery charger charging rate provides approximately 13.2 - 13.8 volts. Set the battery
charger to continuous charge. Do not allow the charger to time out during the flash process.
**ABORTED FLASH REPROGRAMMING RECOVERY**
** The following steps may help recover a non-responsive module when the flash process is
aborted or interrupted.
1. When the Flash ECU screen displays an Error Message, select OK.
2. Turn the ignition to "off" and power down the StarSCAN(R).
3. Turn the vehicle ignition to the "On" position.
4. Power on the StarSCAN®.

NOTE:
If the technician was flashing a PCM, the tool may display "Unknown VIN". Disregard this.
5. Select (ECU) View.
6. Highlight the ECU that was being flashed.
NOTE:
The module may appear to be non-responsive. Highlight the module anyway.
7. Select More Options
8. Select ECU Flash
9. If the "Flash ECU" screen displays "Resident flash files for Part # XXXXX", the module should be
recoverable. If the screen displays "No resident flash files found" the module is not recoverable.
Does the Flash ECU screen display "No resident flash files found?"
a. Yes >> The module must be replaced.
b. No >> proceed to Step # 10.
10. Is a calibration file displayed on the StarSCAN(R)?
a. Yes >> proceed to Step # 11.
b. No >> Select "Browse For New File" and follow on screen instructions. Highlight the calibration
that was previously chosen. Select "Download to Scantool". When the file is downloaded to the
scantool, select "Back" and proceed to Step # 11.
11. Highlight the appropriate calibration.
12. Select "Update Controller" and follow the on screen instructions.
13. When the flash is complete, verify the "Resident flash file part number" matches the 'New PIN"
of the appropriate calibration.
14. Proceed with the steps listed in the Service Bulletin to complete the service action.**
NOTE:
If after following the steps above, you are still having issues performing the flash reprogramming
procedure using a specific StarSCAN(R)/StarMOBILE(R) it is suggested to contact SPX/Miller
Special Tools for service.
Disclaimer:
Information > Technical Service Bulletins > All Other Service Bulletins for PROM - Programmable Read Only Memory: >
18-001-06A > Jul > 06 > Engine Controls - Flash Reprogramming Abort Recovery
Flash Reprogramming Abort Recovery
DATE: July 12, 2006
THIS BULLETIN SUPERSEDES TECHNICAL SERVICE BULLETIN 18-001-06, DATED JANUARY

II, 2006, WHICH SHOULD BE REMOVED FROM YOUR FILES. ALL REVISIONS ARE
HIGHLIGHTED WITH **ASTERISKS** AND INCLUDE ADDITIONAL MODELS, YEARS AND A
REVISED DISCUSSION ABOUT ABORTED FLASH REPROGRAMMING RECOVERY.
SUBJECT: StarSCAN(R)/StarMOBILE(TM) Abort Recovery Procedures
OVERVIEW: This Bulletin provides guidelines to minimize flash reprogramming problems and
recovery procedure information for failed flash attempts.
MODELS:
**2007 (DC) Ram Cab & Chassis**
2006 - **2007** (DR/DH/D1) Ram Truck
2004 - **2007** (HB/HG) Durango/Aspen
2007 (JK) Wrangler
**2007 (KA) Nitro**
2006 - **2007** (KJ) Liberty/Cherokee
2005 - **2007** (LX/LE) 300/Magnum/Charger
**2007 (MK) Compass**
2005 - **2007** (ND) Dakota
**2007 (PM) Caliber**
2006 - **2007* (PT) PT Cruiser
2005 - **2007** (WK/WH) Grand Cherokee
2006 - **2007** (XK/XH) Commander
DISCUSSION:
NOTE:
Many of the reasons a flash reprogramming procedure may not complete are documented in this
service bulletin.
Occasionally a flash update procedure may not complete properly and/or the diagnostic equipment
may lock up or become disconnected during the procedure. Flash Reprogramming is a "CRITICAL
PROCESS"; an error may result in a no-start/failed control module. Most modules, encountering an
interruption or failure while reprogramming, are recoverable. Replacing a module that is
recoverable is not covered under the provisions of the warranty.
This service bulletin covers items that may cause this condition, a process to restart the flash
procedure, and miscellaneous information that will help prevent unnecessary replacement of
control modules.
GENERAL: Flash Reprogramming is only authorized when programming a generic module or by a

specific SERVICE ACTION (Service Bulletin/Recall/Rapid Response Transmittal/Advance Service
Information).
CAUTION:
When updating a module because of a Service Action, it is important to follow the steps outlined in
the Repair Procedure section of the Service Action. Procedures may differ depending on the
module that is being reprogrammed.
Review the entire Service Action prior to performing a flash reprogramming update. Often other
parts may need to be serviced, replaced, or tested, prior to flash reprogramming, and ARE
REQUIRED as part of completing the Service Action.
COMMON CAUSES OF FLASH REPROGRAMMING ERRORS
Interruptions, voltage problems, a variety of other outside interactions, and failure to follow the
steps outlined in the Service Action can potentially interfere with the process. This document seeks
to provide information to minimize problems associated with module flash reprogramming.
SOFTWARE VERSIONS MUST BE CURRENT
Before attempting a flash reprogramming session, make sure you have the most current software
installed in the scan tool (StarSCAN(R)/StarMOBILE(TM)). Refer to the current software release
information available in TechCONNECT, under: Service Info > StarSCAN(R) and StarMOBILE(TM)
Tools > Latest News > Select the most recent release number. The technician will be able to see
the applicable version numbers.
Often, because of multiple StarSCAN(R)/StarMOBILE(TM)s in the shop, not all devices will get
updated in a timely manner. The installed StarSCAN(R)/StarMOBILE(TM) software version and
scan tool operating system version, (Fig. 2), can be verified from the "Home" screen as follows:
StarMOBILE Desktop Client
^ Select "Version Information"

StarSCAN
^ Select "Show Shortcuts"
^ Select "Version Information" Typical Tool Menu (Fig. 1)
NOTE:
The StarSCAN also displays the version number on the right side of the blue header at the top of
each screen.
NOTE:
To read the version on the StarMOBILE(TM), it must be connected and the application running or
the user will receive "N/A" for the "System" value.
GENERAL NOTES FOR CABLES AND VEHICLE CONNECTIONS
Consider ALL cables to be wear items.
It is a good practice to have dedicated cables devoted to "Flash ONLY".
Always have a spare StarSCAN(R) CH9404 (vehicle) cable available.
Always have a spare StarMOBILE(TM) CH9804 (vehicle) cable available (blue cable end).
Diagnosing vehicle cable problems
Inspect vehicle cable connectors for potential problems that might cause communication
interruptions. Use the information available on DealerCONNECT under:
^ eSupport (above the "Marketing" tab)
^ Under "Knowledge Center" - select "Find Answers"
^ In the "Enter link, error message, or topic" area, type "561"
^ In the "Search By" area, select "Answer ID"
^ At the next screen, select the "StarSCAN Flash Lockup.pdf" link to access the information to
diagnose suspect vehicle cable continuity.
FLASH REPROGRAMMING PROBLEM PREVENTION
^ Follow the steps outlined in the Service Action.
^ Pay attention to the screen prompts displayed during the flash process.
^ Replace worn cables.
^ Verify the vehicle is equipped with a known good battery.
^ Ensure the battery charger charging rate provides approximately 13.2 - 13.8 volts. Set the battery
charger to continuous charge. Do not allow the charger to time out during the flash process.
**ABORTED FLASH REPROGRAMMING RECOVERY**
** The following steps may help recover a non-responsive module when the flash process is
aborted or interrupted.
1. When the Flash ECU screen displays an Error Message, select OK.
2. Turn the ignition to "off" and power down the StarSCAN(R).
3. Turn the vehicle ignition to the "On" position.
4. Power on the StarSCAN®.

NOTE:
If the technician was flashing a PCM, the tool may display "Unknown VIN". Disregard this.
5. Select (ECU) View.
6. Highlight the ECU that was being flashed.
NOTE:
The module may appear to be non-responsive. Highlight the module anyway.
7. Select More Options
8. Select ECU Flash
9. If the "Flash ECU" screen displays "Resident flash files for Part # XXXXX", the module should be
recoverable. If the screen displays "No resident flash files found" the module is not recoverable.
Does the Flash ECU screen display "No resident flash files found?"
a. Yes >> The module must be replaced.
b. No >> proceed to Step # 10.
10. Is a calibration file displayed on the StarSCAN(R)?
a. Yes >> proceed to Step # 11.
b. No >> Select "Browse For New File" and follow on screen instructions. Highlight the calibration
that was previously chosen. Select "Download to Scantool". When the file is downloaded to the
scantool, select "Back" and proceed to Step # 11.
11. Highlight the appropriate calibration.
12. Select "Update Controller" and follow the on screen instructions.
13. When the flash is complete, verify the "Resident flash file part number" matches the 'New PIN"
of the appropriate calibration.
14. Proceed with the steps listed in the Service Bulletin to complete the service action.**
NOTE:
If after following the steps above, you are still having issues performing the flash reprogramming
procedure using a specific StarSCAN(R)/StarMOBILE(R) it is suggested to contact SPX/Miller
Special Tools for service.
Disclaimer:
Jeep Workshop Manuals > Transmission and Drivetrain > Actuators and Solenoids - Transmission and Drivetrain >
Actuators and Solenoids - CVT > Pressure Regulating Solenoid, CVT > Component Information > Locations
Component ID: 15
Connector:
Color : BLACK
# of pins : 22
6 GROUND Z967 18BK

12 - -
13 - -
14 - -
15 - -
20 - -
Actuators and Solenoids - CVT > Pressure Regulating Solenoid, CVT > Component Information > Locations > Page 4578
Component ID: 15
Connector:
Color : BLACK
# of pins : 22
6 GROUND Z967 18BK

12 - -
13 - -
14 - -
15 - -
20 - -
Actuators and Solenoids - CVT > Shift Solenoid, CVT > Component Information > Locations
Component ID: 15
Connector:
Color : BLACK
# of pins : 22
6 GROUND Z967 18BK

12 - -
13 - -
14 - -
15 - -
20 - -
Actuators and Solenoids - CVT > Shift Solenoid, CVT > Component Information > Locations > Page 4584
Component ID: 15
Connector:
Color : BLACK
# of pins : 22
6 GROUND Z967 18BK

12 - -
13 - -
14 - -
15 - -
20 - -
Actuators and Solenoids - Differential > Solenoid, Differential Lock > Component Information > Locations
Solenoid: Locations
Component ID: 335
Connector:
Color : # of pins :
Qualifier : (ECC)
Actuators and Solenoids - Differential > Solenoid, Differential Lock > Component Information > Locations > Page 4591
Solenoid: Diagrams
Component ID: 335
Connector:
Color : # of pins :
Qualifier : (ECC)
Jeep Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Control Module, A/T >
Component Information > Technical Service Bulletins > Engine, A/T Controls - PCM/TCM Replacement Requirements
Requirements
INTERNET.

BULLETIN.
MODELS:
2007 (MK49) Compass
2007 (MK74) Patriot
2007 (PM) Caliber
NOTE:
DISCUSSION:
below.
CAUTION:
Page 4599
PARTS REQUIRED:
CAUTION:

down load.
CAUTION:
PROCESS.
NOTE:
NOTE:
NOTE:
Page 4600
drop.
seconds.
CAUTION:
NOTE:
PCM.
NOTE:
StarSCAN(R) screen.
NOTE:
list.

Page 4601
File List" screen?
with step 9.
NOTE:
CAUTION:

down load.
NOTE:
NOTE:
Page 4602
NOTE:
down load.
drop.
number.
NOTE:


Page 4603
File List" screen?
with step 7.
NOTE:
TIME ALLOWANCE:
FAILURE CODE:
Disclaimer:
Page 4604
NUMBER: 18-039-06
INTERNET.
BULLETIN.
SUBJECT:
CAUTION:

BE INSTALLED.
MODELS:
2007 (PM) Caliber
2007 (MK49) Compass
NOTE:
(MDH 1120XX).
NOTE:
DIAGNOSIS:
PARTS REQUIRED:
Page 4605
CAUTION:
NOTE:

seconds.
Page 4606
CAUTION:
PROCESS.
NOTE:
NOTE:
TIME ALLOWANCE:
FAILURE CODE:
Disclaimer:
Jeep Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Differential, Automatic
Transaxle > Differential Fluid - A/T > Component Information > Technical Service Bulletins > Maintenance - Fluid Flushing
Information
Differential Fluid - A/T: Technical Service Bulletins Maintenance - Fluid Flushing Information
NUMBER: 26-001-09

MODELS:
2009 - 2010 (DS) Ram Truck (1500)
2005 - 2009 (HB) Durango
2007 - 2009 (HG) Aspen
2009 - 2010 (JC) Journey
2008 - 2010 (KK) Liberty
2007 - 2010 (KA) Nitro
2005 - 2007 (KJ) Liberty
2005 - 2010 (ND) Dakota
2005 - 2006 (PL) Neon
2007 - 2010 (PM) Caliber

Jeep Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Differential, Automatic
Transaxle > Differential Fluid - A/T > Component Information > Technical Service Bulletins > Maintenance - Fluid Flushing
Information > Page 4612
2005 - 2010 (ZB) Viper
DISCUSSION:
coolant.
operating range.
distilled water.
Disclaimer:
Jeep Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Fluid - A/T > Component
Fluid - A/T: Technical Service Bulletins Maintenance - Fluid Flushing Information
NUMBER: 26-001-09

MODELS:
2009 - 2010 (DS) Ram Truck (1500)
2005 - 2009 (HB) Durango
2007 - 2009 (HG) Aspen
2009 - 2010 (JC) Journey
2008 - 2010 (KK) Liberty
2007 - 2010 (KA) Nitro
2005 - 2007 (KJ) Liberty
2005 - 2010 (ND) Dakota
2005 - 2006 (PL) Neon

2007 - 2010 (PM) Caliber

Jeep Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Fluid - A/T > Component
2005 - 2010 (ZB) Viper
DISCUSSION:
coolant.
operating range.
distilled water.
Disclaimer:
Jeep Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Relays and Modules - A/T >
Control Module, A/T > Component Information > Technical Service Bulletins > Engine, A/T Controls - PCM/TCM
Replacement Requirements
Requirements
INTERNET.

BULLETIN.
MODELS:
2007 (MK49) Compass
2007 (MK74) Patriot
2007 (PM) Caliber
NOTE:
DISCUSSION:
below.
CAUTION:
Replacement Requirements > Page 4623
PARTS REQUIRED:
CAUTION:

down load.
CAUTION:
PROCESS.
NOTE:
NOTE:
NOTE:
drop.
seconds.
CAUTION:
NOTE:
PCM.
NOTE:
StarSCAN(R) screen.
NOTE:
list.

File List" screen?
with step 9.
NOTE:
CAUTION:

down load.
NOTE:
NOTE:
NOTE:
down load.
drop.
number.
NOTE:


File List" screen?
with step 7.
NOTE:
TIME ALLOWANCE:
FAILURE CODE:
Disclaimer:
NUMBER: 18-039-06
INTERNET.
BULLETIN.
SUBJECT:
CAUTION:

BE INSTALLED.
MODELS:
2007 (PM) Caliber
2007 (MK49) Compass
NOTE:
(MDH 1120XX).
NOTE:
DIAGNOSIS:
PARTS REQUIRED:
CAUTION:
NOTE:

seconds.
CAUTION:
PROCESS.
NOTE:
NOTE:
TIME ALLOWANCE:
FAILURE CODE:
Disclaimer:
Jeep Workshop Manuals > Transmission and Drivetrain > Clutch, M/T > Clutch Disc, M/T > Component Information >
Clutch Disc: Description and Operation Description
DESCRIPTION
The modular clutch assembly (1) is located between the engine and manual transaxle in the
transaxle bellhousing, and is responsible for transmitting engine power to the transaxle. The
modular clutch is an assembly which incorporates a self-adjusting design and consists of the
following components:
- Flywheel
- Clutch Disc
- Pressure Plate
- Diaphragm Spring
- Adjusting Ring
- Sensor
- Cover
Clutch Disc: Description and Operation Operation
OPERATION
The modular clutch assembly is designed to transmit power from the engine to the manual
transaxle. This is accomplished by the friction and clamping force generated when the spring
loaded pressure plate locks the clutch disc to the flywheel. The clutch disc, which is splined to the
transaxle input shaft, transmits power until the center of the diaphragm spring is depressed, and
the clamp force is removed from the disc.
The self-adjusting feature of this clutch assembly relies on the sensor ring (4) and the adjuster ring
(5), which works its way around a ramped clutch cover (2), taking up clearance as the clutch disc
wears and maintaining diaphragm spring force throughout the life of the clutch. The primary
benefits of this design are reduced pedal effort, constant release load over clutch life, and extended
clutch life.
Service and Repair > Clutch Disc and Pressure Plate
Clutch Disc: Service and Repair Clutch Disc and Pressure Plate
Removal
REMOVAL
DIESEL
1. Remove transaxle assembly. 2. Mark position of pressure plate (3) on flywheel (1) with paint or
scribe for assembly reference. 3. Loosen and remove six pressure plate-to-flywheel bolts. Remove
pressure plate (3) and clutch disc (2).
Service and Repair > Clutch Disc and Pressure Plate > Page 4640
4. Remove eight flywheel-to-crankshaft bolts and remove flywheel assembly (1).
GAS
1. Remove transaxle assembly. 2. Remove the modular clutch assembly (1).
Installation
INSTALLATION
DIESEL
1. Inspect clutch release bearing and lever for excessive wear and replace as necessary. The
release bearing is integral to the Concentric Slave
Cylinder (CSC).
2. Clean the surfaces of the flywheel (1) and pressure plate to make certain that all oil, grease, and
rust have been removed. 3. Verify the crankshaft mounting flange is free of debris, oil, grease, etc.
Position the flywheel (1) onto the engine crankshaft. 4. Install flywheel to crankshaft. Install eight
(8) flywheel-to-crankshaft bolts and tighten to 45 Nm (33 ft. lbs.) plus an additional 1/4 turn (90
degrees).
5. Apply a very light coating of grease to the splines in the clutch disc hub. 6. Position the clutch
disc (2) to the flywheel (1). Make sure the side marked "FLYWHEEL SIDE" faces the flywheel (1).
7. Install the clutch pressure plate (1) to the flywheel and clutch disc. Finger tighten the six
pressure plate-to-flywheel bolts.
8. Use Clutch Alignment Tool 6724 (3) to position the clutch disc (2) to the center of the flywheel
(1).
9. Tighten pressure plate bolts (2) evenly and in rotation a few threads at a time The bolts must be
tightened evenly and to specified torque to
avoid distorting the pressure plate.
10. Using a "criss-cross" pattern, torque pressure plate bolts (2) to 31 Nm (23 ft. lbs.). Remove the
clutch disc alignment tool. 11. Apply light coat of MOPAR(R) High Temperature Bearing Grease or
equivalent to clutch disc hub and splines of transmission input shaft.
CAUTION: Do not over lubricate shaft splines. This will result in grease contamination of disc.
12. Install transaxle.
GAS
1. Install new modular clutch assembly onto input shaft of transmission. 2. Install the transmission.
Clutch Disc: Service and Repair Modular Clutch
Removal
REMOVAL
1. Remove transaxle (3) from vehicle.
2. Remove modular clutch assembly (1) from transaxle input shaft.

3. Disassemble modular clutch assembly (If individual parts are available). Remove six pressure
plate-to-flywheel bolts (1). Remove pressure plate
(2) and disc from flywheel.
Inspection
INSPECTION
Fluid contamination is a frequent cause of clutch malfunctions. Oil, grease, water, or other fluids on
the clutch contact surfaces will cause faulty operation.
During inspection, note if any components are contaminated. Look for evidence of oil, grease, or
water/road splash on clutch components.
OIL CONTAMINATION
Oil contamination indicates a leak at the rear main seal and/or transaxle input shaft. Oil leaks
produce a residue of oil on the transaxle housing interior, clutch cover and flywheel. Heat buildup
caused by slippage can bake the oil residue onto the components. This glaze-like residue ranges in
color from amber to black.
GREASE CONTAMINATION
Grease contamination is usually a product of over-lubrication. During clutch service, apply only a
small amount of grease to the input shaft splines. Excess grease may be thrown off during
operation, contaminating the disc.
ROAD SPLASH/WATER CONTAMINATION
Road splash contamination is usually caused by driving the vehicle through deep water puddles.
Water can be forced into the clutch housing, causing clutch components to become contaminated.
Facing of disc will absorb moisture and bond to the flywheel and/or, pressure plate, if vehicle is
allowed to stand for some time before use. If this condition occurs, replacement of clutch assembly
may be required. Drive the vehicle until normal clutch operating temperature has been obtained.
This will dry off disc assembly, pressure plate, and flywheel.
Installation
INSTALLATION
1. Install clutch module onto input shaft. 2. Install transaxle into vehicle.
Jeep Workshop Manuals > Transmission and Drivetrain > Clutch, M/T > Clutch Hydraulic System > Clutch Fluid >
Component Information > Technical Service Bulletins > Maintenance - Fluid Flushing Information
Clutch Fluid: Technical Service Bulletins Maintenance - Fluid Flushing Information
NUMBER: 26-001-09

MODELS:
2009 - 2010 (DS) Ram Truck (1500)
2005 - 2009 (HB) Durango
2007 - 2009 (HG) Aspen
2009 - 2010 (JC) Journey
2008 - 2010 (KK) Liberty
2007 - 2010 (KA) Nitro
2005 - 2007 (KJ) Liberty
2005 - 2010 (ND) Dakota
2005 - 2006 (PL) Neon

2007 - 2010 (PM) Caliber

Component Information > Technical Service Bulletins > Maintenance - Fluid Flushing Information > Page 4652
2005 - 2010 (ZB) Viper
DISCUSSION:
coolant.
operating range.
distilled water.
Disclaimer:
Clutch Fluid: Specifications
Clutch Fluid Type
Jeep Workshop Manuals > Transmission and Drivetrain > Clutch, M/T > Clutch Hydraulic System > Clutch Master Cylinder
> Component Information > Technical Service Bulletins > Customer Interest for Clutch Master Cylinder: > 06-006-07 > Dec
> 07 > M/T - Clutch Pedal Squeaks When Operated
Clutch Master Cylinder: Customer Interest M/T - Clutch Pedal Squeaks When Operated
NUMBER: 06-006-07
GROUP: Clutch

OCTOBER 17, 2006, WHICH SHOULD BE REMOVED FROM YOUR FILES. ALL REVISIONS
ARE HIGHLIGHTED WITH **ASTERISKS** AND INCLUDES THE ADDITION OF CLEAN
POINTS.
SUBJECT: Clutch Pedal Squeak
OVERVIEW: This bulletin involves lubricating the clutch master cylinder pushrod ball socket
(attachment at clutch pedal arm).
MODELS:
2007 (JS) Sebring
2007 (PM) Caliber
2007 (MK49) Compass
NOTE:
**This information applies to models equipped with a T-355 or BG6 Manual Transmission (Sales
Code DD7 or DEF) built prior to February 8, 2007 (MDH0208XX)**.
SYMPTOM/CONDITION: A squeak sound may be heard when applying or releasing the clutch
pedal. This may be more noticeable in cold temperatures.
DIAGNOSIS: If the customer describes a squeak sound when applying the clutch pedal, perform
the Repair Procedure
PARTS REQUIRED:
REPAIR PROCEDURE:
1. Remove the lower instrument panel bezel.

> 07 > M/T - Clutch Pedal Squeaks When Operated > Page 4662
2. Disconnect clutch master cylinder pushrod from clutch pedal arm (Fig. 1).
3. Lubricate the pushrod ball socket with a small amount of Silicone Grease pn 05019061AA.
4. Connect clutch master cylinder rod to clutch pedal pin. An audible "click" should be heard.
5. Install lower instrument panel bezel.
TIME ALLOWANCE:
> 07 > M/T - Clutch Pedal Squeaks When Operated > Page 4663
FAILURE CODE:
Disclaimer:
> Component Information > Technical Service Bulletins > All Technical Service Bulletins for Clutch Master Cylinder: >
06-006-07 > Dec > 07 > M/T - Clutch Pedal Squeaks When Operated
Clutch Master Cylinder: All Technical Service Bulletins M/T - Clutch Pedal Squeaks When
Operated
NUMBER: 06-006-07
GROUP: Clutch

POINTS.
MODELS:
2007 (JS) Sebring
2007 (PM) Caliber
2007 (MK49) Compass
NOTE:
PARTS REQUIRED:
REPAIR PROCEDURE:

06-006-07 > Dec > 07 > M/T - Clutch Pedal Squeaks When Operated > Page 4669
TIME ALLOWANCE:
06-006-07 > Dec > 07 > M/T - Clutch Pedal Squeaks When Operated > Page 4670
FAILURE CODE:
Disclaimer:
> Component Information > Description and Operation > Description - LHD
Clutch Master Cylinder: Description and Operation Description - LHD
DESCRIPTION
NOTE: The clutch master cylinder/hydraulic release system does not have its own reservoir. This
system is supplied fluid from the brake master cylinder reservoir.
The clutch master cylinder (1) mounts to the clutch pedal and consists of a push rod, a piston and
cylinder housing, an interconnecting hydraulic tube and a supply hose which connects to the brake
master cylinder reservoir (1) for fluid supply.
> Component Information > Description and Operation > Description - LHD > Page 4673
Clutch Master Cylinder: Description and Operation Operation - LHD
OPERATION
When the clutch pedal is depressed, the push rod moves the piston in the master cylinder (2),
displacing fluid through the hydraulic line and into the release bearing. The release bearing is
forced into the fingers of the clutch diaphragm springs. As the fingers move, they release the
clamping pressure on the clutch disc between the clutch pressure plate and the flywheel. The
clutch becomes disengaged as this pressure is released.
When the clutch pedal is released, the system hydraulic pressure is released. This allows the force
of the clutch diaphragm springs to return to their original position, re-clamping the clutch disc
between the flywheel and the clutch pressure plate. Also, the release bearing and lever are forced
to return, which reverses the movement of the hydraulic system and returns the pedal to its original
position against the up-stop.
> Component Information > Service and Repair > Removal - LHD
Clutch Master Cylinder: Service and Repair Removal - LHD
REMOVAL
1. Remove the engine cover. 2. Remove air cleaner assembly (1). 3. Disconnect battery negative
cable (2). 4. Remove lower instrument panel bezel.
> Component Information > Service and Repair > Removal - LHD > Page 4676
5. Disconnect the pushrod (3) at the clutch pedal. 6. Disconnect hydraulic supply tube at clutch
master cylinder by pulling retaining clip (5) then pulling out on tube. To completely drain clutch
master
cylinder and tubing, remove brake master cylinder cap band drain fluid into suitable container.
7. Disconnect clutch master cylinder supply line from brake master cylinder reservoir (1). Cap off or
collect fluid spillage from reservoir port.
CAUTION: Use care when removing clutch master cylinder from engine compartment. Aggressive
handling can result in a damaged hydraulic tube and improper clutch release operation upon
reassembly.
CAUTION: Brake fluid will damage painted surfaces. If brake fluid is spilled on any painted
surfaces, wash it off immediately with water.
8. Remove master cylinder assembly (1) from mounting position by turning 1/4 turn and carefully
work hydraulic pipe from out of left rail retainer
and engine compartment.

Clutch Master Cylinder: Service and Repair Installation - LHD
INSTALLATION
1. Install clutch master cylinder (1).

2. Insert tube into master cylinder port and install retaining clip (5). 3. Connect clutch master
cylinder supply hose (2) to brake master cylinder reservoir (1). 4. Verify that brake master cylinder
reservoir is full and cap is off. 5. Install clutch master cylinder body to clutch pedal and 1/4 turn to
secure. 6. Connect clutch master cylinder rod to clutch pedal pin. An audible "click" should be
heard. 7. Install lower instrument panel bezel.
8. Connect battery negative cable. 9. Install air cleaner assembly (1).
10. Verify that brake master cylinder reservoir is full. Top off with DOT 3 brake fluid if necessary.
11. Bleed clutch system. 12. Actuate clutch pedal a minimum of fifteen times to allow any air
ingested into the system to vent to the master cylinder reservoir. If residual air
becomes trapped in the system, it is necessary to bleed the clutch hydraulic system.
13. Verify proper clutch release system operation.

Jeep Workshop Manuals > Transmission and Drivetrain > Clutch, M/T > Clutch Hydraulic System > Clutch Slave Cylinder >
Clutch Slave Cylinder: Description and Operation
DESCRIPTION
The clutch slave cylinder (1) consists of a hydraulic piston and cylinder, seal and return spring. It is
fastened to the transaxle bellhousing. The slave cylinder is connected to the clutch master cylinder
hydraulic pipe, which is retained to the cylinder by a pair of retainer clips, and has a bleed port to
facilitate the removal of air from the system.
The clutch release system (1) utilizes a slave cylinder of a concentric design, having all
components fixed about the same axis. The concentric slave cylinder (CSC) is mounted to the
inside of the clutch bellhousing and is serviced only as an assembly.
The concentric design permits high efficiency, resulting in low and consistent pedal effort, as well
as automatic adjustment to compensate for clutch disc wear. The CSC is a self-contained unit,
consisting of a main body (2) and piston (6), spring (5), integrated release bearing (1), and a rubber
boot (4).
Clutch Slave Cylinder: Service and Repair Removal
REMOVAL
NOTE: To prevent drainage of clutch master cylinder assembly upon slave cylinder removal, it is
necessary to make sure brake master cylinder fluid level is full and reservoir cap is installed tight.
1. Remove transaxle from vehicle. 2. Remove bolts to slave cylinder-to-clutch bellhousing bolts and
remove slave cylinder (1) from transaxle.
Clutch Slave Cylinder: Service and Repair Installation
INSTALLATION
1. Install slave cylinder (1) to transaxle using new bolts.
NOTE: Torque three CSC body screws first, then torque the fluid tube attachment.
2. Torque slave cylinder-to-case bolts in three steps:
- 2 Nm (18 in. lbs.)
- 5 Nm (44 in. lbs.)
- 8.4 Nm (74 in. lbs.)
3. Install transaxle. 4. Bleed clutch hydraulic system.

Clutch Slave Cylinder: Service and Repair Clutch Master Cylinder
Removal - LHD
REMOVAL
master
reassembly.
Installation - LHD
INSTALLATION

8. Connect battery negative cable. 9. Install air cleaner assembly (1).
10. Verify that brake master cylinder reservoir is full. Top off with DOT 3 brake fluid if necessary.
11. Bleed clutch system. 12. Actuate clutch pedal a minimum of fifteen times to allow any air
ingested into the system to vent to the master cylinder reservoir. If residual air
becomes trapped in the system, it is necessary to bleed the clutch hydraulic system.
13. Verify proper clutch release system operation.

Jeep Workshop Manuals > Transmission and Drivetrain > Clutch, M/T > Clutch Hydraulic System > Hydraulic Hose, Clutch
> Component Information > Service and Repair > Removal - LHD
Hydraulic Hose: Service and Repair Removal - LHD
REMOVAL
master
reassembly.

Hydraulic Hose: Service and Repair Installation - LHD
INSTALLATION

ERROR: stackunderflow OFFENDING COMMAND: begin
STACK:
Jeep Workshop Manuals > Transmission and Drivetrain > Clutch, M/T > Clutch Pedal Assembly > Component Information >
Technical Service Bulletins > Customer Interest: > 06-006-07 > Dec > 07 > M/T - Clutch Pedal Squeaks When Operated
Clutch Pedal Assembly: Customer Interest M/T - Clutch Pedal Squeaks When Operated
NUMBER: 06-006-07
GROUP: Clutch

POINTS.
MODELS:
2007 (JS) Sebring
2007 (PM) Caliber
2007 (MK49) Compass
NOTE:
PARTS REQUIRED:
REPAIR PROCEDURE:

Technical Service Bulletins > Customer Interest: > 06-006-07 > Dec > 07 > M/T - Clutch Pedal Squeaks When Operated >
Page 4710
TIME ALLOWANCE:
Technical Service Bulletins > Customer Interest: > 06-006-07 > Dec > 07 > M/T - Clutch Pedal Squeaks When Operated >
Page 4711
FAILURE CODE:
Disclaimer:
Technical Service Bulletins > Customer Interest: > 06-005-07 > Oct > 07 > M/T - Squeak When Operating Clutch Pedal
Clutch Pedal Assembly: Customer Interest M/T - Squeak When Operating Clutch Pedal
NUMBER: 06-005-07
GROUP: Clutch
DATE: October 31, 2007
OVERVIEW: This bulletin involves lubricating the clutch return spring.
MODELS:
2007 - 2008 (JS41) Avenger / Sebring
2007 - 2008 (PM) Caliber
2007 - 2008 (MK49) Compass
2007 - 2008 (MK74) Patriot
NOTE:
This information applies to models equipped with a T-355 or BG6 Manual Transmission (Sales
Code DD7 or DEF) built prior to August 6, 2007 (MDH0806XX).
pedal.
PARTS REQUIRED:
REPAIR PROCEDURE:
1. Using grease pn 04318066AB, lubricate the clutch return spring
2. Verify the squeak is eliminated.
TIME ALLOWANCE:
Technical Service Bulletins > Customer Interest: > 06-005-07 > Oct > 07 > M/T - Squeak When Operating Clutch Pedal >
Page 4716
FAILURE CODE:
Disclaimer:
Technical Service Bulletins > Customer Interest: > 06-003-07 > Jun > 07 > Steering - Scrape Noise From Clutch Pedal Area
on Turns
Clutch Pedal Assembly: Customer Interest Steering - Scrape Noise From Clutch Pedal Area on
Turns
NUMBER: 06-003-07
GROUP: Clutch
DATE: June 22, 2007
SUBJECT: Clicking / Scraping Sound From Clutch Pedal Area When Turning Steering Wheel
OVERVIEW: This bulletin involves diagnosing the sound and modifying the clutch switch down stop
flag.
MODELS:
2007 (MK49) Compass

2007 (MK74) Patriot
NOTE:
This bulletin applies to Right Hand Drive (RHD) models built prior to March 27, 2007
(MDH0327XX).
SYMPTOM/CONDITION:
Some customers may experience a clicking or scraping sound coming from the clutch pedal area
when making turns. This sound will only occur when customers tilt the steering column to its full
down position.
DIAGNOSIS:
Start the vehicle and place the transmission in neutral. Place the column tilt mechanism in the full
down position. Rotate the steering wheel while listening for the sound. If the sound is heard,
depress the clutch pedal to see if the sound stops. If the sound stops, inspect the lower steering
column at the area of the clutch switch down stop flag (Fig. 1 ). If witness marks or physical contact
is seen between the clutch switch down stop flag and column shaft, Perform the Repair Procedure.
on Turns > Page 4721
REPAIR PROCEDURE:
1. Unbolt and lower the steering column to provide clearance to grind the down stop flag.
2. Using a small hand grinder, remove material from the clutch switch down stop flag as shown in
(Fig 2).
3. Make sure the corner of the flag is ground to a radius.
4. Reinstall the steering column.
NOTE:
Leave enough material on the downstop flag to provide a contact area for the clutch switch.
TIME ALLOWANCE:
on Turns > Page 4722
FAILURE CODE:
Disclaimer:
Technical Service Bulletins > All Technical Service Bulletins for Clutch Pedal Assembly: > 06-006-07 > Dec > 07 > M/T -
Clutch Pedal Squeaks When Operated
Clutch Pedal Assembly: All Technical Service Bulletins M/T - Clutch Pedal Squeaks When
Operated
NUMBER: 06-006-07
GROUP: Clutch

POINTS.
MODELS:
2007 (JS) Sebring
2007 (PM) Caliber
2007 (MK49) Compass
NOTE:
PARTS REQUIRED:
REPAIR PROCEDURE:

Clutch Pedal Squeaks When Operated > Page 4728
TIME ALLOWANCE:
Clutch Pedal Squeaks When Operated > Page 4729
FAILURE CODE:
Disclaimer:
Technical Service Bulletins > All Technical Service Bulletins for Clutch Pedal Assembly: > 06-005-07 > Oct > 07 > M/T -
Squeak When Operating Clutch Pedal
Clutch Pedal Assembly: All Technical Service Bulletins M/T - Squeak When Operating Clutch
Pedal
NUMBER: 06-005-07
GROUP: Clutch
OVERVIEW: This bulletin involves lubricating the clutch return spring.
MODELS:
2007 - 2008 (JS41) Avenger / Sebring
2007 - 2008 (PM) Caliber
2007 - 2008 (MK49) Compass
2007 - 2008 (MK74) Patriot

NOTE:
This information applies to models equipped with a T-355 or BG6 Manual Transmission (Sales
Code DD7 or DEF) built prior to August 6, 2007 (MDH0806XX).
pedal.
PARTS REQUIRED:
REPAIR PROCEDURE:
1. Using grease pn 04318066AB, lubricate the clutch return spring
2. Verify the squeak is eliminated.
TIME ALLOWANCE:
Technical Service Bulletins > All Technical Service Bulletins for Clutch Pedal Assembly: > 06-005-07 > Oct > 07 > M/T -
Squeak When Operating Clutch Pedal > Page 4734
FAILURE CODE:
Disclaimer:
Technical Service Bulletins > All Technical Service Bulletins for Clutch Pedal Assembly: > 06-003-07 > Jun > 07 > Steering -
Scrape Noise From Clutch Pedal Area on Turns
Clutch Pedal Assembly: All Technical Service Bulletins Steering - Scrape Noise From Clutch Pedal
Area on Turns
NUMBER: 06-003-07
GROUP: Clutch
DATE: June 22, 2007
SUBJECT: Clicking / Scraping Sound From Clutch Pedal Area When Turning Steering Wheel
OVERVIEW: This bulletin involves diagnosing the sound and modifying the clutch switch down stop
flag.
MODELS:
2007 (MK49) Compass

2007 (MK74) Patriot
NOTE:
This bulletin applies to Right Hand Drive (RHD) models built prior to March 27, 2007
(MDH0327XX).
SYMPTOM/CONDITION:
Some customers may experience a clicking or scraping sound coming from the clutch pedal area
when making turns. This sound will only occur when customers tilt the steering column to its full
down position.
DIAGNOSIS:
Start the vehicle and place the transmission in neutral. Place the column tilt mechanism in the full
down position. Rotate the steering wheel while listening for the sound. If the sound is heard,
depress the clutch pedal to see if the sound stops. If the sound stops, inspect the lower steering
column at the area of the clutch switch down stop flag (Fig. 1 ). If witness marks or physical contact
is seen between the clutch switch down stop flag and column shaft, Perform the Repair Procedure.
Scrape Noise From Clutch Pedal Area on Turns > Page 4739
REPAIR PROCEDURE:
1. Unbolt and lower the steering column to provide clearance to grind the down stop flag.
2. Using a small hand grinder, remove material from the clutch switch down stop flag as shown in
(Fig 2).
3. Make sure the corner of the flag is ground to a radius.
4. Reinstall the steering column.
NOTE:
Leave enough material on the downstop flag to provide a contact area for the clutch switch.
TIME ALLOWANCE:
Scrape Noise From Clutch Pedal Area on Turns > Page 4740
FAILURE CODE:
Disclaimer:
Technical Service Bulletins > All Technical Service Bulletins for Clutch Pedal Assembly: > 06-002-06 > Dec > 06 > Clutch -
Clutch Pedal Push Back
Clutch Pedal Assembly: All Technical Service Bulletins Clutch - Clutch Pedal Push Back
NUMBER: 06-002-06
GROUP: Clutch
SUBJECT: Clutch Pedal Push Back
OVERVIEW: This bulletin involves removing the over-center spring (attachment at clutch pedal
arm).
MODELS:
2007 (JS) Sebring
2007 (PM) Caliber
2007 (MK49) Compass
NOTE:
This information applies to models vehicles equipped with a 2.0L Diesel engine (sales code ECD)
and a Manual Transmission (Sales Code DEF) built before January 1, 2007 (MDH 0101XX).
SYMPTOM/CONDITION:
A clutch pedal push back may be felt toward the end (engaged) of the clutch pedal travel.
This may be described as a little bump felt just before the end of the pedal stroke.
DIAGNOSIS:
If the customer describes the symptom condition, perform the Repair Procedure
REPAIR PROCEDURE:

Clutch Pedal Push Back > Page 4745
3. Remove the rubber downstop bumper (Fig. 1).
4. Push the clutch pedal all the way down.
NOTE:
Be sure the rubber downstop bumper is removed. This will allow for more pedal travel to assist in
the next step.
5. Pull the overcenter spring and bracket bushing out of the pedal arm bracket.
6. Pry overcenter clutch springs out of both side bushings and discard.
7. Remove both side bushings and discard.
8. Release clutch pedal.
9. Reinstall the rubber downstop bumper.
10. Reconnect the clutch master cylinder pushrod to the clutch pedal arm (Fig. 1).
11. Install the lower instrument panel bezel.
TIME ALLOWANCE:
FAILURE CODE:
Disclaimer:
Technical Service Bulletins > All Other Service Bulletins for Clutch Pedal Assembly: > 06-002-06 > Dec > 06 > Clutch -
Clutch Pedal Push Back
Clutch Pedal Assembly: All Technical Service Bulletins Clutch - Clutch Pedal Push Back
NUMBER: 06-002-06
GROUP: Clutch
SUBJECT: Clutch Pedal Push Back
OVERVIEW: This bulletin involves removing the over-center spring (attachment at clutch pedal
arm).
MODELS:
2007 (JS) Sebring
2007 (PM) Caliber
2007 (MK49) Compass
NOTE:
This information applies to models vehicles equipped with a 2.0L Diesel engine (sales code ECD)
and a Manual Transmission (Sales Code DEF) built before January 1, 2007 (MDH 0101XX).
SYMPTOM/CONDITION:
A clutch pedal push back may be felt toward the end (engaged) of the clutch pedal travel.
This may be described as a little bump felt just before the end of the pedal stroke.
DIAGNOSIS:
If the customer describes the symptom condition, perform the Repair Procedure
REPAIR PROCEDURE:

3. Remove the rubber downstop bumper (Fig. 1).
4. Push the clutch pedal all the way down.
NOTE:
Be sure the rubber downstop bumper is removed. This will allow for more pedal travel to assist in
the next step.
5. Pull the overcenter spring and bracket bushing out of the pedal arm bracket.
6. Pry overcenter clutch springs out of both side bushings and discard.
7. Remove both side bushings and discard.
8. Release clutch pedal.
9. Reinstall the rubber downstop bumper.
10. Reconnect the clutch master cylinder pushrod to the clutch pedal arm (Fig. 1).
11. Install the lower instrument panel bezel.
TIME ALLOWANCE:
FAILURE CODE:
Disclaimer:
Jeep Workshop Manuals > Transmission and Drivetrain > Clutch, M/T > Pressure Plate > Component Information >
Specifications
Pressure Plate: Specifications
Pressure Plate-to-Flywheel Bolts

..............................................................................................................................................................
28 Nm (23 ft. lbs.)
Pressure Plate: Description and Operation Description
DESCRIPTION
The modular clutch assembly (1) is located between the engine and manual transaxle in the
transaxle bellhousing, and is responsible for transmitting engine power to the transaxle. The
modular clutch is an assembly which incorporates a self-adjusting design and consists of the
following components:
- Flywheel
- Clutch Disc
- Pressure Plate
- Diaphragm Spring
- Adjusting Ring
- Sensor
- Cover
Pressure Plate: Description and Operation Operation
OPERATION
The modular clutch assembly is designed to transmit power from the engine to the manual
transaxle. This is accomplished by the friction and clamping force generated when the spring
loaded pressure plate locks the clutch disc to the flywheel. The clutch disc, which is splined to the
transaxle input shaft, transmits power until the center of the diaphragm spring is depressed, and
the clamp force is removed from the disc.
The self-adjusting feature of this clutch assembly relies on the sensor ring (4) and the adjuster ring
(5), which works its way around a ramped clutch cover (2), taking up clearance as the clutch disc
wears and maintaining diaphragm spring force throughout the life of the clutch. The primary
benefits of this design are reduced pedal effort, constant release load over clutch life, and extended
clutch life.
Jeep Workshop Manuals > Transmission and Drivetrain > Clutch, M/T > Pressure Plate > Component Information > Service
and Repair > Clutch Disc and Pressure Plate
Pressure Plate: Service and Repair Clutch Disc and Pressure Plate
Removal
REMOVAL
DIESEL
1. Remove transaxle assembly. 2. Mark position of pressure plate (3) on flywheel (1) with paint or
scribe for assembly reference. 3. Loosen and remove six pressure plate-to-flywheel bolts. Remove
pressure plate (3) and clutch disc (2).
and Repair > Clutch Disc and Pressure Plate > Page 4763
4. Remove eight flywheel-to-crankshaft bolts and remove flywheel assembly (1).
GAS
1. Remove transaxle assembly. 2. Remove the modular clutch assembly (1).
Installation
INSTALLATION
DIESEL
1. Inspect clutch release bearing and lever for excessive wear and replace as necessary. The
release bearing is integral to the Concentric Slave
Cylinder (CSC).
2. Clean the surfaces of the flywheel (1) and pressure plate to make certain that all oil, grease, and
rust have been removed. 3. Verify the crankshaft mounting flange is free of debris, oil, grease, etc.
Position the flywheel (1) onto the engine crankshaft. 4. Install flywheel to crankshaft. Install eight
(8) flywheel-to-crankshaft bolts and tighten to 45 Nm (33 ft. lbs.) plus an additional 1/4 turn (90
degrees).
5. Apply a very light coating of grease to the splines in the clutch disc hub. 6. Position the clutch
disc (2) to the flywheel (1). Make sure the side marked "FLYWHEEL SIDE" faces the flywheel (1).
7. Install the clutch pressure plate (1) to the flywheel and clutch disc. Finger tighten the six
pressure plate-to-flywheel bolts.
8. Use Clutch Alignment Tool 6724 (3) to position the clutch disc (2) to the center of the flywheel
(1).
9. Tighten pressure plate bolts (2) evenly and in rotation a few threads at a time The bolts must be
tightened evenly and to specified torque to
avoid distorting the pressure plate.
10. Using a "criss-cross" pattern, torque pressure plate bolts (2) to 31 Nm (23 ft. lbs.). Remove the
clutch disc alignment tool. 11. Apply light coat of MOPAR(R) High Temperature Bearing Grease or
equivalent to clutch disc hub and splines of transmission input shaft.
CAUTION: Do not over lubricate shaft splines. This will result in grease contamination of disc.
12. Install transaxle.
GAS
1. Install new modular clutch assembly onto input shaft of transmission. 2. Install the transmission.
Pressure Plate: Service and Repair Modular Clutch
Removal
REMOVAL
1. Remove transaxle (3) from vehicle.
2. Remove modular clutch assembly (1) from transaxle input shaft.

3. Disassemble modular clutch assembly (If individual parts are available). Remove six pressure
plate-to-flywheel bolts (1). Remove pressure plate
(2) and disc from flywheel.
Inspection
INSPECTION
Fluid contamination is a frequent cause of clutch malfunctions. Oil, grease, water, or other fluids on
the clutch contact surfaces will cause faulty operation.
During inspection, note if any components are contaminated. Look for evidence of oil, grease, or
water/road splash on clutch components.
OIL CONTAMINATION
Oil contamination indicates a leak at the rear main seal and/or transaxle input shaft. Oil leaks
produce a residue of oil on the transaxle housing interior, clutch cover and flywheel. Heat buildup
caused by slippage can bake the oil residue onto the components. This glaze-like residue ranges in
color from amber to black.
GREASE CONTAMINATION
Grease contamination is usually a product of over-lubrication. During clutch service, apply only a
small amount of grease to the input shaft splines. Excess grease may be thrown off during
operation, contaminating the disc.
ROAD SPLASH/WATER CONTAMINATION
Road splash contamination is usually caused by driving the vehicle through deep water puddles.
Water can be forced into the clutch housing, causing clutch components to become contaminated.
Facing of disc will absorb moisture and bond to the flywheel and/or, pressure plate, if vehicle is
allowed to stand for some time before use. If this condition occurs, replacement of clutch assembly
may be required. Drive the vehicle until normal clutch operating temperature has been obtained.
This will dry off disc assembly, pressure plate, and flywheel.
Installation
INSTALLATION
1. Install clutch module onto input shaft. 2. Install transaxle into vehicle.
Jeep Workshop Manuals > Transmission and Drivetrain > Continuously Variable Transmission/Transaxle, CVT > Actuators
and Solenoids - CVT > Pressure Regulating Solenoid, CVT > Component Information > Locations
Component ID: 15
Connector:
Color : BLACK
# of pins : 22
6 GROUND Z967 18BK

12 - -
13 - -
14 - -
15 - -
20 - -
and Solenoids - CVT > Pressure Regulating Solenoid, CVT > Component Information > Locations > Page 4775
Component ID: 15
Connector:
Color : BLACK
# of pins : 22
6 GROUND Z967 18BK

12 - -
13 - -
14 - -
15 - -
20 - -
and Solenoids - CVT > Shift Solenoid, CVT > Component Information > Locations
Component ID: 15
Connector:
Color : BLACK
# of pins : 22
6 GROUND Z967 18BK

12 - -
13 - -
14 - -
15 - -
20 - -
and Solenoids - CVT > Shift Solenoid, CVT > Component Information > Locations > Page 4781
Component ID: 15
Connector:
Color : BLACK
# of pins : 22
6 GROUND Z967 18BK

12 - -
13 - -
14 - -
15 - -
20 - -
Jeep Workshop Manuals > Transmission and Drivetrain > Continuously Variable Transmission/Transaxle, CVT > Control
Module, CVT > Component Information > Technical Service Bulletins > Customer Interest for Control Module: > 18-032-07
> May > 07 > A/T - MIL ON Possible DTC P2004
NUMBER: 18-032-07
DATE: May 16, 2007
INTERNET.
BULLETIN.
CAUTION:

BE INSTALLED.
MODELS:
2007 (JS) Sebring
2007 (MK49) Compass
2007 (MK74) Patriot
2007 (PM) Caliber
NOTE:
SYMPTOM/CONDITION:
DIAGNOSIS:
PARTS REQUIRED:
> May > 07 > A/T - MIL ON Possible DTC P2004 > Page 4792
CAUTION:
NOTE:
NOTE:
NOTE:
drop.

seconds.
CAUTION:

PROCESS.
NOTE:
seconds.
CAUTION:
NOTE:
NOTE:
TIME ALLOWANCE:
FAILURE CODE:
Disclaimer:
Module, CVT > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Control Module: >
18-032-07 > May > 07 > A/T - MIL ON Possible DTC P2004
NUMBER: 18-032-07
DATE: May 16, 2007
INTERNET.
BULLETIN.
CAUTION:

BE INSTALLED.
MODELS:
2007 (JS) Sebring
2007 (MK49) Compass
2007 (MK74) Patriot
2007 (PM) Caliber
NOTE:
SYMPTOM/CONDITION:
DIAGNOSIS:
PARTS REQUIRED:
CAUTION:
NOTE:
NOTE:
NOTE:
drop.

seconds.
CAUTION:

PROCESS.
NOTE:
seconds.
CAUTION:
NOTE:
NOTE:
TIME ALLOWANCE:
FAILURE CODE:
Disclaimer:
Module, CVT > Component Information > Technical Service Bulletins > Page 4803
Component ID: 170
Connector:
Color : WHITE
# of pins : 24
Qualifier : (CVT)

7--
8--
9--
16 - -
17 - -
23 - -
24 - -
Connector:
Color : LT. GRAY
# of pins : 24
Qualifier : (CVT)
1 GROUND Z967 18BK
3--
4 FUSED B(+) (I.O.D.) A416 18RD

6--
7--
8--
9--
11 - -

15 - -
16 - -
24 GROUND Z967 18BK
Component ID: 170
Connector:
Color : WHITE
# of pins : 24
Qualifier : (CVT)

7--
8--
9--
16 - -
17 - -
23 - -
24 - -
Connector:
Color : LT. GRAY
# of pins : 24
Qualifier : (CVT)
1 GROUND Z967 18BK
3--
4 FUSED B(+) (I.O.D.) A416 18RD

6--
7--
8--
9--
11 - -

15 - -
16 - -
24 GROUND Z967 18BK
Module, CVT > Component Information > Description and Operation > Description
DESCRIPTION
Module, CVT > Component Information > Description and Operation > Description > Page 4815
OPERATION
Shift Control
"Drive" Position
gear ranges.
Lock-up Control
Selection Control
CAN Communication
Inputs and Outputs

Fail-safe Function
PNP Switch
Lock-up solenoid
Stepping Motor
Backup Power Supply
TCM
Module, CVT > Component Information > Service and Repair > Removal
REMOVAL
Module, CVT > Component Information > Service and Repair > Removal > Page 4822
4. Remove the TCM.

Module, CVT > Component Information > Service and Repair > Removal > Page 4823
INSTALLATION

Jeep Workshop Manuals > Transmission and Drivetrain > Continuously Variable Transmission/Transaxle, CVT >
Differential, CVT > Differential Fluid - CVT > Component Information > Technical Service Bulletins > Maintenance - Fluid
Flushing Information
Differential Fluid - CVT: Technical Service Bulletins Maintenance - Fluid Flushing Information
NUMBER: 26-001-09

MODELS:
2009 - 2010 (DS) Ram Truck (1500)
2005 - 2009 (HB) Durango
2007 - 2009 (HG) Aspen
2009 - 2010 (JC) Journey
2008 - 2010 (KK) Liberty
2007 - 2010 (KA) Nitro
2005 - 2007 (KJ) Liberty
2005 - 2010 (ND) Dakota
2005 - 2006 (PL) Neon
2007 - 2010 (PM) Caliber

Differential, CVT > Differential Fluid - CVT > Component Information > Technical Service Bulletins > Maintenance - Fluid
Flushing Information > Page 4829
2005 - 2010 (ZB) Viper
DISCUSSION:
coolant.
operating range.
distilled water.
Disclaimer:
Jeep Workshop Manuals > Transmission and Drivetrain > Continuously Variable Transmission/Transaxle, CVT > Fluid -
CVT > Component Information > Technical Service Bulletins > Maintenance - Fluid Flushing Information
Fluid - CVT: Technical Service Bulletins Maintenance - Fluid Flushing Information
NUMBER: 26-001-09

MODELS:
2009 - 2010 (DS) Ram Truck (1500)
2005 - 2009 (HB) Durango
2007 - 2009 (HG) Aspen
2009 - 2010 (JC) Journey
2008 - 2010 (KK) Liberty
2007 - 2010 (KA) Nitro
2005 - 2007 (KJ) Liberty
2005 - 2010 (ND) Dakota
2005 - 2006 (PL) Neon

2007 - 2010 (PM) Caliber

CVT > Component Information > Technical Service Bulletins > Maintenance - Fluid Flushing Information > Page 4834
2005 - 2010 (ZB) Viper
DISCUSSION:
coolant.
operating range.
distilled water.
Disclaimer:
CVT > Component Information > Specifications > Capacity Specifications
Fluid - CVT: Capacity Specifications
CVT Transmission Service Fill ............................................................................................................

.............................................................................. 14.8 pints (7.0 liters) Overhaul Fill ........................
.............................................................................................................................................................
17.1 pints (8.1 liters)*
*Note: Dry fill capacity. Depending on type and size of internal cooler, length and inside diameter of
cooler lines, or use of an auxiliary cooler, these figures may vary.
CVT > Component Information > Specifications > Capacity Specifications > Page 4837
Fluid - CVT: Fluid Type Specifications
Automatic Transmission Fluid Type Transmission Fluid .....................................................................

................................................................................................................ Mopar CVTF + 4
CVT > Component Information > Testing and Inspection > Causes Of Burnt Fluid
Fluid - CVT: Testing and Inspection Causes Of Burnt Fluid
CAUSES OF BURNT FLUID
Burnt, discolored fluid is a result of overheating which has three primary causes.
- Internal clutch slippage, usually caused by low line pressure, inadequate clutch apply pressure, or
clutch seal failure.
- A result of restricted fluid flow through the main and/or auxiliary cooler. This condition is usually
the result of a faulty or damaged oil cooler, or severe restrictions in the coolers and lines caused by
debris or kinked lines.
- Heavy duty operation with a vehicle not properly equipped for this type of operation. Trailer towing
or similar high load operation will overheat the transmission fluid if the vehicle is improperly
equipped. Such vehicles should have an auxiliary transmission fluid cooler, a heavy duty cooling
system, and the engine/axle ratio combination needed to handle heavy loads.
CVT > Component Information > Testing and Inspection > Causes Of Burnt Fluid > Page 4840
Fluid - CVT: Testing and Inspection Effects Of Incorrect Fluid Level
EFFECTS OF INCORRECT FLUID LEVEL
A low fluid level allows the pump to take in air along with the fluid. Air in the fluid will cause fluid
pressures to be low and develop slower than normal. If the transmission is overfilled, the gears
churn the fluid into foam. This aerates the fluid and causing the same conditions occurring with a
low level. In either case, air bubbles cause fluid overheating, oxidation, and varnish buildup which
interferes with valve and clutch operation. Foaming also causes fluid expansion which can result in
fluid overflow from the transmission vent or fill tube. Fluid overflow can easily be mistaken for a
leak if inspection is not careful.
CVT > Component Information > Testing and Inspection > Causes Of Burnt Fluid > Page 4841
Fluid - CVT: Testing and Inspection Fluid Contamination
FLUID CONTAMINATION
Transmission fluid contamination is generally a result of:
- adding incorrect fluid
- failure to clean dipstick and fill tube when checking level
- engine coolant entering the fluid
- internal failure that generates debris
- overheat that generates sludge (fluid breakdown)
- failure to replace contaminated converter after repair
The use of non-recommended fluids can result in transmission failure. The usual results are erratic
shifts, slippage, abnormal wear and eventual failure due to fluid breakdown and sludge formation.
Avoid this condition by using recommended fluids only.
The dipstick cap and fill tube should be wiped clean before checking fluid level. Dirt, grease and
other foreign material on the cap and tube could fall into the tube if not removed beforehand. Take
the time to wipe the cap and tube clean before withdrawing the dipstick.
Engine coolant in the transmission fluid is generally caused by a cooler malfunction. The only
remedy is to replace the radiator as the cooler in the radiator is not a serviceable part. If coolant
has circulated through the transmission, an overhaul is necessary.
The torque converter should be replaced whenever a failure generates sludge and debris. This is
necessary because normal converter flushing procedures will not remove all contaminants.
CVT > Component Information > Service and Repair > Check Oil Level
Fluid - CVT: Service and Repair Check Oil Level
CHECK OIL LEVEL
1. Verify that the vehicle is parked on a level surface. 2. Remove the dipstick tube cap.
WARNING: There is a risk of accident from vehicle starting off by itself when engine is running.
There is a risk of injury from contusions and burns if you insert your hands into the engine when it
is started or when it is running. Secure vehicle to prevent it from moving off by itself. Wear properly
fastened and close-fitting work clothes. Do not touch hot or rotating parts.
3. Actuate the service brake. Start engine and let it run at idle speed in selector lever position "P".
4. Shift through the transmission modes several times with the vehicle stationary and the engine
idling. 5. Warm up the transmission, wait at least 2 minutes and check the oil level with the engine
running. Push the Oil Dipstick 9336 into transmission
fill tube until the dipstick tip contacts the oil pan and pull out again, read off oil level, repeat if
necessary.
NOTE: The dipstick will protrude from the fill tube when installed.
CVT TRANSMISSION FILL GRAPH
6. Check transmission oil temperature using the appropriate scan tool. 7. The transmission Oil
Dipstick 9336 has indicator marks every 10 mm. Determine the height of the oil level on the dipstick
and using the height,
the transmission temperature, and the Transmission Fluid Graph, determine if the transmission oil
level is correct.
8. Add or remove oil as necessary and recheck the oil level. 9. Once the oil level is correct, install
the dipstick tube cap.
CVT > Component Information > Service and Repair > Check Oil Level > Page 4844
Fluid - CVT: Service and Repair Fluid And Strainer Service
FLUID AND STRAINER SERVICE
transaxle case.
in.lbs.).
NOTE: Only transmission fluid of the type labeled Mopar(R) CVTF+4 (Automatic Transmission
Fluid) should be used in this transaxle.
11. Check the oil level.

Fluid - CVT: Service and Repair Transmission Cooler Filter
Removal
REMOVAL
transmission.
Installation
INSTALLATION

Fluid - CVT: Service and Repair Transmission Fill
TRANSMISSION FILL
To avoid overfilling transmission after a fluid change or overhaul, perform the following procedure:
1. Verify that the vehicle is parked on a level surface. 2. Remove the dipstick tube cap. 3. Add
following initial quantity of MOPAR(R) CVTF+4, Automatic Transmission Fluid, to the transmission:
a. If only fluid and filter were changed, add 7.0 L (14.8 pts.) of transmission fluid to transmission. b.
If the transmission was completely overhauled or the torque converter was replaced or drained,
add 8.1 L (17.1 pts.) of transmission fluid to
transmission.
4. Check the transmission fluid and adjust as required.

Jeep Workshop Manuals > Transmission and Drivetrain > Continuously Variable Transmission/Transaxle, CVT > Fluid Filter
- CVT > Component Information > Service and Repair > Removal
Fluid Filter - CVT: Service and Repair Removal
REMOVAL
transmission.

- CVT > Component Information > Service and Repair > Removal > Page 4856
Fluid Filter - CVT: Service and Repair Installation
INSTALLATION
- CVT > Component Information > Service and Repair > Removal > Page 4857

Jeep Workshop Manuals > Transmission and Drivetrain > Continuously Variable Transmission/Transaxle, CVT > Fluid
Line/Hose, CVT > Component Information > Service and Repair
Fluid Line/Hose: Service and Repair
STANDARD PROCEDURE - TRANSMISSION COOLER LINE QUICK CONNECT FITTING

DISASSEMBLY/ASSEMBLY
DISCONNECT
1. Remove dust cap by pulling it straight back off of quick connect fitting (1). 2. Place Release Tool
8875A (4) onto transmission cooler line with the fingers of the tool facing the quick connect fitting.
3. Slide Release Tool 8875A down the transmission line and engage the fingers of the tool into the
retaining clip. When properly engaged in the clip,
the tool will fit flush against the quick connect fitting.
4. Rotate the release tool 60° to expand the retaining clip. 5. While holding the release tool against
the quick connect fitting, pull back on the transmission cooler line to remove.
CONNECT
Line/Hose, CVT > Component Information > Service and Repair > Page 4861
1. Align transmission cooler line (3) with quick connect fitting while pushing straight into the fitting.
2. Push in on transmission cooler line until a "click" is heard or felt. 3. Slide dust cap (4) down the
transmission cooler line and snap it over the quick connect fitting until it is fully seated and rotates
freely. Dust cap
will only snap over quick connect fitting when the transmission cooler line is properly installed.
NOTE: If dust cap will not snap into place, repeat assembly step #2.
Jeep Workshop Manuals > Transmission and Drivetrain > Continuously Variable Transmission/Transaxle, CVT > Fluid Pan,
CVT > Component Information > Specifications
Fluid Pan: Specifications
Transmission Fluid Pan Bolts ..............................................................................................................

....................................................... 8 Nm (70 in.lbs.)
Pressure Sensor/Switch, CVT > Component Information > Locations
Component ID: 15
Connector:
Color : BLACK
# of pins : 22
6 GROUND Z967 18BK

12 - -
13 - -
14 - -
15 - -
20 - -
Pressure Sensor/Switch, CVT > Component Information > Locations > Page 4868
Component ID: 15
Connector:
Color : BLACK
# of pins : 22
6 GROUND Z967 18BK

12 - -
13 - -
14 - -
15 - -
20 - -
Jeep Workshop Manuals > Transmission and Drivetrain > Continuously Variable Transmission/Transaxle, CVT > Pressure
Regulating Solenoid, CVT > Component Information > Locations
Component ID: 15
Connector:
Color : BLACK
# of pins : 22
6 GROUND Z967 18BK

12 - -
13 - -
14 - -
15 - -
20 - -
Regulating Solenoid, CVT > Component Information > Locations > Page 4874
Component ID: 15
Connector:
Color : BLACK
# of pins : 22
6 GROUND Z967 18BK

12 - -
13 - -
14 - -
15 - -
20 - -
Jeep Workshop Manuals > Transmission and Drivetrain > Continuously Variable Transmission/Transaxle, CVT > Relays
and Modules - CVT > Control Module, CVT > Component Information > Technical Service Bulletins > Customer Interest for
NUMBER: 18-032-07
DATE: May 16, 2007
INTERNET.
BULLETIN.
CAUTION:

BE INSTALLED.
MODELS:
2007 (JS) Sebring
2007 (MK49) Compass
2007 (MK74) Patriot
2007 (PM) Caliber
NOTE:
SYMPTOM/CONDITION:
DIAGNOSIS:
PARTS REQUIRED:
CAUTION:
NOTE:
NOTE:
NOTE:
drop.

seconds.
CAUTION:

PROCESS.
NOTE:
seconds.
CAUTION:
NOTE:
NOTE:
TIME ALLOWANCE:
FAILURE CODE:
Disclaimer:
and Modules - CVT > Control Module, CVT > Component Information > Technical Service Bulletins > All Technical Service
NUMBER: 18-032-07
DATE: May 16, 2007
INTERNET.
BULLETIN.
CAUTION:

BE INSTALLED.
MODELS:
2007 (JS) Sebring
2007 (MK49) Compass
2007 (MK74) Patriot
2007 (PM) Caliber
NOTE:
SYMPTOM/CONDITION:
DIAGNOSIS:
PARTS REQUIRED:
CAUTION:
NOTE:
NOTE:
NOTE:
drop.

seconds.
CAUTION:

PROCESS.
NOTE:
seconds.
CAUTION:
NOTE:
NOTE:
TIME ALLOWANCE:
FAILURE CODE:
Disclaimer:
and Modules - CVT > Control Module, CVT > Component Information > Technical Service Bulletins > Page 4897
Component ID: 170
Connector:
Color : WHITE
# of pins : 24
Qualifier : (CVT)

7--
8--
9--
16 - -
17 - -
23 - -
24 - -
Connector:
Color : LT. GRAY
# of pins : 24
Qualifier : (CVT)
1 GROUND Z967 18BK
3--
4 FUSED B(+) (I.O.D.) A416 18RD

6--
7--
8--
9--
11 - -

15 - -
16 - -
24 GROUND Z967 18BK
Component ID: 170
Connector:
Color : WHITE
# of pins : 24
Qualifier : (CVT)

7--
8--
9--
16 - -
17 - -
23 - -
24 - -
Connector:
Color : LT. GRAY
# of pins : 24
Qualifier : (CVT)
1 GROUND Z967 18BK
3--
4 FUSED B(+) (I.O.D.) A416 18RD

6--
7--
8--
9--
11 - -

15 - -
16 - -
24 GROUND Z967 18BK
and Modules - CVT > Control Module, CVT > Component Information > Description and Operation > Description
DESCRIPTION
and Modules - CVT > Control Module, CVT > Component Information > Description and Operation > Description > Page
4909
OPERATION
Shift Control
4910
"Drive" Position
gear ranges.
4911
Lock-up Control
Selection Control
CAN Communication
Inputs and Outputs

4912
Fail-safe Function
PNP Switch
4913
Lock-up solenoid
Stepping Motor
Backup Power Supply
TCM
and Modules - CVT > Control Module, CVT > Component Information > Service and Repair > Removal
REMOVAL
and Modules - CVT > Control Module, CVT > Component Information > Service and Repair > Removal > Page 4916
4. Remove the TCM.

and Modules - CVT > Control Module, CVT > Component Information > Service and Repair > Removal > Page 4917
INSTALLATION

Jeep Workshop Manuals > Transmission and Drivetrain > Continuously Variable Transmission/Transaxle, CVT > Seals and
Gaskets, CVT > Component Information > Service and Repair > Seal-Torque Converter
Seals and Gaskets: Service and Repair Seal-Torque Converter
Removal
REMOVAL
1. Remove transmission.
2. Remove torque converter. 3. Remove torque converter seal using Slide Hammer C-3752 and oil
Seal Remover 9667.
Installation
INSTALLATION
1. Install torque converter seal using oil seal Installer 9858.

Gaskets, CVT > Component Information > Service and Repair > Seal-Torque Converter > Page 4922
NOTE: Gauge Bar 6311 can be used for doing the following measurement.
NOTE: When conducting measurements, measure two or more places and calculate the average
value.
2. Install the torque converter on the transaxle and measure the dimension (1) to see if it is at least
13 mm. If the measurement is less than 13 mm,
the torque converter is not fully installed.
NOTE: Use the designated brand of CVT fluid. Use of other brands of CVT fluid other than the
designated brand will deteriorate the driveability and the durability of the CVT, and will cause
damage to the CVT.
3. Install the transmission.

Seals and Gaskets: Service and Repair Seal-Halfshaft Left Side
Removal
REMOVAL
1. Remove halfshaft.
2. Remove left side differential oil seal.
Installation
INSTALLATION
1. Install the left side differential oil seal using Installer 9871 (2) and Handle C-4171 (3). 2. Install
halfshaft. 3. Road test vehicle and inspect for leaks.
Seals and Gaskets: Service and Repair Seal-Halfshaft Right Side
Removal
REMOVAL
1. Remove halfshaft. 2. If all wheel drive remove the PTU.
3. Remove the seal (2) form the transaxle using a screwdriver (3).
Installation
INSTALLATION
1. Install the seal using Installer 9877(2) and Handle C-4171 (3). 2. If all wheel drive install the
PTU. 3. Install Halfshaft. 4. Road test vehicle and inspect for leaks.
Jeep Workshop Manuals > Transmission and Drivetrain > Continuously Variable Transmission/Transaxle, CVT > Sensors
and Switches - CVT > Fluid Pressure Sensor/Switch, CVT > Component Information > Locations
Component ID: 15
Connector:
Color : BLACK
# of pins : 22
6 GROUND Z967 18BK

12 - -
13 - -
14 - -
15 - -
20 - -
and Switches - CVT > Fluid Pressure Sensor/Switch, CVT > Component Information > Locations > Page 4929
Component ID: 15
Connector:
Color : BLACK
# of pins : 22
6 GROUND Z967 18BK

12 - -
13 - -
14 - -
15 - -
20 - -
and Switches - CVT > Transmission Position Switch/Sensor, CVT > Component Information > Locations
Component ID: 15
Connector:
Color : BLACK
# of pins : 22
6 GROUND Z967 18BK

12 - -
13 - -
14 - -
15 - -
20 - -
and Switches - CVT > Transmission Position Switch/Sensor, CVT > Component Information > Locations > Page 4935
and Switches - CVT > Transmission Speed Sensor, CVT > Component Information > Locations
Component ID: 15
Connector:
Color : BLACK
# of pins : 22
6 GROUND Z967 18BK

12 - -
13 - -
14 - -
15 - -
20 - -
and Switches - CVT > Transmission Speed Sensor, CVT > Component Information > Locations > Page 4939
and Switches - CVT > Transmission Temperature Sensor/Switch, CVT > Component Information > Description and
DESCRIPTION


OPERATION
following reasons:
service.
Jeep Workshop Manuals > Transmission and Drivetrain > Continuously Variable Transmission/Transaxle, CVT > Shift
Linkage, CVT > Component Information > Adjustments
Shift Linkage: Adjustments
ADJUSTMENT
1. Place TRS switch and selector lever in the PARK position. 2. Loosen the nut (4) that holds the
shifter cable to the manual lever. 3. While pressing the manual lever towards the front of the
vehicle in the PARK position direction, tighten the nut to 13 Nm (10 ft. lbs.). 4. Make sure that the
park system is engaged when lever is placed in the PARK position. 5. Place the selector lever in
PARK position and turn the ignition switch to on position (engine not running). 6. Make sure that
the selector lever can be shifted to a different position other than PARK when the brake pedal is
depressed. Also make sure the
lever can be shifted from PARK only when the brake pedal is depressed.
7. Move and check for excessive effort, sticking, noise or rattle. 8. Confirm that the selector lever
stops at each position with the feel of engagement when it is moved through all the positions.
Check whether or not
the actual position the selector lever is in matches the position shown by the shift position indicator
and the transaxle valve body.
9. Confirm that the backup lamps illuminate only when the lever is placed in the REVERSE
position. Confirm the backup lamps do not illuminate
when the lever is placed in the PARK or NEUTRAL positions with the lever pushed against the
REVERSE position.
10. Confirm the engine will only start when the lever is placed in the PARK or NEUTRAL positions.
Linkage, CVT > Component Information > Service and Repair > Removal
Shift Linkage: Service and Repair Removal
REMOVAL
1. Remove the air box (1). 2. Disconnect the negative battery cable (2).
3. Remove shifter cable (2) at transmission bracket (3). 4. Remove the nut (4) on the shifter cable
to shift lever.
Linkage, CVT > Component Information > Service and Repair > Removal > Page 4950
5. Remove the grommet (1) at the bulkhead. 6. Remove the shifter.
7. Squeeze clip (2) at cable (1).
8. Pull cable from bracket (2) at bulkhead (1).

9. Pull the cable (1, 2) through the bulkhead into the engine compartment.
Shift Linkage: Service and Repair Installation
INSTALLATION
1. Install the shifter cable (1, 2) through the bulkhead and into the passenger compartment.
2. Install the cable into the bracket (2) at bulkhead (1).

3. Insure that the cable clips into place. 4. Install the shifter.
5. Install the shifter cable grommet (1) at the bulkhead.
6. Clip the cable (2) into the bracket (1) install the nut (4) over the shifter cable at the transmission
shift lever.
7. Connect the negative battery cable (2). 8. Install the air box (1)
Interlock, CVT > Component Information > Description and Operation
Shift Interlock: Description and Operation
DESCRIPTION
The Shifter's serpentine pattern does not require the shifter to have a button on the knob to release
it from "Park". There is a blocking lever within the Shifter that prevents undesired shifting out of
"Park".
The shifter has a solenoid which is actuated by depressing the brake pedal. This prevents shifting
out of "Park" without the brake pedal being depressed. To operate the solenoid, the ignition must
be in the "On" or "Run" position and the brake pedal must be depressed. The Brake Switch sends
a signal to the Cabin Compartment Node (CCN) and the CCN, in turn, energizes the solenoid that
moves the Park Lock Lever to allow the driver to shift out of 'Park". On the right side of the Console
Pod is a plug that allows access to the Park Lock Lever for manual operation.
Interlock, CVT > Component Information > Description and Operation > Page 4958
Shift Interlock: Testing and Inspection
DIAGNOSIS AND TESTING
The Interlock Cable is attached to a lever within the Shifter that prevents the Shift Lever from
moving out of "Park" without the key (theft prevention). The Interlock Cable adjustment is preset at
the factory. When properly adjusted, the Interlock System prevents the key being removed from the
Key Cylinder when the Shift Lever is in a position other then "Park".
Interlock Diagnostic Chart (Part 1)

Interlock Diagnostic Chart (Part 2)

Shift Interlock: Adjustments
ADJUSTMENT
1. Remove shift knob and shift bezel. 2. Remove two screws (1).
3. Pull on side of housing (1) and unsnap housing tabs. 4. Disconnect console housing wire
connector (2) and instrument panel connector (3). 5. Remove from vehicle. 6. Adjust interlock
cable/system as follows:Pry up on cable adjuster lock to release and allow cable to "self-adjust".
Lock cable adjustment by
pressing down on the adjuster lock until bottomed at the cable housing.
Interlock, CVT > Component Information > Service and Repair > Removal
Shift Interlock: Service and Repair Removal
REMOVAL
2. Remove the shifter bezel (1).
3. Remove the screws (1) at the console.

Interlock, CVT > Component Information > Service and Repair > Removal > Page 4964
4. Pull the console (1) back and remove electrical connector (2) (if equipped). 5. Remove the
console (1).
6. Remove the bolts (1) at the shifter. 7. Separate the shift interlock cable from the shifter. 8.
Remove lower shroud at steering column.
9. Place the ignition switch in the ON position.

10. Depress the clip on the shift interlock cable (2) and pull cable out of column (1). 11. Remove
the cable.
Shift Interlock: Service and Repair Installation
INSTALLATION
1. Install the cable between the shifter and the steering column. 2. Clip the shift interlock cable to
the shifter. 3. Install the shifter in place.
4. Install the shifter bolts and tighten to 70 Nm (52 ft. lbs.).
5. Install the console (1). 6. Connect the electrical connector (2) (if equipped).
7. Install the screws (1) at the console.
8. Install the shifter bezel (1).
9. With the ignition switch in the ON position, push the interlock cable (2) into the column (1) until it
clicks into place.
10. Check operation of the ignition-shift interlock feature. 11. Install the lower shroud.
Solenoid, CVT > Component Information > Locations
Component ID: 15
Connector:
Color : BLACK
# of pins : 22
6 GROUND Z967 18BK

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Solenoid, CVT > Component Information > Locations > Page 4971
Component ID: 15
Connector:
Color : BLACK
# of pins : 22
6 GROUND Z967 18BK

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Jeep Workshop Manuals > Transmission and Drivetrain > Continuously Variable Transmission/Transaxle, CVT > Shifter
CVT > Component Information > Technical Service Bulletins > A/T - CVT Shifter Diagnostics
Shifter CVT: Technical Service Bulletins A/T - CVT Shifter Diagnostics
GROUP: Transmission
THIS BULLETIN SUPERSEDES TECHNICAL SERVICE BULLETIN 21-013-06, DATED MAY 5,

HIGHLIGHTED WITH **ASTERISKS** AND INCLUDES AN ADDITIONAL MODEL WITH A
DESCRIPTION ON LABOR TIMES THAT SHOULD BE USED WHEN REPAIRS ARE MADE.
SUBJECT: Continuously Variable Transmission (CVI) Automatic Shifter Diagnostics
MODELS:
2007 (PM) Caliber
**2007 (MK-49174) Compass/Patriot**
**2007 (JS) Sebring Sedan/Stratus Sedan**
NOTE:
This bulletin applies to vehicles equipped with an Continuously Variable Transmission (CVT) (sales
code DAV).
DISCUSSION:
The Automatic Transmission Shifter for 2007 PM, MK and JS vehicles equipped with a CVI
transmission includes several new features:
i. The Shifter's serpentine pattern does not require the shifter to have a button on the knob to
release it from "Park". There is a blocking lever within the Shifter that prevents undesired shifting
out of "Park".
ii. The shifter has a solenoid which is actuated by depressing the brake pedal. This prevents
shifting out of "Park" without the brake pedal being depressed. To operate the solenoid, the ignition
must be in the "On" or "Run" position and the brake pedal must be depressed. The Brake Switch
sends a signal to the Cabin Compartment Node (CCN) and the CCN, in turn, energizes the
solenoid that moves the Park Lock Lever to allow the driver to shift out of "Park". On the right side
of the Console Pod is a plug that allows access to the Park Lock Lever for manual operation.
iii. The Interlock Cable is attached to a lever within the Shifter that prevents the Shift Lever from
moving out of "Park" without the key (theft prevention). The Interlock Cable adjustment is preset at
the factory. When properly adjusted, the Interlock System prevents the key being removed from the
Key Cylinder when the Shift Lever is in a position other then "Park".
CVT > Component Information > Technical Service Bulletins > A/T - CVT Shifter Diagnostics > Page 4978
Shifter Diagnostics
TIME ALLOWANCE:
**When repairing or diagnosing shifter system the following Labor Operation Numbers should be
used:**
Disclaimer:
CVT > Component Information > Technical Service Bulletins > Page 4983
Shifter CVT: Locations
Component ID: 14
Component : ASSEMBLY-SHIFT LEVER
Connector:
Name : ASSEMBLY-SHIFT LEVER
Color : LT. GRAY
# of pins : 8
Qualifier : (AUTOSTICK)
2--

8 BRAKE TRANSMISSION SHIFT INTERLOCK SOLENOID UNLOCK K321 20BR/YL
Connector:
Color : LT. GRAY
# of pins : 4
Qualifier : (EXCEPT AUTOSTICK)

Shifter CVT: Diagrams
Component ID: 14
Component : ASSEMBLY-SHIFT LEVER
Connector:
Color : LT. GRAY
# of pins : 8
Qualifier : (AUTOSTICK)
2--

Connector:
Color : LT. GRAY
# of pins : 4
Qualifier : (EXCEPT AUTOSTICK)

CVT > Component Information > Service and Repair > Removal
Shifter CVT: Service and Repair Removal
REMOVAL
1. Remove shift knob and shift bezel. 2. Remove two screws (1).
3. Pull on side of housing (1) and unsnap housing tabs. 4. Disconnect console housing wire
connector (2) and instrument panel connector (3). 5. Remove from vehicle.
CVT > Component Information > Service and Repair > Removal > Page 4999
6. Remove the bolts (1) at the shifter. 7. Separate the shift cable from the shifter.
8. Lift the shifter enough to gain access to electrical connector.
9. Unplug the electrical connector at the shifter.

10. Remove the shifter.
Shifter CVT: Service and Repair Installation
INSTALLATION
1. Plug the electrical connector in at the shifter.
2. Install the shifter in place. 3. Clip the shift cable to the shifter.
4. Install the shifter bolts and tighten to 70 Nm (52 ft. lbs.).
5. Place console housing (1) over shifter lever ensuring console tabs seat properly.
6. Install screws (1). 7. Replace shift bezel and knob.

Transmission Cooler, CVT > Component Information > Description and Operation
Transmission Cooler: Description and Operation
DESCRIPTION
The automatic transmission cooler is located in the front of the radiator and behind the front fascia
and is combined with the A/C condenser. The transmission cooler is a heat exchanger that allows
heat in the transmission fluid to be transferred to the air passing over the cooler fins.
The Transmission oil cooler/A/C condenser assembly is equipped with quick connect fitting for the
transmission oil cooler lines.
Transmission Cooler, CVT > Component Information > Service and Repair > Procedures
Transmission Cooler: Procedures
Cleaning
CLEANING
Check the external cooler for debris on the cooling fin surfaces. Clean as necessary.
Inspection
INSPECTION
Inspect all hoses, tubes, clamps and connections for leaks, cracks, or damage. Replace as
necessary. Use only approved transmission oil cooler hoses that are molded to fit the space
available.
Inspect external coolers for leaks, loose mounts, or damage. Replace as necessary.
Transmission Cooler, CVT > Component Information > Service and Repair > Procedures > Page 5008
Transmission Cooler: Removal and Replacement
Removal
REMOVAL
1. Remove front fascia. 2. Recover refrigerant. 3. Disconnect A/C lines. 4. Using Tool 8875A
disconnect cooler line from the combination cooler. 5. Remove combination cooler mounting bolts.
6. Remove combination cooler (2).
Installation
INSTALLATION
1. Replace automatic transmission cooler hoses and clamps.

2. Connect hoses to combination cooler (2). 3. Install combination cooler (2). Tighten screws to 8
Nm (70 in. lbs.). 4. Install radiator closure panel center brace. 5. Install upper radiator closure
panel. 6. Install grille. 7. Start engine and check transmission fluid level. Adjust level as necessary.
Removal
REMOVAL
transmission.
Installation
INSTALLATION

Transmission Position Switch/Sensor, CVT > Component Information > Locations
Component ID: 15
Connector:
Color : BLACK
# of pins : 22
6 GROUND Z967 18BK

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Transmission Position Switch/Sensor, CVT > Component Information > Locations > Page 5015
Transmission Pressure Test Port, CVT > Component Information > Locations
Transmission Pressure Test Port: Locations
rwk_23382 12/4/09 Tech Auth ch.21
TEST PORTS
Transmission Speed Sensor, CVT > Component Information > Locations
Component ID: 15
Connector:
Color : BLACK
# of pins : 22
6 GROUND Z967 18BK

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20 - -
Transmission Speed Sensor, CVT > Component Information > Locations > Page 5022
Transmission Temperature Sensor/Switch, CVT > Component Information > Description and Operation > Description
DESCRIPTION


Transmission Temperature Sensor/Switch, CVT > Component Information > Description and Operation > Description >
Page 5027
OPERATION
following reasons:
service.
Jeep Workshop Manuals > Transmission and Drivetrain > Continuously Variable Transmission/Transaxle, CVT > Valve
Body, CVT > Component Information > Description and Operation
Valve Body: Description and Operation
OPERATION
Outline Of The Functions Of The Main Components

Body, CVT > Component Information > Service and Repair > Removal and Replacement
Valve Body: Removal and Replacement
Removal
REMOVAL
transaxle case.
Body, CVT > Component Information > Service and Repair > Removal and Replacement > Page 5033
7. Remove the bolts holding the bracket (1) to the valve body assembly. 8. Remove the bracket
from the valve body assembly.
9. Remove the nut holding the manual lever (1) to the manual shaft.
10. Remove the manual lever from the manual shaft.
CAUTION: Tilt the valve body assembly away from the transaxle case on the manual shaft side to
ease removal. Pay attention to completely remove the terminal body from the transaxle case.
11. Remove the valve body assembly from the transaxle case as follows:
a. Insert a 75 mm (3 in.) long 3 mm (0.118 in.) wide rod or wire into the linkage stopper hole of the
valve body assembly to fix the pulley ratio
linkage (1).
b. Remove the bolts holding the valve body assembly to the transaxle case. c. Remove the valve
body assembly from the transaxle case.
Installation
INSTALLATION
1. To install the control valve body assembly on to the transaxle case, insert a 75 mm (3 in.) long 3
mm (0.118 in.) wide rod or wire into the linkage
stopper hole of the control valve assembly to set the pulley ratio linkage (1) in position.
2. Position the locating tab (1) of the terminal body as shown and install the terminal body into the
transaxle case.
3. Install the control valve assembly (1) up from the bottom side and install it into the transaxle
case.
4. Align the notch (1) of the pulley ratio linkage with the sheave position sensor (2).
CAUTION: Apply CVT fluid when installing the bushing.
5. Install the bushing (1) into the control valve assembly.

6. Tighten the mounting bolts of the control valve body assembly to 8 Nm (70 in. lbs).
7. Install the manual lever (1) onto the manual shaft. Install and tighten the mounting nut to 22 Nm
(16 ft. lbs.).
8. Install the bracket (1) onto the control valve assembly. Install and tighten the mounting bolts to 8
Nm (70 in. lbs.).
in. lbs.).
13. Install the snap ring (1) onto the terminal body. 14. Fill transmission with the required fluid.
Valve Body: Overhaul
Disassembly
DISASSEMBLY
1. Remove and discard the bushing (1) from the valve body.
2. Remove and discard the lip seal (1) from the transaxle case.
CAUTION: Do not drop the pulley ratio linkage.
3. Remove the pulley ratio linkage (1) from the valve body.
4. Remove the return spring (1) from the valve body.

CAUTION: Do not drop the manual valve.
5. Remove the manual valve (1) from the valve body.
6. Remove the valve body harness (1) from the valve body.
7. Remove the stepping motor (1) from the valve body.
Assembly
ASSEMBLY
CAUTION: Do not re-use the lip seal. Apply CVT fluid when installing the lip seal.
1. Install the new lip seal (1) into the transaxle case.
2. Install the stepping motor (1) onto the control valve body. Install and tighten the mounting bolts
3. Install the valve body harness (1) onto the control valve body.
CAUTION: Ensure the manual valve is free of dirt, lint or other debris. Apply CVT fluid when
installing the manual valve.
4. Install the manual valve (1) into the control valve body.
5. Install the return spring (1) into the control valve body.
CAUTION: Apply CVT fluid when installing the pulley ratio linkage.
6. Hook the pawl of the pulley ratio linkage (1) onto the stepping motor and install it on the control
valve.
Jeep Workshop Manuals > Transmission and Drivetrain > Differential Assembly > Actuators and Solenoids - Differential >
Solenoid, Differential Lock > Component Information > Locations
Solenoid: Locations
Component ID: 335
Connector:
Color : # of pins :
Qualifier : (ECC)
Solenoid, Differential Lock > Component Information > Locations > Page 5052
Solenoid: Diagrams
Component ID: 335
Connector:
Color : # of pins :
Qualifier : (ECC)
Jeep Workshop Manuals > Transmission and Drivetrain > Differential Assembly > Differential Lock > Solenoid, Differential
Lock > Component Information > Locations
Solenoid: Locations
Component ID: 335
Connector:
Color : # of pins :
Qualifier : (ECC)
Lock > Component Information > Locations > Page 5059
Solenoid: Diagrams
Component ID: 335
Connector:
Color : # of pins :
Qualifier : (ECC)
Jeep Workshop Manuals > Transmission and Drivetrain > Differential Assembly > Fluid - Differential > Component
Fluid - Differential: Technical Service Bulletins Maintenance - Fluid Flushing Information
NUMBER: 26-001-09

MODELS:
2009 - 2010 (DS) Ram Truck (1500)
2005 - 2009 (HB) Durango
2007 - 2009 (HG) Aspen
2009 - 2010 (JC) Journey
2008 - 2010 (KK) Liberty
2007 - 2010 (KA) Nitro
2005 - 2007 (KJ) Liberty
2005 - 2010 (ND) Dakota
2005 - 2006 (PL) Neon

2007 - 2010 (PM) Caliber

2005 - 2010 (ZB) Viper
DISCUSSION:
coolant.
operating range.
distilled water.
Disclaimer:
Fluid - Differential: Capacity Specifications
Rear Drive Assembly ( RDA ) Fluid Capacity Rear Differential ...........................................................

......................................................................................................................... 500 ml ( 1 - 1.1 pts )
Fluid - Differential: Fluid Type Specifications
Rear Drive Assembly ( RDA ) Fluid Type Mopar Gear & Axle Lubricant SAE 80W-90 API GL 5 or
Fluid - Differential: Service and Repair
STANDARD PROCEDURE - DRAIN AND FILL
1. Remove fill plug (1) and drain plug (2). Drain fluid. 2. Install drain plug (2) and tighten to 32 Nm
(24 ft.lb.). 3. Fill with MOPAR(R) MS9020 SAE 80W90 Gear Lube to bottom of fill plug. 4. Install fill
plug (1) and tighten to 32 Nm (24 ft.lb.).
Jeep Workshop Manuals > Transmission and Drivetrain > Differential Assembly > Seals and Gaskets, Differential > System
Information > Service and Repair > Input Flange Seal - Removal
Seals and Gaskets: Service and Repair Input Flange Seal - Removal
REMOVAL
1. Raise the vehicle on a hoist. 2. Remove the propeller shaft. 3. Unplug the electrical connector (3)
at the ECC. 4. Disconnect ECC breather hose. 5. Remove the ECC to RDA mounting bolts. 6.
Separate and lower ECC. 7. Remove all old gasket material on the mating surfaces of the ECC and
RDA. Remove wave washer 8. Remove wave washer.
9. Remove the input flange seal.

Information > Service and Repair > Input Flange Seal - Removal > Page 5075
Seals and Gaskets: Service and Repair Input Flange Seal - Installation
INSTALLATION
1. Coat the edge face of the seal with the liquid gasket sealer. 2. Install wave washer. 3. Install the
pinion seal using Installer 9931.
4. Install the ECC onto the RDA. 5. Install the mounting bolts (1) that hold the ECC to the RDA and
Tighten to 78 Nm (58 ft. lbs.). 6. Plug in the electrical connector (3). 7. Install the propeller shaft. 8.
Fill RDA as needed. 9. Lower vehicle and road test.
Seals and Gaskets: Service and Repair Output Seal - Removal
REMOVAL
1. Raise the vehicle on a hoist. 2. Remove right side halfshaft. 3. Remove the pinion side seal (2).
4. Remove left side halfshaft. 5. Remove ring gear side seal.

Seals and Gaskets: Service and Repair Output Seal - Installation
INSTALLATION
1. Place the seal on the installer.
2. Install the pinion side seal using Installer 9893 and Handle C-4171. 3. Install right side halfshaft.
4. Place the seal on the installer.
5. Install the ring gear side seal using Installer 9893 and Handle C-4171. 6. Install left side
halfshaft. 7. Fill RDA as needed. 8. Lower vehicle and road test.
Jeep Workshop Manuals > Transmission and Drivetrain > Drive Axles, Bearings and Joints > Axle Shaft Assembly >
Constant Velocity Joint Boot > Component Information > Service and Repair > CV Boot-Inner
Constant Velocity Joint Boot: Service and Repair CV Boot-Inner
Removal
REMOVAL
CAUTION: The inner tripod joints will use a retaining clip inside the housing to keep the spider
assembly in the housing. Do not pull on the interconnecting shaft to disengage tripod housing from
transmission stub shaft. Removal in this manner will cause damage to the inboard joint sealing
boots.
1. Remove the halfshaft requiring boot replacement from the vehicle. 2. Remove large boot clamp
(2) that retains inner tripod joint sealing boot to tripod joint housing (3) and discard. Then remove
small clamp (1) that
retains inner tripod joint sealing boot to interconnecting shaft (5) and discard. Remove the sealing
boot (4) from the tripod housing and slide it down the interconnecting shaft.
CAUTION: When removing the spider joint from the tripod joint housing, hold the rollers in place on
the spider trunnions to prevent the rollers and needle bearings from falling away.
3. Slide the interconnecting shaft and spider assembly (2) out of the tripod joint housing (1).
Constant Velocity Joint Boot > Component Information > Service and Repair > CV Boot-Inner > Page 5085
4. Remove snap ring (3) that retains spider assembly (2) to interconnecting shaft (1).
5. Remove the spider assembly (1) from interconnecting shaft (4). If spider assembly will not come
off interconnecting shaft by hand, it can be
removed by tapping spider assembly with a brass drift (3). Do not hit the outer tripod bearings in an
attempt to remove spider assembly from interconnecting shaft.
6. Slide sealing boot off interconnecting shaft. 7. Thoroughly clean and inspect spider assembly,
tripod joint housing, and interconnecting shaft for any signs of excessive wear. If any parts show
signs of excessive wear, the halfshaft assembly will require replacement. Component parts of
these halfshaft assemblies are not serviceable.
Installation
INSTALLATION
NOTE: The inner tripod joint sealing boots are made from two different types of material.
High-temperature applications (close to exhaust system) use silicone rubber whereas standard
temperature applications use Hytrel plastic. The silicone sealing boots are soft and pliable. The
Hytrel sealing boots are stiff and rigid. The replacement sealing boot MUST BE the same type of
material as the sealing boot that was removed.
1. Slide inner tripod joint seal boot retaining clamp onto interconnecting shaft (4). Then slide the
replacement inner tripod joint sealing boot (1) onto
interconnecting shaft. Inner tripod joint seal boot MUST be positioned on interconnecting shaft, so
the raised bead on the inside of the seal boot is in groove (3) on interconnecting shaft.
NOTE: The rollers can fall off, use caution when installing the tripod
2. Install spider assembly (1) onto interconnecting shaft with chamfer (3) on spider assembly
toward interconnecting shaft (2).
3. Spider assembly (2) must be installed on interconnecting shaft (3) far enough to fully install
spider retaining snap ring. If spider assembly will not
fully install on interconnecting shaft by hand, it can be installed by tapping the spider body with a
brass drift (4). Do not hit the outer tripod bearings in an attempt to install spider assembly on
interconnecting shaft.
4. Install the spider assembly (2) to interconnecting shaft retaining snap ring (3) into groove on end
of interconnecting shaft. Be sure the snap ring is
fully seated into groove on interconnecting shaft (1).

5. Distribute 1/2 the amount of grease provided in the seal boot service package (DO NOT USE
ANY OTHER TYPE OF GREASE) into tripod
housing. Put the remaining amount into the sealing boot (3).
6. Align tripod housing (1) with spider assembly (2) and then slide tripod housing over spider
assembly and interconnecting shaft.
7. Install inner tripod joint seal boot to interconnecting shaft clamp (3) evenly on sealing boot (4). 8.
Clamp sealing boot onto interconnecting shaft using Clamp C-4975-A and the following procedure.
Place Clamp C-4975-A over bridge of clamp.
9. Tighten nut on Clamp C-4975-A until jaws on tool are closed completely together (2), face to
face.
CAUTION: Seal must not be dimpled, stretched, or out-of-shape in any way. If seal is NOT shaped
correctly, equalize pressure in seal and shape it by hand.
10. Position sealing boot into the tripod (3) retaining groove. Install seal boot retaining clamp (2)
evenly on sealing boot (1).
CAUTION: The following positioning procedure determines the correct air pressure inside the inner
tripod joint assembly prior to clamping the sealing boot to inner tripod joint housing. If this
procedure is not done prior to clamping sealing boot to tripod joint housing, boot durability can be
adversely affected.
CAUTION: When venting the inner tripod joint assembly, use care so inner tripod sealing boot does
not get punctured or, in any other way, damaged. If sealing boot is punctured or damaged while
being vented, the sealing boot can not be used.
11. Insert a trim stick (4) between the tripod (3) and the sealing boot (1) to vent inner tripod joint
assembly. When inserting trim stick between
tripod housing and sealing boot, ensure trim stick is held flat and firmly against the tripod housing.
If this is not done, damage to the sealing boot can occur. If inner tripod joint has a Hytrel (hard
plastic) sealing boot, be sure trim stick is inserted between soft rubber insert and tripod housing,
and not the hard plastic sealing boot and soft rubber insert.
12. With trim stick inserted between sealing boot (2) and tripod joint housing (4), position inner
tripod joint on halfshaft until correct sealing boot
edge to edge length (1) is obtained for type of sealing boot material being used. Then remove the
trim stick.
13. With trim stick inserted between sealing boot (2) and tripod housing (4), position inner tripod
joint on halfshaft until correct sealing boot edge to
edge length (1) is obtained for type of sealing boot material being used. Then remove the trim stick.
14. Clamp (1) tripod joint sealing boot (4) to tripod joint (2) using required procedure for type of
boot clamp application. If seal boot uses crimp type
boot clamp, clamp sealing boot onto tripod housing using Clamp C-4975-A (3). Place Clamp
C-4975-A over bridge of clamp (1).
15. Tighten nut on Clamp C-4975-A (3) until jaws on tool (3) are closed completely together (4),
face-to-face.
16. If seal boot (3) uses low profile latching type boot clamp, clamp sealing boot onto tripod
housing using Clamping Tool, Snap-On(R) YA3050 (2)
(or an equivalent). Place prongs of Clamp Locking Tool in the holes of the clamp (1).
17. Squeeze tool together until top band of clamp is latched behind the two tabs (2) on lower band
of clamp. 18. Install the halfshaft requiring boot replacement back on the vehicle.
Constant Velocity Joint Boot: Service and Repair CV Boot-Outer
Removal
REMOVAL
1. Remove halfshaft assembly requiring boot replacement from vehicle. 2. Remove large boot
clamp (4) retaining CV joint sealing boot to CV joint housing (3) and discard. Remove small clamp
(1) that retains outer CV
joint sealing boot to interconnecting shaft (5) and discard. Remove sealing boot (2) from outer CV
joint housing and slide it down interconnecting shaft.
3. Wipe away grease to expose outer CV joint and interconnecting shaft.
4. Remove outer CV joint from interconnecting shaft using the following procedure: Support
interconnecting shaft in a vise equipped with protective
caps on jaws of vise to prevent damage to interconnecting shaft. Then, using a soft-faced hammer
(1), sharply hit the end of the CV joint housing to dislodge housing from internal circlip (3) on
interconnecting shaft. Then slide outer CV joint off end of interconnecting shaft, joint may have to
be tapped off shaft using a soft-faced hammer.
5. Remove large circlip (3) from the interconnecting shaft (2) before attempting to remove outer CV
joint sealing boot. 6. Slide sealing boot off interconnecting shaft. 7. Thoroughly clean and inspect
outer CV joint assembly and interconnecting joint for any signs of excessive wear. If any parts
show signs of
excessive wear, the halfshaft assembly will require replacement. Component parts of these
halfshaft assemblies are not serviceable.
Installation
INSTALLATION
1. Slide new sealing boot clamp (2) onto interconnecting shaft (4). Slide the outer CV joint
assembly sealing boot (1) onto the interconnecting shaft
(4). Seal boot MUST be positioned on interconnecting shaft so the raised bead on the inside of the
seal boot is in groove on interconnecting shaft.
2. Align splines on interconnecting shaft with splines on cross of outer CV joint assembly and start
outer CV joint onto interconnecting shaft. 3. Install outer CV joint assembly onto interconnecting
shaft by using a soft-faced hammer (1) and tapping end of stub axle (2) (with hub nut (4)
installed) until outer CV joint (3) is fully seated on interconnecting shaft.
4. Outer CV joint assembly must be installed on interconnecting shaft until cross (2) of outer CV
joint assembly (3) is seated against circlip on
interconnecting shaft (1).

5. Distribute 1/2 the amount of grease provided in seal boot service package (DO NOT USE ANY
OTHER TYPE OF GREASE) into outer CV joint
assembly housing. Put the remaining amount into the sealing boot (4).
6. Install outer CV joint sealing boot to interconnecting shaft clamp evenly on sealing boot. 7.
Clamp sealing boot onto interconnecting shaft (2) using crimper, Clamp C-4975-A and the following
procedure. Place Clamp C-4975-A (1) over
bridge of clamp (3).
face.
CAUTION: Seal must not be dimpled, stretched, or out-of-shape in any way. If seal is NOT shaped
correctly, equalize pressure in seal and shape it by hand.
9. Position outer CV joint sealing boot (4) into its retaining groove on outer CV joint housing. Install
sealing boot to outer CV joint retaining clamp
(1) evenly on sealing boot.
10. Clamp sealing boot onto outer CV joint housing using Clamp C-4975-A (3) and the following
procedure. Place Clamp C-4975-A over bridge of
clamp (1).
face. 12. Install the halfshaft requiring boot replacement back on the vehicle.
Jeep Workshop Manuals > Transmission and Drivetrain > Drive Axles, Bearings and Joints > Wheel Bearing > Component

Information > Description and Operation > Front Suspension

DESCRIPTION

Information > Description and Operation > Front Suspension > Page 5101
DESCRIPTION
into the hub.
Information > Testing and Inspection > Front Suspension
be replaced.
Inspection.
Information > Testing and Inspection > Front Suspension > Page 5104
HUB AND BEARING
Inspection.
Information > Service and Repair > Front Suspension
Removal
REMOVAL
Nm (40 ft. lbs.).
Nm (40 ft. lbs.).

Information > Service and Repair > Front Suspension > Page 5107
from the knuckle.

race (4).
race.
Installation
INSTALLATION
until it bottoms.
Removal
ALL-WHEEL-DRIVE

(2).
hub and bearing.
Installation
ALL-WHEEL-DRIVE
lbs.).
Jeep Workshop Manuals > Transmission and Drivetrain > Drive Axles, Bearings and Joints > Wheel Hub > Axle Nut >

................................................. 244 Nm (180 ft. lbs.)
Jeep Workshop Manuals > Transmission and Drivetrain > Drive/Propeller Shafts, Bearings and Joints > Drive/Propeller
Shaft > Component Information > Service and Repair > Removal
Drive/Propeller Shaft: Service and Repair Removal
REMOVAL
1. Raise the vehicle on the hoist. 2. Mark (2) propeller shaft and differential (3) for proper
installation.
3. Remove rear propeller shaft to rear axle retaining nuts (2).

Shaft > Component Information > Service and Repair > Removal > Page 5126
4. Remove the three bolts (3) from the center support heat shield (2).
CAUTION: Propeller shaft removal. Never allow propeller shaft to hang while connected to Power
Transfer Unit (PTU), rear driveline module flanges or center bearings. If propeller shaft section is
hung unsupported, damage may occur to joint, boot and/or center bearing from over-angulation.
This may result in vibration/balance issues. A helper may be needed.
5. Remove the heat shield (2). 6. Remove the two center support mounting bolts (3).
7. Remove the propeller shaft (1).

Drive/Propeller Shaft: Service and Repair Installation
INSTALLATION
CAUTION: Propeller shaft installation. Never allow propeller shaft to hang while connected to
Power Transfer Unit (PTU), rear driveline module flanges or center bearings. If propeller shaft
section is hung unsupported, damage may occur to joint, boot and/or center bearing from
over-angulation. This may result in vibration/balance issues. A helper may be needed.
1. Make sure transaxle is in Neutral (N) position. 2. Obtain a helper if needed and lift propeller shaft
assembly into position. Install propeller shaft spline into PTU. 3. Align marks (2) on propeller shaft
with marks on rear axle flange. Slide propeller shaft over studs on rear axle flange.
4. Install the four retaining nuts (2).

5. Raise the center support into position (1).
6. Install center support bolts (3) and tighten to 41 Nm (30 ft. lbs.)).
7. Install propeller shaft nuts (2) and tighten to 58 Nm (43 ft. lbs.).
8. Install heat shield (2) nuts and tighten to 21 Nm (15 ft. lbs.). 9. Check fluid levels starting with
PTU.
Jeep Workshop Manuals > Transmission and Drivetrain > Flex Plate > Component Information > Specifications
Flex Plate: Specifications
Driveplate-to-Crankshaft Bolts .............................................................................................................

.................................................... 95 Nm (70 ft. lbs.)
Jeep Workshop Manuals > Transmission and Drivetrain > Flywheel > Component Information > Specifications
Flywheel: Specifications
Flywheel-to-Crankshaft Bolts Gas .......................................................................................................

..................................................................................................... 95 Nm (70 ft. lbs.)
Jeep Workshop Manuals > Transmission and Drivetrain > Flywheel > Component Information > Specifications > Page 5137
Flywheel: Description and Operation
OPERATION
The flywheel serves to dampen the engine firing pulses. The heavy weight of the flywheel relative
to the rotating mass of the engine components serves to stabilize the flow of power to the
remainder of the drivetrain. The crankshaft has the tendency to attempt to speed up and slow down
in response to the cylinder firing pulses. The flywheel dampens these impulses by absorbing
energy when the crankshaft speeds and releasing the energy back into the system when the
crankshaft slows down.
On a Dual Mass Flywheel, the additional secondary mass coupled to the transmission lowers the
natural frequency of the transmission rotating elements. This decreases the transmission gear
rattle. The damper springs between the two flywheel masses replace the clutch disc damper
springs and assist in a smooth transfer of torque to the transmission.
CAUTION: The Dual Mass Flywheel is serviced as an assembly only and should never be
disassembled.
Jeep Workshop Manuals > Transmission and Drivetrain > Flywheel > Component Information > Service and Repair >
Removal
Flywheel: Service and Repair Removal
REMOVAL
1. Remove transaxle. 2. Remove clutch pressure plate and disc. 3. Remove eight (8)
flywheel-to-crankshaft bolts (2) and remove flywheel assembly (1).
Jeep Workshop Manuals > Transmission and Drivetrain > Flywheel > Component Information > Service and Repair >
Removal > Page 5140
Flywheel: Service and Repair Installation
INSTALLATION
1. Clean the surfaces of the flywheel and pressure plate to make certain that all oil, grease, and
rust have been removed. 2. Install and torque the flywheel-to-crankshaft bolts to 95 Nm (70 ft.lbs.).
3. Install clutch pressure plate and disc. 4. Install transaxle assembly.
Jeep Workshop Manuals > Transmission and Drivetrain > Lamps and Indicators - Transmission and Drivetrain > Lamps and
Indicators - Transfer Case > Four Wheel Drive Indicator Lamp > Component Information > Description and Operation >
Four-Wheel Drive Indicator
Description
DESCRIPTION
(VFD) unit.
cluster.
Operation
OPERATION
deactivated.
Four-Wheel Drive Indicator > Page 5147
Description
DESCRIPTION
Operation
OPERATION
(CAN) data bus.
required.
Indicators - Transfer Case > Malfunction Indicator Lamp - Transfer Case > Component Information > Description and
DESCRIPTION
tachometer.
Indicators - Transfer Case > Malfunction Indicator Lamp - Transfer Case > Component Information > Description and
OPERATION
Jeep Workshop Manuals > Transmission and Drivetrain > Manual Transmission/Transaxle > Differential, Manual Transaxle
> Differential Fluid - M/T > Component Information > Technical Service Bulletins > Maintenance - Fluid Flushing Information
Differential Fluid - M/T: Technical Service Bulletins Maintenance - Fluid Flushing Information
NUMBER: 26-001-09

MODELS:
2009 - 2010 (DS) Ram Truck (1500)
2005 - 2009 (HB) Durango
2007 - 2009 (HG) Aspen
2009 - 2010 (JC) Journey
2008 - 2010 (KK) Liberty
2007 - 2010 (KA) Nitro
2005 - 2007 (KJ) Liberty
2005 - 2010 (ND) Dakota
2005 - 2006 (PL) Neon

2007 - 2010 (PM) Caliber

Jeep Workshop Manuals > Transmission and Drivetrain > Manual Transmission/Transaxle > Differential, Manual Transaxle
> Differential Fluid - M/T > Component Information > Technical Service Bulletins > Maintenance - Fluid Flushing Information
> Page 5161
2005 - 2010 (ZB) Viper
DISCUSSION:
coolant.
operating range.
distilled water.
Disclaimer:
Jeep Workshop Manuals > Transmission and Drivetrain > Manual Transmission/Transaxle > Fluid - M/T > Component
Fluid - M/T: Technical Service Bulletins Maintenance - Fluid Flushing Information
NUMBER: 26-001-09

MODELS:
2009 - 2010 (DS) Ram Truck (1500)
2005 - 2009 (HB) Durango
2007 - 2009 (HG) Aspen
2009 - 2010 (JC) Journey
2008 - 2010 (KK) Liberty
2007 - 2010 (KA) Nitro
2005 - 2007 (KJ) Liberty
2005 - 2010 (ND) Dakota
2005 - 2006 (PL) Neon

2007 - 2010 (PM) Caliber

2005 - 2010 (ZB) Viper
DISCUSSION:
coolant.
operating range.
distilled water.
Disclaimer:
Fluid - M/T: Capacity Specifications
Manual Transmission Fluid Capacity
NV T355 ..............................................................................................................................................
.......................................... 2.4 - 2.7 L ( 2.5 - 2.8 Qt )
BG6 .....................................................................................................................................................
........................................................... 2.0 L ( 2.1 Qt )
Fluid - M/T: Fluid Type Specifications
Manual Transmission Fluid Type Transmission Fluid .........................................................................

................................................................................................ Mopar ATF + 4 MS9602
Information > Service and Repair > BG6 Manual Transaxle
Fluid - M/T: Service and Repair BG6 Manual Transaxle
Fluid Level Checking
FLUID LEVEL CHECKING
The fluid required for this transaxle is Mopar(R) ATF+4 (Automatic Transmission Fluid). Use of
improper or substitute fluids can cause shift problems and/or transaxle failure.
1. Insure the vehicle is level, remove the fill plug and add fluid until the fluid just starts to trickle out.
Fluid Drain And Fill
FLUID DRAIN AND FILL
NOTE: The fluid required for this transaxle is Mopar(R) ATF+4 (Automatic Transmission Fluid).
Use of improper or substitute fluids can cause shift problems and/or transaxle failure.
1. Raise vehicle on hoist. 2. Obtain suitable fluid collection container and place under transaxle. 3.
Remove transaxle drain plug (2). Allow fluid to drain into container until empty. 4. Install the drain
plug (1) with a new gasket and tighten to 39 Nm (29 ft. lbs.). 5. Remove transaxle fill plug (1). 6.
Add the appropriate amount of transaxle fluid to the transaxle.
Information > Service and Repair > BG6 Manual Transaxle > Page 5172
Fluid - M/T: Service and Repair T355 Manual Transaxle
STANDARD PROCEDURE - FLUID DRAIN AND FILL
NOTE: All T355 Manual Transaxles require the use of ATF+4 (Automatic Transmission Fluid).
The transaxle fill plug (1) is located on the left side of the transaxle differential area. The fluid level
should be within 3/16 inch from the bottom of the transaxle fill hole (vehicle must be level when
checking).
The transaxle drain plug (2) is located on the lower right side of the transaxle differential housing.
Tighten drain plug to 14 Nm (120 in. lbs.).
Jeep Workshop Manuals > Transmission and Drivetrain > Manual Transmission/Transaxle > Seals and Gaskets, M/T >
System Information > Service and Repair > BG6 Manual Transaxle
Seals and Gaskets: Service and Repair BG6 Manual Transaxle
Removal
REMOVAL
1. Remove axle shaft. 2. Insert a flat-blade pry tool (2) at outer edge of axle shaft seal (1). 3. Tap
on the pry tool (2) with a small hammer and remove axle shaft seal (1).
Installation
INSTALLATION
1. Clean axle shaft seal bore of any excess sealant.

System Information > Service and Repair > BG6 Manual Transaxle > Page 5177
2. Align (bellhousing side) axle shaft seal with axle shaft seal bore. 3. Install axle seal on Seal
Installer 9928 and Handle C-4171 and insert into axle shaft seal bore. 4. Tap seal into position until
seated against transaxle case.
5. Align axle shaft seal with axle shaft seal bore. 6. Install (case side) axle seal on Seal Installer
9934 and Handle C-4171 and insert into axle shaft seal bore. 7. Tap seal into position until seated
against transaxle case. 8. Install axle shaft. 9. Check transaxle fluid level and adjust as necessary.
Seals and Gaskets: Service and Repair T355 Manual Transaxle
Removal
REMOVAL
1. Remove axle shaft. 2. Insert a flat-blade pry tool (2) at outer edge of axle shaft seal (1). 3. Tap
on the pry tool (2) with a small hammer and remove axle shaft seal (1).
Installation
INSTALLATION
1. Clean axle shaft seal bore of any excess sealant.

2. Align (bellhousing side) axle shaft seal with axle shaft seal bore. 3. Install axle seal on Seal
Installer 9928 and Handle C-4171 and insert into axle shaft seal bore. 4. Tap seal into position until
seated against transaxle case.
5. Align axle shaft seal with axle shaft seal bore. 6. Install (case side) axle seal on Seal Installer
9934 and Handle C-4171 and insert into axle shaft seal bore. 7. Tap seal into position until seated
against transaxle case. 8. Install axle shaft. 9. Check transaxle fluid level and adjust as necessary.
Removal
REMOVAL
1. Remove the transaxle. 2. Remove seal.
Installation
INSTALLATION
1. Install input shaft seal (2) using installer 8864 (1). 2. Install the transaxle.
Removal
REMOVAL
It is not necessary to remove the shift shafts from the transaxle to service the shift shaft seals.
1. Using a pick tool, pry up on the shift shaft seal, and remove seal from bore.
Installation
INSTALLATION
1. Position new shift shaft seal into bore. 2. Install shift shaft seal into bore using an appropriate
size deep-well socket.
Jeep Workshop Manuals > Transmission and Drivetrain > Manual Transmission/Transaxle > Sensors and Switches - M/T >
Transmission Speed Sensor, M/T > Component Information > Description and Operation
Transmission Speed Sensor, M/T > Component Information > Service and Repair > Removal
REMOVAL
Transmission Speed Sensor, M/T > Component Information > Service and Repair > Removal > Page 5187
INSTALLATION
Jeep Workshop Manuals > Transmission and Drivetrain > Manual Transmission/Transaxle > Shifter M/T > Component
Information > Service and Repair > BG6 Manual Transaxle
Shifter M/T: Service and Repair BG6 Manual Transaxle
Removal
REMOVAL
1. Pull up on gearshift knob (1) with moderate force to remove from gearshift mechanism. 2.
Remove shifter boot/bezel (3) assembly from console by lifting up at mounting ring area.
Installation
INSTALLATION
1. Position gearshift boot (3) over the operating lever (2) and apply hand pressure to engage and
snap console into place. 2. Position gearshift knob (1) hole over the gearshift mechanism and align
the shift pattern. 3. Verify that shift pattern is aligned properly. 4. Strike knob (1) with rubber mallet
to engage knob to mechanism.
Removal
REMOVAL
1. Remove gear shift boot. 2. Remove the center console assembly. Remove rear power window
switch (if equipped) and disconnect harness from console.
NOTE: Cable is pushed into a rubber grommet.
3. Remove select cable (2) from shift lever (1).
4. Remove shift cable retaining clip (3) and disconnect cable (2) from the shift lever (1).
5. Remove the shifter assembly to riser bolts (3) and remove shifter from vehicle.
Installation
INSTALLATION
1. Install shifter assembly (1) to riser. Install and tighten bolts (3) to 7 Nm (61 in. lbs.).
2. Install shift cable (2) to shifter lever (1) and secure cable to shifter bracket with clip (3).
3. Install select cable to shifter lever and secure cable to shifter bracket. 4. Install center console
assembly. Install rear power window switch (if equipped) and fasten harness to console. 5. Install
gearshift boot. 6. Verify that shift pattern is aligned properly.
Shifter M/T: Service and Repair T355 Manual Transaxle
Removal
REMOVAL
1. Pull up on gearshift knob (1) with moderate force to remove from gearshift mechanism. 2.
Remove shifter boot/bezel (3) assembly from console by lifting up at mounting ring area.
Installation
INSTALLATION
1. Position gearshift boot (3) over the operating lever (2) and apply hand pressure to engage and
snap console into place. 2. Position gearshift knob (1) hole over the gearshift mechanism and align
the shift pattern. 3. Verify that shift pattern is aligned properly. 4. Strike knob (1) with rubber mallet
to engage knob to mechanism.
Removal
REMOVAL
1. Pull up on gearshift knob (1) with moderate force to remove from gearshift mechanism.
Installation
INSTALLATION
1. Position knob hole (1) over the gearshift mechanism and align the shift pattern. 2. Verify that
shift pattern is aligned properly. 3. Strike knob (1) with rubber mallet to engage knob to mechanism.
Removal
REMOVAL
1. Remove gear shift boot. 2. Remove the center console assembly. Remove rear power window
switch (if equipped) and disconnect harness from console.
NOTE: Cable is pushed into a rubber grommet.
3. Remove select cable (2) from shift lever (1).
4. Remove shift cable retaining clip (3) and disconnect cable (2) from the shift lever (1).
5. Remove the shifter assembly to riser bolts (3) and remove shifter from vehicle.
Installation
INSTALLATION
1. Install shifter assembly. (1) to riser. Install and tighten bolts (3) to 7 Nm (61 in. lbs.).
2. Install shift cable (2) to shifter lever (1) and secure cable to shifter bracket with clip (3).
3. Install select cable to shifter lever and secure cable to shifter bracket. 4. Install center console
assembly. Install rear power window switch (if equipped) and fasten harness to console. 5. Install
gearshift boot. 6. Verify that shift pattern is aligned properly.
Jeep Workshop Manuals > Transmission and Drivetrain > Manual Transmission/Transaxle > Shift Linkage, M/T > Selector
Shaft, M/T > Component Information > Service and Repair > Selector Shaft
Selector Shaft: Service and Repair Selector Shaft
Removal
REMOVAL
1. Disassemble transaxle. 2. With the transaxle disassembled, remove the select shaft seal. 3.
Using snap-ring pliers, remove the snap ring (3) at the select shaft bore. 4. Push the select shaft
(2) in the case and remove the select assembly.
Installation
INSTALLATION
1. Install select shaft to case and install snap ring (3). 2. Install the select shaft seal. 3. Assemble
transaxle.
Jeep Workshop Manuals > Transmission and Drivetrain > Manual Transmission/Transaxle > Shift Linkage, M/T > Selector
Shaft, M/T > Component Information > Service and Repair > Selector Shaft > Page 5205
Selector Shaft: Service and Repair Selector Shaft Bushing
Removal
REMOVAL
1. Install Slide Hammer C-3752 (1) through the select bushing. 2. Thread nut and washer onto slide
hammer. 3. Using the slide hammer, remove the select shaft bushing (2).
Installation
INSTALLATION
1. Position the replacement select shaft bushing over the crossover shaft bushing bore. 2. Using an
appropriate size deep-well socket, install the select shaft bushing into the bushing bore.
Jeep Workshop Manuals > Transmission and Drivetrain > Manual Transmission/Transaxle > Shift Linkage, M/T > Shift
Cable, M/T > Component Information > Adjustments
Shift Cable: Adjustments
ADJUSTMENT
Increase the (4) distance to eliminate 2nd gear downshift blocking condition (3-2, or 4-2 blocking).
NOTE: Must verify reverse shift after adjusting.
Decrease the distance if shifter can not engage reverse.
1. Loosen select lever bracket bolts (2). 2. Adjust gage length fore/aft by pivoting bracket and
re-securing. Torque to 21.4 +/- 5.2 Nm.
Cable, M/T > Component Information > Service and Repair > BG6 Manual Transaxle
Shift Cable: Service and Repair BG6 Manual Transaxle
Removal
REMOVAL
1. Remove the shifter. 2. Raise hood. 3. Remove the resonator. 4. Remove engine cover. 5.
Remove air cleaner assembly. 6. Disconnect both battery cables. 7. Remove battery hold down
clamp and bolt, and remove battery. 8. Remove battery tray. 9. Disconnect cables (1) from the shift
levers at the transaxle.
CAUTION: Pry up with equal force on both sides of shifter cable isolator bushings to avoid
damaging cable isolator bushings.
10. Remove cable retaining clips and remove cables (1) from bracket (3). 11. Remove the
Occupant Restraint Controller (ORC).
Cable, M/T > Component Information > Service and Repair > BG6 Manual Transaxle > Page 5211
12. Remove cable clips at floor pan. 13. Remove cable assembly (1) from vehicle.
Installation
INSTALLATION
CAUTION: Gearshift cable bushings must not be lubricated or the bushings will swell and split.
1. Install cable assembly through floor pan opening until grommet is seated.
2. Route transaxle end of cable assembly into engine compartment and over transaxle assembly.
3. Install cables (1) and NEW retaining clips to bracket.
4. Install gearshift cables to mounting bracket and fasten with NEW clips (2). Make sure clips are
installed flush to bracket. 5. Connect cables (1) to the shift levers (3) at the transaxle. 6. Install
ORC. 7. Install shifter. 8. Install battery tray. 9. Install battery and hold-down clamp.
10. Install the air cleaner assembly. 11. Connect battery cables.
Shift Cable: Service and Repair T355 Manual Transaxle
Removal
REMOVAL
1. Remove the shifter. 2. Raise hood. 3. Remove the resonator. 4. Remove engine cover. 5.
Remove air cleaner assembly. 6. Disconnect both battery cables. 7. Remove battery hold down
clamp and bolt, and remove battery. 8. Remove battery tray. 9. Disconnect cables (1) from the shift
levers at the transaxle (3).
CAUTION: Pry up with equal force on both sides of shifter cable isolator bushings to avoid
damaging cable isolator bushings.
10. Squeeze cable retaining clips (2) and remove cables from bracket (4).
11. Remove the Occupant Restraint Controller (ORC). 12. Squeeze cable retaining clips (2) and
remove cables from bracket. 13. Remove cable assembly (1) from vehicle.
Installation
INSTALLATION
CAUTION: Gearshift cable bushings must not be lubricated or the bushings will swell and split.
1. Install cable assembly through floor pan opening and secure to floor pan with grommet plate. 2.
Route transaxle end of cable assembly into engine compartment and over transaxle assembly. 3.
Connect cables (1) to the shift levers (3) at the transaxle. 4. Install cables (1) to bracket (4).
5. Install gearshift cables (1). 6. Install ORC. 7. Install shifter. 8. Install battery tray. 9. Install battery
and hold-down clamp.
10. Install the air cleaner assembly. 11. Connect battery cables.
Jeep Workshop Manuals > Transmission and Drivetrain > Manual Transmission/Transaxle > Shift Linkage, M/T > Shift Rail,
M/T > Component Information > Service and Repair > Removal
Shift Rail: Service and Repair Removal
REMOVAL
1. Thread Remover 6786 (1) into shift rail bushing. 2. Install slide hammer C-3752 (2) onto tool. 3.
Remove bushing (3) using slide hammer and tool assembly.
Jeep Workshop Manuals > Transmission and Drivetrain > Manual Transmission/Transaxle > Shift Linkage, M/T > Shift Rail,
M/T > Component Information > Service and Repair > Removal > Page 5220
Shift Rail: Service and Repair Installation
INSTALLATION
1. Line up replacement bushing in bore. 2. Using Installer MD998343, tap bushing into bore until
flush with the chamfer in the case.
Jeep Workshop Manuals > Transmission and Drivetrain > Manual Transmission/Transaxle > Transmission Speed Sensor,
M/T > Component Information > Description and Operation
M/T > Component Information > Service and Repair > Removal
REMOVAL
M/T > Component Information > Service and Repair > Removal > Page 5226
INSTALLATION
Jeep Workshop Manuals > Transmission and Drivetrain > Relays and Modules - Transmission and Drivetrain > Relays and
PCM/TCM Replacement Requirements
Requirements
INTERNET.

BULLETIN.
MODELS:
2007 (MK49) Compass
2007 (MK74) Patriot
2007 (PM) Caliber
NOTE:
DISCUSSION:
below.
CAUTION:
PARTS REQUIRED:
CAUTION:

down load.
CAUTION:
PROCESS.
NOTE:
NOTE:
NOTE:
drop.
seconds.
CAUTION:
NOTE:
PCM.
NOTE:
StarSCAN(R) screen.
NOTE:
list.

File List" screen?
with step 9.
NOTE:
CAUTION:

down load.
NOTE:
NOTE:
NOTE:
down load.
drop.
number.
NOTE:


File List" screen?
with step 7.
NOTE:
TIME ALLOWANCE:
FAILURE CODE:
Disclaimer:
NUMBER: 18-039-06
INTERNET.
BULLETIN.
SUBJECT:
CAUTION:

BE INSTALLED.
MODELS:
2007 (PM) Caliber
2007 (MK49) Compass
NOTE:
(MDH 1120XX).
NOTE:
DIAGNOSIS:
PARTS REQUIRED:
CAUTION:
NOTE:

seconds.
CAUTION:
PROCESS.
NOTE:
NOTE:
TIME ALLOWANCE:
FAILURE CODE:
Disclaimer:
NUMBER: 18-032-07
DATE: May 16, 2007
INTERNET.
BULLETIN.
CAUTION:

BE INSTALLED.
MODELS:
2007 (JS) Sebring
2007 (MK49) Compass
2007 (MK74) Patriot
2007 (PM) Caliber
NOTE:
SYMPTOM/CONDITION:
DIAGNOSIS:
PARTS REQUIRED:
CAUTION:
NOTE:
NOTE:
NOTE:
drop.

seconds.
CAUTION:

PROCESS.
NOTE:
seconds.
CAUTION:
NOTE:
NOTE:
TIME ALLOWANCE:
FAILURE CODE:
Disclaimer:
NUMBER: 18-032-07
DATE: May 16, 2007
INTERNET.
BULLETIN.
CAUTION:

BE INSTALLED.
MODELS:
2007 (JS) Sebring
2007 (MK49) Compass
2007 (MK74) Patriot
2007 (PM) Caliber
NOTE:
SYMPTOM/CONDITION:
DIAGNOSIS:
PARTS REQUIRED:
CAUTION:
NOTE:
NOTE:
NOTE:
drop.

seconds.
CAUTION:

PROCESS.
NOTE:
seconds.
CAUTION:
NOTE:
NOTE:
TIME ALLOWANCE:
FAILURE CODE:
Disclaimer:
Component ID: 170
Connector:
Color : WHITE
# of pins : 24
Qualifier : (CVT)

7--
8--
9--
16 - -
17 - -
23 - -
24 - -
Connector:
Color : LT. GRAY
# of pins : 24
Qualifier : (CVT)
1 GROUND Z967 18BK
3--
4 FUSED B(+) (I.O.D.) A416 18RD

6--
7--
8--
9--
11 - -

15 - -
16 - -
24 GROUND Z967 18BK
Component ID: 170
Connector:
Color : WHITE
# of pins : 24
Qualifier : (CVT)

7--
8--
9--
16 - -
17 - -
23 - -
24 - -
Connector:
Color : LT. GRAY
# of pins : 24
Qualifier : (CVT)
1 GROUND Z967 18BK
3--
4 FUSED B(+) (I.O.D.) A416 18RD

6--
7--
8--
9--
11 - -

15 - -
16 - -
24 GROUND Z967 18BK
Modules - CVT > Control Module, CVT > Component Information > Description and Operation > Description
DESCRIPTION
OPERATION
Shift Control
"Drive" Position
gear ranges.
Lock-up Control
Selection Control
CAN Communication
Inputs and Outputs

Fail-safe Function
PNP Switch
Lock-up solenoid
Stepping Motor
Backup Power Supply
TCM
Modules - CVT > Control Module, CVT > Component Information > Service and Repair > Removal
REMOVAL
4. Remove the TCM.

INSTALLATION

Modules - Transfer Case > Control Module, Transfer Case > Component Information > Locations
Component ID: 150
Connector:
Color : # of pins :
16
Qualifier : (AWD)
1--
2--
3--

7--
9--
10 - -
11 - -
13 - -
14 - -
15 GROUND Z967 20BK
Component ID: 150
Connector:
Color : # of pins :
16
Qualifier : (AWD)
1--
2--
3--

7--
9--
10 - -
11 - -
13 - -
14 - -
15 GROUND Z967 20BK
Description
DESCRIPTION
bus.
OPERATION
torque transfer.
condition as well.
fuel economy.
Modules - Transfer Case > Control Module, Transfer Case > Component Information > Service and Repair > Removal
REMOVAL

Modules - Transfer Case > Control Module, Transfer Case > Component Information > Service and Repair > Removal >
Page 5294
INSTALLATION

Jeep Workshop Manuals > Transmission and Drivetrain > Sensors and Switches - Transmission and Drivetrain > Sensors
and Switches - CVT > Fluid Pressure Sensor/Switch, CVT > Component Information > Locations
Component ID: 15
Connector:
Color : BLACK
# of pins : 22
6 GROUND Z967 18BK

12 - -
13 - -
14 - -
15 - -
20 - -
Component ID: 15
Connector:
Color : BLACK
# of pins : 22
6 GROUND Z967 18BK

12 - -
13 - -
14 - -
15 - -
20 - -
and Switches - CVT > Transmission Position Switch/Sensor, CVT > Component Information > Locations
Component ID: 15
Connector:
Color : BLACK
# of pins : 22
6 GROUND Z967 18BK

12 - -
13 - -
14 - -
15 - -
20 - -
and Switches - CVT > Transmission Position Switch/Sensor, CVT > Component Information > Locations > Page 5306
and Switches - CVT > Transmission Speed Sensor, CVT > Component Information > Locations
Component ID: 15
Connector:
Color : BLACK
# of pins : 22
6 GROUND Z967 18BK

12 - -
13 - -
14 - -
15 - -
20 - -
and Switches - CVT > Transmission Speed Sensor, CVT > Component Information > Locations > Page 5310
DESCRIPTION


OPERATION
following reasons:
service.
and Switches - M/T > Transmission Speed Sensor, M/T > Component Information > Description and Operation
and Switches - M/T > Transmission Speed Sensor, M/T > Component Information > Service and Repair > Removal
REMOVAL
and Switches - M/T > Transmission Speed Sensor, M/T > Component Information > Service and Repair > Removal > Page
5322
INSTALLATION
and Switches - Transfer Case > Four Wheel Drive Selector Switch > Component Information > Locations
Component ID: 366
Connector:
Color : BLACK
# of pins : 6
Gender : FEMALE
3--
4--

and Switches - Transfer Case > Four Wheel Drive Selector Switch > Component Information > Locations > Page 5327
Component ID: 366
Connector:
Color : BLACK
# of pins : 6
Gender : FEMALE
3--
4--

Jeep Workshop Manuals > Transmission and Drivetrain > Transfer Case > Control Module, Transfer Case > Component
Component ID: 150
Connector:
Color : # of pins :
16
Qualifier : (AWD)
1--
2--
3--

7--
9--
10 - -
11 - -
13 - -
14 - -
15 GROUND Z967 20BK
Component ID: 150
Connector:
Color : # of pins :
16
Qualifier : (AWD)
1--
2--
3--

7--
9--
10 - -
11 - -
13 - -
14 - -
15 GROUND Z967 20BK
DESCRIPTION
bus.
OPERATION
torque transfer.
condition as well.
fuel economy.
REMOVAL

INSTALLATION

Jeep Workshop Manuals > Transmission and Drivetrain > Transfer Case > Differential, Transfer Case > Differential Fluid -
Transfer Case > Component Information > Technical Service Bulletins > Maintenance - Fluid Flushing Information
Differential Fluid - Transfer Case: Technical Service Bulletins Maintenance - Fluid Flushing
Information
NUMBER: 26-001-09

MODELS:
2009 - 2010 (DS) Ram Truck (1500)
2005 - 2009 (HB) Durango
2007 - 2009 (HG) Aspen
2009 - 2010 (JC) Journey
2008 - 2010 (KK) Liberty
2007 - 2010 (KA) Nitro
2005 - 2007 (KJ) Liberty
2005 - 2010 (ND) Dakota

2005 - 2006 (PL) Neon
2007 - 2010 (PM) Caliber

Jeep Workshop Manuals > Transmission and Drivetrain > Transfer Case > Differential, Transfer Case > Differential Fluid -
Transfer Case > Component Information > Technical Service Bulletins > Maintenance - Fluid Flushing Information > Page
5348
2005 - 2010 (ZB) Viper
DISCUSSION:
coolant.
operating range.
distilled water.
Disclaimer:
Jeep Workshop Manuals > Transmission and Drivetrain > Transfer Case > Fluid - Transfer Case > Component Information
> Technical Service Bulletins > Maintenance - Fluid Flushing Information
Fluid - Transfer Case: Technical Service Bulletins Maintenance - Fluid Flushing Information
NUMBER: 26-001-09

MODELS:
2009 - 2010 (DS) Ram Truck (1500)
2005 - 2009 (HB) Durango
2007 - 2009 (HG) Aspen
2009 - 2010 (JC) Journey
2008 - 2010 (KK) Liberty
2007 - 2010 (KA) Nitro
2005 - 2007 (KJ) Liberty
2005 - 2010 (ND) Dakota
2005 - 2006 (PL) Neon

2007 - 2010 (PM) Caliber

> Technical Service Bulletins > Maintenance - Fluid Flushing Information > Page 5353
2005 - 2010 (ZB) Viper
DISCUSSION:
coolant.
operating range.
distilled water.
Disclaimer:
> Specifications > Capacity Specifications
Fluid - Transfer Case: Capacity Specifications
Power Transfer Unit ( PTU ) Fluid Capacity Transfer Case ................................................................

............................................................................................................................... 540 ml ( 1.1 Pt )
> Specifications > Capacity Specifications > Page 5356
Fluid - Transfer Case: Fluid Type Specifications
Power Transfer Unit ( PTU ) Fluid Type Mopar Gear & Axle Lubricant SAE 80W-90 API GL 5 or
Jeep Workshop Manuals > Transmission and Drivetrain > Transfer Case > Four Wheel Drive Indicator Lamp > Component
Description
DESCRIPTION
(VFD) unit.
cluster.
Operation
OPERATION
deactivated.
Description
DESCRIPTION
Operation
OPERATION
(CAN) data bus.
required.
Jeep Workshop Manuals > Transmission and Drivetrain > Transfer Case > Four Wheel Drive Selector Switch > Component
Component ID: 366
Connector:
Color : BLACK
# of pins : 6
Gender : FEMALE
3--
4--

Component ID: 366
Connector:
Color : BLACK
# of pins : 6
Gender : FEMALE
3--
4--

Jeep Workshop Manuals > Transmission and Drivetrain > Transfer Case > Lamps and Indicators - Transfer Case > Four
Wheel Drive Indicator Lamp > Component Information > Description and Operation > Four-Wheel Drive Indicator
Description
DESCRIPTION
(VFD) unit.
cluster.
Operation
OPERATION
deactivated.
Wheel Drive Indicator Lamp > Component Information > Description and Operation > Four-Wheel Drive Indicator > Page
5375
5376
Description
DESCRIPTION
Operation
OPERATION
(CAN) data bus.
5377
required.
Jeep Workshop Manuals > Transmission and Drivetrain > Transfer Case > Lamps and Indicators - Transfer Case >
Malfunction Indicator Lamp - Transfer Case > Component Information > Description and Operation > Description
DESCRIPTION
tachometer.
Jeep Workshop Manuals > Transmission and Drivetrain > Transfer Case > Lamps and Indicators - Transfer Case >
Malfunction Indicator Lamp - Transfer Case > Component Information > Description and Operation > Description > Page
5382
OPERATION
Jeep Workshop Manuals > Transmission and Drivetrain > Transfer Case > Malfunction Indicator Lamp - Transfer Case >
DESCRIPTION
tachometer.
Jeep Workshop Manuals > Transmission and Drivetrain > Transfer Case > Malfunction Indicator Lamp - Transfer Case >
OPERATION
Jeep Workshop Manuals > Transmission and Drivetrain > Transfer Case > Relays and Modules - Transfer Case > Control
Module, Transfer Case > Component Information > Locations
Component ID: 150
Connector:
Color : # of pins :
16
Qualifier : (AWD)
1--
2--
3--

7--
9--
10 - -
11 - -
13 - -
14 - -
15 GROUND Z967 20BK
Module, Transfer Case > Component Information > Locations > Page 5392
Component ID: 150
Connector:
Color : # of pins :
16
Qualifier : (AWD)
1--
2--
3--

7--
9--
10 - -
11 - -
13 - -
14 - -
15 GROUND Z967 20BK
Module, Transfer Case > Component Information > Description and Operation > Description
DESCRIPTION
bus.
Module, Transfer Case > Component Information > Description and Operation > Description > Page 5397
OPERATION
torque transfer.
condition as well.
fuel economy.
Module, Transfer Case > Component Information > Service and Repair > Removal
REMOVAL

Module, Transfer Case > Component Information > Service and Repair > Removal > Page 5400
INSTALLATION

Jeep Workshop Manuals > Transmission and Drivetrain > Transfer Case > Seals and Gaskets, Transfer Case > System
Information > Service and Repair > Seal-Differential Carrier
Seals and Gaskets: Service and Repair Seal-Differential Carrier
Removal
REMOVAL
1. Remove PTU from transaxle. 2. Use a screw mounted in a slide hammer to remove seal. Be
careful not to damage seal journal when removing seal.
Installation
INSTALLATION
1. Install the carrier case seal using Installer 9851 and Handle C-4171. 2. Install the PTU.
Information > Service and Repair > Seal-Differential Carrier > Page 5405
Seals and Gaskets: Service and Repair Seal-Output Flange
Removal
REMOVAL
1. Remove the propeller shaft. 2. Using a screwdriver remove the output seal.
Installation
INSTALLATION
1. Install the output shaft seal using Installer 9851 and Handle C-4171. 2. Install the propeller shaft.
Seals and Gaskets: Service and Repair Seals-End Cover
Removal
REMOVAL
1. Remove the right halfshaft. 2. Remove the side cover bolts. 3. Remove the side cover.
4. Using a drift remove both inner and outer seals.
Installation
INSTALLATION
1. Install the inner seal into the PTU cover using Installer 9852 and Handle C-4171.
2. Install the outer seal into the PTU cover using Installer 9853 and Handle C-4171.
3. Install the side cover. 4. Tighten side cover bolts (1) to 23 Nm (17 ft. lbs.).
5. Install the right halfshaft.
Seals and Gaskets: Service and Repair Extension Housing Dust Shield
Removal
REMOVAL
1. Remove the propeller shaft. 2. Remove the extension housing bolts (1). 3. Remove the
extension housing. 4. Remove the extension housing O-ring and inspect.
5. Using a chisel (2) remove the dust shield (1) from the extension housing (3).
Installation
INSTALLATION
1. Using a block of wood (2) install the dust shield (3) onto the extension housing (1).
2. Install the extension housing and bolts. 3. Tighten the extension housing bolts to 38 Nm (28 ft.
lbs.). 4. Install the propeller shaft.
Jeep Workshop Manuals > Transmission and Drivetrain > Transfer Case > Sensors and Switches - Transfer Case > Four
Wheel Drive Selector Switch > Component Information > Locations
Component ID: 366
Connector:
Color : BLACK
# of pins : 6
Gender : FEMALE
3--
4--

Wheel Drive Selector Switch > Component Information > Locations > Page 5415
Component ID: 366
Connector:
Color : BLACK
# of pins : 6
Gender : FEMALE
3--
4--

Jeep Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Actuators and Solenoids -
Component ID: 15
Connector:
Color : BLACK
# of pins : 22
6 GROUND Z967 18BK

12 - -
13 - -
14 - -
15 - -
20 - -
Component ID: 15
Connector:
Color : BLACK
# of pins : 22
6 GROUND Z967 18BK

12 - -
13 - -
14 - -
15 - -
20 - -
Component ID: 15
Connector:
Color : BLACK
# of pins : 22
6 GROUND Z967 18BK

12 - -
13 - -
14 - -
15 - -
20 - -
> Page 5430
> Page 5431
Component ID: 15
Connector:
Color : BLACK
# of pins : 22
6 GROUND Z967 18BK

12 - -
13 - -
14 - -
15 - -
20 - -
> Page 5432
> Locations
Solenoid: Locations
Component ID: 335
Connector:
Color : # of pins :
Qualifier : (ECC)
Solenoid: Diagrams
Component ID: 335
Connector:
Color : # of pins :
Qualifier : (ECC)
Jeep Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Lamps and Indicators -
Description
DESCRIPTION
(VFD) unit.
cluster.
Operation
OPERATION
deactivated.
Description
DESCRIPTION
Operation
OPERATION
(CAN) data bus.
required.
DESCRIPTION
tachometer.
OPERATION
Jeep Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Relays and Modules -
Transmission and Drivetrain > Relays and Modules - A/T > Control Module, A/T > Component Information > Technical
Service Bulletins > Engine, A/T Controls - PCM/TCM Replacement Requirements
Requirements
INTERNET.

BULLETIN.
MODELS:
2007 (MK49) Compass
2007 (MK74) Patriot
2007 (PM) Caliber
NOTE:
DISCUSSION:
below.
CAUTION:
Service Bulletins > Engine, A/T Controls - PCM/TCM Replacement Requirements > Page 5460
PARTS REQUIRED:
CAUTION:

down load.
CAUTION:
PROCESS.
NOTE:
NOTE:
NOTE:
drop.
seconds.
CAUTION:
NOTE:
PCM.
NOTE:
StarSCAN(R) screen.
NOTE:
list.

File List" screen?
with step 9.
NOTE:
CAUTION:

down load.
NOTE:
NOTE:
NOTE:
down load.
drop.
number.
NOTE:


File List" screen?
with step 7.
NOTE:
TIME ALLOWANCE:
FAILURE CODE:
Disclaimer:
NUMBER: 18-039-06
INTERNET.
BULLETIN.
SUBJECT:
CAUTION:

BE INSTALLED.
MODELS:
2007 (PM) Caliber
2007 (MK49) Compass
NOTE:
(MDH 1120XX).
NOTE:
DIAGNOSIS:
PARTS REQUIRED:
CAUTION:
NOTE:

seconds.
CAUTION:
PROCESS.
NOTE:
NOTE:
TIME ALLOWANCE:
FAILURE CODE:
Disclaimer:
Transmission and Drivetrain > Relays and Modules - CVT > Control Module, CVT > Component Information > Technical
Service Bulletins > Customer Interest for Control Module: > 18-032-07 > May > 07 > A/T - MIL ON Possible DTC P2004
NUMBER: 18-032-07
DATE: May 16, 2007
INTERNET.
BULLETIN.
CAUTION:

BE INSTALLED.
MODELS:
2007 (JS) Sebring
2007 (MK49) Compass
2007 (MK74) Patriot
2007 (PM) Caliber
NOTE:
SYMPTOM/CONDITION:
DIAGNOSIS:
PARTS REQUIRED:
Service Bulletins > Customer Interest for Control Module: > 18-032-07 > May > 07 > A/T - MIL ON Possible DTC P2004 >
Page 5477
CAUTION:
NOTE:
NOTE:
NOTE:
drop.

Page 5478
seconds.
CAUTION:

PROCESS.
NOTE:
seconds.
CAUTION:
NOTE:
Page 5479
NOTE:
TIME ALLOWANCE:
FAILURE CODE:
Disclaimer:
Service Bulletins > All Technical Service Bulletins for Control Module: > 18-032-07 > May > 07 > A/T - MIL ON Possible
DTC P2004
NUMBER: 18-032-07
DATE: May 16, 2007
INTERNET.
BULLETIN.
CAUTION:

BE INSTALLED.
MODELS:
2007 (JS) Sebring
2007 (MK49) Compass
2007 (MK74) Patriot
2007 (PM) Caliber
NOTE:
SYMPTOM/CONDITION:
DIAGNOSIS:
PARTS REQUIRED:
DTC P2004 > Page 5485
CAUTION:
NOTE:
NOTE:
NOTE:
drop.

DTC P2004 > Page 5486
seconds.
CAUTION:

PROCESS.
NOTE:
seconds.
CAUTION:
NOTE:
DTC P2004 > Page 5487
NOTE:
TIME ALLOWANCE:
FAILURE CODE:
Disclaimer:
Component ID: 170
Connector:
Color : WHITE
# of pins : 24
Qualifier : (CVT)

7--
8--
9--
16 - -
17 - -
23 - -
24 - -
Connector:
Color : LT. GRAY
# of pins : 24
Qualifier : (CVT)
1 GROUND Z967 18BK
3--
4 FUSED B(+) (I.O.D.) A416 18RD

6--
7--
8--
9--
11 - -

15 - -
16 - -
24 GROUND Z967 18BK
Component ID: 170
Connector:
Color : WHITE
# of pins : 24
Qualifier : (CVT)

7--
8--
9--
16 - -
17 - -
23 - -
24 - -
Connector:
Color : LT. GRAY
# of pins : 24
Qualifier : (CVT)
1 GROUND Z967 18BK
3--
4 FUSED B(+) (I.O.D.) A416 18RD

6--
7--
8--
9--
11 - -

15 - -
16 - -
24 GROUND Z967 18BK
Transmission and Drivetrain > Relays and Modules - CVT > Control Module, CVT > Component Information > Description
DESCRIPTION
OPERATION
Shift Control
"Drive" Position
gear ranges.
Lock-up Control
Selection Control
CAN Communication
Inputs and Outputs

Fail-safe Function
PNP Switch
Lock-up solenoid
Stepping Motor
Backup Power Supply
TCM
Transmission and Drivetrain > Relays and Modules - CVT > Control Module, CVT > Component Information > Service and
Repair > Removal
REMOVAL
4. Remove the TCM.

INSTALLATION

Transmission and Drivetrain > Relays and Modules - Transfer Case > Control Module, Transfer Case > Component
Component ID: 150
Connector:
Color : # of pins :
16
Qualifier : (AWD)
1--
2--
3--

7--
9--
10 - -
11 - -
13 - -
14 - -
15 GROUND Z967 20BK
Component ID: 150
Connector:
Color : # of pins :
16
Qualifier : (AWD)
1--
2--
3--

7--
9--
10 - -
11 - -
13 - -
14 - -
15 GROUND Z967 20BK
DESCRIPTION
bus.
OPERATION
torque transfer.
condition as well.
fuel economy.
REMOVAL

INSTALLATION

Jeep Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Sensors and Switches -
> Locations
Component ID: 15
Connector:
Color : BLACK
# of pins : 22
6 GROUND Z967 18BK

12 - -
13 - -
14 - -
15 - -
20 - -
Component ID: 15
Connector:
Color : BLACK
# of pins : 22
6 GROUND Z967 18BK

12 - -
13 - -
14 - -
15 - -
20 - -
Component ID: 15
Connector:
Color : BLACK
# of pins : 22
6 GROUND Z967 18BK

12 - -
13 - -
14 - -
15 - -
20 - -
> Locations
Component ID: 15
Connector:
Color : BLACK
# of pins : 22
6 GROUND Z967 18BK

12 - -
13 - -
14 - -
15 - -
20 - -
DESCRIPTION


OPERATION
following reasons:
service.
REMOVAL
INSTALLATION
Component ID: 366
Connector:
Color : BLACK
# of pins : 6
Gender : FEMALE
3--
4--

Component ID: 366
Connector:
Color : BLACK
# of pins : 6
Gender : FEMALE
3--
4--

Jeep Workshop Manuals > Brakes and Traction Control > Antilock Brakes / Traction Control Systems > ABS Light >
ABS Light: Description and Operation Description
DESCRIPTION
An Antilock Brake System (ABS) indicator is standard equipment on all instrument clusters. This
indicator is located near the top of the cluster overlay, between the speedometer and the
tachometer. Illumination of this indicator may also be accompanied by the display of certain textual
messages in the cluster reconfigurable display.
The ABS indicator consists of a stencil-like cutout of the International Control and Display Symbol
icon for Failure of Anti-lock Braking System in the opaque layer of the instrument cluster overlay.
The dark outer layer of the overlay prevents the indicator from being clearly visible when it is not
illuminated. An amber Light Emitting Diode (LED) behind the cutout in the opaque layer of the
overlay causes the indicator to appear in amber through the translucent outer layer of the overlay
The ABS indicator is serviced as a unit with the instrument cluster.

Jeep Workshop Manuals > Brakes and Traction Control > Antilock Brakes / Traction Control Systems > ABS Light >
ABS Light: Description and Operation Operation
OPERATION
The ABS indicator gives an indication to the vehicle operator when the ABS system, or a circuit or
component of the system is ineffective. This indicator is controlled by a transistor on the instrument
cluster circuit board based upon cluster programming and electronic messages received by the
cluster from the Controller Antilock Brake (CAB) over the Controller Area Network (CAN) data bus.
The ABS indicator Light Emitting Diode (LED) is completely controlled by the instrument cluster
instrument cluster will turn ON the ABS indicator for the following reasons:
- Bulb Test - Each time the ignition switch is turned to the ON position the ABS indicator is
illuminated for about three seconds as a bulb test. The entire bulb test is a function of the CAB.
- ABS Indicator Lamp-On Message - Each time the cluster receives an electronic ABS indicator
lamp-ON message from the CAB, the ABS indicator will be illuminated. The indicator remains
illuminated until the cluster receives a lamp-OFF message from the CAB, or until the ignition switch
is turned to the OFF position, whichever occurs first.
Communication Error - If the cluster receives no lamp-ON or lamp-OFF messages from the CAB
for five consecutive message cycles, the ABS indicator is illuminated. The indicator remains
illuminated until the cluster receives a valid message from the CAB, or until the ignition switch is
turned to the OFF position, whichever occurs first.
- Actuator Test - Each time the instrument cluster is put through the actuator test, the ABS indicator
- ABS Diagnostic Test - The ABS indicator is blinked ON and OFF by lamp-ON and lamp-OFF
messages from the CAB during the performance of the ABS diagnostic tests.
The CAB continually monitors the ABS circuits and sensors to decide whether the system is in
good operating condition. The CAB then sends the proper lamp-ON or lamp-OFF message to the
ElectroMechanical Instrument Cluster (EMIC). If the CAB sends a lamp-ON message after the bulb
test, it indicates that the CAB has detected a system malfunction or that the ABS system has
become ineffective. The CAB will store a Diagnostic Trouble Code (DTC) for any malfunction it
detects. Each time the ABS indicator fails to light due to an open or short in the cluster ABS
indicator circuit, the cluster sends a message notifying the CAB of the condition, then the
instrument cluster and the CAB will each store a DTC and the cluster will flash the brake indicator
ON and OFF as a backup to notify the vehicle operator.
For proper diagnosis of the antilock brake system, the CAB, the EMIC, the CAN data bus or the
electronic communication related to ABS indicator operation a diagnostic scan tool is required.
Jeep Workshop Manuals > Brakes and Traction Control > Antilock Brakes / Traction Control Systems > Electronic Brake
F50 > Feb > 07 > Recall - ABS Module Reprogramming
February 2007
Models
November 18, 2006 (MDH 090701 - 111801).
101019 - 111509).
090707 - 111801).
090707 - 111801).
090707 - 111801).
101813 - 120606).
101813 - 120606).
- 113018).
- 113018).
120811).
NOTE:
IMPORTANT:
Subject
Repair
Parts Information
Special Tools
NOTE:

Dealer Notification
repair.
Service Procedure
NOTE:
NOTE:
13.5 volts.

number.
NOTE:
performed.
13.5 volts.
NOTE:

prompts.
NHTSA06V493000 > Dec > 06 > Recall 06V493000: ABS Control Module Software Update
Update
Brake Control Module: > F50 > Feb > 07 > Recall - ABS Module Reprogramming
February 2007
Models
November 18, 2006 (MDH 090701 - 111801).
101019 - 111509).
090707 - 111801).
090707 - 111801).
090707 - 111801).
101813 - 120606).
101813 - 120606).
- 113018).
- 113018).
120811).
NOTE:
IMPORTANT:
Subject
Repair
Parts Information
Special Tools
NOTE:

Dealer Notification
repair.
Service Procedure
NOTE:
NOTE:
13.5 volts.

number.
NOTE:
performed.
13.5 volts.
NOTE:

prompts.
Brake Control Module: > NHTSA06V493000 > Dec > 06 > Recall 06V493000: ABS Control Module Software Update
Component ID: 151
Connector:
Color : BLACK
# of pins : 47
Gender : FEMALE
2--
3--
4--
5--
6--
7--
9--
10 - -
11 - -
14 - -
15 - -
17 - -
20 - -
21 - -
23 - -
24 - -
25 - -
26 - -
27 - -
28 - -
30 - -
31 - -

38 - -
39 - -
40 - -
41 - -
44 - -

Component ID: 151
Connector:
Color : BLACK
# of pins : 47
Gender : FEMALE
2--
3--
4--
5--
6--
7--
9--
10 - -
11 - -
14 - -
15 - -
17 - -
20 - -
21 - -
23 - -
24 - -
25 - -
26 - -
27 - -
28 - -
30 - -
31 - -

38 - -
39 - -
40 - -
41 - -
44 - -

DESCRIPTION
OPERATION
operation.
the vehicle.
REMOVAL
INSTALLATION
assembly.
Jeep Workshop Manuals > Brakes and Traction Control > Antilock Brakes / Traction Control Systems > Hydraulic Control
Assembly - Antilock Brakes > Component Information > Description and Operation > Hydraulic Control Unit (HCU)
Hydraulic Control Assembly - Antilock Brakes: Description and Operation Hydraulic Control Unit
(HCU)
DESCRIPTION
The Hydraulic Control Unit (HCU) is mounted to the Antilock Brake Module (ABM) as part of the
Integrated Control Unit (ICU). The HCU controls the flow of brake fluid to the brakes using a series
of valves and accumulators. A pump/motor is mounted on the HCU to supply build pressure to the
brakes during an ABS stop.
VALVES AND SOLENOIDS
The valve block contains four inlet valves and four outlet solenoid valves. The inlet valves are
spring-loaded in the open position and the outlet valves are spring-loaded in the closed position
during normal braking. The fluid is allowed to flow from the master cylinder to the wheel brakes.
During an ABS stop, these valves cycle to maintain the proper slip ratio for each wheel. The inlet
valve closes preventing further pressure increase and the outlet valve opens to provide a path from
the wheel brake to the HCU accumulators and pump/motor. This releases (decays) pressure from
the wheel brake, thus releasing the wheel from excessive slippage. Once the wheel is no longer
slipping, the outlet valve is closed and the inlet valve is opened to reapply (build) pressure.
If the ABS includes the traction control feature, there are four other valves in the HCU. Two
Traction Control (TC) valves, mounted in the HCU valve block, are normally in the open position
and close only when the traction control is applied. There are also two shuttle valves which control
pressure return to the master cylinder under ABS and traction control conditions.
These TC valves are used to isolate the rear (non-driving) wheels of the vehicle from the hydraulic
pressure that the HCU pump/motor is sending to the front (driving) wheels when traction control is
being applied. The rear brakes need to be isolated from the master cylinder when traction control is
being applied so the rear wheels do not drag.
BRAKE FLUID ACCUMULATORS
There are two fluid accumulators in the HCU: one for the primary hydraulic circuit, and one for the
secondary hydraulic circuit. Each hydraulic circuit uses a 3 cc accumulator.
The fluid accumulators temporarily store brake fluid that is removed from the wheel brakes during
an ABS cycle. This stored fluid is used by the pump/motor to provide build pressure for the brake
hydraulic system. When the antilock stop is complete, the accumulators are drained by the
pump/motor.
There are two noise dampening chambers in the HCU on this vehicle equipped with traction
control.
PUMP/MOTOR
There are two pump assemblies in the HCU: one for the primary hydraulic circuit, and one for the
secondary hydraulic circuit. Both pumps are driven by a common electric motor. This DC-type
motor is integral to the HCU and is controlled by the ABM.
The pump/motor provides the extra amount of brake fluid needed during antilock braking. Brake
fluid is released to the accumulators when the outlet valve is opened during an antilock stop. The
pump mechanism consists of two opposing pistons operated by an eccentric camshaft. In
operation, these pistons are used to purge fluid from the accumulators back into the master
cylinder circuits. When the antilock stop is complete, the pump/motor drains the accumulators.
The pump motor is also used to build pressure when the system goes into Electronic Stability
Program (ESP(R)) and traction control mode.
The ABM may turn on the pump/motor when an antilock stop is detected. The pump/motor
continues to run during the antilock stop and is turned off after the stop is complete. Under some
conditions, the pump/motor runs to drain the accumulators during the next drive-off.
The pump/motor is not a serviceable item; if it requires replacement, the HCU must be replaced.
Assembly - Antilock Brakes > Component Information > Description and Operation > Hydraulic Control Unit (HCU) > Page
5611
Hydraulic Control Assembly - Antilock Brakes: Description and Operation Integrated Control Unit
(ICU)
Description
DESCRIPTION
The Hydraulic Control Unit (HCU) (2) and the Antilock Brake Module (ABM) (1) used with this
antilock brake system are combined (integrated) into one unit, which is called the Integrated
Control Unit (ICU).
The ICU (1) is located in the engine compartment, mounted to the right side body frame rail near
the strut tower.
The ABS with ESP and All-Speed Traction Control ICU consists of the following components: the
ABM, 12 (build/decay) solenoid valves, two traction control solenoid valves, two hydraulic shuttle
valves, valve block, fluid accumulators, a pump, and an electric pump/motor.
The replaceable components of the ICU are the HCU and the ABM. No attempt should be made to
service any components of the HCU or ABM.
Assembly - Antilock Brakes > Component Information > Description and Operation > Hydraulic Control Unit (HCU) > Page
5612
For additional information on the ABM, Refer to ELECTRICAL/ELECTRONIC BRAKE MODULE -
DESCRIPTION. For additional information on the HCU, Refer to HYDRAULIC CONTROL UNIT) -
DESCRIPTION.
Operation
OPERATION
For information of the ICU, refer to these individual components of the ICU:
- ANTILOCK BRAKE MODULE (ABM) Refer to BRAKE MODULE - DESCRIPTION
- HYDRAULIC CONTROL UNIT (HCU) (Refer to HYDRAULIC CONTROL UNIT - DESCRIPTION

Assembly - Antilock Brakes > Component Information > Service and Repair > Removal and Replacement
Hydraulic Control Assembly - Antilock Brakes: Removal and Replacement
Removal
REMOVAL
To remove the HCU, the ICU must be removed and disassembled. Refer to INTEGRATED
CONTROL UNIT DISASSEMBLY
Installation
INSTALLATION
To install the HCU, assemble and install the ICU. Refer to INTEGRATED CONTROL UNIT -
ASSEMBLY
Removal
INTEGRATED CONTROL UNIT - GAS ENGINE

1. Disconnect and isolate battery negative cable from battery post.
2. Using a brake pedal holding tool as shown, depress the brake pedal past its first 25 mm (1 inch)
of travel and hold it in this position. This will
isolate the master cylinder from the brake hydraulic system and will not allow the brake fluid to
drain out of the master cylinder reservoir while the lines are disconnected.
3. Remove the engine appearance cover. 4. Loosen lower and upper mounting nuts, then remove
the exhaust heat shield from the dash panel. 5. Pull the brake tube bundle routing clips (with tubes)
loose from studs on the dash panel.
Assembly - Antilock Brakes > Component Information > Service and Repair > Removal and Replacement > Page 5615
6. Remove the primary (4) and secondary (1) brake tubes (from master cylinder) at the hydraulic
control unit (7). 7. Remove the remaining brake tubes (2, 3, 5, 6) at the hydraulic control unit (7).
8. Remove the screw (1) fastening the power steering pressure hose routing clamp (2) to the
exhaust manifold.
NOTE: Use this figure in the following step to release the ABM harness connector cover. It shows
the location of the release tabs.
9. Disconnect the ABM harness connector from the Antilock Brake Module (ABM). To do so:
a. Depress the tabs on each side of the connector cover, then b. Pull outward and upward on the
lower half of the cover until it locks into position pointing straight outward (2). The connector can
then be
pulled straight outward off the ABM (1).

10. Loosen, but do not remove, the two mounting screws (2) attaching the ICU (1) mounting
bracket to the body. 11. Lift the ICU and mounting bracket (1) off the mounting screws (2). 12.
Move the brake tubes around as necessary without bending them and remove the ICU with bracket
through the opening between the A/C lines and
the exhaust manifold.
13. To separate the ABM from the HCU, Refer to INTEGRATED CONTROL UNIT) -
DISASSEMBLY.
Installation
1. Install the ICU with bracket (1) through the opening between the A/C lines and the exhaust
manifold using the opposite of how it was removed. 2. Place the mounting bracket for the ICU (1)
over the mounting screws (2) and hang the assembly in place. Tighten the two mounting screws (2)
to
23 Nm (17 ft. lbs.).

CAUTION: Before installing the ABM harness connector on the ABM, be sure the seal is properly
installed in the connector.
3. Insert the ABM wiring harness connector (2) into the socket of the ABM (1) and close the cover,
locking the connector in place.
4. Install the four chassis brake tubes (2, 3, 5, 6) brake tubes at the ICU hydraulic control unit (7).
Tighten the tube nuts to 17 Nm (150 in. lbs.). 5. Install the primary (4) and secondary (1) brake
tubes at the ICU hydraulic control unit (7). Tighten the tube nuts to 17 Nm (150 in. lbs.).
6. Position the power steering pressure hose routing clamp (2) on the exhaust manifold and install
7. Push the brake tube bundle routing clips (with tubes) onto the studs on the dash panel. 8. Install
the heat shield on the dash panel and tighten the lower and upper mounting nuts.
9. Remove the brake pedal holding tool.
10. Install the engine appearance cover. 11. Connect the battery negative cable to the battery post.
It is important that this be performed properly.
12. Hook up the scan tool to initialize the ABM and perform the following:
a. Clear any faults. b. Fill the master cylinder to the proper fill level and bleed the base and ABS
hydraulic systems. c. Check for leaks. d. Perform the ABS Verification Test and road test the
vehicle.
Hydraulic Control Assembly - Antilock Brakes: Overhaul
Disassembly
DISASSEMBLY
1. If the mounting bracket (3) needs to be removed from the ICU, remove the single mounting bolt
(2), then slide the ICU's mounting pins out of the
grommets in the bracket and remove the bracket.
2. Remove the mounting pins from the ICU.

3. Remove the four screws (1) attaching the ABM (2) to the HCU.
4. Separate the ABM (1) from the HCU (2).
Assembly
ASSEMBLY
1. Clean any debris off the mating surfaces of the HCU and ABM.
CAUTION: When installing new O-rings or solenoid valve stem seals, do not use any type of
lubricant.
2. If the seals (1) on the solenoid valve stems (2) are not new, replace them all. Each of the
solenoid valve stem seals must be new to keep out
moisture and debris; do not reuse solenoid valve stem seals.
3. Replace the pump/motor connector O-ring (1) if it is not new. Be sure the O-ring is properly
seated in the mounting groove (2).
4. Align components and install the ABM (1) on the HCU (2).
5. Install the four screws (1) attaching the ABM (2) to the HCU. Tighten the mounting screws to 2
Nm (17 in. lbs.).
6. If necessary, install the mounting pins (1) in the ICU (2) and tighten to 11 Nm (97 in. lbs.).
7. If the mounting bracket (3) needs to be installed on the ICU (1), install the mounting pins in the
ICU as necessary and tighten to 11 Nm (97 in.
lbs.). Insert the mounting pins into the grommets mounted in the bracket, then install the single
mounting bolt (2). Tighten the mounting bolt to 11 Nm (97 in. lbs.).
8. Install the ICU in the vehicle.

Jeep Workshop Manuals > Brakes and Traction Control > Antilock Brakes / Traction Control Systems > Lateral
Component ID: 297
Connector:
Color : BLACK
# of pins : 6
Qualifier : (ESP)
4--
6--
Component ID: 297
Connector:
Color : BLACK
# of pins : 6
Qualifier : (ESP)
4--
6--
DESCRIPTION
REMOVAL
INSTALLATION

Jeep Workshop Manuals > Brakes and Traction Control > Antilock Brakes / Traction Control Systems > Steering Angle
Sensor, Traction Control > Component Information > Locations
Component ID: 325
Connector:
Color : WHITE
# of pins : 4

Component ID: 325
Connector:
Color : WHITE
# of pins : 4

DESCRIPTION
Jeep Workshop Manuals > Brakes and Traction Control > Antilock Brakes / Traction Control Systems > Traction Control
Indicator Lamp > Component Information > Description and Operation > Electronic Stability Program/Brake Assist System
Indicator
Traction Control Indicator Lamp: Description and Operation Electronic Stability Program/Brake
Assist System Indicator
Description
DESCRIPTION
An Electronic Stability Program (ESP)/Brake Assist System (BAS) indicator is standard equipment
on all instrument clusters. This indicator is located near the bottom of the cluster overlay, between
the speedometer and the tachometer.
The ESP/BAS indicator consists of a stencil-like cutout of the text ESP BAS in the opaque layer of
The ESP/BAS indicator is serviced as a unit with the instrument cluster.
Operation
OPERATION
The ESP/BAS indicator gives an indication to the vehicle operator when the Electronic Stability
Program (ESP)/Brake Assist System (BAS) has been activated. This indicator is controlled by a
messages received by the cluster from the Controller Antilock Brake (CAB) and the All-Wheel Drive
Control Module (AWDCM) over the Controller Area Network (CAN) data bus.
The ESP/BAS indicator Light Emitting Diode (LED) is completely controlled by the instrument
transistor. The instrument cluster will turn ON the ESP/BAS indicator for the following reasons:
- Bulb Test - Each time the ignition switch is turned to the ON position the ESP/BAS indicator is
illuminated for about four seconds as a bulb test.
- ESP/BAS Indicator Lamp-On Message - Each time the cluster receives an electronic ESP/BAS
indicator lamp-ON message from the CAB indicating that the ESP/BAS system has been activated,
the ESP/BAS indicator will be illuminated. The indicator remains illuminated until the cluster
receives a lamp-OFF message from the CAB, or until the ignition switch is turned to the OFF
- ESP Deactivated Textual Message - Each time the cluster receives an electronic ESP OFF
indicator lamp-ON message from the CAB indicating that the ESP/BAS system has been manually
disabled, an ESP Deactivated textual message will appear within the cluster reconfigurable display.
The ESP Deactivated textual message remains displayed until the cluster receives a lamp-OFF
message from the CAB, or until the ignition switch is turned to the OFF position, whichever occurs
first.
- Actuator Test - Each time the cluster is put through the actuator test, the ESP/BAS indicator will
be turned ON, then OFF again during the bulb check portion of the test to confirm the functionality
of the LED and the cluster control circuitry.
The CAB and AWDCM continually monitor the ESP/BAS circuits and sensors to decide whether
the system is in good operating condition and the proper outputs to the components of the system.
The CAB or AWDCM then sends the proper lamp-ON or lamp-OFF message to the
ElectroMechanical
Indicator > Page 5653
Instrument Cluster (EMIC).
For proper diagnosis of the ESP/BAS system, the CAB, the AWDCM, the EMIC, the CAN data bus
or the electronic communication related to the ESP/BAS indicator operation a diagnostic scan tool
is required. Refer to the appropriate diagnostic information.
Traction Control Indicator Lamp: Description and Operation Traction Control Indicator
Description
DESCRIPTION
A traction control indicator is standard equipment on all instrument clusters. This indicator is
located on the lower edge of the cluster overlay, between the speedometer and the tachometer.
The traction control indicator consists of a stencil-like cutout of the International Control and
Display Symbol icon for Stability - Anti-Spin in the opaque layer of the instrument cluster overlay.
The dark outer layer of the overlay prevents the indicator from being clearly visible when it is not
illuminated. An amber Light Emitting Diode (LED) behind the cutout in the opaque layer of the
overlay causes the indicator to appear in amber through the translucent outer layer of the overlay
The traction control indicator is serviced as a unit with the instrument cluster.
Operation
OPERATION
The traction control indicator gives an indication to the vehicle operator when the Electronic
Stability Program (ESP)/Brake Assist System (BAS)/Traction Control System (TCS) has been
activated. This indicator is controlled by the instrument cluster logic circuit based upon cluster
programming and electronic messages received by the cluster from the Controller Antilock Brake
(CAB) over the Controller Area Network (CAN) data bus.
The traction control indicator is completely controlled by the instrument cluster logic circuit, and that
logic will only allow this indicator to operate when the instrument cluster receives a battery current
input on the fused ignition switch output (run-start) circuit. Therefore, the indicator will always be
OFF when the ignition switch is in any position except ON or START. The indicator only illuminates
when it is provided a path to ground by the instrument cluster circuitry. The instrument cluster will
turn ON the traction control indicator for the following reasons:
- Bulb Test - Each time the ignition switch is turned to the ON position the traction control indicator
is illuminated for about four seconds as a bulb test. The entire bulb test is a function of the CAB.
- Traction Control Indicator Lamp-On Message - Each time the cluster receives an electronic
traction control indicator lamp-ON message from the CAB indicating that the ESP/BAS/TCS has
been activated, the traction control indicator will be illuminated. The indicator can be flashed ON
and OFF, or illuminated solid, as dictated by the CAB message. The indicator remains illuminated
solid or continues to flash until the cluster receives a lamp-OFF message from the CAB, or until the
- Actuator Test - Each time the cluster is put through the actuator test, the traction control indicator
The CAB continually monitors the traction control switch to determine the proper outputs to the
components of the Antilock Brake System (ABS). The CAB then sends the proper lamp-ON or
lamp-OFF message to the ElectroMechanical Instrument Cluster (EMIC).
For proper diagnosis of the traction control switch, the ESP/BAS/TCS, the CAB, the EMIC, the
CAN data bus or the electronic communication related
to traction control indicator operation a diagnostic scan tool is required.
Relay > Component Information > Diagrams
Component ID: 186
Connector:
Color : # of pins :
C8 - -

Switch > Component Information > Description and Operation
DESCRIPTION
REMOVAL
separately.
INSTALLATION
options.


Jeep Workshop Manuals > Brakes and Traction Control > Antilock Brakes / Traction Control Systems > Wheel Speed
Sensor > Component Information > Locations > Sensor-Wheel Speed-ABS-Left Front
Component ID: 327
Connector:
Color : BLACK
# of pins : 2
Connector:
Color : # of pins :
Component ID: 328
Connector:
Color : BLACK
# of pins : 2
Connector:
Color : # of pins :
Component ID: 329
Connector:
Color : BLACK
# of pins : 2
Connector:
Color : # of pins :
Component ID: 330
Connector:
Color : BLACK
# of pins : 2
Connector:
Color : # of pins :
Sensor > Component Information > Diagrams > Sensor-Wheel Speed-ABS-Left Front
Component ID: 327
Connector:
Color : BLACK
# of pins : 2
Connector:
Color : # of pins :
Component ID: 328
Connector:
Color : BLACK
# of pins : 2
Connector:
Color : # of pins :
Component ID: 329
Connector:
Color : BLACK
# of pins : 2
Connector:
Color : # of pins :
Component ID: 330
Connector:
Color : BLACK
# of pins : 2
Connector:
Color : # of pins :
Sensor > Component Information > Description and Operation > Front Wheel Speed
Description
DESCRIPTION
encoder.
Operation
OPERATION
Description
DESCRIPTION
encoder.
Operation
OPERATION
Sensor > Component Information > Service and Repair > Front Wheel Speed
Removal
REMOVAL
tower.
hose bracket (5).
Installation
INSTALLATION


Removal
ALL-WHEEL-DRIVE
connector (3).
(4).
(4).
Installation
ALL-WHEEL-DRIVE
ft. lbs.).
trailing link (2).

(2) in the hole.
connector (3).

Jeep Workshop Manuals > Brakes and Traction Control > Antilock Brakes / Traction Control Systems > Yaw Rate Sensor >
Component ID: 297
Connector:
Color : BLACK
# of pins : 6
Qualifier : (ESP)
4--
6--
Component ID: 297
Connector:
Color : BLACK
# of pins : 6
Qualifier : (ESP)
4--
6--
DESCRIPTION
REMOVAL
INSTALLATION

Jeep Workshop Manuals > Brakes and Traction Control > Brake Bleeding > System Information > Service and Repair >
Master Cylinder Bleeding
to 17 Nm (150 in. lbs.).
Master Cylinder Bleeding > Page 5728
BASE BRAKE BLEEDING
PROCEDURE).
necessary.
- Left rear wheel
- Right front wheel
- Right rear wheel
- Left front wheel
MANUAL BLEEDING
the hose.
the
PRESSURE BLEEDING
equipment.
the hose.
BLEEDING
steering column.
does, clear them.
hydraulic system.
Jeep Workshop Manuals > Brakes and Traction Control > Brake Pedal Assy > Component Information > Service and Repair
> Removal
Brake Pedal Assy: Service and Repair Removal
BRAKE PEDAL
1. Disconnect and isolate the battery negative cable from its post on the battery. 2. If equipped,
remove the silencer pad below the steering column opening cover. 3. Remove the steering column
opening cover on the instrument panel. 4. Remove the reinforcement behind the steering column
opening cover.
5. Disconnect the wiring connector (4) at the stop lamp switch (3). 6. Remove the stop lamp switch
wiring routing clip (1) from the brake pedal bracket (2).
7. Remove the stop lamp switch (2) and discard it. Do not reuse the stop lamp switch.
> Removal > Page 5737
8. Remove the retaining clip (2) securing the power brake booster push rod (1) to the brake pedal.
To do so, position a small screwdriver under the
center tang of the retaining clip, then rotate the screwdriver enough to allow the retaining clip tang
to pass over the end of the brake pedal pin (3). Remove and discard the clip. Do not reuse the clip.
9. Slide the booster push rod (1) off the brake pedal pin (3).
10. Remove the four nuts (4) attaching the brake pedal (1) (and power brake booster) to the dash
panel. 11. Remove the remaining nut (5) attaching the brake pedal (1) to the dash panel. 12.
Remove the brake pedal (1).
Brake Pedal Assy: Service and Repair Installation
BRAKE PEDAL
1. Carefully install the brake pedal and bracket assembly (1) in the vehicle lining up the bracket
with the power brake booster mounting studs and the
stud (2) on the dash panel.
2. Install the four nuts (4) attaching the brake pedal (1) (and power brake booster) to the dash
panel. Do not tighten the nuts at this time. 3. Install the remaining nut (5) attaching the brake pedal
(1) to the dash panel. To tighten this nut (and the other four from the preceding step), refer
to the following step.
CAUTION: Because of power brake booster design, it is very important to tighten the mounting
nuts in the proper sequence.
4. Tighten the brake pedal/booster mounting nuts in the proper sequence to 23 Nm (17 ft. lbs.).
5. Using Mopar(R) Lubriplate, or an equivalent, coat the surface of the brake pedal pin (3) where it
contacts the brake booster push rod (1). 6. Install the power brake booster push rod (1) on the pin
(3) mounted on the side of the brake pedal. Install a NEW retaining clip (2) on the end of
the pin. Do not reuse the old clip.
CAUTION: Do not reuse the original stop lamp switch. The switch can only be adjusted once. That
is during initial installation of the switch. If the switch is not adjusted properly or has been removed
for some service, a new switch must be installed and adjusted.
7. Install and adjust a NEW stop lamp switch (2) in the brake pedal bracket (1).
8. If not already performed, connect the wiring connector (4) at the stop lamp switch (3). 9. Attach
the stop lamp switch wiring routing clip (1) at the brake pedal bracket (2).
10. Install the steering column opening cover reinforcement in the steering column opening. 11.
Install the steering column opening cover (and airbag if equipped) on the instrument panel. 12. If
equipped, install the silencer pad below the instrument panel. 13. Connect the battery negative
cable to its post on the battery. 14. Check the stop lamps to verify they are operating properly and
not staying on when the pedal is in the released position. 15. Road test the vehicle to ensure
proper operation of the brakes.
Jeep Workshop Manuals > Brakes and Traction Control > Brake Warning Indicator > Component Information > Description
Brake Warning Indicator: Description and Operation Description
DESCRIPTION
A brake indicator is standard equipment on all instrument clusters. This indicator is located above
the engine coolant temperature gauge on the cluster overlay, to the right of the tachometer.
The brake indicator consists of a stencil-like cutout in the opaque layer of the instrument cluster
overlay. The word BRAKE is cutout for vehicles manufactured for sale in the U.S. market, or the
International Control and Display Symbol icon for Brake Failure is cutout for vehicles manufactured
for all other markets. The dark outer layer of the overlay prevents the indicator from being clearly
visible when it is not illuminated. A red Light Emitting Diode (LED) behind the cutout in the opaque
layer of the overlay causes the indicator to appear in red through the translucent outer layer of the
overlay when it is illuminated from behind by the LED, which is soldered onto the instrument cluster
The brake indicator is serviced as a unit with the instrument cluster.

Brake Warning Indicator: Description and Operation Operation
OPERATION
The brake indicator gives an indication to the vehicle operator when the parking brake is applied,
when there are certain brake hydraulic system malfunctions as indicated by a low brake hydraulic
fluid level condition, or when the brake fluid level switch is disconnected. The brake indicator can
also give an indication when certain faults are detected in the Antilock Brake System (ABS). This
indicator is controlled by a transistor on the instrument cluster circuit board based upon cluster
programming, electronic messages received by the cluster from the Controller Antilock Brake
(CAB) over the Controller Area Network (CAN) data bus, and a hard wired input from the park
brake switch.
The brake indicator Light Emitting Diode (LED) is completely controlled by the instrument cluster
instrument cluster will turn ON the brake indicator for the following reasons:
- Bulb Test - Each time the ignition switch is turned to the ON position the brake indicator is
illuminated by the instrument cluster for about three seconds as a bulb test.
- Brake Indicator Lamp-On Message - Each time the cluster receives an electronic brake indicator
lamp-ON message from the CAB, the brake indicator will be illuminated. The CAB may also send
lamp-ON messages as feedback during ABS diagnostic procedures. The indicator remains
illuminated until the cluster receives a lamp-OFF message from the CAB, or until the ignition switch
is turned to the OFF position, whichever occurs first.
- Park Brake Switch Input - Each time the cluster detects ground on the park brake switch sense
circuit (park brake switch closed = park brake applied or not fully released) while the ignition switch
is in the ON position, the brake indicator flashes ON and OFF. The indicator continues to flash until
the park brake switch sense input to the cluster is an open circuit (park brake switch open = park
brake fully released), or until the ignition switch is turned to the OFF position, whichever occurs
first.
- Antilock Brake System (ABS) Indicator Backup - If the instrument cluster detects a fault in the
ABS indicator circuit it will send a message indicating the fault to the Controller Antilock Brake
(CAB), then flash the brake indicator ON and OFF. The cluster will continue to flash the brake
indicator until the ABS indicator circuit fault is resolved, or until the ignition switch is turned to the
- Actuator Test - Each time the instrument cluster is put through the actuator test, the brake
The park brake switch on the park brake lever mechanism provides a hard wired ground input to
the instrument cluster circuitry through the park brake switch sense circuit whenever the park brake
is applied or not fully released. The totally Integrated Power Module (TIPM) monitors the brake fluid
level switch on the brake master cylinder reservoir, then sends the appropriate electronic
messages to the CAB. The CAB continually monitors the ABS system circuits and sensors to
decide whether the system is in good operating condition. The CAB then sends the proper
lamp-ON or lamp-OFF message to the ElectroMechanical Instrument Cluster (EMIC). If the CAB
sends a lamp-ON message after the bulb test, it indicates that the CAB has detected a brake
hydraulic system malfunction or that the ABS system has become ineffective. The CAB will store a
Diagnostic Trouble Code (DTC) for any malfunction it detects.
The hard wired park brake switch input to the instrument cluster may be diagnosed using
conventional diagnostic tools and procedures. For proper diagnosis of the brake fluid level switch,
the ABS, the CAB, the EMIC, the TIPM, the CAN data bus or the electronic communication related
to brake indicator operation a diagnostic scan tool is required.
Brake Warning Indicator: Testing and Inspection
BRAKE INDICATOR
The hard wired park brake switch input to the ElectroMechanical Instrument Cluster (EMIC) may be
diagnosed using conventional diagnostic tools and procedures. The wiring information includes
wiring diagrams, proper wire and connector repair procedures, details of wire harness routing and
retention, connector pin-out information and location views for the various wire harness connectors,
splices and grounds.
However, conventional diagnostic methods may not prove conclusive in the diagnosis of the EMIC,
the Controller Antilock Brake (CAB), the Totally Integrated Power Module (TIPM), the Controller
Area Network (CAN) data bus, or the electronic message inputs also used by the EMIC to provide
brake indicator operation. The most reliable, efficient, and accurate means to diagnose the EMIC,
the CAB, the TIPM, the CAN data bus or the electronic communication related to brake indicator
operation requires the use of a diagnostic scan tool.
Jeep Workshop Manuals > Brakes and Traction Control > Disc Brake System > Brake Caliper > Component Information >
Brake Caliper: Procedures
Cleaning
CLEANING
WARNING: Dust and dirt accumulating on brake parts during normal use may contain asbestos
fibers from production or aftermarket brake linings. Breathing excessive concentrations of asbestos
fibers can cause serious bodily harm. Exercise care when servicing brake parts. Do not sand or
grind brake lining unless equipment used is designed to contain the dust residue. Do not clean
brake parts with compressed air or by dry brushing. Cleaning should be done by dampening the
brake components with a fine mist of water, then wiping the brake components clean with a
dampened cloth. Dispose of cloth and all residue containing asbestos fibers in an impermeable
container with the appropriate label. Follow practices prescribed by the Occupational Safety And
Health Administration (OSHA) and the Environmental Protection Agency (EPA) for the handling,
processing, and disposing of dust or debris that may contain asbestos fibers.
To clean or flush the internal passages of the brake caliper, use fresh brake fluid or Mopar(R)
Non-Chlorinated Brake Parts Cleaner. Never use gasoline, kerosene, alcohol, oil, transmission fluid
or any fluid containing mineral oil to clean the caliper. These fluids will damage rubber cups and
seals.
Inspection
INSPECTION
Inspect the disc brake caliper for the following:
- Brake fluid leaks in and around piston boot area
- Ruptures, brittleness or damage to the piston dust boot
If caliper fails inspection, disassemble and recondition caliper, replacing the seals and dust boots.
Cleaning
CLEANING
seals.
Inspection
INSPECTION

- Brake fluid leaks in and around boot area and inboard lining
- Damaged, dry or brittle guide pin dust boots
Brake Caliper: Removal and Replacement
Removal
REMOVAL
drain out of the master cylinder reservoir when the lines are opened.
4. Remove the banjo bolt (4) connecting the brake flex hose (2) to the brake caliper (5). There are
two washers (3) that will come off with the banjo
bolt. Discard the washers.
NOTE: When removing the caliper guide pin bolts (2, 3) note that one (upper) has a special sleeve
on the end. It important that his bolt be installed in the upper mounting hole when the caliper is
installed.
5. Remove the two brake caliper guide pin bolts (2, 3). 6. Slide the disc brake caliper (4) from the
disc brake adapter bracket (1) and brake pads and remove.
Installation
INSTALLATION
1. Completely retract the caliper piston back into the bore of the caliper. Use a C-clamp to retract
the piston. Place a wood block over the piston
before installing the C-clamp to avoid damaging the piston.

CAUTION: Use care when installing the caliper (4) onto the adapter bracket (1) to avoid damaging
the guide pin boots.
2. Install the disc brake caliper over the brake pads on the brake caliper adapter bracket.
NOTE: When installing the caliper guide pin bolts (2, 3) make sure that the one that has a special
sleeve on the end is installed in the upper mounting hole.
3. Align the caliper guide pin bolt holes with the adapter bracket. Install the upper (with special
sleeve) (2) and lower (3) caliper guide pin bolts.
Tighten the guide pin bolts to 43 Nm (32 ft. lbs.).
4. Install the banjo bolt (4) connecting the brake flex hose (2) to the brake caliper (5). Install NEW
washers (3) on each side of the hose fitting as the
banjo bolt is guided through the fitting. Thread the banjo bolt into the caliper and tighten it to 24 Nm
(18 ft. lbs.).
5. Install the tire and wheel assembly. Install and tighten the wheel mounting nuts (3) to 135 Nm

8. Bleed the caliper as necessary. 9. Road test the vehicle and make several stops to wear off any
foreign material on the brakes and to seat the brake shoes.
Removal
REMOVAL
1. Using a brake pedal holding tool as shown, depress the brake pedal past its first one inch of
travel and hold it in this position. This will isolate the
master cylinder from the brake hydraulic system and will not allow the brake fluid to drain out of the
master cylinder reservoir while the lines are disconnected.
3. Remove the wheel mounting nuts (3), then the rear tire and wheel assembly.
4. Unthread the brake tube nut (2) at the rear flex hose. 5. Remove the clip (3) securing the rear
flex hose to the trailing link mounted bracket. Remove the flex hose from the bracket. 6. Unthread
and remove the brake flex hose (4) from the brake caliper (1).
NOTE: When removing the caliper guide pin bolts (2, 3), note that one bolt has a special sleeve on
the tip and the other does not. Depending on the build date, this special sleeve bolt (3) can be
located in either the top or bottom location. When installing, make sure the bolts are put back in the
same locations as when removed to avoid NVH issues.
7. Remove the two brake caliper guide pin bolts (2, 3). 8. Slide and remove the disc brake caliper
(1) with outboard brake pad attached from the disc brake adapter bracket, inboard brake pad and
rotor. 9. Remove the outboard brake pad from the caliper by prying the brake pad retaining clip
over the raised area on the caliper. Slide the brake pad off
of the brake caliper.
Installation
INSTALLATION
1. If not already performed, completely retract the caliper piston back into the piston bore of the
caliper. Use a C-clamp to retract the piston. Place a
wood block over the piston before installing the C-clamp to avoid damaging the piston.
2. Slide the outboard brake pad onto the caliper. Be sure the retaining clip is squarely seated in the
depressed areas on the caliper beyond the raised
retaining bead.
CAUTION: Use care when installing the caliper onto the disc brake adapter to avoid damaging the
guide pin boots.
3. Install the disc brake caliper with outboard brake pad attached over the inboard brake pad and
rotor, onto the brake caliper adapter bracket.
NOTE: When installing the caliper guide pin bolts (2, 3), make sure the bolts are put back in the
same locations as when removed to avoid NVH issues. Depending on the build date and services
performed, the location of the bolt with the special sleeve on the tip (3) can vary.
4. Align the caliper guide pin bolt holes with the adapter bracket. Install the lower (with special
sleeve) (2) and upper (3) caliper guide pin bolts.
NOTE: Once the caliper is installed, inspect the outboard brake pad to make sure it is correctly
positioned. The retaining clip (2) must be squarely seated in the depressed areas (1) on the caliper
fingers. Also, the nubs on the pad's steel backing plate must be fully seated in the depressions
formed into the inside of the caliper fingers. There should be no gap between the pad backing plate
and the caliper fingers.
5. Thread the rear brake flex hose (4) into the brake caliper (1). Tighten the flex hose fitting at the
caliper to 15 Nm (133 in. lbs.). 6. Route and install the brake flex hose into the trailing link mounted
bracket. Install the clip (3) securing the flex hose to the bracket. 7. Thread the brake tube nut (2)
into brake flex hose. Tighten the brake tube nut to 17 Nm (150 in. lbs.).
11. Bleed the caliper as necessary. 12. Road test the vehicle and make several stops to wear off
any foreign material on the brakes and to seat the brake shoes.
Brake Caliper: Overhaul
Disassembly
DISASSEMBLY
NOTE: Before disassembling the brake caliper, remove it from the vehicle.
NOTE: Before disassembling the brake caliper, clean and inspect it.
WARNING: Under no condition should high pressure air ever be used to remove a piston from a
caliper bore. Personal injury could result from such a practice.
CAUTION: Do not use excessive force when clamping caliper in vise. Excessive vise pressure will
cause bore distortion.
1. Mount the caliper in a vise equipped with protective jaws.
WARNING: Do not place face or hands near caliper and piston if using compressed air pressure to
remove piston. Do not use high pressure.
2. Place a wooden block (1) in the caliper as shown. 3. If necessary, apply low pressure
compressed air to the caliper fluid inlet in short spurts to force the piston out. 4. Remove the piston
from the caliper. 5. Remove the dust boot from the piston and discard it.
CAUTION: Do not use a screw driver or other metal tool for seal removal. Using such tools can
scratch the bore or leave burrs on the seal groove edges.
6. Using a soft tool such as a plastic trim stick (1), work the piston seal (2) out of its groove in
caliper piston bore. Discard the used seal. 7. Clean the piston bore and drilled passage ways with
alcohol or a suitable solvent. Wipe it dry using only a lint-free cloth. 8. Inspect both the piston and
bore for scoring or pitting. Bores that show light scratches or corrosion can usually be cleared of
the light scratches or
corrosion using crocus cloth.
Assembly
ASSEMBLY
NOTE: Always have clean hands when assembling a brake caliper.
NOTE: Always use fresh, clean brake fluid when assembling a brake caliper.
NOTE: Never use an old piston seal.
1. Dip the NEW piston seal in clean brake fluid and install it in the groove (2) of the caliper bore.
The seal (1) should be started at one area of the
groove and gently worked around into the groove using only your clean fingers to seat it.
2. Coat the NEW piston with clean brake fluid. 3. Coat the NEW piston boot with clean brake fluid
leaving a generous amount inside the boot. 4. Position the dust boot over the lower section of the
piston. 5. Extend the dust boot below the bottom of the piston and guide the lip seal into the groove
in the caliper piston bore.
CAUTION: Force applied to the piston (1) to seat it in the bore must be applied uniformly to avoid
cocking and binding of the piston.
6. Install the piston (1) into the bore, carefully pushing it past the piston seal using hand pressure.
Push the piston in until it bottoms in the caliper
bore and the dust boot lip seal falls into the groove near the top of the piston.
7. Install the caliper on the vehicle and bleed the brakes as necessary.
Disassembly
DISASSEMBLY
1. With finger tip, trace around the outside perimeter of the piston dust boot to find the ends of the
boot snap-ring. 2. Using a small screwdriver (2) or like tool, carefully remove the boot snap-ring (1)
making sure not to damage the dust boot, piston or piston bore. 3. Carefully pull the piston dust
boot away from the caliper boot groove.
5. Place a wooden block (2) in the caliper as shown. 6. As necessary, apply low pressure
compressed air to the caliper fluid inlet in short spurts to force the piston (1) out. 7. Remove the
piston (with dust boot) from the caliper. 8. Remove the dust boot from the piston and discard it.
9. Using a soft tool such as a plastic trim stick (2), work the piston seal (1) out of its groove (3) in
the caliper piston bore. Discard the used seal.
10. Clean the piston bore and drilled passage ways with alcohol or a suitable solvent. Wipe it dry
using only a lint-free cloth. 11. Inspect both the piston and bore for scoring or pitting. Bores that
show light scratches or corrosion can usually be cleared of the light scratches or
Assembly
ASSEMBLY

1. Dip the NEW piston seal in clean brake fluid and install it in the groove (2) of the caliper piston
bore. The seal (1) should be started at one area of
the groove and gently worked around into the groove using only clean finger tips to seat it.
2. Coat the NEW piston dust boot (1) with clean brake fluid leaving a generous amount inside the
boot. 3. Position the dust boot over the top of the piston (2) and into the piston groove. Make sure
the side of the dust boot with the outer lip (3) for the
boot snap-ring is positioned upward as shown.
4. Coat the piston with clean brake fluid.
CAUTION: Force applied to the piston to seat it in the bore must be applied uniformly to avoid
5. Insert the piston into the caliper bore, carefully pushing it past the piston seal using hand
pressure. Push the piston in until it bottoms in the
caliper bore.
6. With finger tips, seat the dust boot lip (1) into the boot groove in the caliper bore. Trace around
the outside perimeter of the dust boot with a finger
tip making sure the lip is properly seated in the groove and not much air is trapped behind the boot.
7. Position one end of the boot snap-ring (1) inside the boot outer lip (2), then making a circular
motion, walk the snap-ring around the boot lip,
completely installing and seating it.
8. Inspect whether the two ends of the boot snap-ring are not overlapping one another. If they are,
push the snap ring and dust boot further into
groove removing any overlap of the snap-ring.
Jeep Workshop Manuals > Brakes and Traction Control > Disc Brake System > Brake Pad > Component Information >
Specifications
Brake Pad: Specifications
Measure brake pad minimum thickness. Brake pads must be replaced when usable material on a
brake pad lining measured at its thinnest point measures one millimeter (0.04 inches) or less.
Brake Pad: Procedures
Cleaning
CLEANING
Inspection
INSPECTION
Visually inspect brake pads for uneven lining wear. Also inspect for excessive lining deterioration.
Check the clearance between the tips of the wear indicators (if equipped) on the pads and the
brake rotors.
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, remove the disc brake pads from the vehicle.
NOTE: It is important to inspect both front and rear brake pads during the same inspection.
Typically, front and rear brake pads wear out at the same time.
Replace both disc brake pads (inboard and outboard) at each caliper. It is also necessary to
replace the pads on the opposite side of the vehicle as well as the pads failing inspection to
maintain proper braking characteristics.
If the brake pad assemblies do not require replacement, be sure to reinstall the brake pads in the
original position they were removed from.
Cleaning
CLEANING
Inspection
INSPECTION
Visually inspect brake pads for uneven lining wear. Also inspect for excessive lining deterioration.
Check the clearance between the tips of the wear indicators (if equipped) on the pads and the
brake rotors.
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, remove the disc brake pads from the vehicle.
NOTE: It is important to inspect both front and rear brake pads during the same inspection.
Typically, front and rear brake pads wear out at the same time.
Replace both disc brake pads (inboard and outboard) at each caliper. It is also necessary to
replace the pads on the opposite side of the vehicle as well as the pads failing inspection to
maintain proper braking characteristics.
If the brake pad assemblies do not require replacement, be sure to reinstall the brake pads in the
original position they were removed from.
Brake Pad: Removal and Replacement
Removal
REMOVAL
NOTE: Perform STEP 2 through STEP 5 on each side of the vehicle to complete pad set removal.
installed.
3. Remove the two brake caliper guide pin bolts (2, 3). 4. Remove the disc brake caliper (4) from
the disc brake adapter bracket (1) and hang it out of the way using wire or a bungee cord. Use care
not to
overextend the brake hose when doing this.

5. Remove the brake pads (4, 5) from the caliper adapter bracket (2).
Installation
INSTALLATION
NOTE: Perform STEP 1 through STEP 5 on each side of the vehicle to complete pad set
installation, then proceed to STEP 6.
NOTE: Make sure that the audible wear indicators (if equipped) are placed toward the top when the
inboard brake pads are installed on each side of the vehicle.
1. Place the brake pads (4, 5) in the abutment shims (3) clipped into the disc brake caliper adapter
bracket (2) as shown. Place the pad with the wear
indicator attached on the inboard side (2).
2. Completely retract the caliper piston back into the bore of the caliper.
the boots.
7. Pump the brake pedal several times before moving the vehicle to set the pads to the brake rotor.
8. Check and adjust the brake fluid level in the reservoir (2) as necessary. 9. Road test the vehicle
and make several stops to wear off any foreign material on the brakes and to seat the brake pads.
Removal
REMOVAL
NOTE: If the rear brake pads are being replaced due to a howl or moan while driving in reverse,
proper diagnosis and correction is essential.
NOTE: Perform STEP 2 through STEP 6 on each side of the vehicle to complete pad set removal.
NOTE: In some cases, it may be necessary to retract the caliper piston in its bore a small amount
in order to provide sufficient clearance between the pads and the rotor to easily remove the caliper
from the knuckle. This can usually be accomplished before the guide pin bolts are removed, by
grasping the rear of the caliper and pulling outward working with the guide pins, thus retracting the
piston. Never push on the piston directly as it may get damaged.
4. Rotate the caliper (1) upward hinging off the upper guide pin bolt. Rotate the caliper upward just
enough to allow brake pad removal. Hang the

5. Remove the inboard brake pad (5) from the caliper adapter bracket (3). 6. Remove the outboard
brake pad (2) from the caliper (1) by prying the brake pad retaining clip over the raised area on the
caliper. Slide the brake
pad off of the brake caliper.
Installation
INSTALLATION
NOTE: If the rear brake pads are being replaced due to a howl or moan while driving in reverse,
proper diagnosis and correction is essential.
NOTE: Perform STEP 1 through STEP 6 on each side of the vehicle to complete pad set
installation, then proceed to STEP 7.
1. Completely retract the caliper piston back into the piston bore of the caliper. This is required to
gain the necessary pad-to-rotor clearance for the
caliper installation onto the steering knuckle.
NOTE: Place the brake pad with the audible wear indicator attached on the inboard side. The
audible wear indicator should be positioned at the bottom when installed.
2. Slide the outboard brake pad (2) onto the caliper (1). Be sure the retaining clip is squarely
seated in the depressed areas on the caliper beyond the
raised retaining bead.
3. Place the inboard brake pad (5) in the abutment shims (4) clipped into the disc brake caliper
adapter bracket (3) as shown (see preceding note).
CAUTION: Use care when installing the caliper onto the adapter bracket to avoid damaging the
guide pin boot.
lbs.).
(100 ft. lbs.). 7. Lower the vehicle. 8. Pump the brake pedal several times to ensure the vehicle has
a firm brake pedal before moving the vehicle. 9. Road test the vehicle and make several stops to
wear off any foreign material on the brakes and to seat the brake pads.
Jeep Workshop Manuals > Brakes and Traction Control > Disc Brake System > Brake Rotor/Disc > Component Information
> Specifications
Brake Rotor/Disc: Specifications
BRAKE ROTOR LIMITS/SPECIFICATIONS
NOTE: When refacing a rotor, the required TIR (Total Indicator Reading) and thickness variation
limits MUST BE MAINTAINED.
Brake Rotor/Disc: Testing and Inspection
BRAKE ROTOR
Any servicing of the rotor requires extreme care to maintain the rotor within service tolerances to
ensure proper brake action.
Excessive runout or wobble in a rotor can increase pedal travel due to piston knock-back. This
increases guide pin sleeve wear due to the tendency of the caliper to follow the rotor wobble.
When diagnosing a brake noise or pulsation, the machined disc braking surface should be
inspected.
BRAKING SURFACE INSPECTION
Light braking surface scoring and wear is acceptable. If heavy scoring or warping is evident, the
rotor must be refaced or replaced..
Excessive wear and scoring of the rotor can cause improper lining contact on the rotor's braking
surface. If the ridges on the rotor are not removed before new brake shoes are installed, improper
wear of the shoes will result.
If a vehicle has not been driven for a period of time, the rotor's braking surface will rust in the areas
not covered by the brake shoes at that time. Once the vehicle is driven, noise and chatter from the
disc brakes can result when the brakes are applied.
Some discoloration or wear of the rotor surface is normal and does not require resurfacing when
linings are replaced. If cracks or burned spots are evident, the rotor must be replaced.
ROTOR MINIMUM THICKNESS
Measure rotor thickness (1) at the center of the brake pad contact surface. Replace the rotor if it is
worn below minimum thickness or if machining the rotor will cause its thickness to fall below
specifications.
CAUTION: Do not machine the rotor if it will cause the rotor to fall below minimum thickness.
On front rotors, Minimum thickness specifications (2) are cast on the rotor's unmachined surface on
the inside of the rotor (1). Limits can also be found in this component's specification table.
On rear rotors, Minimum thickness specifications (3) are cast into the rotor's unmachined surface
on the outside of the rotor (1). This area also shows the maximum thickness specifications (2) for
the hat section of the rotor. Limits can also be found in this component's specification table.
ROTOR THICKNESS VARIATION

Thickness variation in a rotor's braking surface can result in pedal pulsation, chatter and surge.
This can also be caused by excessive runout in the rotor or the hub.
Rotor thickness variation measurements should be made in conjunction with measuring runout.
Measure thickness of the brake rotor (2) at 12 equal points around the rotor braking surface with a
micrometer (1) at a radius approximately 25 mm (1 inch) from edge of rotor. If thickness
measurements vary beyond the specification listed in the specification table, the rotor should be
refaced or replaced.
ROTOR RUNOUT
On-vehicle rotor runout is the combination of the individual runout of the hub face and the runout of
the brake rotor (hub runout can be measured separately). To measure rotor runout on the vehicle:
1. Raise and support the vehicle. 2. Remove the tire and wheel assembly. 3. Install standard wheel
mounting nuts, flat side to rotor, on all the wheel studs (2). Progressively tighten the nuts in a
crisscross pattern to 135 Nm
(100 ft. lbs.).
4. Mount Dial Indicator (1), Special Tool C-3339A, with Wheel, Special Tool 25w, or equivalent, to
the knuckle. Position the dial indicator wheel to
contact the rotor braking surface approximately 10 mm (0.39 in.) from the outer edge of the rotor
(3).
5. Slowly rotate the brake rotor checking lateral runout, marking the low and high spots. Record
these measurements. 6. Check and record the runout on the opposite side of the rotor in the same
fashion, marking the low and high spots. 7. Compare runout measurement to specifications.
8. If runout is in excess of specifications, check the lateral runout of the hub face. Before removing
the rotor from the hub, place a chalk mark across
both the rotor (1) and the one wheel stud (2) closest to where the high runout measurement was
taken. This way, the original mounting spot of the rotor on the hub is indexed.
9. Remove the rotor from the hub.
NOTE: Before measuring hub runout, clean the hub face surface with an appropriate cleaner. This
provides a clean surface to get an accurate indicator reading.
10. Mount Dial Indicator (2), Special Tool C-3339A, to the knuckle. Position the dial indicator stem
so it contacts the hub face (1) near the outer
diameter. Care must be taken to position the stem outside of the stud circle, but inside of the
chamfer on the hub rim.
11. Slowly rotate the hub measuring runout. Hub runout should not exceed 0.08 mm (0.003 inch). If
runout exceeds this specification, the hub must be
replaced.
12. If hub runout does not exceed this specification, install the original rotor back on the hub,
aligning the chalk mark on the rotor (2) with a wheel
mounting stud, two studs apart from the original stud (1).
13. Install standard wheel mounting nuts, flat side to rotor, on all the wheel studs (2). Progressively
tighten the nuts in a crisscross pattern to 135 Nm
(100 ft. lbs.).
14. Mount the Dial Indicator (1), Special Tool C-3339A, and remeasure runout on both sides of the
brake rotor as explained in earlier steps to see if
runout is now within specifications. (Refer to 5 - BRAKES/HYDRAULIC/MECHANICAL/ROTOR -

SPECIFICATIONS)
15. If runout is still not within specifications, reface or replace brake rotor.
> Service and Repair > Procedures
Brake Rotor/Disc: Procedures
BRAKE ROTOR MACHINING
NOTE: Refacing the rotor is not required each time the brake pads are replaced, only when the
need is foreseen.
Any servicing of the rotor requires extreme care to maintain the rotor within service tolerances to
ensure proper brake action.
If the rotor surface is deeply scored or warped, or there is a complaint of brake roughness or brake
pedal pulsation, the rotor should be refaced using a hub-mounted on-car brake lathe (1), or
replaced.
The use of a hub-mounted on-car brake lathe (1) is highly recommended to eliminate the possibility
of excessive runout. It trues the brake rotor to the vehicle's hub and bearing.
NOTE: All brake rotors (1) have markings for minimum allowable thickness cast on an unmachined
surface of the rotor (2) or stamped into the hat section. On this vehicle, the minimum thickness
specification for the front brake rotor is located on the inside of the rotor. The minimum thickness
specification for the rear brake rotor is located on the outside of the rotor. Minimum thickness
specifications can also be found in this component's specification table.
Minimum allowable thickness is the minimum thickness which the brake rotor machined surface
may be cut to.
CAUTION: Do not machine the rotor if it will cause the rotor to fall below minimum thickness.
> Service and Repair > Procedures > Page 5792
Before lathe installation, verify the brake rotor face and the hub adapters are free of any chips, rust,
or contamination.
When mounting and using the brake lathe, strict attention to the brake lathe manufacturer's
operating instructions is required.
Machine both sides of the brake rotor at the same time. Cutting both sides at the same time
minimizes the possibility of a tapered or uneven cut.
When refacing a rotor, the required TIR (Total Indicator Reading) and thickness variation limits
MUST BE MAINTAINED. Extreme care in the operation of rotor turning equipment is required.
Specifications for brake rotor machining can be found in this sections specification table.
Brake Rotor/Disc: Removal and Replacement
Front Brake Rotor
FRONT BRAKE ROTOR
grasping the inboard side of the caliper and pulling outward working with the guide pins, thus
retracting the piston. Never push on the piston directly as it may get damaged.
3. Remove the two bolts (3) securing disc brake caliper and adapter bracket (1) to the steering
knuckle (2). 4. Remove the disc brake caliper and adapter bracket (1) from the knuckle (2) and
rotor (4) as an assembly. Hang the assembly out of the way using
wire or a bungee cord. Use care not to overextend the brake hose when doing this.
5. Remove any clips (3) retaining the brake rotor (2) to the wheel studs. 6. Slide the brake rotor (2)
off the hub and bearing (1).
Rear Brake Rotor
REAR BRAKE ROTOR
NOTE: Refer to Warnings and Cautions..
grasping the inboard side of the caliper and pulling outward working with the guide pins, thus
retracting the piston. Never push on the piston directly as it may get damaged.

5. Remove any clips (2) retaining the brake rotor (3) to the wheel studs. 6. Slide the brake rotor (3)
off the hub and bearing (1) and remove.
Front Brake Rotor
FRONT BRAKE ROTOR
NOTE: Inspect disc brake pads before installation.
1. Clean the hub face (1) to remove any dirt or corrosion where the rotor mounts. 2. Install the
brake rotor (2) over the studs on the hub and bearing.
3. Install the disc brake caliper and adapter bracket assembly (1) over the brake rotor (4) and
knuckle (2). 4. Install the mounting bolts (3) securing the caliper adapter bracket to the knuckle (2).
Tighten the bolts to 108 Nm (80 ft. lbs.).
5. Install the tire and wheel assembly (1). Tighten the wheel mounting nuts (3) to 135 Nm (100 ft.
lbs.). 6. Lower the vehicle. 7. Pump the brake pedal several times before moving the vehicle to set
the pads to the brake rotor. 8. Check and adjust the brake fluid level in the reservoir as necessary.
9. Road test the vehicle and make several stops to seat the brake pads to the rotor.
Rear Brake Rotor
REAR BRAKE ROTOR
NOTE: Inspect disc brake pads and parking brake shoes before installation.
1. Clean the hub face (1) to remove any dirt or corrosion where the rotor mounts. 2. Install the
brake rotor (3) over the studs on the hub and bearing (1).
CAUTION: Use care when installing the caliper onto the adapter bracket to avoid damaging the
guide pin boot.
lbs.).
5. Install tire and wheel assembly (1). Install and tighten the wheel mounting nuts (3) to 135 Nm
(100 ft. lbs.). 6. Lower the vehicle. 7. Pump the brake pedal several times before moving the
vehicle to set the pads to the brake rotor. 8. Check and adjust the brake fluid level in the reservoir
as necessary. 9. Road test the vehicle and make several stops to seat the brake pads to the rotor.
Jeep Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Brake Bleeding > System Information
> Service and Repair > Master Cylinder Bleeding
to 17 Nm (150 in. lbs.).
> Service and Repair > Master Cylinder Bleeding > Page 5805
BASE BRAKE BLEEDING
PROCEDURE).
necessary.
- Left rear wheel
- Right front wheel
- Right rear wheel
- Left front wheel
MANUAL BLEEDING
the hose.
the
PRESSURE BLEEDING
equipment.
the hose.
BLEEDING
steering column.
does, clear them.
hydraulic system.
Jeep Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Brake Caliper > Component
Brake Caliper: Procedures
Cleaning
CLEANING
seals.
Inspection
INSPECTION
- Brake fluid leaks in and around piston boot area
Cleaning
CLEANING
seals.
Inspection
INSPECTION

- Brake fluid leaks in and around boot area and inboard lining
- Damaged, dry or brittle guide pin dust boots
Brake Caliper: Removal and Replacement
Removal
REMOVAL
drain out of the master cylinder reservoir when the lines are opened.
4. Remove the banjo bolt (4) connecting the brake flex hose (2) to the brake caliper (5). There are
two washers (3) that will come off with the banjo
bolt. Discard the washers.
installed.
5. Remove the two brake caliper guide pin bolts (2, 3). 6. Slide the disc brake caliper (4) from the
disc brake adapter bracket (1) and brake pads and remove.
Installation
INSTALLATION
1. Completely retract the caliper piston back into the bore of the caliper. Use a C-clamp to retract
the piston. Place a wood block over the piston
before installing the C-clamp to avoid damaging the piston.

the guide pin boots.
4. Install the banjo bolt (4) connecting the brake flex hose (2) to the brake caliper (5). Install NEW
washers (3) on each side of the hose fitting as the
banjo bolt is guided through the fitting. Thread the banjo bolt into the caliper and tighten it to 24 Nm
(18 ft. lbs.).
5. Install the tire and wheel assembly. Install and tighten the wheel mounting nuts (3) to 135 Nm

8. Bleed the caliper as necessary. 9. Road test the vehicle and make several stops to wear off any
foreign material on the brakes and to seat the brake shoes.
Removal
REMOVAL
1. Using a brake pedal holding tool as shown, depress the brake pedal past its first one inch of
travel and hold it in this position. This will isolate the
master cylinder from the brake hydraulic system and will not allow the brake fluid to drain out of the
master cylinder reservoir while the lines are disconnected.
3. Remove the wheel mounting nuts (3), then the rear tire and wheel assembly.
4. Unthread the brake tube nut (2) at the rear flex hose. 5. Remove the clip (3) securing the rear
flex hose to the trailing link mounted bracket. Remove the flex hose from the bracket. 6. Unthread
and remove the brake flex hose (4) from the brake caliper (1).
NOTE: When removing the caliper guide pin bolts (2, 3), note that one bolt has a special sleeve on
the tip and the other does not. Depending on the build date, this special sleeve bolt (3) can be
located in either the top or bottom location. When installing, make sure the bolts are put back in the
same locations as when removed to avoid NVH issues.
7. Remove the two brake caliper guide pin bolts (2, 3). 8. Slide and remove the disc brake caliper
(1) with outboard brake pad attached from the disc brake adapter bracket, inboard brake pad and
rotor. 9. Remove the outboard brake pad from the caliper by prying the brake pad retaining clip
over the raised area on the caliper. Slide the brake pad off
of the brake caliper.
Installation
INSTALLATION
1. If not already performed, completely retract the caliper piston back into the piston bore of the
caliper. Use a C-clamp to retract the piston. Place a
wood block over the piston before installing the C-clamp to avoid damaging the piston.
2. Slide the outboard brake pad onto the caliper. Be sure the retaining clip is squarely seated in the
depressed areas on the caliper beyond the raised
retaining bead.
CAUTION: Use care when installing the caliper onto the disc brake adapter to avoid damaging the
guide pin boots.
3. Install the disc brake caliper with outboard brake pad attached over the inboard brake pad and
rotor, onto the brake caliper adapter bracket.
NOTE: When installing the caliper guide pin bolts (2, 3), make sure the bolts are put back in the
same locations as when removed to avoid NVH issues. Depending on the build date and services
performed, the location of the bolt with the special sleeve on the tip (3) can vary.
4. Align the caliper guide pin bolt holes with the adapter bracket. Install the lower (with special
sleeve) (2) and upper (3) caliper guide pin bolts.
5. Thread the rear brake flex hose (4) into the brake caliper (1). Tighten the flex hose fitting at the
caliper to 15 Nm (133 in. lbs.). 6. Route and install the brake flex hose into the trailing link mounted
bracket. Install the clip (3) securing the flex hose to the bracket. 7. Thread the brake tube nut (2)
into brake flex hose. Tighten the brake tube nut to 17 Nm (150 in. lbs.).
11. Bleed the caliper as necessary. 12. Road test the vehicle and make several stops to wear off
any foreign material on the brakes and to seat the brake shoes.
Brake Caliper: Overhaul
Disassembly
DISASSEMBLY
2. Place a wooden block (1) in the caliper as shown. 3. If necessary, apply low pressure
compressed air to the caliper fluid inlet in short spurts to force the piston out. 4. Remove the piston
from the caliper. 5. Remove the dust boot from the piston and discard it.
6. Using a soft tool such as a plastic trim stick (1), work the piston seal (2) out of its groove in
caliper piston bore. Discard the used seal. 7. Clean the piston bore and drilled passage ways with
alcohol or a suitable solvent. Wipe it dry using only a lint-free cloth. 8. Inspect both the piston and
bore for scoring or pitting. Bores that show light scratches or corrosion can usually be cleared of
the light scratches or
Assembly
ASSEMBLY
1. Dip the NEW piston seal in clean brake fluid and install it in the groove (2) of the caliper bore.
The seal (1) should be started at one area of the
groove and gently worked around into the groove using only your clean fingers to seat it.
2. Coat the NEW piston with clean brake fluid. 3. Coat the NEW piston boot with clean brake fluid
leaving a generous amount inside the boot. 4. Position the dust boot over the lower section of the
piston. 5. Extend the dust boot below the bottom of the piston and guide the lip seal into the groove
in the caliper piston bore.
CAUTION: Force applied to the piston (1) to seat it in the bore must be applied uniformly to avoid
6. Install the piston (1) into the bore, carefully pushing it past the piston seal using hand pressure.
Push the piston in until it bottoms in the caliper
bore and the dust boot lip seal falls into the groove near the top of the piston.
Disassembly
DISASSEMBLY
1. With finger tip, trace around the outside perimeter of the piston dust boot to find the ends of the
boot snap-ring. 2. Using a small screwdriver (2) or like tool, carefully remove the boot snap-ring (1)
making sure not to damage the dust boot, piston or piston bore. 3. Carefully pull the piston dust
boot away from the caliper boot groove.
5. Place a wooden block (2) in the caliper as shown. 6. As necessary, apply low pressure
compressed air to the caliper fluid inlet in short spurts to force the piston (1) out. 7. Remove the
piston (with dust boot) from the caliper. 8. Remove the dust boot from the piston and discard it.
9. Using a soft tool such as a plastic trim stick (2), work the piston seal (1) out of its groove (3) in
the caliper piston bore. Discard the used seal.
10. Clean the piston bore and drilled passage ways with alcohol or a suitable solvent. Wipe it dry
using only a lint-free cloth. 11. Inspect both the piston and bore for scoring or pitting. Bores that
show light scratches or corrosion can usually be cleared of the light scratches or
Assembly
ASSEMBLY

1. Dip the NEW piston seal in clean brake fluid and install it in the groove (2) of the caliper piston
bore. The seal (1) should be started at one area of
the groove and gently worked around into the groove using only clean finger tips to seat it.
2. Coat the NEW piston dust boot (1) with clean brake fluid leaving a generous amount inside the
boot. 3. Position the dust boot over the top of the piston (2) and into the piston groove. Make sure
the side of the dust boot with the outer lip (3) for the
boot snap-ring is positioned upward as shown.
4. Coat the piston with clean brake fluid.
CAUTION: Force applied to the piston to seat it in the bore must be applied uniformly to avoid
5. Insert the piston into the caliper bore, carefully pushing it past the piston seal using hand
pressure. Push the piston in until it bottoms in the
caliper bore.
6. With finger tips, seat the dust boot lip (1) into the boot groove in the caliper bore. Trace around
the outside perimeter of the dust boot with a finger
tip making sure the lip is properly seated in the groove and not much air is trapped behind the boot.
7. Position one end of the boot snap-ring (1) inside the boot outer lip (2), then making a circular
motion, walk the snap-ring around the boot lip,
completely installing and seating it.
8. Inspect whether the two ends of the boot snap-ring are not overlapping one another. If they are,
push the snap ring and dust boot further into
groove removing any overlap of the snap-ring.
Jeep Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Brake Fluid > Component
Brake Fluid: Technical Service Bulletins Maintenance - Fluid Flushing Information
NUMBER: 26-001-09

MODELS:
2009 - 2010 (DS) Ram Truck (1500)
2005 - 2009 (HB) Durango
2007 - 2009 (HG) Aspen
2009 - 2010 (JC) Journey
2008 - 2010 (KK) Liberty
2007 - 2010 (KA) Nitro
2005 - 2007 (KJ) Liberty
2005 - 2010 (ND) Dakota
2005 - 2006 (PL) Neon

2007 - 2010 (PM) Caliber

2005 - 2010 (ZB) Viper
DISCUSSION:
coolant.
operating range.
distilled water.
Disclaimer:
Information > Technical Service Bulletins > Page 5835
Brake Fluid: Specifications
Brake Fluid Type
Brake Fluid: Testing and Inspection
BRAKE FLUID CONTAMINATION
Indications of fluid contamination are swollen or deteriorated rubber parts. Swelling indicates the
presence of petroleum in the brake fluid.
To test for contamination, put a small amount of drained brake fluid in clear glass jar. If the fluid
separates into layers, there is mineral oil or other fluid contamination of the brake fluid.
If the brake fluid is contaminated, drain and thoroughly flush the brake system. Replace all the
rubber parts or components containing rubber coming into contact with the brake fluid including:
the master cylinder and reservoir; proportioning valves (non-ABS); caliper seals; wheel cylinder
seals; ABS hydraulic control unit; and all hydraulic fluid hoses.
Brake Fluid: Service and Repair
BRAKE FLUID LEVEL CHECKING
NOTE: Brake fluid level should be checked a minimum of twice a year.
Master cylinder reservoirs (2) are marked, FULL and ADD, indicating the allowable brake fluid level
range in the master cylinder fluid reservoir.
CAUTION: Use only Mopar(R) Brake Fluid DOT 3 Motor Vehicle or equivalent from a tightly sealed
container. Do not use petroleum-based fluid because seal damage in the brake system will result.
NOTE: Although there is a range, the preferred level is FULL.
1. Remove the cap (1). 2. Adjust the brake fluid level to the FULL mark listed on the side of the
master cylinder fluid reservoir (2) as necessary. Do not overfill the system. 3. Install the cap (1).
Jeep Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Brake Fluid Level Sensor/Switch >
Component ID: 292
Connector:
Color : BLACK
# of pins : 2
Component ID: 292
Connector:
Color : BLACK
# of pins : 2
DESCRIPTION
REMOVAL
INSTALLATION

Jeep Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Brake Hose/Line > Component
Brake Hose/Line: Description and Operation
DESCRIPTION
The brake tubes are steel with a corrosion-resistant nylon coating applied to the external surfaces.
The flex hoses used at each wheel brake are made of reinforced rubber with fittings at each end.
The fitting at each front brake caliper is the banjo-type and requires a special banjo bolt and copper
washers. The fitting at each rear brake caliper is a screw-in type fitting.
Jeep Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Brake Hose/Line > Component
Brake Hose/Line: Testing and Inspection
INSPECTION
Brake tubing should be inspected periodically for evidence of physical damage or contact with
moving or hot components.
Flexible rubber hose is used at both the front and rear wheel brakes. Inspection of the flexible
brake hoses should be performed whenever the brake system is serviced and every 12,000 km
(7,500 miles) or 12 months, whichever comes first. Inspect hydraulic brake hoses for surface
cracking, scuffing, or worn spots. If the fabric casing of the hose becomes exposed due to cracks
or abrasions in the hose cover, the hose should be replaced immediately. Eventual deterioration of
the hose can take place with possible burst failure. Faulty installation can cause twisting, resulting
in wheel, tire, or chassis interference.
NOTE: This vehicle is equipped with more than one size (diameter) brake tube depending on
location on the vehicle. If a brake tube must be replaced, always use the same size brake tubing as
that being replaced. Never use under-size brake tubing.
Jeep Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Hydraulic Control Assembly -
Antilock Brakes > Component Information > Description and Operation > Hydraulic Control Unit (HCU)
Hydraulic Control Assembly - Antilock Brakes: Description and Operation Hydraulic Control Unit
(HCU)
DESCRIPTION
The Hydraulic Control Unit (HCU) is mounted to the Antilock Brake Module (ABM) as part of the
Integrated Control Unit (ICU). The HCU controls the flow of brake fluid to the brakes using a series
of valves and accumulators. A pump/motor is mounted on the HCU to supply build pressure to the
brakes during an ABS stop.
VALVES AND SOLENOIDS
The valve block contains four inlet valves and four outlet solenoid valves. The inlet valves are
spring-loaded in the open position and the outlet valves are spring-loaded in the closed position
during normal braking. The fluid is allowed to flow from the master cylinder to the wheel brakes.
During an ABS stop, these valves cycle to maintain the proper slip ratio for each wheel. The inlet
valve closes preventing further pressure increase and the outlet valve opens to provide a path from
the wheel brake to the HCU accumulators and pump/motor. This releases (decays) pressure from
the wheel brake, thus releasing the wheel from excessive slippage. Once the wheel is no longer
slipping, the outlet valve is closed and the inlet valve is opened to reapply (build) pressure.
If the ABS includes the traction control feature, there are four other valves in the HCU. Two
Traction Control (TC) valves, mounted in the HCU valve block, are normally in the open position
and close only when the traction control is applied. There are also two shuttle valves which control
pressure return to the master cylinder under ABS and traction control conditions.
These TC valves are used to isolate the rear (non-driving) wheels of the vehicle from the hydraulic
pressure that the HCU pump/motor is sending to the front (driving) wheels when traction control is
being applied. The rear brakes need to be isolated from the master cylinder when traction control is
being applied so the rear wheels do not drag.
BRAKE FLUID ACCUMULATORS
There are two fluid accumulators in the HCU: one for the primary hydraulic circuit, and one for the
secondary hydraulic circuit. Each hydraulic circuit uses a 3 cc accumulator.
The fluid accumulators temporarily store brake fluid that is removed from the wheel brakes during
an ABS cycle. This stored fluid is used by the pump/motor to provide build pressure for the brake
hydraulic system. When the antilock stop is complete, the accumulators are drained by the
pump/motor.
There are two noise dampening chambers in the HCU on this vehicle equipped with traction
control.
PUMP/MOTOR
There are two pump assemblies in the HCU: one for the primary hydraulic circuit, and one for the
secondary hydraulic circuit. Both pumps are driven by a common electric motor. This DC-type
motor is integral to the HCU and is controlled by the ABM.
The pump/motor provides the extra amount of brake fluid needed during antilock braking. Brake
fluid is released to the accumulators when the outlet valve is opened during an antilock stop. The
pump mechanism consists of two opposing pistons operated by an eccentric camshaft. In
operation, these pistons are used to purge fluid from the accumulators back into the master
cylinder circuits. When the antilock stop is complete, the pump/motor drains the accumulators.
The pump motor is also used to build pressure when the system goes into Electronic Stability
Program (ESP(R)) and traction control mode.
The ABM may turn on the pump/motor when an antilock stop is detected. The pump/motor
continues to run during the antilock stop and is turned off after the stop is complete. Under some
conditions, the pump/motor runs to drain the accumulators during the next drive-off.
The pump/motor is not a serviceable item; if it requires replacement, the HCU must be replaced.
Antilock Brakes > Component Information > Description and Operation > Hydraulic Control Unit (HCU) > Page 5858
Hydraulic Control Assembly - Antilock Brakes: Description and Operation Integrated Control Unit
(ICU)
Description
DESCRIPTION
The Hydraulic Control Unit (HCU) (2) and the Antilock Brake Module (ABM) (1) used with this
antilock brake system are combined (integrated) into one unit, which is called the Integrated
Control Unit (ICU).
The ICU (1) is located in the engine compartment, mounted to the right side body frame rail near
the strut tower.
The ABS with ESP and All-Speed Traction Control ICU consists of the following components: the
ABM, 12 (build/decay) solenoid valves, two traction control solenoid valves, two hydraulic shuttle
valves, valve block, fluid accumulators, a pump, and an electric pump/motor.
The replaceable components of the ICU are the HCU and the ABM. No attempt should be made to
service any components of the HCU or ABM.
Antilock Brakes > Component Information > Description and Operation > Hydraulic Control Unit (HCU) > Page 5859
For additional information on the ABM, Refer to ELECTRICAL/ELECTRONIC BRAKE MODULE -
DESCRIPTION. For additional information on the HCU, Refer to HYDRAULIC CONTROL UNIT) -
DESCRIPTION.
Operation
OPERATION
For information of the ICU, refer to these individual components of the ICU:
- ANTILOCK BRAKE MODULE (ABM) Refer to BRAKE MODULE - DESCRIPTION
- HYDRAULIC CONTROL UNIT (HCU) (Refer to HYDRAULIC CONTROL UNIT - DESCRIPTION

Antilock Brakes > Component Information > Service and Repair > Removal and Replacement
Hydraulic Control Assembly - Antilock Brakes: Removal and Replacement
Removal
REMOVAL
To remove the HCU, the ICU must be removed and disassembled. Refer to INTEGRATED
CONTROL UNIT DISASSEMBLY
Installation
INSTALLATION
To install the HCU, assemble and install the ICU. Refer to INTEGRATED CONTROL UNIT -
ASSEMBLY
Removal

1. Disconnect and isolate battery negative cable from battery post.
drain out of the master cylinder reservoir while the lines are disconnected.
3. Remove the engine appearance cover. 4. Loosen lower and upper mounting nuts, then remove
the exhaust heat shield from the dash panel. 5. Pull the brake tube bundle routing clips (with tubes)
loose from studs on the dash panel.
Antilock Brakes > Component Information > Service and Repair > Removal and Replacement > Page 5862
6. Remove the primary (4) and secondary (1) brake tubes (from master cylinder) at the hydraulic
control unit (7). 7. Remove the remaining brake tubes (2, 3, 5, 6) at the hydraulic control unit (7).
8. Remove the screw (1) fastening the power steering pressure hose routing clamp (2) to the
exhaust manifold.
NOTE: Use this figure in the following step to release the ABM harness connector cover. It shows
the location of the release tabs.
9. Disconnect the ABM harness connector from the Antilock Brake Module (ABM). To do so:
a. Depress the tabs on each side of the connector cover, then b. Pull outward and upward on the
lower half of the cover until it locks into position pointing straight outward (2). The connector can
then be
pulled straight outward off the ABM (1).

10. Loosen, but do not remove, the two mounting screws (2) attaching the ICU (1) mounting
bracket to the body. 11. Lift the ICU and mounting bracket (1) off the mounting screws (2). 12.
Move the brake tubes around as necessary without bending them and remove the ICU with bracket
through the opening between the A/C lines and
the exhaust manifold.
13. To separate the ABM from the HCU, Refer to INTEGRATED CONTROL UNIT) -
DISASSEMBLY.
Installation
1. Install the ICU with bracket (1) through the opening between the A/C lines and the exhaust
manifold using the opposite of how it was removed. 2. Place the mounting bracket for the ICU (1)
over the mounting screws (2) and hang the assembly in place. Tighten the two mounting screws (2)
to
23 Nm (17 ft. lbs.).

CAUTION: Before installing the ABM harness connector on the ABM, be sure the seal is properly
installed in the connector.
3. Insert the ABM wiring harness connector (2) into the socket of the ABM (1) and close the cover,
locking the connector in place.
4. Install the four chassis brake tubes (2, 3, 5, 6) brake tubes at the ICU hydraulic control unit (7).
Tighten the tube nuts to 17 Nm (150 in. lbs.). 5. Install the primary (4) and secondary (1) brake
tubes at the ICU hydraulic control unit (7). Tighten the tube nuts to 17 Nm (150 in. lbs.).
6. Position the power steering pressure hose routing clamp (2) on the exhaust manifold and install
7. Push the brake tube bundle routing clips (with tubes) onto the studs on the dash panel. 8. Install
the heat shield on the dash panel and tighten the lower and upper mounting nuts.
10. Install the engine appearance cover. 11. Connect the battery negative cable to the battery post.
It is important that this be performed properly.
12. Hook up the scan tool to initialize the ABM and perform the following:
a. Clear any faults. b. Fill the master cylinder to the proper fill level and bleed the base and ABS
hydraulic systems. c. Check for leaks. d. Perform the ABS Verification Test and road test the
vehicle.
Hydraulic Control Assembly - Antilock Brakes: Overhaul
Disassembly
DISASSEMBLY
1. If the mounting bracket (3) needs to be removed from the ICU, remove the single mounting bolt
(2), then slide the ICU's mounting pins out of the
grommets in the bracket and remove the bracket.
2. Remove the mounting pins from the ICU.

3. Remove the four screws (1) attaching the ABM (2) to the HCU.
4. Separate the ABM (1) from the HCU (2).
Assembly
ASSEMBLY
1. Clean any debris off the mating surfaces of the HCU and ABM.
CAUTION: When installing new O-rings or solenoid valve stem seals, do not use any type of
lubricant.
2. If the seals (1) on the solenoid valve stems (2) are not new, replace them all. Each of the
solenoid valve stem seals must be new to keep out
moisture and debris; do not reuse solenoid valve stem seals.
3. Replace the pump/motor connector O-ring (1) if it is not new. Be sure the O-ring is properly
seated in the mounting groove (2).
4. Align components and install the ABM (1) on the HCU (2).
5. Install the four screws (1) attaching the ABM (2) to the HCU. Tighten the mounting screws to 2
Nm (17 in. lbs.).
6. If necessary, install the mounting pins (1) in the ICU (2) and tighten to 11 Nm (97 in. lbs.).
7. If the mounting bracket (3) needs to be installed on the ICU (1), install the mounting pins in the
ICU as necessary and tighten to 11 Nm (97 in.
lbs.). Insert the mounting pins into the grommets mounted in the bracket, then install the single
mounting bolt (2). Tighten the mounting bolt to 11 Nm (97 in. lbs.).
8. Install the ICU in the vehicle.

Jeep Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Brake Master Cylinder > Component
Brake Master Cylinder: Description and Operation Description
DESCRIPTION
The master cylinder used on this vehicle is a Plunger II design supplied by Continental Teves. The
bore diameter for all applications is 20.6 mm (0.812 in.).
All master cylinders (3) are a two-outlet design and the brake tubes from these primary and
secondary outlet ports lead directly to the Integrated Control Unit (ICU) before going to each wheel
brake.
The master cylinder body is an anodized aluminum casting. It has a machined bore to accept the
master cylinder pistons and also has threaded ports with seats for hydraulic brake tube
connections.
The master cylinder has the brake fluid reservoir mounted on top of it which gravity feeds brake
fluid to the master cylinder when it is required. On manual transmission model vehicles the brake
fluid reservoir also feeds the clutch hydraulic circuit. The reservoir is made of see-through plastic
and it houses the brake fluid level switch. A removable brake fluid level switch is mounted in the
right side.
Brake Master Cylinder: Description and Operation Operation
OPERATION
When the brake pedal is pressed, the master cylinder primary and secondary pistons apply brake
pressure through the ABS Integrated Control Unit (ICU) and chassis brake tubes to each brake
assembly. The brake fluid reservoir supplies the brake hydraulic system with the necessary fluid to
operate properly.
ABS (ESP) equipped master cylinder outlet ports supply hydraulic pressure to the ABS ICU where
it is distributed to the individual wheel brakes.
The master cylinder reservoir cap diaphragm is slit to allow atmospheric pressure to equalize on
both sides of the diaphragm.
Brake Master Cylinder: Procedures
to 17 Nm (150 in. lbs.).
Brake Master Cylinder: Removal and Replacement

Removal
MASTER CYLINDER
CAUTION: The vacuum in the power brake booster must be pumped down before removing the
master cylinder to prevent the booster from sucking in any contamination. This can be done by
pumping the brake pedal while the engine is not running until a firm brake pedal is achieved.
1. With the engine not running, pump the brake pedal 4-5 strokes until the pedal feel is firm. 2.
Disconnect the negative (ground) cable from the battery and isolate the cable.
3. Disconnect the wiring harness connector (1) from the brake fluid level switch (2) in the master
4. Disconnect the primary (1) and secondary (2) brake tubes at the master cylinder outlet ports.
Install plugs at all of the open brake tube outlets on
the master cylinder.

5. If equipped with a manual transaxle, remove the clamp and slide the clutch actuator hose (2) off
the reservoir port (1).
6. Clean the area around where the master cylinder (2) attaches to the power brake booster (1)
using a suitable brake cleaner such as Mopar(R) Brake
Parts Cleaner or an equivalent.
7. Remove the two nuts (3) attaching the master cylinder (2) to the power brake booster (1). 8.
Slide the master cylinder straight out of the power brake booster.
Installation
MASTER CYLINDER
NOTE: The master cylinder must be bled before installing it on the vehicle.
1. Bench bleed the master cylinder. 2. Wipe the face of the power brake booster clean where the
vacuum seal on the rear of the master cylinder comes in contact when it's installed. Do
not get any cleaner or debris inside the booster.

CAUTION: When installing a master cylinder on the vehicle, a NEW vacuum seal (2) MUST be
installed on the master cylinder mounting flange (1).
3. If the master cylinder does not have a new vacuum seal (2) on the mounting flange (1), remove
it. Install a NEW vacuum seal on the master
cylinder mounting flange making sure the seal fits squarely in its groove.
CAUTION: If resistance is met during master cylinder insertion into power brake booster, the
master cylinder push rod may not be lined up with the booster push rod. Remove the master
cylinder, realign and insert it again.
4. Line up the master cylinder mounting holes with the mounting studs on the power brake booster.
Ensure the master cylinder piston push rod lines
up with the booster push rod, then carefully slide the master cylinder into the power brake booster
until it contacts the face of the booster.
5. Install two NEW master cylinder mounting nuts (3). Tighten each nut to 25 Nm (18 ft. lbs.).
6. If equipped with a manual transaxle and a new reservoir is being installed, using an appropriate
cutting tool, cut the clutch actuator port at the
center of the "V" groove (2) opening the hydraulic clutch port (1). Discard the severed plug (3).
7. If equipped with a manual transaxle, slide the clutch actuator hose (2) onto the reservoir port (1).
Install the hose clamp just past the upset bead on
the port.
8. Connect the primary (1) and secondary (2) brake tubes to the master cylinder outlet ports.
Tighten the tube nuts to 17 Nm (150 in. lbs.).
9. Connect the wiring harness connector (1) to the brake fluid level switch (2).
WARNING: A reservoir blocker must be installed on the master cylinder brake fluid reservoir.
Failure to install the reservoir blocker can result in fire in the event of an accident, resulting in
serious or fatal injury.
10. If not present, a reservoir blocker (1) must be installed on the fluid reservoir (2). The blocker
can be removed from the original reservoir by
releasing the retaining tab (3) and opening the blocker. To install the blocker, encircle the reservoir
neck with the blocker, close the blocker, snapping the retaining tab into place. Make sure the
blocker is securely latched.
11. Connect the negative (ground) cable on the battery. 12. Fill the master cylinder reservoir to the
proper level.
WARNING: Be certain a firm brake pedal is achieved prior to attempting to operate the vehicle. If a
firm brake pedal cannot be achieved, bleed the brake hydraulic system and check for leaks.
13. Road test the vehicle to ensure proper operation of the brakes.
Brake Master Cylinder: Overhaul
Disassembly
DISASSEMBLY
1. Clean the master cylinder housing and brake fluid reservoir. Use only Mopar(R) Brake Parts
Cleaner or equivalent.
2. Remove the brake fluid reservoir cap (1). Using a syringe or equivalent type tool, empty as much
brake fluid as possible from the reservoir.
CAUTION: When removing the fluid reservoir (1) from the master cylinder, do not attempt to pry it
off using any type of tool. This can damage the fluid reservoir or master cylinder housing.
3. Remove the screw (3) fastening the fluid reservoir (1) to the master cylinder housing.
4. Pull the reservoir (1) straight up and remove it from the grommet seals in master cylinder
housing (2).
5. If the reservoir is being replaced, remove the fluid level switch. Push together the retaining tabs
(1) holding the brake fluid level switch in place in
the brake fluid reservoir (2), then pull the brake fluid level switch out the opposite side of the
reservoir.
6. Remove the vacuum seal (2) from the master cylinder mounting flange (1).
Assembly
ASSEMBLY
1. Install a NEW vacuum seal (2) on the master cylinder mounting flange (1) making sure the seal
fits squarely in its groove.
2. If the reservoir is being replaced, align the brake fluid level switch with its mounting hole on the
left side of the master cylinder brake fluid
reservoir. Push the switch into the fluid reservoir until the switch retaining tabs (1) are expanded on
the other side of the reservoir (2), locking it in place.
3. Lubricate the reservoir mounting area with fresh clean brake fluid. Place the reservoir (1) in
position over the grommet seals in the master cylinder
(2). Slide the reservoir into the grommet seals by firmly pressing down on the fluid reservoir. Once
installed, make sure fluid reservoir is touching the top of both grommet seals.
4. Install the fluid reservoir mounting screw (3). Tighten the screw to 5.5 Nm (48 in. lbs.). 5.
Thoroughly bleed the master cylinder before installing it. 6. Install the master cylinder.
Jeep Workshop Manuals > Brakes and Traction Control > Parking Brake System > Parking Brake Cable > Component
Parking Brake Cable: Service and Repair Removal

REMOVAL
NOTE: The procedure below applies to either of the two rear parking brake cables.
1. Disconnect and isolate the battery negative cable from its post on the battery. 2. Block the tire
and wheel assemblies so the vehicle does not move once the vehicle parking brake lever is
released.
3. Remove the floor center console. 4. Release and lower the parking brake lever (5).
5. Loosen the adjusting nut on the lever's output cable taking tension off parking brake cables. 6.
Remove the parking brake cables (3) from the parking brake cable equalizer (2). 7. Remove the
rear seat cushion.
8. Fold the rear carpeting forward (1) to expose the parking brake cables (4) at the end of the rear
floor. 9. Install the box end of a 1/2 inch (13 mm) wrench (2) over the retainer for either the right (3)
or left (5) parking brake cable. Push the wrench onto
the retainer until the retainer fingers are collapsed. From under the carpeting, grasp the parking
brake cable housing and pull the cable straight out of the bracket attached to the floor.
11. Remove the wheel mounting nuts (3), then the rear tire and wheel assembly (1). 12. Access
and remove the parking brake shoes.
13. Remove the hair pin (1) securing the parking brake cable (2) to the brake support plate (3). 14.
Pull the parking brake cable from the support plate and hole in trailing link.
15. Remove the screw (4) securing the cable routing clamp (3) to the body (2). 16. Remove the nut
(5) securing the cable routing clamp (3) to the fuel tank strap (7). 17. Remove the parking brake
cable (1 - right cable, 9 - left cable) with sealing grommet (6) through the hole (8) in the floor pan of
the vehicle.
Parking Brake Cable: Service and Repair Installation
INSTALLATION
NOTE: The following procedure applies to either of the two rear parking brake cables.
1. From underneath, push the parking brake cable through the hole (8) in the floor pan of the
vehicle making sure the cable sealing grommet (6) is
installed in the floor pan as far as possible (without going all the way through) to ensure a good
seal.
2. Position the cable routing clamp (3) over the stud on the fuel tank strap (7) and install the nut (5).
3. Position the cable routing clamp (3) and install the screw (4) securing the cable (1 - right cable, 9
- left cable) to the body (2).
4. Insert the parking brake cable through the hole in the trailing link and the support plate (3). 5.
Install the hair pin (1) securing the parking brake cable (2) to the brake support plate (3). 6. Install
the parking brake shoes (and check adjustment) and components removed to access them.
(100 ft. lbs.). 8. Lower the vehicle. 9. Block the tire and wheel assemblies so the vehicle does not
move with the vehicle parking brake lever released.
10. Ensure that the seal grommet on the cable installed from underneath is fully seated into the
floor pan. 11. Route the parking brake cable under the carpeting, up to the parking brake cable
retaining bracket (4) on the floor pan. Insert the parking brake
cable (3) through the retaining bracket. Push the cable in until the locking fingers on the cable
retainer lock the cable into place.
CAUTION: A NEW parking brake cable equalizer (2) must be installed when servicing the parking
brake cables or lever. The equalizer has an integrated bent nail tensioner that needs to be
stretched upon installation placing the correct tension on the cables.
12. Remove and install a NEW parking brake cable equalizer (2) on the parking brake lever output
cable. 13. Install the rear parking brake cables (3) into the equalizer (2) on the parking brake lever
output cable. 14. Ensure that the parking brake cables are correctly installed on the equalizer and
aligned with the cable track on the parking brake lever.
NOTE: Actuating the parking brake lever to its fully applied position one time after tightening the
adjustment nut will yield (stretch) the bent nail portion of the equalizer approximately 6 mm (1/4
inch). This process will correctly set the parking brake cable tension.
15. Adjust parking brake cable tension using the following steps:
a. Place the parking brake lever in the fully released (down) position. b. Tighten the adjusting nut
(3) on the parking brake lever output cable until 31 millimeters (1.220 inches) of thread is out past
the end of the
adjustment nut (1).
c. Actuate the parking brake lever to its fully applied position one time, then reposition it to its fully
released (down) position.
16. Raise the vehicle to a point where the rear wheels just clear the floor. 17. Check the rear
wheels of the vehicle; they should rotate freely without dragging. 18. Apply the parking brake.
Check the rear wheels of the vehicle. They should not rotate. 19. Return the parking brake lever to
its fully released (down) position and check the rear wheels. They should rotate freely without
dragging. 20. Apply the parking brake. 21. Lower the vehicle.
22. Install the floor center console. 23. Remove the blocks from the tires and wheel assemblies. 24.
Connect the battery negative cable to its post on the battery.
Jeep Workshop Manuals > Brakes and Traction Control > Parking Brake System > Parking Brake Lever > Component
Parking Brake Lever: Service and Repair Removal

REMOVAL
NOTE: The procedure below applies to either of the two rear parking brake cables.
1. Disconnect and isolate the battery negative cable from its post on the battery. 2. Block the tire
and wheel assemblies so the vehicle does not move once the vehicle parking brake lever is
released.
3. Remove the floor center console. 4. Release and lower the parking brake lever (5).
5. Loosen the adjusting nut on the lever's output cable taking tension off parking brake cables.
Back the nut off until it is flush with the end of the
output cable.
6. Remove the parking brake cables (3) from the parking brake cable equalizer (2).
7. Disconnect the wiring harness connector (2) from the parking brake switch (3).
8. Remove the nuts (1) attaching the parking brake lever (6) to the vehicle. 9. Remove the parking
brake lever (6).
Parking Brake Lever: Service and Repair Installation
INSTALLATION
1. Place the parking brake lever (6) on the mounting studs (5) affixed to the vehicle floor pan. Install
and tighten the nuts to 28 Nm (250 in. lbs.).
2. Connect the wiring harness connector (2) to the parking brake switch (3).
CAUTION: A NEW parking brake cable equalizer (2) must be installed when servicing the parking
brake cables or lever. The equalizer has an integrated bent nail tensioner that needs to be
stretched upon installation placing the correct tension on the cables.
3. Remove and install a NEW parking brake cable equalizer (2) on the parking brake lever output
cable.
4. Install the rear parking brake cables (3) into the equalizer (2) on the parking brake lever output
cable. 5. Ensure that the parking brake cables are correctly installed on the equalizer and aligned
with the cable track on the parking brake lever.
NOTE: Actuating the parking brake lever to its fully applied position one time after tightening the
adjustment nut will yield (stretch) the bent nail portion of the equalizer approximately 6 mm (1/4
inch). This process will correctly set the parking brake cable tension.
6. Adjust parking brake cable tension using the following steps:
a. Place the parking brake lever in the fully released (down) position. b. Tighten the adjusting nut
(3) on the parking brake lever output cable until 31 millimeters (1.220 inches) of thread is out past
the end of the
adjustment nut (1).
c. Actuate the parking brake lever to its fully applied position one time, then reposition it to its fully
released (down) position.
7. Raise the vehicle to a point where the rear wheels just clear the floor. 8. Check the rear wheels
of the vehicle; they should rotate freely without dragging. 9. Apply the parking brake. Check the
rear wheels of the vehicle. They should not rotate.
10. Return the parking brake lever to its fully released (down) position and check the rear wheels.
They should rotate freely without dragging. 11. Apply the parking brake. 12. Lower the vehicle.
13. Install the floor center console. 14. Remove the blocks from the tires and wheel assemblies. 15.
Connect the battery negative cable to its post on the battery.
Jeep Workshop Manuals > Brakes and Traction Control > Parking Brake System > Parking Brake Shoe > Component
Information > Adjustments
Parking Brake Shoe: Adjustments
PARKING BRAKE SHOE ADJUSTMENT
NOTE: The parking brake shoes used in the drum-in-hat park brake system do not automatically
adjust to compensate for brake shoe lining wear. Therefore, it is necessary to manually adjust the
parking brake shoes.
1. Verify the parking brake lever is in the released (down) position. 2. Raise and support the
vehicle.
3. Remove the wheel mounting nuts (3), then the tire and wheel assembly (1). 4. Install a couple
wheel mounting nuts to hold the brake rotor in place while adjustment of the brake shoes is made.
NOTE: To find the adjuster wheel with the drum on position the hole (1) in the front of the rotor
drum as follows: -
Left side - 7 o'clock.
- Right side - 5 o'clock.
NOTE: When adjusting the parking brake shoes with the drum-in hat rotor installed, rotating the
adjuster wheel (2) upward will loosen the adjustment. Rotating the adjuster wheel (2) downward will
tighten the adjustment.
5. Remove the rubber plug from the hole (1) in the front of the rotor. 6. Utilizing the hole (1) in the
front of the rotor, make a fine adjustment of the shoes.
Information > Adjustments > Page 5910
7. Reinstall the rubber plug. 8. Lower the vehicle far enough to access the interior of the vehicle. 9.
Reach inside the vehicle and cycle (fully apply and release) the park brakes.
10. With the parking brake lever in the fully applied (up) position, attempt to hand rotate each rear
brake rotor to ensure that the parking brake shoes
are working properly.
11. With the parking brake lever in the released (down) position, hand rotate each rear brake rotor
to ensure that the parking brake shoes are not
dragging.
13. Remove the wheel mounting nuts and install the tire and wheel assembly (1). Install and tighten
the wheel mounting nuts (3) to 135 Nm (100 ft.
lbs.).

Parking Brake Shoe: Service and Repair Removal
REMOVAL
NOTE: If removing parking brake shoes on both sides of vehicle, perform remaining steps on each
side of the vehicle.
2. Access and remove the rear brake rotor (3). 3. Turn the brake shoe adjuster wheel until the
adjuster is at shortest length.
4. Remove the upper return spring (1) from the anchor pin (3) and the rear brake shoe. 5. Remove
the upper return spring (2) from the anchor pin (3) and the front brake shoe.
6. Remove the brake shoe hold-down springs and pins (1, 2). Rotate the pins 90° to disengage.
7. Remove the parking brake cable from the lever on the rear parking brake shoe.
8. Remove the brake shoes (2, 6), adjuster (5) and lower return spring (3) as an assembly from the
support plate. 9. If necessary, remove the strut (1).
10. Remove the lower return spring (3) and adjuster (5) from the shoes (2, 6).
Parking Brake Shoe: Service and Repair Installation
INSTALLATION
NOTE: If replacing parking brake shoes on both sides of vehicle, perform STEP 1 through STEP 15
on each side of the vehicle to complete shoe set installation, then proceed to STEP 16.
NOTE: Left side shoes are shown in the figure. Right side shoes are a mirror image of the left
except for the adjuster. The threaded portion of the adjuster should always be positioned to the left
side in order to maintain consistent side-to-side rotational direction for adjustment purposes.
1. Install the lower return spring (3) and adjuster (5) between the parking brake shoes (2, 6). The
rear shoe will have the lever mounted on the inside.
Make sure the threaded portion of the adjuster is mounted to the left on both right and left side
parking brake assemblies (see preceding note).
2. If necessary, place the strut (1) above the hub and bearing on the vehicle. Note the curved end
of the strut (1) is positioned to the rear. 3. Install the assembled brake shoes (2, 6), adjuster (5) and
lower return spring (3) over the hub and bearing and onto the support plate and anchor.
Be sure to install the strut between the front shoe and the lever on the rear shoe.
4. Install the parking brake cable onto the lever on the parking brake shoe.
5. Install the brake shoe hold-down springs and pins (1, 2). Rotate the pins 90° to engage.
6. Install the front upper return spring (2) holding the front brake shoe and anchor pin (3). 7. Install
the rear upper return spring (2) holding the rear brake shoe and anchor pin (3).
8. Using Brake Shoe Gauge, Special Tool C-3919, or equivalent, measure the inside diameter of
parking brake drum portion of rotor. Set the Gauge.
9. Place Gauge (2) over the parking brake shoes (1) at their widest point.
10. Using the adjuster wheel, adjust the parking brake shoes until the linings on both parking brake
shoes just touch the jaws on the Gauge.
11. Install the rear brake rotor (3) and install a couple wheel mounting nuts to hold it in place while
a final adjustment is made.
NOTE: To find the adjuster wheel with the drum on position the hole (1) in the front of the rotor
drum as follows: -
Left side - 7 o'clock.
- Right side - 5 o'clock.
NOTE: When adjusting the parking brake shoes with the drum-in hat rotor installed, rotating the
adjuster wheel (2) upward will loosen the adjustment. Rotating the adjuster wheel (2) downward will
tighten the adjustment.
12. Remove the rubber plug from the hole (1) in the front of the rotor. 13. Utilizing the hole (1) in the
front of the rotor, make a final adjustment of the shoes if necessary. 14. Reinstall the rubber plug.
15. Remove the wheel mounting nuts and finish installing the brake rotor (3) as well as all
components removed to access it. 16. Lower the vehicle. 17. Cycle the parking brake lever once,
verifying proper operation of the parking brake.
Jeep Workshop Manuals > Brakes and Traction Control > Parking Brake System > Parking Brake Warning Switch >
Component ID: 356
Connector:
Color : NATURAL
# of pins : 1
Component ID: 356
Connector:
Color : NATURAL
# of pins : 1
DESCRIPTION
mechanism.
replaced.
OPERATION
PARK BRAKE SWITCH
APPLIED
REMOVAL

INSTALLATION
2.5 Nm (24 in. lbs.).

Jeep Workshop Manuals > Brakes and Traction Control > Power Brake Assist > Vacuum Brake Booster > Component
Vacuum Brake Booster: Description and Operation
DESCRIPTION
The power brake booster (3) is mounted to the engine side of the dash panel. The master cylinder
is bolted to the front of the booster. A vacuum check valve is also mounted on the front of the
booster. A vacuum line connects the check valve to engine source vacuum. The booster input rod
extends through the dash panel and connects to the brake pedal.
This vehicle uses a 254 mm single diaphragm power brake booster. Power brake boosters are
internally tuned differently depending on whether the vehicle is equipped with ABS or without ABS.
If the power brake booster requires replacement, be sure it is replaced with the correct part.
The power brake booster can be identified by the tag attached to the body of the booster. This tag
contains the following information:
- The production part number
- The date it was built, and
- The booster manufacturer.

Vacuum Brake Booster: Testing and Inspection
POWER BRAKE BOOSTER
BASIC TEST
1. With engine off, depress and release the brake pedal several times to purge all vacuum from the
power brake booster. 2. Depress and hold the pedal with light effort (15 to 25 lbs. (6.8 to 11.3 kg)
pressure), then start the engine.
The pedal should fall slightly, then hold. Less effort should be needed to apply the pedal at this
time. If the pedal fell as indicated, perform the VACUUM LEAK TEST listed after the BASIC TEST.
If the pedal did not fall, continue on with this BASIC TEST.
3. Disconnect the vacuum hose at the vacuum check and tee-in a vacuum gauge. 4. Start the
engine. 5. When the engine is at warm operating temperature, allow it to idle and check the
vacuum at the gauge.
If the vacuum supply is 12 inches Hg (40.5 kPa) or more, the power brake booster is defective and
must be replaced. If the vacuum supply is below 12 inches Hg, continue on with this BASIC TEST.
6. Shut off the engine. 7. Connect the vacuum gauge to the vacuum reference port on the engine
intake manifold. 8. Start the engine and observe the vacuum gauge.
If the vacuum is still low, check the engine tune and repair as necessary. If the vacuum is above 12
inches, the hose or check to the booster has a restriction or leak.
Once an adequate vacuum supply is obtained, repeat the BASIC TEST.
VACUUM LEAK TEST
1. Disconnect the vacuum hose at the vacuum check and tee-in a vacuum gauge. 2. Start the
engine. 3. Allow the engine to warm up to normal operating temperature and engine idle. 4. Using
vacuum line pliers, close off the vacuum supply hose near the booster and observe the vacuum
gauge.
If the vacuum drop exceeds 1.0 inch Hg (3.3 kPa) in one minute, repeat the above steps to confirm
the reading. The vacuum loss should be less than 1.0 inch Hg in one minute time span. If the loss
is more than 1.0 inch Hg, replace the power brake booster. If it is not, continue on with this test.
5. Remove the pliers from the hose temporarily. 6. Apply light effort (approximately 15 lbs. (6.8 kg)
of force) to the brake pedal and hold the pedal steady. Do not move the pedal once the pressure
is applied or the test results may vary.
7. Have an assistant reattach the pliers to the vacuum supply hose. 8. Allow 5 seconds for
stabilization, then observe the vacuum gauge.
If the vacuum drop exceeds 3.0 inches Hg (10 kPa) in 15 seconds, repeat the above steps to
confirm the reading. The vacuum loss should be less than 3.0 inches Hg in 15 seconds time span.
If the loss is more than 3.0 inches Hg, replace the power brake booster. If it is not, the booster is
not defective.
Vacuum Brake Booster: Service and Repair Removal
POWER BRAKE BOOSTER
1. Disconnect and isolate the battery negative cable from its post on the battery. 2. Remove the
master cylinder.
3. Disconnect the vacuum hose (2) from the check valve (1) on the power brake booster. Do not
remove the check valve from power brake
booster.
4. Remove the steering column opening cover (and airbag if equipped) on the instrument panel.
5. Remove the mounting screws (2) and reinforcement (1) behind the steering column opening
cover.
6. Remove the stop lamp switch (2) and discard it. Do not reuse the stop lamp switch.
7. Remove the retaining clip (2) securing the power brake booster push rod (1) to the brake pedal.
To do so, position a small screwdriver under the
center tang of the retaining clip, then rotate the screwdriver enough to allow the retaining clip tang
to pass over the end of the brake pedal pin (3). Remove and discard the clip. Do not reuse the clip.
8. Slide the booster push rod (1) off the brake pedal pin (3).
9. Remove the four nuts (4) attaching the power brake booster (3) to the dash panel.
10. Slide the power brake booster (3) forward until its mounting studs clear the dash panel, then
remove it through the engine compartment.
Vacuum Brake Booster: Service and Repair Installation
POWER BRAKE BOOSTER
NOTE: Before power brake booster (1) installation, be certain a NEW dash seal (2) is installed on
the booster mounting studs.
1. Install the power brake booster (3) by sliding the push rod and studs through the dash panel and
into mounting position. 2. Under the instrument panel, install the four power brake booster
mounting nuts (4). To tighten the nuts, refer to the following step.
CAUTION: Because of power brake booster design, it is very important to tighten the mounting
nuts in the proper sequence.
3. Tighten the brake pedal/booster mounting nuts in the proper sequence to 23 Nm (17 ft. lbs.).
4. Using Mopar(R) Lubriplate, or an equivalent, coat the surface of the brake pedal pin (3) where it
contacts the brake booster input rod (1). 5. Install the power brake booster push rod (1) on the pin
(3) mounted on the side of the brake pedal. Install a NEW retaining clip (2) on the end of
the pin. Do not reuse the old clip.

CAUTION: Do not reuse the original stop lamp switch. The switch can only be adjusted once. That
is during initial installation of the switch. If the switch is not adjusted properly or has been removed
for some service, a new switch must be installed and adjusted.
6. Install and adjust a NEW stop lamp switch (2) in the brake pedal bracket (1).
7. Install the steering column opening cover reinforcement (1) in the steering column opening.
Install the mounting screws (2). 8. Install the steering column opening cover (and airbag if
equipped) on the instrument panel.
CAUTION: When installing the vacuum hose on the check valve (1), make sure the hose is routed
properly to avoid possible contact with unfriendly surfaces.
9. Connect the vacuum hose (2) to the vacuum check valve (1).
10. Install the master cylinder. 11. Connect the battery negative cable to its post on the battery. 12.
Bleed the base brake system if necessary.
WARNING: Be certain a firm brake pedal is achieved prior to attempting to operate the vehicle.
13. Road test the vehicle to ensure proper operation of the brakes.
Jeep Workshop Manuals > Brakes and Traction Control > Relays and Modules - Brakes and Traction Control > Electronic
Brake Control Module > Component Information > Technical Service Bulletins > Recalls for Electronic Brake Control
Module: > F50 > Feb > 07 > Recall - ABS Module Reprogramming
February 2007
Models
November 18, 2006 (MDH 090701 - 111801).
101019 - 111509).
090707 - 111801).
090707 - 111801).
090707 - 111801).
101813 - 120606).
101813 - 120606).
- 113018).
- 113018).
120811).
NOTE:
IMPORTANT:
Subject
Repair
Parts Information
Special Tools
Module: > F50 > Feb > 07 > Recall - ABS Module Reprogramming > Page 5955
NOTE:

Dealer Notification
repair.
Service Procedure
NOTE:
NOTE:
13.5 volts.

number.
NOTE:
performed.
13.5 volts.
NOTE:

prompts.
Module: > NHTSA06V493000 > Dec > 06 > Recall 06V493000: ABS Control Module Software Update
Update
Brake Control Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins for
Electronic Brake Control Module: > F50 > Feb > 07 > Recall - ABS Module Reprogramming
February 2007
Models
November 18, 2006 (MDH 090701 - 111801).
101019 - 111509).
090707 - 111801).
090707 - 111801).
090707 - 111801).
101813 - 120606).
101813 - 120606).
- 113018).
- 113018).
120811).
NOTE:
IMPORTANT:
Subject
Repair
Parts Information
Special Tools
Electronic Brake Control Module: > F50 > Feb > 07 > Recall - ABS Module Reprogramming > Page 5969
NOTE:

Dealer Notification
repair.
Service Procedure
NOTE:
NOTE:
13.5 volts.

number.
NOTE:
performed.
13.5 volts.
NOTE:

prompts.
Electronic Brake Control Module: > NHTSA06V493000 > Dec > 06 > Recall 06V493000: ABS Control Module Software
Update
Brake Control Module > Component Information > Technical Service Bulletins > Page 5978
Component ID: 151
Connector:
Color : BLACK
# of pins : 47
Gender : FEMALE
2--
3--
4--
5--
6--
7--
9--
10 - -
11 - -
14 - -
15 - -
17 - -
20 - -
21 - -
23 - -
24 - -
25 - -
26 - -
27 - -
28 - -
30 - -
31 - -

38 - -
39 - -
40 - -
41 - -
44 - -

Component ID: 151
Connector:
Color : BLACK
# of pins : 47
Gender : FEMALE
2--
3--
4--
5--
6--
7--
9--
10 - -
11 - -
14 - -
15 - -
17 - -
20 - -
21 - -
23 - -
24 - -
25 - -
26 - -
27 - -
28 - -
30 - -
31 - -

38 - -
39 - -
40 - -
41 - -
44 - -

Brake Control Module > Component Information > Description and Operation > Description
DESCRIPTION
Brake Control Module > Component Information > Description and Operation > Description > Page 5986
OPERATION
operation.
the vehicle.
Brake Control Module > Component Information > Service and Repair > Removal
REMOVAL
Brake Control Module > Component Information > Service and Repair > Removal > Page 5989
INSTALLATION
assembly.
Jeep Workshop Manuals > Brakes and Traction Control > Relays and Modules - Brakes and Traction Control > Traction
Control Relay > Component Information > Diagrams
Component ID: 186
Connector:
Color : # of pins :
C8 - -

Jeep Workshop Manuals > Brakes and Traction Control > Sensors and Switches - Brakes and Traction Control > Brake
Fluid Level Sensor/Switch > Component Information > Locations
Component ID: 292
Connector:
Color : BLACK
# of pins : 2
Fluid Level Sensor/Switch > Component Information > Locations > Page 5997
Component ID: 292
Connector:
Color : BLACK
# of pins : 2
DESCRIPTION
Fluid Level Sensor/Switch > Component Information > Service and Repair > Removal
REMOVAL
Fluid Level Sensor/Switch > Component Information > Service and Repair > Removal > Page 6005
INSTALLATION

Jeep Workshop Manuals > Brakes and Traction Control > Sensors and Switches - Brakes and Traction Control > Lateral
Component ID: 297
Connector:
Color : BLACK
# of pins : 6
Qualifier : (ESP)
4--
6--
Component ID: 297
Connector:
Color : BLACK
# of pins : 6
Qualifier : (ESP)
4--
6--
DESCRIPTION
REMOVAL
INSTALLATION

Jeep Workshop Manuals > Brakes and Traction Control > Sensors and Switches - Brakes and Traction Control > Parking
Brake Warning Switch > Component Information > Locations
Component ID: 356
Connector:
Color : NATURAL
# of pins : 1
Brake Warning Switch > Component Information > Locations > Page 6021
Component ID: 356
Connector:
Color : NATURAL
# of pins : 1
Brake Warning Switch > Component Information > Description and Operation > Description
DESCRIPTION
mechanism.
replaced.
Brake Warning Switch > Component Information > Description and Operation > Description > Page 6026
OPERATION
Brake Warning Switch > Component Information > Description and Operation > Page 6027
PARK BRAKE SWITCH
APPLIED
Brake Warning Switch > Component Information > Service and Repair > Removal
REMOVAL

Brake Warning Switch > Component Information > Service and Repair > Removal > Page 6030
INSTALLATION
2.5 Nm (24 in. lbs.).

Jeep Workshop Manuals > Brakes and Traction Control > Sensors and Switches - Brakes and Traction Control > Steering
Angle Sensor, Traction Control > Component Information > Locations
Component ID: 325
Connector:
Color : WHITE
# of pins : 4

Angle Sensor, Traction Control > Component Information > Locations > Page 6034
Component ID: 325
Connector:
Color : WHITE
# of pins : 4

DESCRIPTION
Jeep Workshop Manuals > Brakes and Traction Control > Sensors and Switches - Brakes and Traction Control > Traction
Control Switch > Component Information > Description and Operation
DESCRIPTION
Control Switch > Component Information > Service and Repair > Removal
REMOVAL
separately.
Control Switch > Component Information > Service and Repair > Removal > Page 6047
INSTALLATION
options.


Jeep Workshop Manuals > Brakes and Traction Control > Sensors and Switches - Brakes and Traction Control > Wheel
Speed Sensor > Component Information > Locations > Sensor-Wheel Speed-ABS-Left Front
Component ID: 327
Connector:
Color : BLACK
# of pins : 2
Speed Sensor > Component Information > Locations > Sensor-Wheel Speed-ABS-Left Front > Page 6052
Connector:
Color : # of pins :
Component ID: 328
Connector:
Color : BLACK
# of pins : 2
Connector:
Color : # of pins :
Component ID: 329
Connector:
Color : BLACK
# of pins : 2
Connector:
Color : # of pins :
Component ID: 330
Connector:
Color : BLACK
# of pins : 2
Connector:
Color : # of pins :
Speed Sensor > Component Information > Diagrams > Sensor-Wheel Speed-ABS-Left Front
Component ID: 327
Connector:
Color : BLACK
# of pins : 2
Speed Sensor > Component Information > Diagrams > Sensor-Wheel Speed-ABS-Left Front > Page 6067
Connector:
Color : # of pins :
Component ID: 328
Connector:
Color : BLACK
# of pins : 2
Connector:
Color : # of pins :
Component ID: 329
Connector:
Color : BLACK
# of pins : 2
Connector:
Color : # of pins :
Component ID: 330
Connector:
Color : BLACK
# of pins : 2
Connector:
Color : # of pins :
Speed Sensor > Component Information > Description and Operation > Front Wheel Speed
Description
DESCRIPTION
encoder.
Operation
OPERATION
Speed Sensor > Component Information > Description and Operation > Front Wheel Speed > Page 6082
Description
DESCRIPTION
encoder.
Operation
OPERATION
Speed Sensor > Component Information > Description and Operation > Front Wheel Speed > Page 6083
Speed Sensor > Component Information > Service and Repair > Front Wheel Speed
Removal
REMOVAL
tower.
Speed Sensor > Component Information > Service and Repair > Front Wheel Speed > Page 6086
hose bracket (5).
Installation
INSTALLATION


Removal
ALL-WHEEL-DRIVE
connector (3).
(4).
(4).
Installation
ALL-WHEEL-DRIVE
ft. lbs.).
trailing link (2).

(2) in the hole.
connector (3).

Jeep Workshop Manuals > Brakes and Traction Control > Sensors and Switches - Brakes and Traction Control > Yaw Rate
Component ID: 297
Connector:
Color : BLACK
# of pins : 6
Qualifier : (ESP)
4--
6--
Component ID: 297
Connector:
Color : BLACK
# of pins : 6
Qualifier : (ESP)
4--
6--
DESCRIPTION
REMOVAL
INSTALLATION

Jeep Workshop Manuals > Starting and Charging > Sensors and Switches - Starting and Charging > Ignition Switch >
Ignition Switch Lock Cylinder > Component Information > Service and Repair > Key/Lock Cylinder
Removal
REMOVAL
(2).

housing.
Installation
INSTALLATION
the RUN position.
clear tilt lever.
properly.
cylinder housing.
it.

Removal
REMOVAL
(2).
column.
housing.
Installation
INSTALLATION

clear tilt lever.
properly.
cylinder housing.
Jeep Workshop Manuals > Starting and Charging > Sensors and Switches - Starting and Charging > Neutral Safety Switch
Component ID: 348
Connector:
Color : BLACK
# of pins : 3
Qualifier : (MTX)
Component ID: 348
Connector:
Color : BLACK
# of pins : 3
Qualifier : (MTX)
Jeep Workshop Manuals > Starting and Charging > Battery > Battery Cable > Component Information > Description and
Operation > Battery Cables - Description
Battery Cable: Description and Operation Battery Cables - Description
DESCRIPTION
The battery cables are large gauge, stranded copper wires sheathed within a heavy plastic or
synthetic rubber insulating jacket. The wire used in the battery cables combines excellent flexibility
and reliability with high electrical current carrying capacity. The battery cables feature a clamping
type female battery terminal made of stamped sheet metal that is die cast onto one end of the
battery cable wire. A pinch-bolt and nut are installed at the open end of the female battery terminal
clamp. Large eyelet type terminals are crimped onto the opposite end of the battery cable wire and
then soldered. The battery positive cable wires feature a larger female battery terminal clamp to
allow connection to the larger battery positive terminal post. The battery negative cable wires have
a smaller female battery terminal clamp.
Both the battery positive and negative cables are available for service replacement only as a unit
with the battery wire harness, which may include portions of the wiring circuits for the generator
and other components on some vehicles.
Operation > Battery Cables - Description > Page 6138
Battery Cable: Description and Operation Battery Cables - Operation
OPERATION
The battery cables connect the battery terminal posts to the vehicle electrical system. These cables
also provide a path back to the battery for electrical current generated by the charging system for
restoring the voltage potential of the battery. The female battery terminal clamps on the ends of the
battery cable wires provide a strong and reliable connection of the battery cable to the battery
terminal posts. The terminal pinch bolts allow the female terminal clamps to be tightened around
the male terminal posts on the top of the battery. The eyelet terminals secured to the opposite ends
of the battery cable wires from the female battery terminal clamps provide secure and reliable
connection of the battery cables to the vehicle electrical system.
One wire has an eyelet terminal that connects the battery positive cable to the B(+) terminal stud of
the Totally Integrated Power Module (TIPM), and the other wire has an eyelet terminal that
connects the battery positive cable to the B(+) terminal stud of the engine starter motor solenoid.
The battery negative cable terminal clamp has one wire as an eyelet terminal that connects the
battery negative cable to the vehicle powertrain through a ground connection, typically on the
engine cylinder block.
Battery Cable: Testing and Inspection
BATTERY CABLES
A voltage drop test will determine if there is excessive resistance in the battery cable terminal
connections or the battery cable. If excessive resistance is found in the battery cable connections,
the connection point should be disassembled, cleaned of all corrosion or foreign material, then
reassembled. Following reassembly, check the voltage drop for the battery cable connection and
the battery cable again to confirm repair.
When performing the voltage drop test, it is important to remember that the voltage drop is giving
an indication of the resistance between the two points at which the voltmeter probes are attached.
EXAMPLE: When testing the resistance of the battery positive cable, touch the voltmeter leads to
the battery positive cable terminal clamp and to the battery positive cable eyelet terminal at the
starter solenoid B(+) terminal stud. If you probe the battery positive terminal post and the battery
positive cable eyelet terminal at the starter solenoid B(+) terminal stud, you are reading the
combined voltage drop in the battery positive cable terminal clamp-to-terminal post connection and
the battery positive cable.
VOLTAGE DROP TEST
The following operation will require a voltmeter accurate to 1/10 (0.10) volt. Before performing this
test, be certain that the following procedures are accomplished:
- The battery is fully-charged and load tested. Refer to Standard Procedures for the proper battery
charging and load test procedures.
- Fully engage the parking brake.
- If the vehicle is equipped with an automatic transmission, place the gearshift selector lever in the
Park position. If the vehicle is equipped with a manual transmission, place the gearshift selector
lever in the Neutral position and block the clutch pedal in the fully depressed position.
- Verify that all lamps and accessories are turned off.
- To prevent the engine from starting, remove the Automatic Shut Down (ASD) relay. The ASD
relay can be found in the Fuse Block located in the left front bumper fascia. See the fuse and relay
layout label affixed to the underside of the Fuse Block cover for ASD relay identification and
location.
1. Connect the positive lead of the voltmeter (1) to the battery (2) negative terminal post. Connect
the negative lead of the voltmeter (1) to the battery
(2) negative cable terminal clamp. Rotate and hold the ignition switch in the Start position. Observe
the voltmeter. If voltage is detected, correct the poor connection between the battery negative
cable terminal clamp and the battery negative terminal post.
2. Connect the positive lead of the voltmeter (1) to the battery (2) positive terminal post. Connect
the negative lead of the voltmeter (1) to the battery
(2) positive cable terminal clamp. Rotate and hold the ignition switch in the Start position. Observe
the voltmeter. If voltage is detected, correct the
poor connection between the battery positive cable terminal clamp and the battery positive terminal
post.
3. Connect the voltmeter (2) to measure between the battery positive cable terminal clamp (1) and
the starter solenoid B(+) terminal stud (3). Rotate
and hold the ignition switch in the Start position. Observe the voltmeter. If the reading is above 0.2
volt, clean and tighten the battery positive cable eyelet terminal connection at the starter solenoid
B(+) terminal stud. Repeat the test. If the reading is still above 0.2 volt, replace the faulty battery
positive cable.
4. Connect the voltmeter (1) to measure between the battery (2) negative cable terminal clamp and
a good clean ground on the engine block (3).
Rotate and hold the ignition switch in the Start position. Observe the voltmeter. If the reading is
above 0.2 volt, clean and tighten the battery negative cable eyelet terminal connection to the
engine block. Repeat the test. If the reading is still above 0.2 volt, replace the faulty battery
negative cable.
Jeep Workshop Manuals > Starting and Charging > Battery > Battery Cable > Component Information > Service and Repair
> Battery Cables - Removal
Battery Cable: Service and Repair Battery Cables - Removal
REMOVAL
2. Rotate the two retaining clips (3) and remove the air cleaner fresh air duct (2).
WARNING: The battery negative and positive cable polarity are different from the gasoline engine
equipped vehicles to the diesel engine equipped vehicles. Please note the location of the positive
and negative cables prior to service of the battery or related components.
NOTE: Diesel battery shown, gasoline battery similar.
3. Remove the nut (2) securing the Totally Integrated Power Module (TIPM) cable (1) to the battery
clamp stud (5).
4. Disconnect and isolate the battery negative cable then the positive cable (3).
> Battery Cables - Removal > Page 6143
5. Remove the nut (1) securing the negative cable (2) to the body ground stud.
6. Remove the battery cable from the B+ terminal of the generator.
7. Remove the battery cable from the B+ terminal of the starter motor.
8. One at a time, trace the battery cable retaining pushpins, fasteners and routing clips until the
cables are free from the vehicle.
9. Remove the battery cables from the engine compartment.

Battery Cable: Service and Repair Battery Cables - Installation
INSTALLATION
1. Position the battery cables in the engine compartment.
2. One at a time, install the battery cable retaining pushpins, fasteners and routing clips until the
cables are installed exactly where they were in the
vehicle.
3. Connect the battery cable to the B+ terminal of the starter motor. Tighten the cable nut to 13 Nm
(115 in. lbs.).
4. Connect the battery cable to the B+ terminal of the generator. Tighten the cable nut to 14 Nm
(125 in. lbs.).
5. Install the nut (1) securing the negative cable (2) to the body ground stud. Tighten the cable nut
to 12 Nm (9 ft. lbs.).
WARNING: The battery negative and positive cable polarity are different from the gasoline engine
equipped vehicles to the diesel engine equipped vehicles. Please note the location of the positive
and negative cables prior to service of the battery or related components.
NOTE: Diesel battery shown, gasoline battery similar.
6. Connect the battery positive cable then the negative cable (3).
7. Tighten the cable clamp nuts to 5 Nm (45 in. lbs.).
8. Install the nut (2) securing the Totally Integrated Power Module (TIPM) cable (1) to the battery
clamp stud (5).
9. Install the air cleaner fresh air duct (2) and secure in place by rotating the two retaining clips (3).
Jeep Workshop Manuals > Starting and Charging > Battery > Battery Tray > Component Information > Description and
Operation
Battery Tray: Description and Operation
DESCRIPTION
The battery is placed and secured in a plastic battery tray (3). The battery tray is located in the left
front side of the vehicle and is secured in place by one nut (2) and four bolts (1).
Jeep Workshop Manuals > Starting and Charging > Battery > Battery Tray > Component Information > Service and Repair >
Battery Retainer - Removal
Battery Tray: Service and Repair Battery Retainer - Removal
REMOVAL
2. Rotate the two retaining clips (3) and remove the air cleaner fresh air duct (2).
3. Remove the battery hold down retaining bolt (1).
4. Remove the battery hold down (2) from the vehicle.

Battery Retainer - Removal > Page 6151
Battery Tray: Service and Repair Battery Retainer - Installation

INSTALLATION
1. Install the battery hold down (2) into the vehicle.
2. Install the battery hold down retaining bolt (1). Tighten the bolt to 7 Nm (62 in. lbs.).
3. Install the air cleaner fresh air duct (2) and secure in place by rotating the two retaining clips (3).

Battery Tray: Service and Repair Battery Tray - Removal
REMOVAL
2. On diesel engine equipped vehicles disconnect the vacuum connector (3) and electrical
connector (1) from the diesel vacuum valve (2).
3. On diesel engine equipped vehicles lift the diesel vacuum valve bracket (1) up disengaging the
mounting tabs from the receptacles (2) in the
battery tray.
4. Remove the battery.

5. Remove the four bolts (1) and one nut (2) securing the battery tray (3) to the left frame rail (4).
6. Lift the battery tray out of the engine compartment and remove from the vehicle.
Battery Tray: Service and Repair Battery Tray - Installation
INSTALLATION
1. Place the battery tray (3) into the engine compartment over the left frame rail (4).
2. Install the one nut (2) and four bolts (1) securing the battery tray (3) to the frame rail (4).
3. Tighten the nut to 10.5 Nm (93 in. lbs.).
4. Tighten the bolts to 10.5 Nm (93 in. lbs.).
5. Install the battery.
6. On diesel engine equipped vehicles install the diesel vacuum valve. Push the bracket (1) down
until the mounting tabs are completely seated into
the receptacles (2) in the battery tray.

7. On diesel engine equipped vehicles connect the vacuum connector (3) and electrical connector
(1) to the diesel vacuum valve (2).

Jeep Workshop Manuals > Starting and Charging > Charging System > Alternator > Component Information > Locations
Alternator: Locations
Component ID: 100
Component : GENERATOR
Connector:
Name : GENERATOR
Color : BLACK
# of pins : 2
1 CHARGE INDICATOR SIGNAL G329 20VT/OR
2 GEN OUTPUT SIGNAL K92 20BR/YL
Jeep Workshop Manuals > Starting and Charging > Charging System > Alternator > Component Information > Locations >
Page 6160
Page 6161
Connector:
Name : GENERATOR
Color : BLACK
# of pins : 2
Qualifier : (GAS)
Page 6162
Page 6163
Connector:
Name : GENERATOR-EYELET
Color : # of pins :
1 B(+) A801 4RD/GY
1 B(+) A801 6RD/GY

Page 6164
Page 6165
Jeep Workshop Manuals > Starting and Charging > Charging System > Alternator > Component Information > Diagrams >
Alternator: Diagram Information and Instructions
Warnings
WARNINGS - GENERAL
the battery.
characteristics.
to function only.
SYMBOLS
TERMINOLOGY
Circuit Functions
models.
Circuit Information
IDENTIFICATION
LOCATIONS
illustrations.
associated wiring.
Removal
REMOVAL

connector.
Installation
INSTALLATION

Removal
REMOVAL
Installation
INSTALLATION
the new diode.
from the elements.
Removal
REMOVAL
Installation
INSTALLATION
repaired.
half/component.
repair.
Wire Splicing
repair area.

Special Tools
WIRING/TERMINAL


Alternator: Diagnostic Aids
vehicle.

good continuity.

SEVERAL LOADS


feed and ground.
position
problem
Alternator: Connector Views
Component ID: 100
Component : GENERATOR
Connector:
Name : GENERATOR
Color : BLACK
# of pins : 2
1 CHARGE INDICATOR SIGNAL G329 20VT/OR
2 GEN OUTPUT SIGNAL K92 20BR/YL
Connector:
Name : GENERATOR
Color : BLACK
# of pins : 2
Qualifier : (GAS)
Connector:
Name : GENERATOR-EYELET
Color : # of pins :
1 B(+) A801 4RD/GY
1 B(+) A801 6RD/GY

Jeep Workshop Manuals > Starting and Charging > Charging System > Alternator > Component Information > Description
Alternator: Description and Operation Description
DESCRIPTION
The generator is belt-driven by the engine. It is serviced only as a complete assembly. If the
generator fails for any reason, the entire assembly must be replaced. The generator produces DC
voltage.
Jeep Workshop Manuals > Starting and Charging > Charging System > Alternator > Component Information > Description
Alternator: Description and Operation Operation
OPERATION
As the energized rotor begins to rotate within the generator, the spinning magnetic field induces a
current into the windings of the stator coil.
The Y type stator winding connections deliver the induced AC current to 3 positive and 3 negative
diodes for rectification. From the diodes, rectified DC current is delivered to the vehicles electrical
system through the generator, battery, and ground terminals.
Noise emitting from the generator may be caused by:
- Worn, loose or defective bearings
- Loose or defective drive pulley
- Incorrect, worn, damaged or misadjusted drive belt
- Loose mounting bolts
- Misaligned drive pulley
- Defective stator or diode
- Damaged internal fine.

Jeep Workshop Manuals > Starting and Charging > Charging System > Alternator > Component Information > Service and
Repair > Removal
Alternator: Service and Repair Removal
2.0/2.4L
4. Remove the underbody air dam.
5. Remove the accessory drive splash shield.

6. Remove the accessory drive idler pulley.
7. Loosen the lower mounting bolt.

8. Loosen the A/C compressor and relocate, pull down and to outboard side of vehicle to make
room to remove generator.
9. Unplug field circuit from generator.

ERROR: undefined
OFFENDING COMMAND: f‘~
STACK:
Alternator: Service and Repair Installation
2.0/2.4L
1. Move A/C compressor to the side to install generator.
2. Rotate generator and set in place.

Make sure battery terminal (1) is in front of A/C line (2).
3. Loose install lower mounting bolt.

4. Loose install upper mounting bolt.
5. Tighten bolts to GAS 54 Nm (40 ft. lbs.) DIESEL 26 Nm (19 ft. lbs.).
6. Install the B+ terminal nut and wire and tighten to GAS & DIESEL 10 Nm (88.5 in. lbs.).
7. Plug in the field circuit to the generator.
8. Install idler pulley and tighten bolt.
9. Install the accessory drive belt.
10. Install splash shield.

11. Install lower air dam.
12. Lower vehicle.

Jeep Workshop Manuals > Starting and Charging > Starting System > Ignition Switch > Ignition Switch Lock Cylinder >
Component Information > Service and Repair > Key/Lock Cylinder
Removal
REMOVAL
(2).
Component Information > Service and Repair > Key/Lock Cylinder > Page 6212

housing.
Installation
INSTALLATION
the RUN position.
clear tilt lever.
properly.
cylinder housing.
it.

Removal
REMOVAL
(2).
column.
housing.
Installation
INSTALLATION

clear tilt lever.
properly.
cylinder housing.
Jeep Workshop Manuals > Starting and Charging > Starting System > Keyless Starting System > System Information >
Technical Service Bulletins > All Technical Service Bulletins for Keyless Starting System: > 08-018-07 > Jun > 07 > Remote
Start System - RKE Inop/Alarm Sounds
Keyless Starting System: All Technical Service Bulletins Remote Start System - RKE Inop/Alarm
Sounds
NUMBER: 08-018-07
GROUP: Electrical
DATE: June 23, 2007
SUBJECT: Mopar Remote Start System - RKE - Intermittent Operation Or Alarm May Sound
OVERVIEW: This bulletin involves the installation of a Mopar Remote Start System - Service
Repair Kit.
MODELS:
2007 (DR/DH/D1/DC) Ram Truck (1500/2500/3500)
2007 (HB/HG) Durango/Aspen
2007 (JK) Wrangler
2007 (JS) Sebring
2007 (KA) Nitro
2007 (MK49) Compass
2007 (MK74) Patriot
2007 (PM) Caliber
NOTE:
This bulletin applies to vehicles installed with a Mopar Remote Start Installation Kit.
SYMPTOM/CONDITION: On vehicles that have had a Mopar Remote Start installation Kit installed
by a dealer, the customer may experience one or more of the following conditions:
A). ON ALL VEHICLES:
An intermittent operation of the Remote Keyless Entry (RKE) system. At times, the RKE system
may not function as designed. This may include intermittent operation of: lock/unlock mode, remote
start mode, or panic mode. The vehicle may be operated manually without issue using the ignition
key to open or lock the door, and to start the vehicle.
B). ON RAM TRUCK AND DURANGO/ASPEN VEHICLES ONLY:
The vehicle alarm may sound when the RKE system is activated by use of the key FOB.
Deactivation of the vehicle alarm occurs when the vehicle engine is started using the ignition switch
and key.
Start System - RKE Inop/Alarm Sounds > Page 6231
The above condition(s) may be present ONLY if one of the following specific kit part numbers for
the Mopar Remote Start Installation Kit had been installed previously on the suspect vehicle.
DIAGNOSIS: If the customer has experienced the above condition, and the vehicle has had a
Mopar Remote Start Installation Kit installed, then perform the Repair Procedure.
PARTS REQUIRED:
REPAIR PROCEDURE:
Install the Remote Start Service Repair Kit. Refer to the detailed instructions included with the
repair kit.
TIME ALLOWANCE:
FAILURE CODE:
Disclaimer:
Starting System - RKE, Int. Operation/Alarm
Keyless Starting System: All Technical Service Bulletins Remote Starting System - RKE, Int.
Operation/Alarm
NUMBER: 18-018-07
GROUP: Electrical
DATE: June 23, 2007
Repair Kit.
MODELS:
2007 (JK) Wrangler
2007 (JS) Sebring
2007 (KA) Nitro
2007 (MK49) Compass
2007 (MK74) Patriot
2007 (PM) Caliber
NOTE:
SYMPTOM/CONDITION:
On vehicles that have had a Mopar Remote Start installation Kit installed by a dealer, the customer
may experience one or more of the following conditions:
and key.
Starting System - RKE, Int. Operation/Alarm > Page 6236
PARTS REQUIRED:
REPAIR PROCEDURE:
repair kit.
TIME ALLOWANCE:
FAILURE CODE:
Disclaimer:
Technical Service Bulletins > Customer Interest for Keyless Starting System: > 08-018-07 > Jun > 07 > Remote Start
System - RKE Inop/Alarm Sounds
Keyless Starting System: Customer Interest Remote Start System - RKE Inop/Alarm Sounds
NUMBER: 08-018-07
GROUP: Electrical
DATE: June 23, 2007
Repair Kit.
MODELS:
2007 (JK) Wrangler
2007 (JS) Sebring
2007 (KA) Nitro
2007 (MK49) Compass
2007 (MK74) Patriot
2007 (PM) Caliber
NOTE:
and key.
Technical Service Bulletins > Customer Interest for Keyless Starting System: > 08-018-07 > Jun > 07 > Remote Start
System - RKE Inop/Alarm Sounds > Page 6242
PARTS REQUIRED:
REPAIR PROCEDURE:
repair kit.
TIME ALLOWANCE:
FAILURE CODE:
Disclaimer:
Technical Service Bulletins > Customer Interest for Keyless Starting System: > 18-018-07 > Jun > 07 > Remote Starting
System - RKE, Int. Operation/Alarm
Keyless Starting System: Customer Interest Remote Starting System - RKE, Int. Operation/Alarm
NUMBER: 18-018-07
GROUP: Electrical
DATE: June 23, 2007
Repair Kit.
MODELS:
2007 (JK) Wrangler
2007 (JS) Sebring
2007 (KA) Nitro
2007 (MK49) Compass
2007 (MK74) Patriot
2007 (PM) Caliber
NOTE:
SYMPTOM/CONDITION:
and key.
Technical Service Bulletins > Customer Interest for Keyless Starting System: > 18-018-07 > Jun > 07 > Remote Starting
System - RKE, Int. Operation/Alarm > Page 6247
PARTS REQUIRED:
REPAIR PROCEDURE:
repair kit.
TIME ALLOWANCE:
FAILURE CODE:
Disclaimer:
Technical Service Bulletins > Customer Interest for Keyless Starting System: > Page 6248
Keyless Starting System: By Symptom
Technical Service Bulletin # 18-018-07 Date: 070623
Remote Starting System - RKE, Int. Operation/Alarm
NUMBER: 18-018-07
GROUP: Electrical
DATE: June 23, 2007
Repair Kit.
MODELS:
2007 (JK) Wrangler
2007 (JS) Sebring
2007 (KA) Nitro
2007 (MK49) Compass
2007 (MK74) Patriot
2007 (PM) Caliber
NOTE:
SYMPTOM/CONDITION:
and key.
PARTS REQUIRED:
REPAIR PROCEDURE:
repair kit.
TIME ALLOWANCE:
FAILURE CODE:
Disclaimer:
Technical Service Bulletin # 08-018-07 Date:
070623
Remote Start System - RKE Inop/Alarm Sounds
NUMBER: 08-018-07
GROUP: Electrical
DATE: June 23, 2007
Repair Kit.
MODELS:
2007 (JK) Wrangler
2007 (JS) Sebring
2007 (KA) Nitro
2007 (MK49) Compass
2007 (MK74) Patriot
2007 (PM) Caliber
NOTE:
and key.
PARTS REQUIRED:
REPAIR PROCEDURE:
repair kit.
TIME ALLOWANCE:
FAILURE CODE:
Disclaimer:
070623
NUMBER: 18-018-07
GROUP: Electrical
DATE: June 23, 2007
Repair Kit.
MODELS:
2007 (JK) Wrangler
2007 (JS) Sebring
2007 (KA) Nitro
2007 (MK49) Compass
2007 (MK74) Patriot
2007 (PM) Caliber
NOTE:
SYMPTOM/CONDITION:
and key.
PARTS REQUIRED:
REPAIR PROCEDURE:
repair kit.
TIME ALLOWANCE:
FAILURE CODE:
Disclaimer:
070623
NUMBER: 08-018-07
GROUP: Electrical
DATE: June 23, 2007
Repair Kit.
MODELS:
2007 (JK) Wrangler
2007 (JS) Sebring
2007 (KA) Nitro
2007 (MK49) Compass
2007 (MK74) Patriot
2007 (PM) Caliber
NOTE:
and key.
PARTS REQUIRED:
REPAIR PROCEDURE:
repair kit.
TIME ALLOWANCE:
FAILURE CODE:
Disclaimer:
070623
NUMBER: 18-018-07
GROUP: Electrical
DATE: June 23, 2007
Repair Kit.
MODELS:
2007 (JK) Wrangler
2007 (JS) Sebring
2007 (KA) Nitro
2007 (MK49) Compass
2007 (MK74) Patriot
2007 (PM) Caliber
NOTE:
SYMPTOM/CONDITION:
and key.
PARTS REQUIRED:
REPAIR PROCEDURE:
repair kit.
TIME ALLOWANCE:
FAILURE CODE:
Disclaimer:
070623
NUMBER: 08-018-07
GROUP: Electrical
DATE: June 23, 2007
Repair Kit.
MODELS:
2007 (JK) Wrangler
2007 (JS) Sebring
2007 (KA) Nitro
2007 (MK49) Compass
2007 (MK74) Patriot
2007 (PM) Caliber
NOTE:
and key.
PARTS REQUIRED:
REPAIR PROCEDURE:
repair kit.
TIME ALLOWANCE:
FAILURE CODE:
Disclaimer:
Jeep Workshop Manuals > Starting and Charging > Starting System > Neutral Safety Switch > Component Information >
Locations
Component ID: 348
Connector:
Color : BLACK
# of pins : 3
Qualifier : (MTX)
Component ID: 348
Connector:
Color : BLACK
# of pins : 3
Qualifier : (MTX)
Jeep Workshop Manuals > Starting and Charging > Starting System > Starter Motor > Component Information > Locations
Starter Motor: Locations
Component ID: 345
Component : STARTER
Connector:
Name : STARTER
Color : BLACK
# of pins : 1
> Page 6271
> Page 6272
> Page 6273
Connector:
Name : STARTER-EYELET-BATTERY SIDE
Color : # of pins :
1 B(+) A0 4RD
> Page 6274
> Page 6275
> Page 6276
Connector:
Name : STARTER-EYELET-GENERATOR SIDE
Color : # of pins :
1 B(+) A802 8LB
1 B(+) A802 10DG

> Page 6277
> Page 6278
> Page 6279
> Page 6280
Starter Motor: Diagrams
Component ID: 345
Component : STARTER
Connector:
Name : STARTER
Color : BLACK
# of pins : 1
> Page 6281
> Page 6282
> Page 6283
Connector:
Name : STARTER-EYELET-BATTERY SIDE
Color : # of pins :
1 B(+) A0 4RD
> Page 6284
> Page 6285
> Page 6286
Connector:
Name : STARTER-EYELET-GENERATOR SIDE
Color : # of pins :
1 B(+) A802 8LB
1 B(+) A802 10DG

> Page 6287
> Page 6288
> Page 6289
Jeep Workshop Manuals > Starting and Charging > Starting System > Starter Motor > Component Information > Service
Starter Motor: Service and Repair Removal
2.0/2.4L
1. Open hood.
2. Remove air cleaner box and air tube.
3. Disconnect and isolate the battery negative cable
4. Remove starter motor mounting bolt.
5. Disconnect the electrical connector at throttle body.

6. Remove Throttle body bolts and remove throttle body.
7. Push starter under intake manifold.
8. Tip starter nose toward cooling module.
9. Pull starter up and out.

10. Disconnect starter motor wiring.
11. Remove starter motor from vehicle.

Starter Motor: Service and Repair Installation
2.0/2.4L
1. Connect starter motor wiring. Tighten battery cable nut to 10 Nm (90 in. lbs.).
2. Reinstall starter motor into vehicle lower engine compartment.

3. Loose install starter into position.
4. Install throttle body
5. Install throttle body bracket.

6. Install starter motor mounting bolts and tighten to 54 Nm (40 ft. lbs.).
7. Connect throttle body electrical connector.
8. Install air cleaner box and inlet tube.
9. Lower vehicle.
10. Connect battery negative cable.

Jeep Workshop Manuals > Starting and Charging > Power and Ground Distribution > Auxiliary Power Outlet > Component
Information > Locations > Power Outlet-AC
Auxiliary Power Outlet: Locations Power Outlet-AC
Component ID: 179
Component : POWER OUTLET-AC
Connector:
Name : POWER OUTLET-AC
Color : ORANGE
# of pins : 6
1 INVERTER ENABLE SWITCH SIGNAL P805 18LG/LB
2--
5--

Information > Locations > Power Outlet-AC > Page 6302
Auxiliary Power Outlet: Locations Power Outlet-Instrument Panel
Component ID: 180
Component : POWER OUTLET-INSTRUMENT PANEL
Connector:
Name : POWER OUTLET-INSTRUMENT PANEL
Color : GRAY
# of pins : 3
2--
Information > Diagrams > Diagram Information and Instructions
Auxiliary Power Outlet: Diagram Information and Instructions
Warnings
WARNINGS - GENERAL
the battery.
characteristics.
to function only.
SYMBOLS
TERMINOLOGY
Circuit Functions
models.
Circuit Information
IDENTIFICATION
LOCATIONS
illustrations.
associated wiring.
Removal
REMOVAL

connector.
Installation
INSTALLATION

Removal
REMOVAL
Installation
INSTALLATION
the new diode.
from the elements.
Removal
REMOVAL
Installation
INSTALLATION
repaired.
half/component.
repair.
Wire Splicing
repair area.

Special Tools
WIRING/TERMINAL


Auxiliary Power Outlet: Diagnostic Aids
vehicle.

good continuity.

SEVERAL LOADS


feed and ground.
position
problem
Auxiliary Power Outlet: Connector Views
Power Outlet-AC
Component ID: 179
Connector:
Color : ORANGE
# of pins : 6
2--
5--
Power Outlet-Instrument Panel
Component ID: 180
Connector:
Color : GRAY
# of pins : 3

2--
Auxiliary Power Outlet: Electrical Diagrams
8w-41-02
8w-41-03
Auxiliary Power Outlet: Description and Operation Description
DESCRIPTION
INSTRUMENT PANEL MOUNTED
An instrument panel mounted cigar lighter/power outlet receptacle is optional equipment on this
model. On models equipped with the optional Smoker's Package, the cigar lighter knob and
heating element are included. On models without the Smoker's Package, the cigar lighter
receptacle is equipped with a snap fit plastic cap and is treated as an auxiliary power outlet. The
cigar lighter receptacle is installed in the instrument panel accessory switch bezel, which is located
near the bottom of the instrument panel center stack area, below the radio. The cigar lighter base is
secured by a snap fit within the center lower bezel. This power outlet has a constant 12 volt battery
feed.
The cigar lighter receptacle is serviced with the accessory switch bezel and if defective, the entire
switch bezel must be replaced. The plastic cap and the knob and heating element unit are available
for service replacement. These components cannot be repaired and, if faulty or damaged, they
must be replaced.
FRONT CONSOLE AND REAR CARGO MOUNTED
A front console mounted power outlet is standard equipment and a rear cargo area power outlet is
optional equipment on this model. The front console mounted power outlet is mounted near the
front of the console just in front of the cup holders. This outlet can be used as a cigar lighter or
power outlet, but only has 12 volt battery voltage when the ignition is in the ON or ACC positions.
The rear power outlet is installed in the right rear quarter trim panel, near the spare tire jack. The
power outlet base and mount are secured by a snap fit within the quarter trim panel. A plastic
protective cap snaps into the power outlet base when the power outlet is not being used, and
hangs from the power outlet base mount by an integral bail strap while the power outlet is in use.
While the power outlet is very similar to a cigar lighter base unit, it does not include the two small
spring-clip retainers inside the bottom of the receptacle shell that are used to secure the cigar
lighter heating element to the insulated contact. It has 12 volt battery voltage when the ignition is in
the ON or ACC positions.
Auxiliary Power Outlet: Description and Operation Operation
OPERATION
CIGAR LIGHTER/POWER OUTLET
The cigar lighter consists of two major components: a knob and heating element unit, and the cigar
lighter base or receptacle shell. The receptacle shell is connected to ground, and an insulated
contact in the bottom of the shell is connected to battery current.
The cigar lighter knob and heating element are encased within a spring-loaded housing, which also
features a sliding protective heat shield. When the knob and heating element are inserted in the
receptacle shell, the heating element resistor coil is grounded through its housing to the receptacle
shell. If the cigar lighter knob is pushed inward, the heat shield slides up toward the knob exposing
the heating element, and the heating element extends from the housing toward the insulated
contact in the bottom of the receptacle shell.
Two small spring-clip retainers are located on either side of the insulated contact inside the bottom
of the receptacle shell. These clips engage and hold the heating element against the insulated
contact long enough for the resistor coil to heat up. When the heating element is engaged with the
contact, battery current can flow through the resistor coil to ground, causing the resistor coil to
heat.
When the resistor coil becomes sufficiently heated, excess heat radiates from the heating element
causing the spring-clips to expand. Once the spring-clips expand far enough to release the heating
element, the spring-loaded housing forces the knob and heating element to pop back outward to
their relaxed position. When the cigar lighter knob and element are pulled out of the receptacle
shell, the protective heat shield slides downward on the housing so that the heating element is
recessed and shielded around its circumference for safety.
POWER OUTLET
The power outlet base or receptacle shell is connected to ground, and an insulated contact in the
bottom of the shell is connected to battery current. The power outlet receives battery voltage from a
fuse in the Totally Integrated Power Module (TIPM) through a fuse in the fuse block when the
ignition is in the ON or ACC positions.
Information > Service and Repair > Cigar Lighter/Power Outlet
Auxiliary Power Outlet: Service and Repair Cigar Lighter/Power Outlet
Removal
REMOVAL
2. Look inside and note position of the retaining bosses (1).
3. Using special tool 9857 Power Outlet Remover. Insert the tool forcing the bosses out of base.
4. Pull out the base through mounting ring by gently rocking the tool (3).
5. Disconnect the base wires.
6. Set base aside and remove base mount ring.
Installation
INSTALLATION
1. Position mount ring to the instrument panel and feed the wires through ring. Index the cap and
the mount ring with the index tab at 9 o'clock to the
key in the instrument panel. Install the ring.
2. Connect wires to base. Orient base alignment rib at 11 o'clock to mate the groove in mount ring
at the same location.
3. Push base into the bezel till it locks.

4. Install cigar lighter cap.

Information > Service and Repair > Cigar Lighter/Power Outlet > Page 6334
Auxiliary Power Outlet: Service and Repair Power Outlet-AC
Removal
REMOVAL
2. Remove the center console.
4. Remove AC power outlet.
Installation
INSTALLATION
1. Install the AC power outlet.
3. Install the center console.

Jeep Workshop Manuals > Starting and Charging > Power and Ground Distribution > Electrical Accessory Panel >
Electrical Accessory Panel: Description and Operation Description
DESCRIPTION
Electrical Accessory Panel: Description and Operation Operation
OPERATION
Electrical Accessory Panel: Service and Repair Removal
REMOVAL
1. Open hood.
bracket.

Electrical Accessory Panel: Service and Repair Installation
INSTALLATION
seated.
9 - 11 Nm (80 - 100 in. lbs.).
6. Close hood.
Jeep Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse > Component Information >
Technical Service Bulletins > Customer Interest for Fuse: > 08-016-06A > Jul > 06 > Electrical Systems - Intermittent
Component Operation
GROUP: Electrical
DATE: July 18, 2006

STYLE.
MODELS:
2007 (PM) Caliber
**2007 (MK-49) Compass**
DISCUSSION:
NOTE:
Technical Service Bulletins > Customer Interest for Fuse: > 08-016-06A > Jul > 06 > Electrical Systems - Intermittent
Component Operation > Page 6351
Disclaimer:
Technical Service Bulletins > All Technical Service Bulletins for Fuse: > 08-016-06A > Jul > 06 > Electrical Systems -
Intermittent Component Operation
GROUP: Electrical
DATE: July 18, 2006

STYLE.
MODELS:
2007 (PM) Caliber
**2007 (MK-49) Compass**
DISCUSSION:
NOTE:
Technical Service Bulletins > All Technical Service Bulletins for Fuse: > 08-016-06A > Jul > 06 > Electrical Systems -
Intermittent Component Operation > Page 6357
Disclaimer:
Locations > Fuse/Relay Block
Fuse/Relay Block

Locations > Fuse/Relay Block > Page 6360

Diagrams > Diagram Information and Instructions
Warnings
WARNINGS - GENERAL
the battery.
characteristics.
to function only.
Diagrams > Diagram Information and Instructions > Page 6363
SYMBOLS
TERMINOLOGY
Circuit Functions
models.
Circuit Information
IDENTIFICATION
LOCATIONS
illustrations.
associated wiring.
Removal
REMOVAL

connector.
Installation
INSTALLATION

Removal
REMOVAL
Installation
INSTALLATION
the new diode.
from the elements.
Removal
REMOVAL
Installation
INSTALLATION
repaired.
half/component.
repair.
Wire Splicing
repair area.

Special Tools
WIRING/TERMINAL


vehicle.

good continuity.

SEVERAL LOADS


feed and ground.
position
problem
Application and ID > Fuse/Relay Block

Application and ID > Fuse/Relay Block > Page 6382
Jeep Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse Block > Component Information
> Locations > Fuse/Relay Block
Fuse/Relay Block

> Locations > Fuse/Relay Block > Page 6387

> Diagrams > Diagram Information and Instructions
Warnings
WARNINGS - GENERAL
the battery.
characteristics.
to function only.
> Diagrams > Diagram Information and Instructions > Page 6390
SYMBOLS
TERMINOLOGY
Circuit Functions
models.
Circuit Information
IDENTIFICATION
LOCATIONS
illustrations.
associated wiring.
Removal
REMOVAL

connector.
Installation
INSTALLATION

Removal
REMOVAL
Installation
INSTALLATION
the new diode.
from the elements.
Removal
REMOVAL
Installation
INSTALLATION
repaired.
half/component.
repair.
Wire Splicing
repair area.

Special Tools
WIRING/TERMINAL


vehicle.

good continuity.

SEVERAL LOADS


feed and ground.
position
problem
> Application and ID > Fuse/Relay Block

> Application and ID > Fuse/Relay Block > Page 6409
> Description and Operation > Description
DESCRIPTION
> Description and Operation > Description > Page 6412
OPERATION
REMOVAL


INSTALLATION

fully seated.

Jeep Workshop Manuals > Starting and Charging > Power and Ground Distribution > Power Distribution Module >
Component Information > Technical Service Bulletins > Recalls: > G42 > Jan > 08 > Campaign - TIPM Software Update for
Antitheft System
January 2008
Anti-Theft System
Models
Markets Only)
NOTE:
July 23, 2007 (MDH 0723XX).
IMPORTANT:
IMPORTANT:

Subject
Repair
Special Tools
Antitheft System > Page 6424
Service Procedure
NOTE:

NOTE:
drop.

Antitheft System > Page 6425
e. Press "Start".
NOTE:
h. Select "Next".
NOTE:
Component Information > Technical Service Bulletins > Recalls: > G19 > Jun > 07 > Recall - Daytime Running Lamp
Reconfiguration
Revised G19
2007-05-15
NOTE:
CANADIAN RECALLS
IMPORTANT:
Vehicle List
Involved Dealers
vehicles.
Criteria
NOTE:
satisfaction.
Reconfiguration > Page 6430
needed.
Update
NOTE:
GRS.
PARTS INFORMATION
SPECIAL TOOLS
REIMBURSEMENT
DealerCONNECT.
Service Procedure
NOTE:
performed.
A. Program the TIPM
8. Select "MISC".
10. Press "START"
11. Press "Next".
13. Press "Next".
15. Press "Next".
17. Press "OK".
19. Press "OK".
21. Press "Next".
22. Press "Finish".
Component Information > Technical Service Bulletins > Customer Interest: > 08-007-08A > Jul > 08 > Antitheft System -
Engine No Crank/No Start Condition
Condition
GROUP: Electrical
DATE: July 04,2008

SKREEM
MODELS:
2007 - 2008 (KA) Nitro
2007 - 2008 (PM) Caliber
NOTE:
DIAGNOSIS:
run.
Engine No Crank/No Start Condition > Page 6439
PARTS REQUIRED:
NOTE:
REPAIR PROCEDURE:
NOTE:
NOTE:
being removed.
NOTE:
with new units.
NOTE:
NOTE:
g. Press "Start".
h. Press "Next".
k. Select "Next".
m. Select "Next".
(TPM) and so on.

CAUTION:
e. Press "Start".
TIME ALLOWANCE:
FAILURE CODE:
Disclaimer:
Component Information > Technical Service Bulletins > All Technical Service Bulletins for Power Distribution Module: >
08-007-08A > Jul > 08 > Antitheft System - Engine No Crank/No Start Condition
Start Condition
GROUP: Electrical
DATE: July 04,2008

SKREEM
MODELS:
2007 - 2008 (KA) Nitro
2007 - 2008 (PM) Caliber
NOTE:
DIAGNOSIS:
run.
08-007-08A > Jul > 08 > Antitheft System - Engine No Crank/No Start Condition > Page 6448
PARTS REQUIRED:
NOTE:
REPAIR PROCEDURE:
NOTE:
NOTE:
being removed.
NOTE:
with new units.
NOTE:
NOTE:
g. Press "Start".
h. Press "Next".
k. Select "Next".
m. Select "Next".
(TPM) and so on.

CAUTION:
e. Press "Start".
TIME ALLOWANCE:
FAILURE CODE:
Disclaimer:
Component Information > Technical Service Bulletins > All Technical Service Bulletins for Power Distribution Module: > G42
> Jan > 08 > Campaign - TIPM Software Update for Antitheft System
January 2008
Anti-Theft System
Models
Markets Only)
NOTE:
July 23, 2007 (MDH 0723XX).
IMPORTANT:
IMPORTANT:

Subject
Repair
Special Tools
> Jan > 08 > Campaign - TIPM Software Update for Antitheft System > Page 6456
Service Procedure
NOTE:

NOTE:
drop.

> Jan > 08 > Campaign - TIPM Software Update for Antitheft System > Page 6457
e. Press "Start".
NOTE:
h. Select "Next".
NOTE:
> Jun > 07 > Recall - Daytime Running Lamp Reconfiguration
Revised G19
2007-05-15
NOTE:
CANADIAN RECALLS
IMPORTANT:
Vehicle List
Involved Dealers
vehicles.
Criteria
NOTE:
satisfaction.
> Jun > 07 > Recall - Daytime Running Lamp Reconfiguration > Page 6462
needed.
Update
NOTE:
GRS.
PARTS INFORMATION
SPECIAL TOOLS
REIMBURSEMENT
DealerCONNECT.
Service Procedure
NOTE:
performed.
A. Program the TIPM
8. Select "MISC".
10. Press "START"
11. Press "Next".
13. Press "Next".
15. Press "Next".
17. Press "OK".
19. Press "OK".
21. Press "Next".
22. Press "Finish".
Component Information > Technical Service Bulletins > All Other Service Bulletins for Power Distribution Module: >
08-007-08A > Jul > 08 > Antitheft System - Engine No Crank/No Start Condition
Start Condition
GROUP: Electrical
DATE: July 04,2008

SKREEM
MODELS:
2007 - 2008 (KA) Nitro
2007 - 2008 (PM) Caliber
NOTE:
DIAGNOSIS:
run.
PARTS REQUIRED:
NOTE:
REPAIR PROCEDURE:
NOTE:
NOTE:
being removed.
NOTE:
with new units.
NOTE:
NOTE:
g. Press "Start".
h. Press "Next".
k. Select "Next".
m. Select "Next".
(TPM) and so on.

CAUTION:
e. Press "Start".
TIME ALLOWANCE:
FAILURE CODE:
Disclaimer:
Component Information > Technical Service Bulletins > All Other Service Bulletins for Power Distribution Module: > G42 >
Jan > 08 > Campaign - TIPM Software Update for Antitheft System
January 2008
Anti-Theft System
Models
Markets Only)
NOTE:
July 23, 2007 (MDH 0723XX).
IMPORTANT:
IMPORTANT:

Subject
Repair
Special Tools
Jan > 08 > Campaign - TIPM Software Update for Antitheft System > Page 6480
Service Procedure
NOTE:

NOTE:
drop.

e. Press "Start".
NOTE:
h. Select "Next".
NOTE:
Jun > 07 > Recall - Daytime Running Lamp Reconfiguration
Revised G19
2007-05-15
NOTE:
CANADIAN RECALLS
IMPORTANT:
Vehicle List
Involved Dealers
vehicles.
Criteria
NOTE:
satisfaction.
Jun > 07 > Recall - Daytime Running Lamp Reconfiguration > Page 6486
needed.
Update
NOTE:
GRS.
PARTS INFORMATION
SPECIAL TOOLS
REIMBURSEMENT
DealerCONNECT.
Service Procedure
NOTE:
performed.
A. Program the TIPM
8. Select "MISC".
10. Press "START"
11. Press "Next".
13. Press "Next".
15. Press "Next".
17. Press "OK".
19. Press "OK".
21. Press "Next".
22. Press "Finish".
Component Information > Locations > Module-Inverter
Component ID: 162
Connector:
Color : # of pins :
2--
6--
7--
9--
Component Information > Locations > Module-Inverter > Page 6492

Component Information > Diagrams > Module-Totally Integrated Power
Component ID: 168
Connector:
Color : BLACK
# of pins : 13
4--
5--

8--
9--
10 - -
11 - -
Component Information > Diagrams > Module-Totally Integrated Power > Page 6497
Connector:
Color : LT. GRAY
# of pins : 8
1--
2--
4--

7--
Connector:
Color : GREEN
# of pins : 22
2--
3--

15 - -
16 - -
18 - -
20 - -
21 GROUND Z971 16BK
Connector:
Color : LT. GRAY
# of pins : 14
3--

8--
9--
12 - -

Connector:
Color : BROWN
# of pins : 16

5--
12 - -
14 - -
Connector:
Color : BLACK
# of pins : 10

5--
6--
7--
10 - -
Connector:
Color : BLUE
# of pins : 14

11 - -
Connector:
Color : LT. GRAY
# of pins : 13
1--
2--
3--
4--

6--
7--
8--
9--
10 - -
11 - -
13 - -
Connector:
Color : LT. GRAY
# of pins : 22
1--

8--
10 - -
12 - -
14 - -

20 - -
Connector:
Color : BLACK
# of pins : 22
5 FUSED B(+) (I.O.D.) A416 18RD

10 - -
15 - -
16 - -
Connector:
Color : # of pins :
1 B(+) A0 6RD
Component ID: 162
Connector:
Color : # of pins :
2--
6--
7--
9--
Component Information > Description and Operation > Totally Integrated Power Module
Description
DESCRIPTION
Operation
OPERATION
Component Information > Description and Operation > Totally Integrated Power Module > Page 6524
Description
DESCRIPTION
Operation
OPERATION
external devices.
Inverter Module
Component Information > Service and Repair > Totally Integrated Power Module
Removal
REMOVAL
1. Open hood.
bracket.
Installation
INSTALLATION
seated.
Component Information > Service and Repair > Totally Integrated Power Module > Page 6528
9 - 11 Nm (80 - 100 in. lbs.).
6. Close hood.
Removal
REMOVAL
Installation
INSTALLATION


Jeep Workshop Manuals > Starting and Charging > Power and Ground Distribution > Power Interrupt Connector/Switch >
Power Interrupt Connector/Switch: Description and Operation Description
DESCRIPTION
All vehicles are equipped with an Ignition-Off Draw (IOD) fuse that is disconnected within the
Totally Integrated Power Module (TIPM) when the vehicle is shipped from the factory. Dealer
personnel are to reconnect the IOD fuse in the TIPM as part of the preparation procedures
performed just prior to new vehicle delivery.
Power Interrupt Connector/Switch: Description and Operation Operation
OPERATION
The term ignition-off draw identifies a normal condition where power is being drained from the
battery with the ignition switch in the Off position. The IOD fuse feeds the memory and sleep mode
functions for some of the electronic modules in the vehicle as well as various other accessories that
require battery current when the ignition switch is in the Off position, including the clock. The only
reason the IOD fuse is disconnected is to reduce the normal IOD of the vehicle electrical system
during new vehicle transportation and pre-delivery storage to reduce battery depletion, while still
allowing vehicle operation so that the vehicle can be loaded, unloaded and moved as needed by
both vehicle transportation company and dealer personnel.
The IOD fuse is disconnected from Totally Integrated Power Module (TIPM) fuse cavities 7 and 8 in
a preset fuse holder. when the vehicle is shipped from the assembly plant. Dealer personnel must
reconnect the IOD fuse when the vehicle is being prepared for delivery in order to restore full
electrical system operation. Once the vehicle is prepared for delivery, the IOD function of this fuse
becomes transparent and the fuse that has been assigned the IOD designation becomes only
another Fused B(+) circuit fuse. The IOD fuse serves no useful purpose to the dealer technician in
the service or diagnosis of any vehicle system or condition, other than the same purpose as that of
any other standard circuit protection device.
The IOD fuse can be used by the vehicle owner as a convenient means of reducing battery
depletion when a vehicle is to be stored for periods not to exceed about thirty days. However, it
must be remembered that disconnecting the IOD fuse will not eliminate IOD, but only reduce this
normal condition. If a vehicle will be stored for more than about thirty days, the battery negative
cable should be disconnected to eliminate normal IOD; and, the battery should be tested and
recharged at regular intervals during the vehicle storage period to prevent the battery from
becoming discharged or damaged.
Power Interrupt Connector/Switch: Service and Repair Removal
REMOVAL
NOTE: When removing or installing the IOD fuse, it is important that the ignition switch be in the Off
position. Failure to place the ignition switch in the Off position can cause the radio display to
become scrambled when the IOD fuse is installed. Removing and installing the IOD fuse again with
the ignition switch in the Off position will usually correct the scrambled radio display condition.
1. Turn the ignition switch to the Off position.
2. Remove the cover from the Totally Integrated Power Module (TIPM).
3. Remove fuse 7/8 from the TIPM.

Power Interrupt Connector/Switch: Service and Repair Installation
INSTALLATION
CAUTION: It is extremely important that the Ignition Off Draw (IOD) fuses are fully seated into the
Totally Integrated Power Module (TIPM) fuse cavities. Failure to install the fuses correctly could
result in erratic electrical systems behavior.
1. Remove TIPM cover.
2. Insert fuse 7/8 into the TIPM. Push fuses down until they are fully seated in the TIPM cavities.
3. Install the cover to the TIPM.

Jeep Workshop Manuals > Starting and Charging > Power and Ground Distribution > Relays and Modules - Power and
Ground Distribution > Power Distribution Module > Component Information > Technical Service Bulletins > Recalls: > G42 >
Jan > 08 > Campaign - TIPM Software Update for Antitheft System
January 2008
Anti-Theft System
Models
Markets Only)
NOTE:
July 23, 2007 (MDH 0723XX).
IMPORTANT:
IMPORTANT:

Subject
Repair
Special Tools
Service Procedure
NOTE:

NOTE:
drop.

e. Press "Start".
NOTE:
h. Select "Next".
NOTE:
Jun > 07 > Recall - Daytime Running Lamp Reconfiguration
Revised G19
2007-05-15
NOTE:
CANADIAN RECALLS
IMPORTANT:
Vehicle List
Involved Dealers
vehicles.
Criteria
NOTE:
satisfaction.
needed.
Update
NOTE:
GRS.
PARTS INFORMATION
SPECIAL TOOLS
REIMBURSEMENT
DealerCONNECT.
Service Procedure
NOTE:
performed.
A. Program the TIPM
8. Select "MISC".
10. Press "START"
11. Press "Next".
13. Press "Next".
15. Press "Next".
17. Press "OK".
19. Press "OK".
21. Press "Next".
22. Press "Finish".
Ground Distribution > Power Distribution Module > Component Information > Technical Service Bulletins > Customer
Interest: > 08-007-08A > Jul > 08 > Antitheft System - Engine No Crank/No Start Condition
Condition
GROUP: Electrical
DATE: July 04,2008

SKREEM
MODELS:
2007 - 2008 (KA) Nitro
2007 - 2008 (PM) Caliber
NOTE:
DIAGNOSIS:
run.
Interest: > 08-007-08A > Jul > 08 > Antitheft System - Engine No Crank/No Start Condition > Page 6563
PARTS REQUIRED:
NOTE:
REPAIR PROCEDURE:
NOTE:
NOTE:
being removed.
NOTE:
with new units.
NOTE:
NOTE:
g. Press "Start".
h. Press "Next".
k. Select "Next".
m. Select "Next".
(TPM) and so on.

CAUTION:
e. Press "Start".
TIME ALLOWANCE:
FAILURE CODE:
Disclaimer:
Ground Distribution > Power Distribution Module > Component Information > Technical Service Bulletins > All Technical
Service Bulletins for Power Distribution Module: > 08-007-08A > Jul > 08 > Antitheft System - Engine No Crank/No Start
Condition
Start Condition
GROUP: Electrical
DATE: July 04,2008

SKREEM
MODELS:
2007 - 2008 (KA) Nitro
2007 - 2008 (PM) Caliber
NOTE:
DIAGNOSIS:
run.
Condition > Page 6572
PARTS REQUIRED:
NOTE:
REPAIR PROCEDURE:
NOTE:
NOTE:
being removed.
NOTE:
with new units.
NOTE:
NOTE:
g. Press "Start".
h. Press "Next".
k. Select "Next".
m. Select "Next".
(TPM) and so on.

CAUTION:
e. Press "Start".
TIME ALLOWANCE:
FAILURE CODE:
Disclaimer:
Service Bulletins for Power Distribution Module: > G42 > Jan > 08 > Campaign - TIPM Software Update for Antitheft System
January 2008
Anti-Theft System
Models
Markets Only)
NOTE:
July 23, 2007 (MDH 0723XX).
IMPORTANT:
IMPORTANT:

Subject
Repair
Special Tools
> Page 6580
Service Procedure
NOTE:

NOTE:
drop.

> Page 6581
e. Press "Start".
NOTE:
h. Select "Next".
NOTE:
Service Bulletins for Power Distribution Module: > G19 > Jun > 07 > Recall - Daytime Running Lamp Reconfiguration
Revised G19
2007-05-15
NOTE:
CANADIAN RECALLS
IMPORTANT:
Vehicle List
Involved Dealers
vehicles.
Criteria
NOTE:
satisfaction.
Service Bulletins for Power Distribution Module: > G19 > Jun > 07 > Recall - Daytime Running Lamp Reconfiguration >
Page 6586
needed.
Update
NOTE:
GRS.
PARTS INFORMATION
SPECIAL TOOLS
REIMBURSEMENT
DealerCONNECT.
Page 6587
Service Procedure
NOTE:
performed.
A. Program the TIPM
Page 6588
8. Select "MISC".
10. Press "START"
11. Press "Next".
13. Press "Next".
15. Press "Next".
17. Press "OK".
19. Press "OK".
21. Press "Next".
22. Press "Finish".
Page 6589
Ground Distribution > Power Distribution Module > Component Information > Technical Service Bulletins > All Other Service
Bulletins for Power Distribution Module: > 08-007-08A > Jul > 08 > Antitheft System - Engine No Crank/No Start Condition
Start Condition
GROUP: Electrical
DATE: July 04,2008

SKREEM
MODELS:
2007 - 2008 (KA) Nitro
2007 - 2008 (PM) Caliber
NOTE:
DIAGNOSIS:
run.
Bulletins for Power Distribution Module: > 08-007-08A > Jul > 08 > Antitheft System - Engine No Crank/No Start Condition >
Page 6595
PARTS REQUIRED:
NOTE:
Page 6596
REPAIR PROCEDURE:
NOTE:
NOTE:
being removed.
NOTE:
with new units.
NOTE:
NOTE:
g. Press "Start".
h. Press "Next".
k. Select "Next".
m. Select "Next".
(TPM) and so on.

Page 6597
CAUTION:
e. Press "Start".
TIME ALLOWANCE:
Page 6598
FAILURE CODE:
Disclaimer:
Bulletins for Power Distribution Module: > G42 > Jan > 08 > Campaign - TIPM Software Update for Antitheft System
January 2008
Anti-Theft System
Models
Markets Only)
NOTE:
July 23, 2007 (MDH 0723XX).
IMPORTANT:
IMPORTANT:

Subject
Repair
Special Tools
Bulletins for Power Distribution Module: > G42 > Jan > 08 > Campaign - TIPM Software Update for Antitheft System > Page
6604
Service Procedure
NOTE:

NOTE:
drop.

Bulletins for Power Distribution Module: > G42 > Jan > 08 > Campaign - TIPM Software Update for Antitheft System > Page
6605
e. Press "Start".
NOTE:
h. Select "Next".
NOTE:
Bulletins for Power Distribution Module: > G19 > Jun > 07 > Recall - Daytime Running Lamp Reconfiguration
Revised G19
2007-05-15
NOTE:
CANADIAN RECALLS
IMPORTANT:
Vehicle List
Involved Dealers
vehicles.
Criteria
NOTE:
satisfaction.
Bulletins for Power Distribution Module: > G19 > Jun > 07 > Recall - Daytime Running Lamp Reconfiguration > Page 6610
needed.
Update
NOTE:
GRS.
PARTS INFORMATION
SPECIAL TOOLS
REIMBURSEMENT
DealerCONNECT.
Service Procedure
NOTE:
performed.
A. Program the TIPM
8. Select "MISC".
10. Press "START"
11. Press "Next".
13. Press "Next".
15. Press "Next".
17. Press "OK".
19. Press "OK".
21. Press "Next".
22. Press "Finish".
Ground Distribution > Power Distribution Module > Component Information > Locations > Module-Inverter
Component ID: 162
Connector:
Color : # of pins :
2--
6--
7--
9--
Ground Distribution > Power Distribution Module > Component Information > Locations > Module-Inverter > Page 6616

Ground Distribution > Power Distribution Module > Component Information > Diagrams > Module-Totally Integrated Power
Component ID: 168
Connector:
Color : BLACK
# of pins : 13
4--
5--

8--
9--
10 - -
11 - -
Ground Distribution > Power Distribution Module > Component Information > Diagrams > Module-Totally Integrated Power >
Page 6621
Page 6622
Connector:
Color : LT. GRAY
# of pins : 8
1--
2--
4--

Page 6623
7--
Page 6624
Connector:
Color : GREEN
# of pins : 22
2--
Page 6625
3--

15 - -
16 - -
18 - -
20 - -
21 GROUND Z971 16BK
Page 6626
Connector:
Color : LT. GRAY
# of pins : 14
3--

Page 6627
8--
9--
12 - -

Page 6628
Connector:
Color : BROWN
# of pins : 16

Page 6629
5--
12 - -
14 - -
Page 6630
Connector:
Color : BLACK
# of pins : 10

Page 6631
5--
6--
7--
10 - -
Page 6632
Connector:
Color : BLUE
# of pins : 14

Page 6633
11 - -
Page 6634
Connector:
Color : LT. GRAY
# of pins : 13
1--
2--
3--
4--

Page 6635
6--
7--
8--
9--
10 - -
11 - -
13 - -
Page 6636
Connector:
Color : LT. GRAY
# of pins : 22
1--

Page 6637
8--
10 - -
12 - -
14 - -

20 - -
Page 6638
Connector:
Color : BLACK
# of pins : 22
5 FUSED B(+) (I.O.D.) A416 18RD

Page 6639
10 - -
15 - -
16 - -
Page 6640
Connector:
Color : # of pins :
1 B(+) A0 6RD
Page 6641
Page 6642
Page 6643
Component ID: 162
Connector:
Color : # of pins :
2--
6--
7--
9--
Page 6644
Page 6645
Ground Distribution > Power Distribution Module > Component Information > Description and Operation > Totally Integrated
Power Module
Description
DESCRIPTION
Operation
OPERATION
Ground Distribution > Power Distribution Module > Component Information > Description and Operation > Totally Integrated
Power Module > Page 6648
Description
DESCRIPTION
Operation
OPERATION
external devices.
Ground Distribution > Power Distribution Module > Component Information > Description and Operation > Page 6649
Inverter Module
Ground Distribution > Power Distribution Module > Component Information > Service and Repair > Totally Integrated Power
Module
Removal
REMOVAL
1. Open hood.
bracket.
Installation
INSTALLATION
seated.
Module > Page 6652
9 - 11 Nm (80 - 100 in. lbs.).
6. Close hood.
Module > Page 6653
Removal
REMOVAL
Installation
INSTALLATION

Module > Page 6654

Ground Distribution > Relay Box > Component Information > Locations > Fuse/Relay Block
Fuse/Relay Block

Ground Distribution > Relay Box > Component Information > Locations > Fuse/Relay Block > Page 6659

Ground Distribution > Relay Box > Component Information > Application and ID > Fuse/Relay Block

Ground Distribution > Relay Box > Component Information > Application and ID > Fuse/Relay Block > Page 6662
Jeep Workshop Manuals > Starting and Charging > Power and Ground Distribution > Relay Box > Component Information >
Locations > Fuse/Relay Block
Fuse/Relay Block

Locations > Fuse/Relay Block > Page 6667

Application and ID > Fuse/Relay Block

Application and ID > Fuse/Relay Block > Page 6670
Jeep Workshop Manuals > Starting and Charging > Power and Ground Distribution > Sensors and Switches - Power and
Ground Distribution > Power Interrupt Connector/Switch > Component Information > Description and Operation >
Description
DESCRIPTION
Ground Distribution > Power Interrupt Connector/Switch > Component Information > Description and Operation >
OPERATION
Ground Distribution > Power Interrupt Connector/Switch > Component Information > Service and Repair > Removal
REMOVAL

Ground Distribution > Power Interrupt Connector/Switch > Component Information > Service and Repair > Removal > Page
6679
INSTALLATION

Jeep Workshop Manuals > Power and Ground Distribution > Auxiliary Power Outlet > Component Information > Locations >
Power Outlet-AC
Auxiliary Power Outlet: Locations Power Outlet-AC
Component ID: 179
Connector:
Color : ORANGE
# of pins : 6
2--
5--

Power Outlet-AC > Page 6685
Auxiliary Power Outlet: Locations Power Outlet-Instrument Panel
Component ID: 180
Connector:
Color : GRAY
# of pins : 3
2--
Jeep Workshop Manuals > Power and Ground Distribution > Auxiliary Power Outlet > Component Information > Diagrams >
Auxiliary Power Outlet: Diagram Information and Instructions
Warnings
WARNINGS - GENERAL
the battery.
characteristics.
to function only.
SYMBOLS
TERMINOLOGY
Circuit Functions
models.
Circuit Information
IDENTIFICATION
LOCATIONS
illustrations.
associated wiring.
Removal
REMOVAL

connector.
Installation
INSTALLATION

Removal
REMOVAL
Installation
INSTALLATION
the new diode.
from the elements.
Removal
REMOVAL
Installation
INSTALLATION
repaired.
half/component.
repair.
Wire Splicing
repair area.

Special Tools
WIRING/TERMINAL


Auxiliary Power Outlet: Diagnostic Aids
vehicle.

good continuity.

SEVERAL LOADS


feed and ground.
position
problem
Auxiliary Power Outlet: Connector Views
Power Outlet-AC
Component ID: 179
Connector:
Color : ORANGE
# of pins : 6
2--
5--
Power Outlet-Instrument Panel
Component ID: 180
Connector:
Color : GRAY
# of pins : 3

2--
Auxiliary Power Outlet: Electrical Diagrams
8w-41-02
8w-41-03
Jeep Workshop Manuals > Power and Ground Distribution > Auxiliary Power Outlet > Component Information > Description
Auxiliary Power Outlet: Description and Operation Description
DESCRIPTION
INSTRUMENT PANEL MOUNTED
An instrument panel mounted cigar lighter/power outlet receptacle is optional equipment on this
model. On models equipped with the optional Smoker's Package, the cigar lighter knob and
heating element are included. On models without the Smoker's Package, the cigar lighter
receptacle is equipped with a snap fit plastic cap and is treated as an auxiliary power outlet. The
cigar lighter receptacle is installed in the instrument panel accessory switch bezel, which is located
near the bottom of the instrument panel center stack area, below the radio. The cigar lighter base is
secured by a snap fit within the center lower bezel. This power outlet has a constant 12 volt battery
feed.
The cigar lighter receptacle is serviced with the accessory switch bezel and if defective, the entire
switch bezel must be replaced. The plastic cap and the knob and heating element unit are available
for service replacement. These components cannot be repaired and, if faulty or damaged, they
must be replaced.
FRONT CONSOLE AND REAR CARGO MOUNTED
A front console mounted power outlet is standard equipment and a rear cargo area power outlet is
optional equipment on this model. The front console mounted power outlet is mounted near the
front of the console just in front of the cup holders. This outlet can be used as a cigar lighter or
power outlet, but only has 12 volt battery voltage when the ignition is in the ON or ACC positions.
The rear power outlet is installed in the right rear quarter trim panel, near the spare tire jack. The
power outlet base and mount are secured by a snap fit within the quarter trim panel. A plastic
protective cap snaps into the power outlet base when the power outlet is not being used, and
hangs from the power outlet base mount by an integral bail strap while the power outlet is in use.
While the power outlet is very similar to a cigar lighter base unit, it does not include the two small
spring-clip retainers inside the bottom of the receptacle shell that are used to secure the cigar
lighter heating element to the insulated contact. It has 12 volt battery voltage when the ignition is in
the ON or ACC positions.
Jeep Workshop Manuals > Power and Ground Distribution > Auxiliary Power Outlet > Component Information > Description
Auxiliary Power Outlet: Description and Operation Operation
OPERATION
CIGAR LIGHTER/POWER OUTLET
The cigar lighter consists of two major components: a knob and heating element unit, and the cigar
lighter base or receptacle shell. The receptacle shell is connected to ground, and an insulated
contact in the bottom of the shell is connected to battery current.
The cigar lighter knob and heating element are encased within a spring-loaded housing, which also
features a sliding protective heat shield. When the knob and heating element are inserted in the
receptacle shell, the heating element resistor coil is grounded through its housing to the receptacle
shell. If the cigar lighter knob is pushed inward, the heat shield slides up toward the knob exposing
the heating element, and the heating element extends from the housing toward the insulated
contact in the bottom of the receptacle shell.
Two small spring-clip retainers are located on either side of the insulated contact inside the bottom
of the receptacle shell. These clips engage and hold the heating element against the insulated
contact long enough for the resistor coil to heat up. When the heating element is engaged with the
contact, battery current can flow through the resistor coil to ground, causing the resistor coil to
heat.
When the resistor coil becomes sufficiently heated, excess heat radiates from the heating element
causing the spring-clips to expand. Once the spring-clips expand far enough to release the heating
element, the spring-loaded housing forces the knob and heating element to pop back outward to
their relaxed position. When the cigar lighter knob and element are pulled out of the receptacle
shell, the protective heat shield slides downward on the housing so that the heating element is
recessed and shielded around its circumference for safety.
POWER OUTLET
The power outlet base or receptacle shell is connected to ground, and an insulated contact in the
bottom of the shell is connected to battery current. The power outlet receives battery voltage from a
fuse in the Totally Integrated Power Module (TIPM) through a fuse in the fuse block when the
ignition is in the ON or ACC positions.
Jeep Workshop Manuals > Power and Ground Distribution > Auxiliary Power Outlet > Component Information > Service and
Repair > Cigar Lighter/Power Outlet
Auxiliary Power Outlet: Service and Repair Cigar Lighter/Power Outlet
Removal
REMOVAL
2. Look inside and note position of the retaining bosses (1).
3. Using special tool 9857 Power Outlet Remover. Insert the tool forcing the bosses out of base.
4. Pull out the base through mounting ring by gently rocking the tool (3).
5. Disconnect the base wires.
6. Set base aside and remove base mount ring.
Installation
INSTALLATION
1. Position mount ring to the instrument panel and feed the wires through ring. Index the cap and
the mount ring with the index tab at 9 o'clock to the
key in the instrument panel. Install the ring.
2. Connect wires to base. Orient base alignment rib at 11 o'clock to mate the groove in mount ring
at the same location.
3. Push base into the bezel till it locks.

4. Install cigar lighter cap.

Jeep Workshop Manuals > Power and Ground Distribution > Auxiliary Power Outlet > Component Information > Service and
Repair > Cigar Lighter/Power Outlet > Page 6717
Auxiliary Power Outlet: Service and Repair Power Outlet-AC
Removal
REMOVAL
2. Remove the center console.
4. Remove AC power outlet.
Installation
INSTALLATION
1. Install the AC power outlet.
3. Install the center console.

Jeep Workshop Manuals > Power and Ground Distribution > Electrical Accessory Panel > Component Information >
Electrical Accessory Panel: Description and Operation Description
DESCRIPTION
Jeep Workshop Manuals > Power and Ground Distribution > Electrical Accessory Panel > Component Information >
Electrical Accessory Panel: Description and Operation Operation
OPERATION
Jeep Workshop Manuals > Power and Ground Distribution > Electrical Accessory Panel > Component Information > Service
Electrical Accessory Panel: Service and Repair Removal
REMOVAL
1. Open hood.
bracket.

Jeep Workshop Manuals > Power and Ground Distribution > Electrical Accessory Panel > Component Information > Service
Electrical Accessory Panel: Service and Repair Installation
INSTALLATION
seated.
9 - 11 Nm (80 - 100 in. lbs.).
6. Close hood.
Jeep Workshop Manuals > Power and Ground Distribution > Fuse > Component Information > Technical Service Bulletins >
All Technical Service Bulletins for Fuse: > 08-016-06A > Jul > 06 > Electrical Systems - Intermittent Component Operation
GROUP: Electrical
DATE: July 18, 2006

STYLE.
MODELS:
2007 (PM) Caliber
**2007 (MK-49) Compass**
DISCUSSION:
NOTE:
All Technical Service Bulletins for Fuse: > 08-016-06A > Jul > 06 > Electrical Systems - Intermittent Component Operation >
Page 6734
Disclaimer:
Customer Interest for Fuse: > 08-016-06A > Jul > 06 > Electrical Systems - Intermittent Component Operation
GROUP: Electrical
DATE: July 18, 2006

STYLE.
MODELS:
2007 (PM) Caliber
**2007 (MK-49) Compass**
DISCUSSION:
NOTE:
Customer Interest for Fuse: > 08-016-06A > Jul > 06 > Electrical Systems - Intermittent Component Operation > Page 6740
Disclaimer:
Jeep Workshop Manuals > Power and Ground Distribution > Fuse > Component Information > Locations > Fuse/Relay
Block
Fuse/Relay Block

Jeep Workshop Manuals > Power and Ground Distribution > Fuse > Component Information > Locations > Fuse/Relay
Block > Page 6743

Jeep Workshop Manuals > Power and Ground Distribution > Fuse > Component Information > Diagrams > Diagram
Warnings
WARNINGS - GENERAL
the battery.
characteristics.
to function only.
SYMBOLS
TERMINOLOGY
Circuit Functions
models.
Circuit Information
IDENTIFICATION
LOCATIONS
illustrations.
associated wiring.
Removal
REMOVAL

connector.
Installation
INSTALLATION

Removal
REMOVAL
Installation
INSTALLATION
the new diode.
from the elements.
Removal
REMOVAL
Installation
INSTALLATION
repaired.
half/component.
repair.
Wire Splicing
repair area.

Special Tools
WIRING/TERMINAL


vehicle.

good continuity.

SEVERAL LOADS


feed and ground.
position
problem
Jeep Workshop Manuals > Power and Ground Distribution > Fuse > Component Information > Application and ID >
Fuse/Relay Block

Jeep Workshop Manuals > Power and Ground Distribution > Fuse > Component Information > Application and ID >
Jeep Workshop Manuals > Power and Ground Distribution > Fuse Block > Component Information > Locations >
Fuse/Relay Block
Fuse/Relay Block

Jeep Workshop Manuals > Power and Ground Distribution > Fuse Block > Component Information > Locations >

Jeep Workshop Manuals > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Diagram
Warnings
WARNINGS - GENERAL
the battery.
characteristics.
to function only.
SYMBOLS
TERMINOLOGY
Circuit Functions
models.
Circuit Information
IDENTIFICATION
LOCATIONS
illustrations.
associated wiring.
Removal
REMOVAL

connector.
Installation
INSTALLATION

Removal
REMOVAL
Installation
INSTALLATION
the new diode.
from the elements.
Removal
REMOVAL
Installation
INSTALLATION
repaired.
half/component.
repair.
Wire Splicing
repair area.

Special Tools
WIRING/TERMINAL


vehicle.

good continuity.

SEVERAL LOADS


feed and ground.
position
problem
Jeep Workshop Manuals > Power and Ground Distribution > Fuse Block > Component Information > Application and ID >
Fuse/Relay Block

Jeep Workshop Manuals > Power and Ground Distribution > Fuse Block > Component Information > Application and ID >
Jeep Workshop Manuals > Power and Ground Distribution > Fuse Block > Component Information > Description and
DESCRIPTION
Jeep Workshop Manuals > Power and Ground Distribution > Fuse Block > Component Information > Description and
OPERATION
Jeep Workshop Manuals > Power and Ground Distribution > Fuse Block > Component Information > Service and Repair >
Removal
REMOVAL


Jeep Workshop Manuals > Power and Ground Distribution > Fuse Block > Component Information > Service and Repair >
Removal > Page 6798
INSTALLATION

fully seated.

Jeep Workshop Manuals > Power and Ground Distribution > Power Distribution Module > Component Information >
Technical Service Bulletins > Recalls: > G42 > Jan > 08 > Campaign - TIPM Software Update for Antitheft System
January 2008
Anti-Theft System
Models
Markets Only)
NOTE:
July 23, 2007 (MDH 0723XX).
IMPORTANT:
IMPORTANT:

Subject
Repair
Special Tools
Technical Service Bulletins > Recalls: > G42 > Jan > 08 > Campaign - TIPM Software Update for Antitheft System > Page
6807
Service Procedure
NOTE:

NOTE:
drop.

Technical Service Bulletins > Recalls: > G42 > Jan > 08 > Campaign - TIPM Software Update for Antitheft System > Page
6808
e. Press "Start".
NOTE:
h. Select "Next".
NOTE:
Technical Service Bulletins > Recalls: > G19 > Jun > 07 > Recall - Daytime Running Lamp Reconfiguration
Revised G19
2007-05-15
NOTE:
CANADIAN RECALLS
IMPORTANT:
Vehicle List
Involved Dealers
vehicles.
Criteria
NOTE:
satisfaction.
Technical Service Bulletins > Recalls: > G19 > Jun > 07 > Recall - Daytime Running Lamp Reconfiguration > Page 6813
needed.
Update
NOTE:
GRS.
PARTS INFORMATION
SPECIAL TOOLS
REIMBURSEMENT
DealerCONNECT.
Service Procedure
NOTE:
performed.
A. Program the TIPM
8. Select "MISC".
10. Press "START"
11. Press "Next".
13. Press "Next".
15. Press "Next".
17. Press "OK".
19. Press "OK".
21. Press "Next".
22. Press "Finish".
Technical Service Bulletins > Customer Interest: > 08-007-08A > Jul > 08 > Antitheft System - Engine No Crank/No Start
Condition
Condition
GROUP: Electrical
DATE: July 04,2008

SKREEM
MODELS:
2007 - 2008 (KA) Nitro
2007 - 2008 (PM) Caliber
NOTE:
DIAGNOSIS:
run.
PARTS REQUIRED:
NOTE:
REPAIR PROCEDURE:
NOTE:
NOTE:
being removed.
NOTE:
with new units.
NOTE:
NOTE:
g. Press "Start".
h. Press "Next".
k. Select "Next".
m. Select "Next".
(TPM) and so on.

CAUTION:
e. Press "Start".
TIME ALLOWANCE:
FAILURE CODE:
Disclaimer:
Technical Service Bulletins > All Technical Service Bulletins for Power Distribution Module: > 08-007-08A > Jul > 08 >
Start Condition
GROUP: Electrical
DATE: July 04,2008

SKREEM
MODELS:
2007 - 2008 (KA) Nitro
2007 - 2008 (PM) Caliber
NOTE:
DIAGNOSIS:
run.
PARTS REQUIRED:
NOTE:
REPAIR PROCEDURE:
NOTE:
NOTE:
being removed.
NOTE:
with new units.
NOTE:
NOTE:
g. Press "Start".
h. Press "Next".
k. Select "Next".
m. Select "Next".
(TPM) and so on.

CAUTION:
e. Press "Start".
TIME ALLOWANCE:
FAILURE CODE:
Disclaimer:
Technical Service Bulletins > All Technical Service Bulletins for Power Distribution Module: > G42 > Jan > 08 > Campaign -
January 2008
Anti-Theft System
Models
Markets Only)
NOTE:
July 23, 2007 (MDH 0723XX).
IMPORTANT:
IMPORTANT:

Subject
Repair
Special Tools
Service Procedure
NOTE:

NOTE:
drop.

e. Press "Start".
NOTE:
h. Select "Next".
NOTE:
Technical Service Bulletins > All Technical Service Bulletins for Power Distribution Module: > G19 > Jun > 07 > Recall -
Daytime Running Lamp Reconfiguration
Revised G19
2007-05-15
NOTE:
CANADIAN RECALLS
IMPORTANT:
Vehicle List
Involved Dealers
vehicles.
Criteria
NOTE:
satisfaction.
Daytime Running Lamp Reconfiguration > Page 6845
needed.
Update
NOTE:
GRS.
PARTS INFORMATION
SPECIAL TOOLS
REIMBURSEMENT
DealerCONNECT.
Service Procedure
NOTE:
performed.
A. Program the TIPM
8. Select "MISC".
10. Press "START"
11. Press "Next".
13. Press "Next".
15. Press "Next".
17. Press "OK".
19. Press "OK".
21. Press "Next".
22. Press "Finish".
Technical Service Bulletins > All Other Service Bulletins for Power Distribution Module: > 08-007-08A > Jul > 08 > Antitheft
System - Engine No Crank/No Start Condition
Start Condition
GROUP: Electrical
DATE: July 04,2008

SKREEM
MODELS:
2007 - 2008 (KA) Nitro
2007 - 2008 (PM) Caliber
NOTE:
DIAGNOSIS:
run.
System - Engine No Crank/No Start Condition > Page 6854
PARTS REQUIRED:
NOTE:
REPAIR PROCEDURE:
NOTE:
NOTE:
being removed.
NOTE:
with new units.
NOTE:
NOTE:
g. Press "Start".
h. Press "Next".
k. Select "Next".
m. Select "Next".
(TPM) and so on.

CAUTION:
e. Press "Start".
TIME ALLOWANCE:
FAILURE CODE:
Disclaimer:
Technical Service Bulletins > All Other Service Bulletins for Power Distribution Module: > G42 > Jan > 08 > Campaign -
January 2008
Anti-Theft System
Models
Markets Only)
NOTE:
July 23, 2007 (MDH 0723XX).
IMPORTANT:
IMPORTANT:

Subject
Repair
Special Tools
Service Procedure
NOTE:

NOTE:
drop.

e. Press "Start".
NOTE:
h. Select "Next".
NOTE:
Technical Service Bulletins > All Other Service Bulletins for Power Distribution Module: > G19 > Jun > 07 > Recall - Daytime
Revised G19
2007-05-15
NOTE:
CANADIAN RECALLS
IMPORTANT:
Vehicle List
Involved Dealers
vehicles.
Criteria
NOTE:
satisfaction.
needed.
Update
NOTE:
GRS.
PARTS INFORMATION
SPECIAL TOOLS
REIMBURSEMENT
DealerCONNECT.
Service Procedure
NOTE:
performed.
A. Program the TIPM
8. Select "MISC".
10. Press "START"
11. Press "Next".
13. Press "Next".
15. Press "Next".
17. Press "OK".
19. Press "OK".
21. Press "Next".
22. Press "Finish".
Locations > Module-Inverter
Component ID: 162
Connector:
Color : # of pins :
2--
6--
7--
9--
Locations > Module-Inverter > Page 6875

Diagrams > Module-Totally Integrated Power
Component ID: 168
Connector:
Color : BLACK
# of pins : 13
4--
5--

8--
9--
10 - -
11 - -
Diagrams > Module-Totally Integrated Power > Page 6880
Connector:
Color : LT. GRAY
# of pins : 8
1--
2--
4--

7--
Connector:
Color : GREEN
# of pins : 22
2--
3--

15 - -
16 - -
18 - -
20 - -
21 GROUND Z971 16BK
Connector:
Color : LT. GRAY
# of pins : 14
3--

8--
9--
12 - -

Connector:
Color : BROWN
# of pins : 16

5--
12 - -
14 - -
Connector:
Color : BLACK
# of pins : 10

5--
6--
7--
10 - -
Connector:
Color : BLUE
# of pins : 14

11 - -
Connector:
Color : LT. GRAY
# of pins : 13
1--
2--
3--
4--

6--
7--
8--
9--
10 - -
11 - -
13 - -
Connector:
Color : LT. GRAY
# of pins : 22
1--

8--
10 - -
12 - -
14 - -

20 - -
Connector:
Color : BLACK
# of pins : 22
5 FUSED B(+) (I.O.D.) A416 18RD

10 - -
15 - -
16 - -
Connector:
Color : # of pins :
1 B(+) A0 6RD
Component ID: 162
Connector:
Color : # of pins :
2--
6--
7--
9--
Description and Operation > Totally Integrated Power Module
Description
DESCRIPTION
Operation
OPERATION
Description and Operation > Totally Integrated Power Module > Page 6907
Description
DESCRIPTION
Operation
OPERATION
external devices.
Inverter Module
Jeep Workshop Manuals > Power and Ground Distribution > Power Distribution Module > Component Information > Service
and Repair > Totally Integrated Power Module
Removal
REMOVAL
1. Open hood.
bracket.
Installation
INSTALLATION
seated.
and Repair > Totally Integrated Power Module > Page 6911
9 - 11 Nm (80 - 100 in. lbs.).
6. Close hood.
Removal
REMOVAL
Installation
INSTALLATION


Jeep Workshop Manuals > Power and Ground Distribution > Power Interrupt Connector/Switch > Component Information >
DESCRIPTION
OPERATION
REMOVAL

INSTALLATION

Jeep Workshop Manuals > Power and Ground Distribution > Relays and Modules - Power and Ground Distribution > Power
January 2008
Anti-Theft System
Models
Markets Only)
NOTE:
July 23, 2007 (MDH 0723XX).
IMPORTANT:
IMPORTANT:

Subject
Repair
Special Tools
Service Procedure
NOTE:

NOTE:
drop.

e. Press "Start".
NOTE:
h. Select "Next".
NOTE:
Revised G19
2007-05-15
NOTE:
CANADIAN RECALLS
IMPORTANT:
Vehicle List
Involved Dealers
vehicles.
Criteria
NOTE:
satisfaction.
needed.
Update
NOTE:
GRS.
PARTS INFORMATION
SPECIAL TOOLS
REIMBURSEMENT
DealerCONNECT.
Service Procedure
NOTE:
performed.
A. Program the TIPM
8. Select "MISC".
10. Press "START"
11. Press "Next".
13. Press "Next".
15. Press "Next".
17. Press "OK".
19. Press "OK".
21. Press "Next".
22. Press "Finish".
Condition
GROUP: Electrical
DATE: July 04,2008

SKREEM
MODELS:
2007 - 2008 (KA) Nitro
2007 - 2008 (PM) Caliber
NOTE:
DIAGNOSIS:
run.
PARTS REQUIRED:
NOTE:
REPAIR PROCEDURE:
NOTE:
NOTE:
being removed.
NOTE:
with new units.
NOTE:
NOTE:
g. Press "Start".
h. Press "Next".
k. Select "Next".
m. Select "Next".
(TPM) and so on.

CAUTION:
e. Press "Start".
TIME ALLOWANCE:
FAILURE CODE:
Disclaimer:
Start Condition
GROUP: Electrical
DATE: July 04,2008

SKREEM
MODELS:
2007 - 2008 (KA) Nitro
2007 - 2008 (PM) Caliber
NOTE:
DIAGNOSIS:
run.
PARTS REQUIRED:
NOTE:
REPAIR PROCEDURE:
NOTE:
NOTE:
being removed.
NOTE:
with new units.
NOTE:
NOTE:
g. Press "Start".
h. Press "Next".
k. Select "Next".
m. Select "Next".
(TPM) and so on.

CAUTION:
e. Press "Start".
TIME ALLOWANCE:
FAILURE CODE:
Disclaimer:
January 2008
Anti-Theft System
Models
Markets Only)
NOTE:
July 23, 2007 (MDH 0723XX).
IMPORTANT:
IMPORTANT:

Subject
Repair
Special Tools
Service Procedure
NOTE:

NOTE:
drop.

e. Press "Start".
NOTE:
h. Select "Next".
NOTE:
Revised G19
2007-05-15
NOTE:
CANADIAN RECALLS
IMPORTANT:
Vehicle List
Involved Dealers
vehicles.
Criteria
NOTE:
satisfaction.
needed.
Update
NOTE:
GRS.
PARTS INFORMATION
SPECIAL TOOLS
REIMBURSEMENT
DealerCONNECT.
Service Procedure
NOTE:
performed.
A. Program the TIPM
8. Select "MISC".
10. Press "START"
11. Press "Next".
13. Press "Next".
15. Press "Next".
17. Press "OK".
19. Press "OK".
21. Press "Next".
22. Press "Finish".
Start Condition
GROUP: Electrical
DATE: July 04,2008

SKREEM
MODELS:
2007 - 2008 (KA) Nitro
2007 - 2008 (PM) Caliber
NOTE:
DIAGNOSIS:
run.
PARTS REQUIRED:
NOTE:
REPAIR PROCEDURE:
NOTE:
NOTE:
being removed.
NOTE:
with new units.
NOTE:
NOTE:
g. Press "Start".
h. Press "Next".
k. Select "Next".
m. Select "Next".
(TPM) and so on.

CAUTION:
e. Press "Start".
TIME ALLOWANCE:
FAILURE CODE:
Disclaimer:
January 2008
Anti-Theft System
Models
Markets Only)
NOTE:
July 23, 2007 (MDH 0723XX).
IMPORTANT:
IMPORTANT:

Subject
Repair
Special Tools
Service Procedure
NOTE:

NOTE:
drop.

e. Press "Start".
NOTE:
h. Select "Next".
NOTE:
Revised G19
2007-05-15
NOTE:
CANADIAN RECALLS
IMPORTANT:
Vehicle List
Involved Dealers
vehicles.
Criteria
NOTE:
satisfaction.
needed.
Update
NOTE:
GRS.
PARTS INFORMATION
SPECIAL TOOLS
REIMBURSEMENT
DealerCONNECT.
Service Procedure
NOTE:
performed.
A. Program the TIPM
8. Select "MISC".
10. Press "START"
11. Press "Next".
13. Press "Next".
15. Press "Next".
17. Press "OK".
19. Press "OK".
21. Press "Next".
22. Press "Finish".
Distribution Module > Component Information > Locations > Module-Inverter
Component ID: 162
Connector:
Color : # of pins :
2--
6--
7--
9--

Distribution Module > Component Information > Diagrams > Module-Totally Integrated Power
Component ID: 168
Connector:
Color : BLACK
# of pins : 13
4--
5--

8--
9--
10 - -
11 - -
Connector:
Color : LT. GRAY
# of pins : 8
1--
2--
4--

7--
Connector:
Color : GREEN
# of pins : 22
2--
3--

15 - -
16 - -
18 - -
20 - -
21 GROUND Z971 16BK
Connector:
Color : LT. GRAY
# of pins : 14
3--

8--
9--
12 - -

Connector:
Color : BROWN
# of pins : 16

5--
12 - -
14 - -
Connector:
Color : BLACK
# of pins : 10

5--
6--
7--
10 - -
Connector:
Color : BLUE
# of pins : 14

11 - -
Connector:
Color : LT. GRAY
# of pins : 13
1--
2--
3--
4--

6--
7--
8--
9--
10 - -
11 - -
13 - -
Connector:
Color : LT. GRAY
# of pins : 22
1--

8--
10 - -
12 - -
14 - -

20 - -
Connector:
Color : BLACK
# of pins : 22
5 FUSED B(+) (I.O.D.) A416 18RD

10 - -
15 - -
16 - -
Connector:
Color : # of pins :
1 B(+) A0 6RD
Component ID: 162
Connector:
Color : # of pins :
2--
6--
7--
9--
Distribution Module > Component Information > Description and Operation > Totally Integrated Power Module
Description
DESCRIPTION
Operation
OPERATION
Distribution Module > Component Information > Description and Operation > Totally Integrated Power Module > Page 7031
Description
DESCRIPTION
Operation
OPERATION
external devices.
Distribution Module > Component Information > Description and Operation > Page 7032
Inverter Module
Distribution Module > Component Information > Service and Repair > Totally Integrated Power Module
Removal
REMOVAL
1. Open hood.
bracket.
Installation
INSTALLATION
seated.
9 - 11 Nm (80 - 100 in. lbs.).
6. Close hood.
Removal
REMOVAL
Installation
INSTALLATION


Jeep Workshop Manuals > Power and Ground Distribution > Relays and Modules - Power and Ground Distribution > Relay
Box > Component Information > Locations > Fuse/Relay Block
Fuse/Relay Block

Box > Component Information > Locations > Fuse/Relay Block > Page 7042

Box > Component Information > Application and ID > Fuse/Relay Block

Box > Component Information > Application and ID > Fuse/Relay Block > Page 7045
Jeep Workshop Manuals > Power and Ground Distribution > Relay Box > Component Information > Locations > Fuse/Relay
Block
Fuse/Relay Block

Jeep Workshop Manuals > Power and Ground Distribution > Relay Box > Component Information > Locations > Fuse/Relay
Block > Page 7050

Jeep Workshop Manuals > Power and Ground Distribution > Relay Box > Component Information > Application and ID >
Fuse/Relay Block

Jeep Workshop Manuals > Power and Ground Distribution > Relay Box > Component Information > Application and ID >
Jeep Workshop Manuals > Power and Ground Distribution > Sensors and Switches - Power and Ground Distribution >
Power Interrupt Connector/Switch > Component Information > Description and Operation > Description
DESCRIPTION
Power Interrupt Connector/Switch > Component Information > Description and Operation > Description > Page 7059
OPERATION
Power Interrupt Connector/Switch > Component Information > Service and Repair > Removal
REMOVAL

Power Interrupt Connector/Switch > Component Information > Service and Repair > Removal > Page 7062
INSTALLATION

Jeep Workshop Manuals > Steering and Suspension > Alignment > System Information > Specifications > Wheel Alignment
Specifications
Alignment: Specifications Wheel Alignment Specifications
Alignment: Specifications Curb Height Specifications
CURB HEIGHT SPECIFICATIONS

Jeep Workshop Manuals > Steering and Suspension > Alignment > System Information > Specifications > Page 7072
Alignment: Description and Operation
DESCRIPTION
Vehicle wheel alignment is the positioning of all interrelated front and rear suspension angles.
These angles affect the handling and steering of the vehicle when it is in motion. Proper wheel
alignment is essential for efficient steering, good directional stability, and proper tire wear.
The method of checking a vehicle's front and rear wheel alignment varies depending on the
manufacturer and type of equipment used. The manufacturer's instructions should always be
followed to ensure accuracy of the alignment, except when DaimlerChrysler Corporation's wheel
alignment specifications differ.
On this vehicle, the suspension angles that can be adjusted are as follows:
Front
- Camber (with cradle shift or service adjustment bolt package)
- Caster (limited adjustment with cradle shift)
- Toe
Rear
- Toe
Check the wheel alignment and make all wheel alignment adjustments with the vehicle standing at
its proper curb height specification. Curb height is the normal riding height of the vehicle. It is
measured from a certain point on the vehicle to the ground or a designated area while the vehicle
is sitting on a flat, level surface. Refer to Curb Height Measurement.
Typical wheel alignment angles and measurements are described in the following paragraphs.
CAMBER
Camber is the inward or outward tilt of the top of the tire and wheel assembly. Inward tilt (2) is
known as negative camber. Outward tilt (1) is known as positive camber. Camber is measured in
degrees of angle relative to a true vertical line. Camber is a tire wearing angle.
- Excessive negative camber will cause tread wear at the inside of the tire.
- Excessive positive camber will cause tread wear on the outside of the tire.
CROSS CAMBER
Cross camber is the difference between left and right camber. To achieve the cross camber
reading, subtract the right side camber reading from the left. For example, if the left camber is -0.7°
and the right camber is -0.5°, the cross camber would be -0.2° (-0.7 - (-0.5) = -0.7 + 0.5 = -0.2).
CASTER
Caster is the forward or rearward tilt of the steering knuckle in reference to the position of the upper
and lower ball joints. Caster is measured in degrees of angle relative to a true vertical center line.
This line is viewed from the side of the tire and wheel assembly.
- Forward tilt (upper ball joint ahead of lower) results in a negative caster angle.
- Rearward tilt (upper ball joint trailing lower) results in a positive caster angle.
Although caster does not affect tire wear, a caster imbalance between the two front wheels may
cause the vehicle to lead to the side with the least positive caster.
CROSS CASTER
Cross caster is the difference between left and right caster. To achieve the cross caster reading,
subtract the right side caster reading from the left. For example, if the left caster is 2.5° and the
right caster is 2.7°, the cross caster would be -0.2° (2.5 - 2.7 = -0.2).
TOE
Toe is the inward or outward angle of the wheels as viewed from above the vehicle.
- Toe-in (1) is produced when the front edges of the wheels on the same axle are closer together
- Toe-out (2) is produced when the front edges of the wheels on the same axle are farther apart
Toe-in and toe-out can occur at the front wheels and the rear wheels.
Toe is measured in degrees or inches. The measurement identifies the amount that the front of the
wheels point inward (toe-in) or outward (toe-out). Toe is measured at the spindle height. Zero toe
means the front and rear edges of the wheels on the same axle are equal distant.
TOE-OUT ON TURNS
Toe-out on turns (1), sometimes referred to as Ackerman Steering, is the relative positioning of the
front wheels while steering through a turn. This compensates for each front wheel's turning radius.
As the vehicle encounters a turn, the outboard wheel must travel in a larger radius circle than the
inboard wheel. The steering system is designed to make each wheel follow its particular radius
circle. To accomplish this, the front wheels must progressively toe outward as the steering is turned
from center. This eliminates tire scrubbing and undue tire wear when steering a vehicle through a
turn.
DYNAMIC TOE PATTERN
Dynamic toe pattern is the inward and outward toe movement of the front and rear tires through the
suspension's jounce and rebound travel. As the vehicle's suspension moves up and down, the toe
pattern varies. Toe pattern is critical in controlling the directional stability of the vehicle while in
motion. Front and rear dynamic toe pattern is preset by the factory at the time the vehicle is
assembled.
It is not necessary to check or adjust front or rear dynamic toe pattern when doing a normal wheel
alignment. The only time dynamic toe pattern needs to be checked or adjusted is if the frame of the
vehicle has been damaged.
STEERING AXIS INCLINATION (S.A.I.)

Steering axis inclination (1) is the angle between a true vertical line starting at the center of the tire
at the road contact point and a line drawn through the center of the upper ball joint (or strut) and
the lower ball joint. S.A.I. is built into the vehicle and is not an adjustable angle. If S.A.I. is not
within specifications, a bent or damaged suspension component may be the cause.
INCLUDED ANGLE (I.A.)

Included angle (3) is the sum of the S.A.I. angle (1) plus or minus the camber angle (2), depending
on whether or not the wheel has positive or negative camber. If camber is positive, add the camber
angle to the S.A.I angle. If camber is negative, subtract the camber angle from the S.A.I. angle.
Included angle is not adjustable, but can be used to diagnose a frame misalignment or bent
suspension component (spindle, strut).
THRUST ANGLE
Thrust angle is the averaged direction the rear wheels are pointing in relation to the vehicle's center
line. The presence of negative or positive thrust angle causes the rear tires to track improperly to
the left or right of the front tires (dog tracking).
- Negative thrust angle means the rear tires are tracking to the left of the front tires.
- Positive thrust angle means the rear tires are tracking to the right of the front tires.
Improper tracking can cause undue tire wear, a lead or pull and a crooked steering wheel.
Excessive thrust angle can usually be corrected by adjusting the rear wheel toe so that each wheel
has one-half of the total toe measurement.
Alignment: Testing and Inspection
SUSPENSION AND STEERING



Jeep Workshop Manuals > Steering and Suspension > Alignment > System Information > Service and Repair > Wheel
Alignment
Alignment: Service and Repair Wheel Alignment
WHEEL ALIGNMENT
PRE-WHEEL ALIGNMENT INSPECTION
Before any attempt is made to change or correct the wheel alignment, the following inspection and
necessary corrections must be made to the vehicle to ensure proper alignment.
1. Verify the fuel tank is full of fuel. If the fuel tank is not full, the reduction in weight will affect the
curb height of the vehicle and the alignment
specifications.
2. The passenger and luggage compartments of the vehicle should be free of any load that is not
factory equipment. 3. Check the tires on the vehicle. The tires are to be inflated to the
recommended air pressure. All tires must be the same size and in good condition
with approximately the same tread wear.
4. Check the front tire and wheel assemblies for excessive radial runout. 5. Inspect all suspension
component fasteners for looseness and proper torque. 6. Inspect the lower front ball joints and all
steering linkage for looseness and any sign of wear or damage. 7. Inspect the rubber bushings on
all the suspension components for signs of wear or deterioration. If any bushings show signs of
wear or
deterioration, they should be replaced prior to aligning the vehicle.
8. Check vehicle curb height to verify it is within specifications.
WHEEL ALIGNMENT SETUP
1. Position the vehicle on an alignment rack. 2. Install all required alignment equipment on the
vehicle, per the alignment equipment manufacturer's instructions. On this vehicle, a four-wheel
alignment is recommended.
NOTE: Prior to reading the vehicle's alignment readouts, the front and rear of vehicle should be
jounced. Induce jounce (rear first, then front) by grasping the center of the bumper and jouncing
each end of vehicle an equal number of times. The bumper should always be released when
vehicle is at the bottom of the jounce cycle.
3. Read the vehicle's current front and rear alignment settings. Compare the vehicle's current
alignment settings to the vehicle specifications for
camber, caster and toe-in.
REAR CAMBER
Rear camber settings on this vehicle are determined at the time the vehicle is designed, by the
location of the vehicle's suspension components. This is referred to as Net Build. The result is no
required adjustment of camber after the vehicle is built or when servicing the suspension
components. Thus, when performing a wheel alignment, rear camber is not considered an
adjustable angle.
FRONT CAMBER AND CASTER

Front camber and caster settings on this vehicle are determined at the time the vehicle is designed,
by the location of the vehicle's suspension components. This is referred to as Net Build. The result
is no required adjustment of camber and caster after the vehicle is built or when servicing the
suspension components. Thus, when performing a wheel alignment, caster and camber are not
normally considered adjustable angles but some adjustment can be made. Camber and caster
should be checked to ensure they meet vehicle specifications.
If individual front camber or caster is found not to meet alignment specifications, each can be
adjusted by shifting the crossmember or by using an available service adjustment bolt package. If
an adjustment bolt package installation is necessary, inspect the suspension components for any
signs of damage or bending first.
ADJUSTMENT BY SHIFTING CROSSMEMBER
CAUTION: Always use care when shifting crossmember to avoid damaging other components on
the vehicle.
1. Loosen the four bolts fastening the front crossmember to the frame just enough to allow
movement of the crossmember. 2. Loosen the bolts fastening the fore/aft crossmember to the
frame just enough to allow movement of the crossmember.
CAUTION: When shifting the front crossmember, keep in mind that the front and rear engine
mounts are attached to the front crossmember and fore/aft crossmember and should be inspected
following the crossmember shift to make sure they are properly aligned.
Alignment > Page 7084
3. Shift front crossmember as necessary to bring camber or caster into specifications. When
shifting crossmember, use care not to move other angles
(camber or caster) that are within specifications, out of specifications.
4. Tighten all previously loosened fasteners (bolts) securing the crossmember to the vehicle to
specifications. 5. Jounce the rear, then front of the vehicle an equal amount of times. 6. Measure
camber and caster. If camber and caster are within specifications, proceed to TOE. If camber
cannot be brought into specifications,
perform the CAMBER ADJUSTMENT BOLT PACKAGE INSTALLATION below.
CAMBER ADJUSTMENT BOLT PACKAGE INSTALLATION
The camber adjustment bolt package contains new bolts and nuts for attaching the strut clevis
bracket to the steering knuckle. The bolts contained in the package are slightly undersize allowing
for movement between the strut clevis bracket and the steering knuckle. The movement allowed by
the undersize bolts provide approximately two degrees of camber adjustment per side of the
vehicle. To install and adjust the camber adjustment bolt package, follow the procedure below.
7. Raise the vehicle until its tires are not supporting the weight of the vehicle.
8. Remove the wheel mounting nuts (3), then the front tire and wheel assembly (1).
CAUTION: The strut clevis-to-knuckle attaching bolt shanks are serrated and must not be turned
during removal. Remove the nuts while holding the bolts stationary, then tap the bolts out using a
punch.
9. Remove the original upper bolt (1) and nut (3) attaching the strut clevis bracket (2) to the knuckle
(5).
10. Install a bolt from the adjustment package into the hole where the original bolt was removed.
Install the bolt as indicated. 11. Install a nut provided in adjustment package on the replacement
bolt. Tighten the nut until it's snug, but still allows the knuckle to slide in the
clevis bracket.
12. Remove the original lower bolt (6) and nut (4) attaching the strut clevis bracket (2) to the
knuckle (5). 13. Install a bolt from the adjustment package into the bottom hole of the strut clevis
bracket. Install the bolt as indicated. 14. Install a nut provided in adjustment package on the
replacement bolt. Tighten the nut until it's snug, but still allows the knuckle to slide in the
clevis bracket.
Nm (100 ft. lbs.). 16. Perform the above procedure to opposite strut as required. 17. Lower the
vehicle and jounce the front and rear of the vehicle.
18. Adjust the front camber to the preferred setting by pushing or pulling on the top of the tire.
When camber is set to specifications, tighten the upper
and lower strut clevis-to-knuckle attaching bolt nuts (3, 4) enough to hold the adjustment. Again
jounce the front and rear of the vehicle, then verify the camber settings.
19. Tighten the front strut clevis-to-knuckle attaching bolt nuts (3, 4) to 84 Nm (62 ft. lbs.). 20. Once
camber is within specifications, adjust toe to meet the preferred specification setting. Refer to
FRONT TOE within this wheel alignment
service procedure.
TOE
1. Center the steering wheel and lock it in place using a steering wheel clamp.
NOTE: When setting toe, make sure to set rear toe to the preferred specifications before setting
front toe to the preferred specifications
REAR TOE
NOTE: Perform the following at each rear wheel as necessary.

2. While holding the cam bolt head (3) stationary, loosen the toe link mounting cam bolt nut (1). 3.
Rotate the cam bolt head (3) left or right until the rear wheel toe for that rear wheel is set to the
preferred specification. 4. While holding the cam bolt head (3) stationary, tighten the toe link
mounting cam bolt nut (1) to 35 Nm (26 ft. lbs.).
FRONT TOE
CAUTION: Do not twist the inner tie rod-to-steering gear rubber boots while turning the inner tie
rods during the front toe adjustment.
NOTE: Perform the following at each front wheel as necessary.
5. Loosen the tie rod adjusting jam nut (1). Grasp the inner tie rod (3) and rotate it one way or the
other until the front wheel toe is set to the preferred
specification.
6. Tighten the tie rod adjusting jam nut to of 75 Nm (55 ft. lbs.). 7. Make sure the inner tie
rod-to-steering gear rubber boot is not twisted.
8. Remove the steering wheel clamp. 9. Remove the alignment equipment.
10. Road test the vehicle to verify the steering wheel is straight and the vehicle does not pull or
wander.
Alignment: Service and Repair Curb Height Measurement
CURB HEIGHT MEASUREMENT
The wheel alignment is to be checked and all alignment adjustments made with the vehicle at its
required curb height specification.
Vehicle height is to be checked with the vehicle on a flat, level surface, preferably a vehicle
alignment rack. The tires are to be inflated to the recommended pressure. All tires are to be the
same size as standard equipment. Vehicle height is checked with the fuel tank full of fuel, and no
passenger or luggage compartment load.
Vehicle height is not adjustable. If the measurement is not within specifications, inspect the vehicle
for bent or weak suspension components. Compare the parts tag on the suspect coil spring(s) to
the parts book and the vehicle sales code, checking for a match. Once removed from the vehicle,
compare the coil spring height to a correct new or known good coil spring. The heights should vary
if the suspect spring is weak.
NOTE: Prior to reading the curb height measurement, the front and rear of the vehicle must be
jounced to settle the suspension. Induce jounce by pushing down on the center of the bumper
(fascia), using care not to damage the vehicle, moving the vehicle up and down, gradually
increasing the suspension travel with each stroke. Release the bumper at the bottom of each
stroke, repeating this action several times. Perform this to both front and rear suspensions an equal
amount of times.
Measure curb height as follows:
1. Jounce the vehicle. Refer to above note.
NOTE: On some vehicles it may be necessary to remove an engine belly pan in order to gain
access to the lower control arm pivot bolt.
2. FRONT - On each side of the vehicle, measure the distance (2) from the center of the lower
control arm rear (vertical) pivot bolt head (1) to the
floor or alignment rack/lift runway surface. It may be necessary to measure to the bottom of a
straight edge (3) placed from lift runway to runway to get an accurate measurement.
3. REAR - On each side of the vehicle, measure the distance (2) from the center of the outboard
trailing arm-to-body mounting bolt (1) to the floor or
alignment rack/lift runway surface.
4. Compare the measurements to specifications listed in the following CURB HEIGHT

SPECIFICATIONS chart. Maximum left-to-right
differential is not to exceed 12.5 mm (0.5 in.).
5. If curb height is found to be out of specification and there is no sign of excessive body damage,
curb height can be changed by replacing the
applicable spring with a spring offering a different check load.

Jeep Workshop Manuals > Steering and Suspension > Relays and Modules - Steering and Suspension > Relays and
Modules - Steering > Steering Column Control Module > Component Information > Description and Operation > Description
DESCRIPTION
Modules - Steering > Steering Column Control Module > Component Information > Description and Operation > Description
> Page 7097
OPERATION
bus.
Modules - Steering > Steering Column Control Module > Component Information > Service and Repair > Removal
REMOVAL
SCCM
Modules - Steering > Steering Column Control Module > Component Information > Service and Repair > Removal > Page
7100
column.
DISASSEMBLY
SCCM.
7101
7102
7103
INSTALLATION
with SCCM STEP 1.
ASSEMBLY
7104
SCCM
7105
Modules - Steering > Steering Control Module > Component Information > Description and Operation > Description
DESCRIPTION
Modules - Steering > Steering Control Module > Component Information > Description and Operation > Description > Page
7110
OPERATION
bus.
Modules - Steering > Steering Control Module > Component Information > Description and Operation > Page 7111
Modules - Steering > Steering Mounted Controls Communication Module > Component Information > Locations
Component ID: 167
Connector:
Color : WHITE
# of pins : 4
Modules - Steering > Steering Mounted Controls Communication Module > Component Information > Locations > Page
7115
7116
7117
7118
Connector:
Color : WHITE
# of pins : 6

7119
7120
7121
7122
Connector:
Color : WHITE
# of pins : 4

7123
7124
7125
7126
Connector:
Color : WHITE
# of pins : 6

7127
7128
7129
7130
7131
Component ID: 167
Connector:
Color : WHITE
# of pins : 4
7132
7133
7134
7135
Connector:
Color : WHITE
# of pins : 6

7136
7137
7138
7139
Connector:
Color : WHITE
# of pins : 4

7140
7141
7142
7143
Connector:
Color : WHITE
# of pins : 6

7144
7145
7146
7147
Modules - Wheels and Tires > Tire Pressure Monitor Receiver / Transponder > Component Information > Locations >
Component ID: 369
Connector:
Color : YELLOW
# of pins : 6
5--
6--
Component ID: 370
Connector:
Color : BLACK
# of pins : 6
4--
5--
6--
Component ID: 371
Connector:
Color : BLACK
# of pins : 6
4--
5--

Modules - Wheels and Tires > Tire Pressure Monitor Receiver / Transponder > Component Information > Diagrams >
Component ID: 369
Connector:
Color : YELLOW
# of pins : 6
5--
6--
Component ID: 370
Connector:
Color : BLACK
# of pins : 6
4--
5--
6--
Component ID: 371
Connector:
Color : BLACK
# of pins : 6
4--
5--

Modules - Wheels and Tires > Tire Pressure Monitor Receiver / Transponder > Component Information > Description and
DESCRIPTION
Modules - Wheels and Tires > Tire Pressure Monitor Receiver / Transponder > Component Information > Description and
OPERATION
Modules - Wheels and Tires > Tire Pressure Monitor Receiver / Transponder > Component Information > Service and
Repair > Removal
Front
FRONT
Rear
REAR
Modules - Wheels and Tires > Tire Pressure Monitor Receiver / Transponder > Component Information > Service and
Front
FRONT
Rear
REAR

Jeep Workshop Manuals > Steering and Suspension > Sensors and Switches - Steering and Suspension > Sensors and
C121A/C2205
NUMBER: 08-010-07
DATE: May 17, 2007
OVERVIEW:
new software.
MODELS:
2007 (JK) Wrangler
2007 (JS) Sebring
2007 (KA) Nitro
2007 (MK49) Compass
2007 (MK74) Patriot
2007 (PM) Caliber
NOTE:
SYMPTOM/CONDITION:
DIAGNOSIS:

Procedure.
FILE:
NOTE:
NOTE:
NOTE:
is complete.
NOTE:
drop.

NOTE:
TIME ALLOWANCE:
FAILURE CODE:
Disclaimer:
C121A/C2205
NUMBER: 08-010-07
DATE: May 17, 2007
OVERVIEW:
new software.
MODELS:
2007 (JK) Wrangler
2007 (JS) Sebring
2007 (KA) Nitro
2007 (MK49) Compass
2007 (MK74) Patriot
2007 (PM) Caliber
NOTE:
SYMPTOM/CONDITION:
DIAGNOSIS:

Procedure.
FILE:
NOTE:
NOTE:
NOTE:
is complete.
NOTE:
drop.

NOTE:
TIME ALLOWANCE:
FAILURE CODE:
Disclaimer:
Switches - Wheels and Tires > Tire Pressure Sensor > Component Information > Service Precautions
CAUTION

Switches - Wheels and Tires > Tire Pressure Sensor > Component Information > Description and Operation > Description
DESCRIPTION
Page 7192
Page 7193
- Valve Stem Core
Page 7194
OPERATION
Switches - Wheels and Tires > Tire Pressure Sensor > Component Information > Service and Repair > Removal
REMOVAL
different metals.

7197

7198
INSTALLATION

installed.
7199
damage may occur.
pressure sensor: a.
7200
b.
beads.
7201
sensor.
new sensor ID.

Jeep Workshop Manuals > Steering and Suspension > Steering > Front Steering Knuckle > Component Information >
Front Steering Knuckle: Description and Operation
DESCRIPTION
The knuckle (1) is a single casting with legs machined for attachment to the front strut assembly on
the top, lower control arm ball joint on the bottom, and steering linkage on the trailing end. The
knuckle also has two machined, drilled and tapped legs on the leading end casting to support and
align the front disc brake caliper adapter.
The knuckle supports the wheel bearing (5) and hub (3). The hub is pressed into a sealed-for-life
wheel bearing that is pressed into the knuckle. A snap ring also holds the bearing in place. A shield
is pressed onto the knuckle behind the hub.
Front Steering Knuckle: Testing and Inspection
KNUCKLE
The front suspension knuckle is not a repairable component of the front suspension. It must be
replaced if found to be damaged in any way. If it is determined that the knuckle is bent when
servicing the vehicle, no attempt is to be made to straighten the knuckle.
Front Steering Knuckle: Service and Repair Removal
REMOVAL
NOTE: Before proceeding, review all Warnings and Cautions.
3. Remove the cotter pin (2) from the hub nut (3). 4. While a helper applies the brakes to keep the
hub (1) from rotating, remove the hub nut (3) and washer (4) from the axle half shaft. 5. Access and
remove the front brake rotor.
6. Remove the routing clip (1) securing wheel speed sensor cable to the knuckle (4). 7. Remove
the screw (2) fastening the wheel speed sensor head (3) to the knuckle (4). Pull the sensor head
out of the knuckle.
8. Remove the nut (2) attaching the outer tie rod (7) to the knuckle (3). To do this, hold the tie rod
end stud with a wrench while loosening and
removing the nut with a standard wrench or crowfoot wrench.
9. Release the outer tie rod end (3) from the knuckle (2) using Remover (1), Special Tool 9360.
10. Remove the outer tie rod from the knuckle.

11. Remove the nut (5) and pinch bolt (4) clamping the ball joint stud (6) to the knuckle (3).
CAUTION: The strut assembly-to-knuckle attaching bolts (5) are serrated and must not be turned
during removal. Proper removal is required. Refer to the following steps for the correct method.
12. While holding the bolt heads stationary, remove the two nuts (2) from the bolts (5) attaching the
strut (3) to the knuckle (6). 13. Remove the two bolts (5) attaching the strut (3) to the knuckle (6)
using a pin punch.
CAUTION: Use care when separating the ball joint stud (4) from the knuckle (1), so the ball joint
seal does not get cut.
14. Using an appropriate prying tool (2), separate the ball joint stud (4) from the knuckle (1) by
prying down on lower control arm (3) and up against
the ball joint boss on the knuckle.
NOTE: Do not allow the half shaft (1) to hang by the inner C/V joint; it must be supported to keep
the joint from separating during this operation.
15. Pull the knuckle (3) off the half shaft (1) outer C/V joint splines and remove the knuckle from the
vehicle.
Front Steering Knuckle: Service and Repair Installation
INSTALLATION
1. Slide the hub of the knuckle (3) onto the splines of the halfshaft outer C/V joint (1). 2. Install the
knuckle (3) onto the ball joint (6) stud aligning the bolt hole in the knuckle boss with the groove
formed into the side of the ball joint
stud.
3. Install a NEW ball joint stud pinch bolt (4) and nut (5). Tighten the nut to 82 Nm (60 ft. lbs.).
during installation. Install the nuts while holding the bolts stationary in the steering knuckle. Refer to
the following step.
4. Position the lower end of the strut assembly (3) in line with the upper end of the knuckle (6),
aligning the mounting holes. Install the two mounting
bolts (5).
5. Install the nuts (2) on the two bolts (5). While holding the bolts in place, tighten the nuts to 84 Nm
(62 ft. lbs.).
6. Install the outer tie rod (7) ball stud into the hole in the knuckle (3) arm. Start the tie rod
end-to-knuckle nut (2) onto the stud. While holding the
tie rod end stud with a wrench, tighten the nut with a wrench or crowfoot wrench to 132 Nm (97 ft.
lbs.).
cable to the knuckle (4). 9. Install the brake rotor, disc brake caliper and adapter.
10. Clean all foreign matter from the threads of the halfshaft outer C/V joint.
11. Install the washer (4) and hub nut (3) on the end of the halfshaft and snug it. 12. While a helper
applies the brakes to keep the hub (1) from rotating, tighten the hub nut (3) to 245 Nm (181 ft. lbs.).
13. Insert the cotter pin (2) through the notches in the nut and the hole in halfshaft. If the notches in
the nut do not line up with the hole in the
halfshaft, continue to tighten the nut until they do. Do not loosen the nut.
Nm (100 ft. lbs.). 16. Lower the vehicle.
NOTE: If the original knuckle is being reinstalled, wheel alignment may not be necessary due to
Net-Build design.
17. Perform wheel alignment as necessary.

Jeep Workshop Manuals > Steering and Suspension > Steering > Power Steering > Power Steering Fluid > Component
Power Steering Fluid: Technical Service Bulletins Maintenance - Fluid Flushing Information
NUMBER: 26-001-09

MODELS:
2009 - 2010 (DS) Ram Truck (1500)
2005 - 2009 (HB) Durango
2007 - 2009 (HG) Aspen
2009 - 2010 (JC) Journey
2008 - 2010 (KK) Liberty
2007 - 2010 (KA) Nitro
2005 - 2007 (KJ) Liberty
2005 - 2010 (ND) Dakota
2005 - 2006 (PL) Neon

2007 - 2010 (PM) Caliber

2005 - 2010 (ZB) Viper
DISCUSSION:
coolant.
operating range.
distilled water.
Disclaimer:
Power Steering Fluid: Specifications
Power Steering Fluid Type
Mopar Power Steering Fluid +4 or Mopar ATF+4 Automatic Transmission Fluid.

Power Steering Fluid: Description and Operation
DESCRIPTION
The recommended fluid for the power steering system is Mopar(R) Power Steering fluid + 4 or
Mopar(R) ATF+4 Automatic Transmission Fluid. Both fluids have the same material standard
specifications (MS-9602).
Mopar(R) ATF+4 (and Mopar(R) Power Steering fluid + 4), when new, is red in color. ATF+4 is
dyed red so it can be identified from other fluids used in the vehicle such as engine oil or
antifreeze. The red color is not permanent and is not an indicator of fluid condition. As the vehicle is
driven, ATF+4 will begin to look darker in color and may eventually become brown. THIS IS
NORMAL. ATF+4 also has a unique odor that may change with age. Consequently, odor and color
cannot be used to indicate the fluid condition or the need for a fluid change.
Power Steering Fluid: Testing and Inspection
POWER STEERING FLUID LEVEL CHECKING
WARNING: Fluid level should be checked with the engine OFF to prevent personal injury from
moving parts and to assure an accurate fluid level reading.
to be used in the power steering system. Both fluids have the same material standard
NOTE: Although not required at specific intervals, the fluid level may be checked periodically.
Check the fluid level anytime there is a system noise or fluid leak suspected.
The power steering fluid level can be viewed through the side of the power steering fluid reservoir.
Compare the fluid level to the markings on the side of the reservoir. When the fluid is at normal
ambient temperature, approximately 21° C to 27° C (70° F to 80° F), the fluid level should read
between the MAX. and MIN. markings. When the fluid is hot, fluid level is allowed to read up to the
MAX. line.
Power Steering Fluid: Service and Repair
POWER STEERING SYSTEM BLEEDING
WARNING: The fluid level should be checked with engine off to prevent injury from moving
components.
to be used in the power steering system. Both Fluids have the same material standard
CAUTION: If the air is not purged from the power steering system correctly, pump failure could
result.
NOTE: Be sure the vacuum tool used in the following procedure is clean and free of any fluids.
1. Check the fluid level. As measured on the side of the reservoir, the level should indicate between
MAX and MIN when the fluid is at normal
ambient temperature. Adjust the fluid level as necessary.

2. Tightly insert Power Steering Cap Adapter (4), Special Tool 9688, into the mouth of the reservoir
(3).
CAUTION: Failure to use a vacuum pump reservoir (1) may allow power steering fluid to be sucked
into the hand vacuum pump.
3. Attach Hand Vacuum Pump (2), Special Tool C-4207 or equivalent, with reservoir (1) attached,
to the Power Steering Cap Adapter (4).
CAUTION: Do not run the engine while vacuum is applied to the power steering system. Damage
to the power steering pump can occur.
NOTE: When performing the following step make sure the vacuum level is maintained during the
entire time period.
4. Using Hand Vacuum Pump (2), apply 68-85 kPa (20-25 in. Hg) of vacuum to the system for a
minimum of three minutes. 5. Slowly release the vacuum and remove the special tools. 6. Adjust
the fluid level as necessary. Refer to STEP 1. 7. Repeat STEP 1 through STEP 6 until the fluid no
longer drops when vacuum is applied. 8. Start the engine and cycle the steering wheel lock-to-lock
three times.
NOTE: Do not hold the steering wheel at the stops.
9. Stop the engine and check for leaks at all connections.
10. Check for any signs of air in the reservoir and check the fluid level. If air is present, repeat the
procedure as necessary.
Jeep Workshop Manuals > Steering and Suspension > Steering > Power Steering > Power Steering Fluid Cooler >
Power Steering Fluid Cooler: Description and Operation
DESCRIPTION
The cooler is placed in series with the power steering fluid return hose, between the steering gear
fluid outlet port and the fluid return hose leading to the power steering fluid reservoir.
Power Steering Fluid Cooler: Service and Repair Removal
REMOVAL
(5).
Power Steering Fluid Cooler: Service and Repair Installation
INSTALLATION
4. Install the front fascia. 5. Lower the vehicle. 6. Fill and bleed the power steering system. 7.
Check for leaks.
Jeep Workshop Manuals > Steering and Suspension > Steering > Power Steering > Power Steering Fluid Reservoir >
Power Steering Fluid Reservoir: Description and Operation
DESCRIPTION
The power steering fluid reservoir (5) is mounted above the right front inner fender well to a bracket
(2).
Power Steering Fluid Reservoir: Service and Repair Removal
REMOVAL
1. Remove engine appearance cover. 2. Remove the fasteners securing the coolant recovery bottle
to its mounts and move it away from the power steering fluid reservoir. It is not
necessary to disconnect the coolant recovery bottle fluid lines.
3. Siphon as much fluid as possible from the power steering fluid reservoir (5). 4. Remove hose
clamp securing cooler return hose (3) to fluid reservoir fitting. Slide the hose off the end of the
reservoir fitting. 5. Remove hose clamp securing pump supply hose (4) to the fluid reservoir fitting.
Slide the hose off the end of the reservoir fitting. 6. Remove the reservoir mounting screw (1) used
to secure the reservoir in place. 7. Remove the reservoir (5). 8. Remove the plastic shield from the
reservoir.
Power Steering Fluid Reservoir: Service and Repair Installation
INSTALLATION
1. Install the plastic shield over the reservoir neck.
2. Attach the reservoir (5) to the strut tower bracket (2) using the mounting screw (1). Tighten
mounting screw (1) to 12 Nm (106 in. lbs.). 3. Slide the pump supply hose (4) onto reservoir fitting.
Expand hose clamp and slide it over hose on reservoir fitting. Secure clamp once it is past
bead formed into fluid reservoir fitting.
4. Slide cooler return hose (3) onto reservoir fitting. Expand hose clamp and slide it over hose on
reservoir fitting. Secure clamp once it is past bead
formed into fluid reservoir fitting.
5. Install the coolant recovery bottle. 6. Fill and bleed the power steering system. 7. Check for
leaks. 8. Install the engine appearance cover.
Jeep Workshop Manuals > Steering and Suspension > Steering > Power Steering > Power Steering Line/Hose >
Component Information > Service and Repair > Fluid Cooler
Power Steering Line/Hose: Service and Repair Fluid Cooler
Removal
REMOVAL
(5).
Installation
INSTALLATION
4. Install the front fascia. 5. Lower the vehicle.

Component Information > Service and Repair > Fluid Cooler > Page 7241
6. Fill and bleed the power steering system. 7. Check for leaks.
Power Steering Line/Hose: Service and Repair Hose-Pressure
Removal
GAS ENGINE
appearance cover. 3. Remove the pressure Hose (3) at the pump pressure port (5). 4. Remove the
pressure hose routing bracket bolt (2) at the upper mount (8).
5. All except 2.4L Engine with All-Wheel-Drive - Remove the pressure hose routing clamp bolt (1)
at the exhaust manifold.
6. 2.4L Engine with All-Wheel-Drive - Remove the pressure hose routing clamp bolt (1) at the
exhaust manifold. 7. Raise and support the vehicle.
9. Remove the return tube (1) at the steering gear (3).
10. Remove the pressure hose (2) at the steering gear (3).
crossmember. 12. Remove the power steering pressure hose from the vehicle.
Installation
GAS ENGINE
CAUTION: Power steering fluid hoses must remain away from the exhaust system, driveshafts,
vehicle components and any unfriendly surface that can possibly damage the hoses.
1. Using a lint free towel, wipe clean the open power steering hose end and the power steering
pump port. Replace any used O-rings with new.
Lubricate the O-ring with power steering fluid.
2. Install the power steering pressure hose into the engine compartment from below. 3. Install the
fasteners (1) securing the power steering hose routing clamps (2) to the crossmember. Use a NEW
push clip on the left and tighten the

4. Install the pressure hose (2) at the gear (3). Tighten the tube nut to 32 Nm (24 ft. lbs.). 5. Install
the return tube (1) at the gear (3). Tighten the tube nut to 20 Nm (15 ft. lbs.).
6. Install the return hose (1) at the return tube (2). 7. Lower the vehicle.
lbs.). 9. Install the pressure hose routing bracket bolt (2) to the upper mount (8).
10. All except 2.4L Engine with All-Wheel-Drive - Position the pressure hose routing clamp (2) at
the exhaust manifold and install the mounting bolt
(1). Tighten the bolt to 9 Nm (80 in. lbs.).
11. 2.4L Engine with All-Wheel-Drive - Position the pressure hose routing clamp (2) at the exhaust
manifold and install the mounting bolt (1). Tighten
the bolt to 9 Nm (80 in. lbs.).

12. Fill and bleed the power steering system. 13. Check for leaks. 14. Install the engine
appearance cover.
Power Steering Line/Hose: Service and Repair Return Hose
Removal
REMOVAL
1. Remove the engine appearance cover. 2. Remove the coolant recovery bottle. 3. Siphon as
much fluid as possible from the power steering fluid reservoir. 4. Remove the power steering fluid
reservoir. 5. Remove the windshield washer reservoir. 6. Remove the front fascia. 7. Raise and
9. Remove the return hose routing clamp screw (2) securing the return hose (7) to the frame rail.
10. Lower the vehicle. 11. Remove the return hose routing clamp screw (1) securing the return
hose (7) to the strut tower. 12. Remove the hose clamps (6) securing the return hose to the power
steering reservoir and cooler. Slide the hose off the end of the cooler tube.
13. Remove the return hose from the vehicle.
Installation
INSTALLATION
1. Install the power steering return hose (7) into the engine compartment. 2. Install the return hose
routing clamp screw (1) securing the return hose (7) to the strut tower. 3. Install the return hose
onto the cooler tubes (5) and install the hose clamps (6). 4. Raise and support the vehicle. 5. Install
the screw (2) securing the return hose to the frame rail. Tighten the screw to 19 Nm (14 ft. lbs.).
6. Install the return hose (1) at the return tube (2). 7. Lower the vehicle. 8. Install the front fascia. 9.
Install the windshield washer reservoir.
10. Install the power steering fluid reservoir. 11. Install the coolant recovery bottle. 12. Fill and
bleed the power steering system. 13. Check for leaks. 14. Install the engine appearance cover.
Power Steering Line/Hose: Service and Repair Hose-Supply
Removal
GAS ENGINE
1. Siphon as much fluid as possible from the power steering fluid reservoir.
2. Remove the clamp (2) securing the supply hose to the power steering pump (3) supply fitting,
then remove the hose from the supply fitting.
3. Remove the hose clamp securing the supply hose (4) to the power steering fluid reservoir (5).
Slide the hose off the end of the reservoir fitting and
remove from vehicle.
Installation
GAS ENGINE
1. Slide hose clamps (2) onto both ends of the power steering fluid supply hose (1) far enough to
clear the fittings on the reservoir and pump once the
hose is installed.
2. Place the pump end of the supply hose (1) onto the pump (3) supply fitting. Expand the hose
clamp (2) and slide it over the hose and pump supply
fitting. Secure the clamp once it is past the bead formed into the fluid supply fitting.
3. Expand the hose clamp (4) at the fluid reservoir (5) and slide it over the hose and fitting. Secure
the clamp once it is past the bead formed into the
fluid reservoir fitting.
4. Perform the POWER STEERING PUMP BLEED PROCEDURE. 5. Check for leaks at all hose
connections.
Jeep Workshop Manuals > Steering and Suspension > Steering > Power Steering > Power Steering Pump > Component
Power Steering Pump: Description and Operation
DESCRIPTION
Hydraulic pressure for operation of the power steering gear is provided by a droop-flow type power
steering pump.
The power steering pump is belt driven. The pulley (1) cannot be serviced separately. The power
steering pump is serviced as a complete assembly.
Power Steering Pump: Testing and Inspection
POWER STEERING PUMP AND HOSES
NOTE: This information is designed to be used in conjunction with the diagnostic charts in
Steering.
CHECKING FOR WEAR OF POWER STEERING PUMP INTERNAL COMPONENTS
1. Place gear selector in PARK (or NEUTRAL) with wheels chalked. 2. With the engine idling, have
a helper turn the steering wheel. 3. Using an electronic listening tool, determine if noise is coming
from the pump. 4. Increase the engine speed and have a helper turn the steering wheel. Does the
noise change with load? 5. Replace the power steering pump if excessive noise is present.
CHECKING FOR POWER STEERING HOSES TOUCHING BODY OR FRAME OF VEHICLE
Check hoses and hose tubes as following:
- Inspect hoses and hose tubes for witness marks. If witness marks are present, adjust hose(s) to
the proper position by loosening, repositioning and tightening attachments to the specified torque.
Do not bend tubing to adjust. Replace the hose assembly if damaged.
- Check fastener torque of hose mounting brackets and tube nuts.
- Have a helper bump the steering gear off of the stops to induce pressure fluctuations which may
move the hose. If hose contact is made, adjust hose(s) to the proper position by loosening,
repositioning and tightening attachments to the specified torque. Do not bend tubing to adjust.
Replace the hose assembly if damaged.
Power Steering Pump: Service and Repair Removal
GAS ENGINE
appearance cover.
3. Remove the pressure hose routing bracket bolt (2) at the upper mount (8). 4. Remove the
pressure hose (3) at the pump pressure port (5).
5. Remove the hose clamp (2) securing the supply hose (1) at the pump. 6. Remove the supply
hose (1) from the pump (3).
7. Remove the drive belt (2). 8. Remove the three pump mounting bolts (1) through the pulley (3)
openings. 9. Remove the power steering pump.
Power Steering Pump: Service and Repair Installation
GAS ENGINE
1. Using a lint free towel, wipe clean the open power steering pressure hose end and the power
steering pump port. Replace any used O-rings with
new. Lubricate the O-ring with clean power steering fluid.
2. Place the pump in mounting position. Install the three bolts (1) through the pulley (3) openings.
Tighten the mounting bolts (1) to 26 Nm (19 ft.
lbs.).
3. Install the drive belt (2).
4. Install the supply hose (1) at the pump (3). 5. Clamp the hose clamp (2) securing the supply
hose (1) to the pump.
lbs.). 7. Install the pressure hose routing bracket bolt (2) to the upper mount (8). 8. Fill and bleed
the power steering system. 9. Check for leaks.
10. Install the engine appearance cover.

Jeep Workshop Manuals > Steering and Suspension > Steering > Power Steering > Steering Control Module > Component
DESCRIPTION
OPERATION
bus.
Jeep Workshop Manuals > Steering and Suspension > Steering > Relays and Modules - Steering > Steering Column
DESCRIPTION
OPERATION
bus.
REMOVAL
SCCM
column.
DISASSEMBLY
SCCM.
INSTALLATION
with SCCM STEP 1.
ASSEMBLY
SCCM
Jeep Workshop Manuals > Steering and Suspension > Steering > Relays and Modules - Steering > Steering Control
Module > Component Information > Description and Operation > Description
DESCRIPTION
Module > Component Information > Description and Operation > Description > Page 7285
OPERATION
bus.
Module > Component Information > Description and Operation > Page 7286
Jeep Workshop Manuals > Steering and Suspension > Steering > Relays and Modules - Steering > Steering Mounted
Controls Communication Module > Component Information > Locations
Component ID: 167
Connector:
Color : WHITE
# of pins : 4
Controls Communication Module > Component Information > Locations > Page 7290
Connector:
Color : WHITE
# of pins : 6

Connector:
Color : WHITE
# of pins : 4

Connector:
Color : WHITE
# of pins : 6

Component ID: 167
Connector:
Color : WHITE
# of pins : 4
Connector:
Color : WHITE
# of pins : 6

Connector:
Color : WHITE
# of pins : 4

Connector:
Color : WHITE
# of pins : 6

Jeep Workshop Manuals > Steering and Suspension > Steering > Sensors and Switches - Steering > Steering Angle
Sensor > Component Information > Technical Service Bulletins > Steering - ESP Lamp On Possible DTC C121A/C2205
C121A/C2205
NUMBER: 08-010-07
DATE: May 17, 2007
OVERVIEW:
new software.
MODELS:
2007 (JK) Wrangler
2007 (JS) Sebring
2007 (KA) Nitro
2007 (MK49) Compass
2007 (MK74) Patriot
2007 (PM) Caliber
NOTE:
SYMPTOM/CONDITION:
DIAGNOSIS:

Procedure.
Sensor > Component Information > Technical Service Bulletins > Steering - ESP Lamp On Possible DTC C121A/C2205 >
Page 7328
FILE:
NOTE:
NOTE:
NOTE:
is complete.
NOTE:
drop.

Page 7329
NOTE:
TIME ALLOWANCE:
FAILURE CODE:
Disclaimer:
Jeep Workshop Manuals > Steering and Suspension > Steering > Steering Angle Sensor > Component Information >
Technical Service Bulletins > Steering - ESP Lamp On Possible DTC C121A/C2205
C121A/C2205
NUMBER: 08-010-07
DATE: May 17, 2007
OVERVIEW:
new software.
MODELS:
2007 (JK) Wrangler
2007 (JS) Sebring
2007 (KA) Nitro
2007 (MK49) Compass
2007 (MK74) Patriot
2007 (PM) Caliber
NOTE:
SYMPTOM/CONDITION:
DIAGNOSIS:

Procedure.
Technical Service Bulletins > Steering - ESP Lamp On Possible DTC C121A/C2205 > Page 7334
FILE:
NOTE:
NOTE:
NOTE:
is complete.
NOTE:
drop.

Technical Service Bulletins > Steering - ESP Lamp On Possible DTC C121A/C2205 > Page 7335
NOTE:
TIME ALLOWANCE:
FAILURE CODE:
Disclaimer:
Jeep Workshop Manuals > Steering and Suspension > Steering > Steering Column > Steering Column Control Module >
DESCRIPTION
OPERATION
bus.
REMOVAL
SCCM
column.
DISASSEMBLY
SCCM.
INSTALLATION
with SCCM STEP 1.
ASSEMBLY
SCCM
Jeep Workshop Manuals > Steering and Suspension > Steering > Steering Column > Steering Column Cover > Component
Information > Service and Repair > Steering Column Opening Cover
Steering Column Cover: Service and Repair Steering Column Opening Cover
Removal
REMOVAL
1. Using a trim stick C-4755 or equivalent, separate the steering column opening cover and
remove.
Installation
INSTALLATION
1. Position the steering column opening cover onto the I/P and seat the retaining clips fully.
Information > Service and Repair > Steering Column Opening Cover > Page 7354
Steering Column Cover: Service and Repair Shroud - Lower
Removal
REMOVAL
Special Tools
1. Remove the screws (2) from the bottom of the steering column opening cover (1). 2. Using Trim
Stick C-4755 separate the steering column opening cover (1) and remove.
3. Position the column tilt at the full-downward position. 4. Remove the two screws (4) attaching the
upper shroud (1) to the lower shroud (2). After removing the screws, unclip the shrouds from each
other
by applying hand pressure along the seams where the shrouds connect on the sides, then remove
the upper shroud.
5. Push the tilt lever (5) downward. 6. Remove the screw (3) attaching the lower shroud (2) to the
steering column (6). Remove the lower shroud.
Installation
INSTALLATION
1. Push the tilt lever (5) downward. 2. Install the lower shroud (2) over the tilt lever and onto the
column. 3. Position the column tilt (5) at the full-upward position. 4. Push the tilt lever (5) upward,
locking it in place. 5. Install the screw (3) attaching the lower shroud (2) to the steering column (6).
6. Position the column tilt at the full-downward position and lock it in place. 7. Install the upper
shroud overthe lower shroud, clipping the shrouds to one another. 8. Install the two screws (4)
attaching the upper shroud (1) to the lower shroud (2).
9. Place the steering column opening cover (1) in place and seat the clips fully. 10. Install the two
screws (2) and tighten until secure.
Steering Column Cover: Service and Repair Shroud - Upper
Removal
REMOVAL
1. Position the column tilt at the full-downward position. 2. Remove the two screws (4) attaching the
upper shroud (1) to the lower shroud (2). After removing the screws, unclip the shrouds from each
other
by applying hand pressure along the seams where the shrouds connect on the sides, then remove
the upper shroud.
Installation
INSTALLATION
1. Position the column tilt at the full-downward position and lock it in place.
2. Install the upper shroud over the lower shroud, clipping the shrouds to one another. 3. Install the
two screws (4) attaching the upper shroud (1) to the lower shroud (2).
Jeep Workshop Manuals > Steering and Suspension > Steering > Steering Column > Steering Column Lock > Component
Information > Technical Service Bulletins > Customer Interest for Steering Column Lock: > 08-007-08A > Jul > 08 > Antitheft
System - Engine No Crank/No Start Condition
Steering Column Lock: Customer Interest Antitheft System - Engine No Crank/No Start Condition
GROUP: Electrical
DATE: July 04,2008

SKREEM
MODELS:
2007 - 2008 (KA) Nitro
2007 - 2008 (PM) Caliber
NOTE:
DIAGNOSIS:
run.
PARTS REQUIRED:
NOTE:
REPAIR PROCEDURE:
NOTE:
NOTE:
being removed.
NOTE:
with new units.
NOTE:
NOTE:
g. Press "Start".
h. Press "Next".
k. Select "Next".
m. Select "Next".
(TPM) and so on.

CAUTION:
e. Press "Start".
TIME ALLOWANCE:
FAILURE CODE:
Disclaimer:
Information > Technical Service Bulletins > All Technical Service Bulletins for Steering Column Lock: > 08-007-08A > Jul >
08 > Antitheft System - Engine No Crank/No Start Condition
Steering Column Lock: All Technical Service Bulletins Antitheft System - Engine No Crank/No Start
Condition
GROUP: Electrical
DATE: July 04,2008

SKREEM
MODELS:
2007 - 2008 (KA) Nitro
2007 - 2008 (PM) Caliber
NOTE:
DIAGNOSIS:
run.
08 > Antitheft System - Engine No Crank/No Start Condition > Page 7375
PARTS REQUIRED:
NOTE:
REPAIR PROCEDURE:
NOTE:
NOTE:
being removed.
NOTE:
with new units.
NOTE:
NOTE:
g. Press "Start".
h. Press "Next".
k. Select "Next".
m. Select "Next".
(TPM) and so on.

CAUTION:
e. Press "Start".
TIME ALLOWANCE:
FAILURE CODE:
Disclaimer:
Jeep Workshop Manuals > Steering and Suspension > Steering > Steering Gear > Component Information > Description
and Operation
Steering Gear: Description and Operation
DESCRIPTION
The steering gear (2) used is the rack-and-pinion type with power assist. It is mounted on the front
suspension crossmember. The outer ends of the outer tie rods attach to the front (steering)
knuckles.
NOTE: The power steering gear should not be serviced or adjusted. If a malfunction or oil leak
occurs with the steering gear, the complete steering gear needs to be replaced.
Jeep Workshop Manuals > Steering and Suspension > Steering > Steering Gear > Component Information > Description
Steering Gear: Testing and Inspection
POWER STEERING GEAR
NOTE: This information is designed to be used in conjunction with the diagnostic charts at the
beginning of the Steering section.
OBJECTIONABLE HISS OR WHISTLE POSSIBLY CAUSED BY A NOISY STEERING GEAR
1. Check and adjust power steering fluid level in the reservoir as necessary. 2. Start the vehicle
and heat system by steering lock-to-lock 5 times with the engine running at 3000 rpm. Do not hold
the gear against the stops for
more than 5 seconds at a time.
3. Return the engine to idle speed. 4. Listen for the noise when turning the wheel slowly off center
during a dry park maneuver. 5. Replace power steering gear if the hiss or whistle is present.
Jeep Workshop Manuals > Steering and Suspension > Steering > Steering Gear > Component Information > Service and
Repair > Removal
Steering Gear: Service and Repair Removal
STEERING GEAR
1. Siphon out as much power steering fluid as possible from the pump.
2. Reposition the floor carpeting to access the intermediate shaft coupling at the base of the
column. 3. Position the front wheels of vehicle in the STRAIGHT-AHEAD position, then turn the
steering wheel to the right until the intermediate shaft
coupling bolt (3) at the base of the column can be accessed.
4. Remove the intermediate shaft coupling bolt (3). Do not separate the intermediate shaft (2) from
the steering gear pinion shaft (4) at this
time.
5. Return the front wheels of vehicle (and steering wheel) to the STRAIGHT-AHEAD position.
Using a steering wheel holder, lock the steering
wheel in place to keep it from rotating. This keeps the clockspring in the proper orientation.
6. Raise and support the vehicle. 7. Remove the wheel mounting nuts (3), then the tire and wheel
assembly (1).
8. On each side of the gear, remove the nut (2) from the out tie rod end (4) at the knuckle (3).
9. On each side of the gear, separate the tie rod end (3) from the knuckle (2) using Remover (1),
Special Tool 9360.
10. If equipped, remove the engine belly pan. 11. Remove the rear engine mount. 12. Remove the
front engine mount through-bolt.
13. Remove the three screws (1, 2) securing the heat shield (3) to the crossmember (4). Remove
the shield.
14. Remove the return hose (1) at the steering gear (3). 15. Remove the pressure hose (2) at the
steering gear (3).
crossmember.
17. Remove the screws (1) securing the stabilizer bushing retainers (3) to the crossmember. 18.
Remove the two stabilizer bushing retainers.
NOTE: Before removing the front suspension crossmember from the vehicle, the location of the
crossmember must be marked on the body of the vehicle. Do this so the crossmember can be
relocated, upon reinstallation, against the body of vehicle in the same location as before removal. If
the front suspension crossmember is not reinstalled in exactly the same location as before
removal, the preset front wheel alignment settings (caster and camber) may be lost.
19. Mark the location of the front crossmember on the body near each mounting bolt using a
marker or crayon. Do not use a scratch awl or other
tool that can penetrate the protective coating on the body.
20. Support the front crossmember with a transmission jack. 21. Remove the four mounting bolts
(two each side) (6) securing the front crossmember (1) to the body.
22. Lower the crossmember enough to access the intermediate shaft coupling (1) at the steering
gear pinion shaft (4). Slide the coupling off the pinion
shaft.
23. Remove the dash seals (3, 5) as necessary.
24. Remove the two bolts (1) securing the steering gear (2) to the crossmember. 25. Rotate the
stabilizer bar up in order to remove the steering gear from the vehicle. 26. Remove the steering
gear from the crossmember.
Steering Gear: Service and Repair Installation
STEERING GEAR
1. Rotate the stabilizer bar up and install the steering gear on the crossmember. 2. Install the two
bolts (1) securing the steering gear (2) to the crossmember. Tighten the steering gear mounting
bolts to 70 Nm (52 ft. lbs.).
3. Install the dash seals (3, 5) as necessary.

4. Center the power steering gear rack in its travel as necessary.
NOTE: When installing the front suspension crossmember (1) back in the vehicle, it is very
important that the crossmember be attached to the body in exactly the same spot as when it was
removed. Otherwise, the vehicle's wheel alignment settings (caster and camber) will be lost.
5. Slowly raise the crossmember (1) into mounted position using the transmission jack matching
the crossmember to the marked locations on the
body made during removal.
6. Check the positioning of the seals at the dash panel and adjust as necessary. 7. Install the four
mounting bolts (two each side) (6) securing the front crossmember (1) to the body. Tighten the
crossmember mounting bolts to 190
Nm (140 ft. lbs.).
8. Remove the transmission jack.
9. Install the retainers (3) over the stabilizer bar cushions. Install all four stabilizer bar cushion
retainer screws (1) and tighten them to 30 Nm (22 ft.
lbs.).
10. Install the fasteners (1) securing the power steering hose routing clamps (2) to the
crossmember. Use a NEW push clip on the left and tighten the
11. Install the pressure hose (2) at the gear (3). Tighten the tube nut to 32 Nm (24 ft. lbs.). 12.
Install the return hose (1) at the gear (3). Tighten the tube nut to 20 Nm (15 ft. lbs.).
13. Position the heat shield (3) and install the three screws (1, 2) securing the shield to the
crossmember (4). Tighten the two front mounting screws
(1) to 4 Nm (35 in. lbs.). Tighten the rear mounting screw (2) to 17 Nm (150 in. lbs.).
14. Install the front engine mount through-bolt. 15. Install the rear engine mount. 16. If equipped,
install the engine belly pan.
NOTE: Prior to attaching the outer tie rod end to the knuckle, inspect the tie rod seal boot. If the
seal boot is damaged, replace the outer tie rod end.
17. On each side of the gear, install the outer tie rod end (4) into the hole in the knuckle arm (3).
Start a NEW tie rod mounting nut (2) onto the stud.
While holding the tie rod end stud with a wrench, tighten the nut with a wrench or crowfoot wrench.
Tighten the nut to 132 Nm (97 ft. lbs.).
18. On each side of the vehicle, install the tire and wheel assembly (1). Install and tighten the
wheel mounting nuts (3) to 135 Nm (100 ft. lbs.). 19. Lower the vehicle.
20. Remove the steering wheel holder.
21. Verify the front wheels of vehicle are in the STRAIGHT-AHEAD position. 22. Center the
intermediate shaft (2) over the steering gear pinion shaft (4), lining up the ends, then slide the
intermediate shaft onto the steering gear
pinion shaft.
23. From center, rotate the steering wheel to the right approximately 90° or until the intermediate
shaft coupling bolt (3) can be easily installed. 24. Install the intermediate shaft coupling bolt (3).
Tighten the bolt to 47 Nm (35 ft. lbs.). 25. Reposition the floor carpet (1) in place. 26. Straighten the
steering wheel to STRAIGHT-AHEAD position. 27. Fill and bleed the power steering system. 28.
Check for fluid leaks. 29. Adjust front wheel toe as necessary.
Jeep Workshop Manuals > Steering and Suspension > Steering > Steering Mounted Controls Communication Module >
Component ID: 167
Connector:
Color : WHITE
# of pins : 4
Connector:
Color : WHITE
# of pins : 6

Connector:
Color : WHITE
# of pins : 4

Connector:
Color : WHITE
# of pins : 6

Component ID: 167
Connector:
Color : WHITE
# of pins : 4
Connector:
Color : WHITE
# of pins : 6

Connector:
Color : WHITE
# of pins : 4

Connector:
Color : WHITE
# of pins : 6

Jeep Workshop Manuals > Steering and Suspension > Steering > Steering Wheel > Component Information > Service and
Repair > Removal
Steering Wheel: Service and Repair Removal
REMOVAL
WARNING:
- Do not place a non-deployed airbag face down on a hard surface. The airbag will propel into the
air if accidentally deployed, and could result in serious or fatal injury.
- Disconnect and isolate the battery negative (ground) cable before beginning steering wheel
removal or installation. This will disable the airbag system. Failure to disconnect the battery could
result in accidental airbag deployment and possible personal injury.
- Allow the airbag system capacitor to discharge for two minutes before removing the steering
wheel or any airbag system component.
1. Adjust the steering wheel so that the tires are in the STRAIGHT-AHEAD position. 2. Disconnect
3. Remove the driver airbag (3).

4. Disconnect the wiring connector (2) at the clockspring.
5. While holding the steering wheel firmly in place, remove the retaining bolt (2) securing the
steering wheel to the steering column shaft.
CAUTION: When installing a wheel puller on the steering wheel, be sure the puller jaws are fully
seated around the steering wheel base (1). If the jaws are not fully seated, the jaws may slip off the
steering wheel while attempting to remove the steering wheel.
Also, threading the retaining bolt (2) back in the end of the shaft until approximately 13 mm (0.5 in.)
of thread is showing between the wheel and the head of the bolt allows a safe reaction surface for
the puller to work against.
6. Thread the wheel retaining bolt (2) back into the end of the shaft until approximately 13 mm (0.5
in.) of thread is showing between the wheel and
the head of the bolt.
7. Remove the screw (3) for the speed control switch in order to install the steering wheel puller
tool. 8. Install a steering wheel puller on the steering wheel.
CAUTION: Do not bump or hammer on steering wheel or steering column shaft when removing
steering wheel from steering column.
9. While holding the steering wheel firmly in the STRAIGHT-AHEAD position, remove steering
wheel from the steering column shaft using the
puller.
10. Remove the wheel retaining bolt (2) and the steering wheel.
Steering Wheel: Service and Repair Installation
INSTALLATION
1. Confirm that:
a. The front wheels are in the STRAIGHT-AHEAD position. b. The turn signal stalk is in the
NEUTRAL position.
CAUTION: Do not install the steering wheel onto the shaft of the steering column by driving it onto
the shaft.
2. Align the steering wheel's wide mounting spline with the steering column shaft missing spline
area and push the wheel onto the shaft. Make sure
the clockspring lines up with the back of the wheel and does not bind.
3. Install the steering wheel retaining bolt (2) and tighten it until the steering wheel is fully installed
on shaft. Tighten the steering wheel retaining
bolt to 43 Nm (32 ft. lbs.).
4. Install the speed control screw (3) that was removed for the puller.
5. Connect the wiring connector (2) at the clockspring.
6. Install the driver airbag (3).
WARNING: Do not connect battery negative cable yet. Refer first to Airbag System Test. Refer to
electrical restraints diagnosis and testing.
7. Reconnect the battery using the Airbag System Test procedure in Restraints. 8. Verify vehicle
and system operation.
Jeep Workshop Manuals > Steering and Suspension > Steering > Tie Rod > Tie Rod End > Component Information >
Testing and Inspection
Tie Rod End: Testing and Inspection
TIE ROD
Tie rod free-play can be measured using the following hand methods:
NOTE: When checking free-play, DO NOT rotate the tie rod. Just because a tie rod rotates easily
does not mean that it is necessarily faulty.
NOTE: Always check and repair (if necessary) outer tie rod free-play before checking inner tie rod
free-play. False results can otherwise be obtained.
OUTER TIE ROD
Grasp the outer tie rod near the ball stud and attempt to move the tie rod straight up and down. If
any free-play is felt, replace the outer tie rod. If no free-play is felt at the outer tie rod, attempt to
move the inner tie rod in the same manner. Refer to the following procedure.
INNER TIE ROD

Testing and Inspection > Page 7442
Grasp the inner tie rod near the steering gear bellows and attempt to move the tie rod straight up
and down. If any free-play is felt, replace the steering gear.
Service and Repair > Removal - Outer Tie Rod End
Tie Rod End: Service and Repair Removal - Outer Tie Rod End
OUTER TIE ROD END
1. Raise and support the vehicle. 2. Remove the wheel mounting nuts (3), then the tire and wheel
assembly (1).
3. Loosen the tie rod jam nut (5). 4. Remove the nut (2) attaching the outer tie rod (4) to the
knuckle (3). To do this, hold the tie rod end stud with a wrench while loosening and
5. Release the tie rod end (3) from the knuckle (2) using Remover, Special Tool 9360 (1)
Service and Repair > Removal - Outer Tie Rod End > Page 7445
6. Remove the outer tie rod (3) from the knuckle (2).
NOTE: When unscrewing the outer tie rod from inner, count the number of revolutions to take it off.
This action will aid in installation, getting the toe close to where it needs to be when setting the
wheel alignment.
7. Remove the outer tie rod from the inner tie rod.
Service and Repair > Removal - Outer Tie Rod End > Page 7446
Tie Rod End: Service and Repair Installation - Outer Tie Rod End
OUTER TIE ROD END
1. If it is not already installed, install the jam nut (5) on the inner tie rod threads. 2. Thread the outer
tie rod (4) onto the inner tie rod approximately the same amount of revolutions as the original was
installed. 3. Thread the jam nut (5) down the inner tie rod far enough to hold the outer tie rod. Do
not tighten the jam nut at this time. 4. Install the outer tie rod ball stud into the hole in the knuckle
arm (3). Start a NEW tie rod mounting nut (2) onto the stud. While holding the tie rod
end stud with a wrench, tighten the nut with a wrench or crowfoot wrench. Tighten the nut to 132
Nm (97 ft. lbs.).
5. Install the tire and wheel assembly (1). Install and tighten wheel mounting nuts (3) to 135 Nm
(100 ft. lbs.). 6. Lower the vehicle. 7. Adjust the front wheel toe setting. 8. Tighten the tie rod jam
nut to 75 Nm (55 ft. lbs.) once wheel toe is set.
Jeep Workshop Manuals > Steering and Suspension > Suspension > Ball Joint > Component Information > Service and
Repair > Removal
Ball Joint: Service and Repair Removal
REMOVAL
CAUTION: This procedure is designed to be used only if a seal boot is damaged during related
service procedures. It is not to be used as a repair procedure for a cut seal boot on a vehicle that
has been driven and exposed to road and weather conditions.
1. Remove the lower control arm from the vehicle. 2. Using a screwdriver or other suitable tool (2),
pry the seal boot (1) off of the ball joint.
Jeep Workshop Manuals > Steering and Suspension > Suspension > Ball Joint > Component Information > Service and
Ball Joint: Service and Repair Installation
INSTALLATION
CAUTION: This procedure is designed to be used only if a seal boot is damaged during related
service procedures. It is not to be used as a repair procedure for a cut seal boot on a vehicle that
has been driven and exposed to road and weather conditions.
1. Place a liberal dab of Mopar(R) Multi-Mileage Lube (No more than 10g) or equivalent around the
base of the ball joint stud at the socket. 2. Position the ball joint stud straight up. 3. Place the NEW
ball joint seal boot over the ball joint stud. 4. By hand, start the seal boot over the sides of the ball
joint.
CAUTION: Prior to installing the sealing boot using Remover/Installer, Special Tool 6289-4, make
sure there are no burrs on the inside of the tool. Remove any burrs and lubricate with a small
amount of Mopar(R) Multi-Mileage Lube or equivalent.
5. Place Remover/Installer, Special Tool 6289-4, onto the screw-drive of Ball Joint Press, Special
Tool C-4212F. 6. Place Remover/Installer, Special Tool 6289-6, angle-cut end up into the cup of
Ball Joint Press, Special Tool C-4212F. Before tightening the set,
turn the Remover/Installer so that the tallest point of the angle-cut is away from the body of the
control arm when installing the seal boot.
7. Place the control arm ball joint into Remover/Installer 6289-6. Rotate the arm left or right until the
tallest point of the angle cut on the
Remover/Installer is away from the body of the control arm.

8. Lower Remover/Installer 6289-4 onto outer lip of ball joint seal. 9. By hand, tighten the Ball Joint
Press screw-drive installing the seal boot. Tighten the screw-drive until the seal boot is seated
squarely down
against the top surface of the lower control arm (3). It may be necessary to use a wrench to seat
the seal boot, but do not overtighten.
10. Remove the tools and wipe any grease off the ball joint stud using a clean shop towel with
Mopar(R) Brake Parts Cleaner applied to it. 11. Install the lower control arm.
Jeep Workshop Manuals > Steering and Suspension > Suspension > Control Arm > Component Information > Testing and
Inspection
Control Arm: Testing and Inspection
LOWER CONTROL ARM
Inspect the lower control arm for signs of damage from contact with the ground or road debris. If
the lower control arm shows any sign of damage, look for distortion. Do not attempt to repair or
straighten a broken or bent lower control arm. If damaged, the lower control arm stamping is
serviced only as a complete component.
Inspect both lower control arm isolator bushings for severe deterioration and replace the lower
control arm as required. Inspect the ball joint per the inspection procedure of the service manual
and replace the lower control arm required.
The only serviceable component of the lower control arm is the ball joint seal boot. It should only be
replaced if damaged during service of a chassis component. Otherwise, replace the entire control
arm.
Jeep Workshop Manuals > Steering and Suspension > Suspension > Control Arm > Component Information > Service and
Repair > Front Suspension
Control Arm: Service and Repair Front Suspension
Lower Control Arm - Removal
REMOVAL
NOTE: Before proceeding, refer to FRONT SUSPENSION WARNING.
3. Remove the nut (5) and pinch bolt (4) clamping the ball joint (6) stud to the knuckle (3).
CAUTION: Upon removing the knuckle from the ball joint stud, do not pull outward on the knuckle.
Pulling the knuckle outward at this point can separate the inner C/V joint on the halfshaft thus
damaging it.
5. Remove the front bolt (2) attaching the lower control arm (3) to the front suspension
crossmember (4). 6. Remove the nut (1) on the rear bolt attaching the lower control arm (3) to the
front suspension crossmember (4). Remove the bolt. 7. Remove the lower control arm (3) from the
crossmember (4).
Lower Control Arm - Installation
INSTALLATION
1. Place the lower control arm (2) into the front suspension crossmember (1). 2. Insert the rear bolt
(3) up through the crossmember (1) and lower control arm (2).
3. Install, but do not fully tighten, the nut (1) on the rear bolt attaching the lower control arm (3) to
the crossmember (4). 4. Install, but do not fully tighten, the front bolt (2) attaching the lower control
arm to the crossmember. 5. With no weight or obstruction on the lower control arm, tighten the
lower control arm rear mounting bolt nut (1) to 183 Nm (135 ft. lbs.). 6. With no weight or
obstruction on the lower control arm, tighten the lower control arm front pivot bolt (2) to 183 Nm
(135 ft. lbs.).
7. Install the ball joint (6) stud into the knuckle (3), aligning the bolt hole in the knuckle boss with
the groove formed in the side of the ball joint stud. 8. Install a NEW ball joint stud pinch bolt (4) and
nut (5). Tighten the nut to 82 Nm (60 ft. lbs.).
(100 ft. lbs.).
10. Lower the vehicle. 11. Perform wheel alignment as necessary.

Control Arm: Service and Repair Rear Suspension
Lower Control Arm - Removal
REMOVAL
3. If equipped, while holding the stabilizer bar link lower stud stationary, remove the nut (2)
securing the link to the lower control arm (4).
4. Remove the lower shock mounting nut (3) and bolt (1).
5. Remove the stay brace (3) mounting screws (2). Remove the stay brace.
6. Remove the nut (2) and bolt (3) securing the lower control arm (4) to the trailing link (1). 7.
Remove the nut (6) and bolt (5) securing the lower control arm (4) to the crossmember (7). 8.
Remove the lower control arm (4).
Lower Control Arm - Installation
INSTALLATION
1. Position the lower control arm and install the bolt (5) and nut (6) securing the lower control arm
(4) to the crossmember (7). Do not tighten at this
time.
2. Install the bolt (3) and nut (2) securing the lower control arm (4) to the trailing link (1). Do not
tighten at this time.
3. Install the stay brace (3) on the crossmember (1). Install and tighten the mounting screws (2) to
25 Nm (18 ft. lbs.).
4. Install the mounting bolt (1) and nut (3) fastening the shock assembly (2) to the lower control arm
(4). Do not tighten at this time.
NOTE: When attaching a stabilizer bar link to the lower control arm it is important that the lower
mounting stud be positioned properly. The lower mounting stud on the right side link needs to point
toward the rear of the vehicle when inserted through the lower control arm mounting flange. The
left side link lower stud needs to point toward the front of the vehicle. Otherwise the suspension
geometry will not function properly.
5. If equipped, attach the stabilizer bar link to the lower control arm (4). Install the nut (2) and while
holding the stabilizer bar link lower stud
stationary, tighten the nut (2) to 58 Nm (43 ft. lbs.).
(100 ft. lbs.). 7. Lower the vehicle. 8. Position the vehicle on an alignment rack/drive-on lift. Raise
the vehicle as necessary to access mounting bolts and nuts. 9. Tighten the lower control arm
mounting bolt nut at the crossmember to 95 Nm (70 ft. lbs.).
10. Tighten the lower control arm mounting bolt nut at the trailing link to 95 Nm (70 ft. lbs.). 11.
Tighten the shock assembly lower mounting bolt nut to 99 Nm (73 ft. lbs.). 12. Perform wheel
alignment as necessary.
Upper Control Arm - Removal
REMOVAL

3. Remove the nut (4) and bolt (3) securing the upper control arm (1) to the trailing link. 4. Remove
the bolt (2) securing the upper control arm (1) to the crossmember. 5. Remove the upper control
arm (1).
Upper Control Arm - Installation
INSTALLATION
1. Position the upper control arm (1) and install the bolt (2) securing the arm to the crossmember.
Do not tighten at this time. 2. Install the bolt (3) and nut (4) securing the upper control arm (1) to the
trailing link. Do not tighten at this time.
(100 ft. lbs.). 4. Lower the vehicle. 5. Position the vehicle on an alignment rack/drive-on lift. Raise
the vehicle as necessary to access mounting bolts and nuts. 6. Tighten the upper control arm
mounting bolt at the crossmember to 95 Nm (70 ft. lbs.). 7. Tighten the upper control arm mounting
bolt nut at the trailing link to 95 Nm (70 ft. lbs.). 8. Perform wheel alignment as necessary.
Toe Link - Removal
REMOVAL
2. Remove the bolt (2) securing the toe link (3) to the trailing link.
3. Mark the position of the cam bolt cam on the crossmember using a paint marker or crayon. This
mark will be used upon installation to help get the
alignment close prior to performing rear wheel alignment. Do not use any type marker that will
scratch or damage the surface of the crossmember.
4. While holding the cam bolt head (3) stationary, loosen and remove the toe link mounting cam
bolt nut (1) and washer. Remove the cam bolt. 5. Remove the toe link (2).
Toe Link - Installation
INSTALLATION
CAUTION: When installing the cam bolt (3) and washer make sure the cams stay inside the
abutments built into the crossmember. Failure to
do so can damage the abutments and make toe adjustment difficult.
1. Position the toe link (2) and install the cam bolt (3) from the front through the crossmember and
link. Match the cam on the bolt to the marks made
during removal or position the top of the cam to the 12 O'clock position.
2. Install the cam washer and nut (1) securing the toe link (2) to the crossmember. Do not tighten at
this time.
3. Install the bolt (2) securing the link to the trailing link. To install the bolt it may be necessary to
flex the trailing link body mount bushing inward
or outward using an appropriate prying tool. Do not tighten at this time.
4. Lower the vehicle. 5. Position the vehicle on an alignment rack/drive-on lift. Raise the vehicle as
necessary to access mounting bolts and nuts. 6. Tighten the toe link mounting bolt at the trailing
link to 95 Nm (70 ft. lbs.). 7. Perform wheel alignment as necessary.
8. Once rear toe is set, while holding the cam bolt head (3) stationary, tighten the toe link mounting
cam bolt nut (1) to 35 Nm (26 ft. lbs.).
Jeep Workshop Manuals > Steering and Suspension > Suspension > Front Steering Knuckle > Component Information >
Front Steering Knuckle: Description and Operation
DESCRIPTION
The knuckle (1) is a single casting with legs machined for attachment to the front strut assembly on
the top, lower control arm ball joint on the bottom, and steering linkage on the trailing end. The
knuckle also has two machined, drilled and tapped legs on the leading end casting to support and
align the front disc brake caliper adapter.
The knuckle supports the wheel bearing (5) and hub (3). The hub is pressed into a sealed-for-life
wheel bearing that is pressed into the knuckle. A snap ring also holds the bearing in place. A shield
is pressed onto the knuckle behind the hub.
Front Steering Knuckle: Testing and Inspection
KNUCKLE
The front suspension knuckle is not a repairable component of the front suspension. It must be
replaced if found to be damaged in any way. If it is determined that the knuckle is bent when
servicing the vehicle, no attempt is to be made to straighten the knuckle.
Front Steering Knuckle: Service and Repair Removal
REMOVAL
NOTE: Before proceeding, review all Warnings and Cautions.
3. Remove the cotter pin (2) from the hub nut (3). 4. While a helper applies the brakes to keep the
hub (1) from rotating, remove the hub nut (3) and washer (4) from the axle half shaft. 5. Access and
remove the front brake rotor.
6. Remove the routing clip (1) securing wheel speed sensor cable to the knuckle (4). 7. Remove
the screw (2) fastening the wheel speed sensor head (3) to the knuckle (4). Pull the sensor head
out of the knuckle.
8. Remove the nut (2) attaching the outer tie rod (7) to the knuckle (3). To do this, hold the tie rod
end stud with a wrench while loosening and
9. Release the outer tie rod end (3) from the knuckle (2) using Remover (1), Special Tool 9360.
10. Remove the outer tie rod from the knuckle.

11. Remove the nut (5) and pinch bolt (4) clamping the ball joint stud (6) to the knuckle (3).
during removal. Proper removal is required. Refer to the following steps for the correct method.
using a pin punch.
NOTE: Do not allow the half shaft (1) to hang by the inner C/V joint; it must be supported to keep
the joint from separating during this operation.
15. Pull the knuckle (3) off the half shaft (1) outer C/V joint splines and remove the knuckle from the
vehicle.
Front Steering Knuckle: Service and Repair Installation
INSTALLATION
1. Slide the hub of the knuckle (3) onto the splines of the halfshaft outer C/V joint (1). 2. Install the
knuckle (3) onto the ball joint (6) stud aligning the bolt hole in the knuckle boss with the groove
formed into the side of the ball joint
stud.
3. Install a NEW ball joint stud pinch bolt (4) and nut (5). Tighten the nut to 82 Nm (60 ft. lbs.).
during installation. Install the nuts while holding the bolts stationary in the steering knuckle. Refer to
the following step.
aligning the mounting holes. Install the two mounting
bolts (5).
5. Install the nuts (2) on the two bolts (5). While holding the bolts in place, tighten the nuts to 84 Nm
(62 ft. lbs.).
6. Install the outer tie rod (7) ball stud into the hole in the knuckle (3) arm. Start the tie rod
end-to-knuckle nut (2) onto the stud. While holding the
tie rod end stud with a wrench, tighten the nut with a wrench or crowfoot wrench to 132 Nm (97 ft.
lbs.).
cable to the knuckle (4). 9. Install the brake rotor, disc brake caliper and adapter.
10. Clean all foreign matter from the threads of the halfshaft outer C/V joint.
11. Install the washer (4) and hub nut (3) on the end of the halfshaft and snug it. 12. While a helper
applies the brakes to keep the hub (1) from rotating, tighten the hub nut (3) to 245 Nm (181 ft. lbs.).
13. Insert the cotter pin (2) through the notches in the nut and the hole in halfshaft. If the notches in
the nut do not line up with the hole in the
halfshaft, continue to tighten the nut until they do. Do not loosen the nut.
Nm (100 ft. lbs.). 16. Lower the vehicle.
NOTE: If the original knuckle is being reinstalled, wheel alignment may not be necessary due to
Net-Build design.
17. Perform wheel alignment as necessary.

Jeep Workshop Manuals > Steering and Suspension > Suspension > Rear Knuckle Alignment Link > Component
Rear Knuckle Alignment Link: Service and Repair Removal
REMOVAL
3. Mark the position of the cam bolt cam on the crossmember using a paint marker or crayon. This
mark will be used upon installation to help get the
alignment close prior to performing rear wheel alignment. Do not use any type marker that will
scratch or damage the surface of the crossmember.
4. While holding the cam bolt head (3) stationary, loosen and remove the toe link mounting cam
bolt nut (1) and washer. Remove the cam bolt. 5. Remove the toe link (2).
Rear Knuckle Alignment Link: Service and Repair Installation
INSTALLATION
CAUTION: When installing the cam bolt (3) and washer make sure the cams stay inside the
abutments built into the crossmember. Failure to do so can damage the abutments and make toe
adjustment difficult.
1. Position the toe link (2) and install the cam bolt (3) from the front through the crossmember and
link. Match the cam on the bolt to the marks made
during removal or position the top of the cam to the 12 O'clock position.
2. Install the cam washer and nut (1) securing the toe link (2) to the crossmember. Do not tighten at
this time.
3. Install the bolt (2) securing the link to the trailing link. To install the bolt it may be necessary to
flex the trailing link body mount bushing inward
or outward using an appropriate prying tool. Do not tighten at this time.

4. Lower the vehicle. 5. Position the vehicle on an alignment rack/drive-on lift. Raise the vehicle as
necessary to access mounting bolts and nuts. 6. Tighten the toe link mounting bolt at the trailing
link to 95 Nm (70 ft. lbs.). 7. Perform wheel alignment as necessary.
8. Once rear toe is set, while holding the cam bolt head (3) stationary, tighten the toe link mounting
cam bolt nut (1) to 35 Nm (26 ft. lbs.).
Jeep Workshop Manuals > Steering and Suspension > Suspension > Sensors and Switches - Suspension > Steering Angle
Sensor > Component Information > Technical Service Bulletins > Steering - ESP Lamp On Possible DTC C121A/C2205
C121A/C2205
NUMBER: 08-010-07
DATE: May 17, 2007
OVERVIEW:
new software.
MODELS:
2007 (JK) Wrangler
2007 (JS) Sebring
2007 (KA) Nitro
2007 (MK49) Compass
2007 (MK74) Patriot
2007 (PM) Caliber
NOTE:
SYMPTOM/CONDITION:
DIAGNOSIS:

Procedure.
Page 7491
FILE:
NOTE:
NOTE:
NOTE:
is complete.
NOTE:
drop.

Page 7492
NOTE:
TIME ALLOWANCE:
FAILURE CODE:
Disclaimer:
Jeep Workshop Manuals > Steering and Suspension > Suspension > Stabilizer Bar, Sway Control > Component Information
> Service and Repair > Front Suspension
Stabilizer Bar: Service and Repair Front Suspension
Removal
REMOVAL
1. Raise and support the vehicle. 2. If equipped, remove the engine belly pan. 3. Remove the rear
engine mount. 4. Remove the front engine mount through-bolt.
crossmember.
6. At each end of the stabilizer bar, while holding the stabilizer bar link (1) lower stud stationary,
remove the nut (3) securing the link to the stabilizer
bar (2).
> Service and Repair > Front Suspension > Page 7497
7. Remove the screws (1) securing the stabilizer bushing retainers (3) to the crossmember. 8.
Remove the two stabilizer bushing retainers. 9. Utilizing the slit cut into the cushions (bushings),
remove the two cushions from the stabilizer bar.
NOTE: Before removing the front suspension crossmember from the vehicle, the location of the
crossmember must be marked on the body of the vehicle. Do this so the crossmember can be
relocated, upon reinstallation, against the body of vehicle in the same location as before removal. If
the front suspension crossmember is not reinstalled in exactly the same location as before
removal, the preset front wheel alignment settings (caster and camber) may be lost.
10. Mark the location of the front crossmember on the body near each mounting bolt. 11. Support
the crossmember with a transmission jack. 12. Remove the four mounting bolts (6) securing the
front crossmember (1) to the body.
13. Remove the two bolts (1) securing the steering gear (2) to the crossmember. 14. Support the
steering gear using a bungee cord or other to keep the steering gear from lowering when the
crossmember is lowered. 15. Slowly lower the crossmember until there is enough space present to
remove the stabilizer bar between the rear of the crossmember and the body.
Due to the fact that the fore-and-aft crossmember is still attached, do not lower crossmember any
more than necessary to remove the stabilizer bar.
16. Remove the stabilizer bar out over rear of crossmember.
Installation
INSTALLATION
NOTE: Before stabilizer bar installation, inspect the cushions and links for excessive wear, cracks,
damage and distortion. Replace any pieces failing inspection.
NOTE: Before installing the stabilizer bar, make sure the bar is not upsidedown. The stabilizer bar
(1) must be installed so that when in mounted position, the ends of the bar curve over the top of the
steering gear before attaching to the links.
1. Install the stabilizer bar, link ends first, from the rear over top of the crossmember. Curve the
ends of the bar over the steering gear.
2. Slowly raise the crossmember (1) into mounted position using the transmission jack matching
the crossmember to the marked locations on the
body made during removal.
3. Install the four mounting bolts (6) securing the front crossmember (1) to the body. Tighten the
crossmember mounting bolts to 190 Nm (140 ft.
lbs.).
4. Remove the transmission jack.

5. Remove the bungee cord or other supporting the steering gear (2). 6. Install the two bolts (1)
securing the steering gear (2) to the crossmember. Tighten the steering gear mounting bolts to 70
Nm (52 ft. lbs.).
7. Install the two cushions (bushings) on the stabilizer bar utilizing the slit cut into the cushion
sides. 8. Install the two stabilizer bushing retainers (3) over the cushions. 9. Install the screws (1)
securing the stabilizer bushing retainers (3) to the crossmember. Tighten all four stabilizer bar
cushion retainer screws to 30
Nm (22 ft. lbs.).
10. Attach the stabilizer bar link (1) at each end of the stabilizer bar (2). At each link, install and
tighten the nut (3) while holding the stabilizer bar
link lower stud stationary. Tighten the nuts to 58 Nm (43 ft. lbs.).
11. Position the power steering hose routing clamps (2) on the crossmember. Install the fasteners.
Tighten the screw to 8 Nm (71 in. lbs.). 12. Install the rear engine mount. 13. If equipped, install the
engine belly pan. 14. Lower the vehicle. 15. Perform wheel alignment as necessary paying special
attention to front camber and caster. The crossmember may need to be shifted on its mounts
slightly to gain preferred setting.

Stabilizer Bar: Service and Repair Rear Suspension
Removal
REMOVAL
NOTE: Before proceeding, refer to REAR SUSPENSION WARNING.
2. On both sides of the vehicle, while holding the stabilizer bar link upper stud stationary, remove
the nut (1) securing the link to the stabilizer bar
(3).
3. If equipped with all-wheel-drive, remove the rear driveline module.
4. On both sides of the vehicle, remove the screws (3) securing the stabilizer bushing retainers (1)
to the crossmember. 5. Remove the two stabilizer bushing retainers.
6. Remove the stabilizer bar (2) from the vehicle. 7. If required, remove the two cushions from the
stabilizer bar utilizing the slit cut into the cushions (bushings).
Installation
INSTALLATION
1. If required, install the two cushions on the stabilizer bar (one on each side) utilizing the slit cut
into the cushions (bushings).
NOTE: When installing the stabilizer bar on a vehicle with all-wheel-drive, position the bar so that
the bar loops under the axle half shafts once installed, not over the axle half shafts.
2. Position the stabilizer bar (2) on the rear crossmember. 3. Install the two retainers (1) over the
cushions at the mounting holes and install the retainer screws (3). Do not tighten the screws at this
time. 4. If equipped with all-wheel-drive, install the rear driveline module.
5. On each side of the vehicle, install the stabilizer link upper stud in the end of the stabilizer bar
(3). Install the nut (1) on each upper stud and while
holding the stabilizer link stud stationary, tighten the nut (2) to 58 Nm (43 ft. lbs.).
6. Tighten the cushion retainer screws to 34 Nm (25 ft. lbs.). 7. Lower the vehicle.
Jeep Workshop Manuals > Steering and Suspension > Suspension > Suspension Strut / Shock Absorber > Component
Information > Technical Service Bulletins > Customer Interest for Suspension Strut / Shock Absorber: > 02-001-09 > Aug >
09 > Suspension - Rough Handling/Front Strut(s) Leaking
Suspension Strut / Shock Absorber: Customer Interest Suspension - Rough Handling/Front Strut(s)
Leaking
NUMBER: 02-001-09
GROUP: Springs/Shocks
SUBJECT: Poor Handling and/or Strut Leaking and/or Rides Rough
OVERVIEW: This bulletin involves replacing the, jounce bumper and dust shield with a new design
if front struts are replaced due to degraded performance.
MODELS:
2007-2009 (PM) Caliber
2007-2009 (MK) Compass/Patriot
NOTE:
This Bulletin applies to vehicles built before April 23, 2009 (MDH 0423XX).
SYMPTOM/CONDITION: The front strut(s) leaking and/or the vehicle handles rough.
DISCUSSION: When replacing front struts due to degraded performance. The jounce bumper/dust
shield must be replaced with the latest design. Perform the inspection/repair procedure to
determine if jounce bumper/dust shield requires replacement

09 > Suspension - Rough Handling/Front Strut(s) Leaking > Page 7512
PARTS REQUIRED:
REPAIR PROCEDURE:
1. Is the jounce bumper and dust shield a one-piece black rubber part?
a. Yes >> Proceed to
b. No >> This bulletin does not apply the latest part design has been implemented.
2. Remove both right and left front struts. Refer to the detailed removal procedures available in
DealerCONNECT > TechCONNECT under: Service
Info > 2-Front Suspension > STRUT, Suspension, Assembly > Removal.
NOTE:
Even though one front strut needs replacement both jounce bumper/dust shields require
replacement.
3. Disassemble the undamaged strut assembly. Refer to the detailed removal procedures available
in DealerCONNECT > TechCONNECT under:
Service Info > 2-Front Suspension > STRUT, Suspension, Assembly> Disassembly.
4. Remove the undamaged front strut assembly jounce bumper.
5. Install jounce bumper(s) p/n 05171137AB on the replacement and undamaged front strut
assembly.
6. Install dust shield cover(s) p/n 05171132AC on both the strut assemblies.
7. Assemble the strut assemblies. Refer to the detailed removal procedures available in
DealerCONNECT > TechCONNECT under: Service Info >
2-Front Suspension > STRUT, Suspension, Assembly > Assembly.
8. Install the strut assemblies. Refer to the detailed installation procedures available in
2-Front Suspension > STRUT, Suspension, Assembly > Installation.
TIME ALLOWANCE:
09 > Suspension - Rough Handling/Front Strut(s) Leaking > Page 7513
FAILURE CODE:
Disclaimer:
Information > Technical Service Bulletins > Customer Interest for Suspension Strut / Shock Absorber: > 02-001-06 > Oct >
06 > Suspension - Swish Sound From Rear of Vehicle On Bumps
Suspension Strut / Shock Absorber: Customer Interest Suspension - Swish Sound From Rear of
Vehicle On Bumps
NUMBER: 02-001-06
GROUP: Suspension
SUBJECT: Swish Sound Heard From Rear Of Vehicle Over Low Speed Bumps
OVERVIEW: This bulletin involves installing a shock cap on both rear shocks.
MODELS:
2007 (PM) Caliber
NOTE:
This bulletin applies to vehicles built prior to October 6, 2006 (MDH 0606XX).
SYMPTOM/CONDITION:
Swish sound heard from the rear of the vehicle. This condition is more noticeable when the vehicle
is traveling over a bumpy road or speed bumps at low speeds.
DIAGNOSIS:
Drive vehicle over speed bumps or a bumpy road a low speeds. If the swish sound can be heard,
PARTS REQUIRED:
REPAIR PROCEDURE:
1. Remove both rear shocks using the procedures available in TechCONNECT, Refer to 2 -
Suspension/Rear/Shock - Removal.
NOTE:
Be sure to clearly mark right and left shock for re-installation.

Information > Technical Service Bulletins > Customer Interest for Suspension Strut / Shock Absorber: > 02-001-06 > Oct >
06 > Suspension - Swish Sound From Rear of Vehicle On Bumps > Page 7518
2. Install the shock cap (p/n 05105949AA) over the top of both shocks (2) (Fig. 1).
3. Install both rear shocks using the procedures available in TechCONNECT, Refer to 2 -
Suspension/Rear/Shock - Installation.
TIME ALLOWANCE:
FAILURE CODE:
Disclaimer:
Information > Technical Service Bulletins > All Technical Service Bulletins for Suspension Strut / Shock Absorber: >
02-001-09 > Aug > 09 > Suspension - Rough Handling/Front Strut(s) Leaking
Suspension Strut / Shock Absorber: All Technical Service Bulletins Suspension - Rough
Handling/Front Strut(s) Leaking
NUMBER: 02-001-09
MODELS:
NOTE:

02-001-09 > Aug > 09 > Suspension - Rough Handling/Front Strut(s) Leaking > Page 7524
PARTS REQUIRED:
REPAIR PROCEDURE:
NOTE:
replacement.
assembly.
TIME ALLOWANCE:
02-001-09 > Aug > 09 > Suspension - Rough Handling/Front Strut(s) Leaking > Page 7525
FAILURE CODE:
Disclaimer:
02-001-06 > Oct > 06 > Suspension - Swish Sound From Rear of Vehicle On Bumps
Suspension Strut / Shock Absorber: All Technical Service Bulletins Suspension - Swish Sound
From Rear of Vehicle On Bumps
NUMBER: 02-001-06
GROUP: Suspension
SUBJECT: Swish Sound Heard From Rear Of Vehicle Over Low Speed Bumps
OVERVIEW: This bulletin involves installing a shock cap on both rear shocks.
MODELS:
2007 (PM) Caliber
NOTE:
This bulletin applies to vehicles built prior to October 6, 2006 (MDH 0606XX).
SYMPTOM/CONDITION:
Swish sound heard from the rear of the vehicle. This condition is more noticeable when the vehicle
is traveling over a bumpy road or speed bumps at low speeds.
DIAGNOSIS:
Drive vehicle over speed bumps or a bumpy road a low speeds. If the swish sound can be heard,
PARTS REQUIRED:
REPAIR PROCEDURE:
1. Remove both rear shocks using the procedures available in TechCONNECT, Refer to 2 -
Suspension/Rear/Shock - Removal.
NOTE:
Be sure to clearly mark right and left shock for re-installation.

02-001-06 > Oct > 06 > Suspension - Swish Sound From Rear of Vehicle On Bumps > Page 7530
2. Install the shock cap (p/n 05105949AA) over the top of both shocks (2) (Fig. 1).
3. Install both rear shocks using the procedures available in TechCONNECT, Refer to 2 -
Suspension/Rear/Shock - Installation.
TIME ALLOWANCE:
FAILURE CODE:
Disclaimer:
Information > Description and Operation > Front Suspension
Suspension Strut / Shock Absorber: Description and Operation Front Suspension
Description
DESCRIPTION
A Macpherson type design strut assembly is used in place of the front suspension upper control
arm and upper ball joint. The bottom of the strut mounts directly to the steering knuckle using two
attaching bolts and nuts going through the strut clevis bracket and knuckle. The top of the strut
mounts directly to the strut tower of the vehicle using the three threaded studs on the strut
assembly's upper mount.
The strut assembly includes the following components:
- Upper mount (rubber isolated) (2)
- Bearing (3)
- Upper spring seat and isolator (4)
- Coil spring (5)

- Dust shield and jounce bumper (6)
- Lower spring isolator (7)
- Strut (damper) (8)
Each component is serviced by removing the strut assembly from the vehicle and disassembling it.
Coil springs are rated separately for each corner or side of the vehicle depending on optional
equipment and type of vehicle service. If a coil spring requires replacement, be sure that it is
replaced with a spring meeting the correct load rating for the vehicle and its specific options.
Operation
OPERATION
The strut assembly cushions the ride of the vehicle, controlling vibration, jounce and rebound of the
suspension.
The coil spring controls ride quality and maintains proper ride height.
The spring isolators isolate the coil spring at the top and bottom from coming into metal-to-metal
contact with the upper mounting seat and the strut.
The jounce bumper limits suspension travel and metal-to-metal contact under full jounce condition.
The strut dampens jounce and rebound motions of the coil spring and suspension.
Information > Description and Operation > Front Suspension > Page 7533
Suspension Strut / Shock Absorber: Description and Operation Rear Suspension
DESCRIPTION
A coil-over shock absorber assembly supports each side of the vehicle. The bottom of the shock
assembly mounts to the lower control arm. The top of the shock assembly mounts to the body.
The shock assembly includes the following major components:
- Upper bushing (3)
- Upper mounting bracket (4)
- Upper spring isolator (5)
- Sleeve (6)
- Lower bushing (7)
- Jounce bumper (9)
- Dust shield (10)

- Coil spring (11)
- Lower spring isolator (12)
- Shock absorber (13)
Later build vehicles also have a noise abatement cap located on top of the assembly.
Each component is serviced by removing the shock assembly from the vehicle and disassembling
it.
Coil springs are rated separately for each corner or side of the vehicle depending on optional
equipment and type of vehicle service. If a coil spring requires replacement, be sure that it is
replaced with a spring meeting the correct load rating for the vehicle and its specific options.
Information > Testing and Inspection > Front Suspension
Suspension Strut / Shock Absorber: Testing and Inspection Front Suspension
STRUT ASSEMBLY
Inspect the strut assembly for the following conditions:
- Inspect for a damaged or broken coil spring (5).
- Inspect for a torn or damaged dust shield (6).
- Lift the dust shield and inspect the strut assembly for evidence of fluid running from the upper end
of the strut fluid 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 between the strut shaft and strut shaft
seal is not unusual and does not affect performance of the strut assembly.
- Inspect the jounce bumper for signs of damage or deterioration.
- Inspect the clearance between the shock tower and the coil spring. Make sure no fasteners are
protruding through the shock tower possibly contacting the coil spring and strut. Because of the
minimum clearance in this area, installation of metal fasteners could damage the coil spring coating
and lead to a corrosion failure of the spring.
CAUTION: At no time when servicing a vehicle can a sheet metal screw, bolt or other metal
fastener be installed into the strut tower (1) to take the place of an original plastic clip. Also, do not
drill holes into the front strut tower for the installation of any metal fasteners into the shock
tower area indicated (3).
Suspension Strut / Shock Absorber: Testing and Inspection Rear Suspension
SHOCK ABSORBER
Inspect the shock absorber for damage and evidence of fluid running from the upper end of the
fluid reservoir. (Actual leakage will be a stream of fluid running down the side of the reservoir tube
and dripping off lower end of unit). A slight amount of seepage between the shaft and shaft seal is
not unusual and does not affect performance of the shock absorber.
Information > Service and Repair > Front Strut / Shock
Suspension Strut / Shock Absorber: Service and Repair Front Strut / Shock
Removal
REMOVAL
NOTE: If both strut assemblies are to be removed, mark the strut assemblies right or left and keep
the parts separated to avoid mix-up. Not all parts of the strut assembly are interchangeable
side-to-side.
3. Remove the screw (1) securing the flex hose (2) routing bracket to the strut (6).
Information > Service and Repair > Front Strut / Shock > Page 7540
4. While holding the stabilizer bar link (1) stud stationary, remove the nut (4) securing the link to the
strut (3).
during removal. Hold the bolts stationary in the knuckle while removing the nuts, then tap the bolts
out using a pin punch.
using a pin punch. 7. Lower the vehicle just enough to open the hood without allowing the tires to
touch the floor.
8. Remove the three nuts (1) attaching the strut assembly (2) upper mount to the strut tower. 9.
Remove the strut assembly (2) from the vehicle.
10. For disassembly, refer to Front Suspension Strut Disassembly.
Disassembly
DISASSEMBLY
NOTE: The strut assembly must be removed from the vehicle for it to be disassembled and
assembled.
For the disassembly and assembly of the strut assembly, use strut spring compressor, teamPSE
tool 223-7400, or the equivalent, to compress the coil spring. Follow the manufacturer's instructions
closely.
WARNING: Do not remove the strut rod nut before the coil spring is properly compressed. The coil
spring is held under pressure. The coil spring must be compressed, removing spring tension from
the upper mount and bearing, before the strut rod nut is removed.
1. If both struts are being serviced at the same time, mark both the coil spring and strut assembly
according to which side of the vehicle the strut is
being removed from.
2. Position the strut assembly (2) in the strut coil spring compressor (1) following the
manufacturer's instructions and set the lower and upper hooks
of the compressor on the coil spring. Position the strut clevis bracket (2) straight outward, away
from the compressor.
3. Compress the coil spring until all coil spring tension is removed from the upper mount and
bearing.
CAUTION: Never use impact or high speed tools to remove the strut rod nut. Damage to the strut
internal bearings can occur.
4. Once the spring is sufficiently compressed, install Strut Nut Wrench (2), Special Tool 9362, on
the strut rod nut. Next, install Strut Shaft Socket
(1), Special Tool 9894, on the end of the strut rod. While holding the strut rod from turning, remove
the nut using the strut nut wrench.
5. Remove the clamp (if installed) from the bottom of the coil spring and remove the strut (damper)
(8) out through the bottom of the coil spring. The
dust shield and jounce bumper will come out with the strut.
6. Remove the lower spring isolator (7) from the strut seat. 7. Slide the dust shield and jounce
bumper (6) from the strut rod. 8. Remove the upper mount (2) and bearing (3) from the top of the
upper spring seat and isolator (4). 9. Remove the upper spring seat and isolator (4) from the top of
the coil spring (5).
NOTE: If the coil spring needs to be serviced, proceed with the next step, otherwise, proceed with
STEP 11.
10. Release the tension from the coil spring by backing off the compressor drive completely. Push
back the compressor hooks and remove the coil
spring.
11. Inspect the strut assembly components for the following and replace as necessary:
- Inspect the strut (damper) (8) for shaft binding over the full stroke of the shaft.
- Inspect the jounce bumper (with dust shield) (6) for cracks and signs of deterioration.
- Check the upper mount (2) for cracks and distortion and its retaining studs for any sign of
damage.
- Check the bearing (3) for any binding.
- Check the upper spring seat and isolator (4) for cracks and distortion.
- Inspect the upper and lower spring isolators (4, 7) for material deterioration and distortion.
- Inspect the coil spring (5) for any sign of damage to the coating.
Assembly
ASSEMBLY
NOTE: If the coil spring has been removed from the spring compressor, proceed with the next step,
otherwise, proceed with STEP 3.
CAUTION: When installing the coil spring, make sure the end with the ID tag is placed downward,
otherwise spring-to-body contact will occur after strut assembly installation.
1. Place the coil spring in the spring compressor following the manufacturer's instructions. Before
compressing the spring, rotate the spring so the
end of the bottom coil is at approximately the 9 o'clock position as viewed above (or to where the
spring was when removed from the compressor). This action will allow the strut (damper) clevis
bracket to be positioned outward, away from the compressor once installed.
2. Slowly compress the coil spring until enough room is available for strut assembly reassembly.
3. Install the upper spring seat and isolator (4) on top of the coil spring (5). 4. Install the bearing (3)
and upper mount (2) on top of the upper spring seat and isolator (4). 5. Install the lower spring
isolator (7) on the spring seat on the strut (8). 6. Slide the dust shield and jounce bumper (6) onto
the strut rod.
7. Install the strut up through the bottom of the coil spring and upper spring seat, mount, and
bearing until the lower spring seat contacts the lower
end of the coil spring. Rotate the strut as necessary until the end of the bottom coil (2) comes in
contact with the stop (1) built into the lower spring isolator.
8. While holding the strut in position, install the nut (1) on the end of the strut rod.
CAUTION: Never use impact or high speed tools to remove the strut rod nut. Damage to the strut
internal bearings can occur.
9. Install Strut Nut Wrench (2), Special Tool 9362, on the strut rod nut. Next, install Strut Shaft
Socket (1), Special Tool 9894, on the end of the strut
rod. While holding the strut rod from turning, tighten the strut rod nut to 60 Nm (44 ft. lbs.) using a
torque wrench on the end of Special Tool 9362.
10. Slowly release the tension from the coil spring by backing off the compressor (1) drive
completely. As the tension is relieved, make sure the upper
mount and bearing align properly. Verify the upper mount does not bind when rotated.
11. Remove the strut assembly from the spring compressor. 12. Install the strut assembly on the
vehicle.
Installation
INSTALLATION
1. Raise the strut assembly (2) into the strut tower, aligning the three studs on the strut assembly
upper mount with the holes in strut tower. Install the
three mounting nuts (1) on the studs. Tighten the three nuts to 48 Nm (35 ft. lbs.).
during installation. Install the nuts while holding the bolts stationary in the knuckle.
aligning the mounting holes. Install the two attaching
bolts (5). Install the nuts (2). While holding the bolts in place, tighten the nuts to 84 Nm (62 ft. lbs.).
3. Attach the stabilizer bar link (1) to the strut (3). Install and tighten the nut (4) while holding the
stabilizer bar link stud stationary. Tighten the nut
to 58 Nm (43 ft. lbs.).

4. Secure the flex hose (2) routing bracket to the strut (6) with the mounting screw (1). Tighten the
mounting screw to 13 Nm (120 in. lbs.).
(100 ft. lbs.) 6. Lower the vehicle. 7. Perform wheel alignment as necessary. If original strut is being
reinstalled, wheel alignment is not necessary.
Suspension Strut / Shock Absorber: Service and Repair Rear Shock Absorber
Removal
REMOVAL
NOTE: Before proceeding, refer to REAR SUSPENSION WARNING.
shock assembly upper mounting nuts through the opening in the bottom of the quarter trim panel.
4. Remove the spare tire.

5. Fold the shock assembly upper mounting nut access door (2) upward. Use this opening and the
one (1) created when the rear floor pan silencer
was removed to access the upper mounting nuts in the following step.
6. Remove the two nuts (1) securing the shock assembly (2) to the body bracket (3). 7. Raise and
9. Remove the shock lower mounting nut (3) and bolt (1).
10. Lower the shock assembly (2) out of the body bracket (1) and lift out over rear suspension.
Disassembly
DISASSEMBLY
NOTE: The shock assembly must be removed from the vehicle for it to be disassembled and
assembled.
For the disassembly and assembly of the shock assembly, use Strut Spring Compressor, teamPSE
tool 223-7400, or the equivalent, to compress the coil spring. Follow the manufacturer's instructions
closely.
WARNING: Do not remove the shock rod nut before the coil spring is properly compressed. The
coil spring is held under pressure. The coil spring must be compressed, removing spring tension
from the upper mounting bracket, before the shock rod nut is removed.
1. If both shocks are being serviced at the same time, mark both the coil spring and shock
assembly according to which side of the vehicle the shock
is being removed from.
2. If equipped, remove the noise abatement cap from top of the shock assembly.
3. Position the shock assembly (2) in the strut spring compressor (1) following the manufacturer's
instructions and set the lower and upper hooks of
the compressor on the coil spring.
4. Compress the coil spring until all spring tension is removed from the upper mounting bracket and
bushings.
CAUTION: Never use impact or high speed tools to remove the shock rod nut. Damage to the
shock internal bearings can occur.
5. Once the spring is sufficiently compressed, install Snap-On(R) Shock Absorber Socket A139, or
equivalent, on the end of the shock rod (1). While
holding the shock rod from turning, remove the nut (2) using a wrench. Remove the washer below
the nut.
6. Remove the shock absorber (13) out through the bottom of the coil spring (11). The washer (8),
jounce bumper (9), dust shield (10) and lower
spring isolator (12) will come out with the shock.
7. Slide the washer (8), jounce bumper (9), dust shield (10) from the shock rod. 8. Remove the
lower spring isolator (12) from the shock spring seat. 9. Remove the upper mounting bracket (4),
bushings (3, 7), sleeve (6) and upper spring isolator (5) from the top of the spring.
10. Remove the bushings (3, 7), sleeve (6) and upper spring isolator (5) from the upper mounting
bracket (4).
NOTE: If the coil spring needs to be serviced, proceed with the next step, otherwise, proceed with
STEP 12.
11. Release the tension from the coil spring by backing off the compressor drive completely. Push
back the compressor hooks and remove the coil
spring.
12. Inspect the shock assembly components for the following and replace as necessary:
- Inspect the shock (13) for shaft binding over the full stroke of the shaft.
- Inspect the jounce bumper (9) for cracks and signs of deterioration.
- Inspect the dust shield (10) for cracks and tears.
- Check the upper mounting bracket (4) for cracks and distortion and its retaining studs for any sign
of damage.
- Inspect the upper (3) and lower (7) bushings, for material deterioration and signs of deterioration.
Inspect the sleeve (6) for wear and
distortion.
- Inspect the upper (5) and lower (12) spring isolators for material deterioration and distortion.
- Inspect the coil spring (11) for any sign of damage to the coating.
Assembly
ASSEMBLY
NOTE: If the coil spring has been removed from the spring compressor, proceed with the next step,
otherwise, proceed with STEP 3.
CAUTION: When installing the coil spring, make sure the end with the ID tag is placed upward,
otherwise spring-to-body contact will occur after shock assembly installation.
1. Place the coil spring in the spring compressor following the manufacturer's instructions. 2. Slowly
compress the coil spring until enough room is available for shock assembly reassembly.
3. Assemble the bushings (3, 7) and sleeve (6) through the upper mounting bracket (4). 4. Install
the upper spring isolator (5) on the upper mounting bracket (4). 5. Install the upper mounting
bracket (4) on top of the coil spring.
6. Install the lower spring isolator (12) on the spring seat of the shock absorber (13). 7. Slide the
dust shield (10), jounce bumper (9) and washer (8) onto the shock rod. 8. Install the shock
absorber (13) up through the bottom of the coil spring and upper mounting bracket until the lower
spring seat contacts the lower
end of the coil spring.
9. While holding the shock absorber in position, install the washer (2) and nut (1) on the end of the
shock rod.
CAUTION: Never use impact or high speed tools to remove the shock rod nut. Damage to the
shock internal bearings can occur.
10. Install Snap-On(R) Shock Absorber Socket A139, or equivalent, on the end of the shock rod
(1). While holding the shock rod from turning, tighten
the nut (2) using a crows foot wrench and a torque wrench. Tighten the shock rod nut to 24 Nm (18
ft. lbs.).
11. Turn the upper mounting bracket or shock absorber as necessary until the mounting studs on
the mounting bracket line up with the lower mounting
bolt eyelet at the bottom of the shock absorber.
12. Slowly release the tension from the coil spring by backing off the compressor (1) drive
completely. 13. Remove the shock assembly from the spring compressor. 14. If equipped, install
the noise abatement cap on top of the shock assembly. 15. Install the shock assembly on the
vehicle.
Installation
INSTALLATION
1. Insert the lower end of the shock assembly (2) down though the lower control arm from above
just enough to clear the body, then lift it up into the
body bracket (1).

2. Install the mounting bolt (1) and nut (3) fastening the shock assembly (2) to the lower control arm
(4). Do not tighten at this time.
NOTE: Use the openings (1, 2) in the interior rear quarter trim panel when installing the upper
mounting nuts in the following step.
5. Install the two nuts (1) securing the shock assembly (2) to the body bracket (3). Tighten the
mounting nuts to 48 Nm (35 ft. lbs.).
6. Fold the shock assembly upper mounting nut access door (2) down closing off the opening.
8. Install the rear floor pan silencer (1). 9. Install the cargo floor cover.
10. Position the vehicle on an alignment rack/drive-on lift. Raise the lift as necessary to access the
shock mounting bolt (1) and nut (3). 11. Tighten the shock assembly lower mounting bolt nut (3) to
99 Nm (73 ft. lbs.).
Jeep Workshop Manuals > Steering and Suspension > Suspension > Suspension Travel Bumper > Component Information
> Technical Service Bulletins > Customer Interest for Suspension Travel Bumper: > 02-001-09 > Aug > 09 > Suspension -
Rough Handling/Front Strut(s) Leaking
Suspension Travel Bumper: Customer Interest Suspension - Rough Handling/Front Strut(s)

Leaking
NUMBER: 02-001-09
MODELS:
NOTE:

Rough Handling/Front Strut(s) Leaking > Page 7567
PARTS REQUIRED:
REPAIR PROCEDURE:
NOTE:
replacement.
assembly.
TIME ALLOWANCE:
Rough Handling/Front Strut(s) Leaking > Page 7568
FAILURE CODE:
Disclaimer:
> Technical Service Bulletins > All Technical Service Bulletins for Suspension Travel Bumper: > 02-001-09 > Aug > 09 >
Suspension - Rough Handling/Front Strut(s) Leaking
Suspension Travel Bumper: All Technical Service Bulletins Suspension - Rough Handling/Front
Strut(s) Leaking
NUMBER: 02-001-09
MODELS:
NOTE:

Suspension - Rough Handling/Front Strut(s) Leaking > Page 7574
PARTS REQUIRED:
REPAIR PROCEDURE:
NOTE:
replacement.
assembly.
TIME ALLOWANCE:
Suspension - Rough Handling/Front Strut(s) Leaking > Page 7575
FAILURE CODE:
Disclaimer:
Jeep Workshop Manuals > Steering and Suspension > Suspension > Trailing Arm > Component Information > Service and
Repair > Removal
Trailing Arm: Service and Repair Removal
REMOVAL
3. Remove the screw (2) securing the brake flex hose (1) to the trailing link (3).
4. Remove the nut (1) securing the brake tube routing bracket to the trailing link. 5. Remove the
brake tube (3) from the routing clip (2) on the trailing link.
6. Remove the two bolts (1) securing disc brake caliper adapter (3) to the brake support plate (4).
7. Remove the disc brake caliper (2) and adapter (3) as an assembly. Hang the assembly out of
the way using wire or a bungee cord. Use care not to
overextend the brake hose and tubing when doing this.
8. If equipped, remove the screw (4) fastening the wheel speed sensor (3) to the trailing link (2). 9.
If equipped, remove the routing clip (1) fastening the wheel speed sensor (3) to the trailing link (2).
10. Remove the brake rotor, then hub and bearing.

11. Remove the parking brake cable from the lever on the parking brake shoe.
12. Remove the hair pin (1) securing the parking brake cable (2) to the brake support plate (3). 13.
Slide the brake support plate (3) with parking brake shoes off the end of the parking brake cable (2)
and remove. 14. Pull the parking brake cable from the trailing link.
16. Remove the nut (2) and bolt securing the lower control arm to the trailing link (3). 17. Remove
the nut (1) and bolt securing the upper control arm to the trailing link (3).
18. Remove the two bolts (2) fastening the leading end of the trailing link (3) to the body (1). 19.
Remove the trailing link.
Trailing Arm: Service and Repair Installation
INSTALLATION
1. Position the trailing link and install the two bolts (2) fastening the leading end of the trailing link
(3) to the body (1). Tighten the two mounting
bolts to 110 Nm (81 ft. lbs.).
2. Position the upper control arm on the trailing link (3) and install the bolt and nut (1) securing the
arm to the link. Tighten the mounting bolt nut to
95 Nm (70 ft. lbs.).
3. Position the lower control arm on the trailing link (3) and install the bolt and nut (2) securing the
arm to the link. Tighten the mounting bolt nut to
95 Nm (70 ft. lbs.).

4. Install the bolt (2) securing the toe link to the trailing link. To install the bolt it may be necessary
to flex the trailing link body mount bushing
inward or outward using an appropriate prying tool. Tighten the mounting bolt to 95 Nm (70 ft. lbs.).
5. Insert the parking brake cable through the trailing link from the inboard side. 6. Slide the parking
brake cable (2) into the brake support plate (3) with parking brake shoes. 7. Install the hair pin (1)
securing the parking brake cable (2) to the brake support plate (3).
8. Install the parking brake cable onto the lever on the parking brake shoe.
9. If equipped, position the wheel speed sensor (3) and install the screw (4) fastening the sensor to
the trailing link (2). Tighten the mounting screw to
18 Nm (13 ft. lbs.).
10. If equipped, position the wheel speed sensor (3) and install the routing clip (1) fastening the
sensor to the trailing link (2). 11. Install the hub and bearing, then install the brake rotor onto the
wheel studs.
12. Slide the disc brake caliper (2) and adapter (3) assembly over brake rotor and brake support
plate. 13. Install the two bolts (1) securing disc brake caliper adapter (3) to the brake support plate
(4). Tighten the mounting bolts to 71 Nm (52 ft. lbs.).
14. Position the brake tube on the trailing link inserting the tube into the routing clip (2) and routing
bracket over the welded stud. 15. Install the nut (1) on the welded stud. Tighten the nut to 15 Nm
(11 ft. lbs.).
16. Position the brake flex hose (1) at the trailing link (3) bracket and install the mounting screw (2).
Tighten the screw to 23 Nm (17 ft. lbs.).
Nm (100 ft. lbs.). 18. Lower the vehicle. 19. Perform wheel alignment as necessary.
Jeep Workshop Manuals > Steering and Suspension > Suspension > Wheel Bearing > Component Information >
Specifications

Description and Operation > Front Suspension

DESCRIPTION

Description and Operation > Front Suspension > Page 7593
DESCRIPTION
into the hub.
Jeep Workshop Manuals > Steering and Suspension > Suspension > Wheel Bearing > Component Information > Testing
and Inspection > Front Suspension
be replaced.
Inspection.
Jeep Workshop Manuals > Steering and Suspension > Suspension > Wheel Bearing > Component Information > Testing
and Inspection > Front Suspension > Page 7596
HUB AND BEARING
Inspection.
Jeep Workshop Manuals > Steering and Suspension > Suspension > Wheel Bearing > Component Information > Service
and Repair > Front Suspension
Removal
REMOVAL
Nm (40 ft. lbs.).
Nm (40 ft. lbs.).

and Repair > Front Suspension > Page 7599
from the knuckle.

race (4).
race.
Installation
INSTALLATION
until it bottoms.
Removal
ALL-WHEEL-DRIVE

(2).
hub and bearing.
Installation
ALL-WHEEL-DRIVE
lbs.).
Jeep Workshop Manuals > Steering and Suspension > Suspension > Wheel Hub > Axle Nut > Component Information >
Specifications

................................................. 244 Nm (180 ft. lbs.)
Jeep Workshop Manuals > Steering and Suspension > Wheels and Tires > Relays and Modules - Wheels and Tires > Tire
Pressure Monitor Receiver / Transponder > Component Information > Locations > Transponder-Tire Pressure-Left Front
Component ID: 369
Connector:
Color : YELLOW
# of pins : 6
5--
6--
Pressure Monitor Receiver / Transponder > Component Information > Locations > Transponder-Tire Pressure-Left Front >
Page 7619
Page 7620
Component ID: 370
Connector:
Color : BLACK
# of pins : 6
4--
5--
6--
Page 7621
Page 7622
Component ID: 371
Connector:
Color : BLACK
# of pins : 6
4--
5--

Page 7623
Pressure Monitor Receiver / Transponder > Component Information > Diagrams > Transponder-Tire Pressure-Left Front
Component ID: 369
Connector:
Color : YELLOW
# of pins : 6
5--
6--
Pressure Monitor Receiver / Transponder > Component Information > Diagrams > Transponder-Tire Pressure-Left Front >
Page 7626
Page 7627
Component ID: 370
Connector:
Color : BLACK
# of pins : 6
4--
5--
6--
Page 7628
Page 7629
Component ID: 371
Connector:
Color : BLACK
# of pins : 6
4--
5--

Page 7630
Pressure Monitor Receiver / Transponder > Component Information > Description and Operation > Description
DESCRIPTION
Pressure Monitor Receiver / Transponder > Component Information > Description and Operation > Description > Page 7633
OPERATION
Pressure Monitor Receiver / Transponder > Component Information > Service and Repair > Removal
Front
FRONT
Rear
REAR
Pressure Monitor Receiver / Transponder > Component Information > Service and Repair > Removal > Page 7636
Front
FRONT
Rear
REAR

Jeep Workshop Manuals > Steering and Suspension > Wheels and Tires > Sensors and Switches - Wheels and Tires > Tire
Pressure Sensor > Component Information > Service Precautions
CAUTION

Pressure Sensor > Component Information > Description and Operation > Description
DESCRIPTION
Pressure Sensor > Component Information > Description and Operation > Description > Page 7643
- Valve Stem Core
OPERATION
Pressure Sensor > Component Information > Service and Repair > Removal
REMOVAL
different metals.

Pressure Sensor > Component Information > Service and Repair > Removal > Page 7648

INSTALLATION

installed.
damage may occur.
pressure sensor: a.
b.
beads.
sensor.
new sensor ID.

Jeep Workshop Manuals > Steering and Suspension > Wheels and Tires > Tire Monitoring System > Low Tire Pressure
Indicator > Component Information > Description and Operation > Description
DESCRIPTION
Jeep Workshop Manuals > Steering and Suspension > Wheels and Tires > Tire Monitoring System > Low Tire Pressure
Indicator > Component Information > Description and Operation > Description > Page 7658
OPERATION
Jeep Workshop Manuals > Steering and Suspension > Wheels and Tires > Tire Monitoring System > Tire Pressure Monitor
Receiver / Transponder > Component Information > Locations > Transponder-Tire Pressure-Left Front
Component ID: 369
Connector:
Color : YELLOW
# of pins : 6
5--
6--
Receiver / Transponder > Component Information > Locations > Transponder-Tire Pressure-Left Front > Page 7663
Component ID: 370
Connector:
Color : BLACK
# of pins : 6
4--
5--
6--
Component ID: 371
Connector:
Color : BLACK
# of pins : 6
4--
5--

Receiver / Transponder > Component Information > Diagrams > Transponder-Tire Pressure-Left Front
Component ID: 369
Connector:
Color : YELLOW
# of pins : 6
5--
6--
Receiver / Transponder > Component Information > Diagrams > Transponder-Tire Pressure-Left Front > Page 7670
Component ID: 370
Connector:
Color : BLACK
# of pins : 6
4--
5--
6--
Component ID: 371
Connector:
Color : BLACK
# of pins : 6
4--
5--

Receiver / Transponder > Component Information > Description and Operation > Description
DESCRIPTION
Receiver / Transponder > Component Information > Description and Operation > Description > Page 7677
OPERATION
Receiver / Transponder > Component Information > Service and Repair > Removal
Front
FRONT
Rear
REAR
Receiver / Transponder > Component Information > Service and Repair > Removal > Page 7680
Front
FRONT
Rear
REAR

Jeep Workshop Manuals > Steering and Suspension > Wheels and Tires > Tire Monitoring System > Tire Pressure Sensor
> Component Information > Service Precautions
CAUTION

DESCRIPTION
- Valve Stem Core
OPERATION
REMOVAL
different metals.


INSTALLATION

installed.
damage may occur.
pressure sensor: a.
b.
beads.
sensor.
new sensor ID.

Jeep Workshop Manuals > Steering and Suspension > Wheels and Tires > Tires > Spare Tire > Component Information >
Technical Service Bulletins > Tire Monitor System - Dashes Displayed Using Spare Tire
Spare Tire: Technical Service Bulletins Tire Monitor System - Dashes Displayed Using Spare Tire
NUMBER: 22-001-06 REV. B
GROUP: Tires & Wheels
THIS BULLETIN SUPERSEDES SERVICE BULLETIN 22-001-06 REV. A, DATED JUNE 29, 2006,
WITH **ASTERISKS** AND INCLUDES ADDITIONAL MODELS.
SUBJECT: Tire Pressure Monitoring System (1PM) Displays Dashes "--" When The Spare Tire Is
Used
MODELS:
2007 (PM) Caliber
**2007 (JS)
**2007 (KA) Nitro**
DISCUSSION:
If the TPM system detects a low tire, it will set a low tire DTC (C0077 - Low Tire Pressure), notify
the customer by illuminating the TPM telltale, and display the low tire pressure values in the EVIC
display. Once the low road tire is replaced by the spare tire and the vehicle is driven above 25 MPH
(40 KPH) for more than 10 minutes; the TPM system will set an additional DTC (C151C - Tire
Pressure Sensor Missing), notify the customer by displaying "CHECK TPM SYSTEM" for 3
seconds, and replaces the low tire pressure value with dashes
If:
^ The original tire with pressure sensor remains inside the vehicle or within a valid Radio
Frequency range with the WCM (TPM receiver).
And:
^ The pressure changes in the low tire by more than 1 PSI or 13 hours expire from the time the low
tire event occurred.
Then:
^ The dashes will be replaced by the actual low tire pressure value.
This low tire / dash "--" cycle will repeat until the pressure is restored in the original tire.
NOTE:
The spare tire is not equipped with a tire pressure monitoring (TPM) sensor.
Do not replace any TPM sensors for this condition. Correct the low tire condition first and then
verify that the C151C - Tire Pressure Sensor Missing and the C0077 - Low Tire Pressure DTC
change to a stored code.
POLICY: Information Only.
Disclaimer:
Jeep Workshop Manuals > Steering and Suspension > Wheels and Tires > Wheels > Component Information > Technical
Service Bulletins > Wheels/Tires - Chrome Clad Wheel Balancing Information
Wheels: Technical Service Bulletins Wheels/Tires - Chrome Clad Wheel Balancing Information
NUMBER: 22-002-09
GROUP: Wheels/Tires
DATE: July 29, 2009
SUBJECT: Chrome Clad Wheel Adapters For Proper Balancing
OVERVIEW: This bulletin describes the use of proper wheel adapters when mounting Chrome
Clad wheels to wheel balancing equipment.
MODELS:
2004-2008 (CS) Pacifica
2007 - 2010 DC) Ram Truck (3500 Chassis Cab)
2009 - 2010 (DS) Ram Truck (1500)
2004 - 2009 (HB) Durango
2007-2009 (HG) Aspen
2009-2010 (JC) Journey
2008 - 2010 (JS27) Sebring Convertible
2007 - 2010 (JS41) Sebring/Avenger
2007-2010 (KA) Nitro
2002-2007 (KJ) Liberty
2002 - 2007 (KJ) Cherokee (International Markets)
2008 - 2010 (KK) Liberty
2005-2010 (ND) Dakota
2007 - 2001 (PM) Caliber

2008 - 2010 (RI) Town & Country/Grand Caravan
Service Bulletins > Wheels/Tires - Chrome Clad Wheel Balancing Information > Page 7705
2008 - 2010 (RI) Town & Country/Grand Voyager (International Markets)
2005-2010 (WK) Grand Cherokee
NOTE:
This information applies to any model equipped with Chrome Clad Wheels.
DISCUSSION:
Models equipped with Chrome Clad wheels require specific piloting on balance equipment to
properly center the wheel and prevent damage to the chrome clad surface. The chrome cladding is
not removable or replaceable and has cladding tabs that extend into the wheel bore. Traditional
high-taper cones will come into contact with the cladding tabs rather than properly seat on the hub
bore chamfer. Many modern aluminum wheel designs cannot be mounted with traditional cones.
Direct-Fit Collets should be used to properly mount clad wheels on balance equipment (Fig 1).
NOTE:
This kit includes the adapters for all Dodge, Chrysler & Jeep models with clad wheels. Individual
adapters for specific wheel sizes can be ordered separately. To order a kit or individual adapters,
contact Pentastar Service Equipment @ 1-800-223-5623.
Disclaimer:
Wheels: Specifications
WHEEL
Torque Specifcations
Torque Specifications
Wheels: Description and Operation
WHEEL
All vehicles use either steel or cast aluminum drop center wheels. The original equipment wheels
are designed for proper operation at all loads up to the specified maximum vehicle capacity.
Every wheel has raised sections between the rim flanges (1) and drop well (3) called safety humps
(2). In case of air loss, these raised sections help hold the tire in position on the wheel until the
vehicle can be brought to a safe stop. When being installed on the wheel, initial inflation of the tire
forces the tire bead over these raised sections into place.
The wheel studs and nuts are designed for specific wheel applications and must be replaced with
equivalent parts. Do not use replacement parts of lesser quality or of a substitute design. All
aluminum and steel wheels have wheel stud nuts with an enlarged nose. This enlarged nose is
necessary to ensure proper retention of the wheels.
Wheels: Testing and Inspection
WHEEL INSPECTION
Inspect wheels for:
- Excessive runout
- Dents, cracks or irregular bends
- Damaged wheel stud (lug) holes
- Air Leaks
NOTE: Do not attempt to repair a wheel by hammering, heating or welding.
If a wheel is damaged, an original equipment replacement wheel should be used. When obtaining
replacement wheels, they must be equivalent in load carrying capacity. The diameter, width, offset,
pilot hole and bolt circle of the wheel should be the same as the original wheel.
WARNING: Failure to use equivalent replacement wheels may adversely affect the safety and
handling of the vehicle.
WARNING: Replacement with used wheels is not recommended. The service history of the wheel
may have included severe treatment or very high mileage. The rim could fail without warning.
WARNING: DaimlerChrysler Corporation does not recommend that customers use "reconditioned"
wheels (wheels that have been damaged and repaired) because they can result in a sudden
catastrophic wheel failure which could cause loss of control and result in injury or death. For
clarification:
- Cosmetic refinishing for the purpose of repairing a superficial flaw is an acceptable procedure
providing it is limited to paint or clear coat only, the wheel is not modified in any way, and there is
no exposure to paint curing heat over 200 degrees Fahrenheit.
- Damaged wheels are those which have been bent, broken, cracked or sustained some other
physical damage which may have compromised the wheel structure.
- Repaired indicates that the wheel has been modified through bending, welding, heating,
straightening, or material removal to rectify damage.
- Re-plating of chrome plated wheels is not an acceptable procedure nor is chrome plating of
original equipment painted or polished wheels, as this may alter mechanical properties and affect
fatigue life.
Wheels: Service and Repair
WHEEL AND WHEEL TRIM CARE
All wheels and wheel trim, especially aluminum and chrome plated, should be cleaned regularly
using mild soap and water to maintain their luster and to prevent corrosion. Wash them with the
same soap solution recommended for the body of the vehicle.
When cleaning extremely dirty wheels, care must be taken in the selection of tire and wheel
cleaning chemicals and equipment to prevent damage to the wheels. Mopar(R) Tire & Wheel
Cleaner, Mopar(R) Wheel Treatment or Mopar(R) Chrome Cleaner is recommended. Any of the
"DO NOT USE" items listed below can damage wheels and wheel trim.
DO NOT USE:
- Any abrasive cleaner
- Any abrasive cleaning pad (such as steel wool) or abrasive brush
- Any cleaner that contains an acid which can react with and discolor the chrome surface. Many
wheel cleaners contain acids that can harm the wheel surface.
- Oven cleaner
- A car wash that uses carbide-tipped wheel cleaning brushes or acidic solutions.
Jeep Workshop Manuals > Steering and Suspension > Wheels and Tires > Wheel Bearing > Component Information >
Specifications

Description and Operation > Front Suspension

DESCRIPTION

Description and Operation > Front Suspension > Page 7715
DESCRIPTION
into the hub.
Testing and Inspection > Front Suspension
be replaced.
Inspection.
Testing and Inspection > Front Suspension > Page 7718
HUB AND BEARING
Inspection.
Service and Repair > Front Suspension
Removal
REMOVAL
Nm (40 ft. lbs.).
Nm (40 ft. lbs.).

Service and Repair > Front Suspension > Page 7721
from the knuckle.

race (4).
race.
Installation
INSTALLATION
until it bottoms.
Removal
ALL-WHEEL-DRIVE

(2).
hub and bearing.
Installation
ALL-WHEEL-DRIVE
lbs.).
Jeep Workshop Manuals > Steering and Suspension > Wheels and Tires > Wheel Hub > Axle Nut > Component Information
> Specifications

................................................. 244 Nm (180 ft. lbs.)
Jeep Workshop Manuals > Steering and Suspension > Wheels and Tires > Wheel Fastener > Component Information >
Specifications
Wheel Fastener: Specifications
WHEEL LUG NUTS
Aluminum Wheel
Steel Wheel
Progressively tighten all wheel mounting nuts in the proper sequence shown. Tighten nuts to a final
torque of 135 Nm (100 ft. lbs.).
Service and Repair > Front
Wheel Fastener: Service and Repair Front
Removal
REMOVAL
1. Access and remove front brake rotor.
2. Install Remover (3), Special Tool 8677, on the hub flange (1) and wheel stud (2). 3. Tighten the
Remover, pushing the wheel mounting stud out the rear of the hub flange. When the shoulder of
the stud is past the flange, remove the

Installation
INSTALLATION
Service and Repair > Front > Page 7740
4. Install the brake rotor and all components previously removed to access it.
Wheel Fastener: Service and Repair Rear
Removal
REMOVAL
1. Access and remove rear brake rotor.
2. Install Remover (1), Special Tool 8677, on the hub flange (2) and wheel stud (3). 3. Rotate the
hub around until an open spot is found directly behind the wheel stud. 4. Tighten the Remover,
pushing the wheel mounting stud out the rear of the hub flange. When the shoulder of the stud is
past the flange, remove the
Installation
INSTALLATION
4. Install the rear brake rotor and all components previously removed to access it.
Jeep Workshop Manuals > Heating and Air Conditioning > Accumulator HVAC > Component Information > Description and
Accumulator HVAC: Description and Operation Description
DESCRIPTION
To protect the A/C compressor from any liquid slugging, an A/C accumulator (1) is used in this A/C
system to retain any refrigerant that may exit from the evaporator in a liquid state.
The A/C accumulator is mounted below the engine compartment behind the right side of the front
fascia. A band and mounting bracket (2) secures the A/C accumulator to the right front frame rail
and the connections are sealed by use of metal gaskets (3) and rubber O-rings (4).
Jeep Workshop Manuals > Heating and Air Conditioning > Accumulator HVAC > Component Information > Description and
Accumulator HVAC: Description and Operation Operation
OPERATION
NOTE: Typical A/C accumulator shown.
Refrigerant enters the A/C accumulator (1) mostly as a low pressure vapor through the inlet tube
(2). Any liquid, oil-laden refrigerant falls to the bottom of the canister, which acts as a separator. A
desiccant bag (3) is mounted inside the accumulator canister to absorb any moisture which may
have entered and become trapped within the refrigerant system. A filter (4) is also mounted inside
the canister to trap any foreign material that may have entered the refrigerant system during
assembly. The low pressure vapor exits the A/C accumulator through the outlet tube (5).
The A/C accumulator has no serviceable parts except for the O-ring seals and gaskets. The O-ring
seals used on the connections are made from a special type of rubber not affected by R-134a
refrigerant. The O-ring seals and gaskets must be replaced whenever the A/C accumulator is
removed and installed.
The A/C accumulator cannot be repaired and must be replaced if found to be leaking or damaged,
or if an internal failure of the A/C compressor has occurred.
Jeep Workshop Manuals > Heating and Air Conditioning > Accumulator HVAC > Component Information > Service and
Repair > Removal
Accumulator HVAC: Service and Repair Removal
REMOVAL
5. Remove the three push-pin retainers (1) and three screws (2) that secure the front portion of the
right front wheelhouse splash shield (3) to body
accumulator.
6. Remove the nut (7) that secures the lower A/C suction line (8) to the accumulator outlet tube (9)
and disconnect the suction line from the
accumulator tube.
7. Remove the bolt (5) and retaining band (6) that secure the A/C accumulator to the mounting
bracket (10).
8. Remove the nut (3) that secures the upper A/C suction line (2) to the accumulator inlet tube (4)
and disconnect the suction line from the
accumulator tube.
9. If necessary remove the accumulator mounting bracket from the body.
10. Remove and discard the O-ring seals and gaskets and install plugs in, or tape over the opened
refrigerant line fittings and the accumulator ports.
Accumulator HVAC: Service and Repair Installation
INSTALLATION
CAUTION: The A/C accumulator must be replaced if an internal failure of the A/C compressor has
occurred. Failure to replace the A/C accumulator can cause serious A/C compressor damage.
NOTE: If only the A/C accumulator is being replaced, add 30 milliliters (1.0 fluid ounce) of
refrigerant oil to the refrigerant system. Use only refrigerant oil of the type recommended for the
1. If removed, install the accumulator mounting bracket (10). Tighten the retaining bolts to 15 Nm
(11 ft. lbs.).
2. Remove the tape or plugs from all of the opened refrigerant line fittings and the accumulator
ports.
3. Lubricate new rubber O-ring seals with clean refrigerant oil and install them and new gaskets
onto the suction line and accumulator fittings. Use
only the specified O-rings as they are made of a special material for the R-134a system. Use only
refrigerant oil of the type recommended for the A/C compressor in the vehicle.
4. Connect the upper A/C suction line (2) to the accumulator inlet tube (4) and install the retaining
nut (3). Tighten the nut to 5 Nm (44 in. lbs.).
5. Install the retaining band (6) and bolt (5) that secure the A/C accumulator (1) to the mounting
bracket. Tighten the bolt to 8 Nm (71 in. lbs.).
6. Connect the lower A/C suction line (8) to the accumulator outlet tube (9) and install the retaining
nut (7). Tighten the nut to 5 Nm (44 in. lbs.).
7. Reposition the front of the right front wheel house splash shield (3) to the body (4) and install the
three push-pin retainers (1) and the three screws
12. If the A/C accumulator is being replaced, add 30 milliliters (1.0 fluid ounce) of refrigerant oil to
the refrigerant system. When replacing multiple
A/C system components, refer to the Refrigerant Oil Capacities chart to determine how much oil
should be added to the refrigerant system. Use only refrigerant oil of the type recommended for the

Jeep Workshop Manuals > Heating and Air Conditioning > Air Door, HVAC > Air Door Actuator / Motor, HVAC > Component
Air Door Actuator / Motor: Locations
Component ID: 1
Component : ACTUATOR-RECIRCULATION DOOR
Connector:
Name : ACTUATOR-RECIRCULATION DOOR
Color : BLACK
# of pins : 6
1 RECIRCULATION DOOR DRIVER (A) C32 20DB/TN
1 RECIRCULATION DOOR DRIVER (B) C132 20DB/GY
2--
3--
4--
5--
Air Door Actuator / Motor: Diagrams
Component ID: 1
Component : ACTUATOR-RECIRCULATION DOOR
Connector:
Name : ACTUATOR-RECIRCULATION DOOR
Color : BLACK
# of pins : 6
2--
3--
4--
5--
Air Door Actuator / Motor: Description and Operation Description
DESCRIPTION
The recirculation door actuator (1) is a reversible, 12 volt direct current (DC) servo motor, which is
connected directly to the pivot shaft lever of the recirculation-air door. The recirculation door
actuator is located on the right side of the HVAC air inlet housing.
The recirculation door actuator is contained within a black molded plastic housing with an integral
wire connector receptacle (2), an output shaft with splines (3) that connect it to the recirculation
door and three integral mounting tabs (4) that allow the actuator to be secured to the air inlet
housing. The recirculation door actuator does not require mechanical indexing to the
recirculation-air door, as it is electronically calibrated by the A/C-heater control.
Air Door Actuator / Motor: Description and Operation Operation
OPERATION
The recirculation door actuator is connected to the A/C-heater control through the vehicle electrical
system by a dedicated two-wire lead and connector of the instrument panel wire harness. The
recirculation door actuator can move the recirculation-air door in two directions. When the
A/C-heater control pulls the voltage on one side of the motor connection high and the other
connection low, the recirculation-air door will move in one direction. When the A/C-heater control
reverses the polarity of the voltage to the motor, the recirculation-air door moves in the opposite
direction. Once the A/C-heater control makes the voltage to both connections high or both
connections low, the recirculation-air door stops and will not move.
The A/C-heater control uses a pulse-count positioning system to monitor the operation and relative
position of the recirculation door actuator and the recirculation-air door. The A/C-heater control
learns the recirculation-air door stop positions during the calibration procedure and will store a
diagnostic trouble code (DTC) for any problems it detects in the recirculation door actuator circuits.
The recirculation door actuator cannot be adjusted or repaired and it must be replaced if found
Air Door Actuator / Motor: Service and Repair Removal
REMOVAL
3. Reach through the glove box opening in the instrument panel and remove the screws (1) that
secure the recirculation door actuator (2) to the right
side of the HVAC air inlet housing (3).
4. Disconnect the wire harness connector (4) from the recirculation door actuator and remove the
actuator.
Air Door Actuator / Motor: Service and Repair Installation
INSTALLATION
NOTE: Illustrations shown with instrument panel removed for clarity.
1. Position the recirculation door actuator (1) to the right side of the HVAC air inlet housing (2).
2. Install the recirculation door actuator onto the air inlet housing. If necessary, rotate the actuator
slightly to align the splines on the actuator output
shaft (3) with those on the recirculation door pivot shaft adapter (4).
3. Install the screws (1) that secure the recirculation door actuator (2) to the air inlet housing (3).
Tighten the screws to 2 Nm (17 in. lbs.).
4. Connect the instrument panel wire harness connector (4) to the recirculation door actuator.

Jeep Workshop Manuals > Heating and Air Conditioning > Air Door, HVAC > Air Door Cable, HVAC > Component
Information > Service and Repair > Cable-Mode Door
Air Door Cable: Service and Repair Cable-Mode Door
Removal
REMOVAL
NOTE: To aid in reinstallation, note the installed position of the mode control cable to the
A/C-heater control prior to removal of the cable.
2. Remove the instrument panel center bezel and disconnect the mode control cable from the
A/C-heater control.
3. On LHD models, remove the glove box.
4. Disengage the metal retaining clip (1) that secures the mode control cable (2) from the right side
of the HVAC air distribution housing (3).
NOTE: To aid in reinstallation, note the position of the mode control cable as it passes through the
instrument panel support prior to removal of the cable.
5. Disconnect the mode control cable from the mode door cam (4) and remove the cable from the
vehicle.
Installation
INSTALLATION

Information > Service and Repair > Cable-Mode Door > Page 7778
1. Position the mode control cable (2) to the right side of the HVAC air distribution housing (3)
through the opening in the instrument panel support.
2. Connect the mode control cable to the mode door cam (4).
3. Engage the metal retaining clip (1) to the right side of the HVAC air distribution housing. Make
sure the retaining clip is fully engaged to the
housing.
4. Connect the mode door control cable to the A/C-heater control and install the instrument panel
center bezel.
5. Visually verify the mode door cam moves from the full defrost position to the full panel position
and then back to the full defrost position using
the mode control knob on the A/C-heater control. If OK, go to step 10. If not OK, proceed to step 6.
CAUTION: Failure to adjust the mode control cable when required can result in operating modes
not being properly obtained.
6. Disengage the mode control cable from the metal retaining clip located on the right side of the
HVAC housing.
7. Turn the mode control knob on the A/C-heater control to the full defrost position.
8. Reach behind the instrument panel and turn the mode door cam clockwise until it stops in the full
defrost position and engage the mode control
cable to the metal retaining clip. Make sure the cam is in the full defrost position and that the cable
is fully engaged to the retaining clip.
9. Verify the mode door cam moves from the full defrost position to the full panel position and then
back to the full defrost position as selected with
the mode control knob on the A/C-heater control. If not, repeat steps 6 thru 9.
10. On LHD models, install the glove box.

Air Door Cable: Service and Repair Cable-Temperature Control
Removal
REMOVAL
NOTE: To aid in reinstallation, note the installed position of the temperature control cable to the
A/C-heater control prior to removal of the cable.
2. Remove the instrument panel center bezel and disconnect the temperature control cable from
the A/C-heater control.
3. On RHD models, remove the glove box.
4. Disengage the metal retaining clip (1) that secures the temperature control cable (2) from the left
side of the HVAC air distribution housing (3).
NOTE: To aid in reinstallation, note the position of the temperature control cable as it passes
through the instrument panel support prior to removal of the cable.
5. Disconnect the temperature control cable from the blend door pivot lever (4) and remove the
cable from the vehicle.
Installation
INSTALLATION

1. Position the temperature control cable (2) to the left side of the HVAC air distribution housing (3)
through the opening in the instrument panel
support.
2. Connect the temperature control cable to the blend door pivot lever (4).
3. Engage the metal retaining clip (1) to the left side of the air distribution housing. Make sure the
retaining clip is fully engaged to the housing.
4. Connect the temperature door control cable to the A/C-heater control and install the instrument
panel center bezel.
5. Visually verify that the blend door pivot lever moves from the full hot position to the full cold
position and then back to the full hot position using
the temperature control knob on the A/C-heater control. If OK, go to step 10. If not OK, proceed to
step 6.
CAUTION: Failure to adjust the temperature control cable can result in full heating or cooling
capabilities not being obtained.
6. Disengage the temperature control cable from the metal retaining clip located on the left side of
the HVAC housing.
7. Turn the temperature control knob on the A/C-heater control to the full hot position.
8. Reach behind the instrument panel and move the blend door pivot lever forward until it stops in
the full hot position and engage the temperature
control cable to the metal retaining clip. Make sure the lever is in the full hot position and that the
cable is fully engaged to the retaining clip.
9. Verify that the blend door pivot lever moves from the full hot position to the full cold position and
then back to the full hot position, as selected
with the temperature control knob on the A/C-heater control. If not, repeat steps 6 thru 9.
10. On RHD models, install the glove box.

Jeep Workshop Manuals > Heating and Air Conditioning > Air Duct > Component Information > Description and Operation
Air Duct: Description and Operation
DESCRIPTION
There is one defroster air outlet (2) located on the top of the instrument panel (1). The airflow from
the defroster outlet is directed by fixed vanes in the outlet and cannot be adjusted. The defroster air
outlet is not serviceable from the instrument panel defroster grille (3).
There are two side window demister air outlets (4). One located on each end of the instrument
panel. The airflow from the side window demister air outlets is directed by fixed vanes in the outlets
and cannot be adjusted. The side window demister air outlets are not serviceable from the
instrument cluster bezel.
There are four rectangular instrument panel air outlets (5). One air outlet is located near each
outboard end of the instrument panel facing the rear of the vehicle and two air outlets are located at
the top of the instrument panel center bezel. Each of the instrument panel air outlets contain
movable vanes that can direct or shut off the flow of the conditioned air leaving each of the
instrument panel outlets. The driver and passenger side air instrument panel air outlets can be
serviced separately. The center outlets are only serviced with the center bezel.
Jeep Workshop Manuals > Heating and Air Conditioning > Air Duct > Component Information > Service and Repair >
Outlets-Air
Air Duct: Service and Repair Outlets-Air
Removal
REMOVAL
NOTE: Driver side air outlet shown. Passenger side outlet similar.
1. Depending on the air outlet being serviced, remove the instrument cluster bezel or the
instrument panel top cover.
NOTE: If the foam seal on the air outlet is deformed or damaged, it must be replaced.
2. Remove the three screws (1) that secure the air outlet (2) to the bezel or cover (3) and remove
the outlet.
Installation
INSTALLATION
NOTE: Driver side air outlet shown. Passenger side outlet similar.
1. Position the air outlet (2) onto the bezel or cover (3).
2. Install the three screws (1) that secure the air outlet. Tighten the screws to 2 Nm (17 in. lbs.).
3. Depending on the outlet being serviced, install the instrument cluster bezel or the instrument
panel top cover.
Outlets-Air > Page 7786
Air Duct: Service and Repair Defroster Duct
Removal
REMOVAL
NOTE: Illustration shown with instrument panel removed from vehicle for clarity.
1. Remove the instrument panel top cover(.
2. Disconnect the right demister hose (6) and the left demister hose (7) from the defroster duct (3).
3. Remove the two screws (2) that secure the defroster duct to the defroster duct support (4).
4. Remove the two screws (1) that secure the defroster duct support to the instrument panel
support (5) and position the defroster duct support out of
the way.
5. Remove the defroster duct from the top of the instrument panel.
Installation
INSTALLATION
NOTE: Illustration shown with instrument panel removed from vehicle for clarity.

1. Position the defroster duct (3) to the top of the instrument panel support (5).
2. Reposition the defroster duct support (4) onto the instrument panel support and install the two
retaining screws (1). Tighten the screws to 3 Nm
(27 in. lbs.).
3. Install the two screws (2) that secure the defroster duct to the defroster duct support. Tighten the
4. Connect the right demister hose (6) and the left demister hose (7) to the defroster duct.
5. Install the instrument panel top cover.

Air Duct: Service and Repair Floor Distribution Ducts
Removal
REMOVAL
instrument panel component diagnosis or service. Disconnect and isolate the battery negative
Failure to take the proper precautions could result in an accidental airbag deployment and possible
PASSENGER FRONT FLOOR DUCT
2. Disconnect the passenger floor duct (1) from the passenger side of the HVAC housing (2) and
remove the duct.
DRIVER FRONT FLOOR DUCT

3. Remove the instrument panel.
4. Disconnect the driver floor distribution duct (1) from the driver side of the HVAC housing (2) and
remove the duct.
REAR FLOOR DISTRIBUTION DUCTS
6. Remove the rear seat floor ducts.
7. Disconnect the left rear floor distribution duct (1) and the right rear floor distribution duct (2) as
required from the HVAC housing (3) and remove
the duct(s).
REAR SEAT FLOOR DUCTS
NOTE: Passenger side rear floor duct shown. Driver side duct similar.
8. Remove the center floor console.
9. Remove the front seat from the side of the vehicle being serviced.
10. Pull the carpet back to gain access to the rear seat floor duct (2).
11. Remove the screw (1) and disengage the retainer that secures the rear seat floor duct to the
floor support (4).
12. Disconnect the rear seat floor duct from the rear floor distribution duct (3) and remove the rear
seat duct(s).
Installation
INSTALLATION
PASSENGER FRONT FLOOR DUCT
1. Connect the passenger front floor duct (1) to the passenger side of the HVAC housing (2). Make
sure the duct is fully engaged to the housing.
DRIVER FRONT FLOOR DUCT
3. Connect the driver front floor duct (1) to the driver side HVAC housing (2). Make sure the duct is
fully engaged to the housing.
4. Install the instrument panel.
REAR FLOOR DISTRIBUTION DUCTS
5. Connect the left rear floor distribution duct (1) and the right rear floor distribution duct (2) as
required to the HVAC housing (3). Make sure the
ducts are fully engaged to the housing.
6. Install the rear seat floor ducts.
REAR SEAT FLOOR DUCTS
NOTE: Passenger side rear floor duct shown. Driver side duct similar.
8. Connect the rear seat floor duct (2) to the rear floor distribution duct (3). Make sure the ducts are
fully engaged to each other.
9. Engage the retainer that secures the rear seat floor duct to the floor support (4) and install the
retaining screw (1). Tighten the screw to 2.2 Nm (20
in. lbs.).
10. Reinstall the carpet.
11. Install the front seat to the side of the vehicle being serviced.
12. Install the center floor console.

Air Duct: Service and Repair Instrument Panel Duct
Removal
REMOVAL
NOTE: Illustrations shown with instrument panel removed from vehicle for clarity.
DRIVER SIDE DUCT
NOTE: The driver side instrument panel duct is serviced only as an assembly with the driver side
demister duct.
1. Remove the instrument panel top cover.
2. Remove the four screws (2) that secure the driver side instrument panel and demister duct
assembly (1) to the instrument panel support (5).
3. Disconnect the driver side demister hose (3) from the demister duct.
4. Disconnect the driver side instrument panel duct from the center duct (4).
5. Remove the instrument panel duct and demister duct assembly from the instrument panel
support.
PASSENGER SIDE DUCT

7. Remove the two screws (2) that secure the passenger side instrument panel duct (4) to the
instrument panel support (5).
8. Disconnect the passenger side instrument panel duct from the passenger side demister duct (3)
and the center duct (1).
9. Remove the passenger side instrument panel duct from the instrument panel support.
CENTER DUCT
10. Remove the instrument panel ducts (1 and 3).
11. Remove the two screws (2) that secure the center instrument panel duct (5) to the two brackets
(4) located on the top of the instrument panel
support (6).
12. Rotate and tilt the instrument panel center duct as necessary to remove it from the instrument
panel support.
Installation
INSTALLATION
DRIVER SIDE DUCT
NOTE: The driver side instrument panel duct is serviced only as an assembly with the driver side
demister duct.
1. Position the driver side instrument panel duct and demister duct assembly (1) onto the top of the
2. Connect the driver side instrument panel duct to the center duct (4). Make sure the ducts are
3. Connect the driver side demister hose (3) to the demister duct. Make sure the hose is fully
engaged to the defroster and demister duct.
4. Install the four screws (2) that secure driver side instrument panel duct and demister duct
assembly to the instrument panel support. Tighten the
screws to 2.2 Nm (20 in. lbs.).
PASSENGER SIDE DUCT
6. Position the passenger side instrument panel duct (4) onto the top of the instrument panel
support (5).
7. Connect the passenger side instrument panel duct to the center duct (1) and the passenger side
demister duct (3). Make sure the ducts are fully
engaged to each other.
8. Install the two screws (2) that secure passenger side instrument panel duct to the instrument
panel support. Tighten the screws to 2.2 Nm (20 in.
lbs.).
CENTER DUCT
10. Position the center instrument panel duct (5) onto the top of instrument panel support (6).
Rotate and tilt the duct as necessary.
11. Install the two screws (2) that secure the center duct to the two brackets (4). Tighten the screws
to 2.2 Nm (20 in. lbs.).
12. Install the instrument panel ducts (1 and 3).

Air Duct: Service and Repair Instrument Panel Demister Duct
Removal
REMOVAL
DRIVER SIDE DUCT
NOTE: The driver side demister duct is serviced only as an assembly with the driver side
instrument panel duct.
2. Remove the four screws (2) that secure the driver side instrument panel and demister duct
assembly (1) to the instrument panel support (5).
3. Disconnect the driver side demister hose (3) from the demister duct.
4. Disconnect the driver side instrument panel duct from the center duct (4).
5. Remove the instrument panel duct and demister duct assembly from the instrument panel
support.
PASSENGER SIDE DUCT

7. Remove the defroster duct (1).
8. Remove the passenger side demister hose (7).
9. Remove the passenger side instrument panel duct (6).
10. Disengage the push-pin type fastener (2) that secures the passenger side demister duct (5) to
the instrument panel support (4).
11. Disengage the demister duct retaining tab (3) from the instrument panel support and remove
the passenger side demister duct through the defroster
duct opening.
Installation
INSTALLATION
DRIVER SIDE DUCT
NOTE: The driver side demister duct is serviced only as an assembly with the driver side
instrument panel duct.
1. Position the driver side instrument panel duct and demister duct assembly (1) onto the top of the
2. Connect the driver side instrument panel duct to the center duct (4). Make sure the ducts are
3. Connect the driver side demister hose (3) to the demister duct. Make sure the hose is fully
engaged to the defroster and demister duct.
4. Install the four screws (2) that secure driver side instrument panel duct and demister duct
assembly to the instrument panel support. Tighten the
PASSENGER SIDE DUCT
6. Position the passenger side demister duct (5) to the instrument panel support (4) through the
defoster duct opening.
7. Engage the demister duct retaining tab (3) to the instrument panel support.
8. Engage the demister duct push-pin type fastener (2) to the instrument panel support.
9. Install the passenger side instrument panel duct (6).
10. Install the passenger side demister hose (7) onto the demister duct.
11. Install the defroster duct (1).

Jeep Workshop Manuals > Heating and Air Conditioning > Ambient Temperature Sensor / Switch HVAC > Component
Component ID: 291
Connector:
Color : BLACK
# of pins : 2
Component ID: 291
Connector:
Color : BLACK
# of pins : 2
Jeep Workshop Manuals > Heating and Air Conditioning > Blower Motor > Component Information > Technical Service
Bulletins > Customer Interest for Blower Motor: > 24-007-06 > Nov > 06 > A/C - Noise From Glove Box Area With Blower
ON
Blower Motor: Customer Interest A/C - Noise From Glove Box Area With Blower ON
NUMBER: 24-007-06
GROUP: Heating & A/C
DATE: November 11, 2006
THIS BULLETIN IS BEING PROVIDED IN ADVANCE. DO NOT ORDER PARTS OR PERFORM

ANY ACTIONS RELATED TO THIS BULLETIN UNTIL NOVEMBER 27, 2006.
SUBJECT: Noisy Blower Motor Due To Debris Ingestion
OVERVIEW: This bulletin involves installing a screen to the recirculation door.
MODELS:
2007 (PM) Caliber
2007 (MK49) Compass
NOTE:
This bulletin applies to vehicles built prior to September 6, 2006 (MDH 0906XX) without sales code
JMA.
SYMPTOM/CONDITION:
The vehicle operator may notice an objectionable sound from the glove box area when blower
motor is on.
DIAGNOSIS:
Operate the blower motor at a medium speed with windows closed. If the objectionable sound can
be detected perform Repair Procedure.
PARTS REQUIRED:
REPAIR PROCEDURE:
2. If equipped, remove the silencer from below the passenger side of the instrument panel.
NOTE:
The blower motor is located on the bottom of the passenger side of the HVAC housing. The blower
motor can be removed from the vehicle without having to remove the HVAC housing.
3. From underneath the instrument panel, disengage the connector lock and disconnect the
instrument panel wire harness connector from the blower motor (2).
ON > Page 7814
4. Remove the three screws that secure the blower motor and the wire lead bracket (if equipped) to
the bottom of the HVAC housing and remove the blower motor (Fig. 1).
NOTE:
LHD model shown. RHD model similar.
5. Clean any debris out of the blower motor. It may be necessary to use shop air to blow it out of
the blower motor.
6. Install the blower motor by positioning the blower motor onto the bottom of the HVAC housing.
7. Install the three screws that secure the blower motor and the wire lead bracket (if equipped) to
the HVAC housing. Tighten the screws to 1.2 N.m (10 in. lbs.).
8. Connect the instrument panel wire harness connector to the blower motor and engage the
connector lock.
9. If equipped, install the silencer below the passenger side of the instrument panel.
10. Open the glove box and carefully use fingers to press inward on the glove box open stops at
the top of the bin, to allow the glove box to rotate down toward the carpet.
11. Rotate the box down and release the door hinges at the bottom and remove the glove box.
ON > Page 7815
12. Disengage the two retaining tabs that secure the particulate air filter cover to the passenger
side of the HVAC housing and remove the cover (Fig. 2).
NOTE:
There will not be a particulate air filter installed on the vehicle.
NOTE:
LHD model shown in illustrations. RHD model similar.
13. Is the vehicle a Caliber (PM)?
a. YES - Refer to Step # 17
b. No - Refer to Step # 14
ON > Page 7816
14. Install a recirculation door screen (pin 68018099AA or 68018098AA) onto the recirculation door
opening. Engage screen into all four mount holes (Fig. 3).
15. Position the particulate air filter cover to the HVAC housing and engage the two retaining tabs
that secure the cover to the housing. Make sure the retaining tabs are fully engaged (Fig. 2).
16. Install the glove box. Repair Complete.
17. Cut the top two tabs off of the recirculation door screen (Fig. 4).
18. Install a piece of foam tape (pin 05019057AA) to the recirculation door screen all along the top
header (Fig. 4).
19. Slide the recirculation door screen (pin 68018099AA or 68018098AA) above the particulate air
filter cover opening and onto the recirculation
ON > Page 7817
door opening. Engage screen into two bottom mount holes only (Fig. 3) and (Fig. 4).
21. Install the glove box.
TIME ALLOWANCE:
FAILURE CODE:
Disclaimer:
Bulletins > All Technical Service Bulletins for Blower Motor: > 24-007-06 > Nov > 06 > A/C - Noise From Glove Box Area
With Blower ON
Blower Motor: All Technical Service Bulletins A/C - Noise From Glove Box Area With Blower ON
NUMBER: 24-007-06

MODELS:
2007 (PM) Caliber
2007 (MK49) Compass
NOTE:
JMA.
SYMPTOM/CONDITION:
motor is on.
DIAGNOSIS:
PARTS REQUIRED:
REPAIR PROCEDURE:
NOTE:
With Blower ON > Page 7823
NOTE:
the blower motor.
connector lock.
NOTE:
NOTE:
header (Fig. 4).
TIME ALLOWANCE:
FAILURE CODE:
Disclaimer:
Blower Motor: Locations
Component ID: 171
Component : MOTOR-BLOWER
Connector:
Name : MOTOR-BLOWER
Color : NATURAL
# of pins : 2
1 BLOWER MOTOR HIGH SPEED C70 12DB/YL
Jeep Workshop Manuals > Heating and Air Conditioning > Blower Motor > Component Information > Diagrams > Diagram
Blower Motor: Diagram Information and Instructions
Warnings
WARNINGS - GENERAL
the battery.
characteristics.
to function only.
SYMBOLS
TERMINOLOGY
Circuit Functions
models.
Circuit Information
IDENTIFICATION
LOCATIONS
illustrations.
associated wiring.
Removal
REMOVAL

connector.
Installation
INSTALLATION

Removal
REMOVAL
Installation
INSTALLATION
the new diode.
from the elements.
Removal
REMOVAL
Installation
INSTALLATION
repaired.
half/component.
repair.
Wire Splicing
repair area.

Special Tools
WIRING/TERMINAL


Blower Motor: Diagnostic Aids
vehicle.

good continuity.

SEVERAL LOADS


feed and ground.
position
problem
Blower Motor: Connector Views
Component ID: 171
Component : MOTOR-BLOWER
Connector:
Name : MOTOR-BLOWER
Color : NATURAL
# of pins : 2
Jeep Workshop Manuals > Heating and Air Conditioning > Blower Motor > Component Information > Description and
Blower Motor: Description and Operation Description
DESCRIPTION
The blower motor (1) is used to control the velocity of air moving through the HVAC housing by
spinning the blower wheel (2) within the HVAC air inlet housing at the selected speed.
The blower motor is a 12-volt, direct current (DC) motor mounted within a plastic housing with an
integral wire harness connector (3) and three mounting tabs (4). The squirrel cage-type blower
wheel is secured to the blower motor shaft and is positioned within the air inlet housing on the
passenger side of the HVAC housing.
Blower Motor: Description and Operation Operation
OPERATION
The blower motor is used to control the velocity of air moving through the HVAC housing by
spinning the blower wheel within the HVAC air inlet housing at the selected speed.
The blower motor will operate whenever the ignition switch is in the Run position and the blower
motor control is in any position except Off. The blower motor receives battery current through the
totally integrated power module (TIPM) whenever the ignition switch is in the Run position.
Blower motor speed is controlled by regulating the ground path through or around the blower motor
resistor and through the blower motor control located within the A/C-heater control.
The blower motor can be accessed for service from underneath the instrument panel.
NOTE: The blower motor is supplied with a 12V feed from the TIPM, through the blower motor
resistor, whenever the ignition switch is in the RUN position. Due to an open circuit condition within
the blower motor control switch the TIPM is UNABLE to detect an OPEN circuit for the blower
motor.
The blower motor control system is diagnosed using a scan tool.
The blower motor and blower motor wheel are factory balanced as an assembly and cannot be
adjusted or repaired and must be replaced if found inoperative or damaged.
Blower Motor: Testing and Inspection
BLOWER MOTOR
performing further diagnosis or service. Failure to take the proper precautions could result in
accidental airbag deployment and possible personal injury or death.
NOTE: The blower motor is supplied with a 12V feed from the TIPM, through the blower motor
resistor, whenever the ignition switch is in the RUN position. Due to an open circuit condition within
the blower motor control switch the TIPM is UNABLE to detect an OPEN circuit for the blower
motor.
To determine if an open condition exists within the blower motor circuit wiring, it is necessary to
disconnect the negative battery cable and check for continuity within the blower motor circuits using
an ohmmeter. For circuit descriptions and diagrams, refer to Air Conditioning/Heater - Wiring
Diagrams.
OPERATION
Possible causes of an inoperative blower motor include:
- Open fuse
- Inoperative blower motor resistor
- Inoperative blower motor switch
- Inoperative blower motor
- Inoperative blower motor circuit wiring or wire harness connectors
NOISE
To determine if the blower motor is the source of the noise, simply switch the blower motor from Off
to On. To verify that the blower motor is the source of the noise, unplug the blower motor wire
harness connector and operate the heater-A/C system. If the noise goes away, possible causes
include:
- Foreign material on fresh air inlet screen
- Foreign material in blower wheel
- Foreign material in HVAC housing
- Improper blower motor mounting
- Deformed or damaged blower wheel
- Worn blower motor bearings or brushes
VIBRATION
Possible causes of a blower motor vibration include:
- Improper blower motor mounting
- Foreign material in blower wheel

- Deformed or damaged blower wheel
- Worn blower motor bearings

Jeep Workshop Manuals > Heating and Air Conditioning > Blower Motor > Component Information > Service and Repair >
Removal
Blower Motor: Service and Repair Removal
REMOVAL
NOTE: The blower motor is located on the bottom of the passenger side of the HVAC housing. The
blower motor can be removed from the vehicle without having to remove the HVAC housing.
instrument panel wire harness connector (1) from the
blower motor (2).
4. Remove the three screws (3) that secure the blower motor and the wire lead bracket (4) (if
equipped) to the bottom of the HVAC housing (5) and
remove the blower motor.

Jeep Workshop Manuals > Heating and Air Conditioning > Blower Motor > Component Information > Service and Repair >
Removal > Page 7864
Blower Motor: Service and Repair Installation
INSTALLATION
1. Position the blower motor (2) into the bottom of the HVAC housing (5).
2. Install the three screws (3) that secure the blower motor and the wire lead bracket (4) (if
equipped) to the HVAC housing. Tighten the screws to
1.2 Nm (10 in. lbs.).
3. Connect the instrument panel wire harness connector (1) to the blower motor and engage the
connector lock.

Jeep Workshop Manuals > Heating and Air Conditioning > Blower Motor Resistor > Component Information > Locations
Blower Motor Resistor: Locations
Component ID: 191
Component : RESISTOR-BLOWER MOTOR
Connector:
Name : RESISTOR-BLOWER MOTOR
Color : GRAY
# of pins : 4
2 FRONT BLOWER M1 SPEED C72 18DB/OR
3 FRONT BLOWER M2 SPEED C73 18DB/VT
4 FRONT BLOWER LOW SPEED C71 18DB/BR
Jeep Workshop Manuals > Heating and Air Conditioning > Blower Motor Resistor > Component Information > Locations >
Page 7868
Page 7869
Page 7870
Page 7871
Page 7872
Page 7873
Blower Motor Resistor: Diagrams
Component ID: 191
Component : RESISTOR-BLOWER MOTOR
Connector:
Name : RESISTOR-BLOWER MOTOR
Color : GRAY
# of pins : 4
Page 7874
Page 7875
Page 7876
Page 7877
Page 7878
Jeep Workshop Manuals > Heating and Air Conditioning > Blower Motor Resistor > Component Information > Description
Blower Motor Resistor: Description and Operation Description
DESCRIPTION
The blower motor resistor is mounted to the HVAC housing on the passenger side of the vehicle.
The blower motor resistor consists of a molded plastic mounting plate (1) with an integral wire
connector receptacle (2). Concealed behind the mounting plate are resistors (3) located between a
two-piece stamped steel base (4).
Blower Motor Resistor: Description and Operation Operation
OPERATION
The blower motor resistor is connected to the vehicle electrical system through a dedicated take
out and connector of the instrument panel wire harness. The blower motor resistor has three
resistors, each of which will reduce the current flow through the blower motor to change the blower
motor speed.
The blower motor control for the heating-A/C system directs the ground path for the blower motor
through the correct resistor to obtain the selected speed. With the blower motor control in the
lowest speed position, the ground path for the blower motor is applied through all of the resistors.
Each higher speed selected with the blower motor control applies the blower motor ground path
through fewer of the resistors, increasing the blower motor speed. When the blower motor control
is in the highest speed position, the blower motor resistor is bypassed and the blower motor
receives a direct path to ground.
The blower motor resistor cannot be adjusted or repaired and it must be replaced if found
Blower Motor Resistor: Testing and Inspection
BLOWER MOTOR RESISTOR
NOTE: For circuit descriptions and diagrams, refer to the appropriate wiring information. The wiring
information includes wiring diagrams, proper wire and connector repair procedures, further details
on wire harness routing and retention, as well as pin-out and location views for the various wire
harness connectors, splices and grounds.
2. Disconnect the wire harness connector from the blower motor resistor.
3. Using an ohmmeter, check for continuity between all of the blower motor resistor terminals. In
each case there should be continuity. If OK, repair
the wire harness circuits between the blower motor speed control and the blower motor resistor or
blower motor as required. If not OK, replace the inoperative blower motor resistor.
Jeep Workshop Manuals > Heating and Air Conditioning > Blower Motor Resistor > Component Information > Service and
Repair > Removal
Blower Motor Resistor: Service and Repair Removal
REMOVAL
WARNING: The blower motor resistor may get very hot during normal operation. If the blower
motor was turned on prior to servicing the blower motor resistor, wait five minutes to allow the
blower motor resistors to cool before performing diagnosis or service. Failure to take this
precaution can result in possible personal injury.
CAUTION: Do not operate the blower motor with the blower motor resistor removed from the
circuit. Failure to take this precaution can result in vehicle damage.
2. Disconnect the wire harness connector (1) from the blower motor resistor (2) located at the
bottom of the HVAC housing (3) on the passenger side
of the vehicle.
3. Remove the two screws (4) that secure the blower motor resistor to the HVAC housing and
remove the resistor.
Jeep Workshop Manuals > Heating and Air Conditioning > Blower Motor Resistor > Component Information > Service and
Blower Motor Resistor: Service and Repair Installation
INSTALLATION
1. Position the blower motor resistor (2) onto the bottom of the HVAC housing (3).
2. Install the two screws (4) that secure the blower motor resistor to the HVAC housing. Tighten the
3. Connect the wire harness connector (1) to the blower motor resistor.

Jeep Workshop Manuals > Heating and Air Conditioning > Cabin Air Filter > Component Information > Description and
Operation
Cabin Air Filter: Description and Operation
DESCRIPTION
Some models are equipped with a particulate air filter (1) that helps purify the outside air entering
the HVAC housing. The filter is mounted in the passenger compartment, behind the glove box bin.
The filter should be replaced at least once a year or every 24,000 km (15,000 miles) and checked if
heating-A/C system performance seems lower than expected. The particulate air filter is labeled
with an arrow (2) to indicate the direction of air flow through the filter.
Jeep Workshop Manuals > Heating and Air Conditioning > Cabin Air Filter > Component Information > Service and Repair >
Procedures
Cabin Air Filter: Procedures
Air Filtration System - If Equipped
An air filter is included in the optional Security Group. Chrysler provides no information on removal
and replacement. See your authorized dealer for service.
Cabin Air Filter: Removal and Replacement
Removal
REMOVAL
2. Disengage the two retaining tabs (1) that secure the particulate air filter cover (2) to the
passenger side of the HVAC housing (3) and remove the
cover.
3. Remove the particulate air filter (1) from the HVAC housing (2) by pulling the filter element
straight out of the housing.
Installation
INSTALLATION
NOTE: The particulate air filter is labeled with an arrow to indicate air flow direction through the
filter. Make sure to properly install the particulate air filter. Failure to properly install the filter will
result in the need to replace the filter sooner than required by design.
1. Install the particulate air filter (1) into the filter opening in the HVAC housing (2). Insert the
particulate air filter directly into the housing with the
arrow on the filter pointing to the floor.
2. Position the particulate air filter cover (2) to the HVAC housing (3) and engage the two retaining
tabs (1) that secure the cover to the housing.
Make sure the retaining tabs are fully engaged.

Jeep Workshop Manuals > Heating and Air Conditioning > Cabin Ventilation Grille > Component Information > Service and
Repair > Removal
Cabin Ventilation Grille: Service and Repair Removal
SCREEN-AIR INLET
1. Remove the cowl grille screen.
2. Disengage the three push-in retainers (1) that secure the HVAC housing air inlet screen (2) to
the cowl panel (3) and remove the screen.
Jeep Workshop Manuals > Heating and Air Conditioning > Cabin Ventilation Grille > Component Information > Service and
Cabin Ventilation Grille: Service and Repair Installation
SCREEN-AIR INLET
1. Position the HVAC housing air inlet screen (2) to the cowl panel (3) and fully engage the three
push-in retainers (1) that secure the screen to the
panel.
2. Install the cowl grille screen.

Jeep Workshop Manuals > Heating and Air Conditioning > Compressor HVAC > Compressor Clutch > Component
Compressor Clutch: Locations
Component ID: 332
Component : SOLENOID-A/C COMPRESSOR
Connector:
Name : SOLENOID-A/C COMPRESSOR
Color : BLACK
# of pins : 2
1 FUSED MAIN RELAY OUTPUT F343 20BR/YL
2 GROUND Z916 20BK
Compressor Clutch: Diagrams
Component ID: 332
Component : SOLENOID-A/C COMPRESSOR
Connector:
Name : SOLENOID-A/C COMPRESSOR
Color : BLACK
# of pins : 2
1 FUSED MAIN RELAY OUTPUT F343 20BR/YL
2 GROUND Z916 20BK
Jeep Workshop Manuals > Heating and Air Conditioning > Condenser HVAC > Component Information > Technical Service
Bulletins > Customer Interest for Condenser HVAC: > 24-006-07 > Aug > 07 > A/C - Compressor Noise or Housing Damage
Condenser HVAC: Customer Interest A/C - Compressor Noise or Housing Damage
NUMBER: 24-006-07
SUBJECT: A/C Compressor Noise or Housing Damage
OVERVIEW: This bulletin involves replacing the A/C Compressor with a new design and a new
Condenser to compensate for revised compressor performance.
MODELS:
2007 (MK49) Compass
2007 (MK74) Patriot
2007 (PM) Caliber
NOTE:
This bulletin applies to 2007 PM/MK vehicles equipped air conditioning (sales code HHA or HAA)
with a 1.8L, 2.0L or 2.4L (non turbo) Gasoline Engine (sales codes EBA, ECN or ED3) and Manual
Transmission (sales codes DD7).
SYMPTOM/CONDITION:
A vehicle that is operated aggressively during cold conditions may experience damage to the A/C
compressor due to refrigerant slugging causing poor or no A/C performance, possible rattle noise
or compressor damage.
DIAGNOSIS:
Inspect the A/C compressor for physical damage to housing or rattle noise from compressor due to
refrigerant slugging. If any of these symptoms exist, perform the Repair Procedure.
NOTE:
Whenever a compressor is damaged internally, the suction/liquid line (liquid line assembly) and
accumulator must be replaced due to potential plugging from debris in the system.
> Page 7915
PARTS REQUIRED:
NOTE:
The new compressor includes a 120 mm pulley and requires a new (longer) drive belt size of 2576
mm. (The old compressor has a 100 mm pulley with 2560 mm drive belt pn 04891598AB).
REPAIR PROCEDURE:
1. Following the procedures outlined in DealerCONNECT>TechCONNECT evacuate the A/C

system.
2. Following the procedures outlined in DealerCONNECT>TechCONNECT, remove vehicle

components to access and remove the A/C Compressor, Condenser, Liquid Line Assembly, and
Accumulator.
3. Completely remove compressor drive belt from the vehicle and discard.
4. Flush and transfer the A/C Discharge Line (compressor to condenser) and A/C Suction Line
(compressor to accumulator).
5. Following the specifications in DealerCONNECT>TechCONNECT, follow the oil fill requirements

based on the components replaced and install the new Liquid/Suction Line pn 05058152AF,
Accumulator pn 5189376AA, Condenser pn 68004052AB, and Compressor pn 55111 555AA.
6. Install new accessory drive belt pn 04891721AB
NOTE:
The new drive belt must be installed due to revised length to accommodate new pulley size.
> Page 7916
7. Following the procedures outlined in DealerCONNECT>TechCONNECT, install any vehicle

components that were removed during disassembly.
8. Following the procedures outlined in DealerCONNECT>TechCONNECT, evacuate and fill the

A/C system with R134A following the under hood placard for system capacities.
NOTE:
Do not start the engine with the A/C system under a vacuum.
9. Verify system operation.
TIME ALLOWANCE:
FAILURE CODE:
Disclaimer:
Bulletins > All Technical Service Bulletins for Condenser HVAC: > 24-006-07 > Aug > 07 > A/C - Compressor Noise or
Housing Damage
Condenser HVAC: All Technical Service Bulletins A/C - Compressor Noise or Housing Damage
NUMBER: 24-006-07
SUBJECT: A/C Compressor Noise or Housing Damage
OVERVIEW: This bulletin involves replacing the A/C Compressor with a new design and a new
Condenser to compensate for revised compressor performance.
MODELS:
2007 (MK49) Compass
2007 (MK74) Patriot
2007 (PM) Caliber
NOTE:
This bulletin applies to 2007 PM/MK vehicles equipped air conditioning (sales code HHA or HAA)
with a 1.8L, 2.0L or 2.4L (non turbo) Gasoline Engine (sales codes EBA, ECN or ED3) and Manual
Transmission (sales codes DD7).
SYMPTOM/CONDITION:
A vehicle that is operated aggressively during cold conditions may experience damage to the A/C
compressor due to refrigerant slugging causing poor or no A/C performance, possible rattle noise
or compressor damage.
DIAGNOSIS:
Inspect the A/C compressor for physical damage to housing or rattle noise from compressor due to
refrigerant slugging. If any of these symptoms exist, perform the Repair Procedure.
NOTE:
Whenever a compressor is damaged internally, the suction/liquid line (liquid line assembly) and
accumulator must be replaced due to potential plugging from debris in the system.
Housing Damage > Page 7922
PARTS REQUIRED:
NOTE:
The new compressor includes a 120 mm pulley and requires a new (longer) drive belt size of 2576
mm. (The old compressor has a 100 mm pulley with 2560 mm drive belt pn 04891598AB).
REPAIR PROCEDURE:
1. Following the procedures outlined in DealerCONNECT>TechCONNECT evacuate the A/C

system.
2. Following the procedures outlined in DealerCONNECT>TechCONNECT, remove vehicle

components to access and remove the A/C Compressor, Condenser, Liquid Line Assembly, and
Accumulator.
3. Completely remove compressor drive belt from the vehicle and discard.
4. Flush and transfer the A/C Discharge Line (compressor to condenser) and A/C Suction Line
(compressor to accumulator).
5. Following the specifications in DealerCONNECT>TechCONNECT, follow the oil fill requirements

based on the components replaced and install the new Liquid/Suction Line pn 05058152AF,
Accumulator pn 5189376AA, Condenser pn 68004052AB, and Compressor pn 55111 555AA.
6. Install new accessory drive belt pn 04891721AB
NOTE:
The new drive belt must be installed due to revised length to accommodate new pulley size.
Housing Damage > Page 7923
7. Following the procedures outlined in DealerCONNECT>TechCONNECT, install any vehicle

components that were removed during disassembly.
8. Following the procedures outlined in DealerCONNECT>TechCONNECT, evacuate and fill the

A/C system with R134A following the under hood placard for system capacities.
NOTE:
Do not start the engine with the A/C system under a vacuum.
9. Verify system operation.
TIME ALLOWANCE:
FAILURE CODE:
Disclaimer:
Jeep Workshop Manuals > Heating and Air Conditioning > Condenser HVAC > Component Information > Description and
Condenser HVAC: Description and Operation Description
DESCRIPTION
NOTE: A/C condenser with automatic transmission cooler shown. A/C Condenser without cooler
similar.
The A/C condenser (1) is located in the front of the engine compartment behind the grille. The A/C
condenser is a heat exchanger that allows the high-pressure refrigerant gas being discharged by
the A/C compressor to give up its heat to the air passing over the condenser fins, which causes the
refrigerant to cool and change to a liquid state.
The A/C condenser is equipped with tapping blocks for the A/C discharge line and the A/C liquid
line (2) and an integral automatic transmission cooler (3), when equipped with an automatic
transaxle.
Jeep Workshop Manuals > Heating and Air Conditioning > Condenser HVAC > Component Information > Description and
Condenser HVAC: Description and Operation Operation
OPERATION
When air passes through the fins of the A/C condenser, the high-pressure refrigerant gas within the
A/C condenser gives up its heat. The refrigerant then condenses as it leaves the A/C condenser
and becomes a high-pressure liquid. The volume of air flowing over the condenser fins is critical to
the proper cooling performance of the A/C system. Therefore, it is important that there are no
objects placed in front of the radiator grille openings at the front of the vehicle or foreign material on
the condenser fins that might obstruct proper air flow. Also, any factory-installed air seals or
shrouds must be properly reinstalled following radiator or A/C condenser service.
The A/C condenser has no serviceable parts except for the O-ring seals and gaskets. The O-ring
seals used on the connections are made from a special type of rubber not affected by R-134a
refrigerant. The O-ring seals and gaskets must be replaced whenever a refrigerant line is removed
from the A/C condenser.
The A/C condenser cannot be repaired and must be replaced if leaking or damaged.
Jeep Workshop Manuals > Heating and Air Conditioning > Condenser HVAC > Component Information > Service and
Repair > Removal
Condenser HVAC: Service and Repair Removal
REMOVAL
injury or death.
CAUTION: Before removing the A/C condenser, note the location of each of the radiator/condenser
air seals. These air seals are used to direct air through the A/C condenser and radiator. The air
seals must be reinstalled in their proper locations in order for the A/C and engine cooling systems
to perform as designed.
3. If equipped with the 2.0L diesel engine, remove the front fascia.
NOTE: It is not necessary to remove the hood latch from the upper radiator support on gasoline
engine equipped models for A/C condenser service.
4. If equipped with a gasoline engine, remove the upper radiator support and position it out of the
way.
5. On gasoline engine equipped models, carefully push the radiator (1) slightly rearward to gain
access to the A/C condenser (2).
6. Remove the nut (3) that secures the A/C discharge line (4) to the right side of the A/C condenser
and remove and discard the O-ring seal and
gasket.
7. Install plugs in, or tape over the opened discharge line fitting and the condenser inlet port.
NOTE: On gasoline engine equipped models, reach up through the opening in the bottom of the
front fascia located in the right front corner of the vehicle to gain access to the A/C liquid line.
9. Remove the nut (1) that secures the A/C liquid line (2) to the right side of the A/C condenser (3).
and gasket.
11. Install plugs in, or tape over the opened liquid line fitting and the condenser outlet port.
NOTE: Illustration shown with front fascia and diesel engine charge air cooler (CAC) (when
equipped) removed for clarity.
12. Remove the two bolts (3) that secure the lower condenser brackets to the radiator (5).

14. If equipped, disconnect the automatic transmission cooler lines (2) from the left side of the A/C
condenser (1).
15. If equipped with the 2.0L diesel engine, remove the charge air cooler (CAC).
16. Carefully lift the A/C condenser straight up and disengage the two upper condenser brackets
(4) from the radiator and remove the condenser from
the engine compartment.

Condenser HVAC: Service and Repair Installation
INSTALLATION
NOTE: If only the A/C condenser is being replaced, add 20 milliliters (0.7 fluid ounce) of refrigerant
oil to the refrigerant system. Use only refrigerant oil of the type recommended for the A/C
compressor in the vehicle.
NOTE: Illustration shown with front fascia and diesel engine charge air cooler (CAC) (when
equipped) removed for clarity.
1. Carefully lower the A/C condenser (1) straight down in front of the radiator (5) and engage the
upper condenser brackets (4) to the radiator.
2. If equipped with the 2.0L diesel engine, install the charge air cooler (CAC).
3. If equipped, connect the automatic transmission cooler lines (2) to the left side of the A/C
condenser.
5. Install the two bolts (3) that secure the lower condenser brackets to the radiator. Tighten the
bolts to 4.5 Nm (40 in. lbs.).
NOTE: On gasoline engine equipped models, reach up through the opening in the bottom of the
front fascia located in the right front corner of the vehicle to gain access to the A/C liquid line.
6. Remove the tape or plug from the liquid line fitting and the condenser outlet port.
8. Connect the A/C liquid line (2) to the A/C condenser (3) and install the retaining nut (1). Tighten
the nut to 5 Nm (44 in. lbs.).
10. Remove the tape or plug from the discharge line fitting and the condenser inlet port.
recommended for the A/C compressor in the
vehicle.
12. On gasoline engine equipped models, carefully push the radiator (1) slightly rearward to gain
access to the A/C condenser (2).
13. Connect the A/C discharge line (4) to the A/C condenser and install the retaining nut (3).
Tighten the nut to 5 Nm (44 in. lbs.).
14. If equipped with a gasoline engine, reposition and install the upper radiator support.
15. If equipped with the 2.0L diesel engine, install the front fascia.
18. If the A/C condenser is being replaced, add 20 milliliters (0.7 fluid ounce) of refrigerant oil to the
refrigerant system. When replacing multiple

Jeep Workshop Manuals > Heating and Air Conditioning > Control Assembly, HVAC > Component Information > Locations
Control Assembly: Locations
Component ID: 53
Component : CONTROL-A/C-HEATER
Connector:
Name : CONTROL-A/C-HEATER C1
Color : BLACK
# of pins : 12
5 A/C INDICATOR DRIVER C4 20LB/RD
6--

8--
9 HVAC MUX RETURN C955 20LB/PK
10 - -
11 HVAC MUX CONTROL C105 20LB/LG
12 REAR WINDOW DEFOGGER SWITCH SIGNAL C215 20LB/BK
> Page 7937
> Page 7938
> Page 7939
Connector:
Color : BLACK
# of pins : 5

> Page 7940
> Page 7941
> Page 7942
Jeep Workshop Manuals > Heating and Air Conditioning > Control Assembly, HVAC > Component Information > Diagrams
> Diagram Information and Instructions
Control Assembly: Diagram Information and Instructions
Warnings
WARNINGS - GENERAL
the battery.
characteristics.
to function only.
SYMBOLS
TERMINOLOGY
Circuit Functions
models.
Circuit Information
IDENTIFICATION
LOCATIONS
illustrations.
associated wiring.
Removal
REMOVAL

connector.
Installation
INSTALLATION

Removal
REMOVAL
Installation
INSTALLATION
the new diode.
from the elements.
Removal
REMOVAL
Installation
INSTALLATION
repaired.
half/component.
repair.
Wire Splicing
repair area.

Special Tools
WIRING/TERMINAL


Control Assembly: Diagnostic Aids
vehicle.

good continuity.

SEVERAL LOADS


feed and ground.
position
problem
Control Assembly: Connector Views
Component ID: 53
Component : CONTROL-A/C-HEATER
Connector:
Color : BLACK
# of pins : 12
5 A/C INDICATOR DRIVER C4 20LB/RD
6--

8--
9 HVAC MUX RETURN C955 20LB/PK
10 - -
11 HVAC MUX CONTROL C105 20LB/LG
12 REAR WINDOW DEFOGGER SWITCH SIGNAL C215 20LB/BK
Connector:
Color : BLACK
# of pins : 5

> Page 7969
Control Assembly: Description and Operation
DESCRIPTION
NOTE: Typical A/C-heater control shown.
The A/C-heater control (1) for the manual temperature control (MTC) single zone system allows
one temperature setting for the entire vehicle. All controls are identified by ISO graphic symbols.
The heating-A/C system uses a combination of electrical and cable operated controls. These
controls provide the vehicle operator with a number of setting options to help control the climate
and comfort within the vehicle.
The A/C-heater control is located in the instrument panel and contains:
- a rotary control for mode control of the discharged air (2).
- a rotary control for blower motor speed selection and to turn the blower motor off (3).
- a rotary control for temperature control of the discharged air (4).
- a push-button control to turn the rear window defogger system on and off (5).
- a push-button control for recirculation control of the discharged air (6).
- a push-button control to turn the A/C system on and off (7).
The A/C-heater control cannot be repaired or adjusted and it must be replaced if found inoperative
or damaged. The control knobs for the A/C-heater control are available for service replacement.
Jeep Workshop Manuals > Heating and Air Conditioning > Control Assembly, HVAC > Component Information > Service
Control Assembly: Service and Repair Removal
REMOVAL
NOTE: Typical A/C-heater control and center bezel shown.
2. Remove the center bezel (7) from the instrument panel and disconnect the wiring connector for
the clock, power window switches and the
accessory switches, as equipped.
NOTE: To aid in reinstallation, note the installed positions of the control cables prior to removal.
3. Using a small screwdriver or similar tool, disengage the retaining clips that secure the control
cables (1 and 9) to the back of the A/C-heater
control (8).
4. Using a small screwdriver or similar tool, disengage the retaining clips that secure the control
cables to the mode control sector gear (2) and the
temperature control sector gear (5).

5. Disconnect the wire harness connectors (3 and 4) from the rear of the A/C-heater control and
place the center bezel on a work bench.
6. Remove the four screws (6) that secure the A/C-heater control to the back of the center bezel
and remove the control.
Jeep Workshop Manuals > Heating and Air Conditioning > Control Assembly, HVAC > Component Information > Service
Control Assembly: Service and Repair Installation
INSTALLATION
NOTE: Typical A/C-heater control and center bezel shown.
1. Install the A/C-heater control (8) into the instrument panel center bezel (7).
2. Install the four screws (6) that secure the A/C-heater control to the center bezel. Tighten the
3. Position the center bezel to the instrument panel and connect the wire harness connectors (3
and 4) to the back of the A/C-heater control.
NOTE: Install the mode control cable onto the A/C heater control first. Then install the temperature
control cable.
4. Connect the control cables (1 and 9) to the mode door control sector gear (2) and the
temperature control sector gear (5) and fully engage the
retaining clips. Make sure the retaining clips are fully engaged to the sector gears.
5. Connect the control cables to the back of the A/C-heater control and fully engage the retaining
clips. Make sure the retaining clips are fully
engaged to the back of the A/C-heater control.
6. Connect the wire harness connectors to the accessory switches, power window switches and
clock, as equipped and install the center bezel.

Jeep Workshop Manuals > Heating and Air Conditioning > Evaporator Core > Component Information > Description and
Evaporator Core: Description and Operation Description
DESCRIPTION
The A/C evaporator (1) for the heating-A/C system is mounted in the HVAC housing, which is
located behind the instrument panel. The A/C evaporator and its insulator (2) are positioned within
the HVAC housing so that all air entering the housing must pass over the evaporator fins before it
is distributed through the heating-A/C system ducts and outlets.
A tapping block (3) and O-ring seals are used to connect and seal the A/C evaporator tubes (4) to
the underhood refrigerant lines.
The A/C evaporator can only be serviced by removing and disassembling the HVAC housing
assembly.
Jeep Workshop Manuals > Heating and Air Conditioning > Evaporator Core > Component Information > Description and
Evaporator Core: Description and Operation Operation
OPERATION
Refrigerant enters the A/C evaporator through the A/C orifice tube as a low-temperature,
low-pressure mixture of liquid and gas. As air flows over the fins of the A/C evaporator, the
humidity in the air condenses on the fins, and the heat from the air is absorbed by the refrigerant.
Heat absorption causes the refrigerant to boil and vaporize. The refrigerant becomes a
low-pressure gas when it leaves the A/C evaporator.
The A/C evaporator has no serviceable parts except for the O-ring seals. The O-ring seals used on
the connections are made from a special type of rubber not affected by R-134a refrigerant. The
O-ring seals must be replaced whenever a refrigerant line is removed from the A/C evaporator.
The A/C evaporator cannot be repaired and must be replaced if found to be leaking or damaged.
Jeep Workshop Manuals > Heating and Air Conditioning > Evaporator Core > Component Information > Service and Repair
> Removal
Evaporator Core: Service and Repair Removal
REMOVAL
NOTE: The HVAC housing assembly must be removed from vehicle and disassembled for service
of the A/C evaporator.
1. Remove the HVAC housing and place it on a workbench.
2. Disassemble the HVAC housing to gain access to the A/C evaporator.
NOTE: If the foam insulator around the A/C evaporator is deformed or damaged, the insulator must
be replaced.
3. Carefully lift the A/C evaporator (1) and the foam insulator (2) out of the lower half of the HVAC
housing (3).
NOTE: If the seal around the evaporator tube tapping block is deformed or damaged, the seal must
be replaced.
4. If required, remove the seal (4) from around the evaporator tube tapping block (5).
Jeep Workshop Manuals > Heating and Air Conditioning > Evaporator Core > Component Information > Service and Repair
Evaporator Core: Service and Repair Installation
INSTALLATION
NOTE: If only the A/C evaporator is being replaced, add 20 milliliters (0.7 fluid ounce) of refrigerant
oil to the refrigerant system. Use only refrigerant oil of the type recommended for the A/C

1. If removed, install the seal (4) onto the evaporator tube tapping block (5).
NOTE: Make sure that the foam insulator is properly positioned in the HVAC housing.
2. Carefully install the A/C evaporator (1) and foam insulator (2) into the lower half of the HVAC
housing (3).
3. Assemble the HVAC housing.
4. Install the HVAC housing.
5. If the A/C evaporator is being replaced, add 20 milliliters (0.7 fluid ounce) of refrigerant oil to the
refrigerant system. When replacing multiple
Jeep Workshop Manuals > Heating and Air Conditioning > Evaporator Drain Tube > Component Information > Description
and Operation
Evaporator Drain Tube: Description and Operation
DESCRIPTION
Condensation that accumulates within the HVAC housing is drained through a port located at the
bottom of the HVAC housing (1). A rubber condensation drain tube (2) is installed onto the drain
port and protrudes through a rubber grommet (3) in the left side floor panel (4) to ensure that any
condensate completely drains out of the HVAC housing and to the ground.
NOTE: The condensation drain tube must be kept open to prevent water from collecting in the
bottom of the HVAC housing.
The drain tube is designed to keep contaminants from entering the HVAC housing. If the tube is
pinched or blocked, condensate cannot drain, causing water to back up and spill into the
passenger compartment. It is normal to see condensation drainage below the vehicle in warm
weather.
If the condensation drain tube is damaged or missing, it must be replaced.

Jeep Workshop Manuals > Heating and Air Conditioning > Evaporator Drain Tube > Component Information > Service and
Repair > Removal
Evaporator Drain Tube: Service and Repair Removal
REMOVAL
1. Pull back the floor carpet to gain access to the condensation drain tube (2) located on the left
side of the vehicle at the front right of the foot well.
2. Disconnect the condensation drain tube from the bottom of the HVAC housing (1).
3. Remove the condensate drain tube from the rubber grommet (3) in the front floor panel (4).
4. If required, remove the rubber grommet from the floor panel.

Jeep Workshop Manuals > Heating and Air Conditioning > Evaporator Drain Tube > Component Information > Service and
Evaporator Drain Tube: Service and Repair Installation
INSTALLATION
1. If removed, install the rubber grommet (3) onto the driver side front floor panel (4). Make sure the
grommet is fully engaged to the floor panel.
2. Connect the condensation drain tube (2) onto the drain port located on the bottom of the HVAC
housing (1).
3. Install the condensation drain tube into the rubber grommet.
4. Reinstall the floor carpet.

Jeep Workshop Manuals > Heating and Air Conditioning > Evaporator Temperature Sensor / Switch > Component
Component ID: 301
Connector:
Color : NATURAL
# of pins : 2
Component ID: 301
Connector:
Color : NATURAL
# of pins : 2
DESCRIPTION
OPERATION
REMOVAL
the vehicle.
INSTALLATION
HVAC housing (2).
housing.
wire harness.

Jeep Workshop Manuals > Heating and Air Conditioning > Expansion Block/Orifice Tube > Component Information >
Expansion Block/Orifice Tube: Description and Operation Description
DESCRIPTION
The A/C orifice tube establishes the pressure differential between the high and low pressure sides
of the A/C system by providing a restriction between the A/C condenser and the A/C evaporator.
The A/C orifice tube in this vehicle is installed in the A/C liquid line and is of a variable orifice valve
(VOV) design.
The variable A/C orifice tube consists of the inlet filter screen (5), the bi-metal coil (4), the fixed port
(3), the variable port (6), metering orifices (1), a nylon mesh diffuser screen (7) and two rubber
O-rings (2) which seal the tube to the inside of the A/C liquid line to prevent refrigerant from
bypassing the metering orifices.
Jeep Workshop Manuals > Heating and Air Conditioning > Expansion Block/Orifice Tube > Component Information >
Expansion Block/Orifice Tube: Description and Operation Operation
OPERATION
The variable A/C orifice tube provides improved A/C system cooling during city driving and when
under heavy loads by controlling refrigerant flow through the two parallel flow paths integral to the
orifice tube. Under normal loads, the refrigerant flows through the inlet filter screen, the fixed and
variable ports and both metering orifices. As the load on the A/C system increases, the
temperature of the refrigerant leaving the A/C condenser increases, which causes the bi-metal coil
to expand and restrict the flow of refrigerant through the variable port of the tube. Restricting the
flow of refrigerant through the variable port and its orifice provides a greater pressure differential
between the high and low pressure sides of the A/C system, resulting in colder refrigerant vapor
traveling through the A/C evaporator to help remove the heat from the conditioned air flowing into
the passenger compartment.
The A/C orifice tube is not serviceable and the A/C liquid line must be replaced if the orifice tube is
found inoperative.
Jeep Workshop Manuals > Heating and Air Conditioning > Heater Core > Component Information > Description and
Heater Core: Description and Operation Description
DESCRIPTION
The heater core (1) for the heating-A/C system is mounted within the HVAC air distribution
housing, which is located behind the instrument panel. The heater core is a heat exchanger made
of rows of tubes with fins and is positioned within the air distribution housing so that only the
selected amount of air entering the housing passes through the heater core before it is distributed
through the heating-A/C system ducts and outlets. One end of the heater core is fitted with a tank
(2) that includes the fittings for the heater core tubes (3).
The heater core can only be serviced by removing the HVAC housing from the vehicle.
Jeep Workshop Manuals > Heating and Air Conditioning > Heater Core > Component Information > Description and
Heater Core: Description and Operation Operation
OPERATION
Engine coolant is circulated through the heater hoses to the heater core at all times. As the coolant
flows through the heater core, heat is removed from the engine and is transferred to the heater
core tubes and fins. Air directed through the heater core picks up the heat from the heater core
fins. The blend-air door allows control of the heater output air temperature by regulating the amount
of air flowing through the heater core. The blower motor speed controls the volume of air flowing
through the HVAC housing.
The heater core cannot be repaired and it must be replaced if inoperative, leaking or damaged.
Jeep Workshop Manuals > Heating and Air Conditioning > Heater Core > Component Information > Service and Repair >
Installation
Heater Core: Service and Repair Installation
INSTALLATION
2. On RHD models, install the air distribution housing (5) onto the HVAC housing (9).
(10 in. lbs.).

7. Install the left side front floor duct.

Jeep Workshop Manuals > Heating and Air Conditioning > Heater Core > Component Information > Service and Repair >
Installation > Page 8017
Heater Core: Service and Repair Removal
REMOVAL
NOTE: The HVAC housing assembly must be removed from vehicle for service of the heater core.
2. Remove the left side front floor duct.
flange.
left side of the air distribution housing (5).
Jeep Workshop Manuals > Heating and Air Conditioning > High Pressure Safety Valve HVAC > Component Information >
Description and Operation > Operation
High Pressure Safety Valve HVAC: Description and Operation Operation
HIGH PRESSURE RELIEF VALVE
The high pressure relief valve vents refrigerant from the A/C system when a discharge pressure of
3445 to 4135 kPa (500 to 600 psi) or above is reached. The high pressure relief valve closes with a
minimum discharge pressure of 2756 kPa (400 psi) is reached.
The high pressure relief valve vents only enough refrigerant to reduce the A/C system pressure,
and then re-seats itself. The majority of the refrigerant is conserved in the A/C system. If the high
pressure relief valve vents refrigerant, it does not mean the valve is inoperative.
The high pressure relief valve is factory-calibrated and cannot be adjusted or repaired, and must
not be removed or otherwise disturbed. The valve is only serviced as a part of the A/C compressor.
Jeep Workshop Manuals > Heating and Air Conditioning > High Pressure Safety Valve HVAC > Component Information >
Description and Operation > Operation > Page 8022
High Pressure Safety Valve HVAC: Description and Operation Description
HIGH PRESSURE RELIEF VALVE
A high pressure relief valve is located on the compressor cylinder head at the rear of the A/C
compressor. This mechanical valve is designed to vent refrigerant from the A/C system to protect
against damage to the A/C compressor and other A/C system components caused by condenser
air flow restriction or an overcharge of refrigerant.
Jeep Workshop Manuals > Heating and Air Conditioning > Hose/Line HVAC > Component Information > Service
Precautions > Warning
Hose/Line HVAC: Service Precautions Warning
WARNING
WARNING: The A/C system contains refrigerant under high pressure. Repairs should only be
performed by qualified service personnel. Serious or fatal injury may result from improper service
procedures.
WARNING: Avoid breathing the refrigerant and refrigerant oil vapor or mist. Exposure may irritate
the eyes, nose, and/or throat. Wear eye protection when servicing the A/C refrigerant system.
Serious eye injury can result from direct contact with the refrigerant. If eye contact occurs, seek
medical attention immediately.
WARNING: Do not expose the refrigerant to open flame. Poisonous gas is created when refrigerant
is burned. An electronic leak detector is recommended. Serious or fatal injury may result from
improper service procedures.
WARNING: If accidental A/C system discharge occurs, ventilate the work area before resuming
service. Large amounts of refrigerant released in a closed work area will displace the oxygen and
cause suffocation and serious or fatal injury.
WARNING: The evaporation rate of R-134a refrigerant at average temperature and altitude is
extremely high. As a result, anything that comes in contact with the refrigerant will freeze. Always
protect the skin or delicate objects from direct contact with the refrigerant.
WARNING: The R-134a service equipment or the vehicle refrigerant system should not be
pressure tested or leak tested with compressed air. Some mixtures of air and R-134a have been
shown to be combustible at elevated pressures. These mixtures are potentially dangerous, and
may result in fire or explosion causing property damage and serious or fatal injury.
WARNING: The engine cooling system is designed to develop internal pressures up to 145
kilopascals (21 pounds per square inch). Do not remove or loosen the coolant pressure cap,
cylinder block drain plugs, radiator drain, radiator hoses, heater hoses, or hose clamps while the
engine cooling system is hot and under pressure. Allow the vehicle to cool for a minimum of 15
minutes before opening the cooling system for service. Failure to observe this warning can result in
serious burns from the heated engine coolant.
Jeep Workshop Manuals > Heating and Air Conditioning > Hose/Line HVAC > Component Information > Service
Precautions > Warning > Page 8027
Hose/Line HVAC: Service Precautions Caution
CAUTION
CAUTION: Never add R-12 to a refrigerant system designed to use R-134a. Do not use R-12
equipment or parts on an R-134a A/C system. These refrigerants are not compatible and damage
to the A/C system will result.
CAUTION: Never use R-12 refrigerant oil in an A/C system designed to use R-134a refrigerant oil.
These refrigerant oils are not compatible and damage to the A/C system will result.
CAUTION: The use of A/C system sealers may result in damage to A/C refrigerant
recovery/evacuation/recharging equipment and/or A/C system. Many federal, state/provincial and
local regulations prohibit the recharge of A/C systems with known leaks. DaimlerChrysler
recommends the detection of A/C system leaks through the use of approved leak detectors and
fluorescent leak detection dyes. Vehicles found with A/C system sealers should be treated as
contaminated and replacement of the entire A/C refrigerant system is recommended. A/C systems
found to be contaminated with A/C system sealers, A/C stop-leak products or seal conditioners
voids the warranty for the A/C system.
CAUTION: Recover the refrigerant before opening any fitting or connection. Open the fittings with
caution, even after the system has been discharged. Never open or loosen a connection before
recovering the refrigerant.
CAUTION: The internal parts of the A/C system will remain stable as long as moisture-free
refrigerant and refrigerant oil is used. Abnormal amounts of dirt, moisture or air can upset the
chemical stability. This may cause operational troubles or even serious damage if present in more
than very small quantities. Before disconnecting a component, clean the outside of the fittings
thoroughly to prevent contamination from entering the refrigerant system. Keep service tools and
the work area clean. Do not open the refrigerant system or uncap a replacement component until
you are ready to service the system. Immediately after disconnecting a component from the
refrigerant system, seal the open fittings with a cap or plug. This will prevent contamination from
entering the A/C system.
CAUTION: Refrigerant oil will absorb moisture from the atmosphere if left uncapped. Do not open a
container of refrigerant oil until you are ready to use it. Replace the cap on the oil container
immediately after using. Store refrigerant oil only in a clean, airtight, and moisture-free container.
CAUTION: Do not overcharge the refrigerant system. Overcharging will cause excessive
compressor head pressure and can cause compressor noise and A/C system failure.
Jeep Workshop Manuals > Heating and Air Conditioning > Hose/Line HVAC > Component Information > Description and
Operation > A/C Discharge Line
Hose/Line HVAC: Description and Operation A/C Discharge Line
DESCRIPTION
NOTE: Typical A/C discharge line shown.
The A/C discharge line (1) is the refrigerant line that carries refrigerant from the A/C compressor to
the A/C condenser and includes the high side service port (2) and a fitting (3) for the A/C pressure
transducer (4).
The A/C discharge line has no serviceable parts except for the metal gaskets (5) and rubber O-ring
seals (6) and the high side service port valve core. The O-ring seals used on the connections are
made from a special type of rubber not affected by R-134a refrigerant. The O-ring seals and
gaskets must be replaced whenever the A/C discharge line is removed.
The A/C discharge line cannot be repaired and must be replaced if found to be leaking or
damaged.
Operation > A/C Discharge Line > Page 8030
Hose/Line HVAC: Description and Operation A/C Liquid Line
DESCRIPTION
The A/C liquid line (1) is the refrigerant line that carries refrigerant from the A/C condenser to the
A/C evaporator. The A/C liquid line contains the low side service port (2) and the variable A/C
orifice tube. The A/C liquid line is only serviced as an assembly with the upper A/C suction line (3).
The A/C liquid/suction line assembly has no serviceable parts except for the metal gaskets (4),
rubber O-ring seals (5) and the low side service port valve core. The O-ring seals used on the
connections are made from a special type of rubber not affected by R-134a refrigerant. The O-ring
seals and gaskets must be replaced whenever the A/C liquid/suction line assembly is removed.
The A/C liquid/suction line assembly cannot be repaired and must be replaced if found to be
leaking or damaged, or if an internal failure of the A/C compressor has occurred.
Hose/Line HVAC: Description and Operation A/C Suction Line
DESCRIPTION
The A/C suction line is serviced in two sections. The upper section of the A/C suction line (1) is the
refrigerant line that carries refrigerant from the A/C evaporator to the A/C accumulator. The lower
section of the A/C suction line (2) carries refrigerant from the A/C accumulator to the A/C
compressor. The upper portion of the A/C suction line is only serviced as an assembly with the A/C
liquid line (5).
The lower A/C suction line and the A/C liquid/suction line assembly has no serviceable parts except
for the rubber O-ring seals (3), metal gaskets (4) and the low side service port valve core. The
O-ring seals used on the connections are made from a special type of rubber not affected by
R-134a refrigerant. The O-ring seals and gaskets must be replaced whenever the lower A/C
suction line and/or the A/C liquid/suction line assembly is removed.
The lower A/C suction line and the A/C liquid/suction line assembly cannot be repaired and must
be replaced if found to be leaking or damaged.
Hose/Line HVAC: Description and Operation Plumbing
Description
DESCRIPTION
The A/C refrigerant lines and hoses are used to carry the refrigerant between the various A/C
system components. The refrigerant lines and hoses for the R-134a A/C system consist of a
barrier-hose design with a nylon tube sandwiched between rubber layers. The nylon tube helps to
contain the R-134a refrigerant, which has a small molecular structure. The ends of the refrigerant
lines are made from lightweight aluminum and braze-less fittings.
Any kinks or sharp bends in the refrigerant lines and hoses will reduce the capacity of the entire
A/C system and can reduce the flow of refrigerant within the system.
Operation
OPERATION
High pressures are produced in the refrigerant system when the A/C compressor is operating.
Extreme care must be exercised to make sure that each of the refrigerant system connections is
pressure-tight and leak free. It is a good practice to inspect all flexible hose refrigerant lines at least
once a year to make sure they are in good condition and properly routed.
Depending on vehicle, model and market application, refrigerant lines are connected to each other
or other A/C system components with block-type or quick-connect type fittings. To ensure the
integrity of the refrigerant system, flat gaskets and O-rings are used to seal the refrigerant system
connections.
The refrigerant lines and hoses cannot be repaired and must be replaced if leaking or damaged.
Jeep Workshop Manuals > Heating and Air Conditioning > Hose/Line HVAC > Component Information > Service and Repair
> A/C Discharge Line
Hose/Line HVAC: Service and Repair A/C Discharge Line
Removal
REMOVAL
NOTE: It is not necessary to completely remove the front fascia for A/C discharge line service.
4. Remove the splash shield from the right side frame rail.
5. Remove the nut (1) that secures the A/C discharge line (2) to the A/C compressor (3).
6. Disconnect the A/C discharge line from the A/C compressor and remove and discard the O-ring
seal and gasket.
7. Install plugs in, or tape over the opened discharge line fitting and the compressor port.

9. Remove the upper radiator closure panel and carefully pull the top of the fascia forward to gain
access to the A/C discharge line (3).
10. Reach down through the opening between the radiator and the front fascia and disconnect the
wire harness connector (1) from the A/C pressure
transducer (2).
11. Remove the nut (5) that secures the A/C discharge line to the right side of the A/C condenser
(4).
12. Disconnect the A/C discharge line from the A/C condenser and remove and discard the O-ring
seal and gasket.
13. Install plugs in, or tape over the discharge line fitting and the condenser port.
14. If necessary, remove the A/C pressure transducer from the A/C discharge line.
Installation
INSTALLATION
1. If removed, install the A/C pressure transducer (2) onto the A/C discharge line (3). Tighten the
A/C pressure transducer securely.
2. Position the A/C discharge line into the engine compartment.
3. Remove the tape or plugs from the discharge line fitting and the condenser port.
5. Reach down through the opening between the radiator and the front fascia and connect the A/C
discharge line to the A/C condenser (4).
6. Install the nut (5) that secures the A/C discharge line to the A/C condenser. Tighten the nut to 5
Nm (44 in. lbs.).
8. Install the upper radiator closure panel.

10. Remove the tape or plugs from the discharge line fitting and the compressor port.
12. Connect the A/C discharge line (2) to the A/C compressor (3).
13. Install the nut (1) that secures the A/C discharge line to the A/C compressor. Tighten the nut to
20 Nm (15 ft. lbs.).
14. Install the splash shield onto the right side frame rail.

Hose/Line HVAC: Service and Repair A/C Liquid Line
Removal
REMOVAL
NOTE: The A/C liquid line is only serviced as an assembly with the upper A/C suction line.

and gasket.
accumulator ports.
shield.
washer bottle.

tower (5).
out of the way.
evaporator (6).
Installation
INSTALLATION
CAUTION: The A/C liquid line must be replaced if an internal failure of the A/C compressor has
occurred. Failure to replace the A/C liquid line can prevent the A/C system from operating as
to the dash panel.
reservoir.
compartment.
(10 in. lbs.).


Hose/Line HVAC: Service and Repair A/C Suction Line
Removal
REMOVAL
NOTE: The A/C suction line is serviced in two sections. The upper section of the A/C suction line is
the refrigerant line that carries refrigerant from the A/C evaporator to the A/C accumulator. The
lower section of the A/C suction line carries refrigerant from the A/C accumulator to the A/C
compressor.
NOTE: The upper portion of the A/C suction line is only serviced as an assembly with the A/C liquid
line.

and gasket.
accumulator ports.
shield.
washer bottle.

tower (5).
out of the way.
evaporator (6).

21. Remove the three push-pin retainers (1) and three screws (2) that secure the front portion of
the right front wheelhouse splash shield (3) to body
accumulator.
22. Remove the nut (2) that secures the lower A/C suction line (3) to the A/C accumulator (1).
23. Disconnect the lower A/C suction line from the A/C accumulator and remove and discard the
24. Install plugs in, or tape over the opened suction line fitting and the accumulator port.
25. Remove the nut (1) that secures the lower A/C suction line (2) to the A/C compressor (3).
26. Disconnect the lower A/C suction line from the A/C compressor and remove and discard the
27. Install plugs in, or tape over the opened suction line fitting and the compressor port.
28. Remove the lower A/C suction line from the engine compartment.
Installation
INSTALLATION
Failure to properly adjust the refrigerant
oil level will prevent the A/C system from operating as designed and can cause serious A/C
compressor damage.
to the dash panel.
reservoir.
compartment.
(10 in. lbs.).

19. Be certain to adjust the refrigerant oil level when servicing the A/C refrigerant system. Use only
refrigerant oil of the type recommended for the
21. Position the lower A/C suction line (2) into the engine compartment.
22. Remove the tape or plugs from the suction line fitting and the compressor port.
24. Connect the lower A/C suction line to the A/C compressor (3).
25. Install the nut (1) that secures the A/C suction line to the A/C compressor. Tighten the nut to 20
Nm (15 ft. lbs.).
26. Remove the tape or plugs from the suction line fitting and the accumulator port.
28. Connect the lower A/C suction line (3) to the A/C accumulator (1).
29. Install the nut (2) that secures the lower A/C suction line to the A/C accumulator. Tighten the
nut to 5 Nm (44 in. lbs.).
30. Reposition the front of the right front wheel house splash shield (3) to the body (4) and install
the three push-pin retainers (1) and the three screws


Jeep Workshop Manuals > Heating and Air Conditioning > Housing Assembly HVAC > Component Information > Technical
Service Bulletins > Customer Interest for Housing Assembly HVAC: > 24-007-06 > Nov > 06 > A/C - Noise From Glove Box
Area With Blower ON
Housing Assembly HVAC: Customer Interest A/C - Noise From Glove Box Area With Blower ON
NUMBER: 24-007-06

MODELS:
2007 (PM) Caliber
2007 (MK49) Compass
NOTE:
JMA.
SYMPTOM/CONDITION:
motor is on.
DIAGNOSIS:
PARTS REQUIRED:
REPAIR PROCEDURE:
NOTE:
Area With Blower ON > Page 8060
NOTE:
the blower motor.
connector lock.
NOTE:
NOTE:
header (Fig. 4).
TIME ALLOWANCE:
FAILURE CODE:
Disclaimer:
Service Bulletins > All Technical Service Bulletins for Housing Assembly HVAC: > 24-007-06 > Nov > 06 > A/C - Noise
From Glove Box Area With Blower ON
Housing Assembly HVAC: All Technical Service Bulletins A/C - Noise From Glove Box Area With
Blower ON
NUMBER: 24-007-06

MODELS:
2007 (PM) Caliber
2007 (MK49) Compass
NOTE:
JMA.
SYMPTOM/CONDITION:
motor is on.
DIAGNOSIS:
PARTS REQUIRED:
REPAIR PROCEDURE:
NOTE:
From Glove Box Area With Blower ON > Page 8069
NOTE:
the blower motor.
connector lock.
NOTE:
NOTE:
header (Fig. 4).
TIME ALLOWANCE:
FAILURE CODE:
Disclaimer:
Housing Assembly HVAC: Description and Operation
DESCRIPTION
NOTE: LHD model shown RHD model similar.
All models are equipped with a common HVAC housing assembly that combines A/C and heating
capabilities into a single unit mounted within the passenger compartment. The HVAC housing
assembly consists of three separate housings:
- HVAC housing - The HVAC housing (1) is mounted to the dash panel behind the instrument panel
and contains the A/C evaporator. The HVAC housing consists of an upper and a lower housing that
are attached together and has mounting provisions for the air inlet housing, blower motor and the
air distribution housing.
- Air distribution housing - The air distribution housing (2) is mounted to the rear of the HVAC
housing and contains the heater core, blend-air and mode-air doors and door linkage.
- Air inlet housing - The air inlet housing (3) is mounted to the passenger side end of the HVAC
housing. The air inlet housing contains the recirculation-air door and actuator when equipped with
A/C.
The heating-A/C system is a blend-air type system. The blend-air door controls the amount of
conditioned air that is allowed to flow through, or around, the heater core.
The A/C system is designed for the use of a non-CFC, R-134a refrigerant and uses an A/C
evaporator to cool and dehumidify the incoming air prior to blending it with the heated air. A
temperature control determines the discharge air temperature by operating the temperature control
cable, which moves the blend-air door. This allows an almost immediate control of the output air
temperature of the system. The mode door cable operates the mode-air doors which direct the flow
of the conditioned air out the various air outlets, depending on the mode selected. When equipped
with A/C, the recirculation door actuator operates the recirculation-air door which closes off the
fresh air intake and recirculates the air already inside the vehicle. The electric recirculation door
actuator and the blower motor are connected to the vehicle electrical system by the instrument
panel wire harness. The blower motor controls the velocity of air flowing through the HVAC housing
assembly by spinning the blower wheel within the HVAC housing at the selected speed by use of
the blower motor resistor, which is located in the dash panel in the engine compartment.
The air distribution housing must be removed from the HVAC housing and disassembled for
service of the blend-air and mode-air doors. The air inlet housing must be removed from HVAC
housing and disassembled for service of the recirculation-air door. The HVAC housing must be
removed from the vehicle and disassembled for service of the A/C evaporator.
Jeep Workshop Manuals > Heating and Air Conditioning > Housing Assembly HVAC > Component Information > Service
and Repair > Removal and Replacement
Housing Assembly HVAC: Removal and Replacement
Air Distribution Housing Removal
HOUSING-AIR DISTRIBUTION
injury or death.
NOTE: The air distribution housing must be removed from the HVAC housing and disassembled for
service of the blend-air and mode-air doors.
NOTE: LHD model with A/C shown in illustrations. RHD and heater-only models similar.
2. Remove all of the floor distribution ducts from the air distribution housing (5).
flange.
left side of the air distribution housing.
and Repair > Removal and Replacement > Page 8076
NOTE: Illustration shown with heater core and tubes removed from view for clarity.
8. Remove the two metal retaining clips (3) that secure the bottom of air distribution housing (2) to
the HVAC housing (4).
9. Remove the seven screws (1) that secure the air distribution housing to the rear of the HVAC
housing.
10. Remove the air distribution housing from the rear of the HVAC housing.
11. If required, disassemble the air distribution housing.
Air Distribution Housing Installation
NOTE: Illustration shown with heater core and tubes removed from view for clarity.
1. Position the air distribution housing (2) onto the rear of the HVAC housing (4).
2. Install the two metal retaining clips (3) that secure the bottom of the air distribution housing to the
HVAC housing.
3. Install the seven screws (1) that secure the air distribution housing to the HVAC housing. Tighten
the screws to 1.2 Nm (10 in. lbs.).
5. On RHD models, install the air distribution housing onto the HVAC housing (9).
(10 in. lbs.).

10. Install all of the floor distribution ducts onto the air distribution housing.
Air Inlet Housing Removal
HOUSING-AIR INLET
injury or death.
NOTE: The air inlet housing must be removed from HVAC housing and disassembled for service of
the recirculation-air door.

2. If equipped, remove the particulate air filter.
3. Remove the four screws (1) that secure the air inlet housing (2) to the top of the HVAC housing
(3).
4. Disengage the two plastic retaining tabs (4) that secure the air inlet housing to the HVAC
housing and remove the inlet housing from the HVAC
housing.
5. If required, disassemble the air inlet housing.
Air Inlet Housing Installation
HOUSING-AIR INLET
1. Install the air inlet housing (2) onto the top of the HVAC housing (3) and engage the two plastic
retaining tabs (4). Make sure the retaining tabs are
fully engaged.
2. Install the four screws (1) that secure the air inlet housing to the HVAC housing. Tighten the
3. If equipped, install the particulate air filter.
HVAC Housing - Removal
HOUSING-HVAC
instrument panel component diagnosis or service. Disconnect and isolate the battery negative
Failure to take the proper precautions could result in an accidental airbag deployment and possible
injury or death.
NOTE: The HVAC housing must be removed from the vehicle and disassembled for service of the
heater core, A/C evaporator, air intake housing and the mode-air and blend-air doors.
3. Partially drain the engine cooling system.
shield.
evaporator (3).
8. Disconnect the heater hoses (4) from the heater core tubes. Install plugs in, or tape over the
opened heater core tubes to prevent coolant spillage
during housing removal.
NOTE: Make sure to remove the five bolts that secure the HVAC housing to the instrument panel
support prior to removing the instrument panel from the vehicle.
10. Remove the rear floor ducts.
11. Remove the condensation drain tube.
12. Remove the nut (1) that secures the passenger side of the HVAC housing (2) to the dash panel
(3).
NOTE: Use care to ensure that the interior is covered in case of loss of residual fluids from the
heater and evaporator cores.
13. Pull the HVAC housing rearward and remove the HVAC housing assembly from the passenger
compartment.
HVAC Housing - Installation
HOUSING - HVAC
1. Position the HVAC housing assembly (2) to the dash panel (3). Be certain that the passenger
side of the HVAC housing is correctly located over
the dash panel mounting stud.
2. Install the nut (1) that secures the HVAC housing to the passenger compartment side of dash
panel. Tighten the nut to 4.5 Nm (40 in. lbs.).
3. Install the condensation drain tube.
4. Install the rear floor ducts.

6. Remove the previously installed plugs or caps and connect the heater hoses (4) to the heater
core tubes.
9. Connect the A/C liquid and suction line assembly (2) to the A/C evaporator (3).
compartment.
(10 in. lbs.).
14. If the heater core is being replaced, flush the cooling system.
15. Refill the engine cooling system.

Housing Assembly HVAC: Overhaul
Air Distribution Housing
NOTE: The air distribution housing must be removed from the HVAC housing and disassembled for
service of the blend-air and mode-air doors.
2. Remove the air distribution housing (2) from the HVAC housing (1).
3. If equipped with the 2.0L diesel engine, remove the electric positive temperature coefficient
(PTC) heater unit from the air distribution housing.
4. Remove the heater core from the air distribution housing.
5. Remove the temperature control cable (1) from the left side of the air distribution housing (2).
6. Remove the screw and washer (5) that secures the blend door cable lever (6) to the air
distribution housing and remove the cable lever.
NOTE: To remove the blend door pivot lever, disengage the retaining tab and pull the lever straight
out of the air distribution housing.
7. Remove the blend door pivot lever (3) from the end of the blend door pivot shaft (4) and remove
the pivot lever.
8. Remove the mode door cable (1) from the right side of the air distribution housing (2).
9. Remove the screw and washer (3) that secure the mode door cam (4) to the air distribution
housing and remove the cam.
NOTE: If any foam seal on the air distribution housing outlets is deformed or damaged, the seal
must be replaced.
10. Carefully cut the two foam seals (1) along the parting line (2) of the two halves of the air
distribution housing (3). If either seal is deformed or
damaged, it must be replaced.
11. Remove the five screws (4) and one metal clip (5) that secure the two halves of the air
distribution housing together.
12. Disengage the three plastic retaining tabs (6) that secure the two halves of the air distribution
housing together and carefully separate the housing.
NOTE: If a seal on an air door is deformed or damaged, the air door must be replaced.
13. Disengage the air door(s) (1, 2, 3 and 4) from the mode door levers and remove the air doors
from the air distribution housing (5).
NOTE: To remove the mode door levers, disengage the retaining tabs on the inside of the air
distribution housing and pull the levers straight out of the housing.
14. Remove the four mode door levers (1, 2, 3 and 4) from the right side of the air distribution
housing (5).
Air Inlet Housing
HOUSING-AIR INLET
NOTE: The air inlet housing must be removed from HVAC housing and disassembled for service of
the recirculation-air door.
2. Remove the air inlet housing (3) from the HVAC housing (1).
3. Remove the two screws (1) that secure the recirculation door actuator (2) to the right side of the
air inlet housing (3) and remove the actuator.
4. To remove the recirculation door pivot shaft adapter from the right end of the recirculation-air
door, first carefully push down on the tab of the
door lever pivot shaft adapter located inside of the air inlet housing, then pull the pivot shaft adapter
straight out of the end of the recirculation-air door pivot shaft.
NOTE: If the foam seal on the air inlet housing is deformed or damaged, the seal must be replaced.
NOTE: If a rubber seal on the recirculation air-door is deformed or damaged, the air-door must be
replaced.
5. Carefully pinch the two ends of the recirculation air-door together and remove the air-door from
the air inlet housing. If the seal on the
recirculation air-door is deformed or damaged, the air-door must be replaced.
HVAC Housing
HOUSING-HVAC
NOTE: The HVAC housing must be removed from the vehicle and disassembled for service of the
A/C evaporator.
2. Remove the air distribution housing (2) from the HVAC housing (1).
3. Remove the air inlet housing (3) from the HVAC housing.
4. Remove the three screws (1) that secure the wire lead bracket (2) and the blower motor (3) to
the bottom of the HVAC housing (4) and remove the
blower motor and wire lead bracket.
5. Remove the two screws (5) that secure the blower motor resistor (6) to the bottom of the HVAC
housing and remove the resistor.
6. Using needle nose pliers (1), disengage the two retaining tabs (2) that secure the evaporator
temperature sensor (3) to the driver side of the HVAC
housing (4) and remove the sensor.

7. Carefully remove the foam seal (2) from the front of the two halves of the HVAC housing (4). If
the seal is deformed or damaged, it must be
replaced.
8. Remove the nine screws (3) and three metal clips (5) that secure the two halves of the HVAC
housing together.
9. Disengage the nine plastic retaining tabs (1) that secure the two halves of the HVAC housing
together and separate the housing.
NOTE: If the foam insulator around the A/C evaporator is deformed or damaged, the insulator must
be replaced.
10. Carefully lift the A/C evaporator (1) and the foam insulator (2) out of the lower half of the HVAC
housing (3).
NOTE: If the seal around the evaporator tube tapping block is deformed or damaged, the seal must
be replaced.
11. If required, remove the seal (4) from around the evaporator tube tapping block (5).
Air Distribution Housing

1. Install the four mode door levers (1, 2, 3 and 4) onto the right side of the air distribution housing
(5) Make sure the lever retaining tabs are fully
engaged to the housing.
NOTE: Properly position the air doors within the air distribution housing by first aligning the four
mode door levers to the scribe lines located on the right outer side of the air distribution housing.
Then, install the air doors onto the mode door levers with the UP mark on each air door facing
toward the top of the housing.
NOTE: If a seal on an air door is deformed or damaged, the air door must be replaced.
2. Align the four mode door levers to the scribe lines on the right outer side of the air distribution
housing (5) and install the air door(s) (1, 2, 3 and
4) onto the mode door levers with the UP mark on each air door facing toward the top of the
housing.
3. Align the air door(s) with the pivot shaft hole(s) in the air distribution housing (3) and install the
two halves of the housing together. Make sure the
three plastic retaining tabs (6) are fully engaged.
4. Install the five screws (4) and one metal clip (5) that secure the two halves of the air distribution
housing together. Tighten the screws to 2.2 Nm
(20 in lbs.). Make sure the metal clip is fully engaged to the housing halves.
NOTE: If any foam seal on the air distribution housing outlets is deformed or damaged, the seal
must be replaced.
5. Inspect the foam seals (1), especially at the parting line (2). If a foam seal is deformed or
damaged, it must be replaced.
NOTE: Align the pins on the mode door levers with the grooves in the back of the mode door cam
prior to installation of the cam.
6. Align the mode door levers on the right side of the air distribution housing (2) to the mode door
cam (4) and install the cam onto the housing.
Make sure the levers are correctly engaged to the cam.
7. Install the screw and washer (3) that secure the mode door cam to the air distribution housing.
Tighten the screw to 0.6 Nm (5 in. lbs.).
8. Install the mode door cable (1).

9. Install the blend door pivot lever (3) onto the end of the blend door pivot shaft (4) located on the
left side of the air distribution housing (2). Make
sure the lever retaining tab is fully engaged to the pivot shaft.
NOTE: Align the pin on the blend door lever with the groove in the pivot lever prior to installation of
the blend door lever.
10. Install the blend door lever (6) onto the air distribution housing. Make sure the levers are
correctly aligned to each other.
11. Install the screw and washer (5) that secure the blend door lever to the air distribution housing.
Tighten the screw to 0.6 Nm (5 in. lbs.).
12. Install the temperature control cable (1).
13. If equipped with the 2.0L diesel engine, install the electric positive temperature coefficient
(PTC) heater unit into the air distribution housing.
14. Install the heater core into the air distribution housing (2).
15. Install the air distribution housing onto the HVAC housing (1).
Air Inlet Housing
HOUSING-AIR INLET
1. Carefully install the recirculation-air door (1) into the air inlet housing (2) by pinching the two
ends of the air-door together and aligning the pivot
shafts of the air-door to the pivot shaft holes in the air inlet housing.
NOTE: Install the recirculation door pivot shaft adapter by carefully pushing it straight into the end
of the recirculation door pivot shaft.
2. Install the recirculation door pivot shaft adapter (3) into the right side pivot shaft of the
recirculation air-door. Make sure the adapter is fully
engaged to the pivot shaft.
3. Install the recirculation door actuator (1) onto the right side of the air inlet housing (2). If
necessary, rotate the actuator slightly to align the splines
of the actuator output shaft (3) with those on the recirculation door pivot shaft adapter (4).
4. Install the air inlet housing (3) onto the HVAC housing (1).
HVAC Housing
HOUSING-HVAC
1. If removed, install the seal (4) onto the evaporator tube tapping block (5).
NOTE: Make sure that the foam insulator is properly positioned in the HVAC housing.
2. Carefully install the A/C evaporator (1) and foam insulator (2) into the lower half of the HVAC
housing (3).
3. Install the two halves of the HVAC housing (4) together and engage the nine plastic retaining
tabs (1). Make sure the retaining tabs are fully
engaged.
4. Install the nine screws (3) and three metal clips (5) that secure the two halves of the HVAC
housing together. Tighten the screws to 1.2 Nm (10 in
lbs.). Make sure the metal clips are fully engaged to the housing halves.
5. Install the foam seal (2) onto the front of the two HVAC housing halves.
6. Install the evaporator temperature sensor (1) into the driver side of the HVAC housing (2). Make
sure the retaining tabs (3) are fully engaged to
the housing.
7. Position the blower motor (3) into the bottom of the HVAC housing (4).
8. Install the wire lead bracket (2) and the three screws (1) that secure the blower motor to the
HVAC housing. Tighten the screws to 1.2 Nm (10 in.
lbs.).
9. Position the blower motor resistor (6) into the HVAC housing.
10. Install the two screws (5) that secure the blower motor resistor to the HVAC housing. Tighten
the screws to 1.2 Nm (10 in. lbs.).
11. Install the air inlet housing (3) onto the HVAC housing (1).
12. Install the air distribution housing (2) onto the HVAC housing.

Jeep Workshop Manuals > Heating and Air Conditioning > Refrigerant > Component Information > Specifications
Refrigerant: Specifications
REFRIGERANT CHARGE LEVEL

Jeep Workshop Manuals > Heating and Air Conditioning > Refrigerant > Component Information > Description and
Refrigerant: Description and Operation Description
DESCRIPTION
The refrigerant used in this air conditioning system is a HydroFluoroCarbon (HFC), type R-134a.
Unlike R-12, which is a ChloroFluoroCarbon (CFC), R-134a refrigerant does not contain
ozone-depleting chlorine. R-134a refrigerant is a non-toxic, non-flammable, clear, and colorless
liquefied gas.
Even though R-134a does not contain chlorine, it must be reclaimed and recycled just like
CFC-type refrigerants. This is because R-134a is a greenhouse gas and can contribute to global
warming.
Refrigerant: Description and Operation Operation
OPERATION
R-134a refrigerant is not compatible with R-12 refrigerant in an A/C system. Even a small amount
of R-12 refrigerant added to an R-134a refrigerant system will cause A/C compressor failure,
refrigerant oil sludge or poor A/C system performance. In addition, the polyalkylene glycol (PAG)
synthetic refrigerant oils used in an R-134a refrigerant system are not compatible with the
mineral-based refrigerant oils used in an R-12 refrigerant system.
R-134a refrigerant system service ports, service tool couplers and refrigerant dispensing bottles
have all been designed with unique fittings to ensure that an R-134a refrigerant system is not
accidentally contaminated with the wrong refrigerant (R-12). There are also labels posted in the
engine compartment of the vehicle and on the A/C compressor to identify that the A/C system is
equipped with R-134a refrigerant.
Refrigerant: Tools and Equipment
REFRIGERANT SYSTEM SERVICE EQUIPMENT
injury or death.
WARNING: Eye protection must be worn when servicing an air conditioning refrigerant system.
Turn off (rotate clockwise) all valves on the equipment being used, before connecting to or
disconnecting from the refrigerant system. Failure to observe these warnings may result in
When servicing the A/C system, an R-134a refrigerant recovery/recycling/charging station that
meets SAE standard J2210 must be used (1). Contact an automotive service equipment supplier
for refrigerant recovery/recycling/charging equipment. Refer to the operating instructions supplied
by the equipment manufacturer for proper care and use of this equipment.
A manifold gauge set (1) may be needed with some recovery/recycling/charging equipment. The
manifold gauge set should have manual shut-off valves (2 and 6), or automatic back-flow valves
located at the service port connector end of the manifold gauge set hoses (4 and 5). This will
prevent refrigerant
from being released into the atmosphere.
MANIFOLD GAUGE SET CONNECTIONS
CAUTION: Do not use an R-12 manifold gauge set on an R-134a system. The refrigerants are not
compatible and system damage will result.
- LOW PRESSURE GAUGE HOSE - The low pressure hose (Blue with Black stripe) attaches to
the low side service port. This port is located on the A/C liquid line near the right front strut tower.
- HIGH PRESSURE GAUGE HOSE - The high pressure hose (Red with Black stripe) attaches to
the high side service port. This port is located on the A/C discharge line near the A/C condenser.
- RECOVERY/RECYCLING/EVACUATION/CHARGING HOSE - The center manifold hose (Yellow,

or White, with Black stripe) is used to recover, evacuate, and charge the refrigerant system. When
the low or high pressure valves on the manifold gauge set are opened, the refrigerant in the system
will escape through this hose.
Jeep Workshop Manuals > Heating and Air Conditioning > Refrigerant Oil > Component Information > Description and
Refrigerant Oil: Description and Operation Description
DESCRIPTION
The refrigerant oil used in R-134a refrigerant systems is a synthetic-based, polyalkylene glycol
(PAG), wax-free lubricant. Mineral-based R-12 refrigerant oils are not compatible with PAG oils and
should never be introduced to an R-134a refrigerant system.
There are different PAG oils available and each contain a different additive package. Always use
only the type of refrigerant oil recommended for the A/C compressor in the vehicle.
Failure to properly adjust the refrigerant oil level can prevent the A/C system from operating as
The Denso 5SE12C A/C compressor used in this vehicle is designed to use ND-8 PAG refrigerant
oil. Use only this type of refrigerant oil in the refrigerant system.
Refrigerant Oil: Description and Operation Operation
OPERATION
After performing any refrigerant recovery or recycling operation, always replenish the refrigerant
system with the same amount of the recommended refrigerant oil as was removed. Too little
refrigerant oil can cause A/C compressor damage, and too much can reduce A/C system
performance.
PAG refrigerant oil is more hygroscopic than mineral oil, and will absorb any moisture it comes into
contact with, even moisture in the air. The PAG oil container should always be kept tightly capped
until it is ready to be used. After use, recap the oil container immediately to prevent moisture
contamination.
Refrigerant Oil: Service and Repair
REFRIGERANT OIL LEVEL
When an A/C system is assembled at the factory, all components except the A/C compressor are
refrigerant oil free. After the refrigerant system has been charged and operated, the refrigerant oil
in the A/C compressor is dispersed throughout the refrigerant system. The A/C accumulator, A/C
evaporator, A/C condenser and the A/C compressor will each retain a significant amount of the
needed refrigerant oil.
It is important to have the correct amount of refrigerant oil in the A/C system. This ensures proper
lubrication of the A/C compressor. Too little oil will result in damage to the A/C compressor, while
too much oil will reduce the cooling capacity of the A/C system and consequently result in higher
discharge air temperatures.
CAUTION: ND-8 PAG refrigerant oil is used in the Denso 5SE12C A/C compressor. Only
refrigerant oil of the same type should be used to service this R-134a A/C system. Do not use any
other refrigerant oil. The refrigerant oil container should be kept tightly capped until it is ready for
use and then tightly capped after use to prevent contamination from moisture and dirt. Refrigerant
oil will quickly absorb any moisture it comes in contact with, therefore, special effort must be used
to keep all R-134a system components moisture-free. Moisture in the refrigerant oil is very difficult
to remove and will cause a reliability problem with the A/C compressor.
NOTE: Most reclaim/recycling equipment will measure the amount of refrigerant oil being removed
during the recovery process. This amount of refrigerant oil should always be added back into the
refrigerant system. Refer to the reclaim/recycling equipment manufacturers instructions.
It will not be necessary to check the oil level within the A/C refrigerant system or to add oil, unless
there has been an oil loss. A refrigerant oil loss may occur due to component replacement or a
rupture or leak from a refrigerant line, connector fitting, component or component seal. If a leak
does occurs, add 30 milliliters (1 fluid ounce) of the recommended refrigerant oil to the refrigerant
system after the repair has been made. Refrigerant oil loss will be evident at the leak point by the
presence of a wet, shiny surface around the leak.
Refrigerant oil must be added when an A/C accumulator, A/C evaporator or A/C condenser is
replaced. Refer to the Refrigerant Oil Capacities chart.
The refrigerant oil level in a new A/C compressor must first be adjusted prior to compressor
installation. Refer to the following COMPRESSOR OIL DRAIN PROCEDURE.
COMPRESSOR OIL DRAIN PROCEDURE
The refrigerant oil in the Denso 5SE12C A/C compressor can only be drained using the procedure
described below. Failure to properly drain the refrigerant oil from the A/C compressor can prevent
the A/C system from operating as designed and cause serious compressor damage.
chart to determine how much oil should be removed from the new A/C compressor (example: new
compressor and accumulator requires 80 ml. (2.7 oz.) of oil to be added to the system. 120 ml. (4.1
oz.) of oil is in new compressor. 120 ml. (4.1 oz.) minus 80 ml. (2.7 oz.) equals 40 ml. (1.4 oz.) oil
to be drained from new compressor).
The Denso 5SE12C A/C compressor is filled with 120 milliliters (4.1 oz.) from the factory. When
only the A/C compressor is being replaced, 70 milliliters (2.4 oz.) of refrigerant oil must first be
drained from the new compressor prior to installation. Use the following procedure to drain and
measure refrigerant oil from the Denso 5SE12C A/C compressor.
1. Place the new A/C compressor (1) on a workbench,
2. Position the A/C compressor so that the refrigerant oil can drain out of the suction port (2) into a
suitable clean measured container. Hold the A/C
compressor in this position until no more oil comes out of the compressor port.
3. Reposition the A/C compressor (1) so that the pulley (2) is facing upward and slowly rotate the
compressor pulley clockwise one full turn.
4. Repeat steps 2 and 3 at least seven times or until 70 milliliters (2.4 oz.) of refrigerant oil is
drained from the new A/C compressor.
CAUTION: Failure to properly adjust the refrigerant oil level prior to installation of a new
compressor can prevent the A/C system from operating as designed and cause serious
compressor damage.
5. Install the new A/C compressor onto the engine.

Jeep Workshop Manuals > Heating and Air Conditioning > Refrigerant Pressure Sensor / Switch, HVAC > Component
Component ID: 368
Connector:
Color : GRAY
# of pins : 4
4--
Component ID: 368
Connector:
Color : GRAY
# of pins : 4
4--
DESCRIPTION
terminals.
OPERATION
REMOVAL
transducer.
O-ring seal (4).
INSTALLATION
discharge line (3).

Jeep Workshop Manuals > Heating and Air Conditioning > Sensors and Switches - HVAC > Ambient Temperature Sensor /
Switch HVAC > Component Information > Locations
Component ID: 291
Connector:
Color : BLACK
# of pins : 2
Switch HVAC > Component Information > Locations > Page 8129
Component ID: 291
Connector:
Color : BLACK
# of pins : 2
Jeep Workshop Manuals > Heating and Air Conditioning > Sensors and Switches - HVAC > Evaporator Temperature
Sensor / Switch > Component Information > Locations
Component ID: 301
Connector:
Color : NATURAL
# of pins : 2
Sensor / Switch > Component Information > Locations > Page 8135
Component ID: 301
Connector:
Color : NATURAL
# of pins : 2
Sensor / Switch > Component Information > Description and Operation > Description
DESCRIPTION
Sensor / Switch > Component Information > Description and Operation > Description > Page 8146
OPERATION
Sensor / Switch > Component Information > Service and Repair > Removal
REMOVAL
the vehicle.
Sensor / Switch > Component Information > Service and Repair > Removal > Page 8149
INSTALLATION
HVAC housing (2).
housing.
wire harness.

Jeep Workshop Manuals > Heating and Air Conditioning > Sensors and Switches - HVAC > Refrigerant Pressure Sensor /
Switch, HVAC > Component Information > Locations
Component ID: 368
Connector:
Color : GRAY
# of pins : 4
4--
Switch, HVAC > Component Information > Locations > Page 8153
Component ID: 368
Connector:
Color : GRAY
# of pins : 4
4--
Switch, HVAC > Component Information > Description and Operation > Description
DESCRIPTION
terminals.
Switch, HVAC > Component Information > Description and Operation > Description > Page 8158
OPERATION
Switch, HVAC > Component Information > Service and Repair > Removal
REMOVAL
transducer.
O-ring seal (4).
Switch, HVAC > Component Information > Service and Repair > Removal > Page 8161
INSTALLATION
discharge line (3).

Jeep Workshop Manuals > Heating and Air Conditioning > Service Port HVAC > Component Information > Description and
Operation
Service Port HVAC: Description and Operation
DESCRIPTION
Refrigerant system service ports are used to recover, recycle, evacuate, charge and test the A/C
refrigerant system. Unique sizes are used on the two service ports for the R-134a refrigerant
system to ensure the system is not accidentally contaminated with R-12 refrigerant or by service
equipment used for R-12 refrigerant.
The high side service port (1) is located on the A/C discharge line (2) in front of the engine, below
the upper radiator hose (3).
The low side service port (1) is located on the A/C liquid line (2) near the right front strut tower (3).
Both the high side and low side A/C service port valve cores are serviceable.
NOTE: The protective cap aids in service port sealing and helps protect the refrigerant system from
contamination. Remember to always reinstall the protective cap onto the service port when
refrigerant system service is complete.
Each of the service ports has a threaded plastic protective cap installed over it from the factory.
The service port caps are serviceable items.
Jeep Workshop Manuals > Heating and Air Conditioning > Service Port HVAC > Component Information > Service and
Repair > Removal
Service Port HVAC: Service and Repair Removal
REMOVAL
following operation. Failure to follow the warnings and cautions may result in serious or fatal injury.
NOTE: Typical A/C service port shown.
1. Remove the protective cap (1) from the service port (2).
3. Using a Schrader-type valve core tool, remove the valve core (3) from the service port.
4. Install a plug in, or tape over the opened service port(s).

Jeep Workshop Manuals > Heating and Air Conditioning > Service Port HVAC > Component Information > Service and
Service Port HVAC: Service and Repair Installation
INSTALLATION
NOTE: Typical A/C service port shown.
1. Lubricate the valve core (3) with clean refrigerant oil prior to installation. Use only refrigerant oil
of the type recommended for the A/C
2. Remove the tape or plug from the service port (2).
CAUTION: A valve core that is not fully seated in the A/C service port can result in damage to the
valve during refrigerant system evacuation and charge. Such damage may result in a loss of
system refrigerant while uncoupling the charge adapters.
3. Using a Schrader-type valve core tool, install and tighten the valve core into the service port(s).

NOTE: The protective cap helps aid in service port sealing and helps protect the refrigerant system
from contamination. Remember to always reinstall the protective cap onto the service port when
refrigerant system service is complete.
6. Install the protective cap (1) onto the service port.

Jeep Workshop Manuals > Restraint Systems > Repairs and Inspections Required After a Collision > System Information >
Service and Repair
Repairs and Inspections Required After a Collision: Service and Repair
SERVICE AFTER A SUPPLEMENTAL RESTRAINT DEPLOYMENT
Any vehicle which is to be returned to use following a supplemental restraint deployment, must
have the deployed restraints replaced. In addition, if the driver airbag has been deployed, the
clockspring and the steering column must be replaced. If the passenger airbag is deployed, the
passenger airbag door and the passenger airbag squib connectors must be replaced. The seat belt
tensioners are deployed by the same signal that deploys the driver and passenger airbags and
must also be replaced along with their squib connectors if either front airbag has been deployed.
If a side curtain airbag has been deployed, the headliner as well as the upper A, B, C and D-pillar
trim must be replaced. The seat airbag is deployed by the same signal that deploys the side curtain
airbag for the same side of the vehicle. If a seat airbag has been deployed, the seat back trim
cover, the seat back foam, the seat back frame and the seat wire harness must be replaced. These
components are not intended for reuse and will be damaged or weakened as a result of a
supplemental restraint deployment, which may or may not be obvious during a visual inspection.
On vehicles with an optional sunroof, the sunroof drain tubes and hoses must be closely inspected
following a side curtain airbag deployment. It is also critical that the mounting surfaces and
mounting brackets for the Occupant Restraint Controller (ORC), side impact sensors, and front
impact sensors be closely inspected and restored to their original conditions following any vehicle
impact damage. Because the ORC and each front and side impact sensor are used by the
supplemental restraint system to monitor or confirm the direction and severity of a vehicle impact,
improper orientation or insecure fastening of these components may cause airbags not to deploy
when required, or to deploy when not required.
All other vehicle components should be closely inspected following any supplemental restraint
deployment, but are to be replaced only as required by the extent of the visible damage incurred.
AIRBAG SQUIB STATUS
Multistage airbags with multiple initiators (squibs) must be checked to determine that all squibs
were used during the deployment event. The driver and passenger airbags in this vehicle are
deployed by electrical signals generated by the Occupant Restraint Controller (ORC) through the
driver or passenger squib 1 and squib 2 circuits to the two initiators in the airbag inflators. Typically,
both initiators are used and all potentially hazardous chemicals are burned during an airbag
deployment event. However, it is possible for only one initiator to be used due to an airbag system
fault; therefore, it is always necessary to confirm that both initiators have been used in order to
avoid the improper handling or disposal of potentially live pyrotechnic or hazardous materials. The
following procedure should be performed using a diagnostic scan tool to verify the status of both
airbag squibs before either deployed airbag is removed from the vehicle for disposal.
CAUTION: Deployed front airbags having two initiators (squibs) in the airbag inflator may or may
not have live pyrotechnic material within the inflator. Do not dispose of these airbags unless you
are certain of complete deployment. Refer to the Hazardous Substance Control System for proper
disposal procedures. Dispose of all non-deployed and deployed airbags and seat belt tensioners in
a manner consistent with state, provincial, local, and federal regulations.
1. Be certain that the diagnostic scan tool contains the latest version of the proper diagnostic
software. Connect the scan tool to the 16-way Data Link
Connector (DLC). The DLC is located on the driver side lower edge of the instrument panel,
outboard of the steering column.
2. Turn the ignition switch to the ON position.
3. Using the scan tool, read and record the active (current) Diagnostic Trouble Code (DTC) data.
Using the active DTC information, refer to the Airbag Squib Status table to determine the status of
both driver and passenger airbag squibs.
Service and Repair > Page 8172
NOTE: If none of the Driver or Passenger Squib 1 or 2 open are active codes, the status of the
airbag squibs is unknown. In this case the airbag should be handled and disposed of as if the
squibs were both live.
CLEANUP PROCEDURE
Following a supplemental restraint deployment, the vehicle interior will contain a powdery residue.
This residue consists primarily of harmless particulate by-products of the small pyrotechnic charge
that initiates the propellant used to deploy a supplemental restraint. However, this residue may also
contain traces of sodium hydroxide powder, a chemical by-product of the propellant material that is
used to generate the inert gas that inflates the airbag. Since sodium hydroxide powder can irritate
the skin, eyes, nose, or throat, be certain to wear safety glasses, rubber gloves, and a long-sleeved
shirt during cleanup.
WARNING: To avoid serious or fatal injury, if you experience skin irritation during cleanup, run cool
water over the affected area. Also, if you experience irritation of the nose or throat, exit the vehicle
for fresh air until the irritation ceases. If irritation continues, see a physician.
Service and Repair > Page 8173
1. Begin the cleanup by using a vacuum cleaner to remove any residual powder from the vehicle
interior. Clean from outside the vehicle and work
your way inside, so that you avoid kneeling or sitting on a non-cleaned area.
2. Be certain to vacuum the heater and air conditioning outlets as well. Run the heater and air
conditioner blower on the lowest speed setting and
vacuum any powder expelled from the outlets.
CAUTION: Deployed front airbags having two initiators (squibs) in the airbag inflator may or may
not have live pyrotechnic material within the inflator. Do not dispose of these airbags unless you
are certain of complete deployment. Refer to AIRBAG SQUIB STATUS. All damaged, ineffective,
or non-deployed supplemental restraints which are replaced on vehicles are to be handled and
disposed of properly. If an airbag or seat belt tensioner unit is ineffective or damaged and
non-deployed, refer to the Hazardous Substance Control System for proper disposal. Be certain to
dispose of all non-deployed and deployed supplemental restraints in a manner consistent with
state, provincial, local and federal regulations.
3. Next, remove the deployed supplemental restraints from the vehicle. Refer to the appropriate
service removal procedures.
4. You may need to vacuum the interior of the vehicle a second time to recover all of the powder.
Jeep Workshop Manuals > Restraint Systems > Air Bag Systems > Air Bag > Component Information > Locations >
Airbag-Passenger Squib 1
Air Bag: Locations Airbag-Passenger Squib 1
Component ID: 4
Component : AIRBAG-PASSENGER SQUIB 1
Connector:
Name : AIRBAG-PASSENGER SQUIB 1
Color : YELLOW/BLACK
# of pins : 2
Airbag-Passenger Squib 1 > Page 8179
Air Bag: Locations Airbag-Passenger Squib 2
Component ID: 5
Component : AIRBAG-PASSENGER SQUIB 2
Connector:
Name : AIRBAG-PASSENGER SQUIB 2
Color : YELLOW/ORANGE
# of pins : 2
Air Bag: Locations Airbag-Side Curtain-Right
Component ID: 9
Component : AIRBAG-SIDE CURTAIN-RIGHT
Connector:
Name : AIRBAG-SIDE CURTAIN-RIGHT
Color : YELLOW/BLACK
# of pins : 2
Jeep Compass 4wd Works

Jeep Compass 4wd Workshop Manual l4 2 4l Vin W 2007

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Alarm Module: Locations

Component ID: 161

Component : MODULE-INTRUSION TRANSCEIVER

Name : MODULE-INTRUSION TRANSCEIVER C1

Pin Description Circuit

1 FUSED B(+) (I.O.D.) A415 20RD/TN

3 CAN B BUS (+) D55 20WT/OR

4 CAN B BUS (-) D54 20WT/PK

5 SIREN SIGNAL CONTROL D96 20WT/BR

6 GROUND Z941 20BK/WT

Name : MODULE-INTRUSION TRANSCEIVER C2

Pin Description Circuit

2 COURTESY LAMPS DRIVER M24 20YL/WT

3 GROUND Z941 20BK/WT

Alarm Module: Diagrams

Component ID: 161

Component : MODULE-INTRUSION TRANSCEIVER

Name : MODULE-INTRUSION TRANSCEIVER C1

Pin Description Circuit

1 FUSED B(+) (I.O.D.) A415 20RD/TN

3 CAN B BUS (+) D55 20WT/OR

4 CAN B BUS (-) D54 20WT/PK

5 SIREN SIGNAL CONTROL D96 20WT/BR

6 GROUND Z941 20BK/WT

Name : MODULE-INTRUSION TRANSCEIVER C2

Pin Description Circuit

2 COURTESY LAMPS DRIVER M24 20YL/WT

3 GROUND Z941 20BK/WT

Alarm Module: Description and Operation Description

Alarm Module: Service and Repair Removal

1. Disconnect and isolate the battery negative cable.

4. Swing the lens outward until it is perpendicular to the housing.

7. Remove the ITM from the vehicle.

Alarm Module: Service and Repair Installation

of the hole in the headliner.

into the housing.

7. Reconnect the battery negative cable.

Keyless Entry Module: Locations

Component ID: 166

Component : MODULE-SENTRY KEY REMOTE ENTRY/WCM

Name : MODULE-SENTRY KEY REMOTE ENTRY/WCM

Pin Description Circuit

1 IGNITION SWITCH SENSE G20 20VT/BR

2 COM-LIN TIRE PRESSURE MONITOR LAN D508 20WT/GY

3 IGNITION SWITCH OUTPUT (RUN-START) F20 20PK/WT

4 GROUND Z937 20BK/YL

5 FUSED B(+) (I.O.D.) A411 20RD/LG

6 CAN B BUS (+) D55 20WT/OR

7 CAN B BUS (-) D54 20WT/PK

Keyless Entry Module: Diagrams

Component ID: 166

Component : MODULE-SENTRY KEY REMOTE ENTRY/WCM

Name : MODULE-SENTRY KEY REMOTE ENTRY/WCM

Pin Description Circuit

1 IGNITION SWITCH SENSE G20 20VT/BR

2 COM-LIN TIRE PRESSURE MONITOR LAN D508 20WT/GY

3 IGNITION SWITCH OUTPUT (RUN-START) F20 20PK/WT

4 GROUND Z937 20BK/YL